Woodward 505HT User manual

Product Manual 35116
(Revision -, 2/2019)
Original Instructions
505HT for Pelton Turbines
8200-1400, 8200-1401
Installation and Operation Manual
Released

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 26455 , Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, 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 26455 , Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, 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 Out-of-date translations are marked with .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— A bold, black line alongside the text identifies changes in this publication since the
last revision.
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.
Manual 35116
Copyright © Woodward, Inc. 2019
All Rights Reserved
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Contents
W ARNINGS AND N OTICES ..............................................................................................................7
E LECTROSTATIC D ISCHARGE A WARENESS ....................................................................................9
R EGULATORY C OMPLIANCE ........................................................................................................10
C HAPTER 1. G ENERAL I NFORMATION ...........................................................................................11
Information ..................................................................................................................................................11
Controller Overview.....................................................................................................................................11
Operator Control Panel...............................................................................................................................12
Features......................................................................................................................................................12
Using the 505HT .........................................................................................................................................12
505 Inputs and outputs................................................................................................................................13
Keypad and Display....................................................................................................................................15
Watchdog Timer/CPU Fault Control ...........................................................................................................17
C HAPTER 2. H ARDWARE S PECIFICATIONS ...................................................................................18
Flex 500 Description and Features.............................................................................................................18
Environmental Specifications......................................................................................................................19
Maintenance Info and Recommendations ..................................................................................................19
Electromagnetic Compatibility (EMC) .........................................................................................................20
Outline Drawing for Installation...................................................................................................................20
Input Power Specification............................................................................................................................22
Visual Indicators (LED’s) & CPU Configuration..........................................................................................22
Communications (Ethernet) ........................................................................................................................23
Communications (CAN) ..............................................................................................................................24
Communications (Service Ports) ................................................................................................................28
Hardware - Terminal Blocks & Wiring.........................................................................................................29
Terminal Block Connectors.........................................................................................................................30
Hardware - Speed Sensor Inputs................................................................................................................31
Hardware - Analog Inputs (4-20 mA) ..........................................................................................................32
Hardware - Analog Outputs (4-20 mA) .......................................................................................................34
Hardware - Actuator Outputs ......................................................................................................................35
Hardware - Discrete Inputs .........................................................................................................................36
Hardware - Relay Outputs...........................................................................................................................37
Troubleshooting Fault Codes......................................................................................................................38
Troubleshooting & Commissioning Checks................................................................................................38
C HAPTER 3. 505HT C ONTROL D ESCRIPTION ...............................................................................41
Description of IO .........................................................................................................................................41
Control Inputs..............................................................................................................................................41
Control Outputs...........................................................................................................................................43
Functions.....................................................................................................................................................45
C HAPTER 4. 505HT D ISPLAY ......................................................................................................60
Program Architecture ..................................................................................................................................60
Display Modes and User Levels .................................................................................................................60
Home...........................................................................................................................................................63
Overview .....................................................................................................................................................64
Custom trend...............................................................................................................................................66
Manual (All Nozzles)...................................................................................................................................67
Manual (Individual Nozzles)........................................................................................................................69
Nozzle Test Screen.....................................................................................................................................70
Baseload Screen.........................................................................................................................................72
Baseload Commands Screen .....................................................................................................................74
General Configuration (1/9) Screen............................................................................................................76
General Configuration (2/9) Screen............................................................................................................78
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General Configuration (3/9) Screen............................................................................................................79
General Configuration (4/9) Screen............................................................................................................81
General Configuration (5/9) Screen............................................................................................................83
General Configuration (6/9) Screen............................................................................................................85
General Configuration (7/9) Screen............................................................................................................87
General Configuration (8/9) Screen............................................................................................................89
General Configuration (9/9) Screen............................................................................................................91
Offline PID Screen ......................................................................................................................................93
Online PID Screen ......................................................................................................................................94
Baseload PID Screen..................................................................................................................................96
Small System Detection PID Screen ..........................................................................................................97
Step Test Screen ........................................................................................................................................99
Nozzle (1) Screen .....................................................................................................................................100
Nozzle (2) Screen .....................................................................................................................................101
Nozzle (3) Screen .....................................................................................................................................102
Nozzle Rotation Screen ............................................................................................................................104
Deflector Screen .......................................................................................................................................105
Deflector Commands Screen....................................................................................................................107
Droop Screen............................................................................................................................................108
Droop Commands Screen.........................................................................................................................110
Isolated Mode Commands Screen............................................................................................................112
Nozzles Mismatch Screen.........................................................................................................................113
Level Screen .............................................................................................................................................115
Level Commands Screen..........................................................................................................................117
Overspeed Test Screen............................................................................................................................119
Remote Alarms Screen.............................................................................................................................121
Communications (Serial Port) Screen.......................................................................................................122
Communications (Ethernet) Screen..........................................................................................................124
Communications (Ethernet IP) Screen .....................................................................................................125
Communications (Default Gateway) Screen.............................................................................................127
Speed Switch Screen................................................................................................................................128
Nozzle Switch Screen ...............................................................................................................................129
Load Switch Screen ..................................................................................................................................130
Status Screen............................................................................................................................................132
Analog Inputs Screen................................................................................................................................133
Speed Input Screen ..................................................................................................................................135
Contact Inputs Screen...............................................................................................................................137
Analog Outputs Screen.............................................................................................................................139
Relay Outputs Screen...............................................................................................................................141
Actuator Outputs Screen...........................................................................................................................143
Force Actuator Outputs Screen ................................................................................................................145
Trip Summary Screen ...............................................................................................................................146
Alarm Summary Screen............................................................................................................................147
Check Configuration Screen.....................................................................................................................148
C HAPTER 5. P RODUCT S UPPORT AND S ERVICE O PTIONS ...........................................................149
Product Support Options...........................................................................................................................149
Product Service Options ...........................................................................................................................149
Returning Equipment for Repair ...............................................................................................................150
Replacement Parts....................................................................................................................................151
Engineering Services................................................................................................................................151
Contacting Woodward’s Support Organization.........................................................................................151
Technical Assistance ................................................................................................................................152
C HAPTER 6. A SSET M ANAGEMENT AND R EFURBISHMENT S CHEDULING P ERIOD ..........................153
A PPENDIX A – A LARM L IST .......................................................................................................154
A PPENDIX B – S HUTDOWN L IST ................................................................................................162
A PPENDIX C – C ONFIGURATION E RROR L IST .............................................................................164
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A PPENDIX D – M ODBUS L IST .....................................................................................................171
Boolean Reads..........................................................................................................................................172
A PPENDIX E – T REND V ARIABLES L IST ......................................................................................188
A PPENDIX F – B LOCK D IAGRAM ................................................................................................189
R EVISION H ISTORY ...................................................................................................................195
D ECLARATIONS ........................................................................................................................196
The following are trademarks of Woodward, Inc.:
GAP
Linknet
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Illustrations and Tables
Figure 1-1. 505 Keypad and Display...........................................................................................................15
Figure 2-1. Functional Block Diagram (505 Control) ..................................................................................18
Figure 2-2. 505D Outline Drawing ..............................................................................................................21
Figure 2-3. COM1 Example RS-485 wiring.................................................................................................27
Figure 2-4. 505 Back Cover Label ..............................................................................................................29
Figure 2-5. Terminal Block Connectors ......................................................................................................30
Figure 2-6. Speed Sensor Block Diagram ..................................................................................................32
Figure 2-7. Analog Input – Self-Powered Block Diagram ...........................................................................33
Figure 2-8. Analog Input – Loop-Powered Block Diagram .........................................................................33
Figure 2-9. Analog Output Block Diagram..................................................................................................34
Figure 2-10. Actuator Output Block Diagram..............................................................................................35
Figure 2-11. Discrete Input Block Diagram.................................................................................................36
Figure 2-12. Relay Output Block Diagram..................................................................................................37
Figure 3-1. Nozzle Limit..............................................................................................................................46
Figure 3-2. Speed Deadband Function.......................................................................................................47
Figure 3-3. Nozzle Position.........................................................................................................................49
Figure 3-4. Pond Level Control Accuracy...................................................................................................52
Figure 4-1. Confirmation Screen.................................................................................................................62
Figure 4-2. Start Confirmation Screen ........................................................................................................63
Figure 4-3. Home Screen............................................................................................................................63
Figure 4-4. Overview Screen ......................................................................................................................64
Figure 4-5. Nozzle Limit popup...................................................................................................................65
Figure 4-6. Custom Trend Screen ..............................................................................................................66
Figure 4-7. Custom Trend Settings Screen ................................................................................................67
Figure 4-8. Manual (All Nozzles) Screen....................................................................................................67
Figure 4-9. Manual (Individual Nozzles) Screen.........................................................................................69
Figure 4-10. Nozzle Test Screen ................................................................................................................70
Figure 4-11. Baseload Screen ....................................................................................................................72
Figure 4-12. Baseload Commands Screen.................................................................................................74
Figure 4-13. General Configuration (1/9) Screen .......................................................................................76
Figure 4-14. General Configuration (2/9) Screen .......................................................................................78
Figure 4-15. General Configuration (3/9) Screen .......................................................................................79
Figure 4-16. General Configuration (4/9) Screen .......................................................................................81
Figure 4-17. General Configuration (5/9) Screen .......................................................................................83
Figure 4-18. General Configuration (6/9) Screen .......................................................................................85
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Figure 4-19. General Configuration (7/9) Screen .......................................................................................87
Figure 4-20. General Configuration (8/9) Screen .......................................................................................89
Figure 4-21. General Configuration (9/9) Screen .......................................................................................91
Figure 4-22. Offline PID Screen..................................................................................................................93
Figure 4-23. Offline PID Settings Screen....................................................................................................93
Figure 4-24. Online PID Screen..................................................................................................................94
Figure 4-25. Online PID Settings Screen....................................................................................................95
Figure 4-26. Baseload PID Screen .............................................................................................................96
Figure 4-27. Baseload PID Settings Screen...............................................................................................96
Figure 4-28. Small System Detection PID Screen......................................................................................97
Figure 4-29. Small System Detection PID Settings Screen........................................................................98
Figure 4-30. Step Test Screen....................................................................................................................99
Figure 4-31. Nozzles (1) Screen...............................................................................................................100
Figure 4-32. Nozzles (2) Screen...............................................................................................................101
Figure 4-33. Nozzles (3) Screen...............................................................................................................102
Figure 4-34. Nozzles Rotation Screen......................................................................................................104
Figure 4-35. Deflector Screen...................................................................................................................105
Figure 4-36. Deflector Commands Screen ...............................................................................................107
Figure 4-37. Droop Screen........................................................................................................................108
Figure 4-38. Droop Commands Screen....................................................................................................110
Figure 4-39. Isolated Mode Commands Screen.......................................................................................112
Figure 4-40. Nozzles Mismatch Screen....................................................................................................113
Figure 4-41. Level Screen.........................................................................................................................115
Figure 4-42. Level Commands Screen.....................................................................................................117
Figure 4-43. Overspeed Test Screen........................................................................................................119
Figure 4-44. Remote Alarms Screen ........................................................................................................121
Figure 4-45. Communications (Serial Port) Screen..................................................................................122
Figure 4-46. Communications (Ethernet) Screen .....................................................................................124
Figure 4-47. Communications (Ethernet IP) Screen.................................................................................125
Figure 4-48. Communications (Default Gateway) Screen ........................................................................127
Figure 4-49. Speed Switches Screen .......................................................................................................128
Figure 4-50. Nozzle Switches Screen.......................................................................................................129
Figure 4-51. Load Switches Screen..........................................................................................................130
Figure 4-52. Status Screen.......................................................................................................................132
Figure 4-53. Analog Inputs Summary Screen...........................................................................................133
Figure 4-54. Analog Inputs Screen ...........................................................................................................133
Figure 4-55. Analog Inputs Calibrate Screen............................................................................................135
Figure 4-56. Speed Signal 1 Screen.........................................................................................................135
Figure 4-57. Speed Sensor Open Wire Test Screen................................................................................137
Figure 4-58. Contact Inputs Summary Screen..........................................................................................137
Figure 4-59. Contact Inputs Screen..........................................................................................................138
Figure 4-60. Analog Outputs Summary Screen........................................................................................139
Figure 4-61. Analog Outputs Screen ........................................................................................................139
Figure 4-62. Relay Outputs Summary Screen..........................................................................................141
Figure 4-63. Relay Outputs Screen ..........................................................................................................142
Figure 4-64. Actuator Outputs Screen ......................................................................................................143
Figure 4-65. Actuator Outputs Screen ......................................................................................................145
Figure 4-66. Trip Summary Screen...........................................................................................................146
Figure 4-67. Alarm Summary Screen .......................................................................................................147
Figure 4-68. Check Configuration Screen.................................................................................................148
Figure F-1. Nozzle Limit............................................................................................................................189
Figure F-2. Level Control ..........................................................................................................................189
Figure F-3. Baseload Control....................................................................................................................190
Figure F-4. Offline Speed Control.............................................................................................................190
Figure F-5. Droop Feedback.....................................................................................................................191
Figure F-6. Online Speed Control.............................................................................................................191
Figure F-7. Nozzle Average Demand .......................................................................................................192
Figure F-8. Nozzle Load Sharing..............................................................................................................193
Figure F-9. Nozzle Auto / Manual Demand...............................................................................................193
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Figure F-10. Deflector Logic......................................................................................................................194
Table 1-1. Selectable functions for 4-20mA Analog Inputs.........................................................................13
Table 1-2. Selectable functions for Discrete Inputs ....................................................................................13
Table 1-3. Selectable functions for 4-20mA Analog Outputs......................................................................14
Table 1-4. Selectable functions for Relay Outputs .....................................................................................14
Table 2-1. Environmental Specifications.....................................................................................................19
Table 2-2. Input Power Connector Pinout...................................................................................................22
Table 2-3. Ethernet Ports #1-4 (10/100).....................................................................................................24
Table 2-4. CAN Specifications....................................................................................................................25
Table 2-5. CAN Connector Pinout ..............................................................................................................25
Table 2-6. CAN Cable Specifications..........................................................................................................26
Table 2-7. Communications (RS-232/RS-485) Specifications....................................................................27
Table 2-8. COM1 Serial port (RS-232/485) ................................................................................................27
Table 2-9. CPU Service Port (3 pin, 2 mm) ................................................................................................28
Table 2-10. Specifications (SSI) .................................................................................................................31
Table 2-11. Specifications (AI)....................................................................................................................32
Table 2-12. Specifications (AO)..................................................................................................................34
Table 2-13. Specifications (ACT)................................................................................................................35
Table 2-14. Specifications (DI)....................................................................................................................36
Table 2-15. Specifications (RO)..................................................................................................................37
Table 2-16. Troubleshooting Fault Codes...................................................................................................38
Table 4-1. Mode Access by User Level......................................................................................................60
Table 4-2. 505HT Display Menus and Basic Functions..............................................................................63
Table 4-3. Manual (All Nozzles) Command Buttons and Parameters........................................................68
Table 4-4. Manual (Individual Nozzles) Command Buttons and Parameters.............................................69
Table 4-5. Nozzle Test Screen Command Buttons and Parameters..........................................................71
Table 4-6. Baseload Screen Command Buttons and Parameters..............................................................73
Table 4-7. Baseload Commands Screen Command Buttons and Parameters..........................................75
Table 4-8. General Configuration (1/9) Screen Command Buttons and Parameters.................................77
Table 4-9. General Configuration (2/9) Screen Command Buttons and Parameters.................................78
Table 4-10. General Configuration (3/9) Screen Command Buttons and Parameters...............................80
Table 4-11. General Configuration (4/9) Screen Command Buttons and Parameters...............................82
Table 4-12. General Configuration (5/9) Screen Command Buttons and Parameters...............................84
Table 4-13. General Configuration (6/9) Screen Command Buttons and Parameters...............................86
Table 4-14. General Configuration (7/9) Screen Command Buttons and Parameters...............................88
Table 4-15. General Configuration (8/9) Screen Command Buttons and Parameters...............................90
Table 4-16. General Configuration (9/9) Screen Command Buttons and Parameters...............................92
Table 4-17. Offline PID Configuration Settings...........................................................................................93
Table 4-18. Online PID Configuration Settings...........................................................................................95
Table 4-19. Baseload PID Configuration Settings ......................................................................................96
Table 4-20. Small System Detection PID Configuration Settings...............................................................98
Table 4-21. Step Test Screen Configuration Settings ................................................................................99
Table 4-22. Nozzles (1) Screen Configuration Values..............................................................................100
Table 4-23. Nozzles (2) Screen Configuration Values..............................................................................101
Table 4-24. Nozzles (3) Screen Configuration Values..............................................................................103
Table 4-25. Nozzle Rotation Screen Configuration Values ......................................................................104
Table 4-26. Deflector Screen Configuration Values .................................................................................106
Table 4-27. Deflector Commands Screen Configuration Values..............................................................107
Table 4-28. Droop Screen Configuration Values......................................................................................109
Table 4-29. Droop Commands Screen Configuration Values...................................................................111
Table 4-30. Isolated Mode Commands Screen Configuration Values......................................................112
Table 4-31. Nozzles Mismatch Screen Configuration Values...................................................................114
Table 4-32. Level Screen Configuration Values .......................................................................................116
Table 4-33. Level Commands Screen Configuration Values....................................................................117
Table 4-34. Overspeed Test Screen Configuration Values......................................................................119
Table 4-35. Remote Alarms Screen Configuration Values.......................................................................121
Table 4-36. Communications (Serial Port) Screen Configuration Values.................................................122
Table 4-37. Communications (Ethernet) Screen Configuration Values....................................................124
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Table 4-38. Communications (Ethernet IP) Screen Configuration Values ...............................................126
Table 4-39. Communications (Default Gateway) Screen Configuration Values.......................................127
Table 4-40. Speed Switches Screen Configuration Values......................................................................128
Table 4-41. Nozzle Switches Screen Configuration Values .....................................................................129
Table 4-42. Load Switches Screen Configuration Values ........................................................................130
Table 4-43. Analog Inputs Screen Configuration Values..........................................................................134
Table 4-44. Speed Signal 1 Screen Configuration Values .......................................................................136
Table 4-45. Contact Inputs Screen Configuration Values.........................................................................138
Table 4-46. Analog Outputs Screen Configuration Values.......................................................................140
Table 4-47. Relay Outputs Screen Configuration Values.........................................................................142
Table 4-48. Actuator Outputs Screen Configuration Values.....................................................................143
Table D-1. Boolean Writes........................................................................................................................171
Table D-2. Analog Reads..........................................................................................................................183
Table D-3. Analog Writes..........................................................................................................................187
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Warnings and Notices
Important Definitions
This is the safety alert symbol 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.
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IOLOCK. When a CPU or I/O module fails, watchdog logic drives it
into an IOLOCK condition where all output circuits and signals are
driven to a known de-energized state as described below. The
System MUST be designed such that IOLOCK and power OFF states
will result in a SAFE condition of the controlled device.
•CPU and I/O module failures will drive the module into an
IOLOCK state
•CPU failure will assert an IOLOCK signal to all modules and
expansion racks to drive them into an IOLOCK state.
•Discrete outputs / relay drivers will be non-active and de-
energized
•Analog and Actuator outputs will be non-active and de-
energized with zero voltage or zero current.
The IOLOCK state is asserted under various conditions including
•CPU and I/O module watchdog failures
•Power Up and Power Down conditions.
•System reset and hardware/software initialization
•Entering configuration mode
NOTE: Additional watchdog details and any exceptions to these
failure states are specified in the related CPU or I/O module section
of the manual.
Emergency
Disconnecting
Device
An emergency switch or circuit breaker shall be included in the
building installation that is in close proximity to the equipment and
within easy reach of the operator. The switch or circuit breaker shall
be clearly marked as the disconnecting device for the equipment.
The switch or circuit breaker shall not interrupt the Protective Earth
(PE) conductor.
Risk of Calibration
and Checkout
The calibration and checkout procedure should only be performed by
authorized personnel knowledgeable of the risks posed by live
electrical equipment.
Fuse Power Supply
Mains
The Power Supply MAINS should be properly fused according the
NEC/CEC or Authority Having Final Jurisdiction per the Input Power
Specifications.
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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.
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Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.
EMC Directive
Declared to Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014 on the harmonization of the laws of the
Member States relating to electromagnetic compatibility. (EMC)
Low Voltage Directive:
Declared to Directive 2014/35/EU on the harmonization of the laws of
the Member States relating to the making available on the market of
electrical equipment designed for use within certain voltage limits.
North American
Compliance:
CSA:
CSA Certified for Ordinary Locations.
For use in Canada and the United States
Certificate 70006135
This product is certified as a component for use in other equipment. The final combination is subject to
acceptance by the authority having jurisdiction or local inspection.
Special Conditions for Safe Use
A fixed wiring installation is required. Field wiring must be in accordance with the Local Inspection
Authority having jurisdiction. On high voltage versions of the control the interior of the enclosure shall not
be accessible in normal operation without the use of a tool.
Field wiring must be suitable for the following temperatures:
•Power Input rated minimum of +95˚C.
•All remaining connections; +10˚C above highest ambient.
A switch or circuit breaker shall be included in the building installation that is in close proximity to the
equipment and within easy reach of the operator. The switch or circuit breaker shall be clearly marked as
the disconnecting device for the equipment. The switch or circuit breaker shall not interrupt the Protective
Earth (PE) conductor.
The 505 Digital Control shall not be installed in areas exceeding Pollution Degree 2 as defined in IEC
60664-1.
Protective Earth Grounding of the 505 Digital Control is required to be connected to the PE terminal.
The Real Time Clock Battery located on the CPU board is not to be recharged and is not user
replaceable. Contact a Woodward Authorized Service Center if a replacement service is needed.
This equipment must be installed in an area or enclosure providing adequate protection against high
impact. (7 Joules) The control is rated for 2 Joules impact.
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Chapter 1.
General Information
Information
This manual describes the Woodward 505HT Digital Governor for Pelton Turbines, including:
•Up to 6 nozzles
•Digital Deflector
The option charts below shows the part numbers and the differences between the models. This manual
does not contain instructions for the operation of the complete turbine system. For turbine or plant
operating instructions, contact the plant-equipment manufacturer.
Part Number options
Part Number Description
8200-1400 505H (LV-STD) PELTON TURBINE CONTROL
8200-1401 505H (HV-STD) PELTON TURBINE CONTROL
Terminology
505 Refers to the overall Woodward Product family / hardware platform
505XT Refers specifically to the Control/GUI application software features described in this manual –
identified on unit p/n label and logo on Home screen
General Installation and Operating Notes and Warnings
Peripheral equipment must be suitable for the location in which it is used.
Note: For additional installation and operating information, see the
Regulatory Compliance section of this manual.
Controller Overview
The 505HT is field programmable which allows a single design to be used in many different control
applications and reduces both cost and delivery time. It uses a built in graphical user interface (GUI) with
multi-lingual menu driven screens to instruct site engineers on configuring the control to a specific
application. The 505HT can be configured to operate as a stand-alone unit or in conjunction with a plant’s
Distributed Control System.
Designed for hydro turbine control, the 505HT control includes three PID controllers (Offline, Online e
Baseload), start-up routine, and multiple protection functions overspeed, Small System Detection, etc.)
which can be configured by a user depending on the specific turbine application’s requirements. Users
can configure the 505’s different PID controllers, start routines, discrete and analog I/O functions and
protection levels themselves without the need for a special control engineer. A first-out indication feature
for system shutdowns reduces troubleshooting time. Once configured, the 505HT performs a
configuration check routine to ensure that the programmer did not make any basic configuration mistakes.
This control is exclusive for Pelton Turbines up to 6 (six) nozzles. The Actuator output 1 is dedicated to
nozzle 1 and the actuator output 2 is dedicated to nozzle 2. If the turbine has more than 2 nozzles it is
necessary to use analog outputs to the other(s) nozzle(s). Front panel ESTOP button will shut down the
actuators circuits 1 and 2, so if this is not desired to the control, configure analog outputs to this function.
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The nozzles routine has the options to rotate the nozzles in some conditions. The conditions are:
•Nozzle fail: If a nozzle is selected and this specific nozzle has a signal fault or a mismatch between
demand and position the rotation will be done.
•Operator command: The operator can give a command to rotate nozzles at any time. The command
can be issued by frontal HMI or Modbus.
•Timer: The rotation can be done by timer (in hours). The timer is initiated every time a new start
command is issued and accepted by the control or an operator rotation command is issued.
Operator Control Panel
The 505HT is a field configurable hydro turbine control and operator control panel (OCP) integrated into
one package. A comprehensive graphical operator control panel display and keypad is located on the
505HT’s front panel. This display can be used to configure the 505, make On-Line program adjustments,
and operate the turbine/system.
Features
The 505HT provides the following features:
•Start / Stop / unload routines
•Black Start routine
•Feed forward control
•Speed Control / Droop Control (kW and Position) / Baseload
•Manual Control (Individual nozzles manual control)
•Small System detection logic
•Level control (pond or Tail)
•Nozzle Sequencing / Rotation
•Speed / Load / Nozzle Switches
•Nozzle limit
•Remote analog setpoints for speed, nozzle, level, power and manual control
•Generator breaker logic
•Level switches for: Speed, Nozzle Position and Load
•Integrated first-out problem indicator
•Trip and Alarm event recorder
•User-friendly menu format
•Real-time trend screens
•Real-time clock synchronization via SNTP
•Ethernet communications
Using the 505HT
The 505HT control has three normal operating modes, Configuration Mode, Service Mode and the Run
Mode.
Configuration Mode –
This mode is used to select the options needed to configure the control to your specific turbine
application. While in this mode, the control will force the hardware into IO LOCK, meaning that no outputs
will be active, all Relays will be de energized, and all Analog output signals will be at 0 current. Once the
control has been configured, the Configuration mode is typically not needed again, unless turbine options
or operation changes. It is available to be viewed at any time. A password is required to log into this
mode.
Anytime the control is in IOLOCK all Relays will be de-energized and
all Analog outputs will be at 0 current. Ensure that the devices
receiving these commands are fail-safe at these states.
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Calibration Mode –
This mode is used to calibrate, tune and adjust certain parameters either while the unit is shutdown, or
during turbine run time. A password is required to log into this mode.
Operation Mode -
This mode is the typical state for normal operations of the control and the turbine. The Run Mode is used
to operate the turbine from start-up through shutdown.
505 Inputs and outputs
Control Inputs
Speed Input Signals
Two redundant speed inputs are configurable to accept MPUs (magnetic pickup units), or active proximity
probes.
Analog 4-20mA Input Signals
There are eight configurable analog inputs available on the 505 hardware, each of which can be
configured as one of the following input functions:
Table 1-1. Selectable functions for 4-20mA Analog Inputs
1- Not used
2- Pond / Tail level
3- Generator Power
4- Speed Bias
5- Remote Speed Reference
6- Nozzle Position Limiter
7- Remote Baseload reference
8- Remote level reference
9- Nozzle 1 Position feedback
10- Nozzle 2 Position feedback
11- Nozzle 3 Position feedback
12- Nozzle 4 Position feedback
13- Nozzle 5 Position feedback
14- Nozzle 6 Position feedback
Discrete Contact Input Signals
Twenty contact inputs are available. The first five inputs are dedicated for Run/Stop (DI-1), Raise
Speed/load (DI-2), Lower Speed/Load (DI-3), Breaker Closed (DI-4) and Emergency Shutdown (DI-5).
The next 4 channels are configurable as per the list below, but for convenience are defaulted to the
following functions: Deflector closed, Deflector Opened, Baseload Enable and Start Permissive. The rest
of the additional contact inputs are available for configuration to function as various controller discrete
input functions as listed below. On the front panel display there are 4 additional keys that are always
available for operational functions (GREEN keys) – Start/Stop/Reset and Adjust Up/Down for raising or
lowering a highlighted value.
Table 1-2. Selectable functions for Discrete Inputs
1- Not Used
2- Manual Nozzle Control Enable
3- Pond / Tail Level Control Enable
4- Nozzle Limit Raise
5- Nozzle Limit Lower
6- Creep input #1
7- Creep input #2
8- Reset
9- External Start Permissive
10- Speed Bias Raise
11 - Speed Bias Lower
12- Baseload Enable
13- Unload
14- Local / Remote
15- load droop Enable
16- Remote Fault #1
25- Manual Nozzle #4 Enable
26- Manual Nozzle #5 Enable
27- Manual Nozzle #6 Enable
28- Nozzle #1 Manual Raise
29- Nozzle #1 Manual Lower
30- Nozzle #2 Manual Raise
31- Nozzle #2 Manual Lower
32- Nozzle #3 Manual Raise
33- Nozzle #3 Manual Lower
34- Nozzle #4 Manual Raise
35- Nozzle #4 Manual Lower
36- Nozzle #5 Manual Raise
37- Nozzle #5 Manual Lower
38- Nozzle #6 Manual Raise
39- Nozzle #6 Manual Lower
40- Manual Deflector Enable
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17 - Remote Fault #2
18 - Remote Fault #3
19 - Remote Fault #4
20 - Remote Fault #5
21 - Remote Fault #6
22- Manual Nozzle #1 Enable
23- Manual Nozzle #2 Enable
24- Manual Nozzle #3 Enable
41- Deflector Manual Close
42- Deflector Closed
43- Deflector Opened
44- Enable Remote Speed
45- Enable Remote Baseload
46- Enable Remote Level
47- Overspeed test Enable
48 – Force Nozzle Rotation
Control Outputs
Actuator Outputs
Two 4-20mA or 20-160mA actuator outputs are available for use. These outputs are defined to be used
as Nozzle 1 and nozzle 2 and cannot be used for other functions.
Front panel ESTOP button
will shutdown the actuators circuits 1 and
2, so if this is not desired to the control, configure analog outputs to
this function. Some valves should remain with 4mA during the
shutdown, and these actuator outputs will not work for this case.
Analog 4-20mA Outputs
Six 4–20 mA analog outputs are available for use and each can be configured as one of the following
output functions:
Table 1-3. Selectable functions for 4-20mA Analog Outputs
1- Not Used
2- Tachometer
3- Nozzle 1 Position
4- Nozzle 2 Position
5- Nozzle 3 Position
6- Nozzle 4 Position
7- Nozzle 5 Position
8- Nozzle 6 Position
9- Nozzle Limit
10- Speed Adjustment
11- Pond/Tail Level
12- Pond/Tail Level Setpoint
13- Speed Bias
14- Generator Power
15- Nozzle 1 Actuator
16- Nozzle 2 Actuator
17- Nozzle 3 Actuator
18- Nozzle 4 Actuator
19- Nozzle 5 Actuator
20- Nozzle 6 Actuator
Relay Outputs
Eight Form-C relay contact outputs are available. The first channel is dedicated to be a Close Deflector
output. The other seven are configurable relays. Each relay can be programmed to provide a contact
related to a conditional state as listed.
Table 1-4. Selectable functions for Relay Outputs
1- Not Used
2- Nozzle Position Switch #1
3- Nozzle Position Switch #2
4- Nozzle Position Switch #3
5- Nozzle Position Switch #4
6- Speed Switch #1
7- Speed Switch #2
8- Speed Switch #3
9- Speed Switch #4
10- Speed Switch #5
11- Speed Switch #6
12- General Shutdown
13- General Governor Alarm
14- Creep indication
22- Active Power Switch #4
23- Ready for Start
24- Turbine Stable Speed
25- Reset Command
26- Close Deflector
27- Open Deflector
28- All Nozzle Position Signal Fail
29- Level Signal Fail
30- Remote Speed Signal Fail
31- Speed Bias Input Signal Fail
32- Incomplete Start
33- All Nozzle position Major Mismatch
34- Total Speed Signal Fail
35- Speed Signal #1 Fault
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15- Speed Bias Enabled
16- Start Permissive Enabled
17- Overspeed Shutdown
18- Gen Breaker open Command
19- Active Power Switch #1
20- Active Power Switch #2
21- Active Power Switch #3
36- Speed Signal #2 Fault
37- Analog Nozzle Limiter Signal Fail
38- Remote Baseload Signal Fail
39- Power Transducer Signal Fail
40- Internal Fault
41- Control Powered On
Control Communication Interfaces
A complete Modbus list of information is available for HMI, plant DCS or other control interfaces. Three
channels are available for this communication method, 2 Ethernet (RJ45) ports and 1 serial port. The
serial port protocol can be either ASCII or RTU and the communications can be RS-232 or RS-485. The
Ethernet links are TCP on either ENET ports 1, 2, 3 and 4.
The control also communicates Servlink protocol (Woodward proprietary) via the Ethernet ports. Using
Woodward’s Servlink to OPC Server tool any PC can use this connection to communicate to the control
and relay OPC data to the various service tools that support the product.
CAN
The CAN communication ports are available for interfacing the control application with other products.
This feature is not being used.
Keypad and Display
Graphical Display Key Inputs
The front panel display is designed to provide the user with multiple levels of access for configuring,
calibrating, tuning, operating, and monitoring the turbine operation. No additional control panels are
required to operate the turbine, every turbine control function can be performed from the 505’s front
panel.
Figure 1-1. 505 Keypad and Display
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A description of each key’s function follows.
Hard Key Commands
NUMERIC KEYPAD: These are available for entering numeric values or text strings directly into the
control when a configurable or programmable edit field has been selected. The
bottom row of keys have some special features.
This is a backspace and delete (used when entering text)
In text mode this functions as a Shift key. When making analog adjustments with the
ADJUST key – pressing this key at the same time as the ADJUST will invoke a ‘Fast’ rate
of adjustment
Brightness key – hold this down and then use the ADJUST key to increase/decrease the
screen brightness
EMERGENCY TRIP KEY: This will Trip the Turbine and remove all current from the Actuator outputs
(zero current).
LED
Four LED’s are on the left side – a Summary Trip, Summary Alarm, IO Lock, and CPU Health. The first
two are controlled solely by the GAP program and relate to the status of the control. The IOLOCK and
CPU LED’s relate to the H/W status and are identical to these same indications on the back of the 505
VIEW buttons will jump to the Trip or Alarm Summary screen to show these events in sequence with time
stamp.
MODE button will jump to a Login screen that allows the user to view current permissions and allow
access to changing the user login level
ESC Key – this will always step the user ‘back’ one page from the current page displayed
HOME Key
Brings the user to the Home menu.
NAVIGATION CROSS KEYS
These are the primary keys for navigating from page to page, or for navigation of the FOCUS on any
page.
Soft Key Commands – Dependent on the screen currently in view – the user must use the navigation
cross keys to move the “Focus” to the desired component
GREEN KEYS
Generally perform Operational Actions – such as Enabling, Disabling, Starting, Stopping, Tuning or
Adjusting values
MAROON KEYS
Generally perform Navigational actions that escort the user through the screen menus
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BLACK KEYS
Are soft-key functions that relate to the display indication located above them. They can be navigational
or operational. These items do not require “Focus”, they are always available on that particular screen.
Watchdog Timer/CPU Fault Control
The IO Lock and CPU Health LED’s on the front left side of the display – are always in an identical state
as the LED’s on the back side of the control. They are completely controlled by the 505 control hardware
and are not controlled by the GAP application.
A watchdog timer and CPU fault circuit monitors the operation of the microprocessor and microprocessor
memory. If the microprocessor fails to reset the timer within 15 milliseconds of the last reset, the CPU
fault-control will activate the reset output. This resets the CPU, de-energizes all relay outputs and turns
off all milliamp outputs.
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Chapter 2.
Hardware Specifications
Flex 500 Description and Features
The Flex505 controller is a significant upgrade to the existing 505 product line with enhanced CPU,
Graphical display, communications, and I/O functions.
Note: This controller supports expanded I/O options when using Woodward CAN distributed I/O
nodes.
Features
•Same installation/mounting as current 505
•8.4” LCD Display (800x600) and Keypad
•(LV) input power: 18-36 Vdc input, isolated
•(HV) input power: 88-264 Vac / 90-150 Vdc, isolated
•Operating range of –30 °C to +70 °C (with display)
Communications
•(4) Ethernet 10/100 communication ports, isolated
•(4) CAN communication ports (1 Mbit), isolated
•RS-232/RS-485 port, isolated
•RS-232 Service port, isolated
I/O circuits
•GAP configurable update rates of 5 ms to 160 ms
•(2) Speed Sensor inputs (MPU/Prox) (with Prox Power)
•(8) Analog input 4-20 mA channels (with Loop Power)
•(6) Analog output 4-20 mA channels
•(2) Actuator output channels (configurable 4-20 mA/20-200 mA)
•(20) Discrete input channels (with Contact Power)
•(8) Relay outputs (form-c)
Figure 2-1. Functional Block Diagram (505 Control)
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