Kujang - Training Module - 505

WOODWARD 505D & 505XT
INTRODUCTION TRAINING
505 Product Family
• 8200-1300 -505 LV, Standard Compliance
• 8200-1301 -505 LV, Full Compliance
• 8200-1302 -505 HV, Standard Compliance
• 8200-1310 -505XT LV, Standard Compliance
• 8200-1311 -505XT LV, Full Compliance
• 8200-1312 -505XT HV, Standard Compliance
LV = 24Vdc (18 –32Vdc)

HV = (88 –264Vac, 90-150Vdc)
Old versus new 505/505XT Hardware
Old 505/505E Models New 505/505XT Models

• 220Vac or 110Vac accepted by same model
•HV & LV Power Supply Options
• 2 Speed Inputs (MPU or Proximity Probes)
•2 Speed Inputs (MPU or Proximity
• 8 Analog Inputs (4-20 mA)
Probes) • 20 Discrete Inputs
•6 Analog Inputs (4-20 mA) • 2 Actuator Drivers (0-20 mA or 0-200 mA)
•16 Discrete Inputs • 6 Analog Outputs (4-20 mA)
•2 Actuator Drivers (0-20 mA or • 8 Relay Outputs
0-200 mA) • 1 Serial Port
•6 Analog Outputs (4-20 mA) • 2 User (LAN) Ethernet Ports
•8 Relay Outputs • 3 CAN (distributed I/O) Ports
• LinkNet-HT modules (505XT Only)
•2 Serial Ports
2 Analog I/O modules – 8 AI, 2AO per module
1 Discrete Input Module – 16 channels
1 Relay Driver Module – 16 channels
1 RTD Input Module – 8 channels
Retained Features
• Basic Start Modes (Man, Semi, Auto)
• Auto Start Sequence (Hot & Cold)
• Valve Limiters
• Local/Remote Control Operation
• Zero Speed (< 0.5 Hz) Detect (Prox Probes)
• Critical Speed Avoidance
• Speed/Load Control PID
• Dual Dynamics for Speed/Load Control
• Cascade Control PID
• Auxiliary PID (limiter or control)
• Over-Speed Protection / Peak Speed Log
• Load Rejection Performance (505-EN)
• PID Dynamic Settings
New Application Functions
• Multi-Lingual integrated GUI
• Turbine/Rotor operation data
• High Speed Datalog (10 ms dynamic data / 3 files)
• Trendlog data (adjustable 1 sec dynamic data / 3 files)
• Time Synchronization via SNTP
• MPU Open wire detection (checked upon a Start command)
• Auxiliary 2 PID (limiter 505D only)
• Stand-alone Process Control PID (for separate AIs and AOs)
• Full manual valve control (with alarm)
• User-defined Device tag names for I/O signals
• Integrated configuration with other Woodward Products – VariStroke and
power generation products (DSLC-2, HighProtec, LS-5, MFR300….)
505D Hardware
The 505 also provides the following features:
• First-Out Trip indication of Alarm and Trip
events with RTC time stamp
• 10 External DI trip inputs
• 10 External Alarm inputs
• Critical Speed Avoidance (3 speed bands)
• Auto Start Sequence (hot & cold starts)
with Temperature Input options
• Dual Speed/Load Dynamics
• Zero Speed Detection
• Peak Speed Indication for Overspeed trip,
and Isochronous Load sharing between
units (with an DSLC-2 control)
• Feed-forward loop
• Acceleration protection at initial startup
• Remote droop
• Frequency dead-band.
505XT Hardware
In addition to the control loops mentioned, the 505XT also provides the following features:
• First-Out Trip indication of Alarm and Trip events with time stamp
• 15 External DI trip inputs and 15 External Alarm DI inputs
• Critical Speed Avoidance (3 speed bands)
• Auto Start Sequence (hot & cold starts) with Temperature Input options
• Dual Speed/Load Dynamics with automatic Optimization tuning of dynamic gains
• A third set of speed dynamics for Ext/Adm units when operating in Ratio Limiter control modes
• Zero Speed Detection, Peak Speed Indication, and Direction of Rotation
• Load Droop and Isochronous Load sharing between units (with an DSLC-2 control)
• Feed-forward loop for compressor units
• High speed (10ms) datalog and Slow speed (1 sec) trendlog capture files
• SNTP time synchronization via an Ethernet IP
• Ability to expand system I/O with Woodward Linknet Distributed I/O nodes
• Multiple digital communication links to other Woodward products (Woodward Links)
505 System Overview
HARDWARE SPECIFICATION
INPUT POWER
SPEED SENSOR: MPU/PROXIMITY
ANALOG INPUT
ANALOG OUTPUT
ACTUATOR OUTPUT
DISCRETE INPUT
RELAY OUTPUT
Power-up & Initialization
• At initial Power-up Screen = BLANK /BLACK
IOLOCK = RED
(24 VDC units have a 5 second delay)
• After about 1:00 Screen = “505 Splash” Screen
TRIPPED/CPU/ALARM LED’s will flash check
• After about 1:10 TRIPPED =ON (RED) (GAP –> Power-up Trip)
IOLOCK = OFF
CPU = ON (GREEN)
• After about 1:30 ALARM LED (YELLOW)
Flashes/Blinks
• After about 2:40 Screen = HOME
• After about 4:40 Screen = HOME (for 505XT)
The CPU and IOLOCK LED’s on the Front & Back will always show the same
indication.
Initial Home Screen
Operator Control Panel Overview
Modes of Operation
•Monitor
•Operation
•Operation & Dynamic Tune
•Configure
Engineering Station Capabilities
•I/O and system troubleshooting
•Configure and Trigger datalog & trendlog
•Set Ethernet Port TCP/IP addresses
•Setup unique Site information and device tag identifiers for I/O signals
HMI Capabilities Include:
•Automatic screen generation based on control configuration
•Security with multiple password levels
•Real-time and historical trending
•Alarm/trip status indication
•Alarm/trip log with time tagging and first-out indication
•Graphic system control screens
•Event status logging and history
User Login/Mode
Configuration Menu Background
Blue gradient
•In Configuration mode
•Unit in IOLOCK
•Config Check
•Edit settings
•Save Settings
Gray / Silver solid

•View only
•In Operation or Calibration mode
Networked Control
Auto Login as Operator
(Service Mode )
•Default User Level
• Automatically login as
“Operator”
•Same as old 505
(no Monitor mode/level)
Internal Simulation Mode
Required Login:
Configure
wg1113
Early revisions of 505D required ServiceUser access
Enable/Disable H/W SIM

will be visible
•Simulates Speed
•Inverts DI01 (ESTOP)
•Overrides Act 1 Fault
•Triggers ALM
Speed Relationship
On-Line/Off-Line Dynamics Selection

CONFIGURATION:
CONFIGURATIONTURBINE START:
CONFIGURATIONSPEED SETPOINT:
CONFIGURATIONSPEED SETPOINT:
CONFIGURATIONSPEED CONTROL:
CONFIGURATIONSPEED CONTROL:
CONFIGURATIONOPERATING PARAMETER:
CONFIGURATIONCOMMUNICATION:
CONFIGURATIONANALOG INPUT:
CONFIGURATIONANALOG INPUT:
CONFIGURATIONANALOG OUTPUT:
CONFIGURATIONANALOG OUTPUT:
CONFIGURATIONCONTACT INPUT:
CONFIGURATIONCONTACT OUTPUT:
Stroking Procedure
• 505 must be shutdown to enter calibration Mode
• Go to the Mode screen by pressing the MODE key
• Press login soft key to enter to Service Mode (Password ……..)
• Enter Calibration Mode by Pressing the Calibration soft key. Permissive must be
met (Unit Shutdown, No speed Detected and Appropriate User Login)
• Navigate to the actuator Driver Summary page by pressing the Driver in either the
Home menu or configure menu.
• select the desired actuator channel
• Press the Calibration soft key to access the calibration options
• Verify the green Calmode Enabled LED is ON to confirm that the units in
calibration mode
• Press the forcing soft key and then confirm on the popup that actuator forcing can
be enabled. Select OK and press Enter to enable forcing
• Verify that the green Forcing enabled LED is ON
Stroking Procedure
• Use the focus navigation to select and adjust items on the screen (Manual adjust,
goto Demand , force rate, Etc
• Actuator current output at min and max can be adjusted by selecting mA at 0%
Demand or mA at 100% Demand. Use the up/down adjust arrows or numerical
keypad and ENTER to the changes values
• Press the commands soft key to access other commands such as Go To Min, Go to
Max, and GO. GO can be used with the GOTO Demand value
• When finished make sure to save the settings by pressing any Save Setting soft
key. A Save settings soft key can be access on the MODE screen
• Exit calibration Mode by pressing the Exit Calmode soft key from the mode page
or if it is desired to stroke another channel , return to the driver or I/O screen to
continue stroking other channel
Turbine Start Procedure
Manual Start Mode The following start-up procedure is employed when the Manual start
mode is configured:
1. Issue a RESET command (to reset all alarms and shutdowns).
The LP demand and LP Limiter behavior is determined by the
turbine type for Extraction Only: The LP Lmtr will ramp to 100%.
2. Issue a START command (verify T&T valve is closed before
issuing):
a. At this point the 505 will ramp open the governor valve to its
maximum position at the ‘Valve Limiter Rate’.
b. The speed set point will ramp from zero to the minimum
controlling speed setting at the ‘Rate To Min’ rate.
3. Open Trip & Throttle valve at a controlled rateWhen turbine
speed increases to the minimum controlling speed, the 505’s
Speed PID will take control of turbine speed by controlling turbine
inlet valve position.
4. Open Trip & Throttle valve to 100% Speed remains controlled at the minimum controlling point until action is taken by the operator
or the ‘Auto Start Sequence’, if programmed, begins controlling.
Note: The ‘Limiter Max Limit’, ‘Valve Limiter Rate’ and ‘Rate To Min’ settings are tunable in the Service mode.
The trip-and-throttle valve must be closed before pushing the ‘RUN’ key
in Manual Start mode. If a START command is given while the trip-andthrottle
valve is open, there exists a possibility of turbine runaway with
resultant serious injury or loss of life.
Semiautomatic Start Mode The following start-up procedure is employed when the
Semiautomatic start mode is configured:
The LP demand and LP Limiter behavior is determined by the
turbine type, for Extraction Only: The LP Limiter will ramp to 100%
2. Open the Trip & Throttle valve (verify that the turbine does not
accelerate)
3. Issue a START command At this point, the speed set point will
ramp from zero to the minimum controlling speed setting at the
‘Rate to Min’ rate.
4. Raise the 505’s VALVE LIMITER at a controlled rate. When turbine
speed increases to the minimum controlling speed, the 505’s Speed
PID will take control of turbine speed by controlling turbine inlet valve
position.
5. Raise 505’s VALVE LIMITER to 100%.Speed remains controlled at
the minimum controlling point until action is taken by the operator or
the ‘AUTO START SEQUENCE’, if programmed, begins controlling.
Note:
The valve limiter will open at the ‘Valve Limiter Rate’ and may be moved using the 505 keypad, external contacts or Modbus
communications. The ‘Limiter Max Limit’, ‘Valve Limiter Rate’ and ‘Rate To Min’ settings are tunable in the Service mode.
in Manual Start mode. If a START command is given while the trip-and throttle
Automatic Start Mode The following start-up procedure is employed when the Automatic
start mode is configured:
The LP demand and LP Limiter behavior is determined by the turbine
type, for Extraction Only: The LP Limiter will ramp to 100%
accelerate)
3. Issue a START command as specific below:
• At this point the 505 will ramp open the governor valve to its “HP
Max at Start” setting at the ‘Valve
• Limiter Rate’ setting.
• The speed set point will ramp from zero to the minimum
controlling speed setting at the ‘Rate to MIN’ rate.
• When turbine speed increases and matches the ramping speed
set point, the 505’s Speed PID will take control of turbine speed by
controlling turbine inlet valve position.
• · Speed remains controlled at the minimum controlling point until action is taken by the operator
• · Once the Speed PID begins controlling turbine speed, the HP Limiter will automatically ramp to the Vlv Lmtr Max Limt’.
Note: Optionally the ‘HP Max at Start’ and ‘Vlv Lmtr Max Limt’, ‘Valve Limiter Rate’ and ‘Rate To Min’ settings can be adjusted in the
Service mode, while the turbine is in operation. The automatic start routine may be aborted at any time by issuing valve limiter raise
or lower commands, or an emergency shutdown.
Automatic Start Mode The following start-up procedure is employed when the Automatic
start mode is configured:
The LP demand and LP Limiter behavior is determined by the turbine
type, for Extraction Only: The LP Limiter will ramp to 100%
accelerate)
3. Issue a START command as specific below:
• At this point the 505 will ramp open the governor valve to its “HP
Max at Start” setting at the ‘Valve
• Limiter Rate’ setting.
• The speed set point will ramp from zero to the minimum
controlling speed setting at the ‘Rate to MIN’ rate.
• When turbine speed increases and matches the ramping speed
set point, the 505’s Speed PID will take control of turbine speed by
controlling turbine inlet valve position.
• · Speed remains controlled at the minimum controlling point until action is taken by the operator
• · Once the Speed PID begins controlling turbine speed, the HP Limiter will automatically ramp to the Vlv Lmtr Max Limt’.
Note: Optionally the ‘HP Max at Start’ and ‘Vlv Lmtr Max Limt’, ‘Valve Limiter Rate’ and ‘Rate To Min’ settings can be adjusted in the
Service mode, while the turbine is in operation. The automatic start routine may be aborted at any time by issuing valve limiter raise
or lower commands, or an emergency shutdown.
PID TUNING AND ADJUSMENT
The Speed, Cascade, Auxiliary (1 & 2), and Acceleration controls utilize PID controllers. The response of each
control loop can be adjusted for optimum response, however it is important to understand what a PID
controller is and the effect each controller adjustment has on the controller response to match the response of
the control loop with the response of the system.
Proportional Control
Proportional response is directly proportional to a process change. Analogy: Setting hand throttle to keep constant
speed on straight and level. The results in a certain speed as long as the car is not subjected to any load change
such as a hill. If a throttle is set to any particular setting, the speed of the car will remain constant as long as the
car remains straight and level. If the car goes up a hill, it will slow down. Of course, going down a hill the car
would gain speed. Proportional gain must be tuned to best respond to a system transient or step change. If
system response is not known, a typical starting value is 5%. If proportional gain is set too high the control will
appear to be overly sensitive, and may oscillate with a cycle time of less than 1 second.
Integral Control
Integral compensates for process and setpoint load changes. Analogy: Cruise control maintains constant speed
regardless of hills. Integral, (sometimes called reset) provides additional action to the original proportional
response as long as the process variable remains away from the setpoint. Integral is a function of the magnitude
and duration of the deviation. In this analogy, the reset response would keep the car speed constant regardless
of the terrain. Integral gain must be tuned for best control at steady state. If system response is not known a
typical starting value is 5%. If the integral gain is set too high the control may hunt or oscillate at cycle times of
over 1 second.
Derivative
Derivative provides a temporary over-correction to compensate for long transfer lags and reduce
stabilization time on process upsets (momentary disturbances). Analogy: Accelerating into high-speed lane
with merging traffic. Derivative, sometimes called “preact” or “rate”, is very difficult to draw an accurate
analogy to, because the action takes place only when the process changes and is directly related to the speed
at which the process changes. Merging into high-speed traffic of a freeway from an “on” ramp is no easy task
and requires accelerated correction (temporary overcorrection) in both increasing and decreasing directions.
The application of brakes to fall behind the car in the first continuous lane or passing gear to get ahead of
the car in the first continuous lane is derivative action.
Tuning Example
If the system is unstable, make sure the governor is the cause. This can be checked by closing the valve limiter
until it has control of the actuator output. If the governor is causing the oscillation, time the oscillation cycle time.
A rule-of–thumb is, if the system’s oscillation cycle time is less than 1 second reduce the Proportional gain term.
A rule-of-thumb is, if the system’s oscillation cycle time is greater the one-second reduce the Integral gain term
(proportional gain may need to increase). On an initial startup with the 505, all PID dynamic gain terms will
require adjustment to match the respective PID’s response to that of its control loop. There are multiple dynamic
tuning methods available that can be used with the 505’s PIDs to assist in determining the gain terms that
provide optimum control loop response times.
The following method can be used to achieve PID gain values that are close to optimum:
1. Increase Derivative Ratio (SDR) to 100 (Service Mode adjustment)
2. Reduce integral gain to 0.01 (Run Mode adjustment)
3. Increase proportional gain until system just starts to oscillate (Run Mode).The optimum gain for this step is when the
system just starts to oscillate and maintains a self-sustaining oscillation that does not increase or decrease in magnitude.
4. Record the critical gain (Kc) and oscillation period (T) in seconds.
5. Set the dynamics as follows:
For PI control: G=P(I/s + 1)
Set: Proportional gain = 0.45*Kc
Integral gain = 1.2/T
Derivative ratio = 100
For PID control: G=P(I/s + 1 + Ds)
Set: Proportional gain = 0.35*Kc
Integral gain = 0.76/T
Deriv ratio = (5.2*T)/Integral Gain for fdbk dominant
= (0.19*Integral Gain)/T for input dominant
This method of tuning will get the gain settings close;
they can be fine-tuned from this point.
Use of the PID_OPTI features

User can tune the Manual settings for OFFLINE and ONLINE (same as old 505)
Can select to use OPTI_Tune – this will automatically populate the OPTI values with the manual values
For OPTI_Tune there is 1 set of dynamics for OFFLINE and a Curve of 1, 2 or 3 points for ONLINE
Recommend to use the 3-pt curve for ONLINE settings using 20%, 50% and 80% load setpoints
505XT: Extraction Control
The Ext/Adm PID controller is used to control the Extraction or Admission Steam pressure or flow. This is only used on Extraction
or Admission types of turbines. The output of this controller is known as the P demand. This value is passed to the Ratio Limiter
logic that also receives the speed PID output known as the S demand. Using the entered steam performance map data, the Ratio
Limiter produces appropriate demands for the HP and LP valves.The Ext/Adm set point is adjustable with raise or lower commands
through the 505 front keypad, through remote contact inputs or through Modbus. In addition, an analog input can be programmed
to remotely position the Ext/Adm set point.
Typically a turbine is controlling speed/load at a rated speed setting and is loaded to a minimum load point before extraction control
is enabled. After a startup, the HP and LP valve limiters should normally both be fully open. If the HP valve limiter is not fully
opened, it will act as a speed/load limiter and will interfere with automatic governor operation.
The Ext/Adm PID controller is used to control the Extraction or Admission Steam pressure or flow. This is only used on Extraction
or Admission types of turbines. The output of this controller is known as the P demand. This value is passed to the Ratio Limiter
logic that also receives the speed PID output known as the S demand. Using the entered steam performance map data, the Ratio
Limiter produces appropriate demands for the HP and LP valves.The Ext/Adm set point is adjustable with raise or lower commands
through the 505 front keypad, through remote contact inputs or through Modbus. In addition, an analog input can be programmed
to remotely position the Ext/Adm set point.
Typically a turbine is controlling speed/load at a rated speed setting and is loaded to a minimum load point before extraction control
is enabled. After a startup, the HP and LP valve limiters should normally both be fully open. If the HP valve limiter is not fully
opened, it will act as a speed/load limiter and will interfere with automatic governor operation.
The Extraction and/or Admission
enable permissives are:
Extr/Adm input not failed
Turbine speed above
programmed permissive speed
Gen breaker closed (if
configured)
Tie breaker closed (if
configured)
Adm or Extr/Adm Enabling procedure: During this operation, the following actions will take place:
1. Verify that all “Extr/Adm enable permissives” are met (listed LP Valve Limiter will ramp closed from 100% to 0%
above). This will cause the load to decrease
2. Match the Extr/Adm setpoint to that of the pressure on the Speed PID control will increase demand to compensate for
plant side of the Extr/Adm T&T valve. (Skip load loss
this step if Setpoint Tracking is used.) When disabling Ext/Adm the opposite actions will take place:
3. Vary the Extr/Adm Demand setpoint to match the turbine’s LP Valve Limiter will ramp open from 0% to 100%
internal Extr/Adm pressure to that of the This will cause the load to increase
pressure on the plant side of the Ext/Adm T&T valve. Speed PID control will decrease demand to compensate for
4. Open the Extr/Adm Trip-and-Throttle valve. load loss
5. Enable Adm or Extr/Adm control.
505XT: Steam Performance Map
The steam map is a graphical representation of the operating range and limitations of an extraction and/or admission steam
turbine. This map is often called a steam envelope, since normal turbine operation must be contained within the envelope lines.
The 505E uses the values programmed to calculate the turbine’s internal pressure ratios and limits. In order to get these values
from your steam map, you must first check the following conditions and, if necessary, modify the map so it meets these
conditions:
• The map must be linear (all lines straight).
• Lines extraction/admission flow = 0% and extraction/admission flow =100%
must be parallel, and lines LP valve = 0% and LP valve = 100% must be
parallel.
The lines on the envelope define the operating characteristics of your turbine.
Refer to the example steam maps in this manual. The different lines or limits of
a Steam map are:
The horizontal axis shows turbine power (S).
The vertical axis shows HP valve position (HP).
The vertical line called S=100 is the maximum power limiter. This limiter
prevents turbine operation beyond the maximum power limit.
The horizontal line called HP=100 is the maximum HP flow limiter. The HP
flow limiter prevents turbine operation beyond the desired maximum HP flow
limit.
The parallel lines called P=0 and P=100 define the extraction/admission flow
range (from no flow or maximum admission flow to maximum extraction flow).
The “P” term is used to represent pressure demand.
The parallel lines called LP=0 and LP=100 define the LP valve position range
(from closed to 100% open).
Before a turbine’s extraction steam map can be programmed into the
control, it must have the intersection points A, B, & C (refer to Figure 3-22).
• Typically Point C the intersection of the LP=O line and the P=0 line does
not exist. If this is the case it will be necessary to convert your steam
map. The only conversion necessary is the extension of the LP=0
• line and the P=0 line until they cross or intersect. This point where the
LP=0 line intersects the P=0 line is defined as Point C, and is required by
the control to calculate the turbine’s internal pressure ratios and limits.
• The eight values needed can be taken from the converted steam map.
As an example, the following data was derived, using the steam map in
left side.
• The MAX POWER value is the load where the S=100 line crosses the s-
axis (about 20 000 kW in our example).
• The MAX HP FLOW value is the flow where the HP=100 line crosses the
HP-axis (about 108 000 lb/h; 48 989 kg/h).
• Point A is where the P=0 and LP=100 lines intersect (MAX POWER @
MIN EXTRACTION = about 15062 kW; HP FLOW @ MIN EXTRACTION
= about 36 000 lb/h; 16 330 kg/h).
• Point B is where the LP=0 and P=100 lines intersect (MIN POWER @
MAX EXTRACTION = about 3623 kW; HP FLOW @ MAX EXTRACTION
= about 86 000 lb/h; 39 010 kg/h).
• Point C is where the LP=0 and P=0 lines intersect (MIN POWER @ MIN
EXTRACTION = about –3000 kW; MIN HP FLOW @ MIN EXTRACTION
= about 6000 lb/h; 2722 kg/h).
Before a turbine’s extraction steam map can be programmed into the
control, it must have the intersection points A, B, & C (refer to Figure 3-22).
• Typically Point C the intersection of the LP=O line and the P=0 line does
not exist. If this is the case it will be necessary to convert your steam
map. The only conversion necessary is the extension of the LP=0
• line and the P=0 line until they cross or intersect. This point where the
LP=0 line intersects the P=0 line is defined as Point C, and is required by
the control to calculate the turbine’s internal pressure ratios and limits.
• The eight values needed can be taken from the converted steam map.
As an example, the following data was derived, using the steam map in
left side.
• The MAX POWER value is the load where the S=100 line crosses the s-
axis (about 20 000 kW in our example).
• The MAX HP FLOW value is the flow where the HP=100 line crosses the
HP-axis (about 108 000 lb/h; 48 989 kg/h).
• Point A is where the P=0 and LP=100 lines intersect (MAX POWER @
MIN EXTRACTION = about 15062 kW; HP FLOW @ MIN EXTRACTION
= about 36 000 lb/h; 16 330 kg/h).
• Point B is where the LP=0 and P=100 lines intersect (MIN POWER @
MAX EXTRACTION = about 3623 kW; HP FLOW @ MAX EXTRACTION
= about 86 000 lb/h; 39 010 kg/h).
• Point C is where the LP=0 and P=0 lines intersect (MIN POWER @ MIN
EXTRACTION = about –3000 kW; MIN HP FLOW @ MIN EXTRACTION
= about 6000 lb/h; 2722 kg/h).
Overspeed Test Function
The 505’s Overspeed Test function allows an operator to increase
turbine speed above its rated operating range to periodically test
turbine electrical and/or mechanical overspeed protection logic and
circuitry. This includes the 505’s internal overspeed trip logic and any
external overspeed trip device’s settings and logic.
Overspeed Test Procedure (from the 505 display)

· Be sure the generator breaker is open if unit is a generator drive
· Raise the Speed Set Point to the maximum governor setting
· If desired, clear the ‘Highest Speed Reached’ value, to record the
highest speed reached during this overspeed test. (Reset Max key)
· This function has a safety timeout to insure the unit does not run in
this mode unattended. Once the mode is entered, the user must
begin to raise the speed within 30 seconds. As long as the user is
adjusting the speed the timeout value will be reset.
· Timeout value is shown, if it expires the test mode will be aborted and
the unit will return to the maximum governor limit
• 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.
Internal (505) Overspeed Test

· To perform an Internal Overspeed Test Press the Enable Int Test key and the above pop-up page will appear. An Alarm
will be annunciated that indicates Overspeed Test Enabled
· Put the Adjust button in Focus and use the ADJUST key to raise the speed above the normal Max Governor limit.
· Once turbine speed reaches the 505’s internal OVERSPEED TRIP (rpm) setting, the 505 will TRIP the turbine
External Overspeed Test
An external trip test is intended to be used to test the unit’s
safety overspeed protection device (in many cases a
Woodward ProTech). In this mode the 505 internal
overspeed trip will be changed to be just an alarm and the
505 will allow the speed to continue increasing up to the
Overspeed Test Limit (rpm). If the
505 speed OR the Setpoint reaches the Overspeed Test
Limit it will TRIP
To perform an External Overspeed Test Press the Enable

Ext Test key and the above pop-up page will appear. An
Alarm will be annunciated that indicates Overspeed Test
Enabled
Put the Adjust button in Focus and use the ADJUST key
to raise the speed above the normal Max Governor limit.
Once turbine speed reaches the 505’s internal
OVERSPEED TRIP (rpm) setting, the 505 will trigger an
alarm that this has been reached
If the timeout expires while the unit is above the
In the configuration of Speed Setpoints be sure Overspeed Trip setting, but below the Overspeed Test Limit,
that the Overspeed Test Limit rpm value is above the 505 will Trip on Overspeed
the expected Overspeed setting of the If the Speed or the Setpoint reach the Overspeed Test
external safety overspeed protection device. Limit the 505 will issue a Trip
Thankyou

Kujang - Training Module - 505

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Kujang - Training Module - 505

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WOODWARD 505D & 505XT

LV = 24Vdc (18 –32Vdc)

Old 505/505E Models New 505/505XT Models

Gray / Silver solid

Enable/Disable H/W SIM

On-Line/Off-Line Dynamics Selection

Use of the PID_OPTI features

Overspeed Test Procedure (from the 505 display)

Internal (505) Overspeed Test

To perform an External Overspeed Test Press the Enable

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