Installatio n and Operation Manual
505 505 Dig Digit ital al Gov Governor ernor for fo r Steam Steam Turbin Turb ines es with Single ing le or Split -Range Actu ators tor s
Volume 1
Manual 85017V1B
WARNING Read Read this entire manual and and all other publ ications pertaining to the work to be performed before installing, operating, or servicin g this equipment. Practice Practice all plant and safety safety instruct ions and precautions. Failure Failure to follow instru ctions can cause personal injury and/or pro perty damage. damage. The engine, engine, turbine, or other type of prime mover should be equipped with an overspeed shutdow n device to protect against runaway or d amage amage to the prime mover with p ossibl e personal injury, loss of life, or property damage. The overspeed overspeed shutdow n device must be totally independent of the prime mover contro l system. An overtemperature overtemperature or overpressure shutd own device may also also be needed needed fo r safety, as appropriate.
CAUTION To prevent damage to a control sys tem that uses an alternator or battery-charging device, make sure the charging device is turned off before disc onnecting th e battery from the system. Electronic Electronic control s contain static-sensitive parts. Observe Observe the following precautions to prevent damage to these parts. Discharge body static before handling handling th e control (with pow er to the control • turned off, contact a grounded surface and maintain contact while handling the control). Av oi d al l p las ti c, vin v in yl, yl , and Styro Sty ro fo am (ex cep t an ti st ati c vers v ers io ns ) aro un d • printed circuit boards. Do not touch the components or conductors on a printed printed circuit board with • your hands or with conductive devices.
IMPORTANT DEFINITIONS WARNI WARNING NG—indicates —indicates a potentially hazardous hazardous situation which , if not avoided, could result in death or serious injury. CAUTI CAUTION ON—indicates —indicates a potentially hazardous hazardous situation whic h, if not avoided, could result in d amage to equipment. NOTE NOTE—provides —provides other helpful inf ormation that does no t fall under the warning o r caution categories.
Revisions Revisions —Text —Text changes are indicated by a black line alongs ide the text.
Woodward Governor Company reserves the right t o update any portion of th is publ ication at any time. Information Information provided by Woodw ard Governor Company is believed to be correct and reliable. However, no responsi bilit y is assumed by Woodward Governor Company unless otherwi se expressly undertaken.
© Woodward 1997 All Rig hts Reserved
WARNING Read Read this entire manual and and all other publ ications pertaining to the work to be performed before installing, operating, or servicin g this equipment. Practice Practice all plant and safety safety instruct ions and precautions. Failure Failure to follow instru ctions can cause personal injury and/or pro perty damage. damage. The engine, engine, turbine, or other type of prime mover should be equipped with an overspeed shutdow n device to protect against runaway or d amage amage to the prime mover with p ossibl e personal injury, loss of life, or property damage. The overspeed overspeed shutdow n device must be totally independent of the prime mover contro l system. An overtemperature overtemperature or overpressure shutd own device may also also be needed needed fo r safety, as appropriate.
CAUTION To prevent damage to a control sys tem that uses an alternator or battery-charging device, make sure the charging device is turned off before disc onnecting th e battery from the system. Electronic Electronic control s contain static-sensitive parts. Observe Observe the following precautions to prevent damage to these parts. Discharge body static before handling handling th e control (with pow er to the control • turned off, contact a grounded surface and maintain contact while handling the control). Av oi d al l p las ti c, vin v in yl, yl , and Styro Sty ro fo am (ex cep t an ti st ati c vers v ers io ns ) aro un d • printed circuit boards. Do not touch the components or conductors on a printed printed circuit board with • your hands or with conductive devices.
IMPORTANT DEFINITIONS WARNI WARNING NG—indicates —indicates a potentially hazardous hazardous situation which , if not avoided, could result in death or serious injury. CAUTI CAUTION ON—indicates —indicates a potentially hazardous hazardous situation whic h, if not avoided, could result in d amage to equipment. NOTE NOTE—provides —provides other helpful inf ormation that does no t fall under the warning o r caution categories.
Revisions Revisions —Text —Text changes are indicated by a black line alongs ide the text.
Woodward Governor Company reserves the right t o update any portion of th is publ ication at any time. Information Information provided by Woodw ard Governor Company is believed to be correct and reliable. However, no responsi bilit y is assumed by Woodward Governor Company unless otherwi se expressly undertaken.
© Woodward 1997 All Rig hts Reserved
Manual 85017V 85017V1 1
505 Digital Governor
Contents ELECTROSTATIC DISCHARGE A WARENESS ............................ .......................................... ...................... ........ V CHAPTER 1. GENERAL INFORMATION............................ .......................................... ............................ ................. ... 1 Introduction.............................................................................................................1 General Description................................................................................................3 505 Inputs Inputs and and Output Outputs s ................................. .................................................. ................................. ................................. ........................5 .......5 Control Overview....................................................................................................8 Speed Control.........................................................................................................8 Auxiliary Auxiliary Control ontrol .................................. .................................................. ................................. .................................. .................................. .................8 8 Load Sharing Input.................................................................................................9 Cascade Control.....................................................................................................9 Valve Limiter.........................................................................................................10 S tartin tarting g Feature eatures s ................................. ................................................. ................................ ................................. ................................. ................10 10 Critical ritical S peed Avoidance Avoidance ............................... ................................................ .................................. .................................. ....................11 ...11 Block Diagrams Diagrams ................................. ................................................. ................................. .................................. .................................. .................11 11 Keypad and Display..............................................................................................14 Watchdog Timer/CPU Fault Control.....................................................................16 CHAPTER 2. INSTALLATION PROCEDURES............................ .......................................... ...................... ........ 17 Introduction...........................................................................................................17 Mechanical Data and Hardwar Hardware e Installation.................... Installation.................................... ................................ .....................17 .....17 Comm ommunications unications Grounding and and Shield S hielding............... ing............................... ................................. ...........................33 ..........33 CHAPTER 3. 505 CONTROL DESCRIPTION ............................ .......................................... ...................... ........ 35 Introduction...........................................................................................................35 Turb Turbine ine Star Start. t... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..3 35 Turb Turbine ine Star Startt Mod Modes .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...3 .37 7 Critical ritical S peed Avoidance Avoidance ............................... ................................................ .................................. .................................. ....................40 ...40 Idle/Rated ................................. ................................................. ................................. .................................. .................................. ..........................41 .........41 Automatic Start Sequence....................................................................................42 No Idle P rogram rogramm med ................................. ................................................. ................................. .................................. ..........................45 .........45 S peed Control ontrol Overview Overview ................................ ................................................ ................................. ................................. .....................45 .....45 Speed PID Operational Modes.............................................................................46 Cascade Control...................................................................................................58 Auxiliary Auxiliary Control ontrol ................................. ................................................. ................................. ................................. ................................. .................64 64 Remote Auxiliary Setpoint....................................................................................68 Valve Limiter.........................................................................................................70 E mergency ergency Shutdow hutdown n ............................... ............................................... ................................. ................................. ..........................70 ..........70 Controlled Shutdown............................................................................................71 Overspeed Test Function.....................................................................................72 Local/Rem Local/R emote ote Function unction ................................ ................................................. .................................. .................................. ......................73 .....73 Function Keys.......................................................................................................74 Relays...................................................................................................................74 CHAPTER 4. CONFIGURATION PROCEDURES .......................... ........................................ .................... ...... 77 P rogram rogram Architectu Architecture re ................................ ................................................ ................................. ................................. ..........................77 ..........77 Programming the 505...........................................................................................78 Exiting the Program Mode..................................................................................101 Valve/Actuator Valve/Actuator Calibration Calibration & Test ............................... ............................................... ................................. .......................105 ......105 Calibration alibration/S /Str troking oking P rocedure rocedure ............................... ................................................ .................................. ..........................106 .........106 Calibration alibration/S /Str troking oking P rocedure rocedure ............................... ................................................ .................................. ..........................108 .........108
505 Digital Governor
Manual 85017V1
Contents CHAPTER 5. 505 OPERATION ...................................................................112 Run Mode Architecture...................................................................................... 112 Keypad and Display........................................................................................... 116 Run Mode Front P anel Keys ............................................................................. 116 Starting Procedures........................................................................................... 117 Speed Key Screens........................................................................................... 118 Overspeed Test Function.................................................................................. 122 F3 and F4 Keys ................................................................................................. 123 Limiter (LMTR) Key Screens ............................................................................. 123 Actuator (ACTR) Key Screens .......................................................................... 124 Control (CONT) Key Screens............................................................................ 125 Dynamics (DYN) Key Screens .......................................................................... 127 Stop Key Screens.............................................................................................. 128 Auxiliary (Aux) Key Screens.............................................................................. 128 Remote/Speed Bias (RMT) Key Screens.......................................................... 131 Unit Load (KW) Key S creens ............................................................................ 134 Cascade (CAS) Key Screens ............................................................................ 135 Alarms................................................................................................................ 137 Trips................................................................................................................... 138 Speed, Cascade, and Auxiliary Dynamics Adjustments ................................... 139 CHAPTER 6. COMMUNICATIONS................................................................143 Modbus® * Communications.............................................................................. 143 Port Adjustments ............................................................................................... 146 505 Control Modbus Addresses........................................................................ 146 Specific Address Information............................................................................. 157 CHAPTER 7. SERVICE OPTIONS ................................................................159 Product Service Options.................................................................................... 159 Returning Equipment for Repair........................................................................ 160 Replacement Parts ............................................................................................ 161 How to Contact Woodward................................................................................ 161 Engineering Services......................................................................................... 162 Technical Assistance......................................................................................... 163 A PPENDIX. 505 PROGRAM MODE WORKSHEETS ......................................164
Manual 85017V 85017V1 1
505 Digital Governor
Illustr llu str ations tio ns and Tables Tables Figure igure 1-1. Typical Typical Single or Dual Dual Inlet Steam team Turbine............... Turbine ............................... .......................... ..........3 3 Figure igure 1-2. Split Range or Admission Admission Type of Turbine Turbine Configuration Configuration ...................3 ...................3 Figure igure 1-3a. Overview Overview of 505 Functionalit Functionality................ y................................. ................................. ........................... ...........6 6 Figure igure 1-3b. Overview Overview of 505 505 Funct F unctionalit ionality................ y................................. ................................. ........................... ...........7 7 Figure igure 1-4. Overview Overview of 505 505 Funct Functionalit ionality y Notes Notes ............................... ................................................ ..................12 .12 Figure igure 1-5. Single or Split-R plit-Range ange Turbine Turbine Configurat Configurations ions ............................... ...................................13 ....13 Figure igure 1-6. Single or Split-R plit-Range ange Turbine Turbine Configurat Configurations ions ............................... ...................................13 ....13 Figure igure 1-7. Single or Split-R plit-Range ange Turbine Turbine Configurat Configurations ions ............................... ...................................14 ....14 Figure 1-8. 505 Key Pad and Display...................................................................14 Figure igure 2-1. 505 505 Control Control Layout (Stan (Standard dard Enclosure)............... nclosure) ............................... ..........................19 ..........19 Figure 2-2. 505 Bulkhead-Mounted Enclosure.....................................................20 Figure igure 2-3. J umper umper Options..... Options..................... ................................. ................................. ................................ ............................ ............21 21 Figure igure 2-4. J umper umper Locations................................ Locations................................................. ................................. .............................. ..............21 21 Figure igure 2-5. CageClam CageC lamp p Terminal Terminal Blocks .................................. ................................................... ...........................23 ..........23 Figure igure 2-6. Control Wiring Diagram................ Diagram ................................. .................................. .................................. ...................24 ..24 Figure igure 2-7. Representativ Representative e 505 I/O Schem S chemati atic c ................................ ................................................ ....................25 ....25 Figure 2-8. Fuse location......................................................................................26 Figure igure 2-9. Shielded hielded Wire Connections Connections ............................... ................................................ ................................ ...............27 27 Figure igure 2-10. Typical RS-232 Comm ommunications unications .................................. .................................................. ..................32 ..32 Figure igure 2-11. Typical RS-422 Comm ommunications unications .................................. .................................................. ..................32 ..32 Figure igure 2-12. Typical RS-485 Comm ommunications unications .................................. .................................................. ..................33 ..33 Figure 2-13. 2-13. Preferred P referred Multipoint Wiring with with a Separate Signal Ground Wire ...33 ...33 Figure 2-14. Alternate Multipoint Wiring without a Separate Signal Ground Wire34 Figure 3-1. Basic Control Overview......................................................................35 Figure igure 3-2. 3-2. Manual Manual Start Mode Example Example ................................ ................................................. ............................. ............38 38 Figure igure 3-3. Sem S emiaut iautom omatic atic Start mode Exam Example ple ............................... ............................................... ..................39 ..39 Figure igure 3-4. Autom Automatic atic S tart tart Mode Example Example ............................... ............................................... ..........................40 ..........40 Figure 3-5. Idle/Rated Start..................................................................................42 Figure igure 3-6. Automatic Automatic Start tart Sequence equence............... ................................ .................................. ................................. ................43 43 Figure 3-7. Speed Control Functional Diagram....................................................46 Figure igure 3-8. Speed P ID Control Control Modes.............. Modes .............................. ................................ ................................ ...................47 ...47 Figure igure 3-9. 3-9. Frequency Frequency and Unit Load Relationship ............................... ............................................. ..............49 49 Figure igure 3-10. Speed Relationships Relationships ............................... ................................................ ................................. ........................51 ........51 Figure 3-11. Loadsharing Logic............................................................................57 Figure igure 3-12. Cascade F unctional unctional Diagram................. Diagram .................................. .................................. ........................59 .......59 Figure 3-13. Aux Control Overview......................................................................64 Figure igure 4-1. 4-1. Basic Progr P rogram am Architect Architecture ure................ ................................. .................................. .............................. .............77 77 Figure igure 4-2. Initial Initial 505 505 Progr Program am Mode Entry.............. Entry............................... ................................. ..........................78 ..........78 Figure igure 4-3a. P rogram rogram Mode Blocks ................................. .................................................. .................................. ...................81 ..81 Figure igure 4-3b. P rogram rogram Mode Blocks ................................. .................................................. .................................. ...................82 ..82 Figure 4-3c. Program Mode Blocks......................................................................83 Figure igure 4-3d. P rogram rogram Mode Blocks ................................. .................................................. .................................. ...................84 ..84 Figure igure 4-4. E xiting xiting the the Program Mode ................................ ................................................ ............................... ...............101 101 Figure igure 4-5. Stroke troke Actuator Actuator ................................. ................................................. ................................ ............................... ...............110 110 Figure igure 4-6. 4-6. Stroking Stroking Dual Dual Actuat Actuators ors ................................. .................................................. .................................. .................111 111 Figure igure 5-1. Basic Progr P rogram am Architect Architecture ure................ ................................. .................................. ............................112 ...........112 Figure igure 5-2a. 5-2a. Overview Overview of Run Mode ................................ ................................................ ................................. ..................113 .113 Figure igure 5-2b. 5-2b. Overv Overview iew of Run Mode ................................ ................................................ ................................. ..................114 .114 Figure 5-3. 505 Keypad and Display..................................................................116 Figure Figure 5-4. 5-4. S P EED EE D Key Screens Screens .................. ............................ ................... ................... ................... ................... ...............1 .....118 18 Figure 5-5. Direct Setpoint Entry........................................................................121 Figure 5-6. Overspeed Test Enable Key Screens..............................................122 Figure 5-7. LMTR Key Screens..........................................................................124 Figure 5-8. ACTR Key Screens..........................................................................125
505 Digital Governor
Manual 85017V1
Illustr ations and Tables Figure 5-9. CONT Key Screens ........................................................................ 126 Figure 5-10. DYN Key Screens......................................................................... 127 Figure 5-11. STOP Key Screens....................................................................... 128 Figure 5-12. AUX Key Screens ......................................................................... 129 Figure 5-13. RMT Key Screens......................................................................... 132 Figure 5-14. KW Key Screens........................................................................... 134 Figure 5-15. CAS Key Screens ......................................................................... 135 Figure 5-16. ALARM Screen............................................................................. 137 Figure 5-17. TRIP Screen.................................................................................. 138 Figure 5-18. Typical Response to Load Change............................................... 142 Figure 6-1. ASCII/RTU Representation of 3...................................................... 144 Figure 6-2. Modbus Frame Definition................................................................ 145 Table 2-1. J umper Options Chart.........................................................................22 Table 3-1. On-Line/Off-Line Dynamics Selection.................................................53 Table 3-2. Load Sharing Logic.............................................................................58 Table 4-1. Actuator Driver Limits....................................................................... 106 Table 5-1. Overview of Run Mode..................................................................... 115 Table 5-2. Idle/Rated Messages ....................................................................... 119 Table 5-3. Auto Start Messages........................................................................ 120 Table 5-4. Controlling Parameter Messages..................................................... 126 Table 5-5. Auxiliary Messages (if using Aux enable) ........................................ 130 Table 5-6. Auxiliary Messages (if using Aux as a limiter).................................. 130 Table 5-7. Remote AUX Messages................................................................... 131 Table 5-8. Remote Speed Messages................................................................ 132 Table 5-9. Control Messages ............................................................................ 133 Table 5-10. Cascade Control Messages........................................................... 136 Table 5-11. Remote Cascade Messages.......................................................... 137 Table 5-12. Alarm Messages ............................................................................ 138 Table 5-13. Trip Messages................................................................................ 139 Table 6-1. ASCII vs RTU Modbus ..................................................................... 144 Table 6-2. Modbus Function Codes.................................................................. 145 Table 6-3. Modbus Error Codes........................................................................ 146 Table 6-4. Maximum Modbus Discrete and Analog Values.............................. 147 Table 6-5. Boolean Write Addresses................................................................. 148 Table 6-6. Boolean Read Addresses ................................................................ 150 Table 6-7. Analog Read Addresses .................................................................. 152 Table 7-8. Analog Write Addresses................................................................... 152 Table 6-9. Last Turbine Trip Cause................................................................... 153 Table 6-10. Control Status................................................................................. 153 Table 6-11. Analog Input Configuration............................................................. 154 Table 6-12. Analog Output Configuration.......................................................... 154 Table 6-13. Relay Configuration........................................................................ 155 Table 6-14. Contact Input Configurations.......................................................... 156 Table 6-15. Units Configuration......................................................................... 156
Manual 85017V1
505 Digital Governor
Electrostatic Disc harge 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 To prevent damage to electronic compo nents caused by impro per handling, read and observe the precautions in Woodw ard manual 82715, Guide for Handling and Protection of Electroni c Controls, Printed Circuit Boards, and Modules.
505 Digital Governor
Manual 85017V1
