Woodward 505E User manual

Product Manual 85018V1
(Revision E)
Original Instructions
505E Digital Governor
for Extraction Steam Turbines
Volume 1
Manual 85018 consists of 2 volumes (85018V1 & 85018V2).
Installation and Operation Manual

General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, on the publications
page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
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. © Woodward 1997
All Rights Reserved

Manual 85018V1 505E Digital Governor
Woodward i
Contents
WARNINGS AND NOTICES........................................................................... VI
ELECTROSTATIC DISCHARGE AWARENESS .................................................VII
REGULATORY COMPLIANCE ......................................................................VIII
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
General Description................................................................................................3
505E Inputs and Outputs........................................................................................4
Control Overview ....................................................................................................8
Speed Control.......................................................................................................10
Auxiliary Control ...................................................................................................11
Load Sharing Input ...............................................................................................12
Cascade Control...................................................................................................12
Extraction/Admission Control ...............................................................................13
Ratio/Limiter .........................................................................................................13
HP and LP Valve Limiters.....................................................................................14
Starting Features ..................................................................................................15
Keypad and Display..............................................................................................21
Watchdog Timer/CPU Fault Control.....................................................................23
CHAPTER 2. INSTALLATION PROCEDURES..................................................24
Introduction...........................................................................................................24
Mechanical Data and Hardware Installation.........................................................24
CHAPTER 3. 505E CONTROL DESCRIPTION................................................42
Introduction...........................................................................................................42
Ratio/Limiter Configurations .................................................................................42
Speed vs. Extr/Adm Priority..................................................................................49
Turbine Start.........................................................................................................51
Turbine Start Modes .............................................................................................52
Critical Speed Avoidance .....................................................................................55
Idle/Rated .............................................................................................................56
Automatic Start Sequence....................................................................................58
No Idle Programmed ............................................................................................60
Speed Control Overview.......................................................................................60
Speed PID Operational Modes.............................................................................61
Synchronization ....................................................................................................70
Extraction and/or Admission Turbine Control.......................................................73
Extraction Control .................................................................................................75
ADMISSION or EXTR/ADM Control.....................................................................76
Remote Extr/Adm Setpoint...................................................................................79
Cascade Control...................................................................................................81
Remote Cascade Setpoint....................................................................................85
Auxiliary Control ...................................................................................................87
Valve Limiters .......................................................................................................92
Emergency Shutdown ..........................................................................................94
Controlled Shutdown ............................................................................................94
Overspeed Test Function .....................................................................................95
Local / Remote Function.......................................................................................96
Function Keys.......................................................................................................97
Relays...................................................................................................................98

505E Digital Governor Manual 85018V1
ii Woodward
Contents
CHAPTER 4. CONFIGURATION PROCEDURES ............................................101
Program Architecture..........................................................................................101
Programming the 505E.......................................................................................103
Exiting the Program Mode ..................................................................................138
Valve / Actuator Calibration and Test.................................................................141
CHAPTER 5. 505E OPERATION.................................................................146
Run Mode Architecture.......................................................................................146
Keypad and Display............................................................................................149
Run Mode Front Panel Keys ..............................................................................150
Starting Procedures............................................................................................151
Overspeed Test Function ...................................................................................155
F3 and F4 Keys ..................................................................................................157
Limiter (LMTR) Key Screens ..............................................................................157
Actuator (ACTR) Key Screens............................................................................159
Control (CONT) Key Screens .............................................................................160
Dynamics (DYN) Key Screens ...........................................................................162
Stop Key Screens...............................................................................................163
Auxiliary (AUX) Key Screens..............................................................................164
Remote / Speed Bias (RMT) Key Screens.........................................................167
Cascade (CAS) Key Screens .............................................................................170
Extraction/ Admission (EXT/ADM) Key Screens ................................................173
Alarms.................................................................................................................176
Trips....................................................................................................................178
Speed, Casc, Aux, and Ext/Adm Dynamics Adjustments ..................................179
CHAPTER 6. COMMUNICATIONS................................................................183
Modbus Communication.....................................................................................183
Port Adjustments ................................................................................................186
505E Control Modbus Addresses.......................................................................186
Specific Address Information..............................................................................199
CHAPTER 7. SERVICE OPTIONS................................................................202
Product Service Options.....................................................................................202
Woodward Factory Servicing Options ................................................................203
Returning Equipment for Repair .........................................................................203
Replacement Parts .............................................................................................204
Engineering Services..........................................................................................204
How to Contact Woodward.................................................................................205
Technical Assistance..........................................................................................205
APPENDIX.505E PROGRAM MODE WORKSHEET......................................206
REVISION HISTORY ..................................................................................209

Manual 85018V1 505E Digital Governor
Woodward iii
Illustrations and Tables
Figure 1-1a. Overview of 505E Functionality (Notes) ............................................5
Figure 1-1b. Overview of 505E Functionality .........................................................6
Figure 1-1c. Overview of 505E Functionality..........................................................7
Figure 1-2. Typical Extraction and/or Admission Steam Turbine...........................9
Figure 1-3. Typical Admission Steam Turbine .....................................................10
Figure 1-4. Overview with Auxiliary Configured as a Limiter................................17
Figure 1-5. Overview with Auxiliary Configured as a Controller...........................18
Figure 1-6. Overview with Decoupled HP & LP Ratio/Limiter, Auxiliary Configured
as a Limiter ......................................................................................19
Figure 1-7. Overview with Decoupled HP & LP Ratio/Limiter, Auxiliary Configured
as a Controller .................................................................................20
Figure 1-8. 505E Key Pad and Display ................................................................21
Figure 2-1. 505E Control Layout (Standard Enclosure) .......................................26
Figure 2-2. 505E Bulkhead-Mounted Enclosure ..................................................27
Figure 2-3. Jumper Options..................................................................................28
Figure 2-4. Jumper Locations...............................................................................28
Figure 2-5. CageClamp Terminal Blocks .............................................................30
Figure 2-6. Control Wiring Diagram......................................................................31
Figure 2-7. Representative 505E I/O Schematic..................................................32
Figure 2-8. Fuse Location.....................................................................................33
Figure 2-9. Shielded Wire Connections................................................................34
Figure 2-10. Typical RS-232 Communications.....................................................39
Figure 2-11. Typical RS-422 Communications.....................................................39
Figure 2-12. Typical RS-485 Communications.....................................................40
Figure 2-13a. Preferred Multipoint Wiring ............................................................41
Figure 2-13b. Alternate Multipoint Wiring .............................................................41
Figure 3-1. Basic Control Overview......................................................................42
Figure 3-2. Coupled HP & LP Mode.....................................................................46
Figure 3-3. Decoupled Inlet (HP) Mode................................................................47
Figure 3-4. Decoupled Exhaust (LP) Mode ..........................................................48
Figure 3-5. Decoupled HP & LP Mode .................................................................49
Figure 3-6. Priority Flow Diagram.........................................................................50
Figure 3-7. Manual Start Mode Example..............................................................53
Figure 3-8. Semiautomatic Start Mode Example..................................................54
Figure 3-9. Automatic Start Mode ........................................................................55
Figure 3-10. Idle / Rated Start ..............................................................................57
Figure 3-11. Automatic Start Sequence ...............................................................58
Figure 3-12. Speed Control Functional Diagram..................................................61
Figure 3-13. Speed PID Control Modes ...............................................................62
Figure 3-14. Frequency and Unit Load Relationship............................................64
Figure 3-15. Speed Relationships ........................................................................65
Figure 3-16. Loadsharing Logic............................................................................72
Figure 3-17. Extr/Adm Control Diagram ...............................................................74
Figure 3-18. Cascade Functional Diagram...........................................................82
Figure 3-19. Aux Control Overview ......................................................................87
Figure 4-1. Basic Program Architecture .............................................................101
Figure 4-2. Initial 505E Program Mode Entry .....................................................102
Figure 4-3a. Program Mode Blocks....................................................................104
Figure 4-3b. Program Mode Blocks....................................................................105
Figure 4-3c. Program Mode Blocks....................................................................106
Figure 4-3d. Program Mode Blocks....................................................................107
Figure 4-3e. Program Mode Blocks....................................................................108
Figure 4-3f. Program Mode Blocks.....................................................................109

505E Digital Governor Manual 85018V1
iv Woodward
Illustrations and Tables
Figure 4-4. Typical Extraction Steam Map .........................................................121
Figure 4-5. Typical Admission Steam Map.........................................................123
Figure 4-6. Typical Extraction & Admission Steam Map ....................................124
Figure 4-7. Exiting the Program Mode ...............................................................138
Figure 4-8. Stroke Actuator/Valve ......................................................................145
Figure 5-1. Basic Program Architecture .............................................................146
Figure 5-2a. Overview of Run Mode...................................................................148
Figure 5-2b. Overview of Run Mode...................................................................149
Figure 5-3. 505E Keypad and Display................................................................150
Figure 5-4. SPEED Key Screens........................................................................152
Figure 5-5. Direct Setpoint Entry ........................................................................155
Figure 5-6. Overspeed Test Enable Key Screens..............................................156
Figure 5-7. LMTR Key Screens ..........................................................................158
Figure 5-8. ACTR Key Screens ..........................................................................159
Figure 5-9. CONT Key Screens..........................................................................160
Figure 5-10. DYN Key Screens ..........................................................................163
Figure 5-11. STOP Key Screens ........................................................................164
Figure 5-12. AUX Key Screens ..........................................................................164
Figure 5-13. RMT Key Screens ..........................................................................167
Figure 5-14. KW Key Screens ............................................................................170
Figure 5-15. CAS Key Screens ..........................................................................171
Figure 5-16. EXT/ADM Key Screens..................................................................173
Figure 5-17. ALARM Screen ..............................................................................177
Figure 5-18. TRIP Screen...................................................................................178
Figure 5-19. Typical Response to Load Change................................................182
Figure 6-1. ASCII/RTU Representation of 3.......................................................184
Figure 6-2. Modbus Frame Definition.................................................................185
Table 1-1. 505s with Polyacrylate Coated Boards .................................................1
Table 2-1. Jumper Options Chart .........................................................................29
Table 3-1. On-Line / Off-Line Dynamics Selection ...............................................68
Table 3-2. Load Sharing Logic .............................................................................73
Table 4-1. Actuator Driver Limits ........................................................................142
Table 5-1. Overview of Run Mode......................................................................147
Table 5-2. Idle/Rated Messages.........................................................................153
Table 5-3. Auto Start Messages .........................................................................154
Table 5-4. Controlling Parameter Messages......................................................161
Table 5-5. Priority Messages..............................................................................162
Table 5-6. Auxiliary Messages (if using Aux enable) .........................................165
Table 5-7. Auxiliary Messages (if using Aux as a limiter)...................................166
Table 5-8. Remote AUX Messages....................................................................166
Table 5-9. Remote Speed Messages.................................................................168
Table 5-10. Control Messages ...........................................................................169
Table 5-11. Cascade Control Messages ............................................................172
Table 5-12. Remote Cascade Messages ...........................................................172
Table 5-13. Extr/Adm Control Messages ...........................................................175
Table 5-14. Remote Extr/Adm Messages ..........................................................176
Table 5-15. Alarm Messages..............................................................................177
Table 5-16. Trip Messages.................................................................................178
Table 6-1. ASCII vs RTU Modbus ......................................................................184
Table 6-2. Modbus Function Codes ...................................................................185
Table 6-3. Modbus Error Codes .........................................................................186

Manual 85018V1 505E Digital Governor
Woodward v
Illustrations and Tables
Table 6-4. Maximum Modbus Discrete and Analog Values ...............................187
Table 6-5. Boolean Write Addresses..................................................................188
Table 6-6a. Boolean Read Addresses ...............................................................189
Table 6-6b. Boolean Read Addresses ...............................................................190
Table 6-7a. Analog Read Addresses .................................................................191
Table 6-7b. Analog Read Addresses .................................................................192
Table 6-7c. Analog Read Addresses..................................................................193
Table 7-8. Analog Write Addresses....................................................................193
Table 6-9a. Control Status..................................................................................194
Table 6-9b. Control Status..................................................................................195
Table 6-10. Analog Input Configuration..............................................................195
Table 6-11. Analog Output Configuration...........................................................196
Table 6-12a. Relay Configuration.......................................................................196
Table 6-12b. Relay Configuration.......................................................................197
Table 6-13. Contact Input Configurations...........................................................198
Table 6-14. Units Configuration..........................................................................199
Table 6-15. Units Configuration..........................................................................199

505E Digital Governor Manual 85018V1
vi Woodward
Warnings and Notices
Important Definitions
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER—Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING—Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE—Indicates a hazard that could result in property damage only
(including damage to the control).
IMPORTANT—Designates an operating tip or maintenance suggestion.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Personal Protective
Equipment
The products described in this publication may present risks that
could lead to personal injury, loss of life, or property damage. Always
wear the appropriate personal protective equipment (PPE) for the job
at hand. Equipment that should be considered includes but is not
limited to:
Eye Protection
Hearing Protection
Hard Hat
Gloves
Safety Boots
Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Automotive
Applications
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
monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
control with possible personal injury, loss of life, or property damage.

Manual 85018V1 505E Digital Governor
Woodward vii
Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
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.
Follow these precautions when working with or near the control.
1. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.

505E Digital Governor Manual 85018V1
viii Woodward
Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.
EMC Directive: Declared to 89/336/EEC COUNCIL DIRECTIVE
of 03 May 1989 on the approximation of the laws
of the Member States relating to electromagnetic
compatibility.
ATEX – Potentially Declared to 94/9/EEC COUNCIL DIRECTIVE of
Explosive 23 March 1994 on the approximation of the laws
Atmospheres of the Member States concerning equipment
Directive: and protective systems intended for use in
potentially explosive atmospheres.
Zone 2, Category 3, Group II G, EEx nA II T3 X
North American Compliance:
These listings are limited only to those units bearing the UL agency identification.
UL: UL Listed for Class I, Division 2, Groups A, B, C,
& D
T3B at 60 °C Ambient (rear enclosure provided)
T3C at 65 °C Ambient (rear enclosure omitted)
For use in Canada and the United States.
UL File E156028
Other International Compliance
C-Tick (ACA/RSM): Declared to Australian Radiocommunications
Act of 1992 and the New Zealand
Radiocommunications Act of 1989.
Gost-R: Certified for use in explosive atmospheres within
the Russian Federation per Gost-R certificate
РОСС US.ГБ04.В01002 with marking
2ExnAIIT3Х
This equipment is considered indicator equipment and is not
to be used as metrology equipment. All measurements need to
be verified using calibrated equipment.
Special Conditions for Safe Use
Wiring must be in accordance with North American Class I, Division 2 or
European Zone 2 wiring methods as applicable, and in accordance with the
authority having jurisdiction.
Field wiring must be stranded copper wire rated at least 75 °C for operating
ambient temperatures expected to exceed 50 °C.
Peripheral equipment must be suitable for the location in which it is used.