Woodward CONTROL-505D User manual

Product Manual 26839V2
(Revision D, 10/2021)
Original Instructions
505 Digital Control for Steam Turbines
Manual 26839 consists of 2 volumes (26839V1 & 26839V2)
Volume 2
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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 Out-of-date translations are marked with .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 26839V2
Copyright © Woodward, Inc. 2017 - 2021
All Rights Reserved
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Contents
WARNINGS AND NOTICES ...............................................................................................................5
ELECTROSTATIC DISCHARGE AWARENESS......................................................................................6
INTRODUCTION ...............................................................................................................................7
CHAPTER 8. SERVICE TOOLS..........................................................................................................8
Overview .......................................................................................................................................................8
Control Assistant (CA)...................................................................................................................................8
Servlink-to-OPC-Server (SOS) .....................................................................................................................8
AppManager (AppMan).................................................................................................................................8
CHAPTER 9. 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.....................................................................................................................................14
Engine Generator Control Package/Load Sharing (EGCP-3 LS)...............................................................15
Applying the 505 with Redundant I/H or I/P Converters.............................................................................19
CHAPTER 10. APPLICATION NOTES...............................................................................................21
Overview .....................................................................................................................................................21
Example Applications..................................................................................................................................22
CHAPTER 11. OPERATOR INTERFACE............................................................................................46
Introduction .................................................................................................................................................46
Graphical Display and Key Inputs...............................................................................................................46
Service Panel Modes and User Levels.......................................................................................................47
CHAPTER 12. SERVICE MENU PROCEDURES .................................................................................49
Overview .....................................................................................................................................................49
Using the Service Menus............................................................................................................................49
Service Mode Parameters...........................................................................................................................53
CHAPTER 13. UNDERSTANDING PID SETTINGS..............................................................................73
Overview .....................................................................................................................................................73
Proportional Response................................................................................................................................74
Proportional + Integral (closed loop)...........................................................................................................75
Derivative Response...................................................................................................................................77
Proportional + Derivative (closed loop).......................................................................................................78
Proportional + Integral + Derivative (closed loop).......................................................................................79
Controller Field Tuning General..................................................................................................................81
CHAPTER 14. HARDWARE/OPERATING SYSTEM FAULTS................................................................83
General........................................................................................................................................................83
Wiring Problems..........................................................................................................................................83
Control Adjustments....................................................................................................................................83
Other Operating Problems..........................................................................................................................84
APPENDIX B. 505 DESIGN SPECIFICATIONS...................................................................................85
Hardware Specifications .............................................................................................................................85
Software Specifications...............................................................................................................................85
APPENDIX C. 505 SERVICE MODE WORKSHEET ............................................................................87
APPENDIX D. PASSWORD INFORMATION........................................................................................97
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General........................................................................................................................................................97
Monitor User Level......................................................................................................................................97
“Operator” User Level Password ................................................................................................................97
“Service” User Level Password...................................................................................................................97
“Configure” User Level Password ...............................................................................................................97
“ServiceUser” User Level Password...........................................................................................................97
APPENDIX E. SERVLINK-TO OPC SERVER (SOS) TOOL.................................................................98
SOS Communication Link...........................................................................................................................98
Installing SOS .............................................................................................................................................98
Connecting a PC/Laptop to the Control......................................................................................................99
APPENDIX F. CONTROL ASSISTANT—SOFTWARE INTERFACE TOOL.............................................102
Features of Control Assistant....................................................................................................................102
Installing Control Assistant........................................................................................................................102
Using Control Assistant.............................................................................................................................104
APPENDIX G. APPMANGER SERVICE TOOL .................................................................................109
File Management with App. Manager.......................................................................................................109
Installing App Manager .............................................................................................................................109
APPENDIX H. CONFIGURING NETWORK TCP/IP ADDRESSES .......................................................116
APPENDIX I. REMOTEVIEW TOOL ................................................................................................118
APPENDIX J. USING 505 INTERNAL SIMULATION MODE................................................................128
APPENDIX K. CUSTOM TAG NAME PROCEDURE...........................................................................129
APPENDIX LDATALOGS..............................................................................................................130
The following are trademarks of Woodward, Inc.:
ProTech
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)
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Illustrations and Tables
Figure 9-1. DSLC-2.......................................................................................................................................9
Figure 9-2. Configuration/Woodward Links/DSLC-2...................................................................................10
Figure 9-3. Service Screen - DSLC-2 Power Parameters..........................................................................10
Figure 9-4. Service Screen - DSLC-2 Status Parameters..........................................................................11
Figure 9-5. VS-II..........................................................................................................................................11
Figure 9-6. Configuration/Woodward Links/VS-II .......................................................................................12
Figure 9-7. Service/VariStroke II.................................................................................................................12
Figure 9-8. Multi-Function Relay.................................................................................................................13
Figure 9-9. LS-5..........................................................................................................................................13
Figure 9-10. Servo Position Controller........................................................................................................14
Figure 9-11. Interface to Servo Position Controller.....................................................................................14
Figure 9-12. Real Power Sensor.................................................................................................................15
Figure 9-13. EGCP-3 Control......................................................................................................................16
Figure 9-14. EGCP-3 LS Functional Diagram.............................................................................................17
Figure 9-15. EGCP-3 LS Interface Wiring...................................................................................................18
Figure 9-16. Typical Redundant I/H System with a Transfer Valve............................................................19
Figure 9-17. Typical Redundant I/P System with a Pressure Selecting Relay Valve.................................19
Figure 10-1. Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting ......24
Figure 10-2. Inlet Pressure Control with AutomaticSynchronizing & Generator Power Limiting................27
Figure 10-3. Exhaust Pressure Control with Generator Power Limiting and Plant Import/Export Limiting.31
Figure 10-4. Plant Import/Export Control with DRFD Servo Interface........................................................35
Figure 10-5. Inlet Pressure Control with Isochronous Loadsharing Control in Island Mode ......................39
Figure 10-6. Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode
................................................................................................................................................42
Figure 11-1 505 Keypad and Display..........................................................................................................46
Figure 12-1. User Login for Service............................................................................................................49
Figure 12-2. Authorized and Unauthorized Components ...........................................................................50
Figure 12-3 Service Menu (page 1)............................................................................................................50
Figure 12-4 Service Menu (page 2)............................................................................................................51
Figure 13-1. Proportional Gain Setting Effects...........................................................................................74
Figure 13-2. Open Loop Proportional and Integral Response....................................................................75
Figure 13-3. Closed Loop Proportional and Integral Response..................................................................76
Figure 13-4. Integral Gain (Reset) Setting Responses...............................................................................77
Figure 13-5. Closed Loop Proportional and Derivative Action....................................................................78
Figure 13-6. Derivative Setting Effects .......................................................................................................79
Figure 13-7. Closed Loop Proportional, Integral and Derivative Action......................................................80
Figure 13-8. Typical Response to Load Change........................................................................................81
Figure E-1. SOS..........................................................................................................................................98
Figure E-2. SOS Install Window .................................................................................................................99
Figure E-3. SOS Server status dialog box..................................................................................................99
Figure E-4. SOS –New Session box........................................................................................................100
Figure E-5. SOS - Enter 505 TCP/IP address ..........................................................................................100
Figure E-6. SOS –Active Links dialog box...............................................................................................100
Figure F-1. Control Assistant License Agreement....................................................................................102
Figure F-2. Control Assistant Install Window............................................................................................103
Figure F-3. Control Assistant Folder Selection.........................................................................................103
Figure F-4. Control Assistant Install Complete.........................................................................................103
Figure F-5. Install Restart Window............................................................................................................104
Figure F-6. Control Assistant Window ......................................................................................................104
Figure F-7. Dialog for Servlink OPC connection.......................................................................................105
Figure F-8. WinPanel Session..................................................................................................................105
Figure F-9. Control Assistant –Retrieve Tunable Dialog box...................................................................106
Figure F-10. Control Assistant –Send Tunable Dialog box......................................................................107
Figure F-11. Control Assistant –Speed Control Trend Script ..................................................................108
Figure F-12. Control Assistant –Create Trend Script File........................................................................108
Figure G-1. App Manager Install Window.................................................................................................109
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Figure G-2. App Manager License Agreement Window...........................................................................110
Figure G-3. App Manager Installation.......................................................................................................110
Figure G-4. App Manager Install Complete ..............................................................................................111
Figure G-5. AppManager Window ............................................................................................................111
Figure G-6. Dialog for App Manager Connection......................................................................................112
Figure G-7. App Manager Connected to a Control...................................................................................112
Figure G-8. AppManager Control Info Window.........................................................................................113
Figure G-9. AppManager Control (GAP) Application Panel......................................................................113
Figure G-10. AppManager GUI Application Panel....................................................................................114
Figure G-11. Retrieving Files....................................................................................................................114
Figure H-1. Configuration/Communications Screen.................................................................................116
Figure H-2. Ethernet Port Layout (Ports on Side).....................................................................................116
Figure I-1. Window Shown when the Time Limit is Exceeded..................................................................118
Figure I-2. Installation Welcome Window..................................................................................................118
Figure I-3. Installation Folder Window ......................................................................................................119
Figure I-4. Installation License Agreement Window .................................................................................119
Figure I-5. Installation Start Menu Shortcuts Window...............................................................................120
Figure I-6. Installation Ready to Install Window........................................................................................120
Figure I-7. Installation Complete Window.................................................................................................121
Figure I-8. Entering an IP Address to be Added to the Control List..........................................................121
Figure I-9. Control Selected in the Control List.........................................................................................122
Figure I-10. Login Window with Fields for User Name and Password .....................................................122
Figure I-11. An Application Selected in the Application List .....................................................................123
Figure I-12. Default View of the Tool ........................................................................................................124
Figure I-13. Simple View of the Tool.........................................................................................................124
Figure I-14. Full View of the Tool..............................................................................................................125
Figure I-15. Entering a Name for the Current Settings.............................................................................125
Figure I-16. A New Settings File Entered in the Predefined Settings List ................................................126
Figure I-17. Remote View Tool (Default Setting) after Opening from the Configuration Window ............127
Figure J-1. HW Simulation Mode Access .................................................................................................128
Figure K-1. The Datalog Service Menu Page...........................................................................................131
Figure K-2. DataLog Graph Properties.....................................................................................................132
Figure K-3. Datalog Plot............................................................................................................................133
Figure K-4. Automated File Collection Configuration................................................................................134
Figure K-5. Automated File Collection Active ...........................................................................................135
Table 9-1. CAN Wiring from 505 to VS-II....................................................................................................12
Table 10-1. Example Application Summary................................................................................................23
Table 11-1 Mode Access by User Level.....................................................................................................47
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Warnings and Notices
Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
•DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
•WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
•CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
•NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
•IMPORTANT - Designates an operating tip or maintenance suggestion.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Personal Protective
Equipment
The products described in this publication may present risks that
could lead to personal injury, loss of life, or property damage.
Always wear the appropriate personal protective equipment (PPE) for
the job at hand. Equipment that should be considered includes but is
not limited to:
•Eye Protection
•Hearing Protection
•Hard Hat
•Gloves
•Safety Boots
•Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
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Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
•Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
•Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
•Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Follow these precautions when working with or near the control.
1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not store
static electric charges as much as synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.
If you must remove the PCB from the control cabinet, follow these precautions:
•Do not touch any part of the PCB except the edges.
•Do not touch the electrical conductors, the connectors, or the components with conductive
devices or with your hands.
•When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.
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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.
Refer to Manual 26839, Volume 1 for Required Safety Instructions,
Special Conditions for Safe Use and Hazardous Location
Requirements to insure the control is used in a safe manner in
Ordinary, Marine, Hazardous, ATEX and IECEx locations. Volume 1
must be fully understood and complied with for all applications.
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Chapter 8.
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
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Chapter 9.
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 9-1. 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.
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Figure 9-2. Configuration/Woodward Links/DSLC-2
This is a “Woodward Link” device.
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 9-3. Service Screen - DSLC-2 Power Parameters
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Figure 9-4. Service Screen - DSLC-2 Status Parameters
VariStroke II (Electro-Hydraulic Actuator)
Figure 9-5. 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.
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Figure 9-6. 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).
Table 9-1. CAN Wiring from 505 to VS-II
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
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 9-7. Service/VariStroke II
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MFR300 (Multi-function Relay)
Figure 9-8. 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 9-9. 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.
The 505’s actuator outputs have the capability of driving a 4–20 mA or 0–200 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.
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Figure 9-10. 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 9-11. Interface to Servo Position Controller
(Example of Integrating Actuator with a 4-wire Feedback device)
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.
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Figure 9-12. 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.
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.
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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.
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 9-13. EGCP-3 Control
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Manual 26839V2 505 Digital Control for Steam Turbines
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Figure 9-14. EGCP-3 LS Functional Diagram
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Manual 26839V2 505 Digital Control for Steam Turbines
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Figure 9-15. 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) *
The following Generator Protections are available with the EGCP-3 LS:
•Over/Under Voltage (59, 27)
•Over/Under Frequency (81O, 81U)
•Directional (Import/Export) Power (32)*
•Negative Sequence Phase Overcurrent (46)
•Negative Sequence Phase Overvoltage (47)
•Phase Overcurrent (51) *
•Directional VAR
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