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Woodward 505HT, Installation And Operation Manual

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Woodward 505HT Installation And Operation Manual Download Page 4

Manual 35116 

505HT for Pelton Turbines 

 

 

 

Woodward 

2 

General Configuration (3/9) Screen ............................................................................................................ 79

 

General Configuration (4/9) Screen ............................................................................................................ 81

 

General Configuration (5/9) Screen ............................................................................................................ 83

 

General Configuration (6/9) Screen ............................................................................................................ 85

 

General Configuration (7/9) Screen ............................................................................................................ 87

 

General Configuration (8/9) Screen ............................................................................................................ 89

 

General Configuration (9/9) Screen ............................................................................................................ 91

 

Offline PID Screen ...................................................................................................................................... 93

 

Online PID Screen ...................................................................................................................................... 94

 

Baseload PID Screen .................................................................................................................................. 96

 

Small System Detection PID Screen .......................................................................................................... 97

 

Step Test Screen ........................................................................................................................................ 99

 

Nozzle (1) Screen ..................................................................................................................................... 100

 

Nozzle (2) Screen ..................................................................................................................................... 101

 

Nozzle (3) Screen ..................................................................................................................................... 102

 

Nozzle Rotation Screen ............................................................................................................................ 104

 

Deflector Screen ....................................................................................................................................... 105

 

Deflector Commands Screen .................................................................................................................... 107

 

Droop Screen ............................................................................................................................................ 108

 

Droop Commands Screen ......................................................................................................................... 110

 

Isolated Mode Commands Screen ............................................................................................................ 112

 

Nozzles Mismatch Screen ......................................................................................................................... 113

 

Level Screen ............................................................................................................................................. 115

 

Level Commands Screen .......................................................................................................................... 117

 

Overspeed Test Screen ............................................................................................................................ 119

 

Remote Alarms Screen ............................................................................................................................. 121

 

Communications (Serial Port) Screen ....................................................................................................... 122

 

Communications (Ethernet) Screen .......................................................................................................... 124

 

Communications (Ethernet IP) Screen ..................................................................................................... 125

 

Communications (Default Gateway) Screen ............................................................................................. 127

 

Speed Switch Screen ................................................................................................................................ 128

 

Nozzle Switch Screen ............................................................................................................................... 129

 

Load Switch Screen .................................................................................................................................. 130

 

Status Screen ............................................................................................................................................ 132

 

Analog Inputs Screen ................................................................................................................................ 133

 

Speed Input Screen .................................................................................................................................. 135

 

Contact Inputs Screen ............................................................................................................................... 137

 

Analog Outputs Screen ............................................................................................................................. 139

 

Relay Outputs Screen ............................................................................................................................... 141

 

Actuator Outputs Screen ........................................................................................................................... 143

 

Force Actuator Outputs Screen ................................................................................................................ 145

 

Trip Summary Screen ............................................................................................................................... 146

 

Alarm Summary Screen ............................................................................................................................ 147

 

Check Configuration Screen ..................................................................................................................... 148

 

C

HAPTER 

5.

 

P

RODUCT 

S

UPPORT AND 

S

ERVICE 

O

PTIONS

 ........................................................... 149

 

Product Support Options ........................................................................................................................... 149

 

Product Service Options ........................................................................................................................... 149

 

Returning Equipment for Repair ............................................................................................................... 150

 

Replacement Parts .................................................................................................................................... 151

 

Engineering Services ................................................................................................................................ 151

 

Contacting Woodward’s Support Organization ......................................................................................... 151

 

Technical Assistance ................................................................................................................................ 152

 

C

HAPTER 

6.

 

A

SSET 

M

ANAGEMENT AND 

R

EFURBISHMENT 

S

CHEDULING 

P

ERIOD

 .......................... 153

 

A

PPENDIX 

A

 

–

 

A

LARM 

L

IST

 ....................................................................................................... 154

 

A

PPENDIX 

B

 

–

 

S

HUTDOWN 

L

IST

 ................................................................................................ 162

 

A

PPENDIX 

C

 

–

 

C

ONFIGURATION 

E

RROR 

L

IST

 ............................................................................. 164

 

Released

Summary of Contents for 505HT

Page 1: ...Product Manual 35116 Revision 2 2019 Original Instructions 505HT for Pelton Turbines 8200 1400 8200 1401 Installation and Operation Manual Released...

Page 2: ...e 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...

Page 3: ...ation 22 Communications Ethernet 23 Communications CAN 24 Communications Service Ports 28 Hardware Terminal Blocks Wiring 29 Terminal Block Connectors 30 Hardware Speed Sensor Inputs 31 Hardware Analo...

Page 4: ...Screen 121 Communications Serial Port Screen 122 Communications Ethernet Screen 124 Communications Ethernet IP Screen 125 Communications Default Gateway Screen 127 Speed Switch Screen 128 Nozzle Switc...

Page 5: ...ram 34 Figure 2 10 Actuator Output Block Diagram 35 Figure 2 11 Discrete Input Block Diagram 36 Figure 2 12 Relay Output Block Diagram 37 Figure 3 1 Nozzle Limit 46 Figure 3 2 Speed Deadband Function...

Page 6: ...s Serial Port Screen 122 Figure 4 46 Communications Ethernet Screen 124 Figure 4 47 Communications Ethernet IP Screen 125 Figure 4 48 Communications Default Gateway Screen 127 Figure 4 49 Speed Switch...

Page 7: ...3 9 Screen Command Buttons and Parameters 80 Table 4 11 General Configuration 4 9 Screen Command Buttons and Parameters 82 Table 4 12 General Configuration 5 9 Screen Command Buttons and Parameters 8...

Page 8: ...es 129 Table 4 42 Load Switches Screen Configuration Values 130 Table 4 43 Analog Inputs Screen Configuration Values 134 Table 4 44 Speed Signal 1 Screen Configuration Values 136 Table 4 45 Contact In...

Page 9: ...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...

Page 10: ...es 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 spec...

Page 11: ...rotection 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 wearin...

Page 12: ...cal 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 mu...

Page 13: ...t and delivery time It uses a built in graphical user interface GUI with multi lingual menu driven screens to instruct site engineers on configuring the control to a specific application The 505HT can...

Page 14: ...ntrol Individual nozzles manual control Small System detection logic Level control pond or Tail Nozzle Sequencing Rotation Speed Load Nozzle Switches Nozzle limit Remote analog setpoints for speed noz...

Page 15: ...ts are dedicated for Run Stop DI 1 Raise Speed load DI 2 Lower Speed Load DI 3 Breaker Closed DI 4 and Emergency Shutdown DI 5 The next 4 channels are configurable as per the list below but for conven...

Page 16: ...osition 4 Nozzle 2 Position 5 Nozzle 3 Position 6 Nozzle 4 Position 7 Nozzle 5 Position 8 Nozzle 6 Position 9 Nozzle Limit 10 Speed Adjustment 11 Pond Tail Level 12 Pond Tail Level Setpoint 13 Speed B...

Page 17: ...can be RS 232 or RS 485 The Ethernet links are TCP on either ENET ports 1 2 3 and 4 The control also communicates Servlink protocol Woodward proprietary via the Ethernet ports Using Woodward s Servli...

Page 18: ...two are controlled solely by the GAP program and relate to the status of the control The IOLOCK and CPU LED s relate to the H W status and are identical to these same indications on the back of the 5...

Page 19: ...side of the display are always in an identical state as the LED s on the back side of the control They are completely controlled by the 505 control hardware and are not controlled by the GAP applicat...

Page 20: ...ut power 18 36 Vdc input isolated HV input power 88 264 Vac 90 150 Vdc isolated Operating range of 30 C to 70 C with display Communications 4 Ethernet 10 100 communication ports isolated 4 CAN communi...

Page 21: ...ears of continuous service for inspection and component upgrades Clock battery The Real Time Clock RTC battery is designed to last approximately 10 years during normal turbine operation When powered t...

Page 22: ...5 Conducted RF Immunity to 10 V rms from 150 kHz to 80 MHz per IEC 61000 4 6 Conducted Low Frequency Injection Immunity at 10 of the nominal supply level from 50 Hz to 12 kHz on Power Inputs per Marin...

Page 23: ...Manual 35116 505HT for Pelton Turbines Woodward 21 Figure 2 2 505D Outline Drawing Released...

Page 24: ...ation to other circuits 3000 Vrms to all other circuits Isolation to EARTH 1500 Vrms to EARTH Input Overvoltage Protection 375 Vdc 25 C Reverse Polarity Protection 375 Vdc Input Undervoltage Shutdown...

Page 25: ...h S1 is reserved for future use and is not active at this time Communications Ethernet There are 4 isolated RJ45 Ethernet Ports 10 100 Mbit sec available to the application software for system use The...

Page 26: ...downloaded from www woodward com software A PC connection must be made to Ethernet 1 ETH1 using a RJ45 Ethernet cable Note AppManager can always be used to discover view the current CPU IP Address Ho...

Page 27: ...otherwise limited to 100 m 125 Kbit 500 m thick cable only otherwise limited to 100 m Network Termination 120 10 is required at each end of the network trunk line The termination resistor is NOT built...

Page 28: ...erent colors lower temperature specs CAN Wiring Shield Terminations Limitations For robust communications performance the CAN cabling needs to minimize the exposed non shielded cable section that occu...

Page 29: ...atches the characteristic impedance of the cable used Cable Note Woodward cable 2008 1512 3 wire is a shielded low capacitance 120 ohm cable that is designed for communications This cable is also used...

Page 30: ...s port is for VxWorks operating system use only and cannot be configured for application software use For debug use a Woodward PN 5417 1344 USB to serial debug cable is required to attach this port to...

Page 31: ...Manual 35116 505HT for Pelton Turbines Woodward 29 Hardware Terminal Blocks Wiring Back cover view with wiring label Figure 2 4 505 Back Cover Label Released...

Page 32: ...Manual 35116 505HT for Pelton Turbines Woodward 30 Terminal Block Connectors Figure 2 5 Terminal Block Connectors Released...

Page 33: ...gurable update rates of 5 ms to 160 ms Table 2 10 Specifications SSI MPU Input Voltage 1 to 35 Vrms MPU Input Frequency 10 Hz to 35 KHz MPU Input Impedance 2000 DC MPU Input Isolation 500 Vrms to EART...

Page 34: ...with short circuit protection Fast AI channel 8 for special control functions Woodward GAP block diagnostics and configuration support GAP configurable update rates of 5 ms to 160 ms GAP configurable...

Page 35: ...Manual 35116 505HT for Pelton Turbines Woodward 33 Figure 2 7 Analog Input Self Powered Block Diagram Figure 2 8 Analog Input Loop Powered Block Diagram Released...

Page 36: ...e rates of 5 ms to 160 ms Table 2 12 Specifications AO Number of Channels 6 each with readback AO Output Range 0 to 24 mA 0 mA during shutdown AO Output Isolation 0 V channel to channel 500 Vrms to EA...

Page 37: ...w 0 24 mA 0 mA during shutdown FS 24 mA ACT Output Range high 0 200 mA 0 mA during shutdown FS 210 mA ACT Output Isolation 0 V channel to channel 500 Vrms to EARTH and all other I O ACT Accuracy 25 C...

Page 38: ...solated power and discrete input group Woodward GAP block diagnostics and configuration support GAP configurable update rates of 5 ms to 160 ms Time stamping capability 1 ms Table 2 14 Specifications...

Page 39: ...cts DC 5 A 5 30 Vdc resistive STD Relay Contacts AC 2 A 115 Vac resistive STD Relay Operate Time 15 ms typical RELAY Coil Readback Coil voltage readback status is available RELAY Coil Rdbk Filter 1 ms...

Page 40: ...the signal common COM1_GND Verify RS 232 network length is within specifications typically 50 feet Verify Signal wires TX RX are not shorted to each other Verify Signal wires TX RX are not shorted to...

Page 41: ...for each AI channel using a simulator source AI Loop power Analog Input wiring checks Verify that external XDCR s are connected to these channels Verify the LPWR voltage level 24 V dc is correct for t...

Page 42: ...is not shorted to PS PS EARTH Verify each TC terminal is not shorted to PS PS EARTH Verify each TC shield wire is not shorted to PS PS Verify no wires are landed accidently on the NC no connect termi...

Page 43: ...ress the generator load This input is mandatory if load droop or baseload mode is desired Speed Bias this analog input comes from a synchronizer load controller If the synchronizer load controller doe...

Page 44: ...ed Unload When the unload contact is closed rising edge triggered it starts to slowly decrease the load reference and either when it reaches a minimum value unload trip level or a certain maximum dela...

Page 45: ...be overridden Front panel ESTOP button will shut down the actuators circuits 1 and 2 so if this is not desired to the control configure analog outputs to this function Some valves should remain with 4...

Page 46: ...s output will pulse to reset optional external equipment Close Deflector Used to send the command to close the deflector during the normal operation The command can be configured as continuous or puls...

Page 47: ...o Load Limit at the Start nozzle Rate It will remain there while the control is synchronizing At some point during this sequence the turbine should reach its rated speed and the Control will start con...

Page 48: ...nce will be reduced to unload trip level When the load is less than the unload trip level a command to open breaker will be issued if used When the breaker opens the turbine will keep running at rated...

Page 49: ...peed not in manual control and the breaker should be opened The test enable switch is hooked up to a configurable timer so that the test is not accidentally left enabled When the overspeed test is ena...

Page 50: ...s open or close the speed set point is temporarily lowered or raised depending on the speed of the nozzles to slightly dampen the controls response When a Synchronizer Load Control unit is used with t...

Page 51: ...ll move the nozzles 20 If the droop is set to 3 the nozzles will move 33 3 for a 1 change in the droop speed set point The speed is always being monitored and reacted to by the control but the control...

Page 52: ...en the generator breaker closes is Baseload After that the baseload reference can be raised or lowered by the Raise and Lower inputs respectively Direct setpoint can also be sent via Modbus or via dis...

Page 53: ...These high and low limits become the limits of the Level set point and they are also used to calculate the Remote Reference for Level Control if used The elevations can be in any unit of measurement...

Page 54: ...l on Level Control Step Test During the initial calibration of the control system the control loops must be calibrated for optimum performance Four step test logic are built into the control to aid in...

Page 55: ...led and the speed is greater than the overspeed limit If the test is forgot enabled it will be disabled automatically after the Time to Disable Test expires When the test is disabled the following thi...

Page 56: ...s constantly moving which reduces stiction or static friction Stiction can cause nozzle hunting if the valve does not respond correctly to the electronic signal Second dither makes a positive lap valv...

Page 57: ...nd is issued A shutdown occurs A Manual Nozzle x Demand is sent via Modbus A Manual Nozzle x Demand is sent via display The turbine speed is greater than 1 Before enabling the Nozzle Auto Test algorit...

Page 58: ...n if Remote mode is enabled a specific Modbus port there are two Ethernet and one serial can have its commands analog and Boolean writes suppressed via configuration of the referred Modbus port Nozzle...

Page 59: ...n called water hammer The deflector can be operated in manual or automatic modes The manual mode can be enabled disabled via discrete input Modbus command or display Every time a shutdown occurs the d...

Page 60: ...s means that the relay energizes as the unit speed is increasing above the set point or decreasing below the set point Each speed switch has a High set point and a Low set point When the speed switch...

Page 61: ...hes or decreasing switches This means that the relay energizes as the unit active power is increasing above the set point or decreasing below the set point Each active power switch has a High set poin...

Page 62: ...vels also determine what parameters the user is authorized to adjust See Table 4 1 Table 4 1 Mode Access by User Level User Level Mode Operation Calibration Configuration Monitor Operator X Service X...

Page 63: ...ion may be monitored only and no changes will be accepted if the turbine is running By pressing the MODE key pressing the soft key for LOGIN and logging in as the Configure user level by entering the...

Page 64: ...t right if needed in the menu A configuration error will cause the control to remain tripped It is possible to exit program mode with such an error but the control will be tripped until the Configurat...

Page 65: ...tor status generator breaker etc Trend To monitors some parameters using custom trend Manual To configure manual control information Baseload To configure baseload control information This button will...

Page 66: ...e all analog inputs Contact Inputs To configure all Contact inputs Analog Outputs To configure all analog outputs Relay Inputs To configure all relay inputs Actuators To configure all actuators Speed...

Page 67: ...ion of the actual load in MW and the status of the generator breaker At the bottom right there are some indications of the actual control mode Depending on what the actual control mode is the third bl...

Page 68: ...igure 4 6 Custom Trend Screen Time Window sec This is the time span of the trend Variable Choose the variable to monitor in the trend There is a list of possible variables Y Max Choose the Maximum Y v...

Page 69: ...stom Trend Settings Screen Manual All Nozzles The purpose of this screen is to configure all parameters related to the manual control mode The screen has command buttons and parameters which are descr...

Page 70: ...nd lower pulse command User Level Service Rate 0 5 0 01 100 0 s Visibility Always Rate that the manual ramp will use to increase or decrease the demand when a pulse command is issued or when the setpo...

Page 71: ...nozzle User Level Operator Disable Command Visibility if specific nozzle is in use This command will disable the manual control mode for this specific nozzle User Level Operator Lower Command Visibil...

Page 72: ...specific nozzle is in use Shows the actual position of the specific nozzle User Level N A Go to Command Visibility Always Command to send the individual manual setpoint to the Go to Value User Level O...

Page 73: ...100 0 100 Visibility Always Maximum demand value to test the nozzle The top of the curve User Level Service Step Value 10 0 100 Visibility Always Step of each increasing or decreasing during the test...

Page 74: ...Manual 35116 505HT for Pelton Turbines Woodward 72 Baseload Screen The purpose of this screen is to configure all parameters related to the baseload control mode Figure 4 11 Baseload Screen Released...

Page 75: ...or greater than the minimum baseload reference User Level Service Unload Level 0 5 0 0 30000 0 MW Visibility Always Enter the unload level this is the value where the control will send the command to...

Page 76: ...Manual 35116 505HT for Pelton Turbines Woodward 74 Baseload Commands Screen The purpose of this screen is to operate the baseload control mode Figure 4 12 Baseload Commands Screen Released...

Page 77: ...Visibility Always Value where the baseload reference goes when a Go to command is issued User Level Operator Enable Remote Baseload Command Visibility Remote baseload in Use This command will enable t...

Page 78: ...nual 35116 505HT for Pelton Turbines Woodward 76 General Configuration 1 9 Screen The purpose of this screen is to configure some general parameters Figure 4 13 General Configuration 1 9 Screen Releas...

Page 79: ...0 0 0 100 0 Visibility Always Speed no Load should be a value a little greater than the necessary opening of the nozzle to run the turbine in the rated speed with no load generator breaker opened User...

Page 80: ...control will wait until it assumes the control of the turbine speed during the startup After this time the auto raise nozzle limit will be enabled if configured User Level Service Auto Raise Nozzle L...

Page 81: ...nual 35116 505HT for Pelton Turbines Woodward 79 General Configuration 3 9 Screen The purpose of this screen is to configure some general parameters Figure 4 15 General Configuration 3 9 Screen Releas...

Page 82: ...r Level Service Low Speed to Stable Speed 98 0 90 0 102 0 Visibility Always Minimum speed used by the control to verify if the speed turbine is stable To consider stable the speed needs to be between...

Page 83: ...nual 35116 505HT for Pelton Turbines Woodward 81 General Configuration 4 9 Screen The purpose of this screen is to configure some general parameters Figure 4 16 General Configuration 4 9 Screen Releas...

Page 84: ...ed control mode will be used CONFIGURATION MODE REQUIRED User Level Configure Speed Bias Type NOT USED Visibility Always Select type of speed bias will be used The options are Not used Analog Input or...

Page 85: ...nual 35116 505HT for Pelton Turbines Woodward 83 General Configuration 5 9 Screen The purpose of this screen is to configure some general parameters Figure 4 17 General Configuration 5 9 Screen Releas...

Page 86: ...Maximum speed reference that the control will accept when in offline control and not in overspeed test CONFIGURATION MODE REQUIRED User Level Configure Maximum Overspeed Test Reference 200 0 75 0 250...

Page 87: ...nual 35116 505HT for Pelton Turbines Woodward 85 General Configuration 6 9 Screen The purpose of this screen is to configure some general parameters Figure 4 18 General Configuration 6 9 Screen Releas...

Page 88: ...0 0 s or MW s Visibility Always Choose the rate to increase and decrease the droop setpoint The engineering unit will be s when in position droop or MW s when in load droop User Level Service Rated Lo...

Page 89: ...nual 35116 505HT for Pelton Turbines Woodward 87 General Configuration 7 9 Screen The purpose of this screen is to configure some general parameters Figure 4 19 General Configuration 7 9 Screen Releas...

Page 90: ...unselected the trip relay output will be deenergized on a 505 trip and will not energize until all trips have cleared and a Reset command is given User Level Service Enable Load rejection TRUE Visibil...

Page 91: ...nual 35116 505HT for Pelton Turbines Woodward 89 General Configuration 8 9 Screen The purpose of this screen is to configure some general parameters Figure 4 20 General Configuration 8 9 Screen Releas...

Page 92: ...evel Service Minimum Load Reference Timeout 10 0 1 0 300 0 s Visibility Always Time the 505 will wait at unload reference to send a command to open the generator breaker during an unload command if en...

Page 93: ...Configuration 9 9 Screen The purpose of this screen is to configure some general parameters The operator can read some operation hours and configure rewrite the actual values in case of a 505 s replac...

Page 94: ...onfiguration 9 9 Screen Command Buttons and Parameters Rewrite Value FALSE Visibility Configuration Mode Write the value in hours that will be written to the non volatile memory when the Rewrite butto...

Page 95: ...ain Input determines the gain of the proportional component of the block s response User Level Service I 0 09 0 001 50 0 Visibility Always The Integral Gain Input determines the gain of the integral c...

Page 96: ...key Step Test to open the step test screen This is a helpful tool in the tuning of the PID Read the Step test Screen explanation below to understand how this screen works Online PID Screen The purpos...

Page 97: ...y Always Set the Feed Forward gain User Level Service Error Gain 1 0 0 5 3 0 Visibility Always Set the Error gain to the PID control User Level Service The operator can navigate between the other PID...

Page 98: ...etermines the gain of the proportional component of the block s response User Level Service I 0 2 0 0 10 0 Visibility Always The Integral Gain Input determines the gain of the integral component of th...

Page 99: ...creen This is a helpful tool in the tuning of the PID Read the Step test Screen explanation below to understand how this screen works Small System Detection PID Screen The purpose of this screen is to...

Page 100: ...y Always Set the Feed Forward gain User Level Service Error Gain 1 0 0 5 3 0 Visibility Always Set the Error gain to the PID control User Level Service The operator can navigate between the other PID...

Page 101: ...p Test Screen Configuration Settings Enable Command Visibility Always Start the step test The demand will increase or decrease depending on the negative step is enabled the amount value for the progra...

Page 102: ...pt too large there might be oscillation between nozzles Therefore this parameter should be kept with its default value as much as possible User Level Service Nozzle x ON 6 1 6 Nozzles Visibility If No...

Page 103: ...0 0 s Visibility If Nozzle x is used Enter the time that the nozzle will spend to go from 0 to 100 This value will be used by 505 to control the rate to the nozzle and it prevents water hammering User...

Page 104: ...le 3 Screen The purpose of this screen is to configure the Nozzles flows This screen has some individual nozzle parameters and it can have different quantity of parameters depending on how many nozzle...

Page 105: ...Enter the nozzle x position necessary to 40 of flow User Level Service Nozzle Position for Flow 50 50 0 0 0 200 0 Visibility If Nozzle x is used Enter the nozzle x position necessary to 50 of flow Use...

Page 106: ...een Rotation 150 0 0 1 600 0 h Visibility Always Time in hours to automatic rotate nozzles if rotate by time is enabled User Level Service Remaining Time Monitor Visibility Always Remaining time in ho...

Page 107: ...Manual 35116 505HT for Pelton Turbines Woodward 105 Deflector Screen The purpose of this screen is to configure the deflector parameters Figure 4 35 Deflector Screen Released...

Page 108: ...en energized during all time If configured to pulse the control will pulse the output to open or close during the pulse time CONFIGURATION MODE REQUIRED User Level Configure Pulse Time 1 5 0 5 10 0 s...

Page 109: ...on Values Enable Commands Visibility Always Enable the deflector manual mode No shutdown is required to enable it User Level Operator Disable Commands Visibility Always Disable the deflector manual mo...

Page 110: ...Manual 35116 505HT for Pelton Turbines Woodward 108 Droop Screen The purpose of this screen is to configure the droop curve Nozzle x Load Figure 4 37 Droop Screen Released...

Page 111: ...of 40 User Level Service Load for Nozzle Demand 50 36 0 100 0 200 0 Visibility Always Enter the load for nozzle demand of 50 User Level Service Load for Nozzle Demand 60 47 0 100 0 200 0 Visibility A...

Page 112: ...Manual 35116 505HT for Pelton Turbines Woodward 110 Droop Commands Screen The purpose of this screen is to send the droop commands Figure 4 38 Droop Commands Screen Released...

Page 113: ...User Level Operator and droop mode enabled Go to Command Visibility Always Command to send the droop setpoint to the Go to Value User Level Operator and droop mode enabled Go to Value 0 0 0 0 100 0 V...

Page 114: ...ed Mode configured to be used Large System Command Visibility Always Send the control to Large System mode User Level Operator and Isolated Mode configured to be used Lower Command Visibility Always T...

Page 115: ...l 35116 505HT for Pelton Turbines Woodward 113 Nozzles Mismatch Screen The purpose of this screen is to configure the nozzles and deflectors mismatch parameters Figure 4 40 Nozzles Mismatch Screen Rel...

Page 116: ...240 0 s Visibility If the specific nozzle is being used Delay time to minor mismatch alarm User Level Service Enable Major Mismatch TRUE Visibility If the specific nozzle is being used Enable the majo...

Page 117: ...Manual 35116 505HT for Pelton Turbines Woodward 115 Level Screen The purpose of this screen is to configure the level control parameters Figure 4 41 Level Screen Released...

Page 118: ...point that the control will use when level control is enabled and the type of transfer is configured to preset level User Level Service Default rate 0 2 0 01 1000 0 ue s Visibility Always Default that...

Page 119: ...evel Operator Lower Command Visibility Always This command will lower the demand to level control when in level control mode User Level Operator and control in Level Control Raise Command Visibility A...

Page 120: ...rol in Level Control Disable Remote Level Command Visibility Remote level in use Disable the remote level control mode User Level Operator and control in Level Control Remote Ref Monitor Visibility Re...

Page 121: ...e User Level Service Lower Command Visibility Always This command will lower the speed setpoint when in overspeed test mode Note The rate of the ramp will be the overspeed rate User Level Service and...

Page 122: ...ically disabled User Level Service Max Speed Reached Monitor Visibility Always Maximum speed reached since the last start or last maximum speed reset User Level Monitor Permissions to Enable Monitor V...

Page 123: ...ction ALARM Visibility Always Choose if the specific remote alarm is an alarm or shutdown CONFIGURATION MODE REQUIRED User Level Configure Delay 0 0 0 0 100 0 s Visibility Always Delay time for the sp...

Page 124: ...baud rate for the serial port the options are 110 300 600 1200 1800 2400 4800 9600 19200 38400 57600 and 115200 User Level Service Data Bits 8 Visibility Always Select the data bits for the serial por...

Page 125: ...Level Service Enable Boolean Write FALSE Visibility Always Enable the Boolean write for the serial port If disable won t be possible to write any Boolean value through this port User Level Service Lin...

Page 126: ...ernet Screen Configuration Values Use Ethernet 1 FALSE Visibility Always Select if the Ethernet specific port communication will be used User Level Service Timeout 10 0 0 5 30 0 s Visibility Always En...

Page 127: ...ect if this shutdown command can be used CONFIGURATION MODE REQUIRED User Level Configure This parameter is common to both serial and Ethernet ports If enabled or disabled on the serial port will disa...

Page 128: ...rk TCP IP address User Level Service ENET 2 SUBNET MASK 255 255 255 0 0 255 Visibility Always Enter the integer corresponding to the network subnet mask User Level Service SET IP2 Command Visibility A...

Page 129: ...4 48 Communications Default Gateway Screen Table 4 39 Communications Default Gateway Screen Configuration Values Default Gateway 10 14 128 1 0 255 Visibility Always Enter the integers corresponding to...

Page 130: ...Level Service High Delay 0 0 0 0 600 0 s Visibility Always Enter the high delay time for the specific speed switch User Level Service Low Value 0 5 0 0 200 0 Visibility Always Enter the low value in f...

Page 131: ...ches or Nozzle Switches when available Nozzle Switch Screen The purpose of this screen is to configure the Nozzle Switches There are four nozzle switches available on the 505 Figure 4 50 Nozzle Switch...

Page 132: ...afe condition since all nozzles position feedback signal fail After this time the switch will go back to its normal state User Level Service The operator can navigate between the switches pressing the...

Page 133: ...ty Always Select if the switch is a decreasing switch User Level Service Decreasing Switch FALSE Visibility Always Select to use fail safe condition User Level Service Fail Safe State OPEN Visibility...

Page 134: ...er some time if configured or can be accessed on the menu Status button In this screen there are two big gauges showing the actual speed and actual load At the top of the screen it is possible to chec...

Page 135: ...it is possible to check if the analog inputs has the signal failed the description tag actual value and the engineering unit of this input see below Figure 4 53 Analog Inputs Summary Screen Click on b...

Page 136: ...Device Tag AI_01 Visibility Always This is a user entered field It allows entry of a short description or tag name for this channel User Level Service Units AI 01 Units Visibility Always This is a use...

Page 137: ...red values at the left top of the screen They are just for monitor purpose they are the speed value for this input in rpm the phase difference for both channels the phase difference output will always...

Page 138: ...of a short description or tag name for this channel User Level Monitor Number of Gear Teeth 60 5 500 teeths Visibility Always Number of gear teeth The number of teeth on the gear the speed sensing de...

Page 139: ...ct Inputs Screen The purpose of this screen is to configure the contact inputs of the control The first screen showed is a summary of the eighth first contact inputs and it is possible to check the st...

Page 140: ...ct inputs The default values showed below are for the contact input 6 All other contact inputs have the same parameters Table 4 45 Contact Inputs Screen Configuration Values Function DEFLECTOR CLOSED...

Page 141: ...alog outputs and it is possible to check is there is a fault in the each channel the description tag actual value and the engineering unit see below Figure 4 60 Analog Outputs Summary Screen Click on...

Page 142: ...its AO 01 Units Visibility Always This is a user entered field It allows entry of a unit label for this channel User Level Service Actuator Type AO 01 Units Visibility If channel is configured to any...

Page 143: ...or User Level Service The operator can navigate between the analog outputs pressing the soft keys with arrows to left or right Relay Outputs Screen The purpose of this screen is to configure the relay...

Page 144: ...ues Description CLOSE DEFLECTOR Visibility Always Choose the function of the specific relay output CONFIGURATION MODE REQUIRED User Level Configure Device tag Relay 01 Visibility Always This is a user...

Page 145: ...puts Screen Configuration Values Actuator range 4 20 mA Visibility Always Choose the range of the actuator output The options are 4 20 or 0 200 mA CONFIGURATION MODE REQUIRED User Level Configure Dith...

Page 146: ...has direct or reverse actuation CONFIGURATION MODE REQUIRED User Level Configure Offline Gain 1 0 0 0 50 0 Visibility If configured to integral Type the offline gain of the actuator User Level Service...

Page 147: ...d Actuator channel 6 In the Actuator channel screen press the Calibration softkey to access the calibration options 7 Verify the green Calmode Enabled LED is ON to confirm that the unit is in Calibrat...

Page 148: ...ly Figure 4 66 Trip Summary Screen On the top of this screen there is an indication of the cause of the last trip occurred This indication will be cleared when a new start command is issued to the con...

Page 149: ...current alarms on the control and the cause of the last trip If an alarm occurs this screen will open automatically if this function is enabled Figure 4 67 Alarm Summary Screen If a remote fault is p...

Page 150: ...Woodward 148 Check Configuration Screen The purpose of this screen is to show the configuration errors on the control Figure 4 68 Check Configuration Screen A list of all possible configuration error...

Page 151: ...uipment system should also be handled through the OEM or Packager Please review your equipment system documentation for details Woodward Business Partner Support Woodward works with and supports a glo...

Page 152: ...air work carries the standard Woodward service warranty Woodward Product and Service Warranty 5 01 1205 on replaced parts and labor Flat Rate Remanufacture Flat Rate Remanufacture is very similar to t...

Page 153: ...ide locations or from one of our Full Service Distributors The field engineers are experienced both on Woodward products as well as on much of the non Woodward equipment with which our products interf...

Page 154: ...f Fuel gas steam etc Power Output Rating Application power generation marine etc Control Governor Information Control Governor 1 Woodward Part Number Rev Letter Control Description or Governor Type Se...

Page 155: ...nd includes no components that require periodic service However to take advantage of related product software and hardware improvements we recommend that your product be sent back to Woodward or to a...

Page 156: ...s above 22mA 8 Analog Input Fault Channel 8 Channel is being used and its current falls below 2mA or goes above 22mA 9 Actuator Fault Channel 1 Channel is being used and hardware senses either a Drive...

Page 157: ...is being used for this function and its current falls below 2mA or goes above 22mA 25 Analog Speed Bias Input Signal Fail A given analog input channel is being used for this function and its current...

Page 158: ...nnel is being used for this function and its current falls below 2mA or goes above 22mA 44 Nozzle 3 Signal Fault A given analog input channel is being used for this function and its current falls belo...

Page 159: ...inor Mismatch Window for more than the Minor Mismatch Delay time 59 Minor Nozzle6 Mismatch Nozzle 6 if used does not match within the Minor Mismatch Window for more than the Minor Mismatch Delay time...

Page 160: ...m not used 91 Spare Alarm not used 92 Spare Alarm not used 93 Spare Alarm not used 94 Spare Alarm not used 95 Spare Alarm not used 96 Spare Alarm not used 97 Spare Alarm not used 98 Spare Alarm not us...

Page 161: ...arm not used 128 Spare Alarm not used 129 Spare Alarm not used 130 Spare Alarm not used 131 Spare Alarm not used 132 Spare Alarm not used 133 Spare Alarm not used 134 Spare Alarm not used 135 Spare Al...

Page 162: ...165 Spare Alarm not used 166 Spare Alarm not used 167 Spare Alarm not used 168 Spare Alarm not used 169 Spare Alarm not used 170 Spare Alarm not used 171 Spare Alarm not used 172 Spare Alarm not used...

Page 163: ...arm not used 190 Spare Alarm not used 191 Spare Alarm not used 192 Spare Alarm not used 193 Spare Alarm not used 194 Spare Alarm not used 195 Spare Alarm not used 196 Spare Alarm not used 197 Spare Al...

Page 164: ...bine does not reach at least Minimum Speed to Incomplete Start within Time to Incomplete Start when a turbine start command is given 9 Modbus Input Shutdown Control received a Modbus Shutdown command...

Page 165: ...set to open but no opened feedback is received within the Deflector Opened Mismatch Delay time 21 I O Lock Control is in Configuration I O Lock Mode 22 Ethernet 1 Link Error Shutdown Ethernet 1 Modbu...

Page 166: ...same function of other DI 7 DI 12 Duplicated Function This discrete input has the same function of other DI 8 DI 13 Duplicated Function This discrete input has the same function of other DI 9 DI 14 D...

Page 167: ...Needed Use Deflector option is not selected but there s a DI configured for Deflector Closed 27 Deflector Opened DI not Needed Use 2 Sensors option is not selected but there s a DI configured for Def...

Page 168: ...for Nozzle 6 Actuator 44 Nozzle 1 Feedback not configured Control is configured for at least 1 nozzle and it s configured for integral control but no Nozzle 1 Position Feedback AI has been configured...

Page 169: ...ed for either Speed Bias Raise or Speed Bias Lower 61 Remote Speed AI Not Configured Use Remote Speed Control is checked but there s no AI configured for Remote Speed Reference 62 Remote Baseload AI N...

Page 170: ...configured for Nozzle 1 Position 79 Nozzle 2 Pos An Out Not Available Control is configured to not use nozzle 2 but there s an AO configured for Nozzle 2 Position 80 Nozzle 3 Pos An Out Not Available...

Page 171: ...ignal Fail 97 Gen Power Dig Out Not Available There s no AI configured for Generator Power but there s a DO configured for Power Transducer Signal Fail 98 At Least one Spd has to be MPU or Prox At lea...

Page 172: ...configured for Manual Nozzle 5 Enable 112 Man Nlz5 Raise DI not Necessary Control is configured to not use nozzle 5 but there s a DI configured for Nozzle 5 Manual Raise 113 Man Nlz5 Lower DI not Nece...

Page 173: ...peed Bias Lower 0 0015 Go to Remote Baseload reference 0 0016 Baseload Enable 0 0017 Baseload Disable 0 0018 Unload Enable 0 0019 Unload Disable 0 0020 Level Control Enable 0 0021 Level Control Disabl...

Page 174: ...e 4 Manual Raise Command 0 0057 Nozzle 4 Manual Lower Command 0 0058 Go to Nozzle 4 Manual Demand 0 0059 Nozzle 5 Manual Raise Command 0 0060 Nozzle 5 Manual Lower Command 0 0061 Go to Nozzle 5 Manual...

Page 175: ...Remote Speed Reference Signal Fail 1 0026 Alm Analog Speed Bias Input Signal Fail 1 0027 Alm Minor Nozzle1 Mismatch 1 0028 Alm Serial Link Error Alarm 1 0029 Alm Governor Shutdown 1 0030 Alm Creep Det...

Page 176: ...m 1 0063 Alm Ethernet 2 Link Error Alarm 1 0064 Alm Spare 1 0065 Alm Spare 1 0066 Alm Spare 1 0067 Alm Spare 1 0068 Alm Spare 1 0069 Alm Spare 1 0070 Alm Spare 1 0071 Alm Spare 1 0072 Alm Spare 1 0073...

Page 177: ...are 1 0113 Alm Spare 1 0114 Alm Spare 1 0115 Alm Spare 1 0116 Alm Spare 1 0117 Alm Spare 1 0118 Alm Spare 1 0119 Alm Spare 1 0120 Alm Spare 1 0121 Alm Spare 1 0122 Alm Spare 1 0123 Alm Spare 1 0124 Al...

Page 178: ...are 1 0158 Alm Spare 1 0159 Alm Spare 1 0160 Alm Spare 1 0161 Alm Spare 1 0162 Alm Spare 1 0163 Alm Spare 1 0164 Alm Spare 1 0165 Alm Spare 1 0166 Alm Spare 1 0167 Alm Spare 1 0168 Alm Spare 1 0169 Al...

Page 179: ...09 Shutdown All Nozzle Position Feedback Fail 1 0210 Shutdown Incomplete Start Timeout 1 0211 Shutdown Modbus Input Shutdown 1 0212 Shutdown Serial Link Error 1 0213 Shutdown External Emergency Input...

Page 180: ...nfigurable 1 0253 DI16 Configurable 1 0254 DI17 Configurable 1 0255 DI18 Configurable 1 0256 DI19 Configurable 1 0257 DI20 Configurable 1 0258 LN1 DI1 Configurable future 1 0259 LN1 DI2 Configurable f...

Page 181: ...ut 15 ON future 1 0297 LN2 Relay Out 16 ON future 1 0298 Governor Run 1 0299 Governor Stop 1 0300 Baseload Mode Enabled 1 0301 Remote Baseload Mode Enabled 1 0302 Unload Mode Enabled 1 0303 Level Mode...

Page 182: ...0349 Spare 1 0350 Spare 1 0351 In Control Nozzle Limit 1 0352 In Control On Line Droop PID 1 0353 In Control Off Line Isoch PID 1 0354 Speed Fault Overspeed Override 1 0355 In Control Analog Nozzle L...

Page 183: ...Level Ref Tracking 1 0387 Level Ref At Rem Spt 1 0388 Level Ref At Lower Lim 1 0389 Level Ref At Upper Lim 1 0390 Level Ref At Modbus 1 0391 Level Ref At QT 1 0392 Full Nozzle Manual Ref Tracking 1 03...

Page 184: ...racking 1 0428 Nozzle 6 Manual Ref At 0 1 0429 Nozzle 6 Manual Ref At 100 1 0430 Nozzle 6 Manual Ref At Modbus 1 0431 Nozzle 6 Manual Ref At QT 1 0432 Nozzle 6 Manual Ref At Auto Test 1 0433 Speed Swi...

Page 185: ...ture EU 1 3 0016 Linknet An Input 8 EU Future EU 1 3 0017 An Input 1 100 3 0018 An Input 2 100 3 0019 An Input 3 100 3 0020 An Input 4 100 3 0021 An Input 5 100 3 0022 An Input 6 100 3 0023 An Input 7...

Page 186: ...Future List 1 3 0061 Linknet An In 5 Function Future List 1 3 0062 Linknet An In 6 Function Future List 1 3 0063 Linknet An In 7 Function Future List 1 3 0064 Linknet An In 8 Function Future List 1 3...

Page 187: ...le 6 Position 100 3 0111 Nozzle 1 Demand 100 3 0112 Nozzle 2 Demand 100 3 0113 Nozzle 3 Demand 100 3 0114 Nozzle 4 Demand 100 3 0115 Nozzle 5 Demand 100 3 0116 Nozzle 6 Demand 100 3 0117 Unit Speed 10...

Page 188: ...100 3 0143 MB Nozzle 3 Man Dmd fdbck 100 3 0144 MB Nozzle 4 Man Dmd fdbck 100 3 0145 MB Nozzle 5 Man Dmd fdbck 100 3 0146 MB Nozzle 6 Man Dmd fdbck 100 3 0147 Spare N A 1 3 0148 Spare N A 1 3 0149 Sp...

Page 189: ...load Setpoint MW MW 0 01 4 0003 Remote Level Setpoint EU EU 0 1 4 0004 Nozzle Average Limit Demand 0 01 4 0005 Manual Nozzle Average Demand 0 01 4 0006 Nozzle 1 Manual Demand 0 01 4 0007 Nozzle 2 Manu...

Page 190: ...Level ERR_EQUAL DEMAND A_NAME Actual Demand GATE_LIMIT GATE_LIMIT A_NAME Nozzle Limit NZ1_FDBCK GATE_POSITION A_NAME Nozzle 1 Position NZ2_FDBCK GATE_POSITION A_NAME Nozzle 2 Position NZ3_FDBCK GATE_P...

Page 191: ...zzle Limit Figure F 2 Level Control NOZZLE LIMIT RAMP 52G BREAKER NOZZLE LIMIT RAISE NOZZLE LIMIT LOWER START STOP ESD RESET SHUTDOWNS ALARMS BREAKAWAY LIMIT SPEED NO LOAD LIMIT MODBUS DEMAND DISPLAY...

Page 192: ...RENCE START STOP 52G BREAKER SPEED RAISE SPEED LOWER SPEED NO LOAD REFERENCE OFFLINE DEMAND PID STEP TEST SPEED SENSOR 1 SPEED SENSOR 2 HSS OVERSPEED TEST LOGIC ENABLE OVERSPEED TEST AVERAGE NOZZLE PO...

Page 193: ...Figure F 5 Droop Feedback Figure F 6 Online Speed Control ENABLE LOAD DROOP DROOP FEEDBACK GENERATOR POWER AI Q Q SET CLR S R BASELOAD ENABLED LEVEL ENABLED SW CTRL NC NO NOZZLE AVERAGE POSITION NOZZ...

Page 194: ...ZZLE LIMITER MANUAL REFERENCE ENABLE MANUAL CONTROL START STOP SPEED RAISE SPEED LOWER MODBUS DEMAND DISPLAY DEMAND STEP TEST AVERAGE NOZZLE POSITION 52G BREAKER SPEED BIAS IN USE NOZZLE AVERAGE DEMAN...

Page 195: ...Manual 35116 505HT for Pelton Turbines Woodward 193 Figure F 8 Nozzle Load Sharing Figure F 9 Nozzle Auto Manual Demand Released...

Page 196: ...Manual 35116 505HT for Pelton Turbines Woodward 194 Figure F 10 Deflector Logic Released...

Page 197: ...Manual 35116 505HT for Pelton Turbines Woodward 195 Revision History New Manual Released...

Page 198: ...Manual 35116 505HT for Pelton Turbines Woodward 196 Declarations Released...

Page 199: ...2 1519 USA 1041 Woodward Way Fort Collins CO 80524 USA Phone 1 970 482 5811 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized distrib...

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