Woodward 505XT User manual
Product Manual 35018V1
(Revision B, 2/2017)
Original Instructions
505XT Digital Control for Steam Turbines
(Single valve, Extraction and/or Admission)
8200-1310, 8200-1311, 8200-1312
Manual 35018 consists of 2 volumes (35018V1 & 35018V2)
Installation and Operation Manual Volume 1
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 Out-of-date translations are marked with .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 35018V1
Copyright © Woodward, Inc. 2017
All Rights Reserved
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 1
Contents
WARNINGS AND NOTICES ...............................................................................................................6
ELECTROSTATIC DISCHARGE AWARENESS......................................................................................8
REGULATORY COMPLIANCE............................................................................................................9
CHAPTER 1. GENERAL INFORMATION............................................................................................14
Introduction ................................................................................................................................................. 14
Controller Overview..................................................................................................................................... 14
Functional Block Diagrams ......................................................................................................................... 17
505 Inputs and Outputs............................................................................................................................... 19
Optional Distributed I/O............................................................................................................................... 23
Keypad and Display .................................................................................................................................... 26
Watchdog Timer/CPU Fault Control ........................................................................................................... 27
CHAPTER 2. HARDWARE SPECIFICATIONS.....................................................................................28
Flex505 Description and Features .............................................................................................................. 28
Environmental Specifications...................................................................................................................... 29
Maintenance Info and Recommendations .................................................................................................. 29
Electromagnetic Compatibility (EMC) ......................................................................................................... 30
Outline Drawing for Installation ................................................................................................................... 30
Input Power Specification............................................................................................................................ 32
Visual Indicators (LED’s) & CPU Configuration .......................................................................................... 32
Communications (Ethernet) ........................................................................................................................ 33
Communications (CAN) .............................................................................................................................. 34
Communications (Service Ports) ................................................................................................................ 37
Hardware - Terminal Blocks & Wiring ......................................................................................................... 38
Terminal Block Connectors ......................................................................................................................... 39
Hardware - Speed Sensor Inputs................................................................................................................ 39
Hardware - Analog Inputs (4-20 mA) .......................................................................................................... 41
Hardware - Analog Outputs (4-20 mA) ....................................................................................................... 42
Hardware - Actuator Outputs ...................................................................................................................... 43
Hardware - Discrete Inputs ......................................................................................................................... 44
Hardware - Relay Outputs........................................................................................................................... 45
Troubleshooting Fault Codes...................................................................................................................... 46
Troubleshooting & Commissioning checks ................................................................................................. 46
CHAPTER 3. 505XT CONTROL DESCRIPTION.................................................................................49
Introduction ................................................................................................................................................. 49
Turbine Start Modes.................................................................................................................................... 49
Start Permissive .......................................................................................................................................... 50
Open Wire Detection on MPU Speed Signals ............................................................................................ 50
Zero Speed Signal Override........................................................................................................................ 50
Direction of Rotation Detection ................................................................................................................... 51
Detecting Zero Speed ................................................................................................................................. 52
Manual Speed Override .............................................................................................................................. 52
Automatic Speed Override .......................................................................................................................... 53
Acceleration Limiter..................................................................................................................................... 53
Turbine Start Mode Procedures.................................................................................................................. 53
Speed Control Overview ............................................................................................................................. 63
Speed PID Operational Modes ................................................................................................................... 64
Manual Demand.......................................................................................................................................... 76
Load Rejection ............................................................................................................................................ 77
Feed-Forward Input..................................................................................................................................... 77
Cascade Control ......................................................................................................................................... 79
Auxiliary Control .......................................................................................................................................... 84
Remote Auxiliary Set Point ......................................................................................................................... 87
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 2
Extraction/Admission Control...................................................................................................................... 89
Steam Performance Map Menu .................................................................................................................. 95
Inlet Steam Pressure Control.................................................................................................................... 108
Exhaust Steam Pressure Control.............................................................................................................. 109
HP Valve Limiter ....................................................................................................................................... 110
LP Valve Limiter ........................................................................................................................................ 111
Manual Valve Demand.............................................................................................................................. 111
Inlet Steam Pressure Compensation ........................................................................................................ 112
Isolated PID Control .................................................................................................................................. 112
Emergency Shutdown ............................................................................................................................... 113
Controlled Shutdown................................................................................................................................. 114
Overspeed Test Function.......................................................................................................................... 115
Local/Remote Function ............................................................................................................................. 115
Relays ....................................................................................................................................................... 117
CHAPTER 4. CONFIGURATION PROCEDURES ...............................................................................119
Program Architecture ................................................................................................................................ 119
Display Modes and User Levels ............................................................................................................... 119
Configuring the 505XT .............................................................................................................................. 120
Exiting the Configure Mode....................................................................................................................... 149
Valve/Actuator Calibration & Test ............................................................................................................. 157
Calibration/Stroking Procedure ................................................................................................................. 157
CHAPTER 5. 505 OPERATION......................................................................................................159
Software Architecture................................................................................................................................ 159
Power-Up Screen...................................................................................................................................... 159
Control Mode Architecture ........................................................................................................................ 161
User Login Levels ..................................................................................................................................... 162
Navigation ................................................................................................................................................. 163
Page Organization .................................................................................................................................... 163
Overview Screen....................................................................................................................................... 165
Speed Control Screen............................................................................................................................... 165
Valve Demand Screen .............................................................................................................................. 166
Controllers Screen .................................................................................................................................... 167
Cascade Control Screen ........................................................................................................................... 167
Auxiliary Control Screen............................................................................................................................ 168
Inlet Control Screen .................................................................................................................................. 168
Extraction/Admission Control Screen ....................................................................................................... 169
Exhaust Control Screen ............................................................................................................................ 170
Steam Map Screen ................................................................................................................................... 170
Analog Input Summary Screen ................................................................................................................. 171
Contact Input Summary Screen................................................................................................................ 172
Analog Output Summary Screen .............................................................................................................. 172
Relay Output Summary Screen ................................................................................................................ 173
Actuator Driver Summary Screen ............................................................................................................. 173
Starting Procedures (Start Curve Screen) ................................................................................................ 174
Overspeed Test Function (Speed Control Screen)................................................................................... 175
Stop Key.................................................................................................................................................... 177
Alarm Summary ........................................................................................................................................ 177
Shutdown Summary.................................................................................................................................. 181
Manual Dynamic Adjustments of Speed, Cascade, Auxiliary, Inlet, Exhaust and Ext/Adm Controls....... 183
CHAPTER 6. COMMUNICATIONS...................................................................................................196
Modbus Communications.......................................................................................................................... 196
Port Adjustments....................................................................................................................................... 199
505 Control Modbus Addresses................................................................................................................ 199
Specific Address Information .................................................................................................................... 220
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS ............................................................222
Product Support Options........................................................................................................................... 222
Product Service Options ........................................................................................................................... 222
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 3
Returning Equipment for Repair ............................................................................................................... 223
Replacement Parts.................................................................................................................................... 224
Engineering Services ................................................................................................................................ 224
Contacting Woodward’s Support Organization ......................................................................................... 224
Technical Assistance ................................................................................................................................ 225
APPENDIX A. 505XT CONFIGURATION MODE WORKSHEETS........................................................226
REVISION HISTORY.....................................................................................................................237
DECLARATIONS ..........................................................................................................................238
The following are trademarks of Woodward, Inc.:
ProTech
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)
Illustrations and Tables
Figure 1-1. Typical Single or Dual Inlet Steam Turbine .............................................................................. 16
Figure 1-2. Typical Extraction and/or Admission Steam Turbine................................................................ 16
Figure 1-3. Explanation of Symbols ............................................................................................................ 18
Figure 1-4. Single or Split-Range Turbine Configurations .......................................................................... 18
(Valve Demand Overview) .......................................................................................................................... 18
Figure 1-5. Turbine Configurations using Extraction and/or Admission ..................................................... 19
(Valve Demand Overview) .......................................................................................................................... 19
Figure 1-6. LinkNet Distributed I/O Node.................................................................................................... 23
Figure 1-7. Vibration Wizard for LinkNet Node 1 ........................................................................................ 24
Figure 1-8. LinkNet Node 1 with 4 Vibration Signals .................................................................................. 24
Figure 1-9. Vibration Monitoring Page ........................................................................................................ 25
Figure 1-10. 505 Keypad and Display......................................................................................................... 26
Figure 2-1. Functional Block Diagram (505 Control) .................................................................................. 28
Figure 2-2. 505D Outline Drawing .............................................................................................................. 31
Figure 2-3. COM1 Example RS-485 wiring................................................................................................. 37
Figure 2-4. 505 Back Cover Label .............................................................................................................. 38
Figure 2-5. Terminal Block Connectors ...................................................................................................... 39
Figure 2-6. Speed Sensor Block Diagram .................................................................................................. 40
Figure 2-7. Analog Input – Self-Powered Block Diagram ........................................................................... 41
Figure 2-8. Analog Input – Loop-Powered Block Diagram ......................................................................... 42
Figure 2-9. Analog Output Block Diagram .................................................................................................. 43
Figure 2-10. Actuator Output Block Diagram .............................................................................................. 44
Figure 2-11. Discrete Input Block Diagram ................................................................................................. 44
Figure 2-12. Relay Output Block Diagram .................................................................................................. 45
Figure 3-1. Open Wire Detection Test ........................................................................................................ 50
Figure 3-2. Speed Input Channel – Phase Difference ................................................................................ 51
Figure 3-3. Speed Probe Rotation Check ................................................................................................... 52
Figure 3-4. Speed Probe Zero Speed Detect ............................................................................................. 52
Figure 3-5. Manual Start Mode Example .................................................................................................... 54
Figure 3-6. Semiautomatic Start mode Example ........................................................................................ 55
Figure 3-7. Automatic Start Mode Example ................................................................................................ 56
Figure 3-8. Idle/Rated Start......................................................................................................................... 58
Figure 3-9. Automatic Start Sequence........................................................................................................ 59
Figure 3-10. Speed Control Functional Diagram ........................................................................................ 64
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 4
Figure 3-11. Speed PID Control Modes...................................................................................................... 66
Figure 3-12. Frequency and Unit Load Relationship .................................................................................. 67
Figure 3-13. Speed Relationships............................................................................................................... 69
Figure 3-14. Load Sharing Logic................................................................................................................. 75
Figure 3-15. Typical Anti-surge Valve and Speed Feed-Forward Logic Trend .......................................... 79
Figure 3-16. Cascade Functional Diagram ................................................................................................. 80
Figure 3-17. Aux Control Overview............................................................................................................. 84
Figure 3-18. Extraction/Admission Control Overview ................................................................................. 89
Figure 3-19. Transitions between Speed only and Ratio Limiter Control – Auto Mode.............................. 91
Figure 3-20. Transitions Between Speed Only and Ratio Limiter Control – Manual .................................. 92
Figure 3-21. Extraction/Admission Control Panel ....................................................................................... 93
Figure 3-22. Typical Extraction Steam Map................................................................................................ 98
Figure 3-23. Typical Admission Steam Map ............................................................................................. 100
Figure 3-24. Typical Extraction & Admission Steam Map......................................................................... 101
Figure 3-32. Ext/Adm Mode Control Priorities .......................................................................................... 107
Figure 3-33. Configured for Full Decoupled mode (No Map).................................................................... 108
Figure 3-34. Inlet Steam Pressure Control Overview ............................................................................... 109
Figure 3-35. Exhaust Steam Pressure Control Overview ......................................................................... 110
Figure 4-1. Initial HOME Screen (unit not configured).............................................................................. 120
Figure 4-2. Configuration Menu – Configuration Mode (Edit) ................................................................... 122
Figure 5-1. Software Architecture ............................................................................................................. 159
Figure 5-2. 505 Splash Screen ................................................................................................................. 160
Figure 5-3. Boot-up to HOME Screen....................................................................................................... 160
Figure 5-4. Control Mode Architecture...................................................................................................... 161
Figure 5-5. Mode Screen .......................................................................................................................... 162
Figure 5-6. Navigation Cross .................................................................................................................... 163
Figure 5-7. Service Menu showing “Speed Control” IN-Focus ................................................................. 163
Figure 5-8. Configuration Menu – Operation Mode (View only) ............................................................... 164
Figure 5-9. Configuration Menu – Configuration Mode (Edit) ................................................................... 164
Figure 5-10. Overview Screen .................................................................................................................. 165
Figure 5-11. Speed Control Screen .......................................................................................................... 165
Figure 5-12. Valve Demand Screen.......................................................................................................... 166
Figure 5-13. Controllers Screen................................................................................................................ 167
Figure 5-14. Cascade Control Screen ...................................................................................................... 167
Figure 5-15. Auxiliary Control Screen ....................................................................................................... 168
Figure 5-16. Inlet Steam Pressure Control Screen ................................................................................... 168
Figure 5-17. Ext/Adm Pressure Control Screen........................................................................................ 169
Figure 5-18. Exhaust Pressure Control Screen ........................................................................................ 170
Figure 5-19. Steam Map Screen............................................................................................................... 170
Figure 5-20. Steam Map – Mode Popup................................................................................................... 171
Figure 5-21. Analog Input Summary Screen............................................................................................. 171
Figure 5-22. Contact Input Summary Screen ........................................................................................... 172
Figure 5-23. Analog Output Summary Screen.......................................................................................... 172
Figure 5-24. Relay Output Summary Screen............................................................................................ 173
Figure 5-25. Actuator Driver Summary Screen......................................................................................... 173
Figure 5-26. HOME Menu showing “Startup Curve” IN-Focus ................................................................. 174
Figure 5-27. Overspeed Test Permissives................................................................................................ 175
Figure 5-28. Internal (505) Overspeed Test.............................................................................................. 176
Figure 5-29. External Overspeed Test...................................................................................................... 176
Figure 5-30. ALARM Screen..................................................................................................................... 177
Figure 5-31. Shutdown Summary Screen................................................................................................. 181
Figure 5-32. Speed Dynamics Adjustment Screen................................................................................... 183
Figure 5-33. Typical Response to Load Change ...................................................................................... 186
Figure 5-34. Overview of the Automated PID Optimizer Routine ............................................................. 187
Figure 5-35. Optimization Routine Overview Trend.................................................................................. 188
Figure 5-36. Configuration Parameters ‘Configure’ Pop-up...................................................................... 189
Figure 6-1. ASCII/RTU Representation of 3 ............................................................................................. 197
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 5
Table 1-1. Selectable functions for 4-20mA Analog Inputs......................................................................... 19
Table 1-2. Selectable functions for Discrete Inputs .................................................................................... 20
Table 1-3. Selectable functions for 4-20mA Analog Outputs...................................................................... 21
Table 1-4. Selectable functions for Relay Output States ............................................................................ 22
Table 1-5. Selectable functions for Relay Output Level switches............................................................... 22
Table 1-6. Available (programmed) distributed I/O Nodes ......................................................................... 23
Table 2-1. Environmental Specifications..................................................................................................... 29
Table 2-2. Input Power Connector Pinout................................................................................................... 32
Table 2-2. Ethernet Ports #1-4 (10/100) ..................................................................................................... 34
Table 2-3. CAN Specifications .................................................................................................................... 35
Table 2-4. CAN Connector Pinout .............................................................................................................. 35
Table 2-5. CAN Cable Specifications.......................................................................................................... 35
Table 2-6. COM1 Serial Port (RS-232/485) ................................................................................................ 36
Table 2-7. CPU Service Port (3 pin, 2 mm) ................................................................................................ 37
Table 2-8. Specifications (AI)...................................................................................................................... 41
Table 2-9. Specifications (AO) .................................................................................................................... 42
Table 2-10. Specifications (ACT) ................................................................................................................ 43
Table 2-11. Specifications (DI).................................................................................................................... 44
Table 2-12. Specifications (Relay Outputs) ................................................................................................ 45
Table 2-13. CPU Fault LED Flash Codes ................................................................................................... 46
Table 3-1. Automatic Start Sequence Settings:.......................................................................................... 59
Table 3-2. Hot And Cold Parameter Interpolation rates and delays ........................................................... 60
Table 3-3. All Required Conditions, If Configured, For a Warm or Hot Start.............................................. 61
Table 3-4. Frequency Arm/Disarm Generator Control Modes .................................................................... 71
Table 3-5. On-Line/Off-Line Dynamics Selection........................................................................................ 71
Table 3-6. Speed Control Mode Based on Contacts .................................................................................. 76
Table 3-7. Alternate Modes for Ext/Adm turbines..................................................................................... 102
Table 3-8. Exceptions to Local Mode Contact Input and Modbus Command Disabled ........................... 116
Table 4-1. Mode Access by User Level .................................................................................................... 119
Table 4-2. Configuration Menu Commands .............................................................................................. 122
Table 4-3. Configuration Error Messages ................................................................................................. 150
Table 4-4. Actuator Driver Limits .............................................................................................................. 157
Table 5-1. ALARM Messages ................................................................................................................... 178
Table 5-2. TRIPPED Messages................................................................................................................ 181
Table 6-1. ASCII vs RTU Modbus............................................................................................................. 197
Table 6-2. Modbus Frame Definition......................................................................................................... 198
Table 6-3. Modbus Function Codes.......................................................................................................... 198
Table 6-4. Modbus Error Codes................................................................................................................ 198
Table 6-5. Modbus Communication Port Adjustments ............................................................................. 199
Table 6-6. Maximum Modbus Discrete and Analog Values...................................................................... 199
Table 6-7. Boolean Write Addresses ........................................................................................................ 200
Table 6-8. Boolean Read Addresses ........................................................................................................ 201
Table 6-9. Analog Read Addresses .......................................................................................................... 208
Table 6-10. Analog Write Addresses ........................................................................................................ 213
Table 6-11. Control Status Message Addresses ...................................................................................... 213
Table 6-12. Analog Read Register (3:0234) Control Status ..................................................................... 214
Table 6-13. Analog Read Register (3:0235) Ratio Limiter Control Status................................................ 214
Table 6-14. Analog Read register (3:0236) Map Limiter Status Messages.............................................. 215
Table 6-15. Analog Read register (3:0001) Control Status....................................................................... 215
Table 6-17. Analog Output Configuration ................................................................................................. 216
Table 6-18. Relay Configuration – for Level Switches.............................................................................. 217
Table 6-19. Relay Configuration – for State indications ........................................................................... 218
Table 6-20. Contact Input Configurations ................................................................................................. 219
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 6
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.
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 7
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 the
NEC/CEC or Authority Having Final Jurisdiction per the Input Power
Specifications.
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 8
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.
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 9
Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking. Refer to DoC for applicability by
part number.
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)
ATEX – Potentially
Explosive
Atmospheres
Directive:
Declared to Directive 2014/34/EU on the harmonization of the laws of the
Member States relating to equipment and protective systems intended for
use in potentially explosive atmospheres.
Zone 2, Category 3, Group II G, Ex ic nA IIC T4 X Gc IP20
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.
Other European and International Compliance:
IECEx: Ex ic nA IIC T4 Gc T4 temperature.
Certificate: IECEx CSA 15.0020X IEC 60079-0: 2011 - Explosive
Atmospheres – Part 0
Equipment General Requirements.
IEC 60079-11: 2011 – Explosive Atmospheres – Part
Part 11: Equipment Protection by Intrinsic Safety “i”
IEC 60079-15: 2010 - Electrical Apparatus for
Explosive Gas Atmospheres; Part 15: Construction,
Test and Marking Type of protection “n”.
EAC Customs Union
These listings are limited only to those units with labels, marking and manuals in Russian language to
comply with their certificates and declaration.
EAC Customs Union: Certified to Technical Regulation TR CU 012/2011 for use in potentially
explosive atmospheres per Certificate
RU C-US.МЮ62.В.04777 as 2Ex ic nA IIC T4 Gc X
Declared to Technical Regulation TR CU 020/2011 On Electromagnetic
Compatibility of Technical Equipment Declaration of Conformity Registration
No: RU Д-US.МЛ66.В.001129
North American Compliance:
These listings are limited only to those units bearing the CSA identification.
Units bearing only the CSA identification are restricted for use only in Ordinary Locations in North
America.
Units bearing the CSA identification in addition to the marking indicating Class I, Div 2, Groups A,B,C
and D are acceptable for use in North American Hazardous Locations.
CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T4 at 70 °C
surrounding air temperature. For use in Canada and the United States.
CSA Certificate 70006135
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 10
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.
Marine Compliance:
Lloyd’s Register of
Shipping: LR Type Approval Test Specification No. 1, July 2013; Environmental
Categories ENV1, ENV2 and ENV3.
DNV-GL Temperature Class D, Humidity Class B, Vibration Class A, EMC Class A,
Enclosure; Required protection according to the Rules shall be provided upon
installation on board.
Lloyd’s: Type Approval Conditions
Where this controller is used to perform safety critical functions or system shutdowns a valid Lloyd’s
Register Software Conformity Assessment Certificate is required. Where the controller is used for control
and alarm purposes a separate, independent safety system must be provided.
Installation of this equipment for marine applications is to be in accordance with current Lloyd’s Register
Rules and Regulations.
Radiated and conducted emissions meet the requirement for equipment in the general power distribution
zones.
DNV-GL: Type Approval Conditions
The Type Approval covers hardware listed under Product description. When the hardware is used in
applications to be classed by DNV, documentation for the actual application is to be submitted for
approval by the manufacturer of the application system in each case. Reference is made to DNV Rules
for Ships Pt. 4 Ch. 9 Control and Monitoring Systems.
Product Certificate
If specified in the Rules, ref. Pt. 4 Ch. 9 Sec. 1, the control and monitoring system in which the above
listed hardware is used shall be delivered with a product certificate. For each such delivery the
certification test is to be performed at the manufacturer of the application system before the system is
shipped to the yard. The test shall be done according to an approved test program. After the certification
the clause for application software control will be put into force.
Clause for application software control
All changes in software are to be recorded as long as the system is in use on board. The records of all
changes are to be forwarded to DNV for evaluation and approval. Major changes in the software are to
be approved before being installed in the computer.
Application/Limitation
Ex-certification is not covered by this certificate. Application in hazardous area to be approved in each
case according to the Rules and Ex-Certification/Special Conditions for Safe Use listed in valid Ex-
certificate issued by a notified/recognized Certification Body.
Special Conditions for Safe Use
The 505XT shall not be installed in areas exceeding Pollution Degree 2 as defined in IEC 60664-1.
A fixed wiring installation is required. Field wiring must be in accordance with North American Class I,
Division 2 (CEC and NEC), or European Zone 2, Category 3 wiring methods as applicable, and 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 connection; +10°C above highest ambient
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 11
Protective Earth Grounding of the 505XT is required to be connected to the PE terminal.
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.
Hazardous Locations
Wiring must be in accordance with Zone 2 wiring methods and in accordance with the authority having
final jurisdiction.
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.
The Low Voltage ATEX 505XT is suitable for use in Class I, Div 2, Gas Groups A, B, C and D &
European Zone 2, Group IIC environments.
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.
ATEX/IECEx locations require that the 505XT Control be installed in a cabinet or enclosure coded Ex nA
or Ex e that provides a minimum IP54 ingress protection for the rear of the control per IEC 60529. The
front bezel, keypad and display have been tested and are rated IP54 while the rear of the control is rated
IP20 due to the ventilation slots required for heat dissipation. The installer shall ensure that the maximum
surrounding air temperature in the enclosure does not exceed the rated temperature of +70˚C.
Transient Protection for the 505XT is to be provided externally by the end user at the supply terminals of
the control. The transient protection device is to be set at a level not exceeding 140% of the peak rated
voltage (36Vdc).
Explosion Hazard
For ATEX/IECEx installation compliance, the input voltage shall be
limited to 36 Vdc. When an external power supply is selected to
supply the Control, it shall be IECEx approved for Class 1, Division 2
Applications.
Explosion Hazard
Due to the Hazardous Location Listings associated with this product,
proper wire type and wiring practices are critical to the operation.
Explosion Hazard
ENCLOSURE REQUIREMENT—
ATEX/IECEx Zone 2, Category 3G applications require the final
installation location provide a minimum IP-54 ingress protection
enclosure against dust and water per IEC 60529. The enclosure must
be coded Ex nA or Ex e.
Explosion Hazard
Do not remove covers or connect/disconnect electrical connectors
unless power has been switched off and the area is known to be non-
hazardous.
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 12
Explosion Hazard
Substitution of components may impair suitability for Class I,
Division 2 or Zone 2.
Explosion Hazard
The external ground lugs shown on the installation drawing must be
properly connected to ensure equipotential bonding. This is will
reduce the risk of electrostatic discharge in an explosive
atmosphere. Cleaning by hand or water spray must be performed
while the area is known to be non-hazardous to prevent an
electrostatic discharge in an explosive atmosphere.
Explosion Hazard
MOUNTING
The control must be mounted in a vertical position. The installer shall
ensure the maximum surrounding air temperature of the control does
not exceed 70˚C at the final location.
Explosion Hazard
Class I, Div 2 Groups A, B, C, D and Zone 2, Group IIC applications
require the input voltage to the relay contacts not exceed 32Vac rms
or 32Vdc.
Risque d'explosion
Ne pas enlever les couvercles, ni raccorder / débrancher les
prises électriques, sans vous en assurez auparavant que le
système a bien été mis hors tension; ou que vous vous
situez bien dans une zone non explosive.
Risque d'explosion
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2
et/ou Zone 2.
Risque d'explosion
Ne pas utiliser les bornes d’essai du block d’alimentation
ou des cartes de commande à moins de se trouver dans un
emplacement non dangereux.
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 13
Safety Symbols
Direct Current
Alternating Current
Both Alternating and Direct Current
Caution, risk of electrical shock
Caution, refer to accompanying documents
Protective conductor terminal
Frame or chassis terminal
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 14
Chapter 1.
General Information
Introduction
This manual describes the Woodward 505XT Digital Governor for all types of steam turbines, including:
Single Valve or split-range actuators turbines
Controlled Extraction or Admission turbines (2 Control valves)
Controlled Extraction and Admission turbines (2 Control valves)
The option charts below shows the part numbers and the differences between the models. Volume 1 of
this manual describes the control, provides installation instructions, defines hardware specifications, and
explains the configuration (programming) and operating procedures. Volume 2 includes notes on applying
the control to specific applications and Service mode information. 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 Power
8200-1310 LVDC (18–36 Vdc) Standard Compliance
8200-1311 AC/DC (88–264 Vac or 90–150 Vdc) Standard Compliance
8200-1312 Marine/ATEX Compliance LVDC (18–36 Vdc)
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.
For the Marine Type approved version, the field wiring must be installed with an additional shield layer
which is grounded to the enclosure. The additional shielding is beyond the standard shielding described
elsewhere in the manual, and it may be made from solid or flexible metal conduit, armored cabling, or a
cable with an overall shield.
Note: For additional installation and operating information, see the Regulatory Compliance section of
this manual.
Controller Overview
General Description
The 505XT 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
generator or mechanical drive application. The 505XT can be configured to operate as a stand-alone unit
or in conjunction with a plant’s Distributed Control System.
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 15
The 505XT control has seven PID controllers that can affect the controlled operation of the steam turbine.
The Speed/load PID controller, the Cascade PID controller, Auxiliary PID controller, Inlet Steam PID
controller, Extraction Steam PID controller, Exhaust Steam PID controller and an Acceleration PID
controller. Depending on the configuration of the 505XT, these PIDs may be used or not used and could
interact differently with each other based upon the type of turbine being controlled. Please refer to the
Block diagrams listed later in this chapter to fully understand PID relationships. An additional PID is
available as an isolated control loop that is optional and can be used to drive an independent Analog
Output signal (that is not driving a Steam Valve) for any single loop ancillary control that may be required
(such as Seal Gas, Gland Seals, or lube oil pressure loops. When using the Isolated PID Control, it is
recommended to select the “Enable Readback Fault” option for the Analog Output channel configured as
the Isolated PID Demand. This will trigger an alarm in the 505XT if a fault of the output circuit is detected.
By default, Analog Output channels are not configured to produce an alarm when the output circuit has a
fault.
When applied to single or split range actuator turbines, the 505XT drives one or two steam turbine throttle
valves to control one turbine parameter at a time, and if desired, limit turbine operation based on other
parameters. The one controlled parameter is typically speed (or load), however, the 505XT could be
utilized to control or limit: turbine inlet pressure or flow, exhaust (back) pressure or flow, first stage
pressure, generator power output, plant import and/or export levels, compressor inlet or discharge
pressure or flow, unit/plant frequency, process temperature, or any other turbine related process
parameter.
When applied to two valve turbines, the 505XT is able to control two turbine parameters at a time. Once
the turbine is started and running online (either as a generator or mechanical drive), the control will
transition into Ratio Limiter control operation. In this mode the control will limit the turbine operation within
an OEM defined turbine performance map that will define the operational area in which the control can
actively control 2 independent parameters (based upon pressures, flows and load).
The 505XT is designed to control extraction, extraction/admission, or admission steam turbines. The
difference between these turbines is the capability of the turbine to allow low pressure steam, which is at
a lower pressure than the inlet, to enter and/or exit the turbine. An extraction turbine allows the lower
pressure (extraction) steam to exit the turbine only and will have a non-return valve in the extraction
header/line to prevent steam from entering the turbine. An admission turbine (also called induction) will
allow excess header steam to enter the turbine through the low pressure inlet. An extraction/admission
turbine will allow low pressure header steam to enter or exit the turbine depending on system pressures.
A turbine with admission capability will have a stop valve or trip-and-throttle valve in the low pressure line
to prevent steam from entering the turbine when the unit is tripped. The type of turbine used will depend
on the system requirements and must be designed by the turbine manufacturer to perform the functions
required.
It is possible to apply the 505XT to an Ext/Adm turbine that also has a split range inlet arrangement (3
total valves). To do this the, one of the valves must be driven either by Analog Output channel 1 (a 4-20
mA output) or by a Woodward digital link to a Varistroke or similar digital driver interface.
Refer to Volume 2 of this manual for details on applications.
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 16
Figure 1-1. Typical Single or Dual Inlet Steam Turbine
TRIP AND
ADMISSION STEAM
EXHAUST STEAM
VALVE
EXTRACTION OR
INLET
STEAM
THROTTLE
Figure 1-2. Typical Extraction and/or Admission Steam Turbine
Operator Control Panel
The 505 is a field configurable steam turbine control and operator control panel (OCP) integrated into one
package. A comprehensive graphical operator control panel display and keypad is located on the 505’s
front panel. This display can be used to configure the 505, make On-Line program adjustments, and
operate the turbine/system. Easy to follow instructions allow operators to view actual process and set
point values at any time during turbine operation. Upon power-up from the factory the default HOME
screen has a tutorial that will quickly give first-time users an overview of navigation and operation. Once
the unit is configured, this tutorial is always available under the Service Menu.
Additional Features
In addition to the control loops mentioned, the 505XT also provides the following features:
• First-Out Trip indication of Alarm and Trip events with time stamp
• 15 External DI trip inputs and 15 External Alarm DI inputs
• Critical Speed Avoidance (3 speed bands)
• Auto Start Sequence (hot & cold starts) with Temperature Input options
• Dual Speed/Load Dynamics with automatic Optimization tuning of dynamic gains
• A third set of speed dynamics for Ext/Adm units when operating in Ratio Limiter control modes
• Zero Speed Detection, Peak Speed Indication, and Direction of Rotation
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 17
• Load Droop and Isochronous Load sharing between units (with an DSLC-2 control)
• Feed-forward loop for compressor units
• High speed (10ms) datalog and Slow speed (1 sec) trendlog capture files
• SNTP time synchronization via an Ethernet IP
• Ability to expand system I/O with Woodward Linknet Distributed I/O nodes
• Multiple digital communication links to other Woodward products (Woodward Links)
Using the 505XT
The 505XT control has three normal operating modes, Configuration Mode, Service Mode and the Run
Mode. See chapter 4 for more information about the User Levels required to enter each of these modes.
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.
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.
Functional Block Diagrams
An overview of the 505XT valve demands is shown in Figure 1-4. Most of the PIDs are optional
controllers, and are shown in the following diagrams for PID relationship purposes only. Later in this
manual, more detailed functional block descriptions will be given in relation to each control loop PID. The
Speed PID is always used and on Extraction/Admission type turbines the Extraction PID is required.
Manual 35018V1 505XT Digital Control System for Steam Turbines
Woodward 18
Figure 1-3. Explanation of Symbols
Figure 1-4. Single or Split-Range Turbine Configurations
(Valve Demand Overview)
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