Category: Woodward

Communication

The 505DR can communicate directly with the plant DCS and/or operator control panel using Modbus

TCP or OPC communications.

Serial communication is also supported using RS-232 or RS-485 and ASCII or RTU Modbus.

Control PIDs can perform process control or be used as limiters for speed/load dynamics,

pumping/discharge pressures, cascade, auxiliary, intake plenum, exhaust plenum, and rotor acceleration.

System Protection

– Integrated overspeed protection logic and test functions

– First open indication on 15 shutdown inputs

– External alarm indication on 15 inputs

– Stuck at critical speed band logic

– Bufferless transfer between control modes and during Syscon switchover

– Operation and configuration password security

Operating Conditions

– Ambient air temperature: -25 to +65C

– Humidity Lloyd’s ENV2 Test #1

– Dry heat Lloyd’s ENV3

– Salt Spray: US MIL-STD-810. Method 509.2 proc. 1

– Shock: US MIL-STD-810C, Method 516.2-1 proc. 1B

– Vibration Lloyd’s ENV2 Test #1

– Resistance to particulate contamination IEC 60664-1 Class 2

– IEC 60068-2-60 part 2.60 methods 1 and 4

– Resistance to gaseous contamination: coating is resistant to NO2. CO2. SO2 and H2S.

– Battelle Laboratories Class III (IEC 60721-3-3 Categories 3C1 and 3C2)

Cost-effective design

The 505DR is a G-efficient redundant turbine controller.

It consists of a turbine controller, system sequencer, operator control panel and first-out indicator.

The design minimises external equipment and wiring for easy troubleshooting.

Like the 505XT, the 505DR can be fully configured in the field

(under password control by knowledgeable personnel) and minor functional

changes can be made while the turbine is running online.

Minor functional changes can be made online while the turbine is running.

Like the MicroNet Plus, the 505XT system designates one controller

as the System Controller (Syscon), actively controlling the fan.

The second device is configured as a backup.

The system automatically evaluates the health of the Syscon and initiates a fast switchover in the event of

a failure.

Switchover can also be initiated manually. The system closely synchronises

the Syscon’s software status and memory with the backup,

ensuring that the control output remains stable and does not affect turbine operation (a true ‘bufferless’

switchover).

Description

Like the MicroNet Plus, the 505XT system designates one controller

as the System Controller (Syscon), actively controlling the fan.

The second device is configured as a backup.

The system automatically evaluates the health of the Syscon and initiates a fast switchover in the

event of a failure.

Switchover can also be initiated manually. The system closely synchronises

the Syscon’s software status and memory with the backup,

ensuring that the control output remains stable and does not affect turbine operation (a true ‘bufferless’

switchover).

If the optional HMI version is selected, the display and keypad are redundant

(input from either keypad will command Syscon, and the display can be independently selected to show

different screens.

For example, one screen can display speed and speed settings, and another can display a steam map.

Woodward’s optional RemoteView programme allows remote monitoring from any networked PC.

The programme can be used either with the rear panel mounted version (as the main HMI)

or as an additional remote monitor to the HMI version.

The optional FTM (Field Terminal Module) allows easy multiplexing of

redundant signals and facilitates fast installation and commissioning.

Shield Installation Notes

• Wires exposed beyond the shield should be as short as possible, not exceeding 50 mm (2 inches).

• The shield termination wire (or drain wire) should be kept as short as possible, not exceeding 50 mm

(2 inches), and the diameter should be maximized where possible.

• Installations with severe electromagnetic interference (EMI) may require additional shielding

precautions. Contact Woodward for more information.

• Do not ground shield on both ends, except where permitted by the control wiring diagram.

Failure to provide shielding can produce future conditions that are difficult to diagnose. Proper shielding

at the time of installation is required to ensure satisfactory operation of the product.

Position Feedback

There are two outputs for valve position feedback on each of the QuickTrip’s three valve modules (12

outputs total). Each of the two outputs features redundant connections. Both TRIP outputs and both RUN

outputs operate as normally open. The outputs can be wired to either switch load from positive supply or

switch load to ground. The user must supply the external 24 V supply for the output to function properly.

If using the Woodward ProTech TPS logic solver, the voltage may be supplied using the on-board discrete

power terminals (24 VDC, 0.050 A).

Voltage Drop Calculation Using American Wire Gauge

Example #1. one power supply per module (3x power supplies): A 18 AWG wire will drop 0.042 V/ft at 2.6

A at maximum ambient temperature. Using 100 feet between the QuickTrip and the power supply would

provide a voltage drop of 100×0.042 = 4.2V.

Example #2. one power supply for all three modules (1x power supply): A 18 AWG wire will drop 0.125

V/ft at 7.8 A at maximum ambient temperature. Using 100 feet between the QuickTrip and the power

supply would provide a voltage drop of 100×0.125 = 12.5V.

It is very important to ensure the voltage at the QuickTrip’s input terminal is within the product power

input specification to achieve maximum performance.

A standard wire cross-sectional area voltage drop at maximum ambient temperature is provided in Table

3-6 and Table 3-7 to assist with cable selection.

Extended Power Input

The Power Wiring Requirements section above specifies the maximum length of 30 meters between the

power source and the QuickTrip. Installations that require a longer power cable run also require a much

larger wire gauge to account for voltage drop. Figure 3-6 below gives a possible solution for installations

required to run at longer distances.

Wire Cross-Sectional Area Voltage Drop

A standard wire cross-sectional area voltage drop at maximum ambient temperature is provided in Table

3-6 and Table 3-7 to assist with cable selection.

Example of Voltage Drop Calculation Using Wire Cross-Sectional Area

0.067 Example #1. one power supply per module (3x power supplies): A 2.5mm2 wire will drop 0.044 V/m

at 2.6 A atmaximum ambient temperature. Using 30m between the QuickTrip and the power supply would

provide a voltage drop of 30 x 0.044 = 1.32V.

Example #2. one power supply for all three modules (1x power supply): A 2.5mm2 wires will drop 0.132

V/m at 7.8 A at maximum ambient temperature. Using 30m between the QuickTrip and the power supply

would provide a voltage drop of 30 x 0.132 = 3.96V.

It is very important to ensure the voltage at the QuickTrip’s input terminal is within the product power

input specification to achieve the maximum performance.

A guideline for allowable voltage drop is to size the wire for <10% of the nominal voltage under

maximumtransient conditions.

Extended Power Input

The Power Wiring Requirements section above specifies the maximum length of 30 meters between the

power source and the QuickTrip. Installations that require a longer power cable run also require a much

larger wire gauge to account for voltage drop. Figure 3-6 below gives a possible solution for installations

required to run at longer distances.

General

Woodward products covered under Woodward Product and Service Warranty (5-09-0690) are warranted

to be free from defects in materials and workmanship, when installed and used in the manner for which

they are intended, for a period of 18 months from the date of shipment from Woodward, defined in

Woodward’s Terms and Conditions.

Repairs and servicing of the QuickTrip must be performed by Woodward or its authorized service facilities

Use of a cable gland or stopping plug that does not meet the hazardous area certification requirements

or thread form or thread size will invalidate the suitability for hazardous locations.

Never remove or alter the nameplate as it bears important information which may be necessary to service

or repair the unit.

QuickTrip Cover Replacement Kit

Servo cover replacement kit may be ordered from Woodward.

Refer to Figure 5-1a which displays the part number. The location and assembly orientation of each kit

component must be installed as depicted in Figure 5-1b using a spanner wrench or Woodward tool

#1013-6603. For additional information see QuickTrip Field Repair Procedure Manual 26842.

Control Input

The QuickTrip valves are controlled with the independent trip relay outputs from a trip system logic solver

such as the Woodward ProTechTPS.

Note: When used with the ProTechTPS, external power is not necessary for these inputs. All voltage

and isolation is provided within the ProTechTPS (24 VDC, 0.5 A).

Trip Points:

• If the input voltage drops below14 VDC, then the input will detect a Trip state.

• If the input voltage rises above 15 VDC, then the input will detect a Run state.

Control Input Isolation: 500 VAC from input to chassis.

Wiring Requirements

• Keep this and all other low level signal cables separated from input power cables to avoid

unnecessary coupling (noise) between them.

• Wire Gauge Range: 0.8 to 1.3 mm² / 16 to 28 AWG stranded wire.

• Shielding: The control inputs are unshielded; however, the wires should be kept in a twisted

configuration for noise immunity.

Position Feedback

There are two outputs for valve position feedback on each of the QuickTrip’s three valve modules (12

outputs total). Each of the two outputs features redundant connections. Both TRIP outputs and both RUN

outputs operate as normally open. The outputs can be wired to either switch load from positive supply or

switch load to ground. The user must supply the external 24 V supply for the output to function properly.

If using the Woodward ProTech TPS logic solver, the voltage may be supplied using the on-board discrete

power terminals (24 VDC, 0.050 A).

Wiring Strain Relief

Tie down points and ratcheting tie wraps are provided to secure the wiring to the PCB mounting plate.

This helps prevent wire strain from being transmitted to the connection at the terminal block and to keep

the wiring from chafing on the cover when tightening and under vibration. Failure to secure the wiring

could result in intermittent connections resulting in intermittent operation or shutdown conditions. Allow

for additional wire service length between the tie down points and the connectors to reduce strain on the

wire at the connector interface and to allow the black pluggable connector to be removed.

Shield Installation Notes

• Wires exposed beyond the shield should be as short as possible, not exceeding 50 mm (2 inches).

• The shield termination wire (or drain wire) should be kept as short as possible, not exceeding 50 mm

(2 inches), and the diameter should be maximized where possible.

• Installations with severe electromagnetic interference (EMI) may require additional shielding

precautions. Contact Woodward for more information.

• Do not ground shield on both ends, except where permitted by the control wiring diagram.

Failure to provide shielding can produce future conditions that are difficult to diagnose. Proper shielding

at the time of installation is required to ensure satisfactory operation of the product.

Position Feedback

There are two outputs for valve position feedback on each of the QuickTrip’s three valve modules (12

outputs total). Each of the two outputs features redundant connections. Both TRIP outputs and both RUN

outputs operate as normally open. The outputs can be wired to either switch load from positive supply or

switch load to ground. The user must supply the external 24 V supply for the output to function properly.

If using the Woodward ProTech TPS logic solver, the voltage may be supplied using the on-board discrete

power terminals (24 VDC, 0.050 A).

Remove the top access cover(s). Pass the wires through the cable gland (not provided) or conduit fitting

and attach wires to the printed circuit board terminal blocks in accordance with the wiring diagram.

Secure each wire into connector terminal using a 2.5 mm flat screwdriver blade, applying a torque of

0.2-0.25 Nm (1.75-2.25 in-lbf). Snap the terminal blocks into the header terminal blocks on the PCB.

Tighten the terminal block flange screws to 0.5 Nm (4.4 in-lbf). Replace the top access cover and torque

it using a 1 meter bar or wrench; tightening until the O-ring seal is compressed and the cover is fully

seated against the housing.

Tighten the cable gland fitting per manufacturer’s instructions or pour the conduit seal to provide strain

relief for the cable and to seal the interface between the wiring cable and the QuickTrip modules.

In order to preserve the QuickTrip’s online reparability, each of the three electrical actuator cavities must

be kept isolated from each other. This allows any individual actuator requiring repair to be electrically de

energized, repaired and placed back online while maintaining safe operation of QuickTrip in potentially

explosive environments.