Installation and Operation Manual 505 Digital Governor for Steam Turbines with Single or Split-Range Actuators Volume 1 Manual 85017V1B WARNING 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. 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. CAUTION 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. 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 WARNING—indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION—indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment. NOTE—provides other helpful information that does not fall under the warning or caution categories. Revisions—Text changes are indicated by a black line alongside the text. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken. © Woodward 1997 All Rights Reserved Manual 85017V1 505 Digital Governor Contents ELECTROSTATIC DISCHARGE AWARENESS..................................................V CHAPTER 1. GENERAL INFORMATION...........................................................1 Introduction.............................................................................................................1 General Description................................................................................................3 505 Inputs and Outputs..........................................................................................5 Control Overview....................................................................................................8 Speed Control.........................................................................................................8 Auxiliary Control.....................................................................................................8 Load Sharing Input.................................................................................................9 Cascade Control.....................................................................................................9 Valve Limiter.........................................................................................................10 Starting Features..................................................................................................10 Critical Speed Avoidance.....................................................................................11 Block Diagrams....................................................................................................11 Keypad and Display..............................................................................................14 Watchdog Timer/CPU Fault Control.....................................................................16 CHAPTER 2. INSTALLATION PROCEDURES..................................................17 Introduction...........................................................................................................17 Mechanical Data and Hardware Installation.........................................................17 Communications Grounding and Shielding..........................................................33 CHAPTER 3. 505 CONTROL DESCRIPTION..................................................35 Introduction...........................................................................................................35 Turbine Start.........................................................................................................35 Turbine Start Modes.............................................................................................37 Critical Speed Avoidance.....................................................................................40 Idle/Rated.............................................................................................................41 Automatic Start Sequence....................................................................................42 No Idle Programmed............................................................................................45 Speed Control Overview......................................................................................45 Speed PID Operational Modes.............................................................................46 Cascade Control...................................................................................................58 Auxiliary Control...................................................................................................64 Remote Auxiliary Setpoint....................................................................................68 Valve Limiter.........................................................................................................70 Emergency Shutdown..........................................................................................70 Controlled Shutdown............................................................................................71 Overspeed Test Function.....................................................................................72 Local/Remote Function........................................................................................73 Function Keys.......................................................................................................74 Relays...................................................................................................................74 CHAPTER 4. CONFIGURATION PROCEDURES..............................................77 Program Architecture...........................................................................................77 Programming the 505...........................................................................................78 Exiting the Program Mode..................................................................................101 Valve/Actuator Calibration & Test......................................................................105 Calibration/Stroking Procedure..........................................................................106 Calibration/Stroking Procedure..........................................................................108 Woodward i 505 Digital Governor Manual 85017V1 Contents CHAPTER 5. 505 OPERATION...................................................................112 Run Mode Architecture......................................................................................112 Keypad and Display...........................................................................................116 Run Mode Front Panel Keys.............................................................................116 Starting Procedures...........................................................................................117 Speed Key Screens...........................................................................................118 Overspeed Test Function..................................................................................122 F3 and F4 Keys.................................................................................................123 Limiter (LMTR) Key Screens.............................................................................123 Actuator (ACTR) Key Screens..........................................................................124 Control (CONT) Key Screens............................................................................125 Dynamics (DYN) Key Screens..........................................................................127 Stop Key Screens..............................................................................................128 Auxiliary (Aux) Key Screens..............................................................................128 Remote/Speed Bias (RMT) Key Screens..........................................................131 Unit Load (KW) Key Screens............................................................................134 Cascade (CAS) Key Screens............................................................................135 Alarms................................................................................................................137 Trips...................................................................................................................138 Speed, Cascade, and Auxiliary Dynamics Adjustments...................................139 CHAPTER 6. COMMUNICATIONS................................................................143 Modbus® * Communications..............................................................................143 Port Adjustments...............................................................................................146 505 Control Modbus Addresses........................................................................146 Specific Address Information.............................................................................157 CHAPTER 7. SERVICE OPTIONS................................................................159 Product Service Options....................................................................................159 Returning Equipment for Repair........................................................................160 Replacement Parts............................................................................................161 How to Contact Woodward................................................................................161 Engineering Services.........................................................................................162 Technical Assistance.........................................................................................163 APPENDIX. 505 PROGRAM MODE WORKSHEETS......................................164 ii Woodward Manual 85017V1 505 Digital Governor Illustrations and Tables Figure 1-1. Typical Single or Dual Inlet Steam Turbine.........................................3 Figure 1-2. Split Range or Admission Type of Turbine Configuration...................3 Figure 1-3a. Overview of 505 Functionality............................................................6 Figure 1-3b. Overview of 505 Functionality............................................................7 Figure 1-4. Overview of 505 Functionality Notes.................................................12 Figure 1-5. Single or Split-Range Turbine Configurations...................................13 Figure 1-6. Single or Split-Range Turbine Configurations...................................13 Figure 1-7. Single or Split-Range Turbine Configurations...................................14 Figure 1-8. 505 Key Pad and Display...................................................................14 Figure 2-1. 505 Control Layout (Standard Enclosure).........................................19 Figure 2-2. 505 Bulkhead-Mounted Enclosure.....................................................20 Figure 2-3. Jumper Options..................................................................................21 Figure 2-4. Jumper Locations...............................................................................21 Figure 2-5. CageClamp Terminal Blocks.............................................................23 Figure 2-6. Control Wiring Diagram.....................................................................24 Figure 2-7. Representative 505 I/O Schematic....................................................25 Figure 2-8. Fuse location......................................................................................26 Figure 2-9. Shielded Wire Connections...............................................................27 Figure 2-10. Typical RS-232 Communications....................................................32 Figure 2-11. Typical RS-422 Communications....................................................32 Figure 2-12. Typical RS-485 Communications....................................................33 Figure 2-13. Preferred Multipoint Wiring with a Separate Signal Ground Wire...33 Figure 2-14. Alternate Multipoint Wiring without a Separate Signal Ground Wire34 Figure 3-1. Basic Control Overview......................................................................35 Figure 3-2. Manual Start Mode Example.............................................................38 Figure 3-3. Semiautomatic Start mode Example.................................................39 Figure 3-4. Automatic Start Mode Example.........................................................40 Figure 3-5. Idle/Rated Start..................................................................................42 Figure 3-6. Automatic Start Sequence.................................................................43 Figure 3-7. Speed Control Functional Diagram....................................................46 Figure 3-8. Speed PID Control Modes.................................................................47 Figure 3-9. Frequency and Unit Load Relationship.............................................49 Figure 3-10. Speed Relationships........................................................................51 Figure 3-11. Loadsharing Logic............................................................................57 Figure 3-12. Cascade Functional Diagram..........................................................59 Figure 3-13. Aux Control Overview......................................................................64 Figure 4-1. Basic Program Architecture...............................................................77 Figure 4-2. Initial 505 Program Mode Entry.........................................................78 Figure 4-3a. Program Mode Blocks.....................................................................81 Figure 4-3b. Program Mode Blocks.....................................................................82 Figure 4-3c. Program Mode Blocks......................................................................83 Figure 4-3d. Program Mode Blocks.....................................................................84 Figure 4-4. Exiting the Program Mode...............................................................101 Figure 4-5. Stroke Actuator................................................................................110 Figure 4-6. Stroking Dual Actuators...................................................................111 Figure 5-1. Basic Program Architecture.............................................................112 Figure 5-2a. Overview of Run Mode..................................................................113 Figure 5-2b. Overview of Run Mode..................................................................114 Figure 5-3. 505 Keypad and Display..................................................................116 Figure 5-4. SPEED Key Screens.......................................................................118 Figure 5-5. Direct Setpoint Entry........................................................................121 Figure 5-6. Overspeed Test Enable Key Screens..............................................122 Figure 5-7. LMTR Key Screens..........................................................................124 Figure 5-8. ACTR Key Screens..........................................................................125 Woodward iii 505 Digital Governor Manual 85017V1 Illustrations 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. Jumper Options Chart.........................................................................22 Table 3-1. On-Line/Off-Line Dynamics Selection.................................................53 Table 3-2. Load Sharing Logic.............................................................................58 Table 4-1. Actuator Driver Limits.......................................................................106 Table 5-1. Overview of Run Mode.....................................................................115 Table 5-2. Idle/Rated Messages.......................................................................119 Table 5-3. Auto Start Messages........................................................................120 Table 5-4. Controlling Parameter Messages.....................................................126 Table 5-5. Auxiliary Messages (if using Aux enable)........................................130 Table 5-6. Auxiliary Messages (if using Aux as a limiter)..................................130 Table 5-7. Remote AUX Messages...................................................................131 Table 5-8. Remote Speed Messages................................................................132 Table 5-9. Control Messages............................................................................133 Table 5-10. Cascade Control Messages...........................................................136 Table 5-11. Remote Cascade Messages..........................................................137 Table 5-12. Alarm Messages............................................................................138 Table 5-13. Trip Messages................................................................................139 Table 6-1. ASCII vs RTU Modbus.....................................................................144 Table 6-2. Modbus Function Codes..................................................................145 Table 6-3. Modbus Error Codes........................................................................146 Table 6-4. Maximum Modbus Discrete and Analog Values..............................147 Table 6-5. Boolean Write Addresses.................................................................148 Table 6-6. Boolean Read Addresses................................................................150 Table 6-7. Analog Read Addresses..................................................................152 Table 7-8. Analog Write Addresses...................................................................152 Table 6-9. Last Turbine Trip Cause...................................................................153 Table 6-10. Control Status.................................................................................153 Table 6-11. Analog Input Configuration.............................................................154 Table 6-12. Analog Output Configuration..........................................................154 Table 6-13. Relay Configuration........................................................................155 Table 6-14. Contact Input Configurations..........................................................156 Table 6-15. Units Configuration.........................................................................156 iv Woodward Manual 85017V1 505 Digital Governor Electrostatic Discharge Awareness All electronic equipment is static-sensitive, some components more than others. To protect these components from static damage, you must take special precautions to minimize or eliminate electrostatic discharges. Follow these precautions when working with or near the control. 1. Before doing maintenance on the electronic control, discharge the static electricity on your body to ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.). 2. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials. Wear cotton or cotton-blend materials as much as possible because these do not store static electric charges as much as synthetics. 3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or folders, plastic bottles, and plastic ash trays) away from the control, the modules, and the work area as much as possible. 4. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary. If you must remove the PCB from the control cabinet, follow these precautions: • 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 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. Woodward v 505 Digital Governor Manual 85017V1 vi Woodward Manual 85017V1 505 Digital Governor Chapter 1. General Information Introduction This manual describes the Woodward 505 Digital Governor for steam turbines. English versions are 9907-162, 9907-163, and 9907-164. The option charts below show the differences between the part numbers. Volume 1 of this manual provides installation instructions, describes the control, and explains the configuration (programming) and operating procedures. Volume 2 includes notes on applying the control to specific applications, Service mode information, and 505 hardware specifications. This manual does not contain instructions for the operation of the complete turbine system. For turbine or plant operating instructions, contact the plant-equipment manufacturer. Manual 85018 describes the 505E Digital Governor for extraction steam turbines. Part Number Options Part Number Power 9907-162 HVAC (180–264 Vac) 9907-163 AC/DC (88–132 Vac or 90–150 Vdc) 9907-164 LVDC (18–32 Vdc) Optional Bulkhead Mounting Box (NEMA 4X) P/N 8923-439 General Installation and Operating Notes and Warnings This equipment is suitable for use in Class I, Division 2 , Groups A, B, C, and D (Class I, Zone 2, Group IIC) or non-hazardous locations. The 505s are suitable for use in European Zone 2, Group II environments per compliance with EN60079-15, Electrical apparatus for explosive atmospheres – Type of protection ‘n’ These listings are limited only to those units bearing the certification identification. Field wiring must be rated at least 75 °C for operating ambient temperatures expected to exceed 50 °C. Peripheral equipment must be suitable for the location in which it is used. Wiring must be in accordance with North American Class I, Division 2 or European Zone 2 wiring methods as applicable, and in accordance with the authority having jurisdiction. WARNING Explosion hazard–Do not connect or disconnect while circuit is live unless area is known to be non-hazardous. Explosion Hazard–Substitution of components may impair suitability for Class I, Division 2. Woodward 1 505 Digital Governor Manual 85017V1 AVERTISSEMENT Risque d’explosion–Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf en cas l’ambiance est décidément non dangereuse. Risque d’explosion–La substitution de composants peut rendre ce matériel inacceptable pour les emplacements de Classe I, Division 2. WARNING Do not use any test points on the power supply or control boards unless the area is known to be non-hazardous. AVERTISSEMENT Ne pas utiliser les bornes d’essai du block d’alimentation ou des cartes de commande à moins de se trouver dans un emplacement non dangereux. 505 Software Changes Covered in This Manual Revision 1. PROGRAM MODE: Added an error check to ensure Rated Speed (when programmed as a gen set) was less than max gov. 2. SERVICE MODE: Changed the hold changes for Min Load to come from the Breaker Logic header's Hold Changes input. Previously the hold changes command was selected under the Speed Control Settings header. 3. SPEED SETPOINT RATES: Changed the minimum adjustment range for all speed setpoint rates to 0.01 (was 0.1). 4. AUX LIMITER or CONTROLLER: Added logic to ensure the inhibited status of Aux control when the input is failed. In addition, changed Aux re- enable logic such that when a failed aux input is restored there is no glitch to the speed LSS. Also changed breaker open logic to correct a Gen Opening Aux actuator output glitch. 5. AUX CONTROLLER: Changed the speed setpoint aux biasing logic to only allow the speed control limiting action (while in aux control) to be active when the speed setpoint reaches max gov. Prior to this fix the speed limiter could come into control during an extreme transient. 6. AUX DIRECT ENTERED SETPT: Changed Aux Entered setpoint to be reset/stopped on a shutdown pulse rather than held disabled on a shutdown condition. This change allows the Aux Limiter function direct setpoint entry even when the unit is tripped. 7. AUX and CASC DROOP: Changed the droop feedback lag-tau tunable range from a max of 10 to a max of 1000. 8. MODBUS: Changed the Gen and Tie Open alarms for Aux, Casc, and Remote to match the Modbus® * listing—the software eventlatch inputs were reversed/backwards with the Modbus listing. *—Modbus is a trademark of Modicon, Inc. 9. CONTROLLED STOP: Made the Controlled Stop abort if speed raise/lower is selected or another control mode is selected. This can be tuned-out by setting CNTRL_STOP.RL_STOP.IN_2=*false in the debug mode. 10. ANALOG INPUTS: Changed max setting on the delay time’s tunable range from 3 ms to 3000 ms. The analog input failure delay setting is defaulted to zero but can be adjusted up to 3000 ms using the debug mode MAIN.AIx.LATCH_DLY where x is the analog input number. Added a tunable single pole filter (LAG) to each analog input. Output/input = 1/(1+st) where t = 1/(2(pi)f) = LAG_TAU. The Lag-tau is defaulted to zero but can be adjusted in the debug mode using MAIN.AIx_LAG.LAG_TAU where x is the analog input number (1-6). 2 Woodward