Woodward 505 User manual

Product Manual 26839V1
(Revision B, 2/2017)
Original Instructions
505 Digital Control for Steam Turbines
8200-1300, 8200-1301, 8200-1302
Manual 26839 consists of 2 volumes (26839V1 & 26839V2)
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 Out-of-date translations are marked with .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 26839V1
Copyright © Woodward, Inc. 2017
All Rights Reserved

Manual 26839V1 505 Digital Control 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............................................................................................................................... 18
Keypad and Display .................................................................................................................................... 23
Watchdog Timer/CPU Fault Control ........................................................................................................... 24
CHAPTER 2. HARDWARE SPECIFICATIONS..................................................................................... 25
Flex505 Description and Features .............................................................................................................. 25
Environmental Specifications...................................................................................................................... 26
Maintenance Info and Recommendations .................................................................................................. 26
Electromagnetic Compatibility (EMC) ......................................................................................................... 27
Outline Drawing for Installation ................................................................................................................... 27
Input Power Specification............................................................................................................................ 29
Visual Indicators (LED’s) & CPU Configuration .......................................................................................... 30
Communications (Ethernet) ........................................................................................................................ 30
Communications (CAN) .............................................................................................................................. 31
Communications (RS-232/RS-485) ............................................................................................................ 33
Communications (Service Ports) ................................................................................................................ 34
Hardware - Terminal Blocks & Wiring ......................................................................................................... 35
Terminal Block Connectors ......................................................................................................................... 36
Hardware - Speed Sensor Inputs................................................................................................................ 37
Hardware - Analog Inputs (4-20 mA) .......................................................................................................... 38
Hardware - Analog Outputs (4-20 mA) ....................................................................................................... 39
Hardware - Actuator Outputs ...................................................................................................................... 40
Hardware - Discrete Inputs ......................................................................................................................... 41
Hardware - Relay Outputs........................................................................................................................... 42
Troubleshooting Fault Codes...................................................................................................................... 43
Troubleshooting & Commissioning checks ................................................................................................. 43
CHAPTER 3. 505 CONTROL DESCRIPTION ..................................................................................... 47
Introduction ................................................................................................................................................. 47
Turbine Start Modes.................................................................................................................................... 47
Start Permissive .......................................................................................................................................... 47
Open Wire Detection on MPU Speed Signals ............................................................................................ 47
Zero Speed Signal Override........................................................................................................................ 48
Manual Speed Override .............................................................................................................................. 48
Automatic Speed Override .......................................................................................................................... 48
Acceleration Limiter..................................................................................................................................... 49
Turbine Start Mode Procedures.................................................................................................................. 49
Speed Control Overview ............................................................................................................................. 58
Speed PID Operational Modes ................................................................................................................... 59
Manual Demand.......................................................................................................................................... 71
Load Rejection ............................................................................................................................................ 71
Feed-Forward Input..................................................................................................................................... 72
Cascade Control ......................................................................................................................................... 74
Auxiliary Control .......................................................................................................................................... 78
Remote Auxiliary Set Point ......................................................................................................................... 82
Auxiliary 2 Control ....................................................................................................................................... 83
Valve Limiter ............................................................................................................................................... 84

Manual 26839V1 505 Digital Control for Steam Turbines
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Inlet Steam Pressure Compensation .......................................................................................................... 85
Isolated PID Control .................................................................................................................................... 85
Emergency Shutdown ................................................................................................................................. 86
Controlled Shutdown................................................................................................................................... 87
Overspeed Test Function............................................................................................................................ 88
Local/Remote Function ............................................................................................................................... 88
Relays ......................................................................................................................................................... 89
CHAPTER 4. CONFIGURATION PROCEDURES ................................................................................. 92
Program Architecture .................................................................................................................................. 92
Display Modes and User Levels ................................................................................................................. 92
Configuring the 505..................................................................................................................................... 93
Exiting the Configure Mode....................................................................................................................... 119
Valve/Actuator Calibration & Test ............................................................................................................. 126
Calibration/Stroking Procedure ................................................................................................................. 127
CHAPTER 5. 505 OPERATION ...................................................................................................... 128
Software Architecture................................................................................................................................ 128
Power-Up Screen...................................................................................................................................... 128
Control Mode Architecture ........................................................................................................................ 130
User Login Levels ..................................................................................................................................... 131
Navigation ................................................................................................................................................. 132
Page Organization .................................................................................................................................... 132
Overview Screen....................................................................................................................................... 134
Speed Control Screen............................................................................................................................... 135
Valve Demand Screen .............................................................................................................................. 135
Controllers Screen .................................................................................................................................... 136
Cascade Control Screen ........................................................................................................................... 137
Auxiliary Control Screen............................................................................................................................ 137
Analog Input Summary Screen ................................................................................................................. 138
Contact Input Summary Screen................................................................................................................ 139
Analog Output Summary Screen .............................................................................................................. 139
Relay Output Summary Screen ................................................................................................................ 140
Actuator Driver Summary Screen ............................................................................................................. 140
Starting Procedures (Start Curve Screen) ................................................................................................ 141
Overspeed Test Function (Speed Control Screen)................................................................................... 142
Stop Key.................................................................................................................................................... 144
Alarm Summary ........................................................................................................................................ 144
Shutdown Summary.................................................................................................................................. 149
Speed, Cascade, and Auxiliary Dynamics Adjustments ........................................................................... 151
CHAPTER 6. COMMUNICATIONS................................................................................................... 164
Modbus Communications.......................................................................................................................... 164
Port Adjustments....................................................................................................................................... 167
505 Control Modbus Addresses................................................................................................................ 167
Specific Address Information .................................................................................................................... 183
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS ............................................................ 185
Product Support Options........................................................................................................................... 185
Product Service Options ........................................................................................................................... 185
Returning Equipment for Repair ............................................................................................................... 186
Replacement Parts.................................................................................................................................... 187
Engineering Services ................................................................................................................................ 187
Contacting Woodward’s Support Organization ......................................................................................... 187
Technical Assistance ................................................................................................................................ 188
APPENDIX A. 505 CONFIGURATION MODE WORKSHEETS ............................................................ 189
DECLARATIONS .......................................................................................................................... 203

Manual 26839V1 505 Digital Control for Steam Turbines
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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 .............................................................................. 15
Figure 1-2. Explanation of Symbols ............................................................................................................ 17
Figure 1-3. Single or Split-Range Turbine Configurations .......................................................................... 18
Figure 1-4. 505 Keypad and Display........................................................................................................... 23
Figure 2-1. Functional Block Diagram (505D Control)................................................................................ 25
Figure 2-2. 505D Outline Drawing .............................................................................................................. 28
Figure 2-3. COM1 Example RS-485 wiring................................................................................................. 34
Figure 2-4. CPU Service Port (3 pin, 2 mm) ............................................................................................... 34
Figure 2-5. 505 Back Cover Label .............................................................................................................. 35
Figure 2-6. Terminal Block Connectors ...................................................................................................... 36
Figure 2-7. Speed Sensor Block Diagram .................................................................................................. 38
Figure 2-8. Analog Input – Self-Powered Block Diagram ........................................................................... 39
Figure 2-9. Analog Input – Loop-Powered Block Diagram ......................................................................... 39
Figure 2-10. Analog Output Block Diagram ................................................................................................ 40
Figure 2-11. Actuator Output Block Diagram .............................................................................................. 41
Figure 2-12. Discrete Input Block Diagram ................................................................................................. 41
Figure 2-13. Relay Output Block Diagram .................................................................................................. 42
Figure 3-1. Open Wire Detection Test ........................................................................................................ 48
Figure 3-2. Manual Start Mode Example .................................................................................................... 50
Figure 3-3. Semiautomatic Start mode Example ........................................................................................ 50
Figure 3-4. Automatic Start Mode Example ................................................................................................ 51
Figure 3-5. Idle/Rated Start......................................................................................................................... 53
Figure 3-6. Automatic Start Sequence........................................................................................................ 54
Figure 3-7. Speed Control Functional Diagram .......................................................................................... 59
Figure 3-8. Speed PID Control Modes........................................................................................................ 61
Figure 3-9. Frequency and Unit Load Relationship .................................................................................... 62
Figure 3-10. Speed Relationships............................................................................................................... 64
Figure 3-11. Load Sharing Logic................................................................................................................. 70
Figure 3-12. Typical Anti-surge Valve and Speed Feed-Forward Logic Trend .......................................... 73
Figure 3-13. Cascade Functional Diagram ................................................................................................. 74
Figure 3-14. Aux Control Overview............................................................................................................. 79
Figure 3-15. Aux 2 Control Overview.......................................................................................................... 84
Figure 4-1. Initial HOME Screen (unit not configured)................................................................................ 93
Figure 4-2. Configuration Menu – Configuration Mode (Edit) ..................................................................... 95
Figure 5-1. Software Architecture ............................................................................................................. 128
Figure 5-2. 505 Splash Screen ................................................................................................................. 129
Figure 5-3. Boot-up to HOME Screen....................................................................................................... 129
Figure 5-4. Control Mode Architecture...................................................................................................... 130
Figure 5-5. Mode Screen .......................................................................................................................... 131
Figure 5-6. Navigation Cross .................................................................................................................... 132
Figure 5-7. Service Menu showing “Speed Control” IN-Focus ................................................................. 132
Figure 5-8. Configuration Menu – Operation Mode (View only) ............................................................... 133
Figure 5-9. Configuration Menu – Configuration Mode (Edit) ................................................................... 133
Figure 5-10. Overview Screen .................................................................................................................. 134
Figure 5-11. Speed Control Screen .......................................................................................................... 135

Manual 26839V1 505 Digital Control for Steam Turbines
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Figure 5-12. Valve Demand Screen.......................................................................................................... 135
Figure 5-13. Controllers Screen................................................................................................................ 136
Figure 5-14. Cascade Control Screen ...................................................................................................... 137
Figure 5-15. Auxiliary Control Screen ....................................................................................................... 137
Figure 5-16. Analog Input Summary Screen............................................................................................. 138
Figure 5-17. Contact Input Summary Screen ........................................................................................... 139
Figure 5-18. Analog Output Summary Screen.......................................................................................... 139
Figure 5-19. Relay Output Summary Screen............................................................................................ 140
Figure 5-20. Actuator Driver Summary Screen......................................................................................... 140
Figure 5-21. HOME Menu showing “Startup Curve” IN-Focus ................................................................. 141
Figure 5-22. Overspeed Test Permissives................................................................................................ 142
Figure 5-23. Internal (505) Overspeed Test.............................................................................................. 143
Figure 5-24. External Overspeed Test...................................................................................................... 143
Figure 5-25. ALARM Screen..................................................................................................................... 145
Figure 5-26. Shutdown Summary Screen................................................................................................. 149
Figure 5-27. Speed Dynamics Adjustment Screen................................................................................... 151
Figure 5-28. Typical Response to Load Change ...................................................................................... 154
Figure 5-29. Overview of the Automated PID Optimizer Routine ............................................................. 155
Figure 5-30. Optimization Routine Overview Trend.................................................................................. 156
Figure 5-31. Configuration Parameters ‘Configure’ Pop-up...................................................................... 157
Figure 6-1. ASCII/RTU Representation of three ....................................................................................... 165
Table 2-1.. Input Power Connector Pinout.................................................................................................. 29
Table 2-2. Ethernet Connector (RJ45) Ports #1-4 (10/100)........................................................................ 31
Table 2-3. CAN Specifications .................................................................................................................... 32
Table 2-4. CAN Connector Pinout .............................................................................................................. 32
Table 2-5. CAN Cable Specifications.......................................................................................................... 32
Table 2-6. COM1 Serial Port (RS-232/485)Connector ............................................................................... 33
Table 2-7. Specifications (MPU / PROX) .................................................................................................... 37
Table 2-8. Specifications (AI)...................................................................................................................... 38
Table 2-9. Specifications (AO) .................................................................................................................... 39
Table 2-10. Specifications (ACT) ................................................................................................................ 40
Table 2-11. Specifications (DI).................................................................................................................... 41
Table 2-12. Specifications (Relay outputs) ................................................................................................. 42
Table 2-13. CPU Fault LED Flash Codes ................................................................................................... 43
Table 3-1. Example Automatic Start Sequence Settings............................................................................ 55
Table 3-2. Unit Tripped for 12 hours, Hot and Cold Parameters Interpolation Rates and Delays.............. 55
Table 3-3. Warm or Host Start Configuration.............................................................................................. 57
Table 3-4. Frequency Arm/Disarm Generator Control Modes .................................................................... 66
Table 3-5. On-Line/Off-Line Dynamics Selection........................................................................................ 66
Table 3-6. Load Sharing Logic.................................................................................................................... 70
Table 4-1. Mode Access by User Level ...................................................................................................... 92
Table 4-2. Configuration Function Definitions............................................................................................. 95
Table 4-3. Analog Input #1 Input Function Menu Options ........................................................................ 112
Table 4-4. Analog Output #1 Output Function Menu Options................................................................... 113
Table 4-5. Options for Actuator Readout .................................................................................................. 115
Table 4-6. CONTACT INPUT OPTIONS .................................................................................................. 116
Table 4-7. Options for Relays if Used to Indicate State............................................................................ 118
Table 4-8. List of Options for Level Switch ............................................................................................... 118
Table 4-9 Configuration Error Messages and Definitions ......................................................................... 119
Table 4-10. Actuator Driver Limits ............................................................................................................ 126
Table 5-1. ALARM Messages ................................................................................................................... 145
Table 5-2. TRIPPED Messages................................................................................................................ 150
Table 6-1. ASCII vs RTU Modbus............................................................................................................. 165
Table 6-2. Modbus Frame Definition......................................................................................................... 166
Table 6-3. Modbus Function Codes.......................................................................................................... 166
Table 6-4. Modbus Error Codes................................................................................................................ 166
Table 6-5. Modbus Communication Port Adjustments ............................................................................. 167
Table 6-6. Maximum Modbus Discrete and Analog Values...................................................................... 167

Manual 26839V1 505 Digital Control for Steam Turbines
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Table 6-7. Boolean Write Addresses ........................................................................................................ 168
Table 6-8. Boolean Read Addresses ........................................................................................................ 170
Table 6-9. Analog Reads .......................................................................................................................... 174
Table 6-10. Analog Write Addresses ........................................................................................................ 180
Table 6-11. Control Status ........................................................................................................................ 180
Table 6-12. Analog Input Configuration .................................................................................................... 181
Table 6-13. Analog Output Configuration ................................................................................................. 181
Table 6-14. Relay Configured As Level Switch......................................................................................... 182
Table 6-15. Relay Configuration to Indicate State .................................................................................... 182
Table 6-16. Contact Input Configurations ................................................................................................. 183

Manual 26839V1 505 Digital Control 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 26839V1 505 Digital Control 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
NEC/CEC or Authority Having Final Jurisdiction per the Input Power
Specifications.

Manual 26839V1 505 Digital Control 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 26839V1 505 Digital Control for Steam Turbines
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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 Certificate: IECEx CSA 15.0020X
IEC 60079-0: 2011 – Explosive Atmospheres – Part 0 Equipment General
Requirements
IEC 60079-11: 2011 – Explosive Atmospheres – 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 portection
“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 26839V1 505 Digital Control 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
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 connections; +10˚C above highest ambient.

Manual 26839V1 505 Digital Control for Steam Turbines
Woodward 11
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
The 505 Digital Control shall not be installed in areas exceeding Pollution Degree 2 as defined in IEC
60664-1.
Wiring must be in accordance with Zone 2 wiring methods and in accordance with the authority having
final jurisdiction.
Protective Earth Grounding of the 505 Digital Control is required to be connected to the PE terminal.
The Real Time Clock Battery located on the CPU board is not to be recharged and is not user
replaceable. Contact a Woodward Authorized Service Center if a replacement service is needed.
The Low Voltage ATEX 505 Digital Control 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 505D 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 505D 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 ATEX/IECEx approved for Zone 2 Group
IIC, Category 3G 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 26839V1 505 Digital Control 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 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 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 26839V1 505 Digital Control 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 26839V1 505 Digital Control for Steam Turbines
Woodward 14
Chapter 1.
General Information
Introduction
This manual describes the Woodward 505 Digital Governor for steam turbines with single or split-range
actuators. Released versions are 8200-1300,
8200-1301, and 8200-1302. The option charts below show the differences between the part numbers.
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
8200-1300 LVDC (18–36 Vdc) Ordinary Location Compliance
8200-1301 AC/DC (88–264 Vac or 90–150 Vdc) Ordinary Location Compliance
8200-1302 Marine/ATEX Compliance LVDC (18–36 Vdc)
General Installation and Operating Notes and Warnings
The Standard Low Voltage and High Voltage Controls are suitable for use in ordinary locations only. The
Low Voltage ATEX Control is suitable for use in Class I, Division 2, Groups A, B, C, and D or Class I,
European Zone 2, Group IIC environments or non-hazardous locations.
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.
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.
Controller Overview
General Description
The 505 controller is designed to control single or dual (split range) actuator steam turbines (extraction
steam turbines require the 505XT version). The 505 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 menu
driven software to instruct site engineers on programming the control to a specific generator or
mechanical drive application. The 505 can be configured to operate as a stand-alone unit or in
conjunction with a plant’s Distributed Control System.

Manual 26839V1 505 Digital Control for Steam Turbines
Woodward 15
The 505 control has five PID controllers that can affect the demand of the inlet steam flow into the turbine;
the Speed/load PID controller, the Auxiliary PID controller, Auxiliary 2 PID controller, and the Cascade
PID controller. Depending on the configuration of the 505, these PIDs interact differently with each other.
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 505 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.
The 505 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 505 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. Refer to Volume 2 of this manual for details on applications.
Figure 1-1. Typical Single or Dual Inlet 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 and set point values
at any time during turbine operation.
Communications
The 505 control can communicate directly with plant Distributed Control Systems and/or Human Machine
Interface (HMI) control panels, through Modbus communication ports. One serial port support RS-232 or
RS-485 communications using ASCII or RTU MODBUS transmission protocols. Two Ethernet ports are
also available to communication this same information between the 505 and a plant DCS.
Additional Features
The 505 also provides the following features:
First-Out Trip indication of Alarm and Trip events with RTC time stamp
10 External DI trip inputs
10 External Alarm inputs
Critical Speed Avoidance (3 speed bands)
Auto Start Sequence (hot & cold starts) with Temperature Input options

Manual 26839V1 505 Digital Control for Steam Turbines
Woodward 16
Dual Speed/Load Dynamics
Zero Speed Detection
Peak Speed Indication for Overspeed trip, and Isochronous Load sharing between units (with an
DSLC-2 control)
Feed-forward loop
Acceleration protection at initial startup
Remote droop
Frequency dead-band.
Using the 505
The 505 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 calibrates, tunes, and adjusts 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
operates the turbine from start-up through shutdown.

Manual 26839V1 505 Digital Control for Steam Turbines
Woodward 17
Functional Block Diagrams
An overview of the 505 valve demands is shown in Figure 1-4. The Cascade and Auxiliary PIDs are
optional controllers, and are shown in the following diagrams for PID relationship purposes only. Later in
this manual, more detailed functional block diagrams will be shown in relative to each control loop PID.
Figure 1-2. Explanation of Symbols

Manual 26839V1 505 Digital Control for Steam Turbines
Woodward 18
Figure 1-3. Single or Split-Range Turbine Configurations
(Valve Demand Overview)
505 Inputs and Outputs
Control Inputs
Two redundant speed inputs are configurable to accept MPUs (magnetic pickup units), proximity probes
or eddy current probes.
Eight programmable analog inputs can be configured as one of the following input functions:
Table 1-1. Input Functions
Input
Function
Description
1 --- Not Used ---
2 Remote Speed Setpoint
3 Synchronizing Input
4 Sync / Load Share
5 KW / Unit Load Input
6 Cascade Input
7 Remote Cascade Setpoint
8 Auxiliary Input
9 Remote Auxiliary Setpoint
10 Auxiliary 2 Input
11 Remote Auxiliary 2 Setpoint
12 Inlet Pressure Input
13 I/H Actuator 1 Feedback
14 I/H Actuator 2 Feedback
15 Speed Feed-Forward
16 Remote Droop
17 Remote KW Setpoint
18 Exhaust Steam Pressure