Woodward 505 User manual

Installation and Operation Manual
505 Digital Governor for Steam Turbines
with Single or Split-Range Actuators
Volume 2
Manual 85017V2C

WARNING
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.
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.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging
device, make sure the charging device is turned off before disconnecting the
battery from the system.
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.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—indicates a potentially hazardous situation which, if not avoided, could
result in damage to equipment.
NOTE—provides other helpful information that does not fall under the warning or
caution categories.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1997
All Rights Reserved

Manual 85017V2 505 Digital Governor
Woodward i
Contents
ELECTROSTATIC DISCHARGE AWARENESS ..................................................III
INTRODUCTION............................................................................................1
CHAPTER 1. PERIPHERAL DEVICES..............................................................2
Overview.................................................................................................................2
505 HMI Software...................................................................................................2
CHAPTER 2. APPLICATION NOTES .............................................................12
Overview...............................................................................................................12
Example Applications...........................................................................................13
CHAPTER 3. OPERATOR INTERFACE ..........................................................39
Introduction...........................................................................................................39
Keypad and Display..............................................................................................39
Service Panel Modes............................................................................................40
Using the Service Mode .......................................................................................40
CHAPTER 4. SERVICE MODE PROCEDURES................................................60
Overview...............................................................................................................60
The 505 Service Mode .........................................................................................61
Service Mode Blocks............................................................................................70
Service Mode Worksheet Parameters .................................................................72
CHAPTER 5. UNDERSTANDING PID SETTINGS............................................92
Overview...............................................................................................................92
Proportional Response.........................................................................................93
Proportional + Integral (closed loop)....................................................................95
Derivative Response ............................................................................................96
Proportional + Derivative (closed loop)................................................................97
Proportional + Integral + Derivative (closed loop)................................................99
Controller Field Tuning General.........................................................................100
CHAPTER 6. HARDWARE/OPERATING SYSTEM FAULTS ............................103
General...............................................................................................................103
General...............................................................................................................103
APPENDIX A. 505 DESIGN SPECIFICATIONS.............................................107
Hardware Specifications.....................................................................................107
Software Specifications......................................................................................110
APPENDIX B. 505 SERVICE MODE WORKSHEET.......................................111
APPENDIX C. PASSWORD INFORMATION ..................................................114
General...............................................................................................................114
Service Mode Password.....................................................................................114
Debug Mode Password......................................................................................114
Configure Mode Password.................................................................................115
OS_FAULTS Mode Password............................................................................115
Download Configuration Function Password.....................................................115

505 Digital Governor Manual 85017V2
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Illustrations and Tables
Figure 1-1. 505 HMI Software ................................................................................3
Figure 1-2. Digital Remote Final Driver..................................................................4
Figure 1-3. Real Power Sensor..............................................................................5
Figure 1-4a. Digital Synchronizer and Load Control..............................................7
Figure 1-4b. Digital Synchronizer and Load Control Functional Diagram..............8
Figure 1-5. DSLC Interface Wiring.........................................................................9
Figure 1-6a. Master Synchronizer and Load Control...........................................10
Figure 1-6b. Master Synchronizer and Load Control Functional Diagram...........11
Figure 2-1. Pump or Compressor Discharge Pressure Control with Turbine Inlet
Pressure Limiting.............................................................................15
Figure 2-2. Inlet Pressure Control with Automatic Synchronizing & Generator
Power Limiting.................................................................................18
Figure 2-3. Exhaust Pressure Control with Generator Power Limiting and Plant
Import/Export Limiting......................................................................22
Figure 2-4. Plant Import/Export Control with DRFD Servo Interface ...................27
Figure 2-5. Inlet Pressure Control with Isochronous Loadsharing Control in Island
Mode................................................................................................31
Figure 2-6. Import/Export Control or Exhaust Pressure Control with Isoch Load
Sharing in Island Mode....................................................................34
Figure 3-1. 505 Keypad and Display....................................................................39
Figure 3-2. Software Structure Overview.............................................................41
Figure 3-3. The Select Mode Level......................................................................42
Figure 3-4. Header Level......................................................................................42
Figure 3-5. Block Level.........................................................................................43
Figure 3-6. Debug Information Arrangement .......................................................49
Figure 3-7. OS_FAULTS Mode Information Arrangement...................................50
Figure 3-8. SYS_INFO Mode Information Arrangement......................................55
Figure 4-1. Service Mode Entry............................................................................60
Figure 4-2a. Service Mode Blocks .......................................................................61
Figure 4-2b. Service Mode Blocks .......................................................................62
Figure 4-2c. Service Mode Blocks........................................................................63
Figure 4-2d. Service Mode Blocks .......................................................................64
Figure 4-2e. Service Mode Blocks .......................................................................65
Figure 4-2f. Service Mode Blocks ........................................................................66
Figure 4-2g. Service Mode Blocks .......................................................................67
Figure 4-2h. Service Mode Blocks .......................................................................68
Figure 4-2i. Service Mode Blocks.........................................................................69
Figure 5-1. Proportional Gain Setting Effects.......................................................93
Figure 5-2. Open Loop Proportional and Integral Response...............................94
Figure 5-3. Closed Loop Proportional and Integral Response.............................95
Figure 5-4. Integral Gain (Reset) Setting Responses..........................................96
Figure 5-5. Closed Loop Proportional and Derivative Action...............................98
Figure 5-6. Derivative Setting Effects...................................................................98
Figure 5-7. Closed Loop Proportional, Integral and Derivative Action.................99
Figure 5-8. Typical Response to Load Change................................................. 101
Table 2-1. Example Summary..............................................................................14

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Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static
electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. 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.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam
cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. 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.
CAUTION
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.

505 Digital Governor Manual 85017V2
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Manual 85017V2 505 Digital Governor
Woodward 1
Introduction
Manual 85017 Volume 2 is a dual purpose manual. It includes application-
specific notes and 505 specific Service mode information.
The first part of this volume gives users an idea of the 505 Digital Control’s
capabilities, and how to apply them to a system. Typical applications are
schematically shown and their functionality explained. Programming and
Start/Run mode notes are given for each application to assist application
programmers in configuring the 505 for their application.
The second part of this volume includes 505 program modes not covered in
Volume 1 of this manual (Service, Debug, SYS_INFO, OPSYS Faults), PID
dynamic setting specifics, and Hardware rating information.
General Installation and Operating Notes and Warnings
This equipment is suitable for use in Class I, Division 2 , Groups A, B, C, and D
(Class I, Zone 2, Group IIC) or non-hazardous locations.
This equipment is suitable for use in European Zone 2, Group II environments
per compliance with EN60079-15, Electrical apparatus for explosive
atmospheres – Type of protection ‘n’
These listings are limited only to those units bearing the certification
identification.
Field wiring must be rated at least 75 °C for operating ambient temperatures
expected to exceed 50 °C.
Peripheral equipment must be suitable for the location in which it is used.
Wiring must be in accordance with North American Class I, Division 2 or
European Zone 2 wiring methods as applicable, and in accordance with the
authority having jurisdiction.
WARNING
Explosion hazard–Do not connect or disconnect while circuit is live unless
area is known to be non-hazardous.
Explosion Hazard–Substitution of components may impair suitability for
Class I, Division 2.
AVERTISSEMENT
Risque d’explosion–Ne pas raccorder ni débrancher tant que l’installation
est sous tension, sauf en cas l’ambiance est décidément non dangereuse.
Risque d’explosion–La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2.

505 Digital Governor Manual 85017V2
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Chapter 1.
Peripheral Devices
Overview
This chapter provides a brief explanation of peripheral devices, that can be used
with the 505. By understanding the functionality of a peripheral device, a better
understanding of the overall control configuration can be achieved.
All the devices covered in this section are manufactured or supported by the
Woodward Governor Company. Peripheral devices manufactured by other
companies can be used with the 505 to perform the functions detailed bellow,
however, the compatibility of them to the 505 and the application should be
verified before system operation.
505 HMI Software
Woodward offers two different HMI software packages, OpView™ and 505View,
which allow an operator to remotely view operating inputs, adjust control
setpoints, issue Run mode commands, and monitor/troubleshoot the turbine
control. Both HMI packages are self-configuring which eliminates all field
engineering–they automatically configure their screens to match the control's
programmed application.
The OpView is comprised of an industrialized NEMA 4 touchscreen hardware
package bundles together with a Woodward developed software interface
program. The 505View is a unbundled Intellution-based software package that
runs on a pc (hardware can be optionally purchased). Both HMI packages are
pre–configured to communicate via Modbus®* protocol with either a 505 or 505E
Woodward steam turbine control and offer the following features:
*—Modbus is a trademark of Modicon, Inc.
• Automatic Screen Generation based on control configuration
• Security with multiple User Levels
• Remote Access Capability1
• Real-Time and Historical Trending2
• Alarm/Trip Status Indication
• Alarm/Trip Log with Time Tagging and First-Out Indication
• I/O and System Troubleshooting
• Graphic System Control screens
• Event Status Logging and History3
Notes:
1 505View only
2 OpView has Real-Time Trending only; 505View has both
3 OpView has Logging only; 505View has Logging and History
By connecting the OpView or 505View to either 505 Modbus port, it automatically
configures its screens to match the 505’s programmed application. If the 505 is
not configured to accept Modbus commands, the HMI functions as a system
monitor only. If the 505 is configured to accept Modbus commands, all 505 Run
Mode operations can be monitored and performed through it (start, stop, mode
enable/disable, setpoint raise/lower). For safety purposes, the Overspeed test
function can not be performed through the HMI. See Volume 1, Chapter 7 of this
manual for more information on programming Modbus ports.

Manual 85017V2 505 Digital Governor
Woodward 3
Figure 1-1. 505 HMI Software
User-friendly touch screens allow operators to view and control multiple modes
of operation and setpoints from one screen. Ten different screens are available
to allow operators the flexibility of viewing. These screens display the following
information:
• Controlling parameter information
• Complete starting sequences
• Turbine and/or Generator information
• Speed, Extr/Adm, Aux, Casc, & Limiter information
• Analog Input and Output levels
• Contact Input and Relay Output states
• Alarm and Shutdown Log
The OpView or 505View can interface with the 505 through serial RS-232, RS-
422, or RS-485 communications. By using RS-422 or RS-485 communications,
the HMI can be located up to 1220 m (4000 ft) from the 505 digital control.
Digital Remote Final Driver
A Digital Remote Final Driver (DRFD) is used to interface the 505 digital control
to existing valve operators or Woodward actuators that are integrating in action
or are not compatible with the 505.

505 Digital Governor Manual 85017V2
4 Woodward
The 505’s actuator outputs have the capability of driving a 4–20 mA or 20–160
mA (200 mA max) proportional signal into an actuator coil. These 505 actuator
output signals represent a demand signal equal to desired valve position
(proportional). If the application’s actuator or servo assembly requires a different
drive signal, or control action (integrating with a null setting), a Digital Remote
Final Driver or equivalent device must be used.
Figure 1-2. Digital Remote Final Driver
Woodward Digital Remote Final Drivers accept a 4–20 mA actuator-drive signal
proportional to desired valve position, and position a servo assembly accordingly.
Integrating or proportional type DRFDs are available depending on the servo
assembly being interfaced to. Woodward DRFDs have the capability of driving
unipolar or bipolar actuator demand signals, up to 0–400 mA or +400 mA
respectively.
The Digital Remote Final Driver is housed in a NEMA-4X enclosure with a hinged
cover and consists of driver and power supply modules. The driver module uses
plug-in jumpers and an alphanumeric display to facilitate field configuration and
calibration.
Proportional type DRFDs can provide an output drive signal of up to 400 mA, to
be compatible with existing servo assemblies. This drive signal is proportional to
the 4–20 mA input signal received from the 505 digital control.
Integrating type DRFDs sense actual valve position (through, LVDTs, RVDTs,
MLDTs, or dc position feedback devices), compare this signal to the input
position demand signal from the 505, and output a drive signal to position a
servo assembly accordingly. See Figure 1-2.
Real Power Sensor
A Real Power Sensor is used to sense the real power being produced by a
generator, or flowing through a tie line. Woodward Real Power Sensors sense
three phase volts, three phase amps, compare each phase’s voltage to current
relationship, and develop a 4–20 mA output proportional to real power.