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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

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

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  • Page 1 Product Manual 26347V2 (Revision H, 4/2014) Original Instructions 505 Enhanced Digital Control for Steam Turbines (with Redundancy) 9907-1181, 9907-1182, 9907-1183 Manual 26347 consists of 2 volumes (26347V1 & 26347V2). Volume 2—Installation and Operation 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 Interfacing to Control Assistant (Service Tool) ............2   Servo Position Controller (SPC) ................2   Utilizing Redundant 505 Units ................4   Applying the 505 with Redundant I/H or I/P Converters ........12 2. A ............. 15  HAPTER PPLICATION OTES  ...
  • Page 4 Mode ....................34 Figure 2-6. Import/Export Control or Exhaust Pressure Control with Isoch Load   Sharing in Island Mode ..............37 Figure 2-7. Redundant 505 configuration for Pump or Compressor Discharge   Pressure Control with Turbine Inlet Pressure Limiting ....42  ...
  • Page 5 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Illustrations and Tables   Figure D-5. Control Assistant Restart Window ........... 129   Figure D-6. Control Assistant – Tunable Connection Choice ......130   Figure D-7. Control Assistant – Receiving Tunables (Transferring) ....131  ...
  • Page 6 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 7 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 8 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Woodward...
  • Page 9 Manual 26347 Volume 2 is a dual purpose manual. It includes application- specific notes and 505 specific Service mode information. The first part of this volume gives users an idea of the 505 Digital Control’s capabilities, and how to apply them to a system. Typical applications are schematically shown and their functionality explained.
  • Page 10 Refer to the Appendices of this volume for instruction on using the Service port to Upload/Download Tunables. This is no longer the default configuration for this port in the 505 Enhanced. The default for this port provides an SOS Servlink OPC Server interface in order to allow Monitor GAP™ and Control Assistant applications to interface with the 505.
  • Page 11 SPC can interface. Below is one example of how the 505 and SPC can be used on Integrating Servo Valves. The SPC can also handle many variations of feedback devices.
  • Page 12 Woodward Real Power Sensors have terminals labeled “Output” and terminals labeled “KW Readout”. The “KW Readout” terminals provide a 4–20 mA signal proportional to real power which is used by and compatible with the 505 control. Thus the RPS terminals labeled “Output” are designed and typically compatible only to Woodward’s 2301 type of control.
  • Page 13 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Interface Wiring  On each unit connect Relay Output # 1 to the Contact Input # 1 on the other unit.  A Modbus Communication link must be connected. 505 #1 505 #2...
  • Page 14 “Select In-Control Unit” command coming from a single selector switch that feeds both 505 units. This method will place the unit receiving this True signal as the In-Control unit. Be aware that with this method there is no override or confirmation to Transfer.
  • Page 15 Contact selects unit load control through the EGCP-3 LS or through the 505’s internal load set point. The EGCP-3 LS interfaces to the 505 via a Speed Bias signal or Raise /Lower Contacts. The 505’s isolated analog #6 input is the only analog input that is directly compatible with the EGCP-3 LS.
  • Page 16 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Figure 1-5. EGCP-3 Control Figure 1-6. EGCP-3 LS Functional Diagram Woodward...
  • Page 17 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Figure 1-7. EGCP-3 LS Interface Wiring The following Bus Protections are available with the EGCP-3 LS:  Over/Under Voltage (59, 27)  Over/Under Frequency (81O, 81U)  Directional (Forward/Reverse) Power (32) * ...
  • Page 18 *—Inverse Time Protections implemented are according to IEEE C37.112 “Very Inverse” curves. The EGCP-3 LS requires a power source of +24 Vdc @ 1 A. The 505 power supplies cannot supply this much power, thus an external power supply may be required.
  • Page 19 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators The EGCP-3 MC’s baseload mode of operation allows an operator to set the plant to a specified load. A proportional or integrating control action can be used with this mode of operation. The integrating mode of operation can be used with systems tying to an unstable grid to allow the plant to control at a constant load and not vary based on grid frequency.
  • Page 20 For more information on Woodward’s EGCP-3 MC and how to apply it, please refer to Woodward manual 26195. The EGCP-3 MC requires a power source of +24 Vdc @ 1 A. The 505 power supplies cannot supply this much power, thus an external power supply may be required.
  • Page 21 Manual transfer between converters can be initiated through discrete input, Modbus, or PC interface commands. Automatic transfer between converters is provided by the 505 based on driver failure(s), converter status, converter output pressures, and servo input pressure feedback signals.
  • Page 22 Functionality Details Utilizing a two-actuator output configuration provides redundancy all the way to the actuator level. The typical redundant I/H (or I/P) system will convert the 505 actuator milliamp output into a corresponding hydraulic (or pneumatic) pressure positioning the servo-cylinder. Both converters are supplying the appropriate pressure to position the steam valves to the demand requested by the control.
  • Page 23 A combination of the Speed PID and its setpoint limits allow this PID to limit unit load. When used as a unit load limiter, it is recommended that the 505 be configured to sense and control only true generator load. If applying the 505 system to a soft grid (utility frequency varies greatly) it is recommended that unit load limiting be performed by the Auxiliary PID not the Speed PID.
  • Page 24 Modbus communications. With this configuration when the Aux PID is enabled the Speed PID is disabled and tracks the Auxiliary PID’s output. To control or limit any of the listed parameters, the 505 must be programmed to accept an Auxiliary analog input signal representing that parameter’s level. The...
  • Page 25 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Example–To configure the 505 to perform a Turbine Exhaust pressure limiting function use Example 1, the “Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting” application for reference. With this example substitute exhaust pressure for inlet pressure and disregard any program settings specified to control pump or compressor discharge pressure.
  • Page 26 Figure 2-1 and described below. With this application pump/compressor discharge pressure control is performed within the 505 through the Cascade controller. Because the discharge pressure being controlled, typically affects many other plant processes, a plant Distributed Control System (DCS) may be used to monitor plant process conditions and set the Cascade setpoint position.
  • Page 27 Modbus commands, or the 505 service panel. The following list of notes is provided as a reference for application programmers to follow when configuring the 505 to achieve any of the control and limiting actions shown in figure 2-1: 505 Configuration Notes for Example 1 Operating Param: This is not a Generator application.
  • Page 28 In this example the turbine can be tripped by several devices, one of these devices is the 505 control. To provide feedback to the 505 control that the turbine is tripped, a contact from the trip string is wired into the External Emergency Shutdown input (TB12).
  • Page 29 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Example 2–Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Figure 2-2. Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Woodward...
  • Page 30 With this application turbine inlet header pressure control is performed within the 505 through the Cascade PID controller. This is an ideal controller for this type of function because it can be enabled and disabled as desired by a system operator.
  • Page 31 Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR8 installed. The 505 was configured to accept a contact from a panel mounted switch to externally enable and disable inlet header pressure control. (Contact Input #3 Function: Casc Control Enable) The Cascade Input was inverted to allow the correct control action.
  • Page 32 When the plant-to-utility tie-line breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load set point up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load set point and is defaulted to 3%.
  • Page 33 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators With this application the Auxiliary control is programmed to be used as a limiter, and be automatically enabled when both the Utility Tie and Generator breakers are closed. When paralleled to the utility, if inlet header pressure demand, and/or...
  • Page 34 In order to limit generator load, the 505 control must be able to sense generator load. As shown in Figure 2-3 generator load is being sensed with a Woodward Real Power Sensor and supplied to the 505’s KW droop input.
  • Page 35 Analog input #1. (Analog Input #1 Function: KW/Unit Load Input) Because the RPS’s KW readout is self powered, the 505 back cover was removed and JPR11 installed. Generator load (when paralleled to the utility) is controlled by the Speed PID and programmed by selecting the KW/Unit load input.
  • Page 36 The system operator can select automatic synchronization through the Auto-Synch select switch ( SW1 in Figure 2-3 ). When this switch is closed the 505’s Synchronizing input is enabled and the EGCP-3 LS’s automatic synchronizing function selected.
  • Page 37 When the plant to utility tie line/breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load setpoint up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load setpoint and is defaulted to 3%.
  • Page 38 With this RPS 12 mA represents zero power flow. Because of this feature the RPS #8272-726 can not, be used with the 505 to sense generator load/power.
  • Page 39 505 Digital Governor for Single/Split-Range Actuators This application uses an EGCP-3 LS for synchronization only. Because the EGCP-3 LS interfaces to the 505 through an analog signal, a 505 analog input must be programmed. The 505’s Analog Input #6 is the only analog input directly compatible with the EGCP-3 LS, thus it is required that this input be programmed to receive the EGCP-3 LS’s Speed Bias signal.
  • Page 40 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Dither is a low frequency ac current modulated on to the 505’s dc actuator– drive current to reduce stiction in linear type actuators. Because the 505’s actuator output is connected to the DRFD, dither was not required or used with this application.
  • Page 41 The system operator can select automatic synchronization through the Auto-Synch select switch ( SW1 in Figure 2-4 ). When this switch is closed the 505’s Synchronizing input is enabled and the EGCP-3 LS’s automatic synchronizing function selected.
  • Page 42 When the unit is paralleled to the utility, the EGCP-3 LS is disabled and the 505’s internal load setpoint or Cascade PID (plant import/export power) is used to control/set unit load.
  • Page 43 EGCP-3 LS. This synchronizing function/ input can be enabled, through a contact input, function key, Modbus command, or the 505 service panel. As shown in Figure 2-5 a panel mounted (DPST) switch is used with this application to select automatic synchronization in both the EGCP-3 LS and 505.
  • Page 44 The system operator can select automatic synchronization through the Auto-Synch select switch ( SW1 in Figure 2-5 ). When this switch is closed the 505’s Synch/Load Sharing input is enabled and the EGCP-3 LS’s automatic synchronizing function is selected.
  • Page 45 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Example 6–Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode Figure 2-6. Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode This application utilizes multiple turbine generators, and requires that all units have the capability to control different plant parameters depending on the status and health of each unit.
  • Page 46 Process Steam control (turbine exhaust pressure), and Loadsharing (used for plant import/export control or unit loadsharing). When a unit is switched to a Manual load control mode, its 505’s internal load setpoint determines unit load. This allows an operator to manually load or unload a unit to a set level if desired.
  • Page 47 505 service panel. The following list of notes are provided as a reference for application programmers to follow when programming the 505 to achieve any control and limiting actions shown in Figure 2-6. 505 Configuration Notes for Example 6 OPERATING PARAM: This is a Generator application.
  • Page 48 The system operator can select automatic synchronization through the Auto-Synch select switch ( SW1 in Figure 2-6 ). When this switch is closed the 505’s Synchronizing input is enabled and the EGCP-3 LS’s automatic synchronizing function selected.
  • Page 49 Example 7–Induction Generator Applications When the 505 is configured for induction generator applications, typically there are only two differences in the programming of the 505 verses programming for synchronous generator applications. The induction generator’s slip frequency must be taken into account. This is achieved by compensating for the slip frequency with the 505’s maximum Speed...
  • Page 50 If a plant Distributed Control System is used to sense and control a process by positioning the load of multiple pumps or compressors (load sharing), the DCS may interface directly to the 505 Speed PID set point through a programmed Remote Speed Set Point analog input. This allows a DCS to monitor and compensate for plant and system conditions by directly changing the speed of multiple pumps or compressors simultaneously.
  • Page 51 The following list of notes is provided as a reference for application programmers to follow when configuring the 505 to achieve any of the control and limiting actions and to setup the Master/Slave configuration as shown in Figure 2-7:...
  • Page 52 In this example the turbine can be tripped by several devices, one of these devices is the 505 control. To provide feedback to the 505 control that the turbine is tripped, a contact from the trip string is wired into the External Emergency Shutdown input (TB12).
  • Page 53 The F3 key can be used to manually transfer control from one 505 to the other. To complete a transfer, press the ‘F3’ key and then the ‘1/YES’ key. If, for some reason, the Modbus link has an error, then a 505 (unit B) can be overridden and forced to take control.
  • Page 54 Chapter 3. Operator Interface Introduction Interface to the control may be performed through the 505’s service panel (located on the front of the control), remote switch contacts, analog inputs, meter readouts, relays, or a Modbus communications line to an operator interface device.
  • Page 55 505 Digital Governor for Single/Split-Range Actuators Service Panel Modes The 505 Service Panel operates in several access modes, each of which has a different purpose. These modes are: SERVICE, CONFIGURE, DEBUG, OS_FAULTS, and SYS_INFO. See Figure 3-2 , Software Structure Overview.
  • Page 56 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Figure 3-2. Software Structure Overview Woodward...
  • Page 57 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Select Mode Level This first level (below the Top Level/Root System block) contains the five different programmable service mode blocks. The five mode blocks are arranged within the first level as shown in Figure 3-3. Scroll left () or right () to display each mode.
  • Page 58 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Block Level The third level, the block level, is shown in Figure 3-5. The programmable service blocks containing the values to be monitored or changed are found at this level. Scroll down () or up () to get to a different block. Push CLEAR to get back to the header level.
  • Page 59 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators This mode can also be used to make direct numeric entries. However, because this mode is intended to be used while the turbine is running, the Service Panel will accept the entry of numeric values for a block only if the proposed change is very small.
  • Page 60 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 The headers and blocks are assigned their names by the application programmer; this is only an example. 5. The @ indicates which half of the split screen display that key entry will affect.
  • Page 61 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators  To exit the mode, use the CLEAR key to get back to the header. Then press CLEAR again to get back to the Top Level/Root block. The values of all variables that were changed will then be stored in EEPROM.
  • Page 62 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Since configuring a control or viewing how a control is configured is such a commonly used mode the PRGM (program) key has been designed to take the user directly to step 4 below from anywhere in programmable service except DEBUG, OS_FAULTS, or SYS_INFO.
  • Page 63 The DEBUG mode is used to troubleshoot a system during development and is not intended for general use. It should be used only by properly trained Woodward personnel or when expressly authorized by Woodward. Entry into the DEBUG mode requires a password.
  • Page 64 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 The information in the DEBUG mode is arranged as shown in Figure 3-6. Scroll down to go from a MOE category to a MOE block; scroll up or down to go to another MOE block.
  • Page 65 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Figure 3-7. OS_FAULTS Mode Information Arrangement 1. To Enter the OS_FAULTS mode: The following message will be displayed when the system is at the select mode level. (MMMMMMMM = name of mode: SERVICE, CONFIGURE, DEBUG, OS_FAULTS or SYS_INFO) 2.
  • Page 66 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 For password information see Appendix C at the back of this manual. If the password information is not in this manual, see the supervisor or equipment engineer. 4. Enter the password on the numeric keys and press the ENTER key. The header shown below will be displayed.
  • Page 67 Top Level/Root display and permit the system to blank the display to save power and prolong its life. The meanings of the fault messages generated by the 505 System are shown in Chapter 7. Alarms Detected Header 1.
  • Page 68 Top Level/Root display and permit the system to blank the display to save power and prolong its life. The meanings of the alarm messages generated by the 505 System are shown in Chapter 7. Clear Alarms Detected Header 1.
  • Page 69 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators If any other key is pressed, the display will return to the header level and only the following message will appear. 3. To go from the Clear Alarms Detected header to the Top Level/Root display, press the CLEAR key.
  • Page 70 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Figure 3-8. SYS_INFO Mode Information Arrangement To enter the SYS_INFO mode: 1. The following message will be displayed when the system is at the select mode level. (MMMMMMMM = name of mode: SERVICE, CONFIGURE, DEBUG, OS_FAULTS or SYS_INFO) 2.
  • Page 71 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators 3. Press the ENTER key. The header shown below will be displayed. 4. Use the scroll left () or scroll right () key to select the desired SYS_INFO mode header. The header will display as shown below.
  • Page 72 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 2. Continue to Press scroll down () to see more system information. The messages will appear as shown below. 3. From a system information message, to go back to the System Information header, press the CLEAR key.
  • Page 73 Top Level/Root display and permit the system to blank the display to save power and prolong its life. Download Configuration Header The Download function is to be used only by Woodward certified technicians. 1. While the Download Configuration header is displaying, use the scroll down () key to enter this function.
  • Page 74 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 3. If the NO key is pressed the system will return to the Download Configuration header. If the YES key is pressed, the system will display the following message. 4. Push CLEAR to abort the configuration download, else download the configuration as described in Chapter 6 under Transferring Configuration Files.
  • Page 75 Service Mode Procedures Overview The service mode of the 505 control has the same easy to follow format as the program mode. The service mode can be used to customize the control to be more application specific. The parameters that are tuned in the service mode may affect system performance, caution is advised.
  • Page 76 * before it can be adjusted. A work sheet is provided at the end of this manual, to document any changes for future reference. Figure 4-2 illustrates the 505 service menus and the questions/options available under each block.
  • Page 77 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators   Figure 4-2a. Service Mode Blocks Woodward...
  • Page 78 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2   Figure 4-2b. Service Mode Blocks Woodward...
  • Page 79 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators   Figure 4-2c. Service Mode Blocks Woodward...
  • Page 80 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2   Figure 4-2d. Service Mode Blocks Woodward...
  • Page 81 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators   Figure 4-2e. Service Mode Blocks Woodward...
  • Page 82 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2   Figure 4-2f. Service Mode Blocks Woodward...
  • Page 83 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators   Figure 4-2g. Service Mode Blocks Woodward...
  • Page 84 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2   Figure 4-2h. Service Mode Blocks Woodward...
  • Page 85 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Figure 4-2i. Service Mode Blocks Woodward...
  • Page 86 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Service Mode Blocks Figure 4-2 shows the 29 service columns/blocks. The actual blocks that appear will vary with the program configuration. To enter the Service Mode, use the procedure described above. To use the Service mode, simply step through the blocks as described above and change the control features for your application.
  • Page 87 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Idle/Rated Ramp Settings—change the program or default settings of; idle rated rate; use ramp to idle; idle priority; rated priority; Sync/Load Share Settings—change the program or default settings of; input bias gain; input bias deadband; lag-tau value;...
  • Page 88 This gives the operator the flexibility in the service mode to display or tune two different values by using the SELECT button . The service blocks contain information detailing each question and/or 505 program service option. Each question/option shows the default (dflt) value and the adjustable range of that parameter (shown in parentheses).
  • Page 89 Set to YES to permanently Hold the changes made to the Set Point Fast Rate, the Entered Rate, and Underspeed settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Alarms When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 90 When set to NO the generator load units are ‘KW’. When YES the units are set to ‘MW’ under the KW/9 key of the 505 front panel. This allows the 505 to display load units in terms of MW as opposed to KW.
  • Page 91 The following information is provided to display the information useful to the auto start sequence. It allows the operator to check all the times and rates that the 505 is using for the present start sequence. IDLE DELAY (MIN) (status indication only) Indicates the hold time any Low Idle, in minutes.
  • Page 92 NO (Yes/No) Set to YES to permanently Hold the changes made to the Load Share Gain (%). To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Remote Speed Settings (only displayed if configured)
  • Page 93 Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Speed Settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Cascade Control Settings (only displayed if configured)
  • Page 94 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 DROOP (%) dflt= xxx (0.0, 100) Cascade control droop setting. This value is set in the program mode. RATED CASC SETPT dflt= xxx (-20000, 20000) This setting is only used to determine the cascade control droop. This set point is defaulted to the cascade maximum set point limit.
  • Page 95 Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Casc Settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Aux Control Settings (only displayed if configured)
  • Page 96 Set to YES to permanently Hold the changes made to the Set Point Fast Rate, Entered Rate, and Rated Aux Set Point. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Woodward...
  • Page 97 Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Aux Settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Breaker Logic (only displayed if a generator)
  • Page 98 50 or 60 Hz. For example, if rated speed is 3600 rpm = 60 Hz, but the grid is actually running at 60.1 Hz, then this value can be tuned to 0.1 Hz so that the deadband in the 505 will be at 3606 rpm, the actual “speed” of the grid.
  • Page 99 HOLD LIMITER CHANGES ? dflt= NO (Yes/No) Set to YES to Hold the changes made to the Entered Rate. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Local/Remote Functions (only displayed if configured)
  • Page 100 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 CONTACTS ENABLED ? (status indication only) Indicates the status of the Contact input commands. When the indication is NO, local control is selected and remote control from the contact inputs is disabled.
  • Page 101 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Relay Outputs When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 102 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Monitor Speed Inputs When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 103 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Monitor Analog Outputs When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 104 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 X-3 VALUE dflt= 20.0 (-5, 110) Input point #3 of the actuator linearization curve, in percentage. (Must be between the ‘X-2 Value’ and the ‘X-4 Value’ settings) Y-3 VALUE dflt= 20.0 (-5, 110) Output point #3 of the actuator linearization curve, in percentage.
  • Page 105 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Pressure Compensation (only displayed if configured) When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 106 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 X-2 VALUE dflt= 10.0 (-5, 110) Input point #2 of the actuator linearization curve, in percentage. (Must be between the ‘X-1 Value’ and the ‘X-3 Value’ settings) Y-2 VALUE dflt= 10.0 (-5, 110) Output point #2 of the actuator linearization curve, in percentage.
  • Page 107 RED ACT1 FLT DELAY dflt = 0.05 (0.00, 5.0) This value is used if the 505 is programmed as a redundant unit. It sets the amount of time an ACT 1 fault must be present before the 505 trips or transfers.
  • Page 108 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 ENABLED WHEN LOCAL IS SELECTED ? dflt= NO (Yes/No) If using Local/Remote only. If YES, allows commands from Modbus to be active even when LOCAL mode is selected. When NO, the Modbus commands are disabled when in LOCAL.
  • Page 109 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators AUX SCALING FACTOR dflt= 1 (1, 3) Multiplier constant for all Auxiliary analog values sent over both Modbus links. When set to a value other than one (1.0), allows the Modbus device to scale inputs that are too small or to allow decimal places to be displayed.
  • Page 110 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 DRIVER dflt = scroll thru options This value is set in the program mode ASCII OR RTU dflt= xx (1, 2) 1 = ASCII 2 = RTU This value is set in the program mode.
  • Page 111 They correspond to the P (proportional), I (integral), and D (derivative) terms, and are displayed by the 505 as follows:  P = Proportional gain (%) ...
  • Page 112 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Derivative, sometimes called “preact” or “rate”, is very difficult to draw an accurate analogy to, because the action takes place only when the process changes and is directly related to the speed at which the process changes.
  • Page 113 If there is no error, then there is no Proportional effect. Integral Response Integral Gain as stated in the Woodward controls is repeats per minute (or Reset Rate). Therefore, a high amount of Integral gain (high number) would result in a large amount of Reset action.
  • Page 114 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Integral response is provided to eliminate the offset that resulted from straight Proportional control. Figure 5-2 shows how the controller action is Proportional to the measurement change, but as we saw earlier, this results in offset. The Integral (or Reset) action is a function of both time and magnitude of the deviation.
  • Page 115 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators In Closed Loop, however (as opposed to Open Loop), as the measurement decays toward the Setpoint the Proportional action is taking place Proportionally to the measurement change, and the Integral action is decaying proportionately to the magnitude and duration of the deviation until the measurement reaches the setpoint at which time the Integral action is zero.
  • Page 116 Proportional action to reduce stabilization time in returning the process to the setpoint after an upset. Derivative will not remove offset. Woodward Derivative is split into two working domains, Input dominant and Feedback dominant. The allowed values for DR range from 0.01 to 100. The most common derivative is Feedback dominant, it is automatically selected with an Derivative Ratio (DR) from 1 to 100.
  • Page 117 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Figure 5-5. Closed Loop Proportional and Derivative Action Derivative (effects of settings) Figure 5-6. Derivative Setting Effects Woodward...
  • Page 118 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Figure 5-6 shows the effect of different Derivative settings. The curves are relative since it depends on what type of control is desired in order to properly adjust Derivative time. For example, if minimum cycling is desired (as is shown here) then Derivative is added to the 1/4 decay cycle provided by Proportional until more than one cycle is removed and of course the 1/4 decay is destroyed.
  • Page 119 The value of the Derivative Ratio (DR) term can range from 0.01 to 100. In order to simplify adjustment of the dynamics of the 505, adjusting the integral gain value sets both the I and D terms of the PID controller. The DR term establishes the degree of effect the integral gain value has on the “D”...
  • Page 120 1 second reduce the Integral gain term (proportional gain may need to be increased also). On an initial startup 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 121 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators The following method can be used to achieve PID gain values that are close to optimum: 1. Increase Derivative Ratio (SDR) to 100 (Service Mode adjustment) 2. Reduce integral gain to 0.01 (Run Mode adjustment) 3.
  • Page 122 Most 505 problems which will be encountered are covered in the manual. Use the table of contents to locate the sections of the manual that may describe a specific problem.
  • Page 123 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators “Reset caused by” “WATCHDOG TIMEOUT” “Reset caused by” “HALT MONITOR” “Reset caused by” “LOSS OF CLOCK” “Reset caused by” “SOFTWARE RESET” “Reset caused by” “TEST SUBMODULE RESET” All the above errors indicate a problem with the CPU module except the “Display Test Failed”...
  • Page 124 GND terminal (11) with input wiring disconnected, replace the 505. The operation of a contact input to the 505 can be checked by verifying that the voltage from the contact input’s (+) terminal measures 24 Vdc with respect to the contact input GND, terminal (11), when the external contact is closed.
  • Page 125 If an actuator hunts, or appears sticky, it may need dither (especially TM type). If the 505 control is not able to fully close or open the governor valves, check to make sure that the actuators are calibrated correctly, and valve linkage is correctly set.
  • Page 126 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Appendix A. 505 Design Specifications Hardware Specifications Package Flush mount package Approximate physical size of 11” x 14” x 4” Environmental Category: Lloyd’s Type ENV2 NEMA: Type 4X or IEC 60529, IP 56 (applies only to front of flush mount package) Optional bulkhead Enclosure (approximate size: 20”...
  • Page 127 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Power Supply Specification Insulation Resistance/HiPot 24 Vdc power supply: 707 Vdc from power input to chassis 120 Vac/dc and 220 Vac version: 2200 Vdc from power input to chassis Power Inputs 1. Low Voltage dc (18–32 Vdc) –input power fuse rating (F1 &...
  • Page 128 2. Isolated +24 V power provided for discrete inputs. 3. 2.5 mA draw on each input when contact is closed. 4. 18–25 Vdc external contact power may be used instead of the 505’s internal power supply. 5. Solid state relays may be used to drive any discrete input: a.
  • Page 129 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Modbus Communications Ports 1. Two isolated Modbus communications ports. 2. Supports RTU and ASCII protocol. 3. Baud rates to 57600. 4. Supports RS-232, RS-422, and RS-485 hardware. 5. Maximum network cable length is 1220 m/4000 ft (15 m/50 ft with RS-232).
  • Page 130 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 Appendix B. 505 Service Mode Worksheet Governor Serial Number __________________ Application ____________________________ Date _______ For details on individual settings, refer to Chapter 4. SPEED CONTROL SETTINGS IDLE/RATED RAMP (if configured) Rate to Min =...
  • Page 131 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators REMOTE CASC SETTINGS (if configured) LOCAL/REMOTE FUNCTIONS (if configured) Rmt N Mtchd Rte = units/s Remote Enabled (status only) Rmt Casc Max Rte = units/s Enable Contacts Min Casc Set = units...
  • Page 132 505 Digital Governor for Single/Split-Range Actuators Manual 26347V2 ANALOG IN ADJUSTMENTS PRESSURE COMPENSATION Input #1 Offset = Std Inlet Press = Input #1 Gain = Use LG Value ? Input #2 Offset = Mx Inlet P Rte = Input #2 Gain =...
  • Page 133 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators PORT 2 SETTINGS (if configured) Port 2 Link Err (status only) Exception Error (status only) Error Code (status only) Use Mod 2 Trip Use 2-Step Trp? Enbl When Local Trp Always Enbld...
  • Page 134 Service Mode Password When the display reads: The password for your control is: 1 1 1 1 Press the keys on the 505 front panel in this sequence followed by ENTER to gain access to the SERVICE mode. Debug Mode Password...
  • Page 135 OS_FAULTS Mode Password When the display reads: The password for your control is: 1 1 1 4 Press the keys on the 505 front panel in this sequence to gain access to the OS_FAULTS mode. Download Configuration Function Password When the display reads:...
  • Page 136 Prior to installing Control Assistant, you must install the Microsoft .net framework program which is available on the Woodward website (www.woodward.com). This will install some operating system library files that are used by Control Assistant.
  • Page 137 Define the desired directory to save Control Assistant and press ‘Next’. It is preferable to use the default, as it will keep all Woodward Software in a common folder. If the program folder field is blank, type in “Woodward” and the install will create a program folder named Woodward.
  • Page 138 You will need to connect a standard 9-pin Null Modem cable between the communication port # 3 (COM 3) of the 505 Control and a user PC. This port has a 9-pin female sub-D connector and is located on the back of the control. This port’s protocol settings are defaulted to the correct settings to communicate with...
  • Page 139 The final step is to enter the DEBUG mode from the front panel and Tune the block A.TUNES_FILE.CTRL to be * FALSE. (This restores the port to Servlink protocol) Control Assistant can now be closed/exited and the 505 rebooted to reconfigure Port 3. Woodward...
  • Page 140 Open the desired tunable file that is to be loaded into the control. Go to the front keypad of the 505, press CLEAR and go to the SYS_INFO mode and scroll to the ‘Download Configuration’ header. BE SURE THE TURBINE IS NOT RUNNING - Scroll down and enter the Password (see Appendix C).
  • Page 141 Trending Control Parameters This can be done at any time and will not interfere with any 505 control functions. Connect to the 505 COM 3 with a null modem cable and launch CA3.4. Click on the New Trend icon or use File/Open to open a previously saved trend script file (if you have one).
  • Page 142 Manual 26347V2 It will build a service interface definition file for this purpose (which could take a few minutes). It will save this file for future connections to the 505. Figure D-12. Servlink-to-OPC Server – Creating interface file After SOS builds this file, a dialog box will appear and the user will be able to build a trend script file for view system parameters by expanding the explorer window on the left and ‘drag &...
  • Page 143 Explorer in Windows. This tool will look very familiar to users with experience using Woodward’s Watch Windows products. To avoid control conflicts in the 505 platform, this tool will not list all of the Service and Configure parameters that are ported to the front panel keypad/display. Therefore this feature has limited usefulness unless the user is very familiar with GAP application program.
  • Page 144 The downloading and uploading of tunables via WinPanel is not available on the 505 platform. It must be done via the procedure detailed above. Attempting to do this will result in error messages as the feature is not supported in this application.
  • Page 145 Manual 26347V2 505 Digital Governor for Single/Split-Range Actuators Revision History Changes in Revision H—  Updated description of Service Mode options for the inlet pressure compensation feature  Clarified ASCII/RTU setting for the Modbus link between redundant 505s  Updated PID tuning recommendations ...
  • Page 146 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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