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

Woodward 505 Installation And Operation Manual

Digital governor for steam turbines with single actuators
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Product Manual 85003
(Revision A)
Original Instructions
505 Digital Governor for
Steam Turbines with Single Actuators
8238-001, 8238-003, 8238-004
Installation and Operation Manual

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Summary of Contents for Woodward 505

  • Page 1 Product Manual 85003 (Revision A) Original Instructions 505 Digital Governor for Steam Turbines with Single Actuators 8238-001, 8238-003, 8238-004 Installation and Operation Manual...
  • Page 2 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 5. S ..............32  HAPTER ERVICE PTIONS   Product Service Options ..................32   Woodward Factory Servicing Options ..............33   Returning Equipment for Repair ................33   Replacement Parts ....................34   Engineering Services .................... 34   How to Contact Woodward ................... 35  ...
  • Page 4 Figure 2-2. Detailed 505 Block Diagram ..............8   Figure 2-3. 505 Keypad ..................9   Figure 2-4. 505 Communication through an RS-232 Line ........12   Figure 2-5. Two-Wire Transducer System ............14   Figure 3-1. Basic Program Architecture ............... 15  ...
  • Page 5 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 6 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 7 Mechanical Data and Hardware Installation Packaging Figure 1-1 shows 505 control layout. All 505 control components are contained in a single, NEMA Type 4 steel enclosure. The standard enclosure (Figure 1-1a) can be bulkhead-mounted. An optional enclosure is designed to be flush- mounted (Figure 1-1b).
  • Page 8 505 Digital Governor Manual 85003 Environmental Data The 505 has been designed to operate in a wide range of environmental conditions, including outdoor operation. Temperature The control operates over a temperature range of –25 to +65 °C (–13 to +149 °F).
  • Page 9 Manual 85003 505 Digital Governor Electromagnetic Interference (EMI) The control is designed to conform to US MIL-STD-461, Part 5, for electromagnetic interference (EMI): Conducted Emissions: ac power leads, control and signal leads CE01 (100 Hz to 15 kHz) ac current...
  • Page 10 505 Digital Governor Manual 85003 Figure 1-1a. 505 Control Layout (standard enclosure) Woodward...
  • Page 11 Manual 85003 505 Digital Governor Figure 1-1b. 505 Control Layout (flush-mounted enclosure) Woodward...
  • Page 12 505 Digital Governor Manual 85003 Figure 1-2. Plant Wiring Diagram Woodward...
  • Page 13 Mode, unless turbine options change. You then select Run Mode to operate the turbine from start-up through shutdown. The 505 functions are shown in a simplified block diagram in Figure 2-1 and in more detail in Figure 2-2. Use this block diagram to configure the control to match your application.
  • Page 14 505 Digital Governor Manual 85003 Figure 2-2. Detailed 505 Block Diagram Woodward...
  • Page 15 (see Figures 3-2 and 3-3). Figure 2-3. 505 Keypad FUNC left/FUNC right (function)—Moves the display left or right through the function blocks. In the Program Mode, you must step the display up to the top of the function block before the FUNC keys have an effect.
  • Page 16 Inputs and Outputs All inputs and outputs to the 505 are made through a terminal block inside the 505 enclosure. Wiring passes through two conduits on the bottom of the control. All inputs and outputs are shown in the block diagram.
  • Page 17 MPUs record the same speed. The 505 has one actuator output, five 4 to 20 mA meter-drive outputs, and eight relay contact outputs.
  • Page 18 (KW) droop feedback. The 4 to 20 mA load droop signal comes from a real-power sensor supplied by Woodward. An I/V (current-to-voltage) converter changes the load current signal to a proportional voltage. A percentage of that signal is then sent on to the control amplifier.
  • Page 19 4 to 20 mA signal from a transducer. The process control compares that signal with an external reference to generate an output to the remote process control portion of the 505. An I/V converter changes this current signal to a proportional voltage. The internal process control compares this voltage to the output of the speed reference.
  • Page 20 Manual 85003 Power Supply The 505 power supply accepts 85 to 132 Vac at 47 to 400 Hz or 100 to 150 Vdc. The power supply provides power for the control and for any external transducers. The 505 is designed to supply power to all transducers through a two-wire system (Figure 2-5).
  • Page 21 Configuration Procedures Programming The 505 is easy to program, due in large part to the menu-driven software. The flowcharts for programming and running the 505 Digital Governor are shown in Figures 3-2 and 3-3. The operating procedures are divided into two sections: the Program Mode (Figure 3-3) and the Run Mode (Figure 3-2).
  • Page 22 505 Digital Governor Manual 85003 The function keys (FUNO left, FUNC right) allow you to move right or left across the tops of the function blocks in both the Run and Program Modes. The STEP up and STEP down keys allow you to move up or down the program columns.
  • Page 23 Manual 85003 505 Digital Governor Program Configuration Completeness Check After the program is configured, push STOP to exit the Program Mode. The control then automatically performs a completeness check on the configured program to assure that required program blocks have values loaded into them.
  • Page 24 505 Digital Governor Manual 85003 Figure 3-2. Starting and Run Mode Procedures Woodward...
  • Page 25 Manual 85003 505 Digital Governor Figure 3-3. Program Mode Procedures Woodward...
  • Page 26 505 Digital Governor Manual 85003 Chapter 4. Operating Procedures Operating Functions There are four operating functions (see Figure 3-2). You can move from function to function by pushing the FUNO keys, and you can move up and down within a function block by pushing the STEP keys.
  • Page 27 Idle/Rated The 505 is equipped with an idle/rated function which can be initiated only from external contacts. There are no keypad controls for this function. The feature must be configured in the Program Mode or the control ignores the idle/rated contacts.
  • Page 28 References The 505 references operate in the same manner as references in other Woodward controls, such as 2301 MOPs and 43027 digital reference modules. You select a reference ramp rate during control programming for each ramp or reference.
  • Page 29 Manual 85003 505 Digital Governor The cascade control can move the speed reference at a variable rate less than the fast rate. When the error between the pressure or temperature requested by the cascade control and the cascade reference is small, the speed reference moves at a very slow rate.
  • Page 30 ADJ up and ADJ down keys. Priorities The 505 has an internal priority scheme to sort out incoming commands. Listed below are the priorities, from the highest to the lowest. Emergency Shutdown: Any type...
  • Page 31 Manual 85003 505 Digital Governor Figure 4-2. Control Function Adjustment Rates An asterisk appearing on the right edge of the LCD display line indicates that the displayed parameter is controlling actuator position. Pushing the GAIN or RST (reset) keys causes an arrow to appear by the appropriate parameter in the display and activates the ADJ keys.
  • Page 32 You can enable either the remote process control or the cascade control once the turbine is up to speed and a load is established. The remote process control is external to the 505. It is usually equipped with both automatic and manual operating capabilities. In the automatic mode, the process control accepts a pressure signal of 4 to 20 mA from a pressure transducer and compares it to a reference signal.
  • Page 33 The cascade control is a secondary speed setting function internal to the 505. It operates in a manner similar to the remote process control in the automatic mode.
  • Page 34 505 Digital Governor Manual 85003 DBAND = The deadband established for the deadband comparator. Maximum (100%) deadband is equal to 10% of the cascade references range. This range is defined as the maximum cascade reference minus the minimum cascade reference. The maximum deadband for the remote process control is defined as 10% of the speed reference’s full range.
  • Page 35 Manual 85003 505 Digital Governor Alarms When an alarm condition exists, the red alarm LED illuminates and the Alarm relay activates. Pushing ALARM displays the reason for the alarm. If there is more than one cause for an alarm, pushing the STEP keys displays these additional causes.
  • Page 36 There are two types of shutdown: a controlled shutdown and an emergency shutdown. A controlled shutdown can be initiated while the 505 is controlling the turbine in the Run Mode. Pressing the STOP key and giving verification places the control in speed control and moves the speed reference to its minimum speed set point at the slow rate.
  • Page 37 Manual 85003 505 Digital Governor Shutdn/No pres in—The actuator is at its minimum position because the pressure (inlet or exhaust) signal has dropped below approximately 3 mA. Shutdown occurs only if the function was controlling the actuator position. Shutdn/Lost Power—The actuator is at its minimum position because one or more of the internal power sources has failed.
  • Page 38 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 39 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 40 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 41 Manual 85003 505 Digital Governor 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 42 Manual 85003 Appendix. 505 Program Mode Worksheet The 505 Program Mode Worksheet provides a step-by-step guide for programming (configuring) the 505 control. If may be a good idea to make copies of the worksheet. Governor Serial Number ___________________________________________ Application ______________________________________________________...
  • Page 43 Manual 85003 505 Digital Governor DROOP AUXILIARY CONTROL SPEED DROOP yes ___ no___ AUXILIARY CONTROL yes ___ no____ Increased actuator position causes decreased The aux. control is a separate control channel (PID) speed setting. with slower dynamics than the speed control channel.
  • Page 44 505 Digital Governor Manual 85003 CASCADE CONTROL TIEBRK OPEN ALARM yes ___ no____ CASCADE CONTROL yes ___ no____ Compares 4-20 mA input with cascade ref. error GENBRK OPEN ALARM yes ___ no____ then moves speed ref. through a deadband comparator.
  • Page 45 Manual 85003 505 Digital Governor VALVE RAMP RELAY Relay No. _______ ANALOG READOUT Assign relay 1 thru 5. ANALOG READOUT yes ___ no___ Are 4-20 mA readouts required? Only four VALVE RAMP SW POINT ________________ % readouts can be selected.
  • Page 46 505 Digital Governor Manual 85003 PRES REF READOUT yes ___ no____ BAUD RATE Remote readout of pressure set point when in Select baud rate for RS-232 port if used. auxiliary control. 300 BAUD yes ___ no___ 1200 BAUD yes ___ no___ PRES REF READOUT Readout No.
  • Page 47 Manual 85003 505 Digital Governor Woodward...
  • Page 48 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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8238-0018238-0038238-004