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Woodward AtlasPC 505CC-2 Hardware And Installation Manual
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Woodward AtlasPC 505CC-2 Hardware And Installation Manual

Woodward AtlasPC 505CC-2 Hardware And Installation Manual

Steam turbine and compressor control
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Product Manual 26240V1
(Revision B)
Original Instructions
505CC-2 Steam Turbine
and Compressor Control
Volume 1, Hardware and Installation Manual
INACTIVE
Part Number 8701-1114
(current P/N is 8701-1356, in manual 26451)
Manual 26240 consists of 4 volumes (26240V1, 26240V2, 26240V3, & 26240sup).
Hardware and Installation Manual

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Summary of Contents for Woodward AtlasPC 505CC-2

  • Page 1 Product Manual 26240V1 (Revision B) Original Instructions 505CC-2 Steam Turbine and Compressor Control Volume 1, Hardware and Installation Manual INACTIVE Part Number 8701-1114 (current P/N is 8701-1356, in manual 26451) Manual 26240 consists of 4 volumes (26240V1, 26240V2, 26240V3, & 26240sup). Hardware and Installation Manual...
  • 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 Hardware Specifications ..................92   CPU Interface Connections .................. 93   6. S ......... 95  HAPTER MART OARD WITH CTUATORS General Description ....................95   Specifications ....................... 97   SmartCore Board Operation ................100   Troubleshooting Guide ..................112   Woodward...
  • Page 4 General Information ....................126   Specifications ......................127   Mounting ......................127   Wiring ........................128   A. D ....129  PPENDIX EFAULT ECURITY EVEL ASSWORDS B. F ..............130  PPENDIX LASH ODES C. C ..........131  PPENDIX ONFIGURATION ORKSHEET ..................133  ECLARATIONS Woodward...
  • Page 5 Figure 6-5. Wiring Example–Proximity Probe to the SmartCore Board ..... 101   Figure 6-6a. Wiring Example–4–20 mA Input Interface to the SmartCore Board ..................... 102   Figure 6-6b. Wiring Example–4–20 mA Input Interface using External Loop Power ..................... 102   Woodward...
  • Page 6   Table 5-1. Ethernet Port Pinout ................94   Table 6-1. SmartCore Failure Codes..............111   Table 7-1. Analog Combo Failure ...............121   Table B-1. SmartCore with Actuators Failure Codes .........130   Table B-2. Analog Combo Failure Codes ............130   Woodward...
  • Page 7 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 8 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 9 Volume 3—Compressor Control This volume describes the 505CC-2’s hardware platform, which is based on the Woodward AtlasPC™ Digital Control. It provides a variety of useful information for the user ranging from simple basic descriptions to detailed information on wiring, specifications, functionality, and initial software configuration.. Included are: ...
  • Page 10 AtlasPC control, the user can view variables and tune the control with a variety of Woodward service tools. Connection to other devices, such as an HMI or DCS system, is accomplished by means of serial Modbus ports on the control.
  • Page 11 Touchscreen HMI as Woodward part number 8928-7037 (see Chapter 9).  Optional Relay Output Module (8928-459)—Because the AtlasPC control requires interposing relays on its discrete output channels, an optional relay output module with cable is available as Woodward part number 8928-459 (see Chapter 8). Woodward...
  • Page 12 RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf en cas l’ambiance est décidément non dangereuse. La substitution de composants peut rendre ce matériel inacceptable pour les emplacements de Classe I, Division 2 ou Zone 2. Woodward...
  • Page 13 Det Norske Veritas Standard for Certification No. 2.4, 2001: Temperature Class B, Humidity Class B, Vibration Class C, and EMC Class A Lloyd’s Register of Shipping LR Type Approval Test Specification No. 1, 2002 for Environmental Categories ENV1, ENV2, and ENV3 Woodward...
  • Page 14 505CC-2 Hardware & Installation Manual Manual 26240V1 5.1 (0.203) THRU HOLES 281.9 (11.100) 260.4 (10.250) 130.2 (5.125) 10.8 (0.425) 168.3 (6.625) 10.8 (0.425) 336.6 (13.250) 358.1 (14.100) 15.9 (0.625) 142.2 (5.600) Figure 1-2. Physical Dimensions (dimensions shown in millimeters (inches)) Woodward...
  • Page 15 10 lb), and has an operating range of –20 to +70 °C ambient air temperature. A minimum of 25 mm (1 inch) of clear space around the outer surfaces of the AtlasPC is adequate for ventilation, however approximately 75 mm (3 inches) of space may be required for wiring, depending on wire size. Woodward...
  • Page 16 After AtlasPC input power is disconnected, the terminal blocks can be removed one at a time by pulling them straight out. Be careful not to pull the plug out at an angle, as this will fracture the end terminal. Woodward...
  • Page 17 This connection will be made using a thread-forming screw (M4 x 6 mm). The conductor providing the connection shall have a properly sized ring lug and wire larger than or equal to 3.3 mm² (12 AWG). Woodward...
  • Page 18 150 kHz and up. Multiple direct connections of a shield to earth risk high levels of current to flow within the shield. See Woodward application note 50532, Interference Control in Electronic Governing Systems, for more information.
  • Page 19 Significant inrush currents are possible when current is applied to the AtlasPC control. The magnitude of the inrush current depends on the power source impedance, so Woodward cannot specify the maximum inrush current. Time- delay fuses or circuit breakers must be used to avoid nuisance trips.
  • Page 20 Reinstall fan guard and secure with the 4 screws.  Trim leads to a reasonable length.  Connect RED wire to the + fan terminal and BLACK wire to - fan terminal.  If desired strain relief leads to cover with a new tie-wrap. Woodward...
  • Page 21 Machine Interface). For hardware troubleshooting help, see the individual chapters describing each board. Turbine I/O / SmartCore Board Most turbine I/O are connected to the AtlasPC SmartCore Board, which is the bottom, full size board in the stack. Table 3-1 lists the SmartCore Board I/O assignments. Woodward...
  • Page 22 RS-232 Serial Port, DB9 Connector SCM-COM3 Serial Port #2 SIO #2 RS-232 / RS-422 / RS-485 Serial Port SCM-TB9 83-92 Serial Port #1 SIO #1 RS-232 / RS-422 / RS-485 Serial Port SCM-TB10 93-102 Table 3-1. AtlasPC SmartCore Board I/O List Woodward...
  • Page 23 No loop power is provided. If loop powered (2-wire) transmitters are used, an external power supply must be utilized. In this case, it is recommended that loops be individually protected with 100 mA fuses. See Figure 3-4 for a sample wiring connection. Woodward...
  • Page 24 Selection between the two is by wiring connection. Jumpers are required when connecting proximity probes. See Figure 3-5 for wiring examples for each. Atlas Atlas Active Pickup Jumper Passive (isol) PNP Type Figure 3-5. SmartCore Speed Input Connections Woodward...
  • Page 25 Figure 3-7. SmartCore Actuator Output Connection Figure 3-8 provides an overall, sample wiring diagram for the turbine I/O on the SmartCore Board. Turbine configurations vary, so this is provided as an example only. The speed input connections shown are for MPUs. Woodward...
  • Page 26 Modbus. COM #3 provides a DB-9 connection and is dedicated as RS-232 for use with Woodward software tools. SIO #1 and SIO #2 provide Modbus interfaces to third-party devices and are software configurable for RS-232, RS- 422, or RS-485.
  • Page 27 LP / V2 Inlet HP / V1 Steam Turbine Exhaust Analog Inputs #1-5 Speed inputs shown Turbine Configurable wired as passive MPUs COM #3 SIO #2 SIO #1 Analog Outputs #1-4 Turbine Configurable Figure 3-8. Turbine I/O / SmartCore Connections Woodward...
  • Page 28 505CC-2 Hardware & Installation Manual Manual 26240V1 855-742A 02-6-17 Figure 3-9. SmartCore Board with Actuators Connections Woodward...
  • Page 29 RS-232 Serial Port, DB9 Connector SCM-COM# Serial Port #2 SIO #2 RS-232 / RS-422 / RS-485 Serial Port SCM-TB9 83-92 Serial Port #1 SIO #1 RS-232 / RS-422 / RS-485 Serial Port SCM-TB10 93-102 Table 3-2. AtlasPC SmartCore Board I/O List Woodward...
  • Page 30 100 mA Fuse 100 mA Fuse 4-20 mA 4-20 mA Transducer Loop Transducer Loop Powered Powered (-) Loop Power Analog Analog Input #1 Input #12 (-) Loop Power Figure 3-10. Analog Combo Analog Input Connections (Inputs 1-11 and 12-15) Woodward...
  • Page 31 Configurable analog outputs are provided on the SmartCore Board. See Figure 3-6 for a wiring example. Figure 3-12 provides an overall, sample wiring diagram for the compressor I/O on the SmartCore and Analog Combo Boards. Compressor configurations vary, so this is provided as an example only. Woodward...
  • Page 32 * SmartCore Board * * Analog Combo Board * COM #3 * Analog Combo Board * * SmartCore Board * Analog Inputs #18-21 Analog Outputs #5-6 Compressor Configurable Compressor Configurable Figure 3-12. Compressor I/O / SmartCore / Analog Combo Connections Woodward...
  • Page 33 18-32 Vdc External Relay Power PS-TB6 22-23 Table 3-4. AtlasPC Power Supply Board I/O List See Figure 3-14 for sample relay wiring using external relays or an optional Woodward 12-Channel Relay Module. See Chapter 8 for more information on the Woodward Relay Module. Woodward...
  • Page 34 65 Watts 18-32 VDC * Analog Combo Board * * Power Supply Board * * Analog Combo Board * Customer Supplied 18-32 VDC Customer Supplied Interposing Relays or Optional Woodward 12-Channel Relay Module Figure 3-14. AtlasPC Power Supply Board Connections Woodward...
  • Page 35 Manual 26240V1 505CC-2 Hardware & Installation Manual Figure 3-15. Optional 12-Channel Relay Module Connections Woodward...
  • Page 36 100 Base-TX or an auto-switching 10/100 Base-TX hub would be necessary. Use shielded Ethernet cable only! Use of non-shielded cable may result in permanent system damage. Ethernet Hub / Switch Optional TouchScreen HMI Figure 3-16. Connection to an Ethernet LAN Woodward...
  • Page 37 AStudio components will be copied. If desired, deselect Demo Files, WinCE 3.0, WinCE 4.x, and Web Tunneling Gateway as shown in Figure 3-18—These are not used by the 505CC-2 HMI/CCT. However, leaving them selected will not cause any problems. Woodward...
  • Page 38 SOS installer. The third piece of software to be installed is Woodward’s Application Manager (AppManager). In addition to providing control over the 505CC-2’s application software, AppManager is the most reliable method for verifying the control’s...
  • Page 39 OPC server configuration must be modified. The simplest way to verify the address is by connecting to the control with Woodward’s AppManager software (available on the HMI/CCT installation CD). See the IP Addresses section later in this chapter for more information.
  • Page 40 Connect TCP. After connecting to the 505CC-2 and polling its OPC tags, the SOS server will indicate a successful connection. Under the File menu, select Save as Default Configuration to save the new IP address as SOS’s default. Woodward...
  • Page 41 To manually shutdown such a session, open the Windows Task Manager (Ctrl-Alt-Del), select the Processes tab, and find and end SOS.exe (see Figure 3-21). Figure 3-21. Windows Task Manager – SOS.exe Process Woodward...
  • Page 42 Upon startup, the uppermost, or home screen, the Main Menu, is available. See Figure 3-23 for an example of the Main Menu Screen and the common screen header and footer. Woodward...
  • Page 43 Select the Unit Overview button to jump to the Unit Overview graphics screen. The Communications Health indicator will blink if the communications link (Modbus) is failed. Once communications are restored and the alarm acknowledged and reset, the indicator will return to normal. Woodward...
  • Page 44 Column widths and sorting are also adjustable via the column headers. The Alarm History screen, similar to the Summary screen shown above, maintains a running list of alarm, acknowledge, and return-to-normal events. The Event History screen lists pre-defined, time-stamped control events. Woodward...
  • Page 45 The same Online Trending screen may be launched by trend buttons located throughout the HMI—The trend will be loaded with data relevant to the button’s location. Woodward...
  • Page 46 Online Trending and four hours for Historical Trending. It may be expanded to 24 hours in either case. The slider at the bottom of the trend will adjust the current view within a 24-hour period. Simply adjusting the Preceding Hours value will do the same. Woodward...
  • Page 47 Save Trend button to access the Trend File Save pop-up. Assign a file name as desired and select Save. A custom configured trend, as well as any existing default trend, may be loaded via the Load Trend button. Select any available trend from the browse window, and select Load. Woodward...
  • Page 48 500 MB. Log-in / Security Levels In the upper left corner of the screen is an indicator of the current log-in level— Click the button to change levels as shown in Figure 3-27. Figure 3-27. Log-in Level Woodward...
  • Page 49 Configuration mode when the unit is shutdown. Upon exiting Online Configuration into Monitor, the control is re-initialized and the new settings will take effect. Other parameters (PID tuning, speed setpoints, etc.) can safely be changed online and, as such, are available in the Engineering and Service levels. Woodward...
  • Page 50 If the control rejects a value that is greater than 10%, re-enter smaller values until the desired value is reached. See the applicable turbine and compressor control manuals for detailed configuration and operation instructions. The following sections provide system level configuration instructions. Woodward...
  • Page 51 The Configuration Menu screen provides single button access to all turbine and compressor configuration screens, configuration file management, and system configuration. Select the System Configuration button to access that screen, facilitating system level configuration including Modbus setup. See Figure 3-29. Woodward...
  • Page 52 “ComputerName” on a tag on the top of the AtlasPC control. The IP Address is defaulted to 190.14.99.220, but it, along with the Control ID, may be verified by connecting to the control with Woodward’s App Manager software, available on the installation CD. These parameters may be configured in the Offline Configuration mode—Then, revert to...
  • Page 53 External Trip 4 Discrete Input External Trip 5 Discrete Input Override MPU Fault Discrete Input Start Permissive Discrete Input Select Online Dynamics Discrete Input Local/Remote Discrete Input Local/Remote Modbus Command (if Modbus is configured) Trip/ESD Modbus Command (if Modbus is configured) Woodward...
  • Page 54 Select the Enable Contacts option to also enable discrete input commands in Local mode. Likewise, Modbus commands can be enabled in Local mode, but one or both Modbus ports must be configured and the respective Enable Commands option selected, as described above and shown in Figure 3-30. Woodward...
  • Page 55 Local/Remote, all commands would be enabled. Configuration File Management As shown in Figure 3-28, the Configuration Menu screen provides a File Upload/Download button to access the Configuration File Management screen, shown in Figure 3-32. Figure 3-31. System Configuration Screen Woodward...
  • Page 56 The configuration is saved as a .XML recipe file in the \WGFiles subdirectory of the Advantech Studio program installation. A typical path would be C:\Program Files\Advantech Studio v6.0\Projects\505CC-2\WGFiles, but this will vary if the path was altered during installation. Woodward...
  • Page 57 Files\Advantech Studio v6.0\Projects\505CC-2\Datalogs, but this will vary if the path was altered during installation. These datalogs are viewable with Woodward’s Control Assistant software, available on the installation CD. Their format is comma-delimited text, so they may also be opened in other editing or trending software.
  • Page 58 The IP address of the laptop computer must be changed to “match” that of the control for the two to communicate. Below are typical instructions for changing the IP address of a Microsoft Windows 2000 compatible computer. Select Settings … Control Panel from the Start Menu. Woodward...
  • Page 59 Manual 26240V1 505CC-2 Hardware & Installation Manual Select Network and Dial-up Connections. Select Local Area Connection. Woodward...
  • Page 60 505CC-2 Hardware & Installation Manual Manual 26240V1 Click the Properties button. Woodward...
  • Page 61 AppManager is launched, it will search for all connected controls, whether one connected directly by an Ethernet crossover cable or several on an Ethernet LAN. All connected controls will be displayed by name and IP address in the left pane of the AppManager window. Woodward...
  • Page 62 To allow changing the IP address, the application software must be stopped. Select the application name, 5418-1740.out, in the right pane of the AppManager window. Then, click the Stop button in the toolbar, or select Stop Application from the Control menu. Woodward...
  • Page 63 Manual 26240V1 505CC-2 Hardware & Installation Manual AppManager will request confirmation before stopping a running application. Woodward...
  • Page 64 If a valid address is entered, the readdressing process will continue as described below, but on its own, AppManager will stop the application software, if running. It is always preferred to manually stop the application as described above, thereby ensuring that the unit has been properly secured. Woodward...
  • Page 65 AppManager will prompt for a new IP address. If installed on an Ethernet LAN, a DHCP server can assign the address, or one may be specified directly. Select OK. Then, select Yes at the confirmation prompt to proceed with the change. Woodward...
  • Page 66 The application software must now be restarted. As before, select the control name to highlight it. Then, select the application name, 5418-1740.out, in the right pane. Click the Start button in the toolbar, or select Start Application from the Control menu Woodward...
  • Page 67 Manual 26240V1 505CC-2 Hardware & Installation Manual The application will initialize, as indicated in the Status column and by messages displayed in the lower right box of the AppManager window. Once complete, the Status column should display Running. Woodward...
  • Page 68 Modbus master and slave. The control contains one list consisting of analog and Boolean inputs and outputs ("reads" and "writes"). The slave must have a dedicated list in the master. The slave list must match the corresponding master list(s) in order for all data to be transferred. Woodward...
  • Page 69 Select Use Modbus #1 (or 2) to enable the port and continue its configuration. The port status is indicated, and buttons become available for Configure Modbus #1 (or 2), Reset Modbus, Turbine Analog Scaling, and Compressor Analog Scaling. See Figure 3-35. Woodward...
  • Page 70 SmartCore board), or TCP/IP Ethernet. If a serial protocol is selected, complete the port configuration by selecting the appropriate Baud Rate, Stop Bits, and Parity to match those of the master device. Woodward...
  • Page 71 Without this selection, the Modbus port will function as read-only. If selected, the Configure Trips button will launch the Modbus #1 (or 2) Trip Configuration pop-up, shown in Figure 3-37. It will facilitate customization of shutdown commands from the Modbus port. Figure 3-37. Modbus #1 (or 2) Configuration Pop-Up Woodward...
  • Page 72 Scaling pop-ups. The groups of parameters requiring scalers are listed in Table 3-6, each with the various data onto which the selected scaler will apply. A group will not be listed in the scaling pop-up if that function has not been configured in the control. Woodward...
  • Page 73 Manual 26240V1 505CC-2 Hardware & Installation Manual Figure 3-38. Modbus Analog Scaling Pop-Ups Woodward...
  • Page 74 Modbus entered setpoint of 48,000 kPa must be scaled down by the value of 10 before being written to the control. The control will scale up the 4,800 value that is received to achieve the desired setpoint of 48,000 kPa. Woodward...
  • Page 75 Modbus list for clarification. If no unit is specified, the value is dimensionless, or its units are dependent upon the configuration. The 505CC-2 Modbus list is based upon that from the Woodward 505/505E control. Thus, if replacing a 505/505E with the 505CC-2, any existing Modbus interface will require minimal changes.
  • Page 76 Disable Manual E/A Pressure Control 0:0092 Lower Manual E/A Demand (Not Used) 0:0093 Raise Manual E/A Demand (Not Used) 0:0094 Enable Remote Manual E/A Demand 0:0095 Disable Remote Manual E/A Demand 0:0096 Go To Modbus Entered E/A Demand 0:0097 Spare Woodward...
  • Page 77 Comp. 2 - Enable Suction Pressure Override 0:0156 Comp. 2 - Goto Modbus Suction Pressure Override Setpoint 0:0157 Comp. 2 - Enable Discharge Pressure Override 0:0158 Comp. 2 - Goto Modbus Discharge Pressure Override Setpoint Table 3-7. Modbus Boolean Writes Woodward...
  • Page 78 Trip - Gen Breaker Open (Not Used) 1:0055 Trip - External Trip (BI_01) 1:0056 Trip - Controlled Shutdown Complete 1:0057 Trip - External Trip 4 1:0058 Trip - External Trip 5 1:0059 Trip - Extraction / Admission Pressure Input Failed 1:0060–63 Trip - Spare Woodward...
  • Page 79 1:0123 Extraction / Admission is Inhibited 1:0124 Remote Extraction / Admission Setpoint Is Enabled 1:0125 Remote Extraction / Admission Setpoint Is Active 1:0126 Remote Extraction / Admission Setpoint Is In Control 1:0127 Remote Extraction / Admission Setpoint Is Inhibited Woodward...
  • Page 80 1st Stage Press. Configured (Not Used) 1:0184 Remote Speed Control Configured 1:0185 Loadsharing Configured (Not Used) 1:0186 ESD (Trip) Configured 1:0187 Gen Set Configured (Not Used) 1:0188 Cascade Control Configured 1:0189 Remote Cascade Setpoint Configured 1:0190 Aux Control Configured (Not Used) Woodward...
  • Page 81 Comp. 1 - FULL MANUAL Mode 1:0346 Comp. 1 - Online 1:0347 Comp. 1 - Suction Pressure Default Value in Use 1:0348 Comp. 1 - Suction Pressure Last Good Value in Use 1:0349 Comp. 1 - Discharge Pressure Default Value in Use Woodward...
  • Page 82 Comp. 2 - Sequence Positioning In Control 1:0441 Comp. 2 - Surge Recovery In Control 1:0442 Comp. 2 - Valve Freeze Active 1:0443 Comp. 2 - AUTO Mode 1:0444 Comp. 2 - MANUAL with BACKUP Mode 1:0445 Comp. 2 - FULL MANUAL Mode Woodward...
  • Page 83 Compressor Discrete Input 3 Closed 1:0495 Compressor Discrete Input 4 Closed 1:0496 Compressor Discrete Input 5 Closed 1:0497 Compressor Discrete Input 6 Closed 1:0498 Compressor Discrete Input 7 Closed 1:0499 Compressor Discrete Input 8 Closed Table 3-8. Modbus Boolean Reads Woodward...
  • Page 84 Extraction / Admission Input (%) x 100 3:0055 Extraction / Admission Setpoint (%) x 100 3:0056 Extraction / Admission Scale Factor 3:0057 Extraction / Admission Input (Scaled) Configurable 3:0058 Extraction / Admission Remote Setpoint Input (Scaled) Configurable 3:0059 Spare 3:0060 Modbus Entered Speed Setpoint (feedback) Woodward...
  • Page 85 Contact Input 12 Config. (Not Used) 3:0118 Aux Units Configured (Not Used) 3:0119 Cascade Units Configured 3:0120 Extraction / Admission Units Configured 3:0121 Spare 3:0122 Inlet / Exhaust Setpoint (Scaled) Configurable 3:0123 Inlet / Exhaust PID Output (%) x 100 Woodward...
  • Page 86 Comp. 1 - HSS Auxiliary Input 1 3:0243 Comp. 1 - HSS Auxiliary Input 2 3:0244 Comp. 1 - Adjacent Stage Valve Demand 3:0245 Comp. 1 - Surge Capture Operating Point Configurable 3:0246 Comp. 1 - Deactivation Routine Output Woodward...
  • Page 87 Comp. 2 - Calculated Average Compressibility 3:0311 Comp. 2 - Calculated Suction Compressibility 3:0312 Comp. 2 - Calculated Flow Compressibility 3:0313 Comp. 2 - HSS Auxiliary Input 1 3:0314 Comp. 2 - HSS Auxiliary Input 2 3:0315 Comp. 2 - Adjacent Stage Valve Demand Woodward...
  • Page 88 Comp. Discrete Input 3 Configuration 3:0370 Comp. Discrete Input 4 Configuration 3:0371 Comp. Discrete Input 5 Configuration 3:0372 Comp. Discrete Input 6 Configuration 3:0373 Comp. Discrete Input 7 Configuration 3:0374 Comp. Discrete Input 8 Configuration 3:0375–393 Spare Table 3-9. Modbus Analog Reads Woodward...
  • Page 89 12 – Pressure Input for HP Valve Compensation 13 – Remote Manual Extraction / Admission Pressure Demand 14 – Pressure Input for LP Valve Compensation 3:0094 – 3:0097 1 – Not Configured Turbine Analog Output 2 – Turbine Speed Woodward...
  • Page 90 51 – HP / V1 Valve Limiter Level Switch 52 – LP / V2 Valve Limiter Level Switch 53 -- HP / V1 Valve Demand Level Switch 54 -- LP / V2 Valve Demand Level Switch 55 – Not Used 3:0106 – 3:0113 0 – Not Configured Woodward...
  • Page 91 7 – Inlet / Exhaust Pressure Input Failed Turbine Alarm First-Out 8 – Remote Speed Setpoint Input Failed 9 – Remote Cascade Setpoint Input Failed 10–11 – Not Used 12 – HP / V1 Actuator Failed 13 – LP / V2 Actuator Failed Woodward...
  • Page 92 14 – AUTO / Auxiliary HSS Input 2 15 – AUTO / Adjacent Stage Valve Demand 16 – AUTO / Deactivation Routine 17 – MANUAL with BACKUP / Shutdown Positioning 18 – MANUAL with BACKUP / Zero Speed Positioning Woodward...
  • Page 93 16 – Compressor 2 Auxiliary HSS Input 2 17 – Compressor 2 Remote Manual Valve Demand 18 – Compressor 2 Redundant Flow Input 19 – Compressor 2 Redundant Suction Pressure Input 20 – Compressor 2 Redundant Discharge Pressure Input Woodward...
  • Page 94 17 – Compressor 2 Select FULL MANUAL Mode 18 – Compressor 2 Purge Position 19 – Compressor 2 Online Auxiliary Input 20 – Compressor 2 Control Margin Increase 21 – Compressor 2 Control Margin Decrease 22 – Compressor 2 Anti-Surge Valve Output Failed Woodward...
  • Page 95 Direct Ethernet connection requires a null (crossover) cable. Networked Ethernet connection requires a regular (straight) cable. Use Woodward’s AppManager software (available on the installation CD) to verify the 505CC-2’s IP address and control name. If the IP address of the control must be changed for installation on an existing network, do so now using the AppManager software and the procedure outlined in Chapter 3.
  • Page 96 Configuration mode to upload a configuration file as detailed earlier in Chapter 3. Each time it is launched from this point, the HMI/CCT is configured to connect to the specified control—These steps are no longer required to establish communications on successive sessions. Woodward...
  • Page 97 B, C, and D, Zone 2, Group IIC, or non-hazardous locations only. Wiring must be in accordance with Class I, Division 2 or Zone 2 wiring methods and in accordance with the authority having jurisdiction. 855-741A 02-5-15 Figure 4-1. Power Supply Board Connections (5503-216) Woodward...
  • Page 98 Troubleshooting Guide Power Supply Checks The following is a troubleshooting guide for checking areas, which may present difficulties. If these checks are made prior to contacting Woodward for technical assistance, system problems can be more quickly and accurately assessed. ...
  • Page 99 (Discrete Output power input current plus 12 times the maximum Discrete Output channel current) shall be provided. Fuse current rating should not exceed 6.25 A (time delay fuses are recommended).  Chapter 8 details an optional relay module that can be used with these discrete outputs. Woodward...
  • Page 100 Hardware Specifications The Pentium CPU conforms to the Ampro/Motorola EBX v1.1 mechanical format and contains both PC/104 and PC/104+ bus connectors for interfacing with other Woodward and PC/104 compatible modules. Electrical  Power requirements are 5.0 Vdc, 2.5 A (max), 2.25 A (typical) ...
  • Page 101 Ethernet cable. To fully realize 100 Base-TX connectivity, downstream devices must be 100 Base-TX capable. As such, when using an Ethernet hub for multiple connections, either a fixed 100 Base-TX or an auto-switching 10/100 Base-TX hub would be necessary. Woodward...
  • Page 102 Figure 5-1. Pentium CPU Board Connections Connector Signal Mnemonic RJ45F Shielded RJ45 female receptacle Shield AC Coupled to Chassis Table 5-1. Ethernet Port Pinout Use shielded Ethernet cable only! Use of non-shielded cable may result in permanent system damage. Woodward...
  • Page 103 Analog inputs are 4–20 mA. Two of the serial ports, may be RS-232, RS-422, or RS-485. The other serial port is a dedicated RS-232 port for software troubleshooting only. 855-742A 03-1-8 Figure 6-1. SmartCore Board with Actuators, Connectors Woodward...
  • Page 104 Clock memory EEPROM non- volatile memory Discrete Input Discrete Inputs(24) buffer 16-bit Sigma-Delta Analog Inputs(6) 0-5Vdc/4-20mAdc A/D Converter PC/104 Bus PC/104 Signals Interface Power Bus Power Bus Signals Interface VIS-001 00-05-31 kdw Figure 6-2. AtlasPC SmartCore Board Block Diagram Woodward...
  • Page 105 80 Hz/s. Typically, at 3600 Hz, noise on the MPU signal due to wiring runs will make the noise contribution due to resolution insignificant.  No proximity probe power provided.  If the proximity probe inputs are used, the corresponding MPU inputs must be jumpered. Woodward...
  • Page 106 2 channels at 1 ms, 2 channels at 3 ms, and 2 channels at 5 ms  Loop power for the analog inputs is NOT available. External loop powered transducers must be individually protected with a 100 mA fuse on each channel. Woodward...
  • Page 107 For EMC compliance, the on-board, isolated, +24 Vdc supply is recommended for use as power to contacts, 100 mA maximum.  All channels are common to each other. Isolation is with respect to the AtlasPC platform and other I/O types. Woodward...
  • Page 108 (reducing speed sensing resolution) and have coupling gear backlash, resulting in less than optimum speed control. For safety purposes, it is also not recommended that the speed sensing device sense turbine speed from a gear coupled the mechanical drive side of a system’s rotor coupling. Woodward...
  • Page 109 Proximity probe power is not provided.  Proximity probes only—External pull-up resistors are required when interfacing to open collector type proximity probes.  If the proximity probe inputs are used, the corresponding MPU inputs must be jumpered as shown. Woodward...
  • Page 110 Self Powered Figure 6-6a. Wiring Example–4–20 mA Input Interface to the SmartCore Board (+) Loop Power Atlas 100 mA Fuse 4-20 mA Transducer Loop Powered (-) Loop Power Figure 6-6b. Wiring Example–4–20 mA Input Interface using External Loop Power Woodward...
  • Page 111  The analog outputs have a 15 V common mode voltage, with respect to AtlasPC control common. Avoid misconnection of the Analog Output (+) to the Actuator Output (–). This will damage internal components, making the control inoperable. Woodward...
  • Page 112 Application software selects the actuator type, the output range, and the dither amount.  The readbacks can be used in the application software for fault detection. Avoid misconnection of the Analog Output (+) to the Actuator Output (–). This will damage internal components, making the control inoperable. Woodward...
  • Page 113 The 24 V isolated contact power is protected by a 0.2 A poly switch. This may not prevent interruption in control operation due to a short in the field wiring, but should protect the control from damage. The poly switch will reset itself when the short condition is resolved. Woodward...
  • Page 114 RS 232 Device Figure 6-10. Serial #1–RS-232 Pinouts Serial #1 - RS-422 Atlas RS 422 Transceiver 422R 422T Twisted Pairs 422R 422T Isolated RS 422 Device Jumper to use optional termination resistor Isolated Ground Figure 6-11. Serial #1–RS-422 Pinouts Woodward...
  • Page 115 Pair Isolated RS 485 Device Jumper to use optional termination resistor Isolated Ground Figure 6-12. Serial #1–RS-485 Pinouts Serial #2 - RS-232 Atlas Isolated RS 232C Isolated Transceiver Ground Twisted Pair RS 232 Device Figure 6-13. Serial #2–RS-232 Pinouts Woodward...
  • Page 116 Jumper to use optional termination resistor Isolated Ground Figure 6-14. Serial #2–RS-422 Pinouts Serial #2 - RS-485 Atlas RS 485 Transceiver Twisted Pair Isolated RS 485 Device Jumper to use optional termination resistor Isolated Ground Figure 6-15. Serial #2–RS-485 Pinouts Woodward...
  • Page 117 505CC-2 Hardware & Installation Manual Serial #3 - RS-232 Atlas Isolated RS 232C Null Transceiver Modem Cable Isolated Ground Figure 6-16. Serial #3–RS-232 Pinouts Figure 6-17. Wiring Example–RS-232 Interface to the SmartCore Board Figure 6-18. Wiring Example–RS-422 Interface to the SmartCore Board Woodward...
  • Page 118  The serial ports must be properly configured for the appropriate communication parameters.  Termination resistors are available on the SmartCore board and should be wired across the network at the ends of the line. Woodward...
  • Page 119 Serial Port Faults—The system monitors the serial communications on the three serial ports, for various communication errors.  Microcontroller Faults—The system monitors a software watchdog, a hardware watchdog, and a software watchdog on the PC/104 bus communications. All outputs are shutdown in the event of a microcontroller fault. Woodward...
  • Page 120 Check the wiring. If the inputs are reading 0 or the engineering units that correspond to 0 mA, look for a loose connection at the terminal blocks and disconnected or misconnected cables. Check for proper jumper installation on the terminal block. Woodward...
  • Page 121 Check the wiring, look for a loose connection at the terminal blocks and disconnected or misconnected cables.  Check the software configuration to ensure that the input is configured properly. After verifying all of the above, the AtlasPC should be returned for service. Woodward...
  • Page 122 Check the software configuration to ensure that the input is configured properly.  Check that the cable is shielded and the shield is properly grounded per the shields and grounding section in Chapter 2. After verifying all of the above, the AtlasPC should be returned for service. Woodward...
  • Page 123 Figure 7-1. AtlasPC Analog Combo Board Connections Physical The AtlasPC Analog Combo board connects to the CPU board through the PC/104 bus. It does not connect to the AtlasPC power bus directly, it requires a SmartCore board for this purpose. Woodward...
  • Page 124 Analog Combo cards from 410 MHz to 450 MHz at field strengths greater than 10 V/m. Fields of 10–20 V/m degrade the steady-state performance from a 0.1% tolerance to a 0.36% tolerance. Installation of the Atlas in a metal cabinet will minimize this degradation. Woodward...
  • Page 125 0.1% tolerance to a 0.36% tolerance. Installation of the Atlas in a metal cabinet will minimize this degradation. Temperature Drift Input Type Typ (ppm/°C) Typ error (%) Max (ppm/°C) Max error (%) 0.68 1.04 4–20 mA Woodward...
  • Page 126 Maximum wire size, one 16 AWG (1.5 mm²), or two 20 AWG (0.5 mm²) wires. AtlasPC Analog Combo Board Operation This board includes no potentiometers and requires no field calibration. An Analog Combo board may be replaced with another board of the same part number without any adjustment. Woodward...
  • Page 127 Input #1 Figure 7-3a. Wiring Example–Analog Input Interface (Channels 1-11) (+) Loop Power Atlas 100 mA Fuse 4-20 mA Transducer Loop Powered Analog Input #1 (-) Loop Power Figure 7-3b. Wiring Example–Analog Input Interface (Channels 1-11) with External Loop Power Woodward...
  • Page 128 External loop powered transducers must be individually protected with a 100 mA fuse on each channel. Analog Outputs The Analog outputs are 4–20 mA with a full scale range of 0–24 mA. The Analog Combo board has four Analog outputs. Woodward...
  • Page 129 Number of LED Flashes Failure Microprocessor failure Bus, address, any unexpected exception error Failure during EE test or erasing Kernel software Watchdog count error Failure during CPU Internal RAM test Dual port RAM error Table 7-1. Analog Combo Failure Woodward...
  • Page 130  Check the software configuration to ensure that the input is configured properly. After verifying all of the above, the AtlasPC should be returned for service. Woodward...
  • Page 131 The Atlas system has 12 relay drivers on the power supply board. For customers that do not wish to wire their own discrete relays, Woodward can provide an integrated 12-channel relay module with cable harness that is certified for use in ordinary, hazardous, and marine locations.
  • Page 132 One end of this cable has been stripped back several inches, and individual wires are labeled with the terminal numbers of the appropriate terminals used on the Atlas power supply board. Refer to the following plant wiring diagram and the power supply chapter of this manual for more details. Woodward...
  • Page 133 Manual 26240V1 505CC-2 Hardware & Installation Manual Figure 8-2. 12-Channel Relay Module Wiring Diagram Woodward...
  • Page 134 HMI Computer, Item Number 1790-9016  HMI Software, Item Number 9928-1048  HMI Kit, Item Number 8928-7037 (this part number contains the HMI computer, touchscreen monitor, software, and a crossover Ethernet cable together) Figure 9-1. 381 mm (15 inch) LCD Touchscreen HMI Woodward...
  • Page 135 See Figure 9-2 for an outline drawing and panel cutout of the monitor. When panel mounted, a water resistant gasket on the back of the bezel provides NEMA 4 / IP65 environmental protection. Figure 9-2. Monitor Outline and Dimensions (mm (inches)) Woodward...
  • Page 136 The key should be installed on the computer’s parallel port. The flat panel monitor is supplied with a 100–230 Vac power supply. Connections between it and the computer, a standard VGA cable and serial/USB interface for the touchscreen functionality, are also supplied. Figure 9-3. HMI Connections Woodward...
  • Page 137 Manual 26240V1 505CC-2 Hardware & Installation Manual Appendix A. Default Log-in/Security Level Passwords The following passwords are the defaults for the 505CC-2’s various login levels. Monitor No Password Operator 1111 Engineering 2222 Service 3333 Online Configure 4444 Offline Configure 5555 Woodward...
  • Page 138 Number of LED Flashes Failure Microprocessor failure Bus, address, any unexpected exception error Failure during EE test or erasing Kernel software Watchdog count error Failure during CPU Internal RAM test Dual port RAM error Table B-2. Analog Combo Failure Codes Woodward...
  • Page 139 The Configuration Worksheet is contained on the next 11 pages, which can be copied, filled in, and faxed as necessary. Or, you can download publication number 26240sup from the Woodward website (www.woodward.com/publications), which is a Microsoft Word form containing the same information, which can be filled out on-screen and e-mailed. Woodward...
  • Page 140 PUT 26240sup HERE...
  • Page 141 Declarations...
  • Page 144 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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