Woodward 505 Manual For Operation And Installation
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Woodward 505 Manual For Operation And Installation

Woodward 505 Manual For Operation And Installation

Enhanced digital control for steam turbines
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Product Manual 26347V1
(Revision L, 4/2014)
Original Instructions
505 Enhanced Digital Control
for Steam Turbines
(with Redundancy)
8923-1704 (Marine LVDC);
9907-1181, 9907-1182, 9907-1183
Manual 26347 consists of 2 volumes (26347V1 & 26347V2).
Volume 1—Installation and Operation

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  • Page 1 Product Manual 26347V1 (Revision L, 4/2014) Original Instructions 505 Enhanced Digital Control for Steam Turbines (with Redundancy) 8923-1704 (Marine LVDC); 9907-1181, 9907-1182, 9907-1183 Manual 26347 consists of 2 volumes (26347V1 & 26347V2). Volume 1—Installation and Operation...
  • Page 2 Revisions—Changes in this publication since the last revision are indicated by a black line alongside the text. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Contents ................  ARNINGS AND OTICES ..........  LECTROSTATIC ISCHARGE WARENESS   ..............EGULATORY OMPLIANCE VIII 1. G ............1  HAPTER ENERAL NFORMATION Introduction ......................1   Controller Overview ....................2  ...
  • Page 4 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Contents 5. 505 O ..............137  HAPTER PERATION Run Mode Architecture ..................137   Keypad and Display ....................141   Run Mode Front Panel Keys ................141   Starting Procedures ....................142   Speed Key Screens ....................143  ...
  • Page 5 Figure 2-15f. Recommended Contact Input Diagram – Using Multiplier ....35   Figure 2-15g. Redundant Contact Input Diagram – DPDT Switches ....36   Figure 2-15h. Two Transducers with One Transducer for each 505 Unit .... 37   Figure 2-15i. One Transducer Using a Current Splitting/Isolation Device ... 37  ...
  • Page 6 Figure 3-14. Redundant 505 Configuration Diagram ........... 90   Figure 4-1. Basic Program Architecture ............... 95   Figure 4-2. Initial 505 Program Mode Entry ............96   Figure 4-3a. Program Mode Blocks ..............99   Figure 4-3b. Program Mode Blocks ..............100  ...
  • Page 7 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Illustrations and Tables Table 5-12. Alarm Messages ................164   Table 5-13. Trip Messages ................. 165   Table 6-1. ASCII vs RTU Modbus ..............171   Table 6-2. Modbus Function Codes ..............172  ...

  • Page 8: Warnings And Notices

    Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...

  • Page 9: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715 , Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.

  • Page 10: Regulatory Compliance

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Regulatory Compliance European Compliance for CE Marking: These listings are limited only to those units bearing the CE Marking. Declared to 2004/108/EC COUNCIL EMC Directive: DIRECTIVE of 15 December 2004 on the...
  • Page 11 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Special Conditions For Safe Use Field wiring must be stranded copper wire rated at least 75 °C for operating ambient temperatures expected to exceed 50 °C. Peripheral equipment must be suitable for the location in which it is used.
  • Page 12 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Woodward...

  • Page 13: Chapter 1. General Information

    505 controls that have this coating will have a label on the side stating “SULFUR RESISTANT CONFORMAL COATED”. All 505 controllers shipped...

  • Page 14: Controller Overview

    NEMA enclosure with a power line filter. Power wires to the line filter must be segregated from the wires from the line filter to the 505. In addition, the field wiring must be installed with an additional shield layer which is grounded to the enclosure.

  • Page 15: Figure 1-1. Typical Single Or Dual Inlet Steam Turbine

    (24 characters each) display, and a set of 30 keys is located on the 505’s front panel. This OCP is used to configure the 505, make On-Line program adjustments, and operate the turbine/system. Easy to follow instructions are presented in English through the OCP’s two-line display and operators can...

  • Page 16: Additional Features

    Acceleration protection, Remote droop, Frequency dead-band. Using the 505 The 505 control has two normal operating modes, the Program Mode and the Run Mode. The Program Mode is used to select the options needed to configure the control to your specific turbine application. Once the control has been configured, the Program Mode is typically never again used, unless turbine options or operation changes.

  • Page 17: Figure 1-3. Explanation Of Symbols

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 1-3. Explanation of Symbols Woodward...

  • Page 18: Figure 1-4. Single Or Split-Range Turbine Configurations

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 ENABLE INPUT REMOTE INPUT RAISE SETPOINT (4−20mA) ACTUATOR LOWER SPEED SCALING DRIVER 1 TURBINE SPEED VALVE ACTUATOR SCALING LIMITER DRIVER 2 855−668 02−12−31 Figure 1-4. Single or Split-Range Turbine Configurations (Speed PID with Remote Set Point)

  • Page 19: Figure 1-6. Single Or Split-Range Turbine Configurations

    In-Control (light annunciated) and allows the user to “transfer” control from this 505 to the other 505. The F4 key (and F3 if not configured for redundancy) can be configured to enable or disable various functions of the control.

  • Page 20: Control Outputs

    In such configurations, one 505 functions as the In-Control unit and controls all aspects of the turbine system. The second 505 functions as a Tracking unit and tracks the In-Control 505’s operating parameters to ensure a smooth transfer if the In-Control 505 fails.

  • Page 21: Keypad And Display

    Figure 1-7. Typical Redundant 505 Application Configuration Keypad and Display The 505’s service panel consists of a keypad and LED display located on the front of the control. The LED display has two, 24 character lines that can be used to display operating parameters and troubleshooting parameters in plain English.

  • Page 22: Figure 1-8. 505 Keypad And Display

    Mode. SELECT: The Select key is used to select control of the 505 display’s top or bottom line variable. The @ sign is used to indicate which line (variable) can be adjusted by the adjust keys. Only when there is a changeable variable on both lines (dynamics, valve calibration modes) does the “select key”...
  • Page 23 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators RUN: Initiates a turbine run or start command from the (CONTROLLING PARAMETER/PUSH RUN or PRGM) state. In redundant operation of two 505s, the system will only respond to this command being entered from the keypad on the In-Control unit.

  • Page 24: Watchdog Timer/Cpu Fault Control

    (illuminate) which unit is In Control. This key will also act as the command key to TRANSFER control over to the Tracking Unit, unless the user configures a discrete input as the Transfer command. If the 505 is not configured for Redundant operation, then this key is a programmable function key for enabling or disabling other programmable control functions.

  • Page 25: Chapter 2. Installation Procedures

    Input/Output circuitry, and all circuitry for the front panel display, touch keypad, and the serial communications. If so labeled on the enclosure, the 505 is UL/cUL listed for use in hazardous locations in UL file E156028. This Equipment is suitable for use in Class I, Division 2 , Groups A, B, C, and D (Class I, Zone 2, Group IIC) or non-hazardous locations only.
  • Page 26 NEMA 4X ratings. A gasket is attached to the rear side of the package’s bezel to properly seal the 505’s face-plate to a panel. All field wiring connects to the 505 through removable terminal blocks located on the 505’s back side.

  • Page 27: Figure 2-1. 505 Control Layout (Standard Enclosure)

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 2-1. 505 Control Layout (Standard Enclosure) Woodward...

  • Page 28: Figure 2-2. 505 Bulkhead-Mounted Enclosure

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Figure 2-2. 505 Bulkhead-Mounted Enclosure Woodward...

  • Page 29: Figure 2-3. Jumper Options

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 2-3. Jumper Options Figure 2-4. Jumper Locations Woodward...

  • Page 30: Electrical Connections

    All inputs and outputs to the 505 are made through “CageClamp” terminal blocks on the bottom of the 505 package. For EMI reasons, it is recommend that all low- current wire (terminals 52 through 121) be separated from all high-current wire (terminals 1 through 51).

  • Page 31: Figure 2-5. Cageclamp Terminal Blocks

    The 505 control is available with three different input power source selections. The part number of the 505 depends on the rating of the input power source it can accept. The input power source rating on each unit can be identified by the back-panel sticker or the control part number.

  • Page 32: Figure 2-6. Control Wiring Diagram

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Figure 2-6. Control Wiring Diagram Woodward...

  • Page 33: Figure 2-7. Representative 505 I/O Schematic

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 2-7. Representative 505 I/O Schematic Woodward...
  • Page 34 180–264 Vac @ 47–63 Hz Power Supply 58 milliseconds A 24 V power supply is available, within the 505, to power external transducers or devices. This supply has two breaker protected output channels. One power supply channel (VA1) is capable of providing 24 Vdc ±10%, @ 200 mA maximum output current, to power 505 current inputs and auxiliary devices.

  • Page 35: Figure 2-8. Fuse Location

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 2-8. Fuse location Shields and Grounding An individual shield termination is provided at the terminal block for each of the speed sensor inputs, actuator outputs, analog inputs, analog outputs, and communications ports. All of these inputs should be wired using shielded, twisted-pair wiring.

  • Page 36: Speed Sensor Inputs

    MPU or proximity probe. By being able to sense turbine speed down to this level, the 505 can be programmed to turn on or off a turbine turning gear, via a relay output. See Figure 2-7 for proximity probe wiring schematic.

  • Page 37: Contact Inputs

    Volume 2 for input specifications. The total current draw through terminals 4, 5, 6, 7, 8, 9, and 10 cannot exceed 100 mA or the 505’s internal power output breaker (CB5) will open resulting in a possible CPU reset and trip condition. all load must be removed from the specified terminals to allow the breaker to reset.

  • Page 38: Analog Inputs

    Analog Outputs Applications using a 505 current output must have the desired analog value assigned or configured to a specific output. There is a choice of six possible 4–20 mA output drivers of which to use to display a parameter externally. Optionally, if Actuator Driver #2 is not being utilized to drive an actuator, it can be programmed to function as a 4–20 mA driver to display one of the values listed below.

  • Page 39: Relay Outputs

    Each actuator driver senses the drive current to allow over- and under-current shutdowns. The 505 can be configured to use one or two actuators. If only one actuator is used and programmed, it must be wired to actuator #1’s output terminals.

  • Page 40: Serial Communications

    RS-232 Wiring A RS-232 link is limited to a distance of 50 feet. The 505 control utilizes terminal blocks 114–117 and 106–109 for RS-232 connections. Figure 2-10 shows typical RS-232 communications connection. The transmit data (TXD), receive data (RXD), and signal ground (SIG GND) must be properly connected as shown.

  • Page 41: Figure 2-10. Typical Rs-232 Communications

    An advantage of RS-422 communications is that it uses a differential voltage and can accommodate much longer transmission distances. A RS-422 link can communicate up to a distance of 4000 feet. The 505 control utilizes terminal blocks 108-113 and 116-121 for RS-422 connections. Figure 2-11 shows a typical RS-422 communications connection.

  • Page 42: Communications Grounding And Shielding

    RS-485 Wiring RS-485 communications can also accommodate transmission distances of up to a distance of 4000 feet. The 505 control utilizes terminal blocks 108-111 and 116-119 for RS-485 connections. Figure 2-12 shows a typical RS- 485 communications connection. The data lines (422R+/485+ and 422R-/485-) and signal ground (SIG GND) must be properly connected as shown.

  • Page 43: Redundant Application Installations

    Unit 1 Modbus Port 1 connected to Unit 2 Modbus Port 1 via RS-422 communications  Unit 1 505 “Unit OK” relay output (# 1) connected to Unit 2 505 “Other Unit OK” contact input (# 1)  Unit 2 505 “Unit OK” relay output (# 1) connected to Unit 1 505 “Other Unit OK”...
  • Page 44 505 controllers. In some cases, all I/O signals will be brought into both 505s; in other cases, one 505 may be a backup unit that is designed to keep the turbine running (in speed control) upon the failure or fault detection of the primary unit.

  • Page 45: Figure 2-15B. Typical Redundant Diagram

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 2-15b. Typical Redundant Diagram Woodward...

  • Page 46: Speed Inputs

    Figure 2-15c. Optional Speed MPU Input Diagram – Different Probes The above installation depicts individual MPU for each 505 in redundant configuration. The second input on both the 505 can be driven in the same manner utilizing separate MPU or a common MPU as desired.

  • Page 47: Figure 2-15E. Recommended Proximity Probe Input Diagram - Different Probes

    Figure 2-15e. Recommended Proximity Probe Input Diagram – Different Probes The installation recommends the wiring scheme if Proximity probes are used as speed sensors. Active power should be taken from the respective 505 to drive the probes in order to avoid any grounding problem.

  • Page 48: Figure 2-15G. Redundant Contact Input Diagram - Dpdt Switches

    The last two External trips (9 and 10) are unique in that they will issue a Shutdown to this 505 and force a Transfer to the Tracking 505. These inputs are designed as Emergency Transfer commands from the user or from an ancillary device such as a redundant CPC skid.

  • Page 49: Figure 2-15H. Two Transducers With One Transducer For Each 505 Unit

    505 unit (if desired) can be accomplished (no opening of the current loops).

  • Page 50: Figure 2-15J. One Transducer Driving Both 505 Inputs

    Special attention to wiring details should be taken to ensure that nuisance trips do not occur and that on-line replacement of a 505 unit (if desired) can be accomplished (no opening of the actuator current loops).

  • Page 51: Figure 2-15K. Single Shared Coil Applications

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators The Actuator 2 output should not be used in redundant configurations. Use of this output can result in erratic speed control when actuator output failures are detected. Figure 2-15k. Single Shared Coil Applications Figure 2-15l.

  • Page 52: Figure 2-15N. Analog Output Switching Diagram

    Analog Output signals from both 505’s, it is possible to use relays to switch to the Analog Output signals from the 505 that is in control. One way to do this is by using the “In-Control” Relay Output to activate a relay bank.

  • Page 53: Figure 2-15O. Relay Outputs (Positive Logic)

    Relay Output Figure 2-15o. Relay Outputs (positive logic) If a Trip command is only given to the Unit 1 “In Control” 505, there may be up to a 350 ms delay between the time the Shutdown Relay Output on Unit 1 indicates a shutdown and the time the Shutdown Relay Output on Unit 2 indicates a Shutdown.

  • Page 54: Figure 2-15Q. Typical Rs-422 Communications Between Master And Slave

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Using relays to switch between Unit 1 and Unit 2, Relay Outputs can interrupt the signal for the switch time of the relay when a transfer of control occurs. At the instant that the relays toggle, the voltage detected in the field may drop to 0 V, resulting from an open circuit while the relays are transitioning.

  • Page 55: Chapter 3. 505 Control Description

    (Start Perm Not Met). The alarm does not need to be cleared but the contact must be closed before the 505 will accept the ‘RUN’ command. After ‘RUN’ has been accepted, the start permissive contact will have no effect on operation.

  • Page 56: Zero Speed Signal Override

    Manual 26347V1 Zero Speed Signal Override The 505 issues a shutdown if no speed signal is detected (magnetic pickup voltage less than 1 Vrms or speed is less than the ‘Failed Speed Level’). To allow the control to start with speed not being sensed, this shutdown logic must be overridden.

  • Page 57: Turbine Start Mode Procedures

    1. Issue a RESET command (to reset all alarms and shutdowns) 2. Issue a RUN command (verify T&T valve is closed before issuing)  At this point the 505 will ramp open the governor valve to its maximum position at the ‘Valve Limiter Rate’. ...

  • Page 58: Figure 3-2. Semiautomatic Start Mode Example

    4. Raise the 505’s VALVE LIMITER at a controlled rate.  When turbine speed increases to the minimum controlling speed, the 505’s Speed PID will take control of turbine speed by controlling turbine inlet valve position. 5. Raise the 505’s VALVE LIMITER to 100%.

  • Page 59: Critical Speed Avoidance

    505 Digital Governor for Single/Split-Range Actuators 3. Issue a RUN command  At this point the 505 will ramp open the governor valve to its “HP Max at Start” setting at the ‘Valve Limiter Rate’ setting.  The speed set point will ramp from zero to the minimum controlling speed setting at the ‘Rate to MIN’...

  • Page 60: No Idle Programmed

    The idle/rated function can also be programmed as a ramp-to-rated function only. If the 505’s Idle/Rated function is programmed, once a ‘RUN’ command is given, the 505 ramps turbine speed from zero to the programmed Idle setting, then waits for a command from the operator to ramp turbine speed to the “Rated...
  • Page 61 If a 505 contact input is programmed to select between Idle or Rated speeds, Idle speed is selected when the contact is open and rated speed is selected when it is closed.

  • Page 62: Automatic Start Sequence

    The Automatic Start Sequence can be used with any one of the three start modes. The 505 can be configured to utilize an Automatic Start Sequence to start the turbine. This sequencing logic allows the 505 to perform a complete controlled system start-up from zero speed to rated speed.

  • Page 63: Figure 3-5. Automatic Start Sequence

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 3-5. Automatic Start Sequence With this sequence, a set of hot-start ramp rates and hold times is programmed for use when a ‘RUN’ command is given and the turbine has been shutdown for less than the programmed ‘HOT START’...
  • Page 64 Cold start curves will be used when the respective contact is open. The Auto Start Sequence can be halted at any time from the 505 keypad, contact input or through Modbus. The sequence can be halted by a halt command, a raise or lower speed set point command, or when a speed set point is directly ‘Entered’...

  • Page 65: Speed Control Overview

    505 Digital Governor for Single/Split-Range Actuators The halting and continuing of the Auto Start Sequence can be performed through the 505 keypad, contact input, or Modbus. The last command given from any of these three sources determines the mode of operation. However, a shutdown condition will disable this function, requiring it to be re-enabled after a start-up has been performed.

  • Page 66: Speed Pid Operational Modes

    Turbine inlet valve position (505 LSS position) control  Generator Load control When not programmed for generator applications, the 505 Speed PID operates in a Speed control mode at all times. When programmed for generator applications, the state of the generator and utility tie breakers determine the operational mode of the Speed PID.

  • Page 67: Frequency Control

    With this configuration, no form of droop or second controlling parameter is used by the PID for stability or control. Refer to Figure 3-6. The following Speed PID mode descriptions are based on the 505 program’s default settings. For information on how to change the 505’s defaulted breaker logic, refer to Volume 2 of this manual.

  • Page 68: Figure 3-7. Speed Pid Control Modes

    PID’s second controlling parameter. A second parameter representing unit load is fed back into the 505’s Speed PID to allow it to control two parameters; speed when operating in an isolated mode, and unit load when paralleled to an infinite bus.

  • Page 69: Figure 3-8. Frequency And Unit Load Relationship

    505 Digital Governor for Single/Split-Range Actuators Figure 3-8. Frequency and Unit Load Relationship Because the 505’s Speed PID and set point are used to control turbine speed and a second parameter, this second parameter (unit load) is normalized to allow all three terms (speed, set point, unit load) to be summed together within the PID summing junction.
  • Page 70 Frequency dead-band (±3 Hz). Used to reduce/prevent constant valve corrections due to a constantly changing grid frequency. To configure the 505 for generator load control when paralleled to a infinite bus, program the ‘KW DROOP’ setting to ‘YES’, and program the 505 to accept an analog input from a Watt transducer sensing generator load..

  • Page 71: Figure 3-9. Speed Relationships

    505 keypad or Modbus communications. To “enter” a specific set point from the 505 keypad, press the SPEED key to view the speed control screen, press the ENTER key, enter the set point level desired, then press the ENTER key again.
  • Page 72 505 discretely. This Sync Window Rate is defaulted to two rpm/s and is only used when the generator breaker is open and the speed set point is within 10 rpm of rated speed.

  • Page 73: Remote Speed Set Point

    Speed PID to be tuned for optimal response. When the 505 is configured for a generator application, the utility tie and generator breakers determine which set of dynamics is used by the Speed PID.
  • Page 74 Since RSS is a secondary speed setting function, the Speed PID must be in- control of the 505’s LSS bus to allow the RSS to position the actuator. When configured as a generator application, the RSS will not take control unless both breakers are closed and the speed PID is in control.
  • Page 75 Synchronization Automatic generator synchronization can be performed through a Woodward EGCP-3. The EGCP-3 connects to a 505 analog input to bias the 505’s speed set point directly to vary generator speed, frequency and phase. Optionally the EGCP-3 can interface with the unit voltage regulator to match system voltage across a generator breaker.
  • Page 76 Synchronizing/Load Sharing The 505 is capable of using an analog input to accept a load sharing signal from Woodward’s EGCP-3. This input in conjunction with the EGCP-3 allows the control to isochronously load share with any other system using an EGCP-3. The 505’s internal summing junction adds this signal with the speed/load PID’s reference.

  • Page 77: Figure 3-10. Load Sharing Logic

    The ‘Sync/Ld Share Enable’ contact input option is used to enable the Sync/Load Share analog input before the generator breaker is closed. Optionally a Function Key (F3 or F4) can be programmed to enable the 505’s Sync/Load Share analog input instead of an external contact. This discrete enable/disable function is ignored after the generator breaker is closed, and must be reselected after the generator breaker opens.

  • Page 78: Load Rejection

    Table 3-2. Load Sharing Logic When programming a Function Key (F3 or F4) instead of a contact input to enable the 505’s analog Sync/Load Share input, a 505 relay output, can be also be programmed to select an EGCP-3’s synchronizing mode. To configure the 505 for this functionality, program the ‘Sync/Ld Share Enable’...

  • Page 79: Feed-Forward Input

    Depending on the use and configuration of the 505 controller in compressor applications, it is possible to experience a coupling effect between an anti-surge controller (external) and the 505’s internal Speed or Cascade PID controllers. If a plant condition exists where the anti-surge controller is required to open and control the anti-surge valve, compressor suction pressure will change.

  • Page 80: Emergency Loop

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 When enabled, if the feed forward analog input increases or decreases, the speed set point will be increased or decreased respectively. This is an offset added to or subtracted from the speed set point. After a feed-forward event, this speed offset will slowly ramp back to zero based on the delay time configured (typically 120 seconds).

  • Page 81: Cascade Control

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 3-11. Typical Anti-surge Valve and Speed Feed-Forward Logic Trend Cascade Control The Cascade control can be configured to control any system process, related to or affected by turbine speed or load. Typically this controller is configured and used as a turbine inlet, or exhaust pressure controller.

  • Page 82: Figure 3-12. Cascade Functional Diagram

    Since Cascade is a secondary speed setting function, the Speed PID must be in control of the 505’s LSS bus in order for Cascade to take control. When the 505 is configured for a generator application, both the utility tie and generator breakers must be closed, before the Cascade PID can begin controlling a process.

  • Page 83: Cascade Set Point

    The other information, such as cascade input signal and remote cascade set point, will not be passed through this link. If the backup 505 unit is not configured for Cascade control, it will revert to speed control authority.
  • Page 84 Cascade set point slow rate is programmed for 10 psi/s, the smallest increment it will move is 0.4 psi (1.2 psi for Modbus). A specific set point may also be directly entered from the 505 keypad or through Modbus communications. When this is performed, the set point will ramp at the ‘Casc Setpt Rate’...
  • Page 85 If the Cascade control is programmed not to use the set point tracking feature the set point will remain at its last setting (running or shutdown). When the 505 is powered-up the set point is reset to the ‘Setpt Initial Value’. With this...
  • Page 86 Depending on configuration and system conditions, the Remote Cascade Set Point may be in one of the following states (505 front panel screen messages): ...

  • Page 87: Auxiliary Control

    The Auxiliary set point is adjustable with raise or lower commands through the 505 front keypad, through remote contact inputs or through Modbus. Also, the set point can be directly set by entering the new set point from the keypad or through Modbus communications.

  • Page 88: Figure 3-13. Aux Control Overview

    (running or shutdown), provided a power-up-reset did not occur. Depending on configuration and system conditions, the Auxiliary Limiter may be in one of the following states (505 front panel screen messages):  Auxiliary is Enabled—Auxiliary has been enabled but the generator and utility tie breaker permissives have not been met (generator applications only).
  • Page 89 100%. Depending on the configuration and system conditions, the Auxiliary PID may be in one of the following states (505 front panel screen messages):  Auxiliary is Disabled—Auxiliary is disabled and will have no effect on the LSS bus.
  • Page 90 The other information, such as auxiliary input signal and remote auxiliary set point, will not be passed through this link. If the backup 505 unit is not configured for Auxiliary control, it will revert to speed control authority.
  • Page 91 Cascade set point slow rate is programmed for 10 psi/s, the smallest increment it will move is 0.4 psi (1.2 psi for Modbus). A specific set point may also be directly entered from the 505 keypad or through Modbus communications. When this is performed, the set point will ramp at the ‘Aux Setpt Rate’...

  • Page 92: Remote Auxiliary Set Point

    The Auxiliary set point can be positioned through an analog signal. Optionally, one of the 505’s six analog inputs can be programmed to position the Auxiliary PID set point. This allows the Auxiliary set point to be positioned remotely by a process control or distributed plant control system.

  • Page 93: Valve Limiter

    505 Digital Governor for Single/Split-Range Actuators When the Auxiliary PID is programmed to function as a limiter, the Remote Auxiliary Set Point may be enabled at any time when the 505 is in the RUN mode. When the Auxiliary PID is programmed as a Controller (enabled/disabled), there...

  • Page 94: Emergency Shutdown

    505 to indicate the cause of an emergency shutdown. By wiring trip conditions directly into the 505, instead of a trip string, the 505 can pass a trip signal directly to its output relay (to trip the T&T valve), and also indicate the first trip condition sensed.

  • Page 95: Controlled Shutdown

    Normal Shutdown, control will Transfer to the “Tracking” unit and the shutdown must be completed on that unit. With the control in the run mode and the turbine turning, when the 505’s “STOP” key is pressed, the control will display a message prompting the operator to verify the command (Manual Shutdown ?/Push YES or NO).

  • Page 96: Overspeed Test Function

    Manual 26347V1 The controlled shutdown sequence can be aborted at any time. During a controlled shutdown sequence, by pressing the STOP key, the 505 will display a ‘Manual Shutdown In Ctrl/Push NO to Disable’ message. Pressing the “NO” key from this screen will cause the shutdown sequence to be aborted, and the control to display a ‘Manual Shutdown Stopped/Push YES to Continue’...

  • Page 97: Local/Remote Function

    (F3, F4), or Modbus command. When Local mode is selected, the 505 is defaulted to be operable from its front panel only. This mode disables all contact inputs and Modbus commands, with...

  • Page 98: Function Keys

    TRANSFER button to allow the transfer of control from the In-Control Unit to the Tracking Unit. This button will also be illuminated on the 505 that is In-Control. If the 505 is NOT configured for redundant operation, the F3 key is available for the optional functions discussed below.

  • Page 99: Relays

    As an example, if the F3 key is programmed to allow an operator to enable and disable the 505’s Remote Speed Set Point, when the F3 key is pressed a (Push Yes to Enable/Rmt Spd Setpt Disabled) message will appear on the front panel display.
  • Page 100 The 505 Control Status OK relay is normally energized, and will only de-energize if unit inlet power is lost, the 505’s CPU fails, or the 505 is in the program mode. The Overspeed Test Enable relay will energize when an Overspeed Test is performed.

  • Page 101: Redundant Configuration Operation

    505 functions as a slave controller (Tracking Unit) and tracks the master 505. If the In Control 505 fails for any of the configured reasons, such as any turbine-related I/O signal loss or a user-defined input only wired to this unit, operation is smoothly transferred to the Tracking 505 controller.

  • Page 102: Figure 3-14. Redundant 505 Configuration Diagram

    Baud Rate = 38400, 1 Stop bit, No Parity Driver = 2 for RS-422. 4. Both 505’s “Other Unit OK” contact inputs (BI 05 = Config Contact Input #1) must be connected to the other 505’s “Unit-OK” relay output (BO 03 = Config Relay Output #1).
  • Page 103 505 Digital Governor for Single/Split-Range Actuators The In Control Unit When used in a redundant configuration, the 505 is designed for the In Control 505 to be in control of all turbine parameters during normal operation, with the Tracking unit tracking the In Control 505’s control state and main level parameters.
  • Page 104 Option 1) The default is for this to be done via the 505 keypad using the F3 function key. If the unit is configured for redundancy, then the F3 key is automatically configured for this function.

  • Page 105: Function Commands

    ‘Emergency Trip’ or other Shutdown command. On-Line Unit Replacement When used in a redundant configuration, the 505 is designed such that either unit can be removed and replaced while the other healthy 505 continues to control and operate the turbine on-line. If this is desired, give careful consideration as to which relay output and actuator output connections are made to the end devices.
  • Page 106 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 11. Issue a ‘Reset’ command. At this point the new 505 will reset related faults or alarms and if they clear, will enter Tracking mode and output a trickle current (equal to half of the minimum actuator current) to verify actuator circuit continuity.

  • Page 107: Chapter 4. Configuration Procedures

    Configuration Procedures Program Architecture The 505 is easy to program, due in large part to the menu-driven software. Basic program architecture is illustrated in Figure 4-1. When the control is powered up, and after the brief CPU self test has been completed, the control displays a ready status (Controlling Parameter/Push Run or Program).

  • Page 108: Programming The 505

    Programming the 505 Before the 505 can be used to operate any turbine, it must be configured with a valid program. A handy 505 Program Mode Worksheet is provided in Appendix A of this manual. This chapter contains additional information related to completing this worksheet and programming the specific application.
  • Page 109 ENTER on the 505 keypad the SHUTDOWN CONTROL Y/N prompt will appear. If YES is pressed the 505 will issue a shutdown and the program mode will be accessed. If NO is pressed the 505 will revert to the Select Mode screen and the program mode will not have been accessed.

  • Page 110: Program Blocks

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Program Blocks Figure 4-3 shows the 13 program columns. To program the control, simply step through the blocks as described above and configure the control features for the desired application. The first seven program columns must be programmed for every installation.

  • Page 111: Figure 4-3A. Program Mode Blocks

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 4-3a. Program Mode Blocks Woodward...

  • Page 112: Figure 4-3B. Program Mode Blocks

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Figure 4-3b. Program Mode Blocks Woodward...

  • Page 113: Figure 4-3C. Program Mode Blocks

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 4-3c. Program Mode Blocks Woodward...

  • Page 114: Figure 4-3D. Program Mode Blocks

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Figure 4-3d. Program Mode Blocks Woodward...

  • Page 115: Figure 4-3E. Program Mode Blocks

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 4-3e. Program Mode Blocks Woodward...
  • Page 116 NO (Yes/No) Select YES followed by the ENTER key to configure an automatic start mode. When configured for an automatic start mode, the 505 controls the turbine speed from zero up to the minimum control speed. The Automatic Start Sequence would be: Operator opens the T&T valve, then push RUN.
  • Page 117 Enter YES followed by ENTER if this function is desired. If NO is selected followed by ENTER, then the program will step to ‘Reset Clears Trip Output’ question. If this function is programmed and RUN is selected, the 505 automatically accelerates the speed set point to a programmable low idle...
  • Page 118 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 LOW IDLE DELAY TIME- HOT (MINUTES) dflt= 1.0 (0.0, 500) Enter the hot start hold time at low idle followed by ENTER. This is the programmable time, in minutes/seconds, that the turbine will wait/hold at the low idle speed when a hot start is determined.
  • Page 119 Select YES followed by the ENTER key to allow the external trip input(s) to de- energize the Trip Relay output. When set to NO, an external trip contact input to the 505 will shut down the 505 control but will not de-energize the 505’s trip relay output.
  • Page 120 If all speed inputs fail, the 505 will issue a trip on loss of speed inputs. (Must be greater than or equal to 0.0204 x Overspeed Test Limit Setting)
  • Page 121 OVERSPEED TRIP LEVEL (rpm) dflt= 1000 (0.0, 20000) Set the 505’s overspeed trip level (in rpm) followed by the ENTER key. This is the governor overspeed trip set point only and is not to be used as ultimate overspeed protection.
  • Page 122 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 ON-LINE SLOW RATE (rpm/s) dflt= 5.0 (0.01, 100) Enter the speed set point slow rate in rpm per second followed by the ENTER key. This is the rate of speed change for normal operation when turbine is On-line.
  • Page 123 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators (Next is for redundant configuration only) USE DI TO XFER CONTROL? dflt= NO (Yes/No) Select YES followed by the ENTER key if the controller is going to use a discrete input as the signal to select the In-Control unit. If this is left as NO then Transfer of Control will be via the F3 TRANSFER key on the keypad.
  • Page 124 Set to YES if using the feed-forward loop followed by the ENTER. The feed-forward loop allows an analog input representing the anti-surge valve demand to offset (bias) the 505’s speed reference in order to assist the anti-surge controller. This bias then slowly decreases back to 0 rpm offset in the configured feed-forward action delay.
  • Page 125 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators ACTION DELAY? (s) dflt = 180 (0,1000) Only when ‘Direct feed-forward?’ = NO. Set the minimum response time (lag) needed to remove the effect of the feed-forward loop. After a feed- forward event, when the speed reference is biased by the feed-forward loop, this parameter determines how long it takes (minimum) for the offset to ramp back to 0 rpm (no speed reference offset).
  • Page 126 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 EMRG MAX FORWARD RATE (%/s) dflt = 100 (7,100) Set the maximum effective rate (positive direction) of the feed-forward analog input, when increasing, followed by the ENTER. This sets the highest level of response for the Emergency Feed-Forward Loop based on the 4-20 mA signal’s rate of increase.
  • Page 127 Select YES followed by ENTER to issue a trip whenever an actuator fault is detected. If YES, the 505 will issue a shutdown if Actuator 1 has a fault. If NO, an actuator fault alarm will be issued when a fault is detected. An...
  • Page 128 Select YES followed by ENTER to issue a trip whenever an actuator fault is detected. If YES, the 505 will issue a shutdown if Actuator 2 has a fault. If NO, an actuator fault alarm will be issued when a fault is detected. An...
  • Page 129 NO (Yes/No) Select YES followed by the ENTER key if the controller is going to be redundant with another 505, it will configure Contact Input 1 for Other Unit OK and skip the function options for Contact Input 1...
  • Page 130 The I/H-Act1 and I/H-Act2 Flt Contact Input options can be configured to provide more protection in case of an actuator failure. These can be used as the input for a Woodward CPC fault relay output, for example. When configured, this input will produce an alarm in the 505 when it is operating as a standalone unit or a Shutdown/Transfer condition if the unit is configured as a redundant 505.
  • Page 131 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators F3 KEY / TRANSFER If the unit is configured for redundancy, then the F3 key is automatically configured for as a TRANSFER command. The F3 key will be illuminated on the unit that is In-Control and this key will allow the user to transfer control from this unit to the other unit.
  • Page 132 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 INVERT AUX INPUT? dflt= NO (Yes/No) Select YES followed by ENTER if the auxiliary control will be reverse acting. If NO, then the control will be forward acting. Typically this will be set to NO, the only time the input would be inverted is if the valve needs to open when the input exceeds the set point.
  • Page 133 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators GENBRKR OPEN AUX DSBL ? dflt= YES (Yes/No) Select YES followed by ENTER if the auxiliary control will be disabled when the generator breaker opens. If NO is selected, then auxiliary control will not be disabled when the generator breaker is opened.
  • Page 134 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 SETPT INITIAL VALUE (UNITS) dflt= 100.0 (-20000, 20000) Set the set point initialization value followed by ENTER. When not using the Set Point Tracking function, this is the value that the cascade set point initializes to upon power-up or exiting the program mode.
  • Page 135 REDUNDANT 505? dflt= NO (Yes/No) Select YES followed by the ENTER key if the controller is going to be redundant with another 505, it will configure Relay #1 for Unit OK and skip the function options for Relay #1 Woodward...
  • Page 136 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 USE RELAY # 1? dflt= NO (Yes/No) Press Set to YES followed by ENTER to use this relay output. Press NO followed by ENTER to skip to the next ‘USE RELAY’ question.
  • Page 137 NO (Yes/No) Set to YES followed by ENTER to use the Modbus communications feature of the 505. There are two identical Modbus ports available. Either or both can be configured for use. Select NO followed by ENTER if Modbus communications will not be used.

  • Page 138: Exiting The Program Mode

    (refer to Figure 4-4 Exiting the Program Mode). To exit the Program mode the “CLEAR’ key is pressed twice. This initiates the 505 to save the configuration and to begin a Configuration Check procedure. If there are no errors in the programming, the 505 front-panel will return to the ready state and display the ‘Controlling Parameter/Press Run or Program’...
  • Page 139 Program mode under the Start Block. Speed > 15000 Hz—The maximum speed input is 15000 hertz. This is a limitation of the 505’s hardware/speed sensing circuitry. The frequency input of the speed sensor must be less than this value. The gear the speed sensor is mounted on may need to be changed to one with less teeth, this will decrease the frequency seen by the speed probes.
  • Page 140 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 No Utility Brkr Config—The unit is programmed for a generator application but no utility tie breaker contact input was programmed. This is a requirement. No Gen Brkr Config—The unit is programmed for a generator application but no utility tie breaker contact input was programmed.
  • Page 141 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators No Cascade Analog Input—The cascade control function was programmed but no cascade analog input was configured. No Rmt Casc Input Prgm—The remote cascade set point control function was programmed but no remote cascade set point analog input was configured.

  • Page 142: Valve/Actuator Calibration & Test

    505 to valve resolution. Figures 4-5 and 4-6 graphically show the steps available to stroke the actuator output(s). The stroking option is only available when the 505 control is in a shutdown state. Also, the screens displayed varies with the number of actuators programmed.

  • Page 143: Calibration/Stroking Procedure

    STEAM TO THE TURBINE MUST BE SHUT OFF BY OTHER MEANS DURING THIS PROCESS. 1. The 505’s Emergency shutdown contact input must be closed or jumpered throughout this procedure (or the 505’s actuator current output will go to ZERO current).

  • Page 144: Calibration/Stroking Procedure

    When calibration is complete, 0 to 100% valve position as displayed by the 505 must equal 0 to 100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the “CLEAR” key twice to save changes and exit Calibration mode.
  • Page 145 When calibration is complete, 0 to 100% valve position as displayed by the 505 must equal 0 to 100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the “CLEAR” key twice to save changes and exit Calibration mode.
  • Page 146 When calibration is complete, 0 to 100% valve position as displayed by the 505 must equal 0 to 100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the “CLEAR” key twice to save changes and exit Calibration mode.

  • Page 147: Figure 4-5. Stroke Actuator

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 4-5. Stroke Actuator Woodward...

  • Page 148: Figure 4-6. Stroking Dual Actuators

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Figure 4-6. Stroking Dual Actuators Woodward...

  • Page 149: Chapter 5. 505 Operation

    Run Mode and the Program Mode. The Program Mode is used to configure the 505 for the specific application and set all operating parameters (see Chapter 4). The Run Mode is simply the normal turbine operation mode and is used to view operating parameters and run the turbine.

  • Page 150: Figure 5-2A. Overview Of Run Mode

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Figure 5-2a. Overview of Run Mode Woodward...

  • Page 151: Figure 5-2B. Overview Of Run Mode

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 5-2b. Overview of Run Mode Woodward...

  • Page 152: Figure 3-4. Idle/Rated Start

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Trip Controlling Parameter Remote Messages Messages Messages Message 8 Message 7 Message 4 External Trip Input Shutdown Disabled Emrg Shutdown Button Controlled Shutdown Inhibited Overspeed Max Actuator Enabled All Speed Probes Failed...

  • Page 153: Keypad And Display

    505, make On-Line program adjustments, and operate the turbine/system. No additional panels are required to operate the turbine, every turbine control function can be from the 505’s front panel. However, the turbine can also be operated remotely. Every front panel control operation can be performed remotely through contacts or Modbus communications.

  • Page 154: Starting Procedures

    An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate. 1. Press the RESET key to clear all alarms and trips. If the 505’s RESET CLEARS TRIP setting is programmed "YES", the 505's shutdown relay will reset or energize upon pressing the RESET key after a shutdown.

  • Page 155: Speed Key Screens

    Idle/Rated Start For details on the idle/rated start-up, refer to Chapter 3. When a RUN command is issued, the 505 automatically displays the SPEED screen and shows the Idle/Rated status. The speed set point is instantly set to the actual turbine’s speed.
  • Page 156 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 When the speed set point is ramping to the Rated Set Point setting it can be stopped at any point that is not within a critical speed avoidance band by issuing a Speed Setpt Raise or Lower command. This can be done by pressing the...

  • Page 157: Auto Start Sequence

    505 Digital Governor for Single/Split-Range Actuators Auto Start Sequence When a RUN command is issued, the 505 automatically displays the SPEED screen (unless used with the Semiautomatic start mode) and shows the Status of the Auto Start Sequence (screen 2). The Speed set point is instantly set to the turbine’s actual speed and the sequence will continue from this point.

  • Page 158: Figure 5-5. Direct Set Point Entry

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 The Speed set point can also be directly entered from either of the Modbus links, however, the allowed range is between the minimum and maximum governor speed settings. The allowed set point range is limited between the minimum load and the maximum governor settings if the unit is driving a generator and the unit is on-line.

  • Page 159: Overspeed Test Function

    “Tracking” mode during this test. If the unit is shut down, it will trip the turbine on overspeed since the overspeed protection logic in the 505 is always active. If desired, the set point in the tracking unit can be raised to ensure that the In Control unit would have tripped the turbine.

  • Page 160: Transfer Key Screens (Redundant Only)

    If an external device’s trip setting is being tested the Speed Set Point can be raised up to the 505’s OVERSPEED TEST LIMIT setting, by not releasing the OSPD key and continuing to adjust the 505’s Speed Set Point. The Overspeed Test LED will blink at a faster rate when the OVERSPEED TEST LIMIT is reached, indicating the maximum speed set point is reached and the unit should have tripped on the external trip device.

  • Page 161: F3 And F4 Keys

    505 Digital Governor for Single/Split-Range Actuators F3 Transfer Control Messages: Unit Status Message This Unit is Shows the current status of this 505 Control In-Control, Tracking or Shutdown Transfer Options Message Transfer Disabled Transfer to other unit Inhibited (Link problem or SD)

  • Page 162: Actuator (Actr) Key Screens

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 The following valve limiter indications are available through the Modbus links: Valve Limiter at Min, Valve Limiter at Max, and Valve Limiter In Control of actuator output. In addition to these indications the Valve Limiter Set Point, Actuator LSS, Actuator #1 Output and Actuator #2 Output analog values are also available.

  • Page 163: Control (Cont) Key Screens

    Figure 5-10 shows the screens that appear when the CONT key is pressed. The CONT key allows operators to monitor what 505 parameter (PID or limiter) is controlling governor valve position (screen 1). From screen 2 the cause of the last turbine shutdown can be viewed and from screen 3 the highest turbine speed reached can be viewed and cleared, if desired.

  • Page 164: Figure 5-10. Cont Key Screens

    Idle/Rated Start The 505 is running and in the Idle/Rated sequence mode Auto Start Sequence The 505 is running and in the Automatic Start Sequence mode Remote/Speed Speed PID is in control, the Speed Set Point is in remote control...

  • Page 165: Dynamics (Dyn) Key Screens

    To adjust the gain settings, the @ symbol must be on the respective display line of the value to be adjusted. The @ symbol is moved by pressing the SELECT key. The controller dynamics are adjustable from the 505’s Service panel only, they cannot be adjusted remotely. Figure 5-11. DYN Key Screens...

  • Page 166: Stop Key Screens

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Stop Key Screens Figure 5-12 shows the possible screens that may appear if the STOP key is pressed. The STOP key is used to perform a controlled/manual turbine shutdown or stop. To perform a Manual Shutdown, select YES from the Status screen or close the Controlled Shutdown contact input (if programmed) or select Controlled Shutdown from a Modbus communications link.

  • Page 167: Figure 5-13. Aux Key Screens

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 5-13. AUX Key Screens Auxiliary as a Controller (using Enable/Disable) When auxiliary control is used as a controller, as opposed to a limiter, the enable/disable function is used to select Auxiliary control. Auxiliary control can be...
  • Page 168 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Auxiliary control is disabled by pressing the front panel NO key from the Aux Status screen (screen 2), opening the Aux Control Enable/Disable contact (if programmed), or selecting “Aux Disable” from either Modbus communications link see Table 5-5).

  • Page 169: Remote/Speed Bias (Rmt) Key Screens

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Relay indications can be programmed to indicate Aux Control Active, Aux Control Enabled, or Aux PID In Control status’. Remote Aux Set Point The Remote Auxiliary Set Point function is used to allow the Auxiliary set point to be remotely positioned by an analog input.

  • Page 170: Figure 5-14. Rmt Key Screens

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Figure 5-14. RMT Key Screens Remote Speed Set Point The Speed PID set point can be remotely set by an analog input, if programmed. This Remote Speed Set Point input can be enabled by pressing the front panel...
  • Page 171 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators The following Remote control indications are available through the Modbus links: Remote Speed Setpt is Enabled, Remote Speed Setpt is Active, Remote Speed Setpt is In Control, Remote Speed Setpt is Inhibited, and the Remote Speed Setpt Input Failed Alarm.

  • Page 172: Unit Load (Kw) Key Screens

    The bottom line of the display on screens 1, 2, & 3 show the Load Set Point. This value and units change depending on the droop mode the 505 is presently using. If the droop is based on the KW input, the units are in ‘KW’ or ‘MW’. If the droop is LSS/Speed Demand (governor valve position), the units are in ‘rpm’.

  • Page 173: Cascade (Cas) Key Screens

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Cascade (CAS) Key Screens For this key to be active, the Cascade function must be programmed. Figure 5-16 shows the possible screens that may appear if the CAS key is pressed. Only the screens related to the Cascade functionality programmed will be displayed.
  • Page 174 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 The Cascade set point can be configured to either track the input for bumpless transfer into control or remain at the last setting. When using the tracking option, the cascade set point cannot be changed until Cascade control is enabled.

  • Page 175: Alarms

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Message 4 Meaning Disabled Remote is not selected Inhibited Remote is inhibited and cannot be enabled Enabled Remote is enabled but not in control of the Setpt Active Remote is in control of the Setpt but not in control of the...
  • Page 176 Each individual alarm condition is available through the Modbus links to monitor the control status. A common alarm indication is also provided. Relay indications can be programmed to indicate a 505 Common Alarm, in addition to the dedicated Alarm Relay output.

  • Page 177: Trips

    Generator Breaker Open Generator breaker was opened after it was closed Power Up Trip 505 lost power and CPU was reset or the Program mode was exited HP Ramp at Max/No Spd HP Valve Limiter ramp is at Max but no speed is detected...

  • Page 178: Speed, Cascade, And Auxiliary Dynamics Adjustments

    D = Derivative (determined by DR and I) If an older type 505 is being replaced by a new 505, the “ P & D ” terms will be the same, however, the “ I ” term should be reduced by a factor of 10 from the old 505’s reset value to achieve the same control response.
  • Page 179 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators In cases where a small change in the 505's output results in a large speed or load change (high mechanical gain) it may not be possible to take the 505's gains low enough to reach stable operation. In those cases the mechanical interface (actuator, linkage, servo, valve rack) design and/or calibration should be reviewed and changed to achieve a gain of one where 0–100% 505 output...

  • Page 180: Tuning Derivative

    1 second reduce the Integral gain term (proportional gain may need to be increased also). On an initial start-up with the 505, all PID dynamic gain terms will require adjustment to match the respective PID’s response to that of its control loop.

  • Page 181: Figure 5-19. Typical Response To Load Change

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Figure 5-19 shows the typical response to a load change when the dynamics are optimally adjusted. Figure 5-19. Typical Response to Load Change For additional information on PID settings, refer to Volume 2.

  • Page 182: Chapter 6. Communications

    By simply connecting a monitoring device, configured to communicate through Modbus, and to the 505’s defaulted protocol settings (parity, stop bits, etc.), this device can be used to monitor all the 505’s controlling parameters, modes, etc. without affecting control.

  • Page 183: Modbus Communication

    Program Mode and can be adjusted in the Service Mode, if required. The 505 control is programmed to function as a slave unit only. As a slave unit, the 505 will only respond to a transaction request by a master device. The 505 can directly communicate with a DCS or other Modbus supporting device on a single communications link, or through a multi-dropped network.

  • Page 184: Figure 6-2. Modbus Frame Definition

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Each message to or from a master has a defined structure called the message “frame”. A frame consists of the slave device address, a code defining the requested data, and error checking information. See Figure 6-2.

  • Page 185: Port Adjustments

    All read/write registers are interpreted by the 505 as signed 16 bit integer values. Since Modbus can only handle integers, values that require a decimal point in the Modbus Master Device are multiplied by a scaling constant before being sent by 505.
  • Page 186 The holding coils available are listed in Table 6-5. Boolean Reads (Input Coils) Input coils are logical signals that are readable from, but not writable to, the 505 control. An example of an Boolean read value would be a turbine trip status indication.
  • Page 187 505 Digital Governor for Single/Split-Range Actuators Analog Writes (Holding Registers) Holding registers are analog values that are writable to the 505 control. These values can also be read from by a device performing error checking. An example of an analog write value would be a direct speed set point value as opposed to raise and lower commands.
  • Page 188 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Addr Description Addr Description 1:0001 Alarm - MPU #1 Failed 1:0060 * Trip - External Trip 6 1:0002 Alarm - MPU #2 Failed 1:0061 * Trip - External Trip 7 1:0003 Alarm - Cascade Input Failed...
  • Page 189 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators 1:0119 * Startup Complete 1:0171 Contact In 9 Closed 1:0120 * Spare E 1:0172 Contact In 10 Closed 1:0121 * Spare E 1:0173 Contact In 11 Closed 1:0122 * Spare E 1:0174...
  • Page 190 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 1:0229 Modbus 1 ESD Configured 1:0240 * Spare 1:0230 * Tracking other 505R 1:0231 * Redundant Configured 1:0232 * Master 505 Configured 1:0233 Controlled Stop In Progress Table 6-6. Boolean Read Addresses...
  • Page 191 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators 3:0050 Actuator 2 Demand (%) x100 3:0051 * Spare E 3:0052 * Spare E 3:0053 * Spare E 3:0054 * Spare E 3:0055 * Spare E 3:0056 * Spare E 3:0057 * Spare E...
  • Page 192 3:0144 Speed Derivative signal rpm/s 3:0145 Speed Accel Rate (%/s of Overspeed Limit x10) Table 6-7. Analog Read Addresses *—Denotes differences between 505 and 505 Enhanced. Analog Writes: Addr Description Units Multiplier 4:0001 Modbus Entered Speed Set Point...

  • Page 193: Controlling Parameters

    Table 6-9. Last Turbine Trip Cause 505 Controlling Parameters The controlling parameter status of the 505 uses an Analog Read register (3:0001) to identify the parameters that are in control. This variable follows what is displayed on the controlling parameter screen, under the ‘CONT’ key. The variable gives the current status of the control and is defined in the following table.
  • Page 194 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Analog Read addresses 3:0088—0093 give the configuration value of the analog inputs, one to six in order. The configuration for the analog inputs are defined in the table below. Value Description Remote Speed Setpt...
  • Page 195 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Value Description Relay Configured As Level Switch Speed Level Switch Speed Set Point Level Switch KW Level Switch Load Share Level Switch Cascade Level Switch Cascade Set Point Level Switch Aux Level Switch...
  • Page 196 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Value Description Value Description Generator Breaker External Trip 4 Utility Tie Breaker External Trip 5 Overspeed Test Controlled Shutdown External Run External Trip 7 Start Permissive External Trip 8 Idle/Rated External Trip/XFER 9...

  • Page 197: Specific Address Information

    (6015/100 = 60.15). A Directly Entered Cascade Set Point (4:0002) of 61.5 would be sent across the link as 6150 and the 505 automatically divides the value by the Casc Scale Factor and uses the value of 61.5 as the set point desired.

  • Page 198: For More Modbus Information

    Two different types of shutdown commands (emergency and controlled) can be issued through Modbus. The Emergency Shutdown command instantly takes the speed set point and actuator current to zero. Optionally the 505 can be configured to ignore this Emergency Shutdown command if it is desired to not allow the unit to be tripped through Modbus.

  • Page 199: Chapter 7. Service Options

    Woodward systems and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc. You can locate your nearest Woodward distributor, AISF, RER, or RTR on our website at: www.woodward.com/directory...

  • Page 200: Woodward Factory Servicing Options

    Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in “like- new” condition and carry with it the full standard Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option is applicable to mechanical products only.

  • Page 201: Packing A Control

    Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website.  Technical Support ...

  • Page 202: How To Contact Woodward

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 How to Contact Woodward For assistance, call one of the following Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service.

  • Page 203: 505 Program Mode Worksheets

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Appendix A. 505 Program Mode Worksheets Governor Serial Number ______________________ Application ________________________________ Date ___________ For details on individual settings, refer to Chapter 4. TURBINE START SPEED CONTROL Manual Start Teeth Seen by MPU...
  • Page 204 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 OPERATING PARAMETERS DRIVER CONFIGURATION Redundant 505 Act#1 is 4–20 mA? Master 505 Invert Driver Output? Use DI to XFER Control Use Act 1 Flt Shutdown Type of Actuator Single Coil shared Act#1 Dither...
  • Page 205 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators ANALOG INPUTS CASCADE CONTROL Analog Input # 1 Function Use Cascade Control? Input 1 4 mA Value Units Invert Cascade ? Input 1 20 mA Value Units Min Cascade Setpt Units Analog Input # 2 Function...
  • Page 206 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 RELAYS COMMUNICATIONS Redundant 505? Use Communications ? Use Relay #1? Use Modbus Port 1? Relay # 1 is Level Switch? Mode Ascii=1 Rtu=2 Relay 1 Is Level Sw For Modbus Device #...

  • Page 207: 505 Marine 8923-1704

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Appendix B. 505 Marine 8923-1704 Woodward...
  • Page 208 505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Woodward...
  • Page 209 Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Woodward...

  • Page 210: Revision History

    505 Digital Governor for Single/Split-Range Actuators Manual 26347V1 Revision History Changes in Revision L—  Added recommendation to not use Actuator 2 in redundant configurations  Removed notes related to the auto-reset function for failed sync / load share inputs ...

  • Page 211: Declarations

    Manual 26347V1 505 Digital Governor for Single/Split-Range Actuators Declarations Woodward...
  • Page 212 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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