Woodward 505 User manual

Product Manual 26839V2
(Revision NEW, 2/2015)
Original Instructions
505 Digital Control
for Steam Turbines
8200-1300, 8200-1301, 8200-1302
Manual 26839 consists of 2 volumes (26839V1 & 26839V2).
Volume 2

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 Out-of-date translations are marked with .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—Changes in this publication since the last revision are indicated by a black line
alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken. Manual 26839V2
Copyright © Woodward 2015
All Rights Reserved

Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 1
Contents
WARNINGS AND NOTICES............................................................................5
ELECTROSTATIC DISCHARGE AWARENESS ..................................................6
INTRODUCTION............................................................................................7
CHAPTER 1. SERVICE TOOLS.......................................................................8
Overview.................................................................................................................8
Control Assistant (CA)............................................................................................8
Servlink-to-OPC-Server (SOS)...............................................................................8
AppManager (AppMan)..........................................................................................8
CHAPTER 2. PERIPHERAL DEVICES..............................................................9
Overview.................................................................................................................9
DSLC-2 (Generator Synchronizer and Load Control)............................................9
VariStroke II (Electro-Hydraulic Actuator) ............................................................11
MFR300 (Multi-function Relay).............................................................................13
LS-5 (Protection/Breaker Control Relay)..............................................................13
Servo Position Controller (SPC)...........................................................................13
Real Power Sensor...............................................................................................15
Engine Generator Control Package/Load Sharing (EGCP-3 LS).........................16
Applying the 505 with Redundant I/H or I/P Converters.......................................19
CHAPTER 3. APPLICATION NOTES .............................................................21
Overview...............................................................................................................21
Example Applications...........................................................................................22
CHAPTER 4. OPERATOR INTERFACE ..........................................................48
Introduction...........................................................................................................48
Graphical Display and Key Inputs........................................................................48
Service Panel Modes and User Levels ................................................................49
CHAPTER 5. SERVICE MENU PROCEDURES................................................51
Overview...............................................................................................................51
Using the Service Menus......................................................................................51
Service Mode Parameters....................................................................................56
CHAPTER 6. UNDERSTANDING PID SETTINGS ............................................78
Overview...............................................................................................................78
Proportional Response.........................................................................................79
Proportional + Integral (closed loop) ....................................................................81
Derivative Response ............................................................................................82
Proportional + Derivative (closed loop) ................................................................83
Proportional + Integral + Derivative (closed loop)................................................85
Controller Field Tuning General...........................................................................86
CHAPTER 7. HARDWARE/OPERATING SYSTEM FAULTS ..............................89
General.................................................................................................................89
Wiring Problems...................................................................................................89
Control Adjustments.............................................................................................90
Other Operating Problems....................................................................................90
APPENDIX A. 505 DESIGN SPECIFICATIONS ...............................................91
Hardware Specifications.......................................................................................91
Software Specifications........................................................................................91
APPENDIX B. 505 SERVICE MODE WORKSHEET.........................................92

505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
2 Woodward
Contents
APPENDIX C. PASSWORD INFORMATION...................................................102
General...............................................................................................................102
Monitor User Level..............................................................................................102
Operator User Level Password ..........................................................................102
Service User Level Password.............................................................................102
Configure User Level Password.........................................................................102
ServiceUser Mode Password.............................................................................102
APPENDIX D. SERVLINK-TO OPC SERVER (SOS) TOOL............................103
SOS Communication Link ..................................................................................103
Installing SOS.....................................................................................................103
Connecting a PC/Laptop to the Control..............................................................104
APPENDIX E. CONTROL ASSISTANT—SOFTWARE INTERFACE TOOL..........106
Features of Control Assistant.............................................................................106
Installing Control Assistant.................................................................................106
Using Control Assistant ......................................................................................108
APPENDIX F. APPMANGER SERVICE TOOL ...............................................114
File Management with App. Manager.................................................................114
Installing App Manager.......................................................................................114
APPENDIX G. CONFIGURING NETWORK TCP/IP ADDRESSES ....................121
APPENDIX H. REMOTEVIEW TOOL............................................................123
APPENDIX I. USING 505 INTERNAL SIMULATION MODE..............................134
APPENDIX J. CUSTOM TAG NAME PROCEDURE ........................................135
REQUIRED TOOLS....................................................................................135
CREATING CUSTOM TAGS........................................................................135
The following are trademarks of Woodward, Inc.:
DSLC easYgen
GAPLINKnet
MicroNet RTCnet
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
VxWorks (Wind River Systems, Inc.)

Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 3
Illustrations and Tables
Figure 2-1. DSLC-2 ................................................................................................9
Figure 2-2. Configuration/Woodward Links/DSLC-2............................................10
Figure 2-3. Service Screen - DSLC-2 Power Parameters....................................10
Figure 2-4. Service Screen - DSLC-2 Status Parameters....................................11
Figure 2-5. VS-II...................................................................................................11
Figure 2-6. Configuration/Woodward Links/VS-II.................................................12
Figure 2-7. Service/VariStroke II..........................................................................12
Figure 2-8. Multi-Function Relay ..........................................................................13
Figure 2-9. LS-5....................................................................................................13
Figure 2-10. Servo Position Controller.................................................................14
Figure 2-11. Interface to Servo Position Controller..............................................14
Figure 2-12. Real Power Sensor..........................................................................15
Figure 2-13. EGCP-3 Control...............................................................................17
Figure 2-14. EGCP-3 LS Functional Diagram......................................................17
Figure 2-15. EGCP-3 LS Interface Wiring............................................................18
Figure 2-16. Typical Redundant I/H System with a Transfer Valve .....................19
Figure 2-17. Typical Redundant I/P System with a Pressure Selecting Relay
Valve................................................................................................20
Figure 3-1. Pump or Compressor Discharge Pressure Control with Turbine Inlet
Pressure Limiting.............................................................................24
Figure 3-2. Inlet Pressure Control with Automatic Synchronizing & Generator
Power Limiting.................................................................................27
Figure 3-3. Exhaust Pressure Control with Generator Power Limiting and Plant
Import/Export Limiting......................................................................31
Figure 3-4. Plant Import/Export Control with DRFD Servo Interface....................36
Figure 3-5. Inlet Pressure Control with Isochronous Loadsharing Control in Island
Mode................................................................................................40
Figure 3-6. Import/Export Control or Exhaust Pressure Control with Isoch Load
Sharing in Island Mode....................................................................43
Figure 4-1 505 Keypad and Display.....................................................................48
Figure 5-1. User Login for Service .......................................................................51
Figure 5-2. Authorized and Unauthorized Components.......................................52
Figure 5-3 Service Menu (page 1)........................................................................53
Figure 5-4 Service Menu (page 2)........................................................................53
Figure 6-1. Proportional Gain Setting Effects.......................................................79
Figure 6-2. Open Loop Proportional and Integral Response ...............................80
Figure 6-3. Closed Loop Proportional and Integral Response.............................81
Figure 6-4. Integral Gain (Reset) Setting Responses ..........................................82
Figure 6-5. Closed Loop Proportional and Derivative Action...............................84
Figure 6-6. Derivative Setting Effects...................................................................84
Figure 6-7. Closed Loop Proportional, Integral and Derivative Action.................85
Figure 6-8. Typical Response to Load Change....................................................87
Figure D-1. SOS.................................................................................................103
Figure D-2. SOS Install Window.........................................................................104
Figure D-3. SOS Server status dialog box.........................................................104
Figure D-4. SOS – New Session box.................................................................105
Figure D-5. SOS - Enter 505 TCP/IP address....................................................105
Figure D-6. SOS – Active Links dialog box........................................................105
Figure E-1. Control Assistant License Agreement .............................................106
Figure E-2. Control Assistant Install Window.....................................................107
Figure E-3. Control Assistant Folder Selection ..................................................107
Figure E-4. Control Assistant Install Complete...................................................107
Figure E-5. Install Restart Window.....................................................................108
Figure E-6. Control Assistant Window................................................................108

505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
4 Woodward
Illustrations and Tables
Figure E-7. Dialog for Servlink OPC connection................................................109
Figure E-8. WinPanel Session............................................................................109
Figure E-9. Control Assistant – Retrieve Tunable Dialog box............................110
Figure E-10. Control Assistant – Send Tunable Dialog box...............................111
Figure E-11. Control Assistant – Speed Control Trend Script............................112
Figure E-12. Control Assistant – Create Trend Script File.................................113
Figure F-1. App Manager Install Window...........................................................114
Figure F-2. App Manager License Agreement Window .....................................115
Figure F-3. App Manager Installation.................................................................115
Figure F-4. App Manager Install Complete ........................................................115
Figure F-5. AppManager Window.......................................................................116
Figure F-6. Dialog for App Manager connection ................................................116
Figure F-7. App Manager Connected to a Control.............................................117
Figure F-8. AppManager Control Info Window...................................................117
Figure F-9. AppManager Control (GAP) Application Panel................................118
Figure F-10. AppManager GUI Application Panel..............................................118
Figure F-11. Retrieving Files..............................................................................119
Figure G-1. Configuration/Communications Screen...........................................121
Figure G-2. Ethernet Port Layout (Ports on Side)..............................................121
Figure H-1. Window Shown when the Time Limit is Exceeded..........................123
Figure H-2. Installation Welcome Window .........................................................123
Figure H-3. Installation Folder Window ..............................................................124
Figure H-4. Installation License Agreement Window .........................................124
Figure H-5. Installation Start Menu Shortcuts Window.......................................125
Figure H-6. Installation Ready to Install Window................................................125
Figure H-7. Installation Complete Window.........................................................126
Figure H-8. Entering an IP Address to be Added to the Control List..................127
Figure H-9. Control Selected in the Control List.................................................127
Figure H-10. Login Window with Fields for User Name and Password .............128
Figure H-11. An Application Selected in the Application List.............................129
Figure H-12. Default View of the Tool ................................................................130
Figure H-13. Simple View of the Tool.................................................................130
Figure H-14. Full View of the Tool......................................................................131
Figure H-15. Entering a Name for the Current Settings.....................................131
Figure H-16. A New Settings File Entered in the Predefined Settings List........132
Figure H-17. Remote View Tool (Default Setting) after Opening from the
Configuration Window....................................................................133
Figure I-1. HW Simulation Mode Access............................................................134
Table 2-1. CAN Wiring from 505 to VS-II.............................................................12
Table 3-1. Example Application Summary...........................................................23
Table 4-1 Mode Access by User Level.................................................................49

Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 5
Warnings and Notices
Important Definitions
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER—Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING—Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE—Indicates a hazard that could result in property damage only
(including damage to the control).
IMPORTANT—Designates an operating tip or maintenance suggestion.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Personal Protective
Equipment
The products described in this publication may present risks that
could lead to personal injury, loss of life, or property damage. Always
wear the appropriate personal protective equipment (PPE) for the job
at hand. Equipment that should be considered includes but is not
limited to:
Eye Protection
Hearing Protection
Hard Hat
Gloves
Safety Boots
Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.

505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
6 Woodward
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 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 7
Introduction
This volume of the manual contains application-specific notes, details on
interfaces to other Woodward products and example configurations of typical
steam turbine applications.
This volume gives users an idea of the 505 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.
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 stranded copper wire rated at least 75 °C for operating
ambient temperatures expected to exceed 50 °C.
Peripheral equipment must be suitable for the location in which it is used.
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.
EXPLOSION HAZARD—Do not connect or disconnect while circuit is
live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher
tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2.

505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
8 Woodward
Chapter 1.
Service Tools
Overview
This chapter provides an overview of the service tool interfaces to the 505.
Instructions for installing and using these tools are found in the Appendices of
this volume of the manual. All service tool interfaces to the 505 are Ethernet
connections and can be used on any of the 4 Ethernet ports. The only
requirement is that the PC connecting to the control has an IP address on the
same domain (as with any typical network).
Default settings for the Ethernet TCP/IP addresses can be found in Volume 1
Chapter 2.
Control Assistant (CA)
This tool is the primary service tool that will provide the following features:
Uploading and Downloading Tunables (your complete configuration
settings)
Live trending of any I/O signal or control parameter
Troubleshooting any system problem by viewing software variables in
the system
Analyzing any Datalog files that are collected from the control
Refer to the Appendices of this volume for instruction on using Woodward’s
Control Assistant Software Service Tool (Version 4.7 or newer).
Servlink-to-OPC-Server (SOS)
Integrated with control assistant is the Woodward Servlink-to-OPC-Server (SOS)
program that provides the communication data link between the 505 and a user
PC or system HMI. The SOS program will run on the PC as a service and
convert the 505 Woodward proprietary Servlink data to OPC data. The Control
Assistant tool will connect as a client to the SOS server. Customers desiring to
link to OPC data from the 505 will need to also connect to SOS.
AppManager (AppMan)
This program is the primary tool for transferring files to and from the control. It will
provide the user with the following services:
Transferring files to and from the control (executable control software,
GUI software, datalog files, system log files, control backup information)
Setting the control Ethernet port IP addresses and the SNTP time
synchronization IP address for network time protocol synchronizing
Installing a software service pack program
Starting / Stopping the control program or GUI program

Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 9
Chapter 2.
Peripheral Devices
Overview
This chapter provides a brief explanation of other Woodward devices, that can be
easily integrated with the 505. By understanding the functionality of a peripheral
device, a better understanding of the overall control configuration can be
achieved.
Some of these devices are able to be connected to the 505 by a digital
communication link (either Ethernet or CAN depending on the product). Through
this link the 505 display will allow the user to monitor many signals and status
LED’s from this external device. In many cases, these connections allow the 505
to receive required input signals, such as KW Load or a Synchronization or Load
Sharing Bias signal. This eliminates the need for wiring these signals to typical
I/O channels, or the digital signal can be used as a redundant/backup signal to a
hard-wired signal.
Devices supported in the 505 control application will be identified with a
“Woodward Link” identifier
All the devices covered in this section are manufactured or supported by
Woodward. 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.
DSLC-2 (Generator Synchronizer and Load Control)
Figure 2-1. DSLC-2
The DSLC-2 when connected to the 505 controller, can be used with generators
to accurately sense 3 phase RMS generator output power and perform generator
breaker synchronization. Other configurable DSLC-2 functions include generator
load-sharing, VAR or Power Factor control, process control, and base load
control.

505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
10 Woodward
This is a “Woodward Link” device.
Figure 2-2. Configuration/Woodward Links/DSLC-2
To enable the Woodward Link feature select the check box on the screen above
and enter the slave address and the IP address of the DSLC-2 device. The figure
above shows the factory default IP addresses of the DSLC-2 and Ethernet port 3
of the 505. These settings will allow these 2 products to communicate
automatically once an RJ45 Ethernet cable is connected between Ethernet Port 3
of the 505 and Network B port on the DSLC-2.
Once this configuration is complete, the DSLC-2 can provide the Synchronization
speed bias signal, the Sync/load sharing bias signal, and the KW output of the
generator. The radio buttons on the screen allow the user to select the functions
desired. The KW valued thru this link can be used as a secondary KW input
signal, is an analog input channel is already configured for a KW input.
The screens below show the available service screens that will now be
accessible to monitor the DSLC-2.
Figure 2-3. Service Screen - DSLC-2 Power Parameters

Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 11
Figure 2-4. Service Screen - DSLC-2 Status Parameters
VariStroke II (Electro-Hydraulic Actuator)
Figure 2-5. VS-II
This is a “Woodward Link” device.
The VariStroke-II is a linear electro-hydraulic actuator that is designed to provide
the linear actuation force to operate steam turbine control valves or valve racks.
This actuator can be directly networked with the 505 controller to reduce system
complexity and wiring requirements.

505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
12 Woodward
Figure 2-6. Configuration/Woodward Links/VS-II
To enable the Woodward Link feature select the check boxes on the screen
above to enable the CAN1 Link and confirm usage of the VariStroke II actuator,
then enter the Device ID. If an analog (4-20 mA) demand signal is going to be
connected to the VariStroke in addition to the CAN link, then select the desired
function for this signal (AI Backup is recommended). Finally select the inlet steam
valve that is being controlled (for most applications it is HP Demand).
CAN Wiring: 505 Function VariStroke II
CAN 1 – terminal 1 COM TB6-A (Top) – terminal 35
CAN 1 – terminal 2 CAN LO TB6-A (Top) – terminal 32
CAN 1 – terminal 4 CAN HI TB6-A (Top) – terminal 31
Connect a termination resistor
across CAN 1 – terminals 2 & 4
Table 2-1. CAN Wiring from 505 to VS-II
Once this configuration is complete, the VariStroke-II digital communication link
will provide the actuator demand signal to the steam valve and the screen below
will now be available under the Service menu to monitor driver information.
Figure 2-7. Service/VariStroke II

Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 13
MFR300 (Multi-function Relay)
Figure 2-8. Multi-Function Relay
This is a “Woodward Link” device.
The MFR 300 is a multi-function generator protection relay used to sense and
protect small generators. This multi-function protection relay integrates all
generator protection functions into one common device reducing overall system
installation complexity and cost.
LS-5 (Protection/Breaker Control Relay)
Figure 2-9. LS-5
This is a “Woodward Link” device.
The LS-5 series protection relays integrate generator breaker synchronization,
power sense and protection functions all into one package. This device is
designed to function in combination with a prime mover controller like the 505 to
allow accurate generator control as well as provide required generator protection.
Servo Position Controller (SPC)
A Servo Position Controller (SPC) can be used to interface the 505 digital
controls to existing valve operators or Woodward actuators that are integrating in
action or are not compatible with the 505 directly.

505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
14 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 actuator output
signals represent a demand signal equal to desired valve position (proportional).
If the turbine’s actuator or servo assembly requires a different drive signal, or
control action (integrating with a null setting), an SPC or equivalent device must
be used.
Woodward Servo Position Controller (SPC) accept a 4–20 mA actuator-drive
signal proportional to desired valve position, and positions a servo assembly
accordingly. Woodward SPCs have the capability of driving unipolar or bipolar
actuator demand signals, up to 0–400 mA or +400 mA respectively, on
proportional or integrating servo assembles.
Figure 2-10. Servo Position Controller
The SPC comes with a user-friendly software interface program that allows the
user to configure the unit to the desired settings. Consult the SPC manual for
complete details on the types of actuators to which the SPC can interface. Below
is one example of how the 505 and SPC can be used on Integrating Servo
Valves. The SPC can also handle many variations of feedback devices.
Figure 2-11. Interface to Servo Position Controller
(Example of Integrating Actuator with a 4-wire Feedback device)

Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 15
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.
Woodward manufactures two types of Real Power Sensors. The first type of RPS
is designed to sense power flow in one direction only (0 to +5 A CT current only),
and output a proportional 4–20 mA signal. This type of RPS was designed for
and should be used to sense generator power output. Many different real power
sensors of this type exist. Some of the optional RPS features include VAR
sensing, Load sharing, 0–1 A CT current sensing, and multiple combinations of
these. Please consult a Woodward certified distributor or a Woodward factory for
the recommended RPS for your application.
Figure 2-12. Real Power Sensor
The second type of RPS manufactured by Woodward is designed to sense
power flow through a bus-to-bus tie line. This RPS (8272-726) senses –5 A to
+5 A CT current to allow its output to represent power flow in both directions.
This RPS provides a 4–20 mA power indication output signal where 12 mA
represents 0 power flow. It is recommended that this RPS be used to sense
power flow through a tie line only. This RPS or equivalent is required to sense
plant Import and Export power.
Woodward Real Power Sensors have terminals labeled “Output” and terminals
labeled “KW Readout”. The “KW Readout” terminals provide a 4–20 mA signal
proportional to real power which is used by and compatible with the 505 control.
Thus the RPS terminals labeled “Output” are designed and typically compatible
only to Woodward’s 2301 type of control.

505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
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Woodward manufactured Real Power Sensors have a 2.5 Hz Low pass filter
(400 ms lag time) on their output to filter out the high frequency noise typically
created in a switch gear type environment. Thus if another vender’s watt
transducer is used, verification that it has similar filtering criteria should be
performed before it is applied with the 505. For more information on Woodward
Real Power Sensors, please refer to Woodward manual 82018.
Engine Generator Control Package/Load Sharing
(EGCP-3 LS)
The Woodward EGCP-3 LS control is a microprocessor based generator load
control designed for use on three-phase ac generators with Woodward speed
controls and automatic voltage regulators. The EGCP-3 LS is a synchronizer, a
load control, a dead bus closing system, a VAR/PF control, a process control,
Power & Energy metering and Protective Relays integrated into one package.
The EGCP-3 LS has a keypad and two 4-line display panels on the front cabinet
mounted chassis. The display can be used to configure and set up the control for
site-specific requirements. The display is also used in normal operating service to
monitor operation and view alarm data. All functions performed and parameters
monitored by the front panel are also available through the three serial ports.
These ports can be configured to use Woodward Watch Window software, an
external HMI and Modbus communication, or Servlink DDE software.
The 505 can be programmed to use the EGCP-3 LS as a synchronizer only, or
as a synchronizer and load control. The EGCP-3 LS provides either phase match
or slip frequency synchronizing, and ties into the unit automatic voltage regulator
to match voltages before paralleling. It interfaces with the 505 via a Speed bias
signal to control generator frequency and phase. When configured to use the
EGCP-3 LS as a synchronizer only, the 505 must be programmed to receive the
EGCP-3 Speed Bias signal through an analog input and have this input enabled
through a contact input or function key.
When used as a synchronizer and load control, the EGCP-3 LS performs
automatic synchronization, and controls unit load based on the EGCP-3 s mode
of operation. The EGCP-3 LS can be in a base-load, load sharing, remote load
setting, or Process control mode, depending on configuration and system
conditions.
The EGCP-3 LS’s load sharing mode is used to share load with any other units
using an EGCP-3 LS and tied to the same isolated bus. This mode is used in
conjunction with an EGCP-3 MC when paralleled to a utility to allow the EGCP-3
MC to control plant frequency or load depending on its state of operation.
The EGCP-3 LS’s remote load setting mode allows load to be set by a remote
4-20 mA signal. The EGCP-3 LS’s Process control mode allows any process
directly related to generator load to be controlled.
After synchronization, unit load can be controlled by the EGCP-3 LS (through the
505 Sync/Ld input) or by the 505’s internal speed/load set point. When the
Sync/Ld Share input is programmed, the position of the Utility Tie Breaker
Contact selects unit load control through the EGCP-3 LS or through the 505’s
internal load set point.

Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators
Woodward 17
Once the generator is synchronized the EGCP-3 LS soft-loads the unit to the
load setting determined by the mode of operation (base load, load sharing,
Process control). When commanded the EGCP-3 LS can also soft-unload the
unit and issue a breaker-open command at a set power level.
The PowerSense board receives the PT and CT inputs for both the generator
and bus for calculation of parameters for the EGCP-3 to use in system control.
The algorithms used are based on IEEE 1459-2000. For the generator and bus
the following parameters are provided: Hz, Vac, Amps, W, VA, VAR, PF, Phase,
Voltage harmonics, Current harmonics, Negative Phase Sequence Voltage,
Negative Phase Sequence Current. Available for selection at the 4–20 mA
analog outputs: Synchroscope, Generator metering, Mains metering.
Figure 2-13. EGCP-3 Control
Figure 2-14. EGCP-3 LS Functional Diagram
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505 Digital Governor for Single/Split-Range Actuators Manual 26839V2
18 Woodward
Figure 2-15. EGCP-3 LS Interface Wiring
The following Bus Protections are available with the EGCP-3 LS:
Over/Under Voltage (59, 27)
Over/Under Frequency (81O, 81U)
Directional (Forward/Reverse) Power (32) *
Negative Sequence Phase Overcurrent (46)
Negative Sequence Phase Overvoltage (47)
Phase Overcurrent (51) *
Voltage Restrained Phase Overcurrent (51V) *
Directional VAR
Phase Current Imbalance (46) *
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