Configuration Manual

505DE Double Extraction

Steam Turbine Control

Volume 4—Configuration Manual

Manual 91349V4 (Revision C)

 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WARNING—OUT-OF-DATE PUBLICATION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.
• Discharge body static before handling the control (with power to the control turned off,
contact a grounded surface and maintain contact while handling the control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit
boards.
• Do not touch the components or conductors on a printed circuit board with your hands
or with conductive devices.

IMPORTANT DEFINITIONS
• A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
• A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
• 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 2004
All Rights Reserved
Manual 91349V4 505DE Configuration Manual

Contents

ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV

CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction.............................................................................................................1
How to Contact Woodward.....................................................................................1
Associated Publications .........................................................................................1
System Compliance................................................................................................2
General Safety Precautions ...................................................................................2
Abbreviations Used in This Manual........................................................................2
CHAPTER 2. INSTALLING THE 505DE HMI ................................................... 3
Introduction.............................................................................................................3
Checks Before HMI Program Installation ...............................................................4
HMI Program Installation Procedure ......................................................................5
If You Need a Non-Standard Network Configuration or IP Address ....................12
CHAPTER 3. CONFIGURING THE 505DE ..................................................... 17
Introduction...........................................................................................................17
Entering and Navigating the Configuration Pages ...............................................17
Security, Access, and Logging-on........................................................................18
Inspecting and Changing Values..........................................................................19
CHAPTER 4. DESCRIPTION OF CONFIGURATION ITEMS................................ 23
Introduction...........................................................................................................23
Main Configuration Page......................................................................................23
Valve Actuators/Limiters.......................................................................................29
Analog Input Channels .........................................................................................37
Analog Readout Channels ...................................................................................43
Contact Input Channels........................................................................................46
Relay Output Channels ........................................................................................57
Speed and Load ...................................................................................................65
Controller Settings ................................................................................................83
Turbine Performance / Steam Map ......................................................................94
Turbine Start/Stop – Sequence Settings ..............................................................97
Miscellaneous Settings.......................................................................................106
CHAPTER 5. COMMISSIONING PROCEDURE .............................................. 112
Introduction.........................................................................................................112
Procedures Prior to Starting ...............................................................................112
Procedures During First Start.............................................................................120

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505DE Configuration Manual Manual 91349V4

Illustrations and Tables

Figure 2-1. The Simplest 505DE Network Configuration .......................................3

Figure 2-2. A More Complicated 505DE Network Configuration ...........................4
Figure 2-3. Installation Screen Shown When an Installation is Restarted ...........10
Figure 3-1. Configuration Navigation Buttons ......................................................17
Figure 3-2. Log-on Access Buttons ......................................................................19
Figure 3-3. Analog Values ....................................................................................20
Figure 3-4. Metric and Imperial Indication ............................................................20
Figure 3-5. The Pop-up Keypad ...........................................................................21
Figure 3-6. Boolean Value....................................................................................22
Figure 3-7. Forcing ...............................................................................................22
Figure 4-1. Main Configuration Page ...................................................................23
Figure 4-2. Save File Dialog .................................................................................25
Figure 4-3. Configuration Comparison Mismatch Report.....................................26
Figure 4-4. Customer Alarms Text Change Dialog ..............................................28
Figure 4-5. Valve Actuators and Limiters Configuration Page .............................29
Figure 4-6. Warning to Check the T&T Valve When its Position is Not Known ...31
Figure 4-7. Stroking Not Available........................................................................31
Figure 4-8. V1 Valve Control Configuration Page ................................................32
Figure 4-9. V2 and V3 Valve Control Configuration Page....................................34
Figure 4-10. V1 Valve Linearization Page............................................................36
Figure 4-11. Allocating Functions to Channels Screen 1 .....................................37
Figure 4-12. S-aux1 Setpoint/Measured Value Input Channel Configuration
Page.................................................................................................41
Figure 4-13. Analog Output Channel Configuration Page ...................................43
Figure 4-14. Analog Output Channel Function Selection Dialog .........................44
Figure 4-15. Contact Input Settings......................................................................55
Figure 4-16. Relay Output Channels Configuration Page....................................61
Figure 4-17. Level Indicators ................................................................................63
Figure 4-18. Off Level...........................................................................................64
Figure 4-19. MPU Settings and Speed Alarm Levels...........................................65
Figure 4-20. Critical Speed Settings.....................................................................68
Figure 4-21. Speed Controller Configuration Page ..............................................70
Figure 4-22. Generator Settings Page .................................................................72
Figure 4-23. Loaded Setpoint Configuration Page...............................................75
Figure 4-24. Monitoring MPU 1 and MPU 2 Configuration Page .........................81
Figure 4-25. Example of Operator’s Regulator Control on HMI ...........................84
Figure 4-26. PID Settings Selection and Tuning Dialogs .....................................85
Figure 4-27. Regulator Settings for S-aux1..........................................................86
Figure 4-28. P1/P2 Regulators.............................................................................91
Figure 4-29. S Auxiliary 1 Range and Units Changing Dialog .............................92
Figure 4-30. Steam Map Configuration Page.......................................................94
Figure 4-31. Priority and Decoupling Configuration Page....................................95
Figure 4-32. Start Configuration Page (1 of 2) .....................................................97
Figure 4-33. Start up Timing Parameters Configuration Page.............................99
Figure 4-34. Configuration Page For Other Start/Stop Related Parameters .... 102
Figure 4-35. 505DE Miscellaneous Settings Page............................................ 106
Figure 4-36. 505DE Miscellaneous Settings Page............................................ 109
Figure 5-1. Actuator Travel Compared to Effective Flow (Example)................. 114
Figure 5-2. V1 Poppet Valve Crack Point.......................................................... 115
Figure 5-3. V1 Effective Area Curve With Overtravel........................................ 116
Figure 5-4. V2 / V3 Effective Area Curve With Minimum Opening
Requirement ................................................................................. 118
Figure 5-5. Temporary Position Indication ........................................................ 119
Figure 5-6. Typical Vibration Speed Curve ....................................................... 120

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Manual 91349V4 505DE Configuration Manual

Illustrations and Tables

Figure 5-7. V1 Effective Area Curve to Match Flow ...........................................122

Figure 5-8. Typical Extraction Valve Arrangement With Check Valves .............123
Figure 5-9. V2 and V3 Effective Area Curve To Match Flow .............................125
Figure 5-10. Typical Pressure Response of Big Steam Header Volume...........126
Figure 5-11. Typical Island Step Response .......................................................127

Table 3-1. Security Levels....................................................................................18

Table 4-1. Configuration File Columns.................................................................26
Table 4-2. Analog Input Selection Options...........................................................39
Table 4-3. Ranges of Calibration and Alarm Level Settings On Analog Input
Channels..........................................................................................42
Table 4-4. Analog Output Selection Options........................................................44
Table 4-5. Fixed Contact Input Channels.............................................................47
Table 4-6. Locatable Contact Input Functions .....................................................47
Table 4-7. Contact Relay Outputs: Fixed Channels.............................................57
Table 4-8. Contact Relay Outputs: Selectable Functions ....................................57
Table 4-9. Level Indicator Source Functions........................................................63
Table 4-10. PID Gain Factor Settings ..................................................................70

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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:

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

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

components with conductive devices or with your hands.

• When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.

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 91349V4 505DE Configuration Manual

Chapter 1.
General Information

Introduction
This Configuration Manual describes the configuration of the 505DE Double
Extraction Steam Turbine Control System software.

To fully understand the information given in this manual, it is necessary to

understand the control and operational characteristics of the 505DE. This
information can be found in the manuals listed below in Associated Publications.

Woodward has highlighted potential dangers that can be encountered during the
installation and operation of the unit, and the instructions must be closely
followed and any safety instructions must be fully obeyed. All involved personnel
must carefully read and understand these instructions, and also understand and
obey all applicable local health and safety regulations.

WARNING—TRAINED PERSONNEL
Use of this equipment by untrained or unqualified personnel could result in
damage to the control or the installation's equipment and possible loss of
life or personal injury. Make sure personnel using or working on this
equipment are correctly trained.

This manual covers only equipment manufactured and software programmed by

Woodward and does not include operating instructions for the prime mover or the
driven devices or processes.

For specific operating information such as start-up, shutdown, and the prime
mover's response to signals from the Woodward control, refer to the prime mover
manufacturer's manual.

How to Contact Woodward

See the information in Chapter 5 of this volume.

Associated Publications
The following Publications are helpful in understanding various aspects of the
505DE. Most of these manuals are included on the 505DE CD. If they are not on
the CD you can download them from the Woodward website at
www.woodward.com.

Manual 91349V2 505DE Installation

Manual 91349V3 505DE Operation
Manual 91349V4 505DE Configuration
App. Note 51204 Grounding and Shield Termination
Manual 82510 Magnetic Pickups & Proximity Switches for Electronic Controls
Manual 82715 Guide for Handling & Protection: Electronic Controls, PCBs,
Modules
App. Note 83402 PID Control

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505DE Configuration Manual Manual 91349V4

System Compliance
This system complies with the relevant industry specifications and regulations.

General Safety Precautions

Obey the following safety precautions when you install the unit:
• Obey all cautions or warnings given in the procedures.
• Never bypass or override machine safety devices.
• Never jumper or force Input/Output signals while operating the machine.
• Do not change software settings unless completely sure of the
consequences of that change.
• Always use sufficiently trained personnel and the right equipment to operate
the machine.

Abbreviations Used in This Manual

ASCII American Standard Code for Information Interchange
CPU Central Processing Unit
DCS Direct Control System or Digital Control System
DI Digital Input
DM Slow Deceleration to Minimum Load
DO Digital Output
ESD Depends on the context:
Emergency Shutdown
Electrostatic Discharge
EU Engineering Units
FSNL Full Speed No Load.
HMI Human Machine Interface, the operator interface system
HP High Pressure
ID Identification
I/O Input/output, the electrical signals to and from a unit
IP Depends on the context:
Internet Protocol
Ingress Protection
Intermediate Pressure
kW Kilowatts
LP Low Pressure
MPU Magnetic pickups for speed sensing
NS Normal Shutdown
PC Personal Computer
PID Proportional Integral Derivative
RTU Real Time Upcall
SD Shutdown
SI Depends on context:
Système international d’unités – The metric
measurement system
Step to idle (gas generator idle), also known as ‘S T I’
UDP User Datagram Protocol

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Chapter 2.
Installing the 505DE HMI

Introduction
This guides you through the installation process of the 505DE configuration
program and operator interface, or HMI (Human Machine Interface). This is a
single program, serving both operators running the turbine and the engineers
performing the configuration of the 505DE.

The 505DE HMI and configuration program is installed on a regular PC running

Microsoft Windows 2000® or later. To install the program you must have
Administrator privileges on the target PC. Alternatively Woodward can supply a
panel PC with the HMI pre-installed.

The installation changes the target PC’s network settings to operate in network
configurations as shown in Figures 2-1 and 2-2. The 505DE itself comes preset
to IP address 192.168.200.2. The 505DE HMI installation program changes the
PC’s IP address to 192.168.200.3, if allowed to do so.

505DE HMI 505DE

192.168.200.3 192.168.200.2
cross cable

Figure 2-1. The Simplest 505DE Network Configuration

A hub or switch is needed if more than 2 pieces of hardware need to

communicate to each other. For instance, a second HMI may be desired It is
recommended to have a hub installed to be prepared for future expansions or for
ease of servicing while running. If a hub is not used, a cross-connecting network
cable is needed.

The IP address of a second HMI PC should be set to an IP address in the range

of 192.168.200.4 to 192.168.200.254. Refer to Changing the 505DE HMI’s own
IP address.

The external network and the router/firewall are not necessary for correct
operation of the 505DE. If external access to the 505DE and/or 505DE HMI is
used, a router and firewall are needed, with network settings compatible with the
shown network. Be sure to install a firewall with appropriate restrictions as the
turbine can be influenced and even stopped by anyone with network access and
the right (freely available) programs. Do not run business network traffic over the
505DE network, as this may impede proper operation.

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505DE Configuration Manual Manual 91349V4

505DE HMI
505DE

192.168.200.2
192.168.200.3 Hub or switch

e.g. 192.168.200.4
192.168.200.1 optional
Router/firewall

Second HMI or External network

Service PC
Figure 2-2. A More Complicated 505DE Network Configuration

Checks Before HMI Program Installation

Make the following checks before you install the program:
• Make sure that you have administrator rights on the PC. Without
administrator rights the installation will fail.
• Make sure you have about 3 GB available on your hard drive. The 505DE
HMI requires a few 100 MBs for its programs, and around 2 GB for the
trending data. Under certain conditions, the size of the trending data can be
reduced later.
• Make sure there are no screensavers installed on your target PC. Some
screensavers can disrupt trend collecting.
• Make sure that there are no power save modes active on your target PC
that reduce processing power. You probably want the 505DE running for
long periods without operator intervention. Check both the BIOS and the
Windows settings for power saving settings. The only desirable power
saving option could be the one that blanks the screen.
• Set the display resolution to 1024x768. This is the resolution that the 505DE
HMI is set up for. The 505DE screens will show without the title-bar. If you
have your display set for more pixels, the HMI graphics are smaller than
intended, and the HMI window title-bar is visible.
• Select “small fonts” for the display. If you have “large fonts” selected, the
texts on the 505DE HMI screens are sometimes too large for the space that
is allotted to them.
• Set the display to 256 colors. This enables the 505DE HMI to show flashing
text lines for all unacknowledged alarms. If you set up your display for 16,
24 or 32 bits color (“High color” or “True color”) you can only tell the
difference between an active unacknowledged alarm and an active
acknowledged alarm by careful inspection of the alarm text.
• Set the PC time display to 24 hour times. This is the time format that fits in
the space allocated to the time display on all HMI pages. You can find this
setting in StartÆ SettingsÆControl PanelÆRegional Options”, then “Time”.
Set the time format string to “H:mm:ss” or “HH:mm:ss”.

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Manual 91349V4 505DE Configuration Manual

HMI Program Installation Procedure

The installation has been set-up to require as few user decisions as possible. In
general the presented choices are the right choices, and can be accepted by
clicking the “OK” or “Next >” button, unless otherwise indicated in the remainder
of this chapter. If you make a mistake, you can go back. If you cannot, or if you
are not sure where you have to go back to, cancel the installation and start all
over again. It is easy to re-install the 505DE HMI over an existing installation.

While installation parts are running, the installation supervisor program “505DE
HMI Install” is waiting in the background for installation parts to finish, so the next
installation part can continue. If you wait for a very long time with responding to
the various installation parts, the supervisor program may time out. It will ask you
if it needs to keep waiting. If program installation is correct, click “OK”. If you
want to abort the installation, click “Cancel” to stop the installation supervisor.

Installation Procedure
1. Make sure you have Administrator privileges on the target PC.
2. Insert the CD in the target PC and start the 505DE HMI installation program.
This start the installation supervisor program that controls the installation of
the various parts of the 505DE HMI, such as the Citect system.

3. Click OK to start the Citect Setup program.

If you are a regular user on this PC (and not logged in with Administrator
rights), the installation of Citect fails and gives a message (e.g. “Setup has
detected that the UninstallShield is in use (. . .) Error 432”). Abort the
installation and reply “Cancel” to the installation supervisor’s message that
Citect was successfully installed. Restart the installation as an
Administrator.

Accept all presented choices, including the Citect location and program
folder choices, and wait for Citect to be installed. This may take a few
minutes. Choosing alternative program locations, etc., will cause
subsequent installation parts to fail.

4. At the end the Citect installation you are prompted to restart the computer.
Do not restart it at this time. Click “Finish”.

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505DE Configuration Manual Manual 91349V4

5. The installation supervisor announces successful installation of the Citect

package. Press “OK”, then “Yes” to continue.

6. The installation supervisor proceeds installing “Citect 5.41 Service Pack B”.

Let the installation search your local drive for the Citect installation and
accept its findings. Choose the “Full Citect for Windows installation” option,
and accept the proposed back-up directory. Ignore the remark about
Sentinel drivers.

It is not necessary to view the v541spkb.doc. Uncheck the check box before
finishing.

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Manual 91349V4 505DE Configuration Manual

7. The Citect Service Pack B installation finishes. A few seconds later, the
supervisor program announces successful installation of the Citect Service
Pack. Press “OK” to continue.

8. A few windows will now flash on the display as some modifications are made
to your registry and a Citect.ini file is copied to your system directory. Do not
touch your keyboard until, after only a few seconds, the supervisor program
announces it is ready to reboot. Click OK to reboot and continue.

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505DE Configuration Manual Manual 91349V4
9. After reboot and after you log in (again as an Administrator), the “505DE HMI
Install part II” program is automatically started. For this to succeed, make
sure that the CD is in the drive while logging in. Press “OK” to close the initial
message.

10. The Citect development environment (called “Citect Explorer”) is now started,
and directed to install the 505DE HMI application and then compile it. This
can take a few minutes. This would be a good time to install the Citect key on
the printer port.

11. When all compilation is done, you are presented with a choice to set the IP
address for the computer or not. If the PC is going to be the first 505DE HMI,
running in an network configuration as shown in Figure 2-1. or Figure 2-2. ,
click Yes. The IP address is then set to 192.168.200.3. If you do not want to
have the IP address of your computer set to this number, click No, and refer
to “If You Need a Non-Standard Network Configuration or IP Address” below
for information about changing communication parameters.

If you are in doubt, click Yes.

12. The 505DE HMI now starts up. A few moments later the Citect Explorer is
closed. Once the Citect Explorer is closed, the supervisor program
announces it is finished.

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Manual 91349V4 505DE Configuration Manual

NOTE
The starting of the 505DE takes a long time for the first start up. During that
time the 505DE HMI is initializing and creating all trending history files that it
will use in the future. Subsequent starts are much faster.

13. After initializing, the 505DE HMI shows its screens and searches for the
505DE.
14. Remove the CD and store it in a safe place.

If the Installation Fails

If the installation fails, restart the installation program (see steps 1 and 2 in the
previous chapter). You are now presented with a screen that allows you to
retrace any of the steps that are recorded as completed successfully.

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Figure 2-3. Installation Screen Shown When an Installation is Restarted

All steps that have not been signaled as “competed successfully” are not shown.
An automated judgment of the successful completion of a step can be wrong.
Therefore redo all steps that you can see but of which you are not absolutely
sure.

Normally you will not have to uninstall the entire Citect installation. However, if
trouble persists, you may want to choose to uninstall the entire Citect
environment and start all over.

The points where you can restart the installation procedure are as follows:

Install everything
This option repeats the entire installation. It is normally not necessary to uninstall
the existing installation.

Citect base installed. Continue with Citect Service Pack installation

This option takes you to the last window in step 5 of the previous chapter. You
are confident that all of the Citect base system installation completed without any
trouble. The installation proceeds with installing the Citect Service Pack.

Citect Service pack installed. Continue with installation phase I

This option takes you to step 8 of the previous chapter. You are confident that all
of the Citect base system and service pack installation completed without any
trouble. You proceed with adjusting some PC system files for use with the
communication protocols and settings needed to allow Citect to run the 505DE
HMI.

This step takes only a few seconds to complete.

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Manual 91349V4 505DE Configuration Manual
Installation Phase I complete. Reboot and continue with installation phase II
Choose this step of you are confident that all of the Citect base system and
service pack installation completed without any problem and no trouble occurred
with adjusting the system files. This step prepares the PC to automatically start
the Installation Phase II program after rebooting. Rebooting is required by Citect
between installing the Citect system and using it.

Installation Phase I complete and rebooted. Continue with installation

phase II
This option takes you to step 9 of the previous chapter. Choose this option if you
did reboot after installing all of Citect and the system files. This step immediately
launches the Installation Phase II program.

Installation Phase II installation successful . Repeat installation phase II

completion
This option takes you to step 11 of the previous chapter. Choose this option if
you are sure that the restore and compile process of step 10 of the previous
chapter was completed successfully. This step installs some links on your
desktop, Start-up folder and Start Menu tree that facilitate starting the 505DE
HMI. It then proceeds with requesting to change the IP settings of your PC and
starting the 505DE HMI.

If the 505DE HMI Complains about “not a project selected”

Occasionally the 505DE HMI can fail during start-up because a project could not
be selected. To correct this:

1. Start the Citect Explorer from the Start menu. Three windows eventually
open, one of them called “…Citect Explorer”. This may take a few seconds.
2. In the project list on the left pane of this window, locate the ”505DE HMI”
project. Click on it (505DE_HMI) to select it.

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505DE Configuration Manual Manual 91349V4
3. Select the menu item “FileÆ Run” or press the F5 button or press this icon
(right arrow). The 505DE HMI starts.
4. While the 505DE HMI is starting, you can close the Citect Explorer window.
This also closes the two other Citect editor windows.

If You Need a Non-Standard Network Configuration or

IP Address
The 505DE received an IP address (192.168.200.2) for its communication at
production. The 505DE HMI received a compatible IP address (192.168.200.3)
during the installation (step 11 in “HMI Program Installation Procedure” above),
unless you prevented this.

Woodward highly recommends that you use these addresses. Changing the
505DE address creates a higher probability that an installation error occurs.

If you want to change the addressing structure, the following information is

provided to give you some guidance. These procedures should only be
attempted if it is absolutely necessary, because failure may result in an unusable
505DE installation. It is not possible to explain all possible deviations in this
manual.

When uncertain, contact Woodward.

Changing the 505DE HMI's Own IP Address

If you prevented the changing of the 505DE HMI IP address at installation time,
you may want to set it to the standard IP address after all. If you have a second
HMI, you may want to set the second one to a slightly different address, such as
192.168.200.4. This is the procedure with the least risk of failure.

The IP address of the 505DE HMI is the IP address of the PC that the HMI is
running on. This PC’s IP address can be changed using any of the methods
available on Windows machines to change PC IP addresses.

The most common way is to access the properties of the Internet (TCP/IP)
protocol of the “Local Area Connection”.

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Another method is to open a command prompt (on Windows 2000 select: Start
Æ Programs Æ Accessories Æ Command Prompt) and enter the following
command (note: this command appears on two lines in this manual, but should
be entered as a single command):
Netsh interface ip set address local static
192.168.200.3 255.255.255.0 192.168.200.1 1

The first 4 digit IP number (192.168.200.3) is the required IP address.

The second is the subnet mask (255.255.255.0).
The third is the default gateway (192.168.200.1).
The fourth needs to be 1.

For example, for a second 505DE HMI, you may want to change the first number
to 192.168.200.4:
Netsh interface ip set address local static
192.168.200.4 255.255.255.0 192.168.200.1 1

Changing the 505DE HMI Target Address

If you have a 505DE simulation running on a regular PC, or you managed to put
the 505DE on a different IP address, you need to inform the 505DE HMI at which
alternate address it can find the 505DE.

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505DE Configuration Manual Manual 91349V4
If this procedure fails, you can either use the Citect editor to correct the problem,
or you can de-install and re-install the entire 505DE HMI and try again.

1. Close the 505DE HMI application (as Configuration or Engineer, go to the HMI
page and click the Shutdown button). This operation does not affect turbine
operation. It does prevent you from monitoring and commanding the 505DE.
2. Open Citect Explorer (StartÆProgramsÆCitectÆCitect Explorer). Three
windows will eventually open.
3. In the “Citect Explorer” window, verify that the selected project is “505DE
HMI”. The selected project is shown in the top left, and can be changed by
clicking on the required project in the tree at the left of the window. See step
2 in ‘If the 505DE HMI Complains about “not a project selected” ‘ above.
4. Once “505DE HMI” is the selected project, switch to the “Citect Project
Editor”. The editor shows the current project in the title bar.
5. Select menu item “Communication Æ Boards”. A dialog window appears.

6. Using the scroll bar on the right side of the dialog, go down until the item
“OPC_Connector” appears in the “Board Name” box.
7. In the “Special Opt” text box, change the IP address (originally at
192.168.200.2) to the required 505DE IP address
8. Press the “Replace” button.

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9. Go to menu item “Communication Æ Ports”. Another dialog window appears.

10. Using the scroll bar on the right side of the dialog, go down until the item
“Ethernet_1_P5555” appears in the “Port Name” box.
11. In the “Special Opt” text box, change the IP address (originally at
192.168.200.2) to the desired 505DE IP address, using the following syntax:
Ixxx.xxx.xxx.xxx -P5555 -U
where xxx.xxx.xxx.xxx is the desired IP address (the same as the IP
address for the “OPC_Connector”. Make sure that the –I (capital i), the –
P5555 and the –U are all in place, and that all spaces are in the right places
and absent elsewhere.
12. Click the “Replace” button.
13. Press the <Alt>-F10 key combination, or select menu item “FileÆCompile”.
The project now compiles and, if no mistakes were made, returns with a
message “Compilation successful, 3621 Points used” (the points number
may be slightly different).
14. Press the F5 key or select menu item “FileÆRun”. The 505DE HMI starts up,
now looking at the new IP address to find a 505DE.
15. Select the “Citect Explorer” window.
16. Close the “Citect Explorer”. This also closes all other Citect editing windows.

Changing the 505DE IP Address

Changing the IP address on the 505DE is not a simple task, and it requires the
use of a Woodward application called “AppManager”. This is available free from
the Woodward internet site www.woodward.com. Install this program on any PC
that can communicate with the 505DE and read the help files carefully before
proceeding. You may want to arrange a Woodward representative to perform this
task.

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At a certain point in this process, it may be necessary to stop the 505DE
application. The 505DE is secured not to allow this with a running turbine. To
stop the 505DE application the following must all be true for at least 2 minutes:
• Emergency Shut Down must be active
• The speed must be below the minimum detectable speed (i.e. maximum
speed / 50)

When you are requested for a username and a password you can use
“ServiceUser” and “ServiceUser” (note the use of capital letters).

As a very last resort, if all network communication is lost, you can attach a
keyboard and a monitor to the 505DE CPU.

CAUTION—EMI
The 505DE monitor and keyboard ports are not protected against Electro-
Magnetic Interference at industrial levels. Severe electro-magnetic
disturbance may damage the ports with wiring connected to it. Keep wires
as short as possible. Do not connect anything to these ports if severe
Electro Magnetic Interference is expected (e.g. electric welding activities).
Keep wires and cords as short as possible. Make connection to these ports
for the shortest time possible.

Now you can change the network settings as with any Windows NT (not
Windows 2000 or Windows XP) computer. Enter the IP configuration menu by
selecting “StartÆSettingsÆControl Panel”, then “Network”, then “Protocols” and
then “Properties”. These actions can be done without using a mouse. Do not
forget to log off again (StartÆShutdownÆlog off ….).

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Chapter 3.
Configuring the 505DE

Introduction
System configuration is done using the 505DE HMI (Human Machine Interface)
that comes with the 505DE. This chapter assumes that you:
• Have successfully installed the 505DE HMI software on a PC
• Have correctly connected the 505DE HMI to the 505DE Control
• Can move between the screens on the 505DE HMI

Refer to Chapter 2 for instructions on installing the 505DE HMI software on a PC

and on connecting the HMI to the Control.

Entering and Navigating the Configuration Pages

The configuration pages are entered by clicking on the “Configuration” button
located on the HMI’s “Main Menu” page.

Anyone can browse the configuration pages. All values that are of significance to
the current set-up are available for inspection to anyone with physical access to
the HMI. However, all items are blocked from changing if the user has not
properly logged into the HMI (refer to “Security, Access, and Logging On” below).

On the Main Configuration page there are some configurable items and some
navigation buttons. Clicking a navigation button opens a configuration page.

Figure 3-1. Configuration Navigation Buttons

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Each page has a number of configuration items (refer to Chapter 4). Most
configuration pages have sub-pages. These are accessible through the row of
buttons that appear on the top of the sub-pages. Some sub-pages share a few
sub-page buttons (i.e. pressing these buttons opens the same sub-page). The
sub-page indicates the buttons that it serves by displaying a blue rectangle
around these buttons, like these “Speed and load” sub-page buttons:

All pages share a few items from the HMI Operator pages. These are on the very
top of the screen and at the very bottom. At the top, there are a few standard
navigation buttons. On the configuration pages they do the following:

Provides a choice of buttons to immediately access the various operator

pages.
Immediately brings you to the Main Menu page of the HMI.
Brings you back to the last main configuration page. This button does not
bring you back to the last sub-page.

These buttons bring you to the previous or next sub-page.

The “Reset” button sends a general alarm reset signal to the 505DE.
The “ESD” button sends an Emergency Shut Down signal to the 505DE.

At the bottom of the screen, there is a single navigation button:

Minimizes the entire HMI screen. Provides access to the rest of the PC. When
correctly installed, it would be difficult to minimize the HMI without this button
as there is no title-bar and no visible Windows Taskbar.

Security, Access, and Logging-on

Four levels of security are provided on the HMI. These levels are accomplished
by requiring that the user enters the desired security level and the associated
password. The names of the security levels and their associated initial
passwords are in Table 3-1.

Table 3-1. Security Levels

Security level Initial password Description
The user has no control items available, but can navigate
None
through all available screens.
The user has control over normal day-to-day operating
Operator Operator
commands. These do not include configuration items.
The user has control over the configuration items that are
Engineer Engineer available during the running of the machine, in addition to the
Operator accessible items.
The user has control over all items, including the items that are
only available when the machine is fully stopped. The machine
Configurator Configurator
must be stopped (sequence step “Turbine Systems Off”) or the
login attempt is rejected.

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The security level can be changed at the Main Menu and the main Configuration
Page. In addition, on all pages the login screen can be accessed by pressing ctrl-
L on the keyboard. Passwords can only be changed from the Main Menu and the
main Configuration Page.

If no keyboard is attached to the HMI, an on-screen keyboard can be used. Go to

the Main Menu page using the “Menu” bottom on the top row, and then click the
button “Keyboard” (bottom right of the screen).

Figure 3-2. Log-on Access Buttons

If passwords are forgotten, they need to be re-initialized by recompiling the HMI.

If you cannot recompile the HMI yourself, please Contact Woodward.

NOTE
Change the initial passwords listed in Table 3-1 as soon as possible. Make a
note of your passwords and store them in a safe location.

When a user attempts to set the security level to Configurator while the machine
is not stopped (i.e. the sequence step is not “Turbine Systems Off”), the security
level is rejected and the login window is displayed again. While the Configurator
level is active, a start inhibit prevents the machine from leaving the stopped
state. On all configuration pages, the Off state of the engine can be determined
from the bar at the bottom of the page, where the “Sequence step” should read
“Turbine Systems Off”.

Inspecting and Changing Values

Anyone can always look at the values of the current configuration. Only if the
security level is correct for the specific setting will the buttons that allow value
changing be enabled. Disabled buttons appear “grayed out” on the screen. Some
buttons and/or settings may be altogether invisible without the proper security
level.

Some settings can cause certain other values to appear or disappear or be

grayed out. Entire sub-pages may be made inaccessible if another setting makes
them irrelevant. For instance, analog input settings will not be available as long
as no channel has been allocated to the function first.

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Analog Values
Analog values appear like this:

Figure 3-3. Analog Values

The left part shows the value and the type of unit. Some units are available both
in metric (°C, kPa) and imperial (°F, psi). This can be changed from the Main
Menu, or by pressing F11. If there is no unit applicable, a dash “-“ is shown. Non-
dimensional rates are indicated as “-”, and fractions are indicated as “/1”

Figure 3-4. Metric and Imperial Indication

Values are changed by entering the value itself or by using the scroll buttons on
the right of the value.

All values have a range within which they can be changed. If the minimum or the
maximum value is exceeded by a change, the change is rejected. Ranges given
in this manual reflect the range using metric units. Changing the unit display
does not change the underlying range. Therefore a range expressed in imperial
units probably is not a multiple of 1, 10 or 100. Ranges (expressed in metric
units) can be obtained from the configuration save file (refer to “Storing, Loading,
and Verifying a Configuration to File” in Chapter 4) or from this manual.

The buttons with double arrow change the value up or down by 10% of the
original value. If the original value is less than 0.1, the steps are exactly equal to
0.01. The buttons with single arrows change the value up or down by 1% of the
original value. If the original value is below 0.1, the steps are exactly equal to
0.001.

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Figure 3-5. The Pop-up Keypad

Alternatively you can click on the value itself. A keypad pops up to allows the
user to enter a value. After entering a value, clicking “OK” causes the 505DE to
attempt and accept the value, clicking “Cancel” leaves the original value
unchanged.

While the turbine is stopped (i.e. the sequence step is “Turbine Systems Off”),
there are no restrictions and any value can be entered. If the minimum or
maximum range boundary is exceeded, the value is set to the respective
boundary. It may take 1 or 2 seconds for the final value to be reached.

While the turbine is not stopped, the entered value is restricted. If the entered
value deviates from the original value by more then 10%, it is rejected, and the
value remains unchanged. Normally you would move a value close towards the
desired target using the arrow buttons, then enter the final value using the
keypad.

Integer Values
Integer values look and behave much like analog values, but they do not have a
decimal point in the value. Like analog values, they can be changed by the
buttons or the keypad popup (see Figure 3-5). However:
• The single arrow buttons change the value by at least 1
• The double arrow buttons change the value by at least 10
• The keypad allows the value to be set anywhere within the allowed range,
without any 10% restrictions at any time.

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Boolean Values
Boolean values look like this:

Figure 3-6. Boolean Value

The value is either True or False. If True, the condition stated in the description is
valid. The value is toggled by clicking the “Change” button.

Forcing
Forcing is the process where a hardware input is controlled from the
configuration pages instead of from a hardware measurement, or where a
hardware output is controlled from the configuration pages instead of from the
normal calculations.

Forcing is protected, and at least security level “Engineer” is required to force a

channel. In addition, forcing must be enabled by the 505DE, and it does so only
when the turbine is stopped. The forcing setpoint is clearly visible only when the
forcing has successfully been enabled.

Figure 3-7. Forcing

Forcing values from speed channels are shown in rpm. Forcing values from
4 - 20 mA channels are shown as a fraction in the 0 to 1 range. Figure 3-7 shows
a force value of a channel that is not connected: this value corresponds to 0 mA
on a 4 – 20 mA channel. The unit indicates that the value is a fraction in the
(normally) 0 to 1 range. A value of 0.5 would indicate 12 mA.

Actuator channels cannot be forced. However, there are stroking facilities

present.

When forcing is enabled on a particular channel, the force value is initially made
equal to the value actually coming in or going out. This effectively “freezes” the
channel. The value can be changed from there, just like any normal analog
configuration value. When a channel is being forced, an alarm is given, indicating
the channel that is being forced. In addition, a start inhibit is activated.

The forcing condition is de-activated by clicking the enable button again. As soon
as forcing is de-activated, the value jumps from the forced value to the normal
operational value.

NOTE
To prevent large value jumps it is recommended to force the value to the
expected operational value before de-activating the forcing condition.

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Chapter 4.
Description of Configuration Items

Introduction
This chapter provides a detailed description of all configuration items and their
function.

Main Configuration Page

This page contains a few configuration items and the navigation buttons to other
pages. Some configuration items and buttons are visible only when the
Configurator has logged in. To log in, refer to Chapter 3, Security.

Figure 4-1. Main Configuration Page

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The following navigation buttons to configuration pages are found here:

Button Configuration items

Valve actuators/limiters These pages contain the settings that control the behavior of the
valves. Some items that concern valve behavior during start-up or
stop can be found on the “Turbine start/stop” pages.
Analog input channels These pages allow you to allocate 4-20 mA analog input channels to
functions, and to define the ranges and alarm levels on these
functions. The use of these channels is defined elsewhere, e.g. on
the “Controller settings” pages.
Analog readout channels These pages allow you to define the function and calibration of all 4-
20 mA analog output channels.
Contact input channels These pages allow you to allocate channels to all discrete input
functions, as well as to define active levels, alarm levels and alarm
delay times.
Relay output channels These pages allow you to define the function and level of the relay
output channels. In addition, level indicators that can drive relay
outputs are defined here.
Speed and load These pages allow you to define your MPU configuration, critical
speeds, speed/load controller behavior, droop and loadsharing
settings and all other speed and load related settings.
Controller settings These pages allow you to define the behavior of all controllers except
the speed/load controller.
Turbine performance These pages allow you to define the steam map, the limiting priorities
and the decoupling behavior of the turbine.
Turbine start/stop These pages allow you to define how the turbine starts and stops,
including initial valve opening rates, warm-up levels and dwell times,
acceleration rates etc.
Miscellaneous settings These pages contain a number of settings that can not logically be
assigned to pages under one of the above page buttons.

Turbine Identification
The turbine ID shown on the top is always visible. These are just two numbers
that the Configurator can change using the “Turbine ID nr 1” and “Turbine ID nr
2” values at the bottom. These numbers are only there to facilitate the tagging of
a certain turbine or configuration by the user. The Configurator chooses if and
how to use these numbers.

Making the Configuration Permanent

Either the Engineer or the Configurator can change values using the various
configuration pages. As long as the 505DE is powered up and not reset, these
changes remain in effect. However, on a reset cycle, all changes can be lost.

The “Save configuration to control” button makes a configuration permanent.

This button transfers the current value of all system tunables, which include the
configuration items, from normal memory to a non-volatile memory that survives
resets and power loss. Both the Configurator and the Engineer have access to
this button. At the end of each configuration cycle, the “Save configuration to
control” button should be used to ensure proper storage of the configuration.
Even if this button is never used, the values are still saved about every 15
minutes. To ensure proper storage, the user is encouraged to use the button
anyway.

NOTE
A configuration can be lost on reset on power down, unless it is saved using
the “Save configuration to control” button.

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Note that all tunables are saved with this button. This includes all system
tunables that are not controlled by the configuration pages. The turbine ID can be
used to detect a failure to permanently store the configuration by changing the ID
on each configuration save cycle.

The remainder of this manual refers to the saved configuration as the

“permanent configuration”, as opposed to the volatile configuration which is the
“current configuration”. Just after a save operation, these two are equal.

The message “This 505DE has never been configured before” indicates that the
connected 505DE has the same permanent configuration as when shipped from
Woodward. This is very unlikely to be a desirable situation. This message
disappears permanently once a save to control operation has completed.

Storing, Loading, and Verifying a Configuration to File

Configurations can be stored in the HMI file system. The buttons “Load
configuration from file” and “Save configuration to file” are used for this purpose
(see Figure 4-1. ). The “Load configuration from file” button is only visible to the
Configurator. The Engineer can save the current configuration at all times.

“Save configuration to file” lets you select a file name:

Figure 4-2. Save File Dialog

The selected file name is appended with the turbine ID and the current date and
time. If a file name is selected which already has such a file name suffix, this
suffix is replaced by a new suffix reflecting the current ID, date and time.

Thus, selecting “505DE_training.csv” as the filename results in a file called

“505DE_training_0705_20041027_1743.csv”, if the turbine ID is 7 and 5, the
save date is October 27, 2004 and the save time is 17:43 (5.43 pm).

Selecting “505DE_training_0005_20041019_1106.csv” as the filename results in

a file that is also called “505DE_training_0705_20041027_1743.csv”.

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After providing a filename, the current configuration is saved to the named file as
a comma separated values (.CSV) file. (See “Making the Configuration
Permanent” above for a definition of current configuration).

All files that are created using the “Save configuration to file” button can be read
back to replace the 505DE’s current configuration using the “Load configuration
from file” button. Use the “Save configuration to control” button if this
configuration is to be made permanent.

The current configuration can be compared to a saved configuration file using the
“Compare config to file” button. After selecting the required configuration file, this
button compares all values in the 505DE to the values in the configuration file.
Differences are presented one by one in a pop-up dialog, presenting the internal
variable name, a description, and the values in the file and in the control.

Figure 4-3. Configuration Comparison Mismatch Report

Only tunables that are controlled by the configuration pages are included in the
saving/loading operations to a file, unlike the “Save configuration to control”
operation that includes all tunables in the system.

NOTE
All configuration actions have an immediate effect on the 505DE. Also, there
is no way to “undo” a configuration action, other then resetting the control.
For this reason, it is strongly recommended that any valid configuration be
immediately saved to a file. These files can then be used to revert to a valid
configuration if an error is made during a subsequent configuration session.

A configuration storage file is a comma separated value file (.CSV) with 6 columns:

Table 4-1. Configuration File Columns

Column Use
1 The Woodward internal database name for the item.
2 The data type of the item: REAL, LONG or DIGITAL.
3 The current configuration value.
4 The minimum value of the range in which the value must be.
5 The maximum value of the range in which the value must be.
6 A description of the item.

Real values and ranges are all expressed in metric units.

CAUTION—CONFIGURATION VALUES
It is strongly recommended that these values are not edited before loading
them. If an editing error of any kind is made, the results can affect your
configuration. Woodward gives no guarantees about which items are read
and how they are read.
Safeguards that compare configuration values against each other, restrict
input values accordingly and thus prevent erroneous configurations are not
present while reading from a file.
Excel may save .csv files in a format that is not compatible with the 505DE.

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Other Configuration Items Found on the Main Configuration

Page
Allow logging of a user

Boolean
When False, this setting disables the Log Off buttons, thus preventing anybody
to log off. This can be desirable if you always want to avoid having to spend time
logging in when a system upset requires immediate response from an operator.
The only way to log off is to log on as someone else.

When True, anybody can log off. This can be desirable if you want the system
secured from unauthorized people.

Allow password changing

Boolean
When False, no passwords can be changed.
When True, everybody logged in at a certain security level can change that
level’s password, i.e. any Operator can change the Operator password.
Only the Configurator can change this setting. Normally he would set this setting
to True, log in as anyone, change the password, log in as Configurator again and
set it to False.

Raise/Lower input contacts speed up delay

Analog. Range: 0.0–30.0 [s]

When a Contact Input Raise or Lower command is given, the setpoint is raised or
lowered at the normal rate. Often there is also a fast rate definition. This setting
defines how long a Contact Input Raise or Lower command must be applied
before the fast raise or lower rate takes effect. The normal and fast rates
themselves are defined elsewhere for the different setpoints.

“Change customer alarms” button

Some contact inputs may be configured as “Customer alarm” or “Customer ESD”
(refer to “Contact Input Channels below). When these alarms are activated, they
show up on the alarms pages as “Customer alarm 1 – Alarm State”. This button
allows you to change these texts into ones that have more meaning for your
operators. It presents you with a dialog showing the current alarm descriptions,
allowing you to change them. If you close this window by pressing “OK”, you
store the changes to take effect with the “Apply and recompile” button. If you
close the window with “Cancel” nothing is done.

“Apply and recompile” button

This button takes the data from the change dialog above, closes the 505DE HMI,
starts the Citect Explorer and lets it compile the 505DE HMI with the data as
provided. It then restarts the HMI with the adapted names, ranges and units.

Note that this button is a copy of the button described in “Change ranges and
units” below. Clicking this button also implements any changes you may have
prepared for the controller settings.

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Figure 4-4. Customer Alarms Text Change Dialog

“Revert to default” button

This button closes the 505DE HMI, starts the Citect Explorer and lets it compile
the 505DE HMI with all data as originally present in the delivery version of the
505D HMI. It then restarts the HMI with the alarm labels.

Note that this button is a copy of the button described in chapter “Change ranges
and units” below. Clicking this button also reverts any changes you may have
made for the controller settings.

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Valve Actuators/Limiters
These pages define the valve properties for the three valves that can be
controlled from the 505DE:
• Valve 1 (V1) is the High Pressure inlet valve
• Valve 2 (V2) is the Intermediate Pressure extraction valve
• Valve 3 (V3) is the Low Pressure extraction valve

In addition the limiters that can restrict the movements of these valves are
configured here.

Actuators/Drivers
This sub-page defines the 505DE hardware actuator driver settings.

Figure 4-5. Valve Actuators and Limiters Configuration Page

The valves are controlled from drivers that can either source between
4 and 20 mA or between 20 and 160 mA. These ranges are not absolute
maximum values and may be exceeded using the calibration settings. This may
result in a slight accuracy decrease. Refer to manual B91349V2 (505DE
Installation Manual) for the absolute maximum ratings.

All drivers have similar settings. They are presented here only once.

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Select 20-160 mA (high current)

Boolean
When False, the driver is configured for 4 – 20 mA operation. When True, the
driver is configured for 20 – 160 mA operation. Using currents slightly outside
these ranges is possible but not recommended.

This setting is a hardware setting. Hardware settings are special in the sense
that they are not adopted by the system until a reset or a power-down/power-up
cycle occurs. The preferred course of action with this type of settings is to adjust
them all, then press the “Save configuration to control” button, then wait a
minute, then reset the 505DE using the toggle switch on the CPU card in the
leftmost slot of the 505DE rack. If this value is adjusted, a start inhibit (“System
configuration – Power Cycle Required”) is activated that does not go away until
this action is done.

Valve current at 0%

Analog. Range: 0.0–24.0 [mA]

Analog. Range: 0.0–100.0 [mA]

These settings define the current that is transmitted to the actuator when the
valve demand is at 0%. The second range is used instead of the first if the
“Select 20-160 mA (high current)” setting is True.

Note that even with a reverse acting valve, the 0% position here refers to the
position with minimum current. Elsewhere, 0% may be referring to the other
position, depending on the reverse acting setting of the valves.

Valve current at 100%

Analog. Range: 4.0–24.0 [mA]

Analog. Range: 20.0–196.0 [mA]

These settings define the current that is transmitted to the actuator when the
valve demand is at 100%. The second range is used instead of the first if the
“Select 20-160 mA (high current)” setting is True.

Setting this value to 20 mA on a small current driver is highly recommended.

Note that even with a reverse acting valve, the 100% position here refers to the
position of maximum current. Elsewhere, 100% may be referring to the other
position, depending on the reverse acting setting of the valves.

Dithering amplitude

Analog. Range: 0.0–50.0 [mA]

Dithering is an operation where the DC control current is modulated with a 5 ms
pulse every 40 ms. This reduces stickiness that can be experienced on some
valve types. This setting defines the current amplitude of the dithering pulse. In
general this setting, if used, should be set so that you can only just feel vibration
with a bare hand on the valve casing. If dithering is not desired, set this value to
0 mA.

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Enable manual forcing

Boolean
Forcing setpoint

Analog. Range: –0.250–1.250 [/1]

Enables the forcing of the input to a chosen value on a 0 to 1 scale.
See “Forcing” in Chapter 3 for an explanation of forcing.

Valve stroking
Valve stroking allows the user to move the valve to any position between
minimum and maximum levels manually by simply stating the desired position.
This is useful during commissioning and maintenance of the installation. The
valve is disconnected from any internally generated demand, and only the
stroking demand determines the valve position. Note that the stroking demand is
the actual hardware demand. No linearization table corrections or reverse acting
corrections are performed.

To perform any valve stroking the following conditions must be met:

• There is no shutdown active.
• During a shutdown, all outputs actuator outputs are disabled and no
manipulation is possible.
• The turbine must be in the stopped state, i.e. the sequence step on the
bottom of the page reads “Turbine Systems Off”.
• The speed must be below the minimum detectable speed.

If stroking is activated and any of the above conditions is violated, stroking is

immediately ended, and the valves returned to their normal position. This might
happen if a start signal is received, or if the Trip and Throttle valve was
inadvertently left open. To guard against the latter, the state of the T&T valve is
shown on this page, or, if the 505DE has not been configured to know the state
of this valve, a warning is shown in red:

Figure 4-6. Warning to Check the T&T Valve When its Position is Not Known

If valve stroking is not enabled, this is visible in the window that pops up if you
click on the disabled/enabled box for a particular valve.

Figure 4-7. Stroking Not Available

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Clicking on the “Manual V1 demand” button, showing the stroking demand,
shows a pop-up window with a numerical keyboard, allowing you to change the
stroking demand. The valves move at a rate that is defined in the valve specific
configuration pages. The “V1 Demand RB” (read back) shows the current valve
position, based on the current as read back by the 505DE’s valve driver.

V1 Valve

Figure 4-8. V1 Valve Control Configuration Page

V1 is a reverse acting valve

Boolean
When False, the valve excitation current must increase to move the valve
towards the open position. When True, the excitation current must increase to
move the valve towards the closed position.

V1 manual stroke maximum rate

Analog. Range: 0.0–5000.0 [%/s]

This setting defines how fast the valve moves during stroking operations initiated
form either the configuration page or the operator page.

Interrupt V1 current output on ESD

Boolean
When True, the V1 excitation current path is interrupted (using a hardware
switch) while an ESD alarm is active, thus guaranteeing a zero excitation current.
When False, the V1 valve(s) are set according to the next two settings.

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V1 position during ESD (0% is min current)

Analog. Range: 0.0–100.0 [%]

This setting defines the demand that is sent to the valve while an Emergency
Shutdown is active. 0% indicates the position of minimum current as defined by
item “Valve current at 0%” in Actuators/Drivers above.

Valve Limiter
There is a manually controlled limiter associated with the V1 valves that limits
how far the V1 valve can open. Normally this limiter is disabled and tracks the
automatic V1 demand. These settings define how the limiter operates. If the
limiter is enabled, the actual V1 demand is the lower of the automatic (505DE)
valve demand and the limiter value.

Limiter release rate

Analog. Range: 0.0–100.0 [%/s]

This setting defines the rate at which valve demand changes back to the
automatic demand at disabling the limiter.

Limiter minimum setpoint

Analog. Range: 0.0–100.0 [%]

This setting defines the lowest value that the V1 limiter can be lowered to.

Limiter maximum setpoint

Analog. Range: 0.0–100.0 [%]

This setting defines the highest value that the V1 limiter can be raised to.

Limiter change rate

Analog. Range: 0.0–50.0 [%/s]

This setting defines how fast the limiter is raised or lowered at normal speed.

Limiter fast change rate

Analog. Range: 0.0–50.0 [%/s]

This setting defines how fast the limiter is raised or lowered at fast speed.

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V2 and V3 Valve

Figure 4-9. V2 and V3 Valve Control Configuration Page

The settings for the V2 and V3 valves are identical. V# is used here to indicate
either V2 or V3.

V# is a reverse acting valve

Boolean
When False, the valve excitation current must increase to move the valve
towards the open position. When True, the excitation current must increase to
move the valve towards the closed position.

V# manual stroke maximum rate

Analog. Range: 0.0–5000.0 [%/s]

This setting defines how fast the valve may move during stroking operations from
the configuration page or the operator pages.

Interrupt V# current output on ESD

Boolean
When True, the excitation current path is interrupted while an ESD alarm is
active, thus guaranteeing a zero excitation current. When False, the valve is set
according to the next settings.

V# position during ESD (0% is min current)

Analog. Range: 0.0–100.0 [%]

This setting defines the demand that is sent to the valve while an Emergency
Shutdown is active. 0% indicates the position of minimum current.
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V2/V3 limiters
There is a manually controlled limiter associated with each of the V2 and V3
valves that limits how far the V2/V3 valve can close. Normally this limiter is
disabled and tracks the valve demand. These settings define how the limiter
operates. If the limiter is enabled, the actual valve demand is the higher of the
automatic (505DE) valve demand and the limiter value.

Limiter release rate

Analog. Range: 0.0–100.0 [%/s]

This setting defines the rate at which valve demand changes back to the
automatic demand at disabling the limiter.

Limiter minimum setpoint

Analog. Range: 0.0–100.0 [%]

This setting defines the lowest demand that the valve limiter can be lowered to.

Limiter maximum setpoint

Analog. Range: 0.0–100.0 [%]

This setting defines the highest demand that valve limiter can be raised to.

Limiter change rate

Analog. Range: 0.0–100.0 [%/s]

This setting defines how fast the limiter is raised or lowered at normal speed.

Limiter fast change rate

Analog. Range: 0.0–100.0 [%/s]

This setting defines how fast the limiter is raised or lowered at fast speed.

Linearization Tables
It may be necessary to compensate for a non-linear valve characteristic, create a
non-linear valve characteristic with a linear valve, or compensate for over-travel
features of a particular valve. All this can help to make the steam map governed
responses of the 505DE fit to reality. The 505DE Principles Manual contains a
chapter on why to linearize and calibrate valves using the linearization tables and
how accuracy may influence control.

The linearization table pages are identical for all valves except for a reading at
the bottom. The identical configuration items present 11 (x, y) pairs that can be
changed to create the desired response curve. Note that no x values may be
duplicated and that the next x value must always be larger then the previous one,
i.e. x0 < x2 < …. < x10. The y values can be freely chosen.

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Figure 4-10. V1 Valve Linearization Page

If V1 is properly linearized, at 0% it should be at cracking point (i.e. about to let

steam flow), at 100% it should flow the amount of steam that corresponds to the
“Maximum inlet flow” setting on the steam map configuration page, and the
actual steam flow should rise linearly with valve demand in between. If this is the
case, S demand can be used to predict the generated power, especially if V2
and V3 are both fully opened (i.e. extraction is disabled). To facilitate linearizing
V1, the calculated load is presented on the V1 linearization pages, just above the
measured load: if these numbers are close (e.g. within 1% of full load) V1 is
flowing the required amount of steam at that working point according to the
steam map.

Once V1 is properly linearized up to the load where extraction cannot be

prevented, V2 can be linearized by comparing the HP extraction flow to the P1
demand. V2 at 0% means that the valve is flowing the minimum flow required to
cool the low pressure stages of the turbine. V2 at 100% means it is fully opened.
To facilitate linearizing V2, the calculated HP extraction flow is presented on the
V2 linearization page. As the 505DE generally is not connected to an HP
extraction flow transmitter, this number needs to be compared with a measured
extraction flow that is obtained elsewhere. If the calculated flow and the
measured flow are close (e.g. within 5% of maximum flow) V2 is flowing the
required amount of steam at that working point.

Likewise, V3 can be linearized, using the calculated LP extraction flow (displayed

on the V3 linearization page) as a guide.

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Analog Input Channels

These pages contain the settings for the analog 4–20 mA input channels.

Most channels have no fixed function. The function needs to be allocated to the
channel. As there are more functions than channels, some functions will not be
allocated to a channel, depending on the application.

The following functions are allocated to fixed channels:

Function Channel # HW Channel
Generator Active Load 1 A102-AI1
HP extraction pressure measured value 2 A102-AI2
HP extraction pressure setpoint 3 A102-AI3
LP extraction pressure measured value 4 A102-AI4
LP extraction pressure setpoint 5 A102-AI5

Allocating Functions to Channels

Figure 4-11. Allocating Functions to Channels Screen 1

All functions are allocated to channels on three sub-pages, “Inputs 1-6”, “Inputs
7-12” and “Inputs 13-16”. The channels are indicated with a channel number and
a hardware channel identification. Also on these sub-pages the channel’s input
current is indicated as a percentage in the 4-20 mA range: 0% means 4 mA,
100% means 20 mA.

These sub-pages provide an opportunity to correct low level channel calibration

errors and to force the channel (i.e. ignore the input current and provide a
manually chosen value to the software).

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The functional values attributed to 4 mA and 20 mA currents (calibrated in kPa,
% or something else) can be set on the 15 sub-pages for the analog input
functions.

If a measured value for a regulator is not assigned to a channel (or a fixed

channel is configured as not connected), the 505DE makes the regulator
unavailable.

If a remote analog setpoint for a regulator is not assigned to a channel (or a fixed
channel is configured as not connected), the setpoint can still be controlled by
hardwired discrete Raise/Lower inputs or by the HMI or customer Modbus® *
Raise/Lower inputs. The initial value of such remote analog setpoints is
configurable.
*—Modbus is a trademark of Modicon, Inc.

Function
This button opens a dialog from which the required function for this channel can
be selected. This button is not available on the first 5 channels with a fixed
function. If a channel is to remain without function, select the “Not used” option”.
There is no protection against selecting the same function for multiple channels.
In that case, the channel with the highest channel number receives the function,
and the other channels remain without a function.

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These are the functions:

Table 4-2. Analog Input Selection Options

Description Remarks
Not used This option is useful to prevent hardware failure alarms
originating from unconnected inputs.

A connected input with this option selected also results in a

hardware failure alarm.
Remote speed setpoint Only needed if internal setpoint generators are considered
insufficient
Remote S-aux1 setpoint
S-aux1 measured value The S-aux1 regulator can be used to limit the S demand from the
speed/load regulator, or to control the S demand.

If this option is not assigned to a channel, the S-aux1 regulator is

not available.
Remote S-aux2 setpoint
S-aux2 measured value The S-aux2 regulator can be used to limit the S demand from the
speed/load regulator, or to control the S demand.

If this option is not assigned to a channel, the S-aux2 regulator is

not available.
Remote S-aux3 setpoint
S-aux3 measured value The S-aux3 regulator can be used to limit the S demand from the
speed/load regulator, or to control the S demand.

If this option is not assigned to a channel, the S-aux3 regulator is

not available.
Remote cascade setpoint
Cascade measured value The cascade regulator can be used to provide the speed
regulator with a setpoint.

If this option is not assigned to a channel, the Cascade regulator

is not available.
Remote P1-aux setpoint
P1-aux measured value The P1-aux regulator can be used to limit the P1 demand from
the HP extraction pressure regulator, or to control the P1
demand.

If this option is not assigned to a channel, the P1-aux regulator is

not available.
Remote P2-aux setpoint
P2-aux measured value The P2-aux regulator can be used to limit the P2 demand from
the LP extraction pressure regulator, or to control the P1 demand.
If this option is not assigned to a channel, the P2-aux regulator is
not available.
Remote extra PID setpoint .
Extra PID measured value The Extra PID can be used as an independent controller.

If this option is not assigned to a channel, the extra regulator is

not available.
Heat soakage level The heat soakage level determines the interpolation between the
cold and the hot engine start-up timing.
Synchronizing Used for separate synchronizer devices with an analog output
Loadsharing input Used for separate load sensing devices with an analog load
biasing output
Sync/Load share input Used for devices with a combined synchronizer/loadsharing bias
analog output, such as Woodward’s DSLC.

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If both the Synchronizer/Loadshare function is selected for one channel and
Loadshare for another channel, the Synchronizer/Loadshare is used during
loaded operation instead of the Loadshare function. This is not useful and should
be avoided.

If both the Synchronizer/Loadshare function is selected for one channel and

Synchronizer function for another channel, both synchronizer signals are added
and used as the sync speed offset during synchronizing. This is not useful and
should be avoided.

Item is connected to hardware

Boolean
This setting is available on the fixed channels only. It can be used to indicate that
the channel is connected to a transmitter or not. If this setting is True and no
transmitter is present, a hardware error is generated. If this setting is False and a
transmitter is present, the same hardware error is generated.

If this setting is false on either “HP extraction pressure measured value” or LP

extraction pressure measured value”, the corresponding extraction pressure
regulator is not available.

Calibration gain factor

Analog. Range: 0.9–1.1 [–]

This factor can be used to compensate for errors in either the transmitter or the
505DE where the full range span no longer corresponds to 16 mA. This can be
detected if a calibrated 4 mA current generates the value set as 4mA value, while
a calibrated 20mA current does not generate the correct value.

Calibration offset

Analog. Range: –0.1–0.1 [/1]

This offset can be used to compensate for errors in either the transmitter or the
505DE where the minimum reading is no longer 4 mA. This can be detected if a
calibrated 4 mA current does not generate the value set as 4mA value.

Enable manual forcing

Boolean
Forcing setpoint

Analog. Range: –0.25–1.25 [/1]

Enables the forcing of the input to a chosen value.

At the hardware level, 4 mA is mapped to 0, while 20 mA is mapped to 1. Thus a

range of –0.25 to 1.25 coincides with 0 to 24 mA. On the function pages, the
4mA and 20 mA are calibrated to Engineering Units. Forcing takes place on the
hardware level. Forcing is inhibited when the turbine is not in the “Turbine
Systems Off” sequence state.

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Analog Input Function Settings

Figure 4-12. S-aux1 Setpoint/Measured Value Input Channel Configuration Page

All analog input functions have their own sub-page button. There are usually two
functions per sub-page. This section lists all the settings for all functions.

If a channel has not been allocated to a function, or it is configured as not

connected, the function’s settings are not available (see for instance the Remote
S-aux1 setpoint in Figure 4-12). If both channels on a sub-page are not available,
its button is grayed (like the “S-aux3 sp & mv” button in Figure 4-12) and the
entire page is not available.

Measured value at 4 mA
Analog
This setting defines the measured value that is read when the transmitter carries
a 4 mA current.

On the Loadsharing channel, the calibration is fixed at –1. On the Loadsharing/

Synchronizer channel, this setting defines the synchronizer calibration: the
loadsharing calibration is –1.

Measured value at 20 mA
Analog
This setting defines the measured value that is read when the transmitter carries
a 20 mA current.

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The ranges between which the calibration can be changed is shown in the next
table. Note that the loadsharing range is fixed, and that the
loadsharing/synchronizer range shows the calibration range for the synchronizer
function only, while the loadsharing range is fixed at –1 to 1. If you have imperial
units displayed, the range is converted accordingly. The shown units cannot be
changed other than changing between SI and imperial units.

Table 4-3. Ranges of Calibration and Alarm Level Settings On Analog Input
Channels

Description Min Max Unit Min Max Unit

Load input –100.0 500.0 MW
Remote speed setpoint 0.0 20000.0 rpm
P1 external setpoint –100.0 10000.0 kPa –14.50 1450 psi
P1 process value –100.0 10000.0 kPa –14.50 1450 psi
P2 external setpoint –100.0 10000.0 kPa –14.50 1450 psi
P2 process value –100.0 10000.0 kPa –14.50 1450 psi
S-aux1 measured value –10.0 110.0 %
Remote S-aux1 setpoint –10.0 110.0 %
S-aux2 measured value –10.0 110.0 %
Remote S-aux2 setpoint –10.0 110.0 %
S-aux3 measured value –10.0 110.0 %
Remote S-aux3 setpoint –10.0 110.0 %
Cascade measured value –10.0 110.0 %
Remote cascade setpoint –10.0 110.0 %
Remote P1-aux setpoint –10.0 110.0 %
P1-aux measured value –10.0 110.0 %
Remote P2-aux setpoint –10.0 110.0 %
P2-aux measured value –10.0 110.0 %
Loadsharing input (fixed calibration) –1 1 –
Synchronizing –500.0 500.0 rpm
Sync/Load share input –500.0 500.0 rpm
Heat soakage level –10.0 110.0 %
Remote extra PID setpoint –10.0 110.0 %
Extra PID measured value –10.0 110.0 %

Filter time constant

Analog. Range: 0.0–100.0 [s]

All analog channels have a low-pass filter that can be used to reduce unwanted
fast transients. This could be used to reduce the effect of electro-magnetic
disturbances (although better wiring practices would probably give better results).
The setting defines the time constant Tau of a single-pole low-pass filter.

The following settings allow the Engineer to set up alarms H1 and H2 above
which an alarm can be triggered, and alarms L1 and L2 below which an alarm
can be triggered. All alarms can be disabled. They are all warning alarms that
cause a message to appear on the HMI, on the customer Modbus and on the
event printer. The ranges between which the alarm levels can be configured
coincide with the calibration ranges as given in Table 4-3.

There is an exception to the general rule on the Active Load alarms: The L2 level
is fixed at 0 kW. The L1 level is configurable. The inhibit of these signals is fixed,
and active while the generator breaker is open, until 30 seconds after closing it.

The alarm levels for “Frequency” can be found on the speed process value
pages (Critical Speeds below)

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H1/H2/L1/L2 alarm inhibit
Boolean
When False, the alarm is active. When True, the alarm is ignored.

H1/H2 alarm level

Analog
These settings define the alarm levels above which an alarm is triggered, if it is
not inhibited.

L1/L2 alarm level

Analog
These settings define the alarm levels below which an alarm is triggered, if it is
not inhibited.

Analog Readout Channels

All eight configurable analog output channels have similar settings.

Figure 4-13. Analog Output Channel Configuration Page

Select
This button opens a dialog from which the required function for this channel can
be selected. If a channel is to remain without function, select the “Do not use”
option”. There is no protection against selecting the same function for multiple
channels. In that case, those channels will be outputting the same signal,
possibly with different calibrations.

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Figure 4-14. Analog Output Channel Function Selection Dialog

Table 4-4 shows the functions that are available for selection. When a function is
assigned to a channel, it is displayed next to the “Select” button.

Table 4-4. Analog Output Selection Options

Description Remarks
Not used This option is useful to prevent hardware failure alarms
originating from unconnected outputs.
Actual speed
Speed setpoint This setpoint is the actual speed regulator setpoint after load
correction in droop operation.
Generator load The measured or (during a signal failure) calculated generator
load.
Active load setpoint The load setpoint. This value reads 0 when not in droop or kW
mode.
S-aux1 setpoint The S-aux1 regulator setpoint before application of droop
correction.
S-aux1 measured value
S-aux2 setpoint The S-aux2 regulator setpoint before application of droop
correction.
S-aux2 measured value
S-aux3 setpoint The S-aux3 regulator setpoint before application of droop
correction.
S-aux3 measured value
Cascade setpoint The cascaded regulator setpoint before application of droop
correction.
Cascade measured value
Cascade demand Cascade regulator demand to the speed/load regulator before
conversion to kW/rpm and before limiting.

The result of the cascade regulation, as presented to the speed

regulator as a setpoint, before it is converted to kW or rpm and
before limiting.

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Description Remarks
P1 setpoint The HP extraction pressure regulator setpoint before application
of droop correction.
P1 measured value
P1-aux setpoint The P1-aux regulator setpoint before application of droop
correction.
P1-aux measure value
P2 setpoint The LP extraction pressure regulator setpoint before application
of droop correction.
P2 measured value
P2-aux setpoint The P2-aux regulator setpoint before application of droop
correction.
P2-aux measure value
S demand The S demand after S-aux1/2/3 limiting, before steam-map
limiting
P1 demand The P1 demand after P1-aux limiting, before steam-map limiting
P2 demand The P2 demand after P2-aux limiting, before steam-map limiting
V1 demand from map The valve demand as the steam map calculates it (when
loaded) or according to the speed regulator (while starting). This
is before load step compensation and before limiting.
V2 demand from map The valve V2 demand as the steam map calculates it. This is
before limiting and excluding all movements during start.
V3 demand from map The valve V3 demand as the steam map calculates it. This is
before limiting and excluding all movements during start.
V1 limiter setpoint The value of the limiter that sets a maximum on V1, if enabled
V2 limiter setpoint The value of the limiter that sets a minimum on V2, if enabled
V3 limiter setpoint The value of the limiter that sets a minimum on V3, if enabled
Extra PID setpoint The extra regulator setpoint before application of droop
correction.
Extra PID measured value
Extra PID loop demand Selecting this output and connecting it to something that
influences the Extra PID measured value is the only way to use
this regulator.
Casing heat soakage [%] Current heat soakage percentage. This may be the calculated
heat soakage if so configured.
Synchronizer/loadshare speed Combined bias signal from synchronizer and load sharing
bias device, also if separate inputs are used.
Ladderlogic Analog Output #1 User programmable output (Ladder Logic option required)
Ladderlogic Analog Output #2 User programmable output (Ladder Logic option required)
Ladderlogic Analog Output #3 User programmable output (Ladder Logic option required)
Ladderlogic Analog Output #4 User programmable output (Ladder Logic option required)
Ladderlogic Analog Output #5 User programmable output (Ladder Logic option required)
Ladderlogic Analog Output #6 User programmable output (Ladder Logic option required)
Ladderlogic Analog Output #7 User programmable output (Ladder Logic option required)
Ladderlogic Analog Output #8 User programmable output (Ladder Logic option required)

Signal value for 4 mA output

Analog. Range: –32000.0–32000.0 [EU]

This setting defines the signal value that corresponds to a 4 mA output current.
These readings are in “EU” (Engineering Units). The actual unit is in the function
description for the channel at the top the configuration box. It is not possible to
convert pressures into another unit for calibration. The Configurator should
convert the desired range to the indicated SI units and enter those values here.
The configuration box continuously shows the channel output, as a percentage of
the 4-20mA range (0% is 4mA, 100% is 20 mA).

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Signal value for 20 mA output

Analog. Range: –32000.0–32000.0 [EU]

This setting defines the signal value that corresponds to a 20 mA output current.
These readings are in “EU” (Engineering Units). The actual unit is in the function
description for the channel at the top the configuration box. It is not possible to
convert pressures into another unit for calibration. The Configurator should
convert the desired range to the indicated SI units and enter those values here.

Calibration gain factor

Analog. Range: 0.0–2.0 [–]

This factor can be used to compensate for errors in either the actuator or the
505DE hardware calibration where the full range signal value change no longer
corresponds to a 16 mA current change. This can be detected if a signal value,
configured to generate 4 mA, does indeed generate 4 mA while a signal value,
configured to generate 20 mA, does not actually generate 20 mA.

Calibration offset
This offset can be used to compensate for errors in either the actuator or the
505DE hardware calibration where the signal value to generate 4 mA does not
actually generate the intended 4 mA.

Enable manual forcing

Boolean
Forcing setpoint

Analog. Range: –0.25–1.25 [/1]

Enables the forcing of the input to a chosen value. This value is always in the 0–
1 range, irrespective of the signal being carried, where 0 corresponds to 4 mA
and 1 corresponds to 20 mA.

Contact Input Channels

These pages contain the settings for the discrete contact input channels.

The first 6 contact input channels have a fixed function. The other 42 contact
inputs channels need to have a function allocated to them. As there are more
functions than available channels, not all functions can be used in the same
configuration. The following tables contain the functions for the discrete inputs.
The “Remarks” indicate the consequences of an alarm, if any, if the DI channel
has its alarm enabled and fired. See the 505DE Operators Manual for a
description of the alarm processing.

If the alarm is indicated to have “no effect”, this is true only for the alarm that is
tied immediately to the contact input. There may be effects, caused by the
contact input, that have alarms of their own, independent of the contact input
alarm.

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Table 4-5. Fixed Contact Input Channels

Description Remarks
Generator breaker closed This input informs the 505DE that the generator breaker is
A104-DI1 closed. This controls, for example, the 505DE’s ability to enter
load control modes (Droop, kW-control) or to share load.

The alarm of this input (at the “generator breaker open” level)
immediately shuts down all extraction.
Utility tie breaker (grid breaker) This input informs the 505DE that there is a speed controlling
closed device on the connected power network. If so, speed control
A104-DI2 modes (isochronous and loadsharing) are abandoned. The
configured priority is active instead of S demand having the
priority.

If so configured on the stop sequence page (0), the alarm of this

input (at tie breaker open) immediately shuts down all extraction.
External Emergency Shutdown The alarm of this input causes an Emergency Shutdown. After
A104-DI3 deactivating this input, a Reset is required to resume normal
operation.
Reset This input requests an alarm reset to be performed. All alarms
A104-DI4 whose cause have disappeared, are reset, and their
annunciations are ended. The other alarms, whose causes are
still present, remain unaffected.

The alarm of this input is registered as an event on alarm bus 7.

Note that you need an HMI or customer Modbus reset pulse to
reset this alarm.
Start This input initiates a start sequence, or aborts a stop sequence.
A104-DI5
The alarm of this input is registered as an event on alarm bus 7.
Stop This input initiates a stop sequence, or aborts a start sequence.
A104-DI6
The alarm of this input is registered as an event on alarm bus 7.

Table 4-6. Locatable Contact Input Functions

Description Remarks
Not used Selection for any unused input
Lower speed/load setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

The alarm of this input is registered as an event on alarm bus 7.

Raise speed/load setpoint The movement continues as long as the input is active. This input
functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising. The alarm of this input
is registered as an event on alarm bus 7.
Enable remote speed setpoint This input enables/disables the use of the configurable analog
input “Remote speed setpoint”. Disabling this input reverts the
setpoint generation to the otherwise available methods.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

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 505DE Configuration Manual Manual 91349V4
Description Remarks
Enable speed PID on S LSS This input allows the speed regulator to limit the values of the
bus other regulators on the Lower Signal Selection bus for the S
demand. If the speed regulator is configured as a controller, it
disables the other controllers on the S demand LSS bus.

A configured alarm has no effect.

Lower HP extraction setpoint / The movement continues as long as the input is active.
P1 demand
This input functions in parallel to the HMI and DCS Modbus
inputs.

If the HP extraction regulator is in manual control, this input

adjusts the manual demand of the regulator. If the HP regulator is
not in manual control, this input adjusts the setpoint to the
regulator.

A configured alarm has no effect.

Raise HP extraction setpoint / The movement continues as long as the input is active. This input
P1 demand functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising.

If the HP extraction regulator is in manual control, this input

adjusts the manual demand of the regulator. If the HP regulator is
not in manual control, this input adjusts the setpoint to the
regulator.

A configured alarm has no effect.

Enable remote HP extraction This input enables/disables the use of the configurable analog
setpoint input “Remote HP extraction setpoint”. Disabling this input reverts
the setpoint generation to the otherwise available methods.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Toggle HP extraction Enable or disable HP extraction. This signal should be pulsed for
at least 320 ms. There is no strict upper limit.

A configured alarm has no effect.

Enable P1 PID on P1 LSS bus This input allows the HP extraction regulator to limit the values of
the other regulator on the Lower Signal Selection bus for the P1
demand. If both regulators are configured as a controller, it
disables the other controller on the P1 demand LSS bus.

A configured alarm has no effect.

Enable manual P1 demand This input switches the HP regulator to manual mode and brings
control the HP extraction controller’s demand directly under authority of
the HP Raise/Lower inputs.

A configured alarm has no effect.

Lower LP extraction setpoint / The movement continues as long as the input is active.
P2 demand
This input functions in parallel to the HMI and DCS Modbus
inputs.

If the LP extraction regulator is in manual control, this input

adjusts the manual demand of the regulator. If the LP extraction
regulator is not in manual control, this input adjusts the setpoint to
the regulator.

A configured alarm has no effect.

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Description Remarks
Raise LP extraction setpoint / The movement continues as long as the input is active. This input
P2 demand functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising.

If the LP extraction regulator is in manual control, this input

adjusts the manual demand of the regulator. If the LP extraction
regulator is not in manual control, this input adjusts the setpoint to
the regulator.

A configured alarm has no effect..

Enable remote LP extraction This input enables/disables the use of the configurable analog
setpoint input “Remote LP extraction setpoint”. Disabling this input reverts
the setpoint generation to the otherwise available methods.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Toggle LP extraction Enable or disable LP extraction. This signal should be pulsed for
at least 320 ms. There is no strict upper limit.

A configured alarm has no effect..

Enable P2 PID on P2 LSS bus This input allows the LP extraction regulator to limit the values of
the other regulator on the Lower Signal Selection bus for the P2
demand. If both regulators are configured as a controller, it
disables the other controller on the P2 demand LSS bus.

A configured alarm has no effect.

Enable manual P2 demand This input switches the LP regulator to manual mode and brings
control the LP extraction controller’s demand directly under authority of
the LP Raise/Lower inputs.

A configured alarm has no effect.

Lower S-aux1 setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

A configured alarm has no effect.

Raise S-aux1 setpoint The movement continues as long as the input is active. This input
functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising.

A configured alarm has no effect.

Enable remote S-aux1 This input enables/disables the use of the configurable analog
setpoint input “Remote S-aux1 setpoint”.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Enable S-aux1 This input allows the S-aux1 regulator to limit the values of the
other regulators on the Lower Signal Selection bus for the S
demand. If the S-aux1 regulator is configured as a controller, it
disables the other controllers on the S demand LSS bus.

A configured alarm has no effect.

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Description Remarks
Lower S-aux2 setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

A configured alarm has no effect.

Raise S-aux2 setpoint The movement continues as long as the input is active. This input
functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising.

A configured alarm has no effect.

Enable external S-aux2 This input enables/disables the use of the configurable analog
setpoint input “Remote S-aux2 setpoint”.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Enable S-aux2 This input allows the S-aux2 regulator to limit the values of the
other regulators on the Lower Signal Selection bus for the S
demand. If the S-aux2 regulator is configured as a controller, it
disables the other controllers on the S demand LSS bus.

A configured alarm has no effect.

Lower S-aux3 setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

A configured alarm has no effect.

Raise S-aux3 setpoint The movement continues as long as the input is active. This input
functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising.

A configured alarm has no effect.

Enable external S-aux3 This input enables/disables the use of the configurable analog
setpoint input “Remote S-aux3 setpoint”.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Enable S-aux3 This input allows the S-aux3 regulator to limit the values of the
other regulators on the Lower Signal Selection bus for the S
demand. If the S-aux3 regulator is configured as a controller, it
disables the other controllers on the S demand LSS bus.

A configured alarm has no effect.

Lower cascade setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

A configured alarm has no effect.

Raise cascade setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

A configured alarm has no effect.

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Description Remarks
Enable remote cascade This input enables/disables the use of the configurable analog
setpoint input “Remote cascade setpoint”.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Lower P1-aux setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

A configured alarm has no effect.

Raise P1-aux setpoint The movement continues as long as the input is active. This input
functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising.

A configured alarm has no effect.

Enable external P1-aux This input enables/disables the use of the configurable analog
setpoint input “Remote P1-aux setpoint”.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Enable P1-aux This input allows the P1-aux regulator to limit the values of the
other regulator on the Lower Signal Selection for the P1 demand.
If both regulators are configured as a controller, it disables the
other controller on the P1 demand LSS bus.

A configured alarm has no effect.

Lower P2-aux setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

A configured alarm has no effect.

Raise P2-aux setpoint The movement continues as long as the input is active. This input
functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising.

A configured alarm has no effect.

Enable external P2-aux This input enables/disables the use of the configurable analog
setpoint input “Remote P2-aux setpoint”.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Enable P2-aux This input allows the P2-aux regulator to limit the values of the
other regulator on the Lower Signal Selection for the P2 demand.
If both regulators are configured as a controller, it disables the
other controller on the P2 demand LSS bus.

A configured alarm has no effect.

Lower extra PID setpoint The movement continues as long as the input is active.

This input functions in parallel to the HMI and DCS Modbus

inputs.

A configured alarm has no effect.

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Description Remarks
Raise extra PID setpoint The movement continues as long as the input is active. This input
functions in parallel to the HMI and DCS Modbus inputs.
Lowering takes precedence over raising.

A configured alarm has no effect.

Enable external extra PID This input enables/disables using the configurable analog input
setpoint “Remote extra PID setpoint”.

If the analog input is configured, but this contact input is not, the
analog input is enabled from the HMI but not it can only be
disabled by a channel fault.

A configured alarm has no effect.

Select operating mode Manual When pulsed, this signal puts the 505DE in the Manual Mode, if
that mode is allowed. Refer to the Operator Manual for a
description of Operation Modes.

This signal should be pulsed for at least 320 ms. There is no

strict upper limit.

A configured alarm has no effect.

Select operating mode Semi- When pulsed, this signal puts the 505DE in Semi Automatic
automatic Mode, if that mode is allowed. Refer to the Operator Manual for a
description of Operation Modes.

This signal should be pulsed for at least 320 ms. There is no

strict upper limit.

A configured alarm has no effect.

Select operating mode Full When pulsed, this signal puts the 505DE in Full Automatic Mode,
automatic if that mode is allowed. Refer to the Operator Manual for a
description of Operation Modes.

This signal should be pulsed for at least 320 ms. There is no

strict upper limit.

A configured alarm has no effect.

Hold sequence This input freezes the Full Automatic start sequence: the speed
setpoint stops changing (except within a critical band), and timers
run to completion but cause no action on time-out.

The alarm of this input is registered as an event on alarm bus 7

and is a start inhibit.
Enable alternate priority This input selects the secondary priority setting instead of the
primary priority setting.

The alarm of this input is registered as an event on alarm bus 7.

Enable overspeed test This input can be used to remotely enable overspeed testing.
This can also be done on the HMI. The generator breaker must
be open for overspeed testing. Once overspeed testing is
enabled, it expires within 60 seconds after the last Raise or Lower
input (hardware or HMI) action, or whenever the contact input is
inactivated. Make sure to have the speed below the normal trip
level by that time, or an overspeed trip will occur.

A configured alarm has no effect.

Disable DCS Modbus - Local When this input is True, the DCS Modbus is prevented from
control giving an input to the 505DE. The local HMI and the hardware
inputs are the only means of control at that time. When this input
is False, all stations (DCS, HMI, hardware) can control the
505DE.

The alarm of this input is registered as an event on alarm bus 7.

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Description Remarks
Kill Horn When pulsed, this input resets the various “Horn” outputs. If real
horns are attached, these are silenced. (refer to Relay Output
Channels below)

A configured alarm has no effect.

T&T valve closed This input causes the display of the T&T valve on the HMI to
show the valve position. There is no further control action related
to this function. If this input is not configured, the valve is always
shown open.

The alarm of this input is registered as an event on alarm bus 7.

Override MPU faults in semi- If a semi-automatic start is issued, a timer is started. If the timer
auto starts expires, and the speed drops below minimum control speed, an
Emergency Shutdown is issued. This input prevents this
Emergency Shutdown while active. It can be used to allow for bad
boiler pressure or similar problems during a semi-automatic start.

A configured alarm has no effect.

Time synchronization pulse This input allows an external timekeeper to synchronize the
505DE and the connected HMI to a certain time of day, every 24
hours. The time of day to synchronize to is configurable.

A configured alarm has no effect.

Select isochronous control This input selects isochronous control mode, if isochronous
mode control mode is a valid control mode at that time (e.g. utility tie
breaker is open). If the input is released again, the control mode
stays active until another selection is made by another contact or
through the HMI or the customer Modbus.

The alarm of this input is registered as an event on alarm bus 7.

Select loadsharing control This input selects loadsharing control mode, if loadsharing control
mode mode is a valid control mode at that time (e.g. there is a valid
load bias input). If the input is released again, the control mode
stays active until another selection is made by another contact or
through the HMI or the customer Modbus.

The alarm of this input is registered as an event on alarm bus 7.

Select droop control mode This selects droop control mode, if droop control mode is a valid
control mode at that time. If the input is released again, the
control mode stays active until another selection is made by
another contact or through the HMI or the customer Modbus.

The alarm of this input is registered as an event on alarm bus 7.

Select kW control mode This selects kW control mode, if kW control mode is a valid
control mode at that time. If the input is released again, the
control mode stays active until another selection is made by
another contact or through the HMI or the customer Modbus.

The alarm of this input is registered as an event on alarm bus 7.

Select cascade control mode A rising edge on this input selects cascade control mode, if
cascade control mode is a valid control mode at that time. If the
input is released again, the control mode stays active until
another selection is made by another contact or through the HMI
or the customer Modbus.

The alarm of this input is registered as an event on alarm bus 7.

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Description Remarks
Select droop in island mode When this input is False and the Grid Breaker is open, the 505DE
regulates speed in Isochronous Mode or Loadsharing Mode.
When this input is True, the 505DE regulates speed in Droop or
kW Mode regardless of the grid breaker position.

This is useful if there is some speed regulating device on the

island network, such as a swing machine or an overall regulating
device that uses all generators in droop to maintain island speed.

The alarm of this input is registered as an event on alarm bus 7.

Lower V1 limit This input lowers the V1 limiter’s value. The V1 limiter puts a
maximum on the V1 opening.

The alarm of this input is registered as an event on alarm bus 7.

Raise V1 limit This input raises the V1 limiter’s value. The V1 limiter puts a
maximum on the V1 opening.

The alarm of this input is registered as an event on alarm bus 7.

Lower V2 limit This input lowers the V2 limiter’s value. The V2 limiter puts a
minimum on the V2 opening.

The alarm of this input is registered as an event on alarm bus 7.

Raise V2 limit This input raises the V2 limiter’s value. The V2 limiter puts a
minimum on the V2 opening.

The alarm of this input is registered as an event on alarm bus 7.

Lower V3 limit This input lowers the V3 limiter’s value. The V3 limiter puts a
minimum on the V3 opening.

The alarm of this input is registered as an event on alarm bus 7.

Raise V3 limit This input raises the V3 limiter’s value. The V3 limiter puts a
minimum on the V3 opening.

The alarm of this input is registered as an event on alarm bus 7.

Remote Decel to Min Load The alarm of this input causes a Decel to Minimum Load alarm,
alarm that causes the 505DE to go to minimum load, if it is running in
Droop or kW mode. After deactivating this input, a Reset is
needed to resume normal operation.
Remote Full Speed No Load The alarm of this input causes a Full Speed No Load alarm, that
alarm causes the 505DE to instantly request the generator breaker to
open and remain running at sync speed. After deactivating this
input, a Reset is needed to resume normal operation.
Remote HP extraction The alarm of this input instantly disables HP extraction. After
emergency stop deactivating this input, a Reset is needed to resume normal
operation.
Remote LP extraction The alarm of this input instantly disables LP extraction. After
emergency stop deactivating this input, a Reset is needed to resume normal
operation.
Remote start permissive While the alarm level of this input is active, a start request is
ignored. A reset is not needed.
Remote synchronization While the alarm of this input is active, the sequence will not
permissive attempt to synchronize. A reset is not needed.
Remote loading permissive While the alarm of this input is active, any raise commands in
Droop or kW mode are ignored. Load is not reduced because of
this input. A reset is not needed.
Remote HP extraction While the alarm of this input is active, any HP extraction enable
permissive command is ignored. Running HP extractions are not affected. A
reset is not needed.
Remote LP extraction While the alarm of this input is active, any LP extraction enable
permissive command is ignored. Running LP extractions are not affected. A
reset is not needed.
Customer alarm #1 The alarms of these inputs cause an alarm on alarm bus 1 and
Customer alarm #2 thus alarm message to be displayed in all appropriate places.
Customer alarm #3 The DCS Modbus also carries this alarm.

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Description Remarks
Customer alarm #4
Customer alarm #5
Customer alarm #6
Customer alarm #7
Customer alarm #8
Customer ESD #1 The alarms of these inputs cause an Emergency Shutdown. After
Customer ESD #2 deactivating this input, a Reset is required to resume normal
Customer ESD #3 operation.
Customer ESD #4
Customer ESD #5
Customer ESD #6
Customer ESD #7
Customer ESD #8

Channel Settings
All channels feature an indication of the position of the physical contact on the
input. Whenever the input contact is open, the yellow light is not shown and the
word “Open” is shown. Whenever the input contact is closed, the yellow light and
the word “Closed” are shown. If there is not an actual contact, but another means
of controlling the discrete input, a high voltage or current represents a closed
contact, while a low voltage or current represents an open contact. For more
information on the contacts, please refer to the 505DE Installation Manual.

Figure 4-15. Contact Input Settings

Most channels have the same settings. On a few channels, some settings are
missing.

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Function
This button opens a dialog from which the required function for this channel can
be selected. This button is not available on the first 6 channels with a fixed
function. If a channel is to remain without function, select the “Not used” option”.
There is no protection against selecting the same function for multiple channels.
In that case, the channel with the highest channel number receives the function,
and the other channels remain without a function.

Invert hardware level

Boolean
Contact input channels have a True or a False value. The meaning of True or
False depends on the formulation of the function of the channel. For instance,
the function “Generator breaker closed” implies that a True value of the channel
means that the generator breaker is closed.

When this setting is False, the value of the signal is True when the input contact
is closed. When this setting is True, the value of the signal is True when the input
contact is opened.

Usually, Raise and Lower signals need a False at this setting (a closed contact
generates a True channel value, indicating active Raise and Lower), while
signals like Emergency Shutdown need a True here to provide an active signal at
wire disconnect.

Alarm override

Boolean
When True, this signal can never cause an alarm. When False, this signal can
cause an alarm, subject to the settings below. The alarms on the Generator
Breaker and Grid Breaker cannot be disabled. Many functions do not have any
alarm associated with them: in those cases enabling the alarm has no
consequence. See Tables 4.5 and 4.6 to check if a signal has an alarm and if so,
what the alarm does.

Alarm level

Boolean
If this setting is False and “Alarm override” is False, an alarm is issued when the
channel value is False. If this setting is True and “Alarm override” is False, an
alarm is issued when the channel value is True.

Alarm delay

Analog. Range: 0.0–10.0 [s]

This setting defines the minimum time that the signal must be at the alarm level
before the alarm is triggered.

Enable manual forcing

Boolean
Forcing setpoint

Boolean
Enables forcing of the input to a chosen value.

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Relay Output Channels

These pages contain the settings for the discrete relay output channels. All
outputs have a normally closed and a normally open contact.

Most channels have no fixed function. The function needs to be allocated to the
channel. There are 4 relay output channels with a fixed function. The other 20
relay output channels need to have a function allocated to them. As there are
more functions than available channels, not all functions can be used in the
same configuration. The following tables contain the functions for the discrete
outputs.

Table 4-7. Contact Relay Outputs: Fixed Channels

Description Remarks
Ready to synchronize This output indicates to an operator or automatic synchronizer
(channel 1) that the 505DE is ready to accept its input, and for the
generator breaker to close.
Warning alarm active A warning alarm (an alarm on alarm bus 1) is active.
(channel 2)
See the 505DE Operator Manual for a discussion on alarm
busses.
Breaker open request The 505DE is waiting for the breaker to be opened. This output
(channel 3) could be tied into the circuitry opening the generator breaker.
Emergency Shutdown active There is an Emergency Shutdown alarm (an alarm on alarm
(channel 4) bus 5) active in the 505DE. There are some exceptions: that
are controlled by the extra settings that can be found at the
configuration page for this relay. When activated, the T&T valve
should be immediately closed. This output could be made to
interrupt current to the T&T valve, such that it closes as quickly
as possible.

Table 4-8. Contact Relay Outputs: Selectable Functions

Description Remarks
Not Used Selection for any unused output
S demand at maximum or S demand is being limited because of a steam map constraint.
minimum limit
P1 demand at maximum or P1 demand is being limited because of a steam map constraint.
minimum limit
P2 demand at maximum or P2 demand is being limited because of a steam map constraint.
minimum limit
Inlet decoupled V1 is decoupled and tied to the S demand
Exhaust decoupled V3 is decoupled and tied to either S or P2 demand. See the
505DE Principles Manual for a discussion on decoupling.
V1 limiter active (i.e. not The limiters on these valves have been activated and are under
tracking) operator or contact input control. If this output is False, the limiter
V2 limiter active (i.e. not is tracking the demand from the 505DE.
tracking)
V3 limiter active (i.e. not
tracking)
Secondary priority selected This output indicates which of the two available priority settings is
active. See “Priority and Decoupling” below for a discussion of
secondary priority.
Time sync pulse This pulse is issued once every 24 hours and can be used to
synchronize external devices to 505DE time. The time of day of
this pulse can be configured.
Reset relay output This output is pulsed for a configurable time period at every
Reset from any source.
Manual mode selected Operating Mode “Manual” is active.

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Description Remarks
Semi automatic mode selected Operating Mode “Semi Automatic” is active.
Automatic mode selected Operating Mode “Full Automatic” is active.
Start in progress The turbine is starting.
Start inhibit active At least one start inhibit is active.
Speed in any critical band The speed is dwelling in one of the critical bands.
Hold active The start sequence is on hold.
P1 extraction enabled HP extraction is starting or active.
P2 extraction enabled LP extraction is starting or active.
Stop in progress The turbine is stopping.
Coastdown active The turbine is coasting down to zero rpm.

This output is not active if it is configured to allow a restart during

coastdown.
Remote speed setpoint active The external speed setpoint is controlling the speed/load setpoint.
Isochronous mode active The 505DE is running in Isochronous control mode.
Loadshare mode active The 505DE is running in Load Sharing control mode.
kW control active The 505DE is running in kW control mode.
Droop mode active The 505DE is running in Droop control mode.
Cascade mode active The speed/load regulator’s setpoint is provided by the cascade
PID.
S-aux1 enabled as limiter The S-aux1 regulator is allowed to limit S demand.
S-aux2 enabled as limiter The S-aux2 regulator is allowed to limit S demand.
S-aux3 enabled as limiter The S-aux3 regulator is allowed to limit S demand.
P1-aux enabled as limiter The P1-aux regulator is allowed to limit P1 demand.
P2-aux enabled as limiter The P2-aux regulator is allowed to limit P2 demand.
S PID in control The speed regulator controls S demand.

At all times at least one signal in the group of signals between “S

PID in control” and “Start ramp in control” is active.
S-aux1 PID in control The S-aux1 regulator controls S demand.

At all times at least one signal in the group of signals between “S

PID in control” and “Start ramp in control” is active.
S-aux2 PID in control The S-aux2 regulator controls S demand.

At all times at least one signal in the group of signals between “S

PID in control” and “Start ramp in control” is active.
S-aux3 PID in control The S-aux3 regulator controls S demand.

At all times at least one signal in the group of signals between “S

PID in control” and “Start ramp in control” is active.
System Off in control The S demand is switched to 0.

At all times at least one signal in the group of signals between “S

PID in control” and “Start ramp in control” is active.
Start-ramp in control The S demand is controlled by the start sequence.

At all times at least one signal in the group of signals between “S

PID in control” and “Start ramp in control” is active.
P1 PID in control The HP extraction regulator controls P1 demand.

At all times at least one of the signals “P1 PID in control” and
“P1-aux PID in control” is active.
P1-aux PID in control The P1-aux regulator controls P1 demand.

At all times at least one of the signals “P1 PID in control” and
“P1-aux PID in control” is active.
P2 PID in control The LP extraction regulator controls P2 demand.

At all times at least one of the signals “P2 PID in control” and
“P2-aux PID in control” is active.

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Description Remarks
P2-aux PID in control The P2-aux regulator controls P2 demand.

At all times at least one of the signals “P2 PID in control” and
“P2-aux PID in control” is active.
V1 limiter in control The V1 limiter is currently limiting the V1 valve.
V2 limiter in control The V2 limiter is currently limiting the V2 valve.
V3 limiter in control The V3 limiter is currently limiting the V3 valve.
Modbus relay 1 The corresponding button on the HMI or the Modbus signal on
Modbus relay 2 the Customer Modbus has been activated.
Modbus relay 3
Modbus relay 4
Modbus relay 5
HMI Modbus disabled The HMI Modbus cannot issue commands to the 505DE.
Customer Modbus disabled The Customer Modbus cannot issue commands to the 505DE.
Level indicator 1 The indicated level indicator is active. Refer to “Level indicators”
Level indicator 2 below for a description of level indicators.
Level indicator 3
Level indicator 4
Level indicator 5
Level indicator 6
Level indicator 7
Level indicator 8
Alarm horn active Any new warning alarm has been activated since the last time the
horns were acknowledged on the HMI, DCS or by the “Kill Horn”
selectable input.
NS, FSNL, DM, ESD horn Any new NS, FSNL, DM or ESD alarm has been activated since
active the last time the horns were acknowledged on the HMI, DCS or
by the “Kill Horn” selectable input.

These alarms all make the 505DE do something, in contrast to

the warning alarm of the “Alarm horn active” function, that only
displays a warning.
HP extraction SD horn active Any new HP extraction SD alarm has been activated since the
last time the horns were acknowledged on the HMI, DCS or by
the “Kill Horn” selectable input.
LP extraction SD horn active Any new LP extraction SD alarm has been activated since the
last time the horns were acknowledged on the HMI, DCS or by
the “Kill Horn” selectable input.
ESD active The 505DE has an active ESD alarm and has shut down the
turbine. This relay is a copy of the relay at channel 4 (see Table
4-7 above) and is influenced by the same special settings. It can
be used to shut down additional equipment.
ESD 10 sec pulse This signal issues a 10 second pulse when the permanent
hardwired ESD signal is activated. Using this signal prevents
ESD loops that prevent resetting ESD states. This signal can be
influenced like all the other hardwired ESD signals, except that it
will always return to False, 10 seconds after the hardwired ESD
has gone active.
Ladder Logic enabled and not The Ladder Logic program is not running, while the configuration
running indicates that there should be Ladder Logic present.
Overspeed test enabled Overspeed testing is active: the maximum setpoint is raised, and
the ESD overspeed level is raised, according to the settings on
the Speed/Load configuration pages.
Speed exceeds alarm level The speed has exceeded the high speed alarm level.
Overspeed shutdown The speed has exceeded the overspeed trip level
Any hardware fault active Any hardware channel is signaling a fault
Power supply 1 failed Power Supply 1 reported a problem
Power supply 2 failed Power Supply 2 has been configured and reported a problem
V2 demand signal failure The 505DE detected a problem on the V2 actuator channel.
V3 demand signal failure The 505DE detected a problem on the V3 actuator channel.
MPU A failed The 505DE detected a problem on the indicated hardware signal.
MPU B failed
MPU C failed

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Description Remarks
Load sensor failed (A102-1) A hardware failure has been detected at channel 102-1 (Load).
P1 measured value failed A hardware failure has been detected at channel 102-2 (HP
(A102-2) extraction pressure measurement).
Remote P1 setpoint failed A hardware failure has been detected at channel 102-3 (HP
(A102-3) extraction pressure setpoint).
P2 measured value failed A hardware failure has been detected at channel 102-4 (LP
(A102-4) extraction pressure measurement).
Remote P2 setpoint failed A hardware failure has been detected at channel 102-5 (LP
(A102-5) extraction pressure setpoint).
Selectable AI 6 signal fault The 505DE detected a problem on the indicated hardware signal.
(A102-6)
Selectable AI 7 signal fault
(A102-7)
Selectable AI 8 signal fault
(A102-8)
Selectable AI 9 signal fault
(A103-1)
Selectable AI 10 signal fault
(A103-2)
Selectable AI 11 signal fault
(A103-3)
Selectable AI 12 signal fault
(A103-4)
Selectable AI 13 signal fault
(A103-5)
Selectable AI 14 signal fault
(A103-6)
Selectable AI 15 signal fault
(A103-7)
Selectable AI 16 signal fault
(A103-8)
Any Extra PID signal fault One of the channels (setpoint, measured value, demand) that the
active extra regulator uses, is in fault.

Channel Settings
All channels have the same settings.

All channels show a “light”. If the coil is energized this light is illuminated yellow,
and the word “Energized” is shown. If the coil is not energized then the light is
extinguished and the word “Released” is shown.

Invert hardware level

Boolean
When True, the relay coil for this signal is energized when the value of the signal
is False, thus closing the normally open contact on False. When False, the relay
coil for this signal is energized when the value of the signal is True, thus closing
the normally open contact on True.

Enable manual forcing

Boolean
Forcing setpoint

Boolean
Enables the forcing of the input to a chosen value.

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Figure 4-16. Relay Output Channels Configuration Page

Special Settings
All signals are active as long as the driving signal is True, with exception of the
“Master reset” signal which is always pulsed. For this signal only, the following
setting applies that is found on the page where this signal is allocated to a
channel.

Reset pulse time

Analog. Range: 0.0–60.0 [s]

This setting defines how long the relay output signal is active when a Master
Reset has been applied to the 505DE.

The “Emergency Shutdown active” relay (both the fixed channel 04 as the option
on other channels) can be influenced by two special settings, described below.
Note also the “ESD 10 sec pulse” pulse signal that is available as a selectable
option. This signal is activated whenever the “Emergency Shutdown active” is
activated, but it falls back to False after 10 seconds.

If the trip relay is de-activated, this does not necessarily mean that there is no
ESD condition present in the 505DE: a start may still be impossible. Only if the
“Include remote ESDs in the trip relay” setting is True and the “Reset clears trip
relay” setting is False, will the relay follow the internal ESD condition. These
settings can be used to break “ESD loops”.

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Include remote ESDs in the trip relay

Boolean
If this setting is True, any possible ESD cause being activated triggers the
“Emergency Shutdown active” relay (also known as the “trip relay”)

If this setting is False, this relay is only activated if no external ESD cause is
active while a new ESD cause comes in. At a reset, the trip relay is deactivated if
there are no ESDs causes active, or if there is any external ESD active. If the
ESD is activated from an internal cause, the trip relay is activated. If after this an
external reset comes in, the trip relay stays activated, until after a reset.

Reset clears trip relay

Boolean
If this setting is False, a reset only clears the “Emergency Shutdown active” relay
if there are no more ESD causes active.

If this setting is True, a reset clears the “Emergency Shutdown active” relay in
spite of any currently active ESD cause. The trip relay can be reactivated only
after the Emergency Shutdown condition has been cleared (so all ESD causes
are removed and a reset is issued).

If the trip relay is de-activated, this does not necessarily mean that there is no
ESD condition present in the 505DE: a start may still be impossible. Only if the
“Include remote ESDs in the trip relay” setting is True and the “Reset clears trip
relay” setting is False, will the relay follow the internal ESD condition.

Level Indicators
As can be seen in Table 4-8, relay outputs can be tied to level indicators. A level
indicator is a signal that indicates when a specific value is over or under a
specific value. The 505DE has 8 level indicators available.

Function
This button opens a level indicator signal selection dialog that allows the user to
select the signal that the level indicator is based on. These are the signals that
can be selected. The unit against which the levels must be specified is indicated
between square brackets.

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Figure 4-17. Level Indicators

Table 4-9. Level Indicator Source Functions

Description
Speed setpoint [rpm]
Actual speed [rpm]
S-aux1 setpoint [%]
S-aux1 measured value [%]
S-aux2 setpoint [%]
S-aux2 measured value [%]
S-aux3 setpoint [%]
S-aux3 measured value [%]
HP extraction setpoint [kPa]
HP extraction measured value [kPa]
P1-aux setpoint [%]
P1-aux measured value [%]
LP extraction setpoint [kPa]
LP extraction measured value [kPa]
P2-aux setpoint [%]
P2-aux measured value [%]
Extra PID setpoint [%]
Extra PID measured value [%]
Generator load [kW]
S demand [%]
P1 demand [%]
P2 demand [%]
Extra PID loop demand [0-1]
Casing heat soakage [%]
Synchronizer/loadshare speed bias [rpm]
V1 demand [%]
V1 limiter demand [%]
V2 demand [%]

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Description
V2 limiter demand [%]
V3 demand [%]
V3 limiter demand [%]
Cascade setpoint [%]
Cascade measured value [%]
Cascade demand [%]
Cascade demand [kW]

The last option is the same as the previous option, after conversion to kilowatts.

ON level

Analog. Range: –100000.0–100000.0 [EU]

This setting defines the level against which the selected source signal value is
compared. If the signal goes above this level, the indicator is activated. The
number is always expressed in units as indicated in Table 4-9.

OFF level

Analog. Range: –10000.0–10000.0 [EU]

This setting defines the level against which the selected source signal is
compared. If the signal goes above this level, the indicator is activated. The
number is always expressed in units as indicated in Table 4-9.

ON

OFF

OFF ON
level level
Figure 4-18. Off Level

If the source signal value is between the ON and OFF level, the indicator does
not s=change state. Thus, if the signal value was above the ON level, the
indicator stays ON until the value is below the OFF level. If the signal value was
below the OFF level, the indicator stays OFF until the value is above the ON
level.

Delay time

Analog. Range: 0.0–7200.0 [s]

This setting defines how long the level must above the ON level for the indicator
to be triggered.

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Invert (signal OFF when above ON level)

Boolean
If False, the indicator is triggered when the selected signal value is above the ON
level.

If True, the indicator is triggered when the selected signal value is below the OFF
level.

Speed and Load

These pages define how speed is read into the 505DE, how speed and load
setpoints are generated and how the speed controller functions. The start and
stop speed setpoints (such as Idle Speed) are handled on the Start/Stop pages.

MPU Settings and Speed Limits and Alarms

Figure 4-19. MPU Settings and Speed Alarm Levels

Turbine speed can be measured with up to three MPUs or proximity switches.

For ease of discussion these are all called MPUs. MPU A, B and C have similar
settings. The descriptions below apply to each one of them. All MPUs show their
current output on this screen.

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Maximum measurable speed

Analog. Range: 100.0–30000.0 [rpm]

This single setting is used by all three channels. It determines both the maximum
and minimum speed that the channels can measure. The maximum measurable
speed is equal to this setting. The minimum speed that can be measured
sufficiently accurately for controlling a valve is 1/50 of the maximum speed.
Below that, the speed measurement is less accurate and can only be used for
display and alarm generation.

This is a hardware setting. Hardware settings are special in the sense that they
are not adopted by the system until a hardware reset on the 505DE CPU or a
power-down/power-up cycle occurs. The preferred course of action with this type
of settings is to set them all up, press the “Save configuration” button, then wait a
minute, then reset the 505DE using the switch on the 505DE CPU.

Each time you change one of these settings, a warning pops up to tell you about
hardware settings. You can ignore the pop up window for a while: this prevents it
from popping up every time again.

Number of teeth per speed gear rotation

Integer. Range: 1–1000 [–]

Speed gear ratio (gear revs/shaft rev)

Analog. Range: 0.05–100.0 [–]

These parameter are used to relate the number of teeth on the speed measuring
wheel passing the MPU every minute to the rotations of the rotating axis. There
may be a gear box between the axis and the measuring wheel, and the
measuring wheel may have different number of teeth on its circumference.

The “Number of teeth per speed gear rotation” defines the number of teeth that is
placed on the circumference of the measuring wheel.

The “Gear ratio” relates the number of rotations of the measuring wheel to the
rotations of the turbine rotor. If the wheel is placed directly on the turbine axis,
this value should be set to 1. If the wheel rotates at twice the speed of the turbine
rotor, this value should be set to 2.

The formula is as follows:

Teeth_seen_each_minute = NumTeeth*GearRatio*turbine_rotations

This setting is a hardware setting. See the previous setting for a discussion on
hardware settings.

Forcing enable

Boolean
Forcing setpoint

Analog. Range: 0.0–30000.0 [rpm]

Enables forcing of the value from the MPU channel to a chosen value.

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Use MPU A
Use MPU B
Use MPU C

Boolean
One or two of the available three MPUs (MPUs B or C) can be disabled, for
example if only a single or double measurement is available on the machine.
MPU A is active at all times to ensure that at least one speed measurement is
available.

Speed Limits and Alarms

These settings define how the speed values (read by the enabled MPUs) are
used.

The actual speed is derived from all the valid and enabled MPU readings. This
value is then called the “selected” value.

Difference alarm level

Analog. Range: 0.0–500.0 [rpm]

A warning alarm is given if two MPUs have readings that differ more than this
setting.

Difference alarm delay time

Analog. Range: 0.0–5.0 [s]

The time that the difference must exist before actually giving the difference
alarm.

High speed alarm level

Analog. Range: 0.0–20000.0 [rpm]

The value of the selected speed above which a high-speed alarm is given. This
is just a warning alarm to indicate that the overspeed trip level is getting close.
This alarm is never disabled.

Overspeed trip level

Analog. Range: 0.0–20000.0 [rpm]

Value of the selected speed above which a overspeed emergency shutdown is
initiated. The overspeed shutdown at this speed level is disabled as long as
overspeed testing is active.

Overspeed test limit

Analog. Range: 0.0–20000.0 [rpm]

During overspeed testing, this value defines the upper limit for the speed
setpoint. If the speed actually reaches this level, a warning alarm “Overspeed
test High Alarm level” is given.

Overspeed trip level during overspeed testing

Analog. Range: 0.0–20000.0 [rpm]

This overspeed shutdown level is always active, even during overspeed testing.
If the external overspeed devices fail during overspeed testing, this overspeed
shutdown level should catch a runaway turbine after all.

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Enable overspeed testing

Boolean
Selects the use of the overspeed alarm levels.

Overspeed testing can also be requested by a discrete hardware input having

the “Enable overspeed test” function assigned to it (refer to Contact Input
Channels above).

The overspeed testing can only be activated while the generator breaker is not
closed and while the speed is just under Maximum Governor Speed. Once
activated, it stays active for 60 seconds. The 60 seconds can be reset by either a
Raise or a Lower command (HMI or hardwired or otherwise). As a result, as long
as the operator is active, the overspeed testing remains enabled. If the operator
is inactive for 60 seconds, the overspeed testing is disabled by time-out.

If overspeed testing is disabled, either by time-out or by command, and the speed is

above the “Overspeed trip level”, the 505DE trips. If the speed is under the “Overspeed
trip level” the speed is returned to under the “Maximum governor speed”.

While overspeed testing is active, a large red “Overspeed active” message is

displayed on almost all screens.

Critical Speeds
These settings define the critical speed bands. There are three critical speed
bands available. Each critical speed band is defined by its lower boundary and its
upper boundary. Between these speeds, the setpoint travels a special “Speed
setpoint change rate within critical bands”.

Figure 4-20. Critical Speed Settings

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Speed setpoint change rate within critical bands

Analog. Range: 0.0–5000.0 [rpm/s]

When the setpoint is within any critical speed band, it is moved at this rate.
Note that there is no protection if the critical speed band is entered while in Semi-
automatic start mode, where speed is not controlled by a setpoint, but by the
operator’s movement of the V1 valve.

Use critical speed band #x

Boolean
When False, this critical speed band is not used.

Critical band #x upper boundary

Analog. Range: 0.0–20000.0 [rpm]

This setting defines the upper boundary of the critical speed band.

Critical speed #x lower boundary

Analog. Range: 0.0–20000.0 [rpm]

This setting defines the lower boundary of the critical speed band.

Pass through time out multiplier

Analog. Range: 0.0–600.0 [–]

Knowing the critical speed band size, and knowing the speed setpoint change
rate within a critical band, a time span can be calculated in which the speed
should be just able to pass the critical speed band. This setting multiplies this
band with the mentioned factor, to provide allowance for inaccuracies,
acceleration delays etc. It is recommended not to set this setting below 3.

Speed Controller
This page defines the settings for the speed controller.

Speed controller PID

These settings define the actions of the PID regulator that controls the speed or
load.

This PID is a controller, not a regulator

Boolean
This setting defines if the speed/load controller is used as a limiter on the S
demand LSS bus, or as a controller.

If it is a limiter, it can be enabled and disabled on the S demand LSS bus, with no
effect on the enabled/disabled state of the other regulators (PIDs) on the LSS
bus.

If it is a controller, enabling this regulator disables all other regulators on the S

demand LSS bus that have been configured to be a controller. See the 505DE
Principles Manual for more details on the issue of controller/limiter.

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Figure 4-21. Speed Controller Configuration Page

Deadband for speed PID

Analog. Range: 0.0–500.0 [rpm]

This setting defines the width of a dead band that is set around the error signal of
the speed regulator. If the difference between setpoint and actual speed is
smaller than this value, the error signal is considered to be 0. This setting can be
used to eliminate control action caused by a small hunting signal on the
measured value around the actual speed.

There are different PID gain factor settings for three different situations:

Table 4-10. PID Gain Factor Settings

1 Off line The generator breaker is opened

2 island mode Only the generator breaker is closed
3 grid mode Both the generator breaker and the grid breaker are closed

Refer to 505DE Principles manual 91349V1 for a discussion on how to determine

PID gain factor settings.

Proportional gain for S control - island mode

Proportional gain for S control - off line
Proportional gain for S control - grid mode

Analog. Range: 0.0–200.0 [–]

These settings define the proportional gain of the speed controller.

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Integrating gain for S control - island mode
Integrating gain for S control - off line
Integrating gain for S control - grid mode

Analog. Range: 0.0–15.0 [–/s]

These settings define the integrating gain of the speed controller.

Signal Derivative Ratio for S control - island mode

Signal Derivative Ratio for S control - off line
Signal Derivative Ratio for S control - grid mode

Analog. Range: 0.01–100.0 [–]

These settings define the derivative gain of the speed controller. This factor can
be used if derivative controller action is required.

Technically, if the integrating gain defines a pole in the regulator’s frequency

response function, the SDR defines the ratio between the frequency of the zero
that is placed in the response function, and the frequency of the pole. If the value
is smaller than 1, its inverse is used.

Often this value is left at 0.01, which eliminates derivative action.

Other speed controller settings

These settings define some other settings related to the speed PID controller.
Many speed setpoint related settings are in the chapters for Generator settings
(0) and Loaded setpoint (0).

Disable S-aux limiting at low load

Boolean
If any S-aux regulator drives the load too low, the S-aux drivers can be
automatically disabled if the S demand is driven too low. The load limit is taken
from the minimum load setpoint in droop mode (refer to “Droop mode” below).

External setpoint track rate

Analog. Range: 0.0–10000.0 [rpm/s]

This setting defines how fast the speed regulator allows the speed setpoint to
change when a remote analog setpoint input is configured. Normally this value
should be set reasonably high. It can be used to guard against disturbances on
an external speed setpoint.

Slow speed setpoint manual adjust rate

Analog. Range: 0.0–100.0 [rpm/s]

This setting defines how fast the setpoint changes when the slow change
controls on the HMI are used to change the setpoint on the speed controller in
semi-automatic mode.

Fast speed setpoint manual adjust rate

Analog. Range: 0.0–100.0 [rpm/s]

This setting defines how fast the setpoint changes when the fast change controls
on the HMI are used to change the setpoint on the speed controller in semi-
automatic mode.

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The setpoint disturbance is an aid that can be used to facilitate correct setting of
the PID gains. See Setpoint Disturbance below for a discussion if setpoint
disturbing.

Setpoint disturbance length

Analog. Range: 0.0–120.0 [s]

Setpoint disturbance amplitude

Analog. Range: –10000.0–10000.0 [rpm]

These settings define the length and amplitude of the setpoint disturbance, once
it is fired from one of the speed PID tuning dialogs.

Slow speed PID output manual adjust rate

Analog. Range: 0.0–100.0 [%/s]

This setting defines how fast the speed controller output changes when the slow
change controls on the HMI are used to change it in manual mode.

Fast speed PID output manual adjust rate

Analog. Range: 0.0–100.0 [%/s]

This setting defines how fast the speed controller output changes when the slow
change controls on the HMI are used to change it in manual mode.

Generator Settings

Figure 4-22. Generator Settings Page

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Synchronizing
Enable synchronize time-out

Boolean
When False, this setting allows infinite time for the synchronizer to close the
breaker.

Synchronize time-out

Analog. Range: 0.0–600.0 [s]

This setting defines the time the 505DE allows between activating the Ready to
Sync discrete output and the closing of the generator breaker. If this time is
exceeded, a warning alarm is given. This setting is ignored if the “Enable
synchronize time-out” setting is True.

Speed reference rate while synchronizing

Analog. Range: 0.001–300.0 [rpm/s]

This setting defines how fast the setpoint travels while synchronization is in
progress.

Accel to min load time-out

Analog. Range: 0.0–600.0 [s]

This setting defines the time the 505DE allows between closing the generator
breaker and reaching minimum load (refer to “Droop mode” below). If the grid
breaker is not closed, this setting is ignored.

Load step compensation

Load step compensation adds a feed-forward component to the V1 valve
setpoint when large changes in demanded load cause rapid and large speed
changes. To do this, the excess energy is estimated, based on speed
measurements and the settings below, and compensated for by applying using
an offset on the V1 setpoint.

Enable load step compensation

Boolean
When False, no load step compensation is ever applied. When True, load step
compensation may influence V1 demand.

Load step speed rate threshold

Analog. Range: 10.0–1000.0 [rpm/s]

This setting defines the absolute value of the speed derivative under which no
load step compensation is applied.

Load step initiation delay

Analog. Range: 0.0–5000.0 [ms]

This setting defines the time that the speed derivative must be over the “load
step speed rate threshold” before load step compensation is applied.

Expected turbine shaft inertia

Analog. Range: 0.01–1000000.0 [kg*m²]

This setting defines the total shaft inertia that the 505DE uses to calculate the
amount of load step compensation.

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Once the speed derivative is sufficiently large for a given time, load step
compensation is applied. At this time, the V1 demand is changed by an amount
that approximates the estimated excess energy. To make this estimation, the
shaft inertia is required along with the actual speed change rate being
experienced. Normal operation resumes once the speed derivative crosses 0
rpm/s.

The shaft inertia is at minimum equal to turbine rotor inertia plus generator rotor
inertia: in this situation all 100% loss-of-load situations are accounted for. In all
other situations (partial loss of load and load pickup) some additional load inertia
is experienced, the amount being different at each situation. As this amount is
unknown, the Configurator can choose to either ignore this or to make a best
estimate of the average remaining load inertia after a load change. The accuracy
of this estimate influences the accuracy of load compensation: if the inertia
setting is estimated too high, the compensation algorithm calculates too much
required energy compensation, and the valve is moved more rigorously than
necessary. If it is too low, the valve compensation is probably less than it should
be.

Note that if the inertia is set at a large value and the threshold is set at a small
value, it is possible for the 505DE to enter a mode where it oscillates between
positive and negative load step corrections.

Frequency
Electrical frequency is not an analog input into the 505DE. It is derived from the
speed measurement, as compared to the synchronous speed. Extra filtering on
this “measurement” is available, as well as separate warning alarms. The alarms
are activated some time after the breaker closes (refer to “Isochronous mode”
below)

If the 505DE is running in kW-control, and the frequency goes above its H2 level
or below its L2 level, the 505DE automatically switches to Droop control. This is
a safeguard that prevents the generator from being switched off the net if the
frequency regulating device (normally the grid) is lost.

Electric frequency at synchronization speed

Analog. Range: 0.0–100.0 [Hz]

This setting defines the electrical frequency at synchronous speed.

Filter time constant

Analog. Range: 0.0–100.0 [s]

The frequency signal passes a single pole low-pass filter. This setting defines the
time constant Tau for this filter.

H1/H2 alarm level

Analog. Range: 0.0–100.0 [Hz]

These settings provide two levels, above which the frequency generates a
warning alarm. They are only active while the machine is loaded. Set them very
high if these alarms are not required.

L1/L2 alarm level

Analog. Range: 0.0–100.0 [Hz]

These settings provide two levels, below which the frequency generates a
warning alarm.

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They are only active while the machine is loaded. Set them very low if these
alarms are not required.

Loaded Setpoint

Figure 4-23. Loaded Setpoint Configuration Page

These pages provide the settings for the speed or load setpoint generation once
the turbine is loaded. For speed setpoint generation settings before the turbine is
loaded, see Turbine Start/Stop–Sequence Settings below.

Isochronous mode
The left side of this screen contains the settings for Isochronous control mode
and Loadsharing control mode. These control modes are related in the sense
that they control speed rather than power. Some of the settings provided in the
Isochronous Mode box are equally valid for Loadsharing Mode. If so, this is
explicitly stated.

Isochronous Mode is implicitly selected while the generator breaker is not closed,
e.g. during start-up.

Minimum governing speed

Analog. Range: 0.0–20000.0 [rpm]

This setting defines the minimum of the range in which the setpoint can be
moved in isochronous or loadsharing control mode.

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Maximum governing speed

Analog. Range: 0.0–20000.0 [rpm]

This setting defines the maximum of the range in which the setpoint can be
moved in isochronous or loadsharing control mode.

Speed reference rate when loaded

Analog. Range: 3.0–300.0 [rpm/s]

This setting defines how fast the setpoint travels with a Raise or Lower command
from any source in Isochronous Mode or Loadsharing Mode after
synchronization has been accomplished.

Maintain current speed on entering isoch mode

Boolean
In general, if a control mode change (e.g. from Droop Mode to Isochronous
Mode) occurs, the setpoint for the new control mode is set such that no bump
occurs. Thus it can occur that Droop Mode is abandoned at a moment where the
speed is different from the programmed synchronous speed.

If this setting is True, the setpoint is made equal to the actual speed at the
moment of entering Isochronous Mode. It is up to the operator to bring it to any
other desired speed. If False, the speed setpoint is initially set to the actual
speed at the moment of entering Isochronous Mode, after which it is
automatically moved towards the programmed synchronous speed (at the loaded
rate defined above).

This setting does not affect Loadsharing Mode.

DM and NS escalate to FSNL (Ladder Logic only)

Boolean
From within Ladder Logic, it is possible to issue alarms that cause a
“Deceleration to Minimum Load” or a “Normal Stop”. These operations call for a
slow reduction of load. If an engine is driving a generator running in Isochronous
Mode, slowly reducing load is not an option, as load is entirely determined by the
loading of the electrical network and not by the 505DE. In those situations the
next available meaningful response is a “Full Speed No Load” or FSNL.

If this setting is True and the machine is running in Isochronous Mode, both
“Decel to Minimum Load” and “Normal Stop” type alarms result in a “Full Speed
No Load” alarm, in addition to the original alarm. When False and the machine is
running in Isochronous Mode, the NS and DM alarms have no effect except to
generate a warning on the HMI.

Load sharing mode

Loadsharing Mode, like Isochronous Mode, is a primarily a speed-controlling
Mode. Thus the setpoint that the operator or the external setpoint provides (the
“operator setpoint”) is a speed at which the machine should be running. The
internal controller receives a slightly different setpoint (the “actual setpoint”),
causing it to pickup or shed a little power as the loadsharing balance input
deviates from the equilibrium position of 12 mA. The speed bias (the difference
between the actual and the operator setpoint) can be manipulated using the
following setpoints.

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Loadsharing soft loading rate

Analog. Range: 0.0–10000.0 [part/s]

When Loadsharing Mode is entered, the 505DE initially runs in Isochronous
Mode and then transfers to Loadsharing Mode. This setting defines how fast the
transfer occurs. For example, a setting of 0.2 defines a 5 second transition
period, a setting of 1 defines a 1 second transition period. A setting of 10000
defines an instantaneous transfer.

Loadsharing input bias gain

Analog. Range: 0.01–5.0 [–]

There are many Loadsharing devices around, such as Real Power Sensor,
DSLC, EGCP3, and others. Many of these have no clear definition of the exact
meaning of their loadsharing output value. This factor is provided to tune the gain
on the Loadsharing input if oscillations should occur. A factor of 0.5 should be a
good starting point in most cases. If the loadshare gain is too high, oscillations
occur where the load is transferred between the sharing generators. If the
loadshare gain is too low, possible load imbalances are regulated away very
slowly.

Technical details:

The speed setpoint bias (SPactual - SPoperator ) is equal to (LIBG * LSBAL * DRP_P
* SYNC).

Where:
SPactual = Actual Setpoint
SPoperator = Operator Setpoint
LIBG = Loadsharing Input Bias Gain
LSBAL = The Loadsharing Balance input signal: 0 if in balance.
DRP_P = Droop percentage.
SYNC = Synchronous speed

The droop percentage is a value that is primarily used for droop mode (refer to
“Droop mode” below). Here it is used as a guideline for a power to speed ratio.
The product DRP_P * SYNC represents a speed budget that is used while going
from maximum to minimum load.

For example: if the loadsharing input is 4 mA (i.e. the maximum load imbalance
that the loadshare device can indicate), the signal value (LSBAL) is at a value of
–1 (refer to “Contact Input Channels” above). With a droop percentage DRP_P of
4%, a synchronous speed (SYNC) of 3000 rpm, and a loadshare gain (LSG) of
0.5, this results in a speed setpoint bias of 60 rpm. Under the same conditions,
with a loadshare device at 10% of full swing (12.8 mA), this results in a speed
setpoint bias of 6 rpm.

Switch to droop on a failed loadshare input

Boolean
When this setting is False and the loadsharing line fails, the control goes to
Isochronous Mode. When this setting is True and the loadsharing line fails, the
control goes to Droop Mode.

In both conditions the transition maintains the current valve position (i.e. power
output): the Isochronous setpoint is set equal to the actual speed at the moment
of transition or the Droop setpoint is set such that at the current speed the
current power output is maintained.

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Breaker
Open breaker at low speed

Boolean
When False, the breaker open request is only issued when alarms or sequencing
request it. When True, a request to open the breaker is also issued when the
speed is below the following speed setting.

Underspeed setting for open breaker

Analog. Range: 0.0–20000.0 [rpm]

If the “Open breaker at low speed” setting is True, this setting determines under
which speed the breaker is requested to open.

Breaker to load alarm delay time

Analog. Range: 0.0–7200.0 [s]

This setting defines how much time elapses after breaker closure before
enabling the alarms on electrical frequency and low load. This allows time for
initial load pickup and possible frequency stabilization.

Open breaker at low load

Boolean
When False, the breaker open request is only issued when alarms or sequencing
request it. When True, a request to open the breaker is also issued when the
load is too negative according to the following setting.

Lower load/time setting for opening breaker

Analog. Range: –60.0–0.0 [MWs]

If the “Open breaker at low load” setting is True, this setting determines under
which load conditions the breaker is requested to open. The setting defines a
load and a time delay in a single setting: the more negative the load is, the
shorter the time that it is allowed to be negative. For example: with a –3 MWs
setting and a 1.5 MW negative load, the breaker is opened after 2 seconds. If the
load is –1 MW, the breaker opens after 3 seconds.

Droop mode
Droop Mode, like Power Control Mode, is not a speed-controlling mode. Speed is
assumed to be regulated by other parties, such as a national grid to which the
generator is connected, or a “swing machine”. In Droop Mode, the power
changes as speed deviates from the programmed synchronous speed, such that
the synchronous speed is supported. In Power Control Mode, the power output is
always regulated equal to the power setpoint irrespective of speed. Refer also to
manual B91349V1 (505DE Principles Manual).

Minimum load setpoint

Analog. Range: 0.0–5000.0 [kW]

This setting defines the minimum load to which the 505DE allows the setpoint to
be lowered when in Droop Mode or Power Control Mode.

This is also the load that the sequence tries to reach after closing the generator
breaker, if the grid or utility tie breaker is already closed. There is a small offset
(50 kW) active for the latter purpose, so if an initial load pick-up is not desired,
setting this value to its minimum effectively disables the feature.

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Speed equivalent for min load setpoint
This value is the translation of the minimum load setpoint in terms of speed
(rpm). This value can not be changed other than by changing the “Minimum load
setpoint” or any other setting that it depends on and is provided for those that are
used to the minimum setting being expressed in rpm.

Maximum load setpoint

Analog. Range: 10.0–500000.0 [kW]

This setting defines the maximum load to which the 505DE allows the setpoint to
be raised in Droop Mode or Power Control Mode.

Speed equivalent for max load setpoint

This value is the translation of the maximum load setpoint in terms of speed
(rpm). This value can not be changed other than by changing the “Maximum load
setpoint” or any other setting that it depends on and is provided for those that are
used to the maximum setting being expressed in rpm.

Droop percentage

Analog. Range: 0.0–10.0 [%]

This setting defines the droop percentage. It is the percentage of synchronous
speed that the actual speed must travel to cause the load to swing from zero
load to maximum load (as defined just above).

Power change rate in droop mode

Analog. Range: 1.0–3000.0 [kW/s]

This is the rate at which the operator setpoint is allowed to travel in Droop Mode,
expressed as a power/sec rate.

NS proceeds into reverse power

Boolean
When False, a Normal Stop (caused by either an alarm or by an operator
request) reduces power until the minimum load setpoint (defined elsewhere in
this chapter) is reached. At this time a request to open the breaker is issued
(refer to “Turbine Identification” above) and the 505DE waits at the minimum load
until the breaker opens before completing the Normal Stop.

When True, the 505DE keeps reducing power below the minimum load setpoint
down to the “Maximum negative power setting”. The generator protection
circuitry is required to ensure timely opening of the breaker and should be tuned
such that the breaker is opened well before the “Maximum negative power
setting” is reached.

Maximum negative power setting

Analog. Range: –10000.0–0.0 [kW]

This is the maximum negative power setpoint that is allowed in Droop Mode or
Power Control Mode, if the “NS proceeds into reverse power” setting is True.

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Use calculated load only

Boolean
When True, the Active Load measurement is disregarded and the load is always
induced from the valve positions and the Steam Map. When False, the calculated
load is only used if the Active Load input channel has failed. The accuracy of the
calculated load depends on the accuracy of the steam map, and the accuracy of
the linearization of primarily the V1 valve.

Power control mode / kW mode

Power Control Mode is also known as “kW Mode”.

Power control mode takes speed completely out of the loop. As a consequence,
when the speed regulating device in the electrical network is lost the network
speed may run away to unacceptable levels, with no reaction whatsoever from
the 505DE. To prevent this, the 505DE always switches to droop control
whenever the frequency (refer to “Frequency” above) runs outside the L2 or H2
limits. The droop setpoint will be such that the programmed load is maintained at
the speed that conforms to the L2 or H2 limit.

If, for example, the load setpoint is 20 MW and the frequency goes up to an H2
level of 50.5 Hz (corresponding to 3030 rpm), the 505DE switches to droop
control with a setpoint that maintains 20 MW at 3030 rpm. With a droop
percentage of 4%, if the 20 MW is full load, then the entire load is shed by the
time that the network frequency reaches 52.5 Hz. If the 20MW is half of full load,
the entire load is shed at 51.5 Hz.

Allow kW mode

Boolean
When False, Power Control Mode cannot be selected by the operator.

Power change rate in kW mode

Analog. Range: 1.0–3000.0 [kW/s]

This setting defines the rate at which the operator setpoint can change when in
Power Control Mode.

Cascade control mode

In cascade control mode, the cascaded regulator provides a setpoint to the
speed/load PID. This mode of operation is treated as a load control mode.
Therefore the cascaded regulator’s demand is translated from 0–100% to a
minimum to maximum load setpoint that is maintained in droop control. The
following settings provide for the necessary data to translate the cascaded
regulator’s output to load setpoints.

Minimum load setpoint from cascade controller

Analog. Range: 0.0–10000.0 [kW]

This setting defines the load setpoint when the cascaded regulator’s demand is
set to its minimum of 0%.

Maximum load setpoint from cascade controller

Analog. Range: 0.0–10000.0 [kW]

This setting defines the load setpoint when the cascaded regulator’s demand is
set to its maximum of 100%.

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Monitor MPU Settings

There are 4 speed probe inputs reserved for general monitoring purposes. They
are provided as a convenience. All sensors have similar settings. The
descriptions below apply to each one of them. These settings are collected on
two very similar pages, of which only one is shown.

Figure 4-24. Monitoring MPU 1 and MPU 2 Configuration Page

Maximum measurable speed

Analog. Range: 100.0–30000.0 [rpm]

This setting determines both the maximum and minimum speed that the channel
can measure. The maximum measurable speed is equal to this setting. The
minimum speed that can be measured with sufficient accuracy for controlling a
valve is 1/50 of the maximum speed. Below that, the speed measurement is less
accurate and can only be used for display and alarm generation.

This is a hardware setting. Hardware settings are special in the sense that they
are not adopted by the system until a hardware reset on the 505DE CPU or a
power-down/power-up cycle occurs. The preferred course of action with this type
of settings is to set them all up, press the “Save configuration” button, then wait a
minute, then reset the 505DE using the switch on the 505DE CPU.

Each time you change one of these settings, a warning pops up to tell you about
hardware settings. You can ignore the pop up window for a while: this prevents it
from popping up every time again.

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Number of teeth per speed gear rotation

Integer. Range: 1–1000.0 [–]

Speed gear ratio (gear revs/shaft rev)

Analog. Range: 0.05–100.0 [–]

These parameter are used to relate the number of teeth on the speed measuring
wheel passing the MPU every minute to the rotations of the rotating axis. There
may be a gear box between the axis and the measuring wheel, and the
measuring wheel may have different number of teeth on its circumference.

The “Number of teeth per speed gear rotation” defines the number of teeth that is
placed on the circumference of the measuring wheel.

The “Gear ratio” relates the number of rotations of the measuring wheel to the
rotations of the turbine rotor. If the wheel is placed directly on the turbine axis,
this value should be set to 1. If the wheel rotates at twice the speed of the turbine
rotor, this value should be set to 2.

The formula is as follows:

Teeth_seen_each_minute = NumTeeth*GearRatio*turbine_rotations

This setting is a hardware setting. See the previous setting for a discussion on
hardware settings.

Disable low reading error

Boolean
This setting disables the Low Reading Error described below. It does not affect
the High Reading Error.

Low reading error setpoint

Analog. Range: 200.0–30000.0 [rpm]

This setting defines the speed below which the channel is considered faulty. This
level should be above 1/50 of the “maximum measurable speed” above for
reliable operation.

As it is not possible to predefine when this alarm should be disabled, this alarm is
always triggered when the speed being measured is near zero for legitimate
reasons. It is up to the Operator to reset this alarm once the measured speed is
above this value, or up to the Engineer or Configurator to disable this alarm
altogether, using the “Disable low reading error” setting.

High reading error setpoint

Analog. Range: 200.0–30000.0 [rpm]

This setting defines the speed above which the channel is considered faulty. This
level should be below the “maximum measurable speed” for reliable operation.

L1 alarm inhibit

Boolean
Speed low alarm level setpoint 1

Analog. Range: 0.0–20000.0 [rpm]

This alarm defines the level below which a warning alarm is issued.

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H1 alarm inhibit

Boolean
Speed high alarm level setpoint 1

Analog. Range: 0.0–20000.0 [rpm]

This alarm defines the level above which a warning alarm is issued.

L2 alarm inhibit

Boolean
Speed low alarm level setpoint 2

Analog. Range: 0.0–20000.0 [rpm]

This alarm defines the level below which a warning alarm is issued

H2 alarm inhibit

Boolean
Speed high alarm level setpoint 2

Analog. Range: 0.0–20000.0 [rpm]

This alarm defines the level above which a warning alarm is issued.

forcing_enable

Boolean
forcing_setpoint

Analog. Range: 0.0–30000.0 [rpm]

Enables forcing of the specific MPU to a chosen value.

Controller Settings
These pages define the settings for all regulators in the system, except the
speed/load regulator. See Speed Controller above for this regulator.

Controllers can be in remote mode, in local mode and in manual mode. The
mode is selected by the Operator at run time. See the 505DE Principles Manual
for a description of the 505DE regulators. Figure 4-25 shows the dialog that the
operator uses to switch regulator mode.

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Figure 4-25. Example of Operator’s Regulator Control on HMI

Setpoint Disturbance
All regulators need to have their proportional, integrating and derivative gain
factors tuned to optimize the regulator action. To facilitate this tuning, there is a
facility called the setpoint disturbance.

The setpoint disturbance adds a small offset to the regular setpoint. The
amplitude of this off-set can be configured separately for each regulator. It should
normally be chosen very small with respect to the setpoint value, for instance 1%
of full scale, or smaller. The offset returns to zero after a time that can be
configured separately for each regulator.

The disturbance is triggered by a button on a dialog that can be made visible

from the trending pages. If the “Full Trend” button on any of the Regulator
Control dialogs (such as displayed in Figure 4-25). is pressed, a Full Trend page
opens. If the Engineer is logged in, the Full Trend page contains a button
“Regulator settings”. Pressing this button opens a dialog where the desired
regulator can be selected (Figure 4-26) The desired regulator tuning dialog is
displayed on top of the trends.

Every trend page that is accessed through a regulator control dialog contains
setpoint, measured value and the demand of that regulator. You can zoom in and
scale the trend display such that the disturbance is easily visible. If you launch a
regulator tuning dialog on such a page, you can disturb the setpoint and watch
the PID response while the gain factors are being tuned.

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Note that, as long as no other full trend page is shown, the zooming and
rescaling of the last full trend page are saved: you can view and change
disturbance settings and then return to the same full trend page without loosing
the zooming and scaling settings.

Figure 4-26. PID Settings Selection and Tuning Dialogs

Droop
All regulators can be configured to have droop compensation. The speed
regulator has its droop defined in a manner that is described in “Droop mode”
above. All other regulators have a droop function that depends on the demand of
the individual regulator.

Droop is generally not needed on the individual regulators. Only if multiple

regulators in a system try to adjust the same process value to their individual
setpoints may droop help to stabilize that system. As an example, a 505DE and
another control may be regulating flow in the same steam header, both trying to
maintain the same header pressure. Because of imperfect process value
measurement and possibly imperfect calculations of the controllers, each having
different internal rounding errors, both controller will be fighting each other to get
the actual pressure to the a value that each controller perceives to be correct. As
a result, without droop, one of the controllers ends up doing a lot more work than
the other.

With droop, the regulator’s setpoint is slightly adjusted according to the

regulator’s demand. Thus the controller having the higher demand of the two will
have a slightly smaller actual setpoint: equilibrium between the two controllers is
quickly established.

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The demand output is multiplied by the droop factor and then subtracted form the
operator’s setpoint. Thus with droop the measured value is always slightly lower
than the external or semi-automatic setpoint. For example, with a pressure
controller with a setpoint range of 0 to 2000 kPa (0 to 290 psi) and a droop factor
of 3%, the setpoint would be lowered by 0.60 kPa (0.087 psi) for every percent of
demand output of the regulator. Maximum droop offset between unadjusted
setpoint and measured value would then be 60 kPa (8.7 psi) at a demand output
of 100%. The offset would be 30 kPa (4.4 psi) at 50% demand.

Droop is disabled by setting the droop factor to 0%.

Regulator Settings
As most settings of most regulators are similar, the s-aux1 regulator will be
described here, after which a list of all settings is presented with their type,
minima and maxima. The examples are derived from the S-aux1 regulator. The
505DE Principles Manual has more information on how the various regulators
interact.

The settings for the regulators are in percentage (%) mostly. The exceptions are
the extraction pressure regulators (P1 andP2) that have their setpoints and
measured values expressed in kPa or psi. As the purpose of the auxiliary
settings are not known before configuration time, they have all been expressed in
%. The “Units and manual” page allows you to change the descriptions and units
and ranges of most regulators, in addition to a pair of other settings.

If necessary, the ranges are taken from various regulators. This should be
obvious to the reader.

Figure 4-27. Regulator Settings for S-aux1

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PID controller main settings
Upper PID setpoint value
Analog. Range: 0.1–100.0 [%]

Analog. Range: 1.0–10000.0 [kPa]

Lower PID setpoint value
Analog. Range: 0.0–100.0 [%]

Analog. Range: 0.0–5000.0 [%]

These settings define the value range between which the remote or local setpoint
can be moved.

Slow setpoint adjust rate

Analog. Range: 0.0–100.0 [%/s]

Analog. Range: 0.0–500.0 [kPa/s]

This setting defines how fast the setpoint changes when the slow change
controls on the HMI are used to change the setpoint on the controller in local
mode. In remote mode, it defines how fast the setpoint is changed with a remote
Raise or Lower command during the first seconds of the command (see also the
setting “Raise/Lower input contacts speed up delay” in “Other Configuration
Items Found on the Main Configuration Page” above).

Fast setpoint adjust rate

Analog. Range: 0.0–100.0 [%/s]

Analog. Range: 0.0–1000.0 [kPa/s]

This setting defines how fast the setpoint changes when the fast change controls
on the HMI are used to change the setpoint on the controller in local mode. In
remote mode, it defines how fast the setpoint is changed with a remote Raise or
Lower command after the first seconds of the command.

This PID is a controller, not a limiter

Boolean
This setting defines if the regulator is used as a limiter on its LSS bus, or as a
controller.

If it is a limiter, it can be enabled and disabled on its LSS bus, with no effect on
the enabled/disabled state of the other regulators (PIDs) on the same LSS bus.

If it is a controller, enabling this regulator disables all other regulators on the

same LSS bus that have been configured to be a controller. See the 505DE
Principles Manual for more details on the issue of controller/limiter.

The cascade regulator and the extra PID do not have this setting as they are not
connected to an LSS bus.

Make PID reverse acting

Boolean
When False, the PID increases its output when the process value decreases.
When True, the PID increases its output when the process value increases.

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Deadband for PID

Analog. Range: 0.0–20.0 [%]

Analog. Range: 0.0–20.0 [kPa]

This setting defines the width of a deadband that is set around the error signal of
the regulator. If the difference between setpoint and process value is smaller
than this value, the error signal is considered to be 0. This setting can be used to
eliminate control action caused by a small hunting signal on the measured
process value.

Initial value / default setpoint on input fail

Analog. Range: –10.0–110.0 [%]

Analog. Range: –100.0–10000.0 [kPa]

This setting serves two purposes.
It provides an initial value for the regulator’s setpoint. This is very useful in case
the setpoint can have a fixed value and needs no raising or lowering ever. The
initial value is only adjusted at power-up of the 505DE.

If an analog setpoint has been configured for the controller, it defines where the
setpoint shall go, if the channel fails, and provided the setting “On fail, ramp
setpoint to default” is True.

PID droop factor

Analog. Range: 0.0–10.0 [%]

This setting determines the regulator’s droop percentage, as described in
“Droop” above.

Proportional gain

Analog. Range: 0.0–100.0 [–]

This setting defines the proportional gain of the regulator.

Integrating gain

Analog. Range: 0.0–50.0 [–/s]

This setting defines the integrating gain of the regulator.

Signal Derivative Ratio

Analog. Range: 0.01–100.0 [–]

This setting defines the derivative gain of the regulator. This factor can be used if
derivative controller action is required.

Technically, if the integrating gain defines a pole in the regulator’s frequency

response function, the SDR defines the ratio between the frequency of the zero
that is placed in the response function, and the frequency of the pole. If the value
is smaller than 1, its inverse is used. Refer to the 505DE Principles Manual for
further details.

Often this value is left at 0.01 or 100, which eliminates derivative action.

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Remote setpoint
If there is no remote analog setpoint configured (see “Analog Input Channels”
above), the settings related to the remote setpoint are disabled, and a message
“No analog input allocated for the remote setpoint” is displayed. If a remote
setpoint is configured, the following settings are active:

Remote setpoint maximum track rate

Analog. Range: 0.0–100.0 [%/s]

Analog. Range: 0.0–10000.0 [kPa/s]

This setting defines the maximum rate at which the remote analog setpoint is
allowed to change. If it changes any faster, the actually used setpoint tracks the
analog input value at this rate.

On fail, ramp setpoint to default

Boolean
If this setting is False, and the allocated remote analog setpoint channel fails, the
setpoint is frozen at the last value believed to be “good”, and this value is used to
continue controlling.

When True, and the analog setpoint channel fails, the setpoint is ramped towards
the setting “Initial value / default setpoint on input fail” in the previous chapter.
The ramp rate is equal to the “Fast setpoint adjust rate” as defined in the
previous chapter.

To re-enable a remote setpoint after a channel failure, the failure must be

resolved, a Master Reset issued, and the operator must press the enable button
on the PID pop-up (see Figure 4-25).

Measured value fail

If the measured value fails, there are three options for the 505DE’s reaction:
1. Emergency shutdown.
In this case, the measured value or the regulator’s action is of no
consequence any more.
2. Ramp the measured value to a default value.
The result is most likely that the regulator integrates its output either to 0% or
to 100%, depending on how the default measured value compares to the
setpoint.
3. Lock in the last measured, supposedly good, value.
This freezes the measured value. The 505DE also puts the regulator in
Manual Mode, thus freezing the regulator’s output. Without this, as the
measured value and the setpoint may be slightly different, the regulator
would slowly integrate away from the desired demand. The operator can set
the regulator back to remote or local mode.

These are the related settings:

Shutdown on failure of measured value

Boolean
When this setting is True, option 1 above is chosen: when a measured value
channel failure occurs, the 505DE trips. The other settings in this chapter are
irrelevant.

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On fail, ramp value to default

Boolean
When this setting is True, option 2 above is chosen: when a measured value
channel failure occurs, the 505DE ramps the measured value to the default value
in the next setting. The ramp occurs at the “Fast setpoint adjust rate”, defined in
“PID controller main settings” above.

Default value on hardware fail

Analog. Range: –10.0–110.0 [%]

Analog. Range: –100.0–10000.0 [kPa]

This setting defines the default value used in option 2 above.

If neither of the “Shutdown on fail of measured value” or “On fail, ramp value to
default” options is configured to True, option 3 is executed. The message
“Currently locking in last value” is highlighted to show this.

Manual mode demand rate

Slow PID manual adjust rate

Analog. Range: 0.0–100.0 [%/s]

This setting defines how fast the controller output changes when the slow
change controls on the HMI are used to change the output of the controller in
manual mode.

Fast PID manual adjust rate

Analog. Range: 0.0–100.0 [%/s]

This setting defines how fast the controller output changes when the fast change
controls on the HMI are used to change the output of the controller in manual
mode.

Tuning disturbance aid

See also Setpoint Disturbance above. These settings define how large the tuning
disturbance is, and how long it lasts. The disturbance is a pulse that is added to
the setpoint directly before the PID.

Setpoint disturbance amplitude

Analog. Range: –100.0–100.0 [%]
Analog. Range: –10000.0–10000.0 [kPa]

Setpoint disturbance length

Analog. Range: 0.0–120.0 [s]
This setting defines the duration of the setpoint disturbance, once it is triggered
from the PID tuning dialog.

Regulator specific settings and data

S-auxiliary regulators
Keep PID enabled in speed control
Boolean
If the speed regulator is in speed control, the penalty of any auxiliary taking over
the S demand is a loss of speed, which is generally a severe consequence. If
load is being controlled , the loss of load is generally considered less severe.

This setting defines that the S-aux regulators are disabled as long as the speed
regulator is in a speed control mode, i.e. in isochronous or in loadsharing mode.

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P1/P2 regulators
If the load demand is very low the temperature at the extraction header may rise
to an unacceptable level. One way to prevent this is to forbid extraction demand
at low loads. The following settings define limiting values to the extraction
demand when the load is low. This is done by defining a load below which no
extraction is allowed and a load above which full extraction is allowed. If the load
at which full extraction is allowed is a negative load, the limiter is effectively
disabled.

Although this setting is located under the P1 and P2 regulator pages, the
limitation applies to the P1-aux and P2-aux regulators as well, as the limiter is
applied on the P1 and P2 LSS busses.

Max
extracti 100

0%
min max Loa

Figure 4-28. P1/P2 Regulators

Load for 0% extraction

Analog. Range: –10.0–500.0 [MW]
This setting defines the load where no extraction is allowed. The default is a
negative value.

Load for 100% extraction

Analog. Range: –10.0–500.0 [MW]
This setting defines the load where full extraction is allowed. The default is a
negative value. This value must be higher than “Load for 0% extraction”.

Extra PID Loop

There is a regulator present in the system that is not involved with the other
functioning of the 505DE. This regulator and its associated features can be used
to control an arbitrary signal to an arbitrary value. If the influence on the rest of
the turbine is small, it could be used for a third extraction regulator. The demand
output should be selected on one of the configurable analog 4–20 mA outputs
(refer to “Analog Readout Channels” above) to be of any use.

Units and manual mode enabling

This sub page has a few settings that are general to all regulators. In addition
this page provides an opportunity to change the displayed units and ranges of
various regulators on the operator’s pages.

Disabling manual and local PID modes

Allow PID manual mode selection on HMI

Boolean
When True, the operator can override the regulator action of any PID and control
the PID demand (output) manually.

When False, manual mode on any PID is not selectable. The operator can not
influence the PID manually.

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Allow PID local mode selection on HMI

Boolean
When True, the operator can override the setpoint of any PID and control that
setpoint locally.

When False, local mode on any PID is not available from the HMI.

Change ranges and units

All auxiliary PID and the extra PID have functions that are not known until
configuration. As the names, ranges and units need to be predefined, these have
been fixed to generic names and 0 to 100%. Once the function of a PID and its
associated signals (such as setpoint and measured value) is known, the
“Change range and units” feature allows the Configurator to change the
appearance of these items on the operator screens. This prevents the Operator
from being burdened with continuous mental conversions. In addition the scales
on the small trends on the operator pages and the default scales on the full trend
pages are adapted. As a result, the trends will be better visible.

Internally and on the configuration screens the appearance of these items is not
changed.

The buttons open up dialogs that allow a new name, new ranges and new units
to be specified for the PID and associated signals. The dialogs present the
following items:

Figure 4-29. S Auxiliary 1 Range and Units Changing Dialog

Comment
This textbox allows you to specify a new prefix for all associated names. This
prefixed is completed with phrases like “ PID”, “ setpoint” and “ measured value” ,
as needed. Note the space before the “ setpoint” etc. The prefix can be no more
than 10 characters long. A prefix like “Boiler pr.” would create names like “Boiler
pr. setpoint”.

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Metric and Imperial
Most analog values on the 505DE can be presented in a metric and in an
imperial unit. This representation can be changed at any time by pressing the
F11 key or pressing the button on the main menu page. The new units can be
made to participate in this capability by specifying two ranges and units. Typically
the primary unit of your choice (metric or imperial) is defined with nice rounded
numbers. The other one must have its 0% and 100% value matching exactly to
the primary unit. Alternatively you can specify both units the same, or leave one
of the units in %.

Units
This is the text that is displayed to indicate the unit. The drop down box contains
a number of examples. You can add your own by typing in the drop down box. If
you use a long unit name, the value reading on the operator pages may expand
outside the space allocated for the reading.

The P1 and P2 regulators provide no option for the units.

Zero scale / Full scale

These are the numbers that need to be displayed instead of the 0% value and at
the 100% value. If using both metric and imperial units, make sure that both are
mapped precisely to the 0% and 100% values.

Note that these do not necessarily coincide with the 4mA and 20mA values, as
the calibration of the analog inputs may be such that a different percentage
number is mapped to these currents.

The P1 and P2 regulators only allow you to change the Full scale: only the range
of these regulators can be changed, to make trends better visible. The unit must
remain as is.

Decimals
The string in this dropdown box influences the way the values and the unit is
displayed. The syntax of this string is important and is as follows:

First a number of ‘#’ symbols. These are placeholders for digits before the
decimal point. At least one is required. If the display value needs more digits, it is
displayed as if sufficient placeholders were provided.

A decimal point. This is optional: an integer value can be displayed without

decimal point.

One or more ‘#’ symbols. These are placeholders for digits after the decimal
point. This defines the resolution with which the value is displayed. All numbers
are rounded if insufficient placeholders are provided. If too may are provided,
zeroes are appended to the display value. Note that the values are sent to the
HMI with a limited resolution. No value can be displayed with more than 5
significant digits.

An optional space character defines a space between the display value and the
unit indication.

If “EU” is appended to the string the text in the “Unit” setting is appended to the
display value, after the optional space character.

The entire string can contain no more then 10 characters, including optional
space and decimal point.

If an invalid string is used, a default is chosen by the 505DE HMI.

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Cancel/OK
These buttons close the change dialog and dismiss (Cancel) or accept (OK) the
changes you made. If they are accepted, the changes are not yet displayed on
the operator pages.

Apply and recompile

This button takes the data from the change dialogs, then closes the 505DE HMI,
starts the Citect Explorer and lets it compile the 505DE HMI with the data as
provided. It then restarts the HMI with the adapted names, ranges and units. Let
the compilation run to completion. The Citect Explorer will close down and the
505DE HMI will be restarted.

Note that this button is a copy of the button described in “Other Configuration
Items Found on the Main Configuration Page” above. Clicking this button also
implements any changes you may have prepared for the custom alarms settings.

Revert to default
This button closes the 505DE HMI, starts the Citect Explorer and lets it compile
the 505DE HMI with the data as originally present in the delivery version of the
505D HMI. It then restarts the HMI with the original names, ranges and units.
Note that this button is a copy of the button described in “Other Configuration
Items Found on the Main Configuration Page” above. Clicking this button also
reverts any changes you may have prepared for the custom alarms settings.

Turbine Performance / Steam Map

These pages define the steam map used by the ratio and limiting logic, and
allows the definition of decoupling modes and limiting priorities. The 505DE
Principles Manual contains an entire chapter on how to read steam maps and on
decoupling and limiting priorities.

Figure 4-30. Steam Map Configuration Page

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Figure 4-30 shows the steam map according to the current settings. All settings
that define the entire steam map are on this single page. Changing the settings
changes the graphics. Refer to manual B91349V1 (505DE Principles Manual) for
a description and explanation of all the parameters used to make the steam map.

The blue box contains the settings that define the HP part of the steam map. The
red box contains the settings for the LP part.

Use the setting “Use points for LP map at P1=1” with caution. Normally these
settings are not needed. Only if the position of the steam map at P1=1 differs
wildly from the calculated shift, it can be useful to use the C’’-D’’-E’’ points.

CAUTION—USE IS RISKY
Use this facility at your own risk.

Using this facility has at least the following disadvantages:

• The 505DE may experience some instability at large P1 demand changes.
Numerical instabilities may occur at some points in the steam map.
• Adding the flows that result from P1 demand and P2 demand at a certain
point in time may lead to calculated extraction flows that are larger than the
calculated flow at V1, which would defy the law of preservation of mass.
• You still need to make sure that the P2=0 line (D’’-C’’) is on top of the P1=0
line.

Priority and Decoupling

This page contains all other settings related to ratioing and decoupling.

Figure 4-31. Priority and Decoupling Configuration Page

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Use single extraction (P1 extraction disabled)

Boolean
This setting makes it easier for the user to use the 505DE for single extraction
steam turbines. The proper control for this kind of turbines is the 505E. In some
cases the customer may elect to use the 505DE after all.
This setting cuts the current to the V2 valve actuator output. In addition, all
hardware faults from the V2 valve actuator channel are disabled. This prevents
nuisance messages from the V2 valve that is not connected in single extraction
operation.
The 505DE Principles Manual contains a chapter on how to configure single
extraction on the 505DE.

Use decoupling

Boolean
If the operation requires that a valve is controlled exclusively by a single demand
(S or P2, as opposed to being influenced by all three demands at once)
decoupling can be used. If this setting is True, the decoupling type can be
selected. If it is False, no decoupling is allowed.

Refer to the 505DE Principles Manual 91349V1 for a further discussion on

coupling, what it is used for and on decoupling.

Decoupling type
This setting is only available if the “Use decoupling” setting is True. It allows you
to select one of the decoupling modes:

Coupling mode Description

No decoupling This is the normal operation of the 505DE. It is recommended to
set “Use decoupling” to False instead.
Inlet decoupling The V1 valve is controlled by the S demand exclusively.
Exhaust decoupling The V3 valve is controlled by the S demand exclusively.
Inlet & exhaust decoupling The V1 valve is controlled by the S demand exclusively and
the V3 valve is controlled by the P2 demand exclusively

Limiter Priorities
If one of the regulators hits a steam map boundary, one or perhaps two of the
regulated demands S, P1 and P2 must be sacrificed to keep up proper regulation
of the others. This item allows the Engineer to select which demand is dropped
first, and which is kept at all times. The highest priority demand is always kept,
the lowest priority demand is dropped at the first limit being encountered.

There are 2 limiter priority selections available. Only one of these is active at any
time. The primary limiter priority is normally active. Only if the function “Select
alternate priority“ has been assigned to a contact input, and if this input is active,
the secondary limiter priority may become active. If such contact input is not
available, a message “No priority selection input allocated” is shown right above
the secondary priority selection box.

If another limiter priority is selected by the input, it may happen that the priority is
not immediately changed. This happens if any steam map limit is changing (i.e.
limiting) a demand. If the priority would change at such a moment, there might be
a bump occurring in the valve positions. To prevent this, the changeover is
delayed until no demand is being limited any more. At this time, the priority
change-over happens bumpless.
However:

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Priority change always allowed
Boolean
This setting makes sure that a limiter priority change request is immediately
satisfied. If limiting is active and the limited value is significantly different from the
unlimited value, this may result to a bump in the system. In such cases, the
previously limited demand jumps from the limited value to the unlimited value,
and the newly limited demand jumps from the unlimited value to the limited value.
Both jumps move the valves immediately , sending a bump through the system. If
the changeover is demanded very shortly after a limit is engaged, this bump may
be very small and acceptable. It is up to the configurator to judge the applicability
of this setting.

There is one other way for the 505DE to change priority. This occurs at the
opening and closing of the Grid Breaker (or rather, the status of the input with
that function). If the grid breaker is opened, it is assumed that the speed is the
overriding priority, and one of two the topmost priority selections, where S has
highest priority, is selected, maintaining the priority order of P1 and P2. For
example, if the normal priority is P2, P1, S and the grid breaker is opened, then
the priority changes to S, P2, P1. If the normal priority is P1, S, P2 and the grid
breaker is opened, the priority changes to S, P1, P2.

Turbine Start/Stop – Sequence Settings

These pages hold all the settings that are relevant in the unloaded stages of the
start and stop sequence.

Manual Start, Initial Valve Positions

Figure 4-32. Start Configuration Page (1 of 2)

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Allow using manual start-up mode

Boolean
If True, the operator is allowed to start the turbine in Manual Mode, using the
T&T valves to bring the turbine to Low Idle speed. See the 505DE Principles
Manual for details on Operating Modes.
If False, the operator does not have the option to select Manual Mode as the
Operating Mode.

V1 level during manual mode

Analog. Range: 0.0–100.0 [%]

If the value of “Enable manual start-up mode” is True, and a start in Manual
Mode is initiated, the V1 valve is opened to the level indicated by this setting.
This setting must be adjusted to a proper value to make Manual Mode work, as
the default is 0%. It is recommended to adjust this setting to a value below 100%,
to have some (small) safeguard against opening the T&T valve too fast and too
wide.

Initial V1 opening rate

Analog. Range: 0.0–10.0 [%/s]

This setting defines how fast V1 opens during a full-automatic start until the
speed regulator takes over. The speed regulator takes over when the turbine
speed reaches the “Minimum detectable speed” as defined in the next chapter.
Until that time, the V1 valve is opened at this rate to allow the turbine to break
away and reach this speed quietly. Once this speed is reached, the V1 valve is
under regulator control.

V1/V2 rate during start

Analog. Range: 5.0–30.0 [%/s]

When the turbine is “Off”, the V2 and V3 valves are closed (0%). During start-up,
these valves are completely opened (100%). This setting defines how fast the
valves travel between the fully open and fully closed position.

Start Speeds and Sequencing

This page defines the start-up speeds, the start-up hold times and many more
start sequence related settings. Many of these settings are only valid during a
fully automatic start. Refer to the 505DE Principles Manual for a description of all
start modes. Start modes are selected by the operator. Manual mode can be
inhibited by setting “Allow using manual start-up mode” in the previous chapter to
False.

Use idle rated

Boolean
If this setting is set to True, the following actions are taken:
• The Mid Idle and High Idle speeds are made equal and kept equal to the
Low Idle speed.
• The Mid Idle and High Idle speed wait times are set to 0.
• The Mid Idle and High Idle acceleration time-outs are set to a maximum
• An automatic hold at Low Idle speed is enabled.

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Figure 4-33. Start up Timing Parameters Configuration Page

The result is a start sequence where, after reaching Low Idle speed (using a
Manual, Semi-automatic or Full-automatic start), the 505DE waits until it receives
a Start pulse. The setpoint then progresses to Rated speed in one acceleration
move. Critical speed bands are crossed faster (as configured in “Critical Speeds”
above). If a Stop pulse is received, the speed setpoint returns to Low Idle.

After setting this value to True, a number of settings on this page and on the
Stop page are changed and then disabled.

Auto hold at all warm-up speeds

Boolean
If this setting is True, the 505DE stops the sequence at all warm-up speeds (Low
to High Idle and Rated speed). The hold time timer continues to run, but after it
has run to completion, the 505DE waits until a Start pulse is received. If the start
pulse is received and the hold time is completed, the start sequence continues.

Allow semi-automatic starts up to rated speed

Boolean
If this setting is False, and the operator starts in semi-automatic mode, the start
sequence changes to full-automatic mode once Low Idle speed has been
reached.

If this setting is True, and the operator starts in semi-automatic mode, the
operator is allowed to use the V1 valve position to regulate the turbine speed all
the way up to rated speed. Once rated speed is reached the sequence continues
with the full-automatic sequence.

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Note that in semi-automatic mode there is no protection against fast
accelerations and against lingering in critical bands. For this reason it ma be
desirable not to allow the operator to bring the turbine up to Rated speed in semi-
automatic mode.

The following two settings, found outside any speed related box, allows the
Configurator to prevent two types of alarms that may be conceived as nuisance
alarms.

Use sequence time-out timers

Boolean
If this setting is False, all sequence time-out timers are disabled. If True, these
timers, on time-out, issue an alarm to the operator, and cause a normal stop.
Normal stops that occur for this reason can be immediately counteracted by
pressing the start button. It may be desirable to have this setting False for
instance if the boiler pressure is not reliable.

Alarm on fail to maintain a warm-up speed

Boolean
There is a set of alarms available on the 505DE that are triggered if the turbine
speed drops 50 rpm below a warm-up speed that is supposed to be maintained
while the hold timer is timing out.

If this setting is True, these alarms are disabled and the 505DE attempts to
regain proper speed control. If False, a normal stop is initiated when the speed is
50 rpm below the speed setpoint and should be holding. These stops can
immediately be counteracted by pressing the start button.

These alarms can protect against boiler pressure dips during start-ups. These
alarms could be enabled after proper tuning of the off-line speed control gain
parameters.

Idle speeds and Rated speed

There are 3 intermediate holding speeds (Low Idle, Mid Idle and High Idle), at
which the 505DE can be instructed to wait a while before raising the speed
setpoint further. After the High Idle speed, the 505DE reaches Rated speed. The
settings for these speed are largely similar. The similar settings are described
here.

Some of these settings are paired: one is valid for a machine that is considered
to be completely cold, the other one is for a machine that is thoroughly warmed
up. These values are interpolated using the “heat soakage” that defines how hot
the turbine is (refer to Heat Soaking below).

If you have no use for a particular warm-up/cooldown speeds, you can disable it
by setting its hold times to 0 s.

Low/Mid/High idle speed / Rated speed

Analog. Range: 1.0–20000.0 [rpm]

These settings define the Low Idle speed, the Mid Idle speed, the High Idle
speed and the Rated speed. These speeds are used to allow the turbine to warm
up or cool down for a period of time without accelerating or decelerating.

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Acceleration rate to xxxxxx speed (cold)

Analog. Range: 0.0–5000.0 [rpm/s]

Acceleration rate to xxxxxx speed (hot)

Analog. Range: 0.0–5000.0 [rpm/s]

These settings define how fast the speed setpoint is changed while increasing
towards the indicated speed. The same rates are also used during deceleration
from the indicated speed downward in the Stop sequence.

Accel to xxxxxx speed time-out

Analog. Range: 0.0–600.0 [s]

These settings define the time that the 505DE allows the machine to accelerate
from the last holding point to this speed. If this time is exceeded, a Normal Stop
alarm is generated and the machine proceeds into the appropriate point in the
cooldown sequence, and ultimately coasts down to zero speed. If the Operator
issues a Reset and a Start pulse, the start sequence is immediately resumed.

This setting is unavailable if “Use sequence time-out timers” is False.

xxxxxx speed hold time (cold)

Analog. Range: 0.0–3600.0 [s]

xxxxxx speed hold time (hot)

Analog. Range: 0.0–3600.0 [s]

These settings define how long the sequence holds at the indicated speed during
warm-up, for either a hot or a cold machine.

At Rated speed, the hold time defines how long the 505DE waits before
asserting the “Ready to sync” relay output after reaching Rated speed.

Low Idle speed, Minimum speed

Before the Low Idle speed is reached, a few other settings play a role in the start-
up sequence.

Minimum detectable speed

Analog. Range: 0.0–10000.0 [rpm]

This setting defines the minimum speed that the 505DE can use to control the
turbine. Below this speed, in a full-automatic start, the turbine is started on a
continuous ramp of the V1 valve (see “Initial V1 opening rate” in “Manual Start,
Initial Valve Positions” above), until the measured speed is equal to or above the
Minimum detectable speed. Above this speed, the appropriate acceleration rate
is applied.

The Minimum detectable speed must be set to at least 1/50 of the maximum
measurable speed, as defined on the “MPU settings” sub-page of the “Speed
and Load” configuration page (see “MPU Settings and Speed Limits and Alarms”
above). If the speed pick-up configuration is not capable of reliably picking up a
speed as low as this, the Configurator can choose to set the minimum speed
higher. The Minimum speed cannot be set higher than the Low Idle speed.

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Hold at low idle in manual or semi-auto start

Boolean
A manual or semi-automatic start is normally performed up to the Low Idle
speed. After this, the start continues as a full-automatic start (note however the
settings “Use idle rated” and “Allow semi-automatic starts up to rated speed” in
“Start Speeds and Sequencing” above). When this happens, the 505DE can go
on accelerating up to Rated speed, or it can be made to halt at Low Idle and wait
for operator input before continuing.

If this setting is True, the sequence waits for operator input before continuing. If
this setting is False, the sequence continues ramping the speed setpoint up from
Low Idle to Mid Idle and onward.

Rated speed
Semi automatic start time out

Analog. Range: 0.0–18000.0 [s]

This is the time that the 505DE allows a semi-automatic start sequence to reach
Low Idle speed (or Rated speed, if the setting “Allow semi-automatic starts up to
rated speed” is True). If these speeds are not reached within this time, a Normal
Stop is initiated.

Other Sequence Related Settings

Figure 4-34. Configuration Page For Other Start/Stop Related Parameters

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Stop
These settings control the timing around Normal Stops, either operator induced
or alarm induced. The speeds described below are the same as the speeds used
in the warming-up sequence (refer to “Idle speeds and Rate speed” above).
Time-out settings given below define times that, when exceeded, issue a warning
alarm for the operator.

Note that these times may be far too short for a turbine that is coasting down
without any break (like most generator drives). In that case, the nuisance alarms
for decel time-outs and maintain to fail speed alarms can only be prevented by
setting the “Use sequence time-out timers” and “Alarm on fail to maintain a
warm-up speed” to true.

Open gen breaker at stop time-out

Analog. Range: 0.0–600.0 [s]

If a Normal Stop is issued and minimum load is reached, the 505DE asserts the
“Breaker open request” relay output and waits for the Generator breaker to open.
This setting defines how long the 505DE keeps waiting before issuing an alarm.
This warning alarm is the only consequence of time-out.

Decel to xxxxxx speed time-out

Analog. Range: 0.0–600.0 [s]

These settings define the time that the 505DE allows the machine to decelerate
to the indicated speed after starting the descent of the speed setpoint. This
setting is ignored if “Use sequence time-out timers” (refer to “Start Speeds and
Sequencing” above) is False.

xxxxxx speed hold time

Analog. Range: 0.0–1800.0 [s]

This settings define how long the sequence holds at the indicated speed during
cool-down.

No coast down to zero required

Boolean
If this setting is True, the sequence waits for the turbine to coast down to below
“Minimum detectable speed” (see “Low Idle speed, Minimum speed” above)
before allowing a new start. If this setting is False, the sequence falls through to
the “Turbine Systems Off” state immediately after leaving Low Idle speed,
allowing a fresh start.

Coast down to zero time-out

Analog. Range: 1.0–600.0 [s]

This setting defines the time that the 505DE allows the machine to decelerate to
“Minimum detectable speed” after completion of the holding time at Low Idle
speed.

Allow stop command from the HMI

Boolean
If this setting is False, the “Stop” buttons on the HMI are disabled for the
operator. As a result the only valid Stop pulses can be received from the
hardwired contact input or from the Customer Modbus. This can be used to
prevent stopping of the turbine if the rest of the plant is not prepared for such an
event.
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If this setting is False, the “Stop” buttons are available to the operator.

Fail to maintain speed during start alarm

These settings define an alarm that is fired if the measured speed and the speed
setpoint differ too much during the steps of the start-up sequence before
synchronization. Once the alarm is triggered, the Hold command is issued to
interrupt the start sequence and freeze the speed setpoint at its current position.
This prevents regulator wind-up in case of poor steam conditions during start-up.

Recovering from this situation is described in the 505DE Operator Manual.

Allowed speed error size on start

Analog. Range: 1.0–1000.0 [rpm]

This setting defines the maximum difference between the actual speed and the
speed setpoint that is allowed at start-ups

Time to allow speed deviation

Analog. Range: 1.0–30.0 [s]

This time value defines how long speed deviations above the “Allowed speed
error size on start” are allowed. If al large enough speed deviation exists for this
time, the “Fail to maintain speed” alarm is triggered.

Extraction enabling/disabling
HP extraction enabling rate
HP extraction disabling rate
LP extraction enabling rate
LP extraction disabling rate

Analog. Range: 0.0–10.0 [%/s]

These settings define how fast extraction is enabled and disabled.

At extraction enabling, first the V2 or V3 valve ramps down from 100% to the
point of zero extraction at the configured enabling rate. When this point is
reached, the V2/V3 limiter is quickly ramped down to zero. After this, the
extraction PID demands are released from 0% to whatever the PID needs. The
PID release is down at the same enabling rate.

At extraction stopping, the PID is first ramped down from the current demand to
0% at the configured disabling rate. When the PID demand (i.e. extraction) is
0%, the V2 or V3 valve is ramped up further to 100% at the same disabling rate.

Continue extraction on grid breaker opening

Boolean
If this setting is True, extraction is continued when the grid breaker opens.

If this setting is False, extraction is disabled when the grid breaker opens. This
may be useful as extraction may be disturbed at large load swings form the
island, sending the turbine into its steam map limits.

In both cases, the priority is changed to make S demand the most important, as
described in “Priority and Decoupling” above.

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Stop HP extraction last
Stop LP extraction last

Boolean
If extraction is disabled by the sequence, for example during a Normal Stop, the
505DE disables both extractions at the same time. It may be desirable to makes
sure that extractions are disabled one at a time. If one of these settings is True,
the corresponding extraction is not disabled until the other one is ready with
being disabled. If both settings are False, both extractions start disabling at the
same time. If both settings are True the 505DE waits for operator to make a
choice and disable one of the extractions manually after which the 505DE
automatically disables the other.

This setting does not influence individual extraction disable commands. Thus
these settings can always be ignored by disabling individual extractions by HMI
action, DCS Modbus action or hardware discrete input action. In such cases, the
operator or the external equipment must make sure that any restrictions are
obeyed.

Heat soaking
A hot machine can be started with different hold timings in the sequence and with
a different setpoint change rates, thus reducing restart time. The degree of being
hot is implemented as a heat soakage percentage with 100% denoting a
completely hot turbine and 0% denoting a completely cold one. This percentage
is used to interpolate between the hot and cold warm-up timers and between the
hot and cold setpoint change rate (refer to “Idle speeds and Rated speed”
above).

The heat soakage can be presented to the 505DE as an analog input. If an

analog input is assigned to this function (refer to “Allocating Functions to
Channels” above), these settings are disabled, and the screen mentions the
channel that carries the heat soakage signal. If these settings are enabled, no
heat soakage channel has been assigned.

Use heat soakage calculation

Boolean
When this setting is False and no analog input has been assigned to the heat
soaking function, then heat soakage is not used, and the 505DE always starts
the machine on the cold start-up settings. When True, a calculated heat soaking
percentage is calculated.

If the calculated heat soaking percentage is used, the following two settings are
important. The 505DE assumes that the turbine is cold until Rated speed is
reached. From that point onward, the turbine is considered hot.

When the turbine speed is under the “Minimum detectable speed” cooling down
commences. However, it is assumed that the heat soakage remains 100% until
the turbine is near zero speed for a certain amount of time. After that time, the
heat soakage decreases linearly until it is zero. The rate of decline heat soakage
is calculated from the following two settings.

Cold start time, when cooling has completed

Analog. Range: 0.0–10000.0 [h]
This setting determines how long it takes for the turbine to completely cool down.
This timer starts when the speed goes below “Minimum detectable speed”. When
it times out, heat soakage is considered to have reached 0%.

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Hot start time, before cooling begins
Analog. Range: 0.0–10000.0 [h]
This setting determines how long it takes for the turbine to begin losing heat
soakage. This timer starts when the speed goes below “Minimum detectable
speed”. Before it times out, heat soakage is considered to remain at 100%. After
time-out, heat soakage starts to decline.

Miscellaneous Settings
These are settings that are difficult to assign to another setting page.

Figure 4-35. 505DE Miscellaneous Settings Page

Serial I/O Ports

The serial I/O ports on the 505DE CPU can handle an event printer and a
Customer Modbus channel, or two Customer Modbus channels. The Customer
Modbus can be interrogated through the serial lines on port COM1 or port
COM2, or through UDP/IP port 5002 on the Ethernet interface. Port COM1 can
alternatively be used to attach an event printer.

Customer Modbus
The “Customer Modbus”, also known as “DCS Modbus”, is a set of 505DE
internal values that is mapped to a series of registers that can be interrogated by
a third party device using the Modbus protocol. The third party device may be a
plant’s DCS. Refer to the 505DE Operator Manual for a listing of the Modbus
register map.

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Some fixed and unchangeable Modbus protocol parameters, as required by the
505DE, are:
• RTU protocol
• Slave address: 1
• Allowed function codes: 01, 02, 03, 04, 05, 06, 15 and 16
• Integers and Booleans only. A multiplier is applied before sending the data
in accordance with the register map in the 505DE Operator Manual
• Maximum number of data bytes per reply: 118 (or 1888 bits). If there are
more registers being interrogated in one message, a Modbus error message
is returned.

Customer Modbus used

Boolean
This setting defines if a Customer Modbus is at all used. If True, the Customer
Modbus is available. If False, the Customer Modbus is disabled. Disabling the
DCS Modbus prevents the Customer Modbus time-out alarm to occur.

Customer Modbus time out

Analog. Range: 0.0–30.0 [s]

This setting defines how the length of the gaps that the 505DE allows between
correctly received interrogations from a Modbus master. If interrogations do not
occur in time, a warning alarm is raised. The Customer Modbus master should
constantly be interrogating the 505DE for at least one register.

COM1 used for the customer Modbus

Boolean
This setting, if False, indicates that an event printer is expected to be attached to
COM port 1. If True, a Customer Modbus master is expected to be attached to
COM port 1.

This is a hardware setting. Hardware settings are special in the sense that they
are not adopted by the system until a hardware reset on the 505DE CPU or a
power-down/power-up cycle occurs. The preferred course of action with this type
of settings is to set them all up, press the “Save configuration” button, then wait a
minute, then reset the 505DE using the switch on the 505DE CPU.

Each time you change one of these settings, a warning pops up to tell you about
hardware settings. You can ignore the pop up window for a while: this prevents it
from popping up every time again.

The following settings are similar for both COM1 and COM2. They define a few
RS232 protocol settings.

Stop bits
The ports can be configured to use 1, 1.5 or 2 stop bits at the end of each byte.

Parity
The port can be set to use No parity, Even parity or Odd parity.

Baud rate
Several baud rates are available.

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Event Printer
A printer, terminal or other logging device can be attached to the COM port 1.
This port produces a line of ASCII text and a time stamp every time a configured
event occurs. Refer to the 505DE Operator Manual for a list of events and
associated messages.

The settings of COM port 1 should be made compatible to the printer or logging
device. Please consult the manuals for these devices. In addition to the settings
that apply to the Customer Modbus on COM port 1, there is 1 additional setting:

Event Printer bits/character

The Event printer port can be configured to use 7 bits or 8 bits per character.

Set 505DE time and date

The 505DE has a real time clock. The current time and date is shown on the box
edge. The time is used by the event printer and is included in datalog print files.
The date can be changed by presetting the Year, Month and Day settings and
then pressing the “change the date” button. The configured date is sent to the
505DE at that time.
The time of day can be changed by presetting the Hours, Minutes and Seconds
settings and then pressing the “change the time” button. The configured time of
day is sent to the 505DE at that time.

Time synchronization
There are some facilities to synchronize the 505DE time to an external clock, or
an external clock to the 505DE.

An external clock can be synchronized to the 505DE by connecting the Time

Sync Pulse signal to a configurable relay output (Refer to “Relay Output
Channels” above). The HMI time is also synchronized to this pulse. The following
two settings control this process.

Enable time sync output pulse

Boolean
When False, the output pulse is not created and not transmitted to DO or HMI.
When True, the output pulse is generated and transmitted to the DO and the
HMI.

Hour of time sync output pulse

Integer. Range: 0–23 [h]

The pulse is generated on the indicated hour, on the hour. The duration of the
pulse is 2 seconds.

If the 505DE is to be synchronized to an external clock, this can be done by

assigning a discrete contact input to the Time Sync Pulse function. The rising
edge of this input transfers the time definition (refer to the previous chapter) into
the 505DE clock. The date is not changed. It is not recommended to synchronize
to midnight as the date is not adjusted to go forward or backward at the time of
the update. It is recommended to use 0200 or 0300 hr.

Enable time sync input pulse alarm

Boolean
This setting enables the following alarm. This should only be set to True if a
discrete input has been assigned to the Time Sync Pulse function.

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External sync input overdue time out

Analog. Range: 86400.0–88200.0 [s]

This setting defines the time that the 505DE waits after the last incoming pulse
before issuing a warning alarm. There are 86400 seconds in 24 hours.

Non-Volatile Memory

Figure 4-36. 505DE Miscellaneous Settings Page

Some parameters are stored in non-volatile memory to survive power-downs and

resets of the 505DE. In general these values can be used to plan the
maintenance of the turbine.

Non-volatile memory save rate

Analog. Range: 1.0–24.0 [h]

The non-volatile memory has a limitation of 100000 updates in the 505DE’s
lifetime. To restrict the number of updates, the data is normally held in volatile
memory and only committed to non-volatile memory:
• Periodically, defined by this setting
• When the turbine is stopped (Off state)
• When an ESD occurs.

If a reset or power-down of the 505DE occurs, the data uses the values that were
last stored in non-volatile memory.

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Preset values
Integer. Range: 0–999999 [–]
If the CPU has to be replaced, or if the turbine is not new, the user may want to
set the counters and timers to values other than the stored ones. To enable this,
preset values are provided.

To preset the values, set them ALL to the desired value. As these values are all
integers, they can be set immediately to the required value (see “Integer Values”
in Chapter 3). Click the button “Load preset values into non-volatile memory” to
load the preset values into the counters and store them in the non-volatile
memory.

Various
Non-latching hardware faults

Boolean
When this setting is False and a hardware error occurs, an alarm is announced
and appropriate measures are taken (such as moving to default values for
analog inputs) as long as the fault persists and until a reset is given.

When True and a hardware error occurs, an alarm is announced and appropriate
measures are taken (such as moving to default values for analog inputs) as long
as the fault persists. However, using the actual input value is resumed as soon
as the error disappears: no reset is necessary. The announcement on HMI and
Customer Modbus remains until a Reset is given.

Power Supply #2 installed

Boolean
Set this item to True if a redundant power supply is actually installed. It enables
hardware alarms that are associated with the second power supply.
If this setting is False while the second power supply is installed, its possible
failure is not detected and announced on the HMI or the Customer Modbus.
If this setting is True, and the second power supply is absent, it is signaled as
faulty. There is no further consequence to the functioning of the 505DE.

Ladder logic sequencing option present

Boolean
When True, it is assumed that the 505DE Ladder Logic kit is installed (a DI/DO
module in slot A105), and that there is a Ladder Logic program loaded and
running. Faults related to this hardware and to the absence of a Ladder Logic
program are enabled. When False, none of the alarms related to the Ladder
Logic or the Kit is enabled. This does not prevent Ladder Logic or the kit from
operating, it only inhibits the related alarms.

HMI Modbus Time out

Analog. Range: 0.0–30.0 [s]

This setting defines how long the Modbus to the operator HMI waits for a correct
message before giving a Link Error warning alarm. Note that this alarm is
immediately visible on the Customer Modbus, while on the HMI it appears only
after restoration of the link.

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Datalog sample rate

Boolean
Set this setting to True to enable the fast datalog facility, and make the
associated controls visible on the HMI operator pages. It also displays the
Datalog Total Time indication.

Datalog sample rate

Integer. Range: 1–1000 [* 5 ms]

The Datalog has a specific data area set aside for collecting logging data. The
maximum data sampling rate is 10 ms. This leaves a very short logging history
(Datalog Total Time). This setting allows the Engineer to multiply the sampling
time with the indicated factor, thus increasing the history length but decreasing
resolution. Note that the “Datalog Total Time” indication is updated only at the
start of a datalog run, not when this setting is changed.

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Chapter 5.
Commissioning Procedure

Introduction
The aim of this commissioning procedure is to provide a practical guideline to set
up the control on a site prior to a first start. Based on practical experience from
previous 505DE site installations, this guide aims to assist the commissioning
crew working with the 505DE control.

Procedures Prior to Starting

Prior to a first start, the mechanical parts of the turbine will be assembled
according to the turbine guidelines. Depending on the site and age of the turbine
package, a lot of information required for a proper 505DE setup may or may not
be available from turbine documentation. An additional source of information may
be practical experience with the installation from the operator crew that has been
working with the installation in the past. Using all the information available, the
next points should be considered.

Check Steam Map Configuration

The most obvious thing to check is the steam map configuration. Depending on
the turbine manufacturer, the steam map may be available in a number of
different shapes and formats. From this steam map the 505DE steam map needs
to be configured. The user needs to be able to read the manufacturer’s steam
map. For information regarding 505DE steam map point construction, see the
505DE Principles manual.

Identify Required Features for Turbine System

The 505DE can operate three individual steam valves. As a result, the system is
able to control three parameters that are measured by the control. In general, the
system parameters to control are generator load, P1 and P2 pressure. Using the
Aux PID features in the 505DE, the system is able to control other parameters
like boiler pressure and/or backpressure. In this case, the Aux PID controlling the
added parameter can be tied to the LSS bus containing the parameter that needs
to be dropped. If for example the boiler pressure needs to be controlled using the
load (i.e. through S demand), the boiler pressure can be tied to the S-Aux1 PID.
If boiler pressure needs to be controlled using the P1 extraction, it can be tied to
the P1-Aux PID.

If an auxiliary PID needs to be controlling the S, P1 or P2 demand for direct

control of the valves, the corresponding load or extraction PID demand can be
set to 100%. This allows the Aux PID to take full control of the LSS bus. If the
auxiliary PID only needs to act as a limiter (MVA, boiler pressure support etc.)
the normal load and extraction demands can remain active as normal. For a
description of a few cases, see the 505DE Principles manual.

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Allocate Functions to Input and Output Channels

Once all the required features are determined, the next step is to allocate the
required I/O for the 505DE. Note that it is possible to create features by wiring
outputs back to inputs. A limiter can for example be activated when the boiler
pressure falls below a certain level. See the 505DE Principles manual for a
description of a few cases.

The easiest way to configure the I/O is to first select the required feature and the
desired I/O channel functions. From the channel configuration pages, select the
functions from the pop-up menus (refer to Chapter4, “Allocating Functions to
Channels”, “Analog Readout Channels”, “Contact Input Channels”, and “Relay
Output Channels”. Once the functions are allocated, set the PID settings.

Work through all pages and settings in the configuration tool. Chapter 4 of this
manual describes all settings in detail. A few configuration items are also
described below.

Configure the Required Auxiliary PIDs to Display the Correct

Engineering Units
In the default out-of-the-box configuration, all auxiliary PIDs are set to display %
as engineering units, with a range running from 0 to 100%. As the operator is
probably used to seeing real engineering units like flow, pressure etc., the
Auxiliary PIDs can be set to these engineering units. Refer to Chapter 4,
“Change Ranges and Units”.

Perform Signal Scaling and Calibration

Configure all analog channels to make them indicate the right values at 4 and 20
mA. Make sure that all I/O is scaled to indicate the correct values. Also check if
the actual measured value in engineering units as displayed on the operator
screens match up with the field values. If any measurements appear to be
affected by EMC interference, the 505DE can be set to an I/O lock, effectively
removing all signals to the field. This allows for easy ground loop finding. It is
also very cost effective to have knife terminals installed that allow any loop to be
quickly opened without having to disconnect wires from the 505DE FTMs.

Check the correct calibration of channels. To do this, it is recommended to go out

in the field and set the field transmitters to 4, 12 and 20 mA. The best way to do
this is to actually put pressure on pressure transducers etc. If the calibration is
correct, the mA values into the control will indicate correctly on the HMI hardware
screens. If these numbers match up with a connected mA measuring device, the
hardware calibration is correct.

Steam Valves
One of the most important items to configure is the effective flow through the
steam valves. To operate the 505DE control in the best way possible, the valves
need to be where the control requires them to create a flow according to the
steam map. This requires a correct position calibration and a correct effective
area curve. This chapter gives a few pointers on how to do this.

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Remember that a valve demand of 0% should equate the minimum flow
requirement, 100% a maximum flow requirement. In general this will not
correspond to 0% to 100% actuator travel.

Valve and actuator size

All steam valves are operated using actuators. In general, the travel of the
actuator is not equal to the effective flow requirement of the valve. In addition,
when the valve is closed, additional actuator travel is still required to force the
valve into the seat to prevent any flow leak in an ESD situation.

For the V1 valve over the complete actuator travel, there are a number of points
that need to be configured in the 505DE control. These points are indicated in
Figure 5-1.

Real actuator travel Effective flow

Mech. max stop / 20 mA / 100%

16.8 mA / 80% 100% / Maximum inlet flow

14.4 mA / 65 % 50% effective inlet flow

Crack point / 7.2 mA / 20% 0% / 0 inlet flow

Mech. min stop / 4 mA / 0%

Overtravel

Figure 5-1. Actuator Travel Compared to Effective Flow (Example)

• 0% actuator demand / overtravel

This is the position of the actuator where the valve is forced into the valve seat.
Depending on the design of the valve rack, this may force the roller arms to be
lifted from the bearings to maintain force. This high force is required to prevent
any leak of steam in an ESD situation.

• 0% effective inlet flow / crack point

The crack point is defined as the point where the valve is just about to leave the
valve seat and let the steam flow through. Between the overtravel point and the
crack point, the actuator in this example moves 20% (!). This point is found by
looking at the valve rack and increasing the valve output demand until the first
cam starts to move the first valve.

The first poppet valve to open is usually the center one to minimize losses. The
remaining poppet valves will then move sequentially left and right of the center
valve until all poppet valves are fully open at maximum actuator stroke. Figure 5-
2 shows the cam on one of the side poppet valves on the V1 valve rack. The
cam shaft needs to rotate approximately 120 degrees to reach its crack point and
this poppet valve will be fully opened at about 180 degrees.

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Figure 5-2. V1 Poppet Valve Crack Point

• Effective flow demand

Indicated in Figure 5-1 is the point for 50% effective inlet flow. In this example,
this flow is reached at an actuator travel of about 65%. Typically the effective flow
demand will not be equal to the actuator position demand. The valve effective
area curves are used to compensate for these differences. 0% flow demand
needs to be mapped to the crack point, 100% flow demand needs to be mapped
to the maximum flow position. Flow demands between these points need to be
mapped such that the flow rises linearly with the demand.

• 100% Effective flow demand

At this flow demand, the valve should deliver the maximum allowable flow into
the turbine. In the example this corresponds to about 80% actuator demand. If
the actuator would open further, this would cause a flow higher then allowed by
the steam map to enter the turbine. In the example, the steam valve is about
20% oversized. Note that if the boiler pressure drops, more valve opening would
be useful to still run the turbine at the maximum inlet flow. The 505DE cannot do
this (yet).

• 100% Actuator demand

This is the mechanical maximum stop of the actuator. For the turbine, this usually
is beyond the point where all the poppet valves are fully open. This point is used
for the calibration of the actuator, but serves no real purpose to the control as it
will not increase the maximum valve opening.

Valve position calibration without a servo positioning controller

Many valve actuators are of an integrating nature. To match the proportional
demand current output of the 505DE to this type of actuator, an intermediate
device is needed, such as Woodward’s SPC.

When the steam valves are operated without an interposing system like a SPC,
the 505DE output is directly driving a proportional actuator. In this situation, a V1
actuator demand of 0% equates to the minimum current setting (e.g. 4 mA) and
should correspond to a V1 valve that is at its overtravel closed position.

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As soon as the 505DE flow demand increases to a value above 0%, the flow is
expected to increase, so the valve needs to first move to the crack point and then
to the required effective flow position. In practice, the assumption is made that a
flow demand of about 0.5 % should take the valve to the crack point. This is done
by adjusting the V1 valve table to map 0% flow demand to 0% actuator demand.
The point of 0.5 % flow demand is then mapped to the crack point (e.g. 20%)
actuator demand.

CAUTION—DETERMINE NUMBERS
The 20% actuator stroke as indicated below is just used to create a clear
example. In practice this number will be different. Determine these numbers
while stroking the valve.

On the high end, a 100% flow demand needs to correspond to 80% actuator
demand. To do this, set the 100% flow demand to 80% actuator output. Between
the points (0.5, 20) and (100, 80) a straight line can be drawn. At this time, the
V1 valve curve looks something like indicated in Figure 5-3.

By design, the shape and opening positions of poppet valves on valve racks are
probably linear in flow as a function of actuator demand. If any valve curves are
available and the valve is not linear by design, the initial guess of a linear valve
can be adjusted later.

80

20

0.5 100

Figure 5-3. V1 Effective Area Curve With Overtravel

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Valve position calibration with SPC
The 505DE can also be operated with integrating valves by using an SPC. This
is a common configuration as most actuators are fitted with a servo valve that
accepts a null current and a current bias to drive the actuator.

In this configuration, the valve effective area correction is still performed in the
505DE. However, the SPC can now be used to limit the available stroke of the
actuator. Fro instance, this allows the demand from the 505DE to the SPC to be
20 ma, while the SPC maps this to the 80% actuator demand.

V2 and V3 minimum opening calibration

The V1 valve needs to close to overtravel during an ESD. During normal
operation, the valve needs to close to zero flow when controlling the turbine. The
V2 and V3 valves do not have the overtravel requirement as the extraction
headers are usually fitted with a check valve that prevents steam entering the
turbine during an ESD.

For the V2 and V3 valves, there are different requirements regarding the
minimum opening. If these valves are completely closed, the back section of the
turbine is starved from steam and will heat up to a critical level within a couple of
minutes. To prevent this and guarantee a minimum flow through the turbine back
section, the V2 and V3 valves need to have a minimum flow opening. Note that a
0% flow demand from the control should match the minimum flow requirement,
NOT a zero flow requirement.

If the turbine design is fitted with a bypass opening, this minimum flow setting is
not required as a closed valve will not close off all steam flow. However, if the
bypass openings are too small, additional flow can be created by increasing the
minimum opening anyway.

The procedure works the same way as with the V1 calibration curve. The only
difference is that the minimum opening is now created by mapping the minimum
flow demand of 0% to an effective opening above the crack point of the valve.
The required opening may not be available, so a conservative first guess of
about 3 or 4% may be used. This number can be adjusted at a later stage.

Stroke valves / Tune SPC

If all initial valve correction curves have been entered, the valves can be stroked
to see if the settings are correct. At this time, the valve stroking page on the HMI
can be used to enter the required valve demands. As a minimum:

• Stroke all valves a number of times to warm up oil in the system

• See if the valve moves smoothly, without any interruptions
• Check if the hydraulic skid is able to maintain pressure during transient
situations
• Test the crack point of the V1 valve by checking the cam of the first V1
poppet valve
• Check that the maximum flow opening of the valve is limited to the required
valve opening, not the mechanical stop

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80

24

4 100

Figure 5-4. V2 / V3 Effective Area Curve With Minimum Opening Requirement

By this time the hydraulic system is probably warmed up. If an SPC is used, it
also needs to be tuned for its dynamics. If the dynamics are configured
incorrectly, the system may start to oscillate and damage the hydraulic linkages
of the actuator. Poor dynamic behavior can also be triggered by:
• Servo valve contamination
• Poor oil pressure supply
• Loose or incorrect linkage
• Mechanical movement from poor supported actuator
• Feedback error / dirt / mount

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If no valve position indication is present at

the turbine, it may be sensible to create a
scale indication e.g. using some
cardboard and duct tape.

On the cardboard a 0 to 100% scale was

determined by stepping the valve to these
positions using 10% increments.

Remove the scale before starting as the

high temperatures may melt or scorch the
scale and/or its fixing.

Figure 5-5. Temporary Position Indication

Valve failure settings

At this time, the valves are all moving to the required position if a specific flow
demand is asked for. The last thing to test is an actual valve demand failure. If a
servo valve is used, depending on the null current the valve will slowly integrate
up or down if the demand signal fails.

To test the failure response, disconnect the servo demand signal. For the V1
valve a safe position would be to close the valve, for the V2 and V3 valves, the
safe position is open. As the SPC will detect failures of these kinds, depending
on where the valve will move to on a fault, the SPC can be configured to create a
customer alarm or ESD.

Critical Speed Settings

Depending on the design of the turbine, a number of critical speeds will be
present and specified by the manufacturer. In general, the first critical will
introduce the highest vibration levels. Higher order critical speeds may or may
not be present. It is recommended to configure the warm-up levels at speeds
well outside any critical band. A typical vibration signature is indicated in Figure
5-6. Note that if the turbine has been opened and reassembled, some other
critical speeds may occur. Refer to “Check Vibrations and Determine Critical
Speeds” below.
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0 100

Figure 5-6. Typical Vibration Speed Curve

Final Walk-through
After making sure the points in this are covered, it is useful to go over each and
every configuration page and make sure that all settings are as desired, or
properly disabled. Give this initial setting a specific identification number and
store it in a configuration file bearing this identification number and preferably a
date in the file name. Refer to “Main Configuration Page” in Chapter 4. Many
settings are not known at this time, before the first start. Make sure that all items
that are yet to be defined have sensible, and at least safe initial values. Most out-
of-the-box default values comply to this requirement.

Procedures During First Start

If all configuration items are set, the turbine will be started up eventually. This
section indicates a number of items that need to be addressed during this first
start procedure.

First Manual Start-up to Minimum Speed

The first start is usually done using the manual start mode. This opens the V1
valve to a predefined position and allows the turbine to be accelerated using the
T&T valve. The turbine is usually taken to a speed below the first critical band
and is warmed up at that speed. This may take up to a couple of hours during
which mechanical checks on the turbine can be performed.

This may be a good time to test the ESD train. Press the ESD button on the HMI
and see if all circuitry between the 505DE and the actual trip valve functions as
intended.

If all looks well, the turbine is accelerated to the minimum speed setpoint and the
505DE swaps to Semi-automatic Mode: the V1 valve ramps close to a maximum
opening and the T&T valve must slowly be opened to maintain speed. As the
T&T valve is opened the V1 valve must be slowly closed from the HMI screen to
maintain the required speed.

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Check Vibrations and Determine Critical Speeds

On the way up from minimum speed onwards, the control will pass through all
critical bands as known by design. Write down all the actual critical speeds to
adjust these for a next start. Determine pass-through rates and timers based on
this information.

In addition rub vibrations may be encountered. Rub vibrations occur if the turbine
has been reassembled after the casing has been opened for inspection,
replacing blades and/or seals. These vibrations are induced by the increasing
speed that will start to wear seal material for the first time. If any rubbing
vibrations occur, reduce speed and wait until the vibrations drop off to an
acceptable level and let the turbine rub in at this speed until the vibration at this
speed has dropped off. Then slowly increase speed until the vibration picks up
again. Continue this cycle until these rub in vibrations are gone. This may take
an hour or so. Make sure that the vibrations are not caused by the actual critical
speeds, these will not wear out.

Tune Speed PID Off-Line Mode

The 505DE uses normalized PID gain settings to minimize any PID tuning
related instabilities. As these are conservative settings, the best performance of
the speed PID is probably not met.

To tune the speed PID, the system can be swapped to Full Automatic Mode. This
allows the speed PID to take control of the V1 valve and maintain speed. The
speed setpoint can be manipulated using the hold button during an acceleration.
When activating the hold input, the setpoint freezes and the PID should provide
an appropriate response. To do the same test again, select semi-automatic
operation and lower the speed using the V1 valve demand. If Full-Automatic
Mode is again selected the speed start accelerating again.

An alternative way to tune the off-line settings is to stay at a fixed speed (by
holding the sequence, or by staying at synchronous speed) and use the PID
setpoint disturber feature to introduce small steps on the speed setpoint and
monitor the responses. Refer to “Setpoint Disturbance” in Chapter 4. The speed
setpoint disturbance does not work if the start mode is semi-automatic, or if the
setpoint is being controlled by Raise/Lower commands. If unsure, while in full-
automatic, hit the start button and then the hold button. If the off-line tuning is
done at synchronous speed, the tuning can be made optimal for preventing
overspeed when the generator breaker opens at high loads.

Overspeed Testing
Overspeed testing should be done as early as possible to make sure that the
entire overspeed trip train functions as intended. The 505DE has an overspeed
test function that allows a temporary increase of the alarm and speed trip levels.
Refer to Chapter 4, “Speed Limits and Alarms”.

Note: Overspeed trip devices using a mechanical bolt tend to have a slight
decrease of the actual speed trip setpoint at each time they are activated. The
size of this decrease depends on design and age. Setpoint changes as large as
20 rpm have been seen.

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Tune Synchronizer Gain

This step may take place at a later time, after the turbine has been manually
synchronized the first time. To synchronize with the analog synchronizer input,
this input needs to be enabled from the generator control page. Disable the
generator breaker at the first attempt. When the synchronizer gain is set
correctly, speed and phase should match the electrical speed and phase in a
matter of seconds, assuming the off-line speed PID settings are tuned correctly.

After tuning the synchronizer gain correctly, the breaker can be closed.

First Generator Breaker Closure

As soon as the generator breaker closes, the V1 valve demand increases to a
position according to the steam map. At this time all the steam map logic is used
and the S demand should match the generator load. Depending on the accuracy
of the estimated linearized V1 valve curve, the turbine may or may not be able to
run at its minimum load setpoint. To match the load and the S demand, the V1
valve curve needs to be calibrated.

V1 Valve Curve Calibration

Per definition, the S demand should match the generator load according to the
steam map. If the size of the V1 valve is too big, the steam flow into the turbine
will be higher then expected and the generator load will be higher than the S
demand indicates. To fit the V1 demand to the actual steam flow as dictated by
the steam map, the V1 valve curve needs to be calibrated. To correct the curve,
open the V1 valve table on the HMI configuration pages. This page indicates the
current load as measured from the generator control panel (this should match the
local AVR panel reading) and the calculated load according to the steam map.
The aim is now to modify the effective area curve so the calculated load matches
the measured load.

Figure 5-7. V1 Effective Area Curve to Match Flow

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Each time the effective area is increased, the valve opens up further, allowing more
steam into the turbine. To compensate for the increased load, the S demand and
hence the calculated load decreases. If the calculated and measured load are
within about 300 kW of each other, proceed to the next load level.

Note that the boiler pressure has an effect on the inlet flow. If the boiler pressure
is unstable, tune the boiler control system first. If this is not possible, consider
using the 505DE as a boiler pressure limiter to assist the boiler pressure control
system. Big improvements have been seen after doing this.

At a certain inlet flow level the system needs to enable the extractions to create
additional inlet flow. Therefore this procedure may need to be continued at a later
time when all extractions are up and running. To verify the created curve, it is
convenient to create an X-Y plot from available DCS data (flow vs. valve
position) to see if the shape matches up.

Operational Configurations
When the V1 curve is calibrated correctly, additional items need to be addressed
for optimum system functionality

Adjust speed PID setting for grid and island operation

If the valves are all linearized with the flow, the speed PID can be tuned for grid
and island operation. On grid operation, as the speed is maintained by the grid
itself, the limits for PID gain are determined by the response of the valves and
MW reading. As a result, the PID gains for grid operation are usually higher then
the off-line and island operation gains.

To tune the speed PID, the load rate of change can be increased to allow the
load setpoint to be modified at a high rate. After this tuning, return the rate of
change to a normal level. Alternatively use the setpoint disturber (refer to
“Setpoint Disturbance” in Chapter 4).

Adjust extraction enable / disable rates

When the turbine is on line and all extraction inhibits are cleared, the extraction
may be enabled. When not sure with which extraction to start first, it may be a
consideration to start with the biggest steam map operating envelope as this will
most likely not trigger any steam map limits.

Assume a valve arrangement as presented below.

V2
P1 P1b

Check valve

P1a

Figure 5-8. Typical Extraction Valve Arrangement With Check Valves

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Without extraction, the V2 (or V3) valve is 100% open, and P1 = P1b. P1a is
maintained at the required process pressure at zero extraction flow (P1a > P1).
As soon as the extraction is enabled, the V2 valve starts to move from the 100%
open position to the position required by the steam map for 0% extraction.
Depending on the specific operating condition, this may demand, for example, a
50% valve opening. During this transient, the differential pressure across V2
increases, so now P1 > P1b. If the valves are all calibrated properly, when the V2
valve reaches the required position (e.g. 50%), the differential pressure across
the check valve is 0.

At this time, the extraction PID demand is released from 0% to start pressure
control. At this time the V2 valve will close further, and as now P1 > P1a the
check valve opens to allow flow into the extraction header.

The volume of the compartment in front of the check valve and the spring
construction of the check valve are unknown. For this reason, the rate at which
the valve travels from its 100% open position to the zero extraction position is a
configuration item.

When the extraction becomes active, the header pressure may already be
controlled by a second PID system. Make sure that the enabling rate allows the
other system to back off its pressure control demand in a smooth fashion. It is
also possible to set the 505DE pressure control setpoint to a lower value to
slowly back out the other system. Alternatively, configure droop on the pressure
PID and flow-share between the two systems.

Disabling an extraction works in the opposite direction: first it backs off the
pressure PID demand to 0% and then it opens the V2 valve.

V2 / V3 Valve curve correction

Like the S demand is mapped to generator load, the P1 and P2 demands are
mapped to extraction flow. The V2 and V3 tables can be calibrated in a similar
fashion as the V1 curve. Instead of adjusting the curve using the generator
calculated load, the V2 and V3 curves can be calibrated using the calculated
extraction flow. This is number is indicated on the V2 and V3 table curves. Note
that the indicated calculated value is presented in the same engineering units as
used while configuring the flow numbers in the steam map.

As the 505DE in general is not fitted with a flow measurement, the flow
information may need to be obtained from elsewhere, for example a DCS
system. If this data is not available, leave the V2 and V3 curves as they are. In
general this will only introduce small errors in the header pressure that the
normal PID action is able to correct. To verify the created curves, it is convenient
to create an X-Y plot from available DCS data (flow vs valve position) to see if
the shape matches up.

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Manual 91349V4 505DE Configuration Manual

Figure 5-9. V2 and V3 Effective Area Curve To Match Flow

Adjust extraction PID settings

When the extraction is enabled and active, the pressure PID needs to be tuned.
Depending on the size of the header, the PID tuning requires more attention. A
typical pressure response is presented below. As the header volume is big,
opening or closing the extraction valve will not result in quick additional pressure
fluctuations. Other valves on the extraction line may be causing the process
value to fluctuate. Note the static offset difference between the setpoint and the
measured value. This is the result of the droop configured for this extraction PID
to flow-share with a pressure regulating valve.

Check minimum flow from exhaust temperature

At this time, the system is tuned for proper pressure responses and all valves
have been calibrated according to the steam map. Now, the minimum flow
requirement can be tested to see if the minimum flow is enough to cool the back
end of the turbine section.

When the system meets a steam map limit that drives the V2 or V3 valve all the
way close to the calibrated minimum opening, it should produce the minimum
flow required to cool the back side of the LP turbine section. If the minimum flow
is enough, the backside temperature should not increase excessively over time.
If this is the case, the minimum flow can be lowered to increase the operating
envelope of the turbine. If on the other hand the temperature does increase, the
minimum flow opening should be increased up to the point where the
temperature remains stable below the required operating level.

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505DE Configuration Manual Manual 91349V4

Figure 5-10. Typical Pressure Response of Big Steam Header Volume

Adjust speed PID setting for island operation

A final system test is island operation. To perform this test, make sure that the
system island load is about the same as the current generator load. If this is the
case, open the grid or tie breaker and see if the islanding response is satisfactory
with a low load pickup or drop-off. If this is the case, create increasing load steps
to see if the response is still correct for higher load fluctuations. If it is not feasible
to switch on or off bigger load consumers, try to swap to island operation from a
higher grid load. This will allow the turbine to reject load without manipulating big
consumers on the island. In the figure presented below, there was an about 6
MW load rejection into island operation on a 30MW generator. This resulted in a
speed increase of about 60 rpm. The 505DE maintained pressure control without
any pressure bump.

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Manual 91349V4 505DE Configuration Manual

Figure 5-11. Typical Island Step Response

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