Product 

Specification 03422 
(Revision NEW, 2/2015) 

505 Digital Control 
for Steam Turbines 

Applications   Field-configurable
The 505 controller is designed  Integrated graphical
to operate industrial steam operator control
turbines of all sizes and
applications. This steam
panel
turbine controller includes
specifically designed
 Automatic start
algorithms and logic to start, routines
stop, control, and protect
industrial steam turbines or  Integrated first-out
turbo-expanders, driving problem indicator
generators, compressors,
pumps, or industrial fans.  Trip and Alarm
The 505 control’s unique PID event recorder
structure makes it ideal for
applications where it is  User-friendly menu
required to control steam plant parameters like turbine speed, turbine load, turbine inlet format
header pressure, exhaust header pressure, or tie-line power.
The control’s special PID-to-PID logic allows stable control during normal turbine operation  Real-time trend
and bumpless control mode transfers during plant upsets, minimizing process over- or screens
undershoot conditions. The 505 controller senses turbine speed via passive or active speed
probes and controls the steam turbine through one or two (split-range) actuators connected to  Turbine run-time
the turbine inlet steam valves. logs
The 505 controller also includes the following turbine protection functions to ensure that the
turbine or its driven load (compressor, pump, generator) is not operated outside of its  Real-time clock
designed limits: synchronization via
 3 Critical speed avoidance bands SNTP
 Overspeed anticipation and shutdown protection
 Configurable under- or over-pressure shutdown logic  Ethernet
 Minimum and maximum speed and load settings communications
Ethernet and serial communications allow users to easily connect the 505 into the plant or
process control system. All controller inputs, outputs, and statuses can be monitored, and all  Same form-fit-
®
start/stop or enable/disable commands can be given through industry standard Modbus * function as previous
TCP or OPC protocols. The 505 uses SNTP (synchronized network time protocol) over
Ethernet to allow users to synchronize the 505’s real-time clock to the plant distributed control
505 versions
system.
* Modbus is a trademark of Schneider Automation Inc.
 Sulfur-resistant
conformal coating
Description   Certified for
The 505 control is packaged in an industrial hardened enclosure designed to be mounted Hazardous
within a system control panel located in a plant control room or next to the turbine. The Locations (low-
control’s front panel serves as both a programming station and operator control panel (OCP). voltage models)
This user-friendly front panel allows engineers to access and program the unit to the specific
plant’s requirements, and plant operators to easily start/stop the turbine and enable/disable
any control mode. Password security is used to protect all unit program mode settings. The
controller’s 8.4-inch (21 cm) graphical display allows operators to view actual and setpoint
values from the same screen, simplifying turbine operation.
Turbine interface input and output wiring access is located on the controller’s lower back
panel. Un-pluggable terminal blocks allow for easy system installation, troubleshooting, and
replacement.
 Woodward 03422 p.2

Designed for steam turbine control, the 505 control includes operator control panel and/or engineering station. Once
four PID controllers (Speed, Cascade, Aux-1, Aux-2), multiple loaded onto a remote computer or touch panel, this software
start-up routines (manual, semi-auto, automatic, remote program allows the computer or touch panel to perform all of
control), and multiple protection functions (overspeed, critical the 505 front panel display functions (monitor, operate, tune,
speed range, max power, etc.) which can be configured by a and configure). Password-based login level security allows
user depending on the specific turbine application’s users to manage which functions they want the remote panel
requirements. Users can configure the 505’s different PID user to have. Refer to product specification 03424 for more
controllers, start routines, and protection levels themselves information on RemoteView’s capabilities.
without the need for a special control engineer. Once
configured, the 505 performs a configuration check routine to The 505 includes a suite of service tools to allow users to
ensure that the programmer did not make any basic perform the following functions:
configuration mistakes.  Download configuration settings files to the 505
 Upload configuration settings files from the 505 to save on
Optionally, users can utilize Woodward’s RemoteView another device
software program with the 505 to function as a remote  View real-time or saved trend files

Figure 1. Example RemoteView Screens

Cost‐Effective Design  System Protection 
The 505 control is designed to function as the turbine control,
system sequencer, operator control panel, and first-out  Integral Overspeed Protection Logic & Test Capability
indicator. This encompassing design minimizes external  First-out Indication (10 individual shutdown inputs)
system devices as well as system installation, wiring, and  Stuck in critical speed band logic
troubleshooting.  Bumpless transfer between control modes if a transducer
failure is detected
This field-configurable controller allows major functional  Local/Remote Control priority and selection
changes to be made on-site, often by knowledgeable plant  Fail-safe Shutdown Logic
personnel, and minor functional changes to be on-line as  Mode login level password security
process changes require. The 505 control’s first-out-indicator
logic indicates internal as well as external system related
alarm and shutdown conditions, greatly simplifying and Control Specifications 
reducing system troubleshooting.
INPUTS
Communications   Power: LV models = 18–32 Vdc
HV models = 88–264 Vac & 90–150 Vdc
The 505 controls can communicate directly with plant  Speed: 2 Passive MPUs or 2 Active Proximity probes
Distributed Control Systems and/or CRT-based operator (0.5—32 000 Hz)
control panels, through four Ethernet ports using Modbus TCP  Discrete Inputs: 20 Configurable Contact Inputs
or OPC communication protocols, or via one serial Modbus  Analog Inputs: 8 Configurable 4–20 mA Inputs
port. The single serial port supports RS-232 or RS-485 OUTPUTS
communications using ASCII or RTU Modbus protocols.
 Valve/Actuator Drivers:
Communications between the 505 and a plant DCS can also 2 Actuator Outputs, 4–20 mA or 20–200 mA
be performed through hard-wired connections.  Discrete Outputs:
8 configurable Relay Outputs (2 relays rated
Control  for 24 Vdc @ 5 A, 6 relays rated for 24 Vdc @ 2 A)
 Analog Outputs:
6 Programmable 4– 20 mA Current Outputs
The following PIDs are available to perform as process
controllers or limiters: COMMUNICATIONS
 Speed/Load PID (with multiple dynamics & Adaptive PID)  Ethernet: 4 ports (Modbus TCP or OPC protocols)
 Auxiliary PID 1 (limiter or control)  Serial: 1 Modbus port (ASCII or RTU) Comm Ports
 Auxiliary PID 2 (limiter) (RS-232 or RS-485 compatible)
 Cascade PID (Header Pressure or Tie-Line Control)  CAN: 4 ports (Woodward CANopen protocol)
 Woodward 03422 p.3

 Remote analog setpoints for Speed/Load, Aux, and

Functionality  Cascade
 High Speed Digital Communications to Woodward
The 505’s control capabilities are: actuators and power management products
 Speed/Frequency Control
 Turbine or Generator Load Control or Limiting Control Accessories 
 Turbine Inlet Header Pressure Control or Limiting
 Turbine Exhaust Header Pressure Control or Limiting RemoteView—Once installed on a computer or touch panel,
 Plant Import/Export Power Control or Limiting the RemoteView software program can be used as an
 Isochronous Load Sharing between units (with DSLC™-II engineering workstation and/or remote operator control panel.
control) As an operator control panel, this software program can be
 Control of any process directly related to unit load used to monitor all system parameters, start and stop the
turbine, and enable/disable all modes of operation.
Features  Control Assistant—The Control Assistant software program
functions as an engineering workstation and/or service tool
 Critical Speed Avoidance (3 speed bands) that can be used with the 505 control to view real-time trends,
 Auto Start Sequence (hot & cold starts) view saved trend files, or compare differences in configuration
 Valve Limiter(s) files. As an engineering workstation, this software program
 Security (program is password protected) can be used to upload and download settings and log files to
 Adaptive Speed/Load PID Dynamics and from the 505 controller (details in product spec 03424).
 First-Out Indication (shutdowns) AppManager—Tool for setting the IP addresses of the
 Zero Speed Detection with proximity probe (< 0.5 Hz) Ethernet ports, setting SNTP functionality, Program
 Peak Speed Indication for overspeed trip upload/download capability, retrieving datalog files, Start/Stop
 Multi-lingual Display (English & Chinese) the Display program (to change languages).

Operating Conditions 
 –30 to +70 °C ambient air temperature range
 Humidity: Lloyd’s ENV2 test #1
 Dry Heat: Lloyd’s ENV3
 Salt Fog: US MIL-STD-810 method 509.2 procedure 1
 Shock: meets US MIL-STD-810C, method 516.2-1, procedure 1B
 Vibration: Lloyd’s ENV2 test #1
Pollution Resistance
 Particulate Pollution Resistance: IEC 664-1 Pollution Degree 2 (normally only non-conductive pollution occurs)
 IEC 60068-2-60:1995 Part 2.60 Methods 1 and 4 (Flowing Mixed Gas Corrosion Test)
 Gaseous Pollution Resistance: Module conformal coating withstands NO2, CO2, SO2, and H2S gases
 Will withstand levels typical of telecommunications and computer installations as defined by Battelle Labs Class III (between
IEC60721-3-3 classification 3C1 and 3C2, light industrial to urban industrial, heavy traffic)

Regulatory Compliance—PENDING 
European Compliance for CE Marking
These listings are limited to only those units bearing the CE Marking.
 EMC Directive: 2006/95/EC COUNCIL DIRECTIVE
 ATEX Directive: 94/9/EC COUNCIL DIRECTIVE Zone 2, Category 3, Group IIG Ex nA [ic] IIC T4 X IP20
Other International Compliance
 CU-TR: Certified for use in explosive atmospheres within the Customs Union per certificate CU-RU-CU-TR
C-US-xxxxxxxxxx US.xxx as 2 Ex nA [ic] IIC T4 X
North American Compliance
 CSA Listed for Class I, Division 2, Groups A, B, C, and D, T4 at +70 °C
Marine Compliance
 Lloyd’s Register (LR): Environmental Category ENV1, ENV2, ENV3, Lloyd’s Register Type Approval Test Specification
Number 1, July, 2013
 Woodward 03422 p.4

Figure 2. Basic Functional Control Diagram

Figure 3. Typical 505 Application

 Woodward 03422 p.5

Figure 4. 505 Dimensions

(Do not use for construction)

For more information contact:

PO Box 1519, Fort Collins CO 80522-1519, USA
1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058
Email and Website—www.woodward.com

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