505 Digital Control for Steam Turbines

Product Manual 26839V2 (Revision A, 10/2015) Original Instructions 505 Digital Control for Steam Turbines 8200-1300, 8200-1301, 8200-1302 Manual 26839 consists of 2 volumes (26839V1 & 26839V2). Volume 2 Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. General Precautions Failure to follow instructions can cause personal injury and/or property damage. Revisions This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, check manual 26455, Customer Publication Cross Reference and Revision Status & Distribution Restrictions, on the publications page of the Woodward website: www.woodward.com/publications The latest version of most publications is available on the publications page. If your publication is not there, please contact your customer service representative to get the latest copy. Proper Use Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings. If the cover of this publication states "Translation of the Original Instructions" please note: The original source of this publication may have been updated since this Translated translation was made. Be sure to check manual 26455, Customer Publication Publications Cross Reference and Revision Status & Distribution Restrictions, to verify whether this translation is up to date. Out-of-date translations are marked with . Always compare with the original for technical specifications and for proper and safe installation and operation procedures. Revisions—Changes in this publication since the last revision are indicated by a black line alongside the text. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken. Manual 26839V2 Copyright © Woodward Inc. 2015 All Rights Reserved Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Contents WARNINGS AND NOTICES ............................................................................ 5 ELECTROSTATIC DISCHARGE AWARENESS .................................................. 6 INTRODUCTION ............................................................................................ 7 CHAPTER 1. SERVICE TOOLS....................................................................... 7 Overview .................................................................................................................8 Control Assistant (CA) ............................................................................................8 Servlink-to-OPC-Server (SOS) ...............................................................................8 AppManager (AppMan) ..........................................................................................8 CHAPTER 2. PERIPHERAL DEVICES .............................................................. 9 Overview .................................................................................................................9 DSLC-2 (Generator Synchronizer and Load Control) ............................................9 VariStroke II (Electro-Hydraulic Actuator) ............................................................11 MFR300 (Multi-function Relay) .............................................................................13 LS-5 (Protection/Breaker Control Relay) ..............................................................13 Servo Position Controller (SPC) ...........................................................................14 Real Power Sensor...............................................................................................15 Engine Generator Control Package/Load Sharing (EGCP-3 LS).........................16 Applying the 505 with Redundant I/H or I/P Converters.......................................20 CHAPTER 3. APPLICATION NOTES ............................................................. 22 Overview ...............................................................................................................22 Example Applications ...........................................................................................23 CHAPTER 4. OPERATOR INTERFACE .......................................................... 49 Introduction ...........................................................................................................49 Graphical Display and Key Inputs ........................................................................49 Service Panel Modes and User Levels ................................................................50 CHAPTER 5. SERVICE MENU PROCEDURES ................................................ 52 Overview ...............................................................................................................52 Using the Service Menus......................................................................................52 Service Mode Parameters ....................................................................................57 CHAPTER 6. UNDERSTANDING PID SETTINGS ............................................ 80 Overview ...............................................................................................................80 Proportional Response .........................................................................................81 Proportional + Integral (closed loop) ....................................................................83 Derivative Response ............................................................................................84 Proportional + Derivative (closed loop) ................................................................85 Proportional + Integral + Derivative (closed loop) ................................................87 Controller Field Tuning General ...........................................................................88 CHAPTER 7. HARDWARE/OPERATING SYSTEM FAULTS .............................. 91 General .................................................................................................................91 Wiring Problems ...................................................................................................91 Control Adjustments .............................................................................................92 Other Operating Problems....................................................................................92 APPENDIX A. 505 DESIGN SPECIFICATIONS ............................................... 93 Hardware Specifications .......................................................................................93 Software Specifications ........................................................................................93 APPENDIX B. 505 SERVICE MODE WORKSHEET ......................................... 95 APPENDIX C. PASSWORD INFORMATION .................................................. 106 Woodward 1 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 General ...............................................................................................................106 Monitor User Level..............................................................................................106 “Operator” User Level Password ........................................................................106 “Service” User Level Password ..........................................................................106 “Configure” User Level Password.......................................................................106 “ServiceUser” User Level Password...................................................................106 APPENDIX D. SERVLINK-TO OPC SERVER (SOS) TOOL............................107 SOS Communication Link ..................................................................................107 Installing SOS .....................................................................................................107 Connecting a PC/Laptop to the Control ..............................................................108 APPENDIX E. CONTROL ASSISTANT—SOFTWARE INTERFACE TOOL..........110 Features of Control Assistant .............................................................................110 Installing Control Assistant .................................................................................110 Using Control Assistant ......................................................................................112 APPENDIX F. APPMANGER SERVICE TOOL ...............................................118 File Management with App. Manager .................................................................118 Installing App Manager .......................................................................................118 APPENDIX G. CONFIGURING NETWORK TCP/IP ADDRESSES ....................125 APPENDIX H. REMOTEVIEW TOOL ............................................................127 APPENDIX I. USING 505 INTERNAL SIMULATION MODE ..............................138 APPENDIX J. CUSTOM TAG NAME PROCEDURE ........................................140 REQUIRED TOOLS ....................................................................................140 CREATING CUSTOM TAGS ........................................................................140 The following are trademarks of Woodward, Inc.: DSLC easYgen GAP LINKnet MicroNet RTCnet Woodward The following are trademarks of their respective companies: Modbus (Schneider Automation Inc.) VxWorks (Wind River Systems, Inc.) 2 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Illustrations and Tables Figure 2-1. DSLC-2 ................................................................................................9 Figure 2-2. Configuration/Woodward Links/DSLC-2 ............................................10 Figure 2-3. Service Screen - DSLC-2 Power Parameters ....................................10 Figure 2-4. Service Screen - DSLC-2 Status Parameters....................................11 Figure 2-5. VS-II ...................................................................................................11 Figure 2-6. Configuration/Woodward Links/VS-II .................................................12 Figure 2-7. Service/VariStroke II ..........................................................................13 Figure 2-8. Multi-Function Relay ..........................................................................13 Figure 2-9. LS-5 ....................................................................................................13 Figure 2-10. Servo Position Controller .................................................................14 Figure 2-11. Interface to Servo Position Controller ..............................................15 Figure 2-12. Real Power Sensor ..........................................................................15 Figure 2-13. EGCP-3 Control ...............................................................................17 Figure 2-14. EGCP-3 LS Functional Diagram ......................................................18 Figure 2-15. EGCP-3 LS Interface Wiring ............................................................19 Figure 2-16. Typical Redundant I/H System with a Transfer Valve .....................20 Figure 2-17. Typical Redundant I/P System with a Pressure Selecting Relay Valve ................................................................................................21 Figure 3-1. Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting .............................................................................25 Figure 3-2. Inlet Pressure Control with Automatic ................................................28 Synchronizing & Generator Power Limiting..........................................................28 Figure 3-3. Exhaust Pressure Control with Generator Power Limiting and Plant Import/Export Limiting ......................................................................32 Figure 3-4. Plant Import/Export Control with DRFD Servo Interface....................37 Figure 3-5. Inlet Pressure Control with Isochronous Loadsharing Control in Island Mode ................................................................................................41 Figure 3-6. Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode ....................................................................44 Figure 4-1 505 Keypad and Display .....................................................................49 Figure 5-1. User Login for Service .......................................................................52 Figure 5-2. Authorized and Unauthorized Components .......................................53 Figure 5-3 Service Menu (page 1)........................................................................54 Figure 5-4 Service Menu (page 2)........................................................................54 Figure 6-1. Proportional Gain Setting Effects .......................................................81 Figure 6-2. Open Loop Proportional and Integral Response ...............................82 Figure 6-3. Closed Loop Proportional and Integral Response .............................83 Figure 6-4. Integral Gain (Reset) Setting Responses ..........................................84 Figure 6-5. Closed Loop Proportional and Derivative Action ...............................86 Figure 6-6. Derivative Setting Effects ...................................................................86 Figure 6-7. Closed Loop Proportional, Integral and Derivative Action .................87 Figure 6-8. Typical Response to Load Change ....................................................89 Figure D-1. SOS .................................................................................................107 Figure D-2. SOS Install Window .........................................................................108 Figure D-3. SOS Server status dialog box .........................................................108 Figure D-4. SOS – New Session box .................................................................109 Figure D-5. SOS - Enter 505 TCP/IP address....................................................109 Figure D-6. SOS – Active Links dialog box ........................................................109 Figure E-1. Control Assistant License Agreement .............................................110 Figure E-2. Control Assistant Install Window .....................................................111 Figure E-3. Control Assistant Folder Selection ..................................................111 Figure E-4. Control Assistant Install Complete...................................................111 Figure E-5. Install Restart Window .....................................................................112 Figure E-6. Control Assistant Window................................................................112 Figure E-7. Dialog for Servlink OPC connection ................................................113 Figure E-8. WinPanel Session ...........................................................................113 Woodward 3 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure E-9. Control Assistant – Retrieve Tunable Dialog box ............................114 Figure E-10. Control Assistant – Send Tunable Dialog box ...............................115 Figure E-11. Control Assistant – Speed Control Trend Script ............................116 Figure E-12. Control Assistant – Create Trend Script File .................................117 Figure F-1. App Manager Install Window ...........................................................118 Figure F-2. App Manager License Agreement Window .....................................119 Figure F-3. App Manager Installation .................................................................119 Figure F-4. App Manager Install Complete ........................................................120 Figure F-5. AppManager Window.......................................................................120 Figure F-6. Dialog for App Manager Connection................................................121 Figure F-7. App Manager Connected to a Control .............................................121 Figure F-8. AppManager Control Info Window ...................................................122 Figure F-9. AppManager Control (GAP) Application Panel ................................122 Figure F-10. AppManager GUI Application Panel ..............................................123 Figure F-11. Retrieving Files ..............................................................................123 Figure G-1. Configuration/Communications Screen...........................................125 Figure G-2. Ethernet Port Layout (Ports on Side) ..............................................125 Figure H-1. Window Shown when the Time Limit is Exceeded ..........................127 Figure H-2. Installation Welcome Window .........................................................127 Figure H-3. Installation Folder Window ..............................................................128 Figure H-4. Installation License Agreement Window .........................................128 Figure H-5. Installation Start Menu Shortcuts Window.......................................129 Figure H-6. Installation Ready to Install Window................................................129 Figure H-7. Installation Complete Window .........................................................130 Figure H-8. Entering an IP Address to be Added to the Control List..................131 Figure H-9. Control Selected in the Control List .................................................131 Figure H-10. Login Window with Fields for User Name and Password .............132 Figure H-11. An Application Selected in the Application List .............................133 Figure H-12. Default View of the Tool ................................................................134 Figure H-13. Simple View of the Tool .................................................................134 Figure H-14. Full View of the Tool ......................................................................135 Figure H-15. Entering a Name for the Current Settings .....................................135 Figure H-16. A New Settings File Entered in the Predefined Settings List ........136 Figure H-17. Remote View Tool (Default Setting) after Opening from the Configuration Window....................................................................137 Figure I-1. HW Simulation Mode Access ............................................................138 Table 2-1. CAN Wiring from 505 to VS-II .............................................................12 Table 3-1. Example Application Summary ...........................................................24 Table 4-1 Mode Access by User Level .................................................................50 4 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Warnings and Notices Important Definitions      This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER—Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING—Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION—Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE—Indicates a hazard that could result in property damage only (including damage to the control). IMPORTANT—Designates an operating tip or maintenance suggestion. Overspeed / Overtemperature / Overpressure Personal Protective Equipment The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate. The products described in this publication may present risks that could lead to personal injury, loss of life, or property damage. Always wear the appropriate personal protective equipment (PPE) for the job at hand. Equipment that should be considered includes but is not limited to:  Eye Protection  Hearing Protection  Hard Hat  Gloves  Safety Boots  Respirator Always read the proper Material Safety Data Sheet (MSDS) for any working fluid(s) and comply with recommended safety equipment. Start-up Be prepared to make an emergency shutdown when starting the engine, turbine, or other type of prime mover, to protect against runaway or overspeed with possible personal injury, loss of life, or property damage. To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system. Battery Charging Device Woodward 5 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Electrostatic Discharge Awareness Electrostatic Precautions Electronic controls contain static-sensitive parts. Observe the following precautions to prevent damage to these parts:  Discharge body static before handling the control (with power to the control turned off, contact a grounded surface and maintain contact while handling the control).  Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards.  Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. Follow these precautions when working with or near the control. 1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials. Wear cotton or cotton-blend materials as much as possible because these do not store static electric charges as much as synthetics. 2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary. If you must remove the PCB from the control cabinet, follow these precautions:  Do not touch any part of the PCB except the edges.  Do not touch the electrical conductors, the connectors, or the components with conductive devices or with your hands.  When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in until you are ready to install it. Immediately after removing the old PCB from the control cabinet, place it in the antistatic protective bag. 6 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Introduction This volume of the manual contains application-specific notes, details on interfaces to other Woodward products and example configurations of typical steam turbine applications. This volume gives users an idea of the 505 Control’s capabilities, and how to apply them to a system. Typical applications are schematically shown and their functionality explained. Programming and Start/Run mode notes are given for each application to assist application programmers in configuring the 505 for their application. Refer to Manual 26839, Volume 1 for Required Safety Instructions, Special Conditions for Safe Use and Hazardous Location Requirements to insure the control is used in a safe manner in Ordinary, Marine, Hazardous, ATEX and IECEx locations. Volume 1 must be fully understood and complied with for all applications. Woodward 7 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Chapter 1. Service Tools Overview This chapter provides an overview of the service tool interfaces to the 505. Instructions for installing and using these tools are found in the Appendices of this volume of the manual. All service tool interfaces to the 505 are Ethernet connections and can be used on any of the 4 Ethernet ports. The only requirement is that the PC connecting to the control has an IP address on the same domain (as with any typical network). Default settings for the Ethernet TCP/IP addresses can be found in Volume 1 Chapter 2. Control Assistant (CA) This tool is the primary service tool that will provide the following features:     Uploading and Downloading Tunables (your complete configuration settings) Live trending of any I/O signal or control parameter Troubleshooting any system problem by viewing software variables in the system Analyzing any Datalog files that are collected from the control Refer to the Appendices of this volume for instruction on using Woodward’s Control Assistant Software Service Tool (Version 4.7 or newer). Servlink-to-OPC-Server (SOS) Integrated with control assistant is the Woodward Servlink-to-OPC-Server (SOS) program that provides the communication data link between the 505 and a user PC or system HMI. The SOS program will run on the PC as a service and convert the 505 Woodward proprietary Servlink data to OPC data. The Control Assistant tool will connect as a client to the SOS server. Customers desiring to link to OPC data from the 505 will need to also connect to SOS. AppManager (AppMan) This program is the primary tool for transferring files to and from the control. It will provide the user with the following services:     8 Transferring files to and from the control (executable control software, GUI software, datalog files, system log files, control backup information) Setting the control Ethernet port IP addresses and the SNTP time synchronization IP address for network time protocol synchronizing Installing a software service pack program Starting / Stopping the control program or GUI program Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Chapter 2. Peripheral Devices Overview This chapter provides a brief explanation of other Woodward devices that can be easily integrated with the 505. By understanding the functionality of a peripheral device, a better understanding of the overall control configuration can be achieved. Some of these devices are able to be connected to the 505 by a digital communication link (either Ethernet or CAN depending on the product). Through this link the 505 display will allow the user to monitor many signals and status LED’s from this external device. In many cases, these connections allow the 505 to receive required input signals, such as KW Load or a Synchronization or Load Sharing Bias signal. This eliminates the need for wiring these signals to typical I/O channels, or the digital signal can be used as a redundant/backup signal to a hard-wired signal. Devices supported in the 505 control application will be identified with a “Woodward Link” identifier All the devices covered in this section are manufactured or supported by Woodward. Peripheral devices manufactured by other companies can be used with the 505 to perform the functions detailed bellow, however, the compatibility of them to the 505 and the application should be verified before system operation. DSLC-2 (Generator Synchronizer and Load Control) Figure 2-1. DSLC-2 The DSLC-2 when connected to the 505 controller, can be used with generators to accurately sense 3 phase RMS generator output power and perform generator breaker synchronization. Other configurable DSLC-2 functions include generator load-sharing, VAR or Power Factor control, process control, and base load control. Woodward 9 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure 2-2. Configuration/Woodward Links/DSLC-2 This is a “Woodward Link” device. To enable the Woodward Link feature select the check box on the screen above and enter the slave address and the IP address of the DSLC-2 device. The figure above shows the factory default IP addresses of the DSLC-2 and Ethernet port 3 of the 505. These settings will allow these 2 products to communicate automatically once an RJ45 Ethernet cable is connected between Ethernet Port 3 of the 505 and Network B port on the DSLC-2. Once this configuration is complete, the DSLC-2 can provide the Synchronization speed bias signal, the Sync/load sharing bias signal, and the KW output of the generator. The radio buttons on the screen allow the user to select the functions desired. The KW valued thru this link can be used as a secondary KW input signal, is an analog input channel is already configured for a KW input. The screens below show the available service screens that will now be accessible to monitor the DSLC-2. Figure 2-3. Service Screen - DSLC-2 Power Parameters 10 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 2-4. Service Screen - DSLC-2 Status Parameters VariStroke II (Electro-Hydraulic Actuator) Figure 2-5. VS-II This is a “Woodward Link” device. The VariStroke-II is a linear electro-hydraulic actuator that is designed to provide the linear actuation force to operate steam turbine control valves or valve racks. This actuator can be directly networked with the 505 controller to reduce system complexity and wiring requirements. Woodward 11 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure 2-6. Configuration/Woodward Links/VS-II To enable the Woodward Link feature select the check boxes on the screen above to enable the CAN1 Link and confirm usage of the VariStroke II actuator, then enter the Device ID. If an analog (4-20 mA) demand signal is going to be connected to the VariStroke in addition to the CAN link, then select the desired function for this signal (AI Backup is recommended). Finally select the inlet steam valve that is being controlled (for most applications it is HP Demand). Table 2-1. CAN Wiring from 505 to VS-II 505 CAN 1 – terminal 1 CAN 1 – terminal 2 CAN 1 – terminal 4 Connect a termination resistor across CAN 1 – terminals 2 & 4 Function COM CAN LO CAN HI VariStroke II TB6-A (Top) – terminal 35 TB6-A (Top) – terminal 32 TB6-A (Top) – terminal 31 Once this configuration is complete, the VariStroke-II digital communication link will provide the actuator demand signal to the steam valve and the screen below will now be available under the Service menu to monitor driver information. 12 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 2-7. Service/VariStroke II MFR300 (Multi-function Relay) Figure 2-8. Multi-Function Relay This is a “Woodward Link” device. The MFR 300 is a multi-function generator protection relay used to sense and protect small generators. This multi-function protection relay integrates all generator protection functions into one common device reducing overall system installation complexity and cost. LS-5 (Protection/Breaker Control Relay) Figure 2-9. LS-5 Woodward 13 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 This is a “Woodward Link” device. The LS-5 series protection relays integrate generator breaker synchronization, power sense and protection functions all into one package. This device is designed to function in combination with a prime mover controller like the 505 to allow accurate generator control as well as provide required generator protection. Servo Position Controller (SPC) A Servo Position Controller (SPC) can be used to interface the 505 digital controls to existing valve operators or Woodward actuators that are integrating in action or are not compatible with the 505 directly. The 505’s actuator outputs have the capability of driving a 4–20 mA or 20–160 mA (200 mA max) proportional signal into an actuator coil. These actuator output signals represent a demand signal equal to desired valve position (proportional). If the turbine’s actuator or servo assembly requires a different drive signal, or control action (integrating with a null setting), an SPC or equivalent device must be used. Woodward Servo Position Controller (SPC) accept a 4–20 mA actuator-drive signal proportional to desired valve position, and positions a servo assembly accordingly. Woodward SPCs have the capability of driving unipolar or bipolar actuator demand signals, up to 0–400 mA or +400 mA respectively, on proportional or integrating servo assembles. Figure 2-10. Servo Position Controller The SPC comes with a user-friendly software interface program that allows the user to configure the unit to the desired settings. Consult the SPC manual for complete details on the types of actuators to which the SPC can interface. Below is one example of how the 505 and SPC can be used on Integrating Servo Valves. The SPC can also handle many variations of feedback devices. 14 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 2-11. Interface to Servo Position Controller (Example of Integrating Actuator with a 4-wire Feedback device) Real Power Sensor A Real Power Sensor is used to sense the real power being produced by a generator, or flowing through a tie line. Woodward Real Power Sensors sense three phase volts, three phase amps, compare each phase’s voltage to current relationship, and develop a 4–20 mA output proportional to real power. Woodward manufactures two types of Real Power Sensors. The first type of RPS is designed to sense power flow in one direction only (0 to +5 A CT current only), and output a proportional 4–20 mA signal. This type of RPS was designed for and should be used to sense generator power output. Many different real power sensors of this type exist. Some of the optional RPS features include VAR sensing, Load sharing, 0–1 A CT current sensing, and multiple combinations of these. Please consult a Woodward certified distributor or a Woodward factory for the recommended RPS for your application. Figure 2-12. Real Power Sensor Woodward 15 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 The second type of RPS manufactured by Woodward is designed to sense power flow through a bus-to-bus tie line. This RPS (8272-726) senses –5 A to +5 A CT current to allow its output to represent power flow in both directions. This RPS provides a 4–20 mA power indication output signal where 12 mA represents 0 power flow. It is recommended that this RPS be used to sense power flow through a tie line only. This RPS or equivalent is required to sense plant Import and Export power. Woodward Real Power Sensors have terminals labeled “Output” and terminals labeled “KW Readout”. The “KW Readout” terminals provide a 4–20 mA signal proportional to real power which is used by and compatible with the 505 control. Thus the RPS terminals labeled “Output” are designed and typically compatible only to Woodward’s 2301 type of control. Woodward manufactured Real Power Sensors have a 2.5 Hz Low pass filter (400 ms lag time) on their output to filter out the high frequency noise typically created in a switch gear type environment. Thus if another vender’s watt transducer is used, verification that it has similar filtering criteria should be performed before it is applied with the 505. For more information on Woodward Real Power Sensors, please refer to Woodward manual 82018. Engine Generator Control Package/Load Sharing (EGCP-3 LS) The Woodward EGCP-3 LS control is a microprocessor based generator load control designed for use on three-phase ac generators with Woodward speed controls and automatic voltage regulators. The EGCP-3 LS is a synchronizer, a load control, a dead bus closing system, a VAR/PF control, a process control, Power & Energy metering and Protective Relays integrated into one package. The EGCP-3 LS has a keypad and two 4-line display panels on the front cabinet mounted chassis. The display can be used to configure and set up the control for site-specific requirements. The display is also used in normal operating service to monitor operation and view alarm data. All functions performed and parameters monitored by the front panel are also available through the three serial ports. These ports can be configured to use Woodward Watch Window software, an external HMI and Modbus communication, or Servlink DDE software. The 505 can be programmed to use the EGCP-3 LS as a synchronizer only, or as a synchronizer and load control. The EGCP-3 LS provides either phase match or slip frequency synchronizing, and ties into the unit automatic voltage regulator to match voltages before paralleling. It interfaces with the 505 via a Speed bias signal to control generator frequency and phase. When configured to use the EGCP-3 LS as a synchronizer only, the 505 must be programmed to receive the EGCP-3 Speed Bias signal through an analog input and have this input enabled through a contact input or function key. When used as a synchronizer and load control, the EGCP-3 LS performs automatic synchronization, and controls unit load based on the EGCP-3 s mode of operation. The EGCP-3 LS can be in a base-load, load sharing, remote load setting, or Process control mode, depending on configuration and system conditions. The EGCP-3 LS’s load sharing mode is used to share load with any other units using an EGCP-3 LS and tied to the same isolated bus. This mode is used in conjunction with an EGCP-3 MC when paralleled to a utility to allow the EGCP-3 MC to control plant frequency or load depending on its state of operation. 16 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators The EGCP-3 LS’s remote load setting mode allows load to be set by a remote 4-20 mA signal. The EGCP-3 LS’s Process control mode allows any process directly related to generator load to be controlled. After synchronization, unit load can be controlled by the EGCP-3 LS (through the 505 Sync/Ld input) or by the 505’s internal speed/load set point. When the Sync/Ld Share input is programmed, the position of the Utility Tie Breaker Contact selects unit load control through the EGCP-3 LS or through the 505’s internal load set point. Once the generator is synchronized the EGCP-3 LS soft-loads the unit to the load setting determined by the mode of operation (base load, load sharing, Process control). When commanded the EGCP-3 LS can also soft-unload the unit and issue a breaker-open command at a set power level. The PowerSense board receives the PT and CT inputs for both the generator and bus for calculation of parameters for the EGCP-3 to use in system control. The algorithms used are based on IEEE 1459-2000. For the generator and bus the following parameters are provided: Hz, Vac, Amps, W, VA, VAR, PF, Phase, Voltage harmonics, Current harmonics, Negative Phase Sequence Voltage, Negative Phase Sequence Current. Available for selection at the 4–20 mA analog outputs: Synchroscope, Generator metering, Mains metering. Figure 2-13. EGCP-3 Control Woodward 17 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure 2-14. EGCP-3 LS Functional Diagram 18 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 2-15. EGCP-3 LS Interface Wiring The following Bus Protections are available with the EGCP-3 LS:          Woodward Over/Under Voltage (59, 27) Over/Under Frequency (81O, 81U) Directional (Forward/Reverse) Power (32) * Negative Sequence Phase Overcurrent (46) Negative Sequence Phase Overvoltage (47) Phase Overcurrent (51) * Voltage Restrained Phase Overcurrent (51V) * Directional VAR Phase Current Imbalance (46) * 19 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 The following Generator Protections are available with the EGCP-3 LS:          Over/Under Voltage (59, 27) Over/Under Frequency (81O, 81U) Directional (Import/Export) Power (32)* Negative Sequence Phase Overcurrent (46) Negative Sequence Phase Overvoltage (47) Phase Overcurrent (51) * Directional VAR Phase Current Imbalance (46) * Speed/Frequency Mismatch *—Inverse Time Protections implemented are according to IEEE C37.112 “Very Inverse” curves. For more information on Woodward’s EGCP-3 LS Control, please refer to Woodward manuals 26122 and 26194. Applying the 505 with Redundant I/H or I/P Converters The 505 can be applied in simplex or redundant actuator systems. For redundant actuator applications Actuator Channel 1 is configured for HP Demand and Channel 2 is configured for HP2 Demand with zero offset. This will supply both actuator driver circuits full current to the driven device Selection between converter output signals can be accomplished using either shuttle valves or solenoid transfer valves. Converter status (I/H or I/P) and pressure feedback signals can be optionally programmed into the 505. If required, relay outputs can be programmed to transfer between converter outputs. Manual transfer between converters can be initiated through discrete input, Modbus, or PC interface commands. Automatic transfer between converters is provided by the 505 based on driver failure(s), converter status, converter output pressures, and servo input pressure feedback signals. Figure 2-16. Typical Redundant I/H System with a Transfer Valve 20 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 2-17. Typical Redundant I/P System with a Pressure Selecting Relay Valve Functionality Details Utilizing a two-actuator output configuration provides redundancy all the way to the actuator level. The typical redundant I/H (or I/P) system will convert the 505 actuator milliamp output into a corresponding hydraulic (or pneumatic) pressure positioning the servo-cylinder. Both converters are supplying the appropriate pressure to position the steam valves to the demand requested by the control. One of the converters will be in control of the valve demand and the other will be in a standby mode. Selection between converter output signals can be accomplished using either shuttle valves or solenoid transfer valves. The shuttle valve will select the higher pressure output between the two converters whereas the solenoid transfer valve selects one converter output and transfers between converters based on a relay command from the 505 control. Either valve type can be used, refer to the transfer valve section for additional information on advantages/disadvantages of each. Converter status (I/H or I/P) and pressure feedback signals should be programmed into the 505, since automatic transfer between converters is provided handled by the status of these signals. If required, a relay output can be programmed (configured as the In-Control relay) to transfer between converter outputs. Automatic transfer is based on the I/O programmed (refer to I/O options available). If a converter malfunction discrete input is programmed, then it is used for malfunction alarming and automatic transfer. Properly installed valves allow on-line converter replacement. For more information on Woodward’s Redundant CPC products, refer to manual 26448 and consult your sales representative about all CPC offerings. Woodward 21 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Chapter 3. Application Notes Overview This chapter is provided to give users an idea of the 505 Digital Control’s capabilities, and how to apply them to a system. Typical applications are schematically shown and their functionality explained. Programming and Start/ Run mode notes are given for each application to assist application programmers in configuring the 505 for their application. Basic peripheral device connections are shown in each application drawing to allow an understanding of how these devices interface to the 505 and expand system capabilities. Speed/Load PID The Speed PID can control and limit:  Unit Speed/Frequency  Unit Load The 505’s Speed PID can be used to control unit speed/frequency when isolated and unit load when paralleled to an infinite bus (utility). The Speed PID can be programmed to sense unit load via its actuator output signal or a 4–20 mA analog input signal from a generator power sensor. When programmed to sense and control generator load via a analog input true unit load is sensed and controlled. By using the generator load signal to control from, any turbine inlet or exhaust pressure variation is sensed and compensated for, thus providing true load control. A combination of the Speed PID and its setpoint limits allow this PID to limit unit load. When used as a unit load limiter, it is recommended that the 505 be configured to sense and control only true generator load. If applying the 505 system to a soft grid (utility frequency varies greatly) it is recommended that unit load limiting be performed by the Auxiliary PID not the Speed PID. Auxiliary PID The 505’s Auxiliary PID can be programmed to control or limit:             22 Turbine Inlet Steam Pressure Turbine Inlet Steam Flow Turbine Exhaust Steam pressure Turbine Exhaust Steam Flow Generator Power output Plant or Tie line Import/Export Power Process Temperature Compressor Suction pressure Compressor Suction Flow Compressor Discharge pressure Compressor Discharge Flow Any process parameter related to unit load, inlet pressure/flow, or exhaust pressure/flow (depending on configuration) Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators The 505’s Auxiliary PID can be used as a limiter or controller (enabled/disabled on command). When programmed as a limiter this PID’s output is Low Signal Selected with the Speed PID’s output. This configuration allows the Auxiliary PID to limit the unit’s load based on the parameter being sensed. When the Auxiliary PID is configured as a controller, it must be enabled and disabled by commands given through the 505’s front panel, contact input, or Modbus communications. With this configuration when the Aux PID is enabled the Speed PID is disabled and tracks the Auxiliary PID’s output. To control or limit any listed parameter, the 505 must be programmed to accept Auxiliary analog input signals representing that parameter’s level. The exception to this rule is when controlling or limiting generator load, the Auxiliary PID can be programmed to use and share the KW/Unit load input with the Speed PID. Cascade PID The 505’s Cascade PID can be programmed to control:             Turbine Inlet Steam Pressure Turbine Inlet Steam Flow Turbine Exhaust Steam pressure Turbine Exhaust Steam Flow Generator Power output Plant or Tie line Import/Export Power Process Temperature Compressor Suction pressure Compressor Suction Flow Compressor Discharge pressure Compressor Discharge Flow Any process parameter related to unit load, inlet pressure, or exhaust pressure (depending on the configuration) The 505’s Cascade PID can be used to control any of the listed parameters. This PID must be enabled and disabled by commands given through the 505’s front panel, contact input, or Modbus communications. The Cascade PID is cascaded with the Speed PID to vary unit speed/load. By directly positioning the Speed PID’s setpoint, the Cascade PID can vary unit speed/load to control its input parameter. This configuration allows for bumpless transfers between the two control modes (Speed/Load and Cascade). Example Applications The example applications in this chapter do not show every possible control configuration or combination. However, these examples can also be used as a reference to apply any of the controlling combinations or parameters not listed or shown. To apply a desired control parameter or combination not shown, refer to one or more of the typical application configurations that are shown and resemble the control configuration desired, then substitute the shown control parameters with the required control parameters. To apply a desired control parameter or combination not shown, refer to one or more of the typical application configurations that are shown and resemble the control configuration desired, then substitute the shown control parameters with the required control parameters. Woodward 23 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Example–To configure the 505 to perform a Turbine Exhaust pressure limiting function use Example 1, the “Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting” application for reference. With this example substitute exhaust pressure for inlet pressure and disregard any program settings specified to control pump or compressor discharge pressure. The examples shown in this chapter are summarized as follows:        Example 1: Pump or Compressor Discharge Pressure Control with Inlet Pressure Limiting Example 2: Inlet Pressure Control with Auto Synchronizing and Generator Power Limiting Example 3: Exhaust Pressure Control with Plant Import/Export Power Limiting Example 4: Plant Import/Export Power Control with DRFD Servo Interface Example 5: Inlet Pressure Control with Isochronous Load Share Control in Island Mode Example 6: Plant Import/Export Power Control with Isochronous Load Share Control in Island Mode Example 7: Induction Generator Control Table 3-1. Example Application Summary Turbine Type Control Functions Control Modes 24 Mechanical Drive Synchronous Generator Induction Generator Auxiliary Limiting Auxiliary Control Cascade Control Synchronizing Load Sharing Frequency Control Inlet Pressure Control Min Inlet Pressure Limiting KW Load Control KW Load Limiting Import/Export Load Control Import/Export Load Limiting 1 X Application Examples 2 3 4 5 6 X X X X X X X X X X X X 7 X X X X X X X X X X X X X X X X X X X X X X Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Example 1–Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting Figure 3-1. Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting This is an example of a typical pump or compressor application. With this application the 505 is configured to normally control pump/compressor discharge pressure, and limit governor valve position based on low turbine inlet steam pressure. Both the Auxiliary and Cascade modes were used for this example application. Other applications may or may not use all the functionality shown in Figure 3-1 and described below. With this application pump/compressor discharge pressure control is performed within the 505 through the Cascade controller. Because the discharge pressure being controlled, typically affects many other plant processes, a plant Distributed Control System (DCS) may be used to monitor plant process conditions and set the Cascade setpoint position. This can be performed through Modbus communications, discrete raise and lower commands, or with an Analog setpoint signal. For this application a limiting type of control function was required to help preserve inlet header pressure in case of system header problems. Because the Auxiliary PID is the only controller that has this capability, it is used to sense turbine inlet pressure and limit governor valve position, based on a low inlet pressure setting. Woodward 25 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 If a plant Distributed Control System is used to sense and control a process by positioning the load of multiple pumps or compressors (loadsharing), the DCS may interface directly to the 505 Speed PID setpoint through a programmed Remote Speed Setpoint analog input. This allows a DCS to monitor and compensate for plant and system conditions by directly changing the speed of multiple pumps or compressors simultaneously. All 505 PID controller setpoints (Speed, Auxiliary, Cascade) may be changed through programmed raise and lower contacts, programmed 4–20 mA inputs, Modbus commands, or the 505 service panel. The following list of notes is provided as a reference for application programmers to follow when configuring the 505 to achieve any of the control and limiting actions shown in Figure 3-1: 505 Configuration Notes for Example 1 Operating Param: This is not a Generator application. (Generator Application? No) Cascade Control: The Cascade control loop was configured to receive a pump/compressor discharge pressure signal through Analog input #1. (Analog Input #1 Function: Cascade Input) Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR10 installed. The 505 was configured to accept a contact from a panel mounted switch to externally enable and disable discharge pressure control. (Contact Input 1 Function: Casc Control Enable) Pump/compressor discharge pressure is directly proportional to turbine inlet valve position, thus input inversion is not required. (Invert Cascade Input? No) With this application, Setpoint Tracking is not used because the system’s pressure setpoint never changes. (Use Setpoint Tracking? No) To protect the generator from being reverse powered by the Cascade PID, the ‘Speed Setpoint Lower Limit’ value was set to 3% above synchronous speed or 3605.4 rpm (5.4 rpm if rated speed is 3600 rpm and using 5% droop). The 505 will automatically limit the Speed Setpoint Lower Limit to a minimum of 3% (min load). If it is desired to allow the Cascade PID to lower load below this setting, the Service mode’s (Cascade Control Settings, Use Min Load) setting must be set to “No”. In this case, because the Cascade PID is not sharing control of discharge pressure with another control, Droop is not needed. (Cascade Droop = 0%) Auxiliary Control: The Auxiliary control loop was configured to receive a turbine inlet header pressure signal through Analog input #2. (Analog Input #2 Function: Auxiliary Input) Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR8 installed. 26 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators The Auxiliary Input was inverted to allow the correct control action. To increase turbine inlet header pressure, the governor valve must decrease. This is considered an indirect action and requires the input to be inverted. (Invert Aux Input? YES) The Auxiliary PID was programmed to perform as a limiter. (Use Aux Enable? No) Because the Auxiliary PID is used only as a limiter and is not sharing control of inlet pressure with another control, Droop is not needed. (Aux Droop = 0%) Trips: In this example the turbine can be tripped by several devices, one of these devices is the 505 control. To provide feedback to the 505 control that the turbine is tripped, a contact from the trip string is wired into the External Emergency Shutdown input (TB12). With this application, the ‘governor trip’ annunciation should only occur if the 505 tripped the turbine and not annunciate when the other external devices shuts down the unit (Turbine Start: Ext Trips in Trip Relay ?–No.) Because the Shutdown relay is used in the trip string to shut down the turbine should the 505 initiate a trip, additional relays are required for annunciating any turbine trip and annunciating a 505 initiated trip. Relay #3 was programmed to annunciate any turbine trip as follows: (Relays: Use Relay #3–Yes ; Relay #3 is a Level Switch?–No ; Relay #3 Energizes on– Shutdown Condition) Relay #4 was programmed to indicate a 505 initiated trip as follows: (Relays: Use Relay #4–Yes ; Relay #4 is a Level Switch?–No ; Relay #4 Energizes on–Trip Relay) Note that Relay #4 de-energizes on a trip condition (excluding external trip inputs) and Relay #3 energizes on a trip (shutdown) condition. Starting and Run Mode Notes for Example 1 Starting and ramping to an idle or minimum speed position can be performed automatically, semi-automatically, or manually. After the unit is started, the Idle/ Rated or Auto Start Sequence functions, if programmed, can be used to assist ramping the control to a rated speed position or an operator can give a raise command to manually increase turbine speed. After the unit has been started and is controlling at a minimum/desired speed position, Cascade control (pump/compressor discharge pressure) can be enabled through contacts, Modbus commands, or the 505 service panel. When Cascade control is enabled, if actual discharge pressure does not match the set point, the control will automatically ramp turbine speed at the ‘SPEED SET POINT SLOW RATE’ setting until the pump/compressor discharge pressure does match the set point. With this application the Auxiliary control is used as a limiter, thus it does not need to be enabled. If turbine inlet pressure decreases below the Auxiliary setpoint at any time the Auxiliary PID will take control of the governor valve and lower it to help preserve inlet header pressure. See the Service mode section of this manual, for information on related tunable values and rates. Woodward 27 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Example 2–Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Figure 3-2. Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting 28 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators This is an example of a typical turbine generator application where plant process steam (turbine inlet header pressure) is desired to be controlled at a single pressure. With this type of application, turbine load varies based on the plant process steam demand. Both the Auxiliary and Cascade modes were used for this example application. Other applications may or may not utilize all the functionality shown in Figure 3-2 and described below. With this application turbine inlet header pressure control is performed within the 505 through the Cascade PID controller. This is an ideal controller for this type of function because it can be enabled and disabled as desired by a system operator. This gives a system operator full authority of when to transfer process pressure control to or from a letdown station or turbine bypass valve. As shown in Figure 3-2 generator load is being sensed with a Woodward Real Power Sensor and supplied to the 505’s KW/unit load input. This allows generator load to be set and controlled by the Speed PID when paralleled to the utility during unit start-up and shutdown. During normal operation unit load is determined by the Cascade PID controlling inlet header pressure. Because turbine load may vary greatly with this application, a limiter is used to protect the generator from being over powered. This protection is performed by the Auxiliary PID configured as a limiter. By configuring the Auxiliary PID as a limiter and to use the generator load input as the PID’s controlling parameter, the maximum load the generator can operate at can be limited. This application uses an EGCP-3 LS for synchronization only. Because the EGCP-3 LS interfaces to the 505 through an analog signal, a 505 analog input must be programmed. The 505’s Analog Input #6 is the only analog input directly compatible with the EGCP-3 LS, thus it is required that this input be programmed to receive the EGCP-3 LS’s Speed Bias signal. When a Synchronizing input/function is programmed, the input can be enabled, through a contact input, function key, Modbus command, or the 505 service panel. As shown in Figure 3-2, a panel-mounted (DPST) switch is used with this application to select automatic synchronization in both the EGCP-3 LS and 505. All 505 PID controller setpoints (Speed, Auxiliary, Cascade) may be changed through programmed raise and lower contacts, programmed 4–20 mA inputs, Modbus commands, or the 505 service panel. The following list of notes are provided as a reference for application programmers to follow when programming the 505 to achieve any of the control and limiting actions shown in Figure 3-2. 505 Configuration Notes for Example 2 Operating Parameter: This is a Generator application. (Generator Application? Yes) Generator and Utility Tie breaker contact inputs are required to be programmed when a generator application is selected. (Contact Input #1 Function: Generator Breaker), (Contact Input #2 Function: Utility Tie Breaker). The 505 was configured to sense the Real Power Sensor’s generator load signal through Analog input #1. (Analog Input #1 Function: KW/Unit Load Input) Woodward 29 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Because the Real Power Sensor’s ‘KW readout’ is self-powered, the 505 back cover was removed and JPR11 installed. Generator load control (when paralleled to the utility) is controlled through the Speed PID and programmed by selecting KW Droop. (Use kW Droop? Yes) For good response and load adjustment resolution, Droop was set to 5% of rated speed. (Droop = 5 %) It was desired to switch to Frequency control at all times, if the plant became isolated form the Utility bus. (Use Freq Arm/Disarm? No) Cascade Control: The Cascade control loop was configured to receive an inlet header pressure signal through Analog input #2. (Analog Input #2 Function: Cascade Input) Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR8 installed. The 505 was configured to accept a contact from a panel mounted switch to externally enable and disable inlet header pressure control. (Contact Input #3 Function: Casc Control Enable) The Cascade Input was inverted to allow the correct control action. To increase turbine inlet header pressure, the governor valve position must decrease. This is considered an indirect action and requires the input to be inverted. (Invert Cascade Input? Yes) With this application, Setpoint Tracking is not used because the system’s pressure setpoint never changes, thus system start-up is simpler. (Use Setpoint Tracking? No) To protect the generator from being reverse powered by the Cascade PID, the ‘Speed Setpoint Lower Limit’ value was set to 5 rpm above synchronous speed. In this case, because the Cascade PID, during normal operation, is not sharing control of inlet header pressure with another controller, Droop is not needed. (Cascade Droop = 0%) Auxiliary Control: The Auxiliary control loop was configured to receive a generator load signal through the KW/Unit Load input, also being used for KW Droop. (Use KW Input? Yes) Unit load is directly proportional to turbine inlet valve position, thus no input inversion is required. (Invert Aux Input? No) The Auxiliary PID was programmed to perform as a load limiter. (Use Aux Enable? No) In this case, because the Auxiliary PID is used only as a limiter, and is not sharing control of generator load with another control, Droop is not needed. (Aux Droop = 0%) With this application, it was desirable to only enable the Auxiliary PID if paralleled to the utility. (Tiebkr Open Aux Dsbl? Yes), (Genbkr Open Aux Dsbl? Yes) 30 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Auto Synchronizing: The 505’s Analog input #6 was programmed to receive the EGCP-3 LS’s speed bias signal for automatic synchronization (Analog Input #6 Function: Synchronizing Input) With this configuration, the analog input’s range is defaulted to provide a certain gain factor for best performance, thus the input’s 4 mA and 20 mA program settings are not used and do not require programming. A contact input was programmed to enable the Synchronizing analog input (Contact Input #4 Function: Synch Enable). Starting and Run Mode Notes for Example 2 Starting and ramping to an idle or minimum speed position can be performed automatically, semi-automatically, or manually. After the unit is started, the Idle/ Rated or Auto Start Sequence functions, if programmed, can be used to assist ramping the control to a rated speed position. Alternatively an operator can give a manual raise command to increase turbine speed as desired. After the unit has been started and is controlling at a rated speed position, the turbine generator can be synchronized manually, or automatically. The system operator can select automatic synchronization through the Auto-Synch select switch (switch SW1 in Figure 3-2). When this switch is closed the 505’s Synchronizing input is enabled and the EGCP-3 LS’s automatic synchronizing function is selected. When the plant-to-utility tie-line breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load set point up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load set point and is defaulted to 3%. The defaulted value is adjustable through the 505’s Service mode (Breaker Logic–Min Load Bias = 5). When the plant-to-utility tie-line breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load set point up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load set point and is defaulted to a “3%5 rpm” step change of the speed/load set point. The defaulted value is adjustable through the 505’s Service mode (Breaker Logic–Min Load Bias = 5). After synchronization the 505’s load setpoint can be positioned through raise and lower Speed/Load setpoint contacts, a programmed 4–20 mA input, Modbus commands, or the 505 service panel. This load control mode may be used to slowly increase turbine load, and take control away from a letdown station or turbine bypass valve. Cascade control (turbine exhaust pressure) can be enabled at any time after the Utility Tie breaker and Generator breakers are closed, through a contact input, Modbus command or the 505 service panel. With this configuration, when Cascade control is enabled, if actual inlet header pressure does not match setpoint, the control will increase generator load at the ‘SPEED SETPOINT SLOW RATE’ setting until the inlet header pressure matches setpoint. Woodward 31 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 With this application the Auxiliary control is programmed to be used as a limiter, and be automatically enabled when both the Utility Tie and Generator breakers are closed. When paralleled to the utility, if inlet header pressure demand, and/or other system conditions try to force the generator to operate above its load limit setting, the Auxiliary PID will take control of the governor valve to limit generator load. Once system conditions demand unit load below that of the Auxiliary setpoint, the Cascade/Speed PIDs will again take control of generator load. Example 3–Exhaust Pressure Control with Generator Power Limiting and Plant Import/Export Limiting Figure 3-3. Exhaust Pressure Control with Generator Power Limiting and Plant Import/Export Limiting 32 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators This is an example of a typical turbine generator application where plant process steam (turbine exhaust pressure) is desired to be controlled at a single pressure level. With this type of application, turbine load varies based on the plant process steam demand. Both the Auxiliary and Cascade modes were used for this example application. Other applications may or may not utilize all the functionality shown in Figure 3-3 and described below. With this application turbine exhaust pressure control is performed within the 505 through the Cascade PID controller. This is an ideal controller for this type of function because it can be enabled and disabled as desired by a system operator. This gives a system operator full authority of when to transfer process pressure control to or from a letdown station or turbine bypass valve. Because turbine load may vary greatly with this application, a limiter is used to protect the generator from being over powered. In order to limit generator load, the 505 control must be able to sense generator load. As shown in Figure 3-3 generator load is being sensed with a Woodward Real Power Sensor and supplied to the 505’s KW droop input. With this application generator over-load protection is performed by a combination of the Speed PID and the Speed Setpoint Maximum limit. By programming the Speed Setpoint Maximum limit to that of rated speed plus the % droop value at 100% load, the speed setpoint cannot be taken over 100% load and the Speed PID will limit generator load to 100%. For this application a limiting type of control function was required to limit the plant export power to zero. The plant does not get reimbursed for any power exported, and it is more economical to make power than purchase it form the utility, thus a zero plant import/export power level is desired. Because the Auxiliary PID is the only 505 controller that has this limiting capability, it was used to sense tie line power and limit turbine/generator output, based on a zero export limit setting. A second Real Power Sensor #8272-726 was used with this application to sense utility tie line power. This RPS is special, in that it senses –5 A to +5 A CT current to allow its output to represent power flow in both the import and export directions. With this RPS 12 mA represents zero power flow. Because of this feature the RPS #8272-726 cannot, be used with the 505 to sense generator load/ power. Please check with a Woodward certified distributor or factory for the correct RPS to use as a generator load sensor. This application uses an EGCP-3 LS for synchronization only. Because the EGCP-3 LS interfaces to the 505 through an analog signal, a 505 analog input must be programmed. The 505’s Analog Input #6 is the only analog input directly compatible with the EGCP-3 LS, thus it is required that this input be programmed to receive the EGCP-3 LS’s Speed Bias signal. When a synchronizing input/function is programmed, the input can be enabled, through a contact input, function key, Modbus command, or the 505 service panel. As shown in Figure 3-3, a panel-mounted (DPST) switch is used with this application to select automatic synchronization in both the EGCP-3 LS and 505. All 505 PID controller setpoints (Speed, Auxiliary, Cascade) may be changed through programmed raise and lower contacts, programmed 4–20 mA inputs, Modbus commands, or the 505 service panel. The following list of notes are provided as a reference for application programmers to follow when programming the 505 to achieve the control and limiting actions shown in Figure 3-3. Woodward 33 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 505 Configuration Notes for Example 3 Operating Param: This is a Generator application. (Generator Application? Yes) Generator and Utility Tie breaker contact inputs are required to be programmed when a generator application is selected. (Contact Input #1 Function: Generator Breaker) (Contact Input #2 Function: Utility Tie Breaker) The 505 was configured to sense a Real Power Sensor’s generator load signal through Analog input #1. (Analog Input #1 Function: KW/Unit Load Input) Because the RPS’s KW readout is self-powered, the 505 back cover was removed and JPR11 installed. Generator load (when paralleled to the utility) is controlled by the Speed PID and programmed by selecting the KW/Unit load input. (Use KW Droop? YES) For good response and load adjustment resolution, Droop was set to 5% of rated speed. (Droop = 5 %) It was desired to switch to Frequency control at all times, if the plant became isolated form the Utility bus. (Use Freq Arm/Disarm? No) Cascade Control: The Cascade control loop was configured to receive an exhaust header pressure signal through Analog input #2. (Analog Input #2 Function: Cascade Input) Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR8 installed. The Function Key F3 was programmed to allow an operator to easily enable and disable Cascade control. (F3 Key Performs: Casc Control Enable). Exhaust header pressure is directly proportional to turbine inlet valve position, thus no input inversion is required. (Invert Cascade Input? No) With this application, Setpoint Tracking is used to allow the 505’s Cascade control, when disabled, to track exhaust header pressure being controlled by a letdown station. (Use Setpoint Tracking? Yes) To protect the generator from being reverse powered by the Cascade PID, the ‘Speed Setpoint Lower Limit’ value was set to 5 rpm above synchronous speed. In this case, because the Cascade PID, during normal operation, is not sharing control of exhaust header pressure with another control, Droop is not needed. (Cascade Droop = 0%) Gen Load Limiting: To limit generator load to 100% the Speed setpoint’s maximum limit was set at the 100% load setting. 5% Droop was programmed for this application. (Max Governor Speed Setpoint = Rated speed x 1.05) 34 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators AUXILIARY Control: The Auxiliary control loop was configured to receive a utility tie line power signal through Analog input #3. (Analog Input #3 Function: Auxiliary Input) he minimum analog input value was programmed for import power based on the tie line power level at –5 A CT current (Input #3 4 mA Value =–XXXX). he maximum analog input value was programmed for export power based on the tie line power level at +5 A CT current (Input #3 20 mA Value = +XXXX). Because the RPS’s KW readout is self-powered, the 505 back cover was removed and JPR15 installed. The utility-tie Real Power Sensor’s CT inputs were wired to allow the RPS’s 4 mA value to represent full import power and the RPS’s 20 mA value to represent full export power. Because this signal is directly proportional to turbine inlet valve position, no input inversion is required. (Invert Aux Input? No) The Auxiliary PID was programmed to perform as a limiter. (Use Aux Enable? No) In this case, because the Auxiliary PID is used as a limiter, and is not sharing control of inlet pressure with another control, Droop is not needed. (Aux Droop = 0%) With this application, it was desirable to only enable the Auxiliary PID if paralleled to the utility. (Tiebkr Open Aux Dsbl? Yes), (Genbkr Open Aux Dsbl? Yes) Auto Synchronizing: The 505’s Analog input #6 was programmed to receive the EGCP-3 LS’s speed bias signal for automatic synchronization (Analog Input #6 Function: Synchronizing Input). With this configuration, the analog input’s range is defaulted to a certain gain value, for best performance, thus the input’s 4 mA and 20 mA settings are not used and do not require programming. A contact input was programmed to enable the Synchronizing analog input (Contact Input #4 Function: Synch Enable). Starting and Run Mode Notes for Example 3 Starting and ramping to an idle or minimum speed position can be performed automatically, semi-automatically, or manually. After the unit is started, the Idle/ Rated or Auto Start Sequence functions, if programmed, can be used to assist ramping the control to a rated speed position. Alternatively, an operator can give a manual raise command to increase turbine speed as desired. After the unit has been started and is controlling at a rated speed position, the turbine generator can be synchronized manually, or automatically. The system operator can select automatic synchronization through the Auto-Synch select switch (SW1 in Figure 3-3). When this switch is closed the 505’s Synchronizing input is enabled and the EGCP-3 LS’s automatic synchronizing function selected. Woodward 35 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 When the plant to utility tie line/breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load setpoint up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load setpoint and is defaulted to 3%. The defaulted value is adjustable through the 505’s Service mode (Breaker Logic–Min Load Bias = 5). After synchronization the 505’s load setpoint can be positioned through raise and lower speed/load setpoint contacts, a programmed 4–20 mA input, Modbus commands, or the 505 service panel. Cascade control (turbine exhaust pressure) can be enabled at any time after the utility tie breaker and generator breaker input contacts are closed. Cascade control can be enabled through a programmed contact, Modbus command, or the 505 service panel. Exhaust pressure control can be transferred from a letdown station or turbine bypass valve in one of the following ways; enabling Cascade control, and backing down the letdown station’ s setpoint, or slowly increasing turbine load with the Speed PID’s setpoint, to allow the letdown station to close, then enable Cascade control. After exhaust pressure control has been transferred to the 505’s Cascade PID, the letdown station or turbine bypass valve must be closed or in a manual control mode. This will stop the two controllers (505 Cascade PID and system letdown station) from fighting for control of one parameter and causing system instability. With this application the Auxiliary control is programmed to be used as a limiter and be automatically enabled when both the utility tie and generator breakers are closed. When paralleled to the utility this 505 and RPS combination allows the plant to import power from the utility, but not export power. If the utility-to-plant tie line power reaches a zero import/export level the Auxiliary PID will begin limiting generator output, until plant conditions require power to be imported again. Optionally the Auxiliary PID’s setpoint can be varied to limit plant power to a different import or export power level as required. Example 4–Plant Import/ Export Control with DRFD Servo Interface This is an example of a typical turbine generator application where plant import/ export control is desired when paralleled with the utility, and frequency control when isolated from the utility. With this type of application, when paralleled to the utility, turbine load varies based on the plant power demand. Other applications may or may not use all the functionality shown in Figure 3-4 and described below. With this application, plant import/export control is performed within the 505 through the Auxiliary PID controller. Optionally the Cascade PID controller could have been used instead. For this application the Auxiliary PID is configured to be enabled and disabled on command, instead of performing a limiting action. This gives a system operator full authority of when to enable or disable plant import/export control. When programmed for this type of control action, the Speed PID is disabled when the Auxiliary PID is enabled, and can only limit the 505’s valve output signal if unit load reaches 100%. Also, the Auxiliary setpoint automatically tracks the PID’s input value when not in-control. 36 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 3-4. Plant Import/Export Control with DRFD Servo Interface A Real Power Sensor #8272-726 was used with this application to sense utility tie line power flow. This RPS is special, in that it senses –5 A to +5 A CT current to allow its output to represent power flow in both the import and export directions. With this RPS 12 mA represents zero power flow. Because of this feature the RPS #8272-726 cannot, be used with the 505 to sense generator load/power. To save buying a second Real Power Sensor, with this application, unit load is sensed through turbine inlet valve position (505 LSS bus), not a generator load signal. Optionally, another Real Power Sensor could be used with this application to sense generator power, and allow true unit load to be sensed, controlled, and limited. With this configuration, when the generator is paralleled to the utility, the Speed PID controls governor valve position, instead of generator power. Thus 100% governor valve position is considered 100% unit load, no matter if system conditions are at rated or not. Woodward 37 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 This application uses an EGCP-3 LS for synchronization only. Because the EGCP-3 LS interfaces to the 505 through an analog signal, a 505 analog input must be programmed. The 505’s Analog Input #6 is the only analog input directly compatible with the EGCP-3 LS, thus it is required that this input be programmed to receive the EGCP-3 LS’s Speed Bias signal. When a synchronizing input/function is programmed, the input can be enabled, through a contact input, function key, Modbus command, or the 505 service panel. As shown in Figure 3-4, a panel-mounted (DPST) switch is used with this application to select automatic synchronization in both the EGCP-3 LS and 505. With this application the existing servo assembly had an actuator which required +50 mA for pilot valve positioning, and a LVDT mounted to the valve rack to feedback actual rack position. Because the 505 does not have a bipolar drive circuit, and cannot perform closed loop servo position control, a Woodward Digital Remote Final Driver (DRFD) was used to interface with the existing servo actuator. The integrating type of DRFD used, accepts a 4–20 mA valve demand signal from the 505, monitors actual valve position (through, LVDTs, MLDTs, or other dc position feedback devices), compares the two signals, and outputs a drive signal to the servo assemblies actuator accordingly. The DRFD interfaces directly with an LVDT, (providing excitation, and demodulation) thus no external converter was required or used. All 505 PID controller setpoints (Speed, Auxiliary, Cascade) may be changed through programmed raise and lower contacts, programmed 4–20 mA inputs, Modbus commands, or the 505 service panel. The following list of notes are provided as a reference for application programmers to follow when programming the 505 to achieve any control and limiting actions shown in Figure 3-4. 505 Configuration Notes for Example 4 Operating Parameter: This is a Generator application. (Generator Application? Yes) Generator and Utility Tie breaker contact inputs are required to be programmed when a generator application is selected. (Contact Input #1 Function: Generator Breaker), (Contact Input #2 Function: Utility Tie Breaker) Because no RPS was used to sense unit load, turbine inlet steam valve position, when paralleled to the utility, is controlled by the Speed PID and programmed by not selecting KW Droop. (Use KW Droop? No) For good response and load adjustment resolution, Droop was set to 5% of rated speed. (Droop = 5 %) It was desired to switch to Frequency control at all times, if the plant became isolated form the Utility bus. (Use Freq Arm/Disarm? No) Driver Configuration: Because the Digital Remote Final Driver used to interface with the servo assembly only accepts a 4–20 mA valve demand signal, the 505 was configured to output a 4–20 mA valve demand signal. (Actuator Is 4–20 mA? Yes) 38 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Dither is a low frequency ac current modulated on to the 505’s dc actuator– drive current to reduce stiction in linear type actuators. Because the 505’s actuator output is connected to the DRFD, dither was not required or used with this application. (Actuator #1 Dither = 0.0%) Auxiliary Control: The Auxiliary control loop was configured to receive a utility tie line power signal through Analog input #3. (Analog Input #3 Function: Auxiliary Input) he minimum analog input value was programmed for import power based on the tie line power level at –5 A CT current (Input #3 4 mA Value =–XXXX). The maximum analog input value was programmed for export power based on the tie line power level at +5 A CT current. (Input #3 20 mA Value = +XXXX). Because the RPS’s KW readout is self-powered, the 505 back cover was removed and JPR15 installed. The 505 was configured to accept a contact from a plant distributed control system to enable and disable import/export control. (Contact Input #3 Function: Aux Control Enable) The utility-tie Real Power Sensor’s CT inputs were wired to allow the RPS’s 4 mA value to represent full import power and the RPS’s 20 mA value to represent full export power. Because this signal is directly proportional to turbine inlet valve position, no input inversion is required. (Invert Aux Input? No) The Auxiliary PID was programmed to be enabled and disabled on command. (Use Aux Enable? Yes) In this case, because the Auxiliary PID is the sole import/export controller, Droop is not needed. (Aux Droop = 0%) With this application, it was desirable to only allow the Auxiliary PID to be enabled if paralleled to the utility. (Tiebkr Open Aux Dsbl? Yes), (Genbkr Open Aux Dsbl? Yes) Auto Synchronizing: The 505’s Analog input #6 was programmed to receive the EGCP-3 LS’s speed bias signal for automatic synchronization (Analog Input #6 Function: Synchronizing Input). With this configuration, the analog input’s range is defaulted to a certain gain value, for best performance, thus input’s 4 mA and 20 mA settings are not used and do not require programming. A contact input was programmed to enable the Synchronizing analog input. (Contact Input #4 Function: Sync Enable) Starting and Run Mode Notes for Example 4 Starting and ramping to an idle or minimum speed position can be performed automatically, semi-automatically, or manually. After the unit is started, the Idle/ Rated or Auto Start Sequence functions, if programmed, can be used to assist ramping the control to a rated speed position. Alternatively, an operator can give a manual raise command to increase turbine speed as desired. Woodward 39 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 After the unit has been started and is controlling at a rated speed position, the turbine generator can be synchronized manually, or automatically. The system operator can select automatic synchronization through the Auto-Synch select switch (SW1 in Figure 3-4). When this switch is closed the 505’s Synchronizing input is enabled and the EGCP-3 LS’s automatic synchronizing function selected. The EGCP-3 LS provides either phase matching or slip frequency synchronizing, and ties into the unit automatic voltage regulator to match voltages before paralleling. It communicates over a LAN using a digital Echelon network with other plant EGCP-3 LSs to perform safe dead bus closing. When the plant-to-utility tie line/breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load setpoint up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load setpoint and is to 3%. The defaulted value is adjustable through the 505’s Service mode (Breaker Logic–Min Load Bias = 5). After synchronization the 505’s load setpoint can be positioned through raise and lower speed/load setpoint contacts, a programmed 4–20 mA input, Modbus commands, or the 505 service panel. With this configuration, Import/Export control (Auxiliary PID) can be enabled at any time after the utility tie breaker and generator breaker input contacts are closed. Auxiliary control can be enabled through the programmed contact, a Modbus command, or the 505 service panel. Because the Auxiliary Setpoint tracks plant Import/Export power before being enabled, the transfer to Auxiliary control is bumpless. Once enabled, the Auxiliary PID’s setpoint can then be positioned to the desired import or export level. Because of the 505’s configuration, this unit will automatically switch to Frequency control, upon the opening of the plant-to-utility tie breaker. Example 5–Inlet Pressure Control with Isochronous Loadsharing Control in Island Mode For this application, it is desired to control Inlet Pressure when paralleled to the utility, and Frequency while loadsharing with three other units, when isolated from the utility. With this type of application, when paralleled to the utility, load varies based on plant process steam demand, and when isolated load varies based on plant power demand. Other applications may or may not utilize all the functionality shown in Figure 3-5 and described below. With this application, turbine inlet header pressure control is performed within the 505 through the Cascade PID controller. This is an ideal controller for this type of function because it can be enabled and disabled as desired by a system operator. This gives a system operator full authority of when to transfer process pressure control to or from a letdown station or turbine bypass valve. To save buying a Real Power Sensor, for this application, unit load is sensed through turbine inlet valve position (505 LSS bus), not a generator load signal. Optionally, another Real Power Sensor could be used with this application to sense generator power, and allow true unit load to be sensed and controlled. With this configuration, 100% governor valve position, is considered to be 100% unit load, no matter what system conditions are. 40 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 3-5. Inlet Pressure Control with Isochronous Loadsharing Control in Island Mode This application uses an EGCP-3 LS for synchronization and isochronous loadsharing. With this configuration, the EGCP-3 LS is disabled when the generator is paralleled to the utility, and enabled when isolated from the utility. When the unit is paralleled to the utility, the EGCP-3 LS is disabled and the 505’s internal load setpoint or Cascade PID (plant import/export power) is used to control/set unit load. When the plant becomes isolated from the utility, (utility tie breaker opens), the EGCP-3 LS is enabled, Cascade control is disabled, and the 505 is switched to a Frequency control/loadsharing mode. An EGCP-3 LS can only interface to a 505 through an analog input signal. The 505’s Analog Input #6 is the only analog input directly compatible with the EGCP3 LS, thus it is required that this input be programmed to receive the EGCP-3 LS’s Speed Bias signal. When a Sync/LD Share analog input is programmed, the input is automatically enabled if the generator breaker input is closed and the utility tie breaker input is open. Woodward 41 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Before the generator breaker is closed, the Synch/Ld Share input can be enabled, to allow automatic synchronization by the EGCP-3 LS. This synchronizing function/ input can be enabled, through a contact input, function key, Modbus command, or the 505 service panel. As shown in Figure 3-5 a panel mounted (DPST) switch is used with this application to select automatic synchronization in both the EGCP-3 LS and 505. All 505 PID controller setpoints (Speed, Auxiliary, Cascade) may be changed through programmed raise and lower contacts, programmed 4–20 mA inputs, Modbus commands, or the 505 service panel. The following list of notes are provided as a reference for application programmers to follow when programming the 505 to achieve any control and limiting actions shown in Figure 3-5. 505 Programming Notes for Example 5 Operating Parameter: This is a Generator application. (Generator Application? Yes) Generator and Utility Tie breaker contact inputs are required to be programmed when a generator application is selected. (Contact Input #1 Function: Generator Breaker), (Contact Input #2 Function: Utility Tie Breaker) Because no RPS was used to sense unit load, turbine inlet steam valve position, when paralleled to the utility, is controlled by the Speed PID and programmed by not selecting KW Droop. (Use KW Droop? No) For good response and load adjustment resolution, Droop was set to 5% of rated speed. (Droop = 5 %) It was desired to switch to Frequency control at all times, if the plant became isolated form the Utility bus. (Use Freq Arm/Disarm? No) Cascade Control: The Cascade control loop was configured to receive an inlet header pressure signal through Analog input #2. (Analog Input #2 Function: Cascade Input). Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR8 was installed. The 505 was configured to accept a contact from a panel mounted switch to externally enable and disable inlet header pressure control. (Contact Input #3 Function: Casc Control Enable) The Cascade Input was inverted to allow the correct control action. To increase turbine inlet header pressure, the governor valve must decrease. This is considered an indirect action and requires the input to be inverted. (Invert Cascade Input? Yes) With this application, Setpoint Tracking is not used because the desired system pressure level never changes, thus system start-up is simpler. (Use Setpoint Tracking? No) To protect the generator from being reverse powered by the Cascade PID, the ‘Speed Setpoint Lower Limit’ value was set to 5 rpm above synchronous speed. 42 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators In this case, because the Cascade PID is sharing control of inlet header pressure with the boiler control, Droop was set at 5%. This allows the Cascade PID to assist the boiler control with inlet header pressure control, without having the two fight over the same parameter. (Cascade Droop = 5%). Synch/Ld Sharing: The 505’s Analog Input #6 was programmed to receive the EGCP-3 LS’s speed bias signal for automatic synchronization, and load sharing. (Analog Input #6 Function: Synch/Load Share Input) With this configuration, the analog input’s range is defaulted to a certain gain value, for best performance, thus input’s 4 mA and 20 mA settings are not used and do not require programming. A contact input was programmed to enable the Synch/Load Share analog input to allow synchronization through the EGCP-3 LS before the generator breaker is closed. (Contact Input #4 Function: Synch/Ld Share Enable). Starting and Run Mode Notes for Example 5 Starting and ramping to an idle or minimum speed position can be performed automatically, semi-automatically, or manually. After the unit is started, the Idle/ Rated or Auto Start Sequence functions, if programmed, can be used to assist ramping the control to a rated speed position. Alternatively, an operator can give a manual raise command to increase turbine speed as desired. When the unit has been started and is controlling at a rated speed position, the turbine generator can be synchronized manually, or automatically. The system operator can select automatic synchronization through the Auto-Synch select switch (SW1 in Figure 3-5). When this switch is closed the 505’s Synch/Load Sharing input is enabled and the EGCP-3 LS’s automatic synchronizing function is selected. After synchronization, generator load is determined by the mode of operation selected, (the position of the utility tie breaker contact input). If the utility tie breaker contact is closed, generator load is determined by the 505’s internal load setpoint, or when enabled, inlet header pressure control (Cascade control). If the utility tie breaker contact is open generator load is determined by the EGCP-3 LS. The EGCP-3 LS can be configured to operate in several different load control modes. For this application the EGCP-3 LS is only used for isochronous loadsharing, when the plant is isolated from the utility. In this plant four generating units use EGCP-3 LSs, and upon the plant-to-utility tie breaker opening they all switch to Frequency control and communicate with each other via a digital LON network to share load. Thus plant frequency is controlled by all units, and plant load is shared proportionally by all four units. With this configuration plant frequency will be the average frequency of all units. The 505, has a feature that resets its frequency setpoint to the ‘RATED SPEED SETPOINT’ setting upon the utility tie breaker opening, thus assuring that all units will be at synchronous speed. An EGCP-3 LS’s Frequency Trimmer function may be programmed to hold frequency within +.1% of the desired frequency. Inlet header pressure (Cascade control) can be enabled any time after the utility tie and generator breaker contacts are closed. Cascade control can be enabled through a programmed contact, a Modbus command, or the 505’s service panel. Woodward 43 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Example 6–Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode Figure 3-6. Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode This application utilizes multiple turbine generators, and requires that all units have the capability to control different plant parameters depending on the status and health of each unit. Normal operation is to have one unit control plant process steam (turbine exhaust pressure) and the other units be controlled based on plant import/export demand. Other applications may or may not utilize all the functionality shown in Figure 3-6 and described below. 44 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators For this application one unit at a time, based on system, health is used to control plant process steam. The other units are used to control a plant export power level of 5 MW. Because the plant is contractually obligated to provide this level of power to the utility, and because it is more economical to make power than purchase it form the utility, a 5 MW plant export power level is desired. Each unit control panel has a mode selection switch which allows an operator to place a unit in one of three different modes of operation. The three modes of operation are Manual load (used to manually load and unload a unit), Plant Process Steam control (turbine exhaust pressure), and Loadsharing (used for plant import/export control or unit loadsharing). When a unit is switched to a Manual load control mode, its 505’s internal load setpoint determines unit load. This allows an operator to manually load or unload a unit to a set level if desired. With this application when a unit is switched to the Plant Process control mode, turbine exhaust pressure control is performed within the 505 through the Cascade PID controller. This is an ideal controller for this type of function because it can be enabled and disabled as desired by a system operator. This gives a system operator full authority of when to transfer process pressure control to or from a letdown station or turbine bypass valve. To save buying a Real Power Sensor, turbine inlet valve position (505 LSS bus) is used to sense unit load, not a generator load signal. With this configuration, 100% governor valve position, is considered to be 100% unit load, no matter what the system conditions. Thus unit overload protection is only performed by limiting the 505’s output to 100%. Optionally, a Real Power Sensor could be used with this application to sense generator power, and allow true unit load to be sensed, controlled and limited. This application uses Woodward EGCP-3 LSs and a MSLC to allow all units to communicate, share plant load, and control plant export power. The EGCP-3 LS is used on each unit, for synchronization and loadsharing. One Master Synchronizer & Load Control is used for plant synchronization and import/export power control. When a unit is in the Loadsharing mode, the MSLC determines its load with the plant-to-utility tie line is closed, and the EGCP-3 LS’s loadsharing circuitry when the plant-to-utility tie line is open. The MSLC, when enabled, sets the load setpoint of each unit EGCP-3 LS (in the Loadsharing mode) to control a plant export level. When the plant-to-utility tie breaker is open, the MSLC is disabled, and each unit communicates with the other units in the Loadsharing mode via the EGCP-3 LS’s LON network to share plant load. An EGCP-3 LS interfaces to a 505 through an analog input signal. The 505’s Analog Input #6 is the only analog input directly compatible with the EGCP-3 LS, thus it is required that this input be programmed to receive the EGCP-3 LS’s Speed Bias signal. When a Sync/LD Share analog input is programmed, the input is automatically enabled if the generator breaker input is closed and the utility tie breaker input is open. Before the generator breaker is closed, the 505’s Sync/Ld Share analog input can be enabled, to allow automatic synchronization by the EGCP-3 LS. This synchronizing function/input can be enabled, through a contact input, function key, Modbus command, or the 505 service panel. As shown in Figure 3-6 a panel mounted (DPST) switch is used, with this application, to select automatic synchronization in both the EGCP-3 LS and 505. Woodward 45 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 All 505 PID controller setpoints (Speed, Cascade) may be changed through programmed raise and lower contacts, programmed 4–20 mA inputs, Modbus commands, or the 505 service panel. The following list of notes are provided as a reference for application programmers to follow when programming the 505 to achieve any control and limiting actions shown in Figure 3-6. 505 Configuration Notes for Example 6 Operating Parameter: This is a Generator application. (Generator Application? Yes) Generator and Utility Tie breaker contact inputs are required to be programmed when a generator application is selected. (Contact Input #1 Function: Generator Breaker), (Contact Input #2 Function: Utility Tie Breaker). Generator load is limited by the Speed PID sensing governor valve position through its LSS bus, and programmed by not selecting KW Droop. (Use KW Droop? No) For good response and load adjustment resolution, Droop (LSS bus position) was set to 5% of rated speed. (Droop = 5 %) It was desired to switch to Frequency/Loadsharing control at all times, if the plant becomes isolated from the Utility bus. (Use Freq Arm/Disarm? No) Cascade Control: The Cascade control loop was configured to receive an exhaust header pressure signal through Analog input #1. (Analog Input #1 Function: Cascade Input) Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR10 installed. A contact input was programmed to allow an operator to easily enable and disable Cascade control via a control panel switch. (Contact Input #3 Function: Casc Control Enable). Exhaust header pressure is directly proportional to turbine inlet valve position, thus no input inversion is required. (Invert Cascade Input? No) With this application, Setpoint Tracking is used to allow the 505’s Cascade control, when disabled, to track exhaust header pressure being controlled by a letdown station. (Use Setpoint Tracking? Yes) To protect the generator from being reverse powered by the Cascade PID, the ‘Speed Setpoint Lower Limit’ value was set to 5 rpm above synchronous speed. In this case, because the Cascade PID, during normal operation, is not sharing control of the exhaust header pressure with another control, Droop is not needed. (Cascade Droop = 0%) 46 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Gen Load Limiting: To limit generator load to 100% the Speed setpoint maximum limit was set at the 100% load setting. 5% Droop was programmed for this application. (Max Governor Speed Setpoint = Rated Speed X 1.05) Sync & Load Sharing: The 505’s Analog input #6 was programmed to receive the EGCP-3 LS’s speed bias signal for automatic synchronization and loadsharing (Analog Input #6 Function: Sync/Load Share input). or best performance, the analog input’s range is defaulted to a certain gain value, thus the input’s 4 mA and 20 mA settings are not used and do not require programming. A contact input is programmed to enable the Sync/Load Share analog input before the generator breaker is closed to enable synchronizing through the EGCP-3 LS (Contact Input #4 Function: Sync/Ld Share Enable). Starting and Run Mode Notes for Example 6 Starting and ramping to an idle or minimum speed position can be performed automatically, semi-automatically, or manually. After the unit is started, the Idle/ Rated or Auto Start Sequence functions, if programmed, can be used to assist ramping the control to a rated speed position. Alternatively, an operator can give a manual raise command to increase turbine speed as desired. After the unit has been started and is controlling at a rated speed position, the turbine generator can be synchronized manually, or automatically. The system operator can select automatic synchronization through the Auto-Synch select switch (SW1 in Figure 3-6). When this switch is closed the 505’s Synchronizing input is enabled and the EGCP-3 LS’s automatic synchronizing function selected. With this configuration the mode of operation the system operates in is dependent on SW2’s position. When SW2 is not selecting the Loadsharing mode, and the generator breaker is closed, unit load is set by the 505’s internal Speed/load setpoint, or the Cascade PID if enabled. Upon the generator breaker closing, the 505 steps the speed/load setpoint up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load setpoint and is defaulted to 3%. The defaulted value is adjustable through the 505’s Service mode (Breaker Logic–Min Load Bias = 5). After synchronization the 505’s load setpoint can be positioned through raise and lower speed/load setpoint contacts, a programmed 4–20 mA input, Modbus commands, or the 505 service panel. Cascade control (turbine exhaust pressure) can be enabled at any time after the utility tie breaker and generator breaker input contacts are closed. The Cascade control can be enabled through a programmed contact, Modbus command, or the 505 service panel. When SW2 is switched to select Loadsharing, the EGCP-3 LS bumplessly ramps load to match the MSLC’s load setpoint, or to a load setting determined by the EGCP-3 LS’s loadsharing circuitry, depending on utility-to-tie breaker position. The MSLC can be used to set all the units in the Loadsharing mode to a base load setting, or vary their load based on a plant import/export demand setting. Woodward 47 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 With this application, during normal operation, one unit is switched to control plant process steam and the other units are switched to the loadsharing mode and are loaded based on the MSLC plant load demand. If the plant should become isolated from the utility, the MSLC will become disabled and all units in the loadsharing mode will share plant load. When desired the MSLC can be enabled to re-synchronize the plant bus to the utility bus and close the plant-toutility tie breaker. After synchronization the MSLC will either ramp plant power to a 5 MW export power level, or ramp plant load to a base load setting, depending on the mode of operation selected. Woodward EGCP-3 LSs can interface directly with a unit’s automatic voltage regulator. This allows units with EGCP-3 LSs to share reactive power as well as real power. This configuration also allows the MSLC to control plant power factor when the utility to tie breaker is closed. Example 7–Induction Generator Applications When the 505 is configured for induction generator applications, typically there are only two differences in the programming of the 505 verses programming for synchronous generator applications. The induction generator’s slip frequency must be taken into account. This is achieved by compensating for the slip frequency with the 505’s maximum Speed Setpoint setting. The ‘MAX GOVERNOR SPEED SETPOINT’ setting must be equal to synchronous speed plus the droop percentage plus the full load slip frequency percentage. 1. MAX GOVERNOR SPEED SETPOINT = SYNC SPEED + (SYNC SPEED * DROOP) + MAX SLIP rpm. 2. The USE TIE BREAKER OPEN TRIP setting must be set to “Yes” if a synchronous generator is not sharing the same plant bus. This will cause the generator to trip when the utility tie breaker opens. 48 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Chapter 4. Operator Interface Introduction Interface to the control may be performed through the 505’s service panel (located on the front of the control), remote switch contacts, analog inputs, meter readouts, relays, or a Modbus communications line to an operator interface device. Screen Tutorial The 505 has a detailed Tutorial that is always accessible through the Service Menu. It provides ‘On-Screen’ help on topics such as Navigation, User Levels, Operating Modes, how to adjust parameters and more. The User should familiarize themselves with these screens Graphical Display and Key Inputs The control’s service panel consists of hard key command buttons, soft key command buttons, and a Graphical User Interface screen. Figure 4-1 505 Keypad and Display The system operator uses the service panel to communicate with the 505 system. The service panel can be used only occasionally to communicate with the system, or it can continuously monitor user interface pages for the operator to view. Woodward 49 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Service Panel Modes and User Levels The 505 Service Panel operates in several modes and access user levels, each of which has a different purpose. The modes are: OPERATION, CALIBRATION, and CONFIGURATION. In order to enter and exit a particular mode, the user must be logged in with an appropriate user level. These user levels are: MONITOR, OPERATOR, SERVICE, and CONFIGURE. In addition to granting authority to enter and exit modes, user levels also determine what parameters the user is authorized to adjust. See table 4-1, Mode Access by User Level. Table 4-1 Mode Access by User Level Operation Mode Calibration Configuration Monitor User Level Operator X Service X X Configure X X X Mode Descriptions The OPERATION mode is the only mode that can be used to run the turbine. This is the default mode. Exiting CALIBRATION or CONFIGURATION mode will return to OPERATION mode. User levels: Operator, Service, or Configure. The CALIBRATION mode is used to force signal outputs in order to calibrate signals and field devices. In this mode, the actuator, analog, and relay outputs can be manually controlled. To enter this mode the turbine speed must be shutdown with no speed detected. User levels: Service or Configure. The CONFIGURE mode is used to set up the parameters for a specific application prior to operation of the unit. To enter this mode the turbine speed must be shutdown with no speed detected. When the unit enters CONFIGURE mode the control is placed in IOLOCK which will disable all Output I/O channels. If the control is not shutdown, navigating through the configuration pages will allow viewing of CONFIGURE, but will not permit any changes to be made. User Level Descriptions The Monitor user level is view-only access. All commands from the front panel are inhibited. All values displayed on each screen are continuously updated. The Operator user level allows for control of the turbine. Front panel commands to start, change setpoints, enable/disable functions, and stop the turbine are accepted. The Service user level allows the same commands as the Operator user level plus tuning of Service menu parameters and issuing of additional commands.. The Configure user level allows the same commands and access as the Service user level plus tuning of Configuration menu parameters. 50 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Adjusting Values To adjust a value you first navigate the In-Focus highlighter to the correct value – then use the green Adjust Key to raise or lower the value. The ADJUST arrows will change a selected Service parameter by 1%. Using the ADJUST arrows in combination with the SHIFT key will change the service parameter by 10%. The view of the Adjust button icon next to the value will change to show the up/down arrows as filled when the SHIFT key is pressed. When making adjustments to an analog value that is at 0.00, initial movement will be very small and you may take a few seconds for the display to show the value is moving – be patient. To make a direct entry, the current displayed value must be within 10% of the value to be entered. To make direct numeric entries: 1. 2. 3. 4. Bring the displayed value to within 10% of the value to be entered Press the ENTER key Press the numerical keys to input the value Press ENTER again. If the value entered is less than the value displayed by more than 10% or greater than the value displayed by more than 10%, an appropriate message will be displayed indicating the value entered is too large or too small. The exception to this 10% adjustment rule is that it is NOT applied if the control is in Configuration Mode. In this mode any direct entry in the appropriate range will be accepted. When making a direct entry of a negative number (for example, a sensor range of –50 to 200), enter the value first and then press the +/– key. When using the SERVICE mode, refer to the Service Mode worksheet in Appendix B. Woodward 51 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Chapter 5. Service Menu Procedures Overview The service menu of the 505 control has the same easy to follow format as the program/configure mode. The service menus can be used to customize the control to be more application specific. The parameters that are tuned in the service menus may affect system performance, caution is advised. The service menus of the 505 can be accessed at any time the control is powered up, and with any user level access. The turbine doesn’t need to be shutdown. This will allow tuning while the turbine is on-line. The ability to change these parameters is restricted to service user level and above. The appropriate password is required to protect against both intentional and inadvertent program changes. The password can be changed if desired, refer to Appendix C of this manual for information on changing passwords. Enter the LOGIN button from the MODE screen to reach the screen below. Figure 5-1. User Login for Service To login to the Service user level, Press the MODE key, press the soft key for LOGIN, and log in as “Service” by entering the password (WG1112). The actual menus that are available may vary with the program configuration. Using the Service Menus Once logged in with an appropriate user level, parameters within the Service menus will become available for adjustment. See Figure 5.2 for an example of how to visually see that a parameter is authorized. A work sheet is provided at the end of this manual, to document any changes for future reference. 52 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 5-2. Authorized and Unauthorized Components The arrow keys (STEP LEFT, STEP RIGHT) allow you to move right or left across the tops of the function the Service mode columns. The STEP UP and STEP DOWN keys allow you to move up or down the columns. Not all of the service headers listed below will appear at all times. Only the headers that are necessary for the application will appear. Some of the headers will not appear unless the turbine is shutdown. The Service menu is accessed from the Home screen by pressing the second soft key (from the left). Use the navigation cross allows for navigation of the Service menus. Press ENTER to go into a menu. There are two Service menu selection pages which can be viewed by pressing the arrow soft keys. The menus that are available depend on the configuration of the unit. Parameters within the Service menus can be adjusted at any time, independent of the current Mode. The user must be logged in with Service user level access or higher to have authorization to change Service parameters. From within a Service menu, pressing the HOME key once will return to the Service menu screen. To return to the main Home screen, press the HOME key again. To return to the last screen, press the ESC key. Service Menus – HOME screen The following figures show the menu list of pages that are available through the Service Menus. The Tutorial pages and the Save Settings (updating tunable values on the control) are always available on the black SoftKey buttons without any focus or navigation. Features that exist in the control, but are not configured will be shown in reduced opacity so the user is aware of the feature. Pressing Enter while on these pages will not navigate to these pages. This is different than the HOME page, where unused functions are completely removed to avoid confusion and simplify navigation. Woodward 53 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure 5-3 Service Menu (page 1) Figure 5-4 Service Menu (page 2) The service menus can be used while the engine/turbine is running or shut down. Access to the Service menus requires the user to be logged in with a Service user level or higher. The intent of the organization and arrangement of the pages is that page 1 contains the page that directly relate to the previous 505 Service header menus on the 2 line display. Page 2 contains features that are new with this product. This mode can also be used to make direct numeric entries. However, because this mode is intended to be used while the turbine is running, the Service Panel will accept the entry of numeric values for a block only if the proposed change is small. 54 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Service Menu list: Speed Control—monitor or change the program or default settings of; rate to min; setpoint slow rate; delay for the fast rate; setpoint fast rate; speed setpoint entered rate; underspeed setting; on-line and off-line derivative; Remote Speed Settings - change the program or default settings of; not matched rate; speed setpoint max rate; min speed setpoint; max speed setpoint; remote deadband value; lag-tau value; Valve Limiter Settings—monitor or change program or default settings of; valve limiter rate; entered rate; limiter max limit; MPU Override Settings—monitor or change program or default settings of; MPU override timer; MPU override time; MPU (s) override timer is on; Idle/Rated Ramp Settings—change the program or default settings of; idle rated rate; use ramp to idle; idle priority; Auto Start Sequence—monitor the status of; low idle delay; rate to hi idle; hi idle delay; rate to rated; hrs since trip; Pressure Compensation – Set system gain compensation vs inlet pressure points; view current system gain; Breaker Logic—change the program or default settings of; freq cntrl armed; sync window rpm; sync window rate; tie breaker open ramp; tie open rate; gen open setback; gen open setpoint; use min load; min load bias; Sync/Load Share—change the program or default settings of; input bias gain; input bias dead band; lag-tau value; Speed Droop—change the program or default settings of; droop percentage; use KW droop; select gen load units; Auxiliary Control—change the program or default settings of; slow rate; fast rate delay; setpoint fast rate; setpoint entered rate; droop % ; rated aux setpoint; aux derivative ratio; aux threshold; Remote Auxiliary—change the program or default settings of; remote not matched rate; remote aux max rate; min remote aux setting; max remote aux setting; remote dead band value; lag-tau value; Auxiliary 2 Control Settings—change the program or default settings of; slow rate; fast rate delay; setpoint fast rate; setpoint entered rate; droop % ; rated aux setpoint; aux derivative ratio; aux threshold; Remote Auxiliary 2 Settings—change the program or default settings of; remote not matched rate; remote aux max rate; min remote aux setting; max remote aux setting; remote dead band value; lag-tau value; Cascade Control—change the program or default settings of; slow rate; fast rate delay; setpoint fast rate; setpoint entered rate; droop %; rated cascade setpoint; cascade not matched rate; max speed rate; max speed setting; min speed setting; cascade dead band; cascade derivative ratio; Remote Cascade Settings—change the program or default settings of; remote not matched rate; remote cascade max rate; min remote cascade Modbus connections. Communications—change or view the default settings for Ethernet, Serial, and Modbus communication links. Woodward 55 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Local/Remote—monitor or change the program or default settings of; remote ennobled; enable contacts; contacts enabled; enable Modbus 1; Modbus 1 enabled; enable Modbus 2; Modbus 2 enabled; Key Options—allow or disable controlled stop and dynamics adjustments; Alarms—monitor or change the program or default settings of; is trip an alarm indication; blink alarm relay; jump to alarm screen; configurable alarms 1,2, and 3; configurable alarms for inlet pressure, exhaust pressure, and valve demand vs position feedback; Actuator Linearization—provides actuator 1 and actuator 2 output linearization adjustments; Real Time Clock – set date and time settings. Custom Trend – trend display; signal selection; time window for trend display. Data Log – manually start and stop data log collection. Operation Values – view operation log values. Adjust turbine operation values. Isolated Process Control – adjust setpoint; view process value; view demand output; enable manual valve control; enable remote setpoint; adjust Isolated PID gains; Screen Settings – screen saver delay; select auto login as operator; Custom Trend – View control parameters on a graphical display. VariStroke II – CAN communication status; demand; position feedback; alarms; shutdowns; Manual Demand – Select manual valve demand usage; manual demand rate; timeout when inactive; Acceleration Limiter – Select acceleration limiter usage; adjust acceleration limiter PID gains; DSLC-2 – generator voltages, currents, real power, reactive power; communications link status LS-5 – generator voltages, currents, real power, reactive power; CAN communication status MFR300 - – generator voltages, currents, real power, reactive power; CAN communication status Each of the Service menu parameters are described in detail below. 56 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Service Mode Parameters Speed Control Settings RATE TO MIN (RPM/S) dflt= xxx (0.01, 2000) Adjusts the rate the set point moves from zero to the minimum controlling speed when the unit is started. The minimum controlling speed will be either ‘idle’ if idle/rated is used or ‘low idle’ if the auto start sequence is used. If neither of these startup features is used, the min speed will be the minimum governor speed set point. This value is set in the program mode. SLOW RATE OFFLINE (RPM/S) dflt= xxx (0.01, 500) Normal speed set point rate of change while in the OFFLINE mode of operation. This value is set in the program mode. SLOW RATE ONLINE (RPM/S) dflt= xxx (0.01, 500) Normal speed set point rate of change while in the ONLINE mode of operation. This value is set in the program mode. FAST RATE DELAY (SEC) dflt= 3.0 (0, 100) Delay, in seconds, before the Setpt ‘Fast Rate’ ONLINE/OFFLINE is selected. FAST RATE OFFLINE (RPM/S) dflt= xxx (0.0099, 500.0) This rate is defaulted to three times (3x) the ‘Slow Rate OFFLINE’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. FAST RATE ONLINE (RPM/S) dflt= xxx (0.0099, 500.0) This rate is defaulted to three times (3x) the ‘Slow Rate ONLINE’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. OVERSPEED RATE (RPM/S) dflt= xxx (0.0099, 500.0) This rate is defaulted to the ‘Slow Rate OFFLINE’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. ENTERED RATE OFFLINE (RPM/S) dflt= xxx (0.0099, 500.0) This is the rate that the Speed set point will move when set point is entered from the front panel of the control or from the communication links while in the OFFLINE mode of operation. This rate is defaulted to the Slow RATE OFFLINE. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. ENTERED RATE ONLINE (RPM/S) dflt= xxx (0.0099, 500.0) This is the rate that the Speed set point will move when set point is entered from the front panel of the control or from the communication links while in the ONLINE mode of operation. This rate is defaulted to the S RATE ONLINE. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. UNDERSPEED SETTING (RPM) dflt= xxx (0.0, 20000) Only used if an underspeed relay is programmed. Speed setting for the underspeed indication. This rate is defaulted to 100 rpm below the ‘Minimum Governor Speed Setpt’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. ONLINE SPEED DEADBAND dflt= 0.0 (0.0, 20.0) When configured as a mechanical drive unit (not a Generator Application), this is the value of a speed deadband that can be configured in RPM. For a generator application, see ‘Frequency Deadband’ in the “Breaker Logic” Service menu. Woodward 57 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 EMERGENCY MINIMUM LOAD RATE dflt= 50.0 (2.0, 10000.0) When Emergency Minimum Load is triggered this is the rate, in RPM/s, that will be used to go to minimum load. DISPLAY GAUGE MULTIPLIER dflt= 1.0 (0.01, 1000.0) This allows scaling of the number for display on the gauge on the 505 runtime screen for this controller. If the number is too big or small to be displayed correctly or as desired, us this setting to multiply by a factor of 10. HOLD SPEED CHANGES ? dflt= NO (Yes/No) Set to YES to permanently Hold the changes made to the Set Point Fast Rate, the Entered Rate, and Underspeed settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Remote Speed Settings (only displayed if configured) Note: Available as the last page of the “Speed Control” Service menu. NOT MATCHED RATE dflt= xxx (0.0099, 200.0) Rate the set point moves when remote is enabled and the remote input doesn’t match the actual set point. This rate is defaulted to the set point slow rate. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. SPEED SETPOINT MAXIMUM RATE dflt= xxx (0.01, 500) Rate the setpoint moves once the remote input and actual set point are matched. This is a maximum rate. Normally the setpoint will follow the remote input setting. This value is set in the configure mode. MINIMUM SPEED SETPOINT dflt= xxx (0.0, 20000) Minimum setting allowed by the remote input. This setting is defaulted to the Speed Setpoint Minimum Governor Speed value. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Governor Speed’ and the ‘Maximum Governor Speed’ settings) MAXIMUM SPEED SETPOINT dflt= xxx (0.0, 20000) Maximum setting allowed by the remote input. This setting is defaulted to the Speed Setpoint Maximum Governor Speed value. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Governor Speed’ and the ‘Maximum Governor Speed’’ settings and greater than Minimum Speed Setting) REMOTE DEADBAND VALUE dflt= 0.0 (0.0, 100) Remote speed setting deadband in RPM. REMOTE LAG-TAU VALUE dflt= 0.0 (0.0, 10) Remote Set Point input lag setting. USE MINIMUM LOAD ? dflt= YES (Yes/No) When set to YES, the speed set point cannot be lowered/decreased by the remote speed set point input below the rated/synchronous speed set point plus the ‘Min Load Bias’ setting. This is used to prevent a reverse power condition as well as allowing the plant to utilize a minimum load setting for the generator. When NO, the remote speed set point can move the speed set point down to the higher of the minimum governor setting or the RSS 4 mA value. HOLD REMOTE CHANGES ? dflt= NO (Yes/No) Set to YES to permanently hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Speed Settings. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. 58 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Valve Limiter Settings LIMITER RATE (%/SEC) dflt= xxx (0.1, 25) The rate at which the valve limiter will move when a raise or lower command is given from the contact inputs or the Modbus connections. This rate is set in the program mode. ENTERED RATE (%/SEC) dflt= xxx (0.1, 100) This is the rate the valve limiter will move at when a new position is entered from the front panel of the control. This rate is defaulted to the slow rate. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. LIMITER MAXIMUM LIMIT (%) dflt= 100.0 (0, 101) Valve Limiter Maximum setting. Normally set to 100%, but this can be set lower to provide a maximum valve lift setting. HP MAXIMUM VALUE AT STARTUP (%) dflt= 100.0 (0, 101) During start up this would restrict the opening of the HP valve to the desired value. SHUTDOWN AT MAXIMUM ? dflt= NO (Yes/No) When set to YES, the control will issue a shutdown whenever the HP ramp exceeds the HP maximum value at startup. When set to NO, this function is disabled. HOLD LIMITER CHANGES ? dflt= NO (Yes/No) Set to YES to Hold the changes made to the Entered Rate. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. MPU Override USE MPU OVERRIDE TIMER ? dflt= NO (Yes/No) When set to YES, the MPU override will go OFF when the MPU Override Time expires after a start is initiated. This provides a maximum time for speed to be sensed on startup before a loss of speed is detected. MPU OVERRIDE TIME (SEC) dflt= 600.0 (0.0, 600) Sets the maximum time after a start is initiated for speed to be sensed above the failure level. Only valid if ‘Use MPU Override Timer?’ is YES. MPU #1 OVERRIDE ON STATUS (status indication only) Indicates when the speed probe failure override is on. MPU #2 OVERRIDE ON STATUS (status indication only) Indicates when the speed probe failure override is on. This status message only appears if the application is using two speed probes. Idle/Rated Ramp (only displayed if configured) HOURS SINCE TRIP (HRS) (status indication only) Indicates the number of hours the unit was tripped, as determined by the control. HOT RESET TIMER dflt= 0 (0.0, 200) Use this to adjust the “Hot Reset Timer” value set in Configuration. This is the time needed, when RST Timer level is reached, to transfer the start-up parameters from COLD to HOT. IDLE/RATED COLD RATE (RPM/S) dflt= xxx (0.01, 2000) Rate at which the speed set point will ramp from idle to rated speed when the turbine is considered COLD. This value is set in the program mode. IDLE/RATED WARM RATE (RPM/S) dflt= xxx (0.01, 2000) Rate at which the speed set point will ramp from idle to rated speed when the turbine is considered WARM. This value is set in the program mode. Woodward 59 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 IDLE/RATED HOT RATE (RPM/S) dflt= xxx (0.01, 2000) Rate at which the speed set point will ramp from idle to rated speed when the turbine is considered HOT. This value is set in the program mode. USE RAMP TO IDLE ? dflt= YES (Yes/No) Set to YES if want to return to idle speed with this function. If set to NO, the Idle/ Rated function acts as a ‘Ramp to Rated’ function and will not return to idle. When set to NO, closing the Idle/Rated contact accelerates the speed set point towards Rated and opening the contact stops the acceleration. IDLE PRIORITY ? dflt= NO (Yes/No) If YES, the set point will move to Idle whenever Idle is selected. If NO, the set point will move to Idle only if Remote Speed Set Point is not enabled, Cascade control is not enabled, Auxiliary ‘controller’ is not enabled, and the Generator Breaker is open. RATED PRIORITY ? dflt= YES (Yes/No) If YES, the Rated command will be allows to move the setpoint to Rated before reaching Idle. If NO, the set point will move to Idle and then the Rated command should be given to move to Rated; the Rated command will not be accepted before reaching Idle. Auto Start Sequence (only displayed if configured) The following information is provided to display the information useful to the auto start sequence. It allows the operator to check all the times and rates that the 505 is using for the present start sequence. HOURS SINCE TRIP (HRS) (status indication only) Indicates the number of hours the unit was tripped, as determined by the control. HOT RESET TIMER dflt= 0 (0.0, 200) Use this to adjust the “Hot Reset Timer” value set in Configuration. This is the time needed, when RST Timer level is reached, to transfer the start-up parameters from COLD to HOT. HOT RESET TIME REMAINING (status indication only) This shows the remaining time for the Hot Reset Timer. When the time is complete, all turbine start parameters will be using the HOT start values. HOT TIME REMAINING (status indication only) This shows the time remaining, after the unit is shut down, until the HOT start values begin ramping to the COLD start values. TIME UNTIL COLD START (status indication only) This shows the time remaining, after the unit is shut down, until the turbine will be considered cold and the COLD start values will be used. RATE TO RATED (RPM/S) (status indication only) Indicates the acceleration rate, in rpm/s; used by the control from High Idle to Rated. IDLE 1 DELAY (MIN) (status indication only) Indicates the hold time at Idle 1, in minutes. RATE TO IDLE2 (RPM/S) (status indication only) Indicates the acceleration rate, in rpm/s; used by the control from Idle to Idle2. IDLE2 DELAY (MIN) (status indication only) Indicates the hold time at Idle 2, in minutes. RATE TO IDLE3 (RPM/S) (status indication only) Indicates the acceleration rate, in rpm/s; used by the control from Idle2 to Idle3. IDLE3 DELAY (MIN) (status indication only) Indicates the hold time at Idle 3, in minutes. 60 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Pressure Compensation (only displayed if configured) The pressure compensation setting are used to bias the actuator 1 (V1) position based on inlet pressure. Pressure 1 dflt= *0.0 (0.0, 10000.0) Input point #1 of the pressure compensation curve, in engineering units. (Must be less than the ‘Pressure 2’ value) Gain 1 dflt= *1.0 (0.65, 1.54) Output point #1 of the pressure compensation curve. Pressure 2 dflt= *25.0 (0.0, 10000.0) Input point #2 of the pressure compensation curve, in engineering units. (Must be between the ‘Pressure 1’ value and the ‘Pressure 3’ value settings) Gain 2 dflt= *1.0 (0.65, 1.54) Output point #2 of the pressure compensation curve. Pressure 3 dflt= *50.0 (0.0, 10000.0) Input point #3 of the pressure compensation curve, in engineering units. (Must be between the ‘Pressure 2’ value and the ‘Pressure 4’ value settings) Gain 3 dflt= *1.0 (0.65, 1.54) Output point #3 of the pressure compensation curve. Pressure 4 dflt= *75.0 (0.0, 10000.0) Input point #4 of the pressure compensation curve, in engineering units. (Must be between the ‘Pressure 3’ value and the ‘Pressure 5’ value settings) Gain 4 dflt= *1.0 (0.65, 1.54) Output point #4 of the pressure compensation curve. Pressure 5 dflt= *100.0 (0.0, 10000.0) Input point #5 of the pressure compensation curve, in engineering units. (Must be greater than the ‘Pressure 4’ value) Gain 5 dflt= *1.0 (0.65, 1.54) Output point #5 of the pressure compensation curve. Breaker Logic (only displayed if a generator) FREQUENCY CONTROL ARMED (status indication only) Displays when Frequency Control is activated for isochronous control. If not, then the control will be in droop. See Frequency Control description in volume 1 of the manual for details. SYNC WINDOW (RPM) dflt= 10.0 (0.0, 200) A set point window, in rpm, that the set point moves at a slower rated to accommodate synchronizing to the bus. This rate is only active while within this window and the generator breaker is open. SYNC WINDOW RATE (RPM/S) dflt= 2.0 (0.1, 100) The rate the speed set point moves at when within the ‘Sync Window’ and the generator beaker is open. This is normally slower than the slow rate to accommodate synchronizing to the bus. TIEBRKR OPEN RAMP ? dflt= YES (Yes/No) If NO, the speed set point is instantly set to the last utility bus speed setting and holds. When set to YES, the speed set point is instantly set to the last utility bus speed setting and moves to the synchronous (rated) speed set point after the utility tie breaker opens and the generator breaker is still closed. TIE OPEN RATE (RPM/S) dflt= 1.0 (0.099, 20000.0) Rate the set point moves to rated speed after the utility tie breaker opens (only used if ‘Tiebrkr Open Sync Ramp’ is YES). Woodward 61 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 GEN OPEN SETPOINT (RPM) dflt= xxx (0.0, 20000) This set point is defaulted to 50 rpm below the synchronous (rated) speed set point (only used if ‘Gen Breaker Open Setback’ is YES). This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Governor’ and ‘Rated Speed Setpt’ settings) ZERO LOAD VALUE (HP Valve %) dflt= xxx (0.0, 100) This value is automatically sampled and held at the actuator/load demand value when the generator breaker is closed. When the steam conditions are not at rated conditions when the breaker is closed, this value can be adjusted to a more reasonable value (2–10%). Every time the generator breaker closes, this value is re-sampled. USE MINIMUM LOAD ? dflt= YES (Yes/No) When set to YES, the speed set point automatically increases to the rated/synchronous speed set point plus the ‘Min Load Bias’ setting when the generator breaker is closed and the unit is on-line (the utility tie breaker is closed). When NO, no automatic set point action occurs. MINIMUM LOAD BIAS (RPM above Rated) dflt= xxx (0.0, 500) This value is the rpm bias above rated speed and the default is calculated as 3% of full load. This is the value the speed set point will increase to upon the generator breaker closure (when the utility tie is closed). MAX SPD ON LOAD dflt= 250.0 (250.0, 20000.0) This the speed level above the rated speed at which the acceleration detection will be activated when the acceleration is high. FREQ OFFSET (Hz) dflt= 0.0 (-2.5, 2.5) This is the deviation, in Hz, from the configured rated speed of 50/60 Hz. It allows the center of the deadband to be adjusted for grid frequencies that are not exactly at 50 or 60 Hz. For example, if rated speed is 3600 rpm = 60 Hz, but the grid is actually running at 60.1 Hz, then this value can be tuned to 0.1 Hz so that the deadband in the 505 will be at 3606 rpm, the actual “speed” of the grid. FREQ Deadband (Hz) dflt= 0.0 (0.0, 3.0) This is the dead band in Hz used during the droop mode of operation to avoid HP valve oscillations. It will allow frequency to vary a certain amount, plus or minus the configured value, from the configured rated speed before the control reacts by moving the valve. HOLD BREAKER CHANGES ? dflt= NO (Yes/No) Set to YES to permanently Hold the changes made to the Gen Breaker Open Set Point and Min Load Bias. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Sync/Load Share Settings (only displayed if configured) INPUT BIAS GAIN (%) dflt= xxx (0.0, 100) Affects the rpm bias the Sync/Load Sharing input has on the speed setting. This setting is defaulted to the Droop (%) value or 3%, whichever is higher. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. 62 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Note that the Input Bias Gain affects both the Synchronizing and Load Sharing functions if configured. A feature has been added to make the Synchronizing input 5 times less sensitive than the load sharing input. Therefore, to avoid instability in load sharing mode, the Input Bias Gain should be tuned for the load sharing mode. If load sharing is not used, this note can be disregarded. INPUT BIAS DEADBAND dflt= 0.0 (0.0, 100) Load Share dead band in rpm. LAG-TAU VALUE dflt= 0.0 (0.0, 10) Load Sharing input lag setting. HOLD CHANGES ? dflt= NO (Yes/No) Set to YES to permanently hold the changes made to the Load Share Gain (%). To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Speed Droop (only if generator unit) ACTUAL DROOP (%) (status indication only) Shows the actual Speed/load control droop being used by the controller. MINIMUM DROOP (%)? dflt= 0.0 (0.0, 4.0) When setting the droop from the keypad this defines the minimum droop value that can be set. MAXIMUM DROOP (%)? dflt= 12.0 (2.0, 15.0) When setting the droop from the keypad this defines the maximum droop value that can be set. USE MW AS LOAD UNITS? dflt= No (Yes/No) When set to Yes, the control will use and display MW as the load units. When set to No, the control will use and display KW as the load units. USE LOAD DROOP ? dflt= YES (Yes/No) When set to NO, the unit is forced to use speed demand/actuator position droop. This setting is used and relevant if Load Droop was programmed. ENTERED DROOP SETPOINT (%) dflt= 5.0 (min, max) When setting the droop from the keypad this sets the desired droop value for control. Auxiliary Control Settings (only displayed if configured) SLOW RATE (UNITS/S) dflt= xxx (0.01, 1000) Normal set point rate of change. This value is set in the program mode. FAST RATE DELAY (SEC) dflt= 3.0 (0.0, 100) Delay, in seconds, before the ‘Fast Rate’ of change is selected. FAST RATE (UNITS/S) dflt= xxx (0.01, 5000) This rate is defaulted to three times (3x) the ‘Set Point Slow Rate’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. SETPT ENTERED RATE (UNITS/S) dflt= xxx (0.01, 1000) This is the rate that the Aux set point will move when set point is entered from the front panel of the control or from the communication links. This rate is defaulted to the Aux set point slow rate. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. Woodward 63 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 DROOP (%) dflt= xxx (0.0, 100) Aux control droop setting. This value is set in the program mode. RATED AUXILIARY SETPOINT dflt= xxx (-20000, 20000) Only used to determine the auxiliary control Droop. This set point is defaulted to the aux maximum set point limit. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Auxiliary Set Point’ and the ‘Maximum Auxiliary Set Point’ settings) PID THRESHOLD (LIMITER) dflt= 10 (0.0, 110) Aux PID threshold setting when aux is used as a limiter. The value of the Threshold input determines how much error (difference between actual and reference) will be permitted before this block's output goes to 101% (LSS) or –1% (HSS), when this block is not in control of the LSS or HSS bus into which it feeds. It is not advisable to set the Threshold to zero. PID THRESHOLD (CONTROLLER) dflt= 100 (0.0, 110) Aux PID threshold setting when aux is used as a controller. The value of the Threshold input determines how much error (difference between actual and reference) will be permitted before this block's output goes to 101% (LSS) or -1% (HSS), when this block is not in control of the LSS or HSS bus into which it feeds. It is not advisable to set the Threshold to zero. PID MINIMUM OUTPUT dflt= 0.00 (0.0, 50) Auxiliary PID min output setting. The auxiliary PID cannot output a lower value to the LSS. This can be used to stop the aux PID from taking the LSS low enough to take the unit off-line or below min governor. DISPLAY GAUGE MULTIPLIER dflt= 1.0 (0.01, 1000.0) This allows scaling of the number for display on the gauge on the 505 runtime screen for this controller. If the number is too big or small to be displayed correctly or as desired, us this setting to multiply by a factor of 10. HOLD AUXILIARY CHANGES ? dflt= NO (Yes/No) Set to YES to permanently Hold the changes made to the Set Point Fast Rate, Entered Rate, and Rated Aux Set Point. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Remote Auxiliary Settings (only displayed if configured) Note: Available as the last page of the “Auxiliary Control” Service menu. REMOTE NOT MATCHED RATE dflt= xxx (0.01, 1000) Rate the set point moves when remote is enabled and the remote input doesn’t match the actual set point. This rate is defaulted to the ‘Aux Set Point Slow Rate’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. REMOTE AUXILIARY MAXIMUM RATE dflt= xxx (0.01, 1000) Rate the set point moves once the remote input and actual set point are matched. This is a maximum rate. Normally the set point will follow the remote input setting. This value is set in the program mode. MINIMUM REMOTE AUXILIARY SETPOINT dflt= xxx (-20000, 20000) Minimum setting allowed by the remote input. This setting is defaulted to the Aux Set Point Minimum Value. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Auxiliary Set Point’ and the ‘Maximum Auxiliary Set Point’ settings) 64 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators MAXIMUM REMOTE AUXILIARY SETPOINT dflt= xxx (-20000, 20000) Maximum setting allowed by the remote input. This setting is defaulted to the Aux Set Point Maximum Value. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Auxiliary Set Point’ and the ‘Maximum Auxiliary Set Point’ settings) REMOTE DEADBAND VALUE dflt= 0.0 (0.0, 500) Remote aux setting input dead band in engineering units. REMOTE LAG-TAU VALUE dflt= 0.0 (0.0, 10) Remote Set Point input lag setting. HOLD REMOTE AUXILIARY CHANGES ? dflt= NO (Yes/No) Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Aux Settings. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Auxiliary 2 Control Settings (only displayed if configured) SLOW RATE (UNITS/S) dflt= xxx (0.01, 1000) Normal set point rate of change. This value is set in the program mode. FAST RATE DELAY (SEC) dflt= 3.0 (0.0, 100) Delay, in seconds, before the ‘Fast Rate’ of change is selected. FAST RATE (UNITS/S) dflt= xxx (0.01, 5000) This rate is defaulted to three times (3x) the ‘Set Point Slow Rate’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. SETPOINT ENTERED RATE (UNITS/S) dflt= xxx (0.01, 1000) This is the rate that the AUX 2 set point will move when set point is entered from the front panel of the control or from the communication links. This rate is defaulted to the AUX 2 set point slow rate. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. PID THRESHOLD (LIMITER) dflt= 10 (0.0, 110) Auxiliary 2 PID threshold setting when AUX 2 is used as a limiter. The value of the Threshold input determines how much error (difference between actual and reference) will be permitted before this block's output goes to 101% (LSS) or –1% (HSS), when this block is not in control of the LSS or HSS bus into which it feeds. It is not advisable to set the Threshold to zero. PID MIN OUTPUT dflt= 0.00 (0.0, 50) Auxiliary PID min output setting. The auxiliary PID cannot output a lower value to the LSS. This can be used to stop the aux PID from taking the LSS low enough to take the unit off-line or below min governor. DISPLAY GAUGE MULTIPLIER dflt= 1.0 (0.01, 1000.0) This allows scaling of the number for display on the gauge on the 505 runtime screen for this controller. If the number is too big or small to be displayed correctly or as desired, us this setting to multiply by a factor of 10. HOLD AUXILIARY 2 CHANGES ? dflt= NO (Yes/No) Set to YES to permanently Hold the changes made to the Set Point Fast Rate, Entered Rate, and Rated AUX 2 Set Point. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Woodward 65 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Remote Auxiliary 2 Settings (only displayed if configured) Note: Available as the last page of the “Auxiliary 2 Control” Service menu. When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change. REMOTE NOT MATCHED RATE dflt= xxx (0.01, 1000) Rate the set point moves when remote is enabled and the remote input doesn’t match the actual set point. This rate is defaulted to the ‘AUX 2 Set Point Slow Rate’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. REMOTE AUXILIARY 2 SETPOINT MAXIMUM RATE dflt= xxx (0.01, 1000) Rate the set point moves once the remote input and actual set point are matched. This is a maximum rate. Normally the set point will follow the remote input setting. This value is set in the program mode. MINIMUM REMOTE AUXILIARY 2 SETPOINT dflt= xxx (-20000, 20000) Minimum setting allowed by the remote input. This setting is defaulted to the AUX 2 Set Point Minimum Value. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Auxiliary 2 Set Point’ and the ‘Maximum Auxiliary 2 Set Point’ settings) MAXIMUM REMOTE AUXILIARY 2 SETPOINT dflt= xxx (-20000, 20000) Maximum setting allowed by the remote input. This setting is defaulted to the AUX 2 Set Point Maximum Value. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Auxiliary 2 Set Point’ and the ‘Maximum Auxiliary 2 Set Point’ settings) REMOTE DEADBAND VALUE dflt= 0.0 (0.0, 500) Remote AUX 2 setting input dead band in engineering units. REMOTE LAG-TAU VALUE dflt= 0.0 (0.0, 10) Remote Set Point input lag setting. HOLD REMOTE AUXILIARY 2 CHANGES ? dflt= NO (Yes/No) Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum AUX 2 Settings. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Cascade Control Settings (only displayed if configured) SLOW RATE (UNITS/S) dflt= xxx (0.01, 1000) Normal set point rate of change. This value is set in the program mode. FAST RATE DELAY (SEC) dflt= 3.0 (0.0, 100) Delay, in seconds, before the ‘Setpt Fast Rate’ is selected. SETPOINT FAST RATE (UNITS/S) dflt= xxx (0.01, 5000) This rate is defaulted to three times (3x) the set point ‘Slow Rate’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. 66 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators SETPOINT ENTERED RATE (UNITS/S) dflt= xxx (0.01, 1000) This is the rate that the Cascade set point will move when set point is entered from the front panel of the control or from the communication links. This rate is defaulted to the Cascade set point slow rate. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. DROOP (%) dflt= xxx (0.0, 100) Cascade control droop setting. This value is set in the program mode. RATED CASCADE SETPOINT dflt= xxx (-20000, 20000) This setting is only used to determine the cascade control droop. This set point is defaulted to the cascade maximum set point limit. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Cascade Set Point’ and the ‘Maximum Cascade Set Point’ settings) CASCADE NOT MATCHED RATE dflt= xxx (0.01, 1000) This rate is defaulted to the ‘Speed Set Point Slow Rate’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. MAXIMUM SPEED SETPOINT RATE dflt= xxx (0.1, 100) The maximum rate at which the cascade control can vary the speed set point. This value is set in the program mode. MAXIMUM SPEED SETPOINT dflt= xxx (0.0, 20000) This setting is defaulted to the maximum speed set point value set in the program mode. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Governor Speed’ and the ‘Maximum Governor Speed’ settings) MINIMUM SPEED SETPOINT dflt= xxx (0.0, 20000) This setting is defaulted to the minimum speed set point value set in the program mode. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Governor Speed’ and the ‘Maximum Governor Speed’ settings) CASCADE DEADBAND dflt= 0.1 (0.0, 50) Cascade PID controller integrator deadband setting in percent. RAISE /LOWER CASCADE SETPOINT ONLY ? dflt= NO (Yes/No) When set to NO, the cascade raise/lower commands will adjust the speed set point when cascade control is disabled and adjust the cascade set point when cascade control is enabled. When YES, the cascade raise/lower commands adjust the cascade set point only. USE MINIMUM LOAD ? dflt= YES (Yes/No) When set to YES, the speed set point cannot be lowered/decreased by the cascade control PID below the rated/synchronous speed set point plus the ‘min load bias’ setting. This is used to prevent a reverse power condition as well as allowing the plant to utilize a minimum load setting for the generator. When NO, the cascade control PID can move the speed set point down to the cascade minimum speed setting value. BREAKER ENABLES CONTROL dflt= YES (Yes/No) Set to TRUE to have unit automatically disable cascade when either the utility or generator breaker opens. If FALSE, then the cascade input will need to be cycled to resume control after the breaker is closed. Woodward 67 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 DISPLAY GAUGE MULTIPLIER dflt= 1.0 (0.01, 1000.0) This allows scaling of the number for display on the gauge on the 505 runtime screen for this controller. If the number is too big or small to be displayed correctly or as desired, us this setting to multiply by a factor of 10. HOLD CASCADE CHANGES ? dflt= NO (Yes/No) Set to YES to permanently Hold the changes made to the Fast Rate, Entered Rate, Rated Setpt, Casc Not Matched Rate, Maximum Speed Setting and Minimum Speed Setting. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Remote Cascade Settings (only displayed if configured) Note: Available as the last page of the “Cascade Control” Service menu. NOT MATCHED RATE dflt= xxx (0.01, 1000) Rate the set point moves when remote is enabled and the remote input doesn’t match the actual set point. This rate is defaulted to the ‘Cascade Set Point Slow Rate’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. REMOTE CASCADE MAXIMUM RATE dflt= xxx (0.01, 1000) Rate the set point moves once the remote input and actual set point are matched. This is a maximum rate. Normally the set point will follow the remote cascade input setting. This rate is set in the Program Mode. MINIMUM REMOTE CASCADE SETPOINT dflt= xxx (-20000, 20000) Minimum setting allowed by the remote input. This setting is defaulted to the Minimum Cascade Set Point Value. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Cascade Set Point’ and the ‘Maximum Cascade Set Point’ settings) MAXIMUM REMOTE CASCADE SETPOINT dflt= xxx (-20000, 20000) Maximum setting allowed by the remote input. This setting is defaulted to the Maximum Cascade Set Point Value. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Cascade Set Point’ and the ‘Maximum Cascade Set Point’ settings) REMOTE DEADBAND VALUE dflt= 0.0 (0.0, 500) Remote cascade setting input deadband in engineering units. REMOTE LAG-TAU VALUE dflt= 0.0 (0.0, 10) Remote Set Point input lag setting. HOLD REMOTE CASCADE CHANGES ? dflt= NO (Yes/No) Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Casc Settings. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Communications (only displayed if configured) When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change. Modbus Settings USE MODBUS TRIP ? dflt= YES (Yes/No) Use trip command through the Modbus link from the Modbus device. 68 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators USE 2-STEP TRIP ? dflt= NO (Yes/No) If using a Modbus Trip, is this a two-step trip. If YES, requires both the Trip command and the Trip Acknowledge command to go YES before a trip from the Modbus link will executed. “Use Modbus Trip” and “Use 2-Step Trip” now apply to all Modbus links (Serial Port 1, Ethernet Port 2, and Ethernet Port 3). Unlike older 2-line display versions of the 505, these options can no longer be selected individually for each link. Serial Port 1 LINK STATUS (status indication only) Displays a green LED if the port is healthy. The `Time-out Delay` or port configuration may need to be adjusted. EXCEPTION ERROR (status indication only) Displays a red LED if the port has a exception error. TIMEOUT DELAY dflt= 10.0 (0, 100) Sets the port timeout. This is the delay, with no communication on the Modbus link, before the link is considered failed and an alarm is issued. ERROR CODE (status indication only) Displays the error code related to the communication problem. 0 = No Errors 1 = Illegal Function 2 = Illegal Data Address 3 = Illegal Data Value 9 = Checksum Error 10= Garbled Message Press RESET to clear the port error. Ethernet Port 2 LINK STATUS (status indication only) Displays a green LED if the port is healthy. The `Time-out Delay` or port configuration may need to be adjusted. EXCEPTION ERROR (status indication only) Displays a red LED if the port has a exception error. TIMEOUT DELAY dflt= 10.0 (0, 100) Sets the port timeout. This is the delay, with no communication on the Modbus link, before the link is considered failed and an alarm is issued. ERROR CODE (status indication only) Displays the error code related to the communication problem. 0 = No Errors 1 = Illegal Function 2 = Illegal Data Address 3 = Illegal Data Value 9 = Checksum Error 10= Garbled Message Press RESET to clear the port error. Ethernet Port 3 LINK STATUS (status indication only) Displays a green LED if the port is healthy. The `Time-out Delay` or port configuration may need to be adjusted. EXCEPTION ERROR (status indication only) Displays a red LED if the port has a exception error. TIMEOUT DELAY dflt= 10.0 (0, 100) Sets the port timeout. This is the delay, with no communication on the Modbus link, before the link is considered failed and an alarm is issued. ERROR CODE (status indication only) Displays the error code related to the communication problem. 0 = No Errors 1 = Illegal Function 2 = Illegal Data Address 3 = Illegal Data Value 9 = Checksum Error 10= Garbled Message Press RESET to clear the port error. Woodward 69 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Servlink Socket 1 IP (status indication only) Shows the Ethernet IP address that is connected to this socket. IP address ‘127.0.0.1’ will be identified as the 505 front panel display, which will be used as “Local” for Local/Remote functionality. See volume 1 of the manual for details. STATUS (status indication only) Displays a green LED if the port is healthy. The `Time-out Delay` or port configuration may need to be adjusted. LEVEL (status indication only) Displays the authority level of this socket. For example, the following at the most common levels a 505 user will encounter:  0 = Monitor  1 = Operator  2 = Service  3 = Configure Socket 2 to 8 These indications have the same meaning as the indications for Socket 1. See above. Local/Remote Functions (only displayed if configured) Normally the Local/Remote function will disable all inputs except the front panel commands when Local is selected. The following questions can customize this feature by allowing the Contacts, Modbus 1, and/or Modbus 2 to be active also when local is selected. LOCAL MODE ENABLED ? (status indication only) Indicates when the Local mode is enabled. When the indication is NO, remote mode is enabled. When YES, only “Local” commands are accepted by the control. See “Local/Remote” mode description in Volume 1. REMOTE MODE ENABLED ? (status indication only) Indicates when the Remote mode is enabled. When the indication is NO, remote mode is disabled and local mode only is selected. ENABLE CONTACTS ? dflt= NO (Yes/No) When set to YES, the contacts are always active regardless of the Local/Remote selection. When set to NO, the contact inputs are disabled when the local mode is selected. CONTACTS ENABLED ? (status indication only) Indicates the status of the Contact input commands. When the indication is NO, local control is selected and remote control from the contact inputs is disabled. ENABLE MODBUS ? dflt= NO (Yes/No) When set to YES, the Modbus commands are always active regardless of the Local/Remote selection. When set to NO, the Modbus commands are disabled when the local mode is selected. MODBUS SERIAL LINK 1 ENABLE WHEN LOCAL ? dflt= NO (Yes/No) If using Local/Remote only. If YES, allows commands from Modbus port 1 to be active even when LOCAL mode is selected. When NO, the Modbus commands from port 1 are disabled when in LOCAL. MODBUS ETHERNET LINK 2 ENABLE WHEN LOCAL ? dflt= NO (Yes/No) If using Local/Remote only. If YES, allows commands from Modbus port 2 to be active even when LOCAL mode is selected. When NO, the Modbus commands from port 2 are disabled when in LOCAL. 70 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators MODBUS ETHERNET LINK 3 ENABLE WHEN LOCAL ? dflt= NO (Yes/No) If using Local/Remote only. If YES, allows commands from Modbus port 3 to be active even when LOCAL mode is selected. When NO, the Modbus commands from port 3 are disabled when in LOCAL. WRITES ENABLED ? (status indication only) Indicates when the write values are allowed for the link. When the indication is NO, that link may not write values to the control. Key Options USE ‘STOP’ COMMAND ? dflt= YES (Yes/No) When set to YES, allows the Controlled Stop command to be used. When NO, the Controlled Stop feature is disabled from front panel, Modbus, and contact commands. Alarms IS TRIP AN ALARM ? dflt= YES (Yes/No) When set to YES, any trip condition will also be annunciated as an alarm. When NO, a trip condition will not necessarily mean an alarm will be issued. BLINK ALARMS ? dflt= NO (Yes/No) Set to YES if want an indication if another alarm occurs when an alarm is already present. When set to YES, the alarm relay blinks when an alarm condition occurs until a reset command is issued. If the alarm still exists, the relay will stay energized, but will stop blinking until another alarm occurs. When NO, the alarm relay indicates an alarm continuously whenever an alarm condition exists. SHUTDOWN ON POWER-UP? dflt= YES (Yes/No) When set to YES, the control will initially power-up in a Shutdown state requiring a operator reset to start. When set to NO the unit will initialize into a ready to start mode if all shutdown conditions are clear. This option should always be set to YES when the control is configured for Redundant operation. HP Linearization (can be configured as actuator output 1 or 2) This is configured by default as the Actuator 1 channel output. HP is the same functionality as “Actuator 1” in the older 2-line display non-extraction 505’s. When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change. The actuator linearization settings can be checked or verified by using the actuator stroke feature when the unit is shut down. X-1 VALUE dflt= 0.0 (-5, 110) Input point #1 of the actuator linearization curve, in percentage. (Must be less than the ‘X-2 Value’) Y-1 VALUE dflt= 0.0 (-5, 110) Output point #1 of the actuator linearization curve, in percentage. X-2 VALUE dflt= 10.0 (-5, 110) Input point #2 of the actuator linearization curve, in percentage. (Must be between the ‘X-1 Value’ and the ‘X-3 Value’ settings) Y-2 VALUE dflt= 10.0 (-5, 110) Output point #2 of the actuator linearization curve, in percentage. X-3 VALUE dflt= 20.0 (-5, 110) Input point #3 of the actuator linearization curve, in percentage. (Must be between the ‘X-2 Value’ and the ‘X-4 Value’ settings) Y-3 VALUE dflt= 20.0 (-5, 110) Output point #3 of the actuator linearization curve, in percentage. Woodward 71 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 X-4 VALUE dflt= 30.0 (-5, 110) Input point #4 of the actuator linearization curve, in percentage. (Must be between the ‘X-3 Value’ and the ‘X-5 Value’ settings) Y-4 VALUE dflt= 30.0 (-5, 110) Output point #4 of the actuator linearization curve, in percentage. X-5 VALUE dflt= 40.0 (-5, 110) Input point #5 of the actuator linearization curve, in percentage. (Must be between the ‘X-4 Value’ and the ‘X-6 Value’ settings) Y-5 VALUE dflt= 40.0 (-5, 110) Output point #5 of the actuator linearization curve, in percentage. X-6 VALUE dflt= 50.0 (-5, 110) Input point #6 of the actuator linearization curve, in percentage. (Must be between the ‘X-5 Value’ and the ‘X-7 Value’ settings) Y-6 VALUE dflt= 50.0 (-5, 110) Output point #6 of the actuator linearization curve, in percentage. X-7 VALUE dflt= 60.0 (-5, 110) Input point #7 of the actuator linearization curve, in percentage. (Must be between the ‘X-6 Value’ and the ‘X-8 Value’ settings) Y-7 VALUE dflt= 60.0 (-5, 110) Output point #7 of the actuator linearization curve, in percentage. X-8 VALUE dflt= 70.0 (-5, 110) Input point #8 of the actuator linearization curve, in percentage. (Must be between the ‘X-7 Value’ and the ‘X-9 Value’ settings) Y-8 VALUE dflt= 70.0 (-5, 110) Output point #8 of the actuator linearization curve, in percentage. X-9 VALUE dflt= 80.0 (-5, 110) Input point #9 of the actuator linearization curve, in percentage. (Must be between the ‘X-8 Value’ and the ‘X-10 Value’ settings) Y-9 VALUE dflt= 80.0 (-5, 110) Output point #9 of the actuator linearization curve, in percentage. X-10 VALUE dflt= 90.0 (-5, 110) Input point #10 of the actuator linearization curve, in percentage. (Must be between the ‘X-9 Value’ and the ‘X-11 Value’ settings) Y-10 VALUE dflt= 90.0 (-5, 110) Output point #10 of the actuator linearization curve, in percentage. X-11 VALUE dflt= 100.0 (-5, 110) Input point #11 of the actuator linearization curve, in percentage. (Must be greater than the ‘X-10 Value’) Y-11 VALUE dflt= 100.0 (-5, 110) Output point #11 of the actuator linearization curve, in percentage. ACT1 DEMAND (%) = (status indication only) Displays the actuator demand (%) before the linearization curve. ACT1 OUTPUT (%) = (status indication only) Displays the actuator demand (%) after the linearization curve. TRACK OFFSET (%) = dflt= 0.0 (0.0, 5.0) Displays the actuator demand (%) after the linearization curve. HP2 Linearization HP2 is the same functionality as “Actuator 2” in the older 2-line display nonextraction 505’s. HP2 can be used for dual inlet or split range valve applications. When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change. The actuator linearization settings can be checked or verified by using the actuator stroke feature when the unit is shut down. 72 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators X-1 VALUE dflt= 0.0 (-5, 110) Input point #1 of the actuator linearization curve, in percentage. (Must be less than the ‘X-2 Value’) Y-1 VALUE dflt= 0.0 (-5, 110) Output point #1 of the actuator linearization curve, in percentage. X-2 VALUE dflt= 10.0 (-5, 110) Input point #2 of the actuator linearization curve, in percentage. (Must be between the ‘X-1 Value’ and the ‘X-3 Value’ settings) Y-2 VALUE dflt= 10.0 (-5, 110) Output point #2 of the actuator linearization curve, in percentage. X-3 VALUE dflt= 20.0 (-5, 110) Input point #3 of the actuator linearization curve, in percentage. (Must be between the ‘X-2 Value’ and the ‘X-4 Value’ settings) Y-3 VALUE dflt= 20.0 (-5, 110) Output point #3 of the actuator linearization curve, in percentage. X-4 VALUE dflt= 30.0 (-5, 110) Input point #4 of the actuator linearization curve, in percentage. (Must be between the ‘X-3 Value’ and the ‘X-5 Value’ settings) Y-4 VALUE dflt= 30.0 (-5, 110) Output point #4 of the actuator linearization curve, in percentage. X-5 VALUE dflt= 40.0 (-5, 110) Input point #5 of the actuator linearization curve, in percentage. (Must be between the ‘X-4 Value’ and the ‘X-6 Value’ settings) Y-5 VALUE dflt= 40.0 (-5, 110) Output point #5 of the actuator linearization curve, in percentage. X-6 VALUE dflt= 50.0 (-5, 110) Input point #6 of the actuator linearization curve, in percentage. (Must be between the ‘X-5 Value’ and the ‘X-7 Value’ settings) Y-6 VALUE dflt= 50.0 (-5, 110) Output point #6 of the actuator linearization curve, in percentage. X-7 VALUE dflt= 60.0 (-5, 110) Input point #7 of the actuator linearization curve, in percentage. (Must be between the ‘X-6 Value’ and the ‘X-8 Value’ settings) Y-7 VALUE dflt= 60.0 (-5, 110) Output point #7 of the actuator linearization curve, in percentage. X-8 VALUE dflt= 70.0 (-5, 110) Input point #8 of the actuator linearization curve, in percentage. (Must be between the ‘X-7 Value’ and the ‘X-9 Value’ settings) Y-8 VALUE dflt= 70.0 (-5, 110) Output point #8 of the actuator linearization curve, in percentage. X-9 VALUE dflt= 80.0 (-5, 110) Input point #9 of the actuator linearization curve, in percentage. (Must be between the ‘X-8 Value’ and the ‘X-10 Value’ settings) Y-9 VALUE dflt= 80.0 (-5, 110) Output point #9 of the actuator linearization curve, in percentage. X-10 VALUE dflt= 90.0 (-5, 110) Input point #10 of the actuator linearization curve, in percentage. (Must be between the ‘X-9 Value’ and the ‘X-11 Value’ settings) Y-10 VALUE dflt= 90.0 (-5, 110) Output point #10 of the actuator linearization curve, in percentage. X-11 VALUE dflt= 100.0 (-5, 110) Input point #11 of the actuator linearization curve, in percentage. (Must be greater than the ‘X-10 Value’) Y-11 VALUE dflt= 100.0 (-5, 110) Output point #11 of the actuator linearization curve, in percentage. ACT2 DEMAND (%) = (status indication only) Displays the actuator demand (%) before the linearization curve. ACT2 OUTPUT (%) = (status indication only) Displays the actuator demand (%) after the linearization curve. Woodward 73 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Real Time Clock USE SNTP SYNCHRONIZATION dflt= NO (Yes/No) Select this option if using an SNTP Server for time synchronization with the 505 internal clock. This will affect alarm and event indication time stamping. Data Log DATA SAMPLE RATE dflt= 1000.0 (10, 1000) Set the number of milliseconds between each data point in the data log. After changing this value, the Data Log must be stopped and started again for this sample rate to be used. FILE LENGTH dflt= 28800.0 (60, 1000000) Set the requested length of the data log in seconds. This is requested because the file length may be limited by memory and file size restrictions, for example, 4 MB. Operation Log NUMBER OF TURBINE STARTS dflt= 0 (0, 999999) This is the number of times a Start command has been issued. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. NUMBER OF HOT TURBINE STARTS dflt= 0 (0, 999999) This is the number of times a Start command has been issued while the turbine is considered HOT. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. TOTAL TRIPS dflt= 0 (0, 999999) This is the number of times a Trip has occurred. The trip latch must be reset/cleared and then triggered again to increment this counter. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. TRIPS WITH LOAD > 25% dflt= 0 (0, 999999) This is the number of times a Trip has occurred above 25% load. Load is determined by the LSS percentage if configured as a mechanical drive unit. As a generator drive unit the load level is determined by the calculated LSS load percentage or the load analog input if configured. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. TRIPS WITH LOAD > 75% dflt= 0 (0, 999999) This is the number of times a Trip has occurred above 75% load. Load is determined by the LSS percentage if configured as a mechanical drive unit. As a generator drive unit the load level is determined by the calculated LSS load percentage or the load analog input if configured. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. TOTAL RUN TIME HOURS dflt= 0.0 (0.0, 1.0e+8) This is the total time the turbine has been running. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. RUN TIME HOURS WITH LOAD > 25% dflt= 0.0 (0.0, 1.0e+8) This is the total time the turbine has been running with more than 25% load. Load is determined by the LSS percentage if configured as a mechanical drive unit. As a generator drive unit the load level is determined by the calculated LSS load percentage or the load analog input if configured. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. 74 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators RUN TIME HOURS WITH LOAD > 75% dflt= 0.0 (0.0, 1.0e+8) This is the total time the turbine has been running with more than 75% load. Load is determined by the LSS percentage if configured as a mechanical drive unit. As a generator drive unit the load level is determined by the calculated LSS load percentage or the load analog input if configured. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. TOTAL RUN TIME HOURS (status indication only) This is the total time the turbine has been running. This is a repeat of the value on the previous page for ease of comparing the run time with the maintenance alarm time. ENABLE MAINTENANCE ALARM dflt= YES (Yes/No) Select this option to turn on the maintenance alarm, which is an alarm based on the number of turbine run hours and reminds the user that the control should be serviced periodically. Unselected this to disable the maintenance alarm. MAINTENANCE INTERVAL dflt= 15000 (10, 100000) This sets the number of turbine run hours that will trigger the maintenance alarm. After the turbine has been running for this many hours, the maintenance alarm will activate to remind the user to service the unit. MAINTENANCE ALARM (status indication only) This indicates the status of the maintenance alarm. A red LED indication is a reminder that the unit should be serviced. This alarm indication can be reset by pressing the “Reset Alarm” soft key at the bottom of the screen if the appropriate security level is logged in. PEAK SPEED REACHED (status indication only) This indicates the maximum turbine speed detected by the 505. MAXIMUM ACCELERATION REACHED (status indication only) This indicates the maximum turbine acceleration detected by the 505. Isolated Control SETPOINT (set by user) This is the setpoint in engineering units. It is the target control point for the Isolated Control PID. PROCESS (status indication only) This is the process value from the analog input in engineering units. It is the parameter to be controlled by the Isolated Control PID. DEMAND (set by user) This is the output of the Isolated Control PID in percent. This can be manually adjusted by a user with the appropriate security login level by enabling manual mode or in the event of an analog process input fault. REMOTE SETPOINT ENABLED (status indication only) This is a status indication that the remote setpoint analog input is driving the Isolated Control setpoint. A green LED indicates the Remote Setpoint is enabled. REMOTE SETPOINT FAULT (status indication only) This is a status indication that the remote setpoint analog input is failed. A red LED indicates the Remote Setpoint fault is present. AUTO CONTROL (status indication only) This is a status indication that the Isolated Control is controlling the process and attempting to maintain the setpoint automatically. A green LED indicates the PID is controlling. PROCESS INPUT FAULT (status indication only) This is a status indication that the process value analog input is failed. A red LED indicates the process analog input fault is present. Woodward 75 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 MANUAL DEMAND (status indication only) This is a status indication that the Isolated Control is not controlling the process. The output of the Isolated Control PID is set manually by the operator. A yellow LED indicates the Isolated Control PID is in manual mode and the PID is not maintaining the setpoint. Setpoint Limits MAXIMUM (status indication only) This is the maximum limit for the Isolated Control setpoint in engineering units. MINIMUM (status indication only) This is the minimum limit for the Isolated Control setpoint in engineering units. INITIAL (status indication only) This is the value in engineering units at which the Isolated Control setpoint ramp will initialize. NORMAL RATE dflt= 1.0 (0.0, 100000.0) This is the rate in engineering units per second at which the Isolated Control setpoint will move when a setpoint raise/lower command is issued. FAST RATE dflt= 3.0 (0.0, 100000.0) This is the rate in percent per second at which the Isolated Control setpoint will move after the setpoint raise/lower command has been active for 5 seconds. Output Limits MAXIMUM dflt= 100.0 (-10.0, 110.0) This is the maximum limit for the Isolated Control PID demand in percent. MINIMUM dflt= 0.0 (-10.0, 110.0) This is the minimum limit for the Isolated Control PID demand in percent. INITIAL dflt= 0.0 (-10.0, 110.0) This is the value in percent at which the Isolated Control setpoint ramp will initialize. NORMAL RATE dflt= 1.0 (0.0, 1000.0) This is the rate in percent per second at which the Isolated Control output will move when a manual demand raise/lower command is issued. FAST RATE dflt= 3.0 (0.0, 1000.0) This is the rate in percent per second at which the Isolated Control output will move after the manual demand raise/lower command has been active for 5 seconds. Commands Remote Setpoint REMOTE SETPOINT (status indication only) This is the remote setpoint for the Isolated Control setpoint in engineering units. When enabled, an analog input is used to drive the setpoint for the Isolated Control PID. The Remote Setpoint can be enabled using the soft key at the bottom of the screen. REMOTE RATE dflt= 5.0 (0.1, 100000.0) This is the maximum rate at which the remote setpoint can move the Isolated Control setpoint in engineering units per second. PID Dynamics P TERM (set by user) This is the Proportional gain setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters. I TERM (set by user) This is the Integral gain setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters. 76 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators DR TERM (set by user) This is the Derivative Ratio setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters. Screen Settings SCREEN SAVER DELAY dflt= 4.0 (0.1, 24.0) Set the time before the screen saver will activate. If no front panel keys are pressed in this length of time, the screen saver will turn on. Note that the current user level will be logged out when the screen saver activates. When the screen saver is deactivated (i.e. waking up the display), either the Operator or Monitor user level will be active. AUTO LOGIN AS OPERATOR dflt= YES (Yes/No) Select this option to determine which user level is active when the 505 initializes. With this option selected, the 505 will initialize like the older 2-line display models in operator mode with operator commands available. If not selected, the 505 will initialize in the Monitor user level with only screen navigation functionality. No operator commands can be issued from the Monitor user level. Note that this will also determine the user level that is logged in any time the user wakes up the display and turns off the screen saver. OPERATOR PASSWORD dflt= wg1111 If “Auto Login as Operator” is selected, this sets the Operator password. If the user level and password have not been changed, the default input will allow the 505 to login the Operator user level as described above. If the Operator password has been changed, then it must be entered here to authorize the 505 to automatically login to the Operator user level. Custom Trend Opening Custom Trend page begins the trend, exiting the page will continue to record data in the background. Trends can be paused using the soft-key. While paused, the data continues to record in the background. Once resumed, the trend snaps to real time. Settings TIME WINDOW dflt= 60 (1, 600) Set the amount of time that is shown on the trend. This is the trend window time in seconds. Setting this to ‘60’, for example, will show 60 seconds of data preceding the present time. Parameter 1 (Red) VARIABLE (set by user) Select the parameter to be displayed by this trend line. The color that will appear for this parameter on the trend is indicated to the left of this selection. Y MAX dflt= 100 (-20000, 20000) Set the maximum value for the Y axis on the trend for this signal. This sets the maximum vertical limit of the trend display for the signal. Y MIN dflt= 0 (-20000, 20000) Set the minimum value for the Y axis on the trend for this signal. This sets the minimum vertical limit of the trend display for the signal. WIDTH dflt= 1 (1, 5) Set the width of the line shown on the trend for this signal. To increase thickness of the line, this number should be increased. SHOW AXIS dflt= YES (Yes/No) Set the maximum value for the Y axis on the trend for this signal. This sets the maximum vertical limit of the trend display for the signal. Woodward 77 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Parameter 2 (Green) The configuration options are similar to that of Parameter 1. See Parameter 1 settings for a description of each option. Parameter 3 (Blue) The configuration options are similar to that of Parameter 1. See Parameter 1 settings for a description of each option. Parameter 4 (Purple) The configuration options are similar to that of Parameter 1. See Parameter 1 settings for a description of each option. Parameter 5 (Orange) The configuration options are similar to that of Parameter 1. See Parameter 1 settings for a description of each option. Values from VariStroke II (HP Valve) This screen contains status information on the VariStroke II connected as the HP valve driver. See the VariStroke II manual for details. Manual Demand USE MANUAL DEMAND dflt= NO (Yes/No) Select this option to allow the use of the manual valve demand feature. This allows the operator to disable all controllers and hold the valve demand steady for a limited period of time for system troubleshooting purposes. Using the Manual Valve Demand feature allows the operator to lock the valve demand. This means that closed loop control is not active. In other words, the Speed PID will not be in control of the turbine speed! Manual Valve Demand MANUAL DEMAND RATE dflt= *0.5 (0.0099, 5.0) Set the rate at which the valve demand can be moved when Manual Valve Demand is enabled. This is a value in percent per second. TIMEOUT WHEN INACTIVE dflt= 120.0 (10.0, 300.0) Set the maximum length of time, in seconds, that Manual Valve Demand may be enabled. If Manual Valve Demand is enabled for this length of time then it will automatically be disabled and the 505 will return to Speed PID Control. Acceleration Limiter USE ACCELERATION LIMITER dflt= NO (Yes/No) Set the amount of time that is shown on the trend. This is the trend window time in seconds. Setting this to ‘60’, for example, will show 60 seconds of data preceding the present time. PROPORTIONAL GAIN (set by user) This is the Proportional gain setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters. INTEGRAL GAIN (set by user) This is the Integral gain setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters. 78 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators DERIVATIVE RATIO (set by user) This is the Derivative Ratio setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters. Woodward 79 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Chapter 6. Understanding PID Settings Overview The Speed, Cascade, Auxiliary (1 & 2), and Acceleration controls utilize PID controllers. The response of each control loop can be adjusted for optimum response, however it is important to understand what a PID controller is and the effect each controller adjustment has on the controller response. Proportional gain, integral gain (stability), and DR (speed derivative ratio) are the adjustable and interacting parameters used to match the response of the control loop with the response of the system. They correspond to the P (proportional), I (integral), and D (derivative) terms, and are displayed by the 505 as follows:  P = Proportional gain (%)  I = Integral gain (%)  D = Derivative (determined by DR and I) Proportional Control Proportional response is directly proportional to a process change. Analogy: Setting hand throttle to keep constant speed on straight and level. Proportional control (using the same analogy) results in a certain speed as long as the car is not subjected to any load change such as a hill. If a throttle is set to any particular setting, the speed of the car will remain constant as long as the car remains straight and level. If the car goes up a hill, it will slow down. Of course, going down a hill the car would gain speed. Integral Control Integral compensates for process and setpoint load changes. Analogy: Cruise control maintains constant speed regardless of hills. Integral, sometimes called reset, provides additional action to the original proportional response as long as the process variable remains away from the setpoint. Integral is a function of the magnitude and duration of the deviation. In this analogy the reset response would keep the car speed constant regardless of the terrain. Derivative Derivative provides a temporary over-correction to compensate for long transfer lags and reduce stabilization time on process upsets (momentary disturbances). Analogy: Accelerating into high speed lane with merging traffic. 80 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Derivative, sometimes called “preact” or “rate”, is very difficult to draw an accurate analogy to, because the action takes place only when the process changes and is directly related to the speed at which the process changes. Merging into high speed traffic of a freeway from an “on” ramp is no easy task and requires accelerated correction (temporary overcorrection) in both increasing and decreasing directions. The application of brakes to fall behind the car in the first continuous lane or passing gear to get ahead of the car in the first continuous lane is derivative action. Proportional Response The amount of controller change is directly related to the process change and the Proportional gain setting on the controller; Controller output change is Proportional to the process change. If there is no process change, there is no change in output from the controller (or valve change) regardless of the deviation. This results in an undesired offset between the original desired Setpoint and the resulting drop in the Control Point. Figure 6-1. Proportional Gain Setting Effects Woodward 81 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Proportional Gain (effect of settings) Figure 6-1 shows the effect of Proportional gain settings on control. Starting at the top of the graph a load change is introduced. With a small Proportional gain (meaning a large process change is required to produce full valve travel), stability is good but offset is very high. With a moderate gain setting (higher number setting) stability is still good–offset is still fairly high. With a high setting, offset is considerably smaller but the stability is poor. The 0.25 ratio effects a minimum area whereby the offset is reduced to a minimum while stability is in a decaying manner at 0.25% ratio. The decay ratio used (0.25%) means that if the second cycle is 1/4 of the first cycle, then each succeeding cycle will be 1/4 of the preceding cycle until the cycle is not visible. Since Proportional gain is adjusted to produce (only) the proper stability of a process, do not continue increasing its effect to correct offset conditions. The amount of stability and offset is directly related to the setting of the Proportional setting. Stability is of course also affected by the stability of the process. In essence, the amount of output from the controller due to the Proportional setting is from the error. If there is no error, then there is no Proportional effect. Integral Response Integral Gain as stated in the Woodward controls is repeats per minute (or Reset Rate). Therefore, a high amount of Integral gain (high number) would result in a large amount of Reset action. Conversely, a low Integral gain (low number) would result in a slower reset action. Figure 6-2. Open Loop Proportional and Integral Response 82 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Integral response is provided to eliminate the offset that resulted from straight Proportional control. Figure 6-2 shows how the controller action is Proportional to the measurement change, but as we saw earlier, this results in offset. The Integral (or Reset) action is a function of both time and magnitude of the deviation. As long as an offset condition (due to load changes) exists, Integral action is taking place. The amount of Integral action is a function of four things:  The magnitude of the deviation  The duration of the deviation  The Proportional gain setting  The Integral setting In this Open Loop figure (5-2), the Integral response is shown increasing due to the offset condition existing between the temperature and the setpoint. The resultant action is the top curve showing the step Proportional response that ends as soon as the measurement stops changing. Then the Integral (or reset) action is added to the Proportional action in an amount equal to the Integral of the deviation. In other words, Reset action continues (in either or both directions) as long as there is a difference (deviation) between the setpoint and the process measurement. In this case, the deviation will never be eliminated (or even reduced) because the system is in Open Loop. Proportional + Integral (closed loop) Figure 6-3 shows the closed loop effects of integral action. The bottom curve displays the load change. The next curve up shows the setpoint and the measured variable, temperature. With the load change the temperature droops or deviates from the setpoint. The next highest curve is the Proportional action and follows the measured variable proportionately. The Integral curve adds to the Proportional curve resulting in a different valve position, thereby returning the process to the Setpoint. Figure 6-3. Closed Loop Proportional and Integral Response Woodward 83 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 In Closed Loop, however (as opposed to Open Loop), as the measurement decays toward the Setpoint the Proportional action is taking place Proportionally to the measurement change, and the Integral action is decaying proportionately to the magnitude and duration of the deviation until the measurement reaches the setpoint at which time the Integral action is zero. Integral (effects of settings) Figure 6-4 shows the effect of fast or slow Integral action. For a given load change an offset results with Proportional response only. Since recovery time (for a given load change) is important, the Integral setting should remove the offset in minimum time without adding additional cycling. If two cycles are added, then too much Integral Gain has been added. Of course, Proportional only must first establish the 1/4 decay ratio. If increased cycling occurs, the Integral must be turned off or the controller switched to “manual” if allowed to go too far. Ideally, the process should not continue to cycle after the setpoint has been reached as in the second curve from the bottom. Figure 6-4. Integral Gain (Reset) Setting Responses Derivative Response In a process control loop the Derivative action is directly related to how fast the process changes (rate of change). If the process change is slow then the Derivative action is proportional to that rate of change. Derivative acts by advancing the Proportional action. Derivative acts at the start of the process change, when the process changes its rate and when the process stops its change. 84 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Derivative action takes place at only three times:  When the process starts to change  When the rate of change takes place in the process  When the process stops changing The net result of Derivative action is to oppose any process change and combined with Proportional action to reduce stabilization time in returning the process to the setpoint after an upset. Derivative will not remove offset. Woodward Derivative is split into two working domains, Input dominant and Feedback dominant. The allowed values for DR range from 0.01 to 100. The most common derivative is Feedback dominant, it is automatically selected with a Derivative Ratio (DR) from 1 to 100. The Input dominant domain is selected with DR values between 0.01 and 1.0. Feedback dominant applies the derivative action to the integrator feedback term of the PID equation and is more stable than input dominant derivative. This will not take corrective action as early and it will be less noise sensitive. When tuning the derivative, the DR will be established in the 1 to 100 range because it is easier to tune and more forgiving of excessive values. Most PIDs will employ feedback dominant derivative. Input dominant derivative applies the DR term before the integrator term of the PID equation. When the DR is less than 1, the derivative is input dominant and reacts very quickly to process upsets. This function is very adapted for PIDs that control the load parameter, such as load shaft turbine speed. Since the input dominant derivative is so sensitive, it should be reserved only for applications without high frequency noise. Except for input dominant and feedback dominant features, the reciprocal of one domain will appear identical in the other domain. As an example, consider a DR of 5.0, the reciprocal being 1/5. That means that a DR of 5.0 will appear the same as DR of 0.200. The difference in response between these values of 5.0 and 0.2 is in the dominance feature. If in doubt about the type of derivative to use, then set up for feedback dominant, 1 < DR < 100. Proportional + Derivative (closed loop) Figure 6-5 shows how Derivative acts to oppose a change in process in either direction. The dashed line shows the Derivative action going through zero to oppose the process deviation traveling toward zero. Notice offset still exists between the desired setpoint and the drooped control point that resulted from the load change. The top curve is the resultant controller output, Proportional plus Derivative. If an upset (momentary) had occurred rather than a load change, there would be no offset. Woodward 85 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure 6-5. Closed Loop Proportional and Derivative Action Derivative (effects of settings) Figure 6-6. Derivative Setting Effects 86 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 6-6 shows the effect of different Derivative settings. The curves are relative since it depends on what type of control is desired in order to properly adjust Derivative time. For example, if minimum cycling is desired (as is shown here) then Derivative is added to the 1/4 decay cycle provided by Proportional until more than one cycle is removed and of course the 1/4 decay is destroyed. However, in most cases it is desirable to retain the 1/4 decay cycle, in which case Derivative is added to the point of removing only one cycle from the 1/4 decay ratio then the gain is increased until the 1/4 decay ratio is restored. In all the above curves, you will note offset exists since offset can only be eliminated by the addition of Integral (or Reset). Proportional + Integral + Derivative (closed loop) Figure 6-7 shows the relationship of valve position to the interaction of the PID modes of control whenever a load change takes place in closed loop. As the temperature drops due to the load change, the proportional action moves the control valve proportionately to the measurement (temperature) change. The integral gain/reset adds to the proportional action as a result of the magnitude and time (duration) of the deviation. And the derivative temporarily over-corrects based on the speed at which the measurement moves in any direction. The resultant curve (at the top) shows a similar over-correction (in this case), but in addition the valve will stay at the new position required to keep the measurement at the setpoint. Figure 6-7. Closed Loop Proportional, Integral and Derivative Action In summary, Derivative provides a temporary over-correction to compensate for long transfer lags and reduce stabilization time on process upsets (momentary disturbances). Woodward 87 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Do not use if high frequency noise is normally in the measured variable or the main lag is dead time. After Proportional is set to 1/4 decay ratio and Derivative is adjusted to remove one cycle as well as decreasing the 1/4 decay ratio, then the Proportional gain can be increased to restore the 1/4 decay ratio. Adding Derivative The value of the Derivative Ratio (DR) term can range from 0.01 to 100. In order to simplify adjustment of the dynamics of the 505, adjusting the integral gain value sets both the I and D terms of the PID controller. The DR term establishes the degree of effect the integral gain value has on the “D” term, and changes the configuration of a controller from input rate sensitive (input dominant) to feedback rate sensitive (feedback dominant) and vice versa. Another possible use of the DR adjustment is to reconfigure the controller from a PID to a PI controller. This is done by adjusting the DR term to its upper or lower limits, depending on whether an 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 response when the governor is coming into control. (i.e. at startup, during a full load change, or during transfer of control from another channel). An input dominant controller is more sensitive to the change-of-rate of its input (i.e. Speed, Cascade in or Auxiliary in), and can therefore prevent overshoot of the setpoint better than a feedback dominant controller. Although this response is desirable during a startup or full load rejections, it can cause excessive control motions in some systems where a smooth transition response is desired. A controller configured as feedback dominant is more sensitive to the change-ofrate of its feedback (LSS). A feedback dominant controller has the ability to limit the rate of change of the LSS bus when a controller is near its setpoint but is not yet in control. This limiting of the LSS bus allows a feedback dominant controller to make smoother control transitions than an input dominant controller. Controller Field Tuning General The quality of regulation obtained from an automatic control system depends upon the adjustments that are made to the various controller modes. Best results are obtained when the adjustment (tuning) is done systematically. Prior training and experience in controller tuning are desirable for effective application of this procedure. 88 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators This procedure will lead to controller settings which will provide after a load change:  Process control without sustained cycling  Process recovery in a minimum time Controller settings derived for given operating conditions are valid over a narrow range of load change. The settings made for one operating set of conditions may result in excessive cycling or highly damped response at some other operating condition. This procedure should be applied under the most difficult operating conditions to assure conservative settings over the normal operating range. It is good practice to keep the average of the setpoint changes near the normal setpoint of the process to avoid excessive departure from normal operating level. After each setpoint change, allow sufficient time to observe the effect of the last adjustment (see Figure 6-8). It is wise to wait until approximately 90% of the change has been completed. Figure 6-8. Typical Response to Load Change Tuning Example If the system is unstable, make sure the governor is the cause. This can be checked by closing the valve limiter until it has control of the actuator output. If the governor is causing the oscillation, time the oscillation cycle time. A rule-of– thumb is, if the system’s oscillation cycle time is less than 1 second reduce the Proportional gain term. A rule-of-thumb is, if the system’s oscillation cycle time is greater the 1 second reduce the Integral gain term (proportional gain may need to be increased also). On an initial startup with the 505, all PID dynamic gain terms will require adjustment to match the respective PID’s response to that of its control loop. There are multiple dynamic tuning methods available that can be used with the 505’s PIDs to assist in determining the gain terms that provide optimum control loop response times. Woodward 89 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 The following method can be used to achieve PID gain values that are close to optimum: 1. Increase Derivative Ratio (SDR) to 100 (Service Mode adjustment) 2. Reduce integral gain to 0.01 (Run Mode adjustment) 3. Increase proportional gain until system just starts to oscillate (Run Mode).The optimum gain for this step is when the system just starts to oscillate and maintains a self-sustaining oscillation that does not increase or decrease in magnitude. 4. Record the critical gain (Kc) and oscillation period (T) in seconds. 5. Set the dynamics as follows: For PI control: G=P(I/s + 1) Set: Proportional gain = 0.45*Kc Integral gain = 1.2/T Derivative ratio = 100 For PID control: G=P(I/s + 1 + Ds) Set: Proportional gain = 0.35*Kc Integral gain = 0.76/T Deriv ratio = (5.2*T)/Integral Gain for fdbk dominant = (0.19*Integral Gain)/T for input dominant This method of tuning will get the gain settings close, they can be fine-tuned from this point. 90 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Chapter 7. Hardware/Operating System Faults General EXPLOSION HAZARD—Do not connect or disconnect while circuit is live unless area is known to be non-hazardous. RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf en cas l’ambiance est décidément non dangereuse. Wiring Problems Most 505 problems are caused by wiring problems. Carefully and thoroughly check all wiring connections at both ends. Be very careful when installing wires into the 505 control terminal blocks. Check all shields for proper grounding. All inputs and outputs can be measured directly at the terminal strips. In addition, from the Hardware pages, the display will show what the 505 measures. This comparison can be used to determine if the 505 is interpreting the input signal correctly. The Hardware pages on the display can be used to monitor and adjust analog inputs and outputs, monitor speed inputs, monitor and adjust actuator outputs, monitor contact inputs, and monitor and force relay outputs. Contact inputs can be verified by measuring the voltage at the terminal blocks. The contact power supply voltage should measure approximately 24 VDC from any contact (+) terminal to the contact GND terminal (11). If 24 VDC is not the voltage measured, disconnect all wiring to the 505 except input power, then remeasure this power supply voltage. If 24 VDC is not the voltage measured, check for wiring problems. If 24 VDC is not measured across the contact input (+) and contact GND terminal (11) with input wiring disconnected, replace the 505. The operation of a contact input to the 505 can be checked by verifying that the voltage from the contact input’s (+) terminal measures 24 VDC with respect to the contact input GND, terminal (11), when the external contact is closed. Any 4–20 mA input or output can be checked by placing a milliamp meter in series with the input or output. Refer to Volume 1 Chapter 2 for actuator wiring concerns or questions. If the serial communications line is not working, check the wiring first. Then check the Program Mode entries for matching communications setup. Woodward 91 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Control Adjustments If, while trying to adjust the Speed Setpoint in the Run Mode, the ADJ up and ADJ down keys will not work, check to make sure that CAS (cascade control) and RMT (remote control) are both disabled. If the system’s steam valve is unsteady or hunts, try manually positioning the steam valve by closing the valve limiter. If the steam valve is blocked in this manner and the actuator output is steady but the turbine still hunts, then the problem is outside the governor. If an actuator hunts, or appears sticky, it may need dither (especially TM type). If the 505 control is not able to fully close or open the governor valves, check to make sure that the actuators are calibrated correctly, and valve linkage is correctly set. If the 505 control is not able to control speed above or below a certain speed, the steam valve may not be adjusted correctly. Verify that the steam valve position is indeed in the position indicated by the 505 (by pressing the ACT key). If these positions do not match, correct the problem (actuator linkage, or current calibration). If an overspeed condition is reached on start-up, verify that the governor valve is closed. Next verify that the governor valve is seated correctly by opening the T&T valve with the governor valve closed. If the T&T valve allows the turbine to turn, then the governor valve is not correctly seated. Other Operating Problems If CAS or RMT will not work, check that the generator and tie breakers are both closed. From the (MANUAL SHUTDOWN) (PUSH YES OR NO) display, you cannot initiate a shutdown. If actual speed is less than the speed called for by the speed setpoint, check for droop (kW or speed). Droop causes the actual speed to be less than the speed reference. 92 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Appendix A. 505 Design Specifications Hardware Specifications Package Flush mount package Approximate physical size of 11” x 14” x 4” Environmental Category: Refer to Regulatory Compliance section of Volume 1 (some listings are dependent on part number) Built-In Graphical User Interface (GUI) 1. 8.4” LCD Display (800x600) and Keypad 2. 34 key multi-function keypad. 3. Emergency stop button (direct to hardware circuits) 4. Alarm, Trip and Hardware status LED indicators. General I/O, Power Supply and Environmental Specifications REFER To CHAPTER 2 OF Volume 1 of this manual Microprocessor Motorola MPC5125 Microprocessor/25 MHz Interfacing to Woodward Service Tools All interfacing to service tools is done via Ethernet (RJ45) communications and can be accessed from any of the Ethernet ports. See the Appendices for instructions on connecting and using each of the service tools. Software Specifications Speed/Load Control NEMA D or better speed regulation. Nominal Software Execution Rate Speed/Load Control: 10 ms Auxiliary Control: 20 ms Cascade Control: 20 ms Remote Speed Setpoint: 40 ms Remote Aux Setpoint: 40 ms Remote Cascade Setpoint: 40 ms Sync/Load Share Control: 20 ms Shutdowns: 10 ms Alarms: 40 ms Relays: a. Trip Relay: 10 ms b. Alarm Relay: 20 ms c. Configurable Relays: 40 ms Readouts: 40 ms Contact Inputs: a. External Trip & Configurable Inputs: 10 ms b. Reset: 40 ms c. Speed Raise & Lower: 20 ms Woodward 93 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 The “nominal rate” listed is the fastest update rate, the worst case response would be twice the nominal rate. 94 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Appendix B. 505 Service Mode Worksheet Governor Serial Number Application __________________ ____________________________ Date _______ For details on individual settings, refer to Chapter 4. SPEED CONTROL Rate to Min RPM/s Slow Rate Offline RPM/s Slow Rate Online RPM/s Fast Rate Delay s Fast Rate Offline RPM/s Fast Rate Online RPM/s Overspeed Rate RPM/s Entered Rate Offline RPM/s Entered Rate Offline RPM/s Underspeed Setting RPM Online Speed Deadband RPM Emergency Minimum Load Rate RPM/s Display Gauge Multiplier Hold Speed Changes YES NO Remote Speed Setpoint Not Matched Rate RPM/s Speed Setpoint Maximum Rate RPM/s Minimum Speed Setpoint RPM Maximum Speed Setpoint RPM Remote Deadband Value RPM Lag-Tau Value s Use Minimum Load YES NO Hold Remote Speed Changes YES NO VALVE LIMITER Limiter Rate %/s Entered Rate %/s Limiter Maximum Limit % HP Maximum at Start % Shutdown at Maximum Woodward YES NO 95 505 Digital Governor for Single/Split-Range Actuators Hold Limiter Changes Manual 26839V2 YES NO YES NO MPU OVERRIDE Use MPU Override Timer? Override Time s MPU 1 Override On (status) MPU 2 Override On (status) IDLE/RATED RAMP (if configured) Hours Since Trip (status) Hrs Hot Reset Timer Min Idle/Rated Cold Rate RPM/s Idle/Rated Warm Rate RPM/s Idle/Rated Hot Rate RPM/s Use Ramp to Idle YES NO Idle Priority YES NO Rated Priority YES NO (status) Hrs AUTOMATIC START SEQ (if configured) Hours Since Trip Hot Reset Timer Min Hot Reset Time Remaining (status) Min Hot Time Remaining (status) Hrs. Time Unit Cold Start (status) Hrs. Rate to Rated (status) RPM/s Idle 1 Delay (status) min Rate to Idle 2 (status) RPM/s Idle 2 Delay (status) min Rate to Idle 3 (status) RPM/s Idle 3 Delay (status) min PRESSURE COMPENSATION Selected Gain Pressure 1 (status) units Gain 1 Pressure 2 units Gain 2 96 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Pressure 3 units Gain 3 Pressure 4 units Gain 4 Pressure 5 units Gain 5 BREAKER LOGIC (if configured) Frequency Control Armed (status) Sync Window RPM RPM Sync Window Rate RPM/s Tie Breaker Open Ramp YES NO Tie Open Rate RPM/s Generator Open Setpoint RPM Zero Load Value (HP valve %) % Use Minimum Load YES NO Minimum Load Bias (RPM above Rated) RPM Frequency Offset (Hz) Hz Frequency Deadband (Hz) Hz Hold Breaker Logic Changes YES NO SYNC/LOAD SHARE (if configured) Input Bias Gain Input Bias Deadband Lag-Tau Value Hold Changes s YES NO SPEED DROOP Actual Droop % Minimum Droop % Maximum Droop % Use MW as Load Units? YES NO Use kW Droop? YES NO Entered Droop Setpoint % AUXILIARY CONTROL (if configured) Slow Rate Woodward units/s 97 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Fast Rate Delay s Fast Rate units/s Entered Rate units/s Droop % Rated Auxiliary Setpoint units Threshold (Limiter) % Threshold (Controller) % PID Minimum Output % Display Gauge Multiplier Hold Auxiliary Changes YES NO Remote Auxiliary Not Matched Rate units/s Remote Auxiliary Maximum Rate units/s Minimum Remote Auxiliary Setpoint units Maximum Remote Auxiliary Setpoint units Remote Deadband Value units Lag-Tau Value s Hold Remote Auxiliary Changes YES NO AUXILIARY 2 CONTROL (if configured) Slow Rate units/s Fast Rate Delay s Fast Rate units/s Entered Rate units/s Threshold (Limiter) % PID Minimum Output % Display Gauge Multiplier Hold Auxiliary 2 Changes YES NO Remote Auxiliary 2 Not Matched Rate units/s Remote Auxiliary 2 Maximum Rate units/s Minimum Remote Auxiliary 2 Setpoint units Maximum Remote Auxiliary 2 Setpoint units Remote Deadband Value units Lag-Tau Value s Hold Remote Auxiliary 2 Changes YES NO CASCADE CONTROL (if configured) Slow Rate 98 units/s Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Fast Rate Delay s Fast Rate units/s Entered Rate units/s Droop % Rated Cascade Setpoint units Cascade Not Matched Rate units/s Maximum Speed Rate RPM/s Minimum Speed Setpoint RPM Maximum Speed Setpoint RPM Cascade Deadband % Raise/Lower Cascade Only YES NO Use Minimum Load YES NO Breaker Enables Control YES NO YES NO Display Gauge Multiplier Hold Cascade Changes Remote Cascade Not Matched Rate units/s Remote Cascade Maximum Rate units/s Minimum Remote Cascade Setpoint units Maximum Remote Cascade Setpoint units Remote Deadband Value units Remote Lag-Tau Value s Hold Remote Cascade Changes YES NO Use Modbus Trip YES NO Use 2-Step Trip YES NO COMMUNICATIONS Modbus Settings Serial Port 1 Link Status (status) Exception Error (status) Timeout Delay Error Code s (status) Ethernet Port 2 Link Status (status) Exception Error (status) Timeout Delay Error Code s (status) Ethernet Port 3 Link Status Woodward (status) 99 505 Digital Governor for Single/Split-Range Actuators Exception Error (status) Timeout Delay Error Code Manual 26839V2 s (status) Servlink Socket 1 IP (status) Status (status) Level (status) Socket 2 IP (status) Status (status) Level (status) Socket 3 IP (status) Status (status) Level (status) Socket 4 IP (status) Status (status) Level (status) Socket 5 IP (status) Status (status) Level (status) Socket 6 IP (status) Status (status) Level (status) Socket 7 IP (status) Status (status) Level (status) Socket 8 IP (status) Status (status) Level (status) LOCAL/REMOTE Local Mode Enabled (status) Remote Mode Enabled (status) 100 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Enable Contacts? YES NO Contacts Enabled (status) Enable Modbus? YES NO Port 1 Enable When Local YES NO Port 2 Enable When Local YES NO Port 3 Enable When Local YES NO Writes Enabled (status) KEY OPTIONS Use STOP Command YES NO Trip is an Alarm YES NO Blink Alarms YES NO Shutdown on Power-Up? YES NO ALARMS ACTUATOR LINEARIZATION HP Linearization X-1 Value % Y-1 Value % X-2 Value % Y-2 Value % X-3 Value % Y-3 Value % X-4 Value % Y-4 Value % X-5 Value % Y-5 Value % X-6 Value % Y-6 Value % X-7 Value % Y-7 Value % X-8 Value % Y-8 Value % X-9 Value % Y-9 Value % X-10 Value % Y-10 Value % Woodward 101 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 X-11 Value % Y-11 Value % HP2 Linearization X-1 Value % Y-1 Value % X-2 Value % Y-2 Value % X-3 Value % Y-3 Value % X-4 Value % Y-4 Value % X-5 Value % Y-5 Value % X-6 Value % Y-6 Value % X-7 Value % Y-7 Value % X-8 Value % Y-8 Value % X-9 Value % Y-9 Value % X-10 Value % Y-10 Value % X-11 Value % Y-11 Value % REAL TIME CLOCK Use SNTP Synchronization YES NO DATA LOG Data Sample Rate ms File Length s OPERATION LOG Number of Turbine Starts Number of Hot Turbine Starts Total Trips Trips with Load > 25% 102 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Trips with Load > 75% Total Run Time Hours hrs Run Time Hours with Load > 25% hrs Run Time Hours with Load > 75% hrs Total Run Time Hours (status) Disable Maintenance Aalrm Maintenance Interval hrs Maintenance Alarm Peak Speed Reached Maximum Acceleration Reached ISOLATED CONTROL Setpoint Process units (status) Demand % Remote Setpoint Enabled (status) Remote Setpoint Fault (status) Auto Control (status) Process Input Fault (status) Manual Demand (status) Setpoint Limits Maximum (status) units Minimum (status) units Initial (status) units Normal Rate units/s Fast Rate units/s Output Limits Maximum % Minimum % Initial % Normal Rate %/s Fast Rate %/s Commands Remote Setpiont Remote Setpoint Remote Rate (status) units/s PID Dynamics P Term I Term DR Term Woodward 103 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 SCREEN SETTINGS Screen Saver Delay Auto Login as Operator? hrs YES NO Operator Password CUSTOM TREND Settings Time Window s Signal 1 (Red) Variable Y Maximum units Y Minimum units Width Show Axis YES NO Signal 2 (Green) Variable Y Maximum units Y Minimum units Width Show Axis YES NO Signal 3 (Blue) Variable Y Maximum units Y Minimum units Width Show Axis YES NO Signal 4 (Purple) Variable Y Maximum units Y Minimum units Width Show Axis YES NO Signal 5 (Orange) Variable Y Maximum units Y Minimum units Width Show Axis 104 YES NO Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators VALUES FROM VARISTROKE II (HP VALVE) Varistroke II status information. (status) See Varistroke II manual for details. MANUAL DEMAND Use Manual Demand YES NO Manual Demand Rate %/s Timeout When Inactive s ACCELERATION LIMITER Use Acceleration Limiter YES NO Proportional Gain Integral Gain Derivative Ratio Woodward 105 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Appendix C. Password Information General The 505 Series control system requires a password to be entered before access can be given to the OPERATOR, SERVICE, CONFIGURE, or ServiceUser modes. These passwords are intended to help prevent unauthorized or untrained personnel from accessing these modes and possibly making changes that could cause damage to the turbine or associated process. If only certain people are to know these passwords, remove this appendix and keep it in a separate place, apart from the manual. To enter the login or password on the front panel display: Navigate so the Login or Password field is highlighted (in-focus) Press Enter on the Navigation Cross Use the keypad to enter the text field (hold key down to scroll options) Press Enter on the Navigation Cross – to accept your entry Monitor User Level There is no password required for to Monitor values – all navigational commands and display information is available on all screens but no operational commands can be entered from the display. The Emergency Stop button is always available. “Operator” User Level Password Login as Operator: Login: Password: Operator wg1111 “Service” User Level Password Login as Service: Login: Password: Service wg1112 “Configure” User Level Password Login as Configure: Login: Password: Configure wg1113 “ServiceUser” User Level Password Login as ServiceUser (no autofill key available, must be entered manually): Login: ServiceUser Password: ServiceUser@1 106 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Appendix D. Servlink-to OPC Server (SOS) Tool SOS Communication Link The Woodward SOS Servlink OPC server ("SOS") provides an OPC interface for Woodward controls. It runs on a Windows PC that accesses data on controls using the Woodward proprietary Servlink protocol through an Ethernet connection. Woodward OPC client applications, such as Monitor GAP and Control Assistant connect to SOS by selecting a 'Servlink OPC server' connection. SOS implements the OPC Data Access 2.0 standard, so other OPC client applications may also function with it. The install for this program is included on the system documentation CD, the latest releases and updates are always available on the Woodward.com website. Features of SOS     Establishes communication link between control and a PC Can support redundant Ethernet links to a single control Can support links to many controls at the same time Can create a .CSV file of all alarm and trip events Prior to installing SOS, you must install the Microsoft .net framework program which is available on the Woodward website (www.woodward.com). This will install some operating system library files that are used by Control Assistant. Installing SOS License agreement & Setup Figure D-1. SOS Woodward 107 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure D-2. SOS Install Window Define the desired directory to save Connecting a PC/Laptop to the Control You will need to connect to the 505 with an RJ45 Ethernet cable. Any Ethernet port can be used, however it is most convenient to use the same network port that handles all LAN communications (if the 505 is connected to a plant network). You will need to know the IP address of the Ethernet port. The Default IP for Ethernet 1 = 172.16.100.15 (subnet = 255.255.0.0) All information in the communication link between the 505 and the PC is done via a Woodward Servlink connection (using the SOS tool). It is recommended to initially launch this tool independently to establish a healthy communication link. Once this is done the PC will cache this information so that future launches will remember 505 controls. Servlink-to-OPC Server (SOS) The Woodward SOS tool is a sub-component of Control Assistant that handles all of the communications between 1 or many 505’s on a network and the PC. It can be run independently which is a useful way to clearly establish a connection prior to using the Control Assistant or other programs. To launch SOS on independently: Under Start / All Programs / Woodward / SOS Servlink OPC Server Click on SOS Servlink OPC Server You should see the following dialog box appear – Figure D-3. SOS Server status dialog box 108 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Under Session – scroll down and select New Session and a dialog box similar to the one below will appear. In the top entry box enter the IP address of the 505. Figure D-4. SOS – New Session box If you are connected to Ethernet Port 1 of the 505, enter the IP address of this port. The 505 default is shown below or enter the IP for your plant LAN network. Then click on the Connect TCP button Figure D-5. SOS - Enter 505 TCP/IP address The SOS program will locate the control and establish a Woodward Servlink connection between the control and your PC. This will take a few seconds to establish, the dialog box should now look like this (with the IP address being equal to what you typed in above). Figure D-6. SOS – Active Links dialog box Woodward 109 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Appendix E. Control Assistant—Software Interface Tool Features of Control Assistant Control Assistant is an optional software interface tool design to help experienced users maintain setup and configuration settings and troubleshoot system problems. It provides a flexible window into the application software with multiple features for the user. The install for this program is included on the system documentation CD, the latest releases and updates are always available on the Woodward.com website. Features  Using WinPanel (similar to the previous Watch Window products)  Receiving Control Tunables (Download/Receive Tunables from 505)  Sending Control Tunables (Upload/Send a Tunable File to the 505)  Trending Control Parameters Viewing Datalog files Prior to installing Control Assistant, you must install the Microsoft .net framework program which is available on the Woodward website (www.woodward.com). This will install some operating system library files that are used by Control Assistant. Installing Control Assistant License Agreement & Setup Figure E-1. Control Assistant License Agreement 110 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure E-2. Control Assistant Install Window Define the desired directory to save Control Assistant and press ‘Next’. It is preferable to use the default, as it will keep all Woodward Software in a common folder. If the program folder field is blank, type in “Woodward” and the install will create a program folder named Woodward. Figure E-3. Control Assistant Folder Selection Choose the desired folder in the ‘Start Menu’ to save the shortcuts. Figure E-4. Control Assistant Install Complete Woodward 111 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 After Control assistant is installed press ‘Close’. You may or may not have to restart your computer depending on whether or not you had a previous version installed. Figure E-5. Install Restart Window Press ‘Yes’ to restart your computer now, or press ‘No’ to restart your computer later. Control Assistant will NOT function properly until the PC is restarted. Using Control Assistant To launch Control Assistant: Under Start / All Programs / Woodward / Control Assistant 4 Click on Control Assistant 4 Use the Control Assistant HELP in the menu list to get familiar with all features of this product, or for additional information about using the features discussed in this chapter. You should see the following dialog box appear – Figure E-6. Control Assistant Window 112 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Next click on the New Winpanel icon box will appear. in the toolbar- and the following dialog Figure E-7. Dialog for Servlink OPC connection Clicking on Connect will open a WinPanel window that will look like the figure below. Figure E-8. WinPanel Session Using WinPanel (.ws files) Control Assistant includes a feature called WinPanel that provides a text listing of all the GAP blocks in the application. The WinPanel window allows viewing of any software variable in the system, and is therefore intended to be used by users familiar with the architecture of the control software. WinPanel is a typical Windows application that provides a powerful and intuitive interface. The menu structures are familiar to Windows users. Variable navigation is provided through the Explorer window similar to the Explorer in Windows. This tool will look very familiar to users with experience using Woodward’s Watch Windows products. The WinPanel window acts as an OPC client and establishes the data link with SOS. For this reason the WinPanel window must be opened and a control selected to enable uploading or downloading the tunables or trending data from the control (next sections). If multiple controls are available in SOS, they will all appear in the WinPanel window. Typical 505 users are not familiar with the GAP and therefore it is not expected to normally need to create new WinPanel views. Woodward 113 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 What is valuable for a 505 user, is the ability to Open Winpanel View files that have been created by Woodward or by commissioning engineers. These files are identified as <filename>.ws files. This is a handy way to be able to gather system information, support tasks such as valve stroking, tuning or system checkout. Retrieving Control Tunables (Tunables from 505 to a PC) Tunables can be RETRIEVED from the control at anytime with no affect on turbine operation. Once the control is configured and the signals are calibrated, it is recommended that the user save a file containing this information. This is useful for setting up a spare unit, as a replacement or for initially configuring other units of the same type. 1. 2. The first step is to follow the above steps up to the point of having a WinPanel open and the correct control selected Select Transfer/Receive Debug Tunable List from the menus or the Retrieve Icon from the tool bar The following box should appear (Note the send icon is not available) Figure E-9. Control Assistant – Retrieve Tunable Dialog box 3. Click on the Open button and the file will be automatically created with the control ID, time and date in the filename and the extension .tc. Save this file. Sending Control Tunables (Tunables from PC to 505) To send tunable settings to the control the 505 must be in the IO Lock condition, therefore the turbine must be shutdown and the 505 must be in a TRIPPED state. Entering into I/O Lock mode while the turbine is running will cause an automatic shutdown of the turbine with resulting process stoppage. Do not enter the I/O Lock to upload tunables into the control while the turbine is running. To load a previously created tunable file (.tc) into a 505, the turbine must be shutdown since the control will need to enter configuration mode to complete this process. Once the turbine is shutdown, follow these steps: 1. 2. From within Control Assistant Open the tunable (.tc) file Follow the steps in the previous section up to the point of having a WinPanel open and the correct control selected 3. From the menu select Control/Lock IO or select the Lock IO icon from the tool bar 114 Woodward Manual 26839V2 4. 505 Digital Governor for Single/Split-Range Actuators 6. Once selected a dialog box will appear asking for the Debug password – Enter 1112 If the 505 TRIPPED LED was ON (Trip is present) a confirmation box will appear that Lock IO was issued. If the 505 TRIPPED LED was OFF (no trips present) then the confirmation box will state it was not allowed Click on the tunable file and select Transfer/Send Tunable List from the 7. menus or the Send Icon from the tool bar retrieve and send are available) The following box should appear 5. (Note in this state both Figure E-10. Control Assistant – Send Tunable Dialog box 8. 9. Click on Store and the control will save these values. Next click back onto the WinPanel window and then select Control/Reset from the menus or the Reset Icon from the tool bar 10. A dialog confirmation box will appear with some warnings and requires a confirmation check that these have been consider. There is also an option to Save Values again if desired. Checking the warning acknowledge box will allow the Reset button to be selected. 11. Selecting Reset will issue a ‘soft’ reset to the control and it will perform a soft reboot – similar to when the user exits the Configuration mode. The procedure is now complete. It is highly recommended that the user keep a current tunable list file available at site. This will make the configuration and setup of a spare unit very simple and assist in troubleshooting system problems. Woodward 115 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Trending Control Parameters This can be done at any time and will not interfere with any 505 control functions. The first step is to follow the previous steps that were listed up to the point of having a WinPanel open and the correct control selected Use File/Open to open a previously saved trend script file (if you have one). To create new trends, the user will need some understanding of how Woodward’s GAP software is constructed as well as some specific knowledge of the 505 application software. If the user is not familiar with GAP they should limit their use to existing trend script files. Opening existing Trend Script Files When you open an existing trend script the graph will automatically begin trending the control data. The graph will auto scale or the scale can be adjusted to fixed values by the user. There are 2 vertical curser lines that the user can slide along the X axis – the Y1 and Y2 values below the graph relate to these values and the Total Difference (lower right corner) will show the time difference between the 2 cursers lines at all times. The control assistant tool bar has Stop/Start/Zoom button and options to save the data buffer of values into a file for later viewing or analysis. Use the Help menu item to learn more. Below is an example of the Speed Control Trend Script. Figure E-11. Control Assistant – Speed Control Trend Script 116 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Creating a Trend Script File Click on the New Trend icon if you want to create a new trend of parameters. A dialog box will appear and the user will be able to build a trend script file for view system parameters by expanding the explorer window on the left and ‘drag & drop’ GAP block field parameters into the window on the right. Figure E-12. Control Assistant – Create Trend Script File Once the script file is complete, clicking on OK will launch the trend file so that live control data can be viewed. For additional information on the trending capabilities refer to the Control Assistant Help menu. Woodward 117 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Appendix F. AppManger Service Tool File Management with App. Manager AppManager is a Windows based remote access tool for Woodward controls. The 505 is loaded with a service that allows it to interface with AppManager. AppManager is used to manage the applications on the 505 and provide access to operating system information. The install for this program is included on the system documentation CD, the latest releases and updates are always available on the Woodward.com website. Features of App. Manager      Send/Retrieve files from the control Retrieve datalogs from the control Change Ethernet Network addresses Start/Stop the GAP or WGUI application that is running on the control Load Service Packs Installing App Manager License agreement & Setup Figure F-1. App Manager Install Window Select Next to continue with the installation. 118 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure F-2. App Manager License Agreement Window To install App Manager, select “I accept the terms in the license agreement”. Once this has been selected, select Next to continue the installation. Figure F-3. App Manager Installation Choose the desired folder in the ‘Start Menu’ to save the shortcuts. Woodward 119 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure F-4. App Manager Install Complete After App Manager is installed press ‘Finish’. You may to restart your computer depending on whether or not you had a previous version installed. The topics covered below will highlight the main functions that a 505 user may want to do using this tool. For user already familiar with this tool the only new feature is the ability to access the GUI files. For complete information on this tool use the help menu To launch App Manager: Under Start / All Programs / Woodward / AppManager Click on AppManager You should see the following dialog box appear – Figure F-5. AppManager Window AppManager will display 3 panels, the left side panel will show the Control Name and IP Address for each control available on the network. The right side panels will not show information until you are logged into a specific control. When that is done, the right upper panel will show the list of applications available and the right bottom panel will show control status information. Next click on the “Control Name” of the 505 you want to connect to. The following dialog box will appear. 120 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure F-6. Dialog for App Manager Connection To connect to the control use the following Connect As: ServiceUser Password: ServiceUser@1 Click OK and the window should look something like this. Figure F-7. App Manager Connected to a Control Control Information Parameters From the main screen – click on the Control Name and then from the Control menu pull-down select Control Information. The figure below shows an example of the all the information available here. This is a useful place to obtain embedded software part numbers, memory usage, Ethernet IP assignments and total hardware run hours (power up time). Woodward 121 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure F-8. AppManager Control Info Window Switching Application Panel Views The application panel has 2 views - the control application panel has a white background while the GUI application window has a maroon background. To toggle between the panels use the swap second button down from the top). button on the far right side (the Figure F-9. AppManager Control (GAP) Application Panel 122 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure F-10. AppManager GUI Application Panel Retrieving Files The most common use of AppManager is to retrieve data files from the control, specifically Data log and Trend log files. This is done by using the menus and selecting Control/Retrieve Files. A dialog box will open and show the files that are available in that particular application directory. All Data and Trend log files are located in the control application folder. Figure F-11. Retrieving Files Transferring Files For most users there will not be any need to transfer new files to the 505, but if this need arises AppManager is the tool for doing this. To transfer files to the control, first be sure you are in the correct application window. For example to transfer a customize or updated GUI file – switch to the GUI application file panel before transferring the new file. Use the menu and select Control/Transfer Application Files. A dialog box will open so that you can browse your PC to fine the correct file needed to be transferred. Woodward 123 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 The control will allow any file to be transferred, unless it says an existing file on the control with the same name. If this occurs the user must first delete the file on the control before the new one can be transferred. Woodward typically adds a revision or a build number to the end of the file name so that any updates can be added to the control and the previous revisions will still be available. All user tunable settings are associated with a specific program revision. Changing the Ethernet IP addresses It is recommended that the user configure the IP addresses and through the GUI in configuration mode at the same time the control is setup. It is possible to set them up with AppManager – but the control applications must be stopped first. It is best to only have experienced users do this via AppManager. In either method the turbine must be shutdown to change the IP addresses. Start/Stop Applications AppManager is the tool that is used to Start or Stop the execution of the GAP (control and IO) program and/or the GUI (display) program. The GAP and the GUI are handled very differently and will be explained below.. GAP applications – Control logic and I/O The GAP program (filename.out) has logic checks to insure that it is never Stopped while the turbine is in operation. Stopping the GAP program puts the control in IOLOCK. There is typically no need for the user to Stop the GAP program unless an OS service pack is being loaded or the unit is being updated to a newer GAP revision. GUI applications – Display Graphics The GUI program (filename.wgui) contains all the pages of information that appear on the front screen. It can be stopped and restarted without any interruption of the turbine operation (does not affect the GAP execution). The typical use of stopping and restarting the GUI program is: 1. Change the program (to a different build revision) 2. Change the default language of the screen To change the language, go to the MODE screen and navigate to the Globe Icon and press Enter. A list of language options will appear – after selecting the desired language the GUI must be restarted. If the turbine is shutdown, you could just power cycle the control. If the turbine is in operation – or it is not desired to stop the GAP application, then the GUI can be selected, stopped and started from the screen shown in Figure F-10. Install a Woodward Service Pack AppManager is the tool that is used if a service pack needs to be installed to update the OS or the real-time process that executes the GUI application. Typically this will only be done by Woodward representatives or a service bulletin that directs the user through the process. In general these are the steps: 1. Shutdown the turbine to a complete stop 2. Stop the GAP and GUI applications that are running 3. Under the Control menu click on Install Service Pack 4. Locate and launch the Woodward service pack (may take minutes) 5. At the end there will be a dialog box asking to Reset the control click yes 6. After the control reboots – log into the control again 7. Start the GAP and GUI applications 124 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Appendix G. Configuring Network TCP/IP Addresses Figure G-1. Configuration/Communications Screen The ENET 1, ENET 2, and ENET 3 configuration refer to the physical Ethernet connections on the unit. ENET 4 is reserved and is not configurable through the front panel. ENET 3 ENET 2 ENET 1 Figure G-2. Ethernet Port Layout (Ports on Side) Woodward 125 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 The Ethernet IP Configuration screen can be accessed by going to the Configuration Menu and then to Communications. In order to make any changes to the IP settings, the unit must be in Configuration Mode and the user must be logged in with User Level Configure. IP Conflicts It is extremely important to be sure that the control is given a unique IP address on your plant network. Duplicate IP’s for multiple 505 units on the same network will cause communication issues that may adversely affect a running unit. Use a standard network command, such as ‘ping’ to verify the availability of an IP prior to assigning it to a 505 control and placing the control on the network To set a new IP address to one of the Ethernet connections:  The current IP and subnet mask being used are displayed at the top of the page  Once a new IP and subnet have been entered, the “Set IP1”, “Set IP2”, or “Set IP3” buttons must be pressed in order to send the new IPs to the control.  Once set, the new IP address and subnet will be displayed at the top of the page. To set a new device gateway:  Open the pop-up page by pressing “Gateway” soft key.  The current device gateway is displayed at the top of the pop-up page.  Once a new gateway address has been entered, the “Set Gateway” button must be pressed in order to send the new gateway to the control.  Once set, the new gateway will be displayed at the top of the pop-up page. 126 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Appendix H. RemoteView Tool The 505 Remote View tool is used to connect to the 505 controller via Ethernet and provide an interface that is identical to the front panel display. The Remote View tool connects to the control, downloads the GUI application, and launches it on a PC. This process guarantees that the Remote View tool displays screens that are identical to the front panel screens. The Remote View tool also includes the same front panel physical buttons, except for the ESTOP button. All operation and configuration tasks can be performed remotely using this tool. The login User Level determines the access capabilities of the Remote View, just as it does at the front panel. The User Level of the Remote View is independent of the front panel User Level, such that different levels of access can be given to the front panel and the Remote View tool. The Remote View tool is disconnected after two hours and must be launched again to reconnect. The following window will be displayed when the time limit has expired. Figure H-1. Window Shown when the Time Limit is Exceeded Installation The installation file is included on the system documentation CD. The name of the installation file will be similar to 9927-2344_NEW_Woodward_505View.exe. The file name may vary slightly as future revisions are released. Execute this file to begin the installation process. When the installation file is executed, the following welcome window will appear: Figure H-2. Installation Welcome Window Woodward 127 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Select “Next” to continue. The Installation Folder window will open. A default installation folder will be shown. If a different installation folder is needed, click the “Browse…” button to select the new folder. Figure H-3. Installation Folder Window Select “Next” to continue. The License Agreement window will open. Review the terms of each license associated with the tool. Installation can only continue if the licenses are accepted. To accept the licenses, select the “I accept the licenses” option. Figure H-4. Installation License Agreement Window Select “Next” to continue. 128 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators The Start Menu shortcuts window will open. A default location in the Woodward program folder will be shown. If a different Start Menu location is needed, type the new location in the window or select one of the locations presented in the list. Figure H-5. Installation Start Menu Shortcuts Window Select “Next” to continue. The Ready to Install window will open. Figure H-6. Installation Ready to Install Window Select “Install” to continue. Woodward 129 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Configuration of the installation is complete and the actual installation process will begin. A window will open showing the progress of the installation. If prompted to do so, give the installation file permission to make changes to the PC. The following window will open when installation is complete. Figure H-7. Installation Complete Window Click “Finish” to close the window. The Remote View tool is now ready for use. Remote View Configuration To start the Remote View tool, go to the Start Menu and select 505 Remote View from the Woodward folder (or in the alternate folder specified at installation). The configuration window will open. This window has the following sections:  Control list  Application list  Display properties  Predefined settings  Log Control List The Control list shows each control that can be connected to the Remote View tool. Controls are identified by their IP address, and each control must be manually added to the list. To add a control, put the cursor in the IP address field and type in the address, as shown in the following figure. 130 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure H-8. Entering an IP Address to be Added to the Control List When the address has been entered, click the “+” button to add the control to the list. When a control is selected in the Control list, the “Get app list” button becomes as available, as shown in the following figure. Figure H-9. Control Selected in the Control List Woodward 131 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Repeat this process for each control on the network that will be accessed via Remote View. A control can be removed from the list by selecting the control and clicking the “-“ button. Click the “Get app list” button to show the applications that are loaded on the selected control. Displaying the applications requires login to the control. When the “Get app list” button is clicked, the login window will open. Figure H-10. Login Window with Fields for User Name and Password The first line in the login window is the user name. The default user name is ServiceUser. The second line is the password. The default password is ServiceUser@1. After entering the login credentials, click “Login”. Application list After a successful login, the application list will show the applications that are loaded on the control. In almost all cases, the 505 control will have a single application loaded. After selecting an application, the “Launch” button will be available. Click the “Launch” button to open the Remote View tool. 132 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure H-11. An Application Selected in the Application List Display properties This section has two options, the Remote View scale and the Remote View panel type. The scale sets the size of the Remote View tool, where 1.00 is full size. If the Remote View tool is too large for the PC monitor, use the slider to reduce the scale. The Remote View panel type has three choices for the appearance of the tool. The Default setting shows the tool as a replica of the actual 505 front panel. The Simple setting shows the tool as a replica of the actual 505 front panel, but with the right and bottom physical buttons hidden. The Full setting shows the tool as just the screen from the front panel (all physical buttons hidden). Click the “Apply” button to confirm the scale and panel type. Woodward 133 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure H-12. Default View of the Tool Figure H-13. Simple View of the Tool 134 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure H-14. Full View of the Tool Predefined settings This dialog is used to manage settings for the Remote View tool. To save the current Remote View settings for the control list and the display properties, enter a name for the settings and the click “Save”. The following figure shows “Demo” entered as the name for the current settings. Figure H-15. Entering a Name for the Current Settings Woodward 135 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 After clicking “Save”, the settings file will be displayed in the list, as shown in the following figure. Figure H-16. A New Settings File Entered in the Predefined Settings List To delete a settings file, select the file from the list and click “Delete”. To load a settings file, double-click on the name of the file. The login window will open. After a success login, the Remote View tool will open. Log The log shows a record of the actions taken by the tool, such as GUI file retrieval from the control and login to the control. The user will generally not need to check the log, but it is useful for troubleshooting. Using Remote View Before using the Remote View tool, complete the follow steps to connect to the 505 control. These steps are described in detail in the Remote View Configuration section.  Enter the IP address of the control in the configuration window  Get the application list for the control (requires login) The Remote View tool is opened by selecting an application in the configuration window and clicking “Launch”. Alternately, the Remote View tool can be opened by selecting a properly configured settings file from the configuration window. 136 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure H-17. Remote View Tool (Default Setting) after Opening from the Configuration Window The Remote View tool serves as an alternate interface to the 505, enabling operation and configuration from a PC. Use the Remote View tool in exactly the same way as the front panel, as described in Volume 1 of the 505 manual. The buttons on the Remote View screen can be selected with the PC mouse. The PC keyboard can be used to enter text. For many users, use of the mouse and keyboard will make configuration through the Remote View tool easier than configuration at the front panel. Be aware that once user is logged into the RemoteView – they can issue all the same commands that are available at the 505 Front Panel. If multiple 505 are available on a network – they can all be accessed through this tool. Be sure that you are connected to the correct unit prior to making operational adjustments. The configuration window can be opened at any time by clicking the gear button at the top right corner of the tool. The Remote View tool can be closed by clicking the X button at the top right corner of the tool. Woodward 137 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Appendix I. Using 505 Internal Simulation Mode The 505 has an available speed simulation mode that is intended to be used as a training tool. Any unit (a spare unit is ideal) can be setup in an office, lab or conference room to use this feature and allow the user to configure and simulate some functions of the 505 prior to using the unit or wiring it to the turbine. This can be extremely valuable. It can be used to:  Test the operation of the configured start routine  Explore all the options available on the product  Train and document startup procedures  Learn how to connect and use the service tools To enter this mode, go to the MODE screen and log in as the following: Login: ServiceUser Password: ServiceUser@1 This will make available 2 buttons and an LED which will Enable and Disable the H/W simulation mode. Figure I-1. HW Simulation Mode Access When this mode is entered the following actions will take place: 1. The DI01 External Trip will be inverted (so that a FALSE = OK, in normal operation this must be TRUE=OK) 2. Actuator fault trips will be overridden 3. Event 102 Alarm will be active stating Simulation is Enabled 4. A simulated speed ramp will produce speed based upon the valve demand increasing If any of these actions take place the H/W Simulation mode will be aborted: 1. Exiting Configuration (505 resets user to Operator) 2. Logging out or Lowering User Level 3. If DI channel 1 goes TRUE (Normal run mode must be True to Run) 4. If Speed is ever seen on the MPUs 138 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Typical use would be: 1. Configure the unit for the required steam turbine start routine 2. Configure any start sequence items and critical speeds 3. Configure the ramp rates at rate times as a fraction of what you want (for example for a 4 hour idle delay use 0.24 minutes instead of 240 min) 4. Exit the configuration mode and re-login as ServiceUser 5. Simulate a start Woodward 139 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Appendix J. Custom Tag Name Procedure Custom tags allow users to input stings for predefined parameters in any characters available in the Arial Unicode MS font family. This allows users to input tag names using a language other than English. The custom tags are input into the “custom_tags.ini” file that resides on the control. The file contains a list of the available parameters. If custom tags are not used, the tag name can be edited from the front panel or RemoteView in English only. When a custom tag is defined within the “custom_tags.ini” file, it will replace the editable tag with a fixed string defined in the file. Note: When adding custom strings to the “custom_tags.ini” file, keep in mind the string length and the space available on the screen for that string. If the string is too long, it will automatically shrink it to avoid truncation. When a new “custom_tag.ini” file is loaded into the control, the GUI must be restarted in order to load the new stings. The available tags are shown in yellow text on the control. Required Tools 1) AppManager 2) Notepad++ (http://notepad-plus-plus.org/) The “custom_tag.ini” file is formatted. An advanced text editor, such as Notepad++, is required. Creating Custom Tags 1) Make a copy of the blank custom_tags.ini file from the System Documentation CD (BCD85282) 2) Open the “custom_tags.ini” file with an advanced text editor, such as Notepad++ 3) The file contains a list of available tag names. Set the desired tag name to the right of the equals sign. a. If a tag does not contain a string, for example “AI_01_Tag =”, where the string to the right of the equals sign is blank, Qt will use the string in control software. In this case, the string is editable from the front panel in English only. If the tag contains a string, for example “AI_01_Tag = Custom(习俗)(風習)”, Qt will pull the string from the “custom_tags.ini” file to be used on the display. 4) Save the “custom_tags.ini” file after changes have been made 5) Connect to the control using AppManager 6) Change to the GUI Application View 7) Open the appropriate GUI application folder, and download the “custom_tags.ini” file 8) Select “Transfer Files to the Current Control” 9) Select the edited “custom_tags.ini” file and press Open. The file will get copied to the control. 140 Woodward Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators 10) Stop and start the appropriate wgui application Woodward 141 We appreciate your comments about the content of our publications. Send comments to: icinfo@woodward.com Please reference publication 26839V2. ÌB26839v2:èA´¸µ»´¹Î PO Box 1519, Fort Collins CO 80522-1519, USA 1000 East Drake Road, Fort Collins CO 80525, 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.