Product Manual 26839V1

(Revision D, 10/2021)
Original Instructions

505 Digital Control for Steam Turbines

Manual 26839 consists of 2 volumes (26839V1 & 26839V2)

Installation and Operation Manual Volume 1

 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.

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
Revisions 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.

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
Proper Use 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 Out-of-date translations are marked with .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— A bold, black line alongside the text identifies changes in this publication since the
last revision.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 26839V1
Copyright © Woodward, Inc. 2017 - 2021
All Rights Reserved
Manual 26839V1 505 Digital Control for Steam Turbines

Contents

WARNINGS AND NOTICES .............................................................................................................. 6

ELECTROSTATIC DISCHARGE AWARENESS .................................................................................... 8
REGULATORY COMPLIANCE .......................................................................................................... 9
CHAPTER 1. GENERAL INFORMATION........................................................................................... 14
Introduction.................................................................................................................................................. 14
Controller Overview ..................................................................................................................................... 15
Functional Block Diagrams ......................................................................................................................... 17
505 Inputs and Outputs ............................................................................................................................... 18
Keypad and Display .................................................................................................................................... 23
Watchdog Timer/CPU Fault Control ........................................................................................................... 24
CHAPTER 2. HARDWARE SPECIFICATIONS ................................................................................... 25
Flex505 Description and Features .............................................................................................................. 25
Maintenance Info and Recommendations .................................................................................................. 26
Electromagnetic Compatibility (EMC) ......................................................................................................... 27
Outline Drawing for Installation ................................................................................................................... 27
Input Power Specification............................................................................................................................ 29
Visual Indicators (LED’s) & CPU Configuration .......................................................................................... 30
Communications (Ethernet) ........................................................................................................................ 30
Communications (CAN) .............................................................................................................................. 31
Communications (RS-232/RS-485) ............................................................................................................ 33
Communications (Service Ports) ................................................................................................................ 34
Hardware - Terminal Blocks & Wiring ......................................................................................................... 35
Terminal Block Connectors ......................................................................................................................... 36
Hardware - Speed Sensor Inputs ................................................................................................................ 37
Hardware - Analog Inputs (4-20 mA) .......................................................................................................... 38
Hardware - Analog Outputs (4-20 mA) ....................................................................................................... 39
Hardware - Actuator Outputs ...................................................................................................................... 40
Hardware - Discrete Inputs ......................................................................................................................... 41
Hardware - Relay Outputs........................................................................................................................... 42
Troubleshooting Fault Codes ...................................................................................................................... 43
Troubleshooting & Commissioning checks ................................................................................................. 43
CHAPTER 3. 505 CONTROL DESCRIPTION .................................................................................... 47
Introduction.................................................................................................................................................. 47
Turbine Start Modes .................................................................................................................................... 47
Start Permissive .......................................................................................................................................... 47
Open Wire Detection on MPU Speed Signals ............................................................................................ 47
Zero Speed Signal Override........................................................................................................................ 48
Manual Speed Override .............................................................................................................................. 48
Automatic Speed Override .......................................................................................................................... 48
Acceleration Limiter ..................................................................................................................................... 49
Turbine Start Mode Procedures .................................................................................................................. 49
Speed Control Overview ............................................................................................................................. 58
Speed PID Operational Modes ................................................................................................................... 59
Manual Demand .......................................................................................................................................... 71
Load Rejection ............................................................................................................................................ 71
Feed-Forward Input ..................................................................................................................................... 72
Cascade Control ......................................................................................................................................... 74
Auxiliary Control .......................................................................................................................................... 78
Remote Auxiliary Set Point ......................................................................................................................... 82
Auxiliary 2 Control ....................................................................................................................................... 83
Valve Limiter ............................................................................................................................................... 84
Inlet Steam Pressure Compensation .......................................................................................................... 85
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Isolated PID Control .................................................................................................................................... 85
Emergency Shutdown ................................................................................................................................. 86
Controlled Shutdown ................................................................................................................................... 87
Overspeed Test Function ............................................................................................................................ 88
Local/Remote Function ............................................................................................................................... 88
Relays ......................................................................................................................................................... 89
CHAPTER 4. CONFIGURATION PROCEDURES ................................................................................ 91
Program Architecture .................................................................................................................................. 91
Display Modes and User Levels ................................................................................................................. 91
Configuring the 505 ..................................................................................................................................... 92
Exiting the Configure Mode ....................................................................................................................... 119
Valve/Actuator Calibration & Test ............................................................................................................. 126
Calibration/Stroking Procedure ................................................................................................................. 127
CHAPTER 5. 505 OPERATION .................................................................................................... 128
Software Architecture ................................................................................................................................ 128
Power-Up Screen ...................................................................................................................................... 128
Control Mode Architecture ........................................................................................................................ 130
User Login Levels ..................................................................................................................................... 131
Navigation ................................................................................................................................................. 132
Page Organization .................................................................................................................................... 133
Overview Screen ....................................................................................................................................... 135
Speed Control Screen ............................................................................................................................... 135
Valve Demand Screen .............................................................................................................................. 136
Controllers Screen .................................................................................................................................... 137
Cascade Control Screen ........................................................................................................................... 137
Auxiliary Control Screen............................................................................................................................ 138
Analog Input Summary Screen ................................................................................................................. 139
Contact Input Summary Screen ................................................................................................................ 139
Analog Output Summary Screen .............................................................................................................. 140
Relay Output Summary Screen ................................................................................................................ 140
Actuator Driver Summary Screen ............................................................................................................. 141
Starting Procedures (Start Curve Screen) ................................................................................................ 141
Overspeed Test Function (Speed Control Screen) ................................................................................... 142
Stop Key .................................................................................................................................................... 145
Alarm Summary ........................................................................................................................................ 145
Shutdown Summary .................................................................................................................................. 150
Speed, Cascade, and Auxiliary Dynamics Adjustments ........................................................................... 152
CHAPTER 6. COMMUNICATIONS ................................................................................................. 164
Modbus Communications.......................................................................................................................... 164
Port Adjustments ....................................................................................................................................... 167
505 Control Modbus Addresses ................................................................................................................ 167
Specific Address Information .................................................................................................................... 183
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS ........................................................... 185
Product Support Options ........................................................................................................................... 185
Product Service Options ........................................................................................................................... 185
Returning Equipment for Repair ............................................................................................................... 186
Replacement Parts .................................................................................................................................... 187
Engineering Services ................................................................................................................................ 187
Contacting Woodward’s Support Organization ......................................................................................... 187
Technical Assistance ................................................................................................................................ 188
APPENDIX A. 505 CONFIGURATION MODE WORKSHEETS............................................................ 189
DECLARATIONS ........................................................................................................................ 203

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The following are trademarks of Woodward, Inc.:

ProTech
Woodward

The following are trademarks of their respective companies:

Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)

Illustrations and Tables

Figure 1-1. Typical Single or Dual Inlet Steam Turbine .............................................................................. 15

Figure 1-2. Explanation of Symbols ............................................................................................................ 17
Figure 1-3. Single or Split-Range Turbine Configurations .......................................................................... 18
Figure 1-4. 505 Keypad and Display ........................................................................................................... 23
Figure 2-1. Functional Block Diagram (505D Control) ................................................................................ 25
Figure 2-2. 505D Outline Drawing .............................................................................................................. 28
Figure 2-3. COM1 Example RS-485 wiring................................................................................................. 34
Figure 2-4. CPU Service Port (3 pin, 2 mm) ............................................................................................... 34
Figure 2-5. 505 Back Cover Label .............................................................................................................. 35
Figure 2-6. Terminal Block Connectors ...................................................................................................... 36
Figure 2-7. Speed Sensor Block Diagram .................................................................................................. 38
Figure 2-8. Analog Input – Self-Powered Block Diagram ........................................................................... 39
Figure 2-9. Analog Input – Loop-Powered Block Diagram ......................................................................... 39
Figure 2-10. Analog Output Block Diagram ................................................................................................ 40
Figure 2-11. Actuator Output Block Diagram .............................................................................................. 41
Figure 2-12. Discrete Input Block Diagram ................................................................................................. 41
Figure 2-13. Relay Output Block Diagram .................................................................................................. 42
Figure 3-1. Open Wire Detection Test ........................................................................................................ 48
Figure 3-2. Manual Start Mode Example .................................................................................................... 50
Figure 3-3. Semiautomatic Start mode Example ........................................................................................ 50
Figure 3-4. Automatic Start Mode Example ................................................................................................ 51
Figure 3-5. Idle/Rated Start ......................................................................................................................... 53
Figure 3-6. Automatic Start Sequence ........................................................................................................ 54
Figure 3-7. Speed Control Functional Diagram .......................................................................................... 59
Figure 3-8. Speed PID Control Modes ........................................................................................................ 61
Figure 3-9. Frequency and Unit Load Relationship .................................................................................... 62
Figure 3-10. Speed Relationships ............................................................................................................... 64
Figure 3-11. Load Sharing Logic ................................................................................................................. 70
Figure 3-12. Typical Anti-surge Valve and Speed Feed-Forward Logic Trend .......................................... 73
Figure 3-13. Cascade Functional Diagram ................................................................................................. 74
Figure 3-14. Aux Control Overview ............................................................................................................. 79
Figure 3-15. Aux 2 Control Overview .......................................................................................................... 84
Figure 4-1. Initial HOME Screen (unit not configured) ................................................................................ 92
Figure 4-2. Configuration Menu – Configuration Mode (Edit) ..................................................................... 94
Figure 4-3. Actuator Driver Summary/Menu ............................................................................................. 115
Figure 4-4. Self-Powered Actuator Screen ............................................................................................... 115
Figure 5-1. Software Architecture ............................................................................................................. 128
Figure 5-2. 505 Splash Screen ................................................................................................................. 129
Figure 5-3. Boot-up to HOME Screen ....................................................................................................... 129
Figure 5-4. Control Mode Architecture ...................................................................................................... 130
Figure 5-5. Mode Screen .......................................................................................................................... 131
Figure 5-6. Navigation Cross .................................................................................................................... 132
Figure 5-7. Service Menu showing “Speed Control” IN-Focus ................................................................. 132
Figure 5-8. Selection Menu – Language Option. ...................................................................................... 133
Figure 5-9. Configuration Menu – Operation Mode (View only) ............................................................... 134
Figure 5-10. Configuration Menu – Configuration Mode (Edit) ................................................................. 134
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Figure 5-11. Overview Screen .................................................................................................................. 135
Figure 5-12. Speed Control Screen .......................................................................................................... 135
Figure 5-13. Valve Demand Screen .......................................................................................................... 136
Figure 5-14. Controllers Screen ................................................................................................................ 137
Figure 5-15. Cascade Control Screen ...................................................................................................... 137
Figure 5-16. Auxiliary Control Screen ....................................................................................................... 138
Figure 5-17. Analog Input Summary Screen............................................................................................. 139
Figure 5-18. Contact Input Summary Screen ........................................................................................... 139
Figure 5-19. Analog Output Summary Screen .......................................................................................... 140
Figure 5-20. Relay Output Summary Screen ............................................................................................ 140
Figure 5-21. Actuator Driver Summary Screen ......................................................................................... 141
Figure 5-22. HOME Menu showing “Startup Curve” IN-Focus ................................................................. 141
Figure 5-23. Overspeed Test Permissives................................................................................................ 142
Figure 5-24. Internal (505) Overspeed Test.............................................................................................. 143
Figure 5-25. External Overspeed Test ...................................................................................................... 144
Figure 5-26. ALARM Screen ..................................................................................................................... 145
Figure 5-27. Shutdown Summary Screen ................................................................................................. 150
Figure 5-28. Speed Dynamics Adjustment Screen ................................................................................... 152
Figure 5-29. Typical Response to Load Change ...................................................................................... 154
Figure 5-30. Overview of the Automated PID Optimizer Routine ............................................................. 155
Figure 5-31. Optimization Routine Overview Trend .................................................................................. 156
Figure 5-32. Configuration Parameters ‘Configure’ Pop-up ...................................................................... 157
Figure 6-1. ASCII/RTU Representation of three ....................................................................................... 165

Table 1-1. Notes for Control Part numbers ................................................................................................. 14

Table 1-2. Input Functions .......................................................................................................................... 18
Table 1-3. Controller Discrete Input Functions ........................................................................................... 19
Table 1-4. Output Functions........................................................................................................................ 20
Table 1-5. Conditional States ...................................................................................................................... 21
Table 1-6. Level Activated Switch ............................................................................................................... 22
Table 2-1. Environmental Specifications ..................................................................................................... 26
Table 2-2. Input Power Connector Pinout ................................................................................................... 29
Table 2-3. Ethernet Connector (RJ45) Ports #1-4 (10/100)........................................................................ 31
Table 2-4. CAN Specifications .................................................................................................................... 32
Table 2-5. CAN Connector Pinout .............................................................................................................. 32
Table 2-6. CAN Cable Specifications .......................................................................................................... 32
Table 2-7. COM1 Serial Port (RS-232/485)Connector ............................................................................... 33
Table 2-8. Specifications (MPU / PROX) .................................................................................................... 37
Table 2-9. Specifications (AI) ...................................................................................................................... 38
Table 2-10. Specifications (AO) .................................................................................................................. 39
Table 2-11. Specifications (ACT) ................................................................................................................ 40
Table 2-12. Specifications (DI) .................................................................................................................... 41
Table 2-13. Specifications (Relay outputs) ................................................................................................. 42
Table 2-14. CPU Fault LED Flash Codes ................................................................................................... 43
Table 3-1. Example Automatic Start Sequence Settings ............................................................................ 55
Table 3-2. Unit Tripped for 12 hours, Hot and Cold Parameters Interpolation Rates and Delays.............. 55
Table 3-3. Warm or Host Start Configuration.............................................................................................. 57
Table 3-4. Frequency Arm/Disarm Generator Control Modes .................................................................... 66
Table 3-5. On-Line/Off-Line Dynamics Selection........................................................................................ 66
Table 3-6. Load Sharing Logic .................................................................................................................... 70
Table 4-1. Mode Access by User Level ...................................................................................................... 91
Table 4-2. Configuration Function Definitions ............................................................................................. 94
Table 4-3. Analog Input #1 Input Function Menu Options ........................................................................ 111
Table 4-4. Analog Output #1 Output Function Menu Options................................................................... 112
Table 4-5. Options for Actuator Readout .................................................................................................. 114
Table 4-6. CONTACT INPUT OPTIONS .................................................................................................. 116
Table 4-7. Options for Relays if Used to Indicate State ............................................................................ 118
Table 4-8. List of Options for Level Switch ............................................................................................... 118
Table 4-9 Configuration Error Messages and Definitions ......................................................................... 119

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Table 4-10. Actuator Driver Limits ............................................................................................................ 126
Table 5-1. ALARM Messages ................................................................................................................... 146
Table 5-2. TRIPPED Messages ................................................................................................................ 150
Table 6-1. ASCII vs RTU Modbus ............................................................................................................. 165
Table 6-2. Modbus Frame Definition ......................................................................................................... 166
Table 6-3. Modbus Function Codes .......................................................................................................... 166
Table 6-4. Modbus Error Codes ................................................................................................................ 166
Table 6-5. Modbus Communication Port Adjustments ............................................................................. 167
Table 6-6. Maximum Modbus Discrete and Analog Values ...................................................................... 167
Table 6-7. Boolean Write Addresses ........................................................................................................ 168
Table 6-8. Boolean Read Addresses ........................................................................................................ 170
Table 6-9. Analog Reads .......................................................................................................................... 174
Table 6-10. Analog Write Addresses ........................................................................................................ 180
Table 6-11. Control Status ........................................................................................................................ 180
Table 6-12. Analog Input Configuration .................................................................................................... 181
Table 6-13. Analog Output Configuration ................................................................................................. 181
Table 6-14. Relay Configured As Level Switch......................................................................................... 182
Table 6-15. Relay Configuration to Indicate State .................................................................................... 182
Table 6-16. Contact Input Configurations ................................................................................................. 183

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Warnings and Notices

Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.

 DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
 WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
 CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
 NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
 IMPORTANT - Designates an operating tip or maintenance suggestion.

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,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure 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
Personal Protective the job at hand. Equipment that should be considered includes but is
not limited to:
Equipment
 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.

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
Start-up property damage.

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Manual 26839V1 505 Digital Control for Steam Turbines

IOLOCK. When a CPU or I/O module fails, watchdog logic drives it

into an IOLOCK condition where all output circuits and signals are
driven to a known de-energized state as described below. The
System MUST be designed such that IOLOCK and power OFF states
will result in a SAFE condition of the controlled device.

 CPU and I/O module failures will drive the module into an
IOLOCK state
 CPU failure will assert an IOLOCK signal to all modules and
expansion racks to drive them into an IOLOCK state.
 Discrete outputs / relay drivers will be non-active and de-
energized
 Analog and Actuator outputs will be non-active and de-
energized with zero voltage or zero current.

The IOLOCK state is asserted under various conditions including

 CPU and I/O module watchdog failures
 Power Up and Power Down conditions.
 System reset and hardware/software initialization
 Entering configuration mode

NOTE: Additional watchdog details and any exceptions to these

failure states are specified in the related CPU or I/O module section
of the manual.

An emergency switch or circuit breaker shall be included in the

building installation that is in close proximity to the equipment and
within easy reach of the operator. The switch or circuit breaker shall
Emergency be clearly marked as the disconnecting device for the equipment.
The switch or circuit breaker shall not interrupt the Protective Earth
Disconnecting (PE) conductor.
Device

The calibration and checkout procedure should only be performed by

authorized personnel knowledgeable of the risks posed by live
electrical equipment.
Risk of Calibration
and Checkout

The Power Supply MAINS should be properly fused according the

NEC/CEC or Authority Having Final Jurisdiction per the Input Power
Specifications.
Fuse Power Supply
Mains

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Manual 26839V1 505 Digital Control for Steam Turbines

Electrostatic Discharge Awareness

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
Electrostatic the control turned off, contact a grounded surface and maintain
Precautions contact while handling the control).
 Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
 Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not store
static electric charges as much as synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.
If you must remove the PCB from the control cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the components with conductive
devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.

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Manual 26839V1 505 Digital Control for Steam Turbines

Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking. Refer to DoC for applicability by
part number.

EMC Directive Declared to Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014 on the harmonization of the laws of the
Member States relating to electromagnetic compatibility. (EMC)

ATEX – Potentially Declared to Directive 2014/34/EU on the harmonization of the laws of the
Explosive Member States relating to equipment and protective systems intended for
Atmospheres use in potentially explosive atmospheres.
Directive: Zone 2, Category 3, Group II G, Ex ic nA nC T4 X Gc IP20

Low Voltage Directive: Declared to Directive 2014/35/EU on the harmonization of the laws of the
Member States relating to the making available on the market of electrical
equipment designed for use within certain voltage limits.

Other European and International Compliance:

IECEx: Ex ic nA nC IIC Gc T4 Certificate: IECEx CSA 15.0020X
IEC 60079-0: 2011 – Explosive Atmospheres – Part 0 Equipment General
Requirements
IEC 60079-11: 2011 – Explosive Atmospheres – Part 11 Equipment
Protection by Intrinsic Safety “i”
IEC 60079-15: 2010 – Electrical Apparatus for Explosive Gas
Atmospheres; Part 15; Construction, Test and Marking Type of protection
“n”.

EAC Customs Union

These listings are limited only to those units with labels, marking and manuals in Russian language to
comply with their certificates and declaration.

EAC Customs Union: Certified to Technical Regulation TR CU 012/2011 for use in potentially
explosive atmospheres per Certificate
RU C-US.МЮ62.В.04777 as 2Ex ic nA IIC T4 Gc X

Declared to Technical Regulation TR CU 020/2011 On Electromagnetic

Compatibility of Technical Equipment Declaration of Conformity
Registration
No: RU Д-US.МЛ66.В.001129

North American Compliance:

These listings are limited only to those units bearing the CSA identification.

Units bearing only the CSA identification are restricted for use only in Ordinary Locations in North
America.

Units bearing the CSA identification in addition to the marking indicating Class I, Div 2, Groups A,B,C
and D are acceptable for use in North American Hazardous Locations.

CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T4 at 70 °C

surrounding air temperature. For use in Canada and the United States.
CSA Certificate 70006135

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Manual 26839V1 505 Digital Control for Steam Turbines

This product is certified as a component for use in other equipment. The final combination is subject to
acceptance by the authority having jurisdiction or local inspection.

Marine Compliance:

Lloyd’s Register of LR Type Approval Test Specification No. 1, July 2013; Environmental
Shipping: Categories ENV1, ENV2 and ENV3.

DNV-GL Temperature Class D, Humidity Class B, Vibration Class A, EMC Class A,

Enclosure; Required protection according to the Rules shall be provided upon
installation on board.
Lloyd’s: Type Approval Conditions
Where this controller is used to perform safety critical functions or system shutdowns a valid Lloyd’s
Register Software Conformity Assessment Certificate is required. Where the controller is used for control
and alarm purposes a separate, independent safety system must be provided.

Installation of this equipment for marine applications is to be in accordance with current Lloyd’s Register
Rules and Regulations.

Radiated and conducted emissions meet the requirement for equipment in the general power distribution
zones.

DNV-GL: Type Approval Conditions

The Type Approval covers hardware listed under Product description. When the hardware is used in
applications to be classed by DNV, documentation for the actual application is to be submitted for
approval by the manufacturer of the application system in each case. Reference is made to DNV Rules
for Ships Pt. 4 Ch. 9 Control and Monitoring Systems.

Product Certificate
If specified in the Rules, ref. Pt. 4 Ch. 9 Sec. 1, the control and monitoring system in which the above
listed hardware is used shall be delivered with a product certificate. For each such delivery the
certification test is to be performed at the manufacturer of the application system before the system is
shipped to the yard. The test shall be done according to an approved test program. After the certification
the clause for application software control will be put into force.

Clause for application software control

All changes in software are to be recorded as long as the system is in use on board. The records of all
changes are to be forwarded to DNV for evaluation and approval. Major changes in the software are to
be approved before being installed in the computer.

Application/Limitation
Ex-certification is not covered by this certificate. Application in hazardous area to be approved in each
case according to the Rules and Ex-Certification/Special Conditions for Safe Use listed in valid Ex-
certificate issued by a notified/recognized Certification Body.

Special Conditions for Safe Use

A fixed wiring installation is required. Field wiring must be in accordance with North American Class I,
Division 2 (CEC and NEC), or European Zone 2, Category 3 wiring methods as applicable, and in
accordance with the Local Inspection Authority having jurisdiction. On high voltage versions of the control
the interior of the enclosure shall not be accessible in normal operation without the use of a tool.

Field wiring must be suitable for the following temperatures:

 Power Input rated minimum of +95˚C.
 All remaining connections; +10˚C above highest ambient.

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Manual 26839V1 505 Digital Control for Steam Turbines
A switch or circuit breaker shall be included in the building installation that is in close proximity to the
equipment and within easy reach of the operator. The switch or circuit breaker shall be clearly marked as
the disconnecting device for the equipment. The switch or circuit breaker shall not interrupt the Protective
Earth (PE) conductor.

Hazardous Locations
The 505 Digital Control shall not be installed in areas exceeding Pollution Degree 2 as defined in IEC
60664-1.

Wiring must be in accordance with Zone 2 wiring methods and in accordance with the authority having
final jurisdiction.
Protective Earth Grounding of the 505 Digital Control is required to be connected to the PE terminal.

The Real Time Clock Battery located on the CPU board is not to be recharged and is not user
replaceable. Contact a Woodward Authorized Service Center if a replacement service is needed.

The Low Voltage ATEX 505 Digital Control is suitable for use in Class I, Div 2, Gas Groups A,B,C and D
& European Zone 2, Group IIC environments.

This equipment must be installed in an area or enclosure providing adequate protection against high
impact. (7 Joules) The control is rated for 2 Joules impact.

ATEX/IECEx locations require that the 505D Control be installed in a cabinet or enclosure coded Ex nA or
Ex e that provides a minimum IP54 ingress protection for the rear of the control per IEC 60529. The front
bezel, keypad and display have been tested and are rated IP54 while the rear of the control is rated IP20
due to the ventilation slots required for heat dissipation. The installer shall ensure that the maximum
surrounding air temperature in the enclosure does not exceed the rated temperature of +70˚C.

Transient Protection for the 505D is to be provided externally by the end user at the supply terminals of
the control. The transient protection device is to be set at a level not exceeding 140% of the peak rated
voltage (36Vdc).

For ATEX/IECEx installation compliance, the input voltage shall be

limited to 36 Vdc. When an external power supply is selected to
supply the Control, it shall be ATEX/IECEx approved for Zone 2 Group
Explosion Hazard IIC, Category 3G Applications.

Due to the Hazardous Location Listings associated with this product,

proper wire type and wiring practices are critical to the operation.

Explosion Hazard

ENCLOSURE REQUIREMENT—
ATEX/IECEx Zone 2, Category 3G applications require the final
installation location provide a minimum IP-54 ingress protection
Explosion Hazard enclosure against dust and water per IEC 60529. The enclosure must
be coded Ex nA or Ex e.

Do not remove covers or connect/disconnect electrical connectors

unless power has been switched off and the area is known to be non-
hazardous.
Explosion Hazard

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Manual 26839V1 505 Digital Control for Steam Turbines

Substitution of components may impair suitability for Class I, Division

2 or Zone 2.

Explosion Hazard

The external ground lugs shown on the installation drawing must be

properly connected to ensure equipotential bonding. This will reduce
the risk of electrostatic discharge in an explosive atmosphere.
Explosion Hazard Cleaning by hand or water spray must be performed while the area is
known to be non-hazardous to prevent an electrostatic discharge in
an explosive atmosphere.

MOUNTING
The control must be mounted in a vertical position. The installer shall
ensure the maximum surrounding air temperature of the control does
Explosion Hazard not exceed 70˚C at the final location.

Class I, Div 2 Groups A, B, C, D and Zone 2, Group IIC applications

require the input voltage to the relay contacts not exceed 32Vac rms
or 32Vdc.
Explosion Hazard

Ne pas enlever les couvercles, ni raccorder / débrancher les

prises électriques, sans vous en assurez auparavant que le
système a bien été mis hors tension; ou que vous situez
Risque d'explosion bien dans une zone non explosive.

La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I, Division 2
et/ou Zone 2.
Risque d'explosion

Ne pas utiliser les bornes d’essai du block d’alimentation ou

des cartes de commande à moins de se trouver dans un
emplacement non dangereux.
Risque d'explosion

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Manual 26839V1 505 Digital Control for Steam Turbines

Safety Symbols
Direct Current
Alternating Current
Both Alternating and Direct Current

Caution, risk of electrical shock

Caution, refer to accompanying documents

Protective conductor terminal

Frame or chassis terminal

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Manual 26839V1 505 Digital Control for Steam Turbines

Chapter 1.
General Information

Introduction
This manual describes the Woodward 505 Digital Governor for steam turbines with single or split-range
actuators. Released versions are 8200-1300,
8200-1301, and 8200-1302. The option charts below show the differences between the part numbers.
Volume 1 of this manual describes the control, provides installation instructions, defines hardware
specifications, and explains the configuration (programming) and operating procedures. Volume 2
includes notes on applying the control to specific applications and Service mode information. This manual
does not contain instructions for the operation of the complete turbine system. For turbine or plant
operating instructions, contact the plant-equipment manufacturer.

Part Number Options

Part Number Power
8200-1300 LVDC (18–36 Vdc) Ordinary Location Compliance
8200-1301 AC/DC (88–264 Vac or 90–150 Vdc) Ordinary Location Compliance
8200-1302 Marine/ATEX Compliance LVDC (18–36 Vdc)

Table 1-1. Notes for Control Part numbers

NOTE:
Control Part All Control Revisions up to and All Control Revisions at this
Number including this revision, utilize the revision and later, utilize the
OS/Footprint p/n 5418-6479 and OS/Footprint p/n 5418-7795 and
require GAP p/n 5418-6768 require GAP p/n 5418-7838
8200-1300 U V
8200-1301 U V
8200-1302 Q R

505D part number 8200-1302, SN: 22475885, 22545020 and 22564758 are equipped with 505XT control
software to meet end user requirements regarding overspeed test limit below 1,000.00RPM.

General Installation and Operating Notes and Warnings

The Standard Low Voltage and High Voltage Controls are suitable for use in ordinary locations only. The
Low Voltage ATEX Control is suitable for use in Class I, Division 2, Groups A, B, C, and D or Class I,
European Zone 2, Group IIC environments or non-hazardous locations.

These listings are limited only to those units bearing the certification identification.

Field wiring must be stranded copper wire rated at least 75 °C for operating ambient temperatures
expected to exceed 50 °C.

Peripheral equipment must be suitable for the location in which it is used.

Wiring must be in accordance with North American Class I, Division 2 or European Zone 2 wiring
methods as applicable, and in accordance with the authority having jurisdiction.

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

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Manual 26839V1 505 Digital Control for Steam Turbines

Controller Overview
General Description
The 505 controller is designed to control single or dual (split range) actuator steam turbines (extraction
steam turbines require the 505XT version). The 505 is field programmable which allows a single design to
be used in many different control applications and reduces both cost and delivery time. It uses menu
driven software to instruct site engineers on programming the control to a specific generator or
mechanical drive application. The 505 can be configured to operate as a stand-alone unit or in
conjunction with a plant’s Distributed Control System.

The 505 control has five PID controllers that can affect the demand of the inlet steam flow into the turbine;
the Speed/load PID controller, the Auxiliary PID controller, Auxiliary 2 PID controller, and the Cascade
PID controller. Depending on the configuration of the 505, these PIDs interact differently with each other.
Please refer to the Block diagrams listed later in this chapter to fully understand PID relationships. An
additional PID is available as an isolated control loop that is optional and can be used to drive an
independent Analog Output signal (that is not driving a Steam Valve) for any single loop ancillary control
that may be required (such as Seal Gas, Gland Seals, or lube oil pressure loops. When using the Isolated
PID Control, it is recommended to select the “Enable Readback Fault” option for the Analog Output
channel configured as the Isolated PID Demand. This will trigger an alarm in the 505 if a fault of the
output circuit is detected. By default, Analog Output channels are not configured to produce an alarm
when the output circuit has a fault.

The 505 drives one or two steam turbine throttle valves to control one turbine parameter at a time, and if
desired, limit turbine operation based on other parameters. The one controlled parameter is typically
speed (or load), however, the 505 could be utilized to control or limit: turbine inlet pressure or flow,
exhaust (back) pressure or flow, first stage pressure, generator power output, plant import and/or export
levels, compressor inlet or discharge pressure or flow, unit/plant frequency, process temperature, or any
other turbine related process parameter. Refer to Volume 2 of this manual for details on applications.

Figure 1-1. Typical Single or Dual Inlet Steam Turbine

Operator Control Panel

The 505 is a field configurable steam turbine control and operator control panel (OCP) integrated into one
package. A comprehensive graphical operator control panel display and keypad is located on the 505’s
front panel. This display can be used to configure the 505, make On-Line program adjustments, and
operate the turbine/system. Easy to follow instructions allow operators to view actual and set point values
at any time during turbine operation.

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Communications
The 505 control can communicate directly with plant Distributed Control Systems and/or Human Machine
Interface (HMI) control panels, through Modbus communication ports. One serial port support RS-232 or
RS-485 communications using ASCII or RTU MODBUS transmission protocols. Two Ethernet ports are
also available to communication this same information between the 505 and a plant DCS.

Additional Features
The 505 also provides the following features:
 First-Out Trip indication of Alarm and Trip events with RTC time stamp
 10 External DI trip inputs
 10 External Alarm inputs
 Critical Speed Avoidance (3 speed bands)
 Auto Start Sequence (hot & cold starts) with Temperature Input options
 Dual Speed/Load Dynamics
 Zero Speed Detection
 Peak Speed Indication for Overspeed trip, and Isochronous Load sharing between units (with an
DSLC-2 control)
 Feed-forward loop
 Acceleration protection at initial startup
 Remote droop
 Frequency dead-band.

Using the 505

The 505 control has three normal operating modes, Configuration Mode, Service Mode and the Run
Mode. See chapter 4 for more information about the User Levels required to enter each of these modes.

Configuration Mode –
This mode is used to select the options needed to configure the control to your specific turbine
application. While in this mode, the control will force the hardware into IO LOCK, meaning that no outputs
will be active, all Relays will be de-energized, and all Analog output signals will be at 0 current. Once the
control has been configured, the Configuration mode is typically not needed again, unless turbine options
or operation changes. It is available to be viewed at any time.
A password is required to log into this mode.

Anytime the control is in IOLOCK all Relays will be de-energized and

all Analog outputs will be at 0 current. Ensure that the devices
receiving these commands are fail-safe at these states.

Calibration Mode –
This mode calibrates, tunes, and adjusts certain parameters either while the unit is shutdown, or during
turbine run time. A password is required to log into this mode.

Operation Mode -
This mode is the typical state for normal operations of the control and the turbine. The Run Mode
operates the turbine from start-up through shutdown.

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Manual 26839V1 505 Digital Control for Steam Turbines

Functional Block Diagrams

An overview of the 505 valve demands is shown in Figure 1-4. The Cascade and Auxiliary PIDs are
optional controllers and are shown in the following diagrams for PID relationship purposes only. Later in
this manual, more detailed functional block diagrams will be shown in relative to each control loop PID.

Figure 1-2. Explanation of Symbols

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Manual 26839V1 505 Digital Control for Steam Turbines

Figure 1-3. Single or Split-Range Turbine Configurations

(Valve Demand Overview)

505 Inputs and Outputs

Control Inputs
Two redundant speed inputs are configurable to accept MPUs (magnetic pickup units), proximity probes
or eddy current probes.

Eight programmable analog inputs can be configured as one of the following input functions:

Table 1-2. Input Functions

Input Description
Function
1 --- Not Used ---
2 Remote Speed Setpoint
3 Synchronizing Input
4 Sync / Load Share
5 KW / Unit Load Input
6 Cascade Input
7 Remote Cascade Setpoint
8 Auxiliary Input
9 Remote Auxiliary Setpoint
10 Auxiliary 2 Input
11 Remote Auxiliary 2 Setpoint
12 Inlet Pressure Input
13 I/H Actuator 1 Feedback
14 I/H Actuator 2 Feedback
15 Speed Feed-Forward
16 Remote Droop
17 Remote KW Setpoint
18 Exhaust Steam Pressure
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Manual 26839V1 505 Digital Control for Steam Turbines
19 HP Valve FDBK Position
20 HP2 Valve FDBK Position
21 Isolated PID PV
22 Remote SP for Isolated PV
23 Signal Monitoring #1
24 Signal Monitoring #2
25 Signal Monitoring #3
26 Start Temperature 1
27 Start Temperature 2

Twenty contact inputs are available. The first four are defaulted for the following functions: shutdown,
reset, raise speed set point, and lower speed set point. If the control is used in a generator application,
two contact inputs must be configured for use as for a generator breaker and utility tiebreaker. The rest of
the additional contact inputs are available for configuration to function as various controller discrete input
functions as listed below. On the front panel display there are four additional keys that are always
available – Start/Stop/Reset and Adjust Up/Down for raising or lowering a highlighted value.

Table 1-3. Controller Discrete Input Functions

Command Description
1 ---Not Used---
2 Reset Command
3 Speed Raise Command
4 Speed Lower Command
5 Generator Breaker
6 Utility Tie Breaker
7 Overspeed Test
8 External Run
9 Start Permissive 1
10 Idle / Rated Command
11 Halt/Continue Auto Start
12 Override MPU Fault
13 Select On-Line Dynamics
14 Local / Remote
15 Rmt Spd Setpt Enable
16 Sync Enable
17 Freq Control Arm/Disarm
18 Casc Setpt Raise
19 Casc Setpt Lower
20 Casc Control Enable
21 Rmt Casc Setpt Enable
22 Aux Setpt Raise
23 Aux Setpt Lower
24 Aux Control Enable
25 Rmt Aux Setpt Enable
26 Auxiliary 2 Setpoint Raise
27 Auxiliary 2 Setpoint Lower
28 Spare 28
29 Remote Auxiliary 2 Enable
30 Valve Limiter Open
31 Valve Limiter Close
32 Controlled Shutdown(STOP)
33 External Trip 2
34 External Trip 3
35 External Trip 4
36 External Trip 5

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Manual 26839V1 505 Digital Control for Steam Turbines
37 External Trip 6
38 External Trip 7
39 External Trip 8
40 External Trip 9
41 External Trip 10
42 External Alarm 1
43 External Alarm 2
44 External Alarm 3
45 External Alarm 4
46 External Alarm 5
47 External Alarm 6
48 External Alarm 7
49 External Alarm 8
50 External Alarm 9
51 Spare
52 I/H Actuator 1 Fault
53 I/H Actuator 2 Fault
54 Speed Forward Enable
55 Instant Min Gov/Load Speed
56 Select Hot Start
57 Remote KW Setpoint Enable
58 Clock SYNC Pulse Contact
59 Enable Rem SP for Isolated PID
60 Isolated Controller Raise
61 Isolated Controller Lower
62 Spare 62

Control Outputs
Two 4–20 mA or 0–200 mA configurable actuator outputs with linearization curves are available for use.
Actuator 1 is defaulted to be the main HP inlet valve demand, but both actuator channels are configurable
to be HP, HP2 (for split range) or a readout

Six 4–20 mA analog outputs are available for use and each can be configured as one of the following
output functions:

Table 1-4. Output Functions

Control Output Description

1 --- Not Used ---
2 Actual Shaft Speed
3 Speed Reference Setpoint
4 Remote Speed Setpoint
5 Load Share Input
6 Synchronizing Input
7 Generator Load
8 Cascade Input Signal
9 Cascade Setpoint
10 Remote Cascade Setpoint
11 Auxiliary Input Signal
12 Auxiliary Setpoint
13 Remote Auxiliary Setpoint
14 Auxiliary 2 Input Signal
15 Auxiliary 2 Setpoint
16 Remote Auxiliary 2 Setpoint
17 Valve Limiter Setpoint
18 LSS Value

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Manual 26839V1 505 Digital Control for Steam Turbines
19 HP Valve Demand
20 HP2 Valve Demand
21 Inlet Pressure Input
22 I/H Actuator 1 Feedback Readout
23 I/H Actuator 2 Feedback Readout
24 Isolated PID Dmd Output
25 Isolated PID PV Input Signal
26 Isolated PID Setpoint
27 Remote Isolated PID Setpoint
28 Remote KW Setpoint
29 Exhaust Pressure Input
30 HP Valve Feedback Position
31 HP2 Valve Feedback Position
32 Signal Monitoring #1
33 Signal Monitoring #2
34 Signal Monitoring #3
35 Start Temperature 1
36 Start Temperature 2
37 Spare 37
38 Spare 38

Eight Form-C relay contact outputs are available. The first channel is dedicated to be a Trip output and
can be configured for use as a complete Summary Trip or a TRIP relay output (where the External Trip
inputs are not included). The other seven are configurable relays, however the second relay is defaulted
to be an Alarm Summary output.

Each relay can be programmed to provide a contact related to a conditional state as listed in the first list,
or it can be triggered as a level-active switch as per the second list

Table 1-5. Conditional States

Conditional States Description

1 --- Not Used ---
2 Summary Shutdown
3 Summary Shutdown (Trip Relay)
4 Summary Alarm
5 All Alarms Clear
6 Control Status OK
7 Overspeed Trip
8 Overspeed Test Enabled
9 Speed PID in Control
10 Remote Speed Setpoint Enabled
11 Remote Speed Setpoint Active
12 Underspeed Switch
13 Auto Start Sequence Halted
14 On-Line Speed PID Dynamics Mode
15 Local Interface Mode Selected
16 Frequency Control Armed
17 Frequency Control
18 Sync Input Enabled
19 Sync / Loadshare Input Enabled
20 Loadshare Mode Active
21 Cascade Control Enabled
22 Cascade Control Active
23 Remote Cascade Setpoint Enabled
24 Remote Cascade Setpoint Active

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Manual 26839V1 505 Digital Control for Steam Turbines
25 Auxiliary Control Enabled
26 Auxiliary Control Active
27 Auxiliary PID in Control
28 Remote Auxiliary Setpoint Enabled
29 Remote Auxiliary Setpoint Active
30 Auxiliary 2 Control Enabled
31 Auxiliary 2 Control Active
32 Auxiliary 2 PID in Control
33 Remote Auxiliary 2 Setpoint Enabled
34 Remote Auxiliary 2 Setpoint Active
35 HP Valve Limiter in Control
36 Command from Modbus BW addresses
37 Reset Pulse (2 sec)
38 Open GEN Breaker Cmd
39 Feed-Forward Enabled
40 Feed-Forward Active
41 Cascade PID in Control
42 Spare 42
43 Spare 43
44 Spare 44
45 Unit OK (No SD)
46 Remote KW SP Enabled
47 Remote KW Setpoint Active
48 Manual Relay Control
49 Isolated Controller in Auto
50 Spare 50

Table 1-6. Level Activated Switch

Value Description
1 --- Not Used ---
2 Actual Speed
3 Speed Setpoint
4 KW Input
5 Sync/Load Share Input
6 Cascade Input
7 Cascade Setpoint
8 Auxiliary Input
9 Auxiliary Setpoint
10 Auxiliary 2 Input
11 Auxiliary 2 Setpoint
12 HP Valve Limiter
13 LSS Value
14 HP Valve Demand Output
15 HP2 Valve Demand Output
16 Inlet Pressure
17 Exhaust Pressure
18 Customer Defined Monitor Input #1
19 Customer Defined Monitor Input #2
20 Customer Defined Monitor Input #3

Control Interfaces
A complete Modbus list of information is available for HMI, plant DCS or other control interfaces. Three
physical ports are available for this communication method, 2 Ethernet (RJ45) ports and 1 serial port. The
serial port protocol can be either ASCII or RTU and the communications can be RS-232 or RS-485. The
Ethernet links can be configured as TCP or UDP on either ENET ports 1 or 2.
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Keypad and Display

Graphical Display Key Inputs
The front panel display is designed to provide the user with multiple levels of access for configuring,
calibrating, tuning, operating, and monitoring the turbine operation. No additional control panels are
required to operate the turbine, every turbine control function can be performed from the 505’s front
panel.

Figure 1-4. 505 Keypad and Display

A description of each key’s function follows.

Hard Key Commands

NUMERIC KEYPAD = These are available for entering numeric values or text strings directly into the
control when a configurable or programmable edit field has been selected. The bottom row of keys have
some special features.

This is a backspace and delete (used when entering text)

In text mode this functions as a Shift key. When making analog adjustments with the ADJUST
key – pressing this key at the same time as the ADJUST will invoke a ‘Fast’ rate of adjustment

Brightness key = hold this down and then use the ADJUST key to increase/decrease the
screen brightness

EMERGENCY TRIP key = This will Trip the Turbine and remove all current from the Actuator outputs
(zero current).

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Manual 26839V1 505 Digital Control for Steam Turbines
LED = Four LED’s are found on the left side – a Summary Trip, Summary Alarm, IO Lock and CPU
Health. The first 2 are controlled solely by the GAP program and relate to the status of the control. The
IOLOCK and CPU LED’s relate to the H/W status and are identical to these same indications on the back
of the 505

VIEW buttons will jump to the Trip or Alarm Summary screen to show these events in sequence with time
stamp.

MODE button will jump to a Login screen that allows the user to view current permissions and allow
access to changing the user login level

ESC key = this will always step the user ‘back’ one page from the current page displayed

HOME key = brings the user to the Home menu for Run, Service, or Configure. Pressing it a second time
will return to the Run (Operate) Menu Home Screen

NAVIGATION CROSS keys = These are the primary keys for navigating from page to page, or for
navigation of the FOCUS on any page.

Soft Key Commands = Dependent on the screen currently in view – the user must use the navigation
cross keys to move the “Focus” to the desired component

GREEN keys = Generally perform Operational Actions – such as Enabling, Disabling, Starting, Stopping,
Tuning or Adjusting values

MAROON keys = Generally perform Navigational actions that escort the user through the screen menus

BLACK keys = Are soft-key functions that relate to the display indication above them. They can be
navigational or operational. These items do not require “Focus”, they are always available on that screen.

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,
Screen Tutorial and more. The User should familiarize themselves with these screens

Watchdog Timer/CPU Fault Control

The IO Lock and CPU Health LEDs on the front left side of the display – are always in an identical state
as the LED’s on the back side of the control. They are completely controlled by the 505 control hardware
and are not controlled by the GAP application.

A watchdog timer and CPU fault circuit monitors the operation of the microprocessor and microprocessor
memory. If the microprocessor fails to reset the timer within 15 milliseconds of the last reset, the CPU
fault-control will activate the reset output. This resets the CPU, de-energizes all relay outputs and turns
off all milliamp outputs.

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Manual 26839V1 505 Digital Control for Steam Turbines

Chapter 2.
Hardware Specifications

Flex505 Description and Features

The Flex505 controller is a significant upgrade to the existing 505 product line with enhanced CPU,
Graphical display, communications, and I/O functions.

Note: This controller supports expanded I/O options when using Woodward CAN distributed I/O nodes
(RTCnet and LINKnet HT). The 505D application does not support this, but the 505XT application
does. For steam turbine control systems requiring more than the base I/O described below, the 505XT
can be applied. The 505XT has many more features than the 505D and supports single valve and two-
valve steam turbine applications.

Features
 Same installation/mounting as current 505
 8.4” LCD Display (800x600) and Keypad
 (LV) input power: 18-36 Vdc input, isolated
 (HV) input power: 88-264 Vac / 90-150 Vdc, isolated
 Operating range of –30 °C to +70 °C (with display)

Communications
 (4) Ethernet 10/100 communication ports, isolated
 (4) CAN communication ports (1 Mbit), isolated
 RS-232/RS-485 port, isolated
 RS-232 Service port, isolated

I/O circuits
 GAP configurable update rates of 5 ms to 160 ms
 (2) Speed Sensor inputs (MPU/Prox) (with Prox Power)
 (8) Analog input 4-20 mA channels (with Loop Power)
 (6) Analog output 4-20 mA channels
 (2) Actuator output channels (configurable 4-20 mA/20-200 mA)
 (20) Discrete input channels (with Contact Power)
 (8) Relay outputs (form-c)

Figure 2-1. Functional Block Diagram (505D Control)

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Manual 26839V1 505 Digital Control for Steam Turbines
Table 2-1. Environmental Specifications

Operating Temperature1 –30 °C to +70 °C (-22˚F to +158˚F) [with display]

Storage Temperature –30 °C to +70 °C (-22˚F to +158˚F)
Recommended 10 °C to 40 °C (50˚F to 104˚F)
Vibration 8.2 Grms, industrial skid mount, per Woodward RV1
Shock2 10 G, 3x each axis, per Woodward MS1 procedure
Humidity3,4 5 % to 95 %, non-condensing
Altitude 3000m (9842 ft.) Maximum
Installation Rating Pollution Degree 2, Overvoltage Category II
Conformal coating Polyacrylate, sulfur resistant (see AppNote #51530)
EMC Emissions5 EN 61000-6-4 (Heavy Industrial)
IACS UR E10 (Commercial Marine)
EMC Immunity5 EN 61000-6-2 (Heavy Industrial)
IACS UR E10 (Commercial Marine)
Ingress Rating As shipped: IP-20
IP-56 when installed in an appropriate IP-56 or higher rated
enclosure. (Non ATEX/IECEx Applications)
IP-54 for ATEX/IECEx Applications when installed in an
enclosure coded Ex nA and providing a minimum ingress
protection rating of IP-54 as defined in IEC 60529.
1Limited by LCD display
2Limited by internal relay specification
3Relative humidity levels of < 55% will prolong LCD life
4Cyclic condensing humidity is supported with an appropriate enclosure
5Marine specification applies to the ATEX/Marine qualified unit

Maintenance Info and Recommendations

The 505 Control is designed for continuous operation in a typical industrial environment and includes no
components that require periodic service. However, to take advantage of related product software and
hardware improvements, we recommend that your product be sent to a Woodward Authorized Service
Facility after every five to ten years of continuous service for inspection and component upgrades.

Clock battery
The Real Time Clock (RTC) battery is designed to last approximately 10 years during normal turbine
operation. When powered, the RTC automatically disables the battery usage to preserve it. During power-
off the battery is enabled and only used to maintain date and time. For long-term storage, the battery is
specified to last > 5 years.

The RTC battery is a replaceable lithium coin cell Woodward PN 1743-1017. Contact a Woodward
Authorized Service Center if a replacement service is needed.

Calibration and Functional verification

It is recommended to verify calibration and functional operation every 24-36 months. This is especially
important for spare units that need to be ready for immediate use. Contact a Woodward Authorized
Service Center for assistance.

Aluminum Electrolytic capacitors

It is recommended to apply power to spare units every 24-36 months for 3 hours to reform the electrolytic
capacitors used in the power module.

Display LCD with backlight

The 505 uses a low power LED backlight display with a life expectancy of 60K hours to half brightness, at
maximum operating temperature. If the display appears dim, use the “SCREEN SETTINGS” menu to
verify the brightness setting and adjust as needed with the ADJ ARROW-BRIGHTNESS keypad
combination. Contact a Woodward Authorize Service Center for a replacement display when damaged or
if display quality is unacceptable.

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Electromagnetic Compatibility (EMC)

The Flex500 / 505 product family complies with Heavy Industrial EMC requirements per EN 61000-6-4 &
EN 61000-6-2 specifications. Marine Type Approval is also met per IACS UR E10 EMC test requirements
when a Marine qualified version is used.

Emissions EN 61000-6-4 & IACS UR E10

 Radiated RF Emissions Limits 150 kHz to 5000 MHz per IEC 61000-6-4 & Marine Type Approval.
 Power Line Conducted RF Emissions Limits 10 kHz to 30 MHz per IEC 61000-6-4 & Marine Type
Approval.

Immunity EN 61000-6-2 & IACS UR E10

 Electrostatic Discharge (ESD) immunity to ±6 kV contact / ±8 kV air per IEC 61000-4-2.
 Radiated RF Immunity to 10 V/m from 80 MHz to 3000 MHz per IEC
61000-4-3.
 Electrical Fast Transients (EFT) Immunity to ±2.0 kV on I/O and Power Supply inputs per IEC 61000-
4-4.
 Surge Immunity on DC Power Supply inputs to ±1.0 kV line to earth and ±0.5 kV line to line per IEC
61000-4-5.
 Surge Immunity on AC Power Supply inputs to ±2.0 kV line to earth and ±1.0 kV line to line per IEC
61000-4-5.
 Surge Immunity on I/O to ±1.0 kV line to earth per IEC 61000-4-5.
 Conducted RF Immunity to 10 V (rms) from 150 kHz to 80 MHz per IEC
61000-4-6.
 Conducted Low Frequency Injection Immunity at 10% of the nominal supply level from 50 Hz to 12 kHz
on Power Inputs per Marine Type Approval test requirements.

Outline Drawing for Installation

The physical outline dimensions for the 505D control are shown below. See Woodward Reference
drawing 9989-3210 for additional details if necessary.

This 505 unit has the identical mounting hole pattern as the previous
version, however the holes do not come through the front of this unit;
therefore, mounting screws of correct length must be used.

Mounting of the 505D, 505XT and Flex500 with the LCD Display and
Keypad must be in the vertical orientation with the ventilation slots at
the top and bottom of the control. The surrounding air temperature of
the control cannot exceed 70˚C.

Panel Mounting information –

 There are 8 x 10-32 UNF-2B tapped holes that are used to mount the 505.
 The holes are tapped to 0.312” min Depth. Choose the proper length screw to not exceed this depth
into the Bezel.
 Use screw 1069-949 (.375 Long, 10-32) for panel thickness (including washers) .065” - .100"
 Use screw 1069-948 (.438 Long, 10-32) for panel thickness (including washers) .101”- .125”
 Use screw 1069-946 (.500 Long, 10-32) For panel thickness (including washers) .126” - .187”

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Manual 26839V1 505 Digital Control for Steam Turbines

Figure 2-2. 505D Outline Drawing

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Manual 26839V1 505 Digital Control for Steam Turbines

Input Power Specification

Specifications (LV)
LV Input Voltage range: 18-36 Vdc
Input Power (max): < 77 W, 4.3 A max
Output Voltage Holdup time: > 14 ms with 24 Vdc input voltage
Isolation to other circuits: > 500 Vrms to all other circuits
Isolation to EARTH: > 500 Vrms to EARTH

Input Overvoltage Protection: ±60 Vdc @ 25 °C

Reverse Polarity Protection: 60 Vdc @ 25 °C
Input Undervoltage shutdown: ~11 Vdc, non-latching

Note: Breaker or powerline fusing of 8 A min is recommended to protect the power wiring
network from possible wiring shorts.

Specifications (HV)
HV Input Voltage range: 88-264 Vac / 90-150 Vdc
HV Input Frequency range: 45-65 Hz
Input Power (AC max): < 73 W, 1.6 A max
Input Power (DC max): < 73 W, 0.8 A max

Output Voltage Holdup time: > 30 ms with 110 Vac input voltage
Output Voltage Holdup time: > 120 ms with 220 Vac input voltage
Isolation to other circuits: > 3000 Vrms to all other circuits
Isolation to EARTH: > 1500 Vrms to EARTH

Input Overvoltage Protection: ±375 Vdc @ 25 °C

Reverse Polarity Protection: 375 Vdc
Input Undervoltage Shutdown: ~65 Vdc, non-latching

Note: Breaker or power-line fusing of 3.5 A min is recommended to protect the power wiring network from
possible wiring shorts.

Power Connector
Input Power is provided through a three position, latching terminal block with removable plug. Green
connectors are used for low voltage DC units. Orange connectors are used for high voltage AC/DC units.

Table 2-2. Input Power Connector Pinout

Board Connection PIN Name Description

1 L+ Input Power (+)
2 L- Input Power (–)
3 EARTH Earth / shield connection
Plug Type: Side entry 7.62 mm, 12 A, pluggable with latching screw down

To reduce the risk of Electrical Shock the Protective Earth (PE) must
be connected to the PE terminal on the enclosure. The conductor
providing the connection must have a properly sized ring lug and
Electric Shock wire gauge equal to or larger than 4mm² (12AWG).

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Visual Indicators (LED’s) & CPU Configuration

Visual indicators are located on the Front Panel keypad, the controller board, back cover, and related
communications ports for diagnostic use.

CPU OK indicator (green/red): This bi-color LED indicates the CPU status is operational (green) or
faulty (red). The CPU will flash fault codes (red) if they exist. This LED exists on both the Front Panel and
back cover.

IOLOCK indicator (red): Indicate the controller is shutdown and held in an IOLOCK state. This LED
exists on both the Front Panel and back cover.

ALARM indicator (yellow): Viewable from the front panel and controlled by GAP software.

TRIPPED indicator (red): Viewable from the front panel and controlled by GAP software.

Ethernet LED's (green=link, yellow=traffic) on each RJ45 connector indicate port status and operation.

CPU Hardware Configuration

The CPU Configuration Switch (S1) is reserved for future use and is not active at this time.

Communications (Ethernet)
There are four isolated RJ45 Ethernet Ports (10/100 Mbit/sec) available to the application software for
system use. These ports are full duplex with auto crossover detection.

Features
 Interface standard: IEEE 802.3 (Ethernet)
 Port Isolation: 1500 Vrms to PS, EARTH, and all other circuits
 Control configuration using Woodward AppManager
 Control monitoring, trending, and datalog collection
 Control configuration of Ethernet IP addresses
 General communications such as Modbus master/slave
 Manage Configuration data and tunables with Control Assistant
 Network time setup and control (SNTP)

Network Configuration. Ethernet ports (ETH1-4) can be configured for the customer network as desired.
See the on-site Network Administrator to define an appropriate I/P address configuration.

ETHERNET CABLES—Max cable length is 100 meters. To ensure

signal integrity and robust operation, double shielded (SSTP) Cat5
Ethernet cables are required for customer installations.
(Woodward PN 5417-394, 10 feet)

This module has been factory configured with fixed Ethernet IP

addresses of
 Ethernet #1 (ETH1) = 172.16.100.15, Subnet Mask = 255.255.0.0
 Ethernet #2 (ETH2) = 192.168.128.20, Subnet Mask = 255.255.255.0
 Ethernet #3 (ETH3) = 192.168.129.20, Subnet Mask = 255.255.255.0
 Ethernet #4 (ETH4) = 192.168.130.20, Subnet Mask = 255.255.255.0

Each of the ETHERNET ports is required to be configured for a

unique subnet (domain) (view default settings as an example).

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Table 2-3. Ethernet Connector (RJ45) Ports #1-4 (10/100)

Board Connection Description

Pin 1 – TX+
Pin 2 – TX-
Pin 3 – RX+
Pin 4 – not used
Pin 5 – not used
Pin 6 – RX-
Pin 7 – not used
Pin 8 – not used
SHIELD = Chassis GND

Network Configuration Utility (AppManager)

Woodward's AppManager software can be used to configure network setting and load Control software
(GAP), HMI display software (QT), and operating system service packs. The AppManager utility can be
downloaded from www.woodward.com/software.

A PC connection must be made to Ethernet #1 (ETH1) using a RJ45 Ethernet cable.

Note: AppManager can always be used to “discover/view” the current CPU IP Address. However, to
modify settings or load applications, the PC running AppManager must be reconfigured to be on the
same “network” as the CPU.

 Locate the ControlName on the module faceplate and highlight it in AppManager.

 To VIEW the IP address configuration, select menu option CONTROL - CONTROL INFORMATION.
Look for the Ethernet adapter addresses under the Footprint Description.

 To CHANGE the IP address configuration, select menu option CONTROL - CHANGE NETWORK
SETTINGS.

Communications (CAN)
(4) Isolated CAN ports are available for general communications as well as simplex or redundant
distributed control. Compatible devices include Woodward RTCnet nodes, LINKnet HT nodes, DVP valve
products, and other 3rd party devices. Removable latching connector plugs are provided for field wiring.

Network Termination: CAN networks must include a 120 Ω termination resistor at each end of the trunk
line.

Network Topology: Daisy chain connections between multiple devices are recommended. Any drop
cable connection of a device to the trunk line should be as short as possible and much less than 6
meters. It is recommended to design the network trunk to be less than 100 meters with a max cumulative
drop length of less than 39 meters.

Important: For 1 Mbit/sec communication it is required that each drop cable be less than 1 meter and as
short as possible.

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Table 2-4. CAN Specifications

Interface Standard CAN 2.0B, CANopen

Network Connections (4) CAN ports, separate connectors
Network Isolation 500 Vrms to EARTH, other CAN ports, all other I/O
Network Speed/Length 1 Mbit @ 30 m
500 Kbit @ 100 m
250 Kbit @ 250 m (thick cable only, otherwise limited to 100 m)
125 Kbit @ 500 m (thick cable only, otherwise limited to 100 m)
Network Termination: (120 ± 10) Ω is required at each end of the network trunk line.
**The termination resistor is NOT built into the hardware.
CAN Address Software configurable
CAN Baud Rate Software configurable for 125 K, 500 K, 250 K, and 1 Mbit
Cable / Part Number 2008-1512 (120 Ω, 3-wire, shielded twisted pair)
—Belden YR58684 or similar
Cable Drops (1 Mbit) CAN Cable drops shall be < 1 m and as short as possible
Cable Drops (500K, etc) CAN Cable drops shall be < 6 m and as short as possible
**If needed, an isolated CAN to USB converter is IXXAT, HW221245

Table 2-5. CAN Connector Pinout

Board Connection PIN Color Description

1 BLACK CAN Signal Ground
2 BLUE CAN Low
3 Shield CAN Shield (30 Meg + AC coupled to EARTH)
4 WHITE CAN High
5 n/a Not used, no internal connection
Plug Type: Side entry 3.5 mm, 8 A, pluggable with latching screw down
Max wire size: 1.3 mm² / 16 AWG for single wires, 0.5 mm² / 20 AWG for two wires

Table 2-6. CAN Cable Specifications

Belden YR58684 (Woodward PN 2008-1512) communications / CAN cable is approved and

recommended. This is a smaller and more flexible 0.3 mm² / 22 AWG, low capacitance cable suitable for
tight routing in industrial environments.

Belden YR58684, bulk cable (Woodward PN 2008-1512)

Impedance: 120 Ω 10 % at 1 MHz

DC resistance: 17.5 Ω per 1000 ft
Cable capacitance: 11 pF/ft at 1 kHz
0.3 mm² / 22 AWG, 7 strands, individually tinned, FEP insulation
Data Pair:
(BLUE, WHITE twisted pair)
Ground: 0.3 mm² / 22 AWG, 7 strands, individually tinned, FEP insulation (BLACK)
Drain / Shield Wire: 0.3 mm² / 22 AWG, 7 strands, individually tinned
Shielding: Foil 100 % with outer Braid 65 %
Jacket: FEP Insulation, BLACK
Cable type: 1.5 pair, twisted shielded
Outer Diameter: 0.244 inch
Bend Radius: 2.5 inches
Temperature: –70 °C to +125 °C
Similar Cable: Belden 3106A (has different colors & lower temperature specs)

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CAN Wiring / Shield Terminations & Limitations

For robust communications performance, the CAN cabling needs to minimize the exposed, non-shielded
cable section that occurs at terminal blocks. The exposed length of CAN wiring must be limited to less
than 3.8 cm / 1.5 inches from the end of the shield to the terminal block.

CAN shields are terminated to chassis (EARTH) through a capacitor-resistor network. This is designed
into the Flex500 / 505 hardware products. However, the shield must also be directly terminated to chassis
(Earth) at one point in the network. In the case of Woodward equipment, the direct ground is meant to be
located at the master device end, as it exits the master device’s enclosure.

Always use shielded cables for improved communications in industrial

environments. Wire terminations should expose as little
un-shielded cable as possible (less than 3.8 cm / 1.5 inches).

Communications (RS-232/RS-485)
An isolated, configurable RS-232 / 485 serial port is available for customer use, as configured by the GAP
software application. RS-422 communications is NOT supported.

Specifications
 Interface standard: RS-232C and RS-485
 Isolation: 500 Vrms to EARTH and all other I/O
 Baud Rates: 19.2K, 38.4K, 57.6K, and 115.2 K
 Max Distance (RS-232): 15 m (50 feet) max
 Max Distance (RS-485): 1220 m (4000 feet) max
 A shielded cable is required when using this port.
 RS-485 networks require termination at both ends with approx 90–120  impedance that matches
the characteristic impedance of the cable used.

Cable Note: Woodward cable 2008-1512 (3-wire) is a shielded, low capacitance 120 ohm cable that is
designed for communications. This cable is also used for CAN communications.

Table 2-7. COM1 Serial Port (RS-232/485)Connector

Board Connection Description

Pin 1 – RS-232 Transmit
Pin 2 – RS-232 Receive
Pin 3 – Signal Common
Pin 4 – Shield (AC)
Pin 5 – RS-485 (+)
(8 pins) Pin 6 – Termination Resistor (+)
Pin 7 – Termination Resistor (-)
Pin 8 – RS-485 (-)
Plug Type: Side entry 3.5 mm, 8 A, pluggable with latching screw down
Max wire size: 1.3 mm² / 16 AWG for single wires, 0.5 mm² / 20 AWG for two wires

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Figure 2-3. COM1 Example RS-485 wiring

Communications (Service Ports)

RS-232 Service Port
An isolated RS-232 service port is located on the CPU board. Isolation is specified at 500 Vrms and baud
rate is fixed at 115.2K baud, 8 data bits, no parity, 1 stop-bit, and no flow control. This port is for VxWorks
operating system use only and cannot be configured for application software use.

For debug use, a Woodward PN 5417-1344, USB to serial debug cable is required to attach this port to a
PC. This port is to be used by trained Field Service personnel only!

Dura-Clik connector (male)

Pin 1 – RS-232 Transmit
Pin 2 – RS-232 Receive
Pin 3 – Signal Ground

Figure 2-4. CPU Service Port (3 pin, 2 mm)

USB Service Port

Note: A USB service port is provided for future use, but is disabled.

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Hardware - Terminal Blocks & Wiring

Figure 2-5. 505 Back Cover Label

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Terminal Block Connectors

Figure 2-6. Terminal Block Connectors

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Hardware - Speed Sensor Inputs

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

Features
 (2) Digital Speed Sensor circuits, isolated individually
 GAP configurable for MPU sensors or Proximity sensor operation
 Separate terminals provided for MPU and Prox sensors
 Isolated Prox Power (+24 Vdc) is provided with short-circuit protection
 Woodward GAP block, diagnostics, and configuration support
 GAP configurable update rates of 5 ms to 160 ms

Table 2-8. Specifications (MPU / PROX)

MPU Input Voltage: 1 to 35 Vrms

MPU Input Frequency: 10 Hz to 35 KHz
MPU Input Impedance: 2000 Ω, DC
MPU Input Isolation: 500 Vrms to EARTH and all other I/O
500 Vrms to other MPU and PROX channels

Prox Input Voltage: 0-32 VDC

Prox Input Frequency: 0.04 Hz to 35 KHz (low limit depends on range)
Prox Input Impedance: 2000 Ω, DC
Prox Threshold: Low is < 8 VDC, High is > 16VDC
Prox Input Isolation: 500 Vrms to EARTH and all other I/O
500 Vrms to other MPU and PROX channels.

Prox Power1+2 out: 24 VDC ± 14%, 0-200 mA, short circuit & diode
protected
Prox Power Isolation: 500 Vrms to EARTH, all other I/O, & other Prox Power

Max Speed Range: software selectable from 5 kHz to 35 kHz

Accuracy (-40,70c): < ±0.01% of full scale range selected
Resolution: > 22 bits
Speed Filter (ms): 5-10,000 ms (2 poles)
Derivative Filter (ms): 5-10,000 ms (speed filter + 1 pole)
Derivative Accuracy: 0.1% of full scale range, over full temperature range
Acceleration limit: 1-10,000 %/sec

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Figure 2-7. Speed Sensor Block Diagram

Hardware - Analog Inputs (4-20 mA)

AI Description and Features
The Flex500 / 505 controller includes (8) 4–20 mA input channels for I/O monitoring and control. Each
channel is differential (self-powered) but can be software configured for Loop Power mode. An Isolated
Loop Power (+24 Vdc) is provided for analog input transducers and includes short-circuit/over-voltage
protection. Note: Do not use the Loop Power output to power any other type devices.

Features
 (8) 4–20 mA Analog Input Channels, 16 bit resolution
 Differential inputs with high common-mode voltage capability
 Isolated Loop Power +24 V is provided with short-circuit protection
 Fast AI channel #8 for special control functions
 Woodward GAP block, diagnostics, and configuration support
 GAP configurable update rates of 5 ms to 160 ms
 GAP configurable for Loop power operation

Table 2-9. Specifications (AI)

Number of channels 8
AI Input Range 0 to 24 mA
0 V channel to channel.
AI Input Isolation
500 Vrms to EARTH and all other I/O (except USB)
AI Accuracy (@ 25 °C) ≤ 0.024 mA (0.1% of FS=24 mA)
AI Accuracy (–40, +70 °C) ≤ 0.06 mA (0.25% of FS=24 mA)
AI Resolution ~16 bits of full scale
2 poles @ ~10 ms
AI Hardware filter
**Fast channel (ch 8) has 2 poles @ ~5 ms
AI Input Impedance 200 ohms (Rsense = 162 ohms)
AI Loop power output 24 V ±14% (0-250 mA) short circuit & diode protected
AI Loop power Isolation 500 Vrms to EARTH and all other I/O

AI CMRR over temp > 70 dB @ 50/60 Hz (typical 86 db)

AI CMVR > 200 V (dc) to EARTH
AI Overvoltage ±36 V (dc) continuous at room temperature

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Figure 2-8. Analog Input – Self-Powered Block Diagram

Figure 2-9. Analog Input – Loop-Powered Block Diagram

Hardware - Analog Outputs (4-20 mA)

This control provides an isolated group of (6) 4-20 mA outputs for customer use. Each output can drive up
to 600 ohm loads and provides fault monitoring of individual source and return currents.

Features
 (6) Analog Output channels (4-20 mA)
 Source and return current monitors
 Group isolated from other circuits
 Capable of driving higher impedance loads up to 600 ohms
 Woodward GAP block, diagnostics, and configuration support
 GAP configurable update rates of 5 ms to 160 ms

Table 2-10. Specifications (AO)

Number of channels 6 (each with readback)

AO Output Range 0 to 24 mA, 0 mA during shutdown
0 V channel to channel
AO Output Isolation
500 Vrms to EARTH and all other I/O
AO Accuracy (@ 25 °C) ≤ 0.024 mA (0.1% of FS=24 mA)
AO Accuracy (–40, +70 °C) ≤ 0.120 mA (0.5% of FS=24 mA)
AO Resolution ~14 bits of full scale
AO Hardware filter (max) 3 poles @ 250 μs
AO Load Capability 600 Ω at 20 mA

AO Output Readbacks (0 to 24) mA, source and return

AO Readback Accuracy < 1% at 25°C, < 3% over full temperature range
AO Readback HW Filter ~0.5 ms nominal
AO circuits are driven to 0 mA during power-up, power-
IOLOCK state
down, core voltage failures, and watchdog failures

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Figure 2-10. Analog Output Block Diagram

Hardware - Actuator Outputs

This control provides an isolated group of (2) Actuator outputs for customer use. Each driver can be
configured for low-range (20 mA) or high-range (200 mA) operation. Fault monitoring of individual source
and return currents is included.

Features
 (2) Actuator Output channels (4-20 mA, 20-200 mA)
 Source and return current monitoring
 Group isolated from other circuits
 Capable of driving higher impedance loads
 Woodward GAP block, diagnostics, and configuration support
 GAP configurable update rates of 5 ms to 160 ms

Table 2-11. Specifications (ACT)

Number of channels (2) proportional drivers with source & return readbacks
ACT Output Range Configurable for 24 mA or 200 mA range
ACT Output Range (low) 0-24 mA, 0 mA during shutdown (FS = 24 mA)
ACT Output Range (high) 0-200 mA, 0 mA during shutdown (FS = 210 mA)
0 V channel to channel
ACT Output Isolation
500 Vrms to EARTH and all other I/O

ACT Accuracy (25 °C) Low Range ≤ 0.024 mA (0.1%) High Range ≤ 0.21 mA (0.1%)
ACT Accuracy (–40, +70 °C) Low Range ≤ 0.120 mA (0.5%) High Range ≤ 1.00 mA (0.5%)

ACT Resolution ~14 bits of full scale

ACT Hardware filter (max) 3 poles @ 500 μs
ACT Load Capability (low) 600 Ω at 20 mA
ACT Load Capability (high) 65 Ω at 200 mA

ACT Output Readbacks (0 to 24) mA, source and return

ACT Readback Accuracy < 1% at 25°C, < 3% over full temperature range, (source & return)
ACT Readback HW Filter ~0.5 ms nominal

Front panel ESTOP button will shutdown the actuator circuit,

ESTOP action
remove actuator power, and set an alarm in GAP software.
During IOLOCK, ACT power is shutdown and ACT circuits are
IOLOCK action driven to 0 mA during power-up, power-down, core voltage
failures, and watchdog failures.

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Figure 2-11. Actuator Output Block Diagram

Hardware - Discrete Inputs

This control provides an isolated group of (20) discrete input channels for use with +24 V (dc) signals. An
isolated Contact Power voltage supply of +24 V (dc) is provided to use with the discrete inputs. This
supply includes short-circuit and over-voltage protection.
Note: Do not use the Contact Power output to power any other devices.

Features
 (20) Discrete Input Channels for +24 V (dc) signals
 +24 V Contact Power with short-circuit and diode protection
 Isolated power and discrete input group
 Woodward GAP block, diagnostics, and configuration support
 GAP configurable update rates of 5 ms to 160 ms
 Time-stamping capability (1 ms)

Table 2-12. Specifications (DI)

Number of Channels 20
DI Input Low State (0 to 8) V (dc)
DI Input High State (16 to 32) V (dc)
DI Input Current < 5 mA per channel
DI Input Impedance 25K approx
DI Hardware Filter 1.0 ms approx at room temp
0 V channel to channel
DI Channel Isolation
500 Vrms to EARTH and all other I/O
DI Overvoltage Overvoltage to 36 V (dc) for inputs
Contact Power Output 24 V ±14 %, 150 mA (max), short circuit & diode protected
Contact Power Isolation 500 Vrms to EARTH and all other I/O

Figure 2-12. Discrete Input Block Diagram

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Hardware - Relay Outputs

This control provides (8) Isolated, Form-C Relay outputs with NO, COM, NC contacts available at the
terminal block.

Features
 Eight Relay Output Channels
 Each Relay Output provides NO, COM, and NC contacts
 Each Relay Output channel provides a coil voltage readback fault
 Woodward GAP block, diagnostics, and configuration support
 Contact isolation maintained at terminal blocks
 ATEX approved version available using hermetically sealed relays
 GAP configurable update rates of 5 ms to 160 ms

Table 2-13. Specifications (Relay outputs)

Number of channels (8) relays

Contact Type Form-C with NO, COM, and NC terminals
STD Relay, contacts (DC) 5 A, 5-30 Vdc (resistive)
STD Relay, contacts (AC) 2 A, 115 Vac (resistive)
STD Relay, operate time < 15 ms typical
RELAY Coil Readback Coil voltage readback status is available
RELAY Coil Rdbk Filter 1 ms approx at room temp

RELAY Output Isolation 500 Vrms minimum to EARTH and all other I/O
RELAY Contact Isolation 500 Vrms minimum between open contacts
RELAY to RELAY Isolation 500 Vrms minimum between relays
Relay outputs are de-energized during power-up, power-down,
IOLOCK State
core voltage failures and watchdog failures

ATEX version: The ATEX approved control uses a Hermetically sealed relay
ATX Relay, contacts (DC) 5 A, 5-30 Vdc (resistive), 0.2-0.5 A (inductive)
ATX Relay, contacts (AC)** 2 A, 115 Vac (resistive), 0.1-0.2 A (inductive), non-hazardous area

**ATEX/IECEx and North American Hazardous Locations

Compliance requires relay contact loads be limited to < 32 Vac
rms / < 32 Vdc.
Explosion Hazard

Figure 2-13. Relay Output Block Diagram

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Troubleshooting Fault Codes

The CPU board runs diagnostics that display troubleshooting messages through the debug Service Port
and AppManager. Additional information on diagnostics tests, subsequent LED flash codes, and serial
port messages is contained in the VxWorks manual.

Table 2-14. CPU Fault LED Flash Codes

Failure Flash Code

CPU not operational, IOLOCK state Solid Red
RAM Test Failure 2, 1
FPGA Test Failure 2, 9
Watchdog not enabled 2, 10
RAM drive error 2, 11
Flash drive error 2, 12

Troubleshooting & Commissioning checks

Power checks
 Verify proper polarity on power connections
 Verify power source and wire size is sufficient for all loads
 Verify input power voltage is correct (i.e.: low voltage unit is 18 V to 36 Vdc)
 Verify PS(+) and PS(–) impedance to EARTH is > 10 MΩ

Ethernet checks
 Verify cabling meets CAT-5 or better performance specs
 Verify cables are shielded properly per Woodward spec (using inner foil and outer braid)
 Verify each port is connected to the desired port & cable is labeled with correct port number
 Verify the cable installation has a bend radius is > 3 inches to prevent cable stress/breakage
 Verify that any tie-wraps used for cable installation are not overly tight to prevent cable stress
 Verify IP Address of each port is set correctly according to your plant network & administrator
 The default IP address for all ports is listed in the Hardware/Ethernet section of this manual.
 The Woodward AppManager tool can be used to review & change IP Address settings
 Verify that Woodward Tools use Ethernet #1 (AppManager, OPC Server, & Control Assistant)
 Consider using color coded tie wraps for ports (i.e.: ETH1 = blue, ETH2=red, ETH3=yellow)
 For best performance, verify that Ethernet traffic is < 70% and GAP rategroup loading is < 80%

RS-232 wiring checks

 Verify the RS-232 wiring uses a high-quality shielded communication cable. For example, Woodward
2008-1512 (Belden YR58684) or equivalent low capacitance, shielded communications wire.
 Verify the RS-232 wiring uses the signal common (COM1_GND)
 Verify RS-232 network length is within specifications (typically < 50 feet)
 Verify Signal wires (TX+,RX-) are not shorted to each other
 Verify Signal wires (TX+,RX-) are not shorted to COM1_GND
 Verify Signal wires (TX+,RX-) are not shorted to COM1_SHLD
 Verify Signal wires (TX+,RX-) are not connected to PS(+), PS(–), EARTH
 Verify COM1_GND is not connected to PS(+), PS(–), EARTH
 Verify the overall cable shield is terminated to EARTH at only (1) location.

RS-485 wiring checks

 Verify the RS-485 wiring uses a high-quality shielded communication cable. For example, Woodward
2008-1512 (Belden YR58684) or equivalent low capacitance, shielded communications wire.
 Verify RS-485 network length is within spec for the baud-rate (typically < 4000 feet)
 Verify the network is terminated properly at both ends with approx 90–120 
 Verify the RS-485 wiring uses the signal common (COM1_GND)

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 Verify Signal wires (RS-485+, RS-485–) are not shorted to each other
 Verify Signal wires (RS-485+, RS-485–) are not shorted to COM1_GND
 Verify Signal wires (RS-485+, RS-485–) are not shorted to COM1_SHLD
 Verify Signal wires (RS-485+, RS-485–) are not connected to PS(+), PS(–), EARTH
 Verify COM1_GND is not connected to PS(+), PS(–), EARTH
 Verify the overall cable shield is terminated to EARTH at only (1) location.

CAN wiring checks

 Verify the CAN wiring uses a high quality, 3-wire, shielded communication cable. For example,
Woodward 2008-1512 (Belden YR58684) or equivalent low capacitance, shielded communications
wire.
 Verify CAN network length is < max length spec for the baud rate being used
 Verify network is terminated properly at both ends with 120 , ±10%
 Verify the CAN wiring uses the signal common (CAN_GND)
 Verify CAN drop cables to each device are as short as possible and meets spec.
 Verify CANH is not connected to PS(+), PS(–), EARTH
 Verify CANL is not connected to PS(+), PS(–), EARTH
 Verify CAN_COM is not connected to PS(+), PS(–), EARTH
 Verify CAN_SHLD shield wire is not shorted to PS(+), PS(–)
 Verify the CAN overall cable shield is terminated to EARTH at only (1) location for each network.
 For redundant CAN, verify redundant networks are not miswired or connected together.

Speed Sensor MPU/PROX wiring checks

 Verify MPU sensors are wired to MPU terminal block location
 Verify PROX sensors are wired to PROX terminal block location
 Verify that each sensor is wired to the correct channel (ie: MPU1 to channel1)
 Verify that MPU+, PROX+ is not connected to PS(+), PS(–), EARTH
 Verify that MPU-, PROX- is not connected to PS(+), PS(–), EARTH
 Verify shield wires are not shorted to signals (MPU+, MPU-, PROX+, PROX-)
 Verify shield wires are not shorted to input power PS(+), PS(–)
 Verify MPU voltage amplitude meets spec (ie: > 1Vrms)
 Verify PROX voltage amplitude meets spec (ie: < 8V for low, >16V for high)
 If Prox Power#1 output is used, make sure it is ONLY used for sensor power1
 If Prox Power#2 output is used, make sure it is ONLY used for sensor power2
 If using Prox Power, verify that wiring is correct and isolation between sensors is maintained
 If using Prox Power, verify PPWR1+,PPWR2+ are not connected to PS(+), PS(-), EARTH
 If using Prox Power, verify PPWR1-,PPWR2- are not connected to PS(+), PS(-), EARTH
 If using Prox Power, verify PPWR1+,PPWR2+ are not connected to each other
 If using Prox Power, verify PPWR1-,PPWR2- are not connected to each other

AI (non-loop), Analog Input wiring checks

 Verify that external XDCR's are NOT used with these self-powered channels.
 Verify each AI(+,–) is not shorted to another input channel.
 Verify each AI(+) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each AI(–) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each AI shield wire is not shorted to PS(+), PS(–).
 Verify each AI shield wire is terminated at the node properly.
 Functionally verify the wiring for each AI channel using a simulator source.

AI (Loop power), Analog Input wiring checks

 Verify that external XDCR's are connected to these channels.
 Verify the LPWR voltage level (+24 V dc) is correct for the XDCR.
 Verify each LPWR(+) terminal is wired to the XDCR POWER(+).
 Verify each LPWR(+) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each AI(–) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each AI shield wire is not shorted to PS(+), PS(–).
 Verify each AI shield wire is terminated at the node properly.
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 Verify that all XDCR's channels use less than 250 mA of LPWR.
 Functionally verify the wiring for each AI channel using a simulator source.

AO, Analog Output wiring checks

 Verify each AO(+,–) is not shorted to another output channel.
 Verify each AO(+,–) is not shorted to another Analog Input channel.
 Verify each AO(+) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each AO(–) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each AO shield wire is not shorted to PS(+), PS(–).
 Verify each AO shield wire is terminated at the node properly.
 Functionally verify the wiring for each AOUT by driving 4 mA and 20 mA to the load from the GAP
application. Verify correct output current with a meter. Verify the correct SRC_RDBK & RET_RDBK
values in GAP.

DI, Discrete Input wiring checks

 Verify each DI(+) is not shorted to another input.
 Verify each DI(+) is not shorted to CPWR(+), CPWR(–), PS(+), PS(–), EARTH.
 Verify each DI(+) wiring is functional by setting each input HIGH (>16 V DC) and then LOW (<8 V
DC). Verify GAP software detects the state change.
 When possible, consider using a shielded DIN cable.

DI, Contact Power (CPWR) wiring checks

 CPWR(+) is an output voltage, it should never be connected to any other supply.
 To maintain node isolation, verify CPWR(–) is not shorted to PS(–).
 Using the internal isolated Contact Power output (CPWR,COM) is highly recommended to maintain
discrete input isolation for other plant devices / controls
 Verify CPWR(+) is not connected to CPWR(–), PS(–), EARTH.
 Verify CPWR(–) is not connected to CPWR(+), PS(+), EARTH.
 Verify CPWR voltage meets spec at the terminal block (18 to 32 V dc).

DO Relays, Relay wiring checks

 Verify each Relay output (NO,C,NC) contact is connected to the load properly
 Verify each Relay output (NO,C,NC) is not shorted to another output channel.
 Verify the function of each Relay output (NC,NO) wiring by driving each output ON then OFF. Verify
the GAP software detects the readback state change.
 When possible, consider using shielded wiring for relay cables.

Additional wiring checks when using RTCnet/LINKnet nodes

TC, Thermocouple Input wiring checks
 Verify each TC(+,–) is not shorted to another input channel.
 Verify each TC(+) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each TC(–) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each TC shield wire is not shorted to PS(+), PS(–).
 Verify no wires are landed accidently on the NC, no-connect terminals.
 Verify each TC shield wire is terminated at the node properly.
 Functionally verify the wiring for each TC channel using a simulator source.
 TC OPENS: A TC input will read MAX DegC if the (+) or (–) wire is broken / open.
 TC SHORTS: A TC input will read 0 DegC if the (+) and (–) wires are shorted.

GROUND FAULTS: Input channels accidently shorted to EARTH will

be more susceptible to spurious noise events related to the
installation and environment.

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RTD, Input wiring checks
 Verify each RTD(+,–) is not shorted to another input channel.
 Verify each RTD(+) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each RTD(–) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each RTD(sense) terminal is not shorted to PS(+), PS(–), EARTH.
 Verify each RTD(sense) terminal is connected properly for 3-wire sensors.
 Verify each RTD(sense) terminal is jumpered to RTD(–) for 2-wire sensors.
 Verify each RTD shield wire is not shorted to PS(+), PS(–).
 Verify each RTD shield wire is terminated at the node properly.
 Functionally verify the wiring for each RTD channel using a simulator source.
 RTD OPENS: RTD channels will read MAX DegC if the (+) or (–) wire is broken.

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Chapter 3.
505 Control Description

Introduction
The 505 has five PID controllers that can affect the demand to the main inlet steam valve; the speed/load
PID controller, an Acceleration PID, two Auxiliary PID controllers, and the Cascade PID controller.
Depending on the configuration of the 505, these PIDs interact differently with each other. Please refer to
the Block diagrams listed earlier in this manual to fully understand PID relationships.

Turbine Start Modes

The 505 has three turbine start modes (manual, semi-automatic or automatic) from which to choose from.
One of these start modes must be chosen and programmed to perform a system start-up. Once a ‘RUN’
command is issued, the speed set point and valve limiter are manipulated automatically by the 505 or
manually by the operator, depending on which start mode is selected. After a turbine start sequenced has
been completed, turbine speed will be controlled at a minimum controlling speed. The minimum
controlling speed may be idle if idle/rated is being used, low idle if the auto start sequence is used, or
minimum governor if neither idle/rated or auto start sequence is used.

A ‘RUN’ command may be issued from the 505 keypad, an external contact, or through Modbus
communications. If an ‘External Run’ contact is programmed, a ‘RUN’ command is issued when the
contact is closed. If the contact is closed prior to start-up it must be opened and re-closed to issue a
‘RUN’ command.

If turbine speed is sensed when a ‘RUN’ command is issued, the control will instantly match the speed set
point to the sensed speed and continue towards the minimum controlling speed. In the event the sensed
turbine speed is greater than the minimum controlling speed setting, the speed set point will match this
sensed speed, the Speed PID will control at this point, and the control will wait for further action to be
taken by the operator (unless auto start sequence is configured). If turbine speed is first sensed within a
critical speed avoidance band when a ‘Run’ command is received, the speed set point will match the
actual speed, decrease to the lower end of the critical avoidance band, and wait for action to be taken by
the operator.

Start Permissive
An external contact may be used as a turbine start-up permissive. When programmed for this
functionality, the contact input must be closed for a ‘RUN’ command to be executed. Should the contact
be open when a ‘RUN’ command is given, an alarm will be issued, and the 505 display will indicate that
the start permissive was not met (Start Perm Not Met). The alarm does not need to be cleared but the
contact must be closed before the 505 will accept the ‘RUN’ command. After ‘RUN’ has been accepted,
the start permissive contact will have no effect on operation.

Example: This input connected to a closed limit switch on a Trip & Throttle valve to verify that it is in the
closed position before a turbine start-up.

Open Wire Detection on MPU Speed Signals

The 505 automatically verifies continuity of the speed MPU circuits each time it prepares to issue a
“Ready to Start” status message. If an open wire is detected it will issue an alarm for this input, if all
MPU’s appear to have open wires a Trip is initiated. This open wire test can be done manually any time
the turbine is stopped, and the speed is zero. It is also possible to disable the automatic test at start from
this screen

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The screen is located under Analog Inputs/Speed Signal X/Open Wire Test.

Figure 3-1. Open Wire Detection Test

Zero Speed Signal Override

The 505 issues a shutdown if no speed signal is detected (magnetic pickup voltage less than 1 Vrms or
speed is less than the ‘Failed Speed Level’). To allow the control to start with speed not being sensed,
this shutdown logic must be overridden. The control can be configured to provide a manual or an
automatic speed override. For added protection, a timed limit on the override is available. The status of
the MPU override logic may be viewed in the Service mode or through Modbus communications. The
override logic applies to both passive and active speed probes.

Manual Speed Override

If the ‘Override MPU Fault’ function is assigned to a contact input, the loss-of- speed detection logic is
overridden as long as this contact is closed; until the maximum time expires. Opening the assigned contact
input, disables the override logic, and re-arms the loss-of-speed detection circuit. Once re-armed, a system
shutdown is executed if the sensed speed drops below the ‘Failed Speed Level’ setting.

A maximum override time limit is provided as an extra level of protection, in the event the contact input is
left closed. A ten-minute maximum time limit is applied to a Manual override command (as defaulted in
the Service Mode). This time starts when the RUN command is initiated and re-arms the loss-of-speed
detection when the time expires. The 505 will execute a system shutdown if turbine speed is not above
the ‘Failed Speed Level’ setting when the time expires.

Automatic Speed Override

If the Manual Speed Override option is not programmed, the Automatic Speed Override logic is used by
the 505 to override the loss-of-speed signal shutdown logic during a turbine start-up. With the Automatic
Override logic, the loss-of-speed signal failure is disarmed when the turbine trips and remains disarmed
until the sensed turbine speed exceeds the programmed (‘Failed Speed Level’ setting + 50 rpm). Once
turbine speed exceeds this level, the loss of speed detection circuit is re-armed, and the control will
execute a system shutdown if sensed speed drops below the ‘Failed Speed Level’ setting.

For added protection, a timed limit is available on the automatic speed override function. The timed speed
override timer deactivates the loss-of-speed override logic after the programmed time expires. If
programmed, this timer starts counting down once a ‘START’ command has been issued. This timer
when programmed provides an extra level of protection, in the event both speed input probes are failed
when the unit is started. This timer may be programmed in the 505’s Service mode.

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Acceleration Limiter
The acceleration limiter is available for startup to significantly reduce speed overshoot to the minimum
controllable speed setpoint at turbine start. The Acceleration Limiter is disabled after reaching the
minimum controllable speed and the 505 will continue the start sequence via the Speed PID.

If the Acceleration Limiter is set to be used via the Service menu, then it will control speed at the ‘Rate to
Min’ rate (RPM/s), as set in the Turbine Start configuration, until the Speed PID is in control at the
Minimum Controllable Speed. When the Start Sequence is set to “No Start Sequence”, the Minimum
Controllable Speed is Minimum Governor. When the Start Sequence is set to “Idle/Rated Sequence” or
“Auto Start Sequence”, the Minimum Controllable Speed is the Lowest Idle setting.

Using the Acceleration Limiter feature carries some risk without

proper tuning of the Acceleration PID. Please monitor actuator
behavior at turbine start. Verify there is no instability in the
Acceleration Control Acceleration Controller that may result in system damage during
oscillation of the actuator/valve if it is unstable. When the response of
the Acceleration Controller is over-damped, it may follow the speed
setpoint very slowly at startup or even move the valve closed but,
after this, acceleration should be controlled fairly well until the
Acceleration Limiter logic is disabled.

Turbine Start Mode Procedures

Manual Start Mode
The following start-up procedure is employed when the Manual start mode is configured:
1. Issue a RESET command (to reset all alarms and shutdowns)
2. Issue a START command (verify T&T valve is closed before issuing)
 At this point the 505 will ramp open the governor valve to its maximum position at the ‘Valve
Limiter Rate’.
 The speed set point will ramp from zero to the minimum controlling speed setting at the ‘Rate To
Min’ rate.
3. Open Trip & Throttle valve at a controlled rate
 When turbine speed increases to the minimum controlling speed, the 505’s Speed PID will take
control of turbine speed by controlling turbine inlet valve position.
4. Open Trip & Throttle valve to 100%
 Speed remains controlled at the minimum controlling point until action is taken by the operator or
the ‘Auto Start Sequence’, if programmed, begins controlling.

The ‘Limiter Max Limit’, ‘Valve Limiter Rate’ and ‘Rate To Min’ settings are tunable in the Service mode.

The trip-and-throttle valve must be closed before pushing the ‘RUN’

key in Manual Start mode. If a START command is given while the
trip-and-throttle valve is open, there exists a possibility of turbine
runaway with resultant serious injury or loss of life.

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Figure 3-2. Manual Start Mode Example

Semiautomatic Start Mode

The following start-up procedure is employed when the Semiautomatic start mode is configured:
1. Issue a RESET command (to reset all alarms and shutdowns)
2. Open the Trip & Throttle valve (verify that the turbine does not accelerate)
3. Issue a START command
 At this point, the speed set point will ramp from zero to the minimum controlling speed setting at
the ‘Rate to Min’ rate.
4. Raise the 505 VALVE LIMITER at a controlled rate.
 When turbine speed increases to the minimum controlling speed, the 505’s Speed PID will take
control of turbine speed by controlling turbine inlet valve position.
5. Raise the 505 VALVE LIMITER to 100%.
 Speed remains controlled at the minimum controlling point until action is taken by the operator or
the ‘AUTO START SEQUENCE’, if programmed, begins controlling.

The valve limiter will open at the ‘Valve Limiter Rate’ and may be moved using the 505 keypad, external
contacts or Modbus communications. The ‘Limiter Max Limit’, ‘Valve Limiter Rate’ and ‘Rate To Min’
settings are tunable in the Service mode.

Figure 3-3. Semiautomatic Start mode Example

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Automatic Start Mode

The following start-up procedure is employed when the Automatic start mode is configured:
1. Issue a RESET command (to reset all alarms and shutdowns)
2. Open the Trip & Throttle valve (verify that the turbine does not accelerate)
3. Issue a START command
 At this point the 505 will ramp open the governor valve to its “HP Max at Start” setting at the
‘Valve Limiter Rate’ setting.
 The speed set point will ramp from zero to the minimum controlling speed setting at the ‘Rate to
MIN’ rate.
 When turbine speed increases and matches the ramping speed set point, the 505’s Speed PID
will take control of turbine speed by controlling turbine inlet valve position.
 Speed remains controlled at the minimum controlling point until action is taken by the operator
or the ‘Auto Start Sequence’, if programmed, begins controlling.
 Once the Speed PID begins controlling turbine speed, the HP Limiter will automatically ramp to
the ‘Vlv Lmtr Max Limt’.

Optionally the ‘HP Max at Start’ and ‘Vlv Lmtr Max Limt’, ‘Valve Limiter Rate’ and ‘Rate To Min’ settings
can be adjusted in the Service mode, while the turbine is in operation. The automatic start routine may be
aborted at any time by issuing valve limiter raise or lower commands, or an emergency shutdown.

Figure 3-4. Automatic Start Mode Example

Critical Speed Avoidance

In many turbines, it is desirable to avoid certain speeds or speed ranges (or pass through them as quickly
as possible) due to excessive turbine vibration or other factors. During programming, three critical speed
ranges may be configured. These bands may be any speed range that is less than the minimum governor
speed setting. Within a critical speed range, the 505 moves the speed set point at the critical speed rate
programmed and does not allow the speed set point to stop within the critical speed avoidance band. If
the turbine is accelerating through a critical avoidance band and excessively high vibrations are
experienced, selecting the speed set point lower command will bring the unit back to the lower limit of the
band.

The speed set point cannot be stopped in the critical band. If a Raise/Lower Speed Set point command is
issued while in a critical band, the speed set point will ramp up or down (depending on raise or lower
command) to the extent of the critical range. Since the lower speed set point has priority over a raise set
point, issuing a lower command while increasing through the band will reverse the set point direction and
return it to the lower limit of the band. If a lower speed set point command is given while in a critical band,
turbine speed must reach the bottom of the band before another command can be executed.

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A speed set point value cannot be directly entered (with the ENTER key) within the programmed critical
speed band settings. In the event this is attempted, an error message will appear on the 505 front panel
display.

If another controlling parameter, besides the Speed PID, drives the turbine’s speed into a critical band for
longer than five seconds, the speed set point will instantly go to the idle setting and an alarm will occur
(Stuck in Critical).

During a start-up routine if the Speed PID cannot accelerate the unit though a programmed band within a
calculated length of time, a “Stuck in Critical” alarm will be issued and the speed set point will instantly
return to idle. The “calculated length of time” is a value of five times the length of time it should normally
take to accelerate through the band (based on the “Critical Speed Rate” setting). If the “Stuck in Critical”
alarm occurs on a regular basis, it may be indicating that the “Critical Speed Rate” is set too fast for the
turbine to respond to.

Critical speed bands are defined in the configure mode. All critical speed band settings must be set below
the ‘Min Governor Speed Set Point’. A configure error will occur if an idle set point is programmed within a
critical speed band. The rate in which the speed set point moves through a critical speed band is set by
the ‘Critical Speed Rate’ setting. The ‘Critical Speed Rate’ setting should be set at but no higher than the
turbine’s rated maximum acceleration rate.

No Start Sequence
If neither, the Idle/Rated or Auto Start Sequence functions are programmed, the speed set point will ramp
from zero to the minimum governor set point at the ‘Rate To Min’ setting rate. Critical speed bands cannot
be programmed with this configuration.

Idle/Rated
The idle/rated function gives an operator the ability to move between a programmed idle speed and a
programmed rated speed at a configured rate. The selection of idle or rated speed set point positions can
be made through the front panel keypad, through remote contact inputs, or through the Modbus
communications links. The idle/rated function can also be programmed as a ramp-to-rated function only.

If the 505’s Idle/Rated function is programmed, once a ‘START’ command is given, the 505 ramps turbine
speed from zero to the programmed Idle setting, then waits for a command from the operator to ramp
turbine speed to the “Rated Speed” setting. When deselected, the turbine speed ramps down to the
application’s Idle Speed setting (as defaulted in the Service Mode).

The Idle/Rated function can be used with any 505 start mode (manual, semiautomatic, automatic). When
a START command is issued, the speed set point will ramp from zero rpm up to and hold at the ‘Idle
Setpt’ setting. When a ramp- to-rated command is given, the speed set point ramps to the ‘Rated Setpt’
setting at the ‘Idle/Rated Rate’. While ramping to a Rated speed, the set point can be stopped by a raise
or lower speed command or a valid entered speed set point.

The 505 will inhibit a ramp-to-idle speed or ramp-to-rated speed command, if the Generator Breaker is
closed, Remote Speed Set Point is enabled, Cascade PID is in control, or the Auxiliary PID is in control
(as defaulted in the Service Mode). Alternatively, the 505’s ‘Idle Priority’ and ‘Use Ramp to Idle Function’
Service mode settings can be configured to change the defaulted idle/rated logic.

Ramp to Rated Feature

The Idle/Rated function can be changed to a “Ramp to Rated” function (see Service Mode). With this
configuration, the speed set point holds at the idle speed setting until a Ramp-to-Rated command is
given. Upon command the speed set point will accelerate to the Rated speed set point, however, it will
not ramp back to the idle speed setting. When Rated is de-selected, the speed set point stops as
opposed to returning to Idle. When this configuration is used, there is no Ramp- to-Idle option; it is not
used.

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If Rated is de-selected while in a critical speed avoidance band (using Ramp to Rated only feature), the
speed set point will stop at the top end of the avoidance band. If the Ramp to Rated function is
stopped/halted using a raise or lower speed set point command, the set point will continue to the upper
limit of the band if a Raise command was used or will reverse direction to the lower limit of the band if a
Lower command was used.

If Idle is selected while in a critical speed avoidance band (not using Ramp to Rated only feature), the
speed set point will return to the Idle set point, continuing to move at the critical avoidance rate while
within the band. The speed set point cannot be stopped within a critical speed avoidance band.
Attempting to stop the ramp to rated while in a critical band will continue the speed set point to the upper
limit of the band if a Raise command was used or will reverse direction to the lower limit of the band if a
Lower command was used.

A Ramp-to-Idle speed or Ramp-to-Rated speed command may be selected from the 505 keypad, contact
input, or Modbus communications. The last command given from any of these three sources dictates the
function performed.

If a 505 contact input is programmed to select between Idle or Rated speeds, Idle speed is selected when
the contact is open and rated speed is selected when it is closed. The Idle/Rated contact can be either
open or closed when a trip condition is cleared. If the contact is open, it must be closed to initiate a
Ramp-to-Rated speed. If the contact is closed, it must be opened and re-closed to initiate a Ramp- to-
Rated speed.

When the turbine is used for mechanical drive applications, rated speed may be set at the minimum
governor speed setting. When the turbine is used to drive a generator, the ‘rated speed’ setting may be
set at or between the minimum governor and synchronous speed settings.

All pertinent Idle/Rated parameters are available through the Modbus links, refer to Chapter 6 for a
complete listing.

Figure 3-5. Idle/Rated Start

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Automatic Start Sequence

This function is not the same as the ‘AUTOMATIC START MODE’.

The Automatic Start Sequence can be used with any one of the three
start modes.

The 505 can be configured to utilize an Automatic Start Sequence to start the turbine. This sequencing
logic allows the 505 to perform a complete controlled system start-up from zero speed to rated speed.
With this function, the turbine’s starting ramp rates and idle speed hold times depending on either the
length of time the unit was shut down or upon optional temperature input signals. This sequence logic
may be used with any of the three start modes (manual, semiautomatic, automatic), and is initiated by a
‘RUN’ command.

With this function, when initiating a ‘START’ command, the following actions take place:
 The Automatic Start Sequence ramps the speed set point to a low idle set point
 Then holds at this setting for the set duration
 Ramps the speed set point to the Idle-2 setting
 Holds at this setting for the set duration
 Ramps the speed set point to Idle-3 setting
 Holds at this setting for the set duration
 Then finally ramps the speed set point to the programmed rated turbine speed setting
All ramp rates and hold times are programmable for both hot start and cold start conditions. The control
differentiates between hot and cold starts by using an “Hours-Since-Trip” timer or a contact input. When
using the “Hours-Since-Trip” timer, the timer starts when a shutdown has been executed and turbine
speed has decreased below the low idle speed setting.

Figure 3-6. Automatic Start Sequence

With this sequence, a set of hot-start ramp rates and hold times is programmed for use when a ‘START’
command is given and the turbine has been shutdown for less than the programmed ‘HOT START’ time
setting. A set of cold-start ramp rates and hold times is also programmed for use when a ‘START’
command is given and the turbine has been shutdown for longer than the programmed ‘COLD START’
time setting.

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If a turbine ‘START’ command is given when the length of time the system has been shutdown is
between the ‘HOT START’ and ‘COLD START’ time settings, the control can be configured to interpolate
between the hot and cold programmed start values to determine starting rates and hold times.

Table 3-1. Example Automatic Start Sequence Settings

COLD START (> xx HRS) = 22 HRS

HOT START (< xx HRS) = 2 HRS
LOW IDLE SETPT = 1000 RPM
LOW IDLE DELAY (COLD) = 30 MINIMUM
LOW IDLE DELAY (HOT) = 10 MINIMUM
USE IDLE 2 = *TRUE
RATE TO IDLE 2 (COLD) = 5 RPM/S
RATE TO IDLE 2 (HOT) = 15 RPM/S
IDLE 2 SETPT = 1500 RPM
USE IDLE 3 = *TRUE
RATE TO IDLE 3 (COLD) = 5 RPM/S
RATE TO IDLE 3 (HOT) = 15 RPM/S
IDLE 3 SETPT = 2000 RPM
IDLE 3 DELAY TIME (COLD) = 30 MINIMUM
IDLE 3 DELAY TIME (HOT) = 20 MINIMUM
RATE TO RATED (COLD) = 10 RPM/S
RATE TO RATED (HOT) = 20 RPM/S
RATED SETPT = 3400 RPM

Table 3-2. Unit Tripped for 12 hours, Hot and Cold Parameters Interpolation Rates and Delays
(Viewed in the Service Mode, see Volume 2):

LOW IDLE DELAY = 20 MINIMUM

RATE TO IDLE 2 = 10 RPM/S
IDLE 2 DELAY = 10 MINIMUM
RATE TO IDLE 3 = 10 RPM/S
IDLE 3 DELAY = 10 MINIMUM
RATE TO RATED = 15 RPM/S

RST Timer Level = 3500 RPM

Hot RST Timer (min) = 10 MINUTES

Based on the example’s configuration and trip time:

 Speed Set Point would ramp to 1000 rpm at the rate to minimum setting and hold for 20 minutes
(turbine speed must also be at or above 1000 rpm)
 Move to 1500 rpm at 10 rpm/s and hold there for 10 minutes
 Move to 2000 rpm at 10 rpm/s and hold there for 10 minutes and lastly
 Move to 3400 rpm at 15 rpm/s. At 3400 rpm, the sequence would be completed.
 However, speed reference must be above the HOT RESET LEVEL during more than HOT RESET
DELAY, to fully use the HOT parameter
 If the unit was tripped for 2 hours or less and restarted, the control would use the hot start
parameters. If the unit was tripped for 22 hours or longer and restarted, the control would use the cold
start parameters.

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The 505 will automatically set the hours-since-trip timer to its

maximum setting of 200 hours to ensure a cold start is selected after
a power up or upon exiting the Configuration mode. The hours-since-
trip timer will reset only when the turbine speed has increased above
the minimum governor speed/RST timer level setting for the Not RST
timer duration.

Optionally, if a contact input is configured for the “Select Hot Start” function, then the Auto Start
Sequence’s Hot Start setting will be selected and used during the start routine when the respective
contact is closed, and the Cold start curves will be used when the respective contact is open.

If it is desired to have the control NOT interpolate between the Cold/Hot ramp times, then the Cold Start
and Hot Start hour settings can be set equal and no DI input is needed (the Cold and Hot Start hours
setting is found in Configuration/Turbine Start menu). The unit will follow the Hot times below this
setting and the Cold Values when this time is exceeded.

Hot/Cold Start Temperature Inputs

An analog input configured as a temperature signal can be used to determine whether the turbine is hot
or cold for startup speed setpoint rates and idle delay times. In addition, a warm setting is also available
for a total of 3 turbine temperature conditions. Cold, warm, and hot starts each have programmable speed
setpoint rates for each speed level in the startup sequence, whether Idle/Rated or Automatic Start with
Idle 1, Idle 2, Idle 3, and Rated speed is used.

To specify cold or hot conditions for the turbine, the Hot/Cold Temperature logic will determine if the “Start
Temperature 1” analog input is greater than the configured “Hot Minimum Temperature”. If so, the HOT
rates and delays will be used for the startup sequence configured. If not, the COLD rates and delays will
be used for the startup sequence configured.

Optionally, a Warm setting is available. If “Use Warm Condition” is selected in the Turbine Start
configuration menu, it provides an intermediate level between Hot and Cold rates and delay times for the
start sequence. Using the Warm setting requires another temperature level to be configured. If the “Start
Temperature 1” analog input is greater than the configured “Hot Minimum Temperature” then the HOT
rates and delays will be used for the startup sequence configured. If the “Start Temperature 1” analog
input is greater than the configured “Warm Minimum Temperature” but less than the “Hot Minimum
Temperature” then the WARM rates and delays will be used for the startup sequence configured. If the
temperature is below both settings, then the COLD rates and delays will be used for start sequence
configured.

A second temperature analog input can be used with the Hot/Warm/Cold feature as well. This requires
configuring a second analog input as “Start Temperature 2” and the “Use Temperature Input 2” checkbox
should be selected in the Turbine Start configuration menu. This will provide a second unique setpoint for
this temperature input for both the Warm and Hot conditions.

When using the second temperature analog input an option to use the temperature difference, as a
condition for a Warm or Hot start, is also available. Select the “Use Temperature Difference” checkbox in
the Turbine Start configuration menu. The difference between Start Temperature 1 and 2 must be less
than the configured amount for Hot/Warm conditions to be met.

If the “Select Hot/Cold” contact input is configured, the Hot/Cold Temperature logic will respond to this
signal. If the contact is open, Cold will be selected. If the contact is closed, it allows for a Warm or Hot
start if all the temperature conditions for the Warm or Hot start are satisfied.

When a temperature input fails then the Hot/Warm conditions for that input will not be met, which means
that the start sequence will use the Cold start values. The start will proceed normally as if the turbine is
running the cold condition.

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See the following for all conditions that are required, if configured, for a Warm or Hot start.

T1 = Start Temperature 1
T2 = Start Temperature 2
Td = Difference between Start Temperature 1 and 2
CI = Select Hot/Cold Contact input

Table 3-3. Warm or Host Start Configuration

Hot/Warm/Cold Start Description of Conditions

COLD HOT or WARM conditions not met
or temperature input failed.
WARM T1 > Warm T1 setpoint
T2 > Warm T2 setpoint
Td < Warm Td Setpoint
CI closed
HOT T1 > Hot T1 setpoint
T2 > Hot T2 setpoint
Td < Hot Td Setpoint
CI closed

Halting the Auto Start Sequence

The Auto Start Sequence can be halted at any time from the 505 keypad, contact input or through
Modbus. The sequence can be halted by a halt command, a raise or lower speed set point command, or
when a speed set point is directly ‘Entered’ from the 505 keypad or through Modbus communications.
When the sequence is halted, the delay timers do not stop if they have already started counting down.
The sequence will resume when a ‘Continue’ command is issued. If there were 15 minutes remaining to
hold at an idle speed and the Halt command was issued for 10 minutes before a issuing a Continue
command, the sequence would remain at the idle speed for the remainder of the ‘Hold Time’—which in
this example is five minutes.

The ‘Hold Time’ is only used if the speed setpoint exactly equals the
associated Idle hold setpoint. If the speed setpoint is different from
this hold point, selecting ‘Continue’ will ramp the setpoint up to the
next hold point regardless of the ‘Hold Time’. Caution should be
taken when raising or lowering the speed set point to ‘Halt’ the
Automatic Start Sequence.

The halting and continuing of the Auto Start Sequence can be performed through the 505 keypad, contact
input, or Modbus. The last command given from any of these three sources determines the mode of
operation. However, a shutdown condition will disable this function, requiring it to be re-enabled after a
start-up has been performed.

If a 505-contact input is programmed to function as a Halt/Continue command, the sequence is halted

when the contact is open, and continued when the contact is closed. The Halt contact can be either open
or closed when a Reset command is given. If the contact is closed, it must be opened to allow the
sequence to be halted. If the contact is open, it must be closed and reopened to issue a halt command.
Alternatively, a relay can be programmed to indicate when the Auto Start Sequence is halted.

An option is available to automatically halt the auto start sequence at the idle set points. This feature
would result in the unit automatically stopping or halting at the low idle set point and at the high idle set
point. If the unit is started and the speed is above the low idle set point, the sequence will initialize as
halted. The sequence must be given a ‘Continue’ command once halted. The hold timers are still active
with this option. If ‘Continue’ is selected and the hold timer has not expired, the sequence will remain in a
timed wait until the hold timer has expired and then continue from that point.

When the ‘Auto Halt at Idle Setpts’ option is programmed, the Auto Start Sequence Continue contact
input only requires a momentary closure to continue the sequence.
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Automatic Start Sequence Idle Temperatures

In addition to the Automatic Start Sequence Idle delay timers and “Auto Halt at Idle Setpoints” features,
temperature analog inputs can be used to determine when the start sequence may continue from an Idle
setpoint. These inputs will allow for a temperature permissive to be configured for each idle speed level.
The start sequence will not continue from that idle until the temperature permissive is met.

If “Use Temperature for Autostart” is configured, the start sequence will determine if the “Start
Temperature 1” analog input is greater than the configured “Temperature 1 Setpoint” for each Idle speed.
If so, the start sequence will continue as long all other permissives are met, which include the idle timer
and any halt command.

A second temperature analog input can be used with the Automatic Start Sequence temperature feature
as well. This requires configuring a second analog input as “Start Temperature 2” and the “Use
Temperature Input 2” checkbox should be selected in the Turbine Start configuration menu under
“Autostart Sequence Settings”.

If this option is programmed, it will be use in one of the following ways -

1) It will provide a second unique setpoint relative to this temperature input for each idle speed level
configured. For the unit to advance from one Idle speed to the next, both temperature conditions must be
met.

2) Using the second temperature analog input makes available an option to use the temperature
difference between these 2 signals. Select the “Use Temperature Difference” checkbox in the Turbine
Start configuration menu under “Autostart Sequence Settings”. For the unit to advance from one Idle
speed to the next, the difference between Start Temperature 1 and 2 must be less than the configured
amount, in addition to the individual temperature setpoints.

When a temperature input fails then the conditions to continue from any idle speed will not be met, which
means that the start sequence will not continue past that idle level. In order to proceed with the start
sequence, the temperature input can be overridden via the Service menu.

If configured, the following conditions must be met to continue from each idle speed:
 “Auto Halt at Idle Setpoints” not selected or operator ‘Continue’ command.
 Idle delay time expired.
 Start Temperature 1 is greater than “Temperature 1 Setpoint”.
 Start Temperature 2 is greater than “Temperature 2 Setpoint”.
 Difference between Start Temperature 1 and 2 is less than “Max Temperature Difference”.

Speed Control Overview

The speed control receives a turbine speed signal from one or two magnetic pickups or proximity probes.
The ‘MPU Gear Ratio’ and the ‘Teeth Seen By MPU’ settings are configured to allow the 505 to calculate
actual turbine speed. The control will always use the highest speed signal received as the validated
turbine speed process variable. The Speed PID (proportional, integral, derivative control amplifier) then
compares this signal to the set point to generate an output signal to the governor valve actuator (through
a low signal select bus).

The speed control’s set point is adjustable with raise or lower commands, through the 505 keypad,
remote contact inputs or the communication line. This set point can also be directly set by entering a new
set point through the 505 keypad or via Modbus/OCP. In addition, an analog input can be programmed to
remotely position the speed set point.

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Figure 3-7. Speed Control Functional Diagram

Speed PID Operational Modes

The Speed PID operates in one of the following modes, depending on configuration and system
conditions:
1. Speed Control
2. Frequency Control
3. Unit Load Control (droop)
 Turbine inlet valve position (505 LSS position) control
 Generator Load control

When not programmed for generator applications, the 505 Speed PID always operates in a Speed control
mode. When programmed for generator applications, the state of the generator and utility tie breakers
determine the operational mode of the Speed PID.

 When the Generator breaker contact is open, the Speed PID operates in a Speed control mode.
 When the generator breaker is closed and the utility tie breaker is open, the Frequency control mode
is selected.
 When both the generator and utility tie breakers are closed, a Unit Load control mode is selected.

Speed Control
While in the Speed Control mode, the Speed PID will control a turbine at the same speed or frequency
regardless of the load it is supplying (up to the unit’s load capability). With this configuration, no form of
droop or second controlling parameter (bias logic) is used by the PID for stability or control.

The following Speed PID mode descriptions are based on the 505 program’s default settings. For
information on how to change the 505’s defaulted breaker logic, refer to Volume 2 of this manual. All
pertinent speed control parameters are available through Modbus communications. See Chapter 6 for a
list of all Modbus parameters.

Frequency Control
The following Frequency Control mode descriptions are based on the 505 program’s default settings. For
information on how to change the 505’s defaulted breaker logic, refer to Volume 2 of this manual.

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The Speed PID operates in the Frequency control mode when the generator breaker is closed, and the
utility tie breaker is open. In the Frequency control mode, the unit will operate at the same speed or
frequency regardless of the load it is supplying (up to the unit’s load capability). Refer to Figure 3-8.

When breaker positions result in the Speed PID switching to Frequency control, the speed set point is
instantly stepped to the last turbine speed (frequency) sensed before Frequency control was selected.
This allows a bumpless transfer between modes. If the last speed sensed was not at the ‘Rated Speed
Set Point’ (synchronous speed) setting, the speed set point will ramp to the ‘Rated Speed Set point’
setting at a defaulted rate of 1 rpm/s (tunable through the Service mode).

In the Frequency control mode, the speed set point can be varied with the Speed Set Point Raise/Lower
commands, as desired, to allow manual synchronization across a tie breaker to an infinite bus. See the
Synchronization section in this Chapter.

For indication purposes, a relay can be programmed to energize when the unit is in Frequency control.

Unit Load Control

The 505’s Speed PID can control two independent parameters when the generator breaker is closed;
frequency when the generator is isolated, and unit load when the generator is paralleled with an infinite
bus. When the generator breaker and utility tie breaker inputs are both closed, the Speed PID operates in
a Unit Load mode. This method of allowing a PID to control a second parameter is referred to as Droop.

Giving the Speed PID two parameters to control allows it to control unit load and act as a stabilizing effect
for any change in bus frequency. With this configuration, when bus frequency decreases or increases,
unit load increases and decreases respectively, based on the unit’s droop setting. The net effect is a
more stable bus. See Figure 3-9 for a frequency and load relationship diagram.

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Figure 3-8. Speed PID Control Modes

The term “droop” was derived from an isolated unit’s speed reaction to an increase in load when another
parameter (unit load) is fed back to a Speed PID’s summing junction. The Droop term, as used
throughout this manual refers to a PID’s second controlling parameter. A second parameter representing
unit load is fed back into the 505’s Speed PID to allow it to control two parameters; speed when operating
in an isolated mode, and unit load when paralleled to an infinite bus. See Figure 3-9.

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Figure 3-9. Frequency and Unit Load Relationship

Because the 505’s Speed PID and set point are used to control turbine speed and a second parameter,
this second parameter (unit load) is normalized to allow all three terms (speed, set point, unit load) to be
summed together within the PID summing junction. This normalization is based on a percentage of rated
speed and creates a direct relationship between unit load and the Speed PID’s set point. Once unit load
(0–100%) is represented as a percent of rated speed, the speed set point can be varied by this percent,
above rated speed, to increase load from 0–100% when paralleled to the utility. Unit load is converted to
a percentage of rated speed as shown in the following example calculation:

DROOP % x (gen load or valve position-%) x Rated Speed = Speed Set Point change in rpm

Example: 5% x 100% x 3600 rpm = 180 rpm

For this example, when paralleled to a utility bus, the speed set point can be adjusted from 3600 rpm
to 3780 rpm to vary unit load from 0 to 100%.

Droop feedback allows the Speed PID to control unit load (generator power or turbine valve position)
once it is paralleled with a utility bus or other generating systems which do not have droop or load sharing
capability. When a turbine generator set is paralleled with a utility bus, the utility determines the unit
frequency/speed, thus the governor must control another parameter. The 505 uses turbine inlet valve
position (LSS bus position) or generator load as a second parameter to control when paralleled to an
infinite bus.

The generator load or turbine inlet valve position droop percentage cannot be set greater that 10%, and is
typically set to 5%.

Optionally, the set droop percentage value can be changed from front panel, while turbine is running, or
via a remote 4–20 mA signal (remote droop), to change the control’s response to grid frequency changes.

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In some extreme cases, where the utility grid frequency is unstable, and changes significantly (day/night),
it is possible to change the unit’s:
 Frequency set point (50 Hz/60 Hz ±2.5 Hz) via front panel
 Frequency dead-band (±3 Hz). Used to reduce/prevent constant valve corrections due to a
constantly changing grid frequency.

To configure the 505 for generator load control when paralleled to an infinite bus, check the ‘Use KW
Droop’ option on the Operating Parameters page of the configuration menu. The 505 must also be
configured to accept a KW Load signal either from an analog input from a Watt transducer sensing
generator load, or from a Woodward Power Management product/device via a digital communication link
(Woodward Links). To configure the 505 for turbine valve position control when paralleled to an infinite
bus, uncheck the ‘Use KW Droop’ option. The generator load or turbine inlet valve position droop
percentage cannot be set greater that 10% and is typically set to 5%.

If the 505 is programmed to control unit load using turbine inlet valve position droop (LSS bus position),
the 505 calculates load based on the valve position at the time the generator breaker was closed. This
valve position is zero load. In a typical application where turbine inlet and exhaust pressures are at rated
levels when the generator breaker is closed, this type of calculation allows unit load to be accurately
sensed, and controlled.

In an application where turbine inlet or exhaust pressures are NOT at

rated levels when the generator breaker is closed, the considered
zero load level will be incorrect when system pressures do reach
rated levels.

If turbine inlet or exhaust pressures are not at rated when the breaker closes, it is recommended that the
user do the following:

Use the available tunable in Service mode to correct the valve position at zero load once the system is
operating at rated steam pressure. To do this, adjust the Zero Load Value, (under the Service mode’s
‘BREAKER LOGIC’ header) and set this value to the correct valve position demand at Sync no load
condition

Speed Set Point

The Speed PID’s set point may be adjusted from the 505 keypad, external contacts, Modbus/OPC
commands, or through a 4–20 mA analog input. A specific set point setting can also be directly entered
through the 505 keypad or Modbus communications. The Cascade PID also directly controls this set point
when it is used.

The Speed PID’s set point may be adjusted from the 505 keypad, external contacts, or through Modbus.
It can be directly entered to a specific value from the 505 keypad or through Modbus commands. It can
be remotely set by the Remote Speed Set Point analog input or it can be manipulated by the Cascade
controller to control the Cascade input parameter.

The speed set point range must be defined in the Configuration mode. Program settings ‘Min Governor
Speed Set Point’ and ‘Max Governor Speed Set Point’ define the normal operating speed range of the
turbine. The speed set point cannot be raised above ‘Max Governor Speed Set Point’ setting unless an
Overspeed Test is being performed. Once the speed set point is taken above the ‘Min Governor Speed
Set Point’ setting, it cannot be varied below this setting again unless the Idle/Rated ramp-to-Idle
command is selected or a Controlled Stop is selected.

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Figure 3-10. Speed Relationships

Once turbine speed is equal to or greater than the ‘Min Governor Speed Set Point’ setting, the speed set
point may be adjusted through discrete raise and lower commands. When a raise or lower speed
command is issued, the set point moves at the programmed ‘Speed Set Point Slow Rate’. If a speed
raise/lower command is selected for longer than three seconds, the speed set point will then move at the
fast rate which is three times the speed set point slow rate. The speed set point slow rate, fast rate delay,
and fast rate can all be adjusted in the Service mode.

The shortest length of time a set point will move for an accepted raise or lower command is 40
milliseconds (120 milliseconds for a Modbus command). If the speed set point slow rate is programmed
for 10 rpm/s, the smallest increment it will move is 0.4 rpm (1.2 rpm for Modbus).

The speed set point may be set to a specific level, by directly entering a set point value through the 505
keypad or Modbus communications.
To “enter” a specific set point from the 505 keypad, follow these steps:

1. Go to the Speed Control page – select Commands/Entered Setpoint

2. Dialog Box will open with target value – click Enter (to highlight value)
3. Use numeric keypad to enter desired setpoint – click Enter (to accept)
4. Click on the GO button to ramp from current setpoint to the new setpoint

If a valid number was entered, the setting will be accepted as the new target setpoint. If an invalid number
is “entered” the setting will not be accepted and the 505’s screen will momentarily display a value out-of-
range message. This ‘Entered’ rate is tunable through the Service mode.

Requirements for valid entries are the following:

 Speed must be below the maximum governor setting
 Speed must be above the idle setting and not within any critical speed avoidance band
 Once the speed set point is above the minimum governor setting, the set point cannot be lowered
below minimum governor
 If the unit is driving a generator and the unit is on-line, the speed set point cannot be set below the
minimum load setting (set in Service)

The speed set point can also be directly entered from Modbus/OPC, however, the allowed range is
between the minimum governor and the maximum governor speed settings. The allowed set point range
is limited to between the minimum load and the maximum governor settings if the unit is driving a
generator and the unit is on-line.

When the 505 is configured for a generator application, a special speed set point rate (Sync Window
Rate) is used to increase set point resolution around synchronous speed. This allows for tighter set point
control to accommodate synchronizing manually or by an automatic synchronizer which interfaces to the
505 using discrete contacts. This Sync Window Rate is defaulted to two rpm/s and is only used when the
generator breaker is open and the speed set point is within 10 rpm of rated speed. Both the synchronizing
rate and the synchronizing window are tunable in the Service mode.

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When configured for generator applications a Minimum Load set point can be used by the 505 to reduce the
chance of reverse powering a unit upon closing the generator breaker. With the utility tie breaker closed,
when a generator breaker closed indication is received, the Speed set point is stepped to the Minimum Load
setting. The Minimum Load setting is defaulted to 3% (changeable in the Service Mode). To disable the use
of the Minimum Load Set Point, set the ‘Use Min Load’ setting (under the Service mode’s ‘BREAKER
LOGIC’ header) to ‘Unchecked’ (Not Used).

As a related feature, if ‘Use Min Load’ is selected and the parameter ‘Reverse Power on Controlled Stop’ in
OPERATING PARAMETERS is NOT selected, then the 505 will use this Minimum Load setting as the lower
speed setpoint limit whenever the breaker is closed

When the 505 is configured for a mechanical drive application, a contact input can be configured to instantly
step the speed setpoint to the minimum governor speed. This feature can only be used after the startup
sequence has been completed. In addition to stepping the speed setpoint to the minimum governor speed,
closing the contact input will also disable the Cascade and Auxiliary controls.

See Chapter 6 for a list of all speed set point related Modbus parameters.

Frequency Arm/Disarm
The Frequency Arm/Disarm feature can be used only when load sharing is not being performed, to allow
multiple units to operate on the same isolated bus. With this feature, one unit on a multiple unit isolated
bus controls frequency and the other units operate in a unit-load mode. The unit controlling frequency is
referred to as the “Swing Machine” because its load will swing (vary) depending on the load of the plant.
Caution should be taken with this configuration to not overload or reverse power the “Swing Machine”.

This feature, when programmed, allows an operator to Arm or Disarm a unit’s Frequency control mode
while it is in operation. When Armed, a unit will switch to Frequency control if the plant-to-utility tie breaker
opens. When Disarmed, a unit will stay in a unit-load control mode when the plant-to-utility tie breaker
opens.

To use this feature, the program’s ‘Use Freq Arm/Disarm’ setting box must be checked, the Sync/Load
Sharing mode cannot be programmed, and a discrete command must programmed. The Frequency
Arm/Disarm mode can be selected from a programmed contact input, Function key, or Modbus command.
When the programmed contact input is closed the unit’s Frequency control mode is Armed. When the
programmed contact input is open the unit’s Frequency control mode is Disarmed.

Depending on a unit’s size, health, and running status, an operator may select which unit is designated as
the plant Frequency control unit if or when the plant- to-utility tie breaker opens. Frequency control can be
Armed at any time, but it will only go into control when the generator breaker is closed and the utility tie
breaker is open.

Only one unit at a time should have its Frequency control mode
armed. If multiple units try to control plant frequency at the same
time, they may fight and cause system instability, with the potential
of damage to the equipment due to overloading or reverse-powering
a machine.

If the ‘Use Freq Arm/Disarm’ setting box is unchecked, Frequency control is always Armed and the unit
will go into Frequency control when the utility tie contact is open. If the program’s ‘Use Freq Arm/Disarm’
setting box is checked, then Frequency control must first be armed before the unit will switch into
Frequency control when the utility tie contact is open.

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Table 3-4. Frequency Arm/Disarm Generator Control Modes

Tie Breaker Gen Breaker Frequency Arm Speed Control Initial Speed Cascade or
Contact Status Contact Status Mode Reference Auxiliary (if used)
closed open XXXX Speed, Off-Line XXXX not active
Dynamics
closed closed XXXX Unit Load Control, Droop active
On-Line Dynamics Setpoint
open open XXXX Speed, Off-Line XXXX not active
Dynamics
open closed Arm Frequency Control, Current Speed not active
Off-Line Dynamics then Rated
open closed Disarm Droop, Off- Line Droop not active
dynamics Setpoint

Speed Control Dynamics

The 505 has a variety of options for the setting of dynamics (PID gain settings). When a system needs
variable response times, due to changing system conditions, these dynamic variables allow the Speed
PID to be tuned for optimal response. There values are separated into 2 main operational conditions, Off-
Line and On-Line.

Off-Line and On-Line -

When the 505 is configured for a generator application, the utility tie and generator breakers determine
which set of dynamics is used by the Speed PID. The speed PID’s off-line dynamics are selected when
either the utility tie or generator breakers are open. The Speed PID’s on-line dynamics are selected if
both breakers are closed (see Table 3-2).

When not configured for a generator application, the 505 uses the programmed ‘Min Governor Speed Set
Point’ setting to determine which set of dynamic values are used by the Speed PID. The Speed PID’s off-
line dynamics are selected when turbine speed is below the ‘Min Governor Speed Set Point’ setting. The
Speed PID’s on-line dynamics are selected when turbine speed is above the ‘Min Governor Speed Set
Point’ setting. (see Table 3-2).

When not configured for a generator application, the 505 will transfer from off- line to on-line dynamics
once minimum governor speed is reached.

Optionally a contact input may be programmed to perform a “Select On-Line Dynamics” function. If this
contact is programmed the utility tie and generator breaker positions (gen applications), and the minimum
speed setting status (non- gen applications) do not affect dynamics selection. When the programmed
contact input is open, off-line dynamics are selected and used by the Speed PID. When the programmed
contact input is closed, on-line dynamics are selected and used by the Speed PID.

A relay can be programmed to indicate that the On-Line Dynamics are selected and used by the Speed
PID.

Table 3-5. On-Line/Off-Line Dynamics Selection

CONFIGURATION ON-LINE DYNAMICS OFF-LINE DYNAMICS

SELECTED SELECTED
GEN SET BOTH BREAKERS CLOSED EITHER BREAKER OPEN
NOT A GEN SET SPD > MIN GOV SETTING SPD < MIN GOV SETTING
*CONTACT INPUT CLOSED OPEN
*The contact input option has priority, when programmed.

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Dynamic Gain Settings –
Dynamic gain values for the speed PID are initially defined in the configure mode and tunable at any time.
For Off-Line settings there is 1 set of values for the Proportional, Integral and Derivative terms. The On-
Line settings can be a single set of values or a curve created by optimizing the dynamics at 2 or 3
different load points.

The procedure for setting these values is as follows.

1. Start by manually setting the gains for both Off-Line and On-Line conditions, referring to the PID
Dynamic Adjustments section in this manual for completing this process.
2. Use the automated PID Dynamic Optimizer routine that will automatically analyze the system
response and calculate ideal gains for that running condition.
3. Once the analysis is complete and the gains are calculated, the user can choose to keep these gains
or return to the manual values. For ONLINE operation, this routine can be performed at low, medium
and high load points to create an ideal gain curve for optimum dynamics at all load conditions.

Refer to the PID Dynamic Adjustments section in this manual for more information on the PID Dynamic
Optimizer procedure.

Remote Speed Set Point

The Speed set point can be positioned remotely through an analog signal by programming the Remote
Speed Set Point analog input function. This allows the Speed set point to be set remotely by a process
control or distributed plant control system.

The remote speed set point input directly affects the 505’s speed set point. The maximum rate at which
the remote input signal can change the speed set point is programmable. When the remote set point is
enabled, the speed set point will move at a much slower rate until the two settings are matched at which
time the speed set point will be allowed to move at the maximum rate.

The Remote Speed Set Point (RSS) range is determined by the programmed Analog input’s 4 mA and 20
mA settings. The Remote Speed Set Point range is tunable in the Service mode (under REMOTE SPEED
SETTINGS), but cannot control outside of the min governor and max governor speed set point values.

Since RSS is a secondary speed setting function, the Speed PID must be in-control of the 505’s LSS bus
to allow the RSS to position the actuator. When configured as a generator application, the RSS will not
take control unless both breakers are closed and the speed PID is in control. When not configured as a
generator application, turbine speed must reach min governor before the RSS can take control. The
Cascade and Auxiliary (if configured to be enabled/disabled) controls are automatically disabled if RSS is
enabled.

The Remote Speed Set Point may be enabled or disabled from the 505 keypad, external contact, or
Modbus. The last command given from any of these three sources dictates the enabled/disabled state. It
does not matter whether the last command was given from the keypad or other devices.

A contact input can be programmed to perform as an external “Remote Speed Set Point Enable” function.
When this programmed contact is open the RSS is disabled, and when it is closed the RSS is enabled.
The contact can be either open or closed when trip condition is cleared. If the contact is open it must be
closed to enable the RSS. If the contact is closed it must be opened and re-closed to enable the RSS
function.

If the milliamp signal to the Remote Speed set point input is out of range (below 2 mA or above 22 mA)
an alarm will occur, and the Remote Speed set point will be inhibited until the input signal is corrected and
the alarm is cleared.

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Remote Speed Set Point Status Messages

The Remote Speed Set Point may be in one of the following states (505 front panel screen messages):
 Disabled—The remote set point function is not enabled and will have no effect on the speed set
point.
 Enabled—The remote set point has been enabled.
 Active—The remote set point is in control of the Speed set point but the speed PID is not in control of
the actuator output.
 In Control—The remote set point is in control of the Speed set point and the speed PID is in control
of the actuator output.
 Inhibited—RSS cannot be enabled. The input signal has failed, a controlled stop is selected, the unit
is shut down, or RSS is not programmed.

When enabled, the Remote Speed set point may not match the Speed set point. In this case, the Speed
set point will ramp to the Remote Speed set point at the programmed ‘Speed Set Point Slow Rate’ setting
(as defaulted in the Service mode). Once in control, the maximum rate that the Speed set point will ramp,
for a RSS change, is at the programmed ‘Remote Speed Set Point Max Rate’ setting. If the ‘Remote
Speed Set Point Max Rate’ were set at 10 rpm/s and the Remote Speed set point analog input instantly
moved from 3600 rpm to 3700 rpm, the Speed set point will move to 3700 rpm at 10 rpm/s.

Refer to Volume 2 of this manual for information on related Service mode tunables.

All pertinent Remote Speed Set Point parameters are available through the Modbus links; refer to
Chapter 6 for a complete listing of Modbus parameters.

Synchronization
Automatic generator synchronization can be performed through a Woodward EGCP-3, easYgen, or
DSLC-2. The DSLC-2 product is the easiest to integrate with the 505 as it can be integrated via a digital
communication connection by using the Woodward Links wizard. In some cases, the analog input signal
interfaces described below are not required but can be used as a redundant signal if desired.

These products connect to a 505 analog input to bias the 505’s speed set point directly to vary generator
speed, frequency and phase. Optionally these products can interface with the unit voltage regulator to
match system voltage across a generator breaker.

When the 505 is configured for a Generator application, a special speed set point rate (Sync Window
Rate) is used to increase set point resolution around synchronous speed. This allows for tighter set point
control to accommodate synchronizing manually or by an automatic synchronizer which interfaces to the
505 discretely. This Sync rate is defaulted to two rpm/s and is only adjustable through the 505’s Service
mode. This rate is only used when the generator breaker is open, and the actual speed is within +10 rpm
of rated speed (also tunable through the Service mode).

These products can be used as a synchronizer only or as a synchronizer and load control. When used as
a synchronizer only, the 505 must be configured to accept the products analog Speed Bias signal and
have this input enabled. A ‘Sync Enable’ contact input can be programmed to enable the 505’s
synchronizing input when synchronization is desired. The Sync Enable command becomes disabled
when the generator breaker closes, however, it may re-enabled again to allow the load management
product to perform tie breaker synchronizations. To re-enable this input the ‘Sync Enable’ contact must be
opened and re-closed. Typically, a double pole single throw (DPST) switch is used on a site’s
synchronizer control panel to select automatic synchronizing by enabling both the load management
product sync mode and 505 analog input at the same time. Alternatively, this signal can be sent to the
505, and the 505 can configure a relay output to send this Enable command to the synchronizer.

To configure the 505 to utilize a load management product for generator synchronization only, program
the ‘Synchronizing input’ function setting and program the ‘Sync Enable” function to a ‘CONTACT INPUT
X’ setting. The ‘Synchronizing input’ function has a menu to allow this signal to come from the digital
communication link, or from an Analog Input. If an AI is used, the range and gain settings are preset and
are tunable only in the Service mode. Thus, the 4 mA and 20 mA Configuration mode settings for the
Synchronizing input are irrelevant and are not used by the function’s operation. See Volume #2 of this
manual.
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When the 505 is programmed to use a load management product for Synchronization, the Speed Control
screen can also be used to access and enable the Synchronizing function and monitor all synchronization
mode messages.

The following synchronizing mode messages can be viewed:

 Disabled—The Synchronizing Input is disabled and will have no effect on the Speed set point.
 Enabled—The Synchronizing Input has been enabled.
 In Control—The Synchronizing Input is biasing the Speed set point.
 Inhibited—The Synchronizing Input is inhibited and cannot be enabled. Input signal is failed, both the
utility tie and generator breakers are closed, the turbine is shut down, a controlled shutdown is being
per-formed, or synchronizing control is not programmed.

Synchronizing/Load Sharing
The 505 is capable of using an analog input to accept a load sharing signal from Woodward’s EGCP-3,
easYgen or DSLC-2. The DSLC-2 product is the easiest to integrate with the 505 as it can be integrated
via a digital communication connection by using the Woodward Links wizard. With this connection, the
analog input signal interfaces described below may not required, but can be used as a secondary backup
signal if desired.

This input in conjunction with these power management products allows the control to isochronously load
share with any other system using the same product. The 505’s internal summing junction adds this signal
with the speed/load PID’s reference. In addition to load sharing, this signal input to the 505 can be used to
synchronize the unit to either the plant bus or to the utility.

Each of these power management products can provide VAR/Power Factor control, allowing all of the
units to reactive load share as well as real power load share. These products sense unit load through
generator PTs & CTs and system load through the network interconnects (a combination of all units on
the same bus).

When used as a synchronizer and load control, these products perform automatic synchronization and
control unit load based on an internal base-load setting, a system average load setting, a process loop’s
control setting, or a Master Synchronizer & Load Control’s (MSLC) demand setting.

After synchronization, unit load can be controlled by the power management product through the
Sync/Load Share input or by the 505’s internal speed/load set point. The Utility Tie Breaker Contact is
used to select unit load control through the 505’s internal load set point. When the 505’s internal load
control is selected (utility tie contact closed), the Speed PID set point is used to control unit load.
Optionally the Cascade or Auxiliary control modes may be used to set unit load based on another system
parameter.

The EGCP-3 interfaces to the 505 via its Speed Bias signal. To configure the 505 to utilize a load
management product for generator synchronizing and load sharing, program the ‘Sync/Load Share input’
function to one of the Analog Inputs setting and program the ‘Sync/Ld Share Enable” function to a
‘Contact Input #X’ setting. The ‘Sync/Ld Share input’ function has preset range and gain settings that are
tunable only in the Service mode (see Volume 2). Thus the 4 mA and 20 mA Configuration Mode settings
for the Synchronizing input are irrelevant and are not used by the function’s operation.

A combination of the Utility Tie Breaker contact, Generator Breaker contact, and Sync/Ld Share Enable
contact define the state of the 505’s synchronizing and load sharing operating modes (See Table 3-3).

The Utility Tie breaker contact input is used to enable and disable Load Sharing when the generator
breaker is closed. If the Utility Tie contact is open, load sharing is enabled, and the 505’s internal Speed
PID droop, Cascade, and Auxiliary modes are disabled (as defaulted in Service mode). If the Utility Tie
contact is closed load sharing is disabled and the 505’s Speed PID droop, Cascade, and Auxiliary modes
are enabled, if used.

The Generator Breaker contact input is used in conjunction with the utility tie contact to activate load
sharing.

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The ‘Sync/Ld Share Enable’ contact input option is used to enable the Sync/Load Share analog input
before the generator breaker is closed. There is also a button on the speed Control screen that can be
used to enable the 505’s Sync/Load Share analog input instead of an external contact. This discrete
enable/disable function is ignored after the generator breaker is closed and must be reselected after the
generator breaker opens. Typically, a double pole single throw (DPST) switch is used on a site’s
synchronizer control panel to select automatic synchronizing by enabling both the power management
product’s sync mode and 505 analog input at the same time.

Figure 3-11. Load Sharing Logic

Table 3-6. Load Sharing Logic

Tie Breaker Gen Breaker Sync/Ld Share Speed Control Initial Speed Cascade or
Contact Status Contact Status Enable Contact Mode Reference Auxiliary (if used)
closed open open Speed, Off-Line XXXX not active
Dynamics
closed closed XXXX Unit Load Control, Droop active
On-Line Dynamics Setpoint
open open open Speed, Off-Line XXXX not active
Dynamics
open open closed Synchronizing Off- XXXX not active
Line Dynamics
open closed XXXX Load Sharing, Off- Current Speed not active
Line dynamics

If using the display screen button to enable Sync/Load Share, then a 505 relay output, can be also be
programmed to select the power management product’s synchronizing mode. To configure the 505 for
this functionality, program the ‘Sync/Ld Share Enabled’ function to a ‘RELAY X ENERGIZES ON’ setting.

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When the 505 is programmed to use a load management product for Synchronization and Load Sharing,
the Speed Control screen can also be used to access and enable these functions and monitor all
synchronization mode messages.

The following synchronizing mode messages can be viewed:

 Disabled—The Sync/Load Share Input is disabled and will have no effect on the Speed set point.
 Enabled—The Sync/Load Share Input has been enabled.
 In Control—The Sync/Load Share Input is biasing the Speed set point.
 Inhibited—The Sync/Load Share Input cannot be enabled; the input signal is failed, the turbine is
shut down, a controlled shutdown is being performed, or the sync/load share feature is not
programmed.
 All pertinent synchronizing and load sharing parameters are available through the Modbus links. See
Chapter 6 for a complete listing of Modbus parameters.

Manual Demand
The manual valve demand feature functions just like the valve limiter except that, instead of providing an
input to the Low Signal Select to limit how high the valve demand can go, it disables all other controllers
(including speed) to ensure that manual demand has full control of the valve demand output. The intent of
this feature is to aid in the troubleshooting of plant stability or oscillation issues. It can be used to
temporarily hold the valve in its current position.

This feature can be selected using the Service Menu. In addition to holding the valve demand output,
manual demand allows the valve demand to be adjusted manually, preferably at a very slow and safe
rate. When selected, the valve ramp rate for this feature can be adjusted. This should be set to a value
that is safe and stable for speed, load, or any process and pressures associated with the turbine that will
be affected by moving this valve. Also, the timeout time can be adjusted. After this time, the feature will
disable if no raise/lower manual demand commands are received. Every time a raise or lower manual
demand command is issued, the timer will restart.

Because of the risk associated with locking the valve in place there are many protections that disable this
function, which will return the unit to Speed PID control, in addition to the normal disable command
functionality and the timeout protection. All items that will disable this feature are as follows:
 Operator interface disable command
 Manual Demand not used (Service menu setting)
 Any Turbine Trip
 Startup not completed or Overspeed Test enabled
 Speed less than Minimum Governor
 Speed greater than Maximum Governor
 Both breakers not closed (generator applications only)
 Timeout due to inactivity

Use caution when adjusting manual demand as the 505 is no longer in

control of any speed, load, or process. It is the responsibility of the
operator to ensure safe operation of all processes related to valve
Manual Valve movement. Use caution even while using this feature to hold the valve
position as the 505 may not react to any system upsets until the
Demand
conditions have become unsafe. Failure to do so may result in loss of
control with possible personal injury, loss of life, or property damage.

Load Rejection
The Generator Load Rejection logic along with Woodward’s PID_OPTI block automatically react to large
load drop events to reduce valve demand (energy) to minimize speed overshoot and prevent an
overspeed trip when a load rejection occurs. For a generator application, there are two types of events
that result in large load transients.

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Event 1—At Generator Breaker Opening:
This case is typically a ‘full load’ rejection of a unit running in Unit Load Control (Droop) against a Utility
grid and all load of the steam turbine is lost.

When the Generator Breaker is opened, and the speed exceeds more than 1% above rated speed, the
control will immediately drive the HP valve demand to zero (0%). It will hold the valve at zero until the
turbine speed decreases back to a level that is with 1% of the speed setpoint. This speed setpoint is
identified as the Generator Breaker Open Setpoint and is defaulted to be 50 rpm below rated speed.

Event 2—At Utility Breaker Opening (with GEN Breaker still closed):
In this case, a unit that is normally running in Unit Load Control (Droop), against a utility, loses the Utility
breaker, but the Generator breaker remains closed, and the unit is switched to ‘Island mode’. In this case there is
usually still some load on the turbine.

When the Utility Breaker is opened, and the speed exceeds more than 1% above rated speed, the control
will immediately drive the HP valve demand to zero (0%). It will hold the valve at zero until the turbine
speed decreases back to a level that is with 1% of the speed setpoint. This speed setpoint is this case is
rated speed.

Feed-Forward Input
For 505 controllers configured for compressor applications, it is possible to experience a coupling effect
between an anti-surge controller (external) and the 505’s internal Speed or Cascade PID controllers. If a
plant condition exists where the anti-surge controller is required to open and control the anti-surge valve,
compressor suction pressure will change. If the 505 Cascade controller is also controlling the compressor
suction pressure, it will then respond to this pressure change, resulting in the two controllers temporarily
affecting (fighting) each other.

The 505 is capable of being configured to use an analog input (feed-forward signal) from an anti-surge
controller. This input allows the 505 controller to decouple the response of its Speed and Cascade PID
controls from that of the anti-surge controller, allowing for increased system stability in all conditions.
Refer to this manual’s Speed Controller block diagram to better understand how this input is applied
within the 505’s controller logic. This signal should represent the anti-surge controller’s anti-surge valve
demand where 0% = 4 mA = Closed and 100% = 20 mA = Open. Delays in this signal should be kept to a
minimum.

This Feed-Forward function is only active when operating within the normal operating range (between Min
Gov and Max Gov) and when it has been enabled. This function can be enabled/disabled through a
contact input, programmable function key, or Modbus communications.

When enabled, if the feed forward analog input increases or decreases, the speed set point will be
increased or decreased respectively. This is an offset added to or subtracted from the speed set point.
After a feed-forward event, this speed offset will slowly ramp back to zero based on the delay time
configured (typically 120 seconds). For example, if the max offset is 100 rpm with the max forward rate at
50%/s and the min offset is –75 rpm with the min forward rate at
–25%/s and “Action Delay” is set to 120 seconds, then the following events describe the feed-forward
action:
1. The speed set point is at Rated speed, X rpm.
2. The Feed-Forward Analog Input increases by 50% in one second.
3. The speed set point is instantly increased by 100 rpm.
4. The set point slowly decreases back to X rpm (at least 120 seconds).
5. The Feed-Forward Analog Input decreases by 25% in one second.
6. The speed set point is lowered by 75 rpm.
7. The set point slowly increases back to X rpm taking at least 120 seconds.

The feed-forward loop can be configured for a temporary response, as described here, or as a direct
action (continuous deviation based on the incoming signal).

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Emergency Loop
In case of a compressor surge event, a large speed upset may occur, and recovery may be very difficult.
If this event occurs, Emergency Feed-Forward action can be programmed to instantly bias the control’s
speed reference using a larger offset than the regular feed-forward loop.

When configured, the Emergency Feed-Forward bias action will increase the anti-surge controller’s effect
for a short period, configured as the ‘Emergency Action Delay’, to assist the anti-surge controller with
protecting the compressor. The Emergency Action takes effect when the Feed-Forward Analog Input
increases or decreases faster than the configured ‘FW Rate to Activate’ (this should be larger than the
‘Min/Max Forward Rate’ used for the regular Feed Forward loop). The ‘Emergency Max Speed Offset’ will
be added to the speed reference. This offset immediately begins ramping down and will reach zero after
the configured ‘Emergency Action Delay’. At this point, only the normal feed forward action offset will be
in effect since the emergency will typically have a much shorter duration.

Direct Action
When configured for direct action, the feed-forward loop will offset the speed set point proportional to its
4–20 mA calibration. This offset will not ramp back to zero; it remains active and offsets the speed
reference based on the actual value of the Feed-Forward Analog Input. For example, if configured for a
max offset of 150 rpm and a min offset of –50 rpm, then Direct Feed-Forward action offsets the set point
by 0 rpm if the analog input is at 8 mA. The offset is 100 rpm if the analog input is at 16 mA, and the
offset will not ramp down to 0; it remains at 100 rpm as long as the analog input is at 16 mA.

The direct action cannot be used to decrease speed below Min governor and above Max Governor.

Figure 3-12. Typical Anti-surge Valve and Speed Feed-Forward Logic Trend

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Cascade Control
The Cascade control can be configured to control any system process, related to or affected by turbine
speed or load. Typically, this controller is configured and used as a turbine inlet, or exhaust pressure
controller.

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

When enabled, the Cascade PID can move the speed set point at a variable rate up to the ‘Max Speed
Set Point Rate’ setting (programmed under the CASCADE CONTROL header).

Figure 3-13. Cascade Functional Diagram

Since Cascade is a secondary speed setting function, the Speed PID must be in control of the 505’s LSS
bus for Cascade to take control. When the 505 is configured for a generator application, both the utility tie
and generator breakers must be closed, before the Cascade PID can begin controlling a process.

The selection of the Process Variable to use for this control is:
 Cascade Analog Input
 KW/Load Input
 Inlet Steam Pressure
 Exhaust Steam Pressure

Cascade control may be enabled and disabled from the 505 keypad, a contact input, or Modbus
communications. The last command given from any of these three sources dictates the Cascade PID’s
control state.

If a contact input is programmed to function as a Cascade Enable contact, when the contact is open
Cascade control is disabled, and when it is closed Cascade control is enabled. This contact can either be
open or closed when a trip condition is cleared. If the contact is open it must be closed to enable Cascade
control. If the contact is closed it must be opened and re-closed to enable Cascade control.

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Cascade Control Status Messages

 Cascade is Disabled—Cascade control is not enabled and will have no effect.
 Cascade is Enabled—Cascade has been enabled but is not active or in control. Permissives have
not been met (speed < min gov, generator or tie breaker open).
 Casc Active/Not Spd Ctl—Cascade has been enabled but the Speed PID is not in control of the LSS
bus (either aux or valve limiter is in control).
 Cascade is In Control—Cascade is in control of the LSS bus.
 Casc Active w/Rmt Setpt—Cascade has been enabled and the Remote Cascade set point is in
control of the set point but the Speed PID is not in control of the LSS bus.
 Casc Control w/Rmt Setpt—Cascade is in control of the LSS bus (via the Speed PID) and the
Remote Cascade Set Point is positioning the Cascade set point.
 Cascade is Inhibited—Cascade cannot be enabled; the Cascade input signal has failed, a controlled
stop is selected, the unit is shut down, or cascade control is not programmed.

Cascade control is automatically disabled on a shutdown condition and must be re-enabled after a
successful system start-up. Cascade control is disabled if Remote Speed Set Point is used and enabled.
Should another parameter on the LSS bus take control of governor valve position from the Speed PID,
Cascade control will stay active, and begin controlling again when the Speed PID is the lowest parameter
on the LSS bus again.

All pertinent cascade control parameters are available through the Modbus links, refer to Chapter 6 for a
complete listing of Modbus parameters.

Cascade Dynamics
The Cascade PID control uses its own set of dynamic settings. These values are programmable and may
be tuned at any time. Refer to the PID Dynamic Adjustments section in this manual.

Cascade Set Point

The Cascade set point can be adjusted from the 505 keypad, external contacts, Modbus commands, or
through a 4–20 mA analog input. A specific setting can also be directly entered from the 505 keypad or
through Modbus commands.

The Cascade set point range must be defined in the Configuration mode. Program settings ‘Min Cascade
Set Point’ and ‘Max Cascade Set Point’ define the range of the Cascade set point and control.

Cascade set point raise/lower contact inputs act as speed set point
raise/lower contacts when Cascade is not active or in control. This
allows a single set of contacts (one SPDT switch) to control the
Speed set point when the generator breaker is open, the load set
point when paralleled to a utility, and the Cascade set point when
enabled. Alternatively, a second set of contacts (speed raise and
lower) could be used to independently control the speed and load set
points.

When a raise or lower Cascade Set Point command is issued, the set point moves at the programmed
‘Casc Setpt Rate’ setting. If a Cascade raise or lower command is selected for longer than three seconds,
the Cascade set point will move at the fast rate which is three times the cascade set point rate. The
Cascade set point rate, fast rate delay, and fast rate can all be adjusted in the Service mode.

The shortest length of time a set point will move for an accepted raise or lower command is 40
milliseconds (120 milliseconds for a Modbus command). If the Cascade set point slow rate is
programmed for 10 psi/s, the smallest increment it will move is 0.4 psi (1.2 psi for Modbus).

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A specific set point may also be directly entered from the 505 keypad or through Modbus
communications. When this is performed, the set point will ramp at the ‘Casc Setpt Rate’ (as defaulted in
Service mode). To “enter” a specific set point from the 505 keypad, press the CAS key to view the
Cascade control screen, press the ENTER key, enter the set point level desired, then press the ENTER
key again. If a valid number was entered, equal-to or between the min and max set point settings, the
setting will be accepted, and the Cascade set point will ramp to the “entered” set point level. If an invalid
number is “entered”, the setting will not be accepted and the 505’s screen will momentarily display a
value out-of-range message.

When a valid set point value is entered, the set point will ramp at the Cascade Set Point Rate to the newly
entered set point value. This ‘Entered’ rate is tunable through the Service mode.

To “enter” a specific set point from the 505 Display use the following steps:

1. From the HOME page go to the Cascade Control page

2. Press the Commands button until ‘Entered Setpoint’ appears
3. Select ‘Entered Setpoint’ and a pop-up will appear
4. Press Enter from the Navigation cross and the pop-up value will highlight
5. Adjust the value with the Adjust keys or enter a value from the keypad
6. Press Enter again when desired value has been entered
7. The value in the pop-up will be accepted if it is valid, if it is out of range then an error message will
appear stating the entered value is invalid
8. Select the GO button to ramp the setpoint to this entered value

Refer to Volume 2 of this manual for information on which programmed settings are tunable through the
505’s Service mode. Service mode values can be tuned/adjusted while the 505 is shutdown or in the
RUN mode.

Cascade Set Point Tracking

To allow a bumpless transfer from turbine Speed/load control to Cascade control, the Cascade PID can
be programmed to track its controlling process input when disabled. When this tracking feature is
programmed, the Cascade PID will be satisfied when enabled, and no turbine speed or load correction
will be performed. After the Cascade control is enabled, its set point can moved, as required, to another
setting.

Cascade Set Point with No Tracking

If the Cascade control is programmed not to use the set point tracking feature the set point will remain at
its last setting (running or shutdown). When the 505 is powered-up the set point is reset to the ‘Setpt
Initial Value’. With this configuration, when Cascade control is enabled, and its sensed process signal
does not match set point, the Cascade control will ramp turbine speed/load up or down to match the two
signals, at a controlled “not-matched” rate (defaulted to the ‘Speed Set Point Slow Rate’ setting, and
tunable through the Service mode).

If Cascade is the controlling parameter and one of the permissives is lost or Cascade is disabled, the
speed set point will remain at its last setting until another parameter adjusts it.

Cascade Droop
When sharing control of a parameter with another external controller, the Cascade PID can also receive a
programmable DROOP feedback signal for control loop stability. This feedback signal is a percentage of
the Cascade PID’s output. By including this second parameter into the control loop, the Cascade PID
becomes satisfied, and does not fight with the other external controller over the shared parameter. If
Cascade droop is used, the Cascade input signal will not match the Cascade set point when in control.
The difference will depend on the amount (%) of droop programmed and the output of the Cascade PID.
The Droop value fed back to the Cascade PID is equal to the following defaulted settings:

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PID OUTPUT % x ‘CASCADE DROOP %’ x ‘MAX CASC SET POINT’ x 0.0001

Where the ‘CASCADE DROOP %’ and ‘MAX CASC SET POINT’ values are set in the Configuration
mode and the ‘PID output %’ is determined by the Cascade demand.

Example: 25% x 5% x 600 psi x 0.0001 = 7.5 psi

Refer to Volume 2 of this manual for information on related Service mode tunables.

Invert Cascade
Depending on the control action required, the Cascade input signal can be inverted. If a decrease in inlet
governor valve position is required to increase the Cascade process signal, program the ‘INVERT
CASCADE INPUT’ setting to ‘YES’. An example of this required control action would be when the
Cascade PID is configured to control turbine inlet steam pressure. To increase turbine inlet steam
pressure, the inlet control valve position must be decreased.

Remote Cascade Set Point

If desired, the Cascade set point can be positioned through an analog signal. Optionally, one of the 505’s
six analog inputs can be programmed to position the Cascade PID set point. This allows the Cascade set
point to be positioned remotely by a process control or distributed plant control system.

The Remote Cascade Set Point (RCS) range is determined by the programmed Analog input’s 4 mA and
20 mA settings. The Remote Cascade Set Point range is tunable in the Service mode but cannot be set
outside of the min and max Cascade Set Point settings.

The Remote Cascade Set Point input may be enabled from the 505 keypad, contact input, or Modbus
communications. The last command given from any of these three sources dictates enable/disable.

If the milliamp signal to the Remote Cascade set point input is out of range (below 2 mA or above 22 mA)
an alarm will occur, and the Remote Cascade set point will be inhibited until the input signal is corrected
and the alarm is cleared. Depending on configuration and system conditions, the Remote Cascade Set
Point may be in one of the following states (505 front panel screen messages):

 Disabled—The Remote Set Point function is not enabled and will have no effect on the Cascade set
point.
 Enabled—The Remote Set Point has been enabled but cascade control is not active. The breakers
are not closed, speed < min gov, or cascade has not taken control.
 Active—The Remote Set Point has been enabled but Cascade is not in control. Cascade has been
enabled and the Remote Cascade set point is in control of the set point but the Speed PID is not in
control of the LSS bus.
 In Control—Cascade is in control of the LSS bus (via the Speed PID) and the Remote Cascade Set
Point is positioning the Cascade set point.
 Inhibited—Remote Set Point cannot be enabled; input signal is failed, Cascade input signal is failed,
a controlled stop is selected, the unit is shut down, or the remote cascade control is not programmed.

When enabled, the Remote Cascade set point may not match the Cascade set point. In this case, the
Cascade set point will ramp to the Remote Cascade set point at the programmed ‘Casc Setpt Rate’
setting (as defaulted in the Service mode). Once in control, the fastest the Remote Cascade set point will
adjust the Cascade set point is at the programmed ‘Rmt Cascade Max Rate’ setting. If the ‘Rmt Cascade
Max Rate’ was set at 10 and the Remote Cascade set point analog input instantly moved from 0 units to
1000 units, the Remote Cascade set point will move to 1000 units at 10 units/s).

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Remote Cascade Enable Logic

There are three different options for enabling Remote Cascade Set Point and Cascade control as follows:

 One Remote Enable contact input or function key command

 Both enable commands programmed; Remote Casc Enable and Cascade Enable
 No enable commands programmed

When only one Remote Enable command is programmed (either F-key or contact input), selecting
‘Enable’ will enable both Cascade control and Remote Cascade control. This configuration allows both
functions to be enabled with one command if this is the normal operation mode. If ‘Disable’ is selected,
both control modes are disabled.

A contact input can be programmed to enable and disable the Remote Cascade Set Point (RCS)
input/function. When this contact is open the RCS is disabled, and when it is closed the RCS is enabled.
The contact can be either open or closed when a trip condition is cleared. If the contact is open it must be
closed to enable the RCS input. If the contact is closed it must be opened and re-closed to enable the
RCS input.

When both Remote Cascade Enable and Cascade Control Enable commands are programmed, each
function is enabled by its respective command selection. If Remote Cascade Enable is selected, only the
Remote Cascade Set Point will be enabled. If Cascade Control Enable is selected, only Cascade control
will be enabled. If Remote Cascade Disable is selected, only the Remote Cascade Set Point will be
disabled. If Cascade Control Disable is selected, both Remote Cascade control and Cascade control will
be disabled. However, if before the Cascade PID was ‘In-control’, a Cascade disabled command is given,
only Cascade control will be disabled.

If no external contact input or function keys are programmed for the ‘Enable’ commands, Cascade
Control and Remote Cascade Control must be enabled from either the front panel keypad or from
Modbus. Since the front panel and Modbus provide both Remote Cascade Enable and Cascade Control
Enable commands, they will operate in the same manner as ‘both enables programmed’.

Refer to Volume 2 of this manual for information on related Service mode tunables. All pertinent Remote
Cascade control parameters are available through the Modbus links. See Chapter 6 for a complete listing
of Modbus parameters.

Auxiliary Control
The Auxiliary PID controller can be used to limit or control generator power, plant import/export power,
turbine inlet pressure, turbine exhaust pressure, pump/compressor discharge pressure, or any other
auxiliary parameters, directly related to turbine speed/load.

The selection of the Process Variable to use for this control is:

 Auxiliary Analog Input

 KW/Load Input
 Inlet Steam Pressure
 Exhaust Steam Pressure

Each of these inputs is a 4 to 20 mA current signal (the KW/Load could be from a ‘Woodward Links’
digital communication link). The PID control amplifier compares this input signal with the Auxiliary set
point to produce a control output to the digital LSS (low signal select) bus. The LSS bus sends the lowest
signal to the actuator driver circuitry.

The Auxiliary set point is adjustable with raise or lower commands through the 505 front keypad, through
remote contact inputs or through Modbus. Also, the set point can be directly set by entering the new set
point from the keypad or through Modbus communications. In addition, an analog input can be
programmed to remotely position the Auxiliary set point.

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Figure 3-14. Aux Control Overview

Auxiliary as a Limiter (not using Enable/Disable)

When configured as a limiter, the Auxiliary control is low signal selected (LSS) with all of the other PIDs,
allowing it to limit turbine speed/load based on any auxiliary parameter which is directly related. To
configure the Auxiliary controller to function as a limiter, do NOT check the configuration parameter of
‘Use Aux as Controller’.

When Auxiliary is configured to act as a limiter the Auxiliary PID will ‘limit’ the LSS bus when the input
reaches the set point. The Aux set point initializes to the programmed ‘Setpoint Initial Value’ setting on a
power-up-reset. This set point may be adjusted at any time and will remain at a setting (running or
shutdown), provided a power-up-reset did not occur.

Depending on configuration and system conditions, the Auxiliary Limiter may be in one of the following
states (505 front panel screen messages):

 Auxiliary is Enabled—Auxiliary has been enabled but the generator and utility tie breaker permissives
have not been met (generator applications only).
 Aux Active/Not Lmting—Auxiliary is configured as a limiter but is not limiting the LSS bus.
 Aux Active w/Rmt Setpt—Auxiliary is not in control of the LSS bus, and the remote Auxiliary input is in
command of the set point.
 Aux Control w/Rmt Setpt—Auxiliary is in limiting the LSS bus and the remote Auxiliary analog input is
in command of the set point.
 Auxiliary is Inhibited—Auxiliary cannot be enabled. The input signal has failed.

For generator applications, Auxiliary control limiting can be configured to be disabled when the generator
and/or utility tiebreakers are open. Program settings ‘Generator Breaker Open Aux Disable’ and ‘Tie
Breaker Open Aux Disable’ may be configured to deactivate Auxiliary PID limiting, depending on system
breaker positions. When both settings are programmed as unchecked (NO), the Auxiliary limiter will
always stay ‘active’. If either setting is programmed as checked (YES), the Auxiliary limiter will be active
only when the tiebreaker or generator breaker respectively, is closed.

If the unit is not configured for a generator application, the utility tie and generator breaker inputs do not
affect Auxiliary limiter status, and the Limiter will be active at all times.

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Auxiliary as a Controller (using Enable/Disable)

When configured as a controller, the Auxiliary PID may enabled and disabled on command. With this
configuration, when Auxiliary control is enabled it instantly takes full control of the LSS bus, and the
Speed PID is switched to a tracking mode. When Auxiliary control is disabled, the Speed PID instantly
takes full control of the LSS bus. To allow a bumpless transfer between modes, when the Auxiliary PID is
enabled, the Speed PID tracks a few (%) above the Auxiliary PID’s LSS bus signal. When the Auxiliary
PID is disabled, its set point tracks the Auxiliary PID’s process signal.

To configure the Auxiliary controller to function as a controller, check the configuration box ‘Use Aux as
Controller’ on the Auxiliary Control configuration page.

The Speed PID will only track the Auxiliary PID LSS bus signal up to 100% speed/load. Thus if turbine
speed/load reaches 100%, the Speed PID will protect the unit by limiting unit speed/load to less than or
equal to 100%.

Depending on the configuration and system conditions, the Auxiliary PID may be in one of the following
states (505 front panel screen messages):

 Auxiliary is Disabled—Auxiliary is disabled and will have no effect on the LSS bus.
 Auxiliary is Enabled—Auxiliary has been enabled but the generator and utility tie breaker permissives
have not been met (generator applications only).
 Aux Active/Not in Ctrl—Auxiliary has been enabled, permissives met, but is not in control of the LSS
bus.
 Aux Active w/Rmt Setpt—Auxiliary has been enabled but is not in control of the LSS bus and the
remote Auxiliary input is controlling the set point.
 Auxiliary in Control—Auxiliary is in control of the LSS bus.
 Aux Control w/Rmt Setpt—Auxiliary is in control of the LSS bus, and the remote Auxiliary analog input
is in control of the set point.
 Auxiliary is Inhibited—Auxiliary cannot be enabled; input signal is failed, 505 is in Frequency Control,
controlled shutdown is selected, unit is shut down or Auxiliary control is not programmed.

For generator applications, Auxiliary control can be configured to be disabled when the generator and/or
utility tie breakers are open. Program settings ‘Generator Breaker Open Aux Disable’ and ‘Tie Breaker
Open Aux Disable’ may be configured to deactivate Auxiliary PID control, depending on system breaker
positions. When both settings are programmed as unchecked (NO), the Auxiliary limiter will always stay
‘active’. If either setting is programmed as checked (YES), the Auxiliary limiter will be active only when the
tie breaker or generator breaker respectively, is closed.

If the unit is not configured for a generator application, the utility tie and generator breaker inputs do not
affect Auxiliary control status, and the controller will be always active (capable of being enabled).

Auxiliary control may be enabled from the 505 keypad (GUI), remote contacts, or Modbus/OPC
communications. The last command given from any of these three sources dictates which state the
Auxiliary control is in. If an external Auxiliary Enable contact is programmed, disable is selected when the
contact is open and enable is selected when it is closed. The contact can be either open or closed when a
trip condition is cleared. If the contact is open it must be closed to enable. If the contact is closed it must
be opened and re-closed to enable.

When configured as enable/disable controller, the Auxiliary control will automatically be disabled upon a
shutdown condition. Auxiliary control will be disabled and inhibited when the 505 is in frequency control. If
the Process Variable (PV) milliamp input signal is out of range (below 2 mA or above 22 mA) an alarm will
occur, and Auxiliary control will be inhibited until the input signal is corrected and the alarm is cleared.
Optionally the unit can be programmed to issue a shutdown on a loss of the Auxiliary input process
variable signal.

Auxiliary Dynamics
The Auxiliary PID control uses its own set of dynamic settings. These values are programmable and may
be tuned at any time. Refer to the PID Dynamic Adjustments section in this manual.

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Generator Load Limiter/Control

On generator applications, the Auxiliary PID may be programmed to use the ‘KW/Unit Load Input’ signal
instead of the Auxiliary input signal for limiting or control. This is the same input signal (KW/Unit Load
input) used by the Speed PID for KW droop. This configuration allows the Auxiliary PID to limit or control
generator power.

Auxiliary Droop
When sharing control of a parameter with another external controller, the Auxiliary control amplifier can
also receive a programmable DROOP feedback signal for control loop stability. This feedback signal is a
percentage of the LSS bus (control valve position). By including this second parameter into the control
loop, the Auxiliary PID becomes satisfied, and does not fight with the other external controller over the
shared parameter. The Droop % fed back to the Auxiliary PID is equal to the following defaulted settings:

LSS BUS OUTPUT % x ‘AUXILIARY DROOP %’ x ‘MAX AUX SET POINT’ x 0.0001

Example: 25% x 5% x 600 psi x 0.0001 = 7.5 psi

Where the ‘AUX DROOP %’ is set in Configuration mode, ‘MAX AUX SET POINT’ value is
determined by the upper range limit of the process variable selected and the ‘LSS bus output %’ is
determined by the Auxiliary demand.

Invert Auxiliary Input

Depending on the control action required, the Auxiliary PID’s input signal can be inverted. If a decrease in
inlet control valve position is required to increase the Auxiliary process signal, program the ‘INVERT AUX
INPUT’ setting to ‘YES’. An example of this control action would be when the Auxiliary PID is configured
to control turbine inlet steam pressure. To increase turbine inlet steam pressure, inlet control valve
position must be decreased.

Auxiliary Set Point

The Auxiliary set point can be adjusted from the 505 keypad, external contacts, Modbus/OPC commands,
or through a 4–20 mA analog input. A specific setting can also be directly entered from the 505 keypad or
through Modbus commands.

The Auxiliary set point range must be defined in the Configuration mode. Program settings ‘Minimum
Auxiliary Setpoint’ and ‘Maximum Auxiliary Setpoint’’ define the range of the Auxiliary set point and
control.

When a raise or lower Auxiliary Set Point command is issued, the set point moves at the programmed
‘Auxiliary Setpoint Rate’ setting. If an Auxiliary raise or lower command is selected for longer than three
seconds, the Auxiliary set point will move at three times at the fast rate which is three times the Auxiliary
set point rate. The Auxiliary set point rate, fast rate delay, and fast rate can all be adjusted in the Service
mode.

The shortest length of time a set point will move for an accepted raise or lower command is 40
milliseconds (120 milliseconds for a Modbus command

A specific set point may also be directly entered from the 505 keypad or through Modbus/OPC
communications. When this is performed, the set point will ramp at the ‘Auxiliary Setpoint Rate’ (as
defaulted in Service mode).

To “enter” a specific set point from the 505 Display follow these steps:

1. From the HOME page go to the Auxiliary Control page

2. Press the Commands button until ‘Entered Setpoint’ appears
3. Select ‘Entered Setpoint’ and a pop-up will appear
4. Press Enter from the Navigation cross and the pop-up value will highlight
5. Adjust the value with the Adjust keys or enter a value from the keypad
6. Press Enter again when desired value has been entered
7. The value in the pop-up will be accepted if it is invalid a message will appear
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8. Select the GO button to ramp the setpoint to this entered value

Refer to Volume 2 of this manual for further information on Service mode and on-line tunables. All
pertinent auxiliary control parameters are available through the Modbus links. See Chapter 6 for a
complete listing of Modbus parameters.

Remote Auxiliary Set Point

Remote Aux Set Point
The Auxiliary set point can be positioned through an analog signal. Optionally, one of the 505’s analog
inputs can be programmed to position the Auxiliary PID set point. This allows the Auxiliary set point to be
positioned remotely by a process control or distributed plant control system.

The Remote Auxiliary Set Point (RAS) range is determined by the programmed Analog input’s 4 mA and
20 mA settings. The Remote Auxiliary Set Point range is tunable in the Service mode but cannot be set
outside of the min and max Auxiliary Set Point settings.

When enabled, the Remote Auxiliary Set Point may not match the Auxiliary set point. In this case, the
Auxiliary set point will ramp to the Remote Auxiliary Set Point at the programmed ‘Aux Set Point Rate’
setting (as defaulted in the Service mode). Once in control, the fastest the Remote Auxiliary Set Point will
adjust the Auxiliary set point is at the programmed ‘Remote Aux Max Rate’ setting. If the ‘Remote Aux
Max Rate’ were set at 10 and the Remote Auxiliary Set Point analog input instantly moved from 0 units to
1000 units, the Auxiliary set point will move to 1000 units at 10 units/s.

If the milliamp signal to the Remote Auxiliary Set Point input is out of range (below 2 mA or above 22 mA)
an alarm will occur and the Remote Auxiliary Set Point will be inhibited until the input signal is corrected
and the alarm is cleared. Depending on configuration and system conditions, the Remote Auxiliary Set
Point may be in one of the following states (505 display screen messages):

 Disabled—The Remote Set Point function is disabled and will have no effect on the Aux set point.
 Enabled—The Remote Set Point has been enabled, but permissives are not met.
 Active—The Remote Set Point has been enabled, permissives are met, but Auxiliary PID is not in
control of the LSS bus.
 In Control—The Remote Set Point is in control of the Auxiliary set point, and the Auxiliary PID is in
control of the LSS bus.
 Inhibited—Remote Set Point cannot be enabled; Remote Set Point input signal is failed, Auxiliary
control is Inhibited, or Remote Auxiliary Set Point is not programmed.

Remote Auxiliary Enable Logic

The Remote Auxiliary Set Point input may be enabled from the 505 keypad, contact input, or
Modbus/OPC communications. The last command given from any of these three sources dictates the
state of the RAS input. A contact input can be programmed to enable and disable the Remote Auxiliary
Set Point input/function. When this contact is open the RAS is disabled, and when it is closed the RAS is
enabled. The contact can be either open or closed when a trip condition is cleared. If the contact is open
it must be closed to enable the RAS input. If the contact is closed it must be opened and re-closed to
enable the RAS input.

When the Auxiliary PID is programmed to function as a limiter, the Remote Auxiliary Set Point may be
enabled at any time when the 505 is in the RUN mode.

When the Auxiliary PID is programmed as a Controller (enabled/disabled), there are three different
options for enabling Remote Auxiliary Set Point and Auxiliary control as follows:

 Contact input configured for Remote Auxiliary Setpoint Enable

 From the 505 Display keypad
 Modbus/OPC command

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When only one Remote Enable command is programmed as a contact input, selecting ‘Enable’ will
enable both Auxiliary control and Remote Auxiliary control. This configuration allows both functions to be
enabled with one command if this is the normal operation mode. If ‘Disable’ is selected, both control
modes are disabled.

When both Remote Auxiliary Enable and Auxiliary Control Enable commands are programmed, each
function is enabled by its respective command selection. If Remote Auxiliary Enable is selected, only the
Remote Auxiliary Set Point will be enabled. If Auxiliary Control Enable is selected, only Auxiliary control
will be enabled. If Remote Auxiliary Disable is selected, only the Remote Auxiliary Set Point will be
disabled. If Auxiliary Control Disable is selected, both Remote Auxiliary control and Auxiliary control will
be disabled. However, if before the Auxiliary PID was ‘In-control’ an Auxiliary Disable command is given,
only Auxiliary control will be disabled.

If no external contact inputs are programmed for the ‘Enable’ commands, Auxiliary Control and Remote
Auxiliary Control must be enabled from either the front panel keypad or from Modbus. Since the front
panel and Modbus provide both Remote Auxiliary Enable and Auxiliary Control Enable commands, they
will operate in the same manner as ‘both enables programmed’.

Refer to Volume 2 of this manual for information on related Service mode tunables. All pertinent Remote
Auxiliary Set Point parameters are available through the Modbus links. See Chapter 6 for a complete
listing of Modbus parameters.

Auxiliary 2 Control
The Auxiliary 2 PID controller can be used to limit generator power, plant import/export power, turbine
inlet pressure, turbine exhaust pressure, pump/compressor discharge pressure, or any other auxiliary
parameters, directly related to turbine speed/load.
The selection of the Process Variable to use for this control is:

 Auxiliary Analog Input

 KW/Load Input
 Inlet Steam Pressure
 Exhaust Steam Pressure

Each of these inputs is a 4 to 20 mA current signal (the KW/Load could be from a ‘Woodward Links’
digital communication link). The PID control amplifier compares this input signal with the Auxiliary set
point to produce a control output to the digital LSS (low signal select) bus. The LSS bus sends the lowest
signal to the actuator driver circuitry.

This control works the same as the Auxiliary Control (last section) with the exception that it can only be a
limiter and not a controller.

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Figure 3-15. Aux 2 Control Overview

Valve Limiter
The valve limiter limits the actuator output signal (governor valve position) to aid in starting up and
shutting down the turbine. The output of the valve limiter is Low-Signal-Selected with the output of the
Speed and Auxiliary PIDs. The PID or limiter asking for the lowest valve position will control valve
position. Thus, the valve limiter, limits the maximum valve position.

The valve limiter can also be used to trouble shoot system dynamics problems. If it is believed that the
505 is the source of system instability, the valve limiter can be positioned to manually take control of the
valve position. Care should be taken when using the valve limiter in this fashion, so as to not allow the
system to reach a dangerous operating point.

The valve limiter level is adjusted through the 505 keypad, contact input, or through Modbus
communications. When raise or lower commands are received, the limiter ramps up or down, at the
‘VALVE LIMITER RATE’. The maximum the limiter can increase is 100%. The Valve Limiter ‘Rate’ and
‘Max Valve position’ settings can be adjusted in the Service mode.

A specific set point may also be directly entered from the 505 keypad or through Modbus
communications. When this is performed, the set point will ramp at the ‘Valve Limiter Rate’ (as defaulted
in Service mode). To “enter” a specific set point from the 505 keypad, press the LMTR key to view the
Valve Limiter screen, press the ENTER key, enter the set point level desired, then press the ENTER key
again. If a valid number was entered, equal-to or between the min and max set point settings, the setting
will be accepted and the Valve Limiter will ramp to the “entered” level. If an invalid number is “entered”,
the setting will not be accepted and the 505’s screen will momentarily display a value out-of-range
message.

To “enter” a specific set point from the 505 Display use the following steps:

1. From the HOME page go to the Auxiliary Control page

2. Press the Commands button until ‘Entered Setpoint’ appears
3. Select ‘Entered Setpoint’ and a pop-up will appear
4. Press Enter from the Navigation cross and the pop-up value will highlight
5. Adjust the value with the Adjust keys or enter a value from the keypad
6. Press Enter again when desired value has been entered
7. The value in the pop-up will be accepted if it is invalid a message will appear
8. Select the GO button to ramp the setpoint to this entered value
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When a valid set point value is entered, the set point will ramp at the ‘Valve Limiter Rate’ to the newly
entered set point value. This ‘Entered’ rate is tunable through the Service mode.

During start-up, if the control is set to use Automatic start-up, and if the valve limiter has been manually
set for trouble shooting, it is possible to automatically ramp it back to 100%, by issuing a ‘Run’ command
again.

Refer to Volume 2 of this manual for further information on Service mode and on-line tunables. All
pertinent valve limiter parameters are available through the Modbus links. See Chapter 6 for a complete
listing of Modbus parameters.

Inlet Steam Pressure Compensation

The inlet pressure compensation feature is used to adjust the control response based on variations in the
inlet steam header pressure. Inlet pressure compensation is enabled in Configure Mode (under Operating
Parameters). To use this feature, an analog input must be configured as inlet steam pressure.

Once this is configured, the Pressure compensation curve will be available in the Service Menu screens.
The compensation factor is determined by a user-defined curve. The X values of the curve points are inlet
pressures in engineering units. The Y values of the curve points are a gain multiplier on the HP valve
demand. By default, all Y values are initially set to 1.0. The X values should be set to the expected range
of inlet pressure for normal operation, with at least one Point being the rated pressure and a gain of 1.0.
Increase the gain (Y values) for pressures less than rated and decrease the gains for pressures greater
than rated. This gain factor is applied to the valve demand prior to the valve linearization curve (if that
option is used).

Example:
Curve for a Steam Turbine rated at 500 psi and operating range of +/-150 psi.
X Y
Point 1 350 1.2
Point 2 400 1.1
Point 3 500 1.0
Point 4 600 0.9
Point 5 650 0.8

All X values entered in the curve must be increasing. The curve block has been implemented such that it
will limit the gain to the first and last points entered by the user. If the inlet steam pressure signal fails,
then the curve is bypassed, and the gain is forced to 1.0.

The gain output of this curve should be left at 1.0 (all Y values at 1.0) until the control PID gains have
been tuned at the rated inlet pressure. Once this is done, then the inlet pressure compensation curve
points can be set for other inlet pressures.

Pressure compensation will affect the accuracy of the droop

calculation when the 505 is configured for droop with valve position
control.

Isolated PID Control

The Isolated PID Controller can be configured to control any system process. Typically, this controller is
configured and used to control seal gas or gland seal pressure, but it can also be used for any type of PID
loop.

The Isolated PID compares a 4–20 mA process signal with an internal setpoint to directly position an
analog output configured as Isolated PID output. The Isolated PID loop can be put in manual and
automatic mode via dedicated contact input, Modbus commands or display.

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If a contact input is programmed to function as an Isolated PID manual contact, Isolated PID Control is in
automatic when the contact is opened and in manual mode when it is closed. If a command is send via
Modbus to put this PID in automatic, then the contact input must be closed/opened to bring back the
manual mode.

Isolated Manual Mode

When the Isolated PID is in manual mode, it is possible to manipulate its output directly using
Raise/Lower demand commands. These commands are available via Modbus, display, or contact inputs
configured as Isolated PID raise/lower demand.

Should a Process value be lost, it is also possible to configure the 505XT to hold the last value, ramp the
PID output up or down automatically.

Isolated PID Dynamics

The Isolated PID control uses its own set of dynamic settings. These values are programmable and may
be tuned at any time from display Interface only.

Isolated Set Point

The Isolated setpoint can be adjusted from the display Interface, external contacts, or Modbus.

When a raise or lower Isolated PID setpoint command is issued, the setpoint moves at the Isolated PID
setpoint rate. If an Isolated PID Set Point raise or lower command is selected for longer than three
seconds, the setpoint will move at the fast rate, which is three times the cascade setpoint rate. The
Isolated setpoint rate, fast rate delay, and fast rate can all be adjusted in the Service Mode.

Invert Isolated PID

Depending on the control action required, the Isolated PV input signal can be inverted. If a decrease of
PID output is required to increase the cascade process signal, program the input to be inverted.

Emergency Shutdown
When an Emergency Shutdown condition occurs, the actuator output signal is stepped to zero milliamps,
the Shutdown relay de-energizes, and the shutdown cause (first shutdown condition sensed) is displayed
on the 505’s front panel. See Chapter 5 for a detailed list of the possible shutdown (Trip) conditions.

Up to ten (10) Emergency Shutdown inputs (contact inputs) can be programmed to allow the 505 to
indicate the cause of an emergency shutdown. By wiring trip conditions directly into the 505, instead of a
trip string, the 505 can pass a trip signal directly to its output relay (to trip the T&T valve), and also
indicate the first trip condition sensed. The 505’s total throughput time is 20 milliseconds (worse case).
Each of these discrete input shutdown inputs will be time-stamped by the real-time clock with 1 ms
resolution. All trip conditions are indicated through the 505’s front panel, and Modbus communications.

The cause of the last trip is displayed by pressing the VIEW key under the TRIP LED. The last trip
indication, is latched-in and can be viewed at any time after a trip and before the next trip condition is
latched in. Once latched-in the last trip indication cannot be reset. This allows an operator to confirm what
the trip condition was hours or days after the unit has been reset and restarted.

In addition to the dedicated Shutdown relay, the other programmable relays may be configured as
Shutdown condition or Trip relays.

The Shutdown Condition relay may be programmed to indicate a shutdown condition on a remote panel
or to a plant DCS. The Shutdown Indication relay is normally de-energized. This relay will energize upon
any shutdown condition and stay energized until all trips have been cleared. The ‘Reset Clears Trip’
function has no effect on the programmable Shutdown Indication relay.

When programmed as a Trip relay, the respective relay will function like the dedicated Shutdown relay
(normally energized and de-energizes on a shutdown) to indicate the position of the dedicated Shutdown
relay.

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Controlled Shutdown
The Controlled Shutdown function is used to stop the turbine in a controlled manner, as opposed to an
Emergency Trip. When a STOP command (controlled shutdown) is issued, the following sequence is
performed:
1. Cascade and Auxiliary(if not a limiter) PID controllers are disabled
2. The Speed Set Point is ramped to min load set point at normal rate (only for generator application).
3. When at min load (only for generator application), the controller will wait until the generator breaker
opens (only if “Reverse Power on Controlled Stop?” = False). If a relay output is configured as
“generator open pulse (2s)”, then this relay will temporarily energize for 2 seconds.
4. The Speed Set Point is ramped to its low idle level.
5. Once the speed set point has reached its low idle point, the HP valve limiter is then ramped to zero
percent at a controlled rate. At this point if the “Controlled Stop & Trip” setting is configured to “no” the
control will then wait for a Start command to restart the turbine. However, if the “Controlled Stop &
Trip” setting is configured to “yes” the control will then execute a turbine shutdown.

With the control in the run mode and the turbine turning, when the 505’s “STOP” key is pressed, the
control will display a message prompting the operator to verify the command (“Initialize Normal Stop?”).
At this point, if the “OK” command is issued, the control will perform the controlled shutdown sequence
explained above. Issuing the “Cancel” command will cause no change in the 505’s operation and the
Normal Stop confirmation pop-up box will disappear. This verification feature prevents an unwanted
shutdown if the STOP key is accidentally pushed.

A controlled shutdown can be initiated or aborted from the 505 front panel, a programmed contact input or
either Modbus communication link. Verification is not required if a controlled shutdown command is
initiated by a programmed contact input or Modbus communication link.

The controlled shutdown sequence can be aborted at any time. During a controlled shutdown sequence,
by pressing the STOP key, the 505 will display an “Abort Normal Stop?” message. Selecting “OK” from
this screen will cause the shutdown sequence to be aborted. At this point the shutdown sequence can be
re-initiated when desired, or the unit can be brought back to a fully operational state.

If an external contact is programmed to issue a controlled shutdown command, closing the contact will
initiate the controlled shutdown sequence. The shutdown sequence will go through the same steps
described above, with the exception that verification of the shutdown sequence is not needed. Opening
the programmed contact will stop the sequence. The contact can be either open or closed when a trip
condition is cleared. If the contact is open it must be closed to issue the command. If the contact is closed
it must be opened and re-closed to issue the command. The Modbus initiated Control Shutdown
Sequence requires two commands, one to start the sequence and the other to stop it.

The speed sensor failure trip, generator breaker open trip, and tie breaker open trip commands are
overridden when a controlled shutdown is initiated.

This command can be disabled through the Service Mode, if desired

(see Key Options). When disabled, the Controlled Stop feature is
disabled from front panel, Modbus, and contact commands.

See Chapter 5 of this Volume for all 505 service panel messages.

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Overspeed Test Function

The 505’s Overspeed Test function allows an operator to increase turbine speed above its rated
operating range to periodically test turbine electrical and/or mechanical overspeed protection logic and
circuitry. This includes the 505’s internal overspeed trip logic and any external overspeed trip device’s
settings and logic. An Overspeed Test will allow the control’s speed set point to be increased above the
normal maximum governor limit. This test can be performed from the front panel of the control or with
external contacts. This test is not permissible through the Modbus.

An overspeed test is allowed only under the following conditions:

 The Speed PID must be in control
 The Auxiliary, Cascade, and Remote Speed Set Point PIDs/functions must be disabled
 If configured for a generator application the Generator breaker must be open.
 The Speed Set Point must be at the, “Max Governor Speed” setting.

If the ‘OSPD’ key is pressed or an external Overspeed Test contact is closed (if programmed) and the
above conditions are not met the control will display an “Overspeed Test/Not Permissible” message.

At any time the Max Peak Speed reached can be seen on the Overspeed Test page – it can be reset if
the user is logged in at Service Mode level or above.

An overspeed test can be performed through an external contact, if the ‘Overspeed Test’ function is
programmed to a ‘Contact Input # Function’ setting. When configured this contact performs the same
function as the 505’s front panel OSPD key.

There are two programmable relay options available to indicate overspeed status. One programmable
relay option indicates an Overspeed Trip condition. The second relay option provides indication that an
Overspeed Test is being performed.

See Chapter 5 of this manual for a complete Overspeed Test Procedure. All pertinent overspeed test
parameters are available through the Modbus links. See Chapter 6 for a complete listing of Modbus
parameters.

Local/Remote Function
The 505’s Local/Remote function allows an operator at the turbine skid or 505 to disable any remote
command (from a remote Control Room) that may put the system in an unsafe condition. This function is
typically used during a system start-up, overspeed test, or shutdown to allow only one operator to
manipulate the 505 control modes and settings.

The Local/Remote function must first be programmed before a Local or Remote mode can be selected by
an operator. This function can be programmed under the OPERATING PARAMETERS BLOCK. If this
function is not programmed all contact inputs and Modbus commands (when Modbus is programmed) are
active at all times. If the Local/Remote function is programmed, Local and Remote modes can be
selected through a programmed contact input, or Modbus command.

When Local mode is selected, the 505 is defaulted to be operable from its front panel only. This mode
disables all contact inputs and Modbus commands, with exceptions noted below:
External trip Contact In (defaulted in program)
External trip 2 Contact In (active at all times, if programmed)
External trip 3 Contact In (active at all times, if programmed)
External trip 4 Contact In (active at all times, if programmed)
External trip 5 Contact In (active at all times, if programmed)
External trip 6 Contact In (active at all times, if programmed)
External trip 7 Contact In (active at all times, if programmed)
External trip 8 Contact In (active at all times, if programmed)
External trip 9 Contact In (active at all times, if programmed)
External trip 10 Contact In (active at all times, if programmed)

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External alarm 1 Contact In (active at all times, if programmed)
External alarm 2 Contact In (active at all times, if programmed)
External alarm 3 Contact In (active at all times, if programmed)
External alarm 4 Contact In (active at all times, if programmed)
External alarm 5 Contact In (active at all times, if programmed)
External alarm 6 Contact In (active at all times, if programmed)
External alarm 7 Contact In (active at all times, if programmed)
External alarm 8 Contact In (active at all times, if programmed)
External alarm 9 Contact In (active at all times, if programmed)
Override MPU Fault Contact In (active at all times, if programmed)
Frequency Arm/Disarm (active at all times, if programmed)
Generator breaker Contact In (active at all times, if programmed)
Utility tie breaker Contact In (active at all times, if programmed)
Start permissive Contact In (active at all times, if programmed
Switched dynamics Contact In (active at all times, if programmed)
Select In-Control Unit Contact In (active at all times, if programmed)
Local/Remote Contact In (active at all times, if programmed)
Modbus Commands (can be active in Local with Service setting)

For users familiar with the previous 505 version with 2-line displays,
this feature is slightly different. In this 505 model, Modbus
commands are inhibited when in local mode unless the “Enable
When Local” Service settings is selected. This is available for each
Modbus link. Note that the trip command and “Local/Remote”
command are no longer exceptions to this rule. All addresses for the
link will be considered either Local or Remote commands.

When the Remote mode is selected the 505 can be operated through its front panel, contact inputs,
and/or all Modbus commands.

When using a contact input to select between Local and Remote modes, a closed contact input selects
the Remote mode, and an open contact input selects the Local mode.

Optionally a relay can be programmed to indicate when Local mode is selected (energizes when the
Local mode is selected). There is also indication of the Local/Remote mode selection through Modbus
(address = true when the Remote mode is selected and false = when the Local mode is selected).

The 505 is defaulted to only allow control operation though its front panel when the Local mode is
selected. If desired, this defaulted functionality can be changed through the 505’s Service mode. The 505
can be modified to also allow operation through contacts inputs, or Modbus port #1 or Modbus port #2
when the Local mode is selected.

All pertinent local/remote control parameters are available through the Modbus links. See Chapter 6 for a
complete listing of all Modbus parameters.

Relays
The 505 has eight relay outputs available. The first of these relays is dedicated for a system shutdown
command from the 505. The second relay is configurable but is defaulted for an alarm indication. The
other six relays can be programmed for a variety of indications, and system functions.

For fail-safe operation, the dedicated Shutdown relay is energized during normal system operation and
will de-energize when a shutdown occurs.

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The dedicated Alarm relay is normally de-energized. This relay will energize upon an alarm condition and
stay energized until the alarm condition is cleared. Optionally this relay can be configured, through the
505’s Service mode, to toggle on and off repeatedly when an alarm conditions has occurred. With this
configuration if a reset command is given and the alarm condition still exists, the relay will stop toggling
and stay energized. The relay will start toggling again, upon a new alarm condition. This option can be
used to inform the operator when another alarm condition has occurred.

Any of the configurable relays can be programmed to function as a level switch or mode indication. When
programmed as a level switch the relay will change state when the selected parameter reaches the
programmed level (energizes when value is higher the programmed level).

Relay Functional Clarifications

The Shutdown Condition relay may be programmed to indicate a shutdown condition on a remote panel
or to a plant DCS. The Shutdown Indication relay is normally de-energized. This relay will energize upon
any shutdown condition and stay energized until all trips have been cleared. The ‘RESET CLEARS TRIP’
function has no effect on the programmable Shutdown Indication relay.

When programmed as a Trip relay, the respective relay will function like the dedicated “Shutdown” relay
(normally energized and de-energizes on a shutdown) to indicate the position of the dedicated Shutdown
relay. This relay output can be programmed to indicate a 505 initiated trip by setting the ‘Ext trips in Trip
Relay’ option to NO. Using this option, 505 trip annunciations will only occur if the 505 tripped the turbine
and not annunciate when the other external devices shuts down the unit (external trips).

The Alarm Condition relay may be programmed to indicate an alarm condition on a remote-control panel
or to a DCS. The Alarm Indication relay is normally de- energized. This relay will energize upon any alarm
condition and stay energized until all alarms have been cleared. If the ‘BLINK ALARMS’ option is ‘YES’
the programmable Alarm Condition relay will toggle on and off repeatedly when an alarm condition has
occurred. With this configuration if a reset command is given and the alarm condition still exists, the relay
will stop toggling and stay energized.

The 505 Control Status OK relay is normally energized and will only de-energize if unit inlet power is lost,
the 505’s CPU fails, or the 505 is in the Configuration mode.

The Overspeed Test Enable relay will energize when an Overspeed Test is performed. This relay
functions like the 505 OSPD key’s LED (it repeatedly toggles on and off when turbine speed is above the
turbine Overspeed trip setting).

An Underspeed Switch function can be programmed to indicate a turbine underspeed or overpower

condition. If the Underspeed option is configured, once turbine speed reaches a level above the minimum
governor speed setting, then decreases 100 rpm below the minimum governor speed setting, the
respective relay energizes (indicating an underspeed condition). The ‘Underspeed setting’ is adjustable
through the Service mode, under the ‘Speed Values’ header.

When the Sync Enabled function is programmed, the assigned relay energizes when a synchronize
command is given. After the unit generator or utility tie breaker is closed this function becomes disabled
and the relay de-energizes. The 505’s Synchronization function can be used to synchronize across a
generator breaker or utility tie breaker.

When the Sync or Load Share Active function is programmed, the assigned relay energizes when a
synchronizing or Load Sharing is active. When both the generator and utility tie breaker inputs are closed
(Load Sharing not selected) this function becomes disabled and the relay de-energizes.

When the Modbus Command function is programmed, the assigned relay energizes when the respective
Modbus command “Turn On Modbus Relay X” is issued, then de-energizes when the respective Modbus
command “Turn Off Modbus Relay X” is issued. This feature allows a 505 relay to be driven directly from
Modbus to control a system related function (synchronizing). In addition, the assigned relay can be
momentarily energized using the Modbus command “Momentarily Energize Modbus Relay X” is issued
(voltage raise/lower commands). Refer to Chapter 6 of this manual for more information on Modbus
commands.

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Chapter 4.
Configuration Procedures

Program Architecture
The 505 is easy to configure, due in large part to the menu-driven software. When the control is powered
up and after the CPU self-test has been completed, the control displays the home screen and the CPU
LED on the left side of the front panel should be green. The operating procedures are divided into two
sections: The Configuration Mode, discussed in this chapter, and the Run Modes (Operation and
Calibration) (refer to Chapter 5 for RUN Mode information). The Configure Mode is used to configure the
505 for the specific application and set all operating parameters. The Run Mode is the normal turbine
operation mode and is used to view operating parameters and run the turbine.

The configuration cannot be changed or altered while the turbine is running, however, it can be accessed,
and all programmed values monitored. This minimizes the possibility of introducing step disturbances into
the system. To monitor or review the program while in the run mode, enter the Configuration menu from
the first (leftmost) soft key on the Home screen.

Display Modes and User Levels

The 505 Display operates in several modes and access user levels, each of which has a different
purpose. The modes are: 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

Mode
Operation Calibration Configuration
Monitor
User Operator X
Level 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.

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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.

Configuring the 505

Before the 505 can be used to operate any turbine, it must be configured with a valid configuration. A
handy 505 Configure Mode Worksheet is provided in Appendix A of this manual. This chapter contains
additional information related to completing this worksheet and configuring the specific application. It is
recommended that this worksheet be completed and used to document your specific configuration.

Figure 4-1 illustrates the 505 screen displayed when power is first applied and the unit is not configured.
This is the HOME screen. It includes tips on how to enter the Configure Mode from this point. A password
is required to protect against both intentional and inadvertent configuration changes. The password can
be changed if desired, refer to Volume 2 for information on changing passwords. This screen will become
the main menu once the unit is configured. From this HOME screen, operational screens as well as the
Service and Configure menus can be accessed.

Figure 4-1. Initial HOME Screen (unit not configured)

Use the following steps to begin configuring the 505:

1. Press the MODE key.

2. Press the LOGIN softkey to open the User Login popup.
3. Login to the ‘Configure’ user level.
4. Close the User Login popup screen.
5. Press the Configuration softkey to enter configuration mode. Verify that the following Calibration and
Configuration Mode Permissives are met:
a. Unit Shutdown
b. No Speed Detected
c. “Configure” User Level or greater is logged in

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6. Press MODE or HOME to return to the HOME screen.
7. Press the Configuration softkey to access the configuration menus.
8. Use the navigation cross to navigate up/down/left/right and use ENTER to select a menu or item.

The 505 configure mode may be accessed if the unit is in a Shutdown state, no speed is detected, and
the correct user level is logged in (Configure or higher). For safety reasons the configuration may be
monitored only, and no changes will be accepted if the turbine is running. By pressing the MODE key,
pressing the soft key for LOGIN, and logging in as the “Configure” user level by entering the password
(wg1113). Select a field using the navigation cross arrows and then press ENTER to enter text. When
finished, press ENTER again.

All configuration values and saved service mode changes are stored in the nonvolatile memory
(EEPROMs) of the 505 control. To ensure that values are saved, exit Configure mode or select ‘Save
Settings’ from the MODE screen. If power is removed from the 505 all saved values will return once
power is restored. No batteries or back up power is required.

The field-configured portion of the configuration settings will be

zeroed out after factory repair. You must reconfigure these values
before the unit is put back into service.

Using Configure Menus

Once the Configure Mode has been entered with the password, the specific application information must
be entered into the 505. To access the configure menu, select the ‘Configuration’ softkey from the HOME
screen.

The navigation arrow keys (red navigation cross keypad; up, down, left, and right) are used for navigation
of the Configure menus. Press ENTER to go into a menu. Then use the navigation cross to move up or
down (left/right, if needed) in the menu. In the Configuration mode, the control will generate an error
message shown on the Configuration menu home screen as well as the MODE screen if an invalid
configuration exits. A configuration error will cause the control to remain tripped. It is possible to exit
Configuration mode with such an error, but the control will be tripped until the Configuration mode is
entered again and the Configuration error is corrected.

See the Tutorial to learn how to adjust a value. The tutorial can be accessed from the HOME screen by
pressing the Tutorial softkey before the unit is configured or from the Service menu any time.

To return to the previous screen, press the ESC key. While in a Configure menu, to return to the main
Configure menu screen, press the HOME key. To return to the main Home screen, press the HOME key
again. To exit the Configure mode, go to the MODE screen, and select the ‘Exit Configuration’ soft key.
This will save values, exit I/O Lock, and reboots the 505.

Configure Menus
To program the control, navigate through the menus and configure the control features for the desired
application. The first four configure menus listed below, as well as drivers and other I/O, must be
programmed for every installation. The remaining menus contain optional features which can be selected
if desired. The configure menus and their basic functions are described below.

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Figure 4-2. Configuration Menu – Configuration Mode (Edit)

Table 4-2. Configuration Function Definitions

Turbine Start– to configure start mode, idle/rated, and auto start sequence settings;
Speed Set Point Values– to configure speed set points, overspeed trip set point, remote speed
setting control and critical speed avoidance bands;
Speed Control– to configure MPU or PROX PROBE information and speed control
dynamics settings;
Operating Parameters– to configure the unit for generator application, feed-forward and to use
the local/remote function;
Auxiliary Control– to configure auxiliary control information;
Auxiliary 2 Control– to configure auxiliary 2 control information;
Cascade Control– to configure pressure, temperature control information;
Isolated Control– to configure isolated PID control information;
Communications– to configure Modbus communication options;
Analog Inputs– to configure analog input options;
Analog Outputs (Readouts)– to configure analog readout options;
Drivers– to configure driver outputs, pressure compensation, and, if not using
driver 2, to use driver 2 for a 4–20 mA readout;
Contact Inputs– to configure contact input options;
Relays– to configure relay options;
Woodward Links– to configure digital communication links to other Woodward products.

The configure menus are described in detail below and contain information detailing each question and/or
505 configuration option. Each question/option shows the default (dflt) value and the adjustable range of
that parameter (shown in parentheses). In addition, any additional constraints on the configuration are
shown in italics following the description. There is a Configuration mode worksheet in Appendix A of this
manual that should be completed/filled-in and used as a guide for your particular application. This
worksheet can also be used for future reference to document your application program.

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Turbine Start Menu

Start Mode:
(One of the three start modes must be selected before the unit will run.)
MANUAL START? dflt= NO (Yes/No)
Select this to configure a manual start mode. When configured for a manual start mode, the operator
controls the turbine speed from zero up to the minimum control speed using an external trip-throttle
valve. The Manual Start Sequence would be: Push RUN. The actuator(s) automatically move to max
position. Lastly, the operator slowly opens the trip-throttle valve until the governor takes control.
AUTOMATIC START? dflt= NO (Yes/No)
Select this to configure an automatic start mode. When configured for an automatic start mode, the
505 controls the turbine speed from zero up to the minimum control speed. The Automatic Start
Sequence would be: Operator opens the T&T valve, then push RUN. The valve limiter opens
automatically until the governor takes control.
SEMIAUTOMATIC START? dflt= NO (Yes/No)
Select this to configure a semiautomatic start mode. When configured, the 505 valve limiter must be
manually opened by the operator, slowly, to open the control valve and bring the turbine speed from
zero up to the minimum control speed. The Semi-automatic Start Sequence would be: Open the T&T
valve, then push RUN. The valve limiter must then be raised by the operator until governor takes
control.
RATE TO MIN (rpm/s) dflt= 10.0 (0.01, 2000)
Enter the speed set point acceleration rate to minimum. This is the rate the set point moves from
zero to the lowest controlling speed on a start command (assuming the turbine is at zero speed). 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 start-up features is used, the min speed will be the minimum
governor speed set point.
VALVE LIMITER RATE (%/s) dflt= 5.0 (0.1, 25)
Enter the Valve Limiter Rate, in percent per second. This is the rate at which the valve limiter moves
when RUN is selected or when the limiter setting is changed through open/close commands. When
using a semiautomatic or automatic start, this setting should be very slow—typically less than 2 %/s.
When using a manual start, this setting is less critical and can be left at the default of 5 %/s.

Start Sequence:
(One of the three start modes must be selected)
NO START SEQUENCE ? dflt= YES (Yes/No)
Select this if this no start sequence is desired. If not, skip to ‘Use Idle/Rated’. If no start sequence is
selected, the control will ramp to a programmable Minimum Governor speed set point when a
START command is issued.
USE IDLE/RATED ? dflt= NO (Yes/No)
If this is selected, the control will ramp from a programmable Idle speed to a programmable Rated
speed set point when Rated is selected through keypad, Modbus or external switch. If not, skip to
‘Use Auto Start Sequence’.
USE AUTO START SEQUENCE ? dflt= NO (Yes/No)
If this function is configured and RUN is selected, the 505 automatically accelerates the speed set
point to a programmable low idle speed and holds for a programmable time then ramps to a
programmable high idle speed and holds for a programmable time then ramps to programmable
rated speed set point. The start sequence can be actuated or halted through the keypad, Modbus or
external switch. If this is not selected, then the program will step to the ‘Use Temperature for
Hot/Cold’ question.
USE TEMPERATURE FOR HOT/COLD dflt= NO (Yes/No)
If this function is selected, it allows the turbine Hot/Cold status for startup to be determined by using
temperature analog inputs. Step to ‘Use Temperature Input 2’. If not selected, step to the ‘Reset
Timer Level (rpm)’ question.
Hot Reset Level (rpm) dflt= 3000 (0.0, 20000)
Enter the Level setting for the Hot Reset Timer. This is the speed setting which is used to determine
that the turbine has reached its HOT level. Speed must be above this level for five seconds to trigger
the Hot Reset Timer.
(Must be greater than or equal to the ‘Minimum Governor’ Setting)

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Hot Reset Timer (min) dflt= 0 (0.0, 200)
Enter the reset LEVEL Setting. This is the time needed, when RST Timer level is reached, to transfer
the start-up parameters from fully COLD to fully HOT.
COLD START (> xx HRS) dflt= 10 (0.0, 200)
Enter the time in hours allowed after a trip before the ‘cold start’ sequence curves are to be used. If
this much time has expired (or more) after a trip condition, then the control will use the cold start
values. If less than this time has expired, the control will interpolate between the hot and cold start
values to determine rates and hold times.
HOT START (< xx HRS) dflt= 1.0 (0.0, 200)
Enter the maximum time allowed after a trip for the ‘hot start’ sequence curves to be used. If less
than this time has expired after a trip condition, then the control will use the hot start values.
(Must be less than or equal to the ‘Cold Start’ Hours)
USE TEMPERATURE INPUT 2 dflt= NO (Yes/No)
If this function is selected, it allows the turbine Hot/Cold status for startup to be determined by using
2 temperature analog inputs. To use the temperature difference feature, Temperature Input 2 must
be used. If not selected, only 1 temperature AI will be used.
HOT MINIMUM TEMPERATURE 1 dflt= 1400.0 (0.0, 1.0e+38)
Set the minimum temperature for the turbine to be considered HOT based on temperature analog
input 1. Above this temperature, the turbine is considered HOT for this input. See the functional
description in this manual for other conditions that may be required for the turbine to be considered
HOT.
HOT MINIMUM TEMPERATURE 2 dflt= 1400.0 (0.0, 1.0e+38)
Set the minimum temperature for the turbine to be considered HOT based on temperature analog
input 2. Above this temperature, the turbine is considered HOT for this input. See the functional
description in this manual for other conditions that may be required for the turbine to be considered
HOT.
USE WARM CONDITION dflt= NO (Yes/No)
If this function is selected, an additional warm condition is available between cold and hot, which
means that each ramp rate and idle will allow a warm rate and hold time to be configured. If not
selected, only Hot/Cold conditions will be used.
WARM MINIMUM TEMPERATURE 1 dflt= 1200.0 (0.0, 1.0e+38)
Set the minimum temperature for the turbine to be considered WARM based on temperature analog
input 1. Above this temperature, the turbine is considered WARM for this input. See the functional
description in this manual for other conditions that may be required for the turbine to be considered
WARM.
WARM MINIMUM TEMPERATURE 2 dflt= 1200.0 (0.0, 1.0e+38)
Set the minimum temperature for the turbine to be considered WARM based on temperature analog
input 2. Above this temperature, the turbine is considered WARM for this input. See the functional
description in this manual for other conditions that may be required for the turbine to be considered
WARM.
USE TEMPERATURE DIFFERENCE dflt= NO (Yes/No)
If this function is selected, it allows the turbine Hot/Cold status for startup to be determined by the
difference between temperature analog inputs 1 and 2. Two temperature inputs must be configured.
If not selected, Hot/Warm/Cold conditions will be based on the value of each temperature analog
input and not the difference between the two.
HOT TEMPERATURE DIFFERENCE dflt= 10.0 (0.0, 1.0e+38)
Set the temperature difference between temperature analog inputs 1 and 2 for the turbine to be
considered HOT. If the difference is less than this value, the turbine is considered HOT. See the
functional description in this manual for other conditions that may be required for the turbine to be
considered HOT.
WARM TEMPERATURE DIFFERENCE dflt= 10.0 (0.0, 1.0e+38)
Set the temperature difference between temperature analog inputs 1 and 2 for the turbine to be
considered WARM. If the difference is less than this value, the turbine is considered WARM. See the
functional description in this manual for other conditions that may be required for the turbine to be
considered WARM.
IDLE SETPOINT (rpm) dflt= 1000 (0.0, 20000)
Enter the Idle Speed set point desired. This is the lowest speed control set point when using the
Idle/Rated function.

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RATED SETPOINT (rpm) dflt= 3600 (0.0, 20000)
Enter the Rated Speed set point desired. This is the speed control set point that the unit accelerates
to when using the Idle/Rated function.
(Must be greater than or equal to the ‘Minimum Governor Speed’ Setting)
IDLE/RATED COLD RATE (rpm/s) dflt= 5.0 (0.01, 2000)
Enter the Idle/Rated cold rate (rpm/second). This is the at which the speed set point moves between
Idle and Rated speed set points when using the Idle/Rated commands and a COLD start is
determined by the Hot/Cold start timer or temperature analog inputs if configured/used.
IDLE/RATED WARM RATE (rpm/s) dflt= 5.0 (0.01, 2000)
Enter the Idle/Rated warm rate (rpm/second). This is the at which the speed set point moves
between Idle and Rated speed set points when using the Idle/Rated commands and a WARM start
is determined by the temperature analog inputs if configured/used. The warm condition is only
available when using temperature analog inputs.
IDLE/RATED HOT RATE (rpm/s) dflt= 5.0 (0.01, 2000)
Enter the Idle/Rated rate (rpm/second). This is the at which the speed set point moves between Idle
and Rated speed set points when using the Idle/Rated commands and a HOT start is determined by
the Hot/Cold start timer or temperature analog inputs if configured/used..
LOW IDLE SETPT (rpm) dflt= 1000 (0.0, 20000)
Enter the Low Idle Speed Setting. This is the first hold speed when using the automatic start
sequence. The speed set point will remain at this setting until the low idle delay/hold time has
expired.
LOW IDLE DELAY TIME—COLD (MINUTES) dflt= 1.0 (0.0, 500)
Enter the cold start hold time desired at low idle. This is the programmable time, in minutes, that the
turbine will wait/hold at the low idle speed when a cold start is determined.
LOW IDLE DELAY TIME—WARM (MINUTES) dflt= 1.0 (0.0, 500)
Enter the warm start hold time desired at low idle. This is the programmable time, in minutes, that the
turbine will wait/hold at the low idle speed when a warm start is determined. The warm condition is
only available when using temperature analog inputs.
LOW IDLE DELAY TIME- HOT (MINUTES) dflt= 1.0 (0.0, 500)
Enter the hot start hold time at low idle. This is the programmable time, in minutes/seconds, that the
turbine will wait/hold at the low idle speed when a hot start is determined. If the turbine has been
shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate
between the Hot and Cold delays to determine the low idle hold time.
Use IDLE 2? dflt= False
When TRUE, the speed reference will ramp to Idle 2 level when timer is passed.
When FALSE is selected, the speed reference will go to rated speed.
RATE TO IDLE 2—COLD (rpm/s) dflt= 5.0 (0.01, 500)
Enter the cold start rate to Idle 2. This is the programmable rate, in rpm per second, that the speed
set point will accelerate at when moving to high idle when a cold start is determined.
RATE TO IDLE 2—WARM (rpm/s) dflt= 5.0 (0.01, 500)
Enter the warm start rate to Idle 2. This is the programmable rate, in rpm per second, that the speed
set point will accelerate at when moving to high idle when a warm start is determined. The warm
condition is only available when using temperature analog inputs.
RATE TO IDLE 2—HOT (rpm/s) dflt= 5.0 (0.01, 500)
Enter the hot start rate to Idle 2. This is the programmable rate, in rpm per second, that the speed
set point will accelerate at when moving to Idle 2 when a hot start is determined. If the turbine has
been shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate
between the Hot and Cold rates to determine the acceleration rate to the Idle 2 set point.
IDLE 2 SETPT (rpm) dflt= 1100 (0.0, 20000)
Enter the Idle 2 Speed Setting. This is the second hold speed when using the automatic start
sequence. The speed set point will remain at this setting until the Idle 2 Delay/hold time has expired.
(Must be greater than the ‘Low Idle’ Setting)
IDLE 2 DELAY TIME—COLD (MINUTES) dflt= 1.0 (0.0, 500)
Enter the cold start hold time desired at Idle 2. This is the programmable time, in minutes, that the
turbine will wait/hold at the Idle 2 speed when a cold start is determined.
IDLE 2 DELAY TIME—WARM (MINUTES) dflt= 1.0 (0.0, 500)
Enter the cold start hold time desired at Idle 2. This is the programmable time, in minutes, that the
turbine will wait/hold at the Idle 2 speed when a warm start is determined. The warm condition is only
available when using temperature analog inputs.

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IDLE 2 DELAY TIME—HOT (MINUTES) dflt= 1.0 (0.0, 500)
Enter the hot start hold time desired at Idle 2. This is the programmable time, in minutes, that the
turbine will wait/hold at the Idle 2 speed when a hot start is determined. If the turbine has been
shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate
between the Hot and Cold delays to determine the hi idle hold time.
Use IDLE 3? dflt= False
When TRUE, the speed reference will ramp to Idle 3 level when timer is passed.
When FALSE is selected, the speed reference will go to RATED speed.
RATE TO IDLE 3—COLD (rpm/s) dflt= 5.0 (0.01, 500)
Enter the cold start rate to Idle 3. This is the programmable rate, in rpm per second, that the speed
set point will accelerate at when moving to high idle when a cold start is determined.
RATE TO IDLE 3—WARM (rpm/s) dflt= 5.0 (0.01, 500)
Enter the warm start rate to Idle 3. This is the programmable rate, in rpm per second, that the speed
set point will accelerate at when moving to high idle when a warm start is determined. The warm
condition is only available when using temperature analog inputs.
RATE TO IDLE 3—HOT (rpm/s) dflt= 5.0 (0.01, 500)
Enter the hot start rate to Idle 3. This is the programmable rate, in rpm per second, that the speed
set point will accelerate at when moving to Idle 3 when a hot start is determined. If the turbine has
been shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate
between the Hot and Cold rates to determine the acceleration rate to the Idle 3 set point.
IDLE 3 SETPT (rpm) dflt= 1200 (0.0, 20000)
Enter the Idle 3 Speed Setting. This is the third hold speed when using the automatic start sequence.
The speed set point will remain at this setting until the Idle 3 Delay/hold time has expired.
(Must be greater than the ‘ Idle 2’ Setting)
IDLE 3 DELAY TIME—COLD (MINUTES) dflt= 1.0 (0.0, 500)
Enter the cold start hold time desired at Idle 3. This is the programmable time, in minutes, that the
turbine will wait/hold at the Idle 3 speed when a cold start is determined.
IDLE 3 DELAY TIME—WARM (MINUTES) dflt= 1.0 (0.0, 500)
Enter the warm start hold time desired at Idle 3. This is the programmable time, in minutes, that the
turbine will wait/hold at the Idle 3 speed when a warm start is determined. The warm condition is only
available when using temperature analog inputs.
IDLE 3 DELAY TIME—HOT (MINUTES) dflt= 1.0 (0.0, 500)
Enter the hot start hold time desired at Idle 3. This is the programmable time, in minutes, that the
turbine will wait/hold at the Idle 3 speed when a hot start is determined. If the turbine has been
shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate
between the Hot and Cold delays to determine the Idle 3 hold time.
USE TEMPERATURE FOR IDLES dflt= NO (Yes/No)
If this function is selected, it allows the temperature analog inputs to be used to determine when the
automatic start sequence can proceed from an idle setpoint. If not selected, only idle timers and
halt/continue commands will be used.
USE TEMPERATURE INPUT 2 dflt= NO (Yes/No)
If this function is selected, it allows 2 temperature analog inputs to be used to determine when the
automatic start sequence can proceed from an idle setpoint. To use the temperature difference
feature, Temperature Input 2 must be used. If not selected, only 1 temperature AI will be used.
USE TEMPERATURE DIFFERENCE dflt= NO (Yes/No)
If this function is selected, it allows the difference between temperature analog inputs 1 and 2 to be
used to determine when the automatic start sequence can proceed from an idle setpoint. Two
temperature inputs must be configured. If not selected, idle hold conditions will be based on the
value of each temperature analog input and not the difference between the two.
TEMPERATURE 1 SETPOINT FOR IDLE 1 dflt= 1500.0 (0.0, 1.0e+38)
Set the temperature that must be reached for the automatic start sequence to continue through the
Idle 1 speed setpoint based on temperature analog input 1. Above this temperature, the Idle 1
condition will be satisfied for this temperature input. See the functional description in this manual for
other conditions that may be required for the automatic start sequence to continue from Idle 1.
TEMPERATURE 2 SETPOINT FOR IDLE 1 dflt= 1500.0 (0.0, 1.0e+38)
Set the temperature that must be reached for the automatic start sequence to continue through the
Idle 1 speed setpoint based on temperature analog input 2. Above this temperature, the Idle 1
condition will be satisfied for this temperature input. See the functional description in this manual for
other conditions that may be required for the automatic start sequence to continue from Idle 1.

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MAX TEMPERATURE DIFFERENCE FOR IDLE 1 dflt= 1500.0 (0.0, 1.0e+38)
Set the temperature difference that must be achieved for the automatic start sequence to continue
through the Idle 1 speed setpoint based on the difference between temperature analog inputs 1 and
2. If the difference between temperature input 1 and 2 is less than this value, the Idle 1 condition will
be satisfied. See the functional description in this manual for other conditions that may be required
for the automatic start sequence to continue from Idle 1.
TEMPERATURE 1 SETPOINT FOR IDLE 2 dflt= 1500.0 (0.0, 1.0e+38)
Set the temperature that must be reached for the automatic start sequence to continue through the
Idle 2 speed setpoint based on temperature analog input 1. Above this temperature, the Idle 2
condition will be satisfied for this temperature input. See the functional description in this manual for
other conditions that may be required for the automatic start sequence to continue through Idle 2.
TEMPERATURE 2 SETPOINT FOR IDLE 2 dflt= 1500.0 (0.0, 1.0e+38)
Set the temperature that must be reached for the automatic start sequence to continue through the
Idle 2 speed setpoint based on temperature analog input 2. Above this temperature, the Idle 2
condition will be satisfied for this temperature input. See the functional description in this manual for
other conditions that may be required for the automatic start sequence to continue through Idle 2.
MAX TEMPERATURE DIFFERENCE FOR IDLE 2 dflt= 10.0 (0.0, 1.0e+38)
Set the temperature difference that must be achieved for the automatic start sequence to continue
through the Idle 2 speed setpoint based on the difference between temperature analog inputs 1 and
2. If the difference between temperature input 1 and 2 is less than this value, the Idle 2 condition will
be satisfied. See the functional description in this manual for other conditions that may be required
for the automatic start sequence to continue through Idle 2.
TEMPERATURE 1 SETPOINT FOR IDLE 3 dflt= 1500.0 (0.0, 1.0e+38)
Set the temperature that must be reached for the automatic start sequence to continue through the
Idle 3 speed setpoint based on temperature analog input 1. Above this temperature, the Idle 3
condition will be satisfied for this temperature input. See the functional description in this manual for
other conditions that may be required for the automatic start sequence to continue through Idle 3.
TEMPERATURE 2 SETPOINT FOR IDLE 3 dflt= 1500.0 (0.0, 1.0e+38)
Set the temperature that must be reached for the automatic start sequence to continue through the
Idle 3 speed setpoint based on temperature analog input 2. Above this temperature, the Idle 3
condition will be satisfied for this temperature input. See the functional description in this manual for
other conditions that may be required for the automatic start sequence to continue through Idle 3.
MAX TEMPERATURE DIFFERENCE FOR IDLE 3 dflt= 10.0 (0.0, 1.0e+38)
Set the temperature difference that must be achieved for the automatic start sequence to continue
through the Idle 3 speed setpoint based on the difference between temperature analog inputs 1 and
2. If the difference between temperature input 1 and 2 is less than this value, the Idle 3 condition will
be satisfied. See the functional description in this manual for other conditions that may be required
for the automatic start sequence to continue through Idle 3.
RATE TO RATED SETPT—COLD (rpm/s) dflt= 5.0 (0.01, 500)
Enter the cold start rate to the rated speed set point. This is the programmable rate, in rpm per
second, that the speed set point will accelerate at when moving to rated when a cold start is
determined.
RATE TO RATED SETPT—WARM (rpm/s) dflt= 5.0 (0.01, 500)
Enter the warm start rate to the rated speed set point. This is the programmable rate, in rpm per
second, that the speed set point will accelerate at when moving to rated when a warm start is
determined. The warm condition is only available when using temperature analog inputs.
RATE TO RATED SETPT—HOT (rpm/s) dflt= 5.0 (0.01, 500)
Enter the hot start rate to the rated speed set point. This is the programmable rate, in rpm per
second, that the speed set point will accelerate at when moving to rated when a hot start is
determined. If the turbine has been shutdown for longer than the Hot time but shorter than the Cold
time, the control will interpolate between the Hot and Cold rates to determine the acceleration rate to
the rated set point.
(Must be greater than or equal to the ‘Rate to Rated—Cold’ Setting)
RATED SETPOINT (rpm) dflt= 3000 (0.0, 20000)
Enter the Rated Speed Setting. This is the final speed setting when using the automatic start
sequence. Once this speed set point is reached, the start sequence is complete.
(Must be greater than or equal to the ‘Minimum Governor’ Setting)

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AUTO HALT AT IDLE SETPOINTS? dflt= NO (Yes/No)
Select YES to automatically halt the auto start sequence at the idle set points. This feature would
result in the unit automatically stopping/halting at the low idle set point and at the high idle set point.
Also, if the unit is started and the speed is above the low idle set point, the sequence will be halted.
Select NO to allow the control to perform its automatic start sequence routine without interruption.

Speed Set Point Values Menu

(The maximum speed input frequency is 35000 hertz.)

OVERSPEED TEST LIMIT (rpm) dflt= 1100 (0.0, 20000)

Set the overspeed test limit (in rpm). This is the maximum speed set point the control will increase to
when overspeed testing the unit. The set point can only be raised to this level when the overspeed
test function is being performed.
OVERSPEED TRIP LEVEL (rpm) dflt= 1000 (0.0, 20000)
Set the 505’s overspeed trip level (in rpm). This is the governor overspeed trip set point only and is
not to be used as ultimate overspeed protection.
(Must be less than the ‘Overspeed Test Limit’ Setting)
MAX GOVERNOR SPEED SET POINT (rpm) dflt= 1.0 (0.0, 20000)
Set the maximum governor control speed. This is the normal governor operation upper limit. For
turbine/generator applications, this value must be at least equal to [Rated Speed + (Droop % x Rated
Speed)].
(Must be less than the ‘Overspeed Trip Level’ Setting)
RATED SPEED (rpm) dflt= 3600 (0.0, 20000)
Set the generator’s rated speed set point.
(Must be greater than or equal to the ‘Minimum Governor Speed’ Setting and less than the/Maximum
Governor Speed’ setting)
MIN GOVERNOR SPEED SET POINT (rpm) dflt= 1.0 (0.0, 20000)
Set the minimum governor control speed. This is the normal governor operation lower limit.
(Must be less than the ‘Maximum Governor Speed’ Setting)
OFF-LINE SLOW RATE (rpm/s) dflt= 5.0 (0.01, 100)
Enter the speed set point slow rate in rpm per second. This is the rate of speed change for normal
operation when turbine is Off-line.
ON-LINE SLOW RATE (rpm/s) dflt= 5.0 (0.01, 100)
Enter the speed set point slow rate in rpm per second. This is the rate of speed change for normal
operation when turbine is On-line.
REMOTE SETPOINT ? dflt= NONE (None/Speed/kW)
Set to Speed or kW if using an analog input to set the Speed/Load Set Point. Select None if no
remote speed or load setpoint will be used.
REMOTE SETPOINT MAX RATE (rpm/s or kW) dflt= 50.0 (0.01, 500)
Enter the Maximum Rate of speed or kW change for the remote setpoint operation.
USE CRITICAL SPEEDS ? dflt= NO (Yes/No)
Set to YES to use the critical speed avoidance logic. When set to YES, allows up to two critical
speed avoidance bands to be programmed. Within the band, the speed set point cannot be stopped.
These bands are used to protect the turbine and driven device from speeds that have inherently high
vibration.
(Must program either ‘Idle/Rated’ or ‘Auto Start Sequence’ to use critical speed avoidance. The
lowest critical speed min must be greater than idle or low idle.)
CRITICAL SPEED RATE (rpm/s) dflt= 50.0 (0.1, 2000)
Set the rate that the speed set point will move through the critical speed avoidance ranges (in
rpm/second)
(Must be greater than the ‘Speed Setpt Slow Rate’ Setting)
CRITICAL SPEED 1 MAX (rpm) dflt= 1.0 (1.0, 20000)
Set the upper limit of the critical speed avoidance band.
(Must be less than the ‘Minimum Governor Speed’ Setting)
CRITICAL SPEED 1 MIN (rpm) dflt= 1.0 (1.0, 20000)
Set the lower limit of the critical speed avoidance band.
(Must be less than the ‘Critical Speed 1 Max’ Setting)
USE CRITICAL SPEED 2 ? dflt= NO (Yes/No)
Select YES to use the second critical speed avoidance band.

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CRITICAL SPEED 2 MAX (rpm) dflt= 1.0 (1.0, 20000)
Set the upper limit of the critical speed avoidance band.
(Must be less than the ‘Minimum Governor Speed’ Setting)
CRITICAL SPEED 2 MIN (rpm) dflt= 1.0 (1.0, 20000)
Set the lower limit of the critical speed avoidance band.
(Must be less than the ‘Critical Speed 2 Max’ Setting)
USE CRITICAL SPEED 3 ? dflt= NO (Yes/No)
Select YES to use the second critical speed avoidance band.
CRITICAL SPEED 3 MAX (rpm) dflt= 1.0 (1.0, 20000)
Set the upper limit of the critical speed avoidance band.
(Must be less than the ‘Minimum Governor Speed’ Setting)
CRITICAL SPEED 3 MIN (rpm) dflt= 1.0 (1.0, 20000)
Set the lower limit of the critical speed avoidance band.
(Must be less than the ‘Critical Speed 3 Max’ Setting)

Speed Control Menu

(The maximum speed input frequency is 35000 hertz.)

PROBE TYPE dflt= MPU (MPU, ACTIVE)

Set the probe type, whether passive or active,
TEETH SEEN BY MPU dflt= 60.0 (1, 300)
Enter the number of teeth on gear that the speed probe is mounted on.
MPU GEAR RATIO dflt= 1.0 (0.05, 100)
Enter the speed sensor gear ratio. This value is the ratio of the speed sensor gear to the turbine
shaft. This gear ratio is the result of dividing the speed of the speed sensor gear by the speed of the
turbine shaft.
MAXIMUM SPEED LEVEL (rpm) dflt= 250 (0.5, 1000)
Enter the Maximum Speed Level (in rpm) to set the speed probe input maximum detectable level. If
speed goes above this level, it will not be read in the control.
(Must be greater than the Overspeed Test Limit Setting)
FAILED SPEED LEVEL (rpm) dflt= 250 (0.5, 1000)
Enter the Failed Speed Level (in rpm) to set the speed probe input failure level. If speed drops below
this level, the control will determine the speed input device is failed and issue an alarm. If all speed
inputs fail, the 505 will issue a trip on loss of speed inputs.
(Must be greater than or equal to 0.0204 x Maximum Speed Level)
Note: The MPU override level is this value + 50 RPM. When speed increases above this level the
speed input override is removed and the failure detection is armed.
USE SPEED INPUT #2? dflt= NO (Yes/No)
Select YES if both speed inputs are to be used.
PROBE TYPE dflt= MPU (MPU, ACTIVE)
Set the probe type, whether passive or active,
TEETH SEEN BY MPU dflt= 60.0 (1, 300)
Enter the number of teeth on gear that the speed probe is mounted on.
MPU GEAR RATIO dflt= 1.0 (0.05, 100)
Enter the speed sensor gear ratio. This value is the ratio of the speed sensor gear to the turbine
shaft. This gear ratio is the result of dividing the speed of the speed sensor gear by the speed of the
turbine shaft.
MAXIMUM SPEED LEVEL (rpm) dflt= 250 (0.5, 1000)
Enter the Maximum Speed Level (in rpm) to set the speed probe input maximum detectable level. If
speed goes above this level, it will not be read in the control.
(Must be greater than the Overspeed Test Limit Setting)
FAILED SPEED LEVEL (rpm) dflt= 250 (0.5, 1000)
Enter the Failed Speed Level (in rpm) to set the speed probe input failure level. If speed drops below
this level, the control will determine the speed input device is failed and issue an alarm. If all speed
inputs fail, the 505 will issue a trip on loss of speed inputs.
(Must be greater than or equal to 0.0204 x Maximum Speed Level)
Note: The MPU override level is this value + 50 RPM. When speed increases above this level the
speed input override is removed, and the failure detection is armed.

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OFF-LINE PROPORTIONAL GAIN dflt= 5.0 (0.0, 100)
Enter the off-line PID proportional gain percentage. This value is used to set speed/load control
response when the Generator or Utility Tie breaker contacts are open (if the unit is a generator) or if
the turbine speed is below minimum governor speed (if the unit is not a generator) or when the
Select Dynamics function is used and the contact is open. This value can be changed in the Run
Mode while the turbine is operating. A recommended starting value is 5%.
OFF-LINE INTEGRAL GAIN dflt= 0.5 (0.01, 50)
Enter the off-line PID integral gain percentage. This value is used to set speed/load control response
when the Generator or Utility Tie breaker contacts are open (if the unit is a generator) or if the turbine
speed is below minimum governor speed (if the unit is not a generator) or when the Select Dynamics
function is used, and the contact is open. This value can be changed in the Run Mode while the
turbine is operating. A recommended starting value is 0.5%.
OFF-LINE DERIVATIVE RATIO dflt= 5.0 (0.01, 100)
Enter the off-line PID derivative ratio. This value is used to set speed/load control response when the
Generator or Utility Tie breaker contacts are open (if the unit is a generator) or if the turbine speed is
below minimum governor speed (if the unit is not a generator) or when the Select Dynamics function
is used and the contact is open. This value can be changed in the Service Mode while the turbine is
operating. When this value is between 0.01 and 1.0, the derivative term is considered to be ‘input
dominant’ and the derivative is equal to (Deriv Ratio)/(Integral Gain). When this value is between 1.0
and 100, the derivative term is considered to be ‘feedback dominant’ and the derivative is equal to
1.0/[(Deriv Ratio)*(Integral Gain)].
ON-LINE PROPORTIONAL GAIN dflt= 5.0 (0.0, 100)
Enter the on-line PID proportional gain percentage. This value is used to set speed/load control
response when the Generator and Utility Tie breaker contacts are closed (if the unit is a generator)
or if the turbine speed is above minimum governor speed (if the unit is not a generator) or when the
Select Dynamics function is used and the contact is closed. This value can be changed in the Run
Mode while the turbine is operating. A recommended starting value is 5%.
ON-LINE INTEGRAL GAIN dflt= 0.5 (0.01, 50)
Enter the on-line PID integral gain percentage. This value is used to set speed/load control response
when the Generator and Utility Tie breaker contacts are closed (if the unit is a generator) or if the
turbine speed is above minimum governor speed (if the unit is not a generator) or when the Select
Dynamics function is used and the contact is closed. This value can be changed in the Run Mode
while the turbine is operating. A recommended starting value is 0.5%.
ON-LINE DERIVATIVE RATIO dflt= 5.0 (0.01,100)
Enter the on-line PID derivative ratio. This value is used to set speed/load control response when the
Generator and Utility Tie breaker contacts are closed (if the unit is a generator) or if the turbine
speed is above minimum governor speed (if the unit is not a generator) or when the Select Dynamics
function is used and the contact is closed. This value can be changed in the Service Mode while the
turbine is operating. See Chapter 5—PID Dynamics Settings for more information. When this value is
between 0.01 and 1.0, the derivative term is considered to be ‘input dominant’ and the derivative is
equal to (Deriv Ratio)/(Integral Gain). When this value is between 1.0 and 100, the derivative term is
considered to be ‘feedback dominant’ and the derivative is equal to 1.0/[(Deriv Ratio)*(Integral
Gain)].

Operating Parameters Block

GENERATOR APPLICATION? dflt= NO (Yes/No)
Select YES if the turbine is driving a generator. If YES, requires a Generator breaker and Utility Tie
breaker to be programmed as contact inputs. If NO, skip to the ‘Use Local/Remote’ question.
USE GEN BREAKER OPEN TRIP? dflt= NO (Yes/No)
Select YES if opening the generator breaker is to initiate a turbine trip. If YES, the unit will trip when
the generator breaker opens after being closed, unless a Controlled Stop is selected. If NO, the
speed set point will instantly reset to the ‘Gen Open Set Point’ which is defaulted to 50 rpm below
rated speed.
USE TIE BREAKER OPEN TRIP? dflt= NO (Yes/No)
Select YES if opening the utility tie breaker is to initiate a turbine trip. If YES, the unit will trip when
the utility tie breaker opens after being closed, unless a Controlled Stop is selected. If NO and the
generator breaker is closed, the speed set point will instantly reset to the speed last seen by the unit
and move to the ‘Rated Speed Set Point’ and an alarm is issued. If NO and the generator breaker is
open, there is only an alarm when the utility tie breaker opens.

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RATED SPEED
(Configured in Speed Setpoints menu).
FREQUENCY AT RATED dflt= 50 Hz (50 Hz, 60 Hz)
Set the generator’s frequency at rated speed set point.
DROOP (%) dflt= 5.0 (0.0, 10)
Enter the droop percentage. Typically set between 4–6% and not more than 10%.
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= NO (Yes/No)
Set to YES to use load droop (generator load control) or NO to use internal Speed droop (turbine
inlet valve position). If YES, generator load feedback is used as the controlling parameter for stability
when the unit is on-line. If NO, internal LSS demand/actuator position droop is used.
MAX LOAD (dflt = KW) dflt= 20000 (0.1, 20000)
Enter the max load. This setting limits the maximum load the turbine/generator can carry.
(Must be less than or equal to the ‘KW Input at 20 mA’ Setting)
PRIMARY Load SIGNAL dflt= None
Select the source for the kW input signal, if used.
SECONDARY Load SIGNAL dflt= None
Select the backup source for the kW input signal (optional).
PRIMARY SYNC/LOAD SHARE SIGNAL dflt= None
Select the source for the synchronization/load share input signal, if used.
SECONDARY SYNC/LOAD SHARE SIGNAL dflt= None
Select the backup source for the synchronization/load share input signal (optional).
PRIMARY SYNC SIGNAL dflt= None
Select the source for the synchronization input signal, if used. If load sharing is used in this
application, this input will not be used, and the sync/load share input should be used.
SECONDARY SYNC SIGNAL dflt= None
Select the backup source for the synchronization input signal (optional).
USE FREQ ARM/DISARM? dflt= NO (Yes/No)
Set to YES is using frequency control arm/disarm. If YES, frequency control must be armed before
the unit will switch into frequency control. If NO, frequency control is always armed, and the unit will
go into frequency control whenever the generator breaker is closed and the utility tie breaker is open.
(CANNOT PROGRAM BOTH FREQ ARM/DISARM AND LOAD SHARING)
REVERSE POWER ON CONTROLLED STOP? dflt = No (Yes/No)
Set to YES if reverse power is allowed during a controlled shutdown. Set to NO if a controlled SD
should ramp the speed reference to “min load” speed and wait for the Generator Breaker Open
signal before continuing the shutdown.
TIE OPN/ALWAYS ACT? dflt = No (Yes/No)
Set to YES if using the Tie breaker opening to enable the load rejection logic followed by the
ENTER.
USE FEED-FORWARD? dflt = No (Yes/No)
Set to YES if using the feed-forward loop followed by the ENTER.
The feed-forward loop allows an analog input representing the anti-surge valve demand to offset
(bias) the 505’s speed reference in order to assist the anti-surge controller. This bias then slowly
decreases back to 0 rpm offset in the configured feed-forward action delay.
FEED FORWARD SPEED DEADBAND (rpm) dflt = 0.1 (0.1,100)
Set the dead band for the Feed-Forward speed bias, followed by the ENTER. This setting is needed
if the Feed-Forward Analog Input signal is noisy.
USE ONLY WHEN CASCADE? dflt = Yes (Yes/No)
Set to YES if the feed-forward loop can only be enabled when cascade is enabled, followed by the
ENTER. If set to NO, then Feed-Forward can be enabled in both speed or cascade control.
CASC DEADBAND WHEN FORWARD ACTIVE? dflt = 0.1 (0,50)
Set the cascade dead band when Feed-Forward is enabled, followed by the ENTER. This value
directly sets the DB input on the Cascade PID.

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DIRECT FEED-FORWARD? dflt = No (Yes/No)

Set to YES if using the feed-forward loop as direct command followed by the ENTER.
If YES is selected, the feed-forward speed bias will be directly proportional to the 4–20 mA signal.
The speed bias, when using direct feed-forward, does not slowly reduce over time. This feature
proportionally affects the speed reference.
SPEED OFFSET AT 4 mA (rpm) dflt = -100 (-1000,0)
Only when direct action is selected, set the speed bias applied when the Feed-Forward Analog Input
is at 4 mA. The range of the values configured for the speed offset at 4 mA and 20 mA determines
the amount that speed reference is changed when the Feed-Forward Analog Input current changes.
If the analog input current is increased/decreased by 25% while Direct Feedforward is enabled, for
example, then the speed reference will be increased/decreased by 25% of the range between
‘Speed Offset at 4 mA’ and ‘Speed Offset at 20 mA’.
SPEED OFFSET AT 20 mA (rpm) dflt = 100 (0,2000)
Only when direct action is selected, set the speed bias applied when the Feed-Forward Analog Input
is at 20 mA. The range of the values configured for the speed offset at 4 mA and 20 mA determines
the amount that speed reference is changed when the Feed-Forward Analog Input current changes.
If the analog input current is increased/decreased by 25% while Direct Feed-Forward is enabled, for
example, then the speed reference will be increased/decreased by 25% of the range between
‘Speed Offset at 4 mA’ and ‘Speed Offset at 20 mA’.
ACTION DELAY? (s) dflt = 180 (0,1000)
Only when ‘Direct feed-forward?’ = NO. Set the minimum response time (lag) needed to remove the
effect of the feed-forward loop. After a feed-forward event, when the speed reference is biased by
the feed-forward loop, this parameter determines how long it takes (minimum) for the offset to ramp
back to 0 rpm (no speed reference offset). Essentially it is the duration of the feed-forward action.
MIN FORWARD RATE (%/s) dflt = -100(-100,-1)
Set the minimum effective rate (negative value) of the feed-forward signal, when decreasing,
followed by the ENTER. This sets the highest level of response for the feed-forward loop based on
the 4-20 mA signal’s rate of decrease.
SPEED OFFSET AT MIN RATE (rpm) dflt =-100(-1000,0)
Set the speed offset at the Min Forward Rate (%/s) followed by the ENTER. This sets the largest
negative offset that can be provided by the feed-forward loop. It is the amount the speed reference
will be biased (RPM) when the Analog Input decreases by the “Min Forward Rate”.
MAX FORWARD RATE (%/s) dflt = 100(1,100)
Set the maximum effective rate (positive value) of the feed-forward signal, when increasing, followed
by the ENTER. This sets the highest level of response for the feed-forward loop based on the 4-20
mA signal’s rate of increase.
SPEED OFFSET AT MAX RATE (rpm) dflt = 100 (0,2000)
Set the speed offset at the Max Forward Rate (%/s) followed by the ENTER. This sets the largest
positive offset that can be provided by the feed-forward loop. It is the amount the speed reference
will be biased (RPM) when the Analog Input increases by the “Max Forward Rate”.
USE EMERGENCY? dflt = No (Yes/No)
Only when ‘Direct feed-forward?’ = NO. Set to YES if using the feed-forward emergency loop
followed by the ENTER. This loop can be configured to provide a larger feed-forward response. For
example, when the compressor is extremely close to a surge condition and the anti-surge valve
demand moves at a greater rate, this can be detected by this loop and a larger offset than the normal
feed-forward response can be introduced. This response can also have a much shorter duration so
that it does not cause problems for the anti-surge controller rather than help it. The Emergency
Feed-Forward Loop effects overlap the normal Feed-Forward Loop; they are not summed. The
Emergency Feed-Forward Loop acts only in the positive direction.
EMERGENCY ACTION DELAY (s) dflt = 10 (2,100)
Set the response time (lag) needed to remove the effect of the emergency feed-forward loop. After
an emergency feed-forward event, when the speed reference is biased by the emergency feed-
forward loop, this parameter determines how long it takes for the emergency offset to ramp back to 0
rpm (no speed reference offset). Essentially it is the duration of the emergency feed-forward action.
After this time expires, only the normal Feed-Forward will be in effect until its Action Delay time
expires.

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FORWARD RATE TO ACTIVATE (%/s) dflt = 10(2,100)
Set the minimum required rate of increase (%/s) to activate the emergency loop, followed by the
ENTER. This is the rate at which the Feed-Forward analog input has to increase in order to trigger
the Emergency Feed-Forward action.
EMERGENCY MAX FORWARD RATE (%/s) dflt = 100 (7,100)
Set the maximum effective rate (positive direction) of the feed-forward analog input, when increasing,
followed by the ENTER. This sets the highest level of response for the Emergency Feed-Forward
Loop based on the 4-20 mA signal’s rate of increase. Must be greater than ‘FW RATE TO
ACTIVATE’.
EMERGENCY MAX SPEED OFFSET dflt = 300 (0,2000)
Set the speed bias at “Emerg Max Forward Rate”, followed by the ENTER. When the Emergency
Feed-Forward action is triggered, this parameter defines the maximum speed offset that will be
applied by the Emergency Feed-Forward Loop when the analog input increases at the “Erg Max
Forward Rate”.
EMERGENCY MAX SPEED RATE (rpm/s) dflt = 500 (0,2000)
Set the max speed bias rate when Emergency Feedforward is activated, followed by the ENTER.
This limits how fast the emergency action can change the speed offset and, hence, limits how fast
the speed reference is increased when the Emergency Feed-Forward Loop is activated.
(end of FW)
EXTERNAL TRIPS IN TRIP RELAY ? dflt= YES (Yes/No)
Select YES to allow the external trip input(s) to de- energize the Trip Relay output. When set to NO,
an external trip contact input to the 505 will shut down the 505 control but will not de-energize the
505’s trip relay output.
RESET CLEARS TRIP OUTPUT ? dflt= NO (Yes/No)
Select YES to configure the Reset Clears Trip Relay output function. When set to YES, a Reset
command will energize the trip relay output even when a trip condition is still sensed by the 505—
typically due to one of the external trip inputs. Once reset, the unit will be ‘Ready to Start’ as soon as
all external trip inputs are closed. When NO, the trip relay output will be de-energized on a 505 trip
and will not energize until all trips have cleared and a ‘Reset’ command is given.
TRIP = Zero Current to Actuators dflt= Yes (Yes/No)
Set to YES to have the control open the actuator circuit upon a TRIP condition which will result in
zero current output to the actuators. Set to NO, then the unit will go to zero % demand upon a TRIP
which will drive the actuators to the minimum current
CONTROLLED STOP & TRIP? dflt= No(Yes/No)
Set to YES if when controlled SD is completed, the unit must be Tripped, followed by the ENTER. If
set to NO, the unit will remain in a stopped but reset state after a controlled shutdown.
USE LOCAL/REMOTE? dflt= NO (Yes/No)
Set to YES if using Local/Remote control logic. If YES, permits the unit to go from REMOTE
(Modbus, contact input and front panel) control to LOCAL (front panel) control only. If NO, all
programmed inputs are active at all times. Refer to the Service Mode information in Volume 2 for
additional settings on the Local/Remote function.
USE PRESSURE COMPENSATION? dflt= NO (Yes/No)
Select YES to enable inlet pressure compensation. Selecting NO disables this function so an inlet
pressure signal will not affect the actuator demand.

Auxiliary Control Menu

USE AUXILIARY CONTROL? dflt= NO (Yes/No)
Select YES to configure the auxiliary control function. Select NO if the auxiliary function is not used.
LOST INPUT SHUTDOWN? dflt= NO (Yes/No)
Select YES if a shutdown command is to be given when the auxiliary input fails. If NO, then no
shutdown command will be given when the auxiliary input fails, only an alarm. If Auxiliary is used as
a limiter (“USE AS CONTROLLER” = NO, see below) and it is limiting the valve demand at the time
of the input failure, then selecting NO will cause the valve limiter to step to the valve demand at the
time of the failure to ensure that the limiting condition is not exceeded until the operator has time to
act.
PROCESS SIGNAL dflt= Auxiliary Input
Select which input the control should use. The input selected here should be configured as an
analog input, which is used as the process value for this controller.

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INVERTED? dflt= NO (Yes/No)
Select YES if the auxiliary control will be reverse acting. If NO, then the control will be forward acting.
Typically, this will be set to NO, the only time the input would be inverted is if the valve needs to
open when the input exceeds the set point. An example where the invert would be YES is for turbine
inlet pressure control.
MIN SETPOINT (UNITS) dflt= 0.0 (-20000, 20000)
Set the min AUX set point. This value is the minimum set point value that the auxiliary set point can
be decreased/lowered to (lower limit of AUX set point).
MAX SETPOINT (UNITS) dflt= 100 (-20000, 20000)
Set the max AUX set point. This value is the maximum set point value that the auxiliary set point can
be increased/raised to (upper limit of AUX set point).
(Must be greater than the ‘Min Aux Setpt’ Setting)
SETPOINT RATE (UNITS/s) dflt= 5.0 (0.01, 1000)
Set the AUX set point rate. This value is the rate (in units per second) at which AUX set point moves
when adjusted.
USE AS CONTROLLER? dflt= NO (Yes/No)
Select YES if using the Auxiliary control enable/disable feature. If YES, Aux will require an enable
command to enable Aux control. If NO, then the Auxiliary function will be enabled constantly and will
act as a controlling limiter. An example of using Aux as a limiter is using Aux to limit the maximum
KW load that the unit carries. The Aux PID is not normally in control of the valve output. But if the
Aux (KW) input exceeds the set point, the Aux PID controller would decrease and take control of the
valve until the KW level decreases below the maximum kW(Aux) setting. Alternatively, if the Aux
enable is used, the Aux set point tracks the Aux input. When enabled, the Aux PID takes control of
the valve and the speed set point tracks the speed/load of the unit for bumpless transfer between
modes.
SETPT INITIAL VALUE (UNITS) dflt= 0.0 (-20000, 20000)
Set the set point initialization value. When not using the Aux Enable function, this is the value that
the auxiliary set point initializes to upon power- up or exiting the Configuration mode.
(Must be less than or equal to the ‘Max Aux Set Point’ Setting)
DROOP (%) dflt= 0.0 (0.0, 100)
Enter the droop percentage. If required, typically set between 4–6%.
PID PROPORTIONAL GAIN (%) dflt= 1.0 (0.0, 100)
Enter the AUX PID proportional gain value. This value is used to set auxiliary control response. This
value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended
starting value is 1%.
PID INTEGRAL GAIN (%) dflt= 0.3 (0.001, 50)
Enter the AUX PID integral gain value. This value is used to set auxiliary control response. This
value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended
starting value is 3%.
PID DERIVATIVE RATIO (%) dflt= 100 (0.01, 100)
Enter the AUX PID derivative ratio. This value is used to set auxiliary control response. This value
can be changed in the Service Mode while the turbine is operating. If unknown, a recommended
starting value is 100%.
TIEBRKR OPEN AUX DSBL? dflt= YES (Yes/No)
Select YES if the auxiliary control will be disabled when the utility tie breaker opens. If NO is
selected, then auxiliary control will not be disabled when the utility tie breaker is opened.
GENBRKR OPEN AUX DSBL? dflt= YES (Yes/No)
Select YES if the auxiliary control will be disabled when the generator breaker opens. If NO is
selected, then auxiliary control will not be disabled when the generator breaker is opened.
USE REMOTE SETPOINT? dflt= NO (Yes/No)
Set to YES to allow the set point to be adjusted from an analog input.
(Must program a ‘remote auxiliary set point’ analog input)
REMOTE MAX RATE (UNITS/s) dflt= 5.0 (0.1, 1000)
Enter the maximum rate at which the remote input will move the remote set point.
UNITS OF MEASURE (Configured with Analog Inputs)
DECIMALS DISPLAYED (Configured with Analog Inputs)

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Auxiliary 2 Control Menu

USE AUXILIARY CONTROL? dflt= NO (Yes/No)
Select YES to configure the auxiliary control function. Select NO if the auxiliary function is not used.
LOST INPUT SHUTDOWN? dflt= NO (Yes/No)
Select YES if a shutdown command is to be given when the auxiliary input fails. If NO, then no
shutdown command will be given when the auxiliary input fails, only an alarm. If Auxiliary is used as
a limiter (“USE AS CONTROLLER” = NO, see below) and it is limiting the valve demand at the time
of the input failure, then selecting NO will cause the valve limiter to step to the valve demand at the
time of the failure to ensure that the limiting condition is not exceeded until the operator has time to
take action.
PROCESS SIGNAL dflt= Auxiliary 2 Input
Select which input the control should use. The input selected here should be configured as an
analog input, which is used as the process value for this controller.
INVERTED? dflt= NO (Yes/No)
Select YES if the auxiliary control will be reverse acting. If NO, then the control will be forward acting.
Typically this will be set to NO, the only time the input would be inverted is if the valve needs to open
when the input exceeds the set point. An example where the invert would be YES is for turbine inlet
pressure control.
MIN SETPOINT (UNITS) dflt= 0.0 (-20000, 20000)
Set the min AUX set point. This value is the minimum set point value that the auxiliary set point can
be decreased/lowered to (lower limit of AUX set point).
MAX SETPOINT (UNITS) dflt= 100 (-20000, 20000)
Set the max AUX set point. This value is the maximum set point value that the auxiliary set point can
be increased/raised to (upper limit of AUX set point).
(Must be greater than the ‘Min Aux Setpt’ Setting)
SETPOINT RATE (UNITS/s) dflt= 5.0 (0.01, 1000)
Set the AUX set point rate. This value is the rate (in units per second) at which AUX set point moves
when adjusted.
USE AS CONTROLLER? dflt= NO
Auxiliary 2 is only available as a limiter.
SETPT INITIAL VALUE (UNITS) dflt= 0.0 (-20000, 20000)
Set the set point initialization value. When not using the Aux Enable function, this is the value that
the auxiliary set point initializes to upon power- up or exiting the Configuration mode.
(Must be less than or equal to the ‘Max Aux Set Point’ Setting)
DROOP (%) dflt= 0.0 (0.0, 100)
Enter the droop percentage. If required, typically set between 4–6%.
PID PROPORTIONAL GAIN (%) dflt= 1.0 (0.0, 100)
Enter the AUX PID proportional gain value. This value is used to set auxiliary control response. This
value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended
starting value is 1%.
PID INTEGRAL GAIN (%) dflt= 0.3 (0.001, 50)
Enter the AUX PID integral gain value. This value is used to set auxiliary control response. This
value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended
starting value is 3%.
PID DERIVATIVE RATIO (%) dflt= 100 (0.01, 100)
Enter the AUX PID derivative ratio. This value is used to set auxiliary control response. This value
can be changed in the Service Mode while the turbine is operating. If unknown, a recommended
starting value is 100%.
TIEBRKR OPEN AUX DSBL? dflt= YES (Yes/No)
Select YES if the auxiliary control will be disabled when the utility tie breaker opens. If NO is
selected, then auxiliary control will not be disabled when the utility tie breaker is opened.
GENBRKR OPEN AUX DSBL? dflt= YES (Yes/No)
Select YES if the auxiliary control will be disabled when the generator breaker opens. If NO is
selected, then auxiliary control will not be disabled when the generator breaker is opened.
USE REMOTE SETPOINT? dflt= NO (Yes/No)
Set to YES to allow the set point to be adjusted from an analog input.
(Must program a ‘remote auxiliary set point’ analog input)
REMOTE MAX RATE (UNITS/s) dflt= 5.0 (0.1, 1000)
Enter the maximum rate at which the remote input will move the remote set point.

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UNITS OF MEASURE (Configured with Analog Inputs)
DECIMALS DISPLAYED (Configured with Analog Inputs)

Cascade Control Menu

USE CASCADE CONTROL? dflt= NO (Yes/No)
Select YES to configure the cascade control function. Select NO if the cascade function is not used.
PROCESS SIGNAL dflt= Cascade Input
Select which input the control should use. The input selected here should be configured as an
analog input, which is used as the process value for this controller.
INVERTED? dflt= NO (Yes/No)
Select YES if the cascade control will be reverse acting. If NO is selected, the control will be forward
acting. Typically, this will be set to NO, the only time the input would be inverted is if the valve needs
to open when the input exceeds the set point. An example where the invert would be YES is for
turbine inlet pressure control.
MIN CASCADE SETPOINT (UNITS) dflt= 0.0 (-20000, 20000)
Set the minimum cascade set point. This value is the minimum set point value that the cascade set
point can be decreased/lowered to (lower limit of cascade set point).
MAX CASCADE SETPOINT (UNITS) dflt= 100 (-20000, 20000)
Set the maximum cascade set point. This value is the maximum set point value that the cascade set
point can be increased/raised to (upper limit of cascade set point).
(Must be greater than the ‘Min Cascade Setpt’ Setting)
CASCADE SETPOINT RATE (UNITS/s) dflt= 5.0 (0.01, 1000)
Set the cascade set point rate. This value is the rate (in units per second) at which cascade set point
moves when adjusted.
USE SETPOINT TRACKING? dflt= NO (Yes/No)
Select YES or NO. If YES, the cascade set point tracks the cascade input to provide bumpless
transfer to cascade control when it is enabled. If NO, the cascade set point remains at the last
position except on power-up or exiting the Configuration mode.
SETPOINT INITIAL VALUE (UNITS) dflt= 100.0 (-20000, 20000)
Set the set point initialization value. When not using the Set Point Tracking function, this is the value
that the cascade set point initializes to upon power-up or exiting the program mode.
(Must be less than or equal to the ‘Max Cascade Setpt’ Setting)
SPEED SETPOINT LOWER LIMIT (rpm) dflt= 3605 (0.0, 20000)
Set the minimum speed set point that the cascade controller can lower the speed set point to. To
protect the unit, this value should be at or above rated speed if the unit is a generator.
(Must be greater than or equal to the ‘Minimum Governor Speed Setpt’ Setting)
SPEED SETPOINT UPPER LIMIT (rpm) dflt= 3780 (0.0, 20000)
Set the maximum speed set point that cascade controller can raise the speed set point to.
(Must be less than or equal to the ‘Maximum Governor Speed Setpt’ Setting)
MAX SPEED SETPOINT RATE (rpm/s) dflt= 20 (0.1, 100)
Set the maximum rate at which the cascade control can vary the speed set point.
CASCADE DROOP (%) dflt= 0.0 (0.0, 100)
Enter the droop percentage. If needed, typically set between 4–6%.
PID PROPORTIONAL GAIN (%) dflt= 5.0 (0.0, 100)
Enter the cascade PID proportional gain value. This value is used to set cascade control response.
This value can be changed in the Run Mode while the turbine is operating. If unknown, a
recommended starting value is 5%.
PID INTEGRAL GAIN (%) dflt= 0.3 (0.001, 50.0)
Enter the cascade PID integral gain value. This value is used to set cascade control response. This
value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended
starting value is 0.3%.
PID DERIVATIVE RATIO (%) dflt= 100 (0.01, 100)
Enter the cascade PID derivative ratio. This value is used to set cascade control response. This
value can be changed in the Service Mode while the turbine is operating. If unknown, a
recommended starting value is 100%. When this value is between 0.01 and 1.0 the derivative term is
considered to be ‘input dominant’ and the derivative is equal to (Deriv Ratio)/(Integral Gain). When
this value is between 1.0 and 100 the derivative term is considered to be ‘feedback dominant’ and
the derivative is equal to 1.0/[(Deriv Ratio)*(Integral Gain)].

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USE REMOTE CASCADE SETPOINT? dflt= NO (Yes/No)
Set to YES to allow the Cascade set point to be adjusted from an analog input.
(Must program a ‘remote cascade set point’ analog input
REMOTE CASCADE MAX RATE (UNITS/s) dflt= 5.0 (0.1, 1000)
Enter the maximum rate at which the remote input will move the cascade set point.
UNITS OF MEASURE (Configured with Analog Inputs)
DECIMALS DISPLAYED (Configured with Analog Inputs)

Isolated Control Menu

USE ISOLATED PID dflt= NO (Yes/No)
Select YES to configure the Isolated PID function. Select NO if this function is not used. When using
the Isolated PID Control, it is recommended to select the “Enable Readback Fault” option for the
Analog Output channel configured as the Isolated PID Demand. This will trigger an alarm in the 505
if a fault of the output circuit is detected. By default, Analog Output channels are not configured to
produce an alarm when the output circuit has a fault.
USE REMOTE SETPOINT dflt= NO (Yes/No)
Set to YES to allow the Cascade set point to be adjusted from an analog input.
OUTPUT ACTION ON INPUT FAULT dflt= HOLD DEMAND
Set to “HOLD Demand” maintain the demand at the time of failure. Set to “Go to Maximum Demand”
to move the demand to 100% output. Set to “Go to Minimum Demand” to move the demand to 0%
output.
INVERTED? dflt= NO (Yes/No)
Select YES if the control will be reverse acting. If NO is selected, the control will be forward acting.
Typically this will be set to NO, the only time the input would be inverted is if the valve needs to open
when the input exceeds the set point.
ALLOW MANUAL CONTROL? dflt= NO (Yes/No)
Set to YES to allow the Isolated PID output to be manipulated by the operator. Set to NO to keep this
controller in automatic, controlled by the PID, at all times except in the event of an input failure.
MAXIMUM SETPOINT dflt= 100.0 (-100000.0, 100000.0)
This is the maximum limit for the Isolated Control setpoint in engineering units.
MINIMUM SETPOINT dflt= 0.0 (-100000.0, 100000.0)
This is the minimum limit for the Isolated Control setpoint in engineering units.
INITIAL SETPOINT dflt= 100.0 (-100000.0, 100000.0)
This is the value in engineering units at which the Isolated Control setpoint ramp will initialize.

Communications Menu

Each of the ETHERNET ports is required to be configured for a

unique subnet (domain) (view default settings as an example).

Ethernet IP Configuration
ENET 1 ADDRESS dflt= 172.16.100.15 (0, 255)
Enter the integers corresponding to the network TCP/IP address.
ENET 1 SUBNET MASK dflt= 255.255.0.0 (0, 255)
Enter the integer corresponding to the network subnet mask.
ENET 2 ADDRESS dflt= 192.168.128.20 (0, 255)
Enter the integers corresponding to the network TCP/IP address.
ENET 2 SUBNET MASK dflt= 255.255.255.0 (0, 255)
Enter the integer corresponding to the network subnet mask.
ENET 3 ADDRESS dflt= 192.168.129.20 (0, 255)
Enter the integers corresponding to the network TCP/IP address.
ENET 3 SUBNET MASK dflt= 255.255.255.0 (0, 255)
Enter the integer corresponding to the network subnet mask.

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NOTE – the ENET 4 address is not changeable at the front panel. It is always available for service tools
and is defaulted to the following:
ENET 4 ADDRESS 192.168.130.20
ENET 4 SUBNET MASK 255.255.255.0

Modbus Configuration
USE MODBUS? dflt= NO (Yes/No)
Set to YES to use the Modbus communications feature of the 505. There are 3 identical Modbus
ports available; 1 via the Serial port and 2 available via Ethernet. Select NO if Modbus
communications will not be used.
USE SERIAL LINK 1? dflt= NO (Yes/No)
Set to YES to use the serial Modbus port.
USE ETHERNET LINK 2 dflt= NO (Yes/No)
Select a protocol to use the Modbus Link 2 via Ethernet. Selecting UDP will use port 5001.
USE ETHERNET LINK 3? dflt= NO (Yes/No)
Select a protocol to use the Modbus Link 3 via Ethernet. Selecting UDP will use port 5002.

Modbus – Link 1 - Serial

DEVICE ADDRESS dflt= 1 (1, 247)
Enter the integer corresponding to the Modbus device number/address required.
ENABLE WRITE COMMANDS dflt= NO (Yes/No)
Select YES to allow this Modbus link to write values to the control. If NO, it will be read only.
PROTOCOL dflt= ASCII (ASCII, RTU)
Select ASCII or RTU to determine the format of the Modbus communications.
BAUD RATE dflt= 115,200
Select the communications baud rate.
BITS dflt= 7 (7, 8)
Select the integer corresponding to the bits required.
STOP BITS dflt= 1 (1, 2, 1.5)
Select the stop bits required.
PARITY dflt= NONE (NONE, ODD, EVEN)
Select the parity required.
DRIVER dflt= RS-232 (RS-232, RS-422, RS-485)
Select the serial communications mode required. Enter RS-232, RS-422, or RS-485
communications.

Modbus Ethernet Link 2

ETHERNET PROTOCOL dflt= TCP (TCP, UDP port 5001)
Select TCP or UDP to determine the Ethernet communication protocol. Selecting UDP will use port
5001 for Link 2.
DEVICE ADDRESS dflt= 2 (1, 247)
Enter the integer corresponding to the Modbus device number/address required.
ENABLE WRITE COMMANDS dflt= NO (Yes/No)
Select YES to allow this Modbus link to write values to the control. If NO, it will be read only.

Modbus Ethernet Link 3

ETHERNET PROTOCOL dflt= TCP (TCP, UDP port 5001)
Select TCP or UDP to determine the Ethernet communication protocol. Selecting UDP will use port
5002 for Link 3.
DEVICE ADDRESS dflt= 2 (1, 247)
Enter the integer corresponding to the Modbus device number/address required.
ENABLE WRITE COMMANDS dflt= NO (Yes/No)
Select YES to allow this Modbus link to write values to the control. If NO, it will be read only.

Analog Inputs Menu

No two analog inputs can be programmed for the same function. In addition, the function that the analog
input uses must be programmed, or an error message will occur. For example, to use the Cascade Input,
the ‘Use Cascade’ function must be programmed.

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ANALOG INPUT # 1
INPUT FUNCTION (must choose from list)
Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER,
using the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the
option/function. Press the ESC key to cancel the selection.

Table 4-3. Analog Input #1 Input Function Menu Options

See the following list of

Remote Load Setpoint
options: --- Not Used ---
Remote Speed Setpoint Exhaust Pressure Input
Synchronizing Input Spare 19
Sync / Load Share HP Valve Feedback Position
Generator Load Input HP2 Valve Feedback Position
Cascade Input Isolated PID PV
Remote Cascade Setpoint Remote SP for Isolated PV
Auxiliary Input Signal Monitoring #1
Remote Auxiliary Setpoint Signal Monitoring #2
Auxiliary 2 Input Signal Monitoring #3
Remote Auxiliary 2 Setpoint Start Temperature 1
Inlet Pressure Input Start Temperature 2
I/H Actuator 1 Feedback Signal Monitoring #4
I/H Actuator 2 Feedback Signal Monitoring #5
Speed Feed-Forward Signal Monitoring #6
Remote Droop Signal Monitoring #7
Signal Monitoring #8

Many of the functions in this list are described in other sections of the manual containing the functional
description. Functions that are not described elsewhere in the manual or need clarification are described
as follows:

Inlet Steam Pressure – This can be configured as the input for a controller to control the inlet steam
header pressure or it must be used if the Inlet Pressure Compensation feature is used.
Exhaust Steam Pressure – This can be configured as the input for a controller to control the exhaust
steam header pressure.

4 mA VALUE (UNITS) dflt= 0.0 (-1.0e+38, 1.0e+38)

Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog input.
20 mA VALUE (UNITS) dflt= 100 (-1.0e+38, 1.0e+38)
Set the value (in engineering units) that corresponds to 20 milliamps (mA) on the analog input.
(Must be greater than the ‘Input 4 mA Value’ Setting)
LOOP POWERED dflt= NO (Yes/No)
Check this box if the 505 should provide loop power for the transmitter.

In previous 505 models, there were jumpers that determined it this

function was used or not. When upgrading the user will need to
remove the cover of the old 505 to determine the proper setting for
this option

DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.
UNITS
This is a user entered field. It allows entry of a unit label for this channel.

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MDOBUS MULTIPLIER dflt= 1.0 (0.01, 0.1, 1.0, 10, 100)
This is the multiplier that will be used for this parameter address on the 505 slave modbus
communication link
DECIMALS DISPLAYED dflt= 1.0 (0, 1, 2, 3)
This is the number of decimals to be displayed on the 505 screens for this parameter

Analog Inputs # 2 through # 8 are configured following the same rules as described for Analog Input # 1.

The Device Tag is a text field that is available for the user to enter a
unique name or identifier for each I/O channel. An example would be
to use the signal device tag such as PT-1234 for an Inlet Steam
Entering Text Pressure sensor. Enter Text characters by focusing on the field,
press Enter, then press and hold down the alphanumeric keys – they
will cycle through the available characters on that key

Analog Outputs Menu

All 4–20 mA analog readouts may be configured. The function that the readout uses must be
programmed or an error message will occur. For example, to use the Cascade Set Point readout, the
‘Use Cascade’ function must be programmed.

ANALOG OUTPUT # 1
OUTPUT FUNCTION (must choose from list)
Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER,
using the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the
option/function. Press the ESC key to cancel the selection.

Table 4-4. Analog Output #1 Output Function Menu Options

ANALOG READOUT OPTIONS--

I/H Actuator 1 Feedback Readout
- Not Used ---
Actual Shaft Speed I/H Actuator 2 Feedback Readout
Speed Reference Setpoint Isolated PID Dmd Output
Remote Speed Setpoint Isolated PID PV Input Signal
Load Share Input Isolated PID Setpoint
Synchronizing Input Remote Isolated PID Setpoint
Generator Load Remote Load Setpoint
Cascade Input Signal Exhaust Pressure Input
Cascade Setpoint HP Valve Feedback Position
Remote Cascade Setpoint HP2 Valve Feedback Position
Auxiliary Input Signal Signal Monitoring #1
Auxiliary Setpoint Signal Monitoring #2
Remote Auxiliary Setpoint Signal Monitoring #3
Auxiliary 2 Input Signal Start Temperature 1
Auxiliary 2 Setpoint Start Temperature 2
Remote Auxiliary 2 Setpoint Signal Monitoring #4
Valve Limiter Setpoint Signal Monitoring #5
LSS Value Signal Monitoring #6
HP Valve Demand Signal Monitoring #7
HP2 Valve Demand Signal Monitoring #8
Inlet Pressure Input

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4 mA VALUE (UNITS) dflt= 0.0 (-1.0e+38, 1.0e+38)
Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog output.
20 mA VALUE (UNITS) dflt= 100 (-1.0e+38, 1.0e+38)
Set the value (in engineering units) that corresponds to 20 milliamps (mA) on the analog output.
(Must be greater than the ‘Readout 4 mA Value’ Setting)
DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.
UNITS
This is a user entered field. It allows entry of a unit label for this channel.
ENABLE READBACK FAULT? dflt= NO (Yes/No)
Select YES to issue an alarm when an actuator fault is detected. If YES, the 505 will issue an alarm
if the analog channel has a fault. If NO, no fault alarm will be issued. A fault will be determined if the
current drops below the failure level or if the difference between the current detected on the source
and return wires of the circuit is greater than approximately 5%. It is recommended to enable this
feature when the Analog Output channel is configured as the “Isolated PID Demand Output” function.

Analog Outputs # 2 through # 6 are configured following the same rules as described for Analog Output
#1.

Driver Configuration Menu

When this header appears in the display, press the down arrow key to configure this block or press a left
or right arrow key to select another block to configure.

ACTUATOR 01
FUNCTION dflt= HP Demand
Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER,
using the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the
option/function. Press the ESC key to cancel the selection. Select ‘Not Used’, ‘HP Demand’, ‘HP2
Demand’, or Readout. The readout option is available for customers who do not need more actuator
drivers and would like an additional readout.
RANGE dflt= 4-20 mA (4-20, 0-200)
Select the actuator channel output current range. Select 4–20 mA or 0–200 mA. The range can be
adjusted via calibration, for example, for a 20-160 mA actuator select the 0-200 mA range.
ACTUATOR 1 DITHER (mA) dflt= 0.0 (0.0, 10)
Enter the dither mA for the actuator channel. Enter 0.0 if no dither is required. Woodward TM-type
actuators typically require dither.
USE ACTUATOR FAULT SHUTDOWN? dflt= YES (Yes/No)
Select YES to issue a trip whenever an actuator fault is detected. If YES, the 505 will issue a
shutdown if Actuator 1 has a fault. If NO, an actuator fault alarm will be issued when a fault is
detected. An actuator fault will be determined if the current drops below or goes above the failure
levels, basically checking for an open or a short circuit in the actuator wires/coil.
INVERT ACTUATOR OUTPUT? dflt= NO (Yes/No)
Set to YES to invert actuator driver output. This is normally set to NO.
When Set to YES, unless the front panel Emergency Stop button is used, the actuator output will go
to 20 mA at shutdown.
DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.
HP2 OFFSET (%) dflt= 0.0 (0.0, 100)
Enter the percentage actuator #1 is opened when actuator #2 begins to open. Enter 0.0 if both
actuators open together.
READOUT FUNCTION: (must choose from list)
Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER,
using the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the
option/function. Press the ESC key to cancel the selection.

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Table 4-5. Options for Actuator Readout

--- Not Used --- I/H Actuator 1 Feedback Readout

Actual Shaft Speed I/H Actuator 2 Feedback Readout
Speed Reference Setpoint Isolated PID Dmd Output
Remote Speed Setpoint Isolated PID PV Input Signal
Load Share Input Isolated PID Setpoint
Synchronizing Input Remote Isolated PID Setpoint
Generator Load Remote Load Setpoint
Cascade Input Signal Exhaust Pressure Input
Cascade Setpoint HP Valve Feedback Position
Remote Cascade Setpoint HP2 Valve Feedback Position
Auxiliary Input Signal Signal Monitoring #1
Auxiliary Setpoint Signal Monitoring #2
Remote Auxiliary Setpoint Signal Monitoring #3
Auxiliary 2 Input Signal Start Temperature 1
Auxiliary 2 Setpoint Start Temperature 2
Remote Auxiliary 2 Setpoint Signal Monitoring #4
Valve Limiter Setpoint Signal Monitoring #5
LSS Value Signal Monitoring #6
HP Valve Demand Signal Monitoring #7
HP2 Valve Demand Signal Monitoring #8
Inlet Pressure Input

(The function that the readout uses must be programmed or an error message will occur. For
example, to use the Cascade Setpoint readout, the ‘Use Cascade’ function must be programmed)
READOUT 4 mA VALUE (UNITS) dflt= 0.0 (-1.0e+38, 1.0e+38)
Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog output. If the
value on the display is correct, just select the ENTER key which will advance you to the next
question.
READOUT 20 mA VALUE (UNITS) dflt= 0.0 (-1.0e+38, 1.0e+38)
Set the value (in engineering units) that corresponds to 20 milliamps (mA) on the analog output. If
the value on the display is correct, just select the ENTER key which will advance you to the next
question.
(Must be greater than the ‘Readout 4 mA Value’ Setting)
ENABLE READBACK FAULT? dflt= NO (Yes/No)
Set to YES to enable alarm annunciation when this channel detects a current fault.
DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.
UNITS
This is a user entered field. It allows entry of a unit label for this channel.
ACTUATOR 02
Actuator 2 is configured following the same rules as Actuator 1.

The 505 supports actuators which are designed to only have hydraulic power while the turbine is rotating.
These types of actuators in Woodward terms, are referred to as “Self-Powered Actuators”. They are often
integrated with trip and throttle valve and require full demand from the control in order to be able to
physically ‘reset’ this valve assembly or to be able to supply any steam to the turbine for a restart.

This requires special logic, because the 505 must raise its actuator demand to full open, while the 505 is
still in a tripped condition. Even though the 505-output demand is at full open, no steam enters the turbine
because there is no hydraulic power on the valve.
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Using the SELF POWERED ACTUATOR option will disable the

internal shutdowns and on the event of a shutdown will cause the
actuator to ramp open. To prevent possible serious injury from an
Overspeed over speeding turbine, make sure the trip and throttle valve or
control valve will properly shut off steam to the turbine. Improper
set-up could cause turbine overspeed.

This section describes how to configure the 505 for these types of actuators.

To use this type of actuator, the Idle/Rated Start sequence must be selected and the option for inverting
the actuator must not be selected. The self-powered actuator screen option is found under the Drivers
menu when Idle/Rated start sequence is selected.

Figure 4-3. Actuator Driver Summary/Menu

Figure 4-4. Self-Powered Actuator Screen

Use Self-Powered Actuator (Y/N) -

Check this box to use the self-powered actuator functionality upon shutdown/trip conditions

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Use MPU Override for Self-Powered Actuator (Y/N) -
Check this box to override the failed MPU condition until speed is over the % of Speed configured

Enable below this % of MinGov Speed (%) – default 20% (1,100)

If the unit is TRIPPED and speed is below this % x MinGov speed AND the minimum delay time after
shutdown has expired, then ramp open the HP actuator to the target valve percentage. The
corresponding speed value setpoint calculated is shown to the right of this percentage.

Actuator Demand % after Shutdown (%) – default 100% (0,100)

This is the percent that the HP valve will ramp open to after a shutdown/trip has occurred and the
minimum time delay has expired

Minimum Time Delay after Shutdown (sec) – default 20 sec (1, 50000)
This time is used to ensure that if the turbine trips, that this logic does not immediately open the valve.
The HP will ramp open to the target demand this many seconds after a TRIP has occurred.

Contact Inputs Menu

If unit is configured as a ‘Generator Set’, then contact inputs must be programmed for generator and tie
breaker contacts. Also, each contact input option may be configured only once. In addition, the function
that the contact input uses must be programmed, or an error message will occur. For example, to use the
Cascade Control Enable contact input, the ‘Use Cascade’ function must be programmed.

CONTACT INPUT 01
FUNCTION Emergency Stop
This channel is a dedicated trip input.
DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.
CONTACT INPUT 02
FUNCTION (must choose from list)
Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER,
using the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the
option/function. Press the ESC key to cancel the selection.

Table 4-6. CONTACT INPUT OPTIONS

---Not Used--- External Trip 2

Reset Command External Trip 3
Speed Raise Command External Trip 4
Speed Lower Command External Trip 5
Generator Breaker External Trip 6
Utility Tie Breaker External Trip 7
Overspeed Test External Trip 8
External Run External Trip 9
Start Permissive 1 External Trip 10
Idle / Rated Command External Alarm 1
Halt/Continue Auto Start External Alarm 2
Override MPU Fault External Alarm 3
Select On-Line Dynamics External Alarm 4
Local / Remote External Alarm 5
Rmt Spd Setpt Enable External Alarm 6
Sync Enable External Alarm 7
Freq Control Arm/Disarm External Alarm 8
Casc Setpt Raise External Alarm 9

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Casc Setpt Lower Spare 51
Casc Control Enable I/H Actuator 1 Fault
Rmt Casc Setpt Enable I/H Actuator 2 Fault
Aux Setpt Raise Speed Forward Enable
Aux Setpt Lower Instant Min Gov/Load Speed
Aux Control Enable Select Hot Start
Rmt Aux Setpt Enable Remote KW Setpoint Enable
Auxiliary 2 Setpoint Raise Clock SYNC Pulse Contact
Auxiliary 2 Setpoint Lower Enable Rem SP for Isolated PID
Spare 28 Isolated Controller Raise
Remote Auxiliary 2 Enable Isolated Controller Lower
Valve Limiter Open
Valve Limiter Close
Controlled Shutdown(STOP)

Many of the functions in this list are described in other sections of the manual containing the functional
description. Functions that are not described elsewhere in the manual or need clarification are described
as follows:

Instant Minimum Governor – This feature will quickly ramp the speed setpoint to the configured Minimum
Governor setpoint, if configured as a mechanical drive application, or to the Minimum Load Setpoint
if configured as a generator application.

DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.
INVERT LOGIC? dflt= NO (Yes/No)
Select this to invert this contact input. Inverting means that a function normally activated when
CLOSED or TRUE will not be activated when the contact is OPEN or FALSE. Note that this is not
required for External Trip inputs because the “Normal” or “Non-Inverted” functionality is already fail-
safe (CLOSED/TRUE = healthy, OPEN/FALSE = trip).

Contact Inputs # 3 through # 20 are entered following the same rules as described for Contact Input # 2.
Relays Menu
You may configure up to seven relays in addition to the one pre-assigned relay (Shutdown). Each relay
can be configured as either a level switch or as an indication. An example of a level switch is a Speed
Switch and an example of an indication is Cascade Control Enabled.

RELAY OUTPUT 01
RELAY OUTPUT FUNCTION Trip Relay
This channel is a dedicated trip output.
DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.

RELAY OUTPUT 02
USE AS LEVEL SWITCH? dflt= NO (Yes/No)
Select this to use this relay output as a level switch. Otherwise, the relay output will be a status
indication.
RELAY OUTPUT FUNCTION (must choose from list)
Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER,
using the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the
option/function. Press the ESC key to cancel the selection.

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Table 4-7. Options for Relays if Used to Indicate State

--- Not Used --- Auxiliary Control Enabled

Summary Shutdown Auxiliary Control Active
Summary Shutdown (Trip Relay) Auxiliary PID in Control
Summary Alarm Remote Auxiliary Setpoint Enabled
All Alarms Clear Remote Auxiliary Setpoint Active
Control Status OK Auxiliary 2 Control Enabled
Overspeed Trip Auxiliary 2 Control Active
Overspeed Test Enabled Auxiliary 2 PID in Control
Speed PID in Control Remote Auxiliary 2 Setpoint Enabled
Remote Speed Setpoint Enabled Remote Auxiliary 2 Setpoint Active
Remote Speed Setpoint Active HP Valve Limiter in Control
Underspeed Switch Command from Modbus BW addresses
Auto Start Sequence Halted Reset Pulse (2 sec)
On-Line Speed PID Dynamics Mode Open GEN Breaker Cmd
Local Interface Mode Selected Feed-Forward Enabled
Frequency Control Armed Feed-Forward Active
Frequency Control Cascade PID in Control
Sync Input Enabled Unit Ready to Start
Sync / Loadshare Input Enabled Unit has Started
Loadshare Mode Active Turbine Started/Running
Cascade Control Enabled Unit OK (No SD)
Cascade Control Active Remote KW SP Enabled
Remote Cascade Setpoint Enabled Remote KW Setpoint Active
Remote Cascade Setpoint Active Manual Relay Control
Isolated Controller in Auto

Table 4-8. List of Options for Level Switch

--- Not Used --- HP Valve Demand Output

Actual Speed HP2 Valve Demand Output
Speed Setpoint Inlet Pressure
KW Input Exhaust Pressure
Sync/Load Share Input Signal Monitor Input #1
Cascade Input Signal Monitor Input #2
Cascade Setpoint Signal Monitor Input #3
Auxiliary Input Signal Monitor Input #4
Auxiliary Setpoint Signal Monitor Input #5
Auxiliary 2 Input Signal Monitor Input #6
Auxiliary 2 Setpoint Signal Monitor Input #7
HP Valve Limiter Signal Monitor Input #8
LSS Value Spare 26

LEVEL ON (UNITS) dflt= 0.0 (-1.0e+38, 1.0e+38)

Enter the level switch ON setting in engineering units. There is an ON and an OFF setting for each
level switch option. This allows the user to program the desired hysteresis for the function selected.

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LEVEL OFF (UNITS) dflt= 0.0 (-1.0e+38, 1.0e+38)
Enter the level switch OFF setting in engineering units.
(Must be less than the ‘Relay On Level’ Setting)
RELAY 1 ENERGIZES ON: (must choose from list)
Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER,
using the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the
option/function. Press the ESC key to cancel the selection.

DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.
INVERT LOGIC? dflt= NO (Yes/No) Use to invert the normal status of the
relay. Note that Normally Open and Normally Closed contacts are available when wiring to the relays
and that these states will be inverted. In the event of a control power failure, the contact will return to
its normal state.

Relay outputs # 3 through # 8 are entered following the same rules as described for Relay output # 2.

Exiting the Configure Mode

Once the programming steps have been completed, the Configuration mode can be exited. To exit the
Configure mode the User Level must still be logged in with Configure privileges. Then the ‘Exit
Configuration’ softkey will be available on the MODE screen. Pressing this initiates the 505 to save the
configuration and exit IO Lock. If there are no errors in the configuration, the 505 will be in the Shutdown
state. At this point it may be ready to reset and run but, if this is the first time the 505 has been configured
with the unit’s actuator/linkage/valve, then it is recommended to run the valve stroking procedure in
calibration mode and adjust current limits as needed. However, if there is an error in the program, the 505
will be in a shutdown state and unable to reset. Configuration errors can be viewed by going to the
Configuration Menu (softkey on the HOME/main menu screen) and pressing the ‘Config Check’ softkey.
The next section identifies the various configuration error messages and explains the meaning of the
error.

There is a procedure in the Appendix on how to restore a unit to the original factory defaults, using a
service tool.

Configuration Error Messages

The control automatically performs a check on the configured values to assure that required program
blocks have values loaded into them. This check cannot determine if the values entered are realistic but it
makes sure that values have been loaded into required parameters. If any errors are found in the
program, the 505 will remain in a shutdown state and a banner message will appear on the Configuration
Menu and MODE screens. They can be displayed by pressing the ‘Config Check’ softkey on the
Configuration Menu screen.

The configuration error message alerts you that a configuration change is required before the 505 can
operate the turbine. All errors must be corrected before in order to be able to reset the 505 to the “Ready
to Start” condition.

Table 4-9 Configuration Error Messages and Definitions

Event Description Error Meaning

ID
1 Duplicate Contact Input Two contact inputs were programmed for the same function.
Channel
2 Contact Input Error Should never appear (always FALSE) since Contact Input 01 is
hard coded as a trip input.

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Event Description Error Meaning
ID
3 Contact Input 02 Error The specified contact input was configured for a function that is
not configured as used. Either the contact input was mis-
configured, or the function required is mis-configured. For
example, contact input #1 is programmed for Remote Cascade
Set Point Enable but Remote Cascade Set Point was not
programmed under the Cascade configure menu.
4 Contact Input 03 Error See "Contact Input 02 Error".
5 Contact Input 04 Error See "Contact Input 02 Error".
6 Contact Input 05 Error See "Contact Input 02 Error".
7 Contact Input 06 Error See "Contact Input 02 Error".
8 Contact Input 07 Error See "Contact Input 02 Error".
9 Contact Input 08 Error See "Contact Input 02 Error".
10 Contact Input 09 Error See "Contact Input 02 Error".
11 Contact Input 10 Error See "Contact Input 02 Error".
12 Contact Input 11 Error See "Contact Input 02 Error".
13 Contact Input 12 Error See "Contact Input 02 Error".
14 Contact Input 13 Error See "Contact Input 02 Error".
15 Contact Input 14 Error See "Contact Input 02 Error".
16 Contact Input 15 Error See "Contact Input 02 Error".
17 Contact Input 16 Error See "Contact Input 02 Error".
18 Contact Input 17 Error See "Contact Input 02 Error".
19 Contact Input 18 Error See "Contact Input 02 Error".
20 Contact Input 19 Error See "Contact Input 02 Error".
21 Contact Input 20 Error See "Contact Input 02 Error".
22 Duplicate Analog Input Two analog inputs were programmed for the same function.
Channel
23 Analog Input 01 Error The specified analog input was configured for a function that is not
configured as used. Either the analog input was mis-configured or
the function required is mis-configured. For example, analog input
#1 is programmed for Remote Cascade Set Point but Remote
Cascade Set Point was not configured under the Cascade
configuration menu.
24 Analog Input 02 Error See "Analog Input 01 Error".
25 Analog Input 03 Error See "Analog Input 01 Error".
26 Analog Input 04 Error See "Analog Input 01 Error".
27 Analog Input 05 Error See "Analog Input 01 Error".
28 Analog Input 06 Error See "Analog Input 01 Error".
29 Analog Input 07 Error See "Analog Input 01 Error".
30 Analog Input 08 Error See "Analog Input 01 Error".
31 Relay 01 Error The specified relay was programmed for a function that is not
configured as used. Either the relay was mis-configured or the
function required is mis-programmed. For example, relay #1 is
configured for Remote Cascade Set Point Enabled but Remote
Cascade Set Point was not configured under the Cascade
configure menu.
32 Relay 02 Error See "Relay 01 Error".
33 Relay 03 Error See "Relay 01 Error".

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Event Description Error Meaning
ID
34 Relay 04 Error See "Relay 01 Error".
35 Relay 05 Error See "Relay 01 Error".
36 Relay 06 Error See "Relay 01 Error".
37 Relay 07 Error See "Relay 01 Error".
38 Relay 08 Error See "Relay 01 Error".
39 Analog Output 01 Error The specified readout was configured for a function that is not
configured as used. Either the readout was mis-configured or the
function required is mis-configured. For example, readout #1 is
configured for Cascade Set Point but Cascade Control was not
configured under the Cascade configure menu.

40 Analog Output 02 Error See "Analog Output 01 Error".

41 Analog Output 03 Error See "Analog Output 01 Error".
42 Analog Output 04 Error See "Analog Output 01 Error".
43 Analog Output 05 Error See "Analog Output 01 Error".
44 Analog Output 06 Error See "Analog Output 01 Error".
45 HP Valve Not No HP actuator channel has been configured. This is required for
Configured control of the steam turbine.
46 Duplicate HP Configured Both actuator channels have been configured for the HP valve
functionality. This function is only allowed on one channel.
47 Duplicate HP2 Both actuator channels have been configured for the HP2 valve
Configured functionality. This function is only allowed on one channel.
48 Actuator 01 Readout The Actuator/Driver channel readout was configured for a function
Error that is not configured as used. Either the readout was mis-
configured or the function required is mis-configured. For example,
readout is configured for Cascade Set Point but Cascade Control
was not configured under the Cascade Program Block.

49 Actuator 02 Readout See "Actuator 01 Readout Error".

Error
50 Max KW Load > Max The KW Max Load setting was programmed at a higher value than
KW AI Scale the maximum KW input (KW input at 20 mA).
51 Selected KW Source Not Occurs when a Primary or Secondary kW Signal source has been
Configured selected under Operating Parameters but that source is not
configured. For example, Primary kW Source is set as 'Analog
Input' but no analog input is configured as a kW Input.

52 Inlet Pressure A controller has been configured to use an Inlet Pressure input but
Configured, No AI no Analog Input is configured as Inlet Pressure.
53 Exhaust Pressure A controller has been configured to use an Exhaust Pressure input
Configured, No AI but no Analog Input is configured as Exhaust Pressure.
54 Auxiliary Configured, No The Auxiliary control function was configured but no Auxiliary
AI analog input was configured.

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Event Description Error Meaning
ID
55 KW AUX Configured, The Auxiliary control function was configured to use the kW
AUX AI Configured analog input but an Auxiliary analog input was configured also.
With this configuration, only the kW analog input is used for the
Auxiliary controller.

56 Remote AUX The Remote Auxiliary set point control function was configured but
Configured, No AI no Remote Auxiliary set point analog input was configured.
57 Inlet Pres AUX Config, The Auxiliary control function was configured to use the Inlet
AUX AI Config Pressure analog input but an Auxiliary analog input was
configured also. With this configuration, only the Inlet Pressure
analog input is used for the Auxiliary controller.

58 Exhaust Pres AUX The Auxiliary control function was configured to use the Exhaust
Config, AUX AI Config Pressure analog input but an Auxiliary analog input was
configured also. With this configuration, only the Exhaust Pressure
analog input is used for the Auxiliary controller.

59 Auxiliary2 Configured, The Auxiliary 2 control function was configured but no Auxiliary 2
No AI analog input was configured.
60 KW AUX2 Configured, The Auxiliary 2 control function was configured to use the kW
AUX AI Configured analog input but an Auxiliary 2 analog input was configured also.
With this configuration, only the kW analog input is used for the
Auxiliary 2 controller.

61 Remote AUX 2 The Remote Auxiliary 2 set point control function was configured
Configured, No AI but no Remote Auxiliary 2 set point analog input was configured.

62 Inlet Pres AUX2 Config, The Auxiliary 2 control function was configured to use the Inlet
AUX2 AI Config Pressure analog input but an Auxiliary 2 analog input was
configured also. With this configuration, only the Inlet Pressure
analog input is used for the Auxiliary 2 controller.

63 Exhst Pres AUX2 The Auxiliary 2 control function was configured to use the Exhaust
Config, AUX2 AI Config Pressure analog input but an Auxiliary 2 analog input was
configured also. With this configuration, only the Exhaust Pressure
analog input is used for the Auxiliary 2 controller.

64 Cascade Configured, No The Cascade control function was programmed but no Cascade
AI analog input was configured.
65 KW CASC Configured, The Cascade control function was configured to use the kW
CASC AI Configured analog input but a Cascade analog input was configured also.
With this configuration, only the kW analog input is used for the
Cascade controller.

66 Remote Casc The Remote Cascade set point control function was configured
Configured, No AI but no Remote Cascade set point analog input was configured.
67 Inlet Pres CASC Config, The Cascade control function was configured to use the Inlet
CASC AI Config Pressure analog input but a Cascade analog input was configured
also. With this configuration, only the Inlet Pressure analog input is
used for the Cascade controller.

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Event Description Error Meaning
ID
68 Exhst Pres CASC The Cascade control function was configured to use the Exhaust
Config, CASC AI Config Pressure analog input but a Cascade analog input was configured
also. With this configuration, only the Exhaust Pressure analog
input is used for the Cascade controller.

69 Spare Not Used

70 Remote Speed The remote speed set point control function was configured but no
Configured, No AI remote speed set point analog input was configured.
71 Feed Forward The Feed Forward function was configured but no Feed Forward
Programmed, No AI analog input is configured.
72 Sync and Sync/Load Both the synchronizing analog input and the sync/load share or
Share Configured load share analog inputs are configured. If the application needs
to perform both synchronizing and load sharing with analog
signals, only the sync/load sharing analog input needs to be
configured.

73 Load Share and Both the frequency arm/disarm function and the load share control
Frequency Arm Cnfg functions are configured. Only one of these modes can be
programmed — either freq arm/disarm OR Load Sharing.

74 Generator Application, The unit is configured for a generator application but no utility tie
No Tie Breaker breaker contact input is configured. This is a requirement.
75 Generator Application, The unit is configured for a generator application but no generator
No Gen Breaker breaker contact input is configured. This is a requirement.

76 Idle 1 in Critical Band Either the Idle speed set point (when using Idle/Rated) or the Idle
1 set point (when using the Automatic Start sequence) is
configured within a critical speed avoidance band.

77 Idle 2 in Critical Band The Idle 2 speed set point (when using the Automatic Start
sequence) is configured within a critical speed avoidance band.
78 Idle 3 in Critical Band The Idle 3 speed set point (when using the Automatic Start
sequence) is configured within a critical speed avoidance band.
79 Min Control Speed < Either the Idle speed set point (when using Idle/Rated) or the Idle
Failed Speed Level 1 set point (when using the Automatic Start sequence) is
configured lower than the Failed Speed Level for speed input 1 or
2.

80 Idle 1 Setpoint > The Idle Speed setpoint is configured at a higher speed than the
Minimum Governor minimum governor speed setpoint.
81 Idle 2 Setpoint > The Idle Speed setpoint is configured at a higher speed than the
Minimum Governor minimum governor speed setpoint.
82 Idle 3 Setpoint > The Idle Speed setpoint is configured at a higher speed than the
Minimum Governor minimum governor speed setpoint.
83 Idle 1 > Idle 2 The Idle 1 speed setpoint is configured at a higher speed than the
Idle 2 speed setpoint.
84 Idle 2 > Idle 3 The Idle 2 speed setpoint is configured at a higher speed than the
Idle 3 speed setpoint.

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Event Description Error Meaning
ID
85 Rate to Idle 2 Error The Cold Rate to Idle 2 (rpm/second) is configured at a higher rate
than the Hot Rate to Idle 2. Or the Warm Rate to Idle 2 (if used) is
configured at a higher rate than the Hot Rate to Idle 2.

86 Rate to Idle 3 Error The Cold Rate to Idle 3 (rpm/second) is configured at a higher rate
than the Hot Rate to Idle 3. Or the Warm Rate to Idle 3 (if used) is
configured at a higher rate than the Hot Rate to Idle 3.

87 Rate to Rated Error The Cold Rate to Rated (rpm/second) is configured at a higher
rate than the Hot Rate to Rated. Or the Warm Rate to Rated (if
used) is configured at a higher rate than the Hot Rate to Rated.

88 Critical Band Rate < The acceleration rate (rpm/second) through the critical speed
Slow Rate avoidance band must be faster than the normal speed set point
rate.

89 Critical Speeds Enabled, A critical speed avoidance band is configured but neither idle/rated
No Idle nor auto start sequence is configured. To use the critical speed
avoidance logic one of these functions that uses an idle speed
must be programmed.

90 Critical Band Below 1st A critical speed avoidance band is configured below either the Idle
Idle Setpoint speed set point (when using Idle/Rated) or the Idle 1 set point
(when using the Automatic Start sequence).

91 Critical Band > Minimum A critical speed avoidance band is configured higher than the
Governor Minimum Governor speed level.
92 Critical Band Min > Max A critical speed avoidance band minimum limit is configured
higher than the maximum limit of that band.
93 Minimum Governor > The Minimum Governor speed level is configured higher than the
Maximum Governor Maximum Governor speed level.
94 Rated Speed < Min Gov The Rated speed set point is configured at a lower speed than the
Minimum Governor speed set point.
95 Rated Speed > Max Gov The Rated speed set point is configured at a higher speed than
the Maximum Governor speed set point.
96 Max Gov > Overspeed The Maximum Governor speed level is configured greater than the
Test Limit Overspeed Test Limit.
97 Overspeed Trip > The Overspeed Trip setpoint is greater than the Overspeed Test
Overspeed Test SP Limit.
98 Overspeed Test Limit > The Overspeed Test Limit is configured greater than the Maximum
Maximum Speed Speed Level for speed input 1 or 2 (if used).
99 Maximum Speed > The maximum speed input is 35000 hertz. This is a limitation of
Probe 1 Freq Range the 505’s hardware/speed sensing circuitry. The frequency input of
the speed sensor must be less than this value. The gear the
speed sensor is mounted on may need to be changed to one with
less teeth, this will decrease the frequency seen by the speed
probes. The Maximum Speed Level for Speed Input Channel 1,
converted to frequency (Hz), is greater than 35000 Hz.

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Event Description Error Meaning
ID
100 Maximum Speed > The maximum speed input is 35000 hertz. This is a limitation of
Probe 2 Freq Range the 505’s hardware/speed sensing circuitry. The frequency input of
the speed sensor must be less than this value. The gear the
speed sensor is mounted on may need to be changed to one with
less teeth, this will decrease the frequency seen by the speed
probes. The Maximum Speed Level for Speed Input Channel 2,
converted to frequency (Hz), is greater than 35000 Hz.
101 Speed Sensor #1 Failed The failed speed setting for speed input #1 is below the minimum
< Freq Range allowed setting. The minimum allowed setting is calculated as
follows: (Maximum Speed Level) * (0.0204).

102 Speed Sensor #2 Failed The failed speed setting for speed input #2 is below the minimum
< Freq Range allowed setting. The minimum allowed setting is calculated as
follows: (Maximum Speed Level) * (0.0204).

103 No Start Mode No start mode is selected in the Configure mode. One of the three
Configured start modes must be selected in the Configure mode under the
Start menu.

104 Remote KW Setpoint The Remote kW Setpoint is configured as used but no analog
Configured, No AI input is configured as a Remote kW Setpoint.
105 Remote Speed and KW Both Remote Speed Setpoint and Remote kW Setpoints are
Setpoint configured as used. Only one of these inputs may be configured.
106 Hot Start greater than The time configured for a Hot Start is greater than the Cold Start.
Cold Start The time remaining after shutdown for a Hot Start must be less
than the time for a Cold Start.

107 Hot Reset Timer Level Hot Reset Timer Level is greater than the Maximum Governor
Error speed level or less than the Minimum Governor speed level. The
Hot Reset Timer Level must be between Minimum and Maximum
Governor.
108 Temperature 1 or 2 A Start Temperature function is configured but no Analog Input is
used, no AI configured as a temperature input.
109 Cascade Speed Limit The Cascade minimum speed limit is configured less than
Error Minimum Governor, the Cascade maximum speed limit is
configured greater than Maximum Governor, or the Cascade
minimum speed limit is greater than the Cascade maximum speed
limit.
110 KW Signal Source Not A controller has been configured to use a kW input but no Primary
Selected or Secondary Signal source has been selected under Operating
Parameters.

111 SYNC Signal Source Not A controller has been configured to use a Synchronization input
Selected but no Primary or Secondary Signal source has been selected
under Operating Parameters.

112 SYNC LS Signal Source A controller has been configured to use a Synchronization/Load
Not Selected Sharing input but no Primary or Secondary Signal source has
been selected under Operating Parameters.

113 Isolated Process Control An analog input for the process value and/or an analog output for
Error the PID demand have not been configured.

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Event Description Error Meaning
ID
114 Selected SYNC Source Occurs when a Primary or Secondary Synchronization Signal
Not Configured source has been selected under Operating Parameters but that
source is not configured. For example, Primary Synchronization
Source is set as 'Analog Input' but no analog input is configured as
a Synchronization Input.

115 Selected SYNC LS Occurs when a Primary or Secondary Synchronization/Load

Source Not Configured Sharing Signal source has been selected under Operating
Parameters but that source is not configured. For example,
Primary Synchronization/Load Sharing Source is set as 'Analog
Input' but no analog input is configured as a Synchronization/Load
Sharing Input.
116 Duplicate Node ID's on Multiple nodes on the CAN3 network have the same Node ID.
CAN3 Network Node ID's on the same network must be unique.
117 Remote KW SP The unit is not a generator unit but the Remote kW Setpoint is
Selected, Not Genset selected.

Valve/Actuator Calibration & Test

Before initial operation or after a turbine overhaul where any actuator or valve travel may have been
affected, the below Valve Calibration procedure should be followed to ensure that the 505 is correctly
calibrated to the turbine control valve(s). When calibration is complete, 0 to 100% actuator position as
displayed by the 505 must equal 0 to 100% actual valve travel.

After a valid configuration has been entered, the actuator and valve minimum and maximum positions can
be adjusted and tested, if needed. Actuator and valve positions are determined by the drive current to the
actuator. The maximum actuator current cannot be adjusted lower than the minimum actuator current
(see Table 4-10 below). The minimum actuator current cannot be adjusted higher than the maximum
actuator current. The driver current ranges are determined by the setting in the Configuration Mode under
the Driver configuration menu.

When adjusting or testing actuator and valve travel, verify that sufficient valve overtravel at the minimum
stop is achieved (1%). This assures that each valve can fully close to completely shut off the steam flow
to the turbine.

Table 4-10. Actuator Driver Limits

Driver Limits 0–200 mA Range 4–20 mA Range

Overcurrent 210 mA 24 mA
Undercurrent 5 mA 0.6 mA
Max Output 10–200 mA 2–24 mA
Current Range
Max Output 65  600 
Impedance
Min Stop Adjust 10–80 mA 2–20 mA
Range
Max Stop Adjust 100–200 mA 10–24 mA
Range

To ensure proper control to actuator resolution do not calibrate the span of the actuator output to less
than a range of 100 mA (20–160 mA output) or 12 mA
(4–20 mA output). If necessary, the actuator to valve linkage may need to be adjusted to ensure proper
505 to valve resolution.

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Calibration Mode, required to force/stroke the actuator(s), is only available when the 505 control is in a
shutdown state. After enabling Calibration Mode, there are options available to adjust the minimum and
maximum stops and to manually stroke the output(s). The manual adjustment mode can be used to
stroke the actuator and valves from 0 to 100% after the minimum and maximum positions have been
adjusted. This allows both the actuator and valve to be tested for binding, play, resolution, linearity, and
repeatability.

As a safety precaution, if turbine speed ever exceeds either of the speed probe failed speed settings the
Calibration mode will be automatically disabled, which disables forcing of the actuator and takes actuator
currents to zero.

Calibration/Stroking Procedure

Before calibrating or testing, the unit must be tripped, and the steam
supply removed. This is to ensure that opening the control valve(s)
will not allow steam into the turbine. Overspeeding the turbine may
cause damage to turbine and can cause severe injury or death to
personnel. STEAM TO THE TURBINE MUST BE SHUT OFF BY OTHER
MEANS DURING THIS PROCESS.

1. The 505 must be shutdown to enter Calibration Mode.

2. Go to the MODE screen by pressing the MODE key.
3. Enter Calibration Mode by pressing the ‘Calibration’ softkey. The following permissives must be met:
a. Unit Shutdown
b. No Speed Detected
c. Appropriate User Level Login
4. Navigate to the Actuator Driver Summary page by pressing the ‘Drivers’ in either the HOME menu or
Configure menu.
5. Select the desired Actuator channel.
6. In the Actuator channel screen, press the ‘Calibration’ softkey to access the calibration options.
7. Verify the green “Calmode Enabled” LED is ON to confirm that the unit is in Calibration Mode.
8. Press the ‘Forcing’ sofkey and then confirm on the popup that actuator forcing can be enabled.
Select ‘OK’ and press ENTER to enable forcing.
9. Verify that the green “Forcing Enabled” LED is now also ON.
10. Use the focus navigation to select and adjust items on the screen (Manual Adjust, Goto Demand,
Force Rate, etc.).
11. Actuator current output at min and max can be adjusted by selecting “mA at 0% Demand” or “mA at
100% Demand”. Use the up/down Adjust arrows or numerical keypad and ENTER key to the change
the values.
12. Press the ‘Commands’ softkey to access other commands such as “Go to Min”, Go to Max”, and
“GO”. “GO” can be used with the “Goto Demand” value.
13. When finished, make sure to save the settings by pressing any ‘Save Settings’ softkey. A ‘Save
Settings’ softkey can be accessed on the MODE screen.
14. Exit Calibration Mode by pressing the ‘Exit Calmode’ softkey from the MODE page or, if it is desired
to stroke another channel, return to the Driver or I/O screen to continue stroking other channels.

If changes are made to the minimum or maximum current values, they can be recorded on the Configure
Mode worksheets. Exiting the Calibration Mode or Forcing Mode will not permanently save any calibration
changes.

Press the ‘Save Settings’ softkey to permanently save any minimum or

maximum actuator settings into the 505. If variables are tuned or
changed but not stored in EEPROM, then those changes will be lost if
power is removed from the control or if the control receives a CPU
reset.

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Chapter 5.
505 Operation

Software Architecture
The 505 is a field configurable steam turbine control and graphical user interface (GUI) integrated into
one package. The 505 control has been designed to run 2 separate, independent programs on the same
platform. One controls the I/O and therefore controls turbine operation. The other program provides all the
visual and command interaction with the user.

Figure 5-1. Software Architecture

The primary application program is the GAP based control application program. This controls all the
system I/O and functional algorithms which control the operation of the turbine.

The secondary application program is the Digia/Qt based graphical user interface (GUI) program. This
controls all the screen information that is displayed to the user. It links to the GAP via an internal
communication link to pass all required interface variables to and from the display.

Both of these programs are automatically launched at power-up. The GAP program MUST always be
executing to run the turbine. However, the GUI program may be ‘Stopped’ using a service tool
(AppManager) and restarted at any time without affecting GAP or the turbine operation. This unique and
useful feature of the 505 allows the following operations to be accomplished (if needed or desired) while
the 505 control is operating the turbine.

 Change the language on the screen

 Update the GUI program (newer build revisions with improvement/enhancements)
 Upgrade the GUI program – load a custom version that may be created for a specific OEM or
customer jobsite

Power-Up Screen
Viewed from the front the 505 – the following is the correct boot-up sequence of a 505 unit loaded with
the standard 505 GAP and Qt GUI applications. Times are approximant.

At Power-up Screen = BLANK /BLACK

After about 1:00 Screen = “505 Splash Screen”
TRIPPED/CPU/ALARM LED’s will flash check

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After about 1:10 TRIPPED=ON (RED)
IOLOCK = OFF
CPU = ON (GREEN)

After about 1:30 ALARM LED (YELLOW) Flashes/Blinks

After about 2:40 Screen = HOME

Figure 5-2. 505 Splash Screen

Any time that a Display application program is not running, the ‘Splash Screen’ will appear. If at power-up
the Alarm LED stops flashing, and this screen still appears – then the GUI program has not initialized
correctly.

Once the unit has been configured, all following power cycles will result in a screen like the following,
dependent on what functionality has been configured.

Figure 5-3. Boot-up to HOME Screen

Refer to Figure 4.1 for the view of an initial power-up of an unconfigured unit.

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There is a Screen Saver function that is invoked after a period of inactivity. It is defaulted to 4 hours
(adjustable in Service / Screen Settings) – when this comes it a small version of the ‘Splash Screen’ will
bounce around on the screen. Press any key to revive the display (maroon keys are recommended).
When awaking from screen saver the user login level will be reduced to Operator. This also is adjustable
in Service / Screen Settings if desired, it can be changed to awaken to Monitor.

Control Mode Architecture

Basic control program architecture is illustrated in Figure 5-1. The 505’s normal operating architecture
divides the control into two states.
Run – which includes Operation and Calibration modes
Program - Configuration mode

Pressing the MODE key at any time will open the Login and Mode Screen

The Configuration Mode is used to configure the 505 for the specific application and set all operating
parameters (see Chapter 4). In this mode the control will issue an IOLOCK (LED) and the state of all
Outputs from the 505 are disabled. This means that all Relays are de-energized, and all Analog/Driver
outputs are at zero current. Initially all 505’s must be placed in this mode to enter a valid configuration of
the I/O and functions desired for the specific turbine application.

The Calibration Mode is used after the configuration of the 505 is complete. It is used to perform
calibration of signals, verification of speed signals and the forcing of outputs of the control in preparation
to run the turbine. All I/O is functional in this state. To enter this mode the turbine must be TRIPPED
(LED).

The Operation Mode is used to view operating parameters and run the turbine. This is the typical mode
the control uses and is the default mode it enters at Power-up. All I/O is functional in this state. The
turbine may be either running or not running in this mode.

Figure 5-4. Control Mode Architecture

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User Login Levels

Pressing the MODE key at any time will open the Login and Mode Screen

Figure 5-5. Mode Screen

Monitor – (logout to enter this)

Even Keypad Green keys inhibited
Operator – (passwords are provided in Vol 2 Appendix C)
Intended for normal turbine operation – default mode
Screen saver initiates to this level
Service – (passwords are provided in Vol 2 Appendix C)
Allows tuning of parameters, while turbine is running (PID dynamics) and entering of Calibration Mode
Configure – (passwords are provided in Vol 2 Appendix C)
Highest user authority / can enter any Mode

EMERGENCY STOP is always available in all modes and logins as it

has direct H/W action to open the Actuator circuits.

To Login –

1. Press the LOGIN button

2. ** Navigate so the Login or Password field is highlighted (in-focus)
3. Press Enter on the Navigation Cross
4. Use the keypad to enter the text field (hold key down to scroll options)
5. Press Enter on the Navigation Cross – to accept your entry

** Or you can navigate to the Autofill buttons and press Enter – it will auto-populate the Login information
so you only need to enter the Password.

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Navigation
This is NOT a touchscreen! Due to quality, robustness, screen cleanliness and long-term reliability
concerns Woodward chose not to implement a touchscreen directly on this product. Using the
RemoteView tool a user can take advantage of either a mouse device or a touchscreen on an external
computer, but for navigation and selection directly on the 505 display, buttons and an IN-Focus
highlighter indication are used.

In general, the maroon buttons provide navigation from page-to-page and throughout the components on
a page. Most of the navigation is done with the Navigation cross.

Figure 5-6. Navigation Cross

1. Use the “Arrow” buttons to move the IN-Focus highlighter to the desired page
2. Press the “Enter” button to launch the page selected
3. Press the “ESC” (Escape) button to go back 1 page from current page
4. Press the “HOME” button to return to the main menu Note: If in Service or Configure menu a
second press of HOME will return to the Operational Home screen

Figure 5-7. Service Menu showing “Speed Control” IN-Focus

Changing Languages on Display

The 505 supports multiple languages on all pages of the display. From the Mode screen, navigate to put
the Globe icon in focus and press ENTER. The popup page below will appear. When user is logged in at
user level Service or higher, choosing the desired language from the selection menu is an option. Once
the choice is made, hit enter and that language will appear in the language selection box. The GUI must
now be re-started to initialize all strings with the translations.

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Restarting the GUI will take about 2-3 minutes, during which the
display will be reinitialized. This can be done with the turbine running,
as the re-initialization of the GUI application will not affect I/O
Reinitializing the operation. RemoteView tool can be used during this time if desired.
GUI

Figure 5-8. Selection Menu – Language Option.

To restart the GUI after changing the language selection, press the Re-Start GUI button and the user will
see the following sequence appear on the front panel display:
1. Screen will temporarily go all GREEN
2. Then the Splash screen will appear while the GUI file re-initializes.
3. After 30 seconds, the Alarm LED will flash while the GUI reboots
4. This sequence will take about 2 ½ minutes

Note: if the LED stops flashing before the display initializes, connect to the control with AppManager
and go to the GUI view for status messages. From there the GUI file can be stopped and restarted.

RemoteView sessions will not be affected by the local display being re-initialized.

Page Organization
Three primary menu lists organize the access to all of the information that is available on the display.
These menu lists are always available. The user simply uses the navigation cross to Focus on the desired
page and press Enter or use the Black ‘soft keys’ (no Focus needed).

Run/Operation menus - The HOME page contains the Run/Operation menus and is automatically
updated to match the configuration of the control.

Service menus - The Service ‘HOME’ page contains navigation buttons to all of the service related
parameters and special feature of the control and it too is automatically updated to match the
configuration of the control.

Configuration menus - The Configuration ‘HOME’ page contains navigation buttons to all features and
options of the 505. When the unit is in Configure Mode (IOLOCK) the background of all pages will be a
blue gradient as shown below, in addition to the status in the upper right.

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Figure 5-9. Configuration Menu – Operation Mode (View only)

Figure 5-10. Configuration Menu – Configuration Mode (Edit)

Refer to chapter 1 for more details about all of the keys – below are some general reminders about the
keypad functions

Green keys – initiate operational commands

Red keys - navigate or enter values via the alpha numeric keys

Black keys – are software dependent and may do either, they never require ‘IN-Focus’ the command
shown in above the key is always available

Start and Stop Keys – always require a Confirmation and user must be logged-in at appropriate
User level (Operator or greater)

EMERGENCY STOP is always available in all modes and logins as it has direct H/W action to open
the Actuator circuits.

When entering string text from the keypad, holding down the key will make is slowly cycle through the
characters available on that key. Releasing the key will select the character shown at that time.

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Overview Screen

Figure 5-11. Overview Screen

The Overview screen will adapt to the configuration of the 505 and show all configured options. During
normal run operation, this screen should provide the user with all of the primary turbine parameter values
and operational status.

The menu bar functions will allow the user to use typical operational commands related to the control loop
selected – such as directly entering a setpoint or enabling or disabling a controller while remaining on the
Overview page

Speed Control Screen

Figure 5-12. Speed Control Screen

The Speed Control screen will adapt to the configuration of the 505 and show all configured options.
During normal run operation, this screen provides the user with all details that are related to the turbine
when operating in speed control.

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The menu bar functions will allow the user to access a number of other screens that are related to speed
control, such as directly entering a setpoint, access to the valve limiter feature, adjusting speed control
dynamic settings, enabling or disabling a remote speed setpoint or performing an Overspeed test. For
generator units the breaker status of the breakers is shown and the menu bar will give the user access to
Enabling the synchronizer.

Valve Demand Screen

Figure 5-13. Valve Demand Screen

The Valve Demand screen will adapt to the configuration of the 505 and show all configured options that
can affect the final output demand to the valve. During normal run operation, this screen provides the
user with a clear picture of what control or ramp is controlling the valve demand output. The Low Signal
Select (LSS) bus will output the lowest value seen at its inputs. The valve logic box represents options
that may be use to adjust this value (such as valve linearization and/or pressure compensation) prior to
output to the HP valve. If these options are not used, the HP valve demand output will always equal the
LSS value.

During normal operation, the Valve Limiter setting is at 100% and not limiting.
Typically, the only time this parameter is adjusted is during a start sequence or to troubleshoot system
dynamics problems.

The menu bar will allow the user to access the valve limiter setpoint and the manual valve demand (if
configured for use).

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Controllers Screen

Figure 5-14. Controllers Screen

The Controllers screen will adapt to the configuration of the 505 and show all configured options. During
normal run operation, this screen provides the user with information similar to the Overview, but in a
graphical gauge view. It provides larger values for distance viewing and control PID information which is
useful for monitoring when the 505 is near transition points between controllers or limiters.

The menu bar functions will allow the user to use typical operational commands related to the control loop
selected – such as directly entering a setpoint or enabling or disabling a controller while remaining on the
Controllers page

Cascade Control Screen

Figure 5-15. Cascade Control Screen

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The Cascade Control screen will adapt to the configuration of the 505. During normal run operation, this
screen provides the user with all details that are related to the cascade control loop. The cascade control
output determines the setpoint for the speed control. This allows the 505 to vary the speed control
setpoint as it relates to another process variable selected by the user.

The menu bar functions will allow the user to access several other screens that are related to cascade
control, such as directly entering a setpoint, access to the valve limiter, or adjusting cascade control
dynamic settings.

Auxiliary Control Screen

Figure 5-16. Auxiliary Control Screen

The Auxiliary Control screen will adapt to the configuration of the 505. During normal run operation, this
screen provides the user with all details that are related to the auxiliary control loop. The auxiliary control
output goes to the LSS bus and can directly affect the HP valve demand output. This can be configured
as a limiter or a controller. If it is a limiter it will always be enabled and provide protection related to the
process variable being used for this function. When configured as a controller it will disable the speed PID
whenever enabled.

The menu bar functions will allow the user to access several other screens that are related to auxiliary
control, such as directly entering a setpoint, access to the valve limiter, or adjusting auxiliary control
dynamic settings.

The Auxiliary 2 Control is identical to the Auxiliary Control with the exception that Auxiliary 2 is only used
as a limiter.

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Analog Input Summary Screen

Figure 5-17. Analog Input Summary Screen

The Analog Input Summary screen will display the status of all channels available on the 505 hardware.
The fault status, function, device tag, engineering value and units are shown for each channel as well as
navigation buttons for each channel that take the user to a page showing all parameters available for that
input.

The menu bar functions will allow the user to access the detailed page of the speed input signals

Contact Input Summary Screen

Figure 5-18. Contact Input Summary Screen

The Contact Input Summary screen will display the status of channels available on the 505 hardware.
The fault status, function, and device tags are shown for each channel as well as navigation buttons for
each channel that take the user to a page showing all parameters available for that input.

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The contact input summary is broken into three pages and the menu bar contains navigation buttons to
view all the channels

Analog Output Summary Screen

Figure 5-19. Analog Output Summary Screen

The Analog Output Summary screen will display the status of all channels available on the 505 hardware.
The fault status, function, device tag, engineering value and units are shown for each channel as well as
navigation buttons for each channel that take the user to a page showing all parameters available for that
output.

Relay Output Summary Screen

Figure 5-20. Relay Output Summary Screen

The Relay Output Summary screen will display the status of all channels available on the 505 hardware.
The coil status, function, and device tag are shown for each channel as well as navigation buttons for
each channel that take the user to a page showing all parameters available for that output.

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Actuator Driver Summary Screen

Figure 5-21. Actuator Driver Summary Screen

The Actuator Driver Summary screen will display the status of the 2 channels available on the 505
hardware. The fault status, function, current value (in mA), engineering value and units are shown for
each channel as well as navigation buttons for each channel that take the user to a page showing all
parameters available for that input.

Starting Procedures (Start Curve Screen)

Figure 5-22. HOME Menu showing “Startup Curve” IN-Focus

Refer to the turbine manufacturer’s operating procedures for complete information on turbine start up, and
Chapter 3 of this manual for a step by step procedure, depending on the start mode selected. The
following is a typical start- up procedure:

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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.

1. Press the RESET key to clear all alarms and trips. If the 505’s RESET CLEARS TRIP setting is
programmed "YES", the 505's shutdown relay will reset or energize upon pressing the RESET key
after a shutdown. If the RESET CLEARS TRIP OUTPUT setting is programmed "NO", the 505's
shutdown relay will reset or energize upon pressing the Reset key ONLY after all trip conditions are
cleared.
2. Press the START key and Confirm, to initiate the selected start-up mode. This will function from any
screen, but it is recommended to be on the Startup Curve page during the turbine startup. It will
automatically be matched to show the correct information relative to the start sequence that has been
configured. If a semi-automatic start mode is configured, the valve limiter must be manually increased
to open the control valve.
 A ‘Start Perm Not Closed’ alarm will be issued if the application is using a Start Permissive
contact input and this contact input was not closed when the RUN command was issued.
3. After the selected start-up mode has been performed, the turbine will operate at the minimum or idle
speed setting. The 505’s speed set point will move to minimum governor speed unless an idle speed
is programmed. The Idle/Rated or Auto Start Sequence functions must be programmed for the turbine
to control at idle speed. An operator at this time may vary turbine speed through the 505's keypad,
external switches or communication links.

Overspeed Test Function (Speed Control Screen)

The 505’s Overspeed Test function allows an operator to increase turbine speed above its rated
operating range to periodically test turbine electrical and/or mechanical overspeed protection logic and
circuitry. This includes the 505’s internal overspeed trip logic and any external overspeed trip device’s
settings and logic. Figure 5-22 shows the screen that is displayed when the ‘Overspeed Test’ key is
pressed from the Speed Control page. It shows the permissives required to be able to perform an
overspeed test (in the case of a mechanical drive application the Generator Breaker Open is not shown)

Figure 5-23. Overspeed Test Permissives

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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.

Overspeed Test Procedure

(from the 505 display)

 Be sure the generator breaker is open or if unit is a generator drive

 Raise the Speed Set Point to the maximum governor setting
 If desired, clear the ‘Highest Speed Reached’ value, to record the highest speed reached during this
overspeed test. (Reset Max key)
 This function has a safety timeout to insure the unit does not run in this mode unattended. Once the
mode is entered, the user must begin to raise the speed within 30 seconds. As long as the user is
adjusting the speed the timeout value will be reset.
 Timeout value is shown, if it expires the test mode will be aborted and the unit will return to the
maximum governor limit

Figure 5-24. Internal (505) Overspeed Test

 To perform an Internal Overspeed Test Press the Enable Int Test key and the above pop-up page will
appear. An Alarm will be annunciated that indicates Overspeed Test Enabled
 Put the Adjust button in Focus and use the ADJUST key to raise the speed above the normal Max
Governor limit.
 Once turbine speed reaches the 505’s internal OVERSPEED TRIP (rpm) setting, the 505 will TRIP
the turbine

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Figure 5-25. External Overspeed Test

An external trip test is intended to be used to test the unit’s safety overspeed protection device (in many
cases a Woodward ProTech). In this mode the 505 internal overspeed trip will be changed to be just an
alarm and the 505 will allow the speed to continue increasing up to the Overspeed Test Limit (rpm). If the
505 speed OR the Setpoint reaches the Overspeed Test Limit it will TRIP

 To perform an External Overspeed Test Press the Enable Ext Test key and the above pop-up page
will appear. An Alarm will be annunciated that indicates Overspeed Test Enabled
 Put the Adjust button in Focus and use the ADJUST key to raise the speed above the normal Max
Governor limit.
 Once turbine speed reaches the 505’s internal OVERSPEED TRIP (rpm) setting, the 505 will trigger
an alarm that this has been reached
 If the timeout expires while the unit is above the Overspeed Trip setting, but below the Overspeed
Test Limit, the 505 will Trip on Overspeed
 If the Speed or the Setpoint reach the Overspeed Test Limit the 505 will issue a Trip

In the configuration of Speed Setpoints be sure that the Overspeed

Test Limit rpm value is above the expected Overspeed setting of the
external safety overspeed protection device.

Recommend performing Overspeed Tests from these screens, either at the control (preferred) or via the
RemoteView service tool. Alternatively, the turbine’s overspeed logic and circuitry can be tested remotely,
by programming an Overspeed Test contact input. The Overspeed Test contact functions as the enable
external test on the display. When the conditions outlined in the above procedure are met, closing this
contact allows the Speed set point to be increased up to the “Overspeed Test limit” setting. The testing
procedure is similar to using the OSPD key. An Overspeed Test Enabled relay can be programmed to
provide the status feedback that testing is enabled.

The Overspeed Test function cannot be performed over the Modbus communications, however, the
Overspeed Test Permissive, Overspeed Test In Progress, Overspeed Alarm, and Overspeed Trip
indications are available through Modbus.

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Stop Key
The STOP key is used to perform a controlled/manual turbine shutdown or stop. To perform a Manual
Shutdown, press the STOP key and confirm from the keypad or close the Controlled Shutdown contact
input (if programmed) or select Controlled Shutdown from a Modbus communications link. Once initiated,
the display dialog box will change to give the user the option to abort the Normal stop sequence. This
dialog box will close after 10 seconds but can be reopened by pressing the STOP key. This function can
be also be stopped by opening the contact or selecting Abort Controlled Shutdown from a Modbus
communications link.

Alarm Summary
The ALARM screen is always available with the VIEW button under the ALARM LED. When an alarm is
detected, it gets latched in the event logic, the Alarm relay is energized, and the ALARM LED illuminates
(Yellow). The cause of the event will be indicated with an Event ID, description and time/date stamp on
the Alarm Summary page. The list will always place the first event at the top of the list, if more than one
alarm condition is present, they will all be listed with their corresponding time stamp.

To clear any alarms that are no longer present, press the RESET key, close the Reset contact input, or
select Reset from either Modbus communications link. If the cause of the event has been corrected the
alarm will clear, it not it will remain, and the timestamp will remain unchanged.

Figure 5-26. ALARM Screen

Each individual alarm condition is available through the Modbus links to monitor the control status. A
common alarm indication is also provided.

Relay indications can be programmed to indicate a 505 Common Alarm, in addition to the dedicated
Alarm Relay output.

The table below lists all the potential alarm conditions and their Event ID.

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Table 5-1. ALARM Messages

Event ID DESCRIPTION MEANING

1 Speed Probe #1 Failed Speed probe #1 failure—(< Failed Speed Level or 1 Vrms)
2 Speed Probe #2 Failed Speed probe #2 failure—(< Failed Speed Level or 1 Vrms)
Remote Speed Setpt analog input failure (> 22 mA or < 2
3 Remote Spd Input Failed
mA)
4 Sync Input Failed Sync analog input failure detected (> 22 mA or < 2 mA)
Load Share analog input failure detected (> 22 mA or < 2
5 Load Share Input Failed
mA)
6 KW Load Input Failed KW analog input failure detected (> 22 mA or < 2 mA)
7 Cascade Input Failed Cascade analog input failure detected (> 22 mA or < 2 mA)
Remote Cascade Setpt analog input failure (> 22 mA or < 2
8 Remote Casc Input Failed
mA)
9 AUX Input Failed Auxiliary analog input failure detected (> 22 mA or < 2 mA)
10 Remote AUX Input Failed Remote Aux Setpt analog input failure (> 22 mA or < 2 mA)
11 AUX2 Input Failed Auxiliary 2 analog input failure detected (> 22 mA or < 2 mA)
12 Remote AUX2 Input Failed Remote Aux 2 Setpt analog input failure (> 22 mA or < 2 mA)
Inlet Header Pressure analog input failure detected (> 22 mA
13 Inlet Press Input Failed
or < 2 mA)
14 IH-A Input press AI FLT Fault indication from hydraulic pressure unit A
15 IH-B Input press AI FLT Fault indication from hydraulic pressure unit B
Feed-Forward analog input failure detected (> 22 mA or < 2
16 Feed-forward input failed
mA)
Remote Droop Setting analog input failure detected (> 22 mA
17 Remote Droop Fault
or < 2 mA)
Remote KW Setpoint
18 Remote KW Setpt analog input failure (> 22 mA or < 2 mA)
Failed
Exhaust Pressure analog input failure detected (> 22 mA or <
19 Exhaust Press Input Failed
2 mA)
20 Spare_020 reserved - not used
HP position FDBK analog input failure detected (> 22 mA or
21 HP Valve Feedback Failed
< 2 mA)
HP2 Valve Feedback HP2 position FDBK analog input failure detected (> 22 mA or
22
Failed < 2 mA)
Isolated PV analog input failure detected (> 22 mA or < 2
23 Isolated PID PV Failed
mA)
Rem SP Isolated PID Rem Setpoint for Iso analog input failure detected (> 22 mA
24
Failed or < 2 mA)
Customer analog input 1 failure detected (> 22 mA or < 2
25 Customer Input #1 Failed
mA)
Customer analog input 2 failure detected (> 22 mA or < 2
26 Customer Input #2 Failed
mA)
Customer analog input 3 failure detected (> 22 mA or < 2
27 Customer Input #3 Failed
mA)
Start Temp 1 analog input failure detected (> 22 mA or < 2
28 Start Temperature 1 Failed
mA)

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Event ID DESCRIPTION MEANING
Start Temp 2 analog input failure detected (> 22 mA or < 2
29 Start Temperature 2 Failed
mA)
30 spare_flt_ai_funct29 reserved - not used
31 spare_flt_ai_funct30 reserved - not used
32 External alarm # 1 External Alarm #1 from contact input
33 External alarm # 2 External Alarm #2 from contact input
34 External alarm # 3 External Alarm #3 from contact input
35 External alarm # 4 External Alarm #4 from contact input
36 External alarm # 5 External Alarm #5 from contact input
37 External alarm # 6 External Alarm #6 from contact input
38 External alarm # 7 External Alarm #7 from contact input
39 External alarm # 8 External Alarm #8 from contact input
40 External alarm # 9 External Alarm #9 from contact input
41 IH-act1 Failed from BI Fault indication from current-to-hydraulic Actuator 1 (CPC)
42 IH-act2 Failed from BI Fault indication from current-to-hydraulic Actuator 2 (CPC)
HP Actuator Fault (Act1 or
43 HP Actuator fault detected (open or short circuit was sensed)
2)
HP2 Actuator Fault (Act1 or HP2 Actuator fault detected (open or short circuit was
44
2) sensed)
45 Start Perm Not Closed Run selected while the Start Perm contact in was not closed
46 Mod Comm Link #1 Failed Modbus com link #1 was detected as failed—time out error
47 Mod Comm Link #2 Failed Modbus com link #2 was detected as failed—time out error

48 Mod Comm Link #3 Failed Modbus com link #3 was detected as failed—time out error

Analog Output Chan 1 readback failure detected (> 22 mA or

49 AO_01 Readback Fault
< 2 mA)
Analog Output Chan 2 readback failure detected (> 22 mA or
50 AO_02 Readback Fault
< 2 mA)
Analog Output Chan 3 readback failure detected (> 22 mA or
51 AO_03 Readback Fault
< 2 mA)
Analog Output Chan 4 readback failure detected (> 22 mA or
52 AO_04 Readback Fault
< 2 mA)
Analog Output Chan 5 readback failure detected (> 22 mA or
53 AO_05 Readback Fault
< 2 mA)
Analog Output Chan 6 readback failure detected (> 22 mA or
54 AO_06 Readback Fault
< 2 mA)
1- Display Backlight Fault
2- CPU OS fault
55 Chassis Summary Alarm
3- 505 Internal temp is high (> 70 deg C)
4- Unit Calibration Fault (Factory Calibration)
56 Turbine Tripped Turbine is tripped alarm indication
57 Overspeed Turbine overspeed alarm
58 Overspeed Test Enabled Overspeed Test mode is Active
59 TIE Breaker Opened Utility Tie breaker was opened after it was closed
60 GEN Breaker Opened Generator breaker was opened after it was closed
61 Tie Open / No Auxiliary Utility Tie breaker was opened when Auxiliary was active
62 Gen Open / No Auxiliary Generator breaker was opened when Auxiliary was active

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Event ID DESCRIPTION MEANING
63 Tie Open / No Cascade Utility Tie breaker was opened when Cascade was active
64 Gen Open / No Cascade Generator breaker was opened when Cascade was active
Util. Tie breaker was opened when Remote Spd Setpt was
65 Tie Open / No Remote
active
Generator breaker was opened when Remote Spd Setpt was
66 Gen Open / No Remote
active
67 Stuck In Critical Band Turbine is stagnating within critical speed window
68 505 Display Comm Fault GAP to Display communication failed
HP Valve Pos Fdbk Diff
69 HP Demand versus Feedback Difference
ALM
HP2 Valve Pos Fdbk Diff
70 HP2 Demand versus Feedback Difference
ALM
71 Limiter in Control reserved - not used
Inlet Steam Pressure Lvl1
72 Inlet Steam Pressure passed alarm level 1 limit
ALM
Inlet Steam Pressure Lvl2
73 Inlet Steam Pressure passed alarm level 2 limit
ALM
Exh Steam Pressure Lvl1
74 Exhaust Steam Pressure passed alarm level 1 limit
ALM
Exh Steam Pressure Lvl2
75 Exhaust Steam Pressure passed alarm level 2 limit
ALM
76 Selected PV 1 Level 1 ALM Signal Monitoring #1 passed alarm level 1 limit

77 Selected PV 1 Level 2 ALM Signal Monitoring #1 passed alarm level 2 limit

78 Selected PV 2 Level 1 ALM Signal Monitoring #2 passed alarm level 1 limit

79 Selected PV 2 Level 2 ALM Signal Monitoring #2 passed alarm level 2 limit

80 Selected PV 3 Level 1 ALM Signal Monitoring #3 passed alarm level 1 limit

81 Selected PV 3 Level 2 ALM Signal Monitoring #3 passed alarm level 2 limit
82 Tunable Alarm reserved - not used
83 Tie Open / No Auxiliary 2 Utility Tie breaker was opened when Auxiliary 2 was active
84 Gen Open / No Auxiliary 2 Generator breaker was opened when Auxiliary 2 was active
85 Actuator 1 Readout Fault Actuator Driver Chan 1 readback failure detected
86 Actuator 2 Readout Fault Actuator Driver Chan 2 readback failure detected
CAN1_DVP1 Summary
87 Summary Alarm from VariStroke device DVP1
ALM
CAN1_DVP2 Summary
88 Summary Alarm from VariStroke device DVP2
ALM
HP Actuator Fault (DVP1
89 HP Actuator fault detected (CAN1 link to VariStroke)
or 2)
HP2 Actuator Fault (DVP1
90 HP2 Actuator fault detected (CAN1 link to VariStroke)
or 2)
Comm Link to DSLC2
91 Digital Comm Link to DSLC-2 Failed
Failed
92 KW Load AI Failed Backup KW signal is faulted (AI or digital link)
Turbine Maintenance
93 Turbine Run Hours Reached Maintenance Interval
Interval Alm
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Event ID DESCRIPTION MEANING
Start Temperature #1
94 Override of Start Temperature #1 Signal is Active
Override Active
Start Temperature #2
95 Override of Start Temperature #2 Signal is Active
Override Active
Comm Link to EasyGen
96 Digital Comm Link to easYgen Failed
Failed
97 Comm Link to LS-5 Failed Digital Comm Link to LS-5 Failed
Comm Link to MFR300
98 Digital Comm Link to MFR300 Failed
Failed
Comm Link to HiProtec
99 Digital Comm Link to HiProtec Failed
Failed
MPU1 Failed Open Wire
100 Open wire detected on speed signal circuit channel 1
Test
MPU2 Failed Open Wire
101 Open wire detected on speed signal circuit channel 2
Test
Internal HW Simulation
102 Internal 505 SIMULATION Mode Active
Enabled
Pressure Compensation
103 Pressure Comp curve error on X-Y points
Curve Error
Actuator Linearization
104 Output valve curve error on X-Y points
Curve Error
105 Selected PV 4 Level 1 ALM Signal Monitoring #4 passed alarm level 1 limit

106 Selected PV 4 Level 2 ALM Signal Monitoring #4 passed alarm level 2 limit

107 Selected PV 5 Level 1 ALM Signal Monitoring #5 passed alarm level 1 limit

108 Selected PV 5 Level 2 ALM Signal Monitoring #5 passed alarm level 2 limit

109 Selected PV 6 Level 1 ALM Signal Monitoring #6 passed alarm level 1 limit

110 Selected PV 6 Level 2 ALM Signal Monitoring #6 passed alarm level 2 limit

111 Selected PV 7 Level 1 ALM Signal Monitoring #7 passed alarm level 1 limit
112 Selected PV 7 Level 2 ALM Signal Monitoring #7 passed alarm level 2 limit
113 Selected PV 8 Level 1 ALM Signal Monitoring #8 passed alarm level 1 limit
114 Selected PV 8 Level 2 ALM Signal Monitoring #8 passed alarm level 2 limit
Customer analog input 4 failure detected (> 22 mA or < 2
115 Customer Input #4 Failed
mA)
Customer analog input 5 failure detected (> 22 mA or < 2
116 Customer Input #5 Failed
mA)
Customer analog input 6 failure detected (> 22 mA or < 2
117 Customer Input #6 Failed
mA)
Customer analog input 7 failure detected (> 22 mA or < 2
118 Customer Input #7 Failed
mA)
Customer analog input 8 failure detected (> 22 mA or < 2
119 Customer Input #8 Failed
mA)

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Shutdown Summary
The Shutdown Summary screen is always available with the VIEW button under the TRIPPED LED.
When a trip is detected, it gets latched in the event logic, the Trip relay is de-energized, all steam valve
demand outputs go to zero, and the TRIPPED LED illuminates (Red). The cause of the event will be
indicated with an Event ID, description, and time/date stamp on the Shutdown Summary page. The list
will always place the first event at the top of the list, if more than one trip condition is present, they will all
be listed with their corresponding time stamp.

To clear any shutdowns that are no longer present, press the RESET key, close the Reset contact input,
or select Reset from either Modbus communications link. If the cause of the event has been corrected,
the event will clear, it not it will remain, and the timestamp will remain unchanged.

Figure 5-27. Shutdown Summary Screen

The table below lists all the potential shutdown conditions.

Table 5-2. TRIPPED Messages

Event
DESCRIPTION MEANING
ID
1 External Trip Input 1 External Trip contact input was opened
2 Emergency Stop Button Front Panel Display Emergency Stop was pressed
3 Overspeed Turbine overspeed was sensed
4 All Speed Probes Failed Loss of all speed probes was sensed
HP Actuator fault detected (an open or short circuit
5 HP Actuator Fault
was sensed)
HP2 Actuator fault detected (an open or short circuit
6 HP2 Actuator Fault
was sensed)
Aux analog input failure detected (> 22 mA or < 2
7 Aux Input Failed
mA)
15 Power Up Trip 505 lost power or the Configuration mode was exited
16 Normal Shutdown Complete Controlled shutdown was performed and completed
10 Trip Command from Modbus Modbus communication link trip was commanded
31 Unit in Calibration Mode 505 is in Calibration Mode

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Event
DESCRIPTION MEANING
ID
32 Configuration Error 505 has a configuration error
13 Tie Breaker Opened Utility tie breaker was opened after it was closed
14 GEN Breaker Opened Generator breaker was opened after it was closed
8 External Trip 2 External Trip #2 contact input was opened
9 External Trip 3 External Trip #3 contact input was opened
17 External Trip 4 External Trip #4 contact input was opened
18 External Trip 5 External Trip #5 contact input was opened
20 External Trip 6 External Trip #6 contact input was opened
21 External Trip 7 External Trip #7 contact input was opened
22 External Trip 8 External Trip #8 contact input was opened
23 External Trip 9 External Trip #9 contact input was opened
24 External Trip 10 External Trip #10 contact input was opened
HP Valve Limiter ramp is at Max but no speed is
25 HP Ramp at Max/No Speed
detected
For Act 1&2 the Min current setting must be Less
33 Actuator Scaling Min>Max than Max current setting (use Invert option to reverse
these)
34 Selected PV 4 Level 2 TRIP Customer Monitor Signal 4 passed trip level limit
35 Selected PV 5 Level 2 TRIP Customer Monitor Signal 5 passed trip level limit
36 Selected PV 6 Level 2 TRIP Customer Monitor Signal 6 passed trip level limit
Inlet Stm Pressure Level2
37 Inlet Steam Pressure passed trip level limit
TRIP
EXH Stm Pressure Level2
38 Exhaust Steam Pressure passed trip level limit
TRIP
39 Selected PV 1 Level 2 TRIP Customer Monitor Signal 1 passed trip level limit
40 Selected PV 2 Level 2 TRIP Customer Monitor Signal 2 passed trip level limit
41 Selected PV 3 Level 2 TRIP Customer Monitor Signal 3 passed trip level limit
30 Tunable Trip reserved for simulation use
42 Configuration Mode (IO Lock) 505 is in Configuration Mode (in IOLOCK)
Aux 2 analog input failure detected (> 22 mA or < 2
43 Aux 2 Input Failed
mA)
44 Open Wire on MPUs Open wires detected on all MPUs
45 Selected PV 7 Level 2 TRIP Customer Monitor Signal 7 passed trip level limit
46 Selected PV 8 Level 2 TRIP Customer Monitor Signal 8 passed trip level limit
47 spare_40 reserved for future use
Each individual trip condition is available through the Modbus links to monitor the control status. A
common trip indication is also provided.

Relay indications can be programmed to indicate a 505 Shutdown Condition (energizes for a shutdown
condition) or a Trip Relay (de-energizes for a shutdown/trip), in addition to the dedicated Emergency Trip
Relay output.

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Speed, Cascade, and Auxiliary Dynamics Adjustments

Dynamic control values are programmed in the configuration mode and adjusted in the RUN (Operation
or Service) mode. The Proportional and Integral Gain and the Derivative Ratio dynamic adjustments are
available under found under Dynamics pages for each controller (SPEED, CASC, AUX, and AUX2). To
adjust the gain settings, the In-Focus highlighter must be on the component value to tune. The In-Focus
highlighter is moved using the navigation Cross. The ADJUST UP and DOWN keys can then be used to
adjust the function In-Focus.

Figure 5-28. Speed Dynamics Adjustment Screen

The Speed, Cascade, Auxiliary and Auxiliary 2 controls are PID controllers. The response of each control
loop can be adjusted by selecting the dynamics mode as described above. Proportional gain, integral
gain (stability), and DR (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)

Tuning P & I Gains

Proportional gain must be tuned to best respond to a system transient or step change. If system response
is not known, a typical starting value is 5%. If proportional gain is set too high, the control will appear to
be overly sensitive, and may oscillate with a cycle time of less than 1 second.

Integral gain must be tuned gain for best control at steady state. If system response is not known, a
typical starting value is 5%. If the integral gain is set too high, the control may hunt or oscillate at cycle
times of over 1 second.

For best response the proportional gain and integral gain should be as high as possible. To obtain a
faster transient response, slowly increase the proportional gain setting until the actuator or final driver
output begins to oscillate or waver. Then adjust the integral gain as necessary to stabilize the output. If
stability cannot be obtained with the integral gain adjustment, reduce the proportional gain setting.

A well-tuned system, when given a step change, should slightly overshoot the control point then come
into control.

A PID control loop’s gain is a combination of all the gains in the loop. The loop’s total gain includes
actuator gain, valve gain, and valve linkage gain, transducer gain, internal turbine gains, and the 505’s
adjustable gains. If the accumulated mechanical gain (actuators, valves, valve linkage, etc.) is very high,
the 505’s gain must be very low to be added to the system gain required for system stability.

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In cases where a small change in the 505's output results in a large speed or load change (high
mechanical gain) it may not be possible to take the 505's gains low enough to reach stable operation. In
those cases, the mechanical interface (actuator, linkage, servo, valve rack) design and/or calibration
should be reviewed and changed to achieve a gain of one where 0–100% 505 output corresponds to 0–
100% valve travel.

Dual Dynamics (Speed/Load)

The Speed PID has two sets of dynamics, On-Line and Off-Line; each include Proportional Gain, Integral
Gain, and Derivative Ratio (DR) variables. There are three cases that determine when the dynamics
switch between On-Line and Off- Line:
 A “Select On-Line Dynamics” contact input is programmed
 Unit is driving a generator
 Unit is driving a mechanical drive (not a generator)

If a contact input is programmed to “Select On-Line Dynamics”, it has priority regardless of the driven
device. When the contact is closed, On-Line dynamics are selected; when open, Off-Line dynamics are
selected.

If the unit is driving a generator and no “Select On-Line Dynamics” contact input is programmed, the
Speed Off-Line dynamics are used by the Speed PID when the generator or utility tie breaker contacts
are open. The speed On-Line dynamics are used by the speed PID when the generator and utility tie
breaker contacts are closed. If the speed dynamics select contact is programmed, the generator and
utility tie contacts do not affect the dynamics selection.

If the unit is not driving a generator and no “Select On-Line Dynamics” contact input is programmed, the
Speed Off-Line dynamic settings are used when the turbine speed is below minimum governor speed;
On-Line dynamics are used if the turbine speed is above minimum governor speed. If the speed
dynamics select contact is programmed, the turbine speed does not affect the dynamics selection.

A relay can be programmed to indicate that the On-Line Dynamics mode is selected.

Cascade/Auxiliary Droop
The Cascade and Auxiliary (1 & 2) controllers can be programmed to use droop for control loop stability.
If the parameter being controlled (Cascade or Auxiliary) is also being controlled by another device
(letdown station, boiler, or other turbine), droop is typically required for control loop stability. If required,
no less than 5% droop is recommended for stable operation.

Tuning Derivative
The value of the Derivative Ratio (DR) term can range from 0.01 to 100. If unsure of the correct value, set
the Speed control’s DR term to 5% and the Aux & Cascade controllers’ DR terms to 100%. In order to
simplify adjustment of the dynamics, 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. (at start-up,
during a full load change, or during transfer of control from another channel).

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An input dominant controller is more sensitive to the change-of-rate of its input (Speed, Cascade in or
Auxiliary in), and can therefore prevent overshoot of the set point better than a feedback dominant
controller. Although this response is desirable during a start-up 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-of- rate of its feedback
(LSS). A feedback dominant controller can limit the rate of change of the LSS bus when a controller is
near its set point 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.

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 start-up 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 (Ziegler Nichols, etc.).

Figure 5-28 shows the typical response to a load change when the dynamics are optimally adjusted.

Figure 5-29. Typical Response to Load Change

For additional information on PID settings, refer to Volume 2.

Automated PID Dynamic Optimizer

The Automated PID Dynamic Optimizer is a routine which allows the control to automatically analyze the
system and calculate the P, I, and D terms. The PID Optimizer routine can be initiated from the controller
Dynamics Optimizer screen and will provide reasonable and stable results. To calculate optimized system
dynamics, small and progressively larger adjustments are made to the valve demand in order to measure
the turbine system. The optimizer routine remains within user specified process and valve movement
limits to ensure that the turbine system remains within acceptable operating limits.

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By running the PID Optimizer, the resulting dynamics provide the following benefits:
1) Improved system response to events such as load changes and load rejection
2) Tighter control at the setpoint
3) Response behavior which matches the control loop and application (offline speed control vs load
control, etc)
4) Improved system diagnostics. The routine provides insight into turbine system control problems
outside of PID tuning and can help to identify them. Some examples include:
a. Non-Linear turbine response due to poppet staging or slew rate limited valve response
b. High system dead-time
c. High signal noise
d. Response time variation due to high system friction, loose linkage or coupling, varying
hydraulic pressure, or varying steam conditions.

Figure 5-30. Overview of the Automated PID Optimizer Routine

The Dynamics Optimizer screen is shown above. The current status is overviewed on the left-hand side of
the screen and results are given on the right. The menu bar on the bottom of the screen contains buttons
which allow the configuration and operation of the Optimizer routine.

The process of finding optimized system dynamics includes two modes: first the analysis mode and then
the setpoint step mode. The trend below gives an overview of the entire Optimization routine. The
actuator demand is given in yellow, speed setpoint in white, and speed in red. The left portion of the trend
is the Analysis Mode. The right portion of the trend is the Setpoint Step Mode.

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Figure 5-31. Optimization Routine Overview Trend

Analysis Mode
During the Analysis Mode, the optimizer begins by making small actuator movements which progressively
increase until the measured process signal movement can be differentiated from signal noise. The initial
movement direction (up or down) depends on system conditions. Once there is enough process signal
movement, the optimizer begins moving the actuator up and down until the process signal moves beyond
the +/- the threshold values (calculated from signal noise) and performs the system analysis to calculate
gains.

On the front panel, the status will progress through the following steps during the Analysis Mode:
 OPID Enabled/Settling
 Analysis Movement
 Movement to Thresholds
 Calculating Gains

Setpoint Step Mode

Once new gains have been calculated for P, I, and D the PID will control at the setpoint using the newly
calculated gains. The routine then performs setpoint step tests to validate the system response.

During the Setpoint Step Mode there are 4 setpoint step tests:
1) Step the setpoint up or down (amount depends on system noise, but less than the Process Limit
configured). Whether it moves up or down depends on the sign of the Process Limit.
2) Step the setpoint back to the initial setpoint
3) Step the setpoint by a higher amount than the first setpoint step test
4) Step the setpoint back to the initial setpoint

At any stage in this mode, if a fault occurs, the optimizer will abort and change the PID gains from the
calculated values back to the initial values.
On the front panel, the status will progress through the following steps during the Setpoint Test Mode:
 Settling at Setpoint
 Step Tests with OPTI Gains
 System Settling
 Complete – Using New Gains

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Once the routine is complete, the new gains can either be accepted by pressing the ‘Accept’ button within
the Test Menu at the bottom of the screen. Alternatively, the gains can be rejected by pressing the ‘Reset
Test’ button at the bottom of the screen, and the PID gains will change back to the initial values. If
accepted, the current dynamics (offline or online, depending on the current operating mode) will be
updated to the calculated values and the optimizer will reset.

Configuring the Automated PID Optimizer

The configuration parameters are provided in the ‘Configure’ pop-up. The defaults for these values should
allow most systems to successfully optimize. If needed, adjustments can be made to these values to
ensure that the automatic tuning completes successfully. Changing any of these values while the
Optimizer test is running will cause the test to fault and abort.

Figure 5-32. Configuration Parameters ‘Configure’ Pop-up

Process Limit (%) dflt= 2.0 (0.0, 10.0)

This value limits the process signal movement allowed. If movement occurs during automatic tuning that
is more than this value, the Automated PID Optimizer routine will abort and control at the initial SP. This
value should be set based on what the system can tolerate. If it is too low, the automatic tuning process
may fault and abort due to normal process changes. The limit is centered around the current process
value at the time the optimizer is enabled.

For example, if the PID Optimizer is calculating Speed PID gains, and the Process Limit is 2% and
current speed signal is 3600RPM
Upper Process Movement Limit: 3600 + 2% = 3672 RPM
Lower Process Movement Limit: 3600 – 2% = 3528 RPM
If the turbine speed moves outside of the Upper Process Movement Limit or Lower Process Movement
Limit, the PID Optimizer routine will be aborted.

Act Limit (offline) (%) dflt= 8.0 (0.0, 100.0)

This value limits how much the actuator demand will move during the Analysis Mode when the turbine is
using Offline dynamics. The percentage will limit the output +/- from the actuator position when the
optimizer is enabled. The optimizer will not abort if this limit is reached, but an alarm will be annunciated.

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Act Limit (online) (%) dflt= 10.0 (0.0, 100.0)
This value limits how much the actuator demand will move during the Analysis Mode when the turbine is
using Online dynamics. The percentage will limit the output +/- from the actuator position when the
optimizer is enabled. The optimizer will not abort if this limit is reached, but an alarm will be annunciated.

Droop Limit (%) dflt= 10.0 (0.0, 50.0)

This value limits the Droop signal movement allowed when using generator load droop. If movement
occurs during automatic tuning that is more than this value, the Automated PID Optimizer routine will be
aborted and control at the initial SP. This value should be based on what the system can tolerate. If it is
too low, the automatic tuning process may fault and abort, due to normal process changes. The limit is
centered around the current Droop value at the time the optimizer is enabled.

For example, if the PID Optimizer is calculating Speed PID gains in Droop mode, and the Process Limit
is 10% and the current kW signal is 50% of Max Load
Upper Droop Process Movement: 50% + 10% = 60% of Max Load
Lower Droop Process Movement: 50% - 10% = 40% of Max Load
If the generator load signal moves outside of the upper or lower limit, the PID Optimizer routine will be
aborted.
It is not necessary to run the PID Optimizer if using Valve Droop.

Response Timeout (sec) dflt= 5.0 (0.005, 100.0)

This value determines how long the PID Optimizer will wait for a response during the automatic tuning
process. This value should be at least 2 times longer than the system slew and settling time. During the
Setpoint Step Mode, this value determines the step times and times between steps. A fault and abort will
occur if the total PID optimizer time exceeds a value of 40 times the Response Timeout.

PID Type dflt= PID (P, PI, PID)

This setting determines the mode of the PID controller and allows the automatic tuning of the appropriate
control loop.
 P = Proportional Only
o P Term Calculated
o I Term 0
o D Term is 0.01 if D is less than 1 or 100 if D is greater than 1
 PI = Proportional and Integral
o P Term Calculated
o I Term Calculated
o D Term is 0.01 if DR is less than 1 or 100 if DR is greater than 1
 PID = Proportional, Integral, and Derivative
o P Term Calculated
o I Term Calculated
o D Term Calculated

In addition, even if automatic tuning mode is not enabled, if this is set to P, the PID will switch to a
proportional controller. Note that selecting PI will not switch the PID to a PI controller, this is done by
changing S_D_R.

Fast/Slow dflt= 50 (0, 100)

This value allows for the calculated system response to be more or less aggressive. If faster response
time is needed, this value should be increased. If slower response time is needed, this value should be
decreased.

System Diagnostics
The Automated PID Optimizer has alarm and fault codes that can be generated at various stages. An
alarm being generated will not abort the optimizer and does not mean that the calculated gains are
unreliable. Alarms are given to indicate response conditions that are less than ideal, but might be
acceptable, the user should monitor the response to decide. A fault will abort the Automated PID
Optimizer routine and indicates that reliable gains could not be calculated.

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Most of the time, an alarm or fault indicates a problem with the steam turbine system that is outside of
PID tuning. The descriptions below help identify what in the system may be causing the less-than-ideal
control conditions. In some cases, suggestions to the Automated PID Optimizer configuration are
included, to try and achieve successful automatic tuning.

Alarms
Alarm 1 - Rate group not fast enough
This alarm indicates that the rate group of the block is not fast enough to provide optimum control for the
control loop, as measured. The rate group should be at least 20 times as fast as the system response.

Some causes of this alarm could be:

 The process loop (like speed) controlled by the PID is too fast for the rate group (RG) of PID
 If the control loop is position droop, the problem may be that there is no lag or other filter on the
between the PID output and the process input.

Some solutions for this alarm could be:

 If it is not possible to change the rate group, the second solution would be to accept the suggested
dynamics if adequate, or detune the PID
 If there is no lag or other filter on the between the PID output and the process input for position droop,
the solution would be to add a lag.

Alarm 2 – High overshoot on test step

This alarm indicates that the overshoot on the test step was greater than 50% of the step size. The
performance might be acceptable, depending on the system.

Some causes of this alarm could be:

 The valve or turbine response is non-linear. This could occur due to:
 Poppet valve staging, resulting in higher flow with the larger movement of the step, and lower flow
with the earlier smaller movements.
 The actuator or valve response is slew rate limited

If the amount of overshoot were unacceptable, some solutions would be:

 Verify that the poppet valve staging is correct.
 If the poppet valve staging cannot be fixed, the turbine operating point could be adjusted (i.e. the
speed (process) and speed setpoint (SP) could be increased) to tune at the higher/lower flow point.
 The FAST/SLOW input may need to be reduced, to achieve the desired response.

Alarm 4 – Response to test step sluggish

The test step response did not reach 50% of the setpoint during the test step, the response was sluggish.
The performance might be acceptable, depending on the system demands.

Some causes of this alarm could be:

 The valve or turbine response is non-linear. This could occur due to:
 Poppet valve staging, resulting in higher flow with the lower movement of the step, and higher flow
with the earlier smaller movements.
 The actuator or valve response is slew rate limited
 The process or sensor has a long deadtime
If the speed or the response is unacceptable, some solutions would be:
 Verify that the poppet valve staging is correct.
 If the poppet valve staging can’t be fixed, the turbine operating point could be adjusted (i.e. the speed
(process) and speed setpoint (SP) could be increased) to tune at the higher or lower flow point.
 The FAST/SLOW input could be increased, to achieve the desired response.

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Alarm 8 - Actuator movement is limited
This alarm indicates that the actuator movement was limited during the Analysis Mode. This can result in
a response that is not optimum, depending on the system conditions.

Some causes of this alarm could be:

 The Act Limit input is too low
 The valve or actuator is close to its end of travel, limiting movement or effect.

If the response is not acceptable, some solutions would be:

 If the response is not acceptable, the Act Limit could be increased
 The system operating point could be moved away from the ends of the actuator and valve travel. This
would mean increasing or decreasing the SP input to the block.

Alarm 16 – High relative deadtime

This alarm indicates high deadtime in the system, relative to the system bandwidth. Deadtime is typically
measured on a step and is defined as the amount of time between when the SP starts to move, and when
the process starts to move.

Some causes of this alarm could be:

 High friction on the valve or actuator
 Lost motion on the valve or actuator or linkage
 Hysteresis in the valve or actuator
 Long lines, such as a pressure transducer or other transducer not located near the pressure of
interest.
 A relatively slow recursion rate in the sensor, control, and/or driver
 Asynchronous I/O in the sensor, control, and/or driver
 Asynchronous communications between the sensor and control or control and driver (if digital)

Some solutions for this alarm could be:

 With an oscilloscope, datalog, or logic analyzer, measure the system deadtimes.
 The optimum solution to this problem would be to fix the system and remove the deadtime. If that is
not possible, the control should be de-tuned, to ensure adequate stability.

Alarm 32– Process movement greater than Droop movement during Droop parameter tuning
This alarm indicates that the movement of the process parameter exceeded the movement of the Droop
parameter during droop tuning.

Some causes of this alarm could be:

 Improper connections in the GAP. The process (speed) should be connected to the process input,
and the droop parameter (load, scaled in RPM) should be connected to the Droop input
 The amount of initial actuator movement is set by the system noise. If this is too high the machine
might move more than the system can support.
 The utility or plant frequency could be moving around.
Some solutions for this alarm could be:
 Ensure that the block is connected correctly.
 Reduce system noise.
 Ensure that the Act Limit field is set correctly.

Alarm 64– Response Timeout too short

This alarm indicates that the movement of the system did not respond enough during the Response
Timeout.

Some causes of this alarm could be:

The Response Timeout is too short for the turbine system response time

Some solutions for this alarm could be:

Increase Response Timeout.

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Faults
Fault 1 – CLR_STATE was toggled TRUE
This fault will only occur if the CLR_STATE input is toggled TRUE
Some causes of this fault could be:
The CLR_STATE input was toggled TRUE
This can occur when system dynamics are changed from Offline to Online

Some solutions for this fault would include:

Ensure that the CLR_STATE logic is correct, CLR_STATE has priority over automatic tuning.

Fault 2 – Process or droop movement limit low with respect to noise

This fault indicates that the process/droop movement (or noise on the process/droop input) is greater than
10% of the Process Limit or Droop Limit during the first seconds after the Automated PID Optimizer
routine is enabled. This is usually due to noise or drift on the process or droop input.

Some causes of this fault could be:

 The Response Timeout is too long, the PID can't increase the output movement fast enough to
counteract system drift.
 The noise or system swing on the process/droop input is greater than 10% of the Process Limit
and/or Droop Limit.
 The system isn’t at steady state. As an example, if the Integral Gain input is low, there could be a
large error between process and setpoint.

Some solutions would include:

 Decrease Response Timeout if the system is much faster than the time-out time.
 Proportional Gain could be adjusted to make the system stable, if applicable.
 Integral Gain could be adjusted to allow system to minimize error and/or slow hunt, if applicable.
 The Process Limit or Droop Limit could be increased, if the system allows.
 Check for excessive noise on process or droop signal, check shielding and grounding on the
applicable sensors and actuator(s).

Fault 3 – High response time variation

This fault indicates that the response variation exceeded the allowable limit. This fault will occur if the
response time variation is greater than a factor or 4, tuning would be unrepeatable.

Some causes of this fault could be:

 The system has high friction, resulting in initial movements which are lower than later movement,
after the actuator or valve has broken free
 The system has loose linkage or coupling, sometimes the system moves a lot, and sometimes it
doesn’t.
 The hydraulic pressure is moving during the tuning process.
 The steam supply pressure is moving during the tuning process.

Some solutions for this fault would include:

 Monitor the performance of the system, including the valve, steam pressure, hydraulic pressure, etc.
 Use a datalog to verify proper I/O to the PID

Fault 4 – Process movement didn’t correlate to actuator movement

This fault indicates that the response did not correlate to the actuator movement.

Some causes of this fault could be:

The hydraulic pressure or steam supply is moving during the tuning process, if the actuator demand
is increasing but the supply is dropping, the actuator could close, or vice versa.

Some solutions for this fault would include:

 Monitor the performance of the system, including the valve, steam pressure, hydraulic pressure, etc.
 Use a datalog to verify proper I/O to the PID

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Fault 5 – Process movement greater than Process Limit
This fault indicates that the process input exceed the Process Limit.

Some causes of this fault could be:

 The Response Timeout is too long, the PID can't increase the output movement fast enough to
counteract system drift.
 The system isn’t at steady state. As an example, if the Integral Gain input is relatively low, there could
be a large error between process and setpoint.
 The Process Limit is too low
 The Act Limit is too high, resulting in actuator movements that are too large for the Process Limit
(this is unlikely).

Some solutions for this fault would include:

 Decrease Response Timeout if the system is much faster than the time-out
 Proportional Gain could be adjusted to make the system stable, if applicable.
 Integral Gain could be adjusted to allow system to minimize error and/or slow hunt, if applicable.
 Process Limit could be increased, if the turbine system allows
 Check for excessive noise on the process input, check shielding and grounding on the applicable
sensors and actuator(s).

Fault 6 – Optimizer time-out

This fault indicated that the optimizer time exceeded the allowable time-out time, of 40 times the specified
Response Timeout, or 20 cycles of movement.

Some causes of this fault could be:

 The Act Limit is too low, this is the most common cause of this fault
 The Response Timeout is too short for the process input response.
 The system response is restricted, by low steam pressure, a partially closed trip and throttle valve,
etc.
 The valve or actuator is against a stop or at the end of its travel, not allowing the PID to control the
process completely.
Some solutions for this fault would include:
 The Act Limit could be increased.
 The Response Timeout could be increased, if the system was still increasing/decreasing at the time-
out times.
 The operating point (Setpoint) could be adjusted, if an actuator or valve is close to the end of its
travel.
 The system variables should be checked, ensure that inlet pressure is high enough, hydraulic
pressure is high enough, the trip and throttle valve is open, etc.

Fault 7 – Droop input movement, greater than limit.

This fault indicates that the Droop input exceeded its allowable movement, similar to fault 5 for the
process input.

Some causes of this fault could be:

 The Response Timeout is too long, the PID can't increase the output movement fast enough to
counteract system drift.
 There is noise on the Droop input
 The system isn’t stable, the Droop input is moving around too much with respect to the Droop Limit
input.
 The system isn’t at steady state. As an example, if the Integral Gain input is relatively low, there could
be a large error between process+droop and setpoint.
 The Droop Limit is too low.
 The Act Limit is too high, resulting in actuator movements that are too large for the Droop Limit (this
is unlikely).

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Some solutions for this fault would include:
 Decrease Response Timeout if the system is much faster than the time-out
 Check the Droop input for noise and for the correct level.
 Proportional Gain could be adjusted to make the system stable, if applicable.
 Integral Gain could be adjusted to allow system to minimize error and/or slow hunt, if applicable.
 Droop Limit could be increased, if system allows.
 Check for excessive noise on Droop input, check shielding and grounding on the applicable sensors
and actuator(s).

Faults 8 through 20 – Input or System status change occurred during the Automatic Tuning routine.
Input conditions and System status are monitored while the optimizer is active to detect changes that
could invalidate the results of the tuning routine.

Fault 16
A copy of the S_D_R input is made when the optimizer is started and is used to detect if the S_D_R input
value crosses 1.0 in either direction. For example, this fault will be annunciated if S_D_R is 0.5 when the
optimizer is started and subsequently S_D_R changes to 1.1 while the optimizer is active. Similarly, this
fault will also be annunciated if S_D_R transitions from greater than 1.0 to less than 1.0 while the
optimizer is active

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Chapter 6.
Communications

Modbus Communications
The 505 control can communicate with plant distributed control systems and/or CRT based operator
control panels through Modbus communication ports. There is one serial port that supports RS-232 and
RS-485 communications using ASCII or RTU MODBUS transmission protocols. There are 2 ports
available for either Modbus UDP or TCP/IP protocol which can be utilized from Ethernet port 1 or 2.
Modbus utilizes a master/slave protocol. This protocol determines how a communication network’s master
and slave devices establish and break contact, how a sender is identified, how messages are exchanged,
and how errors are detected.

Our experience has been that not all serial interfaces on laptops or
Desktop PCs work the same. Many USB-to-Serial converters work,
but some do not.

To use a 505 Modbus port to monitor and/or operate, check the “Use Modbus” checkbox under the
Configurations menu / Communications page.

Monitor Only
The three Modbus communication ports are defaulted as read-only. As read-only ports, the 505 can be
monitored but not controlled from an external device. By simply connecting a monitoring device,
configured to communicate through Modbus, and to the 505’s defaulted protocol settings (parity, stop bits,
etc.), this device can be used to monitor all the 505’s controlling parameters, modes, etc. without affecting
control.

Configuration of the protocol is found on the Communications page under both the Configuration and
Service menus. There are options for the serial settings, slave address number and a checkbox to enable
write commands.

Monitor and Control

Once a Modbus port is configured within the 505’s Configuration mode, the 505 will accept RUN mode
commands from an external network master device (DCS, etc.). This allows a Modbus compatible device to
monitor and perform all 505 RUN mode parameters and commands except for the Overspeed Test enable,
On- Line/Off-Line Dynamics select, and Override Failed Speed Signal commands.

Each Modbus port is independent of the other and can be used simultaneously. Each only must have its
own slave device address and each has its own enable write checkbox. The last command given from
any of the ports has priority or is the mode or function selected.

Modbus Communication
The 505 control supports two Modbus transmission modes. A mode defines the individual units of
information within a message and the numbering system used to transmit the data. Only one mode per
Modbus network is allowed. The supported modes are ASCII (American Standard Code for Information
Interchange), and RTU (Remote Terminal Unit). These modes are defined in the following table.

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Table 6-1. ASCII vs RTU Modbus

Characteristic ASCII RTU

Coding System hexadecimal (uses ASCII 8-bit binary
printable binary characters: 0-9,
A-F)
Start Bits 1 1
Data Bits per Char 7 8
Parity even, odd, or none even, odd, or none
Stop Bits 1, 1.5, or 2 1, 1.5, or 2
Baud Rate 110, 300, 600, 1200, 1800, 110, 300, 600, 1200, 1800,
2400, 4800, 9600, 19200, 2400, 4800, 9600, 19200,
38400, or 57600 38400, or 57600
Error Checking LRC (Longitudinal Redundancy CRC (Cyclical Redundancy
Check) Check)

In the RTU mode, data is sent in 8-bit binary characters and transmitted in a continuous stream. In the
ASCII mode, each binary character is divided into two 4-bit parts (high order and low order), changed to
be represented by a hexadecimal equivalent, then transmitted, with breaks of up to 1 second possible.
Because of these differences, data transmission with the ASCII mode is typically slower (see Figure 6-1
below).

Figure 6-1. ASCII/RTU Representation of three

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

The 505 control is programmed to function as a slave unit only. As a slave unit, the 505 will only respond to
a transaction request by a master device. The 505 can directly communicate with a DCS or other Modbus
supporting devices on a single communications link, or through a multi-dropped network. If multi-dropping is
used, up to 246 devices (505s or other customer devices) can be connected to one Master device on a
single network. The control address is programmed under the 505’s communications block and can be
changed in the service mode, if needed.

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Each message to or from a master has a defined structure called the message “frame”. A frame consists
of the slave device address, a code defining the requested data, and error checking information. See
Table 6-2.

Table 6-2. Modbus Frame Definition

Beginning Slave Function Data Error End of

of Frame Address Code Check Frame
Code
: 2 CHARS 2 CHARS 4 BITS 2 CHARS CR LF
ASCII 8 BITS 8 BITS DATA PER 8 BITS
CHAR

3-CHAR 1 CHAR 1 CHAR 8 BITS 2 CHAR 3 CHAR

RTU DEAD TIME 8 BITS 8 BITS DATA PER 16 BITS DEAD TIME
CHAR

The Modbus function code tells the addressed slaves what function to perform. The following table lists
the function codes supported by this control.

Table 6-3. Modbus Function Codes

Code Definition Reference Address

01 Read Digital Outputs (Raise/Lower and Enable/Disable
0XXXX
Commands)
02 Read Digital Inputs (Status Indications/Alarms and Trips) 1XXXX
03 Read Analog Outputs 4XXXX
04 Read Analog Inputs (Speed, Setpoint, etc.) 3XXXX
05 Write Single Discrete Output (Raise/Lower and Enable/Disable
0XXXX
Commands)
06 Write Single Register (Enter Setpoint Directly) 4XXXX
08 Loopback Diagnostic Test (Subfunction 0 only) N/A
15 Write Digital Outputs 0XXXX
16 Write Analog Outputs 4XXXX

When a Modbus message is received, it is checked for any errors or invalid data. If there is invalid data in
the message, an error code is sent back to the master and the control issues an alarm message. The
error codes are defined in the following table. The exception error status and respective error codes can
be viewed on the Communication pages under the Service Menu.

If the control has not received a message for the configured time-out period, the control will alarm with an
error message, but no message is sent to the master. This time-out is defaulted to 2 seconds and only
applies to units using both monitor and control (adjustable through the Service Menu).

Modbus Slave Exception Error Codes

Table 6-4. Modbus Error Codes

Error Error Code Sent

Code Message To Master Description
0 No Error 0 No Error
1 Bad Modbus function 1 The specified function is not supported for this control.
2 Bad Modbus data address 2 The Modbus value addressed is not valid for this control.
3 Bad Modbus data value 3 Too many values requested or the on/off indicator in
function code 5 is invalid.
9 Bad Modbus checksum None Message checksum did not match.
10 Bad Modbus message None Message could not be decoded.
N/A Lost Modbus link None No messages received for the configured time-out period
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Port Adjustments
Before the 505 will communicate with the master device, the communication parameters must be verified.
These values are set in the Configure Mode and can be adjusted, if required, from the Service Mode.

Table 6-5. Modbus Communication Port Adjustments

Parameter Adjustment Range

Baud Rate 110 TO 57600
Parity NONE, ODD or EVEN
Stop Bits 1 TO 2
Driver RS-232, RS-422, or RS-485

505 Control Modbus Addresses

The Modbus communication ports in the 505 control are programmed for unique Modbus addresses. A
complete listing of these addresses for your application is located at the end of this section in the manual. The
Modbus address listing consists of Boolean Writes, Boolean Reads, Analog Reads, and Analog Writes. The
Boolean reads and writes are also referred to as input and holding coils. The analog reads and writes are also
referred to as input registers and holding registers.

All values that can be addressed by Modbus are discrete and numeric. The discrete values are a 1-bit
binary, on or off value and the numerics are 16-bit values. Discrete values are sometimes referred to as
coils or digitals and numerics are referred to as registers or analogs. All read/write registers are
interpreted by the 505 as signed 16-bit integer values. Since Modbus can only handle integers, values
that require a decimal point in the Modbus Master Device are multiplied by a scaling constant before
being sent by 505. See Tables 6-7 and 6-8 for defaulted communication constants and ranges.

The maximum number of discretes and registers that can be transmitted in one packet is dependent on
each implementation of Modbus. The following table defines these limits.

Table 6-6. Maximum Modbus Discrete and Analog Values

Mode Of Max Discretes Max Registers

Transmission
ASCII 944 59
RTU 1188 118

Boolean Writes (Holding Coils)

Holding coils are logical signals that are both readable from and writable to the 505 control. An example
of a Boolean write value would be raise or lower commands. A logical true denoted by the value 1 will
cause the command listed in the description to be executed. For example, if a 1 is written to address
0:0010 and this corresponded to a speed raise command, the manual speed set point will increase until a
0 is written to address 0:0010. The 505 control supports function codes 1, 5, and 15. These correspond to
reading selected holding coils, writing to a single holding coil, and writing to multiple holding coils,
respectively. The holding coils available are listed in Table 6-5.

Boolean Reads (Input Coils)

Input coils are logical signals that are readable from, but not writable to, the 505 control. An example of a
Boolean read value would be a turbine trip status indication. The input coil will have the value 1 if the
statement in the description column is true and a 0 if false. The `1:’ term in the address identifies an input
coil. The 505 control supports Modbus function code 2, which involves reading selected input coils. The
input coils available are listed in Table 6-6.

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Analog Reads (Input Registers)

Input registers are analog values that are readable from, but not writable to, the 505 control. An example
of an analog read value would be turbine speed. The values of the input registers are stored internal to
the control as floating point numbers representing engineering units (kPa or rpm). The values that are
transmitted are integer values ranging from -32767 to +32767. Since Modbus can only handle integers,
values that have a decimal point are multiplied by a constant before being sent by Modbus. For example,
these input registers may be listed as the Modbus value `x100’ or `x10’ under the description heading to
denote the value is multiplied by a scaling constant. This will allow transmission of decimal parts of a unit
if this is necessary for better resolution.

See the 505 Service mode for defaulted communication constants and ranges. The 505 control supports
Modbus function code 4, which involves reading selected input registers. The input registers available are
listed in Table 6-7.

Analog Writes (Holding Registers)

Holding registers are analog values that are writable to the 505 control. These values can also be read
from by a device performing error checking. An example of an analog write value would be a direct speed
set point value as opposed to raise and lower commands. The value of the holding registers are also
stored in the control as numbers representing engineering units (psi or rpm). The 505 control supports
Modbus function codes 3, 6, and 16. These correspond to reading selected holding registers, writing to a
single holding register, and writing to multiple holding registers, respectively. The holding registers
available are listed in Table 6-8.

The following tables give the address and description of all Boolean and analog, reads and writes:

Table 6-7. Boolean Write Addresses

Addr Description Addr Description

0:0001 Emergency Shutdown 0:0055
Emergency Shutdown
0:0002 0:0056
Acknowledge
0:0003 Controlled Shutdown 0:0057
0:0004 Abort Controlled Shutdown 0:0058
0:0005 System Reset 0:0059
0:0006 Start / Run 0:0060
0:0007 Manual Open VLV Limiter 0:0061
0:0008 Manual Close VLV Limiter 0:0062
0:0009 Lower Speed Setpoint 0:0063
0:0010 Raise Speed Setpoint 0:0064
0:0011 Go To Rated (Idle / Rated) 0:0065
0:0012 Go To Idle (Idle / Rated) 0:0066
0:0013 Halt Auto Start Seq 0:0067
0:0014 Continue Auto Start Seq 0:0068
Enable Remote Speed Setpoint
0:0015 0:0069
Control
Disable Remote Speed Setpoint
0:0016 0:0070 * Enable Droop Setpoint change
Control
Go To Modbus Entered Speed
0:0017 0:0071 * Disable Droop Setpoint change
Setpt
0:0018 Spare 0:0072 * Enable Speed Forwarding

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Addr Description Addr Description

0:0019 Arm Frequency Control 0:0073 * Disable Speed Forwarding
0:0020 Disarm Frequency Control 0:0074
0:0021 Sync Enable 0:0075 Momentarily Energize Relay 2
0:0022 Sync Disable 0:0076 Momentarily Energize Relay 3
0:0023 Enable Cascade Control 0:0077 Momentarily Energize Relay 4
0:0024 Disable Cascade Control 0:0078 Momentarily Energize Relay 5
0:0025 Lower Cascade Setpoint 0:0079 Momentarily Energize Relay 6
0:0026 Raise Cascade Setpoint 0:0080 Momentarily Energize Relay 7
Enable Remote Cascade Setpoint
0:0027 0:0081 Enable Aux 2 Control
Control
Disable Remote Cascade
0:0028 0:0082 Disable Aux 2 Control
Setpoint Control
Go To Modbus Entered Cascade
0:0029 0:0083 Lower Aux 2 Setpoint
Setpt
0:0030 Spare 0:0084 Raise Aux 2 Setpoint
0:0031 Enable Aux Control 0:0085 Enable Remote Aux 2 Setpoint Control
0:0032 Disable Aux Control 0:0086 Disable Remote Aux 2 Setpoint Control
Go To Modbus Entered Auxiliary 2
0:0033 Lower Aux Setpoint 0:0087
Setpt
0:0034 Raise Aux Setpoint 0:0088 Enable Remote KW Setpoint Control
Enable Remote Aux Setpoint
0:0035 0:0089 Disable Remote KW Setpoint Control
Control
Disable Remote Aux Setpoint
0:0036 0:0090 Isolated Controller SP Raise
Control
Go To Modbus Entered Auxiliary
0:0037 0:0091 Isolated Controller SP Lower
Setpt
0:0038 Spare 0:0092 Select Hot Start
Select Remote Ctrl
0:0039 0:0093 Select Cold Start
(Remote/Local)
0:0040 Select Local Ctrl (Remote/Local) 0:0094 Energize Relay 8
0:0041 Spare 0:0095 De-Energize Relay 8
0:0042 Modbus Alarm Acknowledge 0:0096 Momentarily Energize Relay 8
0:0043 Energize Relay 2
0:0044 De-Energize Relay 2
0:0045 Energize Relay 3
0:0046 De-Energize Relay 3
0:0047 Energize Relay 4
0:0048 De-Energize Relay 4
0:0049 Energize Relay 5
0:0050 De-Energize Relay 5
0:0051 Energize Relay 6
0:0052 De-Energize Relay 6
0:0053 Energize Relay 7
0:0054 De-Energize Relay 7

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Manual 26839V1 505 Digital Control for Steam Turbines
Table 6-8. Boolean Read Addresses

Addr Description Addr Description

1:0001 Alarm - MPU #1 Failed 1:0183 Inlet Pressure Configured
1:0002 Alarm - MPU #2 Failed 1:0184 Remote Control Configured
1:0003 Alarm - Cascade Input Failed 1:0185 Loadsharing Configured
1:0004 Alarm - Aux Input Failed 1:0186 HP2 Configured
1:0005 Alarm - KW Input Failed 1:0187 Gen Set Configured
1:0006 Alarm - Sync Input Failed 1:0188 Cascade Control Configured
1:0007 Alarm - Inlet Press Input Failed 1:0189 Remote Cascade Configured
1:0008 Alarm - Remote Speed Input Failed 1:0190 Aux Control Configured
1:0009 Alarm - Remote Cascade Input Failed 1:0191 Remote Aux Configured
1:0010 Alarm - Remote Aux Input Failed 1:0192 Enables Mod Port1 In Local
1:0011 Alarm - Loadshare Input Failed 1:0193 Start Permissive Configured
1:0012 Alarm - HP Actuator Failed 1:0194 Frequency Arm/Disarm Configured
1:0013 Alarm - HP2 Actuator Failed 1:0195 Frequency Control Configured
1:0014 Alarm - Start Permissive Not Met 1:0196 MPU 2 Configured
1:0015 Alarm - Communication Link #1 Failed 1:0197 Local/Remote Configured
1:0016 Alarm - Communication LInk #2 Failed 1:0198 Local Trip Enabled
1:0017 Alarm - Generator Breaker Open 1:0199 Casc Tracking Configured
1:0018 Alarm - Turbine Trip 1:0200 KW Signal OK
1:0019 Alarm - Tie Breaker Open 1:0201 * Spare E
1:0020 Alarm - Overspeed Alarm 1:0202 * Spare E
1:0021 Alarm - Tie Breaker Open / No Aux 1:0203 * Spare E
1:0022 Alarm - Gen Breaker Open / No Aux 1:0204 * Spare E
1:0023 Alarm - Tie Breaker Open / No Casc 1:0205 * Spare E
1:0024 Alarm - Gen Breaker Open / No Casc 1:0206 * Spare E
1:0025 Alarm - Tie Breaker Open / No Remote 1:0207 * TRUE = NEW 505 R
Alarm - Gen Breaker Open / No
1:0026 1:0208 FALSE = 505D, TRUE = 505XT
Remote
1:0027 Alarm - Stuck in Critical Alarm 1:0209 * External Alarm 7
1:0028 * Alarm - spare E 1:0210 * External Alarm 8
1:0029 * Alarm - spare E 1:0211 * External Alarm 9
1:0030 * Alarm - spare E 1:0212 IH-act1 Failed from BI
1:0031 * Alarm - spare E 1:0213 IH-act2 Failed from BI
1:0032 * External Alarm 1 1:0214 * Tunable ALM
1:0033 * External Alarm 2 1:0215 * IH-A Pressure Input Failed
1:0034 * External Alarm 3 1:0216 * AI FW Fault
1:0035 * External Alarm 4 1:0217 * Remote Droop fault
1:0036 * External Alarm 5 1:0218 * Hwr com1 fault
1:0037 * External Alarm 6 1:0219 SPARE
1:0038 CTC Alarm latch 1:0220 SPARE

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Addr Description Addr Description

1:0039 Modbus Alarm Acknowledge 1:0221 SPARE
Alarm Exists (Common Alarm
1:0040 1:0222 * Trip - External Trip 10
Indication)
1:0041 Trip - External Trip 1:0223 * SD HP max
1:0042 Trip - ESD Button 1:0224 SPARE
1:0043 Trip - Overspeed Trip 1:0225 SPARE
1:0044 Trip - Loss of Speed Signals 1:0226 SPARE
1:0045 Trip - HP Actuator Fault 1:0227 SPARE
1:0046 Trip - HP2 Actuator Fault 1:0228 * Tunable SD
1:0047 Trip - Aux Input Failed 1:0229 SPARE
1:0048 Trip - External Trip 2 1:0230 SPARE
1:0049 Trip - External Trip 3 1:0231 SPARE
1:0050 Trip - Modbus Link #1 Trip 1:0232 SPARE
1:0051 GAP Heartbeat (2 sec) 1:0233 Controlled Stop In Progress
1:0052 SPARE 1:0234 SPARE
1:0053 Trip - Tie Breaker Open 1:0235 SPARE
1:0054 Trip - Gen Breaker Open 1:0236 SPARE
1:0055 Trip - Power up 1:0237 SPARE
1:0056 Trip - Manual Stop 1:0238 SPARE
1:0057 Trip - External Trip 4 1:0239 SPARE
1:0058 Trip - External Trip 5 1:0240 * Spare
1:0059 SPARE 1:0241 * IH-B Pressure Input Failed
1:0060 * Trip - External Trip 6 1:0242 Alarm - AUX2 Input Failed
1:0061 * Trip - External Trip 7 1:0243 Alarm - Remote AUX2 Input Failed
1:0062 * Trip - External Trip 8 1:0244 Alarm - Remote KW Setpoint Failed
1:0063 * Trip - External Trip 9 1:0245 Alarm - Exhaust Press Input Failed
1:0064 Shutdown Exists (Trip Indication) 1:0246 SPARE
1:0065 Modbus ESD Acknowledge Enable 1:0247 Alarm - HP Valve Feedback Failed
1:0066 Moving to Min Setpoint 1:0248 Alarm - HP2 Valve Feedback Failed
1:0067 Ramping to Idle (Idle / Rated) 1:0249 Alarm - Isolated PID PV Failed
1:0068 Idle / Rated at Idle 1:0250 Alarm - Rem SP Isolated PID Failed
1:0069 Ramping to Rated (Idle / Rated) 1:0251 Alarm - Customer Input #1 Failed
1:0070 At Rated 1:0252 Alarm - Customer Input #2 Failed
1:0071 Auto Seq - Setpt at Idle 1 1:0253 Alarm - Customer Input #3 Failed
1:0072 Auto Seq - Ramp to Idle 2 1:0254 Alarm - Mod Comm Link #3 Failed
1:0073 Auto Seq - Setpt at Idle 2 1:0255 Alarm - AO_01 Readback Fault
1:0074 Auto Seq - Ramp to rated 1:0256 Alarm - AO_02 Readback Fault
1:0075 Auto Seq - At Rated 1:0257 Alarm - AO_03 Readback Fault
1:0076 Speed PID In Control 1:0258 Alarm - AO_04 Readback Fault
1:0077 Speed Sensor 1 Failed Override ON 1:0259 Alarm - AO_05 Readback Fault

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Addr Description Addr Description

1:0078 Speed Sensor 2 Failed Override ON 1:0260 Alarm - AO_06 Readback Fault
1:0079 Overspeed Test Permissive 1:0261 Alarm - Chassis Temp
1:0080 Overspeed Test In progress 1:0262 Alarm - HP Valve Pos Fdbk Diff
1:0081 Speed At or above Min Gov 1:0263 Alarm - HP2 Valve Pos Fdbk Diff
1:0082 Turbine In Critical Speed Band 1:0264 Alarm - Limiter in Control
1:0083 Remote Speed Setpt Is Enabled 1:0265 Alarm - Inlet Steam Pressure Lvl1
1:0084 Remote Speed Setpt Is Active 1:0266 Alarm - Inlet Steam Pressure Lvl2
1:0085 Remote Speed Setpt Is In Control 1:0267 Alarm - Exh Steam Pressure Lvl1
1:0086 Remote Speed Setpt Is Inhibited 1:0268 Alarm - Exh Steam Pressure Lvl2
1:0087 * Spare E 1:0269 Alarm - Selected PV 1 Level 1
1:0088 Auto Seq - at idle 3 1:0270 Alarm - Selected PV 1 Level 2
1:0089 Turbine Started/Running 1:0271 Alarm - Selected PV 2 Level 1
1:0090 Generator Breaker Closed 1:0272 Alarm - Selected PV 2 Level 2
1:0091 Utility Tie Breaker Closed 1:0273 Alarm - Selected PV 3 Level 1
1:0092 Synchronizing Rate Selected 1:0274 Alarm - Selected PV 3 Level 2
1:0093 Synchronizing Is Enabled 1:0275 Alarm - Tunable Alarm
1:0094 Sync or Load Share Is In Control 1:0276 Alarm - Tie Open / No Auxiliary 2
1:0095 Sync / Load Share Is Inhibited 1:0277 Alarm - Gen Open / No Auxiliary 2
1:0096 Unit has Started (Off once Idle reached) 1:0278 Alarm - Actuator 1 Readout Fault
1:0097 Frequency Control Armed 1:0279 Alarm - Actuator 2 Readout Fault
1:0098 Frequency Control 1:0280 Alarm - CAN1_DVP1 Summary ALM
1:0099 * Reset 1:0281 Alarm - CAN1_DVP2 Summary ALM
1:0100 Cascade Is Enabled 1:0282 Alarm - HP Actuator Fault (DVP1 or 2)
1:0101 Cascade Is Active 1:0283 Alarm - HP2 Actuator Fault (DVP1 or 2)
1:0102 Cascade Is In Control 1:0284 Alarm - Comm Link to DSLC2 Failed
1:0103 Cascade Is Inhibited 1:0285 Alarm - KW Load AI Failed
Alarm - Turbine Maintenance Interval
1:0104 Rmt Cascade Is Enabled 1:0286
Alm
Alarm - Start Temperature #1 Override
1:0105 Rmt Cascade Is Active 1:0287
Active
Alarm - Start Temperature #2 Override
1:0106 Rmt Cascade Is In Control 1:0288
Active
1:0107 Rmt Cascade Is Inhibited 1:0289 Alarm - Comm Link to easYgen Failed
1:0108 * IH Configured 1:0290 Alarm - Comm Link to LS-5 Failed
1:0109 Auxiliary Is Enabled 1:0291 Alarm - Comm Link to MFR300 Failed
1:0110 Auxiliary Is Active 1:0292 Alarm - Comm Link to HiProtec Failed
1:0111 Auxiliary Is In Control 1:0293 Alarm - MPU1 Failed Open Wire Test
1:0112 Aux Active / Not Limiting 1:0294 Alarm - MPU2 Failed Open Wire Test
1:0113 Aux Active / Not In Control 1:0295 Alarm - Internal HW Simulation Enabled
1:0114 Auxiliary is Inhibited 1:0296 Alarm - spare_103
1:0115 Remote Aux Is Enabled 1:0297 Alarm - spare_104

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Manual 26839V1 505 Digital Control for Steam Turbines

Addr Description Addr Description

1:0116 Remote Aux Is Active 1:0298 Alarm - spare_105
1:0117 Rmt Aux Is In Control 1:0299 Alarm - spare_106
1:0118 Rmt Aux Is Inhibited 1:0300 Alarm - spare_107
1:0119 * Startup Complete 1:0301 Alarm - spare_108
1:0120 * Spare E 1:0302 Alarm - spare_109
1:0121 * Spare E 1:0303 Alarm - spare_110
1:0122 * Spare E 1:0304 Alarm - spare_111
1:0123 * Spare E 1:0305 Alarm - spare_112
1:0124 * Spare E 1:0306 Alarm - spare_113
1:0125 * Spare E 1:0307 Alarm - spare_114
1:0126 * Spare E 1:0308 Alarm - spare_115
1:0127 * Spare E 1:0309 Alarm - spare_116
1:0128 * Spare E 1:0310 Alarm - spare_117
1:0129 * Spare E 1:0311 Alarm - spare_118
1:0130 * Spare E 1:0312 Alarm - spare_119
1:0131 * Spare E 1:0313 Alarm - spare_120
1:0132 * Auto seq:ramp to Idle 3 1:0314 Trip - Unit in Calibration Mode
1:0133 * Spare E 1:0315 Trip - Configuration Error
1:0134 * Spare E 1:0316 Trip - Inlet Stm Pressure Level2
1:0135 * Spare E 1:0317 Trip - EXH Stm Pressure Level2
1:0136 * Spare E 1:0318 Trip - Selected PV 1 Level 2
1:0137 VLV Limiter Is Open 1:0319 Trip - Selected PV 2 Level 2
1:0138 VLV Limiter Is Closed 1:0320 Trip - Selected PV 3 Level 2
1:0139 VLV Limiter In Control 1:0321 Trip - Tunable Trip
1:0140 Remote/Local Remote Selected 1:0322 Trip - Configuration Mode (IO Lock)
1:0141 MODBUS Active 1:0323 Trip - Aux 2 Input Failed
1:0142 Start Permissive 1:0324 Trip - Open Wire on MPUs
1:0143 * Spare E 1:0325 Trip - Selected PV 7 Level 2
1:0144 * Spare E 1:0326 Trip - Selected PV 8 Level 2
1:0145 * Spare E 1:0327 Trip - spare_40
1:0146 * Spare E 1:0328 Contact In 17 Closed
1:0147 * Spare E 1:0329 Contact In 18 Closed
1:0148 * Spare E 1:0330 Contact In 19 Closed
1:0149 * Spare E 1:0331 Contact In 20 Closed
1:0150 * Spare E 1:0332 Relay 2 Energized
1:0151 Shutdown Relay Energized(Relay 1) 1:0333 Auxiliary 2 Is Enabled
1:0152 Alarm Relay Driver 1:0334 Auxiliary 2 Is Active
1:0153 Relay 3 Energized 1:0335 Auxiliary 2 Is In Control
1:0154 Relay 4 Energized 1:0336 Aux 2 Active / Not Limiting
1:0155 Relay 5 Energized 1:0337 Aux 2 Active / Not In Control
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Manual 26839V1 505 Digital Control for Steam Turbines

Addr Description Addr Description

1:0156 Relay 6 Energized 1:0338 Auxiliary 2 is Inhibited
1:0157 Relay 7 Energized 1:0339 Remote Aux 2 Is Enabled
1:0158 Relay 8 Energized 1:0340 Remote Aux 2 Is Active
1:0159 ESD Contact Input Closed 1:0341 Rmt Aux 2 Is In Control
1:0160 Contact In 2 Closed 1:0342 Rmt Aux 2 Is Inhibited
1:0161 Contact In 3 Closed 1:0343 Aux 2 Limiter Configured
1:0162 Contact In 4 Closed 1:0344 Aux 2 Control Configured
1:0163 Contact In 5 Closed 1:0345 Remote Aux 2 Configured
1:0164 Contact In 6 Closed 1:0346 Remote KW Setpt Is Enabled
1:0165 Contact In 7 Closed 1:0347 Remote KW Setpt Is Active
1:0166 Contact In 8 Closed 1:0348 Remote KW Setpt Is In Control
1:0167 Contact In 9 Closed 1:0349 Remote KW Setpt Is Inhibited
1:0168 Contact In 10 Closed 1:0350 Remote KW Control Configured
1:0169 Contact In 11 Closed 1:0351 * IHB Configured
1:0170 Contact In 12 Closed 1:0352 Enables Mod Port2 In Local
1:0171 Contact In 13 Closed 1:0353 Enables Mod Port3 In Local
1:0172 Contact In 14 Closed 1:0355 Relay 2 is Level Switch
1:0173 Contact In 15 Closed 1:0356 Relay 3 is Level Switch
1:0174 Contact In 16 Closed 1:0357 Relay 4 is Level Switch
1:0175 Aux Controller Configured 1:0358 Relay 5 is Level Switch
1:0176 Sync Function Configured 1:0359 Relay 6 is Level Switch
1:0177 Modbus- ESD Control Configured 1:0360 Relay 7 is Level Switch
1:0178 Manual Start Configured 1:0361 Relay 8 is Level Switch
1:0179 Auto Start Configured 1:0362 Trip - Actuator Scaling Min > Max
1:0180 Semi-Auto Start Configured 1:0363 Trip - Selected PV 4 Level 2
1:0181 Idle/Rated Start Configured 1:0364 Trip - Selected PV 5 Level 2
1:0182 Auto Start Sequence Configured 1:0365 Trip - Selected PV 6 Level 2

Table 6-9. Analog Reads

Addr Description Units Multiplier

3:0001 Control Parameter 1
3:0002 Speed Sensor #1 Input (RPM) rpm 1
3:0003 Speed Sensor #2 Input (RPM) rpm 1
3:0004 Actual Turbine Speed (RPM) rpm 1
3:0005 Actual Speed (%) x 100 % 100
3:0006 Speed Setpoint (%) x 100 % 100
3:0007 Speed Setpoint (RPM) rpm 1
3:0008 Speed Droop Setpoint (RPM) rpm 1
3:0009 Speed Droop (%) x 100 % 100
3:0010 Speed PID Output (%) % 100
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Manual 26839V1 505 Digital Control for Steam Turbines

Addr Description Units Multiplier

3:0011 Min Governor Speed Setpoint (RPM) rpm 1
3:0012 Highest Speed reached rpm 1
3:0013 Idle / Rated - Idle Speed (RPM) rpm 1
3:0014 Idle / Rated - Rated Speed (RPM) rpm 1
3:0015 Auto Seq - Idle 1 Speed Setpt (RPM) rpm 1
3:0016 Auto Seq- Idle 1 Dly Time (MIN) X 100 min 100
3:0017 Auto Seq-Time Left Idle 1 (MIN) X 100 min 100
3:0018 Auto Seq- Idle 1 to Idle 2 Rate RPM/SEC rpm/s 1
3:0019 Auto Seq - Idle 2 Speed Setpt (RPM) rpm 1
3:0020 Auto Seq- Idle 2 Dly Time (MIN) X 100 min 100
3:0021 Auto Seq-Time Left Idle 2(MIN) X 100 min 100
3:0022 Auto Seq-Time ramp to Rated (RPM/S) rpm/s 1
3:0023 Auto Seq- Rated speed stpt (RPM) rpm 1
3:0024 Auto Seq - Run Time Hours hrs 1
3:0025 Auto Seq-Hours Since trip hrs 1
3:0026 Cascade Setpoint (Scaled) Casc units AI_SCALE
3:0027 Cascade PID Output (%) x 100 % 100
3:0028 Cascade Input (%) % 100
3:0029 Cascade Setpoint (%) % 100
3:0030 Cascade Scale Factor 1
3:0031 Cascade Input (Scaled) Casc units AI_SCALE
3:0032 Remote Cascade Input (Scaled) Casc units AI_SCALE
3:0033 Aux Setpoint (Scaled) aux units AI_SCALE
3:0034 Aux PID Output (%) x 100 % 100
3:0035 Aux Input (%) % 100
3:0036 Aux Setpoint (%) % 100
3:0037 Aux Scale Factor 1
3:0038 Aux Input (Scaled) aux units AI_SCALE
3:0039 Remote Aux Input (Scaled) aux units AI_SCALE
3:0040 Remote Speed Setpoint Input rpm 1
3:0041 Inlet Pressure Scale Factor 1
3:0042 Inlet Pressure Input (Scaled) IP units AI_SCALE
3:0043 Loadshare Scale Factor 1
3:0044 Sync / Loadshare Input (Scaled) rpm AI_SCALE
3:0045 KW Scale Factor 1
3:0046 KW Input (Scaled) kW units AI_SCALE
3:0047 VLV Limiter Output x 100 % 100
3:0048 LSS Demand (%) x100 % 100
3:0049 HP Actuator Demand (%) x100 % 100
3:0050 HP2 Actuator Demand (%) x100 % 100
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Manual 26839V1 505 Digital Control for Steam Turbines

Addr Description Units Multiplier

3:0051 * Spare E
3:0052 * Spare E
3:0053 * Spare E
3:0054 * Spare E
3:0055 * Spare E
3:0056 * Spare E
3:0057 * Spare E
3:0058 * Spare E
3:0059 * Spare
3:0060 Modbus Entered Speed Setpoint (fdbk) rpm 1
3:0061 Mod1 Entered Cascade Setpoint (fdbk) Casc units AI_SCALE
3:0062 Mod#1 Entered Aux Setpoint (fdbk) Aux units AI_SCALE
3:0063 * Spare E
3:0064 * Spare E
3:0065 * Spare E
3:0066 * Spare E
3:0067 * Spare E
3:0068 * Spare E
3:0069 * Spare E
3:0070 * Spare E
3:0071 * Spare E
3:0072 Analog Input 1 (percent x 100) % 100
3:0073 Analog Input 2 (percent x 100) % 100
3:0074 Analog Input 3 (percent x 100) % 100
3:0075 Analog Input 4 (percent x 100) % 100
3:0076 Analog Input 5 (percent x 100) % 100
3:0077 Analog Input 6 (percent x 100) % 100
3:0078 Analog Output 1 (mA x 100) mA 100
3:0079 Analog Output 2 (mA x 100) mA 100
3:0080 Analog Output 3 (mA x 100) mA 100
3:0081 Analog Output 4 (mA x 100) mA 100
3:0082 Analog Output 5 (mA x 100) mA 100
3:0083 Analog Output 6 (mA x 100) mA 100
3:0084 Actuator #1 Output (mA x 100) mA 100
3:0085 Actuator #2 Output (mA x 100) mA 100
3:0086 Last Trip 1
3:0087 KW Units (3=MW 4=KW) 1
3:0088 Analog Input 1 Configuration 1
3:0089 Analog Input 2 Configuration 1
3:0090 Analog Input 3 Configuration 1
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Manual 26839V1 505 Digital Control for Steam Turbines

Addr Description Units Multiplier

3:0091 Analog Input 4 Configuration 1
3:0092 Analog Input 5 Configuration 1
3:0093 Analog Input 6 Configuration 1
3:0094 Analog Output 1 Configuration 1
3:0095 Analog Output 2 Configuration 1
3:0096 Analog Output 3 Configuration 1
3:0097 Analog Output 4 Configuration 1
3:0098 Analog Output 5 Configuration 1
3:0099 Analog Output 6 Configuration 1
3:0100 Relay 1 Configuration 1
3:0101 Relay 2 Configuration 1
3:0102 Relay 3 Configuration 1
3:0103 Relay 4 Configuration 1
3:0104 Relay 5 Configuration 1
3:0105 Relay 6 Configuration 1
3:0106 Contact 2 Configuration 1
3:0107 Contact 3 Configuration 1
3:0108 Contact 4 Configuration 1
3:0109 Contact 5 Configuration 1
3:0110 Contact 6 Configuration 1
3:0111 Contact 7 Configuration 1
3:0112 Contact 8 Configuration 1
3:0113 Contact 9 Configuration 1
3:0114 Contact 10 Configuration 1
3:0115 Contact 11 Configuration 1
3:0116 Contact 12 Configuration 1
3:0117 Contact 13 Configuration 1
3:0118 SPARE 1
3:0119 SPARE 1
3:0120 * Spare E 1
3:0121 * S/W PN54186768 1
3:0122 *S/W Revision 1
3:0123 * Auto Seq-Time ramp to idle 3(RPM/S) rpm/s 1
3:0124 * Auto Seq Idle 3 speed RPM rpm 1
3:0125 * Auto Seq-HH Idle Dly Time (MIN)X 100 min 100
3:0126 * Auto Seq-Time Left Idle 3(MIN) X100 min 100
3:0127 * Max Governor Speed rpm 1
3:0128 SPARE 1
3:0129 * IH-A Scale Factor 1
3:0130 * IH-A Press Units Configured 1
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Manual 26839V1 505 Digital Control for Steam Turbines

Addr Description Units Multiplier

3:0131 SPARE 1
3:0132 SPARE 1
3:0133 SPARE 1
3:0134 * Feed Forward Bias 1
3:0135 SPARE 1
3:0136 * Droop Setting 100
3:0137 * Autostart seq rate to Idle 1 rpm/s 1
3:0138 * Autostart seq CF Cold rte to Idle 2 rpm/s 1
3:0139 * Autostart seq CF Hot rate to Idle 2 rpm/s 1
3:0140 * Autostart seq CF Cold rte to Idle 3 rpm/s 1
3:0141 * Autostart seq CF Hot rate to Idle 3 rpm/s 1
3:0142 * Autostart seq CF Cold rate to rated rpm/s 1
3:0143 * Autostart seq CF Hot rate to rated rpm/s 1
3:0144 Speed Derivative signal rpm/s 1
3:0145 Speed Accel Rate %/s 1
3:0146 Analog Input 7 (percent x 100) % 100
3:0147 Analog Input 8 (percent x 100) % 100
3:0148 Analog Input 7 Configuration 1
3:0149 Analog Input 8 Configuration 1
3:0150 Relay 7 Configuration 1
3:0151 Relay 8 Configuration 1
3:0152 Contact 14 Configuration 1
3:0153 Contact 15 Configuration 1
3:0154 Contact 16 Configuration 1
3:0155 Contact 17 Configuration 1
3:0156 Contact 18 Configuration 1
3:0157 Contact 19 Configuration 1
3:0158 Contact 20 Configuration 1
3:0159 Aux 2 Setpoint (Scaled) AI_SCALE
3:0160 Aux 2 PID Output (%) x 100 % 100
3:0161 Aux 2 Input (%) 100
3:0162 Aux 2 Setpoint (%) 100
3:0163 Aux 2 Scale Factor 1
3:0164 Aux 2 Input (Scaled) AI_SCALE
3:0165 Remote Aux 2 Input (Scaled) AI_SCALE
3:0166 Mod#1 Entered Aux 2 Setpoint (fdbk) AI_SCALE
3:0167 SPARE 1
3:0168 SPARE 1
3:0169 * IH-B Scale Factor 1
3:0170 * IH-B Press Units Configured 1
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Manual 26839V1 505 Digital Control for Steam Turbines

Addr Description Units Multiplier

3:0171 * Autostart seq CF Warm rte to Idle 2 rpm/s 1
3:0172 * Autostart seq CF Warm rte to Idle 3 rpm/s 1
3:0173 * Autostart seq CF Warm rate to rated rpm/s 1
3:0174 Idle / Rated Cold Rate rpm/s 1
3:0175 Idle / Rated Warm Rate rpm/s 1
3:0176 Idle / Rated Hot Rate rpm/s 1
3:0177 Remote KW Setpoint Scale Factor 1
3:0178 Remote KW Setpoint Input AI_SCALE
3:0179 Exhaust Steam Pressure Scale Factor 1
3:0180 Exhaust Steam Pressure Input AI_SCALE
3:0181 HP Valve FDBK Position Scale Factor 1
3:0182 HP Valve FDBK Position Input AI_SCALE
3:0183 HP2 Valve FDBK Position Scale Factor 1
3:0184 HP2 Valve FDBK Position Input AI_SCALE
3:0185 Signal Monitoring #1 Scale Factor 1
3:0186 Signal Monitoring #1 Input AI_SCALE
3:0187 Signal Monitoring #2 Scale Factor 1
3:0188 Signal Monitoring #2 Input AI_SCALE
3:0189 Signal Monitoring #3 Scale Factor 1
3:0190 Signal Monitoring #3 Input AI_SCALE
3:0191 Start Temperature 1 Scale Factor 1
3:0192 Start Temperature 1 Input AI_SCALE
3:0193 Start Temperature 2 Scale Factor 1
3:0194 Start Temperature 2 Input AI_SCALE
3:0195 Signal Monitoring #4 Scale Factor 1
3:0196 Signal Monitoring #4 Input AI_SCALE
3:0197 Signal Monitoring #5 Scale Factor 1
3:0198 Signal Monitoring #5 Input AI_SCALE
3:0199 Signal Monitoring #6 Scale Factor 1
3:0200 Signal Monitoring #6 Input AI_SCALE
3:0201 Signal Monitoring #7 Scale Factor 1
3:0202 Signal Monitoring #7 Input AI_SCALE
3:0203 Signal Monitoring #8 Scale Factor 1
3:0204 Signal Monitoring #8 Input AI_SCALE

*—Denotes differences between 505 and 505 Enhanced.

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Table 6-10. Analog Write Addresses

Addr Description Units Multiplier

4:0001 Modbus Entered Speed Setpoint rpm none
4:0002 Modbus Entered Casc Setpoint Casc units Casc scale factor
4:0003 Modbus Entered Aux Setpoint Aux units Aux scale factor
4:0004 * Spare E
4:0005 * Modbus Droop demand % x0.01
4:0006 Modbus Entered Aux 2 Setpoint Aux 2 Units Aux 2 scale factor
4:0007 Spare
4:0008 Spare

Last Turbine Trip Cause

The cause of the last turbine trip (address 3:0086) is an integer that represents the Event ID found in
Table 5-2.

505 Controlling Parameters

The controlling parameter status of the 505 uses an Analog Read register (3:0001) to identify the
parameters that are in control. This variable follows what is displayed on the controlling parameter
screen, under the ‘CONT’ key. The variable gives the current status of the control and is defined in the
following table.

Table 6-11. Control Status

Value Description Value Description

23 Shutdown 13 Manual Start
22 Controlled Shutdown 12 Auto Start
24 In Tracking Mode 11 Semi Auto Start
20 Max Actuator 10 Idle / Rated Start
19 Valve Limiter 9 Auto Start Sequence
25 Acceleration Limiter 8 Synchronizing
26 Manual Demand 7 Load Share / Speed
18 Remote Auxiliary 6 Frequency / Speed
17 Auxiliary Control 5 Remote Cascade/Speed
27 Remote Auxiliary 2 4 Cascade / Speed
28 Auxiliary 2 Control 3 Remote / Speed
16 Configuration Error 3 Remote / KW
15 Start Perm Not Met 2 Speed / On-Line
14 Ready to Start 1 Speed / Off-Line

Analog Read addresses 3:0088—0093 give the configuration value of the analog inputs in order. The
configuration for the analog inputs are defined in the table below.

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Table 6-12. Analog Input Configuration

Value Description Value Description

13 --- Not Used --- 12 Remote Droop
1 Remote Speed Setpoint 17 Remote KW Setpoint
2 Synchronizing Input 18 Exhaust Pressure Input
3 Sync / Load Share 19 Spare 19
4 KW / Unit Load Input 20 HP Valve Feedback Position
5 Cascade Input 21 HP2 Valve Feedback Position
6 Remote Cascade Setpoint 22 Isolated PID PV
7 Auxiliary Input 23 Remote SP for Isolated PV
8 Remote Auxiliary Setpoint 24 Signal Monitoring #1
14 Auxiliary 2 Input 25 Signal Monitoring #2
15 Remote Auxiliary 2 Setpoint 26 Signal Monitoring #3
9 Inlet Pressure Input 27 Start Temperature 1
10 I/H Actuator 1 Feedback 28 Start Temperature 2
16 I/H Actuator 2 Feedback 29 Spare 29
11 Speed Feed-Forward 30 Spare 30

Analog Read addresses 3:0094—0099 give the configuration value of the analog outputs in order. The
configuration for the analog outputs is defined in the table below.

Table 6-13. Analog Output Configuration

Value Description Value Description

21 --- Not Used --- 20 I/H Actuator 1 Feedback Readout
1 Actual Shaft Speed 25 I/H Actuator 2 Feedback Readout
2 Speed Reference Setpoint 26 Isolated PID Dmd Output
3 Remote Speed Setpoint 27 Isolated PID PV Input Signal
4 Load Share Input 28 Isolated PID Setpoint
5 Synchronizing Input 29 Remote Isolated PID Setpoint
6 Generator Load 30 Remote KW Setpoint
7 Cascade Input Signal 31 Exhaust Pressure Input
8 Cascade Setpoint 32 HP Valve Feedback Position
9 Remote Cascade Setpoint 33 HP2 Valve Feedback Position
10 Auxiliary Input Signal 34 Signal Monitoring #1
11 Auxiliary Setpoint 35 Signal Monitoring #2
12 Remote Auxiliary Setpoint 36 Signal Monitoring #3
22 Auxiliary 2 Input Signal 37 Start Temperature 1
23 Auxiliary 2 Setpoint 38 Start Temperature 2
24 Remote Auxiliary 2 Setpoint 39 Spare 37
13 Valve Limiter Setpoint 40 Spare 38
14 LSS Value 41 Spare 39
17 HP Valve Demand 42 Spare 40
18 HP2 Valve Demand 43 Spare 41
19 Inlet Pressure Input 44 Spare 42

Analog Read addresses 3:0100—0105 give the configuration value of the relays in order. The
configuration for the relays is defined in the tables below. Boolean Read addresses 1:0355—0361 specify
whether each relay is a level switch.

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Table 6-14. Relay Configured As Level Switch

Value Description Value Description

52 --- Not Used --- 9 LSS Value
1 Actual Speed 10 HP Valve Demand Output
2 Speed Setpoint 11 HP2 Valve Demand Output
3 KW Input 13 Inlet Pressure
4 Sync/Load Share Input 16 Exhaust Pressure
5 Cascade Input 17 Customer Defined Monitor Input #1
6 Cascade Setpoint 18 Customer Defined Monitor Input #2
7 Auxiliary Input 19 Customer Defined Monitor Input #3
8 Auxiliary Setpoint 20 Spare 21
14 Auxiliary 2 Input 21 Spare 22
15 Auxiliary 2 Setpoint 22 Spare 23
12 HP Valve Limiter 23 Spare 24
24 Spare 25

Table 6-15. Relay Configuration to Indicate State

Value Description Value Description

52 --- Not Used --- 44 Auxiliary Control Active
21 Summary Shutdown 45 Auxiliary PID in Control
22 Summary Shutdown (Trip Relay) 46 Remote Auxiliary Setpoint Enabled
23 Summary Alarm 47 Remote Auxiliary Setpoint Active
53 All Alarms Clear 63 Auxiliary 2 Control Enabled
24 Control Status OK 64 Auxiliary 2 Control Active
25 Overspeed Trip 65 Auxiliary 2 PID in Control
26 Overspeed Test Enabled 66 Remote Auxiliary 2 Setpoint Enabled
27 Speed PID in Control 67 Remote Auxiliary 2 Setpoint Active
28 Remote Speed Setpoint Enabled 48 HP Valve Limiter in Control
29 Remote Speed Setpoint Active 51 Command from Modbus BW addresses
30 Underspeed Switch 60 Reset Pulse (2 sec)
31 Auto Start Sequence Halted 59 Open GEN Breaker Cmd
32 On-Line Speed PID Dynamics Mode 61 Feed-Forward Enabled
33 Local Interface Mode Selected 62 Feed-Forward Active
34 Frequency Control Armed 68 Cascade PID in Control
35 Frequency Control 69 Spare 42
36 Sync Input Enabled 70 Spare 43
37 Sync / Loadshare Input Enabled 71 Spare 44
38 Loadshare Mode Active 58 Unit OK (No SD)
39 Cascade Control Enabled 72 Remote KW SP Enabled
40 Cascade Control Active 73 Remote KW Setpoint Active
41 Remote Cascade Setpoint Enabled 74 Manual Relay Control
42 Remote Cascade Setpoint Active 75 Isolated Controller in Auto
43 Auxiliary Control Enabled 76 Spare 50

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Analog Read addresses 3:0106—0117 give the configuration value of the contact inputs in order. The
configuration for the contact inputs are defined in the table below.

Table 6-16. Contact Input Configurations

Value Description Value Description

52 --- Not Used --- 26 External Trip 3
53 Reset Command 27 External Trip 4
54 Speed Raise Command 28 External Trip 5
55 Speed Lower Command 48 External Trip 6
1 Generator Breaker 30 External Trip 7
2 Utility Tie Breaker 31 External Trip 8
3 Overspeed Test 32 External Trip 9
4 External Run 33 External Trip 10
5 Start Permissive 1 34 External Alarm 1
6 Idle / Rated Command 35 External Alarm 2
7 Halt/Continue Auto Start 36 External Alarm 3
8 Override MPU Fault 37 External Alarm 4
9 Select On-Line Dynamics 38 External Alarm 5
10 Local / Remote 39 External Alarm 6
11 Rmt Spd Setpt Enable 40 External Alarm 7
12 Sync Enable 41 External Alarm 8
14 Freq Control Arm/Disarm 42 External Alarm 9
15 Casc Setpt Raise 60 Spare 51
16 Casc Setpt Lower 45 I/H Actuator 1 Fault
17 Casc Control Enable 46 I/H Actuator 2 Fault
18 Rmt Casc Setpt Enable 49 Speed Forward Enable
19 Aux Setpt Raise 50 Instant Min Gov/Load Speed
20 Aux Setpt Lower 51 Select Hot Start
21 Aux Control Enable 61 Remote KW Setpoint Enable
22 Rmt Aux Setpt Enable 62 Clock SYNC Pulse Contact
56 Auxiliary 2 Setpoint Raise 63 Enable Rem SP for Isolated PID
57 Auxiliary 2 Setpoint Lower 64 Isolated Controller Raise
58 Spare 28 65 Isolated Controller Lower
59 Remote Auxiliary 2 Enable 66 Spare 62
23 Valve Limiter Open 67 Spare 63
24 Valve Limiter Close 68 Spare 64
29 Controlled Shutdown(STOP) 69 Spare 65
25 External Trip 2 70 Spare 66

Specific Address Information

Entering Set Point from Modbus
 The set point for the Speed, Cascade and Auxiliary can be entered from the Modbus. When the set
point is entered for any of these functions the set point will not move to the entered set point
instantly, but the set point will move towards the entered set point at the entered rate defined for the
function in the Configuration mode. This functions the same as entering the set point from the front
panel of the control.
 There is feedback provided to let the operator know what value was entered. This value will not
change until a new value is entered from the Modbus. The addresses, 3:0060-:0062, are for speed,
cascade, and auxiliary respectively. When a new value is entered from the Modbus, the set point will
move to the new value. If the entered set point that is the same as the feedback, the operator can
use a go to the set point command instead of entering the set point again. This command needs to
be used when the set point to be entered is the same as the feedback.

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Modbus Scale Factors

Modbus has two limitations:
 only integers can be sent across
 the value is limited between -32767 and 32767

These limitations can be overcome by scaling the value before it is sent across the Modbus. The default
scale factor for the analog values is 1. The scale factor can be changed in the service mode between 1
and 100. The following input and set point values that are sent across the Modbus have independent
scale factors: Casc (3:0030), Aux (3:0037), Inlet Steam Pressure (3:0041), Exhaust Steam Pressure
(3:0179) KW (3:0045), and Sync/Load Share (3:0043). These scaled parameters and their scale factor
are available through the Modbus. Values that require a decimal point must be multiplied by the scale
factor (10 or 100) prior to being sent across the Modbus. The value sent must then be divided by the
scale factor in the Master.

The Scale Factor adjusts all associated analog reads and writes accordingly. For example, the Cascade
Scale Factor adjusts the cascade input and set point analog read values as well as the Entered Setpt
analog write value.

For example, if the Cascade set point of 60.15 needs to be sent across the Modbus and have two
decimal places, the Cascade Scale Factor would be set to 100 in the Service Mode. This will change the
value so that the decimal places can be sent across the Modbus communications link (60.15 * 100 =
6015). After the value is sent across the Modbus, it must be rescaled in the Master to the original value
(6015/100 = 60.15). A Directly Entered Cascade Set Point (4:0002) of 61.5 would be sent across the link
as 6150 and the 505 automatically divides the value by the Casc Scale Factor and uses the value of 61.5
as the set point desired.

Modbus Percentage
Some of the analog read addresses have percentages sent across. The formula used in the percentage
calculation is (actual/max) * 100). The percentage is multiplied by 100 before being sent across the
Modbus to provide up to 2 decimal places, if desired.

Modbus Emergency Shutdown

Two different types of shutdown commands (emergency and controlled) can be issued through Modbus.
The Emergency Shutdown command instantly takes the speed set point and actuator current to zero.
Optionally the 505 can be configured to ignore this Emergency Shutdown command if it is desired to not
allow the unit to be tripped through Modbus.

To avoid an inadvertent trip, the emergency shutdown command from Modbus can be configured to
require a two-step process before a shutdown command is issued. When the shutdown is a two-step
process Boolean write address 0001 starts the shutdown process. An “ESD ACKN ENABLE” feedback
(1:0065) is given and an acknowledge on address 0002 has to be given within five seconds for the control
to issue a shutdown command.

See Volume 2 for Service mode tunables.

For More Modbus Information

Detailed information on the Modbus protocol is presented in “Reference Guide PI-MBUS-300” published
by AEC Corp./Modicon Inc., formerly Gould Inc. To implement your own source code, you must register
with Modicon. Registration includes purchasing document PI-MBUS-303 and signing a non-disclosure
agreement. You can register to use Modbus at your nearest Modicon field office. To find the office
nearest you, contact Modicon Technical Support at
1-800-468- 5342.

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Chapter 7.
Product Support and Service Options

Product Support Options

If you are experiencing problems with the installation, or unsatisfactory performance of a Woodward
product, the following options are available:
 Consult the troubleshooting guide in the manual.
 Contact the manufacturer or packager of your system.
 Contact the Woodward Full Service Distributor serving your area.
 Contact Woodward technical assistance (see “How to Contact Woodward” later in this chapter) and
discuss your problem. In many cases, your problem can be resolved over the phone. If not, you can
select which course of action to pursue based on the available services listed in this chapter.

OEM or Packager Support: Many Woodward controls and control devices are installed into the equipment
system and programmed by an Original Equipment Manufacturer (OEM) or Equipment Packager at their
factory. In some cases, the programming is password-protected by the OEM or packager, and they are the
best source for product service and support. Warranty service for Woodward products shipped with an
equipment system should also be handled through the OEM or Packager. Please review your equipment
system documentation for details.

Woodward Business Partner Support: Woodward works with and supports a global network of
independent business partners whose mission is to serve the users of Woodward controls, as described
here:
 A Full Service Distributor has the primary responsibility for sales, service, system integration
solutions, technical desk support, and aftermarket marketing of standard Woodward products within
a specific geographic area and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs,
repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's
primary mission.
 A Recognized Turbine Retrofitter (RTR) is an independent company that does both steam and gas
turbine control retrofits and upgrades globally, and can provide the full line of Woodward systems
and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc.

A current list of Woodward Business Partners is available at www.woodward.com/directory.

Product Service Options

The following factory options for servicing Woodward products are available through your local Full-
Service Distributor or the OEM or Packager of the equipment system, based on the standard Woodward
Product and Service Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture

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Replacement/Exchange: Replacement/Exchange is a premium program designed for the user who
needs immediate service. It allows you to request and receive a like-new replacement unit in minimum
time (usually within 24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime. This is a flat-rate program and includes the full standard
Woodward product warranty (Woodward Product and Service Warranty 5-01-1205).

This option allows you to call your Full-Service Distributor in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the unit is available at the time of
the call, it can usually be shipped out within 24 hours. You replace your field control unit with the like-new
replacement and return the field unit to the Full-Service Distributor.

Charges for the Replacement/Exchange service are based on a flat rate plus shipping expenses. You are
invoiced the flat rate replacement/exchange charge plus a core charge at the time the replacement unit is
shipped. If the core (field unit) is returned within 60 days, a credit for the core charge will be issued.

Flat Rate Repair: Flat Rate Repair is available for the majority of standard products in the field. This
program offers you repair service for your products with the advantage of knowing in advance what the
cost will be. All repair work carries the standard Woodward service warranty (Woodward Product and
Service Warranty 5-01-1205) on replaced parts and labor.

Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option with
the exception that the unit will be returned to you in “like-new” condition and carry with it the full standard
Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option is
applicable to mechanical products only.

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair, please contact your Full-
Service Distributor in advance to obtain Return Authorization and shipping instructions.

When shipping the item(s), attach a tag with the following information:
 Return authorization number
 Name and location where the control is installed
 Name and phone number of contact person
 Complete Woodward part number(s) and serial number(s)
 Description of the problem
 Instructions describing the desired type of repair

Packing a Control
Use the following materials when returning a complete control:
 Protective caps on any connectors
 Antistatic protective bags on all electronic modules
 Packing materials that will not damage the surface of the unit
 At least 100 mm (4 inches) of tightly packed, industry-approved packing material
 A packing carton with double walls
 A strong tape around the outside of the carton for increased strength

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.

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Replacement Parts
When ordering replacement parts for controls, include the following information:
 The part number(s) (XXXX-XXXX) that is on the enclosure nameplate
 The unit serial number, which is also on the nameplate

Engineering Services
Woodward offers various Engineering Services for our products. For these services, you can contact us by
telephone, by email, or through the Woodward website.
 Technical Support
 Product Training
 Field Service

Technical Support is available from your equipment system supplier, your local Full-Service Distributor, or
from many of Woodward’s worldwide locations, depending upon the product and application. This service can
assist you with technical questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business hours by phoning
Woodward and stating the urgency of your problem.

Product Training is available as standard classes at many of our worldwide locations. We also offer
customized classes, which can be tailored to your needs and can be held at one of our locations or at
your site. This training, conducted by experienced personnel, will assure that you will be able to maintain
system reliability and availability.

Field Service engineering on-site support is available, depending on the product and location, from many
of our worldwide locations or from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-Woodward equipment with which
our products interface.

For information on these services, please contact us via telephone, email us, or use our website:
www.woodward.com.

Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service facility, please consult our
worldwide directory at www.woodward.com/directory, which also contains the most current product
support and contact information.

You can also contact the Woodward Customer Service Department at one of the following Woodward
facilities to obtain the address and phone number of the nearest facility at which you can obtain
information and service.

Products Used in Products Used in Products Used in Industrial

Electrical Power Systems Engine Systems Turbomachinery Systems
Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany ------ +49 (711) 78954-510 India --------------- +91 (124) 4399500
Kempen---- +49 (0) 21 52 14 51 India --------------- +91 (124) 4399500 Japan---------------+81 (43) 213-2191
Stuttgart - +49 (711) 78954-510 Japan---------------+81 (43) 213-2191 Korea ---------------+82 (51) 636-7080
India --------------- +91 (124) 4399500 Korea ---------------+82 (51) 636-7080 The Netherlands--+31 (23) 5661111
Japan---------------+81 (43) 213-2191 The Netherlands--+31 (23) 5661111 Poland -------------- +48 12 295 13 00
Korea ---------------+82 (51) 636-7080 United States -----+1 (970) 482-5811 United States -----+1 (970) 482-5811
Poland -------------- +48 12 295 13 00
United States -----+1 (970) 482-5811

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Technical Assistance
If you need to contact technical assistance, you will need to provide the following information. Please write
it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the
Woodward factory:

General
Your Name

Site Location

Phone Number

Fax Number

Prime Mover Information

Manufacturer

Turbine Model Number

Type of Fuel (gas, steam, etc.)

Power Output Rating

Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Control/Governor #2

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Control/Governor #3

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Symptoms
Description

If you have an electronic or programmable control, please have the adjustment setting positions or the menu
settings written down and with you at the time of the call.

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Appendix A.
505 Configuration Mode Worksheets

Governor Serial Number ______________________

Application ________________________________ Date ___________

For details on individual settings, refer to Chapter 4.

TURBINE START
Start Mode
Manual Start YES NO
Semiautomatic Start YES NO
Automatic Start YES NO
Rate to Min (rpm/s) RPM/s
Valve Limiter Rate (%/s) %/s
Start Sequence
No Start Sequence YES NO
Idle/Rated Sequence YES NO
Auto Start Sequence YES NO
Use Temperature for Hot/Cold YES NO
Hot Reset Level (rpm) RPM
Hot Reset Timer (min) MIN
Cold Start = (hr since trip > xx Hrs) HRS
Hot Start = (hr since trip < xx Hrs) HRS
Use Temperature Input 2 YES NO
Hot Minimum Temperature 1 Units
Hot Minimum Temperature 2 Units
Use Warm Condition YES NO
Warm Minimum Temperature 1 Units
Warm Minimum Temperature 2 Units
Use Temperature Difference YES NO
Hot Temperature Difference Units
Warm Temperature Difference Units
Idle/Rated Settings
Idle Setpoint (rpm) RPM
Rated Setpoint (rpm) RPM
Cold Rate (rpm/s) RPM/s
Warm Rate (rpm/s) RPM/s
Hot Rate (rpm/s) RPM/s
Automatic Start Sequence Settings
Idle 1 Setpoint (rpm) RPM
Cold Idle 1 Delay MIN

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Warm Idle 1 Delay MIN

Hot Idle 1 Delay MIN
Use Idle 2 YES NO
Cold Rate to Idle 2 RPM/s
Warm Rate to Idle 2 RPM/s
Hot Rate to Idle 2 RPM/s
Idle 2 Setpt (rpm) RPM
Cold Idle 2 Delay MIN
Warm Idle 2 Delay MIN
Hot Idle 2 Delay MIN
Use Idle 3 YES NO
Cold Rate to Idle 3 RPM/s
Warm Rate to Idle 3 RPM/s
Hot Rate to Idle 3 RPM/s
Idle 3 Setpoint RPM
Cold Idle 3 Delay MIN
Warm Idle 3 Delay MIN
Hot Idle 3 Delay MIN
Use Temperature for Idle YES NO
Use Temperature Input 2 YES NO
Use Temperature Difference YES NO
Temperature 1 Setpoint for Idle 1 Units
Temperature 2 Setpoint for Idle 1 Units
Maximum Temperature Difference for Idle
Units
1
Temperature 1 Setpoint for Idle 2 Units
Temperature 2 Setpoint for Idle 2 Units
Maximum Temperature Difference for Idle
Units
2
Temperature 1 Setpoint for Idle 3 Units
Temperature 2 Setpoint for Idle 3 Units
Maximum Temperature Difference for Idle
Units
3
Cold Rate to Rated RPM/s
Warm Rate to Rated RPM/s
Hot Rate to Rated RPM/s
Rated Setpoint RPM
Auto Halt at Idle Setpoints YES NO

SPEED SETPOINTS
Overspeed Test Limit (rpm) RPM
Overspeed Trip (rpm) RPM
Max Governor Speed (rpm) RPM
Rated Speed (rpm) RPM
Min Governor Speed (rpm) RPM

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Off-line Slow Rate (rpm/s) RPM/s

On-line Slow Rate (rpm/s) RPM/s
Remote Setpoint Speed kW
Remote Speed or kW Setpoint Maximum
Units/s
Rate
Use Critical Speeds? YES NO
Critical Speed Rate RPM/s
Critical Speed 1 Min RPM
Critical Speed 1 Max RPM
Use Critical Band 2 ? YES NO
Critical Speed 2 Min RPM
Critical Speed 2 Max RPM
Use Critical Band 3 ? YES NO
Critical Speed 3 Min RPM
Critical Speed 3 Max RPM

SPEED CONTROL
Select Probe Type MPU Active
Device Tag
Number of Gear Teeth Teeth
Gear Ratio 1
Maximum Speed Level (rpm) RPM
Failed Speed Level (rpm) RPM
Use Speed Input Channel 2 YES NO
Select Probe Type MPU Active
Device Tag
Number of Gear Teeth Teeth
Gear Ratio 2
Maximum Speed Level (rpm) RPM
Failed Speed Level (rpm) PRM
Off-Line Proportional Gain % %
Off-Line Integral Gain rps rps
Off-Line Derivative Ratio % %
On-Line Proportional Gain % %
On-Line Integral Gain rps rps
On-Line Derivative Ratio % %

OPERATING PARAMETERS
Generator Application? YES NO
Generator Settings
Use Generator Breaker Open Trip ? YES NO
Use Tie Breaker Open Trip ? YES NO
Frequency at Rated (50/60 Hz) Hz
Droop (%) %

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Use MW as Load Units? YES NO

Use Load Droop? YES NO
Max Load kW
Primary Generator Load Signal
Secondary Generator Load Signal
Primary Sync/Load Share Signal
Secondary Sync/Load Share Signal
Primary Sync Signal
Secondary Sync Signal
Use Frequency Arm/Disarm? YES NO
Reverse Power on Controlled Stop? YES NO
Mechanical Drive Settings
Use Feed-Forward YES NO
Feed Forward Speed Deadband
Use Only when Cascade YES NO
Cascade Deadband when Forward Active
Use Direct Feed-Forward YES NO
Speed Offset at 4 mA RPM
Speed Offset at 20 mA RPM
Action Delay s
Min Forward Rate %/s
Speed offset at Min Rate RPM
Max Forward Rate %/s
Speed offset at Max Rate RPM
Use Emergency YES NO
Emergency Action Delay s
Forward Rate to Activate %/s
Emrg Max Forward Rate %/s
Emrg Max Speed Offset RPM
Emrg Max Speed Rate RPM/s
Controlled Stop & Trip YES NO
External Trips in Trip Relay YES NO
Reset Clears Trip Output YES NO
Trip = Zero Current to Actuators YES NO
Use Local/Remote YES NO
Use Pressure Compensation YES NO

AUXILIARY CONTROL
Use Auxiliary Control ? YES NO
Lost Input Shutdown? YES NO
Process Signal
Inverted? YES NO
Minimum Setpoint Units
Maximum Setpoint Units

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Setpoint Rate Units/s

Use as Controller? YES NO
Setpoint Initial Value Units
Droop % %
PID Proportional Gain % %
PID Integral Gain rps rps
PID Derivative Ratio % %
Tie Breaker Open Aux Disable YES NO
Gen Breaker Open Aux Disable YES NO
Use Remote Setpoint YES NO
Remote Max Rate Units/s
Configured
Units of Measure
with AI
Configured
Decimals Displayed
with AI

AUXILIARY 2 CONTROL
Use Auxiliary Control ? YES NO
Lost Input Shutdown? YES NO
Process Signal
Inverted? YES NO
Minimum Setpoint Units
Maximum Setpoint Units
Setpoint Rate Units/s
Use as Controller? NO
Setpoint Initial Value Units
PID Proportional Gain % %
PID Integral Gain rps rps
PID Derivative Ratio % %
Use Remote Setpoint YES NO
Remote Max Rate Units/s
Configured
Units of Measure
with AI
Configured
Decimals Displayed
with AI

CASCADE CONTROL
Use Cascade Control? YES NO
Process Signal
Inverted? YES NO
Minimum Cascade Setpoint Units
Maximum Cascade Setpoint Units
Cascade Setpoint Rate (Units/s) Units/s
Use Setpoint Tracking? YES NO
Setpoint Initial Value Units
Speed Setpoint Lower Limit RPM

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Speed Setpoint Upper Limit RPM

Max Speed Setpoint Rate (rpm/s) RPM/s
Cascade Droop % %
PID Proportional Gain % %
PID Integral Gain rps rps
PID Derivative Ratio % %
Use Remote Cascade Setpoint YES NO
Remote Cascade Max Rate Units/s
Configured
Units of Measure
with AI
Configured
Decimals Displayed
with AI

ISOLATED CONTROL
Use Isolated PID YES NO
Use Remote Setpoint YES NO
Output Action on Input Fault
Invert Controller? YES NO
Allow Manual Control? YES NO
Maximum Setpoint Units
Minimum Setpoint Units
Initial Setpoint Units

COMMUNICATIONS
Ethernet IP Configuration
ENET 1 Address
ENET 1 Subnet Mask
ENET 2 Address
ENET 2 Subnet Mask
ENET 3 Address
ENET 3 Subnet Mask
ENET 4 Address
ENET 4 Subnet Mask
Modbus Configuration
Use Modbus YES NO
Use Serial Link 1 YES NO
Use Ethernet Link 2 YES NO
Use Ethernet Link 3 YES NO
Device Address (1-247)
Enable Write Commands YES NO
Protocol ASCII RTU
Baud Rate
Bits 7 8
Stop Bits 1 2
Parity

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Driver
Modbus Ethernet Link 2
Ethernet Protocol TCP UDP 5001
Device Address (1-247)
Enable Write Commands YES NO
Modbus Ethernet Link 3
Ethernet Protocol TCP UDP 5002
Device Address (1-247)
Enable Write Commands YES NO

ANALOG INPUTS
Analog Input 01
Input Function
4 mA Value Units
20 mA Value Units
Loop Powered YES NO
Device Tag
Units
Modbus Multiplier
Decimals Displayed
Analog Input 02
Input Function
4 mA Value Units
20 mA Value Units
Loop Powered YES NO
Device Tag
Units
Modbus Multiplier
Decimals Displayed
Analog Input 03
Input Function
4 mA Value Units
20 mA Value Units
Loop Powered YES NO
Device Tag
Units
Modbus Multiplier
Decimals Displayed
Analog Input 04
Input Function
4 mA Value Units
20 mA Value Units
Loop Powered YES NO
Device Tag

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Units
Modbus Multiplier
Decimals Displayed
Analog Input 05
Input Function
4 mA Value Units
20 mA Value Units
Loop Powered YES NO
Device Tag
Units
Modbus Multiplier
Decimals Displayed
Analog Input 06
Input Function
4 mA Value Units
20 mA Value Units
Loop Powered YES NO
Device Tag
Units
Modbus Multiplier
Decimals Displayed
Analog Input 07
Input Function
4 mA Value Units
20 mA Value Units
Loop Powered YES NO
Device Tag
Units
Modbus Multiplier
Decimals Displayed
Analog Input 08
Input Function
4 mA Value Units
20 mA Value Units
Loop Powered YES NO
Device Tag
Units
Modbus Multiplier
Decimals Displayed

ANALOG OUTPUTS
Analog Output 01
Output Function
4 mA Value Units

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20 mA Value Units
Device Tag
Units
Enable Readback Fault YES NO
Analog Output 02
Output Function
4 mA Value Units
20 mA Value Units
Device Tag
Units
Enable Readback Fault YES NO
Analog Output 03
Output Function
4 mA Value Units
20 mA Value Units
Device Tag
Units
Enable Readback Fault YES NO
Analog Output 04
Output Function
4 mA Value Units
20 mA Value Units
Device Tag
Units
Enable Readback Fault YES NO
Analog Output 05
Output Function
4 mA Value Units
20 mA Value Units
Device Tag
Units
Enable Readback Fault YES NO
Analog Output 06
Output Function
4 mA Value Units
20 mA Value Units
Device Tag
Units
Enable Readback Fault YES NO

DRIVERS
Actuator 01
Function
Range 4-20 mA 0-200 mA

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Dither mA
Use Actuator Fault Shutdown YES NO
Invert Output YES NO
Device Tag
HP2 Offset %
Readout Function
4 mA Value Units
20 mA Value Units
Enable Readback Fault YES NO
Device Tag
Units
Actuator 02
Function
Range 4-20 mA 0-200 mA
Dither mA
Use Actuator Fault Shutdown YES NO
Invert Output YES NO
Device Tag
HP2 Offset %
Readout Function
4 mA Value Units
20 mA Value Units
Enable Readback Fault YES NO
Device Tag
Units

CONTACT INPUTS
Contact Input 01
Emergency
Input Function
Stop
Device Tag
Contact Input 02
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 03
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 04
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 05

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Input Function
Device Tag
Invert Logic? YES NO
Contact Input 06
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 07
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 08
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 09
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 10
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 11
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 12
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 13
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 14
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 15
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 16

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Input Function
Device Tag
Invert Logic? YES NO
Contact Input 17
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 18
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 19
Input Function
Device Tag
Invert Logic? YES NO
Contact Input 20
Input Function
Device Tag
Invert Logic? YES NO

RELAYS
Relay Output 01
Function
Device Tag
Relay Output 02
Use as Level Switch? YES NO
Function
Device Tag
Invert Output YES NO
ON Level Units
OFF Level Units
Relay Output 03
Use as Level Switch? YES NO
Function
Device Tag
Invert Output YES NO
ON Level Units
OFF Level Units
Relay Output 04
Use as Level Switch? YES NO
Function
Device Tag
Invert Output YES NO
ON Level Units

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OFF Level Units

Relay Output 05
Use as Level Switch? YES NO
Function
Device Tag
Invert Output YES NO
ON Level Units
OFF Level Units
Relay Output 06
Use as Level Switch? YES NO
Function
Device Tag
Invert Output YES NO
ON Level Units
OFF Level Units
Relay Output 07
Use as Level Switch? YES NO
Function
Device Tag
Invert Output YES NO
ON Level Units
OFF Level Units
Relay Output 08
Use as Level Switch? YES NO
Function
Device Tag
Invert Output YES NO
ON Level Units
OFF Level Units

WOODWARD LINKS
DSLC-2
Using a DSLC-2? YES NO
Use Synchronization/Load Share? Sync Sync/LS
Device Slave Address (1-255)
Device IP Address
505 Ethernet 3 IP Address
VS-II
Enable CAN 1 Interface Link? YES NO
Using a VariStroke II Actuator? YES NO
DVP1 Device ID (1-31)
Enable DVP1 AI Backup? YES NO
Use AI as Primary Demand? YES NO

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HP
Select Function Split HP2
Demand
Using 2 VariStroke II Actuators? YES NO

When Actuator Outputs have been (In Service) Calibrated and Stroked, record
values here.
Default 505 Unit #1 Value in 505
Actuator # 1 mA at Minimum Position *4.00
Actuator # 1 mA at Maximum Position *20.00
Actuator # 1 Dither (mA) *0.00

Actuator # 2 mA at Minimum Position *4.00

Actuator # 2 mA at Maximum Position *20.00
Actuator # 2 Dither (mA) *0.00

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Declarations

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Manual 26839V1 505 Digital Control for Steam Turbines

Woodward 204
 We appreciate your comments about the content of our publications.
Send comments to: [email protected]

Please reference publication 26839V1.

ÌB26839V1è:èD´¸µº´ºÎ

PO Box 1519, Fort Collins CO 80522-1519, USA

1041 Woodward Way, Fort Collins CO 80524, USA
Phone +1 (970) 482-5811

Email and Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other
authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
 Product Manual 26839V2
(Revision D, 10/2021)
Original Instructions

505 Digital Control for Steam Turbines

Manual 26839 consists of 2 volumes (26839V1 & 26839V2)

Volume 2
 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.

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
Revisions 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.

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
Proper Use 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— A bold, black line alongside the text identifies changes in this publication since the
last revision.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 26839V2
Copyright © Woodward, Inc. 2017 - 2021
All Rights Reserved
Manual 26839V2 505 Digital Control for Steam Turbines

Contents

WARNINGS AND NOTICES .............................................................................................................. 5

ELECTROSTATIC DISCHARGE AWARENESS .................................................................................... 6
INTRODUCTION ............................................................................................................................. 7
CHAPTER 8. SERVICE TOOLS ........................................................................................................ 8
Overview ....................................................................................................................................................... 8
Control Assistant (CA)................................................................................................................................... 8
Servlink-to-OPC-Server (SOS) ..................................................................................................................... 8
AppManager (AppMan) ................................................................................................................................. 8
CHAPTER 9. PERIPHERAL DEVICES................................................................................................ 9
Overview ....................................................................................................................................................... 9
DSLC-2 (Generator Synchronizer and Load Control) ................................................................................... 9
VariStroke II (Electro-Hydraulic Actuator) ................................................................................................... 11
MFR300 (Multi-function Relay) ................................................................................................................... 13
LS-5 (Protection/Breaker Control Relay) .................................................................................................... 13
Servo Position Controller (SPC) ................................................................................................................. 13
Real Power Sensor ..................................................................................................................................... 14
Engine Generator Control Package/Load Sharing (EGCP-3 LS) ............................................................... 15
Applying the 505 with Redundant I/H or I/P Converters ............................................................................. 19
CHAPTER 10. APPLICATION NOTES ............................................................................................. 21
Overview ..................................................................................................................................................... 21
Example Applications .................................................................................................................................. 22
CHAPTER 11. OPERATOR INTERFACE .......................................................................................... 46
Introduction.................................................................................................................................................. 46
Graphical Display and Key Inputs ............................................................................................................... 46
Service Panel Modes and User Levels ....................................................................................................... 47
CHAPTER 12. SERVICE MENU PROCEDURES ................................................................................ 49
Overview ..................................................................................................................................................... 49
Using the Service Menus ............................................................................................................................ 49
Service Mode Parameters........................................................................................................................... 53
CHAPTER 13. UNDERSTANDING PID SETTINGS ............................................................................ 73
Overview ..................................................................................................................................................... 73
Proportional Response................................................................................................................................ 74
Proportional + Integral (closed loop) ........................................................................................................... 75
Derivative Response ................................................................................................................................... 77
Proportional + Derivative (closed loop) ....................................................................................................... 78
Proportional + Integral + Derivative (closed loop) ....................................................................................... 79
Controller Field Tuning General .................................................................................................................. 81
CHAPTER 14. HARDWARE/OPERATING SYSTEM FAULTS............................................................... 83
General........................................................................................................................................................ 83
Wiring Problems .......................................................................................................................................... 83
Control Adjustments .................................................................................................................................... 83
Other Operating Problems .......................................................................................................................... 84
APPENDIX B. 505 DESIGN SPECIFICATIONS ................................................................................. 85
Hardware Specifications ............................................................................................................................. 85
Software Specifications ............................................................................................................................... 85
APPENDIX C. 505 SERVICE MODE WORKSHEET ........................................................................... 87
APPENDIX D. PASSWORD INFORMATION ...................................................................................... 97

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Manual 26839V2 505 Digital Control for Steam Turbines
General........................................................................................................................................................ 97
Monitor User Level ...................................................................................................................................... 97
“Operator” User Level Password ................................................................................................................ 97
“Service” User Level Password ................................................................................................................... 97
“Configure” User Level Password ............................................................................................................... 97
“ServiceUser” User Level Password ........................................................................................................... 97
APPENDIX E. SERVLINK-TO OPC SERVER (SOS) TOOL ................................................................ 98
SOS Communication Link ........................................................................................................................... 98
Installing SOS ............................................................................................................................................. 98
Connecting a PC/Laptop to the Control ...................................................................................................... 99
APPENDIX F. CONTROL ASSISTANT—SOFTWARE INTERFACE TOOL ............................................ 102
Features of Control Assistant .................................................................................................................... 102
Installing Control Assistant ........................................................................................................................ 102
Using Control Assistant ............................................................................................................................. 104
APPENDIX G. APPMANGER SERVICE TOOL ................................................................................ 109
File Management with App. Manager ....................................................................................................... 109
Installing App Manager ............................................................................................................................. 109
APPENDIX H. CONFIGURING NETWORK TCP/IP ADDRESSES....................................................... 116
APPENDIX I. REMOTEVIEW TOOL ............................................................................................... 118
APPENDIX J. USING 505 INTERNAL SIMULATION MODE ............................................................... 128
APPENDIX K. CUSTOM TAG NAME PROCEDURE ......................................................................... 129
APPENDIX L DATALOGS ............................................................................................................ 130

The following are trademarks of Woodward, Inc.:

ProTech
Woodward

The following are trademarks of their respective companies:

Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)

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Manual 26839V2 505 Digital Control for Steam Turbines

Illustrations and Tables

Figure 9-1. DSLC-2 ....................................................................................................................................... 9

Figure 9-2. Configuration/Woodward Links/DSLC-2 ................................................................................... 10
Figure 9-3. Service Screen - DSLC-2 Power Parameters .......................................................................... 10
Figure 9-4. Service Screen - DSLC-2 Status Parameters .......................................................................... 11
Figure 9-5. VS-II .......................................................................................................................................... 11
Figure 9-6. Configuration/Woodward Links/VS-II........................................................................................ 12
Figure 9-7. Service/VariStroke II ................................................................................................................. 12
Figure 9-8. Multi-Function Relay ................................................................................................................. 13
Figure 9-9. LS-5 .......................................................................................................................................... 13
Figure 9-10. Servo Position Controller ........................................................................................................ 14
Figure 9-11. Interface to Servo Position Controller ..................................................................................... 14
Figure 9-12. Real Power Sensor ................................................................................................................. 15
Figure 9-13. EGCP-3 Control ...................................................................................................................... 16
Figure 9-14. EGCP-3 LS Functional Diagram............................................................................................. 17
Figure 9-15. EGCP-3 LS Interface Wiring................................................................................................... 18
Figure 9-16. Typical Redundant I/H System with a Transfer Valve ............................................................ 19
Figure 9-17. Typical Redundant I/P System with a Pressure Selecting Relay Valve ................................. 19
Figure 10-1. Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting ...... 24
Figure 10-2. Inlet Pressure Control with AutomaticSynchronizing & Generator Power Limiting ................ 27
Figure 10-3. Exhaust Pressure Control with Generator Power Limiting and Plant Import/Export Limiting. 31
Figure 10-4. Plant Import/Export Control with DRFD Servo Interface ........................................................ 35
Figure 10-5. Inlet Pressure Control with Isochronous Loadsharing Control in Island Mode ...................... 39
Figure 10-6. Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode
................................................................................................................................................ 42
Figure 11-1 505 Keypad and Display .......................................................................................................... 46
Figure 12-1. User Login for Service ............................................................................................................ 49
Figure 12-2. Authorized and Unauthorized Components ........................................................................... 50
Figure 12-3 Service Menu (page 1) ............................................................................................................ 50
Figure 12-4 Service Menu (page 2) ............................................................................................................ 51
Figure 13-1. Proportional Gain Setting Effects ........................................................................................... 74
Figure 13-2. Open Loop Proportional and Integral Response .................................................................... 75
Figure 13-3. Closed Loop Proportional and Integral Response.................................................................. 76
Figure 13-4. Integral Gain (Reset) Setting Responses ............................................................................... 77
Figure 13-5. Closed Loop Proportional and Derivative Action .................................................................... 78
Figure 13-6. Derivative Setting Effects ....................................................................................................... 79
Figure 13-7. Closed Loop Proportional, Integral and Derivative Action ...................................................... 80
Figure 13-8. Typical Response to Load Change ........................................................................................ 81
Figure E-1. SOS .......................................................................................................................................... 98
Figure E-2. SOS Install Window ................................................................................................................. 99
Figure E-3. SOS Server status dialog box .................................................................................................. 99
Figure E-4. SOS – New Session box ........................................................................................................ 100
Figure E-5. SOS - Enter 505 TCP/IP address .......................................................................................... 100
Figure E-6. SOS – Active Links dialog box ............................................................................................... 100
Figure F-1. Control Assistant License Agreement .................................................................................... 102
Figure F-2. Control Assistant Install Window ............................................................................................ 103
Figure F-3. Control Assistant Folder Selection ......................................................................................... 103
Figure F-4. Control Assistant Install Complete ......................................................................................... 103
Figure F-5. Install Restart Window ............................................................................................................ 104
Figure F-6. Control Assistant Window ...................................................................................................... 104
Figure F-7. Dialog for Servlink OPC connection ....................................................................................... 105
Figure F-8. WinPanel Session .................................................................................................................. 105
Figure F-9. Control Assistant – Retrieve Tunable Dialog box ................................................................... 106
Figure F-10. Control Assistant – Send Tunable Dialog box...................................................................... 107
Figure F-11. Control Assistant – Speed Control Trend Script .................................................................. 108
Figure F-12. Control Assistant – Create Trend Script File ........................................................................ 108
Figure G-1. App Manager Install Window ................................................................................................. 109
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Figure G-2. App Manager License Agreement Window ........................................................................... 110
Figure G-3. App Manager Installation ....................................................................................................... 110
Figure G-4. App Manager Install Complete .............................................................................................. 111
Figure G-5. AppManager Window ............................................................................................................ 111
Figure G-6. Dialog for App Manager Connection ..................................................................................... 112
Figure G-7. App Manager Connected to a Control ................................................................................... 112
Figure G-8. AppManager Control Info Window ......................................................................................... 113
Figure G-9. AppManager Control (GAP) Application Panel ...................................................................... 113
Figure G-10. AppManager GUI Application Panel .................................................................................... 114
Figure G-11. Retrieving Files .................................................................................................................... 114
Figure H-1. Configuration/Communications Screen ................................................................................. 116
Figure H-2. Ethernet Port Layout (Ports on Side) ..................................................................................... 116
Figure I-1. Window Shown when the Time Limit is Exceeded .................................................................. 118
Figure I-2. Installation Welcome Window.................................................................................................. 118
Figure I-3. Installation Folder Window ...................................................................................................... 119
Figure I-4. Installation License Agreement Window ................................................................................. 119
Figure I-5. Installation Start Menu Shortcuts Window ............................................................................... 120
Figure I-6. Installation Ready to Install Window ........................................................................................ 120
Figure I-7. Installation Complete Window ................................................................................................. 121
Figure I-8. Entering an IP Address to be Added to the Control List .......................................................... 121
Figure I-9. Control Selected in the Control List ......................................................................................... 122
Figure I-10. Login Window with Fields for User Name and Password ..................................................... 122
Figure I-11. An Application Selected in the Application List ..................................................................... 123
Figure I-12. Default View of the Tool ........................................................................................................ 124
Figure I-13. Simple View of the Tool ......................................................................................................... 124
Figure I-14. Full View of the Tool .............................................................................................................. 125
Figure I-15. Entering a Name for the Current Settings ............................................................................. 125
Figure I-16. A New Settings File Entered in the Predefined Settings List ................................................ 126
Figure I-17. Remote View Tool (Default Setting) after Opening from the Configuration Window ............ 127
Figure J-1. HW Simulation Mode Access ................................................................................................. 128
Figure K-1. The Datalog Service Menu Page ........................................................................................... 131
Figure K-2. DataLog Graph Properties ..................................................................................................... 132
Figure K-3. Datalog Plot ............................................................................................................................ 133
Figure K-4. Automated File Collection Configuration ................................................................................ 134
Figure K-5. Automated File Collection Active ........................................................................................... 135

Table 9-1. CAN Wiring from 505 to VS-II .................................................................................................... 12

Table 10-1. Example Application Summary ................................................................................................ 23
Table 11-1 Mode Access by User Level ..................................................................................................... 47

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Manual 26839V2 505 Digital Control for Steam Turbines

Warnings and Notices

Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.

 DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
 WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
 CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
 NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
 IMPORTANT - Designates an operating tip or maintenance suggestion.

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,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure 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
Personal Protective the job at hand. Equipment that should be considered includes but is
not limited to:
Equipment
 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.

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
Start-up property damage.

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Manual 26839V2 505 Digital Control for Steam Turbines

Electrostatic Discharge Awareness

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
Electrostatic the control turned off, contact a grounded surface and maintain
Precautions contact while handling the control).
 Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
 Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not store
static electric charges as much as synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.
If you must remove the PCB from the control cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the components with conductive
devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.

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Manual 26839V2 505 Digital Control for Steam Turbines

Introduction

This volume of the manual contains application-specific notes, details on interfaces to other Woodward
products and example configurations of typical steam turbine applications.

This volume gives users an idea of the 505 Control’s capabilities, and how to apply them to a system.
Typical applications are schematically shown and their functionality explained. Programming and
Start/Run mode notes are given for each application to assist application programmers in configuring the
505 for their application.

Refer to Manual 26839, Volume 1 for Required Safety Instructions,

Special Conditions for Safe Use and Hazardous Location
Requirements to insure the control is used in a safe manner in
Ordinary, Marine, Hazardous, ATEX and IECEx locations. Volume 1
must be fully understood and complied with for all applications.

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Manual 26839V2 505 Digital Control for Steam Turbines

Chapter 8.
Service Tools

Overview
This chapter provides an overview of the service tool interfaces to the 505. Instructions for installing and
using these tools are found in the Appendices of this volume of the manual. All service tool interfaces to
the 505 are Ethernet connections and can be used on any of the 4 Ethernet ports. The only requirement
is that the PC connecting to the control has an IP address on the same domain (as with any typical
network).

Default settings for the Ethernet TCP/IP addresses can be found in Volume 1 Chapter 2.

Control Assistant (CA)

This tool is the primary service tool that will provide the following features:

 Uploading and Downloading Tunables (your complete configuration settings)

 Live trending of any I/O signal or control parameter
 Troubleshooting any system problem by viewing software variables in the system
 Analyzing any Datalog files that are collected from the control

Refer to the Appendices of this volume for instruction on using Woodward’s Control Assistant Software
Service Tool (Version 4.7 or newer).

Servlink-to-OPC-Server (SOS)
Integrated with control assistant is the Woodward Servlink-to-OPC-Server (SOS) program that provides
the communication data link between the 505 and a user PC or system HMI. The SOS program will run
on the PC as a service and convert the 505 Woodward proprietary Servlink data to OPC data. The
Control Assistant tool will connect as a client to the SOS server. Customers desiring to link to OPC data
from the 505 will need to also connect to SOS.

AppManager (AppMan)
This program is the primary tool for transferring files to and from the control. It will provide the user with
the following services:

 Transferring files to and from the control (executable control software, GUI software, datalog files,
system log files, control backup information)
 Setting the control Ethernet port IP addresses and the SNTP time synchronization IP address for
network time protocol synchronizing
 Installing a software service pack program
 Starting / Stopping the control program or GUI program

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Manual 26839V2 505 Digital Control for Steam Turbines

Chapter 9.
Peripheral Devices

Overview
This chapter provides a brief explanation of other Woodward devices that can be easily integrated with
the 505. By understanding the functionality of a peripheral device, a better understanding of the overall
control configuration can be achieved.

Some of these devices are able to be connected to the 505 by a digital communication link (either
Ethernet or CAN depending on the product). Through this link the 505 display will allow the user to
monitor many signals and status LED’s from this external device. In many cases, these connections allow
the 505 to receive required input signals, such as KW Load or a Synchronization or Load Sharing Bias
signal. This eliminates the need for wiring these signals to typical I/O channels, or the digital signal can be
used as a redundant/backup signal to a hard-wired signal.

Devices supported in the 505 control application will be identified with a “Woodward Link” identifier

All the devices covered in this section are manufactured or supported by Woodward. Peripheral devices
manufactured by other companies can be used with the 505 to perform the functions detailed bellow,
however, the compatibility of them to the 505 and the application should be verified before system
operation.

DSLC-2 (Generator Synchronizer and Load Control)

Figure 9-1. DSLC-2

The DSLC-2 when connected to the 505 controller, can be used with generators to accurately sense 3
phase RMS generator output power and perform generator breaker synchronization. Other configurable
DSLC-2 functions include generator load-sharing, VAR or Power Factor control, process control, and
base load control.

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Figure 9-2. Configuration/Woodward Links/DSLC-2

This is a “Woodward Link” device.

To enable the Woodward Link feature select the check box on the screen above and enter the slave
address and the IP address of the DSLC-2 device. The figure above shows the factory default IP
addresses of the DSLC-2 and Ethernet port 3 of the 505. These settings will allow these 2 products to
communicate automatically once an RJ45 Ethernet cable is connected between Ethernet Port 3 of the
505 and Network B port on the DSLC-2.

Once this configuration is complete, the DSLC-2 can provide the Synchronization speed bias signal, the
Sync/load sharing bias signal, and the KW output of the generator. The radio buttons on the screen allow
the user to select the functions desired. The KW valued thru this link can be used as a secondary KW
input signal, is an analog input channel is already configured for a KW input.

The screens below show the available service screens that will now be accessible to monitor the DSLC-2.

Figure 9-3. Service Screen - DSLC-2 Power Parameters

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Figure 9-4. Service Screen - DSLC-2 Status Parameters

VariStroke II (Electro-Hydraulic Actuator)

Figure 9-5. VS-II

This is a “Woodward Link” device.

The VariStroke-II is a linear electro-hydraulic actuator that is designed to provide the linear actuation
force to operate steam turbine control valves or valve racks. This actuator can be directly networked with
the 505 controller to reduce system complexity and wiring requirements.

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Figure 9-6. Configuration/Woodward Links/VS-II

To enable the Woodward Link feature select the check boxes on the screen above to enable the CAN1
Link and confirm usage of the VariStroke II actuator, then enter the Device ID. If an analog (4-20 mA)
demand signal is going to be connected to the VariStroke in addition to the CAN link, then select the
desired function for this signal (AI Backup is recommended). Finally select the inlet steam valve that is
being controlled (for most applications it is HP Demand).

Table 9-1. CAN Wiring from 505 to VS-II

505 Function VariStroke II

CAN 1 – terminal 1 COM TB6-A (Top) – terminal 35
CAN 1 – terminal 2 CAN LO TB6-A (Top) – terminal 32
CAN 1 – terminal 4 CAN HI TB6-A (Top) – terminal 31
Connect a termination resistor
across CAN 1 – terminals 2 & 4

Once this configuration is complete, the VariStroke-II digital communication link will provide the actuator
demand signal to the steam valve and the screen below will now be available under the Service menu to
monitor driver information.

Figure 9-7. Service/VariStroke II

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MFR300 (Multi-function Relay)

Figure 9-8. Multi-Function Relay

This is a “Woodward Link” device.

The MFR 300 is a multi-function generator protection relay used to sense and protect small generators.
This multi-function protection relay integrates all generator protection functions into one common device
reducing overall system installation complexity and cost.

LS-5 (Protection/Breaker Control Relay)

Figure 9-9. LS-5

This is a “Woodward Link” device.

The LS-5 series protection relays integrate generator breaker synchronization, power sense and
protection functions all into one package. This device is designed to function in combination with a prime
mover controller like the 505 to allow accurate generator control as well as provide required generator
protection.

Servo Position Controller (SPC)

A Servo Position Controller (SPC) can be used to interface the 505 digital controls to existing valve
operators or Woodward actuators that are integrating in action or are not compatible with the 505 directly.

The 505’s actuator outputs have the capability of driving a 4–20 mA or 0–200 mA (200 mA max)
proportional signal into an actuator coil. These actuator output signals represent a demand signal equal to
desired valve position (proportional). If the turbine’s actuator or servo assembly requires a different drive
signal, or control action (integrating with a null setting), an SPC or equivalent device must be used.

Woodward Servo Position Controller (SPC) accept a 4–20 mA actuator-drive signal proportional to
desired valve position and positions a servo assembly accordingly. Woodward SPCs have the capability
of driving unipolar or bipolar actuator demand signals, up to 0–400 mA or +400 mA respectively, on
proportional or integrating servo assembles.
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Figure 9-10. Servo Position Controller

The SPC comes with a user-friendly software interface program that allows the user to configure the unit
to the desired settings. Consult the SPC manual for complete details on the types of actuators to which
the SPC can interface. Below is one example of how the 505 and SPC can be used on Integrating Servo
Valves. The SPC can also handle many variations of feedback devices.

Figure 9-11. Interface to Servo Position Controller

(Example of Integrating Actuator with a 4-wire Feedback device)

Real Power Sensor

A Real Power Sensor is used to sense the real power being produced by a generator, or flowing through
a tie line. Woodward Real Power Sensors sense three phase volts, three phase amps, compare each
phase’s voltage to current relationship, and develop a 4–20 mA output proportional to real power.

Woodward manufactures two types of Real Power Sensors. The first type of RPS is designed to sense
power flow in one direction only (0 to +5 A CT current only), and output a proportional 4–20 mA signal.
This type of RPS was designed for and should be used to sense generator power output. Many different
real power sensors of this type exist. Some of the optional RPS features include VAR sensing, Load
sharing, 0–1 A CT current sensing, and multiple combinations of these. Please consult a Woodward
certified distributor or a Woodward factory for the recommended RPS for your application.

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Figure 9-12. Real Power Sensor

The second type of RPS manufactured by Woodward is designed to sense power flow through a bus-to-
bus tie line. This RPS (8272-726) senses –5 A to
+5 A CT current to allow its output to represent power flow in both directions. This RPS provides a 4–20
mA power indication output signal where 12 mA represents 0 power flow. It is recommended that this
RPS be used to sense power flow through a tie line only. This RPS or equivalent is required to sense
plant Import and Export power.

Woodward Real Power Sensors have terminals labeled “Output” and terminals labeled “KW Readout”.
The “KW Readout” terminals provide a 4–20 mA signal proportional to real power which is used by and
compatible with the 505 control. Thus the RPS terminals labeled “Output” are designed and typically
compatible only to Woodward’s 2301 type of control.

Woodward manufactured Real Power Sensors have a 2.5 Hz Low pass filter (400 ms lag time) on their
output to filter out the high frequency noise typically created in a switch gear type environment. Thus if
another vender’s watt transducer is used, verification that it has similar filtering criteria should be
performed before it is applied with the 505. For more information on Woodward Real Power Sensors,
please refer to Woodward manual 82018.

Engine Generator Control Package/Load Sharing (EGCP-3 LS)

The Woodward EGCP-3 LS control is a microprocessor based generator load control designed for use on
three-phase ac generators with Woodward speed controls and automatic voltage regulators. The EGCP-3
LS is a synchronizer, a load control, a dead bus closing system, a VAR/PF control, a process control,
Power & Energy metering and Protective Relays integrated into one package.

The EGCP-3 LS has a keypad and two 4-line display panels on the front cabinet mounted chassis. The
display can be used to configure and set up the control for site-specific requirements. The display is also
used in normal operating service to monitor operation and view alarm data. All functions performed and
parameters monitored by the front panel are also available through the three serial ports. These ports can
be configured to use Woodward Watch Window software, an external HMI and Modbus communication,
or Servlink DDE software.
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The 505 can be programmed to use the EGCP-3 LS as a synchronizer only, or as a synchronizer and
load control. The EGCP-3 LS provides either phase match or slip frequency synchronizing, and ties into
the unit automatic voltage regulator to match voltages before paralleling. It interfaces with the 505 via a
Speed bias signal to control generator frequency and phase. When configured to use the EGCP-3 LS as
a synchronizer only, the 505 must be programmed to receive the EGCP-3 Speed Bias signal through an
analog input and have this input enabled through a contact input or function key.

When used as a synchronizer and load control, the EGCP-3 LS performs automatic synchronization, and
controls unit load based on the EGCP-3 s mode of operation. The EGCP-3 LS can be in a base-load,
load sharing, remote load setting, or Process control mode, depending on configuration and system
conditions.

The EGCP-3 LS’s load sharing mode is used to share load with any other units using an EGCP-3 LS and
tied to the same isolated bus. This mode is used in conjunction with an EGCP-3 MC when paralleled to a
utility to allow the EGCP-3 MC to control plant frequency or load depending on its state of operation.

The EGCP-3 LS’s remote load setting mode allows load to be set by a remote 4-20 mA signal. The
EGCP-3 LS’s Process control mode allows any process directly related to generator load to be controlled.

After synchronization, unit load can be controlled by the EGCP-3 LS (through the 505 Sync/Ld input) or
by the 505’s internal speed/load set point. When the Sync/Ld Share input is programmed, the position of
the Utility Tie Breaker Contact selects unit load control through the EGCP-3 LS or through the 505’s
internal load set point.

Once the generator is synchronized the EGCP-3 LS soft-loads the unit to the load setting determined by
the mode of operation (base load, load sharing, Process control). When commanded the EGCP-3 LS can
also soft-unload the unit and issue a breaker-open command at a set power level.

The PowerSense board receives the PT and CT inputs for both the generator and bus for calculation of
parameters for the EGCP-3 to use in system control. The algorithms used are based on IEEE 1459-2000.
For the generator and bus the following parameters are provided: Hz, Vac, Amps, W, VA, VAR, PF,
Phase, Voltage harmonics, Current harmonics, Negative Phase Sequence Voltage, Negative Phase
Sequence Current. Available for selection at the 4–20 mA analog outputs: Synchroscope, Generator
metering, Mains metering.

Figure 9-13. EGCP-3 Control

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Figure 9-14. EGCP-3 LS Functional Diagram

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Figure 9-15. EGCP-3 LS Interface Wiring

The following Bus Protections are available with the EGCP-3 LS:

 Over/Under Voltage (59, 27)

 Over/Under Frequency (81O, 81U)
 Directional (Forward/Reverse) Power (32) *
 Negative Sequence Phase Overcurrent (46)
 Negative Sequence Phase Overvoltage (47)
 Phase Overcurrent (51) *
 Voltage Restrained Phase Overcurrent (51V) *
 Directional VAR
 Phase Current Imbalance (46) *

The following Generator Protections are available with the EGCP-3 LS:

 Over/Under Voltage (59, 27)

 Over/Under Frequency (81O, 81U)
 Directional (Import/Export) Power (32)*
 Negative Sequence Phase Overcurrent (46)
 Negative Sequence Phase Overvoltage (47)
 Phase Overcurrent (51) *
 Directional VAR
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 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 9-16. Typical Redundant I/H System with a Transfer Valve

Figure 9-17. Typical Redundant I/P System with a Pressure Selecting Relay Valve

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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.

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Chapter 10.
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:

 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)

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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.

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.

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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 10-1. Example Application Summary

Application Examples
1 2 3 4 5 6 7
Turbine Mechanical Drive X
Type Synchronous Generator X X X X X
Induction Generator X
Control Auxiliary Limiting X X X X
Functions Auxiliary Control X
Cascade Control X X X X X
Synchronizing X X X X X
Load Sharing X X
Frequency Control X X
Control Inlet Pressure Control X X
Modes Min Inlet Pressure Limiting X
KW Load Control X
KW Load Limiting X X
Import/Export Load Control X X
Import/Export Load Limiting X

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Example 1–Pump or Compressor Discharge Pressure Control with Turbine Inlet

Pressure Limiting

Figure 10-1. 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 10-1 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.

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.
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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 10-1:

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)

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)

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.

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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.

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Example 2–Inlet Pressure Control with Automatic Synchronizing & Generator

Power Limiting

Figure 10-2. Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting

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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
10-2 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 10-2 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 overpowered. 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 10-2.

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)

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)

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Manual 26839V2 505 Digital Control for Steam Turbines

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)

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)

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 10-2). When this switch is closed the 505’s
Synchronizing input is enabled, and the EGCP-3 LS’s automatic synchronizing function is selected.

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Manual 26839V2 505 Digital Control for Steam Turbines
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.

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.

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Manual 26839V2 505 Digital Control for Steam Turbines

Example 3–Exhaust Pressure Control with Generator Power Limiting and Plant
Import/Export Limiting

Figure 10-3. Exhaust Pressure Control with Generator Power Limiting and Plant Import/Export Limiting

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 10-3 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.

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Manual 26839V2 505 Digital Control for Steam Turbines
Because turbine load may vary greatly with this application, a limiter is used to protect the generator from
being overpowered. To limit generator load, the 505 control must be able to sense generator load. As
shown in Figure 10-3 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 10-3.

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)

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)

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Manual 26839V2 505 Digital Control for Steam Turbines

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.

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)

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).

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.

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Manual 26839V2 505 Digital Control for Steam Turbines

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 10-3). When this switch is closed the 505’s
Synchronizing input is enabled, and the EGCP-3 LS’s automatic synchronizing function selected.

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 10-4 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.

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Manual 26839V2 505 Digital Control for Steam Turbines

Figure 10-4. 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.

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Manual 26839V2 505 Digital Control for Steam Turbines
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 10-4, 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 10-4.

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)

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).

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)

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Manual 26839V2 505 Digital Control for Steam Turbines
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.

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 10-4). 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.

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Manual 26839V2 505 Digital Control for Steam Turbines

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 10-5 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.

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Manual 26839V2 505 Digital Control for Steam Turbines

Figure 10-5. 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 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.

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Manual 26839V2 505 Digital Control for Steam Turbines
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 10-5 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 10-5.

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).

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.

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.

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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 10-5). 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.

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Example 6–Import/Export Control or Exhaust Pressure Control with Isoch Load

Sharing in Island Mode

Figure 10-6. 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 10-6 and described below.

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.

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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 10-6 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, 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 10-6.

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)
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For good response and load adjustment resolution, Droop (LSS bus position) was set to 5% of rated
speed. (Droop = 5 %)

It was desired to always switch to Frequency/Loadsharing control, 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)

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%)

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 10-6). 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).

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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.

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-to-utility 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.

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Chapter 11.
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.

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
Screen Tutorial 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 11-1 505 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.

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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 11-1,
Mode Access by User Level.

Table 11-1 Mode Access by User Level

Mode
Operation Calibration Configuration
Monitor
User Operator X
Level 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.

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.

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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. Bring the displayed value to within 10% of the value to be entered

2. Press the ENTER key
3. Press the numerical keys to input the value
4. 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.

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Chapter 12.
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 12-1. 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 12.2 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.

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Figure 12-2. 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.

Figure 12-3 Service Menu (page 1)

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Figure 12-4 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.

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 setpoint; use min load; min load bias;

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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.

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

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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.

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.

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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.
Online Speed Dynamics Speed Level dflt= Min Gov (Low Idle, Max Gov)
For Mechanical Drive only. When Speed increases above this value the control switches to Online
Dynamics. The value default is Minimum 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 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.
GENERATOR BREAKER OPEN DISABLE ? dflt= NO (Yes/No)
When set to YES, the control will automatically disable the Remote Speed Setpoint whenever the
Generator Breaker opens.

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UTILITY BREAKER OPEN DISABLE ? dflt= NO (Yes/No)
When set to YES, the control will automatically disable the Remote Speed Setpoint whenever the Utility
Tie Breaker opens.

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.

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)
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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. This setting only affects how the
command to rated is handled, it is independent of the Idle Priority selection chosen above.

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.

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)
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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).
GEN OPEN SETPOINT (RPM) dflt= xxx (0.0, 20000)
This set point is defaulted to 50 rpm below the synchronous (rated) speed set point. 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

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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.

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.
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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.
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.

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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)

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.

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.

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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.
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)

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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.
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.

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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.
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.

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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.

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.

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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.
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.
Use TRIP from Remote View? dflt= No (Yes/No) -
Check this box to enable a TRIP command option from the STOP button popup dialog box. This is
intended for issuing a Trip command from RemoteView, however it will be available on the local
display also.

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.

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.

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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.
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.

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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 non-extraction 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.

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)

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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.

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. This requires that the 505 have an Ethernet
connection to the plant network.
SNTP IP Address Enter your network time sync IP
SNTP Rate (sec) How often the 505 will get the sync pulse from the network
SNTP Timeout (sec) Failure to receive an update from the network within this time will result in an
SNTP fault alarm

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.
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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.
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.
MANUAL DEMAND (status indication only)
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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.
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.

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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.
SELECT BOOT-UP SCREEN dflt= HOME (Run/Operate Screens) -
This option allows the user to select which screen the display switches to after it boots-up
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.
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.
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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.
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.

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Chapter 13.
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.

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.

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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 13-1. Proportional Gain Setting Effects

Proportional Gain (effect of settings)

Figure 13-1 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.

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Figure 13-2. Open Loop Proportional and Integral Response

Integral response is provided to eliminate the offset that resulted from straight Proportional control. Figure
13-2 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 13-3 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.

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Figure 13-3. Closed Loop Proportional and Integral Response

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 13-4 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.

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Figure 13-4. 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.

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.

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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 13-5 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.

Figure 13-5. Closed Loop Proportional and Derivative Action

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Derivative (effects of settings)

Figure 13-6. Derivative Setting Effects

Figure 13-6 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 13-7 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.

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Figure 13-7. 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).

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.

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A controller configured as feedback dominant is more sensitive to the change-of-rate 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.

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
13-8). It is wise to wait until approximately 90% of the change has been completed.

Figure 13-8. 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.

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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.

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Chapter 14.
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 re-
measure 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.

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).

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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.

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Appendix B.
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

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The “nominal rate” listed is the fastest update rate, the worst case
response would be twice the nominal rate.

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Appendix C.
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 YES NO
Hold Limiter Changes YES NO

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MPU OVERRIDE
Use MPU Override Timer? YES NO
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

AUTOMATIC START SEQ (if configured)

Hours Since Trip (status) Hrs
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 (status)
Pressure 1 units
Gain 1
Pressure 2 units
Gain 2
Pressure 3 units
Gain 3
Pressure 4 units
Gain 4
Pressure 5 units
Gain 5

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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 s
Hold Changes 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 units/s
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

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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 units/s
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

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Breaker Enables Control YES NO

Display Gauge Multiplier
Hold Cascade Changes YES NO
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

COMMUNICATIONS
Modbus Settings
Use Modbus Trip YES NO
Use 2-Step Trip YES NO
Serial Port 1
Link Status (status)
Exception Error (status)
Timeout Delay s
Error Code (status)
Ethernet Port 2
Link Status (status)
Exception Error (status)
Timeout Delay s
Error Code (status)
Ethernet Port 3
Link Status (status)
Exception Error (status)
Timeout Delay s
Error Code (status)
Servlink
Socket 1
IP (status)
Status (status)
Level (status)
Socket 2
IP (status)
Status (status)
Level (status)
Socket 3
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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)
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
Use TRIP from Remote View? YES NO

ALARMS
Trip is an Alarm YES NO

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Blink Alarms YES NO

Shutdown on Power-Up? YES NO

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 %
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 %
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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%
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 units
Process (status)
Demand %
Remote Setpoint Enabled (status)
Remote Setpoint Fault (status)
Auto Control (status)
Process Input Fault (status)

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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 (status)
Remote Rate units/s
PID Dynamics
P Term
I Term
DR Term

SCREEN SETTINGS
Screen Saver Delay hrs
Select Boot-Up Screen
Auto Login as Operator? 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

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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 YES NO

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

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Appendix D.
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: Operator
Password: wg1111

“Service” User Level Password

Login as Service:
Login: Service
Password: wg1112

“Configure” User Level Password

Login as Configure:
Login: Configure
Password: wg1113

“ServiceUser” User Level Password

Login as ServiceUser (no autofill key available, must be entered manually):
Login: ServiceUser
Password: ServiceUser@1

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Appendix E.
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 E-1. SOS

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Figure E-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 E-3. SOS Server status dialog box

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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 E-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 E-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 E-6. SOS – Active Links dialog box

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Changing the Control ID

The default Control ID of production units can be found on the back label that includes the default IP. For
example

FLEX00042364 172.16.100.15

The Control ID can be changed via SOS by right clicking the session and selecting “Set ControlId” Type
in the new Control ID and press ‘Set’ to commit the change. The new Control ID can be used with Control
Assistant Trend Scripts, etc.

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Appendix F.
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 F-1. Control Assistant License Agreement

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Figure F-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 F-3. Control Assistant Folder Selection

Choose the desired folder in the ‘Start Menu’ to save the shortcuts.

Figure F-4. Control Assistant Install Complete

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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 F-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

The System Documentation (BCD-85282) for the 505 contains files that can be used with Control
Assistant.
1. Trend Script files (.ts) that can be used as a template to view live data
2. A tunable file (.tc) of the Factory Default settings of all tunable settings in the control.

The Factory Default tunables are useful when training personnel on how a spare unit will look when
initially powered, and then step through the procedure below to install site specific settings.

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 F-6. Control Assistant Window

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Next click on the New Winpanel icon in the toolbar- and the following dialog box will appear.

Figure F-7. Dialog for Servlink OPC connection

Clicking on Connect will open a WinPanel window that will look like the figure below.

Figure F-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.

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.

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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. The first step is to follow the above steps up to the point of having a WinPanel open and the correct
control selected
2. Select Transfer/Receive Debug Tunable List from the menus or the Retrieve Icon from the tool bar

(Note the send icon is not available)

The following box should appear

Figure F-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. From within Control Assistant Open the tunable (.tc) file

2. 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
4. Once selected a dialog box will appear asking for the Debug password – Enter 1112
5. 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

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6. Click on the tunable file and select Transfer/Send Tunable List from the menus or the Send Icon from

the tool bar (Note in this state both retrieve and send are available)
7. The following box should appear

Figure F-10. Control Assistant – Send Tunable Dialog box

8. Click on Store and the control will save these values.

9. 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.

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 always show the time difference between the 2
cursers lines.

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.

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Figure F-11. Control Assistant – Speed Control Trend Script

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 F-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.

Opening a Trend Script File as a Template

Opening a trend script file that was saved for a different control can be opened for a different control (with
a different control ID) by opening the trend scrip as a template.

Click File > Open script as a template… > Select the Trend Script

Control Assistant will then pull up a list of all the controls available in SOS. Select the control you would
like to apply the Trend Script to.

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Appendix G.
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 G-1. App Manager Install Window

Select Next to continue with the installation.

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Figure G-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 G-3. App Manager Installation

Choose the desired folder in the ‘Start Menu’ to save the shortcuts.

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Figure G-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 G-5. AppManager Window

AppManager will display three 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.

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Figure G-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 G-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).

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Figure G-8. AppManager Control Info Window

Switching Application Panel Views

The application panel has two 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 button
on the far right side (the second button down from the top).

Figure G-9. AppManager Control (GAP) Application Panel

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Figure G-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 G-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.

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.

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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

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Appendix H.
Configuring Network TCP/IP Addresses

Figure H-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 H-2. Ethernet Port Layout (Ports on Side)

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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.

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
IP Conflicts 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.

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Appendix I.
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 I-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
like 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 I-2. Installation Welcome Window

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.

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Figure I-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 I-4. Installation License Agreement Window

Select “Next” to continue.

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.

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Figure I-5. Installation Start Menu Shortcuts Window

Select “Next” to continue.

The Ready to Install window will open.

Figure I-6. Installation Ready to Install Window

Select “Install” to continue.

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.

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Figure I-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.

Figure I-8. Entering an IP Address to be Added to the Control List

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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 I-9. Control Selected in the Control List

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 I-10. Login Window with Fields for User Name and Password

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The first line in the login window is the username. The default username 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.

Figure I-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.

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Figure I-12. Default View of the Tool

Figure I-13. Simple View of the Tool

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Figure I-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 I-15. Entering a Name for the Current Settings

After clicking “Save”, the settings file will be displayed in the list, as shown in the following figure.

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Figure I-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.

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Figure I-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 manuals. 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.

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Appendix J.
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 two buttons and an LED which will Enable and Disable the H/W simulation mode.

Figure J-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

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

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Appendix K.
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.

10) Stop and start the appropriate wgui application

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Appendix L
Datalogs

Overview
The 505 controller has two internal datalog functions which collect time series data into a memory buffer.
The buffer contains data for the amount of time given in the ‘Collection Time’ field on the Datalog page
within the Service Menu. Only the latest data is stored in the buffer meaning that old data outside of the
Collection Time window is overwrite with new data as it comes in. The buffer is written to a file after an
event such that it can be retrieved for analysis (using AppManager and Control Assistant).

The Fast DataLog is a fixed configuration which samples and stores data every 10ms and contains
approximately three minutes of data per file. The TrendLog is configurable down to 10ms sample rates,
but is defaulted for one second and is intended to provide historical process data (about five hours of data
per file). The data which is stored includes all IO channels, controller inputs and output, limiters, and other
pertinent information in order to analyze the system. This data set is fixed for the Fast DataLog. The
TrendLog contains the same base data set but can also have signals added through a configuration file.

The datalog buffer begins collecting data automatically when any of the following occur
1. User command from the Datalog page in the Service Menu
2. The turbine is started
3. A file is stored on the drive

The datalog stops when

1. User command from the Datalog page in the Service Menu
2. A shutdown

A datalog file is automatically printed to the Hard Drive for retrieval when the datalog is stopped, which in
turn restarts the datalog buffer when the file is printed. The control will store three log files per datalog
type and will then overwrite previous datalog files when a new file is generated. The files are indexed with
a value from 1 to 3 which increments each time a new file is generated.

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Figure K-1. The Datalog Service Menu Page

Datalog File Retrieval

Datalog files can be retrieved from the 505 for analysis using AppManager (see Appendix F).

Datalog File Analysis

Datalog files can be opened with Control Assistant once it has been downloaded onto your PC from the
505 using AppManager. With Control Assistant open, go to File > Open… and navigate to file location on
your PC and select Open.

The Graph Properties page will open with the list of available signals in the left window. Signals to be
plotted, referred to as pens, can be moved from the available signals list to the right window. Once in the
right window, the pen color and order can be customized:

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Figure K-2. DataLog Graph Properties

The graph can be generated by selecting OK in the Graph Properties Menu. Once generated, the plot is
given in the top portion of the screen and the pen details are given on the bottom. The Scale(Low) and
Scale(High) are automatically set initially but can also be set manually. Two cursors can be dragged on
the plots in order to see exact values and compare data between two-time stamps (Y1 column in the Pen
details is Cursor 1, Y2 column is Cursor 2, and Delta-Y is the change in the signal value between the two
cursors). In the bottom right-hand corner of the window, the ‘Time Difference’ is given in seconds and is
the amount of time difference between the cursors. Please see the help menu within Control Assistant for
detailed information on all menu options.

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Figure K-3. Datalog Plot

Automated File Collection

The Automated File Collection feature of AppManager can be used to download new datalog files from
the control to a PC to ensure that datalogs are backed up. In this case, AppManager will download Fast
Datalogs, TrendLogs, and the ‘ae_eventlog.csv’ every time a new file is generated (in the case of a trip or
manual datalog).

In AppManager, go to Automated File Collection > Configure Automated File Collection Task. Select the
control from the ‘Available Control’ list and add it to the ‘Controls to gather files from’ list. Within the
‘Datalog retrieval options’, set the folder on your PC where files will be stored. Press ‘OK’ to exit the
configuration menu.

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Figure K-4. Automated File Collection Configuration

After clicking OK you will be prompted if you would like to start collecting now – if yes – it will gather all
current datalog files on the control (including all existing FAST_DLOG and TREND_DLOG files). To begin
collecting files you can also go to Automated File Collection > Start Automated File Collection Task. Once
started, AppManager will display ‘Monitoring Network for New Files’ in the bottom window indicating that
new files on the control are automatically saved to your PC.

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Figure K-5. Automated File Collection Active

Adding Signals to the TrendLog

If needed – additional parameters can be added to this datalog file at run-time. Using AppManager
retrieve the current file from the control (filename = trend_dlog.logconfig). Use Control Assistant to modify
the file. Increment the revision number at the top for reference (this can be seen in GAP / WinPanel to
verify file being used). Then use AppManager to place the file back on the control in the control
applications folder.

The datalogging must be stopped and then restarted to use the updated file.

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 We appreciate your comments about the content of our publications.
Send comments to: [email protected]

Please reference publication 26839V2.

ÌB26839V2è:èD´ºµ¸¶¸Î

PO Box 1519, Fort Collins CO 80522-1519, USA

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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.