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Manual 35018V1 

505XT Digital Control System for Steam Turbines 

 

 

 

Woodward 

14 

Chapter 1. 

General Information 

 
 

Introduction 

 
This manual describes the Woodward 505XT Digital Governor for all types of steam turbines, including: 

  Single Valve or split-range actuators turbines 

  Controlled Extraction or Admission turbines (2 Control valves) 

  Controlled Extraction and Admission turbines (2 Control valves) 

 
The option charts below shows the part numbers and the differences between the models. Volume 1 of 
this manual describes the control, provides installation instructions, defines hardware specifications, and 
explains the configuration (programming) and operating procedures. Volume 2 includes notes on applying 
the control to specific applications and Service mode information. This manual does not contain 
instructions for the operation of the complete turbine system. For turbine or plant operating instructions, 
contact the plant-equipment manufacturer. 
 

Part Number Options 

 

Part Number  Power 

8200-1310 

LVDC (18–36 Vdc) Standard Compliance 

8200-1311 

AC/DC (88–264 Vac or 90–150 Vdc) Standard Compliance 

8200-1312 

Marine/ATEX Compliance LVDC (18–36 Vdc) 

 

Terminology 

505   

Refers to the overall Woodward Product family / hardware platform 

505XT  Refers specifically to the Control/GUI application software features described in this manual – 
identified on unit p/n label and logo on Home screen 
 

General Installation and Operating Notes and Warnings 

Peripheral equipment must be suitable for the location in which it is used. 
 
For the Marine Type approved version, the field wiring must be installed with an additional shield layer 
which is grounded to the enclosure. The additional shielding is beyond the standard shielding described 
elsewhere in the manual, and it may be made from solid or flexible metal conduit, armored cabling, or a 
cable with an overall shield. 
 

Note: 

For additional installation and operating information, see the Regulatory Compliance section of 

this manual. 

 

Controller Overview 

 

General Description 

 
The 505XT is field programmable which allows a single design to be used in many different control 
applications and reduces both cost and delivery time. It uses a built in graphical user interface (GUI) with 
multi-lingual menu driven screens to instruct site engineers on configuring the control to a specific 
generator or mechanical drive application. The 505XT can be configured to operate as a stand-alone unit 
or in conjunction with a plant’s Distributed Control System. 
 
 

 

Summary of Contents for 505XT

Page 1: ... 2 2017 Original Instructions 505XT Digital Control for Steam Turbines Single valve Extraction and or Admission 8200 1310 8200 1311 8200 1312 Manual 35018 consists of 2 volumes 35018V1 35018V2 Installation and Operation Manual Volume 1 ...

Page 2: ...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 ...

Page 3: ... Communications CAN 34 Communications Service Ports 37 Hardware Terminal Blocks Wiring 38 Terminal Block Connectors 39 Hardware Speed Sensor Inputs 39 Hardware Analog Inputs 4 20 mA 41 Hardware Analog Outputs 4 20 mA 42 Hardware Actuator Outputs 43 Hardware Discrete Inputs 44 Hardware Relay Outputs 45 Troubleshooting Fault Codes 46 Troubleshooting Commissioning checks 46 CHAPTER 3 505XT CONTROL DE...

Page 4: ...161 User Login Levels 162 Navigation 163 Page Organization 163 Overview Screen 165 Speed Control Screen 165 Valve Demand Screen 166 Controllers Screen 167 Cascade Control Screen 167 Auxiliary Control Screen 168 Inlet Control Screen 168 Extraction Admission Control Screen 169 Exhaust Control Screen 170 Steam Map Screen 170 Analog Input Summary Screen 171 Contact Input Summary Screen 172 Analog Outp...

Page 5: ...ibration Wizard for LinkNet Node 1 24 Figure 1 8 LinkNet Node 1 with 4 Vibration Signals 24 Figure 1 9 Vibration Monitoring Page 25 Figure 1 10 505 Keypad and Display 26 Figure 2 1 Functional Block Diagram 505 Control 28 Figure 2 2 505D Outline Drawing 31 Figure 2 3 COM1 Example RS 485 wiring 37 Figure 2 4 505 Back Cover Label 38 Figure 2 5 Terminal Block Connectors 39 Figure 2 6 Speed Sensor Bloc...

Page 6: ...161 Figure 5 5 Mode Screen 162 Figure 5 6 Navigation Cross 163 Figure 5 7 Service Menu showing Speed Control IN Focus 163 Figure 5 8 Configuration Menu Operation Mode View only 164 Figure 5 9 Configuration Menu Configuration Mode Edit 164 Figure 5 10 Overview Screen 165 Figure 5 11 Speed Control Screen 165 Figure 5 12 Valve Demand Screen 166 Figure 5 13 Controllers Screen 167 Figure 5 14 Cascade C...

Page 7: ...or Control Modes 71 Table 3 5 On Line Off Line Dynamics Selection 71 Table 3 6 Speed Control Mode Based on Contacts 76 Table 3 7 Alternate Modes for Ext Adm turbines 102 Table 3 8 Exceptions to Local Mode Contact Input and Modbus Command Disabled 116 Table 4 1 Mode Access by User Level 119 Table 4 2 Configuration Menu Commands 122 Table 4 3 Configuration Error Messages 150 Table 4 4 Actuator Drive...

Page 8: ... 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 thi...

Page 9: ... watchdog failures Power Up and Power Down conditions System reset and hardware software initialization Entering configuration mode NOTE Additional watchdog details and any exceptions to these failure states are specified in the related CPU or I O module section of the manual Emergency Disconnecting Device An emergency switch or circuit breaker shall be included in the building installation that i...

Page 10: ...or 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 remo...

Page 11: ...mospheres Part 0 Equipment General Requirements IEC 60079 11 2011 Explosive Atmospheres Part Part 11 Equipment Protection by Intrinsic Safety i IEC 60079 15 2010 Electrical Apparatus for Explosive Gas Atmospheres Part 15 Construction Test and Marking Type of protection n EAC Customs Union These listings are limited only to those units with labels marking and manuals in Russian language to comply w...

Page 12: ...d in the Rules ref Pt 4 Ch 9 Sec 1 the control and monitoring system in which the above listed hardware is used shall be delivered with a product certificate For each such delivery the certification test is to be performed at the manufacturer of the application system before the system is shipped to the yard The test shall be done according to an approved test program After the certification the c...

Page 13: ...e that provides a minimum IP54 ingress protection for the rear of the control per IEC 60529 The front bezel keypad and display have been tested and are rated IP54 while the rear of the control is rated IP20 due to the ventilation slots required for heat dissipation The installer shall ensure that the maximum surrounding air temperature in the enclosure does not exceed the rated temperature of 70 C...

Page 14: ...osition The installer shall ensure the maximum surrounding air temperature of the control does not exceed 70 C at the final location Explosion Hazard Class I Div 2 Groups A B C D and Zone 2 Group IIC applications require the input voltage to the relay contacts not exceed 32Vac rms or 32Vdc Risque d explosion Ne pas enlever les couvercles ni raccorder débrancher les prises électriques sans vous en ...

Page 15: ...for Steam Turbines Woodward 13 Safety Symbols Direct Current Alternating Current Both Alternating and Direct Current Caution risk of electrical shock Caution refer to accompanying documents Protective conductor terminal Frame or chassis terminal ...

Page 16: ...Vdc Terminology 505 Refers to the overall Woodward Product family hardware platform 505XT Refers specifically to the Control GUI application software features described in this manual identified on unit p n label and logo on Home screen General Installation and Operating Notes and Warnings Peripheral equipment must be suitable for the location in which it is used For the Marine Type approved versi...

Page 17: ...rge pressure or flow unit plant frequency process temperature or any other turbine related process parameter When applied to two valve turbines the 505XT is able to control two turbine parameters at a time Once the turbine is started and running online either as a generator or mechanical drive the control will transition into Ratio Limiter control operation In this mode the control will limit the ...

Page 18: ...rocess and set point values at any time during turbine operation Upon power up from the factory the default HOME screen has a tutorial that will quickly give first time users an overview of navigation and operation Once the unit is configured this tutorial is always available under the Service Menu Additional Features In addition to the control loops mentioned the 505XT also provides the following...

Page 19: ...e the control has been configured the Configuration mode is typically not needed again unless turbine options or operation changes It is available to be viewed at any time A password is required to log into this mode Anytime the control is in IOLOCK all Relays will be de energized and all Analog outputs will be at 0 current Ensure that the devices receiving these commands are fail safe at these st...

Page 20: ...Manual 35018V1 505XT Digital Control System for Steam Turbines Woodward 18 Figure 1 3 Explanation of Symbols Figure 1 4 Single or Split Range Turbine Configurations Valve Demand Overview ...

Page 21: ...nitoring 3 2 Remote Speed Setpoint 27 Start Temperature 1 3 Synchronizing Input 28 Start Temperature 2 4 Sync Load Share 29 Extraction Admission Input 5 Generator Load Input 30 Remote Extr Adm Setpoint 6 Cascade Input 31 Remote Manual Extr Adm P Demand 7 Remote Cascade Setpoint 32 Remote Exhaust Pressure Setpoint 8 Auxiliary Input 33 Remote Inlet Pressure Setpoint 9 Remote Auxiliary Setpoint 34 LP...

Page 22: ...H Actuator 2 Fault 4 Speed Lower Command 54 Speed Forward Enable 5 Generator Breaker 55 Instant Min Gov Load Speed 6 Utility Tie Breaker 56 Select Hot Start 7 Overspeed Test 57 Remote KW Setpoint Enable 8 External Run 58 Clock SYNC Pulse Contact 9 Start Permissive 1 59 Enable Rem SP for Isolated PID 10 Idle Rated Command 60 Isolated Controller Raise 11 Halt Continue Auto Start 61 Isolated Controll...

Page 23: ...ated PID Setpoint 3 Speed Reference Setpoint 28 Remote KW Setpoint 4 Remote Speed Setpoint 29 Exhaust Pressure Input 5 Load Share Input 30 HP Valve Feedback Position 6 Synchronizing Input 31 HP2 Valve Feedback Position 7 Generator Load 32 Signal Monitoring 1 8 Cascade Input Signal 33 Signal Monitoring 2 9 Cascade Setpoint 34 Signal Monitoring 3 10 Remote Cascade Setpoint 35 Start Temperature 1 11 ...

Page 24: ... Input Enabled 59 Remote Inlet Pressure Setpoint Enabled 20 Loadshare Mode Active 60 Remote Inlet Pressure Setpoint Active 21 Cascade Control Enabled 61 Exhaust Pressure Control Enabled 22 Cascade Control Active 62 Exhaust Pressure Control Active 23 Remote Cascade Setpoint Enabled 63 Exhaust Pressure PID In Control 24 Remote Cascade Setpoint Active 64 Remote Exhaust Pressure SP Enabled 25 Auxiliar...

Page 25: ...m Setpoint Optional Distributed I O Additional I O has been pre programmed using Woodward s LinkNet distributed I O nodes These are available via the Configuration Menu under Woodward Links and the user is free to select any or all of the nodes listed below All distributed I O channels have the same menu of functional choices as the lists above for the 505 hardware I O These nodes are Table 1 6 Av...

Page 26: ... be radial or axial user can enter description in TAG field see channel info below Each channel has range fault detection and Alarm and Trip or Second ALM Level Settings There is a setting to Trip if too many Vibration sensors are failed in the screen shot below 4 sensors are brought into the 505 and 2 sensors minimum are required to run turbine There will be a monitor page as shown below availabl...

Page 27: ... available for this communication method 2 Ethernet RJ45 ports and 1 serial port The serial port protocol can be either ASCII or RTU and the communications can be RS 232 or RS 485 The Ethernet links can be configured as TCP or UDP on either ENET ports 1 or 2 Ethernet port 3 is dedicated to use for pre programmed communication links to other Woodward devices found in the Woodward Link section of th...

Page 28: ...igurable or programmable edit field has been selected The bottom row of keys have some special features This is a backspace and delete used when entering text In text mode this functions as a Shift key When making analog adjustments with the ADJUST key pressing this key at the same time as the ADJUST will invoke a Fast rate of adjustment Brightness key hold this down and then use the ADJUST key to...

Page 29: ...m Navigational actions that escort the user through the screen menus BLACK KEYS Are soft key functions that relate to the display indication above them They can be navigational or operational These items do not require Focus they are always available on that particular screen Screen Tutorial The 505 has a detailed Tutorial that is always accessible through the Service Menu It provides On Screen he...

Page 30: ...and Keypad LV input 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 communication ports 1 Mbit isolated RS 232 RS 485 port isolated RS 232 Service port isolated I O circuits GAP configurable update rates of 5 ms to 160 ms 2 Speed Sensor inputs MPU Prox with ...

Page 31: ...5 Control is designed for continuous operation in a typical industrial environment and 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 to a Woodward Authorized Service Facility after every five to ten years of continuous service for inspection and component upgrades Clock bat...

Page 32: ... to 1 0 kV line to earth and 0 5 kV line to line per IEC 61000 4 5 Surge Immunity on AC Power Supply inputs to 2 0 kV line to earth and 1 0 kV line to line per IEC 61000 4 5 Surge Immunity on I O to 1 0 kV line to earth per IEC 61000 4 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...

Page 33: ...Manual 35018V1 505XT Digital Control System for Steam Turbines Woodward 31 Figure 2 2 505D Outline Drawing ...

Page 34: ...tion to EARTH 1500 Vrms to EARTH Input Overvoltage Protection 375 Vdc 25 C Reverse Polarity Protection 375 Vdc Input Undervoltage Shutdown 65 Vdc non latching Note Breaker or power line fusing of 3 5 A min is recommended to protect the power wiring network from possible wiring shorts Power Connector Input Power is provided through a 3 position latching terminal block with removable plug Green conn...

Page 35: ...ports are full duplex with auto crossover detection Features Interface standard IEEE 802 3 Ethernet Port Isolation 1500 Vrms to PS EARTH and all other circuits Control configuration using Woodward AppManager Control monitoring trending and datalog collection Control configuration of Ethernet IP addresses General communications such as Modbus master slave Manage Configuration data and tunables with...

Page 36: ...rolName on the module faceplate and highlight it in AppManager To VIEW the IP address configuration select menu option CONTROL CONTROL INFORMATION Look for the Ethernet adapter addresses under the Footprint Description To CHANGE the IP address configuration select menu option CONTROL CHANGE NETWORK SETTINGS Communications CAN Four 4 Isolated CAN ports are available for general communications as we...

Page 37: ...on PIN Color Description 1 BLACK CAN Signal Ground 2 BLUE CAN Low 3 Shield CAN Shield 30 Meg AC coupled to EARTH 4 WHITE CAN High 5 n a Not used no internal connection Plug Type Side entry 3 5 mm 8 A pluggable with latching screw down Max wire size 1 3 mm 16 AWG for single wires 0 5 mm 20 AWG for two wires CAN Cable Specifications Belden YR58684 Woodward PN 2008 1512 communications CAN cable is ap...

Page 38: ...hes Communications RS 232 RS 485 An isolated configurable RS 232 485 serial port is available for customer use as configured by the GAP software application RS 422 communications is NOT supported Specifications Interface standard RS 232C and RS 485 Isolation 500 Vrms to EARTH and all other I O Baud Rates 19 2K 38 4K 57 6K and 115 2 K Max Distance RS 232 15 m 50 feet max Max Distance RS 485 1220 m ...

Page 39: ...ty 1 stop bit and no flow control This 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 a PC This port is to be used by trained Field Service personnel only Table 2 7 CPU Service Port 3 pin 2 mm Dura Clik connector male Pin 1 RS 232 Transmit Pin 2 RS...

Page 40: ...Manual 35018V1 505XT Digital Control System for Steam Turbines Woodward 38 Hardware Terminal Blocks Wiring Back cover view with wiring label Figure 2 4 505 Back Cover Label ...

Page 41: ...ler includes two 2 Digital Speed Sensor circuits that are capable of interfacing to MPU and Proximity speed probe sensors Each channel is isolated from each other and may be configured for either MPU or PROX sensors A dedicated and isolated PROX power 24 V is provided on each channel for proximity sensor use Note Do not use the Prox Power outputs to power any other type devices ...

Page 42: ... I O 500 Vrms to other MPU and PROX channels Prox Input Voltage 0 32 VDC Prox Input Frequency 0 04 Hz to 35 KHz low limit depends on range Prox Input Impedance 2000 Ω DC Prox Threshold Low is 8 VDC High is 16VDC Prox Input Isolation 500 Vrms to EARTH and all other I O 500 Vrms to other MPU and PROX channels Prox Power1 2 outputs 24 VDC 14 0 200 mA short circuit diode protected Prox Power Isolation...

Page 43: ...ion 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 for Loop power operation Table 2 8 Specifications AI Number of channels 8 AI Input Range 0 to 24 mA AI Input Isolation 0 V channel to channel 500 Vrms to EARTH and all other I O except USB AI Accuracy 25 C 0 024 mA 0 1 of FS 2...

Page 44: ... diagnostics and configuration support GAP configurable update rates of 5 ms to 160 ms Table 2 9 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 EARTH and all other I O AO Accuracy 25 C 0 024 mA 0 1 of FS 24 mA AO Accuracy 40 70 C 0 120 mA 0 5 of FS 24 mA AO Resolution 14 bits of full s...

Page 45: ...nfigurable for 24 mA or 200 mA range ACT Output Range low 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 Low Range 0 024 mA 0 1 High Range 0 21 mA 0 1 ACT Accuracy 40 70 C Low Range 0 120 mA 0 5 High Range 1 00 mA 0 5 ACT Resolution 14 bits of full ...

Page 46: ...r with short circuit and diode protection Isolated 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 11 Specifications DI Number of Channels 20 DI Input Low State 0 to 8 V dc DI Input High State 16 to 32 V dc DI Input Current 5 mA per channel DI Input Impedance 25K approx DI ...

Page 47: ...rminals STD Relay contacts 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 approx at room temp RELAY Output Isolation 500 Vrms minimum to EARTH and all other I O RELAY Contact Isolation 500 Vrms minimum between open contacts RELAY to RELAY Isolation 5...

Page 48: ... 232 wiring uses 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 COM1_GND Verify Signal wires TX RX are not shorted to COM1_SHLD Verify Signal wires TX RX are not connected to PS PS EARTH Verify COM1_GND is not connected to PS PS EARTH Verify the o...

Page 49: ...rify the wiring 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 the XDCR Verify each LPWR terminal is wired to the XDCR POWER Verify each LPWR terminal is not shorted to PS PS EARTH Verify each AI terminal is not shorted to PS PS EARTH Verify each A...

Page 50: ...y each TC terminal 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 terminals Verify each TC shield wire is terminated at the node properly Functionally verify the wiring for each TC channel using a simulator source TC OPENS A TC input will read MAX DegC ...

Page 51: ...limiter control In ratio limiter control both the HP and LP valves are controlled to maintain 2 different parameters selectable by the user Turbine Start Modes The 505XT has three turbine start modes manual semi automatic or automatic from which to choose from One of these start modes must be chosen and programmed to perform a system start up Once a RUN command is issued the speed set point and va...

Page 52: ...inuity of the speed MPU circuits each time it prepares to issue a Ready to Start status message If an open wire is detected it will issue an alarm for this input if all MPU s appear to have open wires a Trip is initiated This open wire test can be done manually any time the turbine is stopped and the speed is zero It is also possible to disable the automatic test at start the Speed Sensor screen T...

Page 53: ...indicate the number of degrees from speed signal 1 to speed signal 2 Both channels must be healthy for the Phase Difference value to be meaningful If probes are setup as the above diagram a reading of approximately 270 degrees indicates that the turbine is spinning clockwise and a reading of 90 degrees indicates it is spinning counter clockwise Figure 3 2 Speed Input Channel Phase Difference There...

Page 54: ...obe also detects zero speed This indication is sent out via Modbus and can also be used to drive a relay output state Figure 3 4 Speed Probe Zero Speed Detect Manual Speed Override If the Override MPU Fault function is assigned to a contact input the loss of speed detection logic is overridden as long as this contact is closed until the maximum time expires Opening the assigned contact input disab...

Page 55: ... significantly reduce speed overshoot to the minimum controllable speed setpoint at turbine start The Acceleration Limiter is disabled after reaching the minimum controllable speed and the 505XT will continue the start sequence via the Speed PID If the Acceleration Limiter is set to be used via the Service menu then it will control speed at the Rate to Min rate RPM s as set in the Turbine Start co...

Page 56: ...ttle valve must be closed before pushing the RUN key in Manual Start mode If a START command is given while the trip and throttle valve is open there exists a possibility of turbine runaway with resultant serious injury or loss of life Figure 3 5 Manual Start Mode Example Semiautomatic Start Mode The following start up procedure is employed when the Semiautomatic start mode is configured 1 Issue a...

Page 57: ...P Limiter behavior is determined by the turbine type a Extraction Only The LP Limiter will ramp to 100 b Admission Only or Extraction Admission The LP Limiter will ramp to 100 The LP valve position will vary to maintain zero admission flow defined by the steam map i For Full Decoupled configurations with any admission control the LP Valve Limiter will remain at the LP Minimum demand 2 Open the Tri...

Page 58: ...a critical band the speed set point will ramp up or down depending on raise or lower command to the extent of the critical range Since the lower speed set point has priority over a raise set point issuing a lower command while increasing through the band will reverse the set point direction and return it to the lower limit of the band If a lower speed set point command is given while in a critical...

Page 59: ...aise or lower speed command or a valid entered speed set point The 505XT will inhibit a ramp to idle speed or ramp to rated speed command if the Generator Breaker is closed Remote Speed Set Point is enabled Cascade PID is in control or the Auxiliary PID is in control as defaulted in the Service Mode Alternatively the 505 s Idle Priority and Use Ramp to Idle Function Service mode settings can be co...

Page 60: ...set at or between the minimum governor and synchronous speed settings All pertinent Idle Rated parameters are available through the Modbus links refer to Chapter 6 for a complete listing Figure 3 8 Idle Rated Start Automatic Start Sequence This function is not the same as the AUTOMATIC START MODE The Automatic Start Sequence can be used with any one of the three start modes The 505 can be configur...

Page 61: ...speed has decreased below the low idle speed setting Figure 3 9 Automatic Start Sequence With this sequence a set of hot start ramp rates and hold times is programmed for use when a START command is given and the turbine has been shut down for less than the programmed HOT START time setting A set of cold start ramp rates and hold times is also programmed for use when a START command is given and t...

Page 62: ...ELAY to fully use the HOT parameter If the unit was tripped for 2 hours or less and restarted the control would use the hot start parameters If the unit was tripped for 22 hours or longer and restarted the control would use the cold start parameters The 505 will automatically set the hours since trip timer to its maximum setting of 200 hours to ensure a cold start is selected after a power up or u...

Page 63: ...e temperature is below both settings then the COLD rates and delays will be used for start sequence configured A second temperature analog input can be used with the Hot Warm Cold feature as well This requires configuring a second analog input as Start Temperature 2 and the Use Temperature Input 2 checkbox should be selected in the Turbine Start configuration menu This will provide a second unique...

Page 64: ... If the contact is open it must be closed and reopened to issue a halt command Alternatively a relay can be programmed to indicate when the Auto Start Sequence is halted An option is available to automatically halt the auto start sequence at the idle set points This feature would result in the unit automatically stopping or halting at the low idle set point and at the high idle set point If the un...

Page 65: ...nue command Idle delay time expired Start Temperature 1 is greater than Temperature 1 Setpoint Start Temperature 2 is greater than Temperature 2 Setpoint Difference between Start Temperature 1 and 2 is less than Max Temperature Difference Speed Control Overview The speed control receives a turbine speed signal from one or two magnetic pickups or proximity probes The MPU Gear Ratio and the Teeth Se...

Page 66: ...r is open the Frequency control mode is selected When both the generator and utility tie breakers are closed a Unit Load control mode is selected Speed Control While in the Speed Control mode the Speed PID will control a turbine at the same speed or frequency regardless of the load it is supplying up to the unit s load capability With this configuration no form of droop or second controlling param...

Page 67: ...be varied with the Speed Set Point Raise Lower commands as desired to allow manual synchronization across a tie breaker to an infinite bus See the Synchronization section in this Chapter For indication purposes a relay can be programmed to energize when the unit is in Frequency control Unit Load Control The 505 s Speed PID can control two independent parameters when the generator breaker is closed...

Page 68: ...oad when another parameter unit load is fed back to a Speed PID s summing junction The Droop term as used throughout this manual refers to a PID s second controlling parameter A second parameter representing unit load is fed back into the 505 s Speed PID to allow it to control two parameters speed when operating in an isolated mode and unit load when paralleled to an infinite bus See Figure 3 9 ...

Page 69: ...Speed Set Point change in rpm Example 5 x 100 x 3600 rpm 180 rpm For this example when paralleled to a utility bus the speed set point can be adjusted from 3600 rpm to 3780 rpm to vary unit load from 0 to 100 Droop feedback allows the Speed PID to control unit load generator power or turbine valve position once it is paralleled with a utility bus or other generating systems which do not have droop...

Page 70: ...s when the generator breaker is closed the considered zero load level will be incorrect when system pressures do reach rated levels If turbine inlet or exhaust pressures are not at rated when the breaker closes it is recommended that the user do the following Use the available tunable in Service mode to correct the valve position at zero load once the system is operating at rated steam pressure To...

Page 71: ...f a valid number was entered the setting will be accepted as the new target setpoint If an invalid number is entered the setting will not be accepted and the 505 s screen will momentarily display a value out of range message This Entered rate is tunable through the Service mode Requirements for valid entries are the following Speed must be below the maximum governor setting Speed must be above the...

Page 72: ...ecause its load will swing vary depending on the load of the plant Caution should be taken with this configuration to not overload or reverse power the Swing Machine This feature when programmed allows an operator to Arm or Disarm a unit s Frequency control mode while it is in operation When Armed a unit will switch to Frequency control if the plant to utility tie breaker opens When Disarmed a uni...

Page 73: ...cted if both breakers are closed see Table 3 2 When not configured for a generator application the 505 uses the programmed Min Governor Speed Set Point setting to determine which set of dynamic values are used by the Speed PID The Speed PID s off line dynamics are selected when turbine speed is below the Min Governor Speed Set Point setting The Speed PID s on line dynamics are selected when turbin...

Page 74: ...oint input directly affects the 505 s speed set point The maximum rate at which the remote input signal can change the speed set point is programmable When the remote set point is enabled the speed set point will move at a much slower rate until the two settings are matched at which time the speed set point will be allowed to move at the maximum rate The Remote Speed Set Point RSS range is determi...

Page 75: ...quency and phase Optionally these products can interface with the unit voltage regulator to match system voltage across a generator breaker When the 505 is configured for a Generator application a special speed set point rate Sync Window Rate is used to increase set point resolution around synchronous speed This allows for tighter set point control to accommodate synchronizing manually or by an au...

Page 76: ...ll units on the same bus When used as a synchronizer and load control these products perform automatic synchronization and control unit load based on an internal base load setting a system average load setting a process loop s control setting or a Master Synchronizer Load Control s MSLC demand setting After synchronization unit load can be controlled by the power management product through the Syn...

Page 77: ...to enable the 505 s Sync Load Share analog input instead of an external contact This discrete enable disable function is ignored after the generator breaker is closed and must be reselected after the generator breaker opens Typically a double pole single throw DPST switch is used on a site s synchronizer control panel to select automatic synchronizing by enabling both the power management product ...

Page 78: ...bited The Sync Load Share Input cannot be enabled the input signal is failed the turbine is shut down a controlled shutdown is being performed or the sync load share feature is not programmed All pertinent synchronizing and load sharing parameters are available through the Modbus links See Chapter 6 for a complete listing of Modbus parameters Manual Demand The manual valve demand feature functions...

Page 79: ... is typically a full load rejection of a unit running in Unit Load Control Droop against a Utility grid and all load of the steam turbine is lost When the Generator Breaker is opened and the speed exceeds more than 1 above rated speed the control will immediately drive the HP valve demand to zero 0 It will hold the valve at zero until the turbine speed decreases back to a level that is with 1 of t...

Page 80: ...oint is lowered by 75 rpm 7 The set point slowly increases back to X rpm taking at least 120 seconds The feed forward loop can be configured for a temporary response as described here or as a direct action continuous deviation based on the incoming signal Emergency Loop In case of a compressor surge event a large speed upset may occur and recovery may be very difficult If this event occurs Emergen...

Page 81: ...sure controller Cascade control is a PID controller that is cascaded with the Speed PID The Cascade PID compares a 4 20 mA process signal with an internal set point to directly position the speed set point thus changing turbine speed or load until the process signal and set point match By Cascading two PIDs in this fashion a bumpless transfer between the two controlling parameters can be performed...

Page 82: ...ct can either be open or closed when a trip condition is cleared If the contact is open it must be closed to enable Cascade control If the contact is closed it must be opened and re closed to enable Cascade control Cascade Control Status Messages Cascade is Disabled Cascade control is not enabled and will have no effect Cascade is Enabled Cascade has been enabled but is not active or in control Pe...

Page 83: ...led to a utility and the Cascade set point when enabled Alternatively a second set of contacts speed raise and lower could be used to independently control the speed and load set points When a raise or lower Cascade Set Point command is issued the set point moves at the programmed Casc Setpt Rate setting If a Cascade raise or lower command is selected for longer than three seconds the Cascade set ...

Page 84: ...signal does not match set point the Cascade control will ramp turbine speed load up or down to match the two signals at a controlled not matched rate defaulted to the Speed Set Point Slow Rate setting and tunable through the Service mode If Cascade is the controlling parameter and one of the permissives is lost or Cascade is disabled the speed set point will remain at its last setting until anothe...

Page 85: ...e is in control of the LSS bus via the Speed PID and the Remote Cascade Set Point is positioning the Cascade set point Inhibited Remote Set Point cannot be enabled input signal is failed Cascade input signal is failed a controlled stop is selected the unit is shut down or the remote cascade control is not programmed When enabled the Remote Cascade set point may not match the Cascade set point In t...

Page 86: ...d Service mode tunables All pertinent Remote Cascade control parameters are available through the Modbus links See Chapter 6 for a complete listing of Modbus parameters Auxiliary Control The Auxiliary PID controller can be used to limit or control generator power plant import export power turbine inlet pressure turbine exhaust pressure pump compressor discharge pressure or any other auxiliary para...

Page 87: ...ammed as unchecked NO the Auxiliary limiter will always stay active If either setting is programmed as checked YES the Auxiliary limiter will be active only when the tie breaker or generator breaker respectively is closed If the unit is not configured for a generator application the utility tie and generator breaker inputs do not affect Auxiliary limiter status and the Limiter will be active at al...

Page 88: ...ured as enable disable controller the Auxiliary control will automatically be disabled upon a shutdown condition Auxiliary control will be disabled and inhibited when the 505 is in frequency control If the Process Variable PV milliamp input signal is out of range below 2 mA or above 22 mA an alarm will occur and Auxiliary control will be inhibited until the input signal is corrected and the alarm ...

Page 89: ...r command is 40 milliseconds 120 milliseconds for a Modbus command A specific set point may also be directly entered from the 505 keypad or through Modbus OPC communications When this is performed the set point will ramp at the Auxiliary Setpoint Rate as defaulted in Service mode To enter a specific set point from the 505 Display use the following steps 1 From the HOME page go to the Auxiliary Con...

Page 90: ...e RAS is enabled The contact can be either open or closed when a trip condition is cleared If the contact is open it must be closed to enable the RAS input If the contact is closed it must be opened and re closed to enable the RAS input When the Auxiliary PID is programmed to function as a limiter the Remote Auxiliary Set Point may be enabled at any time when the 505 is in the RUN mode When the Au...

Page 91: ...and performed after one of the 505XT s three starts have been accomplished and any related extraction permissives have been met All related Extraction enable permissives must be met before the control will allow the Extraction PID to take control of a process The Extraction and or Admission enable permissives are Extr Adm input not failed Turbine speed above programmed permissive speed Gen breaker...

Page 92: ...hen disabling Ext Adm the opposite actions will take place LP Valve Limiter will ramp open from 0 to 100 This will cause the load to increase Speed PID control will decrease demand to compensate for load loss During these operations the LP limiter ramp rate and the speed dynamic settings will have an effect the amount of load change during the transition Slow LP limiter rates and well tuned speed ...

Page 93: ...he LP valve limiter to the LP valve s present position then raise the LP limiter to its maximum open position at the LP valve limiter rate setting At some point depending on system conditions the Extr Adm PID will lose control of its process Manual Enable Disable Enabling is done by the operator manually lowering the LP limiter value from 100 to 0 The LP demand output will follow this value until ...

Page 94: ...r Ratio Limiter or LP demand In Control w Remote Setpoint Ext Adm is enabled and in control and the remote Ext Adm input is controlling the set point Active w Rmt Setpt Ext Adm has been enabled but is not in control of the bus and the remote Ext Adm input is controlling the set point Enabled w Rmt Setpt Ext Adm has been enabled but is not in control of the bus and the remote Ext Adm input is contr...

Page 95: ...amp the LP valve demand to 100 Extraction Admission Control Dynamics The Ext Adm PID control uses a single set of dynamic settings These values are programmable and may be tuned at any time If the unit is expected to run normally in both fully decoupled and coupled modes uncommon it is important to understand that the dynamic settings will be only optimum for one of these conditions In tuning this...

Page 96: ... will move at three times at the fast rate which is three times the Ext Adm set point rate The Ext Adm set point rate fast rate delay and fast rate can all be adjusted in the Service mode The shortest length of time a set point will move for an accepted raise or lower command is 40 milliseconds 120 milliseconds for a Modbus command A specific set point may also be directly entered from the 505 key...

Page 97: ...ntact is closed it must be opened and re closed to enable the remote input There are three different options for enabling Remote Ext Adm Set Point and Ext Adm control as follows Contact input configured for Remote Ext Adm Setpoint Enable From the 505 Display keypad Modbus OPC command When only one Remote Enable command is programmed as a contact input selecting Enable will enable both Ext Adm cont...

Page 98: ...5E it does not matter which units you use as long as you use the same units throughout for power and the same units throughout for HP and extraction admission flow The 505E calculates an extraction and or admission turbine s ratios and limits from the steam map s Max power Max HP Flow point A point B and point C values as shown in the following example figures The points A B and C are entered thro...

Page 99: ...MAX HP FLOW value is the flow where the HP 100 line crosses the HP axis about 108 000 lb h 48 989 kg h Point A is where the P 0 and LP 100 lines intersect MAX POWER MIN EXTRACTION about 15 062 kW HP FLOW MIN EXTRACTION about 36 000 lb h 16 330 kg h Point B is where the LP 0 and P 100 lines intersect MIN POWER MAX EXTRACTION about 3623 kW HP FLOW MAX EXTRACTION about 86 000 lb h 39 010 kg h Point C...

Page 100: ...int C for programming If only point A exists your map will have to be modified to include points B C The LP 0 line will need to be created To create the LP 0 line you must know the minimum required steam flow through the back end of the turbine In our example steam map Figure 4 5 the minimum required flow was 10 000 lb h 4536 kg h 1 Extend the zero admission or induction line p 100 Refer to Figure...

Page 101: ...e s axis about 10 000 kW in our example The MAX HP FLOW value is the flow where the HP 100 line crosses the HP axis about 105 000 lb h 47 628 kg h Point A is where the P 0 and LP 100 lines intersect MAX POWER MAX ADMISSION about 9500 kW HP FLOW MAX ADMISSION about 75 000 lb hr 34 020 kg h The ADMISSION FLOW MAX ADMISSION about 50 000 lb h 22 680 kg h Point B is where the LP 0 and P 100 lines inter...

Page 102: ... and the zero extraction and admission flow line until they cross or intersect this is Point C for programming If point A does not exist the extension of the LP 100 line and the zero extraction and admission flow line until they cross or intersect is Point A for programming If points B C do not exist your map will have to be modified to include points B C The LP 0 line will need to be created To c...

Page 103: ... parallel to the LP 100 line through the mark created in step 4 This will be your LP 0 line or LP valve closed line 6 Mark the intersection of the maximum extraction line and the created LP 0 line This will be Point B for programming Points A B and C are required by the control to calculate the turbine s internal pressure ratios and limits Figure 3 24 Typical Extraction Admission Steam Map The ten...

Page 104: ... can also be achieved if the unit has the process variable and the control mode is configured for use The table below shows the operational modes available in the configuration of the 505XT To use a mode the listed control must be enabled for use as a Controller and the appropriate PV for that loop is healthy Table 3 7 Alternate Modes for Ext Adm turbines MODE Control 1 Control 2 Ratio Limiter Use...

Page 105: ...to any one PID output but a calculation involving two PID outputs HP K1 S K2 P K3 LP K4 S K5 P K6 Transferring Modes The 505XT always controls in Mode 0 Speed and Extraction Admission after Extr Adm is enabled Transfering between modes can be done from the Steam Map page In the Mode popup which is accessed from the soft keys the desired mode can be selected from the drop down list Modes 1 through ...

Page 106: ...D1 0 D2 1 D3 0 D4 K4 K5 K1 K2 D5 K5 K2 D6 K6 K3 K5 K2 The inlet pressure is determined by HP demand only without any effect of LP Pt HP This mode is used when the two controlled parameters during normal operation are turbine speed load and inlet pressure or flow Mode 2 Extraction and Inlet HP D1 St D2 Pt D3 LP D4 St D5 Pt D6 St Q Inlet Pt P Extraction D1 1 D2 0 D3 0 D4 K4 K1 D5 K5 K4 K2 K1 D6 K6 K...

Page 107: ...ed and Exhaust HP D1 St D2 Pt D3 1 LP D4 St D5 Pt D6 2 St S Speed Pt R Exhaust Pressure D1 K1 K2 K4 K5 D2 K2 K5 D3 K3 K2 K6 K5 D4 0 D5 1 D6 0 This mode is used when the two controlled parameters during normal operation are turbine speed load and exhaust pressure or flow Mode 4 Extraction and Exhaust HP D1 St D2 Pt D3 1 LP D4 St D5 Pt D6 2 St R Exhaust Pt P Extraction D1 K1 K4 D2 K2 K1 K5 K4 D3 K3 ...

Page 108: ...guration can select which parameter is maintained For example consider a mechanical drive application turbine running in Mode 0 Speed Extraction If a valve or map limit is reached the control must select Speed Control as priority and sacrifice lose control of Extraction pressure For a generator application turbine running in Mode 0 in Droop against a utility grid the user could choose to maintain ...

Page 109: ...ere is a high probability of the control demands conflicting with each other fighting and one controller tending to slowly oscillate around its desired setpoint hunting Typically the dynamic response of only 1 parameter can be optimized in this mode Under the Extraction Admission Configuration menu there is a selection to Allow the use of Full Decoupled Mode If that box is checked then the screen ...

Page 110: ... compares this input signal with the Inlet Steam Pressure set point to produce a control output In a single valve application this signal is sent to the digital Speed LSS low signal select bus If the application is for an Extraction Admission type turbine then the output is sent directly to the ratio limiter controller This control works exactly the same as the Auxiliary Control Limiter in a singl...

Page 111: ... Process Variable to use for this control is Exhaust Steam Pressure This input is a 4 to 20 mA current signal The PID control amplifier compares this input signal with the Exhaust Steam Pressure set point to produce a control output In a single valve application this signal is sent to the digital Speed LSS low signal select bus If the application is for an Extraction Admission type turbine then th...

Page 112: ...ived the limiter ramps up or down at the VALVE LIMITER RATE The maximum the limiter can increase is 100 The Valve Limiter Rate and Max Valve position settings can be adjusted in the Service mode A specific set point may also be directly entered from the 505 keypad or through Modbus communications When this is performed the set point will ramp at the Valve Limiter Rate as defaulted in Service mode ...

Page 113: ...ve demand feature functions just like the valve limiter except that instead of providing an input to the Low Signal Select to limit how high the valve demand can go it disables all other controllers including speed to ensure that manual demand has full control of the valve demand output The intent of this feature is to aid in the troubleshooting of plant stability or oscillation issues It can be u...

Page 114: ... pressure for normal operation with at least one Point being the rated pressure and a gain of 1 0 Increase the gain Y values for pressures less than rated and decrease the gains for pressures greater than rated This gain factor is applied to the valve demand prior to the valve linearization curve if that option is used Example Curve for a Steam Turbine rated at 500 psi and operating range of 150 p...

Page 115: ...se the cascade process signal program the input to be inverted Emergency Shutdown When an Emergency Shutdown condition occurs the actuator output signal is stepped to zero milliamps the Shutdown relay de energizes and the shutdown cause first shutdown condition sensed is displayed on the 505 s front panel See Chapter 5 for a detailed list of the possible shutdown Trip conditions In addition to the...

Page 116: ...nd Initialize Normal Stop At this point if the OK command is issued the control will perform the controlled shutdown sequence explained above Issuing the Cancel command will cause no change in the 505 s operation and the Normal Stop confirmation pop up box will disappear This verification feature prevents an unwanted shutdown if the STOP key is accidentally pushed A controlled shutdown can be init...

Page 117: ...indicate overspeed status One programmable relay option indicates an Overspeed Trip condition The second relay option provides indication that an Overspeed Test is being performed Reduced Overspeed Test In support of compressor applications where often the drive unit must be uncoupled to perform an actual overspeed test the 505 XT has the ability to perform a Reduced speed overspeed test In Servic...

Page 118: ...mes if programmed External alarm 9 Contact In active at all times if programmed External alarm 10 Contact In active at all times if programmed External alarm 11 Contact In active at all times if programmed External alarm 12 Contact In active at all times if programmed External alarm 13 Contact In active at all times if programmed External alarm 14 Contact In active at all times if programmed Exter...

Page 119: ...elays can be programmed to function as a level switch or mode indication When programmed as a level switch the relay will change state when the selected parameter reaches the programmed level energizes when value is higher the programmed level Relay Functional Clarifications The Shutdown Condition relay may be programmed to indicate a shutdown condition on a remote panel or to a plant DCS The Shut...

Page 120: ...onization function can be used to synchronize across a generator breaker or utility tie breaker When the Sync or Load Share Active function is programmed the assigned relay energizes when a synchronizing or Load Sharing is active When both the generator and utility tie breaker inputs are closed Load Sharing not selected this function becomes disabled and the relay de energizes When the Modbus Comm...

Page 121: ...d and all programmed values monitored This minimizes the possibility of introducing step disturbances into the system To monitor or review the program while in the run mode enter the Configuration menu from the first leftmost soft key on the Home screen Display Modes and User Levels The 505 Display operates in several modes and access user levels each of which has a different purpose The modes are...

Page 122: ...nfiguring the 505XT Before the 505XT can be used to operate any turbine it must be configured with a valid configuration A 505XT Configure Mode Worksheet is provided in Appendix A of this manual This chapter contains additional information related to completing this worksheet and configuring the specific application Recommended completing this worksheet documenting your specific configuration It i...

Page 123: ...figure these values before the unit is put back into service Using Configure Menus Once the Configure Mode has been entered with the password the specific application information must be entered into the 505 To access the configure menu select the Configuration softkey from the HOME screen The navigation arrow keys red navigation cross keypad up down left and right are used for navigation of the C...

Page 124: ...ap configure steam turbine performance map information Isolated Control configure isolated PID control information Communications configure Modbus communication options Analog Inputs configure analog input options Analog Outputs Readouts configure analog readout options Drivers configure driver outputs pressure compensation and if not using driver 2 to use driver 2 for a 4 20 mA readout Contact In...

Page 125: ... 25 Enter the Valve Limiter Rate in percent per second This is the rate at which the HP valve limiter moves when RUN is selected or when the limiter setting is changed through open close commands When using a semiautomatic or automatic start this setting should be very slow typically less than 2 s When using a manual start this setting is less critical and can be left at the default of 5 s Start S...

Page 126: ...cted an additional warm condition is available between cold and hot which means that each ramp rate and idle will allow a warm rate and hold time to be configured If not selected only Hot Cold conditions will be used WARM MINIMUM TEMPERATURE 1 dflt 1200 0 0 0 1 0e 38 Set the minimum temperature for the turbine to be considered WARM based on temperature analog input 1 Above this temperature the tur...

Page 127: ...NUTES dflt 1 0 0 0 500 Enter the hot start hold time at low idle This is the programmable time in minutes seconds that the turbine will wait hold at the low idle speed when a hot start is determined If the turbine has been shutdown for longer than the Hot time but shorter than the Cold time the control will interpolate between the Hot and Cold delays to determine the low idle hold time Use IDLE 2 ...

Page 128: ...urbine will wait hold at the Idle 3 speed when a warm start is determined The warm condition is only available when using temperature analog inputs IDLE 3 DELAY TIME HOT MINUTES dflt 1 0 0 0 500 Enter the hot start hold time desired at Idle 3 This is the programmable time in minutes that the turbine will wait hold at the Idle 3 speed when a hot start is determined If the turbine has been shutdown ...

Page 129: ...s temperature input See the functional description in this manual for other conditions that may be required for the automatic start sequence to continue through Idle 3 TEMPERATURE 2 SETPOINT FOR IDLE 3 dflt 1500 0 0 0 1 0e 38 Set the temperature that must be reached for the automatic start sequence to continue through the Idle 3 speed setpoint based on temperature analog input 2 Above this tempera...

Page 130: ...r control speed This is the normal governor operation lower limit Must be less than the Maximum Governor Speed Setting OFF LINE SLOW RATE rpm s dflt 5 0 0 01 100 Enter the speed set point slow rate in rpm per second This is the rate of speed change for normal operation when turbine is Off line ON LINE SLOW RATE rpm s dflt 5 0 0 01 100 Enter the speed set point slow rate in rpm per second This is t...

Page 131: ...vel in rpm to set the speed probe input failure level If speed drops below this level the control will determine the speed input device is failed and issue an alarm If all speed inputs fail the 505 will issue a trip on loss of speed inputs Must be greater than or equal to 0 0204 x Maximum Speed Level Note The MPU override level is this value 50 RPM When speed increases above this level the speed i...

Page 132: ...acts are closed if the unit is a generator or if the turbine speed is above minimum governor speed if the unit is not a generator or when the Select Dynamics function is used and the contact is closed This value can be changed in the Run Mode while the turbine is operating A recommended starting value is 5 ON LINE INTEGRAL GAIN dflt 0 5 0 01 50 Enter the on line PID integral gain percentage This v...

Page 133: ...gnal if used SECONDARY SYNC LOAD SHARE SIGNAL dflt None Select the backup source for the synchronization load share input signal optional PRIMARY SYNC SIGNAL dflt None Select the source for the synchronization input signal if used If load sharing is used in this application this input will not be used and the sync load share input should be used SECONDARY SYNC SIGNAL dflt None Select the backup so...

Page 134: ... followed by the ENTER This sets the highest level of response for the feed forward loop based on the 4 20 mA signal s rate of decrease SPEED OFFSET AT MIN RATE rpm dflt 100 1000 0 Set the speed offset at the Min Forward Rate s followed by the ENTER This sets the largest negative offset that can be provided by the feed forward loop It is the amount the speed reference will be biased RPM when the A...

Page 135: ...lay output even when a trip condition is still sensed by the 505 typically due to one of the external trip inputs Once reset the unit will be Ready to Start as soon as all external trip inputs are closed When NO the trip relay output will be de energized on a 505 trip and will not energize until all trips have cleared and a Reset command is given TRIP ZERO CURRENT TO ACTUATORS dflt YES Yes No When...

Page 136: ... enabled the Aux PID takes control of the valve and the speed set point tracks the speed load of the unit for bumpless transfer between modes SETPT INITIAL VALUE UNITS dflt 0 0 20000 20000 Set the set point initialization value When not using the Aux Enable function this is the value that the auxiliary set point initializes to upon power up or exiting the Configuration mode Must be less than or eq...

Page 137: ...itializes to upon power up or exiting the program mode Must be less than or equal to the Max Cascade Setpt Setting SPEED SETPOINT LOWER LIMIT rpm dflt 3605 0 0 20000 Set the minimum speed set point that the cascade controller can lower the speed set point to To protect the unit this value should be at or above rated speed if the unit is a generator Must be greater than or equal to the Minimum Gove...

Page 138: ...t be greater than the Min Inlet Setpt Setting SETPOINT RATE UNITS s dflt 5 0 0 01 1000 Set the INLET set point rate This value is the rate in units per second at which INLET set point moves when adjusted USE AS CONTROLLER dflt NO Inlet pressure is only available as a controller on Ext Adm turbines it can be used as a limiter on single valve turbines SETPT INITIAL VALUE UNITS dflt 0 0 20000 20000 S...

Page 139: ...pper limit of EXT ADM set point Must be greater than the Min Ext Adm Setpt Setting SETPOINT RATE UNITS s dflt 5 0 0 01 1000 Set the EXT ADM set point rate This value is the rate in units per second at which EXT ADM set point moves when adjusted USE SETPOINT TRACKING dflt YES Select YES or NO If YES the Ext Adm set point tracks the Ext Adm PV input to provide bumpless transfer to control when it is...

Page 140: ...e valve limiter to step to the valve demand at the time of the failure to ensure that the limiting condition is not exceeded until the operator has time to take action INVERTED dflt NO Yes No Select YES if the exhaust pressure control will be reverse acting If NO then the control will be forward acting Typically this will be set to NO the only time the input would be inverted is if the valve needs...

Page 141: ...Admission For Ext Adm types either a steam turbine performance map or ratio limiter gains must be entered NO MAP AVAILABLE ENTER GAINS ONLY dflt NO Yes No Set to YES if no performance map is available and only the ratio limiter gains K values are to be entered MAXIMUM POWER dflt 100 0 100000 0 100000 0 This is the maximum power limit for the in engineering units corresponds to the S 100 line on th...

Page 142: ...in Ext Adm Pt C dflt 100 0 100000 0 100000 0 This is the min HP valve steam flow at min extraction in engineering units Flow must be less than Pt A MIN LP LIFT dflt 0 0 0 100 Enter the minimum position limit of the LP Valve output SELECT PRIORITIES MODE 0 SPEED EXTRACTION dflt Speed or Extraction All Ext Adm type turbines will initially run in this mode same as Coupled mode in the old 505E The Mod...

Page 143: ... only time the input would be inverted is if the valve needs to open when the input exceeds the set point ALLOW MANUAL CONTROL dflt NO Yes No Set to YES to allow the Isolated PID output to be manipulated by the operator Set to NO to keep this controller in automatic controlled by the PID at all times except in the event of an input failure MAXIMUM SETPOINT dflt 100 0 100000 0 100000 0 This is the ...

Page 144: ...001 USE ETHERNET LINK 3 dflt NO Yes No Select a protocol to use the Modbus Link 3 via Ethernet This will be available on an RJ45 connection to Ethernet Port 2 Selecting UDP will use port 5002 Modbus Link 1 Serial DEVICE ADDRESS dflt 1 1 247 Enter the integer corresponding to the Modbus device number address required ENABLE WRITE COMMANDS dflt NO Yes No Select YES to allow this Modbus link to write...

Page 145: ...fication are described as follows Inlet Steam Pressure This can be configured as the input for a controller to control the inlet steam header pressure or it must be used if the Inlet Pressure Compensation feature is used Exhaust Steam Pressure This can be configured as the input for a controller to control the exhaust steam header pressure 4 mA VALUE UNITS dflt 0 0 1 0e 38 1 0e 38 Set the value in...

Page 146: ...It allows entry of a short description or tag name for this channel UNITS This is a user entered field It allows entry of a unit label for this channel ENABLE READBACK FAULT dflt NO Yes No Select YES to issue an alarm when an actuator fault is detected If YES the 505 will issue an alarm if the analog channel has a fault If NO no fault alarm will be issued A fault will be determined if the current ...

Page 147: ...e ENTER key again to select the option function Press the ESC key to cancel the selection OPTIONS FOR ACTUATOR READOUT See tables in chapter 1 for the list of functional options same as AO options The function that the readout uses must be programmed or an error message will occur For example to use the Cascade Setpoint readout the Use Cascade function must be programmed READOUT 4 mA VALUE UNITS d...

Page 148: ...n DEVICE TAG This is a user entered field It allows entry of a short description or tag name for this channel INVERT LOGIC dflt NO Yes No Select this to invert this contact input Inverting means that a function normally activated when CLOSED or TRUE will not be activated when the contact is OPEN or FALSE Note that this is not required for External Trip inputs because the Normal or Non Inverted fun...

Page 149: ...s able to easily interface with other Woodward product via a variety of digital communications links This section allows the user to quickly configure the control to send and receive data from these devices Most of the default settings shown for these devices below match the described products default settings such as baud rates and subnet masks to allow out of the box compatibility LINKNET I O NO...

Page 150: ...nt eng units dflt 0 0 90000 90000 Enter the alarm level 1 setting in engineering units Invert Action on this alarm dflt NO Yes No Level 2 Setpoint eng units dflt 0 0 90000 90000 Enter the alarm level 2 setting in engineering units Invert Action on this alarm dflt NO Yes No Setpoint hysteresis eng units dflt 0 0 100 100 Enter the hysteresis setting in engineering units for both alarms A negative se...

Page 151: ...Configuration dflt Wye Delta Wye LINK TO LS 5 CAN on Port 3 Use an LS 5 Circuit Breaker Protection dflt NO Yes No Transmit PDO1 dflt 1 1 127 Baud Rate 0 3 dflt 1 0 3 0 100K 1 250K 2 500K 3 1M System A Configuration dflt Wye Delta Wye System A Description dflt Generator System B Configuration dflt Wye Delta Wye System B Description dflt Utility Exiting the Configure Mode Once the programming steps ...

Page 152: ...hard coded as a trip input 3 Contact Input 02 Error The specified contact input was configured for a function that is not configured as used Either the contact input was mis configured or the function required is mis configured For example contact input 1 is programmed for Remote Cascade Set Point Enable but Remote Cascade Set Point was not programmed under the Cascade configure menu 4 Contact Inp...

Page 153: ...ot configured under the Cascade configure menu 32 Relay 02 Error See Relay 01 Error 33 Relay 03 Error See Relay 01 Error 34 Relay 04 Error See Relay 01 Error 35 Relay 05 Error See Relay 01 Error 36 Relay 06 Error See Relay 01 Error 37 Relay 07 Error See Relay 01 Error 38 Relay 08 Error See Relay 01 Error 39 Analog Output 01 Error The specified readout was configured for a function that is not conf...

Page 154: ...gured for as a Single Valve unit but an LP Valve Driver has been configured 54 Auxiliary Configured No AI The Auxiliary control function was configured but no Auxiliary analog input was configured 55 KW AUX Configured AUX AI Configured The Auxiliary control function was configured to use the kW analog input but an Auxiliary analog input was configured also With this configuration only the kW analo...

Page 155: ...igured 72 Sync and Sync Load Share Configured Both the synchronizing analog input and the sync load share or load share analog inputs are configured If the application needs to perform both synchronizing and load sharing with analog signals only the sync load sharing analog input needs to be configured 73 Load Share and Frequency Arm Cnfg Both the frequency arm disarm function and the load share c...

Page 156: ...dance band must be faster than the normal speed set point rate 89 Critical Speeds Enabled No Idle A critical speed avoidance band is configured but neither idle rated nor auto start sequence is configured To use the critical speed avoidance logic one of these functions that uses an idle speed must be programmed 90 Critical Band Below 1st Idle Setpoint A critical speed avoidance band is configured ...

Page 157: ... Start Mode Configured No start mode is selected in the Configure mode One of the three start modes must be selected in the Configure mode under the Start menu 104 Remote KW Setpoint Configured No AI The Remote kW Setpoint is configured as used but no analog input is configured as a Remote kW Setpoint 105 Remote Speed and KW Setpoint Both Remote Speed Setpoint and Remote kW Setpoints are configure...

Page 158: ...N3 network have the same Node ID Node ID s on the same network must be unique 117 Remote KW SP Selected Not Genset The unit is not a generator unit but the Remote kW Setpoint is selected 118 Generator Load Casc Input Not Genset The unit is not a generator unit but the CASC control is trying to use Generator Load 119 Generator Load Aux Input Not Genset The unit is not a generator unit but the AUX c...

Page 159: ...0 6 mA Max Output Current Range 10 200 mA 2 24 mA Max Output Impedance 65 600 Min Stop Adjust Range 10 80 mA 2 20 mA Max Stop Adjust Range 100 200 mA 10 24 mA To ensure proper control to actuator resolution do not calibrate the span of the actuator output to less than a range of 100 mA 20 160 mA output or 12 mA 4 20 mA output If necessary the actuator to valve linkage may need to be adjusted to en...

Page 160: ...oto Demand Force Rate etc 11 Actuator current output at min and max can be adjusted by selecting mA at 0 Demand or mA at 100 Demand Use the up down Adjust arrows or numerical keypad and ENTER key to the change the values 12 Press the Commands softkey to access other commands such as Go to Min Go to Max and GO GO can be used with the Goto Demand value 13 When finished make sure to save the settings...

Page 161: ...nformation that is displayed to the user It links to the GAP via an internal communication link to pass all required interface variables to and from the display Both of these programs are automatically launched at power up The GAP program MUST always be executing to run the turbine However the GUI program may be Stopped using a service tool AppManager and restarted at any time without affecting GA...

Page 162: ... GUI program has not initialized correctly Once the unit has been configured all following power cycles will result in a screen similar to the following dependent on what functionality has been configured The numbers in indicate that there is a quick keypad command to get to that screen For example pressing 2 will jump to the Speed Control screen from that screen if you press 7 it will jump to the...

Page 163: ...uration Mode is used to configure the 505 for the specific application and set all operating parameters see Chapter 4 In this mode the control will issue an IOLOCK LED and the state of all Outputs from the 505 are disabled This means that all Relays are de energized and all Analog Driver outputs are at zero current Initially all 505 s must be placed in this mode to enter a valid configuration of t...

Page 164: ... is running PID dynamics and entering of Calibration Mode Configure passwords are provided in Vol 2 Appendix C Highest user authority can enter any Mode EMERGENCY STOP is always available in all modes and logins as it has direct H W action to open the Actuator circuits To Login 1 Press the LOGIN button 2 Navigate so the Login or Password field is highlighted in focus 3 Press Enter on the Navigatio...

Page 165: ... Navigation Cross 1 Use the Arrow buttons to move the IN Focus highlighter to the desired page 2 Press the Enter button to launch the page selected 3 Press the ESC Escape button to go back 1 page from current page 4 Press the HOME button to return to the main menu Note If in Service or Configure menu a second press of HOME will return to the Operational Home screen Figure 5 7 Service Menu showing ...

Page 166: ...e status in the upper right Figure 5 8 Configuration Menu Operation Mode View only Figure 5 9 Configuration Menu Configuration Mode Edit Refer to chapter 1 for more details about all of the keys below are some general reminders about the keypad functions Green keys initiate operational commands Red keys navigate or enter values via the alpha numeric keys Black keys are software dependent and may d...

Page 167: ...n The Overview screen will adapt to the configuration of the 505XT and show all configured options During normal run operation this screen should provide the user with all of the primary turbine parameter values and operational status The menu bar functions will allow the user to use typical operational commands related to the control loop selected such as directly entering a setpoint or enabling ...

Page 168: ...reen will adapt to the configuration of the 505XT and show all configured options that can affect the final output demand to the HP valve For Ext Adm turbine configurations it will have a navigation button to switch to the LP valve demand During normal run operation this screen provides the user with a clear picture of what control or ramp is controlling the valve demand output The Low Signal Sele...

Page 169: ...ated to the control loop selected such as directly entering a setpoint or enabling or disabling a controller while remaining on the Controllers page Cascade Control Screen Figure 5 14 Cascade Control Screen The Cascade Control screen will adapt to the configuration of the 505XT During normal run operation this screen provides the user with all details that are related to the cascade control loop T...

Page 170: ... protection related to the process variable being used for this function When configured as a controller it will disable the speed PID whenever it is enabled The menu bar functions will allow the user to access a number of other screens that are related to auxiliary control such as directly entering a setpoint access to the valve limiter or adjusting auxiliary control dynamic settings Inlet Contro...

Page 171: ...e user to access a number of other screens that are related to inlet pressure control such as directly entering a setpoint access to the valve limiter or adjusting auxiliary control dynamic settings Extraction Admission Control Screen Figure 5 17 Ext Adm Pressure Control Screen The Extraction Admission Control screen will adapt to the configuration of the 505XT During normal run operation this scr...

Page 172: ...tection related to the process variable being used for this function When configured as a controller it will disable the speed PID whenever it s enabled The exhaust pressure control output goes to the LSS bus and can directly affect the HP valve demand output On an Ext Adm turbine this is always a controller and the output of this PID goes into the Ratio Limiter logic where it can be used in alter...

Page 173: ...lternate Modes of control from the Mode Pop up shown below Figure 5 20 Steam Map Mode Popup Analog Input Summary Screen Figure 5 21 Analog Input Summary Screen The Analog Input Summary screen will display the status of all channels available on the 505 hardware The fault status function device tag engineering value and units are shown for each channel as well as navigation buttons for each channel...

Page 174: ... user to a page showing all parameters available for that input The contact input summary is broken into three pages and the menu bar contains navigation buttons to view all the channels Analog Output Summary Screen Figure 5 23 Analog Output Summary Screen The Analog Output Summary screen will display the status of all channels available on the 505 hardware The fault status function device tag eng...

Page 175: ...as navigation buttons for each channel that take the user to a page showing all parameters available for that output Actuator Driver Summary Screen Figure 5 25 Actuator Driver Summary Screen The Actuator Driver Summary screen will display the status of the 2 channels available on the 505 hardware The fault status function current value in mA engineering value and units are shown for each channel a...

Page 176: ...down If the RESET CLEARS TRIP OUTPUT setting is programmed NO the 505 s shutdown relay will reset or energize upon pressing the Reset key ONLY after all trip conditions are cleared 2 Press the START key and Confirm to initiate the selected start up mode This will function from any screen but it is recommended to be on the Startup Curve page during the turbine startup It will automatically be match...

Page 177: ... 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 Overspeed Test Procedure from the 505 display Be s...

Page 178: ...ode the 505 internal overspeed trip will be changed to be just an alarm and the 505 will allow the speed to continue increasing up to the Overspeed Test Limit rpm If the 505 speed OR the Setpoint reaches the Overspeed Test Limit it will TRIP To perform an External Overspeed Test Press the Enable Ext Test key and the above pop up page will appear An Alarm will be annunciated that indicates Overspee...

Page 179: ...trolled manual turbine shutdown or stop To perform a Manual Shutdown press the STOP key and confirm from the keypad or close the Controlled Shutdown contact input if programmed or select Controlled Shutdown from a Modbus communications link Once initiated the display dialog box will change to give the user the option to abort the Normal stop sequence This dialog box will close after 10 seconds but...

Page 180: ...lt Remote Droop Setting analog input failure detected 22 mA or 2 mA 18 Remote KW Setpoint Failed Remote KW Setpt analog input failure 22 mA or 2 mA 19 Exhaust Press Input Failed Exhaust Pressure analog input failure detected 22 mA or 2 mA 20 Temp for Hot Cold Starts Failed Temp for Hot Cold analog input failure detected 22 mA or 2 mA 21 HP Valve Feedback Failed HP position FDBK analog input failur...

Page 181: ...r it was closed 61 Tie Open No Auxiliary Utility Tie breaker was opened when Auxiliary was active 62 Gen Open No Auxiliary Generator breaker was opened when Auxiliary was active 63 Tie Open No Cascade Utility Tie breaker was opened when Cascade was active 64 Gen Open No Cascade Generator breaker was opened when Cascade was active 65 Tie Open No Remote Util Tie breaker was opened when Remote Spd Se...

Page 182: ...anual P Demand Input Failed Remote Manual P Demand analog input failure detected 22 mA or 2 mA 106 Remote Exhaust SP Input Failed Remote Exhaust Setpoint analog input failure detected 22 mA or 2 mA 107 Remote Inlet Pressure SP Input Failed Remote Inlet Setpoint analog input failure detected 22 mA or 2 mA 108 LP Position Feedback Input Failed LP Valve Position Feedback analog input failure detected...

Page 183: ...date stamp on the Shutdown Summary page The list will always place the first event at the top of the list if more than one trip condition is present they will all be listed with their corresponding time stamp To clear any shutdowns that are no longer present press the RESET key close the Reset contact input or select Reset from either Modbus communications link If the cause of the event has been c...

Page 184: ...ed is detected 25 Actuator Scaling Min Max For Act 1 2 the Min current setting must be Less than Max current setting use Invert option to reverse these 26 Inlet Pressure Input Signal Failed Inlet Pressure Input Signal failure detected 22 mA or 2 mA 27 Ext Adm Pressure Input Signal Failed Ext Adm Pressure Input Signal failure detected 22 mA or 2 mA 28 Exhaust Pressure Input Signal Failed Exhaust Pr...

Page 185: ...ion control loops the OPTI tune feature is available to calculate idea dynamic settings for the overall system Refer to the OPTI Tune section of this manual Dynamic control values are programmed in the configuration mode and adjusted in the RUN Operation or Service mode The Proportional and Integral Gain and the Derivative Ratio dynamic adjustments are available under found under Dynamics pages fo...

Page 186: ...ts in a large speed or load changes high mechanical gain it may not be possible to take the 505 s gains low enough to reach stable operation In those cases the mechanical interface actuator linkage servo valve rack design and or calibration should be reviewed and changed to achieve a gain of one where 0 100 505 output corresponds to 0 100 valve travel Multiple Dynamics for Speed Load Control The S...

Page 187: ...n input or feedback dominant controller is desired A DR setting of 1 to 100 selects feedback dominant mode A DR setting of 01 to 1 selects input dominant mode A DR setting of 01 or 100 selects a PI only controller input and feedback dominant respectively The change from one of these configurations to the other may have no effect during normal operation however it can cause great differences in res...

Page 188: ... the turbine system The optimizer routine remains within user specified process and valve movement limits to ensure that the turbine system remains within acceptable operating limits By running the PID Optimizer the resulting dynamics provide the following benefits 1 Improved system response to events such as load changes and load rejection 2 Tighter control at the setpoint 3 Response behavior whi...

Page 189: ...ar on the bottom of the screen contains buttons which allow the configuration and operation of the Optimizer routine The process of finding optimized system dynamics includes two modes first the analysis mode and then the setpoint step mode The trend below gives an overview of the entire Optimization routine The actuator demand is given in yellow speed setpoint in white and speed in red The left p...

Page 190: ...o Thresholds Calculating Gains Setpoint Step Mode Once new gains have been calculated for P I and D the PID will control at the setpoint using the newly calculated gains The routine then performs setpoint step tests to validate the system response During the Setpoint Step Mode there are 4 setpoint step tests 1 Step the setpoint up or down amount depends on system noise but less than the Process Li...

Page 191: ...up Process Limit dflt 2 0 0 0 10 0 This value limits the process signal movement allowed If movement occurs during automatic tuning that is more than this value the Automated PID Optimizer routine will abort and control at the initial SP This value should be set based on what the system can tolerate If it is too low the automatic tuning process may fault and abort due to normal process changes The...

Page 192: ...ue should be at least 2 times longer than the system slew and settling time During the Setpoint Step Mode this value determines the step times and times between steps A fault and abort will occur if the total PID optimizer time exceeds a value of 40 times the Response Timeout PID Type dflt PID P PI PID This setting determines the mode of the PID controller and allows the automatic tuning of the ap...

Page 193: ...t be acceptable depending on the system Some causes of this alarm could be The valve or turbine response is non linear This could occur due to Poppet valve staging resulting in higher flow with the larger movement of the step and lower flow with the earlier smaller movements The actuator or valve response is slew rate limited If the amount of overshoot were unacceptable some solutions would be Ver...

Page 194: ...ynchronous I O in the sensor control and or driver Asynchronous communications between the sensor and control or control and driver if digital Some solutions for this alarm could be With an oscilloscope datalog or logic analyzer measure the system deadtimes The optimum solution to this problem would be to fix the system and remove the deadtime If that is not possible the control should be de tuned...

Page 195: ... adjusted to allow system to minimize error and or slow hunt if applicable The Process Limit or Droop Limit could be increased if the system allows Check for excessive noise on process or droop signal check shielding and grounding on the applicable sensors and actuator s Fault 3 High response time variation This fault indicates that the response variation exceeded the allowable limit This fault wi...

Page 196: ...is too low this is the most common cause of this fault The Response Timeout is too short for the process input response The system response is restricted by low steam pressure a partially closed trip and throttle valve etc The valve or actuator is against a stop or at the end of its travel not allowing the PID to control the process completely Some solutions for this fault would include The Act Li...

Page 197: ...nding on the applicable sensors and actuator s Faults 8 through 20 Input or System status change occurred during the Automatic Tuning routine Input conditions and System status are monitored while the optimizer is active to detect changes that could invalidate the results of the tuning routine Fault 16 A copy of the S_D_R input is made when the optimizer is started and is used to detect if the S_D...

Page 198: ...and to the 505 s defaulted protocol settings parity stop bits etc this device can be used to monitor all the 505 s controlling parameters modes etc without affecting control Configuration of the protocol is found on the Communications page under both the Configuration and Service menus There are options for the serial settings slave address number and a checkbox to enable write commands from each ...

Page 199: ...us protocol allows one master and up to 247 slaves on a common network Each slave is assigned a fixed unique device address in the range of 1 to 247 With the Modbus protocol only the network master can initiate a transaction A transaction consists of a request from the master to a slave unit and the slave s response The protocol and Modbus device number are set in the Configuration mode and can be...

Page 200: ...XXX When a Modbus message is received it is checked for any errors or invalid data If there is invalid data in the message an error code is sent back to the master and the control issues an alarm message The error codes are defined in the following table The exception error status and respective error codes can be viewed on the Communication pages under the Service Menu If the control has not rece...

Page 201: ...ice are multiplied by a scaling constant before being sent by 505 See Tables 6 8 and 6 9 for defaulted communication constants and ranges The maximum number of discretes and registers that can be transmitted in one packet is dependent on each implementation of Modbus The following table defines these limits Table 6 6 Maximum Modbus Discrete and Analog Values Mode Of Transmission Max Discretes Max ...

Page 202: ... The holding registers available are listed in Table 6 8 The following tables give the address and description of all Boolean and analog reads and writes Table 6 7 Boolean Write Addresses Addr Description Addr Description 0 0001 Emergency Shutdown 0 0056 Spare 0 0002 Emergency Shutdown Acknowledge 0 0057 Enable Extraction Control 0 0003 Controlled Shutdown 0 0058 Disable Extraction Control 0 0004 ...

Page 203: ...e Remote Exhaust Setpoint Control 0 0047 Energize Relay 3 0 0102 Disable Remote Exhaust Setpoint Control 0 0048 De Energize Relay 3 0 0103 Go To Modbus Entered Exhaust Setpt 0 0049 Energize Relay 4 0 0104 Request Alternate Mode Transfer 0 0050 De Energize Relay 4 0 0105 Mode 0 Request 0 0051 Energize Relay 5 0 0106 Enable Manual P Demand 0 0052 De Energize Relay 5 0 0107 Disable Manual P Control 0...

Page 204: ...r 1 0299 Alarm Remote Exhaust SP Input Failed 1 0029 Alarm Gen Breaker Open No Extr 1 0300 Alarm Remote Inlet Pressure SP Input Failed 1 0030 Alarm Extr Input Failed 1 0301 Alarm LP Position Feedback Input Failed 1 0031 Alarm Remote Extr Input Failed 1 0302 Alarm Reverse Rotation Detected 1 0032 Alarm External Alarm 1 1 0303 Alarm LinkNet Summary Alarm 1 0033 Alarm External Alarm 2 1 0304 Spare 1 ...

Page 205: ...o Idle 2 1 0343 Inlet Limiter Configured 1 0073 Auto Seq Setpt at Idle 2 1 0344 Inlet Control Configured 1 0074 Auto Seq Ramp to rated 1 0345 Remote Inlet Configured 1 0075 Auto Seq At Rated 1 0346 Remote KW Setpt Is Enabled 1 0076 Speed PID In Control 1 0347 Remote KW Setpt Is Active 1 0077 Speed Sensor 1 Failed Overide ON 1 0348 Remote KW Setpt Is In Control 1 0078 Speed Sensor 2 Failed Overide ...

Page 206: ... Aux Active Not Limiting 1 0383 Illegal Steam Map 1 0113 Aux Active Not In Control 1 0384 Ratio Limiter Active 1 0114 Auxiliary is Inhibited 1 0385 RTD Units True F False C 1 0115 Remote Aux Is Enabled 1 0386 LinkNet Node 4 BI 01 1 0116 Remote Aux Is Active 1 0387 LinkNet Node 4 BI 02 1 0117 Rmt Aux Is In Control 1 0388 LinkNet Node 4 BI 03 1 0118 Rmt Aux Is Inhibited 1 0389 LinkNet Node 4 BI 04 1...

Page 207: ...Relay 3 Energized 1 0424 LinkNet Node 2 Failed 1 0154 Relay 4 Energized 1 0425 LinkNet Node 3 Failed 1 0155 Relay 5 Energized 1 0426 LinkNet Node 4 Failed 1 0156 Relay 6 Energized 1 0427 LinkNet Node 5 Failed 1 0157 Relay 7 Energized 1 0428 LinkNet Node 1 AI_1 Fault 1 0158 Relay 8 Energized 1 0429 LinkNet Node 1 AI_2 Fault 1 0159 ESD Contact Input Closed 1 0430 LinkNet Node 1 AI_3 Fault 1 0160 Con...

Page 208: ... LinkNet Node 1 AI 5 Alarm Level 2 1 0195 Frequency Control Configured 1 0466 LinkNet Node 1 AI 6 Alarm Level 1 1 0196 MPU 2 Configured 1 0467 LinkNet Node 1 AI 6 Alarm Level 2 1 0197 Local Remote Configured 1 0468 LinkNet Node 1 AI 7 Alarm Level 1 1 0198 Local Trip Enabled 1 0469 LinkNet Node 1 AI 7 Alarm Level 2 1 0199 Casc Tracking Configured 1 0470 LinkNet Node 1 AI 8 Alarm Level 1 1 0200 KW S...

Page 209: ...rogress 1 0504 LinkNet CAN2 Link Error 1 0234 SPARE 1 0505 LinkNet Errors on TX RX msg 1 0235 SPARE 1 0506 LinkNet Errors on RT TX RX msg 1 0236 SPARE 1 0507 SPARE_90 1 0237 SPARE 1 0508 Trip Actuator Scaling Min Max 1 0238 SPARE 1 0509 Trip Inlet Input Signal Failed 1 0239 SPARE 1 0510 Trip Exhaust Input Signal Failed 1 0240 Spare 1 0511 Trip External Trip 11 1 0241 IH B Pressure Input Failed 1 0...

Page 210: ... Control Parameter 1 3 0002 Speed Sensor 1 Input RPM rpm 1 3 0003 Speed Sensor 2 Input RPM rpm 1 3 0004 Actual Turbine Speed RPM rpm 1 3 0005 Actual Speed x 100 100 3 0006 Speed Setpoint x 100 100 3 0007 Speed Setpoint RPM rpm 1 3 0008 Speed Droop Setpoint RPM rpm 1 3 0009 Speed Droop x 100 100 3 0010 Speed PID Output 100 3 0011 Min Governor Speed Setpoint RPM rpm 1 3 0012 Highest Speed reached rp...

Page 211: ...raction Setpoint 100 3 0056 Extraction Scale Factor 1 3 0057 Extraction Input Scaled ext units AI_SCALE 3 0058 Remote Extr Input Scaled ext units AI_SCALE 3 0059 Spare 3 0060 Modbus Entered Speed Setpoint fdbk rpm 1 3 0061 Modbus Entered Cascade Setpoint fdbk Casc units AI_SCALE 3 0062 Modbus Entered Aux Setpoint fdbk Aux units AI_SCALE 3 0063 Modbus Entered Extr Setpoint fdbk Ext AI_SCALE 3 0064 ...

Page 212: ...guration 1 3 0103 Relay 4 Configuration 1 3 0104 Relay 5 Configuration 1 3 0105 Relay 6 Configuration 1 3 0106 Contact 2 Configuration 1 3 0107 Contact 3 Configuration 1 3 0108 Contact 4 Configuration 1 3 0109 Contact 5 Configuration 1 3 0110 Contact 6 Configuration 1 3 0111 Contact 7 Configuration 1 3 0112 Contact 8 Configuration 1 3 0113 Contact 9 Configuration 1 3 0114 Contact 10 Configuration ...

Page 213: ...ct 19 Configuration 1 3 0158 Contact 20 Configuration 1 3 0159 Inlet Setpoint Scaled INL units AI_SCALE 3 0160 Inlet PID Output x 100 100 3 0161 Inlet Input 100 3 0162 Inlet Setpoint 100 3 0163 Inlet Scale Factor 1 3 0164 Inlet Input Scaled INL units AI_SCALE 3 0165 Remote Inlet Input Scaled INL units AI_SCALE 3 0166 Modbus Entered Inlet Setpoint fdbk INL units AI_SCALE 3 0167 SPARE 1 3 0168 SPARE...

Page 214: ...E 3 0211 LinkNet Node 1 AI 08 Value AI_SCALE 3 0212 LinkNet Node 2 AI 01 Value AI_SCALE 3 0213 LinkNet Node 2 AI 02 Value AI_SCALE 3 0214 LinkNet Node 2 AI 03 Value AI_SCALE 3 0215 LinkNet Node 2 AI 04 Value AI_SCALE 3 0216 LinkNet Node 2 AI 05 Value AI_SCALE 3 0217 LinkNet Node 2 AI 06 Value AI_SCALE 3 0218 LinkNet Node 2 AI 07 Value AI_SCALE 3 0219 LinkNet Node 2 AI 08 Value AI_SCALE 3 0220 Link...

Page 215: ... Controlling Parameters The controlling status parameter messages that appear on the display of the 505 are sent over the Modbus links Customers implementing new interfaces or those with the ability to change their operator interface should use the new addresses shown These addresses will have messaging in a straight forward order and will contain the complete list of all messages available Logic ...

Page 216: ...uration Error 18 Start Perm Not Met 19 Ready to Start 20 Manual Start Table 6 13 Analog Read Register 3 0235 Ratio Limiter Control Status Value Description Value Description 1 No Ratio Limiter Control 21 Remote Inlet Remote Exhaust 2 Remote Speed Remote Extraction 22 Inlet Remote Exhaust 3 Remote Speed Extraction 23 Remote Inlet Exhaust 4 Speed Remote Extraction 24 Inlet Exhaust 5 Speed Extraction...

Page 217: ...nalog Read register 3 0001 Control Status Value Description Value Description 23 Shutdown 14 Ready to Start 22 Controlled Shutdown 13 Manual Start 24 Transferring to Ratio Limiter Control 12 Auto Start 25 Transferring to Speed Only Controll 11 Semi Auto Start 26 LP Limiter Ramping 10 Idle Rated Start 20 Max Actuator 9 Auto Start Sequence 27 HP Valve Limiter and LP Valve Limiter 8 Synchronizing 19 ...

Page 218: ... Remote Droop 41 Vibration Signal 1 17 Remote KW Setpoint 42 Vibration Signal 2 18 Exhaust Pressure Input 43 Vibration Signal 3 19 Spare 19 44 Vibration Signal 4 20 HP Valve Feedback Position 45 Vibration Signal 5 21 HP2 Valve Feedback Position 46 Vibration Signal 6 22 Isolated PID PV 47 Vibration Signal 7 23 Remote SP for Isolated PV 48 Vibration Signal 8 24 Signal Monitoring 1 49 Spare_49 25 Sig...

Page 219: ...49 25 Isolated PID PV Input Signal 50 Spare_50 Analog Read addresses 3 0100 0105 give the configuration value of the relays in order The configuration for the relays is defined in the table below Boolean Read addresses 1 0355 0361 specify whether each relay is a level switch Table 6 18 Relay Configuration for Level Switches Value Description Value Description 1 Not Used 19 Customer Defined Monitor...

Page 220: ... Pressure Control Enabled 17 Frequency Control 57 Inlet Pressure Control Active 18 Sync Input Enabled 58 Inlet Pressure PID In Control 19 Sync Loadshare Input Enabled 59 Remote Inlet Pressure Setpoint Enabled 20 Loadshare Mode Active 60 Remote Inlet Pressure Setpoint Active 21 Cascade Control Enabled 61 Exhaust Pressure Control Enabled 22 Cascade Control Active 62 Exhaust Pressure Control Active 2...

Page 221: ...e Dynamics 63 LP Valve Limiter Close 14 Local Remote 64 Extr Adm Setpoint Raise 15 Rmt Spd Setpt Enable 65 Extr Adm Setpoint Lower 16 Sync Enable 66 Extr Adm Control Enable 17 Freq Control Arm Disarm 67 Extr Adm Remote Setpoint Enable 18 Casc Setpt Raise 68 Enable Manual Extr Adm P Demand 19 Casc Setpt Lower 69 Inlet Pressure Setpoint Raise 20 Casc Control Enable 70 Inlet Pressure Setpoint Lower 2...

Page 222: ...used when the set point to be entered is the same as the feedback Modbus Scale Factors Modbus has two limitations only integers can be sent across the value is limited between 32767 and 32767 These limitations can be overcome by scaling the value before it is sent across the Modbus The default scale factor for the analog values is 1 The scale factor can be changed in the service mode between 1 and...

Page 223: ...nadvertent trip the emergency shutdown command from Modbus can be configured to require a two step process before a shutdown command is issued When the shutdown is a two step process Boolean write address 0001 starts the shutdown process An ESD ACKN ENABLE feedback 1 0065 is given and an acknowledgement on address 0002 has to be given within five seconds for the control to issue a shutdown command...

Page 224: ...s Woodward Business Partner Support Woodward works with and supports a global network of independent business partners whose mission is to serve the users of Woodward controls as described here A Full Service Distributor has the primary responsibility for sales service system integration solutions technical desk support and aftermarket marketing of standard Woodward products within a specific geog...

Page 225: ...st will be All repair 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 the Flat Rate Repair option with the exception that the unit will be returned to you in like new condition and carry with it the full standard Woodward product warranty Woodward Produ...

Page 226: ...any of our worldwide 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 interface For information on these services please contact us via telephone email us or use our website www woodward com Contacting Woodward s Support Organization For the name of your near...

Page 227: ...odel Number Type of 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 Serial Number Control Governor 2 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 3 Woodward Part Number Rev Letter Control Descripti...

Page 228: ...Rated Rate rpm s 20 rpm s Use Temp Input for Hot Cold NO YES NO Use Temp Input 2 NO YES NO Hot Min Temp on Temp 1 1400 Temp deg Hot Min Temp on Temp 2 1400 Temp deg Use Warm Condition NO YES NO Warm Min Temp on Temp 1 1200 Temp deg Warm Min Temp on Temp 2 1200 Temp deg Use Temperature Difference 1 2 NO YES NO Hot Temp Diff between 1 2 10 value Warm Temp Diff between 1 2 10 value Use Auto Start Seq...

Page 229: ...Halt at Idle Setpts NO YES NO SPEED SETPOINT VALUES Default Site Value Overspeed Test Lmt rpm 1100 rpm Overspeed Trip rpm 1000 rpm Max Governor Speed rpm 1 rpm Nominal Speed rpm 3600 Min Governor Speed rpm 1 rpm Off line Slow Rate rpm s 5 rpm s On line Slow Rate rpm s 5 rpm s Use Remote Speed Setpt NO YES NO Remote Speed Setpt Max Rate 50 rpm s Use Critical Speeds NO YES NO Critical Speed Rate 50 ...

Page 230: ...um Load 5000 KW MW Primary Gen Load Signal none AI DSLC 2 Secondary Gen Load Signal none AI DSLC 2 Primary Sync LS Signal none AI DSLC 2 Secondary Sync LS Signal none AI DSLC 2 Primary Sync Signal none AI DSLC 2 Secondary Sync Signal none AI DSLC 2 Use Freq Arm Disarm NO YES NO Tie Open activates Load Rejection YES YES NO Controlled Stop Trip NO YES NO Ext Trips in Trip Relay YES YES NO Reset Clea...

Page 231: ...Units Speed Setpoint Lower Limit 0 Rpm Speed Setpoint Upper Limit 0 Rpm Max Speed Setpoint Rate 20 Rpm s Casc Droop 0 Casc PID Prop Gain 1 00 Casc PID Integral Gain 0 300 rps Casc Derivative Ratio 100 Tiebrkr Open Casc Disable NO YES NO Genbrkr Open Casc Disable NO YES NO Use Remote Casc Setpoint NO YES NO Remote Casc Max Rate 5 Units s Casc Units of Measure User text Decimals Displayed 1 value IN...

Page 232: ... Exhaust Setpoint NO YES NO Remote Exhaust Max Rate 5 Units s Exhaust Units of Measure User text Decimals Displayed 1 value EXTR ADM CONTROL Default Site Value Use Extraction Admission Control NO YES NO Lost E A Input Trip NO YES NO Min Extr Adm Setpt Units 0 Units Max Extr Adm Setpt Units 100 Units Setpoint Rate units sec Units 5 Units s Use Setpoint Tracking NO YES NO Setpoint Initial Value Unit...

Page 233: ... Power at Min Extract Adm Pt C 4 Units Min HP Flow at Min Extract Adm Pt C 11 6 Units Min LP Lift 0 Min HP Lift if Adm 0 Mode 0 Speed Extraction Speed Spd Ext Mode 1 Speed Inlet Speed Spd Inlet Mode 2 Extraction Inlet Inlet Inlet Ext Mode 3 Speed Exhaust Speed Spd Exhaust Mode 4 Extraction Exhaust Exhaust Exhaust Ext Mode 5 Inlet Exhaust Inlet Inlet Exhaust Mode 6 Inlet Exhaust Inlet Inlet Exhaust...

Page 234: ... NO Use Ethernet Link 3 NO YES NO Device Address 1 247 1 Enable Write Commands NO YES NO Protocol Ascii Asci rtu Baud Rate 115200 110 115K Bits 8 7 8 Stop Bits 1 1 1 5 2 Parity OFF Off odd even Driver RS 232 232 485 Modbus Ethernet Link 2 Ethernet Protocol Ethernet TCP TCP UDP Device Address 1 247 2 Enable Write Commands NO YES NO Modbus Ethernet Link 3 Ethernet Protocol Ethernet TCP TCP UDP Devic...

Page 235: ...ergency Stop Yes 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Analog Output Channels Ch Function Val 4 Val 20 Ena Rdbk Flt TAG Units 1 2 3 4 5 6 Actuator Output Channels Ch Function Range mA 0 mA 100 Dither Act Flt SD Inv TAG 1 2 Discrete Output Relays Ch Level or State Function Invert Logic Level ON Level OFF TAG 1 2 3 4 5 6 7 8 ...

Page 236: ... 8 channels Analog Input 4 20mA 2 channels Analog Output 4 20mA Ch Function Val 4 Val 20 Units Modbus Mult Dec Disp TAG 1 2 3 4 5 6 7 8 1 2 Node 3 8 channels RTD Input 100 or 200 ohm Function Min Val Max Val Deg F C Mod Mult Dec Disp Crv E A ohm val TAG 1 2 3 4 5 6 7 8 For each of the Analog Input Node channels above events can be configured if desired NODE 1 Events Ch Use Alm1 Use Alm2 Use Trip L...

Page 237: ...vel 1 SP Inv Level 2 SP Inv Setpoint Hysteresis Delay Ena Spd Spd Hys 1 2 3 4 5 6 7 8 NODE 3 Events Ch Use Alm1 Use Alm2 Use Trip Level 1 SP Inv Level 2 SP Inv Setpoint Hysteresis Delay Ena Spd Spd Hys 1 2 3 4 5 6 7 8 Node 4 16 channel Discrete Input 24Vdc Ch Function Invert Logic TAG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ...

Page 238: ...el OFF TAG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 When Actuator Outputs have been In Service Calibrated and Stroked record values here Default 505 Unit 1 Value in 505 Actuator 1 mA at Minimum Position 4 00 Actuator 1 mA at Maximum Position 20 00 Actuator 1 Dither 0 00 Actuator 2 mA at Minimum Position 4 00 Actuator 2 mA at Maximum Position 20 00 Actuator 2 Dither 0 00 ...

Page 239: ...eplaced step 1 in Semiautomatic Start Mode of Turbine Start Mode Procedure Replaced step 1 in Automatic Start Mode of Turbine Start Mode Procedure Removed ADM Admission referenced from Enabling Disabling Extraction Control section Added new paragraph to from Enabling Disabling Extraction Control section Changed Armed to Disarmed in Automatic Speed Override section Removed bottom two rows from Turb...

Page 240: ...Manual 35018V1 505XT Digital Control System for Steam Turbines Woodward 238 Declarations ...

Page 241: ...Manual 35018V1 505XT Digital Control System for Steam Turbines Woodward 239 ...

Page 242: ...lins CO 80522 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 distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website ...

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