DOC.

NUMBER 11-MC-E-32907 735/2307

Installation and Operation Manual

505 Digital Governor for Steam Turbines

with Single or Split-Range Actuators

9907-162, 9907-163, 9907-164

Volume 1

Manual 85017V1 (Revision B)

 DOC. NUMBER 11-MC-E-32907 736/2307

WARNING—DANGER OF DEATH OR PERSONAL INJURY

WARNING—FOLLOW INSTRUCTIONS
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. Failure to follow instructions can cause personal injury and/or
property damage.
WARNING—OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNING—OVERSPEED PROTECTION
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.
WARNING—PROPER USE
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or property
damage, including damage to the equipment. Any such unauthorized modifications: (i)
constitute "misuse" and/or "negligence" within the meaning of the product warranty
thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product
certifications or listings.

CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTION—BATTERY CHARGING
To prevent damage to a control system that uses an alternator or battery-charging device, make
sure the charging device is turned off before disconnecting the battery from the system.
CAUTION—ELECTROSTATIC DISCHARGE
Electronic controls contain static-sensitive parts. Observe the following precautions to
prevent damage to these parts.
x Discharge body static before handling the control (with power to the control turned off,
contact a grounded surface and maintain contact while handling the control).
x Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit
boards.
x Do not touch the components or conductors on a printed circuit board with your hands
or with conductive devices.

IMPORTANT DEFINITIONS
x A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
x A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
x A NOTE provides other helpful information that does not fall under the warning or caution
categories.

Revisions—Text changes are indicated by a black line alongside the text.

Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1997
All Rights Reserved
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Manual 85017V1 505 Digital Governor

Contents

ELECTROSTATIC DISCHARGE AWARENESS .................................................. V

CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
General Description ................................................................................................3
505 Inputs and Outputs ..........................................................................................5
Control Overview ....................................................................................................8
Speed Control.........................................................................................................8
Auxiliary Control .....................................................................................................8
Load Sharing Input .................................................................................................9
Cascade Control .....................................................................................................9
Valve Limiter .........................................................................................................10
Starting Features ..................................................................................................10
Critical Speed Avoidance .....................................................................................11
Block Diagrams ....................................................................................................11
Keypad and Display..............................................................................................14
Watchdog Timer/CPU Fault Control .....................................................................16
CHAPTER 2. INSTALLATION PROCEDURES .................................................. 17
Introduction ...........................................................................................................17
Mechanical Data and Hardware Installation.........................................................17
Communications Grounding and Shielding ..........................................................33
CHAPTER 3. 505 CONTROL DESCRIPTION .................................................. 35
Introduction ...........................................................................................................35
Turbine Start .........................................................................................................35
Turbine Start Modes .............................................................................................37
Critical Speed Avoidance .....................................................................................40
Idle/Rated .............................................................................................................41
Automatic Start Sequence ....................................................................................42
No Idle Programmed ............................................................................................45
Speed Control Overview ......................................................................................45
Speed PID Operational Modes.............................................................................46
Cascade Control ...................................................................................................58
Auxiliary Control ...................................................................................................64
Remote Auxiliary Setpoint ....................................................................................68
Valve Limiter .........................................................................................................70
Emergency Shutdown ..........................................................................................70
Controlled Shutdown ............................................................................................71
Overspeed Test Function .....................................................................................72
Local/Remote Function ........................................................................................73
Function Keys .......................................................................................................74
Relays ...................................................................................................................74
CHAPTER 4. CONFIGURATION PROCEDURES .............................................. 77
Program Architecture ...........................................................................................77
Programming the 505 ...........................................................................................78
Exiting the Program Mode ..................................................................................101
Valve/Actuator Calibration & Test ......................................................................105
Calibration/Stroking Procedure ..........................................................................106
Calibration/Stroking Procedure ..........................................................................108

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505 Digital Governor Manual 85017V1

Contents

CHAPTER 5. 505 OPERATION ...................................................................112

Run Mode Architecture ...................................................................................... 112
Keypad and Display........................................................................................... 116
Run Mode Front Panel Keys ............................................................................. 116
Starting Procedures ........................................................................................... 117
Speed Key Screens ........................................................................................... 118
Overspeed Test Function .................................................................................. 122
F3 and F4 Keys ................................................................................................. 123
Limiter (LMTR) Key Screens ............................................................................. 123
Actuator (ACTR) Key Screens .......................................................................... 124
Control (CONT) Key Screens ............................................................................ 125
Dynamics (DYN) Key Screens .......................................................................... 127
Stop Key Screens .............................................................................................. 128
Auxiliary (Aux) Key Screens .............................................................................. 128
Remote/Speed Bias (RMT) Key Screens .......................................................... 131
Unit Load (KW) Key Screens ............................................................................ 134
Cascade (CAS) Key Screens ............................................................................ 135
Alarms................................................................................................................ 137
Trips ................................................................................................................... 138
Speed, Cascade, and Auxiliary Dynamics Adjustments ................................... 139
CHAPTER 6. COMMUNICATIONS ................................................................143
Modbus® * Communications .............................................................................. 143
Port Adjustments ............................................................................................... 146
505 Control Modbus Addresses ........................................................................ 146
Specific Address Information ............................................................................. 157
CHAPTER 7. SERVICE OPTIONS ................................................................159
Product Service Options .................................................................................... 159
Woodward Factory Servicing Options ............................................................... 160
Returning Equipment for Repair ........................................................................ 161
Replacement Parts ............................................................................................ 161
Engineering Services......................................................................................... 162
How to Contact Woodward ................................................................................ 162
Technical Assistance ......................................................................................... 163
APPENDIX. 505 PROGRAM MODE WORKSHEETS.......................................164
DECLARATIONS .......................................................................................167

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Manual 85017V1 505 Digital Governor

Illustrations and Tables

Figure 1-1. Typical Single or Dual Inlet Steam Turbine .........................................3

Figure 1-2. Split Range or Admission Type of Turbine Configuration ...................3
Figure 1-3a. Overview of 505 Functionality ............................................................6
Figure 1-3b. Overview of 505 Functionality ............................................................7
Figure 1-4. Overview of 505 Functionality Notes .................................................12
Figure 1-5. Single or Split-Range Turbine Configurations ...................................13
Figure 1-6. Single or Split-Range Turbine Configurations ...................................13
Figure 1-7. Single or Split-Range Turbine Configurations ...................................14
Figure 1-8. 505 Key Pad and Display...................................................................14
Figure 2-1. 505 Control Layout (Standard Enclosure) .........................................19
Figure 2-2. 505 Bulkhead-Mounted Enclosure.....................................................20
Figure 2-3. Jumper Options ..................................................................................21
Figure 2-4. Jumper Locations...............................................................................21
Figure 2-5. CageClamp Terminal Blocks .............................................................23
Figure 2-6. Control Wiring Diagram .....................................................................24
Figure 2-7. Representative 505 I/O Schematic ....................................................25
Figure 2-8. Fuse location ......................................................................................26
Figure 2-9. Shielded Wire Connections ...............................................................27
Figure 2-10. Typical RS-232 Communications ....................................................32
Figure 2-11. Typical RS-422 Communications ....................................................32
Figure 2-12. Typical RS-485 Communications ....................................................33
Figure 2-13. Preferred Multipoint Wiring with a Separate Signal Ground Wire ... 33
Figure 2-14. Alternate Multipoint Wiring without a Separate Signal Ground
Wire .................................................................................................34
Figure 3-1. Basic Control Overview......................................................................35
Figure 3-2. Manual Start Mode Example .............................................................38
Figure 3-3. Semiautomatic Start mode Example .................................................39
Figure 3-4. Automatic Start Mode Example .........................................................40
Figure 3-5. Idle/Rated Start ..................................................................................42
Figure 3-6. Automatic Start Sequence .................................................................43
Figure 3-7. Speed Control Functional Diagram....................................................46
Figure 3-8. Speed PID Control Modes .................................................................47
Figure 3-9. Frequency and Unit Load Relationship .............................................49
Figure 3-10. Speed Relationships ........................................................................51
Figure 3-11. Loadsharing Logic............................................................................57
Figure 3-12. Cascade Functional Diagram ..........................................................59
Figure 3-13. Aux Control Overview ......................................................................64
Figure 4-1. Basic Program Architecture ...............................................................77
Figure 4-2. Initial 505 Program Mode Entry .........................................................78
Figure 4-3a. Program Mode Blocks .....................................................................81
Figure 4-3b. Program Mode Blocks .....................................................................82
Figure 4-3c. Program Mode Blocks ......................................................................83
Figure 4-3d. Program Mode Blocks .....................................................................84
Figure 4-4. Exiting the Program Mode ...............................................................101
Figure 4-5. Stroke Actuator ................................................................................110
Figure 4-6. Stroking Dual Actuators ...................................................................111
Figure 5-1. Basic Program Architecture .............................................................112
Figure 5-2a. Overview of Run Mode ..................................................................113
Figure 5-2b. Overview of Run Mode ..................................................................114
Figure 5-3. 505 Keypad and Display ..................................................................116
Figure 5-4. SPEED Key Screens .......................................................................118
Figure 5-5. Direct Setpoint Entry ........................................................................121
Figure 5-6. Overspeed Test Enable Key Screens..............................................122
Figure 5-7. LMTR Key Screens ..........................................................................124

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Illustrations and Tables

Figure 5-8. ACTR Key Screens ......................................................................... 125

Figure 5-9. CONT Key Screens ........................................................................ 126
Figure 5-10. DYN Key Screens ......................................................................... 127
Figure 5-11. STOP Key Screens ....................................................................... 128
Figure 5-12. AUX Key Screens ......................................................................... 129
Figure 5-13. RMT Key Screens ......................................................................... 132
Figure 5-14. KW Key Screens ........................................................................... 134
Figure 5-15. CAS Key Screens ......................................................................... 135
Figure 5-16. ALARM Screen ............................................................................. 137
Figure 5-17. TRIP Screen.................................................................................. 138
Figure 5-18. Typical Response to Load Change............................................... 142
Figure 6-1. ASCII/RTU Representation of 3 ...................................................... 144
Figure 6-2. Modbus Frame Definition ................................................................ 145

Table 2-1. Jumper Options Chart .........................................................................22

Table 3-1. On-Line/Off-Line Dynamics Selection .................................................53
Table 3-2. Load Sharing Logic .............................................................................58
Table 4-1. Actuator Driver Limits ....................................................................... 106
Table 5-1. Overview of Run Mode ..................................................................... 115
Table 5-2. Idle/Rated Messages ....................................................................... 119
Table 5-3. Auto Start Messages ........................................................................ 120
Table 5-4. Controlling Parameter Messages ..................................................... 126
Table 5-5. Auxiliary Messages (if using Aux enable) ........................................ 130
Table 5-6. Auxiliary Messages (if using Aux as a limiter).................................. 130
Table 5-7. Remote AUX Messages ................................................................... 131
Table 5-8. Remote Speed Messages ................................................................ 132
Table 5-9. Control Messages ............................................................................ 133
Table 5-10. Cascade Control Messages ........................................................... 136
Table 5-11. Remote Cascade Messages .......................................................... 137
Table 5-12. Alarm Messages ............................................................................ 138
Table 5-13. Trip Messages ................................................................................ 139
Table 6-1. ASCII vs RTU Modbus ..................................................................... 144
Table 6-2. Modbus Function Codes .................................................................. 145
Table 6-3. Modbus Error Codes ........................................................................ 146
Table 6-4. Maximum Modbus Discrete and Analog Values .............................. 147
Table 6-5. Boolean Write Addresses................................................................. 148
Table 6-6. Boolean Read Addresses ................................................................ 150
Table 6-7. Analog Read Addresses .................................................................. 152
Table 7-8. Analog Write Addresses................................................................... 152
Table 6-9. Last Turbine Trip Cause................................................................... 153
Table 6-10. Control Status................................................................................. 153
Table 6-11. Analog Input Configuration............................................................. 154
Table 6-12. Analog Output Configuration .......................................................... 154
Table 6-13. Relay Configuration ........................................................................ 155
Table 6-14. Contact Input Configurations.......................................................... 156
Table 6-15. Units Configuration ......................................................................... 156

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Manual 85017V1 505 Digital Governor

Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).

2. 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.

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.

4. 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:

x Do not touch any part of the PCB except the edges.

x Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.

x 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.

CAUTION—ELECTROSTATIC DISCHARGE
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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Manual 85017V1 505 Digital Governor

Chapter 1.
General Information

Introduction
This manual describes the Woodward 505 Digital Governor for steam turbines.
English versions are 9907-162, 9907-163, and 9907-164. The option charts
below show the differences between the part numbers. Volume 1 of this manual
provides installation instructions, describes the control, and explains the
configuration (programming) and operating procedures. Volume 2 includes notes
on applying the control to specific applications, Service mode information, and
505 hardware specifications. 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.

Manual 85018 describes the 505E Digital Governor for extraction steam turbines.

Part Number Options

Part Number Power
9907-162 HVAC (180–264 Vac)
9907-163 AC/DC (88–132 Vac or 90–150 Vdc)
9907-164 LVDC (18–32 Vdc)
Optional Bulkhead Mounting Box (NEMA 4X) P/N 8923-439

General Installation and Operating Notes and Warnings

This equipment is suitable for use in Class I, Division 2 , Groups A, B, C, and D
(Class I, Zone 2, Group IIC) or non-hazardous locations.

The 505s are suitable for use in European Zone 2, Group II environments per
compliance with EN60079-15, Electrical apparatus for explosive atmospheres –
Type of protection ‘n’

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

Field wiring must be 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.

WARNING—EXPLOSION HAZARD
Do not connect or disconnect while circuit is live unless area is known to be
non-hazardous.

Substitution of components may impair suitability for Class I, Division 2.

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505 Digital Governor Manual 85017V1

AVERTISSEMENT—RISQUE D’EXPLOSION
Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf
en cas l’ambiance est décidément non dangereuse.

La substitution de composants peut rendre ce matériel inacceptable pour

les emplacements de Classe I, Division 2.

WARNING—EXPLOSION HAZARD
Do not use any test points on the power supply or control boards unless the
area is known to be non-hazardous.

AVERTISSEMENT—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.

505 Software Changes Covered in This Manual Revision

1. PROGRAM MODE: Added an error check to ensure Rated Speed (when
programmed as a gen set) was less than max gov.
2. SERVICE MODE: Changed the hold changes for Min Load to come from the
Breaker Logic header's Hold Changes input. Previously the hold changes
command was selected under the Speed Control Settings header.
3. SPEED SETPOINT RATES: Changed the minimum adjustment range for all
speed setpoint rates to 0.01 (was 0.1).
4. AUX LIMITER or CONTROLLER: Added logic to ensure the inhibited status
of Aux control when the input is failed. In addition, changed Aux re- enable
logic such that when a failed aux input is restored there is no glitch to the
speed LSS. Also changed breaker open logic to correct a Gen Opening Aux
actuator output glitch.
5. AUX CONTROLLER: Changed the speed setpoint aux biasing logic to only
allow the speed control limiting action (while in aux control) to be active when
the speed setpoint reaches max gov. Prior to this fix the speed limiter could
come into control during an extreme transient.
6. AUX DIRECT ENTERED SETPT: Changed Aux Entered setpoint to be
reset/stopped on a shutdown pulse rather than held disabled on a shutdown
condition. This change allows the Aux Limiter function direct setpoint entry
even when the unit is tripped.
7. AUX and CASC DROOP: Changed the droop feedback lag-tau tunable
range from a max of 10 to a max of 1000.
8. MODBUS: Changed the Gen and Tie Open alarms for Aux, Casc, and
®
Remote to match the Modbus * listing—the software eventlatch inputs were
reversed/backwards with the Modbus listing.
*—Modbus is a trademark of Schneider Automation Inc.
9. CONTROLLED STOP: Made the Controlled Stop abort if speed raise/lower
is selected or another control mode is selected. This can be tuned-out by
setting CNTRL_STOP.RL_STOP.IN_2=*false in the debug mode.
10. ANALOG INPUTS: Changed max setting on the delay time’s tunable range
from 3 ms to 3000 ms. The analog input failure delay setting is defaulted to
zero but can be adjusted up to 3000 ms using the debug mode
MAIN.AIx.LATCH_DLY where x is the analog input number. Added a tunable
single pole filter (LAG) to each analog input. Output/input = 1/(1+st) where t
= 1/(2(pi)f) = LAG_TAU. The Lag-tau is defaulted to zero but can be adjusted
in the debug mode using MAIN.AIx_LAG.LAG_TAU where x is the analog
input number (1-6).

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Manual 85017V1 505 Digital Governor

General Description
General
The 505 microprocessor-based control is designed to control single or dual (split
range) actuator steam turbines (extraction steam turbines require the 505E
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.

)18'40148#.8'
6 6
8#.8'
+0.'6
56'#/

6 6
8#.8'
+0.'6
56'#/

)18'40148#.8'
Ä
':*#756 ÄÄ,//
56'#/

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

*2#%6
)18'40148#.8'
6 6
8#.8'
+0.'6
56'#/

+0.'6
56'#/
6 6 Ä
8#.8' ÄÄ,//
.2#%6
)18'40148#.8' ':*#756
56'#/

Figure 1-2. Split Range or Admission Type of Turbine Configuration

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505 Digital Governor Manual 85017V1

Operator Control Panel

The 505 is a field configurable steam turbine control and operator control panel
(OCP) integrated into one package. A comprehensive operator control panel,
including a two-line (24 characters each) display, and a set of 30 keys is located
on the 505’s front panel. This OCP is used to configure the 505, make On-Line
program adjustments, and operate the turbine/system. Easy to follow instructions
are presented in English through the OCP’s two-line display and operators can
view actual and setpoint values from the same screen.

Turbine Control Parameters

The 505 interfaces with one or two control valves to control one parameter at a
time and limit an additional parameter, if desired. 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.

Communications
The 505 can communicate directly with plant Distributed Control Systems and/or
CRT based operator control panels, through two Modbus communication ports.
These ports support RS-232, RS-422, or RS-485 communications using ASCII or
RTU MODBUS transmission protocols. Communications between the 505 and a
plant DCS can also be performed through hardwired connections. Since all 505
PID setpoints can be controlled through analog input signals, interface resolution
and control is not sacrificed.

Additional Features
The 505 also provides the following features: First-Out Trip Indication (5 total trip
inputs), Critical Speed Avoidance (2 speed bands), Auto Start Sequence (hot &
cold starts), Dual Speed/Load Dynamics, Zero Speed Detection, Peak Speed
Indication for Overspeed trip, and Isochronous Loadsharing between units (with
a DSLC™ control).

Using the 505

The 505 control has two normal operating modes, the Program Mode and the
Run Mode. The Program Mode is used to select the options needed to configure
the control to your specific turbine application. Once the control has been
configured, the Program Mode is typically never again used, unless turbine
options or operation changes. Once configured, the Run Mode is used to operate
the turbine from start-up through shutdown. In addition, on-line adjustments can
be made using the Service Mode (see Volume 2).

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Manual 85017V1 505 Digital Governor

505 Inputs and Outputs

Control Inputs
Two speed inputs that are jumper configurable for MPU (magnetic pickup units)
inputs or proximity probes.

Six programmable analog inputs can be used as one of the following options:
auxiliary input, remote auxiliary setpoint, cascade input, remote cascade
setpoint, kW (load) input, remote speed setpoint, synchronizing, load sharing,
both synchronizing and load sharing, and first stage pressure. The sixth analog
input has isolation circuitry and should be used for a self-powered signal that is
not isolated.

Sixteen contact inputs are available. Four are dedicated for shutdown, reset,
raise speed setpoint, and lower speed setpoint. Another two contact inputs must
be dedicated for generator breaker and utility tie breaker if the control is used in
a generator application. Ten additional contact inputs can be configured. If the
unit is not used in a generator application, then twelve additional contact inputs
can be configured.

Four function keys on the front panel of the control. F1 and F2 are dedicated to
alarm and overspeed, respectively. F3 and F4 can be used to enable or disable
various functions of the control.

Control Outputs
Two actuator outputs with linearization curves; the second actuator output can be
used as an extra readout if not used as an actuator output. Six 4–20 mA outputs,
for meters or other readouts.

Eight Form-C relay contact outputs, six that are configurable. The two dedicated
relay outputs are for shutdown and alarm indication.

Control Interfaces
Two Modbus ports, to be used as control interfaces. The protocol can be either
ASCII or RTU and the communications can be RS-232, RS-422, or RS-485.

One computer (PC) port to be used for program configuration storage.

An overview of the 505 functions is shown in Figure 1-3. Use this block diagram
to match the control features to the site-specific application required.

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Figure 1-3a. Overview of 505 Functionality

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Manual 85017V1 505 Digital Governor

Figure 1-3b. Overview of 505 Functionality

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Control Overview
The 505 has two independent control channels, the speed/load and auxiliary
controllers. The outputs of these two controllers are low-signal-selected (LSS)
with another channel, the valve limiter. The output of the LSS directly sets the
position of the actuator driver’s output. In addition to these channels, the
speed/load controller can be manipulated by another controller, the cascade
controller. The cascade controller is ‘cascaded’ into the speed controller,
whereby the speed controller setpoint is changed directly by the cascade
controller output. The auxiliary controller can act as either a control channel or as
a limiting channel. All three of these PID controllers have the option of utilizing an
analog input signal to remotely position their setpoints. Additional features of the
505 include frequency control, isochronous loadsharing (with a DSLC), critical
speed avoidance, idle/rated control and an automatic start sequence. There are
two serial communications ports which can be used to monitor and control the
turbine using Modbus protocol.

Speed Control
The speed control receives a turbine speed signal from one or two magnetic
pickups or proximity probes. The speed PID (proportional, integral, derivative)
control amplifier then compares this signal to the speed setpoint to generate an
output signal to the actuator (through a low signal select bus).

The speed control’s setpoint is adjustable with raise or lower commands through
the keypad on the front of the control, remote contact inputs or the
communication line. The setpoint can also be directly set by entering the new
setpoint from the keypad or through either Modbus communications. In addition,
an analog input can be programmed to remotely position the speed setpoint.

Remote Speed Setpoint

One of the 4–20 mA inputs can be configured to control the speed setpoint.
Typically, a process control external to the 505 interfaces with this input to
regulate the turbine’s speed or load to control a related process.

The remote speed setpoint input directly affects the 505’s speed setpoint. The
maximum rate at which the remote input signal can change the speed setpoint is
programmable. When the remote setpoint is enabled, the speed setpoint will
move at a much slower rate until the two settings are matched at which time the
speed setpoint will be allowed to move at the maximum rate. The remote speed
function can be enabled and disabled as required from the front-panel keypad,
remote contact inputs or the communication line.

Auxiliary Control
The Auxiliary control channel can be used to either control a parameter or limit a
parameter. The Auxiliary PID controller can be used to control or limit unit
load/power, plant import/export levels, inlet pressure, exhaust pressure,
temperature or any other process directly related to turbine load.

The Auxiliary input is a 4–20 mA current signal. The Auxiliary PID control
amplifier compares this input signal with a setpoint 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.
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Manual 85017V1 505 Digital Governor

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

Remote Aux Setpoint

One of the 4–20 mA inputs can be configured to remotely adjust the aux setpoint.
The remote aux setpoint input directly affects the Auxiliary setpoint. The
maximum rate at which the remote input signal can change the auxiliary setpoint
is programmable. When the remote setpoint is enabled, the Auxiliary setpoint will
move at a much slower rate until the two settings are matched at which time the
setpoint will be allowed to move at the maximum rate. The remote aux function
can be enabled and disabled as required from the front panel keypad, the remote
contact inputs, or the communication links.

Load Sharing Input

The 505 is capable of using an analog input to accept a load sharing signal from
Woodward’s Digital Synchronizer and Load Control (DSLC). This input in
conjunction with the DSLC allows the control to isochronously loadshare with any
other system using a DSLC. The 505’s internal summing junction adds this signal
with the speed/load PID’s reference. In addition to loadsharing, the DSLC input to
the 505 can be used to synchronize the unit to either the plant bus or to the utility.

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 used as a turbine
inlet or exhaust pressure controller.

The cascade control is a PID controller that compares a 4–20 mA process signal
with the cascade setpoint. The PID controller sets the speed controller setpoint
until the process signal and the setpoint match.

The cascade setpoint is adjustable with raise or lower commands through the
keypad on the front of the control, the remote contact inputs, or the
communication links. Also, the setpoint can be directly set by entering the new
setpoint from the keypad or through Modbus communications. In addition, a
remote cascade setpoint analog input can be programmed to remotely position
the cascade setpoint.

Remote Cascade Setpoint

One of the 4–20 mA inputs can be configured to remotely adjust the cascade
setpoint. The remote cascade setpoint input directly affects the 505’s cascade
setpoint. The maximum rate at which the remote input signal can change the
cascade setpoint is programmable and can be changed in the Run mode. When
the remote setpoint is enabled, the cascade setpoint will move at a much slower
rate until the two settings are matched at which the setpoint will be allowed to
move at the maximum rate. The remote cascade function can be enabled and
disabled as required from the front-panel keypad, the remote contact inputs or
the communication links.
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505 Digital Governor Manual 85017V1

Valve Limiter
The valve limiter limits the actuator output signal or valve position to aid in
starting up and shutting down a turbine. The output of the valve limiter is low-
signal-selected with the output of the speed/load and auxiliary control channels.
The control or limiter channel asking for the lowest valve position will control
valve position. Thus, the valve limiter limits the maximum valve position. The
valve limiter can be adjusted through the keypad, external contact closures, or
Modbus commands.

The valve limiter can also be used to troubleshoot 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.

Starting Features
The 505 provides options for three different starting modes: automatic, semi-
automatic, and manual. One of these modes must be programmed to get the
turbine from a shutdown state to speed control at minimum speed. The start
mode configured and minimum governor controlling speed will depend on normal
plant starting procedures and turbine manufacturer’s recommendations.

If an idle speed is programmed (either idle/rated or auto start sequence modes),

the 505 can provide automatic speed control and critical speed avoidance. A
‘Run’ command can be given through the 505 keypad, a remote contact input, or
Modbus communications. In addition, an optional ‘Start Permissive’ contact input
can be programmed to prevent a start if, for example, the trip-throttle or stop
valve is not closed.

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 setpoint 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.

Auto Start Sequence

The auto start sequence function gives the operator the ability to start from a
programmed low idle speed, hold there until the programmed warm-up time has
expired, then go to a programmed high idle speed, hold there until the
programmed high idle warm-up time has expired, and finally move to the
programmed rated speed setpoint. The hold times and the acceleration rates are
dependent on whether the turbine is considered ‘hot’ or ‘cold’ based on the time
the turbine has been shut down. When the turbine is between hot and cold
conditions, the control interpolates between the hot and cold data points to
determine the appropriate startup rates and hold times.

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Manual 85017V1 505 Digital Governor

The auto start sequence can be stopped and started, if desired, by programming
and using the auto start sequence halt/continue commands. The selection of halt
or continue can be made through the 505 keypad, remote contact inputs or
Modbus communications. In addition, the auto start sequence can be
programmed to automatically halt at each idle setpoint.

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, two critical speed avoidance bands may be
selected. These bands may be any speed ranges that is less than the minimum
governor speed setting. Either the Idle/Rated or the Auto Start Sequence
functions must be programmed to perform critical speed avoidance. Within a
critical speed range, the 505 moves the speed setpoint at the critical speed rate
programmed and does not allow the speed setpoint 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
setpoint lower command will bring the unit back to the lower limit of the band.

Block Diagrams
Overviews of possible 505 configurations are shown in Figures 1-5 through 1-7.
Use these block diagrams to match the control features to the site-specific
application requirements. Figure 1-4 lists symbols and their respective
explanations. The Cascade and auxiliary PIDs are optional controllers, and are
shown in the following diagrams for PID relationship purposes only.

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505 Digital Governor Manual 85017V1

Figure 1-4. Overview of 505 Functionality Notes

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Manual 85017V1 505 Digital Governor

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Figure 1-6. Single or Split-Range Turbine Configurations

(Auxiliary PID Configured as a Limiter)

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505 Digital Governor Manual 85017V1

6+'$4'#-'4 &4112
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Figure 1-7. Single or Split-Range Turbine Configurations

(Auxiliary PID Configured as a Controller)

Keypad and Display

The 505’s service panel consists of a keypad and LED display located on the
front of the control. The LED display has two, 24 character lines that can be used
to display operating parameters and troubleshooting parameters in plain English.
Also, there are 30 keys available to provide complete control from the front of the
505. No additional control panels are required to operate the turbine, every
turbine control function can be performed from the 505’s front panel.

Figure 1-8. 505 Key Pad and Display

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Manual 85017V1 505 Digital Governor

A description of each key’s function follows. Some descriptions refer to the
function blocks contained in the programming (Chapter 4) and operating
flowcharts (Chapter 5).

SCROLL :
The large diamond shaped button in the middle of the keypad with arrows at each
of it’s four corners. The < > (scroll left, right) moves the display left or right through
the function blocks of the Program or Run Mode. The , (scroll up, down)
moves the display up or down within a function block of the Program or Run Mode.

SELECT:
The Select key is used to select control of the 505 display’s top or bottom line
variable. The @ sign is used to indicate which line (variable) can be adjusted by
the adjust keys. Only when there is a changeable variable on both lines
(dynamics, valve calibration modes) does the “select key” and @ sign determine
which line variable can be adjusted. When there is only one variable per screen
the “select key” and @ sign’s position are irrelevant.

ADJ (adjust):
In the Run Mode, “ “ moves any adjustable parameter up (larger) and “ “ moves
any adjustable parameter down (smaller).

PRGM (program):
When the control is shutdown this key selects the Program Mode. While in the
Run Mode this key selects a Program Monitor Mode. In the Program Monitor
Mode the program can be viewed but not changed.

RUN:
Initiates a turbine run or start command from the (CONTROLLING
PARAMETER/PUSH RUN or PRGM) state.

STOP:
Initiates a controlled turbine shutdown (Run Mode) once verification is given. The “Stop”
command can be disabled through a Service Mode setting (under ‘Key Options’).

RESET:
Resets/clears Run Mode alarms and shutdowns. Pressing the key also returns
the control to the (CONTROLLING PARAMETER/PUSH RUN OR PRGM) status
after a shutdown.

0/NO:
Enters 0/NO or disable.

1/YES:
Enters 1/YES or enable.

2/ACTR (actuator):
Enters 2 or displays the actuator position (Run Mode).

3/CONT (control):
Enters 3 or displays the parameter which is in control (Run Mode); press the
Scroll down arrow to display the control’s last trip cause, highest speed reached,
and local/remote status (if used).

4/CAS (cascade):
Enters 4 or displays the cascade control information (Run Mode).

5/RMT (remote):
Enters 5 or displays the remote speed setpoint control information (Run Mode).
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505 Digital Governor Manual 85017V1

6/LMTR (valve limiter):
Enters 6 or displays the valve limiter information (Run Mode)

7/SPEED:
Enters 7 or displays the speed control information (Run Mode).

8/AUX (auxiliary):
Enters 8 or displays the auxiliary control information (Run Mode).

9/KW (load):
Enters 9 or displays the kW/load or first stage pressure information (Run Mode).

CLEAR:
Clears Program Mode and Run Mode entries and takes control out of it’s present
mode.

ENTER:
Enters new values in the Program Mode, and allows the “direct entry” of specific
setpoint values in the Run Mode.

DYNAMICS (+/–):
Accesses the dynamic settings of the parameter controlling the actuator position
in the Run Mode. The dynamics adjustments can be disabled through a Service
Mode setting (under ‘Key Options’). This key will also change the sign of a value
being entered.

x (DECIMAL KEY)
Enters decimal point in number being entered from front panel.

ALARM (F1):
Displays the reason for any alarm condition (last/newest alarm) when the key’s
LED indicator is illuminated. Press the Scroll down arrow (diamond key) to
display additional alarms.

OVERSPEED TEST ENABLE (F2) :

Permits the speed reference to be raised beyond the maximum controlling speed
set point to test either the electrical or mechanical overspeed trip.

F3 (function key):
Programmable function key for enabling or disabling programmable control
functions.

F4 (function key):
Programmable function key for enabling or disabling programmable control
functions.

EMERGENCY SHUTDOWN BUTTON:

Large red octagonal button on the front of the enclosure. This is an Emergency
Shutdown command for the control.

Watchdog Timer/CPU Fault Control

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 85017V1 505 Digital Governor

Chapter 2.
Installation Procedures

Introduction
This chapter provides instructions on how to mount and connect the 505 into a
system. Hardware dimensions, ratings, and jumper configurations are given to
allow a customer to mount, wire, and configure the 505 package to a specific
application.

Electrical ratings, wiring requirements, and options, are provided to allow a

customer to fully install the 505 into a new or existing application.

Mechanical Data and Hardware Installation

If so labeled on the enclosure, the 505 is UL/CUL listed for use in hazardous
locations in UL file E156028. This Equipment is suitable for use in Class I,
Division 2 , Groups A, B, C, and D (Class I, Zone 2, Group IIC) or non-hazardous
locations only.

The 505s are suitable for use in European Zone 2, Group II environments per
compliance with EN60079-15, Electrical apparatus for explosive atmospheres –
Type of protection ‘n’

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

Field wiring must be rated at least 75 °C for operating ambient temperatures

expected to exceed 50 °C.

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.

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

WARNING—EXPLOSION HAZARD
Do not connect or disconnect while circuit is live unless area is known to be
non-hazardous.

Substitution of components may impair suitability for Class I, Division 2.

AVERTISSEMENT—RISQUE D’EXPLOSION
Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf
en cas l’ambiance est décidément non dangereuse.

La substitution de composants peut rendre ce matériel inacceptable pour

les emplacements de Classe I, Division 2.

WARNING—EXPLOSION HAZARD
Do not use any test points on the power supply or control boards unless the
area is known to be non-hazardous.

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505 Digital Governor Manual 85017V1

AVERTISSEMENT—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.

Enclosures
Figure 2-1 shows 505 control layout and mounting pattern. The 505 digital
control is housed in a flush mount enclosure. This enclosure is designed for
installation within a control room panel or cabinet, and by itself, cannot be
bulkhead-mounted. The 505 package, once properly installed within a NEMA4X
panel or cabinet meets NEMA 4X ratings. A gasket is attached to the rear side of
the package’s bezel to properly seal the 505’s face-plate to a panel. All field
wiring connects to the 505 through removable terminal blocks located on the
505’s back side.

The 505’s internal components are industrial grade. These components include
the CPU (central processing unit), its memory, the switching power supply, all
relays, all Input/Output circuitry, and all circuitry for the front panel display, touch
keypad, and the serial communications.

An optional NEMA-4X enclosure is available to allow the 505 to be bulkhead

mounted (Figure 2-2). The 505 digital control mounts on the front door of the
enclosure. This allows for easy service access through the enclosure’s front
door. This bulkhead mounted enclosure has two removable gland plates
attached to the bottom. A user may cut appropriately sized conduit openings (up
to 1.5”) as required, in the removable gland plates for wiring access. For EMI
reasons, it is recommend that all low-current wire (terminals 52 through 121) be
separated from all high-current wire (terminals 1 through 51).

Mounting
The standard 505 package must be mounted to allow sufficient room for wiring
access. Eight front panel screws permit secure mounting. The standard 505
weighs approximately 4 kg (9 lb), and has an operating range of –25 to +65 °C
ambient air temperature.

The optional enclosure permits the control to be bulkhead mounted. See Figure
2-2 for mounting dimensions. This enclosure weighs approximately 10 kg (22 lb),
and allows an operating range of –20 to +60 °C ambient air temperature.

505 Hardware Jumpers

To allow the 505 the flexibility of interfacing with different types of speed probes,
transducers, and communication cables, user changeable jumpers are used.
These jumpers are accessed by taking the 505’s back cover off and are located
on the I/O module. Refer to Table 2-1 for jumper options and Figure 2-4 for
jumper locations. Each set of jumpers is used to select between two or three
interface options for one circuit (see Figure 2-3). Of the three position jumper
options provided only one interface option at a time can be selected. Power
should be removed before the jumpers are accessed, and proper ESD
precautions should be taken before any contact is made with any part of the
circuit board.

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Manual 85017V1 505 Digital Governor

Figure 2-1. 505 Control Layout (Standard Enclosure)

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Figure 2-2. 505 Bulkhead-Mounted Enclosure

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Manual 85017V1 505 Digital Governor

Figure 2-3. Jumper Options

Figure 2-4. Jumper Locations

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505 Digital Governor Manual 85017V1

Function Jumpers
SPEED SENSOR #1 MPU JPR7, JPR21 *
SPEED SENSOR #1 PROX. PROBE JPR6, JPR20
SPEED SENSOR #2 MPU JPR5, JPR19 *
SPEED SENSOR #2 PROX. PROBE JPR4, JPR18
ANALOG INPUT #1-LOOP POWERED-(2—WIRE) JPR10
ANALOG INPUT #1-SELF-POWERED JPR11 *
ANALOG INPUT #2-LOOP POWERED-(2—WIRE) JPR8
ANALOG INPUT #2—SELF-POWERED JPR9 *
ANALOG INPUT #3-LOOP POWERED-(2—WIRE) JPR14
ANALOG INPUT #3—SELF-POWERED JPR15 *
ANALOG INPUT #4-LOOP POWERED-(2—WIRE) JPR12
ANALOG INPUT #4—SELF—POWERED JPR13 *
ANALOG INPUT #5-LOOP POWERED-(2—WIRE) JPR16
ANALOG INPUT #5—SELF—POWERED JPR17 *
COMM PORT #1 NO TERMINATIONS JPR23, JPR26 *
COMM PORT #1 RS485/RS422 RECEIVE TERMINATION JPR22, JPR25
COMM PORT #1 RS422 TRANSMIT TERMINATION JPR24, JPR27
COMM PORT #2 NO TERMINATIONS JPR29, JPR32 *
COMM PORT #2 RS485/RS422 RECEIVE TERMINATION JPR28, JPR31
COMM PORT #2 RS422 TRANSMIT TERMINATION JPR30, JPR33
* = DEFAULT

Table 2-1. Jumper Options Chart

Electrical Connections
Refer to Figure 2-7 for a representative 505 I/O interface schematic, and Volume
2 of this manual, for hardware Input/Output specifications.

All inputs and outputs to the 505 are made through “CageClamp” terminal blocks
on the bottom of the 505 package. For EMI reasons, it is recommend that all low-
current wire (terminals 52 through 121) be separated from all high-current wire
(terminals 1 through 51).

The terminal blocks are screwless CageClamp style blocks. The spring clamp
can be actuated by using a standard 3 mm or 1/8in flat bladed screwdriver or a
snap-on thumb lever (Figure 2-5). Two snap-on thumb levers are provided with
the 505 unit. The 505 terminal blocks accept wires from 0.08–2.5 mm² (27–12
AWG) wire. Two 0.8 mm² (18 AWG) or three 0.5 mm² (20 AWG) wires can be
easily installed in each terminal.

The 505 control’s terminal blocks are designed to be removed by hand. After 505
input power is disconnected, the terminal blocks can be removed one at a time
by prying them off using ones finger tips. When removing a terminal block, never
pull on the wires connected to the terminal block.

Wires for the fixed mounted power terminals should be stripped 5–6 mm (0.22”)
long. Wire for the pluggable I/O terminals should be stripped 8–9 mm (0.33”)
long.

When a bulkhead enclosure is required, all electrical connections must be made

through the gland plates provided on the bottom of the bulkhead mount
enclosure to the terminal blocks inside. See Figure 2-2.

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Manual 85017V1 505 Digital Governor

Figure 2-5. CageClamp Terminal Blocks

Power Supplies
The 505 is available with three different input power source selections. The part
number of the 505 depends on the rating of the input power source it can accept.
The ratings of the required input power source on each unit can be identified by
the back panel sticker or control part number. The sticker will show the correct
source power ratings for each unit by a punched hole next to the rating. Refer to
Volume 2 for all power supply specifications.

The 505’s input power supply terminal blocks accept wires from 0.08–2.5 mm²
(27–12 AWG) wire. Internal fuses, in series with each input power trace, are
used to protect the 505’s input circuitry. All fuses are rated as slow-blow type
fuses. These fuses are accessed by taking the 505’s back cover off and are
located on its power supply module (bottom module). Refer to Figure 2-8 for fuse
locations. The ratings for the different sources of input power accepted by the
505 and the 505’s internal fuse sizes are listed as follows:

18–32 Vdc (6.25 A internal fuse, 77 VA maximum draw)

88–132 Vac @ 47–63 Hz
or 90–150 Vdc (2.5 A internal fuse, 143 VA maximum draw)
180–264 Vac @ 47–63 Hz (1.5 A internal fuse, 180 VA maximum draw)

Each 505 requires a power source capable of a certain output voltage and
current. In most cases this power rating is stated in Volt-Amps (VA). The
maximum VA of a source can be calculated by taking the rated output voltage
times the maximum output current at that voltage. This value should be greater
than or equal to the 505 VA requirement.

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Figure 2-6. Control Wiring Diagram

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Manual 85017V1 505 Digital Governor

Figure 2-7. Representative 505 I/O Schematic

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505 power supply holdup times are determined by the 505 power supply and
input power used. The below times are based on worse case conditions (88 Vac
with a possible range of 88–132 Vac when power is lost). These holdup times
should be used when the 505 is powered by an Uninterruptible Power Source
(UPS) to evaluate if the UPS’s switch over time is quick enough avoid a system
trip. A UPS’s switch-over time must be less than the below specified holdup
times:

Power Supply Holdup Times

18–32 Vdc Power Supply 14 milliseconds
88–132 Vac @ 47–63 Hz
or 90–150 Vdc Power Supply 30 milliseconds
180–264 Vac @ 47–63 Hz Power Supply 58 milliseconds

A 24 V power supply is available, within the 505, to power external transducers

or devices. This supply has two breaker protected output channels. One power
supply channel (VA1) is capable of providing 24 Vdc ±10%, @ 200 mA maximum
output current, to power 505 current inputs and auxiliary devices. Power
connections can be made through terminals 55, 59, 63, 70, and 74 with terminal
78 as the common. Refer to Figure 2-7.

WARNING—MAXIMUM CURRENT DRAW

The total current draw through terminals 55, 59, 63, 70, and 74 cannot
exceed 200 mA or the 505’s internal power supply breaker (CB1) will open
resulting in a possible CPU reset and trip condition. All load must be
removed from the specified terminals to allow the breaker to reset.

The second power supply channel is capable of providing 24 Vdc ±10%, @ 200
mA maximum output current, to power 505 current outputs and auxiliary devices.
Power connections can be made through terminals 85, 88, 91, 97, 100, and 103
with terminal 78 as the common. Refer to Figure 2-7.

WARNING—MAXIMUM CURRENT DRAW

The total current draw through terminals 85, 88, 91, 97, 100 and 103 cannot
exceed 200 mA or the 505’s internal power output breaker (CB2) will open
resulting in a possible CPU reset and trip condition. All load must be
removed from the specified terminals to allow the breaker to reset.

Figure 2-8. Fuse location

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Manual 85017V1 505 Digital Governor

Shields and Grounding

An individual shield termination is provided at the terminal block for each of the
speed sensor inputs, actuator outputs, analog inputs, analog outputs, and
communications ports. All of these inputs should be wired using shielded,
twisted-pair wiring. The shields should be connected to earth ground at all
intermediate terminal blocks, as well as terminated at the control terminal block.
The exposed wire length, beyond the shield, should be limited to one inch. Relay
outputs, contact inputs, and power supply wiring do not normally require
shielding, but can be shielded if desired.

For EMI reasons, it is recommend that all low-current wire (terminals 52 through
121) be separated from all high-current wire (terminals 1 through 51). Input
Power ground terminal #3 should also be wired to external ground. Refer to
Figure 2-7.

Figure 2-9. Shielded Wire Connections

Speed Sensor Inputs

To sense speed, the control accepts signals from one or two passive magnetic
pickup units (MPUs) or active proximity probes mounted off of a gear which is
connected or coupled to the turbine’s rotor.

Because of the differences between passive MPUs, active proximity probes, and
the sensing circuits required for each type, jumpers are provided to allow field
configuration of each speed input depending on the type of probe used. See
Table 2-1 for jumper options, and Figure 2-4 for jumper locations. Verification of
jumper location is recommended before system startup or operation.

A passive MPU provides a frequency output signal corresponding to turbine

speed by sensing the movement of a gear’s teeth past the MPU’s pole piece.
The closer the MPU’s pole piece is to a gear’s teeth and the faster the gear turns
the higher a passive MPU’s output amplitude will be. The 505 must sense an
MPU voltage of 1 to 25 Vrms for proper operation.

With proper MPU, gear size, and MPU-to-gear clearance, speed measurement
should be capable down to 100 Hz. Standard MPU clearance is recommended to
be 0.25 to 1.02 mm (0.010 to 0.040”) from tooth face to pole piece. For
information on selecting the correct MPU or gear size please refer to Woodward
manual 82510. See Figure 2-7 for wiring schematic.

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505 Digital Governor Manual 85017V1

A proximity probe may be used to sense very low speeds. With a proximity
probe, speed can be sensed down to 0.5 Hz. The input voltage must be between
16 and 28 Vdc for proper operation. The speed sensor input channels are
isolated, so either channel can be jumper configured for a MPU or proximity
probe. By being able to sense turbine speed down to this level, the 505 can be
programmed to turn on or off a turbine turning gear, via a relay output. See
Figure 2-7 for proximity probe wiring schematic.

It is not recommended that gears mounted on an auxiliary shaft coupled to the

turbine rotor be used to sense turbine speed. Auxiliary shafts tend to turn slower
than the turbine rotor (reducing speed sensing resolution) and have coupling
gear back-lash, resulting in less than optimum speed control. For safety
purposes it is also not recommend that the speed sensing device sense speed
from a gear coupled to a generator or mechanical drive side of a system’s rotor
coupling.

An application may use two of the same type of speed probes, or two different
types of speed probes (one MPU and one proximity probe). Both speed sensing
inputs use the same programmed gear ratio and number of teeth to calculate
speed, thus the speed probes used should sense speed from the same gear.

The 505 can be programmed to sense only one speed input signal. However, it is
recommended that the 505 be programmed to sense two speed inputs, and that
two speed probes be used with all applications to increase system reliability.

NOTE
The speed signal that the 505 can accept must be within the following limits:
(T x M x R)/60 must be < 15000 Hz
T = Gear Teeth
M = Overspeed Test Limit Setting
R = Gear Ratio

If the signal is not within these limits, the 505 will respond with a speed sensor
frequency error during the program checking procedure.

Contact Inputs
In general, contacts must change state for a minimum of 15 milliseconds for the
control to sense and register a change in state. All contact inputs accept dry
contacts. Contact wetting voltage is available through terminals 4, 5, 6, 7, 8, 9,
and 10. If desired, an external 18–26 Vdc power source can be used for the
circuit wetting voltage. In this case terminal 11 (contact input common) must be
connected to the external power source’s common to establish a common
reference point. Each contact input pulls 2.5 mA when closed and requires at
least 1 mA and 14 V to recognize a closure command. See Figures 2-6 and 2-7
for wiring information, and Volume 2 for input specifications.

WARNING—MAXIMUM CURRENT DRAW

The total current draw through terminals 4, 5, 6, 7, 8, 9, and 10 cannot
exceed 100 mA or the 505’s internal power output breaker (CB5) will open
resulting in a possible CPU reset and trip condition. all load must be
removed from the specified terminals to allow the breaker to reset.

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If the 16 contact inputs available, four have functions already assigned to them
(preset) and cannot be changed, the other 12 are user-configurable. The Preset
Contact Inputs are:
x External Emergency Shutdown
x External Reset
x Raise Speed Setpoint
x Lower Speed Setpoint

Before starting, the External Emergency Shutdown contact must have an

external switch wired in and closed or be jumpered closed. The control will
initiate an emergency shutdown any time the contact is opened. This input is
typically tied into the system’s trip string and provides trip feedback to the control.

The external reset contact can be used to remotely clear alarms and return the
control to the (Controlling Parameter/Push Run or Prgm) state after a shutdown.

The raise and lower speed setpoint contact inputs can be used to remotely raise
and lower speed or load.

Applications requiring external contact inputs must have the desired function
assigned or configured to a specific input. There is a choice of twelve possible
contact inputs and twenty-seven programmable functions. If the 505 is
configured for a generator application two of the contacts must be configured for
the Generator and Utility breaker inputs. The Generator Breaker contact must be
wired so it is closed when the generator breaker is closed. The Utility Tie Breaker
contact must be wired so it is closed when the utility tie breaker is closed.

Refer to Chapter 4 of this manual for a complete list of programmable contact

input functions.

Analog Inputs
Analog inputs # 1, 2, 3, 4, and 5 may be used with two-wire ungrounded (loop
powered) transducers or isolated (self-powered) transducers. Jumpers are
available to match the analog input circuit to the transducer being interfaced with,
or the power supply common may be jumpered on the terminal block. Verification
of jumper location is recommended before system startup or operation. See
Table 2-1 for jumper options and Figure 2-4 for jumper locations.

Because inputs 1-5 are not fully isolated, care must be taken in their application
and maintenance to avoid “ground-loop” type problems. If interfacing to a non-
isolated device with one of these inputs, the use of a loop isolator is
recommended to break any return current paths, which could result in erroneous
readings.

Analog input # 6 is a fully isolated input and is designed to be used with a non-
isolated source such as a Distributed Control System (DCS). This input does not
use or have jumpers for hardware configuration options. Refer to Figure 2-7,
Option #1 for correct wiring configuration.

All six analog inputs are programmable, and have an input impedance of 200 :.
Refer to Chapter 4 of this manual for a complete list of programmable analog
input options.

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Analog Outputs
Applications using a 505 current output must have the desired analog value
assigned or configured to a specific output. There is a choice of six possible 4–
20 mA output drivers of which to use to display a parameter externally.
Optionally, if Actuator Driver #2 is not being utilized to drive an actuator, it can be
programmed to function as a 4–20 mA driver to display one of the values listed
below. The analog output connections for the 505 are shown in Figure 2-7. All
505 analog outputs can drive into a maximum of 600 :.

Refer to Chapter 4 of this manual for a complete list of programmable analog

output options.

Actuator Outputs
Two actuator outputs are available and programmable to interface with
Woodward Governor Company actuators (20–160 mA drive currents) or non-
Woodward actuators (4–20 mA drive currents).

Each actuator output can be individually configured to interface with Woodward

or non-Woodward type actuators. Actuator drive current is selected in the
Program Mode. Maximum impedance for each 4 to 20 mA actuator output driver
is 360 : (actuator impedance + wire resistance). Maximum impedance for each
20 to 160 mA actuator output is 45 : (actuator impedance + wire resistance).
Dither is available for either output.

Each actuator driver senses the drive current to allow over- and under-current
shutdowns. The 505 can be configured to use one or two actuators. If only one
actuator is used and programmed, it must be wired to actuator #1’s output
terminals. If two actuators are used they can be programmed to operate in a
staggered or parallel mode. If the “Actuator #2 Offset” percentage is set to 50%
then actuator #2 will begin opening when actuator #1 reaches 50%. The control
will continue to open both valves to 100% with a position difference of 50%. To
operate the two actuators in parallel set “Actuator #2 Offset” percentage to zero.
This will force both actuators to operate at the same level or in parallel.

Optionally, if actuator #2 driver is not used as an actuator output driver it can be

used as a 4–20 mA current output to drive a meter or DCS input. Refer to
Chapter 4 of this manual for a complete list of programmable analog output
options.

In addition, an eleven (11) point actuator linearization adjustment curve is

available through the Service Mode for each actuator output (see Service Mode
adjustments in volume 2).

Relay Outputs
There are eight relay outputs available from the 505. All relay contacts are Form
C type contacts.

For relay load ratings, refer to Appendix A in Volume 2.

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NOTE
Before installation verify that the 505’s relay contacts meet the power
requirements of the circuit with which it is being interfaced. Interposing
relays are required, in cases where the interfaced circuit demands relay
contacts with a higher power rating. If interposing relays are required, it is
recommended that interposing relays with surge (inductive kick-back)
protection be used. Improper connection could cause serious equipment
damage.

Two of the eight relay outputs available are dedicated to a function and are as
follows:
x Alarm relay—energizes for any alarm condition
x Shutdown relay—de-energizes for any shutdown condition

The remaining six relays can be programmed to energize upon a function

change of state or an analog value level. Applications requiring programmable
relay outputs must have the desired switch condition, or specific analog value
assigned to them. Refer to Chapter 4 of this manual for a complete list of
programmable relay output options.

Serial Communications
There are three serial communications ports on the 505. Ports one and two are
for Modbus communications and can be configured for RS-232, RS-422, or RS-
485 communications. Figures 2-10, 11, and 12, show the communications port
connections for ports #1, and #2. Ports one and two are accessed though
terminal blocks located on the 505’s back side. RS-422 and RS-485
communication lines can function up to a length of 4000 feet Refer to the
Modbus section of this manual for a list of all the commands and parameters
available through ports one and two. The third port, utilizing a 9-pin Sub-D
connector, is dedicated for uploading and downloading unit configuration values
at the factory.

The Program Mode can not be accessed through the communication ports.
Program configuration must be done from the keypad on the front of the control.

Modbus Wiring
The 505 control can communicate to two devices via RS-232, RS-422, RS-485
using an ASCII or RTU Modbus transmission protocol. The communications port
is brought out to terminal blocks for wiring. Each communications mode is wired
to different terminals. The following sections identify the terminal landings
required for each mode.

RS-232 Wiring
A RS-232 link is limited to a distance of 50 feet. The 505 control utilizes terminal
blocks 114-117 and 106-109 for RS-232 connections. Figure 2-10 shows typical
RS-232 communications connection. The transmit data (TXD), receive data
(RXD), and signal ground (SIG GND) must be properly connected as shown. In
addition the shield (SHLD) should be connected in at least one location..

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Figure 2-10. Typical RS-232 Communications

RS-422 Wiring
An advantage of RS-422 communications is that it uses a differential voltage and
can accommodate much longer transmission distances. A RS-422 link can
communicate up to a distance of 4000 feet. The 505 control utilizes terminal
blocks 108-113 and 116-121 for RS-422 connections. Figure 2-11 shows a
typical RS-422 communications connection. The transmit data pairs (422T+ and
422T-), receive data pairs (422R+ and 422R-), and signal ground (SIG GND)
must be properly connected as shown. In addition, the shield (SHLD) should be
connected in at least one location. The last unit in the Modbus network chain,
and only the last unit, should have it’s receiver terminated with a resistor. The
505 control has termination resistors built-in. See the jumper option chart (Table
2-1) to connect the termination resistor..

Figure 2-11. Typical RS-422 Communications

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RS-485 Wiring
RS-485 communications can also accommodate transmission distances of up to
a distance of 4000 feet. The 505 control utilizes terminal blocks 108-111 and
116-119 for RS-485 connections. Figure 2-12 shows a typical RS- 485
communications connection. The data lines (422R+/485+ and 422R-/485-) and
signal ground (SIG GND) must be properly connected as shown. In addition, the
shield (SHLD) should be connected in at least one location. The last unit in the
Modbus network chain, and only the last unit, should have it’s receiver
terminated with a resistor. The 505 control has termination resistors built-in. See
the jumper option chart (Table 2-1) to connect the termination resistor.

Figure 2-12. Typical RS-485 Communications

Communications Grounding and Shielding

All three 505 communications ports are fully isolated from earth ground. The RS-422
and RS-485 specifications state that a ground wire is needed if there is no other
ground path between units. the preferred method to do this for isolated ports is to
include a separate wire in the ground cable that connects the circuit grounds together.
Connect the shield to earth ground in at least one location, see Figure 2-13.

Figure 2-13. Preferred Multipoint Wiring with a Separate Signal Ground Wire
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505 Digital Governor Manual 85017V1

Non-isolated nodes may not have a signal ground available. If signal ground is
not available, use the alternate wiring scheme as shown in Figure 2-14. The
alternate way is to connect all circuit grounds of isolated nodes to the shield, and
then connect the shield to earth ground at a non-isolated node.

Figure 2-14. Alternate Multipoint Wiring without a Separate Signal Ground Wire

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Manual 85017V1 505 Digital Governor

Chapter 3.
505 Control Description

Introduction
The 505 uses a digital Low Signal Select (LSS) bus to allow the lowest of three
signals to position the turbine’s governor valve. The three signals available to
control governor valve position, are a Speed PID output, a programmable
Auxiliary PID output, and a valve limiter output. The output of the LSS directly
sets the actuator output current.

Figure 3-1. Basic Control Overview

Turbine Start
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 startup. Once a ‘RUN’ command is issued, the
speed setpoint 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 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.

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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 setpoint 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 setpoint 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 the
turbine speed is first sensed within a critical speed avoidance band when ‘Run’ is
selected, the speed setpoint will match the actual speed and increase to the upper
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 startup permissive. When
programmed for this functionality, the contact input must be closed in order 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. If used, this input is typically connected to a Trip &
Throttle valve’s closed limit switch to verify that it is in the closed position before
a turbine startup is performed.

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 isn’t above the ‘Failed Speed Level’ setting when the time expires.

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Manual 85017V1 505 Digital Governor

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
during a turbine startup. With the Automatic Override logic, the loss-of-speed
signal failure is armed when the turbine trips and remains armed until the sensed
turbine speed exceeds the programmed (‘Failed Speed Level’ setting + 250
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 ‘RUN’ 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.

Turbine Start Modes

Manual Start Mode
The following startup procedure is employed when the Manual start mode is
configured:
1. Issue a RESET command (to reset all alarms and shutdowns)
2. Issue a RUN command (verify T&T valve is closed before issuing)
x At this point the 505 will ramp open the governor valve to its maximum
position at the ‘Valve Limiter Rate’.
x The speed setpoint 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
x 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%
x 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.

WARNING—OVERSPEED
The trip-and-throttle valve must be closed before pushing the ‘RUN’ key in
Manual Start mode. If a RUN 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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505 Digital Governor Manual 85017V1

 8#.8'.+/+6'4

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Figure 3-2. Manual Start Mode Example

Semiautomatic Start Mode

The following startup 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 RUN command
x At this point the speed setpoint will ramp from zero to the minimum
controlling speed setting at the ‘Rate to Min’ rate.
4. Raise the 505’s VALVE LIMITER at a controlled rate.
x 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’s VALVE LIMITER to 100%.
x 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.

38 Woodward
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Manual 85017V1 505 Digital Governor



64+2 6*4166.' 8#.8'.+/+6'4

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Figure 3-3. Semiautomatic Start mode Example

Automatic Start Mode

The following startup 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 RUN command
x At this point the 505 will ramp open the governor valve to its maximum
position at the ‘Valve Limiter Rate’ setting.
x The speed setpoint will ramp to the minimum controlling speed setting
at the ‘Rate to MIN’ rate.
x When turbine speed increases and matches the ramping speed
setpoint, the 505’s Speed PID will take control of turbine speed by
controlling turbine inlet valve position.
x 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 automatic start routine may be aborted at any
time by issuing valve limiter raise or lower commands, or an emergency
shutdown.

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505 Digital Governor Manual 85017V1



64+2 6*4166.' 8#.8'.+/+6'4

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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, two critical speed ranges may be configured. The
Idle/Rated or Auto Start Sequence function must be programmed to perform
critical speed avoidance.

The speed setpoint cannot be stopped in the critical band. If a Raise/Lower

Speed Setpoint command is issued while in a critical band, the speed setpoint
will ramp up or down (depending on raise or lower command) to the extent of the
critical range. Since the lower speed setpoint has priority over a raise setpoint,
issuing a lower command while increasing through the band will reverse the
setpoint direction and return it to the lower limit of the band. If a lower speed
setpoint command is given while in a critical band, turbine speed must reach the
bottom of the band before another command can be executed.

A speed setpoint 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 setpoint will
instantly go to the idle setting and an alarm will occur (Stuck in Critical).

During a startup 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 setpoint 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.

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Critical speed bands are defined in the Program mode under the SPEED
SETPOINT VALUES header. All critical speed band settings must be set below
the ‘Min Governor Speed Setpoint’. A configure error will occur if an idle setpoint
is programmed within a critical speed band. The rate in which the speed setpoint
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.

Idle/Rated
The 505 is equipped with an Idle/Rated function which allows the 505 to
automatically ramp turbine speed to the application’s 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 RUN command is issued, the speed setpoint
will ramp from zero rpm up to and hold at the ‘Idle Setpt’ setting. When a ramp-
to-rated command is given, the speed setpoint ramps to the ‘Rated Setpt’ setting
at the ‘Idle/Rated Rate’. While ramping to a Rated speed, the setpoint can be
stopped by a raise or lower speed command or a valid entered speed setpoint.

The 505 will inhibit a ramp-to-idle speed or ramp-to-rated speed command, if the
Generator Breaker is closed, Remote Speed Setpoint 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 setpoint holds at the idle speed
setting until a Ramp-to-Rated command is given. Upon command the speed
setpoint will accelerate to the Rated speed setpoint, however, it will not ramp
back to the idle speed setting. When Rated is de-selected, the speed setpoint
stops as opposed to returning to Idle. When this configuration is used, there is no
Ramp- to-Idle option; it is not used.

If Rated is de-selected while in a critical speed avoidance band (using Ramp to

Rated only feature), the speed setpoint 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 setpoint command, the setpoint 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 setpoint will return to the Idle setpoint, continuing
to move at the critical avoidance rate while within the band. The speed setpoint
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 setpoint 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.

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Figure 3-5. Idle/Rated Start

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.

Automatic Start Sequence

NOTE
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.

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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 startup from zero speed to rated speed. With this function, the turbine’s
starting ramp rates and idle speed hold times depend on the length of time the
unit was shutdown. 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 a ‘RUN’ command is given, the Automatic Start
Sequence ramps the speed setpoint to a low idle setpoint, holds at this setting for
a duration, ramps the speed setpoint to a high idle setpoint, holds at this setting
for a duration, then ramps the speed setpoint to a rated 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 a
hours-since-trip timer. This 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 ‘RUN’ 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 ‘RUN’ command is
given and the turbine has been shutdown for longer than the programmed ‘COLD
START’ time setting.

If a turbine ‘RUN’ 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 will interpolate between the hot and cold programmed start values to
determine starting rates and hold times.

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For example, if the unit had the following 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 MIN
LOW IDLE DELAY (HOT) = 10 MIN
HI IDLE SETPT = 2000 rpm
RATE TO HI IDLE (COLD) =5 rpm/sec
RATE TO HI IDLE (HOT) = 15 rpm/sec
HI IDLE DELAY TIME (COLD) = 20 MIN
HI IDLE DELAY TIME (HOT) = 30 MIN
RATE TO RATED (COLD) = 10 rpm/sec
RATE TO RATED (HOT) = 20 rpm/sec
RATED SETPT = 3400 rpm

If the unit was tripped for 12 hours, the 505 would interpolate between the Hot
and Cold parameters and use the following rates and delays (viewed in the
Service Mode):
LOW IDLE DELAY = 20 MIN
RATE TO HI IDLE = 10 rpm/sec
HI IDLE DELAY = 10 MIN
RATE TO RATED = 15 rpm/sec
HOURS SINCE TRIP = 12 HOURS

Based on the example’s configuration and trip time, the speed setpoint would
ramp to 1000 rpm at the ‘Rate to Min’ setting and hold for 20 minutes, move to
2000 rpm at 10 rpm/sec and hold there for 10 minutes, and lastly, move to 3400
at 15 rpm/sec. At 3400 rpm, the sequence would be completed.

If the unit was tripped for 2 hours or less and restarted, the 505 would use the
Hot Start parameters. If the unit was tripped for 22 hours or longer and restarted,
the 505 would use the Cold Start parameters. . The ‘Hours since Trip’ timer starts
counting when the unit shuts down and the speed has coasted down below the
low idle speed setting.

NOTE
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 Program mode. The hours-since-trip timer will reset only
when the turbine speed has increased above the minimum governor speed
setting.

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 setpoint command, or when a speed setpoint 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 5 minutes.

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.

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If a 505 contact input is programmed to function as an 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
setpoints. This feature would result in the unit automatically stopping or halting at
the low idle setpoint and at the high idle setpoint. If the unit is started and the
speed is above the low idle setpoint, 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.

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

Speed Control Overview

Turbine speed is sensed through one or two MPUs 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. One MPU and one proximity probe can
be used at the same time, however, they must be mounted on the same gear
since the ‘gear ratio’ and ‘teeth seen by the MPU’ must be the same for both
inputs. The Speed PID (proportional, integral, derivative control amplifier) then
compares this signal to the its setpoint to generate an output signal to the
governor valve actuator (through a low signal select bus).

NOTE
The 505 is factory set (jumpers installed) to interface with passive MPUs, if
proximity probes are used, the jumpers must be changed (see Chapter 2 for
jumper options).

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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)
x Turbine inlet valve position (505 LSS position) control
x Generator Load control

When not programmed for generator applications, the 505 Speed PID operates
in a Speed control mode at all times. 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.

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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 is used by the PID for stability or control. Refer to Figure 3-6.

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.

Figure 3-8. Speed PID Control Modes

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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.

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 3-5.

When breaker positions result in the Speed PID switching to Frequency control,
the speed setpoint 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 Setpoint’
(synchronous speed) setting, the speed setpoint will ramp to the ‘Rated Speed
Setpoint’ setting at a defaulted rate of 1 rpm/sec (tunable through the Service
mode).

In the Frequency control mode the speed setpoint can be varied with the Speed
Setpoint 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 3-6 for a frequency and load relationship diagram.

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 3-5.

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Figure 3-9. Frequency and Unit Load Relationship

Because the 505’s Speed PID and setpoint are used to control turbine speed and
a second parameter, this second parameter (unit load) is normalized to allow all
three terms (speed, setpoint, 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 setpoint.
Once unit load (0-100%) is represented as a percent of rated speed, the speed
setpoint 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

Setpoint change in rpm

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

For this example when paralleled to a utility bus, the speed setpoint 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 loadsharing 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.

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It is recommended that a Woodward Real Power Sensor or equivalent watt
transducer be used to sense generator load and feed it back to the 505’s KW
input for KW droop control. However, if KW droop is not used or programmed,
the 505 uses its LSS bus position to represent or sense turbine inlet valve
position when paralleled with an infinite bus. If while controlling generator load,
the KW input signal fails the 505 will issue an alarm and revert to turbine inlet
valve position to control from.

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

To configure the 505 for generator load control when paralleled to a infinite bus,
program the ‘KW DROOP’ setting to ‘YES’, and program the 505 to accept an
analog input from a Watt transducer sensing generator load.. To configure the
505 for turbine valve position control when paralleled to an infinite bus, program
the KW DROOP setting to ‘NO’. 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 considered to
be 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.

However, 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. With this type of
application it is recommended that the Minimum Load setpoint not be used. To
disable the use of the Minimum Load Setpoint, configure the ‘Use Min Load’
setting (under the Service mode’s ‘BREAKER LOGIC’ header) to ‘No’.

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

The Speed PID’s setpoint may be adjusted a variety of ways. It can be adjusted
up or down from the 505 keypad, external contacts, or through Modbus
commands. 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
Setpoint analog input or it can be manipulated by the Cascade controller to
control the cascade input parameter.

The speed setpoint range must be defined in the program mode. Program
settings ‘Min Governor Speed Setpoint’ and ‘Max Governor Speed Setpoint’
define the normal operating speed range of the turbine. The speed setpoint
cannot be raised above ‘Max Governor Speed Setpoint’ setting unless an
Overspeed Test is performed. Once the speed setpoint is taken above the ‘Min
Governor Speed Setpoint’ 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
Setpoint’ setting, the speed setpoint may be adjusted through discrete raise and
lower commands. When a raise or lower speed command is issued, the setpoint
moves at the programmed ‘Speed Setpoint Slow Rate’. If a speed raise/lower
command is selected for longer than three seconds, the speed setpoint will then
move at the fast rate which is three times the speed setpoint slow rate. The
speed setpoint slow rate, fast rate delay, and fast rate can all be adjusted in the
Service mode.

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

The speed setpoint may be set to a specific level, by directly entering a setpoint
value through the 505 keypad or Modbus communications. To “enter” a specific
setpoint from the 505 keypad, press the SPEED key to view the speed control
screen, press the ENTER key, enter the setpoint level desired, then press the
ENTER key again. If a valid number was entered, the setting will be accepted
and the Speed setpoint will ramp to the “entered” setpoint 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 setpoint value
is entered, the setpoint will ramp at the speed setpoint slow rate to the newly
entered setpoint value. This ‘Entered’ rate is tunable through the Service mode.

When using the ENTER key from the front panel keypad, the 505 checks the
validity of the new entered setpoint. The speed setpoint must be below the
maximum governor setting and above the idle setting and not within a critical
speed avoidance band. Once the speed setpoint is above the minimum governor
setting, the setpoint cannot be lowered below minimum governor. Also, if the unit
is driving a generator and the unit is on-line, the speed setpoint cannot be set
below the minimum load setting. The minimum load setting is defaulted to 5 rpm
above the isochronous speed setpoint (changeable in the Service Mode).

The speed setpoint can also be directly entered from either of the Modbus links,
however, the allowed range is between the minimum governor and the maximum
governor speed settings. The allowed setpoint 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.

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

When configured for generator applications a Minimum Load setpoint is 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 setpoint 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 Setpoint, configure the ‘Use Min
Load’ setting (under the Service mode’s ‘BREAKER LOGIC’ header) to ‘No’.

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

Frequency Arm/Disarm
The Frequency Arm/Disarm feature can be used only when loadsharing 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 must be set to
‘Yes’, 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.

CAUTION—FREQUENCY CONTROL MODE

Only one unit at a time should be 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.

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If the ‘Use Freq Arm/Disarm’ setting is set to ‘No’, 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 is set to ‘Yes’ then
Frequency control must first be armed before the unit will switch into Frequency
control when the utility tie contact is open.

Speed Control Dual Dynamics

The Speed PID has a two sets of dynamics; off-line and on-line. 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.

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 3-1).

When not configured for a generator application, the 505 uses the programmed
‘Min Governor Speed Setpoint’ 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 Setpoint’ setting. The
Speed PID’s on-line dynamics are selected when turbine speed is above the ‘Min
Governor Speed Setpoint’ setting. (see Table 3-1).

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 effect 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.

Dynamic values are defined in the program mode and tunable at any time. Refer
to the PID Dynamic Adjustments section in this manual.

ON-LINE DYNAMICS OFF-LINE DYNAMICS

CONFIGURATION 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.

Table 3-1. On-Line/Off-Line Dynamics Selection

Remote Speed Setpoint

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

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

Setpoint 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 setpoint input is out of range (below 2
mA or above 22 mA) an alarm will occur and the Remote Speed setpoint will be
inhibited until the input signal is corrected and the alarm is cleared.

Remote Speed Setpoint Status Messages

The Remote Speed Setpoint may be in one of the following states (505 front
panel screen messages):
x Disabled—The remote setpoint function is not enabled and will have no
effect on the speed setpoint.
x Enabled—The remote setpoint has been enabled.
x Active—The remote setpoint is in control of the Speed setpoint but the
speed PID is not in control of the actuator output.
x In Control—The remote setpoint is in control of the Speed setpoint and the
speed PID is in control of the actuator output.
x 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 setpoint may not match the Speed setpoint.
In this case, the Speed setpoint will ramp to the Remote Speed setpoint at the
programmed ‘Speed Setpoint Slow Rate’ setting (as defaulted in the Service
mode). Once in control, the maximum rate that the Speed setpoint will ramp, for
a RSS change, is at the programmed ‘Remote Speed Setpoint Max Rate’ setting.
If the ‘Remote Speed Setpoint Max Rate’ were set at 10 rpm/sec and the Remote
Speed setpoint analog input instantly moved from 3600 rpm to 3700 rpm, the
Speed setpoint will move to 3700 rpm at 10 rpm/sec.

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

tunables.

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

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Synchronization
Automatic generator synchronization can be performed through a Woodward
Digital Synchronizer & Load Control (DSLC). The DSLC connects to a 505
analog input to bias the 505’s speed setpoint directly to vary generator speed,
frequency and phase. Optionally the DSLC 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 setpoint
rate (Sync Window Rate) is used to increase setpoint resolution around
synchronous speed. This allows for tighter setpoint control to accommodate
synchronizing manually or by an automatic synchronizer which interfaces to the
505 discretely. This Sync rate is defaulted to two rpm/sec and is only adjustable
through the 505’s Service mode. This rate is only used when the generator
breaker is open the speed setpoint is within +10 rpm of rated speed (also tunable
through the Service mode).

The DSLC can be used as a synchronizer only or as a synchronizer and load

control. When the DSLC is used as a synchronizer only, the 505 must be
configured to accept the DSLC’s analog Speed Bias signal and have this input
enabled. A ‘Sync Enable’ contact input or function key (F3 or F4) 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 DSLC 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 DSLC sync mode and 505 analog input at the
same time.

To configure the 505 to utilize a DSLC for generator synchronization only,

program the ‘Synchronizing input’ function to the ‘ANALOG INPUT #6’ setting
and program the ‘Sync Enable” function to a ‘CONTACT INPUT X’ setting.
Analog Input #6 is isolated and is the only input directly compatible with the
DSLC’s output signal. The ‘Synchronizing input’ function has preset range and
gain settings that are tunable only in the Service mode. Thus the 4 mA and 20
mA Program Mode settings for the Synchronizing input are irrelevant and are not
used by the function’s operation. See Volume #2 of this manual or Woodward
manual 02007 for more information on applying the DSLC.

When programming a Function Key (F3 or F4), instead of a contact input, to

enable the 505’s analog Synchronizing input, a 505 relay output can also be
programmed to select a DSLC’s synchronizing mode. To configure the 505 for
this functionality, program the ‘Sync Enable’ function to a ‘FX KEY PERFORMS’
setting, and the ‘Sync Enabled’ function to a ‘RELAY X ENERGIZES ON’ setting.

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When the 505 is programmed to use the DSLC for Synchronization, the RMT key
can also be used to access and enable the Synchronizing function and monitor
all synchronization mode messages. See Chapter 5 for information on how to
enable this function through the RMT key. By pressing the RMT key and scrolling
up or down through the RMT screens, the following synchronizing mode
messages can be viewed:
x Disabled—The Synchronizing Input is disabled and will have no effect on
the Speed setpoint.
x Enabled—The Synchronizing Input has been enabled.
x In Control—The Synchronizing Input is biasing the Speed setpoint.
x 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/Loadsharing
A Woodward Digital Synchronizer & Load Control (DSLC) is used with a 505 to
allow automatic generator synchronization to a bus and the sharing of load with
other units (using DSLCs on the same bus). The Woodward DSLC is a
microprocessor based generator load control designed for use on three-phase
AC generators with Woodward speed controls and automatic voltage regulators.

A DSLC with VAR/Power Factor control, allows all units with DSLCs to reactive
load share as well as real power load share. The DSLC senses unit load through
generator PTs & CTs and system load through the DSLC LON network (a
combination of all units on the network). The DSLC uses a digital Echelon
Network (LON) to communicate with other DSLCs on the same bus.

When used as a synchronizer and load control, the DSLC performs automatic
synchronization and controls 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 DSLC through the
Sync/Load Share input or by the 505’s internal speed/load setpoint. The Utility
Tie Breaker Contact is used to select unit load control through the DSLC or
through the 505’s internal load setpoint. When the 505’s internal load control is
selected (utility tie contact closed), the Speed PID setpoint 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 DSLC interfaces to the 505 via its Speed Bias signal. To configure the 505
to utilize a DSLC for generator synchronizing and load sharing, program the
‘Sync/Load Share input’ function to the ‘Analog Input #6’ setting and program the
‘Sync/Ld Share Enable” function to a ‘Contact Input #X’ setting. Analog Input #6
is isolated, and the only input directly compatible with the DSLC’s output signal.
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
Program 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
loadsharing operating modes (See Table 3-2).

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Figure 3-11. Loadsharing Logic

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,
loadsharing 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 loadsharing 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 loadsharing.

The ‘Sync/Ld Share Enable’ contact input option is used to enable the Sync/Load
Share analog input before the generator breaker is closed. Optionally a Function
Key (F3 or F4) can be programmed 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 DSLC sync mode and 505 analog input at the same time.

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

Table 3-2. Load Sharing Logic

When programming a Function Key (F3 or F4) instead of a contact input to

enable the 505’s analog Sync/Load Share input, a 505 relay output, can be also
be programmed to select a DSLC’s synchronizing mode. To configure the 505 for
this functionality, program the ‘Sync/Ld Share Enable’ function to a ‘FX KEY
PERFORMS’ setting, and the ‘Sync/Ld Share Enabled’ function to a ‘RELAY X
ENERGIZES ON’ setting.

When the 505 is programmed to use the DSLC for Synchronization and Load
Sharing, the RMT key can be used to access and enable the Sync/Load Share
function and monitor all function mode messages. See Chapter 5 for information
on how to enable this function through the RMT key. By pressing the RMT key
and scrolling up or down through the RMT screens, the following Sync/Load
Share mode messages can be viewed:
x Disabled—The Sync/Load Share Input is disabled and will have no effect on
the Speed setpoint.
x Enabled—The Sync/Load Share Input has been enabled.
x In Control—The Sync/Load Share Input is biasing the Speed setpoint.
x 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.
x All pertinent synchronizing and loadsharing parameters are available
through the Modbus links. See Chapter 6 for a complete listing of Modbus
parameters.

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 setpoint to
directly position the speed setpoint, thus changing turbine speed or load until the
process signal and setpoint 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 setpoint at a variable rate
up to the ‘Max Speed Setpoint Rate’ setting (programmed under the CASCADE
CONTROL header).

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Figure 3-12. Cascade Functional Diagram

Since Cascade is a secondary speed setting function, the Speed PID must be in
control of the 505’s LSS bus in order 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.

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

x Cascade is Disabled—Cascade control is not enabled and will have no

effect.
x 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).
x 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).
x Cascade is In Control—Cascade is in control of the LSS bus.
x Casc Active w/Rmt Setpt—Cascade has been enabled and the Remote
Cascade setpoint is in control of the setpoint but the Speed PID is not in
control of the LSS bus.
x Casc Control w/Rmt Setpt—Cascade is in control of the LSS bus (via the
Speed PID) and the Remote Cascade Setpoint is positioning the Cascade
setpoint.
x 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 startup. Cascade control is disabled if
Remote Speed Setpoint 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 Setpoint
The Cascade setpoint 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 setpoint range must be defined in the program mode. Program
settings ‘Min Cascade Setpoint’ and ‘Max Cascade Setpoint’ define the range of
the Cascade setpoint and control.

NOTE
Cascade setpoint raise/lower contact inputs act as speed setpoint
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 setpoint when
the generator breaker is open, the load setpoint when paralleled to a utility,
and the Cascade setpoint when enabled. Alternatively, a second set of
contacts (speed raise and lower) could be used to independently control the
speed and load setpoints.

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

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

A specific setpoint may also be directly entered from the 505 keypad or through
Modbus communications. When this is performed, the setpoint will ramp at the
‘Casc Setpt Rate’ (as defaulted in Service mode). To “enter” a specific setpoint
from the 505 keypad, press the CAS key to view the Cascade control screen,
press the ENTER key, enter the setpoint level desired, then press the ENTER
key again. If a valid number was entered, equal-to or between the min and max
setpoint settings, the setting will be accepted and the Cascade setpoint will ramp
to the “entered” setpoint 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 setpoint value is entered, the setpoint will ramp at the Cascade
Setpoint Rate to the newly entered setpoint value. This ‘Entered’ rate is tunable
through the Service mode.

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 Setpoint 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 setpoint can moved, as
required, to another setting.

Cascade Setpoint with No Tracking

If the Cascade control is programmed not to use the setpoint tracking feature the
setpoint will remain at its last setting (running or shutdown). When the 505 is
powered-up the setpoint is reset to the ‘Setpt Initial Value’. With this
configuration, when Cascade control is enabled, and its sensed process signal
does not match setpoint, 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 Setpoint 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 setpoint will remain at its last setting until another
parameter adjusts it.

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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 setpoint 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:

PID OUTPUT % x ‘CASCADE DROOP %’ x ‘MAX CASC SETPOINT’ x

0.0001

Where the ‘CASCADE DROOP %’ and ‘MAX CASC SETPOINT’ values are
set in the Program 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 Setpoint

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

The Remote Cascade Setpoint (RCS) range is determined by the programmed

Analog input’s 4 mA and 20 mA settings. The Remote Cascade Setpoint range is
tunable in the Service mode, but cannot be set outside of the min and max
Cascade Setpoint settings.

The Remote Cascade Setpoint 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.

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If the milliamp signal to the Remote Cascade setpoint input is out of range (below
2 mA or above 22 mA) an alarm will occur and the Remote Cascade setpoint will
be inhibited until the input signal is corrected and the alarm is cleared.
Depending on configuration and system conditions, the Remote Cascade
Setpoint may be in one of the following states (505 front panel screen
messages):
x Disabled—The Remote Setpoint function is not enabled and will have no
effect on the Cascade setpoint.
x Enabled—The Remote Setpoint has been enabled but cascade control is
not active. The breakers are not closed, speed < min gov, or cascade has
not taken control.
x Active—The Remote Setpoint has been enabled but Cascade is not in
control. Cascade has been enabled and the Remote Cascade setpoint is in
control of the setpoint but the Speed PID is not in control of the LSS bus.
x In Control—Cascade is in control of the LSS bus (via the Speed PID) and
the Remote Cascade Setpoint is positioning the Cascade setpoint.
x Inhibited—Remote Setpoint 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 setpoint may not match the Cascade
setpoint. In this case, the Cascade setpoint will ramp to the Remote Cascade
setpoint at the programmed ‘Casc Setpt Rate’ setting (as defaulted in the Service
mode). Once in control, the fastest the Remote Cascade setpoint will adjust the
Cascade setpoint is at the programmed ‘Rmt Cascade Max Rate’ setting. If the
‘Rmt Cascade Max Rate’ was set at 10 and the Remote Cascade setpoint analog
input instantly moved from 0 units to 1000 units, the Remote Cascade setpoint
will move to 1000 units at 10 units/sec).

Remote Cascade Enable Logic

There are three different options for enabling Remote Cascade Setpoint and
Cascade control as follows:
x One Remote Enable contact input or function key command
x Both enable commands programmed; Remote Casc Enable and Cascade
Enable
x 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
Setpoint (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.

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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 Setpoint 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
Setpoint 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 Auxiliary input is a 4 to 20 mA current signal.
The PID control amplifier compares this input signal with the Auxiliary setpoint 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.

Figure 3-13. Aux Control Overview

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Auxiliary as a Limiter (not using Enable/Disable)

When configured as a limiter, the Auxiliary control is low signal selected (LSS)
with the Speed PID, 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, program the ‘Use Aux Enable’ setting to ‘NO’.

When Auxiliary is configured to act as a limiter the Auxiliary PID will ‘limit’ the
LSS bus when the input reaches the setpoint. The Aux setpoint initializes to the
programmed ‘Setpt Initial Value’ setting on a power-up-reset. This setpoint 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):
x Auxiliary is Enabled—Auxiliary has been enabled but the generator and
utility tie breaker permissives have not been met (generator applications
only).
x Aux Active/Not Lmting—Auxiliary is configured as a limiter but is not limiting
the LSS bus.
x Aux Active w/Rmt Setpt—Auxiliary is not in control of the LSS bus and the
remote Auxiliary input is in command of the setpoint.
x Aux Control w/Rmt Setpt—Auxiliary is in limiting the LSS bus and the
remote Auxiliary analog input is in command of the setpoint.
x Auxiliary is Inhibited—Auxiliary cannot be enabled. The input signal has
failed.

For generator applications, Auxiliary control can be configured to be disabled

when the generator and/or utility tie breakers are open. Program settings ‘Genbkr
Open Aux Dsbl’ and ‘Tiebkr Open Aux Dsbl’ may be configured to deactivate
Auxiliary PID limiting, depending on system breaker positions. When both
settings are programmed ‘NO’, the Auxiliary limiter will always stay ‘active’. If
either setting is programmed ‘YES’, the Auxiliary limiter will be active only when
the tie breaker or generator breaker respectively, is closed.

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

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 setpoint tracks the
Auxiliary PID’s process signal.

To configure the Auxiliary controller to function as a controller, program the ‘Use

Aux Enable’ setting to ‘YES’.

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%.

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Depending on the configuration and system conditions, the Auxiliary PID may be
in one of the following states (505 front panel screen messages):
x Auxiliary is Disabled—Auxiliary is disabled and will have no effect on the
LSS bus.
x Auxiliary is Enabled—Auxiliary has been enabled but the generator and
utility tie breaker permissives have not been met (generator applications
only).
x Aux Active/Not in Ctrl—Auxiliary has been enabled, permissives met, but is
not in control of the LSS bus.
x 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 setpoint.
x Auxiliary in Control—Auxiliary is in control of the LSS bus.
x Aux Control w/Rmt Setpt—Auxiliary is in control of the LSS bus and the
remote Auxiliary analog input is in control of the setpoint.
x 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
‘TIEBKR OPEN AUX DSBL’ and ‘GENBKR OPEN AUX DSBL’ may be
configured to deactivate Auxiliary control depending on system breaker positions.
When both settings are programmed ‘NO’, the Auxiliary control will always stay
‘active’.

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 active at all times (capable of being enabled).

Auxiliary control may be enabled from the 505 keypad, remote contacts, or
Modbus 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 Auxiliary
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 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. Program the ‘USE KW/UNIT LOAD INPUT’ to ‘YES’ if this
configuration is desired.

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 SETPOINT’ x

0.0001

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

Where the ‘AUXILIARY DROOP %’ and ‘MAX AUX SETPOINT’ values are
set in the Program Mode 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 Setpoint
The Auxiliary setpoint 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 Auxiliary setpoint range must be defined in the program mode. Program
settings ‘Min Aux Setpoint’ and ‘Max Aux Setpoint’ define the range of the
Auxiliary setpoint and control.

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

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

A specific setpoint may also be directly entered from the 505 keypad or through
Modbus communications. When this is performed, the setpoint will ramp at the
‘Aux Setpt Rate’ (as defaulted in Service mode). To “enter” a specific setpoint
from the 505 keypad, press the AUX key to view the Auxiliary control screen,
press the ENTER key, enter the setpoint level desired, then press the ENTER
key again. If a valid number was entered, equal-to or between the min and max
setpoint settings, the setting will be accepted and the Auxiliary setpoint will ramp
to the “entered” setpoint 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 setpoint value is entered, the setpoint will ramp at the Auxiliary
Setpoint Rate to the newly entered setpoint value. This ‘Entered’ rate is tunable
through the Service mode.

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 Setpoint

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

The Remote Auxiliary Setpoint (RAS) range is determined by the programmed

Analog input’s 4 mA and 20 mA settings. The Remote Auxiliary Setpoint range is
tunable in the Service mode, but cannot be set outside of the min and max
Auxiliary Setpoint settings.

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

If the milliamp signal to the Remote Auxiliary Setpoint input is out of range (below
2 mA or above 22 mA) an alarm will occur and the Remote Auxiliary Setpoint will
be inhibited until the input signal is corrected and the alarm is cleared.
Depending on configuration and system conditions, the Remote Auxiliary
Setpoint may be in one of the following states (505 front panel screen
messages):
x Disabled—The Remote Setpoint function is disabled and will have no effect
on the Aux setpoint.
x Enabled—The Remote Setpoint has been enabled, but permissives are not
met.
x Active—The Remote Setpoint has been enabled, permissives are met, but
Auxiliary PID is not in control of the LSS bus.

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x In Control—The Remote Setpoint is in control of the Auxiliary setpoint, and
the Auxiliary PID is in control of the LSS bus.
x Inhibited—Remote Setpoint cannot be enabled; Remote Setpoint input
signal is failed, Auxiliary control is Inhibited, or Remote Auxiliary Setpoint is
not programmed.

Remote Auxiliary Enable Logic

The Remote Auxiliary Setpoint input may be enabled from the 505 keypad,
contact input, or Modbus 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 Setpoint 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 Setpoint 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 Setpoint and Auxiliary
control as follows:
x One Remote Enable contact input or function key command
x Both enable commands programmed; Remote Aux Enable and Auxiliary
Enable
x No enable commands programmed

When only one Remote Enable command is programmed (either F-key or

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 Setpoint 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
Setpoint 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 input or function keys 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 Setpoint parameters are available
through the Modbus links. See Chapter 6 for a complete listing of Modbus
parameters.

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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.

The shortest length of time a setpoint will move for an accepted raise or lower
command is 40 milliseconds (120 milliseconds for a Modbus command). If the
Valve limiter slow rate is programmed for 10 %/sec, the smallest increment it will
move is 0.4 % (.2 % for a Modbus command).

A specific setpoint may also be directly entered from the 505 keypad or through
Modbus communications. When this is performed, the setpoint will ramp at the
‘Valve Limiter Rate’ (as defaulted in Service mode). To “enter” a specific setpoint
from the 505 keypad, press the LMTR key to view the Valve Limiter screen,
press the ENTER key, enter the setpoint level desired, then press the ENTER
key again. If a valid number was entered, equal-to or between the min and max
setpoint 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.

When a valid setpoint value is entered, the setpoint will ramp at the ‘Valve Limiter
Rate’ to the newly entered setpoint value. This ‘Entered’ rate is tunable through
the Service mode.

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.

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.
Pressing the scroll down key from this screen will reveal any additional shutdown
conditions that were sensed. See Chapter 5 for a detailed list of the possible
shutdown (Trip) conditions.

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Up to five 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). All trip conditions are indicated through the 505’s front panel, and Modbus
communications.

The cause of the last trip can also be seen by pressing the ‘CONT’ key, then
pressing the scroll down key. 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.

Controlled Shutdown
The 505’s 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. All control PIDs and functions are disabled except the Speed PID controller
2. The Speed Setpoint is ramped to zero at the speed setpoint slow rate
3. After the Speed Setpoint reaches zero, the valve limiter is instantly stepped
to zero
4. When the valve limiter reaches zero, the 505 executes a Shutdown
command
5. A “TRIP/Shutdown Complete” message is displayed on the 505 front panel

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 (Manual Shutdown ?/Push YES or NO). At this point if the
“YES” key is pressed the control will perform the controlled shutdown sequence
explained above. Pushing the “NO” key will cause no change in the 505’s
operation, and the ‘CONTROLLING PARAMETER’ screen will be displayed. 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 an programmed
contact input or Modbus communication link.

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The controlled shutdown sequence can be aborted at any time. During a
controlled shutdown sequence, by pressing the STOP key, the 505 will display a
‘Manual Shutdown In Ctrl/Push NO to Disable’ message. Pressing the “NO” key
from this screen will cause the shutdown sequence to be aborted, and the control
to display a ‘Manual Shutdown Stopped/Push YES to Continue’ message. 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.

NOTE
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.

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 setpoint 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:

x The Speed PID must be in control
x The Auxiliary, Cascade, and Remote Speed Setpoint PIDs/functions must
be disabled
x If configured for a generator application the Generator breaker must be
open.
x The Speed Setpoint 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 a
“Overspeed Test/Not Permissible” message.

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.

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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 a unsafe condition. This function is typically used during a system
startup 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, programmed
function key (F3, F4), 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)
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)
Local/Remote Contact In (active at all times, if programmed)
Local/Remote Modbus Command (active at all times, if Modbus
programmed)
Trip Command Modbus Command (active at all times, if Modbus
programmed)

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).

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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.

Function Keys
Function keys, F3 & F4 are located on the 505’s front panel, and can be
programmed independently to function as a control panel switch. These keys
allow functions to be enabled and disabled from the 505’s front panel, without
requiring the use of an external switch. The following is a list of the
programmable options for the function keys:
Local/Remote Cascade Enable
Idle/Rated Remote Cascade Setpoint Enable
Halt Continue Auto Start Seq Auxiliary Enable
Remote Speed Setpoint Enable Remote Auxiliary Setpoint Enable
Sync Enable Relay Output
Frequency Control Arm/Disarm

A two step process is required to enable or disable any function. Pressing a

programmed function key will cause the 505’s service panel to display the
current state of the function and prompt the operator to press the YES or NO
keys to enable or disable the function.

A function’s prompt will change depending on the state of the function at that
time. As an example, if the F3 key is programmed to allow an operator to enable
and disable the 505’s Remote Speed Setpoint, when the F3 key is pressed a
(Push Yes to Enable/Rmt Spd Setpt Disabled) message will appear on the front
panel display. Pressing YES will enable the Remote Speed Setpoint function and
the message will change to (Push No to Disable/Rmt Spd Setpt In Control).

Relays
The 505 has eight relay outputs available. Two of these relays are dedicated;
one for a system shutdown command from the 505 and one for 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.

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.

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Any of the other six 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). The following is a list of the 505’s relay
options for level indication:
Speed Aux Setpoint
Speed Setpoint Actuator Demand
KW Input Actuator 1 Demand
Sync/Load Share Input Actuator 2 Demand
Cascade Input Valve Limiter
Casc Setpoint First Stage Pressure
Aux Input

The present relay state (energized/de-energized) and relay configuration is

indicated through both Modbus communication links.

Relays not used as level switches can be programmed to indicate control states.
Except for the Trip relay, when programmed to indicate a state or event, relay will
energize upon the respective state or event occurring. The following is a list of
options for relays if used to indicate a control mode or state:
Shutdown Condition Sync Enabled
Trip Relay (additional trip relay output) Sync or Load Share Enabled
Alarm Condition Load Share Control Enabled
505 Control Status OK Casc Control Enabled
Overspeed Trip Cascade Control Active
Overspeed Test Enabled Remote Casc Setpt Enabled
Speed PID in Control Remote Casc Setpt Active
Remote Speed Setpt Enabled Aux Control Enabled
Remote Speed Setpt Active Aux Control Active
Underspeed Switch Auxiliary PID in Control
Auto Start Sequence Halted Remote Aux Setpt Enabled
On-Line PID Dynamics Mode Remote Aux Setpt Active
Local Control Mode Valve Limiter in Control
Frequency Control Armed F3 Key Selected
Frequency Control F4 Key Selected
Modbus Command

Relay 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 annunciation will only
occur if the 505 tripped the turbine and not annunciate when the other external
devices shuts down the unit (external trips).

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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 program 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 (F3,F4) Key Selected function is programmed, the assigned relay
energizes when the respective function key is pressed and an enable/disable
command issued. This feature allows the 505’s F3 and F4 function keys to be
used as panel switches to select and/or enable system related functions
(synchronizers).

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 program, due in large part to the menu-driven software. Basic
program architecture is illustrated in Figure 4-1. When the control is powered up,
and after the brief CPU self test has been completed, the control displays a
ready status (Controlling Parameter/Push Run or Program). The operating
procedures are divided into two sections: the Program Mode (Figure 4-3) and the
Run Mode (refer to Chapter 5 for RUN Mode information). The Program 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.

Figure 4-1. Basic Program Architecture

The program 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, simply press the ‘PRGM’ key then step
across or step down as necessary. If a wrong key is pressed the display will
revert to the last screen displayed before entering the program mode or the
screen designated to the key pressed.

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The touch keypad has several dual-function keys. Pushing any dual-function key
in the Program Mode enters the appropriate numeric or yes/no value printed on
the key. Pushing the key in the Run Mode enters the operating parameter printed
on the key, unless the “ENTER” key has been pressed to enter a specific
numeric setpoint value.

Programming the 505

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

Figure 4-2 illustrates the 505 screens displayed when power is applied and how
to enter the Program Mode from this point. The password is required to protect
against both intentional and inadvertent program changes. The password can be
changed if desired, refer to Volume 2 for information on changing passwords.

Figure 4-2. Initial 505 Program Mode Entry

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The 505 program mode (configuration) may be accessed once the configuration
check is complete and the turbine is not running. For safety reasons the program
may be monitored only and no changes will be accepted if the turbine is running.
By pressing the PRGM key and entering the password (1113) then pressing
ENTER on the 505 keypad the SHUTDOWN CONTROL Y/N prompt will appear.
If YES is pressed the 505 will issue a shutdown and the program mode will be
accessed. If NO is pressed the 505 will revert to the Select Mode screen and the
program mode will not have been accessed.

All configuration (program mode) values and saved service mode changes are
stored in the nonvolatile memory (EEPROMs) of the 505 control. If power is
removed from the 505 all saved values will return once power is restored. No
batteries or back up power is required.

CAUTION—RECONFIGURE PROGRAM MODE

The field-configured portion of the program will be zeroed out after factory
repair. To prevent damage to your equipment, you must reconfigure the
Program Mode before the unit is put back into service.

Using Program Menus

Once the Program Mode has been entered with the password, the specific
application information must be entered into the 505. Figure 4-3 illustrates the
505 configuration menus and the questions/options available under each
header/column.

The arrow keys (SCROLL LEFT, SCROLL RIGHT) allow you to move right or left
across the tops of the function the Program mode columns. The SCROLL UP
and SCROLL DOWN keys allow you to move up or down the columns. In the
Program Mode, the control will not step down beyond the current step with an
invalid entry (or with no entry). A valid entry must be made before the control will
allow you to step down to the next parameter.

The control displays previously entered values with each program step. If a
displayed value is satisfactory, press the SCROLL UP, SCROLL DOWN, or
ENTER keys to continue. If a new value is required, enter it, then press ENTER.
The ENTER key must be pressed to enter any new value. Also, when the
ENTER key is pressed, the control will automatically advance to the next step.

To return to the header of a program block, press the CLEAR key. To completely
exit out of the Program Mode, press the CLEAR key from the top of the header.
This will save the programmed values and initiate the program configuration
check procedure.

All steps in the program must contain valid entries. The default values are listed
along with any adjustment ranges, where applicable. If an invalid entry is made,
the control displays an invalid entry message. If ENTER is pressed, the control
displays the program step again so a valid entry can be made.

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Program Blocks
Figure 4-3 shows the 13 program columns. To program the control, simply step
through the blocks as described above and configure the control features for the
desired application. The first seven program columns must be programmed for
every installation. The remaining six columns contain optional features which can
be selected if desired. The 13 columns and their basic functions are described in
detail below.

Required Configuration Blocks:

Turbine Start– to configure start mode, idle/rated, and auto start
sequence settings;
Speed Control– to configure MPU or PROX PROBE information
and speed control dynamics settings;
Speed Setpoint Values– to configure speed setpoints, overspeed trip
setpoint, remote speed setting control and
critical speed avoidance bands;
Operating Parameters– to configure the unit for generator application
and to use the local/remote function;
Driver Configuration– to configure driver outputs and, if not using
driver 2, to use driver 2 for a 4–20 mA readout;
Analog Inputs– to configure analog input options;
Contact Inputs– to configure contact input options;

Optional Configuration Blocks:

Function Keys– to configure F3 and F4 function keys options;
Auxiliary Control– to configure auxiliary control information;
Cascade Control– to configure pressure, temperature control
information;
Readouts– to configure analog readout options;
Relays– to configure relay options;
Communications– to configure Modbus communication options.

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Figure 4-3a. Program Mode Blocks

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Figure 4-3b. Program Mode Blocks

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Figure 4-3c. Program Mode Blocks

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Figure 4-3d. Program Mode Blocks

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Each of the program blocks are described in detail below. Figure 4-3 can be
referred to for a graphical program block reference. After a column has been
configured and the display is back at the top of the column, use the left or right
arrow keys to select the next column to configure or check.

All control program questions will be displayed on the top line of the display; all
entries made will be displayed on the lower line of the display. At the beginning
of each column the control will display the header, pushing the down arrow will
access the column.

The program blocks (Figure 4-3) contain information detailing each question
and/or 505 program 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 program mode worksheet in the appendix 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.

Turbine Start Block

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.

MANUAL START? dflt= NO (Yes/No)

Select YES followed by the ENTER key 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 YES followed by the ENTER key 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 YES followed by the ENTER key 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.
(One of the three start modes must be selected before the unit will run.)
RATE TO MIN ( rpm/sec) dflt= 10.0 (0.01, 2000)
Enter the speed setpoint acceleration rate to minimum followed by the
ENTER key. This is the rate the setpoint 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
startup features is used, the min speed will be the minimum governor speed
setpoint.

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VALVE LIMITER RATE ( %/sec) dflt= 5.0 (0.1, 25)
Enter the Valve Limiter Rate, in percent per second, followed by ENTER.
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 %/sec. When using a manual start, this setting is less
critical and can be left at the default of 5 %/sec.
USE IDLE/RATED ? dflt= NO (Yes/No)
Select YES followed by ENTER if this function is desired. If NO, skip to ‘Use
Auto Start Sequence’. If YES is selected, the control will ramp from a
programmable Idle speed to a programmable Rated speed setpoint when
Rated is selected through keypad, Modbus or external switch.
IDLE SETPT (rpm) dflt= 1000 (0.0, 20000)
Enter the Idle Speed setpoint desired followed by the ENTER key. This is
the lowest speed control setpoint when using the Idle/Rated function.
RATED SETPT (rpm) dflt= 3600 (0.0, 20000)
Enter the Rated Speed setpoint desired followed by the ENTER key. This is
the speed control setpoint 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 SETPT RATE ( rpm/sec) dflt= 5.0 (0.01, 2000)
Enter the Idle/Rated rate (rpm/second) followed by ENTER. This is the at
which the speed setpoint moves between Idle and Rated speed setpoints
when using the Idle/Rated commands.
USE AUTO START SEQUENCE ? dflt= NO (Yes/No)
Enter YES followed by ENTER if this function is desired. If NO is selected
followed by ENTER, then the program will step to ‘Reset Clears Trip Output’
question. If this function is programmed and RUN is selected, the 505
automatically accelerates the speed setpoint 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 setpoint. The start sequence can be actuated or
halted through the keypad, Modbus or external switch.
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 followed by the ENTER key. 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 followed by the ENTER key. 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)
LOW IDLE SETPT (rpm) dflt= 1000 (0.0, 20000)
Enter the Low Idle Speed Setting followed by the ENTER key. This is the
first hold speed when using the automatic start sequence. The speed
setpoint 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 followed by ENTER. This is
the programmable time, in minutes, that the turbine will wait/hold at the low
idle speed when a cold start is determined.

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LOW IDLE DELAY TIME- HOT (MINUTES) dflt= 1.0 (0.0, 500)
Enter the hot start hold time at low idle followed by ENTER. 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.
(Must be less than or equal to the ‘Low Idle Delay—Cold’ Setting)
RATE TO HI IDLE—COLD (rpm/sec) dflt= 5.0 (0.01, 500)
Enter the cold start rate to high idle followed by ENTER. This is the
programmable rate, in rpm per second, that the speed setpoint will
accelerate at when moving to high idle when a cold start is determined.
RATE TO HI IDLE—HOT (rpm/sec) dflt= 5.0 (0.01, 500)
Enter the hot start rate to high idle followed by ENTER. This is the
programmable rate, in rpm per second, that the speed setpoint will
accelerate at when moving to high idle 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 hi idle setpoint.
(Must be greater than or equal to the ‘Rate to Hi Idle—Cold’ Setting
HI IDLE SETPT (rpm) dflt= 2000 (0.0, 20000)
Enter the Hi Idle Speed Setting followed by the ENTER key. This is the
second hold speed when using the automatic start sequence. The speed
setpoint will remain at this setting until the Hi Idle Delay/hold time has
expired.
(Must be greater than the ‘Low Idle’ Setting)
HI IDLE DELAY TIME—COLD (MINUTES) dflt= 1.0 (0.0, 500)
Enter the cold start hold time desired at hi idle followed by ENTER. This is
the programmable time, in minutes, that the turbine will wait/hold at the hi
idle speed when a cold start is determined.
HI IDLE DELAY TIME—HOT (MINUTES) dflt= 1.0 (0.0, 500)
Enter the hot start hold time desired at hi idle followed by ENTER. This is
the programmable time, in minutes, that the turbine will wait/hold at the hi
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 hi idle hold
time.
(Must be less than or equal to the ‘Hi Idle Delay—Cold’ Setting)
RATE TO RATED SETPT—COLD (rpm/sec) dflt= 5.0 (0.01, 500)
Enter the cold start rate to the rated speed setpoint followed by ENTER.
This is the programmable rate, in rpm per second, that the speed setpoint
will accelerate at when moving to rated when a cold start is determined.
RATE TO RATED SETPT—HOT (rpm/sec) dflt= 5.0 (0.01, 500)
Enter the hot start rate to the rated speed setpoint followed by ENTER. This
is the programmable rate, in rpm per second, that the speed setpoint 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 setpoint.
(Must be greater than or equal to the ‘Rate to Rated—Cold’ Setting)
RATED SETPT (rpm) dflt= 3600 (0.0, 20000)
Enter the Rated Speed Setting followed by the ENTER key. This is the final
speed setting when using the automatic start sequence. Once this speed
setpoint 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 SETPTS? dflt= NO (Yes/No)
Select YES followed by the ENTER key to automatically halt the auto start
sequence at the idle setpoints. This feature would result in the unit
automatically stopping/halting at the low idle setpoint and at the high idle
setpoint. Also, if the unit is started and the speed is above the low idle
setpoint, the sequence will be halted. Select NO to allow the control to
perform its automatic start sequence routine without interruption.
EXTERNAL TRIPS IN TRIP RELAY ? dflt= YES (Yes/No)
Select YES followed by the ENTER key 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 followed by the ENTER key 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.

Speed Control Block

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.

(The maximum turbine speed is 20000 rpm and the maximum speed input
frequency is 15000 hertz.)

TEETH SEEN BY MPU dflt= 60.0 (1, 300)

Enter the number of teeth on gear that the speed probe is mounted on
followed by the ENTER key.
MPU GEAR RATIO dflt= 1.0 (0.05, 100)
Enter the speed sensor gear ratio followed by the ENTER key. 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.
FAILED SPEED LEVEL (rpm) dflt= 250 (0.5, 1000)
Enter the Failed Speed Level (in rpm) followed by the ENTER key 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 Overspeed Test Limit Setting)
USE SPEED INPUT #2? dflt= NO (Yes/No)
Select YES followed by ENTER if both speed inputs are to be used.
FAILED SPEED LEVEL (rpm) dflt= 250 (0.5, 1000)
Enter the failed speed level (in rpm) followed by the ENTER key 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 Overspeed Test Limit Setting)

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OFF-LINE PROPORTIONAL GAIN dflt= 5.0 (0.0, 100)
Enter the off-line PID proportional gain percentage followed by ENTER. 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 followed by ENTER. 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 followed by ENTER. 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. A
recommended starting value is 5% .
ON-LINE PROPORTIONAL GAIN dflt= 5.0 (0.0, 100)
Enter the on-line PID proportional gain percentage followed by ENTER. 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 followed by ENTER. 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 followed by ENTER. 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. A
recommended starting value is 5% (see Chapter 5—PID Dynamics Settings
for more information).

Speed Setpoint Values Block

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.

(The maximum turbine speed is 20000 rpm and the maximum speed sensor
input frequency is 15000 hertz.)

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OVERSPEED TEST LIMIT (rpm) dflt= 1100 (0.0, 20000)
Set the overspeed test limit (in rpm) followed by the ENTER key. This is the
maximum speed setpoint the control will increase to when overspeed testing
the unit. The setpoint 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) followed by the ENTER key. This
is the governor overspeed trip setpoint only and is not to be used as
ultimate overspeed protection.
(Must be less than the ‘Overspeed Test Limit’ Setting)
MAX GOVERNOR SPEED SETPOINT (rpm) dflt= 0.0 (0.0, 20000)
Set the maximum governor control speed followed by the ENTER key. 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)
MIN GOVERNOR SPEED SETPOINT (rpm) dflt= 0.0 (0.0, 20000)
Set the minimum governor control speed followed by the ENTER key. This
is the normal governor operation lower limit.
(Must be less than the ‘Maximum Governor Speed’ Setting)
SPEED SETPOINT SLOW RATE (rpm/sec) dflt= 5.0 (0.01, 100)
Enter the speed setpoint slow rate in rpm per second followed by the
ENTER key. This the rate of speed change for normal operation.
USE REMOTE SPEED SETPOINT ? dflt= NO (Yes/No)
Set to YES followed by ENTER if using an analog input to set the
Speed/Load Setpoint.
RMT SPEED SETPT MAX RATE (rpm/sec) dflt= 50.0 (0.01, 500)
Enter the Maximum Rate of speed change for remote speed setpoint
operation followed by the ENTER key.
USE CRITICAL SPEEDS ? dflt= NO (Yes/No)
Set to YES followed by ENTER 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 setpoint 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/sec) dflt= 50.0 (0.1, 2000)
Set the rate that the speed setpoint will move through the critical speed
avoidance ranges (in rpm/second) followed by the ENTER key
(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 followed by the
ENTER key.
(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 followed by the
ENTER key.
(Must be less than the ‘Critical Speed 1 Max’ Setting)
USE CRITICAL SPEED 2 ? dflt= NO (Yes/No)
Select YES followed by the ENTER key to use the second critical speed
avoidance band.
CRITICAL SPEED 2 MAX (rpm) dflt= 1.0 (1.0, 20000)
Set the upper limit of the critical speed avoidance band followed by the
ENTER key.
(Must be less than the ‘Minimum Governor Speed’ Setting)

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CRITICAL SPEED 2 MIN (rpm) dflt= 1.0 (1.0, 20000)
Set the lower limit of the critical speed avoidance band followed by the
ENTER key.
(Must be less than the ‘Critical Speed 2 Max’ Setting)

Operating Parameters Block

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.

GENERATOR APPLICATION? dflt= NO (Yes/No)

Select YES followed by the ENTER key 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 followed by the ENTER key 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 setpoint will instantly reset to the ‘Gen Open Setpoint’ which is
defaulted to 50 rpm below rated speed.
USE TIE BREAKER OPEN TRIP? dflt= NO (Yes/No)
Select YES followed by the ENTER key 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 setpoint will instantly reset to the
speed last seen by the unit and move to the ‘Rated Speed Setpoint’ and an
alarm is issued. If NO and the generator breaker is open, there is only an
alarm when the utility tie breaker opens.
USE KW DROOP? dflt= NO (Yes/No)
Set to YES to use KW droop (generator load control) or NO to use internal
Speed droop (turbine inlet valve position) followed by the ENTER key. If
YES, generator KW 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.
KW MAX LOAD (KW) dflt= 20000 (0.1, 20000)
Enter the max load followed by the ENTER key. 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)
DROOP ( % ) dflt= 5.0 (0.0, 10)
Enter the droop percentage followed by the ENTER key. Typically set
between 4-6% and not more than 10%.
RATED SPEED SETPOINT (rpm) dflt= 3600 (0.0, 20000)
Set the generator’s rated speed setpoint followed by the ENTER key.
(Must be greater than or equal to the ‘Minimum Governor Speed’ Setting
and less than the/Maximum Governor Speed’ setting)
USE FREQ ARM/DISARM? dflt= NO (Yes/No)
Set to YES is using frequency control arm/disarm followed by the ENTER
key. 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 Loadsharing)

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USE LOCAL/REMOTE? dflt= NO (Yes/No)
Set to YES if using Local/Remote control logic followed by the ENTER key.
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.

Driver Configuration Block

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 1 IS 4–20 mA ? dflt= NO (Yes/No)

Select actuator #1 output current range. Select YES for 4–20 mA or NO for
20–160 mA followed by the ENTER key. Most Woodward actuators are 20–
160 mA.
INVERT DRIVER OUTPUTS ? dflt= NO (Yes/No)
Set to YES to invert actuator driver output(s) followed by the ENTER key.
This is normally set to NO and is typically only used in certain applications
where the 505 has a backup controller that takes control when the 505 fails.
USE ACT 1 FAULT SHUTDOWN ? dflt= YES (Yes/No)
Select YES followed by ENTER 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.
ACTUATOR 1 DITHER (%) dflt= 0.0 (0.0, 10)
Enter the dither percentage for actuator #1 followed by the ENTER key.
Enter 0.0 if no dither is required. Woodward TM-type actuators typically
require dither. This value can be changed in the Run Mode while the turbine
is operating. See Run Mode—Chapter 5.
USE ACTUATOR NUMBER 2? dflt= NO (Yes/No)
Select YES followed by ENTER if using both Actuator outputs (Act 1 & Act
2). If NO skip to ‘Use Actuator 2 as a Readout’.
ACTUATOR 2 IS 4–20 mA ? dflt= NO (Yes/No)
Select actuator #2 output current range. Select YES for 4–20 mA or NO for
20- 160 mA followed by the ENTER key. Most Woodward actuators are 20–
160 mA.
ACTUATOR 2 OFFSET ( % ) dflt= 0.0 (0.0, 100)
Enter the percentage actuator #1 is opened when actuator #2 begins to
open followed by the ENTER key. Enter 0.0 if both actuators open together.
USE ACT 2 FAULT SHUTDOWN? dflt= YES (Yes/No)
Select YES followed by ENTER to issue a trip whenever an actuator fault is
detected. If YES, the 505 will issue a shutdown if Actuator 2 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.
ACTUATOR 2 DITHER ( % ) dflt= 0.0 (0.0, 10)
Enter the dither percentage for actuator #2 followed by the ENTER key.
Enter 0.0 if no dither is required. Woodward TM-type actuators typically
require dither. This value can be changed in the Run Mode while the turbine
is operating. See Run Mode—Chapter 5.

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USE ACTUATOR 2 AS A READOUT? dflt= NO (Yes/No)
Select YES followed by ENTER to use the actuator output as an additional
readout. When set to NO, the actuator #2 output is not used for anything.
This option is available for customers who do not need two actuator drivers
and would like an additional readout.
ACTUATOR 2 READOUT IS: (must choose from list)
Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
OPTIONS FOR ACTUATOR 2 READOUT
Actual Speed Rmt Cascade Setpt
Speed Setpoint Auxiliary Input
Remote Speed Setpt Auxiliary Setpoint
Sync/Load Share Input Rmt Auxiliary Setpt
KW Input Valve Limiter Setpoint
Cascade Input Actuator 1 Readout
Cascade Setpoint First Stage Press 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 (-20000, 20000)

Set the value (in engineering units) that corresponds to 4 milliamps (mA) on
the analog output followed by the ENTER key. 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 (-20000, 20000)
Set the value (in engineering units) that corresponds to 20 milliamps (mA)
on the analog output followed by the ENTER key. 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)

Analog Inputs Block

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.
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.

The first five (1-5) analog inputs are differential inputs that can be from a self-
powered or a loop-powered (24 Vdc from 505) transducer. However, analog
input #6 is an isolated analog input and should be used when isolation is
required (refer to Chapter 2 for information on the analog input hardware).

ANALOG INPUT # 1 FUNCTION (must choose from list)

Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
ANALOG INPUT OPTIONS
Remote Speed Setpt Remote Cascade Setpt
Synchronizing Input Auxiliary Input
Sync/Load Share Input Remote Aux Setpt
KW/Unit Load Input First Stage Press Input
Cascade Input (Not Used)

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INPUT 1—4 mA VALUE (UNITS) dflt= 0.0 (-20000, 20000)
Set the value (in engineering units) that corresponds to 4 milliamps (mA) on
the analog input followed by the ENTER key. If the value on the display is
correct, just select the ENTER key which will advance you to the next
question.
INPUT 1—20 mA VALUE (UNITS) dflt= 100 (-20000, 20000)
Set the value (in engineering units) that corresponds to 20 milliamps (mA)
on the analog input followed by the ENTER key. 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 ‘Input 4 mA Value’ Setting

Analog Inputs # 2 through # 6 are entered following the same rules as described
for Analog Input # 1.

Contact Inputs Block

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.

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 1 FUNCTION (must choose from list)

Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
CONTACT INPUT OPTIONS
(Not Used) Casc Setpt Raise
Generator Breaker Casc Setpt Lower
Utility Tie Breaker Casc Control Enable
Overspeed Test Remote Casc Setpt Enable
External Run Aux Setpt Raise
Start Permissive Aux Setpt Lower
Idle/Rated Aux Control Enable
Halt/Continue Auto Start Sequence Remote Aux Setpt Enable
Override MPU Fault Valve Limiter Open
Select On-Line Dynamics Valve Limiter Close
Local/Remote External Trip 2
Remote Speed Setpt Enable External Trip 3
Sync Enable External Trip 4
Controlled Shutdown (Manual) External Trip 5
Freq Control Arm/Disarm

Contact Inputs # 2 through # 12 are entered following the same rules as

described for Contact Input # 1.

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Function Keys Block

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.
Each function key option may be configured only once. In addition, the function
that the function key uses must be programmed or an error message will occur.
For example, to use the Cascade Control Enable function key, the ‘Use Cascade’
function must be programmed.

F3 KEY PERFORMS (must choose from list)

Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
OPTIONS FOR FUNCTION KEYS F3 & F4
(Not Used) Freq Arm/Disarm
Local/Remote Casc Control Enable
Idle/Rated Remote Casc Setpt Enable
Halt/Continue Auto Start Sequence Aux Control Enable
Remote Speed Setpt Enable Remote Aux Setpt Enable
Sync Enable Energize Relay Output
BLINK F3 LED WHEN NOT ACTIVE? dflt= NO (Yes/No)
Select YES followed by ENTER to blink the function key’s LED when the
function is not active but is enabled. The LED will be ON whenever the
function is active. If NO, the function key LED is ON when the function is
enabled, active, or in control.
F4 KEY PERFORMS (must choose from list)
Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
BLINK F4 LED WHEN NOT IN CNTRL? dflt= NO (Yes/No)
Select YES followed by ENTER to blink the function key’s LED when the
function is not active but is enabled. The LED will be ON whenever the
function is active or in control. If NO, the function key LED is ON when the
function is enabled, active, or in control.

Auxiliary Control Block

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.

USE AUXILIARY CONTROL? dflt= NO (Yes/No)

Select YES followed by ENTER to configure the auxiliary control function.
Select NO if the auxiliary function is not used.
LOST AUX INPUT SHUTDOWN? dflt= NO (Yes/No)
Select YES followed by ENTER 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.
USE KW INPUT? dflt= NO (Yes/No)
If YES, allows the AUX control channel to use the KW Input programmed.
When YES, no AUX analog input is needed. When NO, an AUX analog
input must be programmed.
INVERT AUX INPUT? dflt= NO (Yes/No)
Select YES followed by ENTER 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 setpoint. An example where the invert would be YES
is for turbine inlet pressure control.

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MIN AUX SETPOINT (UNITS) dflt= 0.0 (-20000, 20000)
Set the min AUX setpoint followed by ENTER. This value is the minimum
setpoint value that the auxiliary setpoint can be decreased/lowered to (lower
limit of AUX setpoint).
MAX AUX SETPOINT (UNITS) dflt= 100 (-20000, 20000)
Set the max AUX setpoint followed by ENTER. This value is the maximum
setpoint value that the auxiliary setpoint can be increased/raised to (upper
limit of AUX setpoint).
(Must be greater than the ‘Min Aux Setpt’ Setting)
AUX SETPOINT RATE (UNITS/sec) dflt= 5.0 (0.01, 1000)
Set the AUX setpoint rate followed by ENTER. This value is the rate (in units
per second) at which AUX setpoint moves when adjusted.
USE AUX ENABLE? dflt= NO (Yes/No)
Select YES followed by ENTER 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
setpoint, 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 setpoint tracks the Aux
input. When enabled, the Aux PID takes control of the valve and the speed
setpoint tracks the speed/load of the unit for bumpless transfer between
modes.
SETPT INITIAL VALUE (UNITS) dflt= 0.0 (-20000, 20000)
Set the setpoint initialization value followed by ENTER. When not using the
Aux Enable function, this is the value that the auxiliary setpoint initializes to
upon power- up or exiting the program mode.
(Must be less than or equal to the ‘Max Aux Setpoint’ Setting)
AUX DROOP (%) dflt= 0.0 (0.0, 100)
Enter the droop percentage followed by the ENTER key. If required, typically
set between 4-6%.
AUX PID PROPORTIONAL GAIN (%) dflt= 1.0 (0.0, 100)
Enter the AUX PID proportional gain value followed by ENTER. 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%.
AUX PID INTEGRAL GAIN (%) dflt= 0.3 (0.001, 50)
Enter the AUX PID integral gain value followed by ENTER. 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%.
AUX PID DERIVATIVE RATIO (%) dflt= 100 (0.01, 100)
Enter the AUX PID derivative ratio followed by ENTER. 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 followed by ENTER 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 followed by ENTER 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 AUX SETTING ? dflt= NO (Yes/No)
Set to YES to allow the aux setpoint to be adjusted from an analog input.
(Must program a ‘remote auxiliary setpoint’ analog input)

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REMOTE AUX MAX RATE (UNITS/sec) dflt= 5.0 (0.1, 1000)
Enter the maximum rate at which the remote input will move the aux
setpoint followed by the ENTER key.
AUXILIARY UNITS OF MEASURE: (must choose from list)
Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
Options:
psi t/h
kPa k#/hr
MW #/hr
KW kg/cm2
degF bar
degC atm
(none)

Cascade Control Block

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.

USE CASCADE CONTROL? dflt= NO (Yes/No)

Select YES followed by ENTER to configure the cascade control function.
Select NO if the cascade function is not used.
INVERT CASCADE INPUT? dflt= NO (Yes/No)
Select YES followed by ENTER 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 setpoint. 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 setpoint followed by ENTER. This value is the
minimum setpoint value that the cascade setpoint can be
decreased/lowered to (lower limit of cascade setpoint).
MAX CASCADE SETPOINT (UNITS) dflt= 100 (-20000, 20000)
Set the maximum cascade setpoint followed by ENTER. This value is the
maximum setpoint value that the cascade setpoint can be increased/raised
to (upper limit of cascade setpoint).
(Must be greater than the ‘Min Cascade Setpt’ Setting)
CASC SETPT RATE (UNITS/sec) dflt= 5.0 (0.01, 1000)
Set the cascade setpoint rate followed by ENTER. This value is the rate (in
units per second) at which cascade setpoint moves when adjusted.
USE SETPOINT TRACKING? dflt= NO (Yes/No)
Select YES or NO followed by ENTER. If YES, the cascade setpoint tracks
the cascade input to provide bumpless transfer to cascade control when it is
enabled. If NO, the cascade setpoint remains at the last position except on
power-up or exiting the program mode.
SETPT INITIAL VALUE (UNITS) dflt= 100.0 (-20000, 20000)
Set the setpoint initialization value followed by ENTER. When not using the
Setpoint Tracking function, this is the value that the cascade setpoint
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 setpoint that the cascade controller can lower the
speed setpoint to followed by ENTER. 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)
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SPEED SETPOINT UPPER LIMIT (rpm) dflt= 3780 (0.0, 20000)
Set the maximum speed setpoint that cascade controller can raise the
speed setpoint to followed by the ENTER key.
(Must be less than or equal to the ‘Maximum Governor Speed Setpt’
Setting)
MAX SPEED SETPOINT RATE (rpm/sec) dflt= 20 (0.1, 100)
Set the maximum rate at which the cascade control can vary the speed
setpoint followed by the ENTER key.
CASCADE DROOP (%) dflt= 0.0 (0.0, 100)
Enter the droop percentage followed by the ENTER key. If needed, typically
set between 4-6%.
CASCADE PID PROPORTIONAL GAIN (%) dflt= 5.0 (0.0, 100)
Enter the cascade PID proportional gain value followed by ENTER. 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%.
CASCADE PID INTEGRAL GAIN (%) dflt= 0.3 (0.001, 50.0)
Enter the cascade PID integral gain value followed by ENTER. 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%.
CASCADE PID DERIVATIVE RATIO (%) dflt= 100 (0.01, 100)
Enter the cascade PID derivative ratio followed by ENTER. 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%.
USE REMOTE CASCADE SETTING? dflt= NO (Yes/No)
Set to YES to allow the Cascade setpoint to be adjusted from an analog
input.
(Must program a ‘remote cascade setpoint’ analog input
RMT CASCADE MAX RATE (UNITS/sec) dflt= 5.0 (0.1, 1000)
Enter the maximum rate at which the remote input will move the cascade
setpoint followed by the ENTER key.
CASCADE UNITS OF MEASURE: (must choose from list)
Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
Options:
psi kPa
MW KW
degF degC
t/h k#/hr
kg/cm² bar
atm #/hr
(none)

Readouts
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.
All six 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 Setpoint readout, the ‘Use Cascade’ function must be
programmed.

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ANALOG READOUT # 1 FUNCTION (must choose from list)
Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
ANALOG READOUT OPTIONS
Actual Speed Auxiliary Input
Speed Setpoint Auxiliary Setpoint
Remote Speed Setpt Rmt Auxiliary Setpt
Load Share Input Valve Limiter Setpoint
Sync Input Actuator Demand Readout
KW Input Actuator 1 Readout
Cascade Input Actuator 2 Readout
Cascade Setpoint First Stg Press Input
Rmt Cascade Setpt (Not Used)
READOUT 1—4 mA VALUE (UNITS) dflt= 0.0 (-20000, 20000)
Set the value (in engineering units) that corresponds to 4 milliamps (mA) on
the analog output followed by the ENTER key. If the value on the display is
correct, just select the ENTER key which will advance you to the next
question.
READOUT 1—20 mA VALUE (UNITS) dflt= 100 (-20000, 20000)
Set the value (in engineering units) that corresponds to 20 milliamps (mA)
on the analog output followed by the ENTER key. 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)

Readouts # 2 through # 6 are entered following the same rules as described for
Readout # 1.

Relays Block
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.

You may configure up to six relays in addition to the two pre-assigned relays
(Alarm, Shutdown). The 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.

USE RELAY # 1? dflt= NO (Yes/No)

Press Set to YES followed by ENTER to use this relay output. Press NO
followed by ENTER to skip to the next ‘USE RELAY’ question.
IS RELAY # 1 A LEVEL SWITCH? dflt= NO (Yes/No)
Press YES followed by ENTER to use this relay output as a level switch.
Press NO followed by ENTER to skip to the ‘RELAY ENERGIZES ON:’
question..
RELAY 1 IS LEVEL SWITCH FOR : (must choose from list)
Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
LIST OF OPTIONS FOR LEVEL SWITCH
Actual Speed Level Aux Setpoint Level
Speed Setpoint Level Valve Limiter Level
KW Input Level Actuator Demand (hand valve)
Sync/Load Share Level Act 1 Output Level
Cascade Input Level Act 2 Output Level
Cascade Setpoint Level First Stg Press Level
Aux Input Level Switch
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RELAY 1 ON LEVEL (UNITS) dflt= 0.0 (-20000, 20000)
Enter the level switch ON setting in engineering units followed by the
ENTER key. 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.
RELAY 1 OFF LEVEL (UNITS) dflt= 0.0 (-20000, 20000)
Enter the level switch OFF setting in engineering units followed by the
ENTER key.
(Must be less than the ‘Relay On Level’ Setting)
RELAY 1 ENERGIZES ON : (must choose from list)
Scroll through the option list by using the Adjust Up/Down Arrows or by
selecting the NO key until the option desired appears, then press the YES
or ENTER keys to select the option/function.
OPTIONS FOR RELAYS IF USED TO INDICATE STATE
Shutdown Condition Sync Enabled
Trip Relay (add’l trip relay output) Sync/Load Share Active
Alarm Condition Load Share Control
505 Control OK Casc Control Enabled
Overspeed Trip Cascade Control Active
Overspeed Test Enabled Remote Casc Setpt Enabled
Speed PID in Control Remote Casc Setpt Active
Remote Speed Setpt Enabled Aux Control Enabled
Remote Speed Setpt Active Aux Control Active
Underspeed Switch Auxiliary PID in Control
Auto Start Sequence Halted Remote Aux Setpt Enabled
On-Line PID Dynamics Mode Remote Aux Setpt Active
Local Control Mode Valve Limiter in Control
Frequency Control Armed F3 Key Selected
Frequency Control F4 Key Selected
Modbus Command Selected

Relay outputs # 2 through # 6 are entered following the same rules as described
for Relay output # 1.

Communications Block
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.

USE COMMUNICATIONS? dflt= NO (Yes/No)

Set to YES followed by ENTER to use the Modbus communications feature
of the 505. There are two identical Modbus ports available. Either or both
can be configured for use. Select NO followed by ENTER if Modbus
communications will not be used.
USE MODBUS PORT 1? dflt= NO (Yes/No)
Set to YES followed by ENTER to use the Modbus Port 1. Set to NO
followed by ENTER to skip to ‘Use Modbus Port 2’. If the displayed value is
already correct, simply select ENTER.
MODE: ASCII OR RTU dflt= 2 (1, 2)
Enter the integer corresponding to the Modbus transmission mode required
followed by the ENTER key. Enter a ‘1’ for ASCII mode or a ‘2’ for RTU
mode. For more information on the difference between these modes, refer
to Chapter 6. If the displayed value is already correct, simply select ENTER.
MODBUS DEVICE NUMBER dflt= 1 (1, 247)
Enter the integer corresponding to the Modbus device number/address
required followed by the ENTER key. If the displayed value is already
correct, simply select ENTER.

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COMMUNICATIONS MODE dflt= 1 (1, 3)
Enter the integer corresponding to the serial communications mode required
followed by the ENTER key. Enter a ‘1’ for RS-232, a ‘2’ for RS-422 or a ‘3’
for RS-485 communications. If the displayed value is already correct, simply
select ENTER.
PORT1 BAUD RATE dflt= 9 (1, 11)
Enter the integer corresponding to the communications baud rate followed
by the ENTER key. If the displayed value is already correct, simply select
ENTER.
1 = 110 2 = 300 3 = 600 4 = 1200
5 = 1800 6 = 2400 7 = 4800 8 = 9600
9 = 19200 10 = 38400 11 = 57600
PORT 1 STOP BITS dflt= 1 (1, 3)
Enter the integer corresponding to the stop bits required followed by the
ENTER key. If the displayed value is already correct, simply select ENTER.
Enter a ‘1’ for 1 stop bit, a ‘2’ for 1.5 stop bits or a ‘3’ for 2 stop bits.
PORT 1 PARITY dflt= 1 (1, 3)
Enter the integer corresponding to the parity required followed by the
ENTER key. If the displayed value is already correct, simply select ENTER.
Enter a ‘1’ for none, a ‘2’ for odd parity or a ‘3’ for even parity.
USE MODBUS PORT 2? dflt= NO (Yes/No)
Set to YES followed by ENTER to use the Modbus Port 2. If the displayed
value is already correct, simply select ENTER. Modbus Port # 2 is entered
following the same rules as described for Modbus Port # 1.

Exiting the Program Mode

Figure 4-4. Exiting the Program Mode

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Once the programming steps have been completed, the Program Mode can be
exited (refer to Figure 4-4 Exiting the Program Mode). To exit the Program mode
the “CLEAR’ key is pressed twice. This initiates the 505 to save the configuration
and to begin a Configuration Check procedure. If there are no errors in the
programming, the 505 front-panel will return to the ready state and display the
‘Controlling Parameter/Press Run or Program’ screen. However, if there is an
error in the program, the ‘Config ERROR—Press PRGM’ display will appear
along will the programming error(s) discovered. The next section identifies the
various configuration error messages and explains the meaning of the error.

Program Configuration Error Messages

When the Program Mode is exited, the control automatically performs a
completeness check on the configured program 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 ‘Config
ERROR—Press PRGM’ display will appear along with the programming error(s)
discovered. If there is more than one error discovered, they can be displayed by
pressing the down arrow key. This key will scroll through all the error messages
and allow you to determine their cause(s).

The configuration error message alerts you that a programming change is

required before the configured program can operate the turbine. You must re-
enter the Program Mode and fix the problem before the control will allow the
turbine to run. The completeness check will continue to fail until the control is
satisfied that the configured program is complete.

This section of the manual identifies the various configuration error messages
that may appear and explains the meaning of the error.

Start/Speed Program Errors

No Start Mode Selected—RUN was selected but no start mode was selected in
the Program mode. One of the three start modes must be selected in the
Program mode under the Start Block.

Speed > 15000 Hz—The maximum speed input is 15000 hertz. This is a
limitation of 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.

Spd #1 Fld < Freq Range—The failed speed setting for speed input #1 is below
the minimum allowed setting. The minimum allowed setting is calculated as
follows: (Overspeed Test Limit) * (0.0204).

Spd #2 Fld < Freq Range—The failed speed setting for speed input #2 is below
the minimum allowed setting. The minimum allowed setting is calculated as
follows: (Overspeed Test Limit) * (0.0204).

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Critical Speed Program Errors

Crit Rate < Slow Rate—The acceleration rate (rpm/second) through the critical
speed avoidance band must be faster than the normal speed setpoint rate.

Crit Spd Err/No Idle—A critical speed avoidance band was programmed but
neither idle/rated or auto start sequence was programmed. To use the critical
speed avoidance logic one of these functions that uses an idle speed must be
programmed.

Lo Idle set in Critical—Either the idle speed setpoint (when using idle/rated) or
the low idle setpoint (when using the auto start sequence) was programmed
within a critical speed avoidance band.

Hi Idle set in Critical—The hi idle speed setpoint (when using the auto start
sequence) was programmed within a critical speed avoidance band.

Idle Program Errors

Idle Setpt > Min Gov—The Idle Speed setpoint was programmed at a higher
speed than the minimum governor speed setpoint.

Rated Speed > Max Gov—The Rated Speed setpoint was programmed at a
higher speed than the maximum governor speed setpoint.

Generator Program Errors

KW Max Load > KW Input—The KW Max Load setting was programmed at a
higher value than the maximum KW input (KW input at 20 mA).

No Utility Brkr Config—The unit is programmed for a generator application but no

utility tie breaker contact input was programmed. This is a requirement.

No Gen Brkr Config—The unit is programmed for a generator application but no

utility tie breaker contact input was programmed. This is a requirement.

No Freq Arm/Dsarm Prgmd—The frequency arm/disarm function was

programmed but no means of arming or disarming were programmed. Either a
function key or a contact input must be programmed to arm/disarm frequency
control if you wish to use the frequency arm/disarm function.

Sync & Sync/Ld Shr Pgmd—Both the synchronizing analog input and the
sync/load share or load share analog inputs were programmed. If the application
needs to perform both synchronizing and load sharing with analog signals, only
the sync/load sharing analog input needs to be programmed.

Freq Arm & Ld Shr Pgmd—Both the frequency arm/disarm function and the load
share control functions were programmed. Only one of these modes can be
programmed — either freq arm/disarm OR Load Sharing.

Contact Input Program Errors

Two Identical Contacts—Two contact inputs were programmed for the same
function.

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Contact #xx Program Err—The specified contact input was programmed for a
function that is not also programmed to be used. Either the contact input was
mis-programmed or the function required is mis-programmed. For example,
contact input #1 is programmed for Remote Cascade Setpoint Enable but
Remote Cascade Setpoint was not programmed under the Cascade Program
Block.

Analog Input Program Errors

Two Identical Analogs—Two analog inputs were programmed for the same
function.

Analog #x Program Err—The specified analog input was programmed for a

function that is not also programmed to be used. Either the analog input was mis-
programmed or the function required is mis-programmed. For example, analog
input #1 is programmed for Remote Cascade Setpoint but Remote Cascade
Setpoint was not programmed under the Cascade Program Block.

No Rmt Speed Input Prgm—The remote speed setpoint control function was
programmed but no remote speed setpoint analog input was configured.

No KW Analog Input—Either the auxiliary control function was programmed to

use the KW input or KW droop was programmed but no KW analog input was
configured.

No Sync Analog Input—A synchronizing contact input was programmed but no

synchronizing analog input was configured.

No Ld Share Analog In—A load share or sync/load share contact input was
programmed but no load share analog input was configured.

No Cascade Analog Input—The cascade control function was programmed but

no cascade analog input was configured.

No Rmt Casc Input Prgm—The remote cascade setpoint control function was
programmed but no remote cascade setpoint analog input was configured.

No Aux Analog Input—The auxiliary control function was programmed but no

auxiliary analog input was configured.

KW & Aux Config for Aux—The auxiliary control function was programmed to use
the KW analog input but an auxiliary analog input was configured also. With this
configuration, only the KW analog input is used for the auxiliary controller.

No Rmt Aux Input Prgm—The remote auxiliary setpoint control function was
programmed but no remote auxiliary setpoint analog input was configured.

Function Key Program Errors

Identical Function Keys—Both function keys were programmed for the same
function.

No F-Key Relay Prgmd—A function key was programmed to energize a relay but
no relay outputs were configured for F3 or F4 key relays.

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F3 Key Program Error—The F3 key was programmed for a function that is not
also programmed to be used. Either F3 was mis-programmed or the function
required was mis-programmed. For example, the F3 key is programmed for
Remote Cascade Setpoint Enabled but Remote Cascade Setpoint was not
programmed under the Cascade Program Block.

F4 Key Program Error—The F4 key was programmed for a function that is not
also programmed to be used. Either F4 was mis-programmed or the function
required was mis-programmed. For example, the F4 key is programmed for
Remote Cascade Setpoint Enabled but Remote Cascade Setpoint was not
programmed under the Cascade Program Block.

Relay Program Errors

Relay #x Program Error—The specified relay was programmed for a function that
is not also programmed to be used. Either the relay was mis-programmed or the
function required is mis-programmed. For example, relay #1 is programmed for
Remote Cascade Setpoint Enabled but Remote Cascade Setpoint was not
programmed under the Cascade Program Block.

Readout Program Errors

Readout #x Program Err—The specified readout was programmed for a function
that is not also programmed to be used. Either the readout was mis-programmed
or the function required is mis-programmed. For example, readout #1 is
programmed for Cascade Setpoint but Cascade Control was not programmed
under the Cascade Program Block.

Driver 2 Readout Err—The Actuator/Driver 2 readout was programmed for a

function that is not also programmed to be used. Either the readout was mis-
programmed or the function required is mis-programmed. For example, driver 2
is programmed for Cascade Setpoint but Cascade Control was not programmed
under the Cascade Program Block.

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 insure 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 program 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 can not be adjusted lower than the minimum actuator current
(see table 4-1 below). The minimum actuator current can not be adjusted higher
than the maximum actuator current. The driver current ranges are determined by
the setting in the Program Mode under the Driver Configuration Block.

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.

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Driver Limits 20–160 mA Range 4–20 mA Range
Overcurrent 217 mA 26 mA
Undercurrent 5 mA 0.6 mA
Max Output Current Range 10-200 mA 2-24 mA
Max Output Impedance 45 : 360 :
Min Stop Adjust Range 10-80 mA 2-20 mA
Max Stop Adjust Range 100-200 mA 10-24 mA

Table 4-1. Actuator Driver Limits

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.

Figures 4-5 and 4-6 graphically show the steps available to stroke the actuator
output(s). The stroking option is only available when the 505 control is in a
shutdown state. Also, the screens displayed varies with the number of actuators
programmed.

After enabling the stroke 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. The actuator and valve positions can be varied by using the ADJ
UP and DOWN keys or keying in the position desired and pressing the ENTER
key. When the ENTER key is pressed, the actuator output will step to the entered
position.

Press any available Run Mode key to exit the STROKE ACTUATORS mode. For
example, pressing the SPEED key will disable the stroking function and display
the ‘speed’ information. To return to the STROKE ACTUATORS mode, the ACT
key must be selected again and the keystrokes to enter this mode must be
repeated. As a safety precaution, if the turbine speed ever exceeds 1000 rpm,
the STROKE ACTUATORS mode is disabled.

As a safety precaution, if turbine speed ever exceeds 1000 rpm, the STROKE
ACTUATORS mode will be automatically disabled, and actuator currents taken
to zero.

Calibration/Stroking Procedure
(for single actuator output configuration)

WARNING—OVERSPEED
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. Overspeed sensing and its relay are disabled during
this process. 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.

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1. The 505’s Emergency shutdown contact input must be closed or jumpered
throughout this procedure (or the 505’s actuator current output will go to
ZERO current).
2. Execute a system RESET command (Press the 505 “Reset” key).
3. Press the 505’s front panel “Emergency Shutdown” button.
4. Press the ‘ACT’ key then the SCROLL DOWN key until the “Stroke
Actuators—Dsbled, Steam Must be Off” message appears. (Verify that the
turbine’s steam supply has been shutoff before by an external Trip and
Throttle valve.)
5. Press the “YES” key (This will cause the screen to display a “Stroke to Min—
Enabled, Min Curr Adjust * 20.000” message).
6. Press the “YES” key to enable this mode or the “Scroll Down Arrow” to step
to the mode desired. (Refer to Figure 4-5).
6a. Stroke to Min—Enabld, Min Curr Adjust * XXX.XX—Press YES to
force the actuator output to the minimum stop. The message will
display ‘At Min’ and the actuator output current will move to its
minimum setting. The minimum current value can be adjusted only
when the ‘at sign’ (@) is on the bottom line of the display. Press the
SELECT key to move the @ symbol between the top and bottom lines.
Press the ADJ UP or DOWN keys to change the 0% actuator current
level. Press the SCROLL DOWN ARROW to step the next desired
mode, or the “CLEAR” key twice to save changes, and exit Calibration
mode.
6b. Stroke to Max—Enabld, Max Curr Adjust * XXX.XX—Press YES to
force the actuator output to the maximum stop. The message will
display ‘At Max’ and the actuator output current will move to its
maximum setting. The maximum current value can be adjusted only
when the ‘at sign’ (@) is on the bottom line of the display. Press the
SELECT key to move the @ symbol between the top and bottom lines.
Press the ADJ UP or DOWN keys to change the 100% actuator current
DOWN ARROW to step the next desired mode, or the “CLEAR” key
twice to save changes and exit Calibration mode.
6c. Manually Adjust—Enabld, Stroke Valve XXX.XX—Press the ADJ
UP, ADJ DOWN keys from this screen to move the valve’s output
current between 0-100% at a 5%/second rate. This allows both the
actuator and valve to be tested for binding, play, resolution, linearity,
and repeatability.

Press the “YES” key at any time to allow a setting to be directly

‘Entered’. The message will display ‘Manual’ when the ENTER mode is
allowed. When in the ‘Manual’ mode, press the “ENTER” key, enter the
setting desired, then press the “ENTER” key again. This will step the
actuator output to a specific position instantly. Press the “ADJ
UP/DOWN” or “No” keys at any time to switch back to the “Enabld”
mode.

When calibration is complete, 0 to 100% valve position as displayed by

the 505 must equal 0 to 100% actual valve travel. Press the SCROLL
DOWN ARROW to step the next desired mode, or the “CLEAR” key
twice to save changes and exit Calibration mode.

7. Press the CLEAR key twice to permanently save any minimum or

maximum actuator settings into the 505. If variables are tuned or
changed but not stored in EEPROM by pressing the CLEAR key twice,
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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Calibration/Stroking Procedure
(for dual actuator output configuration)

WARNING—OVERSPEED
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. Overspeed sensing and its relay are disabled during
this process. 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’s Emergency shutdown contact input must be closed or jumpered

throughout this procedure (or the 505’s actuator current output will go to
ZERO current.
2. Execute a system RESET command (Press the 505 “Reset” key).
3. Press the 505’s front panel “Emergency Shutdown” button.
4. Press the ACT key then the SCROLL DOWN key until the “Stroke
Actuators—Dsbld, Steam Must be Off” message appears. (Verify that the
turbine’s steam supply has been shutoff before by an external Trip and
Throttle valve.)
5. Press the “YES” key (This will cause the screen to display a “Act #1 to Min—
Enabld, Min Curr Adjust * 20.000” message).
6. Press the “YES” key to enable this mode or the “Scroll Down Arrow” to step
to the mode desired. (Refer to Figure 4-6).
6a. Act #1 to Min—Enabld, Min Curr Adjust * XXX.XX—Press YES to
force the actuator output to the minimum stop. The message will
display ‘At Min’ and the actuator output current will move to its
minimum setting. The minimum current value can be adjusted only
when the ‘at sign’ (@) is on the bottom line of the display. Press the
SELECT key to move the @ symbol between the top and bottom lines.
Press the ADJ UP or DOWN keys to change the 0% actuator current
level. Press the SCROLL DOWN ARROW to step the next desired
mode, or the “CLEAR” key twice to save changes, and exit Calibration
mode.
6b. Act #1 to Max—Enabld, Max Curr Adjust * XXX.XX—Press YES to
force the actuator output to the maximum stop. The message will
display ‘At Max’ and the actuator output current will move to its
maximum setting. The maximum current value can be adjusted only
when the ‘at sign’ (@) is on the bottom line of the display. Press the
SELECT key to move the @ symbol between the top and bottom lines.
Press the ADJ UP or DOWN keys to change the 100% actuator current
DOWN ARROW to step the next desired mode, or the “CLEAR” key
twice to save changes and exit Calibration mode.
6c. Manually Adjust—Enabld, Stroke Valve XXX.XX—Press the ADJ
UP, ADJ DOWN keys from this screen to move the valve’s output
current between 0-100% at a 5%/second rate. This allows both the
actuator and valve to be tested for binding, play, resolution, linearity,
and repeatability.

Press the “YES” key at any time to allow a setting to be directly

Entered. The message will display ‘Manual’ when the ENTER mode is
allowed. When in the ‘Manual’ mode, press the “ENTER” key, enter the
setting desired, then press the “ENTER” key again. This will step the
actuator output to a specific position instantly. Press the “ADJ
UP/DOWN” or “No” keys at any time to switch back to the “Enabld”
mode.

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When calibration is complete, 0 to 100% valve position as displayed by
the 505 must equal 0 to 100% actual valve travel. Press the SCROLL
DOWN ARROW to step the next desired mode, or the “CLEAR” key
twice to save changes and exit Calibration mode.

7. Similarly, for Act #2:

7a. Act #2 to Min—Enabld, Min Curr Adjust * XXX.XX — Press YES to
force the actuator output to the minimum stop. The message will
display ‘At Min’ and the actuator output current will move to its
minimum setting. The minimum current value can be adjusted only
when the ‘at sign’ (@) is on the bottom line of the display. Press the
SELECT key to move the @ symbol between the top and bottom lines.
Press the ADJ UP or DOWN keys to change the 0% actuator current
level. Press the SCROLL DOWN ARROW to step the next desired
mode, or the “CLEAR” key twice to save changes, and exit Calibration
mode.
7b. Act #2 to Max—Enabld, Max Curr Adjust * XXX.XX— Press YES to
force the actuator output to the maximum stop. The message will
display ‘At Max’ and the actuator output current will move to its
maximum setting. The maximum current value can be adjusted only
when the ‘at sign’ (@) is on the bottom line of the display. Press the
SELECT key to move the @ symbol between the top and bottom lines.
Press the ADJ UP or DOWN keys to change the 100% actuator current
DOWN ARROW to step the next desired mode, or the “CLEAR” key
twice to save changes and exit Calibration mode.
7c. Manually Adjust—Enabld, Stroke Valve XXX.XX — Press the ADJ UP,
ADJ DOWN keys from this screen to move the valve’s output current
between 0-100% at a 5%/second rate. This allows both the actuator
and valve to be tested for binding, play, resolution, linearity, and
repeatability.

Press the “YES” key at any time to allow a setting to be directly

Entered. The message will display ‘Manual’ when the ENTER mode is
allowed. When in the ‘Manual’ mode, press the “ENTER” key, enter the
setting desired, then press the “ENTER” key again. This will step the
actuator output to a specific position instantly. Press the “ADJ
UP/DOWN” or “No” keys at any time to switch back to the “Enabld”
mode.

When calibration is complete, 0 to 100% valve position as displayed by

the 505 must equal 0 to 100% actual valve travel. Press the SCROLL
DOWN ARROW to step the next desired mode, or the “CLEAR” key
twice to save changes and exit Calibration mode.

8. Press the CLEAR key twice to permanently save any minimum or

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

If changes are made to the minimum or maximum current values, they can be
recorded on the Program Mode worksheets under the ‘Driver Configurations’
block.

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Pressing any available Run Mode key will exit the STROKE
ACTUATORS/VALVE mode. Exiting the STROKE ACTUATORS/VALVE mode
by a RUN MODE key will not permanently save any calibration changes.

CAUTION—SAVE CHANGES
Press the CLEAR key twice to permanently save any minimum or maximum
actuator settings into the 505. If variables are tuned or changed but not
stored in EEPROM by pressing the CLEAR key twice, then those changes
will be lost if power is removed from the control or if the control receives a
CPU reset.

Figure 4-5. Stroke Actuator

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Stroke Actuator Messages
Message 7 Meaning
Dsbld Stroke actuators function is disabled
Enabld Stroke actuators function is enabled
At Min Actuator output is set to the minimum value ( 0% )
At Max Actuator output is set to the maximum value ( 100% )
Manual Actuator output is in manual mode

CAUTION—SAVE CHANGES
Press the CLEAR key twice to permanently save any minimum or maximum
actuator settings into the 505. If variables are tuned or changed but not
stored in EEPROM by pressing the CLEAR key twice, then those changes
will be lost if power is removed from the control or if the control receives a
CPU reset.

Figure 4-6. Stroking Dual Actuators

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Chapter 5.
505 Operation

Run Mode Architecture

The 505 is designed to be interfaced with through a user-friendly service panel,
discrete and analog input/outputs or Modbus communications. Basic program
architecture is illustrated in Figure 5-1. When the control is powered up and after
the brief CPU self test has been completed, the control displays a ready status
(Controlling Parameter/Push Run or Program). The 505’s normal operating
architecture is divided into two sections: the Run Mode and the Program Mode.
The Program Mode is used to configure the 505 for the specific application and
set all operating parameters (see Chapter 4). The Run Mode is simply the normal
turbine operation mode and is used to view operating parameters and run the
turbine. A Service Mode is also available to make additional on-line adjustments
while the unit is running. See Volume 2 for information on the Service Mode.

Figure 5-1. Basic Program Architecture

An overview of Run mode keys and screens is shown in Figure 5-2. This diagram
shows all of the potential screens that could appear. However, only the screens
that are related to the 505’s programmed functionality will appear. Figure 5-2
also shows the keys that are active for each screen. The ‘hot’ keys (Speed, Aux,
etc.) are always active if the function is programmed. The ADJUST UP/DOWN,
ENTER, YES/NO keys, however, are only active with certain screens. Figure 5-2
can be referred to, when determining what keys are active and what screens will
appear on the display.

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Figure 5-2a. Overview of Run Mode

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Figure 5-2b. Overview of Run Mode

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Trip Controlling Parameter Remote
Messages Messages Messages
Message 8 Message 7 Message 4
External Trip Input Shutdown Disabled
Enter Shutdown Button Controlled Shutdown Inhibited
Overspeed Max Actuator Enabled
All Speed Probes Failed Valve Limiter Active
Actuator #1 Fault Remote Auxiliary In Control
Actuator #2 Fault Auxiliary Control
Aux Input Failed Configuration Error Cascade Control
External Trip 2 Start Perm Not Met Messages
External Trip 3 Ready to Start Message 6
External Trip 4 Manual Start Disabled
External Trip 5 Auto Start Inhibited
Comm Link #1 Trip Semi Auto Start Enabled
Comm Link #2 Trip Idle/Rated Start In Control
KW Input Failed Auto Start Sequence Active/Not Spd Ctrl
Tie Breaker Opened Frequency/Speed Active w/Rmt Setpt
Generator Breaker Open Synchronizing In Ctrl w/Rmt Setpt
Power Up Trip Load Share/Speed
Shutdown Complete Remote Cascade/Speed Units Options
Cascade/Speed (for Aux/Casc)
Idle/Rated Messages Remote/Speed psi
Message 1 Speed/On-Line kPa
Stopped Speed/Off-Line MW
Speed/Off-Line KW
Mvg to Idle Aux Messages degF
At Idle Spd (if using aux enable) degC
In Crit Band Message 5 t/h
Mvg to Rated Disabled k#/hr
At Rated Spd Inhibited #/hr
Rtd Inhibited Enabled kg/cm2
Idle Inhibited Active/Not in Ctrl bar
Active w/Rmt Setpt atm
Auto Start Messages In Control (none)
Message 2 Remote Control
Disabled
Halted Aux Messages
Mvg Low Idle (if using aux as a limiter)
At Low Idle Message 5
Mvg Hi Idle Inhibited
In Crit Band Enabled
At High Idle Enabled w/Rmt Setpt
Mvg to Rated Active w/Rmt Setpt
Completed Active/Not Lmting
Control w/Rmt Setpt
Control Messages In Control
Message 3
Disabled
Inhibited
Enabled
In Control
Remote Control

Table 5-1. Overview of Run Mode

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Keypad and Display

The 505 is a field configurable steam turbine control and operator control panel
(OCP) integrated into one package. The 505’s service panel consists of a 30-key
keypad and LED display located on the front of the control. The LED display has
two, 24 character lines that can be used to display operating parameters and
trouble-shoot parameters in plain English. The service panel is used to configure
the 505, make On-Line program adjustments, and operate the turbine/system.
No additional panels are required to operate the turbine, every turbine control
function can be from the 505’s front panel. However, the turbine can also be
operated remotely. Every front panel control operation can be performed
remotely through contacts or Modbus communications. For safety purposes,
however, the 505’s Overspeed Test function cannot be performed through a
Modbus link.

Figure 5-3. 505 Keypad and Display

Run Mode Front Panel Keys

For a detailed description of each 505 key functionality see Chapter 1.

Of the thirty front panel keys, not all are active at all times in the Run mode.
However, from the 505’s service panel, the keys that are active will be apparent
since there is immediate display feedback when an active key is pressed. When
a respective “Hot” key (Aux, Casc, KW, etc.) function is not programmed, a
FUNCTION NOT PROGRAMMED message will be appear if the key is pressed.
The following are generalizations when determining what keys will function:

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x The ADJUST UP/DOWN keys are active when a setpoint is displayed and
the setpoint is not in a remote control or tracking mode.
x The ENTER key is active whenever the ADJUST UP/DOWN keys are
active. This is when the setpoint is shown on the display and the setpoint is
not in remote control or tracking mode.
x The YES/NO keys are active whenever a status indication is shown on the
display and an enable/disable function is valid.
x The CAS, AUX, KW, and RMT keys are only active if the function is
configured in the Program Mode.
x The SPEED, ACTR, LMTR, CONT, and DYN keys are always active.
x The PRGM, RUN, STOP, RESET, and ALARM keys are always active.
x The F3 and F4 function keys are only active if they are configured.
x The OVERSPEED TEST ENBL is conditionally active (only active when
OSPD test is permissible).

Starting Procedures
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:

WARNING—OVERSPEED PROTECTION
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 RUN key to initiate the selected start-up mode. The front panel
display will automatically jump to the SPEED screen (if auto or manual start
is programmed) or to the LMTR screen (if semi-auto start is programmed). If
a semi-automatic start mode is configured, the valve limiter must be
manually increased to open the control valve.
x 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 setpoint 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.

The ‘Run’ and ‘Reset’ commands can be selected from the 505’s service panel,
contact input closures (if programmed), or from a Modbus communications link.
In addition, the following indications are available through the Modbus links:
Speed Setpt Moving to Min, Start Permissive closed, and Start Permissive Not
Closed Alarm indication.
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Speed Key Screens

Figure 5-4 shows the possible screens that may appear if the SPEED key is
pressed. Only the screens related to the Speed control’s programmed
functionality will be displayed. In addition, the order of the screens may change
depending on the status of the control. Screens 4, 5 and 6 will always appear. If
idle/rated is programmed, screen 1 will appear. If the auto start sequence if
programmed, screens 2 and 3 will appear. Once the auto start sequence is
complete, these screens no longer appear.

Figure 5-4. SPEED Key Screens

Idle/Rated Start
For details on the idle/rated startup, refer to Chapter 3. When a RUN command
is issued, the 505 automatically displays the SPEED screen and shows the
Idle/Rated status. The speed setpoint is instantly set to the actual turbine’s
speed. To increase the speed to the programmed ‘Rated Setpt’ setting, select
the Rated command. A Rated command can be issued by pressing the front
panel YES key from the Idle/Rtd screen (screen 1), closing the Idle/Rated
contact (if programmed) or selecting a Go To Rated command from Modbus
communications.

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When the speed setpoint is ramping to the Rated Setpoint setting it can be
stopped at any point that is not within a critical speed avoidance band by issuing
a Speed Setpt Raise or Lower command. This can be done by pressing the
ADJUST UP or DOWN from the front panel SPEED screen (screens 1,2,3 or 4),
closing a Speed Raise/Lower contact input or selecting Speed Raise or Lower
from a Modbus communications link.

The Speed setpoint will again ramp to the Rated Speed setting if the Rated
command is re-issued. To re-issue the Rated command press the front panel
YES key from the Idl/Rtd screen (screen 1), toggle the Idle/Rated contact open
and closed again (if programmed) or select Go To Rated from a Modbus
communications link.

The Speed setpoint will ramp to the Idle Speed setting upon startup. However,
the Idle Speed setting can be re-selected, when conditions allow, (see Chapter
3) by pressing the front panel NO key from the Idl/Rtd screen (screen 1), opening
the Idle/Rated contact (if programmed), or selecting Go To Idle from a Modbus
communications link.

Another feature of Idle/Rated function is the ‘Ramp to Rated’ option which allows
the Speed setpoint to only move to the Rated Speed setting; Idle is not
selectable. This feature is configurable in the Service Mode only. When this
feature is used with the Idle/Rated contact input, closing the contact results in the
Speed setpoint ramping to the Rated Speed setting and opening the contact
stops the speed setpoint ramp—rather than selecting Idle. To continue ramping
to the Rated Speed setting, re-close the contact, press the front panel YES key
from the Idl/Rtd screen (screen 1) or select Go To Rated from Modbus
communications.

Table 5-2 lists the Idle/Rated status messages that may appear on the front
panel display and the meanings of each.

Message 1 Meaning
Stopped Idle/Rated ramp has been stopped
Mvg to Idle Speed Setpt is moving to idle
At Idle Spd Speed Setpt is at the idle Setpt
In Crit Band Speed Setpt is moving through the critical avoidance band
Mvg to Rated Speed Setpt is moving to the rated Setpt
At Rated Spd Speed Setpt is at the rated Setpt
Rtd Inhibited Selection of rated is not allowed
Idle Inhibited Selection of idle is not allowed

Table 5-2. Idle/Rated Messages

The following indications are available through the Modbus links: Ramping to
Idle, At Idle, Turbine in Critical Speed Band, Ramping to Rated, and At Rated. In
addition to these indications, the Idle Speed Setpoint and Rated Speed Setpoint
analog values are also available.

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Auto Start Sequence

When a RUN command is issued, the 505 automatically displays the SPEED
screen (unless used with the Semiautomatic start mode) and shows the Status of
the Auto Start Sequence (screen 2). The Speed setpoint is instantly set to the
turbine’s actual speed and the sequence will continue from this point. This
sequence is automatic, however the sequence can be halted. Halting the Auto
Start Sequence can be performed by pressing the front panel NO key from the
Sequence Status screen (screen 2), opening the Halt/Continue contact (if
programmed), selecting Halt from a Modbus communications link, or selecting
Speed Setpt Raise or Lower. To provide feedback, a relay can be programmed
to indicate the Auto Start Sequence is Halted.

The Sequence can be restarted again by pressing the front panel YES key from
the Sequence Status screen (screen 2), closing the Halt/Continue contact, or
selecting Continue from a Modbus communications link. Table 5-3 lists the Auto
Start status messages that may appear on the display and the meanings of each.

Message 2 Meaning
Disabled Auto Start Sequence is disabled
Halted Sequence has been halted
Mvg Low Idle Speed Setpt is moving to low idle
At Low Idle Speed Setpt is holding at the low idle Setpt
Mvg Hi Idle Speed Setpt is moving to high idle
In Crit Band Speed Setpt is moving through the critical avoidance band
At High Idle Speed Setpt is holding at the high idle Setpt
Mvg to Rated Speed Setpt is moving to rated Setpt
Completed Auto Start Sequence is completed

Table 5-3. Auto Start Messages

The following Auto Start Sequence indications are available through the Modbus
links: Setpt Moving to Min, Setpt at Low Idle, Ramping to High Idle, Setpt at High
Idle, Turbine in Critical Speed Band, Ramping to Rated, and At Rated. In addition
to these indications, the Low Idle Speed Setpoint, Low Idle Delay Time, Time
Remaining at Low Idle, Low Idle to High Idle Rate, High Idle Speed Setpoint,
High Idle Delay Time, Time Remaining at High Idle, High Idle to Rated Rate,
Rated Speed Setpoint, Run Time (hours), and Hours Since Trip analog values
are also available providing comprehensive sequence information.

Direct Setpoint Entry

The Speed setpoint can be directly set to a specific value, that is not within a
critical speed avoidance band, using the ENTER key from the Speed Setpt
screen (screen 4). The messages that appear on the display are shown in Figure
5-5. There are limits on the range of the Speed setpoint that can be entered. The
Speed setpoint must be below the maximum governor setting and above the idle
setting. Also, if the unit is driving a generator and the unit is on-line, the speed
setpoint cannot be set below the minimum load setting (tunable in the Service
Mode).

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The Speed setpoint can also be directly entered from either of the Modbus links,
however, the allowed range is between the minimum and maximum governor
speed settings. The allowed setpoint range is limited between the minimum load
and the maximum governor settings if the unit is driving a generator and the unit
is on-line. Both the speed setpoint and the Modbus Entered Speed setpoint are
available over the communication link to provide feedback for directly entered
Modbus values.

Figure 5-5. Direct Setpoint Entry

Speed Control
Once the turbine is in speed control at minimum governor speed or rated speed,
the speed setpoint can be adjusted with the ADJUST UP or DOWN front panel
keys from the Speed screen (screen 4), Speed Setpoint Raise or Lower contact
inputs, or commands through a Modbus link. In addition the setpoint can be
directly entered using the ENTER key from a Setpoint display or through the
communication links (see Direct Setpoint Entry above).

The following speed control indications are available through the Modbus links:
Speed PID in Control and Speed at or above Min Gov. In addition to these
indications the Speed Setpoint, Actual Turbine Speed, Speed Sensor #1 Input,
Speed Sensor #2 Input, and Speed Control PID Output analog values are also
available.

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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. Figure 5-6 shows the screens that are displayed when the ‘OSPD’ key
is pressed. These will only be displayed when the speed setpoint has been
raised to the maximum governor and the unit is Off-Line (if driving a generator).
Before these conditions are met, the screen will indicate the overspeed test
permissives are not met.

Figure 5-6. Overspeed Test Enable Key Screens

Overspeed Test Procedure

(from the 505’s Service Panel)

x Raise the Speed Setpoint to the maximum governor setting.

x If desired, clear the ‘Highest Speed Reached’ value, to record the highest
speed reached during this overspeed test. (Press the OSPD key, scroll
down to screen 2 and press the YES key. Note: This value can also be
cleared or read from under the Control (CONT) key.
x Press the OSPD key and Adjust Up command at the same time to allow the
Speed Setpoint to be raised for testing. The Overspeed Test Enable LED in
the OSPD key will turn ON when the setpoint is raised above the maximum
governor setting.
If the OSPD key is released, the speed setpoint will move back to the
maximum governor setting.
x Once turbine speed reaches the 505’s internal OVERSPEED TRIP LEVEL
setting, the OSPD key’s LED will blink and the screen will flash a ‘Speed >
Trip’ message.
x If the OSPD key is released while the Overspeed Test LED is blinking, the
unit will trip on overspeed.

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x If an external device’s trip setting is being tested the Speed Setpoint can be
raised up to the 505’s OVERSPEED TEST LIMIT setting, by not releasing
the OSPD key and continuing to adjust the 505’s Speed Setpoint. The
Overspeed Test LED will blink at a faster rate when the OVERSPEED TEST
LIMIT is reached, indicating the maximum speed setpoint is reached and
the unit should have tripped on the external trip device.

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 OSPD key on the 505’s service panel. When the conditions
outlined in the above procedure are met, closing this contact allows the Speed
setpoint 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 same status feedback as the front panel
Overspeed Test LED.

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.

F3 and F4 Keys
The F-key (F3 & F4) screens appear only when programmed for a specific
function. The screens that appear will vary depending on the function
programmed. The F-keys can be programmed to perform a variety of functions
including:
Local/Remote Casc Control Enable
Idle/Rated Remote Casc Setpt Enable
Halt/Continue Auto Start Sequence Aux Control Enable
Remote Speed Setpt Enable Remote Aux Setpt Enable
Sync Enable Energize Relay Output
Freq Arm/Disarm

In the RUN mode, the assigned function may be selected or deselected by

pressing the assigned function key, then the Yes or No keys respectively. The
screen will display the present status of the function and prompt the appropriate
(Yes/No) key required to change the status.

Limiter (LMTR) Key Screens

Figure 5-7 shows the screens that appear when the LMTR key is pressed. These
screens are always active and always displayed. 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 actuator demand and the limiter
setpoint can be viewed from screen 2. To manually position the governor valve
with the Valve Limiter setpoint, the limiter setpoint must be decreased below the
actuator demand signal (LSS bus output). Once below or equal to this signal, the
limiter setting will be the actuator output signal and thus governor valve position
will be set manually by the limiter.

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The valve limiter can be adjusted with the ADJUST UP or DOWN front panel
keys from any Limiter screen, Valve Limiter Raise or Lower contact inputs (if
programmed), or commands through a Modbus link. In addition the setpoint can
be directly entered using the ENTER key from any Limiter screen.

The following valve limiter indications are available through the Modbus links:
Valve Limiter at Min, Valve Limiter at Max, and Valve Limiter In Control of
actuator output. In addition to these indications the Valve Limiter Setpoint,
Actuator LSS, Actuator #1 Output and Actuator #2 Output analog values are also
available.

Figure 5-7. LMTR Key Screens

Actuator (ACTR) Key Screens

Figure 5-8 shows the possible screens that may appear if the ACTR key is
pressed. The only parameter that can be adjusted from these screens is the
dither setting. To adjust the dither setting (if required), the @ symbol must be on
the display line containing the asterisk/dither value to tune. The @ symbol is
moved using the SELECT key.

The dual actuator output option displays both actuator output demand values as
well as the LSS demand. If the Actuator #2 offset is zero, all of these values will
be the same. If the offset is not zero, the LSS will display the total lift demand for
both outputs. The LSS will be zero when Actuator #1 is zero and reach 100%
when Actuator #2 reaches 100%. The communications links will display the
Actuator LSS, Actuator #1 Demand, Actuator #2 Demand values as well as the
actual Actuator Output Current for both actuators in milliamps.

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Figure 5-8. ACTR Key Screens

Control (CONT) Key Screens

Figure 5-9 shows the screens that appear when the CONT key is pressed. The
CONT key allows operators to monitor what 505 parameter (PID or limiter) is
controlling governor valve position (screen 1). From screen 2 the cause of the
last turbine shutdown can be viewed and from screen 3 the highest turbine
speed reached can be viewed and cleared, if desired.

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Figure 5-9. CONT Key Screens

Table 5-4 shows a complete listing of all possible controlling parameters and
their meanings.

Message 7 Meaning
Shutdown Control is tripped
Controlled Shutdown A controlled shutdown is being executed
Start Perm Not Met The start permissive contact input is not closed
Max Actuator The actuator output is at its maximum position
Valve Limiter The Valve Limiter is in control of the actuator output
Ready to Start The unit’s start permissives are OK and the unit is ready to
start
Manual Start The 505 is running and in the Manual start mode
Auto Start The 505 is running and in the Automatic start mode
Semi Auto Start The 505 is running and in the Semi-automatic start mode
Idle/Rated Start The 505 is running and in the Idle/Rated sequence mode
Auto Start Sequence The 505 is running and in the Automatic Start Sequence mode
Remote/Speed Speed PID is in control, the Speed Setpoint is in remote control
Speed/On-Line Speed PID is in control using On-Line dynamics
Speed/Off-Line Speed PID is in control using Off-Line dynamics
Frequency/Speed Speed PID is in control with the gen. breaker closed and tie
breaker open
Synchronizing Speed PID is in control with the Synch. analog input biasing its
setpoint
Load Share/Speed Speed PID is in control with Sync/Ld Share analog input
biasing its setpoint
Auxiliary Control Aux PID is in control of the actuator output
Remote Auxiliary Aux PID is in control and the Aux Setpt is in remote control
Cascade/Speed Casc & Speed PIDs are in control
Rmt Cascade/Speed Casc & Speed PIDs are in control, and Casc Setpt is in remote
control
Configuration Error The 505 program has been configured incorrectly

Table 5-4. Controlling Parameter Messages

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For a complete listing of Shutdown/Trip causes, refer to the Trips section later in
this chapter.

The Controlling Parameter and Highest Speed Reached values are also
available through the Modbus links.

Dynamics (DYN) Key Screens

Figure 5-10 shows the possible screens that may appear if the DYN key is
pressed. This mode is used to adjust controller dynamics. When the DYN key is
pressed, the dynamics for the parameter that is in control, at that time will be
displayed. To tune the dynamic settings of the other controllers, the key for the
specific controller must be pressed and the STEP DOWN selected until the
dynamics parameters appear. For information on tuning PIDs, refer to Chapter 3
of this manual.

To adjust the gain settings, the @ symbol must be on the respective display line
of the value to be adjusted. The @ symbol is moved by pressing the SELECT
key.

The controller dynamics are adjustable from the 505’s Service panel only, they
cannot be adjusted remotely.

Figure 5-10. DYN Key Screens

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Stop Key Screens

Figure 5-11 shows the possible screens that may appear if the STOP key is
pressed. The STOP key is used to perform a controlled/manual turbine shutdown
or stop. To perform a Manual Shutdown, select YES from the Status screen or
close the Controlled Shutdown contact input (if programmed) or select Controlled
Shutdown from a Modbus communications link. This function can be stopped or
aborted by pressing the front panel NO key from the Manual Shutdown Status
screen, opening the contact, or selecting Abort Controlled Shutdown from a
Modbus communications link.
The Controlled Shutdown sequence can be restarted again by pressing the front
panel YES key from the Manual Shutdown Status screen, re-closing the contact,
or re-selecting Controlled Shutdown from a Modbus communications link. The
link will display the Controlled Stop In Progress and Controlled Shutdown Trip
completed status’.

Figure 5-11. STOP Key Screens

Auxiliary (Aux) Key Screens

For this key to be active, the Auxiliary function must be programmed. Figure 5-12
shows the possible screens that may appear if the AUX key is pressed. Only the
screens related to the Auxiliary control’s programmed functionality will be
displayed. If Remote Aux Setpoint is programmed, screen 3 will appear. The
Auxiliary PID dynamics and droop level (if required) can be adjusted from these
screens.

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Figure 5-12. AUX Key Screens

Auxiliary as a Controller (using Enable/Disable)

When auxiliary control is used as a controller, as opposed to a limiter, the
enable/disable function is used to select Auxiliary control. Auxiliary control can be
enabled by pressing the front panel YES key from the Status screen (screen 2)
or by closing the Aux Control Enable/Disable contact (if programmed) or by
selecting Aux Enable from either Modbus communications link.

With this configuration, prior to enabling Auxiliary control, the Auxiliary setpoint
tracks the Auxiliary analog input to accommodate bumpless transfers between
control modes. As a result, the Auxiliary setpoint cannot be changed until the
Auxiliary PID is enabled. Once enabled, the Auxiliary setpoint can be changed by
pressing the ADJUST UP or DOWN from the front panel Aux Setpt screen
(screen 1), closing a Aux Setpt Raise/Lower contact input, or selecting Aux
Setpoint Raise or Lower from either Modbus communications link. In addition,
the Auxiliary setpoint can be directly set to a value by pressing the front panel
ENTER key from the Auxiliary Setpoint screen or by “Entering” a new Auxiliary
Setpoint through either Modbus communications link.

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Auxiliary control is disabled by pressing the front panel NO key from the Aux
Status screen (screen 2), opening the Aux Control Enable/Disable contact (if
programmed), or selecting “Aux Disable” from either Modbus communications
link see Table 5-5). Auxiliary control is also disabled if Cascade control is
enabled, or Remote Speed Setpoint control is enabled. Aux control is disabled
and ‘inhibited’ if a controlled shutdown is selected, the Auxiliary input fails or the
unit shuts down. Auxiliary control can be enabled but not active if the generator
and/or utility tie breaker disable features are programmed.

Message 5 Meaning
Disabled Aux control is disabled
Inhibited Aux is inhibited and cannot be enabled
Enabled Aux is enabled but not in control due to gen/tie breaker status
Active/Not In Ctrl Aux is active but the PID is not in control (valve limiter control)
Active w/Rmt Setpt Aux is active but not in control and the Setpt is in remote
control
In Control Aux is active and in control of the actuator output
Remote Control Aux is in control and the Setpt is in remote control

Table 5-5. Auxiliary Messages (if using Aux enable)

Auxiliary as a Limiter (not using Enable/Disable)

When Auxiliary control is used as a limiter, as opposed to a controller, the
enable/disable function is not used and Auxiliary control is always enabled.
The Auxiliary setpoint can be changed by issuing Auxiliary Setpt Raise or Lower
commands. This can be done by pressing the ADJUST UP or DOWN from the
front panel Aux Setpt screen (screen 1), closing the Auxiliary Setpoint
Raise/Lower contact inputs, or selecting Auxiliary Setpoint Raise or Lower from
either Modbus communications link. In addition, the Auxiliary setpoint can be
directly set to a value by selecting the front panel ENTER key from the Aux Setpt
screen or “Entering” a new Aux Setpt through either Modbus communications
link.

Auxiliary control is inhibited if a controlled shutdown is selected, the Auxiliary

input fails, or the unit shuts down. See Table 5-6. Auxiliary control can be
‘enabled’ but not ‘active’ if the generator and/or utility tie breaker disable features
are programmed. Aux will be In Control if the Auxiliary PID is active and limiting
the Auxiliary input parameter.

Message 5 Meaning
Inhibited Aux is inhibited and is not active
Enabled Aux is enabled but generator or tie breaker is open
Enabled w/Rmt Setpt Aux is enabled but not active and the Setpt is in Remote
control
Active w/Rmt Setpt Aux is active but not limiting and the Setpt is in Remote control
Active/Not Lmting Aux is active but not limiting the actuator output
Control w/Rmt Setpt Aux is in control (limiting) and the Setpt is in Remote control
In Control Aux is in control and limiting the actuator output

Table 5-6. Auxiliary Messages (if using Aux as a limiter)

The following auxiliary control indications are available through the Modbus links:
Aux is Enabled, Aux is Active, Aux is In Control, Aux is Inhibited, Aux Active/Not
Limiting, Aux Active/Not In Control, and the Aux Input Failed Alarm. In addition to
these indications the Aux Setpoint, Aux Input, and Aux PID Output analog values
are also available.

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Relay indications can be programmed to indicate Aux Control Active, Aux Control
Enabled, or Aux PID In Control status’.

Remote Aux Setpoint

The Remote Auxiliary Setpoint function is used to allow the Auxiliary setpoint to
be remotely positioned by an analog input. When configured to an analog input,
this function/input can be enabled by pressing the front panel YES key from the
Remote Aux Status screen (screen 3), closing the Remote Aux Setpoint
Enable/Disable contact (if programmed), or selecting Remote Aux Enable from
either Modbus communications link.

Remote Auxiliary Setpoint is disabled by pressing the front panel NO key from
the Remote Aux Status screen (screen 3), opening the Remote Aux Control
Enable/Disable contact (if programmed), or selecting Remote Aux Disable from
either Modbus communications link. See Table 5-7 for all possible Remote Aux
control messages.

Message 4 Meaning
Disabled Remote Aux Setpoint is not selected
Inhibited Remote Aux Setpoint is inhibited and cannot be enabled
Enabled Remote Aux Setpoint is enabled but not in control of the Setpt
Active Remote Aux Setpoint is in control, Aux PID is not controlling
the actuator
In Control Remote Aux Setpoint is in control, Aux PID is controlling the
actuator

Table 5-7. Remote AUX Messages

The following remote auxiliary control indications are available through the
Modbus links: Remote Aux is Enabled, Remote Aux is Active, Remote Aux is In
Control, Remote Aux is Inhibited, and Remote Aux Input Failed Alarm. In addition
to these indications, the Remote Aux Input Setpoint is also available.
Relay indications can be programmed to indicate Remote Aux Control Active and
Remote Aux Control Enabled status’.

Remote/Speed Bias (RMT) Key Screens

For this key to be active, the Remote Speed Setting, Synchronizing, or Load
Sharing functions must be programmed. The Synchronizing and Load Sharing
functions are configured by programming the respective function to an analog
input. Figure 5-13 shows the possible screens that may appear if the RMT key is
pressed. Only the screens related to the functions programmed will be displayed.
Screens 3 and 4 appear when the Synchronizing analog input is programmed,
screens 1 and 2 appear when Sync/Load Sharing analog input is programmed,
and screens 5 and 6 appear when Remote Speed Setpoint input is programmed.

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Figure 5-13. RMT Key Screens

Remote Speed Setpoint

The Speed PID setpoint can be remotely set by an analog input, if programmed.
This Remote Speed Setpoint input can be enabled by pressing the front panel
YES key from the Remote Speed Status screen (screen 6), closing the Remote
Speed Setpoint Enable/Disable contact (if programmed), or selecting Enable
Remote Speed Setpt Control from either Modbus communications link (see
Table 5-8).

Remote Speed Setpoint input is disabled by pressing the front panel NO key
from the Remote Speed Status screen (screen 6), opening the Remote Speed
Control Enable/Disable contact (if programmed), or selecting Disable Remote
Speed Setpt Control from either Modbus communications link.

Message 4 Meaning
Disabled Remote is not selected
Inhibited Remote is inhibited and cannot be enabled
Enabled Remote is enabled but not in control of the Setpt
Active Remote is in control of the Setpt but not in control of the
actuator output
In Control Remote is in control of the Setpt and in control of the actuator
output

Table 5-8. Remote Speed Messages

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The following Remote control indications are available through the Modbus links:
Remote Speed Setpt is Enabled, Remote Speed Setpt is Active, Remote Speed
Setpt is In Control, Remote Speed Setpt is Inhibited, and the Remote Speed
Setpt Input Failed Alarm. In addition to these indications, Remote Speed Setpt
Input analog value is also available.

Relay indications can be programmed to indicate Remote Speed Setpt Active

and Remote Speed Setpt Enabled status’.

Synchronizing and/or Loadsharing

The Synchronizing feature allows an analog input to bias the speed setpoint
when using a DSLC for synchronization. The Synchronizing analog input is
enabled by pressing the front panel YES key from the Sync Status screen
(screen 4), closing the Sync Enable contact (if programmed), issuing an enable
demand through a “F” key, or selecting Sync Enable from either Modbus
communications link.

The Synchronizing & Load Sharing feature allows an analog input to bias the
speed setpoint when using a DSLC for synchronizing and load sharing. Load
sharing is enabled automatically based on the generator and utility tie breaker
status inputs. The Sync/Load Share input is enabled by pressing the front panel
YES key from the Sync Status screen (screen 4), closing the Sync/Ld Share
Enable contact (if programmed), issuing an enable command through a “F” key,
or selecting Sync Enable from either Modbus communications link.

The Synchronizing or Sync/Ld Share inputs are disabled by pressing the front
panel NO key from the respective Status screen, opening the respective
function’s Enable/Disable contact (if programmed), or selecting the Sync Disable
command from either Modbus communications link. The Synchronizing analog
input is automatically disabled when the generator breaker closes, but can be re-
enabled with the generator breaker closed, to allow synchronization across a tie
line breaker. The Sync/Load Share analog input is automatically disabled when
the generator breaker opens. Table 5-9 lists the possible
synchronizing/loadsharing control messages.

Message 3 Meaning
Disabled Function is in disabled mode
Inhibited Function is inhibited and cannot be enabled
Enabled Function is enabled but not in control of the Setpt
In Control Function is in control of the actuator output

Table 5-9. Control Messages

The following synchronizing and loadsharing control indications are available

through the Modbus links: Generator Breaker Status, Utility Tie Breaker Status,
Frequency Control, Sync is Enabled, Sync or Loadshare is In Control, Sync or
Loadshare is Inhibited, and the Sync/Loadshare Input Failed Alarm. In addition to
these indications, Sync/Loadshare Input analog value is also available.

Relay indications can be programmed to indicate Sync Enabled, Sync/Loadshare

Enabled, Loadshare Control and Frequency Control status’.

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Unit Load (KW) Key Screens

This key is active if the unit is programmed for a generator application or if a first
stage pressure analog input is configured. Figure 5-14 shows the possible
screens that may appear if the KW key is pressed. Only the screens related to
the functions programmed will be displayed. If a first stage pressure analog input
is configured, screen 4 will appear. When the unit is programmed for a generator
application, only one of the first three screens will appear, depending on the
mode of operation (governor valve position droop or KW/unit load input signal
droop).

Screen 1 or 2 is displayed when the unit is programmed with a KW/Unit Load

analog input and the input is not failed. Screen 3 is displayed if no KW/Unit Load
analog input is programmed or the input is failed. When the units on the ‘Load’
parameter are ‘KW’ or ‘MW’, the screen is displaying actual load units from the
KW/Unit Load analog input. When units on the ‘Load’ parameter is ‘%’, the
screen is displaying a calculated load value.

The bottom line of the display on screens 1, 2, & 3 show the Load Setpoint. This
value and units change depending on the droop mode the 505 is presently using.
If the droop is based on the KW input, the units are in ‘KW’ or ‘MW’. If the droop
is LSS/Speed Demand (governor valve position), the units are in ‘rpm’.

The Load Setpoint can be changed when the unit is On-Line from screens 1, 2,
or 3 by selecting the ADJUST UP or DOWN. In addition, the Load Setpt can be
adjusted by closing a Speed Setpoint Raise/Lower contact inputs or selecting
Speed Setpoint Raise or Lower commands from either Modbus communications
link. In addition, the Load setpoint can be directly set to a value by pressing the
ENTER key from the SPEED screen and entering a speed setpoint value, or
Entering a new Speed/Load Setpoint through either Modbus communications
link.

Figure 5-14. KW Key Screens

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Cascade (CAS) Key Screens

For this key to be active, the Cascade function must be programmed. Figure 5-
15 shows the possible screens that may appear if the CAS key is pressed. Only
the screens related to the Cascade functionality programmed will be displayed.
Only when the Remote Cascade Setpoint is programmed, will screen 3 appear.
The Cascade PID dynamic and droop values can be adjusted from these
screens.

Cascade control can be enabled by pressing the front panel YES key from the
Status screen (screen 2), closing the Cascade Control Enable/Disable contact (if
programmed), or selecting Cascade Enable from either Modbus communications
link.

Cascade control is disabled by pressing the front panel NO key from the
Cascade Status screen (screen 2), opening the Cascade Control Enable/Disable
contact (if programmed), or selecting Cascade Disable from either Modbus
communications link. Cascade control is also disabled if Auxiliary control is
enabled or Remote Speed Setpoint input is enabled. Cascade control is disabled
and ‘inhibited’ if a controlled shutdown is selected, the cascade input fails, or the
unit shuts down. Cascade control can be ‘enabled but not active’ if the generator
and/or utility tie breaker are open. Since the Cascade PID controls through the
Speed setpoint and Speed PID, Cascade will only be “In Control” when the
Speed PID is “In Control” of the actuator output. See Table 5-10 for all possible
cascade control messages.

Figure 5-15. CAS Key Screens

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The Cascade setpoint can be configured to either track the input for bumpless
transfer into control or remain at the last setting. When using the tracking option,
the cascade setpoint cannot be changed until Cascade control is enabled.

The Cascade setpoint can be changed by pressing the ADJUST UP or DOWN

keys from the Cascade setpoint screen (screen 1), closing a Cascade Setpt
Raise/Lower contact input, or selecting Cascade Setpoint Raise or Lower
commands from either Modbus communications link. In addition, the Cascade
setpoint can be directly set to a value by pressing the front panel ENTER key
from the Cascade Setpt screen or by Entering a new Cascade Setpt through
either Modbus communications link.

The Cascade Setpt Raise/Lower contact inputs have a dual function. If either
contact is closed and the Cascade control is active, the cascade setpoint will be
adjusted. If either contact is closed and the cascade control is not active, the
Speed setpoint will be adjusted. The advantage of this feature is that only one
set of raise/lower switches is required to adjust either setpoint.

The Cascade setpoint can be directly set to a value by selecting the front panel
ENTER key from the Cascade Setpt screen or by Entering a new Cascade Setpt
through either Modbus communications link.

Message 5 Meaning
Disabled Cascade control is disabled
Inhibited Cascade is inhibited and cannot be enabled
Enabled Cascade is enabled but not in control of actuator
In Control Cascade is in control of actuator output
Active/Not Spd Ctrl Cascade is active but Speed PID is not in control of actuator
Active w/Rmt Setpt Cascade is active but Speed PID is not in control, Setpt is in
remote control
In Ctrl w/Rmt Setpt Cascade is in control, Speed PID is in control, Setpt is in
remote control

Table 5-10. Cascade Control Messages

The following Cascade control indications are available through the Modbus
links: Cascade is Enabled, Cascade is Active, Cascade is In Control, Cascade is
Inhibited, and the Cascade Input Failed Alarm. In addition to these indications
the Cascade Setpoint, Cascade Input, and Cascade PID Output analog values
are also available.

Relay indications can be programmed to indicate Cascade Control Active, and

Cascade Control Enabled.

Remote Cascade Setpoint

The Cascade control setpoint can be remotely positioned by an analog input (if
programmed). The Remote Cascade Setpoint input can be enabled by pressing
the front panel YES key from the Remote Cascade Status screen (screen 3),
closing the Remote Cascade Setpoint Enable/Disable contact (if programmed),
or selecting Remote Cascade Enable from either Modbus communications link.
Remote Cascade Setpoint input is disabled by pressing the front panel NO key
from the Remote Cascade Status screen (screen 3), opening the Remote
Cascade Enable/Disable contact (if programmed), or selecting Remote Cascade
Disable from either Modbus communications link. See Table 5-11 for all possible
Remote Cascade control messages.

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Message 4 Meaning
Disabled Remote is not selected
Inhibited Remote is inhibited and cannot be enabled
Enabled Remote is enabled but not in control of the Setpt
Active Remote is in control of the Setpt but not in control of the
actuator output
In Control Remote is in control of the Setpt and in control of the actuator
output

Table 5-11. Remote Cascade Messages

The remote cascade control indications shown in Table 5-11 are available
through the Modbus links: Remote Cascade is Enabled, Remote Cascade is
Active, Remote Cascade is In Control, Remote Cascade is Inhibited, and
Remote Cascade Input Failed Alarm. In addition to these indications, the Remote
Cascade Input Setpoint is also available.

Relay indications can be programmed to indicate Remote Cascade Control

Active and Remote Cascade Control Enabled status’.

Alarms
The ALARM key is always active in the RUN mode. Figure 5-16 shows the
screen that appears when this key is pressed. If there are no alarms detected,
the screen will display the ‘Alarms Cleared’ message. When an alarm is
detected, the Alarm relay is energized and the front panel Alarm key illuminates.
In addition, the screen will automatically “jump” to the ALARM screen (as
defaulted in the Service mode) and display the alarm condition.

Table 5-12 lists all the potential alarm conditions and their cause. If more than
one alarm condition is present, pressing the Down Arrow key will scroll through
all active alarms. To view the most recent alarm, select the ALARM key. To clear
any alarms that are no longer present, press the front panel RESET key, close
the Reset contact input, or select Reset from either Modbus communications link.

Figure 5-16. ALARM Screen

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Alarm Messages Meaning
Speed Probe #1 Failed Speed probe #1 failure—( < Failed Speed Level or 1 Vrms)
Speed Probe #2 Failed Speed probe #2 failure—( < Failed Speed Level or 1 Vrms)
Cascade Input Fld Cascade analog input failure detected ( > 22 mA or < 2 mA)
Aux Input Fld Auxiliary analog input failure detected ( > 22 mA or < 2 mA)
KW Input Failed KW analog input failure detected (> 22 mA or < 2 mA)
FSP Input Failed FSP analog input failure detected (> 22 mA or < 2 mA)
Remote Spd Input Failed Remote Speed Setpt analog input failure ( > 22 mA or < 2
mA)
Remote Casc Input Fld Remote Cascade Setpt analog input failure ( > 22 mA or < 2
mA)
Remote Aux Input Fld Remote Aux Setpt analog input failure ( > 22 mA or < 2 mA)
Load Share Input Fld Load Share analog input failure detected ( > 22 mA or < 2
mA)
Act #1 Fault Actuator #1 fault detected (an open or short circuit was
sensed)
Act #2 Fault Actuator #2 fault detected (an open or short circuit was
sensed)
Start Perm Not Closed Run was selected while the Start Perm contact in was not
closed
Comm Link #1 Failed Modbus com link #1 was detected as failed—time out error
Comm Link #2 Failed Modbus com link #2 was detected as failed—time out error
Turbine Trip Turbine is tripped alarm indication
Overspeed Turbine overspeed alarm
Tie Breaker Opened Utility Tie breaker was opened after it was closed
Gen Breaker Opened Generator breaker was opened after it was closed
Tie Brkr Open/No Casc Utility Tie breaker was opened when Cascade was active
Gen Brkr Open/No Casc Generator breaker was opened when Cascade was active
Tie Brkr Open/No Remote Util. Tie breaker was opened when Remote Spd Setpt was
active
Gen Brkr Open/No Remote Generator breaker was opened when Remote Spd Setpt was
active
Tie Brkr Open/No Aux Utility Tie breaker was opened when Auxiliary was active
Gen Brkr Open/No Aux Generator breaker was opened when Auxiliary was active
Alarms Cleared All alarms are cleared—no alarms are present

Table 5-12. Alarm Messages

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.

Trips
Figure 6-17 shows the screen that appears when there is a trip condition. The
cause of the last trip can be seen under the CONT key (screen 2). Table 5-13
lists all the potential trip conditions and their cause.

Figure 5-17. TRIP Screen

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Message 6 Meaning
External Trip Input External Trip contact input was opened
External Trip 2 External Trip #2 contact input was opened
External Trip 3 External Trip #3 contact input was opened
External Trip 4 External Trip #4 contact input was opened
External Trip 5 External Trip #5 contact input was opened
Emer Shutdown Button Emergency Shutdown on the 505 front panel was pressed
Overspeed Turbine overspeed was sensed
All Speed Probes Failed Loss of all speed probes was sensed
Actuator #1 Fault Actuator #1 fault detected (an open or short circuit was
sensed)
Actuator #2 Fault Actuator #2 fault detected (an open or short circuit was
sensed)
Aux Input Failed Aux analog input failure detected ( > 22 mA or < 2 mA)
Comm Link #1 Trip Modbus #1 communication link trip was commanded
Comm Link #2 Trip Modbus #2 communication link trip was commanded
KW Input Failed KW analog input failure detected ( > 22 mA or < 2 mA)
Tie Breaker Opened Utility tie breaker was opened after it was closed
Generator Breaker Open Generator breaker was opened after it was closed
Power Up Trip 505 lost power and CPU was reset or the Program mode
was exited
Shutdown Complete Controlled shutdown was performed and completed

Table 5-13. Trip Messages

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.

Speed, Cascade, and Auxiliary Dynamics

Adjustments
Dynamic control values are programmed in the program mode and adjusted in
the RUN mode. While in the run mode, pressing the DYN key calls up the
dynamic adjustments of the parameter in control. The Proportional and Integral
Gain dynamic adjustments are available under their respective keys (SPEED,
CAS, & AUX). The Derivative term adjustments are made in the Service Mode—
see volume 2). To adjust the gain settings, the @ symbol must be on the display
line containing the asterisk/gain value to tune. The @ symbol is moved using the
SELECT key. The ADJUST UP and DOWN keys can then be used to adjust the
function on the line with the @ symbol.

The Speed, Cascade and Auxiliary 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)

If an older type 505 is being replaced by a new 505, the “ P & D ” terms will be
the same, however, the “ I ” term should be reduced by a factor of 10 from the
old 505’s reset value to achieve the same control response.

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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 cycles 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.

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:
x A “Select On-Line Dynamics” contact input is programmed
x Unit is driving a generator
x 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 effect the dynamics selection.

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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 effect 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 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 recommend 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.
x A DR setting of 1 to 100 selects feedback dominant mode.
x A DR setting of .01 to 1 selects input dominant mode.
x 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 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

(Speed, Cascade in or Auxiliary in), and can therefore prevent overshoot of the
setpoint better than a feedback dominant controller. Although this response is
desirable during a startup or full load rejections, it can cause excessive control
motions in some systems where a smooth transition response is desired.

A controller configured as feedback dominant is more sensitive to the change-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.

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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 (Ziegler Nichols, etc.). The following method is a simplified
version of other tuning methods, and can be used to achieve PID gain values
that are close to optimum:
1. Increase Derivative Ratio (DR) to 100 (This is the default setting).
2. Reduce integral gain to minimum.
3. Increase proportional gain until system just starts to oscillate.
4. Record the system gain (G) and oscillation period (T).
5. Set the dynamics as follows:
x For PID control set the proportional gain=0.60*G; integral gain=20/T;
DR=5
x For PI control set the proportional gain=0.45*G; integral gain=12/T;
DR=100

This method of tuning will get the gain settings close, they can be fine-tuned from
this point. Figure 5-18 shows the typical response to a load change when the
dynamics are optimally adjusted.

Figure 5-18. Typical Response to Load Change

NOTE
For additional information on PID settings, refer to Volume 2.

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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 two Modbus® * communication ports.
These ports support RS-232, RS-422, RS-485 communications using ASCII or
RTU MODBUS transmission protocols. 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.
*—Modbus is a trademark of Modicon, Inc.

Monitor Only
The two Modbus communication ports, as defaulted from the factory, are not
programmed. Although these ports are not programmed they continue to update
all information to all registers. This allows the 505 to 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 effecting control.

To use a 505 port to only monitor 505 parameters and operational modes or not
use the port at all (Boolean and analog write commands are ignored), program
the port’s ‘Use Modbus Port’ setting to ‘NO’.

Monitor and Control

Once a Modbus port is configured within the 505’s Program 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.

Both Modbus ports are independent of each other, and can be used
simultaneously. The last command given between the two ports has priority or is
the mode or function selected.

To use a 505 Modbus port to monitor and operate the 505 through, program the
port’s ‘Use Modbus Port’ setting to ‘YES’.

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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Characteristic ASCII RTU
Coding System hexadecimal (uses 8-bit binary
ASCII printable binary
characters: 0-9,A-F)
Start Bits 1 1
Data Bits per Char 7 8
Parity even, odd even, odd
or none or none
Stop Bits 1, 1.5, or 2 1, 1.5, or 2
Baud Rate 110, 300, 600, 1200 110,300, 600, 1200
1800,2400, 4800, 9600 1800, 2400, 4800, 9600
19200, 38400, or 57600 19200, 38400, or 57600
Error Checking LRC(Longitudinal CRC(Cyclical
Redundancy Check) Redundancy Check)

Table 6-1. ASCII vs RTU Modbus

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 3

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
Program 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 device 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.

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 Figure 6-2.

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Figure 6-2. Modbus Frame Definition

The Modbus function code tells the addressed slaves what function to perform.
The following table lists the function codes supported by this control.

Modbus Function Codes

Code Definition Reference Address
01 Read Digital Outputs 0XXXX
(Raise/Lower and Enable/Disable Commands)
02 Read Digital Inputs 1XXXX
(Status Indications/Alarms and Trips)
03 Read Analog Outputs 4XXXX
04 Read Analog Inputs 3XXXX
(Speed, Setpt, etc.)
05 Write Single Discrete Output 0XXXX
(Raise/Lower and Enable/Disable Commands)
06 Write Single Register 4XXXX
(Enter Setpt Directly)
08 Loopback Diagnostic Test N/A
(Subfunction 0 only)
15 Write Digital Outputs 0XXXX
16 Write Analog Outputs 4XXXX

Table 6-2. Modbus Function Codes

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 in the Service mode under PORT # SETTINGS, where # is the number of
the port (1 or 2).

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 in the Service Mode).

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Modbus Slave Exception 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

Table 6-3. Modbus Error Codes

Port Adjustments
Before the 505 will communicate with the master device, the communication
parameters must be verified. These values are set in the Program Mode and can
be adjusted, if required, from the Service Mode.

Modbus Communication Port Adjustments

Parameter Adjustment Range
Baud Rate 110 TO 57600
Parity NONE, ODD or EVEN
Stop Bits 1 TO 2
Driver RS232, RS422, or RS485

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 considered to be 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 &
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.

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Mode Of Max Max
Transmission Discretes Registers
ASCII 944 59
RTU 1188 118

Table 6-4. Maximum Modbus Discrete and Analog Values

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 setpoint 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 an 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.

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.

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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 setpoint 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:

Addr Description Addr Description

0.0001 Emergency Shutdown 0.0041 Spare
0.0002 Emergency Shutdown Acknowledge 0.0042 Modbus Alarm Acknowledge
0.0003 Controlled Shutdown 0:0043 Turn On/Energize Modbus Relay 1
0.0004 Abort Controlled Shutdown 0:0044 Turn Off/De-Energize Modbus Relay 1
0.0005 System Reset 0:0045 Turn On/Energize Modbus Relay 2
0.0006 Start/Run 0:0046 Turn Off/De-Energize Modbus Relay 2
0.0007 Manual Open Valve Limiter 0:0047 Turn On/Energize Modbus Relay 3
0.0008 Manual Close Valve Limiter 0:0048 Turn Off/De-Energize Modbus Relay 3
0.0009 Lower Speed Setpoint 0:0049 Turn On/Energize Modbus Relay 4
0.0010 Raise Speed Setpoint 0:0050 Turn Off/De-Energize Modbus Relay 4
0.0011 Go To Rated (Idle/Rated) 0:0051 Turn On/Energize Modbus Relay 5
0.0012 Go To Idle (Idle/Rated) 0:0052 Turn Off/De-Energize Modbus Relay 5
0.0013 Halt Auto Start Sequence 0:0053 Turn On/Energize Modbus Relay 6
0.0014 Continue Auto Start Sequence 0:0054 Turn Off/De-Energize Modbus Relay 6
0.0015 Enable Remote Speed Setpt Control 0:0055 Spare
0.0016 Disable Rmt Speed Setpt Control 0:0056 Spare
0.0017 Go To Modbus Entered Speed Setpt 0:0057 Spare
0.0018 Spare 0:0058 Spare
0.0019 Arm Frequency Control 0:0059 Spare
0.0020 Disarm Frequency Control 0:0060 Spare
0.0021 Sync Enable 0:0061 Spare
0.0022 Sync Disable 0:0062 Spare
0.0023 Enable Cascade Control 0:0063 Spare
0.0024 Disable Cascade Control 0:0064 Spare
0.0025 Lower Cascade Setpoint 0:0065 Spare
0.0026 Raise Cascade Setpoint 0:0066 Spare
0.0027 Enable Rmt Cascade Setpt Control 0:0067 Spare
0.0028 Disable Rmt Cascade Setpt Control 0:0068 Spare
0.0029 Go To Modbus Entered Cascade Setpoint 0:0069 Spare
0.0030 Spare 0:0070 Spare
0.0031 Enable Aux control (Aux controller only) 0:0071 Spare
0.0032 Disable Aux Control (Aux controller only) 0:0072 Spare
0.0033 Lower Aux setpoint 0:0073 Spare
0.0034 Raise Aux Setpoint 0:0074 Spare
0.0035 Enable Rmt Aux Setpt Control 0:0075 Momentarily Energize Modbus Relay #1
0.0036 Disable Rmt Aux Setpt Control 0:0076 Momentarily Energize Modbus Relay #2
0.0037 GoTo Modbus Entered Aux Setpt 0:0077 Momentarily Energize Modbus Relay #3
0.0038 Spare 0:0078 Momentarily Energize Modbus Relay #4
0.0039 Select Remote Ctrl (Remote/Local) 0:0079 Momentarily Energize Modbus Relay #5
0.0040 Select Local Ctrl (Remote/Local) 0:0080 Momentarily Energize Modbus Relay #6

Table 6-5. Boolean Write Addresses

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Addr Description Addr Description

1:0001 Alarm—MPU #1 Failed 1:0043 Trip—Overspeed Trip
1:0002 Alarm—MPU #2 Failed 1:0044 Trip—Loss of Speed Signals
1:0003 Alarm—Cascade Input Failed 1:0045 Trip—Actuator # 1 Fault
1:0004 Alarm—Aux Input Failed 1:0046 Trip—Actuator # 2 Fault
1:0005 Alarm—KW Input Failed 1:0047 Trip—Aux Input Failed
1:0006 Alarm—Sync Input Failed 1:0048 Trip—External Trip 2
1:0007 Alarm—First Stage Press Input Failed 1:0049 Trip—External Trip 3
1:0008 Alarm—Remote Speed Input Failed 1:0050 Trip—Modbus Link #1 Trip
1:0009 Alarm—Remote Cascade Input Failed 1:0051 Trip—Modbus Link #2 Trip
1:0010 Alarm—Remote Aux Input Failed 1:0052 Trip—spare
1:0011 Alarm—Loadshare Input Failed 1:0053 Trip—Tie Breaker Open
1:0012 Alarm—Actuator #1 Failed 1:0054 Trip—Gen Breaker Open
1:0013 Alarm—Actuator #2 Failed 1:0055 Trip—Power up
1:0014 Alarm- Start Permissive Not Met 1:0056 Trip—Manual Stop
1:0015 Alarm—Communication Link #1 Failed 1:0057 Trip—External Trip 4
1:0016 Alarm—Communication Link #2 Failed 1:0058 Trip—External Trip 5
1:0017 Alarm—Generator Breaker Open 1:0059 Trip—spare
1:0018 Alarm—Turbine Trip 1:0060 Trip—spare
1:0019 Alarm—Tie Breaker Open 1:0061 Trip—spare
1:0020 Alarm—Overspeed Alarm 1:0062 Trip—spare
1:0021 Alarm—Tie Breaker Open/No Aux 1:0063 Trip—spare
1:0022 Alarm—Gen Breaker Open/No Aux 1:0064 Shutdown Exists (Trip Indication)
1:0023 Alarm—Tie Breaker Open/No Casc 1:0065 ESD Acknowledge Enable
1:0024 Alarm—Gen Breaker Open/No Casc 1:0066 Moving to Min Setpoint
1:0025 Alarm—Tie Breaker Open/No Remote 1:0067 Idle/Rated—Ramping to Idle
1:0026 Alarm—Gen Breaker Open/No Remote 1:0068 Idle/Rated—At Idle
1:0027 Alarm—Stuck in Critical Alarm 1:0069 Idle/Rated—Ramping to Rated
1:0028 Alarm—spare 1:0070 Idle Rated—At Rated
1:0029 Alarm—spare 1:0071 Auto Seq—Setpt at Lo Idle
1:0030 Alarm—spare 1:0072 Auto Seq—Ramping to High Idle
1:0031 Alarm—spare 1:0073 Auto Seq—Setpt at High Idle
1:0032 Alarm—spare 1:0074 Auto Seq—Ramping to Rated
1:0033 Alarm—spare 1:0075 Auto Seq—At Rated
1:0034 Alarm—spare 1:0076 Speed PID In Control
1:0035 Alarm—spare 1:0077 Speed Sensor 1 Failed Override ON
1:0036 Alarm—spare 1:0078 Speed Sensor 2 Failed Override ON
1:0037 Alarm—spare 1:0079 Overspeed Test Permissive
1:0038 OpView Alarm latch 1:0080 Overspeed Test In Progress
1:0039 Alarm Acknowledge 1:0081 Speed At or above Min Gov
1:0040 Alarm Exists (Common Alarm Indication) 1:0082 Turbine In Critical Speed Band
1:0041 Trip—External Trip 1:0083 Remote Speed Setpt Is Enabled
1:0042 Trip—ESD Button 1:0084 Remote Speed Setpt Is Active
1:0085 Remote Speed Setpt Is In Control 1:0129 Spare
1:0086 Remote Speed Setpt Is Inhibited 1:0130 Spare
1:0087 Spare 1:0131 Spare
1:0088 Spare 1:0132 Spare
1:0089 Spare 1:0133 Spare
1:0090 Generator Breaker Closed 1:0134 Spare
1:0091 Utility Tie Breaker Closed 1:0135 Spare
1:0092 Synchronizing Rate Selected 1:0136 Spare
1:0093 Synchronizing Is Enabled 1:0137 Valve Limiter Is Open
1:0094 Sync or Load Share Is In Control 1:0138 Valve Limiter Is Closed
1:0095 Sync/Load Share Is Inhibited 1:0139 Valve Limiter In Control
1:0096 Spare 1:0140 Remote/Local-Remote Selected
1:0097 Frequency Control Armed 1:0141 Remote/Local—Modbus #1 Active
1:0098 Frequency Control 1:0142 Start Permissive
1:0099 Spare 1:0143 Controlled Stop In Progress
1:0100 Cascade Is Enabled 1:0144 Spare
1:0101 Cascade Is Active 1:0145 Spare

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1:0102 Cascade Is In Control 1:0146 Spare
1:0103 Cascade Is Inhibited 1:0147 Spare
1:0104 Rmt Cascade Is Enabled 1:0148 Spare
1:0105 Rmt Cascade Is Active 1:0149 Spare
1:0106 Rmt Cascade Is In Control 1:0150 Spare
1:0107 Rmt Cascade Is Inhibited 1:0151 Shutdown Relay Energized
1:0108 Spare 1:0152 Alarm Relay Energized
1:0109 Auxiliary Is Enabled 1:0153 Relay 1 Energized
1:0110 Auxiliary Is Active 1:0154 Relay 2 Energized
1:0111 Auxiliary Is In Control 1:0155 Relay 3 Energized
1:0112 Aux Active/Not Limiting 1:0156 Relay 4 Energized
1:0113 Aux Active/Not In Control 1:0157 Relay 5 Energized
1:0114 Auxiliary is Inhibited 1:0158 Relay 6 Energized
1:0115 Remote Aux Is Enabled 1:0159 ESD Contact Input Closed
1:0116 Remote Aux Is Active 1:0160 Reset Contact Input Closed
1:0117 Rmt Aux Is In Control 1:0161 Raise Speed Contact Input Closed
1:0118 Rmt Aux Is Inhibited 1:0162 Lower Speed Contact Input Closed
1:0119 Spare 1:0163 Contact In 1 Closed
1:0120 Spare 1:0164 Contact In 2 Closed
1:0121 Spare 1:0165 Contact In 3 Closed
1:0122 Spare 1:0166 Contact In 4 Closed
1:0123 Spare 1:0167 Contact In 5 Closed
1:0124 Spare 1:0168 Contact In 6 Closed
1:0125 Spare 1:0169 Contact In 7 Closed
1:0126 Spare 1:0170 Contact In 8 Closed
1:0127 Spare 1:0171 Contact In 9 Closed
1:0128 Spare 1:0172 Contact In 10 Closed
1:0173 Contact In 11 Closed 1:0187 Gen Set Configured
1:0174 Contact In 12 Closed 1:0188 Cascade Control Configured
1:0175 Aux Limiter Configured 1:0189 Remote Cascade Configured
1:0176 Sync Function Configured 1:0190 Aux Control Configured
1:0177 ESD Control Configured 1:0191 Remote Aux Configured
1:0178 Manual Start Configured 1:0192 Enables Mod1 in local
1:0179 Auto Start Configured 1:0193 Start Permissive Configured
1:0180 Semi-Auto Start Configured 1:0194 Frequency Arm/Disarm Configured
1:0181 Idle/Rated Start Configured 1:0195 Frequency Control Configured
1:0182 Auto Start Sequence Configured 1:0196 MPU 2 Configured
1:0183 First Stage Pressure Configured 1:0197 Local/Remote Configured
1:0184 Remote Control Configured 1:0198 Local Trip Enabled
1:0185 Loadsharing Configured 1:0199 Casc Tracking Configured
1:0186 Actuator 2 Configured 1:0200 KW Signal OK

Table 6-6. Boolean Read Addresses

Addr Description Units Multiplier

3:0001 Control Parameter * none none
3:0002 Speed Sensor #1 Input rpm none
3:0003 Speed Sensor #2 Input rpm none
3:0004 Actual Turbine Speed rpm none
3:0005 Actual Speed (%) % 100
3:0006 Speed Setpoint (%) % 100
3:0007 Speed Setpoint rpm none
3:0008 Speed Droop Setpoint rpm none
3:0009 Speed Droop % 100
3:0010 Speed PID Output % 100
3:0011 Min Governor Speed Setpoint rpm none
3:0012 Highest Speed Reached rpm none
3:0013 Idle/Rated—Idle Speed rpm none
3:0014 Idle/Rated—Rated Speed rpm none
3:0015 Auto Seq-Low Idle Speed Setpt rpm none
3:0016 Auto Seq-Low Idle Delay Time min 100

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Addr Description Units Multiplier
3:0017 Auto Seq-Time Left At Low Idle min 100
3:0018 Auto Seq-Low Idle to High Idle Rate rpm/sec none
3:0019 Auto Seq-High Idle Speed Setpoint rpm none
3:0020 Auto Seq-High Idle Delay Time min 100
3:0021 Auto Seq-Time Remaining At High Idle min 100
3:0022 Auto Seq-High Idle to Rated Rate rpm/sec none
3:0023 Auto Seq—Rated Speed Setpt rpm none
3:0024 Auto Seq—Run Time Hours hrs none
3:0025 Auto Seq—Hours Since Alarm hrs none
3:0026 Cascade Setpoint (Scaled) Casc units cascade scale factor
3:0027 Cascade PID Output % 100
3:0028 Cascade Input (%) % 100
3:0029 Cascade Setpoint (%) % 100
3:0030 Cascade Scale Factor none none
3:0031 Cascade Input (Scaled) Casc units cascade scale factor
3:0032 Remote Cascade Input (Scaled) Casc units cascade scale factor
3:0033 Aux Setpoint (Scaled) aux units aux scale factor
3:0034 Aux PID Output % 100
3:0035 Aux Input (%) % 100
3:0036 Aux Setpoint (%) % 100
3:0037 Aux Scale Factor none none
3:0038 Aux Input (Scaled) aux units aux scale factor
3:0039 Remote Aux Input (Scaled) aux units aux scale factor
3:0040 Remote Speed Setpoint Input rpm none
3:0041 FSP Scale Factor none none
3:0042 FSP Input (Scaled) FSP units FSP scale factor
3:0043 Loadshare Scale Factor none none
3:0044 Sync/Loadshare Input (Scaled) rpm ldshr scale factor
3:0045 KW Scale Factor none none
3:0046 KW Input (Scaled) kW units kW scale factor
3:0047 Vlv Limiter Setpt % 100
3:0048 Actuator Demand % 100
3:0049 Actuator 1 Demand % 100
3:0050 Actuator 2 Demand % 100
3:0051 Spare
3:0052 Spare
3:0053 Spare
3:0054 Spare
3:0055 Spare
3:0056 Spare
3:0057 Spare
3:0058 Spare
3:0059 Spare
3:0060 Modbus Entered Speed Setpoint (fdbk) rpm none
3:0061 Modbus Entered Cascade Setpt (fdbk) Casc units Casc scale factor
3:0062 Modbus Entered Aux Setpt (fdbk) Aux units Aux scale factor
3:0063 Spare
3:0064 Spare
3:0065 Spare
3:0066 Spare
3:0067 Spare
3:0068 Spare
3:0069 Spare
3:0070 Spare
3:0071 Spare
3:0072 Analog Input 1 % 100
3:0073 Analog Input 2 % 100
3:0074 Analog Input 3 % 100
3:0075 Analog Input 4 % 100
3:0076 Analog Input 5 % 100
3:0077 Analog Input 6 % 100
3:0078 Analog Output 1 mA 100
3:0079 Analog Output 2 mA 100
3:0080 Analog Output 3 mA 100
3:0081 Analog Output 4 mA 100
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Addr Description Units Multiplier
3:0082 Analog Output 5 mA 100
3:0083 Analog Output 6 mA 100
3:0084 Actuator #1 Output mA 100
3:0085 Actuator #2 Output mA 100
3:0086 Last Trip none none
3:0087 KW units (3 = MW, 4 = KW) none none
3:0088 Analog Input 1 Configuration * none none
3:0089 Analog Input 2 Configuration * none none
3:0090 Analog Input 3 Configuration * none none
3:0091 Analog Input 4 Configuration * none none
3:0092 Analog Input 5 Configuration * none none
3:0093 Analog Input 6 Configuration * none none
3:0094 Analog Output 1 Configuration * none none
3:0095 Analog Output 2 Configuration * none none
3:0096 Analog Output 3 Configuration * none none
3:0097 Analog Output 4 Configuration * none none
3:0098 Analog Output 5 Configuration * none none
3:0099 Analog Output 6 Configuration * none none
3:0100 Relay 1 Configuration * none none
3:0101 Relay 2 Configuration * none none
3:0102 Relay 3 Configuration * none none
3:0103 Relay 4 Configuration * none none
3:0104 Relay 5 Configuration * none none
3:0105 Relay 6 Configuration * none none
3:0106 Contact Input 1 Configuration * none none
3:0107 Contact Input 2 Configuration * none none
3:0108 Contact Input 3 Configuration * none none
3:0109 Contact Input 4 Configuration * none none
3:0110 Contact Input 5 Configuration * none none
3:0111 Contact Input 6 Configuration * none none
3:0112 Contact Input 7 Configuration * none none
3:0113 Contact Input 8 Configuration * none none
3:0114 Contact Input 9 Configuration * none none
3:0115 Contact Input 10 Configuration * none none
3:0116 Contact Input 11 Configuration * none none
3:0117 Contact Input 12 Configuration * none none
3:0118 Aux Units Configured * none none
3:0119 Cascade Units Configured * none none
3:0120 Spare
* Look up table at end of section

Table 6-7. Analog Read 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
4:0005 Spare
4:0006 Spare
4:0007 Spare
4:0008 Spare

Table 7-8. Analog Write Addresses

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Last Turbine Trip Cause

The cause of the last turbine trip (address 3:0086) is an integer that represents
the following cause:
Value Description
1. External Trip Input
2. Emergency Shutdown Button (front panel push-button)
3. Overspeed Trip
4. All Speed Probes Failed
5. Act #1 Fault
6. Act #2 Fault
7. Aux Input Failed
8. External Trip 2
9. External Trip 3
10. Comm Link #1 Trip
11. Comm Link #2 Trip
12. KW Input Failed
13. Utility Tie Breaker Opened
14. Generator Breaker Opened
15. Power up Shutdown
16. Manual (controlled) Shutdown
17. External Trip 4
18. External Trip 5

Table 6-9. Last Turbine Trip Cause

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.

Value Description
1. Speed/Off—Line
2. Speed/On—Line
3. Remote/Speed
4. Cascade/Speed
5. Remote Cascade/Speed
6. Frequency/Speed
7. Load Share/Speed
8. Synchronizing
9. Auto Start Sequence
10. Idle/Rated Start
11. Semi Auto Start
12. Auto Start
13. Manual Start
14. Ready to Start
15. Start Perm Not Met
16. Configuration Error
17. Auxiliary
18. Remote Auxiliary
19. Valve Limiter
20. Max Actuator
21. Spare for future use
22. Controlled Shutdown
23. Shutdown

Table 6-10. Control Status

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Analog Read addresses 3:0088—0093 give the configuration value of the analog
inputs, one to six in order. The configuration for the analog inputs are defined in
the table below.

Value Description
1. Remote Speed Setpt
2. Synchronizing Input
3. Sync/Load Share Input
4. KW/Unit Load Input
5. Cascade Input
6. Remote Cascade Setpt
7. Auxiliary Input
8. Remote Aux Setpt
9. First Stage Press Input
10. (Not Used)

Table 6-11. Analog Input Configuration

Analog Read addresses 3:0094—0099 give the configuration value of the analog
outputs, one to six in order. The configuration for the analog outputs are defined
in the table below.

Value Description
1. Actual Speed
2. Speed Setpoint
3. Remote Speed Setpt
4. Load Share Input
5. Sync Input
6. KW Input
7. Cascade Input
8. Cascade Setpoint
9. Rmt Cascade Setpt
10. Auxiliary Input
11. Auxiliary Setpoint
12. Rmt Auxiliary Setpt
13. Valve Limiter Setpoint
14. Actuator Demand Readout
15. Actuator 1 Readout
16. Actuator 2 Readout
17. First Stg Press Input
18. (Not Used)

Table 6-12. Analog Output Configuration

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Analog Read addresses 3:0100—0105 give the configuration value of the relays,
one to six in order. The configuration for the relays are defined in the table below.

Value Description
Relay Configured As Level Switch
0. Under speed Switch
1. Speed Level Switch
2. Speed Setpoint Level Switch
3. KW Level Switch
4. Load Share Level Switch
5. Cascade Level Switch
6. Cascade Setpoint Level Switch
7. Aux Level Switch
8. Aux Setpoint Level Switch
9. Actuator Demand Level Switch
10. Act 1 Demand Level Switch
11. Act 2 Demand Level Switch
12. Valve Limiter Level Switch
13. First Stage Pressure Level Switch
Relay Configured To Indicate State
21. Shutdown Condition
22. Trip Relay (additional trip relay output)
23. Alarm Condition
24. Control Status OK
25. Overspeed Trip
26. Overspeed Test Enabled
27. Speed PID in Control
28. Remote Speed Setpt Enabled
29. Remote Speed Setpt Active
30. Underspeed Switch
31. Auto Start Sequence Halted
32. On-Line PID Dynamics Mode
33. Local Control Mode
34. Frequency Control Armed
35. Frequency Control
36. Sync Enabled
37. Sync/Load Share Active
38. Load Share Control
39. Casc Control Enabled
40. Cascade Control Active
41. Remote Casc Setpt Enabled
42. Remote Casc Setpt Active
43. Aux Control Enabled
44. Aux Control Active
45. Auxiliary PID in Control
46. Remote Aux Setpt Enabled
47. Remote Aux Setpt Active
48. Valve Limiter in Control
49. F3 Key Selected
50. F4 Key Selected
51. Modbus Command
52. (Not Used)

Table 6-13. Relay Configuration

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Analog Read addresses 3:0106—0117 give the configuration value of the
contact inputs, one to twelve in order. The configuration for the contact inputs are
defined in the table below.

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

Table 6-14. Contact Input Configurations

Analog Read addresses 3:0118-0119 give the configuration value of the Aux
units and the Cascade units, in order. The configuration for the units are defined
in the table below.

Value Description
1. psi
2. kPa
3. MW
4. KW
5. degF
6. degC
7. t/h
8. k#/hr
9. #/hr
10. kg/cm2
11. bar
12. atm
13. (none)

Table 6-15. Units Configuration

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Specific Address Information

Entering Setpoint from Modbus

x The setpoint for the Speed, Cascade and Auxiliary can be entered from the
Modbus. When the setpoint is entered for any of these functions the setpoint
will not move to the entered setpoint instantly, but the setpoint will move
towards the entered setpoint at the entered rate defined for the function in
the program mode. This functions the same as entering the setpoint from
the front panel of the control.
x 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 the a new value is entered from the Modbus,
the setpoint will move to the new value. If the entered setpoint that is the
same as the feedback, the operator can use a go to the setpoint command
instead of entering the setpoint again. This command needs to be used
when the setpoint to be entered is the same as the feedback.

Modbus Scale Factors

Modbus has two limitations:
x only integers can be sent across
x 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
setpoint values that are sent across the Modbus have independent scale factors:
Casc (3:0030), Aux (3:0037), FSP (3:0041), 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 setpoint
analog read values as well as the Entered Setpt analog write value.

For example, if the Cascade setpoint 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 Setpoint (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 setpoint
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

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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 setpoint 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.
Service Options

Product Service Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
x Consult the troubleshooting guide in the manual.
x Contact the manufacturer or packager of your system.
x Contact the Woodward Full Service Distributor serving your area.
x 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 and 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:
x 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.
x 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.
x A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
x 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/support.

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Woodward Factory Servicing 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:
x Replacement/Exchange (24-hour service)
x Flat Rate Repair
x Flat Rate Remanufacture

Replacement/Exchange: Replacement/Exchange is a premium program

designed for the user who is in need of 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.

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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:
x return number;
x name and location where the control is installed;
x name and phone number of contact person;
x complete Woodward part number(s) and serial number(s);
x description of the problem;
x instructions describing the desired type of repair.

Packing a Control
Use the following materials when returning a complete control:
x protective caps on any connectors;
x antistatic protective bags on all electronic modules;
x packing materials that will not damage the surface of the unit;
x at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
x a packing carton with double walls;
x a strong tape around the outside of the carton for increased strength.

CAUTION—ELECTROSTATIC DISCHARGE
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.

Replacement Parts
When ordering replacement parts for controls, include the following information:
x the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
x the unit serial number, which is also on the nameplate.

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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.
x Technical Support
x Product Training
x 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 and reference www.woodward.com/support, and then
Customer Support.

How to Contact Woodward

For assistance, call one of the following Woodward facilities to obtain the
address and phone number of the facility nearest your location where you will be
able to get information and service.

Electrical Power Systems Engine Systems Turbine Systems

Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number
Australia ----------- +61 (2) 9758 2322 Australia ----------- +61 (2) 9758 2322 Australia ----------- +61 (2) 9758 2322
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:
Kempen --- +49 (0) 21 52 14 51
Stuttgart ----- +49 (711) 78954-0 Stuttgart ----- +49 (711) 78954-0
India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191
Korea--------------- +82 (51) 636-7080 Korea--------------- +82 (51) 636-7080 Korea--------------- +82 (51) 636-7080
The Netherlands - +31 (23) 5661111 The Netherlands - +31 (23) 5661111
Poland -------------- +48 12 618 92 00
United States----- +1 (970) 482-5811 United States----- +1 (970) 482-5811 United States----- +1 (970) 482-5811

You can also contact the Woodward Customer Service Department or consult our
worldwide directory on Woodward’s website (www.woodward.com/support)
for the name of your nearest Woodward distributor or service facility.

For the most current product support and contact information, please refer to the
latest version of publication 51337 at www.woodward.com/publications.
162 Woodward
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Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:

General
Your Name
Site Location
Phone Number
Fax Number

Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application

Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number
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.
505 Program Mode Worksheets

Governor Serial Number ______________________

Application ________________________________ Date ___________

For details on individual settings, refer to Chapter 4.

TURBINE START SPEED SETPOINT VALUES

Manual Start YES NO Overspeed Test Lmt (rpm) rpm
Automatic Start YES NO Overspeed Trip (rpm) rpm
Semiautomatic Start YES NO Max Governor Speed (rpm) rpm
Rate to Min (rpm/Sec) rpm/sec Min Governor Speed (rpm) rpm
Valve Lmtr Rate (%/Sec) %/sec Setpt Slow Rate(rpm/sec) rpm/sec
Use Idle/Rated? YES NO Use Remote Speed Setpt ? YES NO
Idle Setpt (rpm) rpm Rmt Spd Setpt Max Rate rpm/sec
Rated Setpt (rpm) rpm Use Critical Speeds? YES NO
Idle/Rtd Rate (rpm/sec) rpm/sec Critical Speed Rate rpm/sec
Use Auto Start Sequence YES NO Critical Speed 1 Max rpm
Cold Start = ( > xx Hrs) HRS Critical Speed 1 Min rpm
Hot Start = ( < xx Hrs) HRS Use Critical Band 2 ? YES NO
Low Idle Setpt (rpm) rpm Critical Speed 2 Max rpm
Low Idle Delay (Cold) MIN Critical Speed 2 Min rpm
Low Idle Delay (Hot) MIN
Rate to Hi Idle (Cold) rpm/sec OPERATING PARAMETERS
Rate to Hi Idle (Hot) rpm/sec Generator Application? YES NO
High Idle Setpt (rpm) rpm Use Gen Brkr Open Trip ? YES NO
High Idle Delay (Cold) MIN Use Tie Brkr Open Trip ? YES NO
High Idle Delay (Hot) MIN Use KW Droop? YES NO
Rate to Rated (Cold) rpm/sec KW Max Load KW
Rate to Rated (Hot) rpm/sec Droop (%) %
Rated Setpt (rpm) rpm Rated Spd Setpt rpm
Auto Halt at Idle Setpts YES NO Use Freq Arm/Disarm ? YES NO
Ext Trips in Trip Relay YES NO Use Local/Remote YES NO
Reset Clears Trip Output YES NO
DRIVER CONFIGURATION
SPEED CONTROL Act #1 is 4–20 mA? YES NO
Teeth Seen by MPU Invert Driver Outputs ? YES NO
Gear Ratio 1 : Use Act 1 Flt Shutdown YES NO
Failed Speed Level(rpm) rpm Act #1 Dither %
Use Speed Input #2? YES NO Use Actuator #2? YES NO
Failed Speed Level(rpm) rpm Act #2 is 4–20 mA? YES NO
Off-Line Prop Gain % Act #2 Offset (%) %
Off-Line Int Gain rps Use Act 2 Flt Shutdown YES NO
Off-Line Deriv Ratio % Act #2 Dither (%) %
On-Line Prop Gain % Use Act #2 as Readout? YES NO
On-Line Int Gain rps Act #2 Readout is: %
On-Line Deriv Ratio % Readout 4 mA Value Units
Readout 20 mA Value Units

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ANALOG INPUTS CASCADE CONTROL

Analog Input # 1 Function Use Cascade Control? YES NO
Input 1 4 mA Value Units Invert Cascade ? YES NO
Input 1 20 mA Value Units Min Cascade Setpt Units
Analog Input # 2 Function Max Cascade Setpt Units
Input 2 4 mA Value Units Casc Setpt Rate (/sec) Units/sec
Input 2 20 mA Value Units Use Setpoint Tracking ? YES NO
Analog Input # 3 Function Setpt Initial Value Units
Input 3 4 mA Value Units Speed Setpt Lower Limit rpm
Input 3 20 mA Value Units Speed Setpt Upper Limit rpm
Analog Input # 4 Function Max Speed Rate(rpm/sec) rpm/Sec
Input 4 4 mA Value Units Cascade Droop %
Input 4 20 mA Value Units Casc PID Prop Gain %
Analog Input # 5 Function Casc PID Integral Gain rps
Input 5 4 mA Value Units Casc Derivative Ratio %
Input 5 20 mA Value Units Use Remote Casc Setting YES NO
Analog Input # 6 Function Remote Casc Max Rate Units/sec
Input 6 4 mA Value Units Casc Units of Measure
Input 6 20 mA Value Units
READOUTS
CONTACT INPUTS Analog Readout 1 Is
Contact Input 1 Function Readout 1 4 mA Value Units
Contact Input 2 Function Readout 1 20 mA Value Units
Contact Input 3 Function Analog Readout 2 Is
Contact Input 4 Function Readout 2 4 mA Value Units
Contact Input 5 Function Readout 2 20 mA Value Units
Contact Input 6 Function Analog Readout 3 Is
Contact Input 7 Function Readout 3 4 mA Value Units
Contact Input 8 Function Readout 3 20 mA Value Units
Contact Input 9 Function Analog Readout 4 Is
Contact Input 10 Fctn Readout 4 4 mA Value Units
Contact Input 11 Fctn Readout 4 20 mA Value Units
Contact Input 12 Fctn Analog Readout 5 Is
Readout 5 4 mA Value Units
FUNCTION KEYS Readout 5 20 mA Value Units
F3 Key Performs Analog Readout 6 Is
Blink when not Active? YES NO Readout 6 4 mA Value Units
F4 Key Performs Readout 6 20 mA Value Units
Blink when not Active? YES NO

AUXILIARY CONTROL
Use Auxiliary Control ? YES NO
Lost Aux Input Shutdown? YES NO
Use KW Input ? YES NO
Invert Aux ? YES NO
Min Aux Setpt Units
Max Aux Setpt Units
Aux Setpt Rate units/sec Units/sec
Use Aux Enable? YES NO
Setpt Initial Value Units
Aux Droop %
Aux PID Prop Gain %
Aux PID Integral Gain rps
Aux Derivative Ratio %
Tiebrkr Open Aux Disable YES NO
Genbrkr Open Aux Disable YES NO
Use Remote Aux Setting YES NO
Remote Aux Max Rate Units/sec
Aux Units of Measure

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RELAYS COMMUNICATIONS
Use Relay #1? YES NO Use Communications ? YES NO
Relay # 1 is Level Switch? YES NO Use Modbus Port 1? YES NO
Relay 1 Is Level Sw For Mode Ascii=1 Rtu=2
Relay 1 ON Level Units Modbus Device #
Relay 1 OFF Level Units Port #1 Driver
Relay 1 Energizes On Port #1 Baud Rate
Use Relay # 2? YES NO Port #1 Stop Bits
Relay # 2 is Level Switch? YES NO Port #1 Parity
Relay 2 Is Level Sw For Use Modbus Port 2? YES NO
Relay 2 On Level Units Mode Ascii=1 Rtu=2
Relay 2 Off Level Units Modbus Device #
Relay 2 Energizes On Port #2 Driver
Use Relay # 3? YES NO Port #2 Baud Rate
Relay # 3 is Level Switch? YES NO Port #2 Stop Bits
Rly 3 Is Level Sw For Port #2Parity
Relay 3 On Level Units
Relay 3 Off Level Units
Relay 3 Energizes On
Use Relay # 4? YES NO
Relay # 4 is Level Switch? YES NO
Rly 4 Is Level Sw For
Relay 4 On Level Units
Relay 4 Off Level Units
Relay 4 Energizes On
Use Relay # 5? YES NO
Relay # 5 is Level Switch? YES NO
Rly 5 Is Level Sw For
Relay 5 On Level Units
Relay 5 Off Level Units
Relay 5 Energizes On
Use Relay # 6? YES NO
Relay # 6 is Level Switch? YES NO
Rly 6 Is Level Sw For
Relay 6 On Level Units
Relay 6 Off Level Units
Relay 6 Energizes On

166 Woodward