Woodward 505XT Product Manual
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Woodward 505XT Product Manual

Digital control for steam turbines, single valve, extraction and/or admission
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Released
Product Manual 35018V3
(Revision -, 3/2020)
Original Instructions
505XT Digital Control for Steam Turbines
(Single Valve, Extraction and/or Admission)
Manual 35018 consists of 3 volumes (35018V1, 35018V2 & 35018V3)
505XT Dual Redundant Volume 3

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  • Page 1 Released Product Manual 35018V3 (Revision -, 3/2020) Original Instructions 505XT Digital Control for Steam Turbines (Single Valve, Extraction and/or Admission) Manual 35018 consists of 3 volumes (35018V1, 35018V2 & 35018V3) 505XT Dual Redundant Volume 3...
  • Page 2 Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    ..................7 LECTROSTATIC ISCHARGE WARENESS 15. G ................... 8 HAPTER ENERAL NFORMATION Feature Differences between the 505DR and previous 505/505XT ............10 16. R .............. 11 HAPTER EDUNDANT ETUP AND ONFIGURATION Hardware Setup ............................11 Input and Output Signals ..........................12 Actuator Drivers ............................
  • Page 4 Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Illustrations and Tables Figure 15-1. Typical Redundant 505XT Application Configuration ............... 9 Figure 16-1. 505DR with FTM ........................12 Figure 16-2. Single Coil Shared Driver ....................... 17 Figure 16-3 Single Coil Shared Driver with 505DR FTM ................17 Figure 16-4 Dual Coil Driver........................
  • Page 5 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Table 16-1. Field Termination Module Kit Bill of Materials ................. 11 Table 16-2. Analog Input Fault Table ......................13 Table 16-3. Single Speed Signal Fault Table ..................... 13 Table 16-4. 2 Speed Signal Fault Table ..................... 13 Table 16-5.

  • Page 6: Warnings And Notices

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Warnings and Notices Important Definitions This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

  • Page 7: Electrostatic Discharge Awareness

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Electrostatic Discharge Awareness 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...

  • Page 8: Chapter 15. General Information

    Controlled Extraction and Admission turbines (2 Control valves) The 505XT uses the term Primary to describe the unit with DIP Switch position 0001 and the term Secondary to describe the unit with DIP Switch position 0002 (please refer to Appendix A in the Flex500 hardware manual 26838 for DIP switch configuration instructions).

  • Page 9: Figure 15-1. Typical Redundant 505Xt Application Configuration

    Unlike commands over communication paths (Local Panel, RemoteView, or DCS Modbus Commands), only the SYSCON processes hardwired Discrete Input signals. Therefore, the system is designed to have Discrete Input signals wired to each 505XT controller so that a command or system signal is seen by both 505XT units simultaneously.

  • Page 10: Feature Differences Between The 505Dr And Previous 505/505Xt

    505XT Dual Redundant Control System for Steam Turbines Part Number Options In order to be used as a redundant system, the 505XT must be purchased as a redundant controller using the part numbers below. The simplex 505 and 505XT part numbers listed in Volume 1 of this manual cannot be applied in a redundant application.

  • Page 11: Chapter 16. Redundant Setup And Configuration

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Chapter 16. Redundant Setup and Configuration Hardware Setup Detailed hardware setup information is covered in the Flex500 Manual 26838 Appendix A. The following is a bullet list of the hardware configuration and control interlocks required to operate the 505DR controllers in a redundant mode.

  • Page 12: Input And Output Signals

    All signal scaling and calibration is applied to both units as the I/O signals are shared between both units for each channel. The details for each IO channel type below describe how the channels function specifically in the 505XT application and how failure modes are handled.
  • Page 13 The automatic Open Wire Detection function that is available on the simplex versions of the 505 and 505XT, is not available on the DR version. This is due to the fact that the MPU signals are paralleled between the 2 controls. The open wire detection routine can be used as a manual check prior to starting...
  • Page 14 SYSCON and BACKUP Contact Input signals will be annunciated as a difference alarm. In the case of a signal difference, the 505XT control will always follow the SYSCON signal status. If a DI difference alarm is present, an operator action or event causing a SYSCON transfer may result in unexpected results, including a TRIP.
  • Page 15 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Table 16-5. Analog Output Fault Table SYSCON BACKUP BACKUP SYSCON Channel FAULT FAULT STAT Transfer Analog Output (RO) FALSE FALSE Available Analog Output (RO) TRUE FALSE Available Analog Output (RO)

  • Page 16: Actuator Drivers

    Actuators for both the HP and LP valve output demands. In addition, the driver demands can also be routed to Woodward Digital Drivers or a LinkNet RTC node for bumpless SYSCON transfers. For split- range applications, HP2 and LP2 are supported as a Single Coil configuration.

  • Page 17: Figure 16-2. Single Coil Shared Driver

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Primary 505DR Secondary 505DR Single Coil Shared ACT 1 ACT 2 ACT 1 ACT 2 Twisted Pair Shield Figure 16-2. Single Coil Shared Driver It is recommended to use the 505DR FTM which builds-in the diode and wire junctions between Actuator Output channels on the Primary and Secondary units.

  • Page 18: Figure 16-4 Dual Coil Driver

    0%. The application will automatically account for providing the correct output current required on the healthy channels due to any faults detected. The following are a couple examples of redundant actuators that are available from Woodward that would be configured as redundant actuators in the 505DR.

  • Page 19: Figure 16-6. Redundant (Parallel) Actuator Driver

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Table 16-8. Woodward Redundant Actuators Product Name Part Number Description 8918-116 (10 Bar) Current to Pressure Converter Dual Transfer Skid CPC-DX 8918-118 (25 Bar) (manual 26758) 8918-165, -167 (Zone 1)

  • Page 20: Figure 16-8. Actuator Driver With Redundant Demands

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines When a Redundant Actuator is configured, the Boolean Input function lists can be used to provide the health status of each actuator driver back to the 505DR. The Boolean input can be configured for the following options: Table 16-9.
  • Page 21 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Table 16-10. Driver Fault Current Table SYSCON Unit BACKUP Unit System Status Actuator Type Act Current Output Healthy Single Coil SYSCON = Valve Demand + ½ of the Min Act...
  • Page 22 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines SYSCON Unit BACKUP Unit System Status Actuator Type Act Current Output BACKUP Redundant SYSCON = Unavailable Actuators Valve1 = Full Demand + full Min Act current Valve2 = Full Demand + full Min Act current...

  • Page 23: Figure 16-9. Actuator Type Configuration

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Configuration of Actuator Drivers 1. Login to the Configure User Level and then enable Configuration Mode from the Mode Screen 2. Navigate to the Configuration Menu, then select the Drivers page 3.

  • Page 24: Figure 16-10. Driver Channel Configuration

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-10. Driver Channel Configuration If an SPC is configured, an option for an Analog Backup driver will be made available. This demand signal can be configured on an Analog Output channel of the 505DR to provide the drive signal in the case of a CAN communication failure.

  • Page 25: Figure 16-11. Ma Backup Channel Configuration

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-11. mA Backup Channel Configuration If an SPC or RTCNet AO channel is used, the CAN network needs to be enabled in the Woodward Links configuration menu. Once a channel has been selected, the configuration of that channel function is overridden by the control logic.

  • Page 26: Can Devices - Optional I/O And Digital Drivers

    The CAN communication ports are available for interfacing the control application with other products. The 505XT has been programmed these to be used for the following: CAN #1 Link to digital drivers/actuators (such as the SPC and VariStroke family)

  • Page 27: Figure 16-13. Servo Position Controller

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Servo Position Controller (SPC) Four SPC’s (p/n 8200-227) are pre-programmed in the control application to have CAN interfaces to this product. These digital drivers (manual 26236) support a variety of actuator interfaces including proportional or integrating valves, single coil drives of up to +/- 250 mA, with single or redundant position feedback.

  • Page 28: Figure 16-14. Spc Driver Can Links

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines CAN Wiring- Primary 505DR Secondary 505DR 55 COM 56 LOW CAN#1 CAN#1 57 SHLD BKUP BKUP BKUP BKUP HP Actuator 58 HIGH Daisy chain this COMM link thorugh all...

  • Page 29: Figure 16-15A. Spc Driver Configuration For Redundant Actuators

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-15a. SPC Driver Configuration for Redundant Actuators...

  • Page 30: Figure 16-15B. Spc Driver Configuration For Redundant Actuators

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-15b. SPC Driver Configuration for Redundant Actuators...

  • Page 31: Figure 16-15C. Spc Driver Configuration For Redundant Actuators

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-15c. SPC Driver Configuration for Redundant Actuators...

  • Page 32: Figure 16-15D. Spc Driver Configuration For Redundant Actuators

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-15d. SPC Driver Configuration for Redundant Actuators...

  • Page 33: Figure 16-15E. Spc Driver Configuration For Redundant Actuators

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-15e. SPC Driver Configuration for Redundant Actuators Figure 16-15f. SPC Driver Configuration for Redundant Actuators...

  • Page 34: Figure 16-15G. Spc Driver Configuration For Redundant Actuators

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-15g. SPC Driver Configuration for Redundant Actuators If using 2 SPC’s for dual coil actuators – configure the following parameters • Set Servo Controller Min & Max Position Currents to the appropriate currents for the proportional actuator being used (below example is a 20-160 mA coil) •...

  • Page 35: Figure 16-16B. Spc Driver Configuration For Dual Coil Actuators

    In the 505DR, additional I/O has been pre-programmed using Woodward’s RTCNet distributed I/O nodes. These are available via the Configuration Menu (under Woodward Links) and the user is free to select any or all of the nodes listed below. All distributed I/O channels have the same menu of functional choices as the lists above for the 505 hardware I/O.
  • Page 36 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines The RTCNet nodes can be individually purchased (1 or more) and installed based on the needs of the application. In general, the following functionality is available through Expandable I/O: 1.

  • Page 37: Figure 16-17. Expandable I/O Node 26 Driver (Bumpless Syscon Transfer)

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 16-17. Expandable I/O Node 26 Driver (bumpless SYSCON transfer)

  • Page 38: Communications

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Communications Ethernet Each 505DR unit has 3 Ethernet ports available to interface to the controllers for a total of 6 available ports to be used for Modbus communications or WWD Service Tools. Since the operating system processes all commands to the SYSCON, the turbine can be operated via Modbus from either the SYSCON or BACKUP controllers.

  • Page 39: Configuration Menu

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Configuration Menu The 505DR should be configured for the application as described in Volume 1 and Volume 2 of this manual, 35018. When Configuration, Service, or Runtime settings are adjusted in either the SYSCON or BACKUP the two units will automatically synchronize the settings changes so that both units contain identical settings.
  • Page 40 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Communications Menu – Secondary Chassis From the Factory, the Primary and Secondary chassis will have identical IP addresses for each of the ENET ports. The addresses should be set to a unique IP address to avoid IP address conflicts when placed on a network.
  • Page 41 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Woodward Links Menu RTCNet I/O NODES Enable Using RTCNet I/O Nodes? dflt= NO (Yes/No) Enable Node 21 (AIO) dflt= NO (Yes/No) If YES – set the Node Address on this device to 21...
  • Page 42 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Redundant Sensor 2 Good Equation dflt = Average (HSS, LSS, Avg) When both redundant sensors are healthy this value sets the equation used to calculate the Validated Signal for control. HSS = High Signal Select between the two sensors, LSS = Low Signal Select between the two sensors, AVG = Average of the two sensors.
  • Page 43 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines MSG_ Menu # Remote Speed Setpoint #2 Generator Load Input #2 Cascade Input #2 Auxiliary Input #2 Inlet Pressure Input #2 Exhaust Pressure Input #2 Extraction/Admission Input #2 Vibration Signal #1...
  • Page 44 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines MSG_ Menu # Isolated PID Setpoint Remote Isolated PID Setpoint Remote KW Setpoint Exhaust Pressure Input HP Valve Feedback Position HP2 Valve Feedback Position Signal Monitoring #1 Signal Monitoring #2...
  • Page 45 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Table 16-15. Boolean Input Function List MSG_ Menu # ---Not Used--- Reset Command Speed Raise Command Speed Lower Command Generator Breaker Utility Tie Breaker Overspeed Test External Run Start Permissive 1...
  • Page 46 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines MSG_ Menu # External Alarm 3 External Alarm 4 External Alarm 5 External Alarm 6 External Alarm 7 External Alarm 8 External Alarm 9 Spare 51 Redundant HP A Health Contact...
  • Page 47 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines MSG_ Menu # Spare_88 External Trip 11 External Trip 12 External Trip 13 External Trip 14 External Trip 15 External Alarm 10 External Alarm 11 External Alarm 12 External Alarm 13...
  • Page 48 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines MSG_ Menu # Remote Auxiliary Setpoint Active Turbine Started Spare 31 Primary Unit is SYSCON Secondary Unit is SYSCON Healthy Redundant Mode (Backup Ready) HP Valve Limiter in Control...
  • Page 49 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines MSG_ Menu # Inlet Pressure Input Failed Exhaust Pressure Input Failed Zero Speed Detected Spare_74 Spare_75 Spare_76 Spare_77 Spare_78 Spare_79 Spare_80...
  • Page 50 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Table 16-17. Relay Output Level Switch Function List Relay Level Switch Menu MSG_ Menu # --- Not Used --- Actual Speed Speed Setpoint KW Input Sync/Load Share Input Cascade Input...
  • Page 51 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Actuator Driver Function List Menu List See the Actuator Drivers section in this chapter for details on the available channels for the following functions. Actuator functions are configured in the Driver Configuration Menu. The menu does not chose a function based on the channel configuration like the other IO channels.
  • Page 52 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Event ID Description Error Meaning Contact Input 11 Error See "Contact Input 02 Error". Contact Input 12 Error See "Contact Input 02 Error". Contact Input 13 Error See "Contact Input 02 Error".
  • Page 53 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Event ID Description Error Meaning Analog Output 04 Error See "Analog Output 01 Error". Analog Output 05 Error See "Analog Output 01 Error". Analog Output 06 Error See "Analog Output 01 Error".
  • Page 54 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Event ID Description Error Meaning The Cascade control function was configured to use the Inlet Pressure analog input but an Cascade Inlet Pres CASC Config, CASC AI analog input was configured also. With this...
  • Page 55 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Event ID Description Error Meaning The Cold Rate to Idle 2 (rpm/second) is configured at a higher rate than the Hot Rate to Idle 2. Or the Warm Rate to Idle 2 Error Rate to Idle 2 (if used) is configured at a higher rate than the Hot Rate to Idle 2.
  • Page 56 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Event ID Description Error Meaning The maximum speed input is 35000 hertz. This is a limitation of the 505’s hardware/speed sensing circuitry. The frequency input of the speed sensor must be less than this value.
  • Page 57 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Event ID Description Error Meaning Occurs when a Primary or Secondary Synchronization Signal source has been selected under Operating Selected SYNC Source Not Parameters but that source is not configured. For...
  • Page 58 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Event ID Description Error Meaning RTCNet Node 22 Analog Input 02 See "Analog Input 01 Error". Error RTCNet Node 22 Analog Input 03 See "Analog Input 01 Error". Error RTCNet Node 22 Analog Input 04 See "Analog Input 01 Error".
  • Page 59 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Event ID Description Error Meaning RTCNet Node 24 Boolean Input See "Contact Input 02 Error". 15 Error RTCNet Node 24 Boolean Input See "Contact Input 02 Error". 16 Error RTCNet Node 25 Relay Error 01 See "Relay 01 Error".

  • Page 60: Service Menu

    Service Menu The 505DR Service Menu should be adjusted for the application as described in Volume 1 and Volume 2 of this manual, 35018. The same Service Menu options of the simplex 505XT apply to the 505DR redundant application as well.

  • Page 61: Calibration

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Calibration Calibration of the Actuator Outputs, Analog Outputs and Analog Inputs should be done following the instructions in Volume 1 of this manual. The SYSCON and BACKUP units will keep all settings in-sync, such that calibration values are automatically set in both units.

  • Page 62: Chapter 17. Redundant Operation

    SYSCON transfer, and document any lists (Alarm, Trip, Modbus) that have changed in the redundant version of the 505XT control. For details on turbine operation using the 505DR, please refer to Chapter 5 of Volume 1 in this manual, as the turbine operation is identical to the 505XT simplex model.

  • Page 63: Figure 17-1. Wait Run Permissive Screen

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Run-Alone Command When a unit is powered on with a fault on the Ethernet 4 and discrete CrissCross it will initialize into the Wait-Run Perm state, and hold IOLOCK. This state will occur for both the Primary and Secondary units.

  • Page 64: System Diagnostics

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines System Diagnostics The Redundancy Overview page can be reached from the Home screen of a configured unit or the Configuration Menu of a unit at factory defaults. Figure 17-2. Navigating to the DR Overview Screen The Redundancy Overview page provides system diagnostic indications as well as information about the SYSCON and BACKUP unit status’.
  • Page 65 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Table 17-1. System Diagnostic Descriptions Description Backup Fault The health of the backup is bad for any reason. DR Diagnostic Fault An error has been detected during the startup of a Dual-Redundant system.

  • Page 66: Figure 17-3. System Diagnostics Screen

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 17-3. System Diagnostics Screen...

  • Page 67: The Syscon Unit

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines The SYSCON Unit The SYSCON unit is the system controller. It controls all aspects of the turbine control processing its own local I/O. All control states of the SYSCON are communicated to the BACKUP unit over the Ethernet 4 communication link such that the SYSCON keeps the BACKUP unit completely in sync.

  • Page 68: Figure 17-5. Front Panel Cpu Led Sycon/Backup Indication

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines On the front panel of the 505DR units, the CPU LED is used to identify the current SYSCON and BACKUP units. Table 17-3. Front Panel CPU LED SYCON/BACKUP Descriptions...
  • Page 69 (Application transfers). Critical transfers are those that would trip a system if the transfer to the BACKUP unit did not occur. The following critical conditions will initiate a SYSCON transfer: • SYSCON 505XT failure (CPU or internal problem) (OS transfer) • Loss of power to the SYSCON 505(OS transfer) •...

  • Page 70: The Backup Unit

    505XT Dual Redundant Control System for Steam Turbines SYSCON I/O Signal Monitoring The SYSCON I/O signals are available on the main 505XT Hardware screens. Figure 17-6. SYSCON I/O Monitoring Pages The signals within the main Hardware screens display the signals that are currently being read and driven from the SYSCON unit.

  • Page 71: Figure 17-7. Backup Unit Available Screen

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines If the Backup Fault system diagnostic is TRUE, the BACKUP unit cannot become the SYSCON even on an OS triggered transfer (see The SYSCON Unit section of this manual). If the Backup Fault system...

  • Page 72: Figure 17-8. Backup Unit Inhibited Screen

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 17-8. BACKUP Unit Inhibited Screen After an Application inhibit condition is repaired, an alarm Reset command will clear the inhibit condition and the BACKUP will indicate that it is available for a transfer.

  • Page 73: Figure 17-9. Backup I/O Monitoring Menu

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines BACKUP I/O Signal Monitoring The BACKUP unit I/O signals can be monitored from the Redundancy Overview screen using the navigation Menu on the right hand side of the screen.

  • Page 74: Figure 17-10 Backup Analog Inputs Screen

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 17-10 BACKUP Analog Inputs Screen The Speed Inputs screen shows the RPM signals being read from Both the SYSCON and BACKUP units. A fault indication is given for both the SYSCON and BACKUP. If there is a difference (default of 1.0% of the current speed) between the SYSCON and BACKUP signals on a channel, an alarm will be annunciated.

  • Page 75: Figure 17-12. Backup Analog Outputs Screen

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines The Analog Output screen shows the raw mA output signals from the SYSCON and BACKUP, as well as the total mA being sent per channel. For each unit, the mA demand (requested amount) and the mA readback (at the negative terminal) are shown.

  • Page 76: Figure 17-13. Backup Actuator Outputs Screen

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 17-13. BACKUP Actuator Outputs Screen The Boolean Inputs screen shows the input states for all channels on the SYSCON and BACKUP units. If a difference between the SYSCON and BACKUP channel exists, the control will always follow what the SYSCON signal level indication is indicating.

  • Page 77: Figure 17-14. Backup Boolean Inputs Screen

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 17-14. BACKUP Boolean Inputs Screen The Relay Output screen shows the output states for all channels on the SYSCON and BACKUP units. If the internal 505DR readback state of the relay is different between a SYSCON and BACKUP channel, an alarm will be annunciated and the BACKUP will be inhibited.

  • Page 78: Operational Commands And Settings

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Reset Backup Command The “Reset Backup” command becomes available from the Redundancy Overview screen when the BACKUP unit is inhibited. This command has two functions: 1. When the BACKUP is Inactive, this command will restart the BACKUP unit’s control application, and resync the BACKUP unit.

  • Page 79: Online Unit Repairs

    When used in a redundant configuration, the 505DR is designed such that I/O signals can be disconnected from the BACKUP unit while the healthy 505XT continues to control and operate the turbine on-online. The system is designed so that either unit can be removed and replaced while the other healthy 505XT continues to control and operate the turbine on-line.

  • Page 80: Figure 17-17. User Unsync Backup Command

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 17-17. User Unsync Backup Command 3. Issue a Reset Backup command. This will take the BACKUP unit offline for 20 seconds. Figure 17-18. User Reset Backup Command 4. Remove power to unit being replaced.

  • Page 81: Figure 17-19. System Diagnostic Faults Cleared

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 6. Replace respective 505DR with another unit, making sure that it has the same DIP switch setting as the previous unit. The replacement 505DR unit must have the same GAP Part Number and revision and same Footprint Part Number as the running unit in order to sync in.

  • Page 82: Remoteview Connections

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Figure 17-20. BACKUP Available 11. Transfer control to new unit if desired. Synchronizing an Offline Unit to the SYSCON When a unit is running as SYSCON and the BACKUP unit is offline, the following steps will sync in the offline unit.

  • Page 83: Figure 17-21. Session Connections Dialog Box

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines For installation, configuration, and usage instructions, please see the RemoteView Appendix in Volume 2 of this manual. The Connection dialog box has been updated to support redundant connections. This dialog will appear and give the user an option to modify the IP for the active connection, enter the control IP and if a redundant connection is desired, click the Enable Failover checkbox and add a redundant IP to use.

  • Page 84: Failover Performance

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Failover Performance When a SYSCON failover occurs, Actuator and Analog output currents will experience a small bump as the new SYSCON increases its output to match the last demand level. A transfer of SYSCON at 20mA output will dip around 6mA and recover back to full current within 80ms, as seen at the final driver.

  • Page 85: Alarms

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines In above trend graph following events occurred – User XFER Fail CAN2 on Backup (no XFER) then Reset Fail CAN2 on Syscon (XFER) then Reset Fail Power on Syscon (XFER) – reset after Reboot Constant output of 13.65 mA to valve –...
  • Page 86 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines ALARM Number Description Redundant LP B FDBK Failed ALM_012 Inlet Control Disabled PV Failed ALM_013 Redundant HP A FDBK Failed ALM_014 Redundant HP B FDBK Failed ALM_015 Feed-forward input failed...
  • Page 87 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines ALARM Number Description Turbine Tripped ALM_056 Overspeed ALM_057 Overspeed Test Enabled ALM_058 TIE Breaker Opened ALM_059 GEN Breaker Opened ALM_060 Tie Open / No Auxiliary ALM_061 Gen Open / No Auxiliary...
  • Page 88 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines ALARM Number Description MPU1 Failed Open Wire Test ALM_100 MPU2 Failed Open Wire Test ALM_101 Internal HW Simulation Enabled ALM_102 Pressure Compensation Curve Error ALM_103 Actuator Linearization Curve Error...
  • Page 89 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines ALARM Number Description Backup AI 4 Fault ALM_144 Backup AI 5 Fault ALM_145 Backup AI 6 Fault ALM_146 Backup AI 7 Fault ALM_147 Backup AI 8 Fault ALM_148 spare_149...
  • Page 90 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines ALARM Number Description SPC 13 Driver Summary Fault ALM_188 SPC 14 Driver Summary Fault ALM_189 DVP 15 Driver Summary Fault ALM_190 DVP 16 Driver Summary Fault ALM_191 HP Driver Fault...
  • Page 91 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines When using the 505DR, if RTCnet nodes (distributed I/O) are used then this alarm list will apply. It details the summary of alarm events that come from the CAN2 network.
  • Page 92 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines ALARM Number Description ALM_041 Node 21 AI 1 Alarm Level 1 ALM_042 Node 21 AI 1 Alarm Level 2 ALM_043 Node 21 AI 2 Alarm Level 1 ALM_044 Node 21 AI 2 Alarm Level 2...
  • Page 93 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines ALARM Number Description ALM_085 Node 23 RTD 7 Alarm Level 1 ALM_086 Node 23 RTD 7 Alarm Level 2 ALM_087 Node 23 RTD 8 Alarm Level 1 ALM_088 Node 23 RTD 8 Alarm Level 2...

  • Page 94: Trips

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Trips When using the 505DR, the Trip List in Volume 1 of this manual is replaced with the following list. Table 17-6. Trip Messages TRIP Number Description External Trip Input 1...
  • Page 95 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines TRIP Number Description External Trip 11 SD_41 External Trip 12 SD_42 External Trip 13 SD_43 External Trip 14 SD_44 External Trip 15 SD_45 Trip cmd from Display/RemoteView SD_46 LP2 Actuator Fault...

  • Page 96: Modbus Addressing

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines TRIP Number Description Node 3 RTD_7 Level 2 Trip SD_24 Node 3 RTD_8 Level 2 Trip SD_25 Spare26 SD_26 Spare27 SD_27 Spare28 SD_28 Spare29 SD_29 Spare30 SD_30 Spare31 SD_31...
  • Page 97 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 0:0044 De-Energize Relay 2 0:0081 Enable Inlet Control 0:0045 Energize Relay 3 0:0082 Disable Inlet Control 0:0046 De-Energize Relay 3 0:0083 Lower Inlet Setpoint 0:0047 Energize Relay 4 0:0084...
  • Page 98 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Boolean Read Addresses Table 17-9. Boolean Read Addresses Addr Description 1:0039 Modbus Alarm Acknowledge 1:0001 Alarm - MPU #1 Failed 1:0040 Alarm Exists (Common Alarm Indication) 1:0041 Trip - External Trip...
  • Page 99 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 1:0078 Speed Sensor 2 Failed Override ON 1:0121 Extraction Is Active 1:0079 Overspeed Test Permissive 1:0122 Extraction Is In Control 1:0080 Overspeed Test In progress 1:0123 Extraction is Inhibited...
  • Page 100 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 1:0164 Contact In 6 Closed 1:0207 * TRUE = NEW 505 R 1:0165 Contact In 7 Closed 1:0208 FALSE = 505D, TRUE = 505XT 1:0166 Contact In 8 Closed...
  • Page 101 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 1:0250 Alarm - Rem SP Isolated PID Failed 1:0293 Alarm - MPU1 Failed Open Wire Test 1:0251 Alarm - Customer Input #1 Failed 1:0294 Alarm - MPU2 Failed Open Wire Test...
  • Page 102 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 1:0333 Inlet Is Enabled 1:0376 Exhaust Limiter Configured 1:0334 Inlet Is Active 1:0377 Exhaust Control Configured 1:0335 Inlet Is In Control 1:0378 Remote Exhaust Configured 1:0336 Inlet Active / Not Limiting...
  • Page 103 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 1:0419 LinkNet Node 2 Comm Fault 1:0462 LinkNet Node 1 AI 4 Alarm Level 1 1:0420 LinkNet Node 3 Comm Fault 1:0463 LinkNet Node 1 AI 4 Alarm Level 2...
  • Page 104 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 1:0505 LinkNet Errors on TX/RX msg 1:0548 Secondary Unit is SYSCON 1:0506 LinkNet Errors on RT TX/RX msg 1:0549 Backup Unit Faulted 1:0507 SPARE_90 1:0550 Backup Unit Unavailable 1:0508 Trip - Actuator Scaling Min >...
  • Page 105 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 1:0591 Alarm - Backup Unit Unavailable 1:0634 ALM180 1:0592 ALM138 1:0635 ALM181 1:0593 ALM139 1:0636 ALM182 1:0594 ALM140 1:0637 ALM183 1:0595 ALM141 1:0638 ALM184 1:0596 ALM142 1:0639 ALM185 1:0597...
  • Page 106 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines 1:0677 ALM223 - spare 1:0678 ALM224 - spare Analog Read Addresses Table 17-10. Analog Read Addresses Addr Description Units Multiplier 3:0001 Control Parameter 3:0002 Speed Sensor #1 Input (RPM)
  • Page 107 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Addr Description Units Multiplier 3:0037 Aux Scale Factor 3:0038 Aux Input (Scaled) aux units AI_SCALE 3:0039 Remote Aux Input (Scaled) aux units AI_SCALE 3:0040 Remote Speed Setpoint Input 3:0041...
  • Page 108 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Addr Description Units Multiplier 3:0079 Analog Output 2 (mA x 100) 3:0080 Analog Output 3 (mA x 100) 3:0081 Analog Output 4 (mA x 100) 3:0082 Analog Output 5 (mA x 100)
  • Page 109 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Addr Description Units Multiplier 3:0121 * S/W PN54186768 3:0122 *S/W Revision 3:0123 * Auto Seq-Time ramp to idle 3(RPM/S) rpm/s 3:0124 * Auto Seq Idle 3 speed RPM 3:0125...
  • Page 110 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Addr Description Units Multiplier 3:0163 Inlet Scale Factor 3:0164 Inlet Input (Scaled) INL units AI_SCALE 3:0165 Remote Inlet Input (Scaled) INL units AI_SCALE 3:0166 Modbus Entered Inlet Setpoint (fdbk)
  • Page 111 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Addr Description Units Multiplier 3:0205 LinkNet Node 1: AI 02 Value AI_SCALE 3:0206 LinkNet Node 1: AI 03 Value AI_SCALE 3:0207 LinkNet Node 1: AI 04 Value AI_SCALE 3:0208...
  • Page 112 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Addr Description Units Multiplier 3:0246 Peak Speed Reached 3:0247 Maximum Acceleration Reached 3:0248 Number of Overspeed Trips 3:0249 LP Valve Limiter x100 3:0250 spare 3:0251 **Start of DR added Parameters**...
  • Page 113 Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Analog Write Addresses Table 17-11. Analog Write Addresses Addr Description Units Multiplier Modbus Entered Speed 4:0001 none Setpoint 4:0002 Modbus Entered Casc Setpoint Casc units Casc scale factor 4:0003...

  • Page 114: Revision History

    Released Manual 35018V3 505XT Dual Redundant Control System for Steam Turbines Revision History New Volume—...
  • Page 115 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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