1901

Product Manual 1901
(Revision New, 9/2019)

Original Instructions
Flex500 Digital Control for Hydro Application

(Francis or Kaplan Hydro Turbines)
Panel Mount
Bulkhead Mount
Installation and Operation Manual

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.
General
Failure to follow instructions can cause personal injury and/or property
Precautions
damage.
Any unauthorized modifications to or use of this equipment outside its

specified mechanical, electrical, or other operating limits may cause
personal injury and/or property damage, including damage to the
Proper Use equipment. Any such unauthorized modifications: (i) constitute "misuse"
and/or "negligence" within the meaning of the product warranty thereby
excluding warranty coverage for any resulting damage, and (ii) invalidate
product certifications or listings.
This publication may have been revised or updated since this copy was
produced. To verify that you have the latest revision, please contact
Madsen Controls & Engineering:
Revisions sales@madsencontrols.ca
www.madsencontrols.ca
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
Madsen Controls & Engineering 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.
Manual 1901
Copyright © Madsen Controls & Engineering. 2019
All Rights Reserved
Manual 1901 Flex500 for Hydro Application
Contents
WARNINGS AND NOTICES ............................................................................................................... 8

ELECTROSTATIC DISCHARGE AWARENESS ................................................................................... 10
REGULATORY COMPLIANCE .......................................................................................................... 12
CHAPTER 1 – GENERAL INFORMATION .......................................................................................... 16
Introduction ................................................................................................................................................. 16
5001 Product Family................................................................................................................................... 18
CHAPTER 2 – INSTALLATION ......................................................................................................... 20
Introduction ................................................................................................................................................. 20
Shipping Carton .......................................................................................................................................... 20
General Installation..................................................................................................................................... 20
General Wiring Guidance ........................................................................................................................... 21
CHAPTER 3 – HARDWARE SPECIFICATION ..................................................................................... 23

5001 Description and Features .................................................................................................................. 23
Maintenance Info and Recommendations .................................................................................................. 25
Electromagnetic Compatibility (EMC) ......................................................................................................... 25
Outline Drawing for Installation................................................................................................................... 26
Input Power Specification ........................................................................................................................... 30
Visual Indicators (LED’s) & CPU Configuration .......................................................................................... 31
Communications (Ethernet) ........................................................................................................................ 32
Communications (CAN) .............................................................................................................................. 33
Communications (RS-232/RS-485) ............................................................................................................ 35
Communications (Service Ports) ................................................................................................................ 37
Hardware - Terminal Blocks & Wiring......................................................................................................... 38
Terminal Block Connectors ........................................................................................................................ 39
Hardware - Speed Sensor Inputs ............................................................................................................... 40
Hardware - Analog Inputs (4-20 mA) .......................................................................................................... 41
Hardware - Analog Outputs (4-20 mA) ....................................................................................................... 42
Hardware - Actuator Outputs ...................................................................................................................... 43
Hardware - Discrete Inputs ......................................................................................................................... 44
Hardware - Relay Outputs .......................................................................................................................... 45
Troubleshooting Fault Codes ..................................................................................................................... 47
Troubleshooting & Commissioning checks................................................................................................. 47
CHAPTER 4 – MANUAL NETWORK SETUP ...................................................................................... 51
Factory Set IP Addresses for the Control ................................................................................................... 51
Factory Set Network Passwords ................................................................................................................ 51
Network setup instructions for the control .................................................................................................. 51
Software Tools............................................................................................................................................ 59
Overview..................................................................................................................................................... 59
Programming Tools .................................................................................................................................... 59
Service Tools .............................................................................................................................................. 61
Obtaining Software Tools ........................................................................................................................... 62
CHAPTER 5 – DISTRIBUTED I/O EXPANSION .................................................................................. 63
CHAPTER 6 – CONTROL OVERVIEW............................................................................................... 67
Speed Control............................................................................................................................................. 67
Position Control .......................................................................................................................................... 67
Power Control ............................................................................................................................................. 68
Madsen Controls & Engineering 1

Level Control .............................................................................................................................................. 68

Gate Limiter ................................................................................................................................................ 68
Manual Control ........................................................................................................................................... 68
Keypad and Display.................................................................................................................................... 68
Watchdog Timer/CPU Fault Control ........................................................................................................... 70
CHAPTER 7 – CONTROL DESCRIPTION .......................................................................................... 72
Start, Stop, and Gate Limit ......................................................................................................................... 72
External Start Permissive ........................................................................................................................... 73
Open Wire Detection on MPU Speed Signals ............................................................................................ 73
Speed Signal Processing ........................................................................................................................... 74
Offline/Isochronous Speed Control............................................................................................................. 75
Online/Droop Speed Control ...................................................................................................................... 76
Remote Reference Control Mode ............................................................................................................... 77
Manual/Maintenance Modes ...................................................................................................................... 78
Auto-Follow Control Mode .......................................................................................................................... 79
Head/Tail Level Control .............................................................................................................................. 79
Valve Driver ................................................................................................................................................ 80
Creep Detection.......................................................................................................................................... 81
Overspeed Test .......................................................................................................................................... 82
Speed Switches .......................................................................................................................................... 82
Gate Position Switches............................................................................................................................... 82
Active Power Switches ............................................................................................................................... 83
Baseload Control ........................................................................................................................................ 83
Small System Detection ............................................................................................................................. 84
Unload Command....................................................................................................................................... 84
Alarms and Shutdowns............................................................................................................................... 84
CHAPTER 8 – INPUTS AND OUTPUTS ............................................................................................. 89
Description of I/O ........................................................................................................................................ 89
Control Inputs ............................................................................................................................................. 89
Control Outputs .......................................................................................................................................... 93
CHAPTER 9 – CONFIGURATION PROCEDURES ............................................................................... 98
Program Architecture.................................................................................................................................. 98
Display Modes and User Levels ................................................................................................................. 98
Configuring the 5001 .................................................................................................................................. 99
How to License the 5001 Application ....................................................................................................... 101
Using Configure Menus ............................................................................................................................ 102
Configuration Mode Parameters............................................................................................................... 104
Exiting the Configure Mode ...................................................................................................................... 118
Valve/Actuator Calibration & Test............................................................................................................. 120
Calibration/Stroking Procedure................................................................................................................. 120
CHAPTER 10 – SERVICE MENU PROCEDURES ............................................................................. 122
Overview................................................................................................................................................... 122
Using the Service Menus.......................................................................................................................... 122
Service Mode Parameters ........................................................................................................................ 126
Step Test .................................................................................................................................................. 147
Gate Timer................................................................................................................................................ 147
CHAPTER 11 – PERIPHERAL DEVICES ......................................................................................... 148
Overview................................................................................................................................................... 148
DSLC-2 (Generator Synchronizer and Load Control)............................................................................... 148
VariStroke II (Electro-Hydraulic Actuator)................................................................................................. 151
MFR300 (Multi-function Relay) ................................................................................................................. 152
HighPROTEC (Generator Protection Unit) ............................................................................................... 155

CHAPTER 12 – 5001 OPERATION ................................................................................................ 157

Software Architecture ............................................................................................................................... 157
Power-Up Screen ..................................................................................................................................... 158
Control Mode Architecture ........................................................................................................................ 159
User Login Levels ..................................................................................................................................... 160
Navigation................................................................................................................................................. 161
Page Organization .................................................................................................................................... 162
Overview Screen ...................................................................................................................................... 163
Speed Control Screen .............................................................................................................................. 164
Valve Demand Screen.............................................................................................................................. 165
Controllers Screen .................................................................................................................................... 165
Start Curve Screen ................................................................................................................................... 166
Custom Trend Screen .............................................................................................................................. 167
Analog Inputs Summary Screen ............................................................................................................... 167
Contact Input Summary Screen ............................................................................................................... 168
Analog Output Summary Screen .............................................................................................................. 169
Relay Output Summary Screen ................................................................................................................ 169
Actuator Driver Summary Screen ............................................................................................................. 170
Starting Procedures (Start Curve Screen) ................................................................................................ 171
Overspeed Test Function (Speed Control Screen) .................................................................................. 172
Stop Key ................................................................................................................................................... 173
Alarm Summary ........................................................................................................................................ 173
Shutdown Summary ................................................................................................................................. 174
Manual Dynamic Adjustments of Offline, Small System, Online, and Load Controls ............................... 174
CHAPTER 13 – COMMUNICATIONS ............................................................................................... 178
Modbus Communications ......................................................................................................................... 178
Port Adjustments ...................................................................................................................................... 181
5001 Control Modbus Addresses ............................................................................................................. 181
CHAPTER 14 – PRODUCT SUPPORT AND SERVICE OPTIONS ........................................................ 195
Product Support Options .......................................................................................................................... 195
Product Service Options ........................................................................................................................... 195
Returning Equipment for Repair ............................................................................................................... 196
Replacement Parts ................................................................................................................................... 197
Engineering Services................................................................................................................................ 197
Contacting Woodward’s Support Organization......................................................................................... 198
Technical Assistance ................................................................................................................................ 199
APPENDIX A – CONFIGURATION MODE WORKSHEETS ................................................................. 200
APPENDIX B – SERVICE MODE WORKSHEETS ............................................................................. 209
APPENDIX C – PASSWORD INFORMATION .................................................................................... 222
General ..................................................................................................................................................... 222
Monitor User Level ................................................................................................................................... 222
“Operator” User Level Password .............................................................................................................. 222
“Service” User Level Password ................................................................................................................ 222
“Configure” User Level Password............................................................................................................. 222
“ServiceUser” User Level Password......................................................................................................... 222
REVISION HISTORY ..................................................................................................................... 223

The following are trademarks of Woodward, Inc.:

Flex500
ProTech
Woodward
The following are trademarks of their respective companies:

Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)


Illustrations and Tables
Figure 1: 5001P Digital Control (With Display) ........................................................................................... 18

Figure 2: 5001B Digital Control (Without Display) ...................................................................................... 19
Figure 3: Functional Block Diagram ........................................................................................................... 24
Figure 4: 5001P Outline Drawing ............................................................................................................... 27
Figure 5: 5001B Outline Drawing ............................................................................................................... 28
Figure 6: 5001B Outline Drawing ............................................................................................................... 29
Figure 7: COM1 Example RS-485 wiring ................................................................................................... 36
Figure 8: CPU Service Port (3 pin, 2 mm) .................................................................................................. 37
Figure 9: 5001P Back Cover Label............................................................................................................. 38
Figure 10: 5001B Back Cover Label........................................................................................................... 38
Figure 11: 5001 Terminal Block Connectors .............................................................................................. 39
Figure 12: Speed Sensor Block Diagram ................................................................................................... 41
Figure 13: Analog Input – Self-Powered Block Diagram ............................................................................ 42
Figure 14: Analog Input – Loop-Powered Block Diagram .......................................................................... 42
Figure 15: Analog Output Block Diagram ................................................................................................... 43
Figure 16: Actuator Output Block Diagram ................................................................................................. 44
Figure 17: Discrete Input Block Diagram .................................................................................................... 45
Figure 18: Relay Output Block Diagram ..................................................................................................... 46
Figure 19: Network Setup Flowchart .......................................................................................................... 52
Figure 20: Network Cable Connections ...................................................................................................... 54
Figure 21: AppManager Control Dropdown Menu ...................................................................................... 55
Figure 22: AppManager Control Information Page ..................................................................................... 56
Figure 23: Control Network Configuration Page ......................................................................................... 57
Figure 24: AppManager Yes/No Window ................................................................................................... 57
Figure 25: AppManager Reboot Prompt Window ....................................................................................... 57
Figure 26: LinkNet Distributed I/O Node..................................................................................................... 63
Figure 27: Vibration Wizard for LinkNet Node 1 ......................................................................................... 64
Figure 28: LinkNet Node 1 with 4 Vibration Signals ................................................................................... 65
Figure 29: Vibration Monitoring Page ......................................................................................................... 65
Figure 30: 5001 Keypad and Display ......................................................................................................... 69
Figure 31: Gate Limit .................................................................................................................................. 72
Figure 32: Open Wire Detection Test ......................................................................................................... 74
Figure 33: Speed Deadband Function........................................................................................................ 75
Figure 34: Gate Position ............................................................................................................................. 77
Figure 35: Head Level Control Accuracy .................................................................................................... 80
Figure 36: Analog Input Summary Screen ................................................................................................. 90
Figure 37: Contact Input Summary Screen ................................................................................................ 92
Figure 38: Analog Output Summary Screen............................................................................................... 94
Figure 39: Actuator Driver Summary Screen.............................................................................................. 95
Figure 40: Initial HOME Screen (unit not configured) ............................................................................... 100
Figure 41: Initial HOME Screen (unit configured) ..................................................................................... 101
Figure 42: Site Information Screen ........................................................................................................... 102
Figure 43: Configuration Menu – Configuration Mode (Edit) .................................................................... 103
Figure 44: User Login for Service ............................................................................................................. 122
Figure 45:Authorized and Unauthorized Components ............................................................................. 123
Figure 46: Service Menu (page 1) ............................................................................................................ 124
Figure 47: Service Menu (page 2) ............................................................................................................ 124
Figure 48: Blade Curve............................................................................................................................. 133
Figure 49: Blade Fixed Curve ................................................................................................................... 133
Figure 50: Net Head Configuration ........................................................................................................... 134
Figure 51: DSLC-2.................................................................................................................................... 148

Figure 52: Configuration/Woodward Links/DSLC-2.................................................................................. 149

Figure 53: Service Screen - DSLC-2 Power Parameters ......................................................................... 149
Figure 54: Service Screen - DSLC-2 Status Parameters ......................................................................... 150
Figure 55: VS-II ........................................................................................................................................ 151
Figure 56: Configuration/Woodward Links/VS-II ...................................................................................... 151
Figure 57: Service/VariStroke II................................................................................................................ 152
Figure 58: MFR300 Multi-Function Relay ................................................................................................. 152
Figure 59: Configuration/Woodward Links/MFR300................................................................................. 153
Figure 60: Service Screen1/Woodward Links/MFR300............................................................................ 154
Figure 61: Service Screen2/Woodward Links/MFR300............................................................................ 154
Figure 62: HighPROTEC .......................................................................................................................... 155
Figure 63: Configuration Screen/Woodward Links/HighPROTEC............................................................ 155
Figure 64: Service Screen/Woodward Links/HighPROTEC ..................................................................... 156
Figure 65:Software Architecture ............................................................................................................... 157
Figure 66: Boot-up to HOME Screen........................................................................................................ 158
Figure 67: Control Mode Architecture....................................................................................................... 159
Figure 68: Mode Screen ........................................................................................................................... 160
Figure 69: Navigation Cross ..................................................................................................................... 161
Figure 70: Service Menu showing “Turbine Start” IN-Focus .................................................................... 161
Figure 71: Configuration Menu – Operation Mode (View only) ................................................................ 162
Figure 72: Configuration Menu – Configuration Mode (Edit) .................................................................... 163
Figure 73: Overview Screen ..................................................................................................................... 164
Figure 74: Valve Demand Screen ............................................................................................................ 165
Figure 75: Controllers Screen................................................................................................................... 166
Figure 76: Start Curve Screen .................................................................................................................. 166
Figure 77: Custom Trend Screen ............................................................................................................. 167
Figure 78: Analog Input Summary Screen ............................................................................................... 168
Figure 79: Contact Input Summary Screen .............................................................................................. 168
Figure 80: Analog Output Summary Screen............................................................................................. 169
Figure 81: Relay Output Summary Screen............................................................................................... 170
Figure 82: Actuator Driver Summary Screen............................................................................................ 170
Figure 83: HOME Menu showing “Startup Curve” IN-Focus .................................................................... 171
Figure 84: Overspeed Test Permissives .................................................................................................. 172
Figure 85: ALARM Screen........................................................................................................................ 173
Figure 86: Shutdown Summary Screen.................................................................................................... 174
Figure 87: Offline Dynamics Adjustment Screen ...................................................................................... 175
Figure 88: Typical Response to Load Change ......................................................................................... 177
Figure 89: ASCII/RTU Representation of 3 .............................................................................................. 179
Table 1: 5001P Part Number Options ........................................................................................................ 16

Table 2: 5001B Part Number Options ........................................................................................................ 16
Table 3: 5001J Part Number Options ......................................................................................................... 17
Table 4: Environmental Specifications ....................................................................................................... 24
Table 5: Specifications (LV)........................................................................................................................ 30
Table 6: Specifications (HV) ....................................................................................................................... 30
Table 7: Input Power Connector Pinout...................................................................................................... 31
Table 8: Ethernet Ports #1-4 (10/100) ........................................................................................................ 32
Table 9: CAN Specifications ....................................................................................................................... 34
Table 10: CAN Connector Pinout ............................................................................................................... 34
Table 11: Belden YR58684, bulk cable (Woodward PN 2008-1512) ......................................................... 35
Table 12: COM1 Serial Port Connector ...................................................................................................... 36
Table 13: Specifications (MPU/PROX) ....................................................................................................... 40
Table 14: Specifications (AI)....................................................................................................................... 42
Table 15: Specifications (AO) ..................................................................................................................... 43
Table 16: Specifications (ACT) ................................................................................................................... 44
Table 17: Specifications (DI) ...................................................................................................................... 45

Table 18: Specifications (Relay outputs) .................................................................................................... 46

Table 19: CPU Fault LED Flash Codes ...................................................................................................... 47
Table 20: Factory set IP addresses for the Flex500 CPU .......................................................................... 51
Table 21: Factory set account names and passwords for newer controls.................................................. 51
Table 22: Available (programmed) distributed I/O Nodes .......................................................................... 63
Table 24: List of Alarms .............................................................................................................................. 84
Table 25: Analog Input Functions ............................................................................................................... 89
Table 26: Contact Input Functions.............................................................................................................. 91
Table 27: Analog Output Functions ............................................................................................................ 94
Table 28: Relay Output Functions .............................................................................................................. 95
Table 29: Mode Access by User Level ....................................................................................................... 98
Table 30: Configuration Menu Commands ............................................................................................... 103
Table 31: Configuration Error Messages .................................................................................................. 119
Table 32: Actuator Driver Limits ............................................................................................................... 120
Table 33: Current CANOPEN NMT State Values Displayed .................................................................... 145
Table 34: Current CANOPEN State Values Displayed............................................................................. 146
Table 35: Parameter ID’s from DSCLC-2 to 5001 .................................................................................... 150
Table 36: CAN Wiring from 5001 to VS-II................................................................................................. 152
Table 37: CAN Wiring from 5001 to MFR300 ........................................................................................... 153
Table 38: ASCII vs RTU Modbus ............................................................................................................. 179
Table 39: Modbus Frame Definition ......................................................................................................... 180
Table 40: Modbus Function Codes........................................................................................................... 180
Table 41: Modbus Error Codes ................................................................................................................ 181
Table 42: Modbus Communication Port Adjustments .............................................................................. 181
Table 43: Maximum Modbus Discrete and Analog Values ....................................................................... 182
Table 44: Boolean Write Addresses ......................................................................................................... 183
Table 45: Boolean Read Addresses ......................................................................................................... 184
Table 46: Analog Read Addresses ........................................................................................................... 190
Table 47: Analog Write Addresses ........................................................................................................... 194


Warnings and Notices

Important Definitions
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death.
• DANGER—Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING—Indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
• CAUTION—Indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury.
• NOTICE—Indicates a hazard that could result in property damage only (including damage to the
control).
• IMPORTANT—Designates an operating tip or maintenance suggestion.
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 independent of the prime mover

control system. An overtemperature or overpressure shutdown device may
also be needed for safety, as appropriate.
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.
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.
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
Overspeed / Over possible personal injury, loss of life, or property damage.
Temperature / Overpressure The overspeed shutdown device must be totally
independent of the prime mover control system. An over
temperature or overpressure shutdown device may also be
needed for safety, as appropriate.

Be prepared to make an emergency shutdown when starting

the engine, turbine, or other type of prime mover, to protect
against runaway or overspeed with possible personal injury,
Start-up loss of life, or property damage.
The products described in this publication may present

risks that could lead to personal injury, loss of life, or
property damage. Always wear the appropriate personal
Personal Protective protective equipment (PPE) for the job at hand. Equipment
that should be considered includes but is not limited to:
Equipment
• Eye Protection
• Hearing Protection
• Hard Hat
• Gloves
• Safety Boots
• Respirator
Always read the proper Material Safety Data Sheet (MSDS)
for any working fluid(s) and comply with recommended
safety equipment.
IOLOCK. When a CPU or I/O module fails, watchdog logic

drives it into an IOLOCK condition where all output circuits
and signals are driven to a known de-energized state as
described below. Design the System such that IOLOCK and
power OFF states will result in a SAFE condition of the
controlled device.
• CPU and I/O module failures will drive the module into
an IOLOCK state
• CPU failure will assert an IOLOCK signal to all modules
and expansion racks to drive them into an IOLOCK
state.
• Discrete outputs / relay drivers will be non-active and
deenergized
• Analog and Actuator outputs will be non-active and de-
energized with zero voltage or zero current.
The IOLOCK state is asserted under various conditions
including:
• CPU and I/O module watchdog failures
• Power Up and Power Down conditions
• System reset and hardware/software initialization
• Entering configuration mode
NOTE: Specify additional watchdog details and any

exceptions to these failure states in the related CPU or I/O
module section of the manual.

An emergency switch or circuit breaker shall be included in

the
building installation that is in close proximity to the
equipment and within easy reach of the operator. The switch
Emergency Disconnecting
or circuit breaker shall be clearly marked as the
Device disconnecting device for the equipment. The switch or circuit
breaker shall not interrupt the Protective Earth (PE)
conductor.
Authorized personnel knowledgeable of the risks posed by

live electrical equipment should only perform the calibration
and checkout procedure.
Risk of Calibration and
Checkout
Properly fuse the Power Supply MAINS according to the

NEC/CEC or Authority Having Final Jurisdiction per the Input
Power Specifications
Fuse Power Supply Mains
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
Electrostatic Precautions (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

Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit
Boards, and Modules.
Follow these precautions when working with or near the control.

1. 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.
2. 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.

Woodward manual 82715, Guide for Handling and Protection
of Electronic Controls, Printed Circuit Boards, and Modules.

Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking. Refer to DoC for applicability
by part number.
EMC Directive: Declared to Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014 on the harmonization of the laws of the Member
States relating to electromagnetic compatibility. (EMC)
ATEX – Potentially Declared to Directive 2014/34/EU on the harmonization of the laws of the
Explosive Member States relating to equipment and protective systems
Atmospheres intended for use in potentially explosive atmospheres.
Directive: Zone 2, Category 3, Group II G, Ex ic nA IIC T4 X Gc IP20
Low Voltage Declared to Directive 2014/35/EU on the harmonization of the laws of the
Directive: Member States relating to the making available on the market of electrical
equipment designed for use within certain voltage limits.
Other European and International Compliance:

IECEx: Ex ic nA IIC T4 Gc T4 Certificate: IECEx CSA 15.0020X
IEC 60079-0: 2011 – Explosive Atmospheres – Part 0 Equipment General
Requirements
IEC 60079-11: 2011 – Explosive Atmospheres – Part 11 Equipment Protection
by Intrinsic Safety “i”
IEC 60079-15: 2010 – Explosive Atmospheres – Part 15: Equipment
protection by type of protection “n”
EAC Customs Union

These listings are limited only to those units with labels, marking and manuals in Russian language
to comply with their certificates and declaration.
EAC Customs Union: Certified to Technical Regulation TR CU 012/2011 for use in potentially
explosive atmospheres per Certificate
RU C-US.МЮ62.В.04777 as 2Ex ic nA IIC T4 Gc X
Declared to Technical Regulation TR CU 020/2011 On Electromagnetic

Compatibility of Technical Equipment Declaration of Conformity Registration
No: RU Д-US.МЛ66.В.001129
North American Compliance:
These listings are limited only to those units bearing the CSA identification.
Units bearing only the CSA identification are restricted for use only in Ordinary Locations in North
America.
Units bearing the CSA identification in addition to the marking indicating Class I, Div 2, Groups A, B, C
and D are acceptable for use in North American Hazardous Locations.
CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T4 at 70 °C surrounding air
temperature. For use in Canada and the United States.
CSA Certificate 70006135
This product is certified as a component for use in other equipment. The final combination is subject to
acceptance by the authority having jurisdiction or local inspection.
Marine Compliance:

Lloyd’s Register of LR Type Approval Test Specification No. 1, July 2013; Environmental Shipping:
Categories ENV1, ENV2 and ENV3
DNV-GL Temperature Class D, Humidity Class B, Vibration Class A, EMC Class A,
Enclosure; Required protection according to the Rules shall be provided upon
installation on board.
Lloyd’s: Type Approval Conditions

Where this controller is used to perform safety critical functions or system Shutdowns, a valid Lloyd’s
Register Software Conformity Assessment Certificate Is required. Where the controller is used for control
and alarm purposes, a separate, independent safety system must be provided.
Installation of this equipment for marine applications is to be in accordance with current Lloyd’s Register
Rules and Regulations.
Radiated and conducted emissions meet the requirement for equipment in the general power distribution
zones.
DNV-GL: Type Approval Conditions

The Type Approval covers hardware listed under Product description. When the hardware is used in
applications to be classed by DNV, documentation for the actual application is to be submitted for
approval by the manufacturer of the application system in each case. Reference is made to DNV Rules
for Ships Pt. 4 Ch. 9 Control and Monitoring Systems.
Product Certificate
If specified in the Rules, ref. Pt. 4 Ch. 9 Sec. 1, the control and monitoring system in which the above
listed hardware is used shall be delivered with a product certificate. For each such delivery the
certification test is to be performed at the manufacturer of the application system before the system is
shipped to the yard. The test shall be done according to an approved test program. After the certification
the clause for application software control will be put into force.
Clause for application software control

Record all changes in software as long as the system is in use on board. Forward the records of all changes
to DNV for evaluation and approval. Verify approved major changes in the software before installing the
software in the computer.
Application/Limitation
Ex-certification is not covered by this certificate. Application in hazardous area to be approved in each
case according to the Rules and Ex-Certification/Special Conditions for Safe Use listed in valid Ex-
certificate issued by a notified/recognized Certification Body.
Special Conditions for Safe Use
The Flex500 Digital Control shall not be installed in areas exceeding Pollution Degree 2 as defined in
IEC 60664-1 and Overvoltage Category II.
The controls containing a LCD and Keypad must be mounted in a vertical position with air vents located
at the top and bottom of the unit. The Bulkhead mount control can be mounted in a vertical or horizontal
position. Regardless of the mounting orientation, the air temperature surrounding the control cannot
exceed 70˚C.
A fixed wiring installation is required. Field wiring must be in accordance with North American Class I,
Division 2 (CEC and NEC), or European Zone 2, Category 3 wiring methods as applicable, and in
accordance with the Local Inspection Authority having jurisdiction. On high voltage versions of the control
the interior of the enclosure shall not be accessible in normal operation without the use of a tool.

A switch or circuit breaker shall be included in the building installation that is in close proximity to the
equipment and within easy reach of the operator. The switch or circuit breaker shall be clearly marked as
the disconnecting device for the equipment. The switch or circuit breaker shall not interrupt the Protective
Earth (PE) conductor.
Field wiring must be suitable for the following temperatures:

Power Input rated minimum of +95˚C.
All remaining connections; +10˚C above highest ambient temperature.
Protective Earth Grounding of the Flex500 Digital Control connection to the PE terminal is required.
Hazardous Locations
The Low Voltage ATEX Flex500 Digital Control is suitable for use in Class I, Div 2, Gas, Groups A, B, C
and D & European Zone 2, Group IIC environments
The risk of electrostatic discharge is reduced by permanent installation of the Flex500, proper connection
of the equipotential ground lugs, and care when cleaning. Verify that the area is non-hazardous prior to
the device being cleaned or wiped off.
The Real Time Clock Battery located on the CPU board is not to be recharged and is not user replaceable.
Contact a Woodward Authorized Service Center if replacement service is needed.
The controls with an LCD and Keypad must be installed in an area or enclosure providing adequate protection
against high impact. (4 Joules and 7 Joules) The control is rated for 2 Joules impact.
The Flex500 Bulkhead control must be installed in an area or enclosure that protects the control from any
impact.
ATEX/IECEx locations require that the Flex500 Control with a keypad and display be installed in a
cabinet or enclosure coded Ex nA or Ex e that provides a minimum IP54 ingress protection per IEC
60529 for the rear of the control. The front bezel, keypad and display have been tested and are rated
IP54 while the rear of the control is rated IP20 due to the ventilation slots required for heat dissipation.
The installer shall ensure that the maximum surrounding air temperature in the enclosure does not
exceed the rated temperature of +70˚C.
The Flex500 Bulkhead Control without the front panel display or keyboard must be installed in a cabinet
or enclosure coded Ex nA or Ex e that provides a minimum IP54 ingress protection per IEC 60529. The
installer shall ensure that the maximum surrounding air temperature in the enclosure does not exceed the
rated temperature of +70˚C.
Transient Protection for the Flex500 is to be provided externally by the end user at the supply terminals
of the control. The transient protection device is to be set at a level not exceeding 140% of the maximum
rated peak voltage of 36Vdc.

For ATEX/IECEx installation compliance, the

input voltage shall be limited to 36 Vdc. When
selecting an external power supply to supply
Explosion Hazard the Control, it shall be ATEX/IECEx approved
for Zone 2 Group IIC, Category 3G Applications
Substitution of components may impair suitability

for Class I, Division 2 or Zone 2 applications.
Due to the Hazardous Location Listings

associated with this product, proper wire type
and wiring practices are critical to the
Explosion Hazard operation.
ENCLOSURE REQUIREMENT—
ATEX/IECEx Zone 2, Category 3G applications
require the final installation location provide a
Explosion Hazard minimum IP-54 ingress protection enclosure
against dust and water per IEC 60529. The
enclosure must be coded Ex nA or Ex e.
Do Not Remove Covers or Connect/Disconnect

electrical connectors unless power has been
switched off or the area is known to be
Explosion Hazard nonhazardous
Substitution of components may impair

suitability for Class 1, Division 2, or Zone 2.
Explosion Hazard
Properly connect the external ground lugs

shown on the installation drawing to ensure
equipotential bonding. This will reduce the risk
Explosion Hazard of electrostatic discharge in an explosive
atmosphere. Perform cleaning by hand or water
spray while the area is non-hazardous to
prevent an electrostatic discharge in an
explosive atmosphere.

Chapter 1 – General Information
Introduction
The 5001 Digital Control is designed based on Woodward’s Flex500 platform, a real-time, deterministic
turbine controller that is available with or without an integrated HMI display. Enhanced communication
options for Serial, Ethernet, and CAN are key features for improved networking and I/O expansion.
Controller I/O may be easily expanded into rugged environments using CAN and Woodward RTCnet and
LinkNet-HT nodes.
5001P versions are panel mounted and include a color graphical display that has the capability of
customization to unique turbine, OEM, and customer requirements.
Table 1: 5001P Part Number Options
Part Number
5001-0101 LVDC (18-36 Vdc) Ordinary Location Compliance
5001-0102 AC/DC (88-264 Vac or 90-150 Vdc) Ordinary Locations Compliance
5001B is a bulkhead-mounted version of the 5001. Configured without a display, the 5001B is ideal for
remote environments.
Table 2: 5001B Part Number Options
Part Number
5001J versions are mounted in a junction box and include a color graphical display that has the capability
of customization to unique turbine, OEM, and customer requirements.

Table 3: 5001J Part Number Options
Part Number
Product Highlights
• Designed for real-time, deterministic control
• Designed for easy expansion with Woodward RTCnet / LinkNet HT nodes
• Plug-N-Play integration with Woodward GAP software and RateGroups
Features
• Operating temperature range of –30 °C to +70 °C (with display)
• Operating temperature range of –40 °C to +70 °C (without display)
• Input power options for Low Voltage (24VDC) and High Voltage (AC/DC)
• Real-time I/O with deterministic and synchronous updates of 5 ms to 160 ms
• Isolated communication ports for Ethernet, CAN, and RS232/485
• CAN ports support Woodward valves and I/O nodes (RTCnet / LinkNet-HT)
A 5001 Digital Control system using RTCnet / LinkNet-HT distributed I/O nodes and with Woodward’s
GAP programmed software provides a powerful control environment. Woodward’s unique RateGroup
structure ensures that control functions execute with determinism at intervals defined by the System
Engineer. GAP allows critical control loops to be processed as fast as 5 milliseconds while less critical
code is assigned to a slower execution rate like 160 ms. The RateGroup structure prevents the possibility
of changing system dynamics when adding additional code so the control functions are always
deterministic and predictable.
Flex500 Digital Control provides control configuration, diagnostics, and monitoring through standard
Woodward interface and GAP tools like Monitor GAP and SOS OPC server.

5001 Product Family

Figure 1: 5001P Digital Control (With Display)


Figure 2: 5001B Digital Control (Without Display)

Chapter 2 – Installation
Introduction
This chapter provides the basic installation guidance for mounting location selection, installation, and
wiring of the controller, including hardware dimensions, ratings, and requirements for mounting and wiring
the control in a specific application.
Shipping Carton
Before unpacking the Flex500, refer to the inside front cover and page VI of this manual for WARNINGS
and CAUTIONS. Be careful when unpacking the Control. Check for signs of damage such as bent or
dented panels, scratches, and loose or broken parts. If you detect any damage, immediately notify the
shipper.
The Control ships from the factory in an anti-static foam lined carton. Use this carton for transportation or
storage when the Controller is separate from the system.
General Installation
When selecting a location for mounting the Control, consider the following:
• Protect the unit from direct exposure to water or to a condensation-prone environment.
• The control design is ideal for installation in a protective metal enclosure such as a standard
cabinet with ingress protection rating of IP54 or greater for Hazardous locations.
• For best airflow, mount the Flex500 in a vertical orientation with ventilation slots at the top and
bottom of the control.
• Provide an ESD strap or other discharge methods as ESD mitigation inside the cabinet; it must
be used for handling the equipment and plugging/unplugging the connectors.
• Provide adequate ventilation for cooling. Mount in a location that is able to maintain an ambient
operating temperature within the range of rated maximum and minimum ambient temperatures.
Shield the unit from radiant heat sources as needed to maintain ambient temperature within the
rated range.
• Do not install the unit or its connecting wires near inductive, high-voltage, or high-current devices.
If this is not possible, shield both the system connecting wires and the interfering devices and/or
its wires.
• Allow adequate space around the unit for airflow, servicing, and wiring.
• Do not install where damage may occur from objects dropped on the terminals or inside the unit.
• Use the chassis ground lugs with a large a gage wire to Earth Ground the unit for proper safety
and shielding effectiveness. Recommend use of the power input ground wire, especially when
installed in noisy, high corrosion, or high vibration environments.

General Wiring Guidance
Terminal block wiring must use multi-stranded wires to

provide best results.
Do not tin (solder) the wires that terminate at the node

terminal blocks. The spring-loaded CageClamp or screw down
terminal blocks is designed to flatten stranded wire, and if
those strands are tinned together, the connection loses
surface area and is degraded. The solder tinned wire end will
also cold flow over time potentially further degrading or break
the connection.
CAN NETWORKS. It is possible to disrupt an existing CAN

network by attaching an improperly configured device.
Shielded Wire, Shield Termination Lead Preparation

1. Where shielded cable is required, cut the cable to the desired length, and prepare the cable as
instructed below.
2. Strip outer insulation from both ends, exposing the braided or spiral wrapped shield. Do not cut
the shield or nick the wire inside the shield.
3. Using a sharply pointed tool carefully spread the strands of the braided shield to form a hole.
4. Take hold of the inner conductor(s) wire’s insulation and pull the wires out of the shield one at a
time.
a. If the shield is the braided type, twist the braid it to prevent fraying; twist it with the drain
wire if one is present. Use as much of the shield braid and drain combined as possible to
terminate the shield.
b. Foil shields or shields of foil combined with braid require the drain to be brought out and
excess foil may be removed.
5. Remove 6 mm (1/4 inch) of insulation from the inner insulated signal conductors.
6. Connect wiring and shield as shown in plant wiring diagram.
7. If a shield connection is not required or desired, fold back and secure or remove the excess
shield as needed. (If there is a landing/connection point for the shield, it should be used to get
optimal signal performance.)
General Wiring Installation
All signal lines except power supply, Discrete Input and Discrete Output, wiring should be shielded to
prevent picking up stray signals from adjacent equipment. These may also be shielded if desired.
For noise suppression reasons, it is recommended that all low current and low voltage wires be separated
from all high current and/or high-voltage wiring.
Recommend strain relief for cables as strain relief of cables is a wise practice.

Input power ground terminal, not power return, should also be wired/bonded to earth ground in applicable
cases like environments that lead to corrosion or hazardous atmosphere environments.
All shielded cable must be twisted conductor pairs, triples or multiple pairs. The nodes are designed with
AC (Capacitor) and direct shield terminations to earth ground at the cable landing points to facilitate
shield termination.
Installations with severe electromagnetic interference (EMI) and maintaining electromagnetic compatibility
(EMC) may require additional shielding precautions, such as wire run in conduit or double shielding. In
general, the devices are designed with a level of immunity to EMI and to maintain EMC for the typical
installation environment and added pre-cautions are not needed. Contact Woodward for more
information.
In general, terminate shields to their landing point on the terminal block. They may also be required to be
landed/terminated at the opposite end.
Directly ground shields from the unit to its loads or input sources to earth at both ends, but only if the
cable length is sufficiently short to prevent ground loop current in the shield. (E.g. Shields within a single
cabinet or where the shortest straight-line distance between shield to chassis/earth connection points is
no further than 10 m to 30 m apart).
If long cables are used where termination end point separations are greater than 10 to 30 m, and both
shield ends must be terminated, a capacitor must be used at one end to terminate the shield to
earth/chassis. The preferred point for the capacitor is at the remote end, but individual device sensitivity
makes this a determinative process, to find the end most applicable to using it. Using a 0.01 μF, 1500 V,
capacitor is typically sufficient.
If intervening terminal blocks are used in routing a shielded signal cable, the shield should be continued
through the terminal block. If shield grounding is desired at the terminal block, it should be AC (capacitor)
coupled to earth. It is suggested to limit the number of TB break points along the cabling between the field
device end and node end to a minimum, zero would be best. In general, at least 39 inches (1 m) of cable
with an intact shield should present between breaks in the shield. Daisy chained CAN drop cabling has an
exception.
Avoid multiple, spread out, direct or high capacitance connections of a shield to earth. Multiple
connections of shielding runs the risk of high levels of low frequency ground current, like 50/60 Hz,
flowing within the shield. If there are multiple connections made, add the impedance of them up and make
sure it is much greater than safety grounds impedance required by local laws.
Shielding and Enclosure Installations: If the device is installed in a metal enclosure, as expected and
intended by hazardous location installations, shielded I/O must be AC or DC terminated directly to the
enclosure (earth ground) at the entry to the enclosure, as well as at the intended shield pins on the
nodes.
As noted, shield termination can be a deterministic process. AC shield connections (capacitors) on shield
I/O may be dictated at the node, instead of the direct earth connection provided. Typically, shields at
signal inputs are connected directly to earth, and shields at signal outputs are AC-coupled to earth or
floating. All shields from the nodes, except CAN are designed directly terminated to earth / chassis. See
Woodward application notes 50532, Interference Control in Electronic Governing Systems, and 51204,
Grounding and Shield Termination, for more information.
Specifics are in each individual installation section.

Chapter 3 – Hardware Specification
5001 Description and Features

The 5001 Digital Control is a real-time, deterministic turbine controller that is available with or without an
integrated HMI display. Enhanced communication options for Serial, Ethernet, and CAN are key features
for improved networking and I/O expansion. To expand Controller I/O use into rugged environments use
CAN and Woodward RTCnet and LinkNet-HT nodes.
5001P and 5001J versions are panel mounted and include a color graphical display that has the
capability of customization to unique turbine, OEM, and customer requirements.
5001B is a bulkhead-mounted version of the Flex500. Configured without a display, the Flex500B is ideal
for remote environments.
Power Input
(LV) input power: 18-36 Vdc input, isolated
(HV) input power: 88-264 Vac / 90-150 Vdc, isolated
Communications
(4) Ethernet 10/100 communication ports,
isolated (4) CAN communication ports (1 Mbit),
isolated
RS-232/RS-485 port, isolated

RS-232 Service port, isolated
I/O circuits
GAP configurable update rates of 5 ms to 160 ms
(4) Speed Sensor inputs (2 MPU and 2 Prox with Prox

Power) (8) Analog input 4-20 mA channels (with Loop Power)
(6) Analog output 4-20 mA channels
(2) Actuator output channels (configurable 4-20 mA/20-200 mA)

(20) Discrete input channels (with Contact Power)
(8) Relay outputs (form-c)
I/O Expansion options using RTCnet / LinkNet-HT

Refer to RTCnet / LinkNet-HT manual # 26640
Analog Inputs (4-20mA), RTD inputs, Thermocouple inputs

+24V Discrete Inputs, Discrete Outputs, Analog Outputs (4-20mA)

HMI
8.4” LCD Display (800x600) and Keypad (Flex500P)

Figure 3: Functional Block Diagram
Table 4: Environmental Specifications
Operating range of –30 °C to +70 °C (with display)

Operating Temperature1
Operating range of –40 °C to +70 °C (without display)
Storage Temperature Recommended 10 °C to 40 °C (50˚F to 104˚F)
Flex500P 8.2 Grms, industrial skid mount, per Woodward RV1
Vibration
Flex500B 1.04 Grms control room per Woodward RV5
10 G, 3x each axis, 11 ms Half Sine Pulse per Mil-STD 202F
Shock2
method 213B basic test J
Humidity3,4 5 % to 95 %, non-condensing
Altitude 3000m (9842 ft.) Maximum
Installation Rating Pollution Degree 2, Overvoltage Category II
Conformal coating Polyacrylate, sulfur resistant (see AppNote #51530)
EN 61000-6-4 (Heavy Industrial)
EMC Emissions5
IACS UR E10 (Commercial Marine)
EN 61000-6-2 (Heavy Industrial)
EMC Immunity5
IACS UR E10 (Commercial Marine)
As shipped: IP-20
IP-56 when installed in an appropriate IP-56 or higher rated
enclosure. (Non ATEX/IECEx Applications)
Ingress Rating
IP-54 for ATEX/IECEx Applications when installed in an enclosure
coded Ex nA and providing a minimum ingress protection rating of
IP-54 as defined in IEC 60529.
1
Limited by LCD display
2
Limited by internal relay specification
3
Relative humidity levels of < 55% will prolong LCD life
4
Cyclic condensing humidity is supported with an appropriate enclosure

5
Marine specification applies to the ATEX/Marine qualified unit
Maintenance Info and Recommendations

The Flex500 Digital Control design allows for continuous operation in a typical industrial environment and
includes no components that require periodic service. However, to take advantage of related product
software and hardware improvements, we recommend that you send your product to a Woodward
Authorized Service Facility after every five to ten years of continuous service for inspection and
component upgrades.
Clock battery
The Real Time Clock (RTC) battery is designed to last approximately 10 years during normal turbine
operation. When powered, the RTC automatically disables the battery usage to preserve it. During power-
off the battery is enabled and only used to maintain date and time. For long-term storage, the battery is
specified to last > 5 years.
The RTC battery is a replaceable lithium coin cell Woodward PN 1743-1017. Contact a Woodward
Authorized Service Center if a replacement service is needed.
Calibration and Functional verification

Recommend calibration verification and functional operation every 24-36 months. This is especially
important for spare units that need to be ready for immediate use. Contact a Woodward Authorized Service
Center for assistance.
Aluminum Electrolytic capacitors

Recommend to apply power to spare units every 24-36 months for 3 hours to reform the electrolytic
capacitors used in the power module.
Display LCD with backlight

The Flex500 display version uses a low power LED backlight display with a life expectancy of 60K hours
to half brightness, at maximum operating temperature. If the display appears dim, use the “SCREEN
SETTINGS” menu to verify the brightness setting and adjust as needed with the ADJ ARROW-
BRIGHTNESS keypad combination. When display damage or quality is unacceptable, contact a
Woodward Authorize Service Center for a replacement display.
Electromagnetic Compatibility (EMC)

The Flex500 Digital Control family complies with Heavy Industrial EMC requirements per EN 61000-6-4 &
EN 61000-6-2 specifications. Marine Type Approval is also met per IACS UR E10 EMC test requirements
when a Marine qualified version is used.
Emissions EN 61000-6-4 & IACS UR E10

• Radiated RF Emissions Limits 150 kHz to 5000 MHz per IEC 61000-6-4 & Marine Type Approval.
• Power Line Conducted RF Emissions Limits 10 kHz to 30 MHz per IEC 61000-6-4 & Marine Type
Approval.
Immunity EN 61000-6-2 & IACS UR E10

• Electrostatic Discharge (ESD) immunity to ±6 kV contact / ±8 kV air per IEC 61000-4-2.

• Radiated RF Immunity to 10 V/m from 80 MHz to 3000 MHz per IEC 61000-4-3.
• Electrical Fast Transients (EFT) Immunity to ±2.0 kV on I/O and Power Supply inputs per IEC
61000- 4-4.
• Surge Immunity on DC Power Supply inputs to ±1.0 kV line to earth and ±0.5 kV line to line per
IEC 61000-4-5.
• Surge Immunity on AC Power Supply inputs to ±2.0 kV line to earth and ±1.0 kV line to line per
IEC 61000-4-5.
• Surge Immunity on I/O to ±1.0 kV line to earth per IEC 61000-4-5.
• Conducted RF Immunity to 10 V (rms) from 150 kHz to 80 MHz per IEC 61000-4-6.
• Conducted Low Frequency Injection Immunity at 10% of the nominal supply level from 50 Hz to
12 kHz on Power Inputs per Marine Type Approval test requirements.
Outline Drawing for Installation

See figures below for the physical outline dimensions for the Flex500 Digital Control. See Woodward
Reference drawing 9989-3210 for additional details if necessary.
This Flex500 Digital Control has the identical mounting hole pattern as
the older 505 and Atlas controls, however the holes do not come
through the front of this unit; therefore mounting screws of correct
length must be used.
5001P / 5001J Panel Mounting information:

• There are 8 x 10-32 UNF-2B tapped holes to mount the Flex500.
• The holes are tapped to 0.312” min Depth. Choose the proper length screw to not exceed
this depth into the Bezel.
• Use screw 1069-949 (.375 Long, 10-32) for panel thickness (including washers) .065” - .100"
• Use screw 1069-948 (.438 Long, 10-32) for panel thickness (including washers) .101”- .125”
• Use screw 1069-946 (.500 Long, 10-32) For panel thickness (including washers) .126” - .187”


Figure 4: 5001P Outline Drawing

5001B Panel Mounting information:

• There are 8x.268” diameter clearance holes for mounting the Flex500HL. The holes are for 8 x
10-32 bolts with a nut and washer to mount the unit.
• Use screw length 1069-955 (.750 Long, 10-32) for panel thicknesses .100” or less. This assumes
using a .25” thick nut and two .062” thick washers to mount the unit.
• Use screw length 1031-1216 (.875 Long, 10-32) for panel thicknesses .101” i - .187”. This
assumes using a .25” thick nut and two .062” thick washers to mount the unit.

Figure 5: 5001B Outline Drawing


Figure 6: 5001B Outline Drawing

Input Power Specification
Table 5: Specifications (LV)
LV Input Voltage range: 18-36 Vdc

< 77 W, 4.3 A max (5001P / 5001J)
Input Power (max): < 71 W, (5001B)
Output Voltage Holdup time: > 14 ms with 24 Vdc input voltage
Isolation to other circuits: > 500 Vrms to all other circuits
Isolation to EARTH: > 500 Vrms to EARTH
Input Overvoltage Protection: ±60 Vdc @ 25 °C
Reverse Polarity Protection: 60 Vdc @ 25 °C
Input Undervoltage shutdown: ~11 Vdc, non-latching
Note: Recommend breaker or power-line fusing of 8 A min to protect the power-wiring network
from possible wiring shorts.
Table 6: Specifications (HV)
HV Input Voltage range: 88-264 Vac / 90-150 Vdc

HV Input Frequency range: 47-63 Hz
< 73 W, 1.6 A max (Flex500P)
Input Power (AC max): < 67 W, 1.5 A max (Flex500B)
< 73 W, 0.8 A max (Flex500P)
Input Power (DC max):
< 67 W, .75 A Max (Flex500B)
Output Voltage Holdup time: > 30 ms with 110 Vac input voltage
Output Voltage Holdup time: > 120 ms with 220 Vac input voltage
Isolation to other circuits: > 3000 Vrms to all other circuits
Isolation to EARTH: > 1500 Vrms to EARTH
Input Overvoltage Protection: ±375 Vdc @ 25 °C
Reverse Polarity Protection: 375 Vdc
Input Undervoltage Shutdown: ~65 Vdc, non-latching
Note: Recommend breaker or power-line fusing of 3.5 A min to protect the power-wiring network
from possible wiring shorts.
Power Connector
Input Power is provided through a three-position, latching terminal block with removable plug. Green
connectors are used for low voltage DC units. Orange connectors are used for high voltage AC/DC units.

Table 7: Input Power Connector Pinout
To reduce the risk of Electrical Shock the Protective Earth

(PE) must be connected to the PE terminal on the enclosure.
The conductor providing the connection must have a properly
Electric Shock sized ring lug and wire gauge equal to or larger than 4mm²
(12AWG).
Visual Indicators (LED’s) & CPU Configuration

Visual indicators are located on the Front Panel keypad, the controller board, back cover, and related
communications ports for diagnostic use.
CPU OK indicator (green/red):
This bi-color LED indicates the CPU status is operational (green) or faulty (red). The CPU will flash fault
codes (red) if they exist. This LED exists on both the Front Panel and back cover.
IOLOCK indicator (red):
Indicate the controller is shutdown and held in an IOLOCK state. This LED exists on both the Front Panel
and back cover.
ALARM indicator (yellow):
Viewable from the front panel and controlled by GAP software.
TRIPPED indicator (red):
Viewable from the front panel and controlled by GAP software.
Ethernet LED's:
(Green=link, Yellow=traffic) on each RJ45 connector indicate port status and operation.
CPU Hardware Configuration
The CPU Configuration Switch (S1) is reserved for future use and is not active at this time.

Communications (Ethernet)
There are four isolated RJ45 Ethernet Ports (10/100 Mbit/sec) available to the application software for
system use. These ports are full duplex with auto crossover detection.
Features
• Interface standard: IEEE 802.3 (Ethernet)
• Port Isolation: 1500 Vrms to PS, EARTH, and all other circuits
• Control configuration using Woodward AppManager
• Control monitoring, trending, and datalog collection
• Control configuration of Ethernet IP addresses
• General communications such as Modbus master/slave
• Manage Configuration data and tunables with Control Assistant
• Network time setup and control (SNTP)
Network Configuration
Ethernet ports (ETH1-4) can be configured for the customer network as desired. See the on-site Network
Administrator to define an appropriate I/P address configuration.
ETHERNET CABLES—Max cable length is 100 meters. To

ensure signal integrity and robust operation, double shielded
(SSTP) Cat5 Ethernet cables are required for customer
installations. (Woodward PN 5417-394, 10 feet)
Each of the ETHERNET ports is required to be configured for

a unique subnet (domain) (view default settings as an
example).
Ethernet Connector (RJ45)

Table 8: Ethernet Ports #1-4 (10/100)

Network Configuration Utility (AppManager)
Use Woodward's AppManager software to configure network setting and load Control software (GAP),
HMI display software (QT), and operating system service packs. Download the AppManager utility from
www.woodward.com/software.
A PC connection must be made to Ethernet #1 (ETH1) using a RJ45 Ethernet cable.
Note: Use AppManager to “discover/view” the current CPU IP Address, however, to

modify settings or load applications, when the PC running. Reconfigure AppManager on
the same “network” as the CPU.
• Locate the ControlName on the module faceplate and highlight it in AppManager.

• To VIEW the IP address configuration, select menu option CONTROL - CONTROL
INFORMATION. Look for the Ethernet adapter addresses under the Footprint Description.
• To CHANGE the IP address configuration, select menu option CONTROL - CHANGE
NETWORK SETTINGS.
Communications (CAN)
Four Isolated CAN ports are available for general communications as well as simplex or redundant
distributed control. Compatible devices include Woodward RTCnet nodes, LINKnet HT nodes, DVP valve
products, and other third party devices. Removable latching connector plugs are provided for field wiring.
Network Termination:
CAN networks must include a 120 Ω termination resistor at each end of the trunk line.
Network Topology:
Recommend Daisy chain connections between multiple devices. Any drop cable connection of a device to
the trunk line should be as short as possible and much less than six meters.
Recommend the network trunk design be less than 100 meters with a max cumulative drop length of less
than 39 meters.
Important:
For one Mbit/sec communication it is required that each drop cable be less than one meter and as short
as possible.


Table 9: CAN Specifications
Interface Standard CAN 2.0B, CANopen

Network Connections (4) CAN ports, separate connectors
Network Isolation 500 Vrms to EARTH, other CAN ports, all other I/O
1 Mbit @ 30 m
500 Kbit @ 100 m
Network Speed/Length 250 Kbit @ 250 m (thick cable only, otherwise limited to 100
m) 125 Kbit @ 500 m (thick cable only, otherwise limited to
100 m)
(120 ± 10) Ω is required at each end of the network trunk line.
Network Termination:
**The termination resistor is NOT built into the hardware.
CAN Address Software configurable
CAN Baud Rate Software configurable for 125 K, 500 K, 250 K, and 1 Mbit
2008-1512 (120 Ω, 3-wire, shielded twisted pair)
Cable / Part Number
—Belden YR58684 or similar
Cable Drops (1 Mbit) CAN Cable drops shall be < 1 m and as short as possible
Cable Drops (500K, etc.) CAN Cable drops shall be < 6 m and as short as possible
**If needed, an isolated CAN to USB converter is IXXAT, HW221245
Table 10: CAN Connector Pinout
CAN Cable Specifications
Belden YR58684 (Woodward PN 2008-1512) communications / CAN cable is approved and

recommended. This is a smaller and more flexible 0.3 mm² / 22 AWG, low capacitance cable suitable for
tight routing in industrial environments.


Table 11: Belden YR58684, bulk cable (Woodward PN 2008-1512)
Impedance: 120 Ω ±10 % at 1 MHz

DC resistance: 17.5 Ω per 1000 ft.
Cable capacitance: 11 pF/ft. at 1 kHz
0.3 mm² / 22 AWG, 7 strands, individually tinned, FEP insulation
Data Pair:
(BLUE, WHITE twisted pair)
0.3 mm² / 22 AWG, 7 strands, individually tinned, FEP insulation
Ground:
(BLACK)
Drain / Shield Wire: 0.3 mm² / 22 AWG, 7 strands, individually tinned
Shielding: Foil 100 % with outer Braid 65 %
Jacket: FEP Insulation, BLACK
Cable type: 1.5 pair, twisted shielded
Outer Diameter: 0.244 inch
Bend Radius: 2.5 inches
Temperature: –70 °C to +125 °C
Similar Cable: Belden 3106A (has different colors & lower temperature specs)
CAN Wiring / Shield Terminations & Limitations
For robust communications performance, the CAN cabling needs to minimize the exposed, non-shielded
cable section that occurs at terminal blocks. The exposed length of CAN wiring must be limited to less
than 3.8 cm / 1.5 inches from the end of the shield to the terminal block.
CAN shields are terminated to chassis (EARTH) through a capacitor-resistor network. This is designed
into the Flex500 hardware products. However, the shield must also be directly terminated to chassis
(Earth) at one point in the network. In the case of Woodward equipment, the direct ground is meant to be
located at the master device end, as it exits the master device’s enclosure.
Always use shielded cables for improved communications in

industrial environments. Wire terminations should expose as
little un- shielded cable as possible (less than 3.8 cm / 1.5
inches).
Communications (RS-232/RS-485)
An isolated, configurable RS-232/485 serial port is available for customer use, as configured by the GAP
software application. RS-422 communications is NOT supported

Specifications
• Interface standard: RS-232C and RS-485
• Isolation: 500 Vrms to EARTH and all other I/O
• Baud Rates: 19.2K, 38.4K, 57.6K, and 115.2 K
• Max Distance (RS-232): 15 m (50 feet) max
• Max Distance (RS-485): 1220 m (4000 feet) max
• A shielded cable is required when using this port.
• RS-485 networks require termination at both ends with approx. 90–120 impedance that
matches the characteristic impedance of the cable used.
Cable Note: Woodward cable 2008-1512 (3-wire) is a shielded, low capacitance 120-ohm cable that is
designed for communications. This cable is also used for CAN communications.
Table 12: COM1 Serial Port Connector
Plug Type: Side entry 3.5 mm, 8 A, pluggable with latching screw down
Max wire size: 1.3 mm² / 16 AWG for single wires, 0.5 mm² / 20 AWG for two wires

Figure 7: COM1 Example RS-485 wiring

Communications (Service Ports)
RS-232 Service Port
An isolated RS-232 service port is located on the CPU board. Isolation is specified at 500 Vrms and baud
rate is fixed at 115.2K baud, 8 data bits, no parity, 1 stop-bit, and no flow control. This port is for VxWorks
operating system use only and cannot be configured for application software use.
For debug use, a Woodward PN 5417-1344, USB to serial debug cable is required to attach this port to a
PC. Trained Field Service personnel use this port only!
Figure 8: CPU Service Port (3 pin, 2 mm)
USB Service Port
Note: Currently, a USB service port one of the service ports, but is disabled.


Hardware - Terminal Blocks & Wiring
Figure 9: 5001P Back Cover Label
Figure 10: 5001B Back Cover Label

Terminal Block Connectors
Figure 11: 5001 Terminal Block Connectors

Hardware - Speed Sensor Inputs

This controller includes four Digital Speed Sensor circuits. Two circuits are capable of interfacing to MPU
sensors and two circuits are capable of interfacing to Proximity speed probe sensors. The channels are
isolated from each other. A dedicated and isolated, PROX power (+24 V) is provided on each channel for
proximity sensor use.
Note: Do not use the Prox Power outputs to power any other type devices.
Features
• Four Digital Speed Sensor circuits, group isolated as MPU/Prox pair
• Two MPU sensors and two Proximity sensors
• Separate terminals provided for MPU and Prox sensors
• Isolated Prox Power (+24 Vdc) is provided with short-circuit protection
• Woodward GAP block, diagnostics, and configuration support
• GAP configurable update rates of 5 ms to 160 ms
Table 13: Specifications (MPU/PROX)
MPU Input Voltage: 1 to 35 Vrms

MPU Input Frequency: 10 Hz to 35 KHz
MPU Input Impedance: 2000 Ω, DC
500 Vrms to EARTH and all other I/O
MPU Input Isolation:
500 Vrms to other MPU and PROX channels
Prox Input Voltage: 0-32 VDC
Prox Input Frequency: 0.04 Hz to 35 KHz (low limit depends on range)
Prox Input Impedance:
Low is < 8 VDC
Prox Threshold:
High is > 16VDC
Prox Input Isolation:
500 Vrms to other MPU and PROX channels.
Prox Power1+2 out: 24 VDC ± 14%, 0-200 mA, short circuit & diode protected
Prox Power Isolation: 500 Vrms to EARTH, all other I/O, & other Prox Power
Max Speed Range: software selectable from 5 kHz to 35 kHz
Accuracy (-40,70c): < ±0.01% of full scale range selected
Resolution: > 22 bits
Speed Filter (ms): 5-10,000 ms (2 poles)
Derivative Filter (ms): 5-10,000 ms (speed filter + 1 pole)
Derivative Accuracy: 0.1% of full scale range, over full temperature range
Acceleration limit: 1-10,000 %/sec


Figure 12: Speed Sensor Block Diagram
Hardware - Analog Inputs (4-20 mA)
AI Description and Features
The Flex500 Digital Controller includes eight 4–20 mA input channels for I/O monitoring and control. Each
channel is differential (self-powered) but can be software configured for Loop Power mode. An Isolated
Loop Power (+24 Vdc) is provided for analog input transducers and includes short-circuit/over-voltage
protection.
Note: Do not use the Loop Power output to power any other type devices.
Features
• Eight 4–20 mA Analog Input Channels, 16 bit resolution
• Differential inputs with high common-mode voltage capability
• Isolated Loop Power +24 V is provided with short-circuit protection
• Fast AI channel #7 and #8 for special control functions
• GAP configurable for Loop power operation

Table 14: Specifications (AI)
Number of channels 8
AI Input Range 0 to 24 mA
0 V channel to channel.
AI Input Isolation
500 Vrms to EARTH and all other I/O (except USB)
AI Accuracy (@ 25 °C) ≤ 0.024 mA (0.1% of FS=24 mA)
AI Accuracy (–40, +70 °C) ≤ 0.06 mA (0.25% of FS=24 mA)
AI Resolution ~16 bits of full scale
2 poles @ ~10 ms
AI Hardware filter
**Fast channels (Ch. 7 & Ch. 8) have 2 poles @ ~5ms
AI Input Impedance 200 ohms (Rsense = 162 ohms)
AI Loop power output 24 V ±14% (0-250 mA) short circuit & diode protected
AI Loop power Isolation 500 Vrms to EARTH and all other I/O
AI CMRR over temp > 70 dB @ 50/60 Hz (typical 86 db)
AI CMVR > 200 V (dc) to EARTH
AI Overvoltage ±36 V (dc) continuous at room temperature

Figure 13: Analog Input – Self-Powered Block Diagram

Figure 14: Analog Input – Loop-Powered Block Diagram
Hardware - Analog Outputs (4-20 mA)

This control provides an isolated group of six 4-20 mA outputs for customer use. Each output can drive up
to 600-ohm loads and provides fault monitoring of individual source and return currents.
Features
• Six Analog Output channels (4-20 mA)

• Source and return current monitors

• Group isolated from other circuits
• Capable of driving higher impedance loads up to 600 ohms
Table 15: Specifications (AO)
Number of channels 6 (each with readback)

AO Output Range 0 to 24 mA, 0 mA during shutdown
0 V channel to channel
AO Output Isolation
AO Accuracy (@ 25 °C) ≤ 0.024 mA (0.1% of FS=24 mA)
AO Accuracy (–40, +70 °C) ≤ 0.120 mA (0.5% of FS=24 mA)
AO Resolution ~14 bits of full scale
AO Hardware filter (max) 3 poles @ 250 μs
AO Load Capability 600 Ω at 20 mA
AO Output Readbacks (0 to 24) mA, source and return
AO Readback Accuracy < 1% at 25°C, < 3% over full temperature range
AO Readback HW Filter ~0.5 ms nominal
AO circuits are driven to 0 mA during power-up, power- down,
IOLOCK state
core voltage failures, and watchdog failures

Figure 15: Analog Output Block Diagram
Hardware - Actuator Outputs

This control provides an isolated group of two Actuator outputs for customer use. Each driver can be
configured for low-range (20 mA) or high-range (200 mA) operation. Fault monitoring of individual source
and return currents is included.
Features
• Two Actuator Output channels (4-20 mA, 20-200 mA)
• Source and return current monitoring
• Group isolated from other circuits
• Capable of driving higher impedance loads

Table 16: Specifications (ACT)
Number of channels 2 proportional drivers with source & return readbacks

ACT Output Range Configurable for 24 mA or 200 mA range
ACT Output Range (low) 0-24 mA, 0 mA during shutdown (FS = 24 mA)
ACT Output Range (high) 0-200 mA, 0 mA during shutdown (FS = 210 mA)
ACT Output Isolation 0 V channel to channel
ACT Accuracy (25 °C) Low Range ≤ 0.024 mA (0.1%) High Range ≤ 0.21 mA (0.1%)
High Range ≤ 0.21 mA (0.1%) Low Range ≤ 0.120 mA (0.5%) High Range ≤ 1.00 mA (0.5%)
ACT Resolution ~14 bits of full scale

ACT Hardware filter (max) 3 poles @ 500 μs
ACT Load Capability (low) 600 Ω at 20 mA
ACT Load Capability (high) 65 Ω at 200 mA
ACT Output Readbacks (0 to 24) mA, source and return

ACT Readback Accuracy < 1% at 25°C, < 3% over full temperature range, (source & return)
ACT Readback HW Filter ~0.5 ms nominal
ESTOP action Front panel ESTOP button will shutdown the actuator circuit,
remove actuator power, and set an alarm in GAP software
IOLOCK action During IOLOCK, ACT power is shutdown and ACT circuits are
driven to 0 mA during power-up, power-down, core voltage
failures, and watchdog failures.

Figure 16: Actuator Output Block Diagram
Hardware - Discrete Inputs

This control provides an isolated group of 20 discrete input channels for use with +24 V (dc) signals. An
isolated Contact Power voltage supply of +24 V (dc) is provided for use with the discrete inputs. This
supply includes short-circuit and over-voltage protection.
Note: Do not use the Contact Power output to power any other devices.
Features
• 20 Discrete Input Channels for +24 V (dc) signals
• +24 V Contact Power with short-circuit and diode protection

• Isolated power and discrete input group

• Time-stamping capability (1 ms)
Table 17: Specifications (DI)
Number of Channels 20
DI Input Low State (0 to 8) V (dc)
DI Input High State (16 to 32) V (dc)
DI Input Current < 5 mA per channel
DI Input Impedance 25K approx
DI Hardware Filter 1.0 ms approx at room temp
DI Channel Isolation 0 V channel to channel
DI Overvoltage Overvoltage to 36 V (dc) for inputs
Contact Power Output 24 V ±14 %, 150 mA (max), short circuit & diode protected
Contact Power Isolation 500 Vrms to EARTH and all other I/O

Figure 17: Discrete Input Block Diagram
Hardware - Relay Outputs

This control provides eight Isolated, Form-C Relay outputs with NO, COM, NC contacts available at the
terminal block.
Features
• Eight Relay Output Channels
• Each Relay Output provides NO, COM, and NC contacts
• Each Relay Output channel provides a coil voltage readback fault
• Contact isolation maintained at terminal blocks
• ATEX approved version available using hermetically sealed relays

Table 18: Specifications (Relay outputs)
Number of channels 8 relays

Contact Type Form-C with NO, COM, and NC terminals
STD Relay, contacts (DC) 5 A, 5-30 Vdc (resistive)
STD Relay, contacts (AC) 2 A, 115 Vac (resistive)
STD Relay, operate time < 15 ms typical
RELAY Coil Readback Coil voltage readback status is available
RELAY Coil Rdbk Filter 1 ms approx at room temp
RELAY Output Isolation 500 Vrms minimum to EARTH and all other I/O
RELAY Contact Isolation 500 Vrms minimum between open contacts
RELAY to RELAY Isolation 500 Vrms minimum between relays
IOLOCK State Relay outputs are de-energized during power-up, power-down,
core voltage failures and watchdog failures
ATEX version: The ATEX approved control uses a Hermetically sealed relay
ATX Relay, contacts (DC) 5 A, 5-30 Vdc (resistive), 0.2-0.5 A (inductive)
ATX Relay, contacts (AC)** 2 A, 115 Vac (resistive), 0.1-0.2 A (inductive), non-hazardous
area
**ATEX/IECEx and North American Hazardous Locations

Compliance requires relay contact loads be limited to < 32
Vac rms / < 32 Vdc.
Explosion Hazard

Figure 18: Relay Output Block Diagram

Troubleshooting Fault Codes

The CPU board runs diagnostics that display troubleshooting messages through the debug Service Port
and AppManager. Additional information on diagnostics tests, subsequent LED flash codes, and serial
port messages is contained in the VxWorks manual.
Table 19: CPU Fault LED Flash Codes
Failure Flash Code

CPU not operational, IOLOCK state Solid Red
RAM Test Failure 2, 1
FPGA Test Failure 2, 9
Watchdog not enabled 2, 10
RAM drive error 2, 11
Flash drive error 2, 12
Troubleshooting & Commissioning checks

Power checks
• Verify proper polarity on power connections
• Verify power source and wire size is sufficient for all loads
• Verify input power voltage is correct (i.e.: low voltage unit is 18 V to 36 Vdc)
• Verify PS(+) and PS(–) impedance to EARTH is > 10 MΩ
Ethernet checks
• Verify cabling meets CAT-5 or better performance specs
• Verify cables are shielded properly per Woodward spec (using inner foil and outer braid)
• Verify each port is connected to the desired port & cable is labeled with correct port number
• Verify the cable installation has a bend radius is > 3 inches to prevent cable stress/breakage
• Verify that any tie-wraps used for cable installation are not overly tight to prevent cable stress
• Verify IP Address of each port is set correctly according to your plant network & administrator
• A list of the default IP address for all ports is in the Hardware/Ethernet section of this manual.
• The Woodward AppManager tool can be used to review & change IP Address settings
• Verify that Woodward Tools use Ethernet #1 (AppManager, OPC Server, & Control Assistant)
• Consider using color coded tie wraps for ports (i.e.: ETH1 = blue, ETH2=red, ETH3=yellow)
• For best performance, verify that Ethernet traffic is < 70% and GAP rategroup loading is < 80%
RS-232 wiring checks

• Verify the RS-232 wiring uses a high quality shielded communication cable. For example,
Woodward 2008-1512 (Belden YR58684) or equivalent low capacitance, shielded
communications wire.
• Verify the RS-232 wiring uses the signal common (COM1_GND)
• Verify RS-232 network length is within specifications (typically < 50 feet)
• Verify Signal wires (TX+,RX-) are not shorted to each other
• Verify Signal wires (TX+,RX-) are not shorted to COM1_GND
• Verify Signal wires (TX+,RX-) are not shorted to COM1_SHLD
• Verify Signal wires (TX+,RX-) are not connected to PS(+), PS(–), EARTH
• Verify COM1_GND is not connected to PS(+), PS(–), EARTH
• Verify the overall cable shield is terminated to EARTH at only (1) location.

RS-485 wiring checks

• Verify the RS-485 wiring uses a high quality shielded communication cable. For example,
• Verify RS-485 network length is within spec for the baud-rate (typically < 4000 feet)
• Verify the network is terminated properly at both ends with approx. 90–120
• Verify the RS-485 wiring uses the signal common (COM1_GND)
• Verify Signal wires (RS-485+, RS-485–) are not shorted to each other
• Verify Signal wires (RS-485+, RS-485–) are not shorted to COM1_GND
• Verify Signal wires (RS-485+, RS-485–) are not shorted to COM1_SHLD
• Verify Signal wires (RS-485+, RS-485–) are not connected to PS(+), PS(–), EARTH
• Verify COM1_GND is not connected to PS(+), PS(–), EARTH
• Verify the overall cable shield is terminated to EARTH at only (1) location.
CAN wiring checks

• Verify the CAN wiring uses a high quality, 3-wire, shielded communication cable. For example,
• Verify CAN network length is < max length spec for the baud rate being used
• Verify network is terminated properly at both ends with 120 , ±10%
• Verify the CAN wiring uses the signal common (CAN_GND)
• Verify CAN drop cables to each device are as short as possible and meets spec.
• Verify CANH is not connected to PS(+), PS(–), EARTH
• Verify CANL is not connected to PS(+), PS(–), EARTH
• Verify CAN_COM is not connected to PS(+), PS(–), EARTH
• Verify CAN_SHLD shield wire is not shorted to PS(+), PS(–)
• Verify the CAN overall cable shield is terminated to EARTH at only (1) location for each network.
• For redundant CAN, verify redundant networks are not miswired or connected together.
Speed Sensor MPU/PROX wiring checks

• Verify MPU sensors are wired to MPU terminal block location
• Verify PROX sensors are wired to PROX terminal block location
• Verify that each sensor is wired to the correct channel (ie: MPU1 to channel1)
• Verify that MPU+, PROX+ is not connected to PS(+), PS(–), EARTH
• Verify that MPU-, PROX- is not connected to PS(+), PS(–), EARTH
• Verify shield wires are not shorted to signals (MPU+, MPU-, PROX+, PROX-)
• Verify shield wires are not shorted to input power PS(+), PS(–)
• Verify MPU voltage amplitude meets spec (i.e.: > 1Vrms)
• Verify PROX voltage amplitude meets spec (i.e.: < 8V for low, >16V for high)
• If Prox Power#1 output is used, make sure it is ONLY used for sensor power1
• If Prox Power#2 output is used, make sure it is ONLY used for sensor power2
• If using Prox Power, verify that wiring is correct and isolation between sensors is maintained
• If using Prox Power, verify PPWR1+,PPWR2+ are not connected to PS(+), PS(-), EARTH
• If using Prox Power, verify PPWR1-,PPWR2- are not connected to PS(+), PS(-), EARTH
• If using Prox Power, verify PPWR1+,PPWR2+ are not connected to each other
• If using Prox Power, verify PPWR1-,PPWR2- are not connected to each other
AI (non-loop), Analog Input wiring checks

• Verify that external XDCR's are NOT used with these self-powered channels.

• Verify each AI (+,–) is not shorted to another input channel.

• Verify each AI (+) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each AI (–) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each AI shield wire is not shorted to PS (+), PS (–).
• Verify each AI shield wire is terminated at the node properly.
• Functionally verify the wiring for each AI channel using a simulator source.
AI (Loop power), Analog Input wiring checks

• Verify that external XDCR's are connected to these channels.
• Verify the LPWR voltage level (+24 V dc) is correct for the XDCR.
• Verify each LPWR (+) terminal is wired to the XDCR POWER (+).
• Verify each LPWR (+) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each AI (–) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each AI shield wire is not shorted to PS (+), PS (–).
• Verify each AI shield wire is terminated at the node properly.
• Verify that all XDCR's channels use less than 250 mA of LPWR.
• Functionally verify the wiring for each AI channel using a simulator source.
AO, Analog Output wiring checks

• Verify each AO (+,–) is not shorted to another output channel.
• Verify each AO (+,–) is not shorted to another Analog Input channel.
• Verify each AO (+) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each AO (–) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each AO shield wire is not shorted to PS (+), PS (–).
• Verify each AO shield wire is terminated at the node properly.
• Functionally verify the wiring for each AOUT by driving 4 mA and 20 mA to the load from the GAP
application. Verify correct output current with a meter. Verify the correct SRC_RDBK &
RET_RDBK values in GAP.
DI, Discrete Input wiring checks
• Verify each DI (+) is not shorted to another input.
• Verify each DI (+) is not shorted to CPWR (+), CPWR (–), PS (+), PS (–), EARTH.
• Verify each DI (+) wiring is functional by setting each input HIGH (>16 V DC) and then LOW (<8
V DC). Verify GAP software detects the state change.
• When possible, consider using a shielded DIN cable.
DI, Contact Power (CPWR) wiring checks

• CPWR (+) is an output voltage, it should never be connected to any other supply.
• To maintain node isolation, verify CPWR (–) is not shorted to PS (–).
• Using the internal isolated Contact Power output (CPWR,COM) is highly recommended to
maintain discrete input isolation for other plant devices / controls
• Verify CPWR (+) is not connected to CPWR (–), PS (–), EARTH.
• Verify CPWR (–) is not connected to CPWR (+), PS (+), EARTH.
• Verify CPWR voltage meets spec at the terminal block (18 to 32 V dc).
DO Relays, Relay wiring checks

• Verify each Relay output (NO, C, NC) contact is connected to the load properly
• Verify each Relay output (NO, C, NC) is not shorted to another output channel.
• Verify the function of each Relay output (NC, NO) wiring by driving each output ON then OFF.
Verify the GAP software detects the readback state change.

• When possible, consider using shielded wiring for relay cables.
Additional wiring checks when using RTCnet/LINKnet nodes
TC, Thermocouple Input wiring checks

• Verify each TC (+,–) is not shorted to another input channel.
• Verify each TC (+) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each TC (–) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each TC shield wire is not shorted to PS (+), PS (–).
• Verify no wires are landed accidently on the NC, no-connect terminals.
• Verify each TC shield wire is terminated at the node properly.
• Functionally verify the wiring for each TC channel using a simulator source.
• TC OPENS: A TC input will read MAX DegC if the (+) or (–) wire is broken / open.
• TC SHORTS: A TC input will read 0 DegC if the (+) and (–) wires are shorted.
GROUND FAULTS: Input channels accidently shorted to EARTH will be

more susceptible to spurious noise events related to the installation
and environment.
RTD, Input wiring checks

• Verify each RTD (+,–) is not shorted to another input channel.
• Verify each RTD (+) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each RTD (–) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each RTD (sense) terminal is not shorted to PS (+), PS (–), EARTH.
• Verify each RTD (sense) terminal is connected properly for 3-wire sensors.
• Verify each RTD (sense) terminal is jumpered to RTD (–) for 2-wire sensors.
• Verify each RTD shield wire is not shorted to PS (+), PS (–).
• Verify each RTD shield wire is terminated at the node properly.
• Functionally verify the wiring for each RTD channel using a simulator source.
• RTD OPENS: RTD channels will read MAX DegC if the (+) or (–) wire is broken.

Chapter 4 – Manual Network Setup
Factory Set IP Addresses for the Control
Table 20: Factory set IP addresses for the Flex500 CPU
Port name IP address Subnet Mask

Ethernet #1 172.16.100.15 255.255.0.0
Ethernet #2 192.168.128.20 255.255.255.0
Ethernet #3 192.168.129.20 255.255.255.0
Ethernet #4 192.168.130.20 255.255.255.0
Default Gateway <none>
Factory Set Network Passwords

Note: See AppManager Help for more information.
The control Operating System enforces security by requiring the user to login with valid permissions
before accessing privileged control services. A login is required in order to connect the AppManager tool
to the control.
The following logins are the default account settings for accessing the control. The Administrator login
is reserved for the system administrator and is only valid when Account Management is enabled.
The Administrator account may be used to create, modify, and delete other accounts.
Note: All account names and passwords are case sensitive!
Table 21: Factory set account names and passwords for newer controls
Account name Password Level Permissions

Administrator Admin@1 15 Read, Write, Execute
ServiceUser ServiceUser@1 11 Read, Write, Execute
Configure wg1113 3 Read
Service wg1112 2 Read
Operator wg1111 1 Read
Datalog Datalog@1 1 Read
Network setup instructions for the control

Here is a simple flowchart, which shows the steps for configuring the control’s network settings to work on
your network. The listing of factory set IP addresses are in Table 4-1 and detailed instructions for the
steps in the flowchart are below:

Step 1:
Determine control's IP address
Step 2:
Check if control's IP address is
compatible with your network
Step 3:
Use Ping to determine if the YES
control's IP address is unique
NO
Step 4:
Select an IP address for the
NO
control meeting the criteria of
Steps 2&3
Step 5:
Change PC's network settings to
create an isolated network
Step 6:
Use AppManager to set the
control's IP address
Step 7:
YES
Return PC's network configuration
to original settings
Step 8:
Put the control on your network
Figure 19: Network Setup Flowchart
Detailed network setup instructions for the control
Execute the following steps (up to 8) to configure your control to work with your network. The control’s
primary IP address must be compatible with your network, but cannot collide with an existing device’s
address.
1. Get control’s current IP address:
Determine the current IP address of your control. The current address listed under “Ethernet #1” in table
4-1, 4-2, or 4-3 at the beginning of this chapter.

2. Check control’s IP address for network compatibility:
Determine if the control’s primary IP address is compatible with your network. This compatibility can be
determined by looking at the IP address and subnet mask on your PC. These are viewed by running
“ipconfig” from a cmd window on your PC (to open a cmd window, click on “Run…” in the Start menu and
type in “cmd”). You are likely to be interested in the values for the Local Area Connection.
If you translate the Subnet Mask of your PC to binary, you can see which values of the control IP address
must match the PC’s IP address. For example, if the subnet address is “255.255.0.0”, then the first two
octets must match:
• 172.16.99.4 matches 172.16.100.1
• 172.18.100.1 does not match 172.16.100.2
For example, if the subnet address is “255.255.240.0”, then the first two octets must match and the first 4
bits of the third octet must match (240 is 11110000 in binary and “1”s indicate a required bit position
match):
• 172.16.107.4 matches 172.16.100.1 because 110 is “01100100” in binary and 107 is “01101011”
in binary
• 172.16.116.4 does not match 172.16.100.1 because 100 is “01100100” in binary and 116 is
“01110100” in binary
If you are not sure what the PC’s IP address or subnet mask are or if your network has some other
complexity, consult with your IT department for help in determining or establishing a compatible IP
address for the control.
Is the control’s primary IP address compatible with the PC’s network?
If NO, or if you need to change the network settings for another reason, go to Step 4 below.
If YES, continue to STEP 3 below.
3. Check control’s IP address for uniqueness:
Determine if the current IP address of your control (from Step 1) is in use in your network. To see if it is
already used, Ping the IP address from a PC on the network. The description of the Ping command is in
Chapter 8 Ethernet Networking. If it does not respond with “Destination host unreachable.”, the IP
address is already used and is not available for the new control. If this is the case, skip to Step 4 where
you will change the control’s primary IP address.
Is the control’s IP address already in use?
If YES, or if you need to change the network settings for another reason, go to Step 4 below.
If NO, jump to STEP 8.
4. Select a new IP address for the control’s Ethernet #1 port:
If your network contains many devices, you should consult with your network administrator to find an
available IP address for you to claim and use. If your network is simple or you do not have an
administrator, you could try guessing a suitable IP address by taking your PC’s IP address and changing
the final octet to a different number until you find an available IP address (see STEP 3). For example, if
your PC’s IP address is “10.14.129.37”, you could try “10.14.129.38”, “10.14.129.39”, etc. Keep trying
different values until you find one that works.

Note: Any IP address you choose must still match the subnet mask of the PC, as described in Step 2.
5. Create an isolated network between the PC and the control:
To avoid IP address conflicts on your network, isolate the control and the PC that you will be using for
setting up the control from the network. Two examples of recommended methods appear in Figure 20.
1. On your PC, shut down your network applications but do not log off.
2. Temporarily change your PC’s IP address to be compatible with the current IP address of the control
(from Step 1). A simple compatible IP address would be to take the control’s address and add 1 to the
final octet (e.g. use “172.16.100.2” to connect with a control at “172.16.100.1”. Keep a record of your
PC’s current IP address.
3. Connect as shown in Figure 2-2 and power up the Woodward control.
Figure 20: Network Cable Connections
When you have the proper connection between the Woodward control’s Ethernet Port #1 and your PC,
you will see the green “Link” LED remain on (solid) on your PC and on the control.
A Hub/Switch will cause your PC’s Link light to be on even

when a control is not connected. The Flex500 has two LEDs
for each connector.
If you cannot see the control in AppManager, open a DOS

Command Prompt window on your PC and try to “ping” the
control’s IP address of the port to which you are connected.
See the “Pinging the Network” section of the Ethernet
Networking chapter. If pinging is successful, your PC’s
networking settings may need to be changed. Contact your
Network Administrator.
6. Configure the Ethernet port:
The Woodward software tool “AppManager” is needed to change the Woodward control’s Ethernet IP
settings to make the control’s Ethernet port accessible to your local PC. Download AppManager from the
Woodward website. See “Obtaining Software Tools” section within this chapter for details on obtaining
AppManager. Install AppManager on your PC if it is not already there.

Using AppManager, change the control network settings as follows:
1. On your PC, open AppManager.exe.
2. You should see the Woodward control’s Computer Name in the AppManager window. Select the
control’s Computer Name. If necessary, Login by using the credentials from Table 4-4 or 4-5. If the
control name is not listed, check your connections and verify that the Link lights are on. If clicking on
the control produces an error, verify that you have chosen a compatible IP address for your PC in
Step 5.
3. Click “Control” in the top header of the AppManager window, use the pull down menu, and select
“Change Network Settings”.
Figure 21: AppManager Control Dropdown Menu
AppManager—Control Information screen
The AppManager Control Information screen shows information about the CPU board and its hard drive.
Use this screen to confirm the application of new network configurations above.
Select the control in the Control Window (login if required). Then select Control Information from the
Control menu or press the Control Information button in the toolbar:

Figure 22: AppManager Control Information Page
4. Select the desired Ethernet port (adapter) and the desired IP Address settings to affect the desired
change. Port 1 is the only port that supports a Default Gateway, and Port 1 is the only port that
supports DHCP.


Figure 23: Control Network Configuration Page
5. Select “Yes” to change the settings
Figure 24: AppManager Yes/No Window
6. AppManager will report that the control settings changes and prompt to reboot the control. The
changes are invoked when the control reboots.
Figure 25: AppManager Reboot Prompt Window

7. Configure the PC’s network configuration to its original settings:
When the control has rebooted, the IP address changes that you specified are viewable. The control
may no longer be compatible with your current PC settings. If you had changed your PC network
settings, you should now revert to the previous settings. If everything worked correctly, the control will
now be compatible with your PC’s network.
8. Connect the PC and the control to the network:
Physically reconnect the PC and control to your network. Confirm that the control has the correct
network settings using the Control Information feature of AppManager:
AppManager—Control Information Screen
The AppManager Control Information screen shows information about the CPU board and its hard drive.
This page confirms the network configurations that you entered above are or are not applied.
Select the control in the Control Window (login if required). Then select Control Information from the
Control menu or press the Control Information button in the toolbar:

Software Tools
Overview
Programming Tools build a control application. GAP (Graphical Application Programmer) and Ladder
Logic creates the application. The output feeds into the Coder, which assembles, compiles, and links the
code with the resulting executable file is loaded into the target control. Use the Woodward NetSim
simulation tool to test the application on a PC.
Service Tools are the interface programs that allow an operator to move files, start and stop the
application, configure settings, troubleshoot hardware and software, view status, and ultimately operate
the controlled machinery.
An unsafe condition could occur with improper use of these

software tools. Only trained personnel should have access to
these tools.
Programming Tools
These tools are useful for creating new applications or for modifying existing ones.
All of the following programming tools will only function in a

Windows Operating System such as Windows XP, Vista, 7, 8,
or 10. The Windows .NET library version 4.0, which is usually
included on such PCs, is required for most of these tools to
run.
Woodward GAP
GAP (Graphical Application Programmer) allows users to design their control system logic with an
integrated drawing package that runs on a PC in the Windows environment. Once you graphically enter
the control logic, GAP checks the application for correctness and generates a meta-data (.cdr) file for use
with Woodward Coder.
Monitor GAP
Monitor GAP is a mode in GAP that allows the engineer to view and tune GAP values in context
while the application is running. It interfaces with the Ethernet or serial ports via the Woodward SOS
Servlink OPC Server tool.


Woodward Coder
Coder is the program that converts the GAP application into code. If there are no problems, it
calls the assembler, compiler, and linker to create the file that can be loaded onto the hardware using
AppManager. Error files help in debugging if the Coder finds problems.
Secured Application Tool
SAT is a program used to manage Authorization Encryption Files (AEF) and to create Secured
Applications from GAP output (.out) files. Secured Applications run only on Secured Application controls
for which they have been programmed.
NetSim
NetSim is Woodward’s Windows PC based simulator software used for testing control software. It
provides a closed loop simulation environment when connected to a modeling package or open loop
testing when run in stand-alone mode. NetSim supports connections to ACSL based and
MATLAB/Simulink modeling packages. The NetSim Control Executive (“NetSim CE”) communicates with
the Woodward SOS Servlink OPC Server to provide OPC data to presentation tools like Monitor GAP and
Control Assistant.
Ladder Logic
Woodward Ladder Logic extends a GAP application and permits customer programming and
monitoring of a Woodward control. It is easy for anyone familiar with the basic structure of ladder logic to
write and use Woodward Ladder Logic. Activate commands using a simple point and click Windows
interface.
The Woodward Ladder Logic program runs on a Windows PC connected to a serial or Ethernet port of a
Woodward digital control system. The Ladder Logic program can be written and changed using the PC
while the hardware is controlling the running prime mover—changes do not take effect until the Ladder
Logic program is loaded into the hardware.
Qt Creator
Qt Creator is a design environment used to develop the Graphical User Interface (GUI) screens for
the Flex500. This package includes Woodward component libraries (gauges, adjust buttons, analog
adjust components, display components etc.) which can be placed on screens and tied directly to GAP
parameters. Once the GUI screens are developed, Qt Creator compiles the screens into a *.WGUI file
that can be loaded and run on the control (Flex500 Panel Mount) or loaded on to the control and
launched from a remote PC.

The Flex500 control supports only Ladder Logic versions 2.10

or higher.
Service Tools
These tools are useful for system debugging, variable monitoring, tunable maintenance, real time data
collection, data analysis, and remote control. See your Woodward sales engineer for additional
information.
All of the following service tools will only function in a

Windows Operating System such as Windows XP, Vista, 7, 8,
or 10. The Windows .NET library version 4.0, which is usually
included on such PCs, is required for these tools to run.
Application Manager
AppManager is a Windows based remote access tool for Woodward CPUs. AppManager allows local
and remote access to control applications for transferring files, retrieving files, starting, stopping, and
restarting. The MicroNet Plus, 505, Flex500 and Atlas-II are loaded with a service that allows them to
interface with AppManager. AppManager can change Ethernet Network addresses, Administer Accounts,
load service packs, and continuously retrieve Datalog files.
AppManager will only function in a Windows Operating

System such as Windows XP, Vista, 7, 8, or 10.
Control Assistant
Control Assistant is a Windows program designed to support the following control features via OPC
Ethernet communications:
• Tunable Maintenance. This feature supports tunable capture, sorting, comparing vs.
baseline/GAP, saving, and uploading of new tunable values into the control.
• Variable Trending. Using a strip chart displays live variable information. It requires a software
license to run.
• Datalog Plotting. This feature supports the capture and plotting of high-speed Datalog
information. It requires a software license to run.
• WinPanel is an OPC client designed for communication with the Woodward Servlink OPC Server
to display and control all control system data. Variables can be selected from this interface for
both control and monitoring purposes.
• Variable access through the Servlink OPC Server.
• Loading and saving of different configurations.
• Hierarchical Tree View of available data.

• The WinPanel views support multiple data sheets.

• Tunable modifications.
• Updating of EEPROMs.
Servlink OPC Server (SOS)
The SOS Servlink OPC Server is an OPC server designed to communicate with a control using the
Woodward Servlink Protocol over an Ethernet or Serial connection. This protocol allows OPC clients like
Control Assistant, Monitor GAP and off-the-shelf HMI programs to access and modify internal control
parameters.
ToolKit
Use ToolKit to create and run custom administration tools for many Woodward electronic products.
Use the resulting tools to configure, calibrate, monitor, and troubleshoot your device over a serial, CAN,
or TCP/IP connection.
Obtaining Software Tools

The following software tools are available on the Woodward web site (www.woodward.com/software)
• AppManager
o No license required unless using enterprise version of automatic file retrieval (4+ controls
at once)
• Control Assistant
o License required for graphing/trending features only
• GAP Editor and Monitor
o Separate licenses required for Editing and Monitoring
• GAP Programmer (Woodward Coder)
o No license required (license required for GAP Editor)
• Ladder Logic
o No license required
• NetSim
o License required
• Secured Application Tool
• SOS Servlink OPC Server
• ToolKit
o The Basic version requires no license. It may be used to open and work with pre-built
tools
o A Developer license is required for designing custom tools
• Woodward Control Service Packs
• Qt Creator
o License required for screen development


Chapter 5 – Distributed I/O Expansion
Additional I/O has been pre-programmed using Woodward’s LinkNet 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
on chapter 8.
These nodes are:
Table 22: Available (programmed) distributed I/O Nodes
Node Device Part Number Description I/O type/quantity

1 8200-1203 Analog 4-20 mA I/O 8 AI and 2 AO
2 8200-1203 Analog 4-20 mA I/O 8 AI and 2 AO
3 8200-1200 RTD Temperature Inputs 8 RTD
4 8200-1204 Discrete Input 16 DI
5 8200-1205 Discrete Output 16 DO
Figure 26: LinkNet Distributed I/O Node
Adding Vibration Sensing
By adding one AI/AO LinkNet Node the 5001 can support up to 8 Vibration monitoring input signals (4-20
mA inputs).
• There is a ‘Configuration Wizard’ to help program these into the LinkNet AI channels – from 1-8
channels
• Signals can be radial or axial – user can enter description in TAG field (see channel info below)
• Each channel has range fault detection and Alarm and Trip (or Second ALM) Level Settings

• There is a setting to Trip if too many Vibration sensors are failed (in the screen shot below – 4
sensors are brought into the 5001 and 2 sensors minimum are required to run turbine)
• There will be a monitor page (as shown below) available from the Startup Curve page
Figure 27: Vibration Wizard for LinkNet Node 1

Figure 28: LinkNet Node 1 with 4 Vibration Signals
Figure 29: Vibration Monitoring Page

Using External Trips on LinkNet Discrete Input Module
When External Trip signals are used on the LinkNet modules, the signal is automatically inverted. When
the signal goes FALSE, the contact is open, and then the Trip signal will be sent to the control. Unlike
External Trips wired into the CORE DI channels on the 5001 unit, 1ms time stamping resolution is not
available on the LinkNet External Trip signals.

Chapter 6 – Control Overview
The 5001 controller is designed for Francis or Kaplan hydraulic turbines. Its unique PID structure makes it
ideal for applications where is required to control hydro plant parameters such as turbine speed, head/tail
level, gate position, blade position, or tie-line power.
The controller special PID-to-PID logic allows stable control during normal turbine operation and
bumpless control mode transfers during plant upsets, minimizing process over or undershoot conditions.
The 5001 controller senses turbine speed via passive or active speed probes and controls the hydro
turbine through one or two actuators
The 5001 controller also include the following turbine protection functions to ensure that the turbine is not
operated outside of its designed limits:
• Overspeed and shutdown protection
• Minimum and maximum speed, gate and load settings
• Creep detection
Ethernet and serial communications allow users to easily connect the 5001 into the plant or process
control system. All controller inputs, outputs, and statuses can be monitored and all start/stop or
enable/disable commands can be given through industry standard Modbus® * TCP or OPC protocols.
The 5001 uses SNTP (synchronized network time protocol) over Ethernet to allow users to synchronize
the 5001’s real-time clock to the plant distributed control system.
The 5001 has six independent Governor References which are divided into two different sets of Controls.
The Droop, Isochronous, and Loadsharing References are all associated with the Speed Control, while
the Gate, Level, and Power References are associated with the Position Control. The outputs of these
two Controls are limited at the PID by the gate limit. The selected output sets the actuator output current.
Many of the Governor References have the option of an External Signal to determine the position
setpoint. An integrated manual control is also provided to allow manual setting of the gate servomotor
(and blade servomotor, if it exists). The manual control signal overrides the signals from either of the
controllers. Additional features of the 5001 include frequency control, isochronous loadsharing, brake
circuit, creep detection, and small system detection.
Speed Control
Speed control is the normal “small system”, or isolated operating condition for the 5001. The unit speed
compared to the speed setpoint through a speed PID (proportional plus integral plus derivative) to
generate a setpoint signal to the actuator(s). The primary governor references in speed control are droop,
isochronous, and loadsharing.
Position Control
Position control is quite similar to speed control, except that primary setting device is a position setpoint,
as opposed to a speed setpoint. In this case, the speed error signal is generated by the difference
between the gate position setpoint and the gate position. Position control would typically be used in “large
system”, or interconnected applications, as any deviation from normal speed will cause a position error.
This position error may be the source of confusion under normal operating circumstances. The primary
governor reference in position control is the gate position.

Power Control
Power control is similar to position control, except that primary setting device is a power setpoint, as
opposed to a position setpoint. In this case, the speed error signal is generated by the difference between
the power setpoint and the power signal feedback. Power control would typically be used in “large
system”, or interconnected applications, as any deviation from normal speed will cause a position error.
This position error may be the source of confusion under normal operating circumstances. The primary
governor reference in power control is the generator power.
Level Control
In this control mode, the speed error signal is generated by the difference between the calculated level
gate reference and the gate position. The level gate reference is determined by the Gate Null Position
and the water level error. This is applicable (configurable) to both forebay and tailbay water level control.
The primary governor reference in level control is the gate position.
Gate Limiter
The gate limiter limits the gate setpoint signal to aid in starting or stopping the turbine. In addition, it can
be used to determine a maximum gate opening during normal operation. The gate limiter can be adjusted
either up or down via the keypad, programmable contact inputs, or the Modbus interface.
The output of the gate limit is low-signal selected with the output of the speed or position control. The
control or limit asking for the lowest gate position will control the gate position. Thus, the gate limiter limits
the maximum gate position.
Manual Control
Integrated Manual Control is available to manually position the gate servomotor. This operates
equivalently to an external manual controlling device, in that the setpoint signal provided by either the
speed control or position control is ignored, and only the Manual Control signal is used to determine the
gate position.
Keypad and Display

Graphical Display Key Inputs
The front panel display is designed to provide the user with multiple levels of access for configuring,
calibrating, tuning, operating, and monitoring the turbine operation. No additional control panels are
required to operate the turbine, every turbine control function can be performed from the 5001’s front
panel

Figure 30: 5001 Keypad and Display
A description of each key’s function follows.
Hard Key Commands
Numeric Keypad
These are available for entering numeric values or text strings directly into the control when a
configurable or programmable edit field has been selected. The bottom row of keys have some special
features.
This is a backspace and delete (used when entering text)
In text mode this functions as a Shift key. When making analog adjustments with the ADJUST
key – pressing this key at the same time as the ADJUST will invoke a ‘Fast’ rate of adjustment
Brightness key – hold this down and then use the ADJUST key to increase/decrease the screen
brightness
Emergency Trip Key
This will Trip the Turbine and remove all current from the Actuator outputs (zero current).
LED

Four LED’s are on the left side – a Summary Trip, Summary Alarm, IO Lock, and CPU Health. The first
two are controlled solely by the GAP program and relate to the status of the control. The IOLOCK and
CPU LED’s relate to the H/W status and are identical to these same indications on the back of the 5001
VIEW buttons will jump to the Trip or Alarm Summary screen to show these events in sequence with time
stamp.
MODE button will jump to a Login screen that allows the user to view current permissions and allow
access to changing the user login level
ESC Key – this will always step the user ‘back’ one page from the current page displayed
Home Key
Brings the user to the Home menu for Run, Service, or Configure. Pressing it a second time will return to
the Run (Operate) Menu Home Screen
Navigation Cross Keys
These are the primary keys for navigating from page to page, or for navigation of the FOCUS on any
page.
Soft Key Commands – Dependent on the screen currently in view – the user must use the navigation
cross keys to move the “Focus” to the desired component
Green Keys
Generally perform Operational Actions – such as Enabling, Disabling, Starting, Stopping, Tuning or
Adjusting values
Maroon Keys
Generally perform Navigational actions that escort the user through the screen menus
Black Keys
Are soft-key functions that relate to the display indication above them. They can be navigational or
operational. These items do not require “Focus”, they are always available on that particular screen.
The 5001 has a detailed Tutorial that is always accessible through the
Service Menu. It provides ‘On-Screen’ help on topics such as
Navigation, User Levels, Operating Modes, how to adjust
parameters,and more. The User should familiarize themselves with
these screens
Watchdog Timer/CPU Fault Control

The IO Lock and CPU Health LED’s on the front left side of the display – are always in an identical state
as the LED’s on the back side of the control. They are completely controlled by the 5001 control hardware
and are not controlled by the GAP application.
A watchdog timer and CPU fault circuit monitors the operation of the microprocessor and microprocessor

memory. If the microprocessor fails to reset the timer within 15 milliseconds of the last reset, the CPU
fault-control will activate the reset output. This resets the CPU, de-energizes all relay outputs and turns
off all milliamp outputs.

Chapter 7 – Control Description
The functions of the 5001 Digital Speed Control are described in detail in this section. The values that are
in “quotes” can be configured for the specific application. Configuration of these values is discussed in
greater detail in this manual.
Start, Stop, and Gate Limit
When the Control is given a start command, the control resets itself, and pauses for 4 to 5 seconds. This
allows some time for the alarms and shutdown conditions to clear. Once all shutdowns have cleared and
the optional input “Start Permissive” is true, if used, the Gate Limit steps to the “Breakaway Limit”, and
stays there for the “Hold at Breakaway Time” (see Figure 29). Since the control does not have any speed
signal yet, the gates will follow the Gate Limit. After the “Hold at Breakaway Time” expires, the Gate Limit
ramps to the “Speed-No-Load Limit” at the “Start Gate Rate”. It will remain there while the control is
synchronizing. At some point during this sequence, the turbine should reach its rated speed and the
Control will start controlling speed. If the control does not sense at least the “Start Speed” by the time the
“Time to Start Speed” timer has expired, then the control issues an emergency shutdown due to an
Incomplete start.
When the breaker closes, the gate limit steps to the “Maximum Gate Limit”.
If the unit experiences a load rejection, the gate limit will automatically step to the “Speed-No-Load Limit”.
If the load rejection algorithm is used the gate limit will step to the load rejection gate limit and while the
algorithm is running and then step back to the “Speed-No-Load Limit”.
Figure 31: Gate Limit
When a stop command is issued, there are some actions that can be taken.

1. If the Breaker is opened the gate limit will instantly decrease to zero.
2. If the breaker is closed and the control mode is baseload the setpoint will decrease until the
configured minimum baseload value at the programmed rate and will wait until the breaker is
opened. After this opening the gate limit will instantly decrease to zero.
3. If the breaker is closed and the control mode is not baseload the gate limit will decrease until zero
at the programmed rate. In sometime the breaker will be opened and the gate limit will instantly
decrease to zero.
If a stop command is issued and the speed delays more than a programmed time, an Incomplete Stop trip
command will be issued.
The start and stop sequences discussed above occur automatically. The Gate Limit can be controlled
manually at any time if necessary. Two discrete inputs can be configured as Gate Limit Raise and Gate
Limit Lower, or the parameter can be accessed via the keypad. The rate at which the Gate Limit will
change is dictated by the “Manual Raise/Lower Rate”.
When the control is in Manual, Maintenance, or Follow Mode, the Gate Limit is raised to 100%.
External Start Permissive

An external start permissive is available when one of the configurable inputs is configured to do it. When
the unit is started up and the control resets, the start permissive contact must be closed before the unit
issue a governor run command.
Open Wire Detection on MPU Speed Signals

The 5001 automatically verifies continuity of the speed MPU circuits each time it prepares to issue a
“Ready to Start” status message. If an open wire is detected it will issue an alarm for this input, if all
MPU’s appear to have open wires a Trip is initiated. This open wire test can be done manually any time
the turbine is stopped and the speed is zero. It is also possible to disable the automatic test at start the
Speed Sensor screen.
The screen is located under Analog Inputs/Speed Signal X/Open Wire Test.

Figure 32: Open Wire Detection Test
Speed Signal Processing

The 5001 has two speed signal inputs, but only one speed signal is required. Using the second speed
signal provides redundancy. If one speed signal fails, the control sends out an alarm, but does not shut
the unit down, providing the other speed signal has not failed. When both speed signals are used, the
speed signals are passed through a high signal select bus.
The Control accepts any sine wave or square wave provided by a speed sensor that is proportional to the
speed of the turbine. This can come from magnetic pickups, active pickups or directly from generator
voltage (in this case a PT should be used to decrease the voltage and a transducer should be used to
convert voltage to frequency).
The Control must be configured according to the type of speed signal being provided, the rated speed
(rpm) of the turbine, the number of gear teeth (if applicable), and the system frequency (60 Hz or 50 Hz).
The Control then converts the speed signal frequency into percent of rated speed. All speed values
during the configuration and operation of the control are in terms of percent of rated speed unless stated
otherwise.
The Control monitors speed signal failures and overspeeds. When the turbine is stopped or moving very
slowly, the control will not have a valid speed signal, but the control should not see this as a speed signal
failure. When the turbine is started, the speed signal is ignored by the control until the “Time to Start
Speed” expires. When the turbine is stopped, the speed signal is ignored once the speed drops below
50% and the gates are closed. If more than one speed inputs are used, both would have to fail to cause a
shutdown.
The Control has an electronic overspeed detection, which issues a shutdown to the control. The
“Overspeed” value configured in the control is in percent of rated speed. The overspeed detection is also
ignored at the same time the speed signal failure is ignored, as mentioned above. When the control is in
Maintenance Mode, all speed signals, speed signal failures, and overspeeds are ignored.
An overspeed test feature is available so that the mechanical overspeed (or independent secondary
overspeed) trip can be easily tested. To enable the overspeed test, the turbine should be at the rated
speed and the breaker should be opened. The test enable switch is hooked up to a configurable timer so

that the test is not accidentally left enabled. When the overspeed test is enabled, the electronic
overspeed trip is disabled, the isochronous speed reference ceiling is raised to the overspeed test limit,
and the raise/lower rate on the isochronous speed reference is increased to the overspeed test rate. The
speed reference must be raised until the turbine trips from the mechanical overspeed.
The Control has a speed deadband function that can be enabled. The speed deadband function is a
configurable window around rated speed within which the Control will not respond to speed changes. The
deadband window has configurable setpoints above and below rated speed. In the example below, the
high setpoint is 100.05% rated speed (60.03 Hz on a 60 Hz system), and the low setpoint is 99.97% rated
speed (59.98 Hz on a 60 Hz system). When the unit’s speed fluctuates around rated speed the control
will not respond unless the speed gets outside the configurable window
Figure 33: Speed Deadband Function
Sometimes it is not desirable to have the unit responding to these slight frequency fluctuations. The
speed deadband can be enabled and the deadband window adjusted accordingly. When the speed
deadband function is set up, there are three options. The speed deadband function can be enabled at all
times, disabled at all times, or only when the unit is online. This function is independently available for
both speed signals.
Offline/Isochronous Speed Control

The Control has two PID control algorithms, an online/droop algorithm and an offline/isochronous
algorithm. When the unit is offline or in isochronous online control, the Offline/Isochronous algorithm is
used. The Offline/Isochronous algorithm controls the turbine speed to a setpoint determined by the
operator. The droop setting does not affect offline or isochronous control.
For example, if the unit is offline and the operator adjusts the setpoint to 95% rated speed, the Control will
position the gates appropriately to control the turbine speed at 95% rated speed. If the operator raises the
setpoint to 100% rated speed, the control reacts by opening the gates and raising the turbine speed to
100%. The operator can synchronize the turbine to the system and close the generator breaker. The
control functions exactly the same way when the turbine is online and in isochronous control (isochronous
controls means that the unit is acting as a slave of a load controller)
When the control is given a Start command, the control pre-positions the speed setpoint to the “Speed-
No-Load Reference”. The speed setpoint can be adjusted from the Raise and Lower discrete inputs,
Modbus or via keypad. The high and low limits for the speed setpoint are set up as “Minimum Speed
Reference” and “Maximum Speed Reference”.

The speed setpoint follows actual speed when the turbine is online and not in Isochronous control, or
when the turbine is offline and in Manual or Auto-Follow control. This provides a bumpless transfer into
Offline or Isochronous control.
The Control has two sets of PID gains, offline and online. The only difference between offline control and
isochronous control is that the offline gains are used during offline control and the online gains are used
during isochronous control.
When the offline/isochronous PID algorithm is in control, a temporary compensation function is available
to help dampen any control instability. The PID gains should be tuned properly for optimum control
response before the “Temporary Compensation” is adjusted. The temporary compensation acts much like
a mechanical dashpot. As the gates open or close, the speed setpoint is temporarily lowered or raised
depending on the speed of the gates to slightly dampen the controls response.
When a Synchronizer/Load Control unit is used with the Control, the speed reference in the internal ramp
of the control is fixed to 100%, so the final speed reference becomes 100% ± Speed Bias, and the
offline/isochronous PID algorithm is used to control the unit. The Synchronizer/Load Control unit controls
the turbine by biasing the fixed speed setpoint through the Synchronizer/Load Control signal input. The
Synchronizer/Load Control speed setpoint biasing is ignored by the Control if it isn’t being used with a
Synchronizer/Load Control unit, if the speed is not stable, or if the unit is online but not in
Synchronizer/Load Control.
Online/Droop Speed Control

The Online/Droop PID algorithm is used when the unit is online and in Level Control, Remote Reference
Control or Droop Speed Control. The Online/Droop PID algorithm allow the unit to be paralleled with other
units and remain stable. The droop value, the droop speed setpoint, and the turbine speed, together
determine how far the gates move, or how much load the turbine picks up.
There are two possible droop modes: kW droop or actuator droop. When the controller is in kW droop
mode the controller will use the generator active power as a droop feedback. So, the controller will keep
the active power in the desired value, given by the curve droop. If actuator droop is selected the controller
will keep the gate position at the desired value, given by the droop curve. For the kW droop the controller
actually picks the active power value (from a 4–20 mA analog input). In case there is a failure on the
active power signal the control until can stay on kW droop, but it uses a 2D-curve for the relationship
between the gate position and the generator active power. There is no tracking between kW and actuator
position droop. So, if the controller is in kW droop mode with 50% load and, for example, the gate position
in order to maintain this load is 60% and we revert the droop feedback to actuator position droop then the
gate demand will become 50%, and therefore the generator load will get lower.
For the example below let’s assume that the controller is configured for actuator position droop.
For example, if the speed is fixed at 100% rated speed and the droop is set to 5%, a 1% droop speed
setpoint change will move the gates 20%. If the droop is set to 3%, the gates will move 33.3% for a 1%
change in the droop speed setpoint. The speed is always being monitored and reacted by the control, but
the control will only respond by an amount determined by the droop setting. For example, at 5% droop a
+0.1% speed change (60.00 Hz to 60.06 Hz) will result in a gate position change of 2.0%. At 3% droop,
the same speed fluctuation would result in a gate position change of 3.3%.

Figure 34: Gate Position
The Level Control and Remote Reference Control algorithms calculate a droop speed setpoint to position
the gates in a desired position.
When the generator breaker closes, the default control mode is given by a configurable parameter, which
can be Droop Speed Control, Level Control or Baseload Control. The droop speed setpoint can be raised
and lowered using the Raise/Lower discrete inputs, Modbus, or via keypad. The Low Limit is 85%, and
the High Limit is 100% plus the Droop percentage. For example, at 5% Droop, the High Limit would be
105%.
When the online/Droop PID algorithm is not in control (Manual, Maintenance, Auto-Follow, Isochronous,
Baseload control modes), it calculates a droop speed setpoint based on the current speed and gate
position. This provides a bumpless transfer into Online/Droop speed control.
The online/Droop PID algorithm has a Feed Forward function that manipulates the PID feedback to
accelerate the control’s response to setpoint changes. Feed Forward is only enabled when the control is
using the Online/Droop PID algorithm.
The output of the Online/Droop PID is also clamped by a “PID Clamp Window” value to eliminate setpoint
wind up in the control.
Remote Reference Control Mode

The Remote Reference control mode provides a way of directly controlling the Control setpoint remotely.
The Remote Reference can be the 4 to 20 mA from one of the analog inputs , or it can be a value from
Modbus. The Remote Reference Control Mode can be enabled by closing BOTH the Raise and Lower
discrete inputs at the same time. It can also be enabled through Modbus or via keypad. If the analog input
signal is selected for control and it fails, Remote Reference Control Mode is disabled and an alarm will

indicate the signal failure. If the Modbus value is selected and found to be out of range, Remote
Reference Control Mode is disabled.
The 4 to 20 mA signal (if used) is scaled to 0 to 100%. The Modbus Remote Reference Setpoint is the
first analog write value in the Modbus block and is divided by 100 at the control. This provides two
decimals of precision to the setpoint. The Modbus device must send 0 to 10000 for 0 to 100%.
When the Remote Reference is enabled, the Remote Reference (0 to 100%) is converted to a Droop
Speed setpoint. For example, if the droop is set to 5% and the unit is at rated speed, a Remote Reference
of 20.00% would result in a Droop Speed Set Point of 101.0%. This will result in a gate position of 20%
(for actuator droop feedback) or 20% load (for kW droop feedback). If the Remote Reference is raised to
55%, the Droop Speed Setpoint will increase to 102.75%. This will result in a gate position of 55% (for
actuator droop feedback) or 55% load (for kW droop feedback). The Remote Reference is essentially the
gate or load position setpoint, but remember that the control is always monitoring the unit speed. Any
speed error will result in a slightly different gate position, depending on the droop setpoint.
When the control is in Head/Tail Level Control and Remote Reference is enabled, the Remote Reference
(0 to 100%) is converted to a Head/Tail Level Setpoint. The Head/Tail Level Setpoint is based on the
Head/Tail Level transducer limits. The Level Setpoint is calculated as a percentage of the full transducer
range plus the low limit. The Head/Tail Level Setpoint is calculated using the following equation:
(𝑅𝑒𝑚 𝑅𝑒𝑓) 𝑥 (𝑀𝑎𝑥 𝑉𝑎𝑙 – 𝑀𝑖𝑛 𝑉𝑎𝑙)

𝐿𝑒𝑣𝑒𝑙 𝑆𝑒𝑡𝑝𝑜𝑖𝑛𝑡 = + (𝑀𝑖𝑛 𝑉𝑎𝑙)
100
For example, if the transducer is calibrated for 4 to 20 mA for 500 ft. to 540 ft. respectively, a Remote
Reference of 35% would result in a Head/Tail Level setpoint of 514 ft.
Manual/Maintenance Modes
The Control has two “manual” modes of operation, Manual and Maintenance, that allow the operator to
manually position the gates. The biggest difference between Manual and Maintenance is that the control
still monitors speed failures and overspeeds in Manual control. Manual control can be enabled using the
discrete inputs, Modbus or via keypad, but Maintenance control can only be enabled using the keypad or
Modbus.
Maintenance mode should only be enabled when the unit is dewatered.

No speed monitoring functions are active when the control is in
Maintenance mode.
Manual control mode can be enabled when the unit is running or when the unit is stopped. Maintenance
mode can only be enabled with the manual mode already enabled (maintenance mode is like a sub mode
of the manual mode). Both Manual and Maintenance modes follow the actual setpoint when they are not
enabled. This provides a bumpless transfer into Manual and Maintenance control modes.
The gate position in both modes can be controlled by the Raise and Lower gate position discrete inputs,
Modbus or via keypad. The rate at which the manual position moves is configurable.

Auto-Follow Control Mode

The Control has an Auto-Follow control mode which is used when the control is used as a backup
governor. When this mode has been configured and the discrete input is closed, the Control tracks
current gate position and forces all control modes to follow. When the discrete input opens up, the Control
will assume control in the control mode that is selected at the time the “Auto-Follow” discrete input
opened up. The same contact that controls the “Auto-Follow” discrete input must control the transfer relay
which switches the actuator control current from the primary control to the Control Actuator Output.
When the Control is used as a backup governor, independent speed signals and gate position
transducers should always be used. This will provide true governor redundancy, and eliminate the
possibility of single point failure. If the speed signal(s) or the gate position signal to the primary control
fail, it would be less likely to shut down the Control.
When the actuator control current is switched from the primary control to the Control, the actuator current
will be zero for an instant, and the gates will “bump” slightly. The amplitude of the “bump” on the actuator
will vary depending on the relay used to transfer the actuator control current. When the Control is tracking
the gate position, the actuator output is forced to 0 mA. This keeps the control from saturating the output
voltage trying to drive the current through an open circuit. Without this, the actuator would bump open
during the actuator control transfer. By forcing the actuator output to 0 mA when the Control is not in
control, it forces the gates to bump closed during the transfer from the Primary Controller to the Control.
For the Control to function as a backup governor, it must be used with a customizable Woodward digital
control as the primary control. This primary control will support the software algorithms to allow the
Control to be used as a backup governor.
Head/Tail Level Control

The Head/Tail Level Control mode can control the forebay level (head level) or the tailbay level to a
setpoint by opening and closing the gates. Level Control can be enabled using the “Head/Tail Level
Control Enable” discrete input, Modbus or via keypad. The head/tail level input signal must be valid for
Level Control mode to be enabled. If the level signal is lost, an alarm will indicate the failure, and the
control will disable Level Control.
The only difference between Head and Tail Level control is that the gates will move in opposite directions
as a result of the Level Error. If the control is configured for Tail Level Control and the level is greater than
the setpoint, the gates must close to reduce the error. However, if the control is configured for Head Level
Control and the level is greater than the set point, the gates must open to reduce the error.
If you are controlling the Head Level (forebay level), be aware that
increasing your Head Level setpoint results in decreasing the gate
position, and vice-versa. Thus, the Raise input will result in moving the
gates in the closing direction.
When Level Control is enabled, the Raise and Lower contact inputs control the Level Setpoint. The Level
Setpoint “Raise/Lower Rate” controls how fast the setpoint ramps up and down. The level setpoint can
also be adjusted using Modbus.
When Level Control is enabled, there are two options. The control can be configured to maintain a preset
level setpoint, or it can be configured to “follow” actual level and gate position. If the application always
requires the same level setpoint when in Level Control, the control should be set up to maintain the preset
level setpoint. Each time the Level Control mode is enabled, the control will use the preset level setpoint.

The setpoint can still be adjusted using the Raise and Lower commands. If a bumpless transfer is needed
or desired when Level Control is enabled, the control should be set to “follow” actual level and gate
position. When Level Control is enabled, the gates will stay where they are at that time.
The level transducer range must also be entered into the Control during the initial configuration. The
“Elevation at 4 mA” and the “Elevation at 20 mA” refer to the elevation of the water level when the level
transducer is generating 4 and 20 mA. These high and low limits become the limits of the Level setpoint,
and they are also used to calculate the Remote Reference for Level Control (if used). The elevations can
be in any unit of measurement, but the units must stay consistent for all other values relating to Head/Tail
Level control (level feedback signal, level setpoint, and desired accuracy). The “Maximum Gate Position”
and “Minimum Gate Position” in Level Control mode must also be configured. This can prevent the unit
from motoring or from overloading in Level Control.
The Level Control algorithm is designed so that several units can be controlling head/tail level together
without any communication between controls and without fighting each other. However, the consequence
of being able to do this is that the control does not integrate out all error between actual level and the
level reference. By design, the only gate position where there will not be any level error is the midpoint
between “Maximum Gate Position” and “Minimum Gate Position”. Therefore, the “Level Control Window”
must be configured. This window has the same units as the elevation levels discussed above. If the level
control window is 1 foot, the Control will control the level, but there may be some error (less than 1 foot)
remaining during steady state.
Figure 35: Head Level Control Accuracy
The smaller the “Level Control Window” value is, the steeper the slope will be on the above graph. This
will result in a very high “gain” on the gate position, and small error fluctuations in the Head/Tail Level,
and will move the gates very quickly. The “Level Control Window” value should be made as large as
possible for each given application.
Valve Driver
The Control's valve driver can be configured for many different applications. The valve driver (actuator
output) can be configured as a proportional signal or as an integrating signal.
For explaining purposes let’s suppose that the actuator output has been configured for 4–20 mA.

A proportional signal is a 4 to 20 mA signal that is proportional to the actuator setpoint, 0 to 100%. The
proportional signal is 4 mA for 0% gate position, 12 mA for 50% gate position, and 20 mA for 100% gate
position. No gain or offset adjustments are available in the Control when a proportional signal is supplied
due to the nature of the signal.
An integrating signal is a 4 to 20 mA signal that positions a proportional valve, or pilot stage valve. The
integrating signal is about 12 mA to center the proportional, or pilot stage, valve. When the current is less
than 12 mA the valve moves one way, and when the current is greater than 12 mA the valve moves the
other way. The further the signal is from the null current, the further the proportional valve plunger moves
from its center position. Typically, the proportional valve ports oil to another valve, or hydraulic amplifier,
which then positions the servomotor.
The integrating signal has three adjustments that must be made. The first adjustment is to configure the
control for a reverse acting valve or a forward acting valve. Most valves will be forward acting, meaning
that an increase in the actuator control current (greater than the null current, 12 mA) results in the gates
opening. If the system is reverse acting, meaning that a decrease in the control current results in the
gates opening, then “Reverse Actuator” must be tuned TRUE. The second adjustment is the “Valve
Offset”. The null current will probably never be equal to exactly 12.00 mA, so the valve offset makes up
for this difference. If this is not adjusted properly, the gate position will not match the gate position
demand. The third adjustment that needs to be made to the integrating signal is the “Valve Gain”. This
controls how much the current deviates from the null current for a given gate position error. If the gates
are sluggish to step changes, the gain can be adjusted to increase the gate response, or if the gates
overshoot during a step change, the gain can be adjusted to decrease the response.
The Control has a dither function designed into its valve driver output. The valve dither function induces
an AC current on the actuator output. Valve dither accomplishes two things. First, it keeps the valve
plunger(s) constantly moving which reduces “stiction”, or static friction. “Stiction” can cause gate hunting if
the valve does not respond correctly to the electronic signal. Second, dither makes a positive lap valve
respond as though it were a zero lap valve.
The Control continuously compares the actual gate position to the gate position demand in the control. If
they do not match within the “Minor Mismatch Window” for more than the “Minor Mismatch Delay” time,
the control will issue a “Minor Mismatch” alarm. If the gate position does not match the demand within the
“Gross Mismatch Window” for more than the “Gross Mismatch Delay” time, the control will issue a “Gross
Mismatch” Shutdown.
Creep Detection
The Control can be configured to detect unit Creep. Two discrete inputs are required to use this function.
The inputs come from proximity switches focused on the speed gear. One proximity switch must be
centered on a gear tooth, and the other proximity switch must be centered on a gear trough (or in
between two gear teeth). The Control will detect a creep as slight as one gear tooth of rotation.
When Creep has been configured, the Control will start looking for Creep once the unit is given a “Stop”
command, the speed has decreased below the “Creep Speed”, and the “Dead Stop Time” has expired.
Once a creep is detected, the control will stay in the alarm condition until the “Reset Creep Time” expires.
The Control will look for creep again when the “Look Again Time” has expired.
The Creep alarm is sent to the general governor alarms and to Modbus. A configurable relay output can
be configured to energize upon a Creep Detection.

Overspeed Test
When the overspeed test is enabled, the electronic overspeed trip is disabled, the isochronous speed
reference ceiling is raised to “Overspeed Test Limit” and the raise/lower rate on the isochronous speed
reference is increased to configurable rate.
To perform the overspeed test, the test must be enabled and the unit must be running off-line. The speed
reference must be raised until the unit trips from the mechanical overspeed. If the mechanical
overspeed device does not trip the unit, the speed reference will have to be manually lowered or the unit
can be tripped manually to prevent a trip if the test is disabled and the speed is greater than the
overspeed limit. This test will be automatically disabled after a configurable time and the speed will be
bring back to the rated speed.
When this test is performed, there is NO internal overspeed

protection in the Control. If the mechanical overspeed device
does NOT trip the unit, the speed reference will have to be
manually lowered or the unit can be tripped manually.
To prevent possible serious damage or injury from an

overspeeding turbine, be prepared to make an EMERGENCY
SHUTDOWN when performing this test, to protect against
runaway or failure of mechanical or other secondary
overspeed devices.
Speed Switches
There are ten speed switches that can be used in one of the configurable outputs. All speed switches are
also passed along to Modbus.
The speed switches can be configured as increasing switches or decreasing switches. This means that
the relay energizes as the unit speed is increasing above the setpoint or decreasing below the setpoint.
Each speed switch has a High setpoint and a Low setpoint. When the speed switch is configured as an
increasing switch, the High setpoint is the trip point and the Low setpoint is the switch’s reset point. When
the speed switch is configured as a decreasing switch, the Low setpoint is the trip point, and the High
setpoint is the reset point. There are also configurable delays for activation and deactivation of the
switches.
Here is an example of a speed switch setup: A speed switch is desired to turn on the unit’s exciter when
the unit reaches 90% rated speed after a start up. Configurable relay #2 is configured as speed switch #1.
The speed switch is configured as an increasing switch. The High setpoint is adjusted to 90%. It is
decided that the switch should reset at 80% rated speed, so the Low setpoint is adjusted to 80%.
Gate Position Switches

There are six gate switches that can be used in one of the configurable outputs. All gate switches are also
passed along to Modbus.
The gate position switches can be configured as increasing switches or decreasing switches. This means
that the relay energizes as the gate position is increasing or decreasing compared to the setpoint. Each
gate position switch has a High setpoint and a Low setpoint. When the gate position switch is configured

as an increasing switch, the High setpoint is the trip point and the Low setpoint is the switch’s reset point.
When the gate position switch is configured as a decreasing switch, the Low setpoint is the trip point, and
the High setpoint is the reset point.
Here is an example of a gate position switch setup: A gate position switch is desired to turn on a light
when the gates are closed. Configurable relay #2 is configured as gate position switch #1. The gate
position switch is configured as a decreasing switch. The Low setpoint is adjusted to 1%, setting this
switch slightly above zero will take care of any drifting calibration of the gate position transducer. It is
decided that the switch should reset at 4% gate position, so the High setpoint is adjusted to 4%.
Active Power Switches

There are six active power switches that can be used in one of the configurable outputs. All active power
switches are also passed along to Modbus.
The active power switches can be configured as increasing switches or decreasing switches. This means
that the relay energizes as the unit active power is increasing above the setpoint or decreasing below the
setpoint. Each active power switch has a High setpoint and a Low setpoint. When the active power switch
is configured as an increasing switch, the High setpoint is the trip point and the Low setpoint is the
switch’s reset point. When the active power switch is configured as a decreasing switch, the Low setpoint
is the trip point, and the High setpoint is the reset point. There are also configurable delays for activation
and deactivation of the switches.
Here is an example of an active power switch setup: An active power switch is desired to provide a
permissive for opening the generator breaker when the unit reaches 3% rated active power. Configurable
relay #2 is configured as active power switch #1. The active power switch is configured as a decreasing
switch. The Low setpoint is adjusted to 3%. It is decided that the switch should reset at 5% rated active
power, so the High setpoint is adjusted to 5%.
Baseload Control
When the unit is in parallel with the grid it may be desired to put it into Baseload control. In this mode the
unit will assume a fixed amount of load given by the Baseload Reference. In order to perform that action
an electrical transducer is needed to convert the load power into a 4–20 mA signal and a PID that
compares the actual load with the Baseload Reference in order to generate a speed setpoint to the
controller. At the moment that the Baseload mode is enabled the load reference ramps to the “Initial
Baseload Reference” at a configurable rate.
After that the baseload reference can be raised or lowered by the Raise and Lower inputs, respectively.
A Remote Baseload Reference can be used as well. There are three ways to enable the Remote
Baseload Reference: closing both the Raise and Lower inputs when in Baseload Mode, or by enabling it
via a Modbus Command, or via keypad. The remote baseload reference can either come from a 4–20 mA
analog input or through Modbus communication.
If there is a failure in the Remote Baseload signal the remote baseload control is automatically disabled
and an alarm is given.
If there is a failure in the Electrical Transducer signal the baseload control is automatically disabled and
an alarm is given.
When the baseload control is disabled the control tracks the generator load and maintain it, making a
bumpless transfer between the baseload mode and the other control modes.

Small System Detection

When the turbine is in parallel to the grid it may be desirable to detect if the turbine is in island mode. This
algorithm has this function. In order to do it, it monitors the turbine speed (when the turbine is in parallel to
the grid) and verifies if both the speed and its derivative value are within configurable windows. In case
either one of these parameters is outside its configurable window the controller automatically send a
disable Baseload, disable Level and disable Remote Speed control. It also issues an alarm
Unload Command
The Control has a configurable input that can be used as an unload command. When the unit is in parallel
with the grid in Baseload mode and an unload command is set the baseload reference starts lowering
slowly (configurable rate) in order to unload the unit. When the generator breaker opens the unit stays
isolated waiting for a stop command or a command to re-synchronize to the grid.
Alarms and Shutdowns

The control monitors several control functions and issues an Alarm when something goes wrong with a
control parameter. When the control parameter(s) in question are crucial to the safe operation of the unit,
the control will issue a Shutdown and an Alarm.
All Alarms and Shutdowns are latched until the condition is cleared and the control is given a “Reset”
command. A reset command can be issued to the control through a configurable discrete input, the
keypad, or Modbus. A reset is automatically issued during every “Start” command to the control.
The following is a list of conditions that result in an Alarm only:
Table 23: List of Alarms
Speed signal #1 trouble

Speed signal #2 trouble
Maintenance Alarm
Active power transducer signal fail
Speed bias signal fail
Remote speed reference signal fail
Gate position limiter signal fail
Remote baseload reference signal fail
Net head signal fail
Remote level reference signal fail
Blade position limiter signal fail
Tail level signal fail
Minor gate mismatch
Governor shutdown")
Creep detected
Minor blade mismatch
Remote fault #1
Remote fault #2

Remote fault #3
Remote fault #4
Remote fault #5
Remote fault #6
Remote fault #7
Remote fault #8
Remote fault #9
Remote fault #10
Remote fault #11
Remote fault #12
Discrete output #1 readback fault
Chassis Summary Alarm
Speed sensor #1 hardware fault
Speed sensor #2 hardware fault
Integrating Actuator - Gate Feedback#1 not Configured
Analog input #1 general fault
Analog output #1 hardware fault
Analog output #1 readback alarm
Linknet #1 - Analog output #1 readback alarm

Actuator output #1 driver fault

Actuator output #2 driver fault
Actuator output #1 open load fault
Actuator output #2 open load fault
Actuator output #1 hardware fault
Actuator output #2 hardware fault
Chassis temperature alarm
Display backlight fault
CPU Fault
Alarm - modbus link #1 fault
Small system detection
Gate LVDT signal fail (prop valve)
Blade LVDT signal fail (prop valve)
Minor gate mismatch (from valve LVDT)
Minor blade mismatch (from valve LVDT)
Any force mode enabled
Incomplete stop
Gate position #1 input fault
Gate position #2 input fault
Gate position mismatch
Incomplete start
Below is a description of the main alarms (not all alarms)
• Speed Signal #1 to 2 Trouble: If two speed signals are used and one speed signal fails, this
alarm goes TRUE.
• Level Signal Failure: If the Head/Tail Level input signal fails, this alarm goes TRUE. Head/Tail
Level control mode is also disabled.
• Remote Reference Signal Failure: If the Remote Reference input signal fails, this alarm goes
TRUE. Remote Reference control mode is also disabled.
• Speed Bias Signal Failure: If the Synchronizer/Load Control input signal fails, this alarm goes
TRUE.
• Minor/Small Gate Position Mismatch: If the gate position does not match the control’s gate
position demand within the “Minor Mismatch Window” for the “Minor Mismatch Delay Time”, this
alarm goes TRUE.
• Modbus Link Error (Unless Calibrated as a Shutdown): When a Modbus link error occurs, this
alarm goes TRUE.
• Creep Detected: When creep is detected, this alarm goes TRUE.
• Electrical Transducer Signal Failure: If the Electrical Transducer input signal fails, this alarm
goes TRUE. Baseload control mode is also disabled.
• Remote Baseload Signal Failure: If the Remote Baseload input signal fails, this alarm goes
TRUE. Remote Baseload control mode is also disabled.
• Gate Limiter Signal Failure: If the Gate Limiter input signal fails, this alarm goes TRUE.
• Small System Detection: If small system algorithm is used and detects that the turbine is in
island mode this alarm goes TRUE.
• Remote Level Signal Failure: If the Remote Level input signal fails, this alarm goes TRUE.
Remote Level control mode is also disabled.
• Remote Fault #1 to #12: This alarm goes TRUE if there is any input configured for remote fault,

this fault is configured for alarm and its condition goes true.
Any of these alarm conditions can be corrected while the unit is running, and the control can be given a
“Reset” command.
Shutdown conditions will de-energize or energize the ESD (Emergency Shutdown), depending on the
relay configuration. This relay should be tied to the application’s Emergency Shutdown circuit. The control
cannot be started after an emergency shutdown until a “Stop” command is given and then another “Start”
command is issued. There are parameters to include or not the each trip in the trip relay and another
parameter to decide if the trip relay output is supposed to be reset even if there are still active shutdowns.
The following is a list of conditions that result in a Shutdown and a “Governor Shutdown” alarm:
• All Speed Signals Failure: When the speed signal fails the control will shutdown the unit.
• Overspeed: When the unit’s speed exceeds the “Overspeed Setpoint”, the control will shutdown
the unit.
• Incomplete Start: When the unit is given a “Start” command and does not reach the “Start
Speed” set point before the “Time to Start Speed” timer expires, the control will shutdown the
unit.
• ESD Discrete Input: When the unit is given an “Emergency Shutdown” command through a
discrete input, the control will shutdown the unit.
• Power-up Trip: When the controller is powered up this, the control will shutdown the unit.
• Gross Gate Mismatch: When the gate position does not match the control’s gate position
demand within the “Gross Mismatch Window” for the “Gross Mismatch Delay Time”, the
control will shutdown the unit.
• Gross Blade Mismatch: When the Blade position does not match the control’s Blade position
demand within the “Gross Mismatch Window” for the “Gross Mismatch Delay Time”, the
control will shutdown the unit. This parameter is used only for Kaplan turbines.
• Gate Position Feedback Fail: When the gate position signal is lost (or goes below the “Minimum
Gate Position Signal Current”), the control will shutdown the unit.
• Blade Position Feedback Fail: When the Blade position signal is lost (or goes below the
“Minimum Blade Position Signal Current”), the control will shut down the unit. This parameter is
used only for Kaplan turbines.
• Net Head Signal Fail: When the Net Head signal is lost (or goes below the “Minimum Net Head
Signal Current”), the control will shutdown the unit.
• Actuator Output #1 to #2 Fault: If there is a problem in the specific actuator output the control
will shutdown the unit. It is possible to select for each actuator output if this trip is needed.
• Estop from keypad: When the unit is given an “Emergency Shutdown” command through the
keypad, the control will shutdown the unit.
• Open Wire on MPUs: When it is detected an open wire on the speed MPU circuit in both
channel, the control will shutdown the unit.
• Remote Fault #1 to #12: This shutdown goes TRUE if there is any input configured for remote
fault, this fault is configured for shutdown and its condition goes true.
• Head or Tail Signal Fail: When the Head or Tail signal is lost (or goes below the “Minimum Head
or Tail Signal Current”), the control will shutdown the unit.
• Gate Gross Mismatch (Prop. Valve): When the gate Proportional valve position does not match
the control’s gate proportional valve position demand within the “Gross Mismatch Window” for
the “Gross Mismatch Delay Time”, the control will shutdown the unit.
• Blade Gross Mismatch (Prop. Valve): When the blade Proportional valve position does not
match the control’s blade proportional valve position demand within the “Gross Mismatch
Window” for the “Gross Mismatch Delay Time”, the control will shutdown the unit. This
parameter is used only for Kaplan turbines.
• Gate LVDT Signal Fail (Prop. Valve): When the gate proportional valve position signal is lost (or

goes below the “Minimum Gate Proportional Valve Position Signal Current”), the control will
shutdown the unit.
• Blade LVDT Signal Fail (Prop. Valve): When the blade proportional valve position signal is lost
(or goes below the “Minimum Blade Proportional Valve Position Signal Current”), the control
will shutdown the unit.
• Trip with unload: When an unload trip command is issued, and it is selected to send a trip
command after the turbine speed is less than 20% this trip will be issued.
• Configuration Error: If any errors are found in the program, the 5001 will remain in a shutdown
state and a banner message will appear on the Configuration Menu and MODE screens.
• Incomplete Stop: When a stop command is given, and the speed spends more than a
configurable time to reach a configurable value this trip will be issued. This timer can start at the
moment of the stop command or at the moment that the breaker opens.
• Emergency Shutdown from Modbus: When the command to trip the turbine is given from
Modbus communication.
• Configuration Mode (IO Lock): The 5001 will remain in a shutdown state when it is in
configuration mode.
• LinkNet Summary Trip: When the command to trip the turbine is given from a LinkNet

Chapter 8 – Inputs and Outputs
Description of I/O
The 5001 Speed Control has a wide selection of functions to choose from a fixed amount of I/O (inputs
and outputs). The control can be configured in the field to use the I/O to best fit the specific application.
During the initial setup of the control, the functions that are needed for the specific application are
selected and the necessary I/O points are assigned accordingly
Control Inputs
Speed Input Signals
Two redundant speed inputs are configurable to accept MPUs (magnetic pickup units), or active proximity
Probes
Analog 4-20 mA Input Signals
There are eight configurable analog inputs available on the 5001 hardware, each of which can be
configured as one of the following input functions:
Table 24: Analog Input Functions
1 --- Not Used --- 9 Blade Position Feedback

2 Head Level 10 Net Head
3 Electrical Transducer 11 Remote Level Reference
4 Speed Bias 12 Blade Position Limiter
5 Gate Position Feedback #1 13 Tail Level
6 Remote Speed Reference 14 Gate Position from Prop. Valve
7 Gate Position Limiter 15 Blade Position from Prop. Valve
8 Remote Baseload Reference 16 Gate Position Feedback #2

Figure 36: Analog Input Summary Screen
Each function is detailed below:
• Head/Tail Level: this analog input is mandatory if pond/tail level control is desired.
• Electrical Transducer: this analog input is used to express the generator load. This input is
mandatory if kW droop or baseload mode is desired.
• Speed Bias: this analog input comes from a synchronizer/load controller. If the synchronizer/load
controller doesn’t have an analog speed bias output there can be used alternatively digital inputs
in the Control to perform this function (called Speed Bias Raise and Speed Bias Lower).
• Gate Position Feedback #1: this analog input provides information about gate actual position.
This is mandatory if Integrating Actuators are used. If Proportional Actuators are used this input
can be used as well just for monitoring purposes.
• Remote Speed Reference: this analog input is used to provide either a remote speed reference,
if droop control is used (either actuator droop or kW droop), or a remote level reference, if level
control is used.
• Gate Position Limiter: this analog input is used if it’s necessary for any reason to limit the gate
position to a certain value. If this gate limit is desired but an analog input is not available there are
two digital inputs there can be used alternatively (gate limit raise and gate limit lower).
• Remote Baseload Reference: this analog input is used if the control is in Baseload mode and a
remote Baseload reference is needed.
• Remote Level Reference: this analog input is used if the control is in head/tail level control mode
and a remote head/tail level reference is needed.
• Blade Position Feedback: this analog input provides information about blade actual position (for
Kaplan turbines). This is mandatory if Integrating Actuators are used. If Proportional Actuators are
used this input can be used as well just for monitoring purposes.
• Net head: this analog input provides information about Net head for be used in the curves of the
blade control (for Kaplan turbines).
• Blade Position Limiter: this analog input is used if it’s necessary for any reason to limit the

blade position to a certain value. If this blade limit is desired but an analog input is not available
there are two digital inputs there can be used alternatively (blade limit raise and blade limit lower).
This analog input is used only for Kaplan turbines.
• Gate Position from Prop. Valve: this analog input is used to monitor or control (if necessary) the
gate proportional valve
• Blade Position from Prop. Valve: this analog input is used to monitor or control (if necessary)
the blade proportional valve
• Gate Position Feedback #2: this analog input provides redundant information about gate actual
position. This is not a required input.
Contact Inputs
Twenty contact inputs (on/off switches) are available. Contact Input channel #1 is dedicated trip input.
The other contact inputs on the control are configurable.
Table 25: Contact Input Functions
1 --- Not Used --- 24 Remote Fault #3

2 Manual Gate Control Enable 25 Remote Fault #4
3 Head/Tail Level Control Enable 26 Remote Fault #5
4 Unload 27 Remote Fault #6
5 Gate Limit Raise 28 Remote Fault #7
6 Gate Limit Lower 29 Remote Fault #8
7 Creep Input #1 30 Remote Fault #9
8 Creep Input #2 31 Remote Fault #10
9 Shutdown with Unload 32 Remote Fault #11
10 Governor Reset 33 Remote Fault #12
11 External Start Permissive 34 Manual Gate Position Raise
12 Speed Bias Raise 35 Manual Gate Position Lower
13 Speed Bias Lower Manual Gate (Prop Valve)
36
14 Baseload Enable Enable
15 kW Droop Enable Manual Blade (Prop Valve)
37
16 Blade Tilt Enable
17 Blade Lock 38 Disable Small System Detection
18 Manual Blade Control Enable 39 Generator Breaker
19 Manual Blade Position Raise 40 External Run
20 Manual Blade Position Lower 41 Stop Command
21 Local / Remote 42 Speed/Load Raise
22 Remote Fault #1 43 Speed/Load Lower
23 Remote Fault #2

Figure 37: Contact Input Summary Screen
• Manual Control Enable: when this discrete input is closed, the gates can be controlled
“manually” with the Raise and Lower discrete inputs. Manual control can also be enabled through
Modbus or HMI.
• Manual Gate Position Raise / lower: these inputs are used to raise or lower the gate position
when the gate is in manual mode.
• Head/Tail Level Control Enable: when this discrete input is closed, the control will switch into
head/tail level control. The Raise and Lower discrete inputs will raise and lower the head level
setpoint. Head/Tail Level Control can also be enabled through Modbus or HMI.
• Auto Follow Enable: this input should be used when the Control is being used as a back-up
governor. When this discrete input is closed, the control will track current gate position in all
control modes, and the Raise and Lower inputs are disabled. When this discrete input opens, the
Control will assume control of the unit in whatever control mode is selected. Auto Follow control
can also be enabled through Modbus or by using Woodward Control Assistant.
• Gate Limit Raise / Lower: when one of these discrete inputs is closed, the Gate Limit ramps up
or down at a configurable rate. The Control is designed so that Gate Limit control is not
necessary, but it is available if required by the application. Gate Limit Raise and Lower can also
be done through Modbus or HMI.
• Creep Input #1 & Creep Input #2: creep detection requires two inputs from proximity probes. By
monitoring the Creep #1 and Creep #2 discrete inputs, the control can detect when the unit is
creeping.
• Governor Reset: all shutdowns and alarms are latched until the fault condition clears and the
control is reset. When this input is closed, it resets the control. The control can be reset through
Modbus or keypad
• External Start Permissive: after a start input, the control waits for a momentary closure of this
discrete input before starting the unit if this function is used.

• Speed Bias Raise / Lower: when one of these discrete inputs is closed, the Speed Bias internal
ramp ramps up or down at a configurable rate. For using these discrete inputs the speed bias
source must be configured to digital. Speed Bias Raise and Lower can also be done through
Modbus or by using the Woodward Control Assistant.
• Baseload Enable: this input is used to enable the Baseload control mode. In Baseload the
generator load will stay in a setpoint determined either by the Raise Speed/Load inputs, or by a
remote Baseload input or by a Baseload Modbus reference. The following conditions must also
be present in order to the baseload control be enabled: the generator breaker must be closed,
there must be a valid electrical transducer signal and the manual, auto-follow and level control
modes must be disabled. Baseload Enable can also be done through Modbus or by using the
Woodward Control Assistant.
• Unload: when in parallel and baseload operation it may be desired to unload the generator and
open the generator breaker. When the unload contact is closed (rising edge triggered) it starts to
slowly decrease the load reference and either when it reaches a minimum value (unload trip
level) or a certain maximum delay after the reference reaches the unload trip level (configurable)
it gives an open breaker command (if configured). After that the turbine stays in its rated speed
waiting for another command.
• Local/Remote: this input defines if the controller will accept commands coming from digital inputs
(local mode) or via Modbus (remote mode). If there is no input configured for this function the
controller accepts only local commands.
• kW Droop Enable: this input is used to enable the kW droop. In this mode the droop feedback is
given by the generator active power. This mode is automatically enable every time that the
Baseload mode is enabled. The kW Droop enable/disable command can also be sent via
Modbus.
• Remote Fault #1 to #12: these inputs are used for alarm or trip (they can be configured for any
of these functions). It’s possible to also define a delay (configurable parameter) for each one of
these alarms/trips.
• Shutdown with Unload: this input is designed to shutdown the turbine, but the load will be
decreased before stop the turbine.
The functions described below are used only for Kaplan turbines:
• Blade Tilt: this input is designed to enabled the blade tilt function.
• Blade Lock: this input is designed to enabled the blade lock function.
• Manual Blade Control Enable: When this discrete input is closed, the blade can be controlled
“manually” with the Raise and Lower discrete inputs. Manual control can also be enabled through
Modbus or HMI
• Manual Blade Position Raise / lower: these inputs are used to raise or lower the blade position
when the blade is in manual mode.
Control Outputs
Analog Outputs
Six analog outputs are available. All analog outputs are 4–20 mA. The configurable analog outputs have
the following options:

Table 26: Analog Output Functions
1 --- Not Used --- 11 Speed Bias

2 Tachometer 12 Generator Active Power
3 Gate Position 13 Gate Limit Value
4 Blade Position 14 Blade Limit Value
5 Head Level 15 Remote speed Reference
6 Tail Level 16 Remote Level Reference
7 Net Head 17 Remote Baseload Reference
8 Speed Reference 18 Droop Value
9 Level Reference 19 Generator Load (%)
10 Baseload Reference
Figure 38: Analog Output Summary Screen
Actuator outputs
5001 has 2 actuator outputs that can be used for gate demand and, when controlling a Kaplan turbine, for
blade demand.

Figure 39: Actuator Driver Summary Screen
Relay Outputs
Eight relay outputs are available. All relay outputs can be used as normally open or normally closed
(configurable). Relay channel #1 is dedicated to trip relay. This relay is a dedicated “Shutdown” relay
(normally energized and de-energizes on a shutdown) to indicate the position of the dedicated Shutdown
relay.
The other relays outputs on the control are configurable and the available configuration is shown below:
Table 27: Relay Output Functions
1 --- Not Used --- 15 Gate Position Switch #4

2 Alarm Indication 16 Gate Position Switch #5
3 Shutdown Indication 17 Gate Position Switch #6
4 Creep Detected 18 Active Power Switch #1
5 Small System Detected 19 Active Power Switch #2
6 Speed Switch #1 20 Active Power Switch #3
10 Speed Switch #5 24 Control in Remote Mode
11 Speed Switch #6 25 Gate Demand in Manual
12 Gate Position Switch #1 26 Blade Demand in Manual
13 Gate Position Switch #2 27 Ready for Start Turbine
14 Gate Position Switch #3 28 Turbine Speed Stable

29 Reset Command 45 Remote Alarm #3

30 Generator Breaker Closed 46 Remote Alarm #4
31 Baseload Mode Enabled 47 Remote Alarm #5
32 kW Droop Enabled
33 Not Used 48 Remote Alarm #6
34 Incomplete Start Timeout 49 Remote Alarm #7
35 Incomplete Stop Timeout 50 Remote Alarm #8
38 Overspeed 53 Remote Alarm #11
39 Speed Switch #7
54 Remote Alarm #12
40 Speed Switch #8
55 Gate Limit in Control
41 Speed Switch #9
56 Zero Speed Detected
42 Speed Switch #10
57 Brake Permissive
43 Remote Alarm #1
44 Remote Alarm #2

• Alarm Indication: this relay option closes the relay when an alarm condition is present. All
shutdown conditions are also considered alarms.
• Shutdown Indication: this relay will energize upon any shutdown condition and stay energized
until all trips have been cleared. This relay may be programmed to indicate a shutdown condition
on a remote panel or to a plant DCS. The Shutdown Indication relay is normally de-energized. It
will energize upon any shutdown condition and stay energized until all trips have been cleared.
The ‘RESET CLEARS TRIP function has no effect on the programmable Shutdown Indication
relay.
• Creep Detected: this relay option closes the relay when creep is detected on the unit. The relay
will stay closed until a configurable time after the unit stops creeping. At that point the relay will
open, and the control will continue monitoring the unit for another creep condition.
• Small System Detected: this output will be energized when the control detects that the
generator is not connected to the grid. In other words, the control detects if the generator is not in
parallel with the grid.
• Speed Switch #1-10: this switch can be set to trigger at a specific % of rated speed as the speed
increases or decreases.
• Gate Position Switch #1 - 6: this switch can be set to trigger at a specific gate position as the
gates go open or as it close.
• Active Power Switch #1 - 6: this switch can be set to trigger at a specific active power.
• Control in Remote Mode: if the control is in remote mode this output will indicate it.
• Gate Demand in Manual: this output will indicate if the gate demand is in manual mode.
• Ready for Start Turbine: this output will be energized when the control has no shutdown and the
start permissive discrete input is energized or not configured.
• Turbine Stable Speed: this relay option closes if the turbine speed is stable. The values for
speed window and speed delay on speed window in order to define if the turbine speed is stable
or not are all configurable.
• Reset Command: this output will be energized for 3 seconds when a reset command is issued.
• Generator Breaker Closed: this output will be energized while the generator breaker is closed.
• Baseload Mode Enabled: this output will be energized while the baseload mode is enabled.
• kW Droop Enabled: this output will be energized while the kW droop mode is enabled.
• Incomplete Start Timeout: this output will be energized when we get an incomplete start alarm.
This means that a start command was issued but the speed did not reach a configurable value
during a configurable time.
• Incomplete Stop Timeout: this output will be energized when we get an incomplete stop alarm.

This means that a stop command was issued but the speed did not decrease to a configurable
value during a configurable time.
• Overspeed: this output will be energized if an overspeed trip occurs.
• Remote Alarm 1-12: these outputs can be used for indicating that the remote alarm was
actuated. It is possible to configure one output for the specific remote alarm.
• Gate Limit in Control: this output will be energized if the gate is being limited by the gate limit.
• Zero Speed Detected: this output will be energized if zero speed is detected by proximity
probes.
• Brake Permissive: this relay option closes the relay when the control is in the “STOP” mode, the
gates are closed, speed and gate position signals are valid, and the speed is below a
configurable value.
The output options described below will be used only when you are controlling a Kaplan turbine.
• Blade Demand in Manual: this output will indicate if the blade demand is in manual mode.

Chapter 9 – Configuration Procedures
Program Architecture
The 5001 is easy to configure from the built-in graphical user interface (GUI). When the control is
powered up and after the CPU self-test has been completed, the control displays the home screen and
the CPU LED on the left side of the front panel should be green. At this point the configuration can be
done locally on the display or remotely using the RemoteView tool on a user PC. Using the remote tool
may be more convenient as you can use a mouse to navigate and the full keyboard to enter data.
The operating procedures are divided into two sections: the Configuration Mode, discussed in this
chapter, and the Run Modes (Operation and Calibration) (refer to Chapter 9 for RUN Mode information).
The Configure Mode is used to configure the 5001 for the specific application and set all operating
parameters. The Run Mode is the normal turbine operation mode and is used to view operating
parameters and run the turbine.
The configuration cannot be changed or altered while the turbine is running, however, it can be accessed,
and all programmed values monitored. This minimizes the possibility of introducing step disturbances into
the system. To monitor or review the program while in the run mode, enter the Configuration menu from
the first (leftmost) soft key on the Home screen.
Display Modes and User Levels

The 5001 Display operates in several modes and access user levels, each of which has a different
purpose. The modes are: OPERATION, CALIBRATION, and CONFIGURATION. In order to enter and
exit a particular mode, the user must be logged in with an appropriate user level. These user levels are:
MONITOR, OPERATOR, SERVICE, and CONFIGURE. In addition to granting authority to enter and exit
modes, user levels also determine what parameters the user is authorized to adjust. See Table 4-1, Mode
Access by User Level.
Table 28: Mode Access by User Level
Mode Descriptions
The OPERATION mode is the only mode that can be used to run the turbine. This is the default mode.
Exiting CALIBRATION or CONFIGURATION mode will return to OPERATION mode. User levels:
Operator, Service, or Configure.

The CALIBRATION mode is used to force signal outputs in order to calibrate signals and field devices. In
this mode, the actuator, analog, and relay outputs can be manually controlled. To enter this mode the
turbine speed must be shutdown with no speed detected. User levels: Service or Configure.
The CONFIGURE mode is used to set up the parameters for a specific application prior to operation of
the unit. To enter this mode the turbine speed must be shutdown with no speed detected. When the unit
enters CONFIGURE mode the control is placed in IOLOCK which will disable all Output I/O channels. If
the control is not shutdown, navigating through the configuration pages will allow viewing of
CONFIGURE, but will not permit any changes to be made.
User Level Descriptions
The Monitor user level is view-only access. All commands from the front panel are inhibited. All values
displayed on each screen are continuously updated.
The Operator user level allows for control of the turbine. Front panel commands to start, change
setpoints, enable/disable functions, and stop the turbine are accepted.
The Service user level allows the same commands as the Operator user level plus tuning of Service
menu parameters and issuing of additional commands.
The Configure user level allows the same commands and access as the Service user level plus tuning of
Configuration menu parameters.
Configuring the 5001

Before the 5001 can be used to operate any turbine, it must be configured with a valid configuration. A
5001 Configure Mode Worksheet is provided in Appendix A of this manual. This chapter contains
additional information related to completing this worksheet and configuring the specific application.
Recommended completing this worksheet, documenting your specific configuration.
It is also possible to configure a unit by loading the configuration (tunable) file from another unit. This is
the recommended method for configuring a spare unit. Refer to the appropriate appendix in Volume 2 for
installing and using the Control Assistant service tool. It will describe how to retrieve and send these file
to and from the control.
Figure 38 illustrates the 5001 screen displayed when power is first applied and the unit is not configured.
This is the HOME screen. It includes tips on how to enter the Configure Mode from this point. A password
is required to protect against both intentional and inadvertent configuration changes. The password can
be changed if desired, refer to Product Manual 26336 for information on changing passwords. This
screen will become the main menu once the unit is configured. From this HOME screen, operational
screens as well as the Service and Configure menus can be accessed.

Figure 40: Initial HOME Screen (unit not configured)
Use the following procedure to begin configuring the 5001:

1. Press the MODE key.
2. Press the LOGIN softkey to open the User Login popup.
3. Login to the ‘Configure’ user level.
4. Close the User Login popup screen.
5. Press the Configuration softkey to enter configuration mode. Verify that the following Calibration
and Configuration Mode Permissives are met:
o Unit Shutdown
o No Speed Detected
o Configure” User Level or greater is logged in
6. Press MODE or HOME to return to the HOME screen.
7. Press the Configuration softkey to access the configuration menus.
8. Using the navigation cross, navigate up/down/left/right and use ENTER to select a menu or item.
The 5001 configure mode may be accessed if the unit is in a Shutdown state, no speed is detected, and
the correct user level is logged in (Configure or higher). For safety reasons the configuration may be
monitored only and no changes will be accepted if the turbine is running. By pressing the MODE key,
pressing the soft key for LOGIN, and logging in as the “Configure” user level by entering the password
(wg1113). Select a field using the navigation cross arrows and then press ENTER to enter text. When
finished, press ENTER again.
All configuration values and saved service mode changes are stored as a file on the 5001 control. To
ensure that values are saved, exit Configure mode or select ‘Save Settings’ from the MODE screen. If
power is removed from the unit all saved values will return once power is restored. No batteries or back
up power is required.

The field-configured portion of the configuration settings will be zeroed

out after factory repair. You must reconfigure these values before the
unit is put back into service.
How to License the 5001 Application

If not licensed in the factory, a purchased software license will be required to allow the unit to exit
IOLOCK and run a turbine. Each control hardware serial number will require a unique site key. Consult
you sales/commercial representative to purchase the License number above and receive a site key (you
must have the serial number of the target control H/W at the time of purchasing this key).
The following is the process to enter the license site key onto the hardware:
1. Login as user level CONFIGURE or higher.
2. Enter CONFIGURATION Mode (which will put the unit in IOLOCK).
3. From the Home screen or Configuration Menu, navigate to the Site Info page.

Figure 41: Initial HOME Screen (unit configured)

4. From this screen navigate to the CORE License page:

Figure 42: Site Information Screen
The CORE License page will allow you to enter a site license key when in Configuration Mode – using the
keypad press Enter, then use the numeric keys to enter the site license key for this control serial number,
then press Enter again to accept your entry. If the correct license key is entered for the serial number
shown, the LED will turn GREEN indicating the license has been validated and accepted. Close this
dialog box and ‘Save Settings’ to save the license key into the tunable settings for this control.
Using Configure Menus

Once the Configure Mode has been entered with the password, the specific application information must
be entered into the 5001. To access the configure menu, select the ‘Configuration’ softkey from the
HOME screen.
The navigation arrow keys (red navigation cross keypad; up, down, left, and right) are used for navigation
of the Configure menus. Press ENTER to go into a menu. Then use the navigation cross to move up or
down (left/right, if needed) in the menu. In the Configuration mode, the control will generate an error
message shown on the Configuration menu home screen as well as the MODE screen if an invalid
configuration exits. A configuration error will cause the control to remain tripped. It is possible to exit
Configuration mode with such an error but the control will be tripped until the Configuration mode is
entered again and the Configuration error is corrected.
See the Tutorial to learn how to adjust a value. The tutorial can be accessed from the HOME screen by
pressing the Tutorial softkey before the unit is configured or from the Service menu any time.
To return to the previous screen, press the ESC key. While in a Configure menu, to return to the main
Configure menu screen, press the HOME key. To return to the main Home screen, press the HOME key
again. To exit the Configure mode, go to the MODE screen and select the ‘Exit Configuration’ soft key.
This will save values, exit I/O Lock, and reboots the 5001.


Configure Menus
To program the control, navigate through the menus and configure the control features for the desired
application. The first four configure menus listed below, as well as drivers and other I/O, must be
programmed for every installation. The remaining menus contain optional features which can be selected
if desired. The configure menus and their basic functions are described below.
Figure 43: Configuration Menu – Configuration Mode (Edit)
Table 29: Configuration Menu Commands
Operating Parameters configure turbine type, nominal frequency and generator settings
Speed Setpoint configure speed setpoints, overspeed trip setpoint, and online and
offline ramp rates
Speed Sensors configure MPU or PROX PROBE information
Power Switches configure power switches
Speed Switches configure speed switches
Gate Switches configure gate switches
Trip Relays configure which trips will energize the trip relay output
Break configure the break permissive parameters
Communications configure Modbus communication options
Analog Inputs configure analog input options
Analog Outputs configure analog readout options
Drivers configure driver outputs
Contact Inputs configure contact input options
Relays configure relay options
Woodward Links configure digital communication links to other Woodward products
The configure menus are described in detail below and contain information detailing each question and/or
5001 configuration option. Each question/option shows the default (dflt) value and the adjustable range of

that parameter (shown in parentheses). In addition, any additional constraints on the configuration are
shown in italics following the description. There is a Configuration mode worksheet in Appendix A of this
manual that should be completed/filled-in and used as a guide for your particular application. This
worksheet can also be used for future reference to document your application program.
Configuration Mode Parameters

Operating Parameters Menu
TURBINE TYPE dflt= BLANK (Francis/Kaplan)

Select Francis if the 5001 is controlling a Francis turbine. If the application is a Kaplan turbine, select this
option. If Kaplan turbine is selected, all blade parameters will be available for customization.
NOMINAL FREQUENCY dflt= 60 Hz (50 Hz /60 Hz)

Set the generator’s frequency at rated speed setpoint.
DROOP dflt= 5.0 (0.0, 10)

Enter the droop percentage. Typically set between 4–6% and not more than 10%.
RESET CLEARS TRIP RELAY? dflt= NO (Yes/No)

Select YES to configure the Reset Clears Trip Relay output function. When set to YES, a Reset
command will energize the trip relay output even when a trip condition is still sensed by the 5001 –
typically due to one of the external trip inputs. Once reset, the unit will be ‘Ready to Start’ as soon as all
external trip inputs are closed. When NO, the trip relay output will be de-energized on a 5001 trip and will
not energize until all trips have cleared and a ‘Reset’ command is given.
ALLOW REMOTE CONTROL? dflt= YES (Yes/No)

Set to YES if using Local/Remote control logic. If YES, permits the unit to go from REMOTE (Modbus)
control to LOCAL (front panel and digital inputs) control based on a discrete input signal. If NO, no remote
control is allowed.
SPEED BIAS SIGNAL dflt= NOT USED (Not Used, Analog Speed Bias, Digital Speed Bias)
Set the type of speed bias signal used by the 5001, if used.
PRIMARY LOAD SIGNAL dflt= NONE (None, Analog Input, from DSLC-2)
Select the source for the power input signal, if used.
SECONDARY LOAD SIGNAL dflt= NONE (None, Analog Input, from DSLC-2)
Select the backup source for the power input signal, if used.
Speed Setpoints Menu
OVERSPEED TRIP (%) dflt= 150 (0.0, 300)

Set the 5001’s overspeed trip level (in %). This is the governor overspeed trip setpoint only and is not to
be used as ultimate overspeed protection.
(Must be less than the ‘Overspeed Test Limit’ Setting)
OVERSPEED TRIP DELAY (s) dflt= 0.0 (0.0, 200)

This parameter determines how long it takes to the controller send the trip command due to overspeed.
OVERSPEED TEST LIMIT (%) dflt= 160.0 (75.0, 250.0)

Set the overspeed test limit (in rpm). This is the maximum speed setpoint the control will increase to when

overspeed testing the unit. The setpoint can only be raised to this level when the overspeed test function
is being performed.
OVERSPEED SPEED RATE (%/s) dflt= 2.5 (0.001, 100.0)

Set the rate that the speed setpoint will move during the overspeed test (in %/second)
NOMINAL SPEED (rpm) dflt= 180.0 (10.0, 100000.0)

Set the generator’s rated speed setpoint
OFFLINE RATE (%/s) dflt= 0.1 (0.001, 100.0)

Enter the offline speed setpoint rate in % per second. This is the rate of speed change for normal
operation when turbine is offline.
ONLINE RATE (%/s) dflt= 1.0 (0.1, 20.0)

Enter the online speed setpoint rate in % per second. This is the rate of speed change for normal
operation when turbine is online.
ONLINE REMOTE RATE (%/s) dflt= 0.8 (0.1, 20.0)

Enter the online remote speed setpoint rate in % per second. This is the rate of speed change for normal
operation when turbine is online.
ONLINE LEVEL RATE (%/s) dflt= 1.0 (0.1, 20.0)

Enter the online level setpoint rate in % per second. This is the rate of level change for normal operation
when turbine is online.
USE CREEP DETECTION dflt= NO (Yes/No)

If this function is selected, allows to configure the creep detection.
CREEP SPEED (%) dflt= 5.0 (0.0, 10.0)

Set the creep speed in percentage. Below this speed the governor will enable the creep detection logic.
DEAD STOP TIME (s) dflt= 60.0 (10.0, 600.0)

Set the dead stop time in seconds. This is the time it takes for the turbine to come to a dead stop.
RESET CREEP TIME (s) dflt= 5.0 (0.0, 600.0)

Set the reset creep time in seconds. This is the time after stopping sensing the creep to reset the alarm
condition
LOOK AGAIN TIME (s) dflt= 5.0 (0.0, 600.0)

Enter the time in seconds the governor will start to monitor the creep after leaving a creep condition.
Speed Sensors Menu

(The maximum speed input frequency is 35000 hertz.)
PROBE TYPE dflt= MPU (MPU, Active)

Set the probe type, whether passive or active.
NUMBER OF GEAR TEETH SEEN BY MPU dflt= 60.0 (1, 300)

Enter the number of teeth on gear that the speed probe is mounted on.
GEAR RATIO dflt= 1.0 (0.1, 10.0)

Enter the speed sensor gear ratio. This value is the ratio of the speed sensor gear to the turbine shaft.
This gear ratio is the result of dividing the speed of the speed sensor gear by the speed of the turbine
shaft.

MAXIMUM SPEED LEVEL (rpm) dflt= 350.0 (10.0, 10000.0)

Enter the Maximum Speed Level (in rpm) to set the speed probe input maximum detectable level. If
speed goes above this level, it will not be read in the control.
FAILED SPEED LEVEL (rpm) dflt= *15.0 (0.0, 1000.0)

Enter the Failed Speed Level (in rpm) to set the speed probe input failure level. If speed drops below this
level, the control will determine the speed input device is failed and issue an alarm. If all speed inputs fail,
the 5001 will issue a trip on loss of speed inputs.
(Must be greater than or equal to 0.0204 x Maximum Speed Level)
Note: The 5001 will override the speed signal if the speed is less than 50% of the nominal speed, the
gates are closed, and the controller is in shutdown state.
USE SPEED INPUT #2? dflt= NO (Yes/No)
PROBE TYPE dflt= MPU (MPU, Active)

Set the probe type, whether passive or active.
NUMBER OF GEAR TEETH SEEN BY MPU dflt= 60.0 (1, 300)

Enter the number of teeth on gear that the speed probe is mounted on.
GEAR RATIO dflt= 1.0 (0.1, 10.0)

Enter the speed sensor gear ratio. This value is the ratio of the speed sensor gear to the turbine shaft.
This gear ratio is the result of dividing the speed of the speed sensor gear by the speed of the turbine
shaft.
MAXIMUM SPEED LEVEL (rpm) dflt= 350.0 (10.0, 10000.0)

Enter the Maximum Speed Level (in rpm) to set the speed probe input maximum detectable level. If
speed goes above this level, it will not be read in the control.
FAILED SPEED LEVEL (rpm) dflt= 15.0 (0.0, 1000.0)

Enter the Failed Speed Level (in rpm) to set the speed probe input failure level. If speed drops below this
level, the control will determine the speed input device is failed and issue an alarm. If all speed inputs fail,
the 5001 will issue a trip on loss of speed inputs.
(Must be greater than or equal to 0.0204 x Maximum Speed Level)
Note: The 5001 will override the speed signal if the speed is less than 50% of the nominal speed, the
gates are closed, and the controller is in shutdown state.
Power Switches Menu
HIGH VALUE (%) dflt= 100.0 (-50.0, 200.0)

Set the high setpoint in % for the selected switch.
HIGH DELAY (s) dflt= 0.0 (0.0, 600.0)

Set the time in seconds that a selected switch must remain above the high value setpoint for the switch to
be active.
LOW VALUE (%) dflt= 98.0 (-50.0, 200.0)

Set the low setpoint in % for the selected switch.
LOW DELAY (s) dflt= 0.0 (0.0, 600.0)

Set the time in seconds that a selected switch must remain below the low value setpoint for the switch to
be reset.

INVERT dflt= NO (Yes/No)

Select NO for increasing switch. When the active power switch is configured as an increasing switch, the
high setpoint value is the trip point and the low setpoint value is the switch’s reset point. If YES, the active
power switch is configured as a decreasing switch being the low setpoint value its trip point, and the high
setpoint value its reset point.
Speed Switches Menu
HIGH VALUE (%) dflt= 1.0 (0.0, 200.0)

HIGH DELAY (s) dflt= 0.0 (0.0, 600.0)

be active.
LOW VALUE (%) dflt= 1.0 (0.0, 200.0)

LOW DELAY (s) dflt= 0.0 (0.0, 600.0)

be reset.

Select NO for increasing switch. When the speed switch is configured as an increasing switch, the high
setpoint value is the trip point and the low setpoint value is the switch’s reset point. If YES, the speed
switch is configured as a decreasing switch being the low setpoint value its trip point, and the high
Gate Switches Menu
HIGH VALUE (%) dflt= *100.0 (0.0, 200.0)

HIGH DELAY (s) dflt= 0.0 (0.0, 600.0)

be active.
LOW VALUE (%) dflt= *98.0 (0.0, 200.0)

LOW DELAY (s) dflt= 0.0 (0.0, 600.0)

be reset.

Select NO for increasing switch. When the gate switch is configured as an increasing switch, the high
setpoint value is the trip point and the low setpoint value is the switch’s reset point. If YES, the gate
switch is configured as a decreasing switch being the low setpoint value its trip point, and the high

Trip Relays Menu
ALL SPEED SIGNAILS FAILURE dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to failure in all speed signals.
OVERSPEED dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to overspeed.
INCOMPLETE START dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to incomplete start.
ESD DISCRETE INPUT dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to ESD discrete input.
POWER-UP TRIP dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to power-up.
GROSS GATE MISMATCH dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to gross gate mismatch.
GROSS BLADE MISMATCH dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to gross blade mismatch.
GATE POSITION FEEDBACK FAIL dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to gate position feedback fail.
BLADE POSITION FEEDBACK FAIL dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to blade position feedback fail.
NET HEAD SIGNAL FAIL dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to net head signal fail.
ACTUATOR OUTPUT #1 FAULT dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to fault in the actuator output #1.
ACTUATOR OUTPUT #2 FAULT dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to fault in the actuator output #2.
ESTOP FROM KEYPAD dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to Estop from keypad.
OPEN WIRE TEST TRIP dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to open wire in the speed sensing circuit.
REMOTE FAULT #1 TO #12 dflt= NO (Yes/No)

Select YES to energize the trip relay output in case of trip due to remote fault.
HEAD/TAIL LEVEL SIGNAL FAIL dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to head/tail level signal fail.
GATE GROSS MISMATCH (PROP. VALVE) dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to gate gross mismatch (prop. valve).
BLADE GROSS MISMATCH (PROP. dflt= YES (Yes/No)

VALVE)
Select YES to energize the trip relay output in case of trip due to blade gross mismatch (prop. valve).

GATE LVDT SIGNAL FAIL (PROP. VALVE) dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to gate LVDT signal fail (prop. valve).
BLADE LVDT SIGNAL FAIL (PROP. VALVE) dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to blade LVDT signal fail (prop. valve).
TRIP WITH UNLOAD dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip with unload.
CONFIGURATION ERROR dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to configuration error.
INCOMPLETE STOP dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of trip due to an incomplete stop.
EMERGENCY SHUTDOWN (MODBUS) dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of a trip command is issued through Modbus.
CONFIGURATION MODE (I/O LOCK) dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of a trip due to the unit is in configuration mode.
LINKNET SUMMARY TRIP dflt= YES (Yes/No)

Select YES to energize the trip relay output in case of a trip due to any trip from Linknet.
Brake Menu
USE BRAKE dflt= NO (Yes/No)

If this function is selected, allows to configure the brake permissive.
MAXIMUM SPEED TO APPLY THE BRAKE (%) dflt= 50.0 (0.0, 100.0)
The brake is applied when the speed is below this value (in %). The control must be in STOP mode, the
gates must be closed and, the speed and gate signals must be valid.
BRAKE PULSE ON TIME DELAY (s) dflt= 15.0 (0.0, 10000.0)

Set the time (in seconds) of the brake pulse ON.
BRAKE PULSE OFF TIME DELAY (s) dflt= 10.0 (0.0, 10000.0)
Set the time (in seconds) of the brake pulse OFF.
MAXIMUM TIME TO APPLY THE BRAKE (s) dflt= 60.0 (0.0, 10000.0)
Set the maximum time (in seconds) that the brake will be applied.
Communications Menu
Each of the ETHERNET ports is required to be configured for

a unique subnet (domain) (view default settings as an
example).
The IP’s can be set by other service tools.

The top of the screen shows the current IP addresses in use

on for each port
Ethernet IP Configuration
ENET 1 ADDRESS dflt= 172.16.100.15 (0, 255)

Enter the integers corresponding to the network TCP/IP address
ENET 1 SUBNET MASK dflt= 255.255.0.0 (0, 255)

Enter the integer corresponding to the network subnet mask
SET IP1 dflt= NO (Yes/No)

Press this button to trigger resetting the IP of ENET 1 to the entered value






GATEWAY dflt= 0.0.0.0 (0, 255)

Enter the integers corresponding to the network gateway.
Note: the ENET 4 address is not changeable at the front panel. It is always available for service tools and
is defaulted to the following:
ENET 4 ADDRESS 192.168.130.20

ENET 4 SUBNET MASK 255.255.255.0
Modbus Configuration
USE MODBUS dflt= NO (Yes/No)

Set to YES to use the Modbus communications feature of the 5001. There are 3 identical Modbus ports
available; 1 via the Serial port and 2 available via Ethernet. Select NO if Modbus communications will not
be used.
USE SERIAL LINK 1? dflt= NO (Yes/No)

Set to YES to use the serial Modbus port.
USE ETHERNET LINK 2? dflt= NO (Yes/No)

Select a protocol to use the Modbus Link 2 via Ethernet. This will be available on an RJ45 connection to
Ethernet Port 1. Selecting UDP will use port 5001.

USE ETHERNET LINK 3? dflt= NO (Yes/No)

Select a protocol to use the Modbus Link 3 via Ethernet. This will be available on an RJ45 connection to
Ethernet Port 2. Selecting UDP will use port 5002.
Modbus – Link 1 - Serial
DEVICE ADDRESS dflt= 1 (1, 247)

Enter the integer corresponding to the Modbus device number/address required.
ENABLE WRITE COMMANDS dflt= NO (Yes/No)

Select YES to allow this Modbus link to write values to the control. If NO, it will be read only.

PROTOCOL dflt= ASCII (ASCII, RTU)

Select ASCII or RTU to determine the format of the Modbus communications.
BAUD RATE dflt= 115,200

Select the communications baud rate.
BITS dflt= 115,200

Select the integer corresponding to the bits required.
STOP BITS dflt= 1 (1, 2, 1.5)

Select the stop bits required.
PARITY dflt= NONE (NONE, ODD, EVEN)

Select the parity required.
DRIVER dflt= RS-232 (RS-232, RS-422, RS-485)

Select the serial communications mode required. Enter RS-232, RS-422, or RS-485 communications.
Modbus Ethernet Link 2
ETHERNET Port 1 – IP Address = <display only>
ETHERNET PROTOCOL dflt= TCP (TCP, UDP port 5001)

Select TCP or UDP to determine the Ethernet communication protocol. Selecting UDP will use port 5001
for Link 2.


ETHERNET Port 2 – IP Address = <display only>
ETHERNET PROTOCOL dflt= TCP (TCP, UDP port 5001)

Select TCP or UDP to determine the Ethernet communication protocol. Selecting UDP will use port 5002
for Link 3.



Analog Inputs Menu
No two analog inputs can be programmed for the same function.
ANALOG INPUT #1
INPUT FUNCTION (must choose from list)
Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER, using
the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the option/function. Press
the ESC key to cancel the selection.
See table 23 for the list of functional options:
4 mA VALUE (UNITS) dflt= 0.0 (-1.0e+38, 1.0e+38)

Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog input.
20 mA VALUE (UNITS) dflt= 100 (-1.0e+38, 1.0e+38)

Set the value (in engineering units) that corresponds to 20 milliamps (mA) on the analog input.
(Must be greater than the ‘Input 4 mA Value’ Setting)
LOOP POWERED dflt= NO (Yes/No)

Check this box if the 5001 should provide loop power for the transmitter.
In previous 505 models, there were jumpers that determined it this

function was used or not. When upgrading the user will need to remove
the cover of the old 505 to determine the proper setting for this option
DEVICE TAG
This is a user entered field. It allows entry of a short description or tag name for this channel.
UNITS
This is a user entered field. It allows entry of a unit label for this channel.
MODBUS MULTIPLIER dflt= 1.0 (0.01, 0.1, 1.0, 10, 100)

This is the multiplier that will be used for this parameter address on the 5001 slave Modbus
communication link
DECIMALS DISPLAYED dflt= 1.0 (0, 1, 2, 3)

This is the number of decimals to be displayed on the 5001 screens for this parameter
Analog Inputs #2 through #8 are configured following the same rules as described for Analog Input #1.
The Device Tag is a text field that is available for the user to
enter a unique name or identifier for each I/O channel. Enter
Text characters by focusing on the field, press Enter, then

Entering Text press and hold down the alphanumeric keys – they will cycle
through the available characters on that key
Analog Outputs Menu
All 4–20 mA analog readouts may be configured.
ANALOG OUTPUT #1
OUTPUT FUNCTION (must choose from list)
See table 25 for the list of functional options:
4 mA VALUE (UNITS) dflt= 0.0 (-1.0e+38, 1.0e+38)

Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog output.
20 mA VALUE (UNITS) dflt= 100 (-1.0e+38, 1.0e+38)

Set the value (in engineering units) that corresponds to 20 milliamps (mA) on the analog output.
(Must be greater than the ‘Input 4 mA Value’ Setting)
DEVICE TAG
UNITS
This is a user entered field. It allows entry of a unit label for this channel.
ENABLE READBACK FAULT ? dflt= NO (Yes/No)

Select YES to issue an alarm when an actuator fault is detected. If YES, the 5001 will issue an alarm if
the analog channel has a fault. If NO, no fault alarm will be issued. A fault will be determined if the current
drops below the failure level or if the difference between the current detected on the source and return
wires of the circuit is greater than approximately 5%. It is recommended to enable this feature when the
Analog Output channel is configured as the “Isolated PID Demand Output” function.
Analog Outputs #2 through #6 are configured following the same rules as described for Analog Output #1.
Driver Configuration Menu
ACTUATOR #1
ACTUATOR FUNCTION dflt= NOT USED (Gate Demand/Blade Demand)
ACTUATOR RANGE dflt= 4-20 mA (0-20, 0-200)

Select the actuator channel output current range. Select 4–20 mA or 20–200 mA. The range can be
adjusted via calibration, for example, for a 20-200 mA actuator select the 0-200 mA range.
mA AT 0% DEMAND (mA) dflt= 4.0/20.0 (0, 25 or 200)

Set the mA value that corresponds to 0% demand.

mA AT 100% DEMAND (mA) dflt= 20.0/160.0 (0, 25 or 200)

Set the mA value that corresponds to 100% demand.
DITHER dflt= 0.0 (0.0, 20.0)

Enter the dither mA amount for the actuator channel. Enter 0.0 if no dither is required. Woodward TM-
type actuators typically require dither.
USE ACTUATOR FAULT SHUTDOWN dflt= YES (Yes/No)

Select YES to issue a trip whenever an actuator fault is detected. If YES, the 5001 will issue a shutdown if
Actuator 1 has a fault. If NO, an actuator fault alarm will be issued when a fault is detected. An actuator
fault will be determined if the current drops below or goes above the failure levels, basically checking for
an open or a short circuit in the actuator wires/coil
TRIP = 0mA dflt= YES (Yes/No)

When set to YES any TRIP condition will ‘open’ the actuator circuit and result in 0 mA of current to the
actuators. If set to NO then a TRIP condition will set the demand to 0% and the current will go to the
minimum current value, for example 4 mA for a 4-20 mA configuration.
Note: The Emergency Stop button on the front panel is unique. It is a hard wired circuit that is
independent of the control application s/w and will directly ‘open’ the actuator output current drivers. This
button always results in 0 mA to the two actuator output channels.
REVERSE ACTUATOR dflt= NO (Yes/No)

Set to YES to invert actuator driver output. This is normally set to NO. When Set to YES, unless the front
panel Emergency Stop button is used, the actuator output will go to 20 mA at shutdown.
DEVICE TAG
TYPE OF CONTROL dflt= INTEGRAL (Proportional/Integral)

If selected for Proportional the control will send the current proportional to the percent of demand, if
selected to Integral the control will send 50% of demand and increase or decrease this current until the
gate or blade reaches the desired position.
USE 2-STAGE ACTUATOR? dflt= YES (Yes/No)

If YES is selected, the control will drive both gate / blade and the proportional valve. If NO, the control will
drive only the gate / blade (one stage)
Actuator #2 is configured following the same rules as described for Actuator #1.
Contact Inputs Menu
No two contact inputs can be programmed for the same function.
CONTACT INPUT #01

FUNCTION Emergency Stop
This channel is a dedicated trip input.
DEVICE TAG
INVERT LOGIC? dflt= YES (Yes/No)

Select this to invert this contact input. Note that this is not required for External Trip inputs because the

“Normal” or “Non-Inverted” functionality is already failsafe (CLOSED/TRUE = healthy, OPEN/FALSE =

trip).
CONTACT INPUT #02

FUNCTION (must choose from list)
DEVICE TAG
INVERT LOGIC? dflt= NO (Yes/No)

Select this to invert this contact input. Inverting means that a function normally activated when CLOSED
or TRUE and will not be activated when the contact is OPEN or FALSE.
Contact Inputs #3 through #20 are entered following the same rules as described for Contact Input #2.
Relay Menu
You may configure up to seven relays in addition to the one pre-assigned relay (Shutdown).
RELAY OUTPUT #1
FUNCTION Trip Relay
This channel is a dedicated trip output
DEVICE TAG

Use to invert the normal status of the relay. Note that Normally Open and Normally Closed contacts are
available when wiring to the relays and that these states will be inverted. In the event of a control power
failure, the contact will return to its normal state.
RELAY OUTPUT #2
FUNCTION (must choose from list)
DEVICE TAG

Use to invert the normal status of the relay. Note that Normally Open and Normally Closed contacts are
available when wiring to the relays and that these states will be inverted. In the event of a control power
failure, the contact will return to its normal state.
Relay Outputs #3 through #8 are entered following the same rules as described for Relay Output #2.

Woodward Links Menu
The 5001 is able to easily interface with other Woodward product via a variety of digital communications
links. This section allows the user to quickly configure the control to send and receive data from these
devices. Most of the default settings shown for these devices below match the described products default
settings (such as baud rates and subnet masks) to allow ‘out of the box’ compatibility.
LINKNET I/O NODES

Enable Using LinkNet HT I/O Nodes? dflt= NO (Yes/No)
Enable Node 1 (AIO) dflt= NO (Yes/No)
If YES – set the Node Address on this device to 1
Enable Node 2 (AIO) dflt= NO (Yes/No)
Enable Node 3 (RTD) dflt= NO (Yes/No)
Enable Node 4 (BI) dflt= NO (Yes/No)
Enable Node 5 (BO) dflt= NO (Yes/No)
General comments about using Linknet distributed I/O:

• Once configured a LinkNet I/O button will appear on the HOME run screen to provide quick
access to the channel and node status info
• It is not intended that these channels be used for closed loop control PV signals or valve driver
output signals – use 5001 local channels for those signals
• There is no ‘Loop Powered’ configuration selection for AI’s – this is determined by the p/n of the
AIO node that is purchased
• It is not recommended to program External Trips on these channels, since a loss of a node or the
CAN communication link will result in a Trip
• Linknet I/O specific alarms and/or trips, relating to channels or nodes will produce a summary
event on the VIEW screens. From the VIEW screen a button will be available to display these
specific events
• The addition of vibration monitoring signals was designed to be done via the Vibration Wizard tool
to help configure Vibration monitoring channels (1-8) on NODE 1. They must be done this way to
have access to the gauge/monitoring screen for vibration that is available from the Startup Curve
page, therefore it is recommended that all vibration sensors be connected to NODE 1.
For Nodes 1 and 2 –
Each node has 8 analog input and 2 analog output channels. For information on these configuration
parameters refer to the ‘Analog Inputs Menu’ and the ‘Analog Outputs Menu’ sections above.
Under the VIB Wizard screen –

Use Node 1 for Vibration Signals? dflt= NO (Yes/No)
How many signals (1-8)? dflt= 1 (1,8)
Enter the number of vibration sensors that will be connected to the 5001
Number of healthy signals required to run (1-8)? dflt= 0 (1,8)
Enter minimum total number of channels required to keep running. If this number equals the
number of channels used, then a single channel fault will result in a Trip
Under the Node Events screen –
Analog Input xx Signal – (for each AI channel)

Use Alarm Setpoint 1? dflt= NO (Yes/No)
Use Alarm Setpoint 2? dflt= NO (Yes/No)

Use Level 2 Setpoint as a TRIP? dflt= NO (Yes/No)
Level 1 Setpoint (eng units) dflt= 0.0 (-90000, 90000)

Enter the alarm level 1 setting in engineering units.
Invert Action on this alarm? dflt= NO (Yes/No)
Level 2 Setpoint (eng units) dflt= 0.0 (-90000, 90000)
Enter the alarm level 2 setting in engineering units
Invert Action on this alarm? dflt= NO (Yes/No)
Setpoint hysteresis (eng units) dflt= 0.0 (-100, 100)
Enter the hysteresis setting in engineering units for both alarms. A negative setting will allow
the event to occur at the programmed setpoint and stay true until the value falls below the
setpoint by this amount
Delay for Event Action (sec) dflt= 2.0 (0, 300)
Enter any desire delay to avoid nuisance events – this delay is applied to both events
Enable Speed Setpoint (rpm) dflt= 100.0 (0, 10000)
Enter a value here to inhibit any event from this channel until the turbine has reached this
speed
Enable Speed Hysteresis (rpm) dflt= 10.0 (-100, 100)
Enter a hysteresis value here that will be applied to the speed setpoint.
LINK TO DSLC-2 (TCP Modbus on Ethernet Port 3)

Use a DSLC-2 (Digital Synchronizer/Load Control)? dflt= NO (Yes/No)
(Radio buttons select one).
Use Synchronization? _____
Use Sync/Load Share? _____
Use KW Signal Only? _____
Device Slave Address (1-255) dflt= 247 (1, 255)

Device IP Address dflt= 192.168.1.3 (0, 255)
Enter the integers corresponding to the network TCP/IP address.
5001 ENET3 IP Address dflt= 192.168.129.20 (0,
255)
LINK TO VS-II (Digital valve positioner (DVP) on CAN Port 1)

Enable the CAN 1 network interface Link? dflt= NO (Yes/No)
Using a VariStroke II Actuator dflt= NO (Yes/No)
DVP1 Device ID (1-31) dflt= 1 (1, 31)
Enable DVP1 AI Backup dflt= NO (Yes/No)
If selected – program an Actuator channel as same demand and connect to VS-II
DVP1 FUNCTION dflt= none
Select desired function – gate or blade demand
Using 2 VariStroke II Actuator? dflt= NO (Yes/No)
If yes a pop-up will be available with following parameters
DVP2 FUNCTION dflt= none
Select desired function – gate or blade demand
DVP2 Device ID (1-31) dflt= 2 (1, 31)
Enable DVP2 AI Backup dflt= NO (Yes/No)
If selected – program an Actuator channel as same demand and connect to VS-II
LINK TO HIGHPROTEC (TCP Modbus on Ethernet Port 3)

Use a HighProtec (Generator Protection Unit)? dflt= NO (Yes/No)
Device Slave Address (1-255) dflt= 247 (1, 255)
Device IP Address dflt= 192.168.1.5 (0, 255)
LINK TO MFR300 (CAN on Port 3)

Use an MFR300 (Multfunction Protection Relay)? dflt= NO (Yes/No)

Device ID dflt= 0 (1, 127)
Defaulted to 0 so it will not conflict with LS-5 (more commonly used) the MFR300 is factory
defaulted to device ID 1
Baud Rate (0-3) dflt= 1 (0, 3)
0=100K, 1=250K, 2=500K, 3=1M
System Configuration dflt= Wye (Delta/Wye)
Exiting the Configure Mode
Once the programming steps have been completed, the Configuration mode can be exited. To exit the
Configure mode the User Level must still be logged in with Configure privileges. Then the ‘Exit
Configuration’ softkey will be available on the MODE screen. Pressing this initiates the 5001 to save the
configuration and exit IO Lock. If there are no errors in the configuration, the 5001 will be in the Shutdown
state. At this point it may be ready to reset and run but, if this is the first time the 5001 has been
configured with the unit’s actuator/linkage/valve, then it is recommended to run the valve stroking
procedure in calibration mode and adjust current limits as needed. However, if there is an error in the
program, the 5001 will be in a shutdown state and unable to reset. Configuration errors can be viewed by
going to the Configuration Menu (softkey on the HOME/main menu screen) and pressing the ‘Config
Check’ softkey. The next section identifies the various configuration error messages and explains the
meaning of the error.
There is a procedure in the Appendix on how to restore a unit to the original factory defaults, using a
service tool
Configuration Error Messages
The control automatically performs a check on the configured values to assure that required program
blocks have values loaded into them. This check cannot determine if the values entered are realistic but it
makes sure that values have been loaded into required parameters. If any errors are found in the
program, the 5001 will remain in a shutdown state and a banner message will appear on the
Configuration Menu and MODE screens. They can be displayed by pressing the ‘Config Check’ softkey
on the Configuration Menu screen.
The configuration error message alerts you that a configuration change is required before the 5001 can
operate the turbine. All errors must be corrected before in order to be able to reset the 5001 to the “Ready
to Start” condition.
The table below identifies the various configuration error messages that may appear and explains the
meaning of the error.


Table 30: Configuration Error Messages
Event ID Description Error Meaning

1 Flex500 Software not Licensed The license key was not entered.
Two analog inputs were programmed for the same
2 Duplicate Analog Input Channel
function.
Two contact inputs were programmed for the same
3 Duplicate Contact Input Channel function.
No gate actuator channel has been configured. This is
4 Gate Actuator Not Configured
required for control of the hydro turbine.
Both actuator channels have been configured for the
Duplicate Gate Actuator
5 Gate valve functionality. This function is only allowed
Configured
on one channel.
The failed speed setting for speed input #1 is below
Speed Sensor #1 Failed < Freq the minimum allowed setting. The minimum allowed
6
Range setting is calculated as follows: (Maximum Speed
Level) * (0.0204).
The failed speed setting for speed input #2 is below
Speed Sensor #2 Failed < Freq the minimum allowed setting. The minimum allowed
7 Range setting is calculated as follows: (Maximum Speed
Level) * (0.0204).
Both actuator channels have been configured for the
Duplicate Blade Actuator
8 Blade valve functionality. This function is only allowed
Configured
on one channel.
Blade Act Configured - Francis The unit is configured for Francis turbine and requires
9 Turbine a blade valve driver to be configured
No turbine type is selected in the Configure mode. One
10 Turbine Type Not Configured of the two options must be selected in the Configure
mode under the Operating Parameters menu.
A blade actuator channel has been configured for a
11 Blade Actuator not Configured
Francis turbine
Analog Speed Bias - AI not The analog speed bias function was configured but no
12 Configured analog speed bias analog input was configured.
The digital speed bias function was configured but
Digital Speed Bias - DI not
13 neither speed bias raise nor speed bias lower contact
Configured input was configured.
Creep Detection - DI not The creep detection was enabled but neither creep
14
Configured input #1 nor creep input #2 was configured.

Valve/Actuator Calibration & Test

Before initial operation or after a turbine overhaul where any actuator or valve travel may have been
affected, the below Valve Calibration procedure should be followed to ensure that the 5001 is correctly
calibrated to the turbine control valve(s). When calibration is complete, 0 to 100% actuator position as
displayed by the 5001 must equal 0 to 100% actual valve travel.
After a valid configuration has been entered, the actuator and valve minimum and maximum positions can
be adjusted and tested, if needed. Actuator and valve positions are determined by the drive current to the
actuator. The maximum actuator current cannot be adjusted lower than the minimum actuator current
(see Table 30 below). The minimum actuator current cannot be adjusted higher than the maximum
actuator current. The driver current ranges are determined by the setting in the Configuration Mode under
the Driver configuration menu.
When adjusting or testing actuator and valve travel, verify that sufficient valve overtravel at the minimum
stop is achieved (1%). This assures that each valve can fully close to completely shut off the steam flow
to the turbine.
Table 31: Actuator Driver Limits
Driver Limits 20–200 mA Range 4–20 mA Range

Overcurrent 210 mA 24 mA
Undercurrent 5 mA 0.6 mA
Max Output Current Range 10–200 mA 2–24 mA
Max Output Impedance 65 W 600 W
Min Stop Adjust Range 10–80 mA 2–20 mA
Max Stop Adjust Range 100–200 mA 10–24 mA
To ensure proper control to actuator resolution do not calibrate the span of the actuator output to less
than a range of 100 mA (20–160 mA output) or 12 mA (4–20 mA output). If necessary, the actuator to
valve linkage may need to be adjusted to ensure proper 5001 to valve resolution.
Calibration Mode, required to force/stroke the actuator(s), is only available when the 5001 control is in a
shutdown state. After enabling Calibration Mode, there are options available to adjust the minimum and
maximum stops and to manually stroke the output(s). The manual adjustment mode can be used to
stroke the actuator and valves from 0 to 100% after the minimum and maximum positions have been
adjusted. This allows both the actuator and valve to be tested for binding, play, resolution, linearity, and
repeatability.
As a safety precaution, if turbine speed ever exceeds either of the speed probe failed speed settings the
Calibration mode will be automatically disabled, which disables forcing of the actuator and takes actuator
currents to zero.
Calibration/Stroking Procedure
Before calibrating or testing, the unit must be tripped and the
water supply removed. This is to ensure that opening the
control valve(s) will not allow water into the turbine.
Overspeeding the turbine may cause damage to turbine and
can cause severe injury or death to personnel. WATER TO
THE TURBINE MUST BE SHUT OFF BY OTHER MEANS
DURING THIS PROCESS.
1. The 5001 must be shutdown to enter Calibration Mode.

2. Go to the MODE screen by pressing the MODE key.
3. Enter Calibration Mode by pressing the ‘Calibration’ softkey. The following permissive must be
met:
a. Unit Shutdown
b. No Speed Detected
c. Appropriate User Level Login
4. Navigate to the Actuator Driver Summary page by pressing the ‘Drivers’ in either the HOME
menu or Configure menu.
5. Select the desired Actuator channel.
6. In the Actuator channel screen, press the ‘Calibration’ softkey to access the calibration options.
7. Verify the green “Calmode Enabled” LED is ON to confirm that the unit is in Calibration Mode.
8. Press the ‘Forcing’ sofkey and then confirm on the popup that actuator forcing can be enabled.
Select ‘OK’ and press ENTER to enable forcing.
9. Verify that the green “Forcing Enabled” LED is now also ON.
10. Use the focus navigation to select and adjust items on the screen (Manual Adjust, Goto Demand,
Force Rate, etc.).
11. 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 key to the
change the values.
12. Press the ‘Commands’ softkey to access other commands such as “Go to Min”, Go to Max”, and
“GO”. “GO” can be used with the “Goto Demand” value.
13. When finished, make sure to save the settings by pressing any ‘Save Settings’ softkey. A ‘Save
Settings’ softkey can be accessed on the MODE screen.
14. Exit Calibration Mode by pressing the ‘Exit Calmode’ softkey 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
channels.
If changes are made to the minimum or maximum current values, they can be recorded on the Configure
Mode worksheets. Exiting the Calibration Mode or Forcing Mode will not permanently save any calibration
changes
Press the ‘Save Settings’ softkey to permanently save any minimum or

maximum actuator settings into the 5001. If variables are tuned or
changed but not saved, then those changes will be lost if power is
removed from the control or if the control receives a CPU reset.

Chapter 10 – Service Menu Procedures
Overview
The service menu of the 5001 control has the same easy to follow format as the program/configure mode.
The service menus can be used to customize the control to be more application specific. The parameters
that are tuned in the service menus affect system performance, caution is advised.
The service menus of the 5001 can be accessed at any time the control is powered up, and with any user
level access. The turbine doesn’t need to be shutdown. This will allow tuning while the turbine is on-line.
The ability to change these parameters is restricted to service user level and above. The appropriate
password is required to protect against both intentional and inadvertent program changes.
Enter the LOGIN button from the MODE screen to reach the screen below.
Figure 44: User Login for Service
To login to the Service user level, Press the MODE key, press the soft key for LOGIN, and log in as
“Service” by entering the password (wg1112). The actual menus that are available may vary with the
program configuration.
Using the Service Menus

Once logged in with an appropriate user level, parameters within the Service menus will become
available for adjustment. See Figure below for an example of how to see that a parameter is authorized,
use a work sheet (provided at the end of this manual), to document any changes for future reference.

Figure 45:Authorized and Unauthorized Components
The STEP RIGHT and STEP LEFT keys, allow you to move right, or left across the tops of the function
the Service mode columns. The STEP UP and STEP DOWN keys allow you to move up or down the
columns.
Not all the service headers listed below will be available at all times.
The Service menu is accessed from the Home screen by pressing the second soft key (from the left). Use
the navigation cross allows for navigation of the Service menus. Press ENTER to go into a menu. There
are two Service menu selection pages which can be viewed by pressing the arrow soft keys. The
available menus depend upon the configuration of the unit. Parameters within the Service menus can be
adjusted at any time, independent of the current Mode. The user must be logged in with Service user
level access or higher to have authorization to change Service parameters.
From within a Service menu, pressing the HOME key once will return to the Service menu screen. To
return to the main Home screen, press the HOME key again. To return to the last screen, press the ESC
key.
HOME screen
The following figures show the menu list of pages that are available through the Service Menus. The
Tutorial pages and the Save Settings (updating tunable values on the control) are always available on the
black Soft Key buttons without any focus or navigation. Features that exist in the control but are not
configured will be shown in reduced opacity so the user is aware of the feature. Pressing Enter while on
these pages will not navigate to these pages. This is different from the HOME page, where unused
functions are completely removed to avoid confusion and simplify navigation.

Figure 46: Service Menu (page 1)
Figure 47: Service Menu (page 2)
The service menus can be used while the turbine is running or shutdown. Access to the Service menus
requires the user to be logged in with a Service user level or higher.
This mode can also be used to make direct numeric entries. However, because this mode is intended to
be used while the turbine is running, the Service Panel will accept the entry of numeric values for a block
only if the proposed change is small.

Service Menu List
Turbine Start: Monitor or change the program or default settings of stable speed window and incomplete
start.
Turbine Stop: Monitor or change the program or default settings of incomplete stop.
Speed Control: Monitor or change the program or default speed control dynamics (offline, small system,
online and load).
Speed Signals: monitor or change program or default settings of speed sensor override timer, deadband
and filter. If permissive is ok, it allows to enable remote speed control.
Gate Parameters: monitor or change program or default settings of speed-no-load; dwell time; start gate
rate; breakaway limit, gate limiter; gate load rejection.
Position/kW Droop: monitor or change program or default settings of the droop type in use and
configure the Gate x Power curve used in case of failure in the power sensor
Level Control: monitor or change program or default settings of level control.
Baseload: monitor or change program or default settings of baseload or remote baseload control.
Blade Parameters: monitor or change program or default settings of blade.
Blade Curves: monitor or change program or default settings of blade position based on gate position
and net head value.
Valve Driver: monitor or change program or default settings of loop control for the valve position.
Valve Mismatches: monitor or change program or default settings of valve mismatches errors and
delays.
Manual/Maintenance: monitor or change program or default settings of manual/maintenance for the gate
or blade.
Custom Trend: trend display; signal selection; time window for trend display.
Field Tools: monitor or change program or default settings of step test and gate timer.
Data Log: manually start and stop data log collection.
Operation Log: view operation log values. Adjust turbine operation values.
Screen Options: screen saver delay; select auto login as operator.
Real Time Clock: set date and time settings.
Communications: change or view the default settings for Ethernet, Serial, and Modbus communication
links.
DSLC-2: generator voltages, currents, real power, reactive power; communications link status.
VariStroke: CAN communication status; demand; position feedback; alarms; shutdowns.

MFR300: generator voltages, currents, real power, reactive power; CAN communication status.
High Protec: generator voltages, currents, real power, reactive power; communication status.
Service Mode Parameters

Turbine Start Menu
LOW SPEED TO STABLE SPEED (%) dflt= 98.0 (90.0, 102.0)

Minimum speed in percentage to consider that the turbine is stable.
HIGH SPEED TO STABLE SPEED (%) dflt= 102.0 (98.0, 110.0)

Maximum speed in percentage to consider that the turbine is stable.
TIME TO STABLE SPEED (s) dflt= 15.0 (1.0, 120.0)

This is the time in seconds that the turbine should be between “Low Speed to Stable Speed” and “High
Speed to Stable Speed” to consider that the turbine is stable.
TIME TO INCOMPLETE START (s) dflt= 600.0 (1.0, 600.0)

It is the time in seconds that the software will wait until the turbine reaches the “Minimum Speed for
Incomplete Start” parameter. If this does not happen an Incomplete Start trip will occur.
MINIMUM SPEED FOR INCOMPLETE START (%) dflt= 25.0 (-10.0, 100.0)
This is the minimum speed in percentage that the control will consider turbine started.
Turbine Stop Menu
SPEED TO CONSIDER TURBINE STOPPED (%) dflt= 2.0 (0.0, 100.0)

Maximum speed in percentage to consider that the turbine is stopped.
TIME TO INCOMPLETE STOP (s) dflt= 800.0 (0.0, 1200.0)

That in seconds that the control will wait to send a incomplete stop trip if the speed is still greater than the
“Speed to consider turbine stopped” parameter.
WAIT BREAKER OPEN TO START TIMER dflt= NO (Yes/No)

If this parameter is YES the timer will start only when the breaker opens, otherwise the timer will start
immediately after the stop command.
ENABLE INCOMPLETE STOP TRIP dflt= YES (Yes/No)

If YES, this parameter will enable the incomplete stop trip.
Speed Control Menu
OFFLINE DYNAMICS
PROPORTIONAL GAIN dflt= 3.85 (0.001, 100.0)
Enter the offline PID proportional gain percentage. This value is used to set speed/load control response
when the Generator breaker contacts are open.
INTEGRAL GAIN dflt= 0.03 (0.001, 100.0)
Enter the offline PID integral gain percentage. This value is used to set speed/load control response when
the Generator breaker contacts are open.

DERIVATIVE GAIN dflt= 100.0 (0.01, 100.0)

Enter the offline PID derivative gain percentage. This value is used to set speed/load control response
when the Generator breaker contacts are open.
SPEED-NO-LOAD-REFERENCE (%) dflt= 100.05 (75.0, 125.0)
Initial speed setpoint in percentage when the turbine is accelerated until rated speed.
MINIMUM SPEED REFERENCE (%) dflt= 90.0 (0.0, 100.0)
Minimum offline speed reference in percentage
MAXIMUM SPEED REFERENCE (%) dflt= 110.0 (75.0, 250.0)
Maximum offline speed reference in percentage
TEMPORARY COMPENSATION dflt= 0.05 (0.0, 10.0)
Enter the compensation factor.
SMALL SYSTEM
USE SMALL SYSTEM DETECTION dflt= YES (Yes/No)
If this parameter is YES the small system detection algorithm will be used
USE SPEED STABLE SETPOINT DELAY dflt= YES (Yes/No)
If this parameter is YES the algorithm will wait for the speed stabilization according to the parameters
configured in “Speed Setpoints”
SPEED WINDOW TO ACTIVATE SSD (%) dflt= 1.0 (0.1, 100.0)
Speed window to activate the Small System Detection (SSD) algorithm. If the speed is out of this window
the algorithm will be activated
SPEED DERIVATIVE TO ACTIVATE SSD (%) dflt= 10.0 (0.1, 100.0)
Speed derivative window to activate the algorithm. If the speed derivative is out of this window the
algorithm will be activated
USE BREAKER STATUS dflt= YES (Yes/No)
If this parameter is YES the small system detection algorithm will be on only after the turbine the breaker
is closed.
USE TIMER DELAY AFTER BREAKER CLOSES dflt= YES (Yes/No)
If this parameter is YES the small system detection algorithm will wait the “Delay” after the breaker closes
to start monitoring the system.
DELAY (MINUTES) dflt= 5.0 (0.1, 10000.0)
Set the time in minutes the algorithm must wait to be active after the breaker closes.
USE DISABLE TIMER DELAY dflt= NO (Yes/No)
If this parameter is YES the small system detection algorithm will reset after the “Delay” time expires.
After this reset, the algorithm will start to monitor again.
DELAY (MINUTES) dflt= 10.0 (0.1, 10000.0)
Set the time in minutes the algorithm must wait to be reset after detecting a small system.
SMALL SYSTEM DYNAMICS

when a small system is detected.
INTEGRAL GAIN dflt= 0.05 (0.0, 100.0))
a small system is detected.
when a small system is detected.


ONLINE DYNAMICS
when the Generator breaker contacts are closed.
the Generator breaker contacts are closed.
when the Generator breaker contacts are closed.
FIRST CONTROL MODE WHEN BREAKER CLOSES dflt= POSITION/kW DROOP CONTROL
It defines the initial control mode when the generator breaker is closed. The options are: Baseload, Level,
Remote Baseload or Position/kW Droop Control.
PID CLAMP WINDOW (%) dflt= 4.0 (0.0, 5.0)
Set the PID clamp window value in percentage to eliminate setpoint wind up in the control
LOAD DYNAMICS
when the unit is in Baseload or Remote Baseload Control.
the unit is in Baseload or Remote Baseload Control.
when the unit is in Baseload or Remote Baseload Control.
Speed Signal Menu
OVERRIDE OVERSPEED TRIP AFTER START (s) dflt= 10.0 (1.0, 600.0)
Time in seconds that the control will wait to enable the overspeed trip and pickup alarms after a start
command.
OVERRIDE TIMER REMAINING (s) <display only>

Remaining time to enable overspeed trip and pickup alarms.
DEADBAND SELECTION dflt= Deadband Online Only (must choose from list)
the ESC key to cancel the selection. The speed deadband function can be enabled at all times, disabled
at all times, or only when the unit is online.
SPEED DEADBAND (%) dflt= 0.05 (0.0, 5.0)

Set the speed deadband window in percentage.
SPEED SENSOR #1 FILTER dflt= 0.01 (0.001, 5.0)

Set the lag in the speed sensor #1.
SPEED SENSOR #1 (rpm) <display only>

Shows the speed in rpm detected by the speed sensor #1.

SPEED SENSOR #2 FILTER dflt= 0.01 (0.001, 5.0)

Set the lag in the speed sensor #2.
SPEED SENSOR #2 (rpm) <display only>

Shows the speed in rpm detected by the speed sensor #2.
ENABLE REMOTE SPEED CONTROL

Enables the remote speed control. All the permissive must be OK before enabling remote control.
Gate Parameters Menu
GATE CONFIGURATION
MAXIMUM GATE LIMIT (%) dflt= 100.0 (0.0, 100.0)
Set the maximum gate limit in percentage.
BREAKWAY LIMIT (%) dflt= 25.0 (0.0, 100.0)
Set the breakaway limit in percentage.
DWELL TIME (s) dflt= 15.0 (0.001, 30.0)
Set the dwell time in seconds.
SPEED NO LOAD GATE LIMIT (%) dflt= 15.0 (0.0, 100.0)
Set the speed no load gate limit in percentage.
START GATE RATE (%/s) dflt= 1.0 (0.01, 100.0)
Set the start gate rate in percentage per seconds.
STOP GATE RATE (%/s) dflt= 1.0 (0.01, 100.0)
Set the stop gate rate in percentage per seconds.
GATE LOAD REJECTION

ENABLE GATE LOAD REJECTION dflt= YES (Yes/No)
If YES, the load rejection logic will be used.
GATE POSITION VALUE (%) dflt= 7.0 (0.0, 100.0)
Set the value that will be used to the gate when a load rejection is detected.
SPEED DERIVATIVE THRESHOLD (%/s) dflt= 7.0 (0.0, 200.0)
Enter the speed derivative value that will be used to detect load rejection.
MAXIMUM ALGORITHM TIME (s) dflt= 7.0 (0.0, 600.0)
Maximum time in seconds that the load rejection load will be active. After this time even the speed is not
stable the speed control will be active again.
dflt= 110.0 (100.0, 200.0)
SPEED THRESHOLD (%)
Set the speed threshold in percentage that will be used to detect load rejection.
Position/kW Droop Menu
ACTIVE DROOP FEEDBACK <display only>

Displays the active droop feedback (kW Droop or Position Droop).
ACTUAL DROOP (%) <display only>

Displays the actual droop.
FORCE GATE X POWER CURVE WHEN IN KW DROOP MODE dflt= NO (Yes/No)

If YES, the control will always use the gate x power curve and ignore the active power sensor. This
function can be used to commissioning the table after the pre configuration is adjusted.


ENABLE KW DROOP
Enables kW droop feedback.
ENABLE POSITION DROOP

Enables position droop feedback.
GATE X POWER CURVE

Set the gate x power curve that will be used in case of the active power sensor fail.
Level Control Menu
LEVEL CONTROL TYPE dflt= Head Level Control (must choose from list)
the ESC key to cancel the selection. It defines if the control will use a head or tail sensor.
LEVEL SETPOINT TYPE dflt= Bumpless Transfer (must choose from list)
the ESC key to cancel the selection. It defines if the initial setpoint will be a preset value or the actual
level (bumpless transfer).
PRESET VALUE dflt= 0.0 (0.0, 30000.0)

Enter the initial value in case of the parameter “Level Setpoint Type” is set to preset level value.
FIXED SPEED IN LEVEL CONTROL dflt= NO (Yes/No)

If YES, the control will assume that the speed is always 100% and will not check the value read.
LEVEL SETPOINT RAISE/LOWER RATE (EU/s) dflt= 1.0 (0.01, 1000.0)

Set the rate that the setpoint will change when discrete inputs to raise or lower is closed. This rate is also
used for remote setpoint changes.
MINIMUM GATE SETPOINT (%) dflt= 20.0 (0.0, 100.0)

Set the minimum value that the level control can assume as setpoint.
MAXIMUM GATE SETPOINT (%) dflt= 100.0 (0.0, 100.0)

Set the maximum value that the level control can assume as setpoint.
LEVEL CONTROL WINDOW (EU) dflt= 0.5 (0.0, 10000.0)

This parameter defines the level control window. If the error is greater than this value in the positive way
the gate setpoint will be the maximum gate setpoint. If the error is greater than this value in the negative
way than the gate setpoint will be the minimum gate setpoint. If the error is between the window the
control will calculate an interpolation between minimum gate setpoint and the maximum gate setpoint to
define the gate setpoint.
ENABLE
Enables the level control. All the permissive must be OK before enabling the level control.
DISABLE
Disables the level control.

Baseload Menu
UNLOAD LEVEL (MW) dflt= 1.0 (0.0, 30000.0)

Set the load level in MW to be reached when an unload command is issued.
RATED LOAD (MW) dflt= 300.0 (0.0, 30000.0)

Enter the generator rated load in MW.
MINIMUM REFERENCE (MW) dflt= 1.0 (0.0, 30000.0)

Set the minimum possible load reference in MW.
MAXIMUM REFERENCE (MW) dflt= 300.0 (0.0, 30000.0)

Set the maximum possible load reference in MW.
INITIAL REFERENCE (MW) dflt= 5.0 (0.0, 30000.0)

Set the initial reference baseload when the control is enabled. This parameter is only valid if baseload is
the first control after the breaker is closed. If the baseload is enabled after the breaker is already closed
this parameter will not be used to prevent bump in the load.
TIME TO DECREASE (s) dflt= 150.0 (1.0, 2000.0)

Set the time in seconds to go from the maximum reference to the minimum reference.
TIME TO INCREASE (s) dflt= 150.0 (1.0, 2000.0)

Set the time in seconds to go from the minimum reference to the maximum reference.
ENABLE
Enables baseload control. All the permissive must be OK before enabling the baseload control.
DISABLE
Disables baseload control.
MINIMUM REMOTE REFERENCE (MW) dflt= 1.0 (0.0, 30000.0)

Set the minimum possible remote load reference in MW.
MAXIMUM REMOTE REFERENCE (MW) dflt= 300.0 (0.0, 30000.0)

Set the maximum possible remote load reference in MW.
TIME TO DECREASE (s) dflt= 150.0 (1.0, 2000.0)

Set the time in seconds to go from the maximum remote reference to the minimum remote reference.
TIME TO INCREASE (s) dflt= 150.0 (1.0, 2000.0)

Set the time in seconds to go from the minimum remote reference to the maximum remote reference.
ENABLE
Enables remote baseload control. All the permissive must be OK before enabling the remote baseload
control.
DISABLE
Disables remote baseload control.
Blade Parameters Menu
BLADE RATE (%/s) dflt= 3.0 (0.0, 1000.0)

Set the Rate that the blade will be moved when the setpoint is changed.

BLADE TILT VALUE (%) dflt= 0.0 (0.0, 100.0)

Set the value that the blade will assume when the blade tilt is enabled.
ENABLE START BLADE TILT dflt= YES (Yes/No)

If YES, the blade tilt is enabled.
START BLADE TILT VALUE (%) dflt= 30.0 (0.0, 100.0)

Set the value that the blade will assume when the start blade tilt is active.
SPEED TO DISABLE START TILT (%) dflt= 50.0 (2.0, 100.0)

Set the value to consider that the turbine is already started and the start blade tilt will be de-activated.
ENABLE TILT
Enables blade tilt control. All the permissive must be OK before enabling the blade tilt control.
DISABLE
Disables blade tilt control.
ENABLE STOP BLADE TILT dflt= YES (Yes/No)

If YES, the stop blade tilt will be enabled. The control sends the blade to a predefined value during the
stop of the turbine.
STOP BLADE TILT VALUE (%) dflt= 50.0 (0.0, 100.0)

Set the value that the blade will assume when the stop blade tilt is active.
SPEED TO DISABLE STOP TILT (%) dflt= 25.0 (2.0, 90.0)

Set the value to consider that the turbine is already stopped, and the stop blade Tilt will be de-activated.
ENABLE BLADE LOAD REJECTION dflt= YES (Yes/No)

If YES, the control sends the blade to a predefined value when a load rejection is detected.
BLADE LOAD REJECTION VALUE (%) dflt= 100.0 (0.0, 100.0)

Set the value that the blade will assume when a load rejection is detected, if this logic is enabled.
USE BLADE PRE POSITION ON STARTUP dflt= YES (Yes/No)

If YES, enables the blade preposition. This will send the blade to a predefined value before starting the
turbine.
WINDOW (%) dflt= 5.0 (1.0, 10.0)

When the blade real position is near the blade demand (preposition demand), this window will define if
the blade can be considered positioned to start the turbine.
STABLE TIME (s) dflt= 3.0 (1.0, 120.0)

Set the time that the blade should be stable to permit the turbine start.
MAXIMUM TIME (s) dflt= 35.0 (1.0, 120.0)

Set the maximum time to have the blade positioned. After this time an incomplete start trip will be issued.
LOCK BLADE
The control will lock the blade in the actual value. All the permissive must be OK before locking the blade.
UNLOCK BLADE
The control will unlock the blade.

Blade Curves Menu
This menu is used to configure the blade curves (for Kaplan turbines). These curves are used to
determine the blade position for each gate position and Net Head value. There are 14 available curves
and each curve has 11 available parameters.
Figure 48: Blade Curve
The fixed curve can also be configured in this menu. Fixed curve is used when the net head
measurement is not reliable or if the sensor is in fault condition. The blade will keep a position for each
gate position, and will not be worry about the net head value.
Figure 49: Blade Fixed Curve

It is also possible to define which action will be taken when the net head, head or tail sensor is failed. The
available actions are “Blade Lock”, “Revert to Manual Blade Control”, “Trip” or “Revert to Fixed Blade
Curve”.
Figure 50: Net Head Configuration
Valve Driver Menu
It is possible to configure the loop control for the valve position of the unit.
VALVE DRIVER - GATE

USE OFFLINE/ONLINE GAIN dflt= NO (Yes/No)
This parameter defines if one or two sets of gains will be used in the control. If the parameter is NO it
means that only the offline valve gain will be used, if YES, the offline valve gain will be used while the
generator breaker is opened, and the online valve gain will be used while the generator breaker is closed.
OFFLINE VALVE GAIN dflt= 1.0 (0.0, 50.0)
Set the valve gain when the generator breaker is opened or if configured to not use offline/online gain.
VALVE OFFSET dflt= 0.0 (-100.0, 100.0)
This parameter defines the offset related to the center of the valve null. For example, for a 4–20 mA valve
if the null is not 12 mA, but a little out of the 12 mA, it is possible to change the center to correct this.
ONLINE VALVE GAIN dflt= 1.0 (0.0, 50.0)
Set the valve gain when the generator breaker is closed.
ADAPTATIVE VALVE OFFSET CALCULATION
A series of parameters that automatically calculates the offset value. This algorithm is based in the
stationary position error of the proportional valve and adjust the offset in order get zero error. The
parameters of this algorithm are described below:
INITIAL VALVE OFFSET dflt= 0.0 (-100.0, 100.0)
That is the value of the offset when the button “Go to initial Value” is pressed or when the
algorithm is started.
ALGORITHM SAMPLE TIME (MIN) dflt= 15.0 (1.0, 30.0)
This is the time sample of the algorithm. For example, if it is configured for 15 minutes, it means
that the control will integer the position error during 15 minutes in order to define a new offset
value.
OFFSET MAXIMUM STEP CHANGE dflt= 0.2 (0.01, 5.0)
This is the maximum change between each sample time

ACTUAL VALVE OFFSET <display only>

Displays the actual valve offset.
START ALGORITHM
When pressed the algorithm will start running.
GO TO INITIAL
When pressed the offset will go to the “Initial Valve Offset”.
The adaptive algorithm is designed to correct small errors in

the valve. This logic should not be used to hide problems in
the valves, during the time.
VALVE DRIVER – GATE (PROP. VALE)

value.
START ALGORITHM
GO TO INITIAL


VALVE DRIVER – BLADE

value.
START ALGORITHM
GO TO INITIAL

VALVE DRIVER – BLADE (PROP. VALE)


value.
START ALGORITHM
GO TO INITIAL

Valve Mismatches Menu
It is possible to configure the error and delay related to the minor mismatch alarm and gross mismatch
trip. These mismatches errors are available for gate, blade, gate proportional valve and blade proportional
valve.
GATE MISMATCHES
ENABLE MINOR MISMATCH dflt= YES (Yes/No)
If YES, enables the gate minor mismatch alarm.
MINOR MISMATCH VALUE (%) dflt= 5.0 (1.0, 20.0)
Set the minor mismatch value in percentage.
MINOR MISMATCH ALARM DELAY (s) dflt= 15.0 (0.0, 90.0)
Set the time delay in seconds the gate position must match to the gate position demand before the unit
issues a “Minor Mismatch” alarm.
ENABLE GROSS MISMATCH dflt= YES (Yes/No)
If YES, enables the gate gross mismatch shutdown.
GROSS MISMATCH VALUE (%) dflt= 10.0 (1.0, 20.0)
Set the gross mismatch value in percentage.
GROSS MISMATCH SHUTDOWN DELAY (s) dflt= 30.0 (0.0, 90.0)
issues a “Gross Mismatch” shutdown.
GATE MISMATCHES (PROP. VALVE)

ENABLE MINOR MISMATCH dflt= NO (Yes/No)
If YES, enables the gate minor mismatch (prop. valve) alarm.
ENABLE GROSS MISMATCH dflt= NO (Yes/No)
If YES, enables the gate gross mismatch shutdown.


BLADE MISMATCHES
ENABLE MINOR MISMATCH dflt= YES (Yes/No)
If YES, enables the blade minor mismatch alarm.
Set the time delay in seconds the blade position must match to the blade position demand before the unit
If YES, enables the blade gross mismatch shutdown.
BLADE MISMATCHES (PROP. VALVE)

ENABLE MINOR MISMATCH dflt= NO (Yes/No)
If YES, enables the blade minor mismatch (prop. valve) alarm.
If YES, enables the blade gross mismatch shutdown.
Manual/Maintenance Menu
In the manual / maintenance screen it is possible to enable or disable the manual or maintenance mode
for the gate or blade (when Kaplan turbine) and adjust the rates for each control.
MANUAL GATE MODE

MANUAL RAISE/LOWER RATE (%/s) dflt= 0.5 (0.01, 20.0)
This is the rate that the gate setpoint will move when setpoint is entered from the front panel of the control
or from the communication
ENABLE
Enables manual control. All the permissive must be OK before enabling the manual control.
DISABLE
Disables the manual control.
MAINTENANCE GATE MODE

ENABLE

Enables maintenance gate mode. The turbine must be dewatered before enabling maintenance gate
mode.
DISABLE
Disables the maintenance gate mode.
MANUAL GATE MODE (PROP VALVE)

This is the rate that the gate setpoint will move when setpoint is entered from the front panel of the control
or from the communication
ENABLE
Enables manual control for proportional valve. All the permissive must be OK before enabling the manual
control.
DISABLE
Disables the manual control for proportional valve.
MANUAL BLADE MODE

This is the rate that the blade setpoint will move when setpoint is entered from the front panel of the
control or from the communication
ENABLE
Enables manual control. All the permissive must be OK before enabling the manual control.
DISABLE
Disables the manual control.
MANUAL BLADE MODE (PROP VALVE)

This is the rate that the blade setpoint will move when setpoint is entered from the front panel of the
control or from the communication
ENABLE
Enables manual control for proportional valve. All the permissive must be OK before enabling the manual
control.
DISABLE
Disables the manual control for proportional valve.
Custom Trend Menu
Opening Custom Trend page begins the trend, exiting the page will continue to record data in the
background. Trends can be paused using the soft-key. While paused, the data continues to record in the
background. Once resumed, the trend snaps to real time.
TIME WINDOW (s) dflt= 60 (1, 600)

Set the amount of time that is shown on the trend. This is the trend window time in seconds. Setting this
to ‘60’, for example, will show 60 seconds of data preceding the present time.


Parameter 1 (Red)
VARIABLE (set by user)
Select the parameter to be displayed by this trend line. The color that will appear for this parameter on the
trend is indicated to the left of this selection.
Y MAX dflt= 100 (-20000, 20000)
Set the maximum value for the Y axis on the trend for this signal. This sets the maximum vertical
limit of the trend display for the signal
Y MIN dflt= 0 (-20000, 20000)
Set the minimum value for the Y axis on the trend for this signal. This sets the minimum vertical limit
of the trend display for the signal
WIDTH dflt= 1 (1, 5)
Set the width of the line shown on the trend for this signal. To increase thickness of the line, this number
should be increased.
SHOW AXIS dflt= YES (Yes/No)
Set the maximum value for the Y axis on the trend for this signal. This sets the maximum vertical limit of
the trend display for the signal.
Parameter 2 (Green)
The configuration options are similar to that of Parameter 1. See Parameter 1 settings for a description of
each option
Parameter 3 (Blue)
each option
Parameter 4 (Purple)
each option
Parameter 5 (Orange)
each option
Field Tools Menu
STEP TEST
MAGNITUDE OF STEP INPUT (%) dflt= 1.0 (-10.0, 10.0)
Enter the magnitude of step input, in percent of rated speed.
STEP TEST LENGTH (s) dflt= 30.0 (0.0, 1200.0)
Enter the duration of the step
NEGATIVE STEP dflt= NO (Yes/No)
Set the step change as negative
REMAINING TIME (s) <display only>
Displays the remaining time of the step\
ENABLE
Enables step test.
DISABLE
Disables step test.


GATE TIMER
USE GATE TIMER dflt= NO (Yes/No)
If YES, enables the gate timer. Turbine must be de-watered and in manual mode before moving the gate
GO TO 5%
Forces the gate to go to the 5% position.
GO TO 95%
Forces the gate to go to the 95% position.
RESET TIMER
Resets the gate timer.
Data Log Menu
START DATALOG
Manually starts data log.
STOP DATALOG
Manually stops data log.
Operation Log Menu
NUMBER OF TURBINE STARTS dflt= 0 (0, 999999)

This is the number of times a Start command has been issued. This number can be reset by pressing the
‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu.
TOTAL TRIPS dflt= 0 (0, 999999)

This is the number of times a Trip has occurred. The trip latch must be reset/cleared and then triggered
again to increment this counter. This number can be reset by pressing the ‘Reset Values’ soft key to reset
all Operation Values to the “Rewrite Value” specified in this menu.
TRIPS WITH LOAD > 25% dflt= 0 (0, 999999)

This is the number of times a Trip has occurred above 25% load. The load level is determined by the
calculated LSS load percentage or the load analog input if configured. This number can be reset by
pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this
menu.
TRIPS WITH LOAD > 75% dflt= 0 (0, 999999)

menu.
OVERSPEED TRIPS dflt= 0 (0, 999999)

This is the number of overspeed trips. This number can be reset by pressing the ‘Reset Values’ soft key
to reset all Operation Values to the “Rewrite Value” specified in this menu.
TOTAL RUN TIME HOURS dflt= 0.0 (0.0, 1.0e+8)

This is the total time the turbine has been running. This number can be reset by pressing the ‘Reset
Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu.
RUN TIME HOURS WITH LOAD > 25% dflt= 0.0 (0.0, 1.0e+8)
This is the total time the turbine has been running with more than 25% load. The load level is determined
by the calculated LSS load percentage or the load analog input if configured. This number can be reset
by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in

this menu.
TRIPS WITH LOAD > 75% dflt= 0.0 (0.0, 1.0e+8)

menu.
TOTAL RUN TIME HOURS (status indication only)

This is the total time the turbine has been running. This is a repeat of the value on the previous page for
ease of comparing the run time with the maintenance alarm time.
ENABLE MAINTENANCE ALARM dflt= NO (Yes/No)

Select this option to turn on the maintenance alarm, which is an alarm based on the number of turbine run
hours and reminds the user that the control should be serviced periodically. Unselected this to disable the
maintenance alarm.
MAINTENANCE INTERVAL dflt= 15000 (10, 100000)

This sets the number of turbine run hours that will trigger the maintenance alarm. After the turbine has
been running for this many hours, the maintenance alarm will activate to remind the user to service the
unit.
MAINTENANCE ALARM (status indication only)

This indicates the status of the maintenance alarm. A red LED indication is a reminder that the unit should
be serviced. This alarm indication can be reset by pressing the “Reset Alarm” soft key at the bottom of the
screen if the appropriate security level is logged in.
PEAK SPEED REACHED (status indication only)

This indicates the maximum turbine speed detected by the 5001.
Screen Options Menu
SCREEN SAVER DELAY dflt= 4.0 (0.1, 24.0)

Set the time before the screen saver will activate. If no front panel keys are pressed in this length of time,
the screen saver will turn on.
Note that the current user level will be logged out when the screen saver activates. When the screen
saver is deactivated (i.e. waking up the display), either the Operator or Monitor user level will be active.
AUTO LOGIN AS OPERATOR dflt= YES (Yes/No)

Select this option to determine which user level is active when the 5001 initializes. With this option
selected, the 5001 will initialize like the older 2-line display models in operator mode with operator
commands available. If not selected, the 5001 will initialize in the Monitor user level with only screen
navigation functionality. No operator commands can be issued from the Monitor user level. Note that this
will also determine the user level that is logged in any time the user wakes up the display and turns off the
screen saver.
OPERATOR PASSWORD dflt= wg1111

If “Auto Login as Operator” is selected, this sets the Operator password. If the user level and password
have not been changed, the default input will allow the 5001 to login the Operator user level as described
above. If the Operator password has been changed, then it must be entered here to authorize the 5001 to
automatically login to the Operator user level.


DISABLE SCREEN SAVER dflt= NO (Yes/No)

Disables the screen saver
SCREEN UPDATE RATE (ms) (status indication only)

This is the rate that values are being updated on the screen. This time can change from page to page.
CPU IDLE TIME (%) (status indication only)

This indicates the amount of available CPU horsepower
INTERNAL OPERATING TEMP OF 5001 (C) (status indication only)

This value is measured internally on the 5001.
SCREEN BRIGHTNESS (%) (status indication only)

Current brightness of the screen. This can be adjusted by holding the Brightness key on the front panel
and using the Adjust button.
Reak Time Clock Menu
SYSTEM DATE <display only>

Displays the current date in the controller.
SYSTEM TIME (24HR) <display only>

Displays the current time in the controller.
USE SNTP SYNCHRONIZATION dflt= NO (Yes/No)

Select this option if using an SNTP Server for time synchronization with the Vertex internal clock. This will
affect alarm and event indication time stamping.
TIME ZONE dflt= 0

[-12, -11, -10, -9, -8, -7, -6, -5, -4, -3, -2, -1, 0,
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12]
This value will change the local time on the control. The hardware time will be set to GMT. Changing this
input will have no effect on the actual hardware keeping track of time. Therefore, if the Time Zone is
changed after the hardware time is setup, the Local time will change as it offsets a different Time Zone to
the Local Time.
YEAR dflt= 15 (0, 99)

When ‘SET CLOCK’ is pressed (or the Clock SYNC Pulse Contact Input is closed), the hardware time will
be set to this value.
MONTH dflt= 1 (1, 12)

DAY dflt= 1 (1, 31)

HOUR dflt= 0 (0, 23)



MINUTES dflt= 0 (0, 59)

SECONDS dflt= 0 (0, 59)

Communications Menu
Serial Port 1
LINK STATUS (status indication only)
Displays a green LED if the port is healthy. The “Time-out Delay” or port configuration may need to be
adjusted.
EXCEPTION ERROR (status indication only)
Displays a red LED if the port has an exception error.
TIMEOUT DELAY dflt= 10.0 (0, 100)
Sets the port timeout. This is the delay, with no communication on the Modbus link, before the link is
considered failed and an alarm is issued.
ERROR CODE (status indication only)
Displays the error code related to the communication problem.
0 = No Errors 1 = Illegal Function
2 = Illegal Data Address 3 = Illegal Data Value
9 = Checksum Error 10= Garbled Message
Press RESET to clear the port error.
Ethernet Port 2
adjusted.
Ethernet Port 3
adjusted.


Servlink
Socket 1
IP (status indication only)
Shows the Ethernet IP address that is connected to this socket. IP address ‘127.0.0.1’ will be identified as
the 5001 front panel display, which will be used as “Local” for Local/Remote functionality. See volume 1
of the manual for details.
STATUS (status indication only)
Shows the availability of the current ethernet socket (-1,0,1,2,3):
• 0 = Port not in use
• 1 = In use. Read Access only
• 2 = In use. Read & Write Access
• 3 = In use. Read & Exclusive Write Access
LEVEL (status indication only)
Displays the authority level of this socket. For example, the following at the most common levels a 5001
user will encounter:
• 0 = Monitor
• 1 = Operator
• 2 = Service
• 3 = Configure
Socket 2 to 8
These indications have the same meaning as the indications for Socket 1. See above
CAN Communications
CAN PORT 1
PORT ENABLED (status indication only)
If LED is ON, PORT 1 has been configured for use
LINK ERROR (status indication only)
If LED is ON, PORT 1 has a Link Error indicating no CAN activity for a timeout period.
RX ERROR (status indication only)
If LED is ON, PORT 1 has accumulated greater than 127 Receive Network errors.
CAN LOAD (%) (status indication only)
This value displays the current loading of CAN PORT 1 in %. It provides a “real time” monitor of the
network load.
NMT STATUS (status indication only)
Table 32: Current CANOPEN NMT State Values Displayed
Status Meaning
0 Bootup
4 Stopped
5 Operational
127 Pre-Operational

STATE (status indication only)
Table 33: Current CANOPEN State Values Displayed
Status Meaning
0 Pre-Operational
1 Initializing
2 Operational
3 Faulted
CAN PORT 2-3

These indications have the same meaning as the indications for CAN PORT 1. See above.


Step Test
During the initial calibration of the control system, the control must be calibrated for optimum
performance. Step test logic is built into the control to aid in the tuning of the offline PID gains and the
intermediate valve gains.
The offline PID gains must be tuned when the unit is offline or in isochronous mode on an isolated
system. When the step test is enabled, the step test logic introduces a step change, in percent of rated
speed, to the speed reference. The step change causes the control to respond and correct the resulting
speed error, and the PID gains can be adjusted until the optimum control response is observed.
The intermediate valve gain can also be adjusted using this step test. This gain should only be adjusted
when the unit is de-watered and it is safe to operate the gates. If the Control is in Manual or Maintenance
Mode of operation, the step test introduces a step change, in percent gate position, to the manual gate
position.
The step change can be positive or negative. The duration of the step can be adjusted, and when this
adjustable time expires, the step change will always return to zero. This avoids an offset in the speed
reference, in case the step test is accidentally left enabled.
Gate Timer
Gate timing can only be done when the unit is de-watered and
it is safe to operate the gates. Gate timing should only be set
to the turbine manufacturer’s specifications.
In order to use the Gate Timer, the 5001 must be in Manual mode. Also, the Gate Timer must be turned
on in the FIELD TOOLS service menu. In this same menu, the gates can be manually forced to go to 5%
or 95% at the full hydraulic rate.
To measure the opening timing, the gates must be forced to 5%. The timer must be reset in case any
time has been accumulated on the timer. The gates must then be forced from 5% to 95% at full hydraulic
rate. The 5001 measures the time that it takes to the gates to get from 25% to 75% gate position. This
time is then multiplied by two to get the gate timing in the opening direction. This time can be recorded, or
adjustments can be made to the timing.
To measure the closing timing, the timer must be reset to clear the timer value. The gates must then be
forced from 95% to 5% at the full hydraulic rate. The control measures the time it takes for the gates to go
from 75% to 25% and multiplies it by two to get the gate timing in the opening direction.

Chapter 11 – Peripheral Devices
Overview
This chapter provides a brief explanation of other Woodward devices, which easily integrate with the
5001. By understanding the functionality of a peripheral device, a better understanding of the overall
control configuration is achieved.
Some of these devices connect to the 5001 by a digital communication link (either Ethernet or CAN
depending on the product). Through this link, the 5001 display will allow the user to monitor many signals
and status LED’s from this external device. In many cases, these connections allow the 5001 to receive
required input signals, such as KW Load or a Synchronization or Load Sharing Bias signal. This
eliminates the need for wiring these signals to typical I/O channels, or the digital signal can be used as a
redundant/backup signal to a hard-wired signal. Devices supported in the 5001 control application is
identified with a “Woodward Link” identifier.
All the devices covered in this section are manufactured and/or supported by Woodward. Peripheral
devices manufactured by other companies can be used with the 5001 to perform the functions detailed
bellow, however, the compatibility of them to the 5001 and the application should be verified before
system operation.
DSLC-2 (Generator Synchronizer and Load Control)

Figure 51: DSLC-2
The DSLC-2 when connected to the 5001 controller can be used with generators to accurately sense 3-
phase RMS generator output power and perform generator breaker synchronization. Other configurable
DSLC-2 functions include generator load-sharing, VAR or Power Factor control, process control, and
base load control.
This is a “Woodward Link” device.


Figure 52: Configuration/Woodward Links/DSLC-2
To enable the Woodward Link feature, select the check box on the screen above and enter the slave
address and the IP address of the DSLC-2 device. The figure above shows the factory default IP
addresses of the DSLC-2 and Ethernet port 3 of the 5001. These settings will allow these two products to
communicate automatically once an RJ45 Ethernet cable is connected between Ethernet Port 3 of the
5001 and Network B port on the DSLC-2.
Once this configuration is complete, the DSLC-2 can provide the Synchronization speed bias signal, the
Sync/load sharing bias signal, and the KW output of the generator. The radio buttons on the screen allow
the user to select the functions desired. The KW valued thru this link can be used as a secondary KW
input signal, is an analog input channel is configured for a KW input.
The screens below show the available service screens that will now be accessible to monitor the DSLC-2.

Figure 53: Service Screen - DSLC-2 Power Parameters


Figure 54: Service Screen - DSLC-2 Status Parameters
The following table shows the parameter ID’s of the values available in the 5001 from the DSLC-2
Table 34: Parameter ID’s from DSCLC-2 to 5001
Parameter ID Description
144 Generator Frequency
209 Busbar Frequency
246 Generator Total Active Power
247 Generator Total Reactive Power
248 GEN Voltage L1-L2
251 GEN Voltage L1-N
254 Busbar Voltage
255 GEN Current 1
256 GEN Current 2
257 GEN Current 3
4151 Conditions Flag 1 (Bit packed States Decoded to LED’s)
4634 Load Control Mode (Bit packed States Decoded to LED’s)
4635 Reactive Load Control Mode (Bit packed States Decoded to LED’s)
4636 Sync Control State (Bit packed States Decoded to LED’s)

VariStroke II (Electro-Hydraulic Actuator)

Figure 55: VS-II
The VariStroke-II is a linear electro-hydraulic actuator designed to provide the linear actuation force to
operate turbine control valves or valve racks. This actuator can be directly networked with the 5001
controller to reduce system complexity and wiring requirements.

Figure 56: Configuration/Woodward Links/VS-II
To enable the Woodward Link feature, select the check boxes on the screen above to enable the CAN1
Link and confirm usage of the VariStroke II actuator, then enter the Device ID. If an analog (4-20 mA)
demand signal is going to be connected to the VariStroke in addition to the CAN link, then select the
desired function for this signal (AI Backup is recommended). Finally select the type of valve being
controlled.

Table 35: CAN Wiring from 5001 to VS-II
5001 Function VariStroke II

CAN 1 – terminal 1 COM TB6-A (Top) – terminal 35
CAN 1 – terminal 2 CAN LO CAN LO TB6-A (Top) – terminal 32
CAN 1 – terminal 4 CAN HI CAN HI TB6-A (Top) – terminal 31
Connect a termination resistor
across CAN 1 – terminals 2 & 4
Once this configuration is complete, the VariStroke-II digital communication link will provide the actuator
demand signal to the valve and the screen below will now be available under the Service menu to monitor
driver information.

Figure 57: Service/VariStroke II
MFR300 (Multi-function Relay)

Figure 58: MFR300 Multi-Function Relay

The MFR 300 is a multi-function generator protection relay used to sense and protect small generators.
This multi-function protection relay integrates all generator protection functions into one common device
reducing overall system installation complexity and cost.

Figure 59: Configuration/Woodward Links/MFR300
To enable this Woodward Link feature, select the check box on the screen above to enable the CAN3
Link and confirm usage of the MFR300 multifunction relay, then enter the Device ID, Baud Rate, and
system configuration.
Table 36: CAN Wiring from 5001 to MFR300
5001 Function MFR300

CAN 1 – terminal 1 COM
CAN 1 – terminal 2 CAN LO terminal 03
CAN 1 – terminal 4 CAN HI terminal 04
Connect a termination resistor
across CAN 1 – terminals 2 & 4
Once selected and configured, the screens below will become available on the Service Screens.


Figure 60: Service Screen1/Woodward Links/MFR300

Figure 61: Service Screen2/Woodward Links/MFR300

HighPROTEC (Generator Protection Unit)

Figure 62: HighPROTEC
The HighPROTEC is a family of generator protection devices designed to provide complete protection for
generators and or power distribution. Various models and configurations exist that provide multiple ANSI
standard protection functions.
The 5001 is programmed to communicate only to HighPROTEC model numbers of that communicate via
Modbus TCP. Check the final letter of the part number to identify the communication protocol that is
supported. The letter C indicates it is a unit configurable to use Modbus TCP (for example model
MCDGV4-A-0-A-C would work). If the final letter is a “C”, then an RJ45 Ethernet connection jack will exist
on terminal X100 on the rear of the unit.

Figure 63: Configuration Screen/Woodward Links/HighPROTEC
To enable the Woodward Link feature select the check box on the screen above and enter the slave
address and the IP address of the HighPROTEC device. The figure above shows the factory default IP
addresses of the HighPROTEC and Ethernet port 3 of the 5001. These settings will allow these two

products to communicate automatically once an RJ45 Ethernet cable is connected between Ethernet Port
3 of the 5001 and Network B port on the HighPROTEC. Note that if a DSLC-2 and a HighPROTEC are
both connected to this network, which the default Slave Address of one of these devices will need to be
changed.

Figure 64: Service Screen/Woodward Links/HighPROTEC

Chapter 12 – 5001 Operation
Software Architecture
The 5001 is a field configurable hydro turbine control and graphical user interface (GUI) integrated into
one package. The 5001 control has been designed to run 2 separate, independent programs on the same
platform. One controls the I/O and therefore controls turbine operation. The other program provides all the
visual and command interaction with the user.
5001 Turbine Control
Woodward GAP Control Qt GUI Application

Application 5001-GAP01_Rev.out 5001-GUI01_Rev.wgui
Figure 65:Software Architecture
The primary application program is the GAP based control application program. This controls all the
system I/O and functional algorithms which control the operation of the turbine.
The secondary application program is the Digia/Qt based graphical user interface (GUI) program. This
controls all the screen information that is displayed to the user. It links to the GAP via an internal
communication link to pass all required interface variables to and from the display.
Both of these programs are automatically launched at power-up. The GAP program MUST always be
executing to run the turbine. However the GUI program may be ‘Stopped’ using a service tool
(AppManager) and restarted at any time without affecting GAP or the turbine operation. This unique and
useful feature of the 5001 allows the following operations to be accomplished (if needed or desired) while
the 5001 control is operating the turbine.
• Update the GUI program (newer build revisions with improvement/enhancements)

• Upgrade the GUI program – load a custom version that may be created for a specific OEM or
customer jobsite

Power-Up Screen
Viewed from the front the 5001– the following is the correct boot-up sequence of a 5001 unit loaded with
the standard 5001 GAP and Qt GUI applications. Times are approximant.
At Power-up Screen = BLANK /BLACK

IOLOCK = ON (RED)
After about 0:45 Screen = “Flex500 Splash Screen”

TRIPPED/CPU/ALARM LED’s will flash check
IOLOCK = ON
After about 1:10 TRIPPED=ON (RED)

IOLOCK = OFF
CPU = ON (GREEN)
After about 1:45 ALARM LED (YELLOW) Flashes/Blinks
After about 3:45 Screen = HOME
Any time that a Display application program is not running, the ‘Splash Screen’ will appear. If at power-up
the Alarm LED stops flashing, and this screen still appears – then the GUI program has not initialized
correctly.
Once the unit has been configured, all following power cycles will result in a screen similar to the
following. The numbers in () indicate that there is a quick keypad command to get to that screen. For
example, pressing 2 will jump to the Speed Control screen, from that screen if you press 5 it will jump to
the Startup Curve screen. From any operational screen, pressing HOME will always return to this screen.

Figure 66: Boot-up to HOME Screen
There is a Screen Saver function that is invoked after a period of inactivity. It is defaulted to 4 hours
(adjustable in Service / Screen Settings) – when this comes it a small version of Madsen Controls &
Engineering’s logo will bounce around on the screen. Press any key to revive the display (maroon keys

are recommended). When awaking from screen saver the user login level will be reduced to Operator.
This also is adjustable in Service / Screen Settings if desired, it can be changed to awaken to Monitor.
Control Mode Architecture

Basic control program architecture is illustrated in Figure below. The 5001’s normal operating architecture
divides the control into two states.
Run – which includes Operation and Calibration modes
Program - Configuration mode
Pressing the MODE key at any time will open the Login and Mode Screen
The Configuration Mode is used to configure the 5001 for the specific application and set all operating
parameters (see Chapter 9). In this mode the control will issue an IOLOCK (LED) and the state of all
Outputs from the 5001 are disabled. This means that all Relays are de-energized and all Analog/Driver
outputs are at zero current. Initially all 5001s must be placed in this mode to enter a valid configuration of
the I/O and functions desired for the specific turbine application.
The Calibration Mode is used after the configuration of the 5001 is complete. It is used to perform
calibration of signals, verification of speed signals and the forcing of outputs of the control in preparation
to run the turbine. All I/O is functional in this state. To enter this mode the turbine must be TRIPPED
(LED).
The Operation Mode is used to view operating parameters and run the turbine. This is the typical mode
the control uses and is the default mode it enters at Power-up. All I/O is functional in this state. The
turbine may be either running or not running in this mode.

Figure 67: Control Mode Architecture

User Login Levels

Pressing the MODE key at any time will open the Login and Mode Screen

Figure 68: Mode Screen
Monitor – (logout to enter this)

Even Keypad Green keys inhibited
Operator – (passwords are provided in Appendix B)
Intended for normal turbine operation – default mode
Screen saver initiates to this level
Service – (passwords are provided in Appendix B)
Allows tuning of parameters, while turbine is running (PID dynamics) and entering of Calibration Mode
Configure – (passwords are provided in Appendix B)
Highest user authority / can enter any Mode
EMERGENCY STOP is always available in all modes and

logins as it has direct H/W action to open the Actuator
circuits.
To Login –
1. Press the LOGIN button
2. ** Navigate so the Login or Password field is highlighted (in-focus)
3. Press Enter on the Navigation Cross
4. Use the keypad to enter the text field (hold key down to scroll options)
5. Press Enter on the Navigation Cross – to accept your entry
** Or you can navigate to the Autofill buttons and press Enter – it will auto-populate the Login information
so you only need to enter the Password.

Navigation
This is NOT a touchscreen! Due to quality, robustness, screen cleanliness and long term reliability
concerns Woodward chose not to implement a touchscreen directly on this product. Using the
RemoteView tool a user can take advantage of either a mouse device or a touchscreen on an external
computer, but for navigation and selection directly on the 5001 display, buttons and an IN-Focus
highlighter indication are used.
In general, the maroon buttons provide navigation from page-to-page and throughout the components on
a page. Most of the navigation is done with the Navigation cross.

Figure 69: Navigation Cross
1. Use the “Arrow” buttons to move the IN-Focus highlighter to the desired page
2. Press the “Enter” button to launch the page selected
3. Press the “ESC” (Escape) button to go back 1 page from current page
4. Press the “HOME” button to return to the main menu Note: If in Service or Configure menu a
second press of HOME will return to the Operational Home screen

Figure 70: Service Menu showing “Turbine Start” IN-Focus

Page Organization
There are three primary menu lists that organize the access to all of the information that is available on
the display. These menu lists are available at all times. The user simply uses the navigation cross to
Focus on the desired page and press Enter, or use the Black ‘soft keys’ (no Focus needed).
Run/Operation menus - The HOME page contains the Run/Operation menus and is automatically
updated to match the configuration of the control.
Service menus - The Service ‘HOME’ page contains navigation buttons to all of the service related
parameters and special feature of the control and it is automatically updated to match the configuration of
the
Configuration menus - The Configuration ‘HOME’ page contains navigation buttons to all features and
options of the 5001. When the unit is in Configure Mode (IOLOCK) the background of all pages will be a
blue gradient as shown below, in addition to the status in the upper right.

Figure 71: Configuration Menu – Operation Mode (View only)


Figure 72: Configuration Menu – Configuration Mode (Edit)
Refer to chapter 6 for more details about all of the keys – below are some general reminders about the
keypad functions:
Green keys – initiate operational commands

Red keys - navigate or enter values via the alpha numeric keys
Black keys – are software dependent and may do either, they never require ‘IN-Focus’ the
command shown in above the key is always available
Start and Stop Keys – always require a Confirmation and user must be logged-in at appropriate
User level (Operator or greater)
EMERGENCY STOP is always available in all modes and logins as it has direct H/W action to
open the Actuator circuits.
When entering string text from the keypad, holding down the key will make is slowly cycle through the
characters available on that key. Releasing the key will select the character shown at that time.
Overview Screen
The Overview screen will adapt to the configuration of the 5001 and show all configured options. During
normal run operation, this screen should provide the user with all of the primary turbine parameter values
and operational status.


Figure 73: Overview Screen
Speed Control Screen

During normal run operation, this screen provides the user with all details that are related to the turbine
when operating in speed control.
The menu bar function will allow the user to perform an Overspeed test. It is also possible to change the
speed setpoint. The breaker status is shown as well as the operational mode.

Valve Demand Screen

The Valve Demand screen will show all configured options that can affect the final output demand to the
Gate valve. For Kaplan turbine configurations, it will have a navigation button to switch to the Blade valve
demand. During normal run operation, this screen provides the user with a clear picture of what control or
ramp is controlling the valve demand output. The Low Signal Select (LSS) bus will output the lowest value
seen at its inputs. The valve logic box represents options that may be used to adjust this value (such as
valve linearization, 2-stage valve, integrating valve) prior to output to the Gate or Blade valve. If these
options are not used, the valve demand output will always equal the LSS value.
The function options will allow the user to access the valve limiter setpoint and the manual valve demand
(if configured for use).

Figure 74: Valve Demand Screen
Controllers Screen
The Controllers screen will adapt to the configuration of the 5001 and show all configured options. During
normal run operation, this screen provides the user with information similar to the Overview, but in a
graphical gauge view. It provides larger values for distance viewing and control PID information which is
useful for monitoring when the 5001 is near transition points between controllers or limiters.
The function options will allow the user to use typical operational commands related to the control loop
selected – such as directly entering a setpoint.


Figure 75: Controllers Screen
Start Curve Screen

The Start Curve screen will adapt to the configuration of the 5001 and show all configured options.
The function options will allow the user to change the speed setpoint and the gate limiter setpoint.

Figure 76: Start Curve Screen

Custom Trend Screen

Opening Custom Trend page begins the trend, exiting the page will continue to record data in the
background. Trends can be paused using the soft-key. While paused, the data continues to record in the
background. Once resumed, the trend snaps to real time.

Figure 77: Custom Trend Screen
Analog Inputs Summary Screen

The Analog Input Summary screen will display the status of all channels available on the 5001 hardware.
The fault status, function, device tag, engineering value and units are shown for each channel as well as
navigation buttons for each channel that take the user to a page showing all parameters available for that
input.
The menu bar functions will allow the user to access the detailed page of the speed input signals.


Figure 78: Analog Input Summary Screen
Contact Input Summary Screen

The Contact Input Summary screen will display the status of channels available on the 5001 hardware.
The fault status, function, and device tags are shown for each channel as well as navigation buttons for
each channel that take the user to a page showing all parameters available for that input.
The contact input summary is broken into three pages and the menu bar contains navigation buttons to
view all the channels

Figure 79: Contact Input Summary Screen

Analog Output Summary Screen

The Analog Output Summary screen will display the status of all channels available on the 5001
hardware. The fault status, function, device tag, engineering value and units are shown for each channel
as well as navigation buttons for each channel that take the user to a page showing all parameters
available for that output.

Figure 80: Analog Output Summary Screen
Relay Output Summary Screen

The Relay Output Summary screen will display the status of all channels available on the 5001 hardware.
The coil status, function, and device tag are shown for each channel as well as navigation buttons for
each channel that take the user to a page showing all parameters available for that output


Figure 81: Relay Output Summary Screen
Actuator Driver Summary Screen

The Actuator Driver Summary screen will display the status of the 2 channels available on the 5001
hardware. The fault status, function, current value (in mA), engineering value and units are shown for
each channel as well as navigation buttons for each channel that take the user to a page showing all
parameters available for that input.

Figure 82: Actuator Driver Summary Screen

Starting Procedures (Start Curve Screen)

Figure 83: HOME Menu showing “Startup Curve” IN-Focus
Refer to the turbine manufacturer’s operating procedures for complete information on turbine start up, and
Chapter 7 of this manual for a step-by-step procedure, depending on the start mode selected. The
following is a typical startup procedure:
The turbine 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.
1. Press the RESET key to clear all alarms and trips. If the 5001’s RESET CLEARS TRIP setting is
programmed "YES", the 5001's shutdown relay will reset or energize upon pressing the RESET
key after a shutdown. If the RESET CLEARS TRIP OUTPUT setting is programmed "NO", the
5001’s shutdown relay will reset or energize upon pressing the Reset key ONLY after all trip
conditions are cleared.
2. Press the START key and Confirm, to initiate the selected start-up mode. This will function from
any screen, but it is recommended to be on the Startup Curve page during the turbine startup.
A ‘Start Perm Not Closed’ alarm will be issued if the application is using a Start Permissive
contact input and this contact input was not closed when the RUN command was issued.
3. After the start-up, the turbine will operate at the nominal speed setting. The 5001’s speed setpoint
will move to nominal speed setpoint. An operator at this time may vary turbine speed through the
5001's keypad, external switches or communication links.

Overspeed Test Function (Speed Control Screen)

The 5001’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 5001’s internal overspeed trip logic and any external overspeed trip device’s
settings and logic. The figure below shows the screen that is displayed when the ‘Overspeed Test’ key is
pressed from the Speed Control page. It shows the permissives required to be able to perform an
overspeed test.
Figure 84: Overspeed Test Permissives
The turbine 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.
Overspeed Test Procedure (from the 5001 display)
1. Be sure the generator breaker is open
2. Raise the Speed Set Point to the maximum governor setting
3. If desired, clear the ‘Maximum Speed Reached’ value, to record the highest speed reached
during this overspeed test. (Reset Max Spd key)
4. This function has a safety timeout to ensure the unit does not run in this mode unattended.
5. Timeout value is shown, if it expires the test mode will be aborted and the unit will return to the
rated speed

Stop Key
The STOP key is used to perform a controlled/manual turbine shutdown or stop. To perform a Manual
Shutdown, press the STOP key and confirm from the keypad or close the Controlled Shutdown contact
input (if programmed) or select Controlled Shutdown from a Modbus communications link. Once initiated,
the display dialog box will change to give the user the option to abort the Normal stop sequence. This
dialog box will close after 10 seconds, but can be reopened by pressing the STOP key. This function can
be also be stopped by opening the contact or selecting Abort Controlled Shutdown from a Modbus
communications link.
Alarm Summary
The ALARM screen is always available with the VIEW button under the ALARM LED. When an alarm is
detected, it gets latched in the event logic, the Alarm relay is energized, and the ALARM LED illuminates
(Yellow). The cause of the event will be indicated with an Event ID, description and time/date stamp on
the Alarm Summary page. The list will always place the first event at the top of the list, if more than one
alarm condition is present they will all be listed with their corresponding time stamp.
To clear any alarms that are no longer present, press the RESET key, close the Reset contact input, or
select Reset from either Modbus communications link. If the cause of the event has been corrected the
alarm will clear, it not it will remain and the time-stamp will remain unchanged.

Figure 85: ALARM Screen
Each individual alarm condition is available through the Modbus links to monitor the control status. A
common alarm indication is also provided.
Relay indications can be programmed to indicate a 5001 Common Alarm, in addition to the dedicated
Alarm Relay output.
The lists with all the potential alarm conditions can be found in the chapter 7.

Shutdown Summary
The Shutdown Summary screen is always available with the VIEW button under the TRIPPED LED.
When a trip is detected, it gets latched in the event logic, the Trip relay is de-energized, all valve demand
outputs go to zero, and the TRIPPED LED illuminates (Red). The cause of the event will be indicated with
an Event ID, description and time/date stamp on the Shutdown Summary page. The list will always place
the first event at the top of the list, if more than one trip condition is present, they will all be listed with their
corresponding time stamp.
To clear any shutdowns that are no longer present, press the RESET key, close the Reset contact input,
or select Reset from either Modbus communications link. If the cause of the event has been corrected the
event will clear, it not it will remain and the time-stamp will remain unchanged

Figure 86: Shutdown Summary Screen
The lists with all the potential shutdown conditions can be found in the chapter 7.
Each individual trip condition is available through the Modbus links to monitor the control status. A
common trip indication is also provided.
Relay indications can be programmed to indicate a 5001 Shutdown Condition (energizes for a shutdown
condition) in addition to the dedicated Emergency Trip Relay output.
Manual Dynamic Adjustments of Offline, Small System, Online, and

Load Controls
This section will cover the basics of the manual tuning of the PID dynamics that need to be performed
initially on the unit. The speed control loop (offline and online controls) is used on every system, the other
controls need not be tuned if they are not configured for use.
Dynamic control values are programmed in the configuration mode and adjusted when logged as Service
or Configure level. The Proportional and Integral Gain and the Derivative Ratio dynamic adjustments are
available under Dynamics pages for each controller (Offline, Small System, Online and Load). To adjust
the gain settings, the In-Focus highlighter must be on the component value to tune. The In-Focus

highlighter is moved using the navigation Cross. The ADJUST UP and DOWN keys can then be used to
adjust the function In-Focus.

Figure 87: Offline Dynamics Adjustment Screen
The Offline, Online, Small System and Load controls are PID controllers. The response of each control
loop can be adjusted by selecting the dynamics mode as described above. Proportional gain, integral
gain (stability), and DR (derivative ratio) are the adjustable and interacting parameters used to match the
response of the control loop with the response of the system. They correspond to the P (proportional), I
(integral), and D (derivative) terms, and are displayed by the 5001 as follows:
P = Proportional gain (%)

I = Integral gain (%)
D = Derivative (determined by DR and I)
Tuning P & I Gains
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 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.
For best response the proportional gain and integral gain should be as high as possible. To obtain a
faster transient response, slowly increase the proportional gain setting until the actuator or final driver
output begins to oscillate or waver. Then adjust the integral gain as necessary to stabilize the output. If
stability cannot be obtained with the integral gain adjustment, reduce the proportional gain setting.
A well-tuned system, when given a step change, should slightly overshoot the control point then come
into control.
A PID control loop’s gain is a combination of all the gains in the loop, also known as the system gain. The
loop’s total gain includes actuator gain, valve gain, and valve linkage gain, transducer gain, internal

turbine gains, and the 5001’s adjustable gains. If the accumulated mechanical gain (actuators, valves,
valve linkage, etc.) is very high, the 5001’s gain must be very low to be added to the system gain required
for system stability.
In cases where a small change in the 5001's output results in a large speed or load changes (high
mechanical gain) it may not be possible to take the 5001's gains low enough to reach stable operation. In
those cases, the mechanical interface (actuator, linkage, servo, valve rack) design and/or calibration
should be reviewed and changed to achieve a gain of one where 0–100% 5001 output corresponds to 0–
100% valve travel.
Tuning Derivative
The value of the Derivative Ratio (DR) term can range from 0.01 to 100. If unsure of the correct value, set
the Speed control’s DR term to 5%. In order to simplify adjustment of the dynamics, adjusting the integral
gain value sets both I and D terms of the PID controller. The DR term establishes the degree of effect the
integral gain value has on the "D" term, and changes the configuration of a controller from input rate
sensitive (input dominant) to feedback rate sensitive (feedback dominant) and vice versa.
Another possible use of the DR adjustment is to reconfigure the controller from a PID to a PI controller.
This is done by adjusting the DR term to its upper or lower limits, depending on whether an input or
feedback dominant controller is desired.
• A DR setting of 1 to 100 selects feedback dominant mode.

• A DR setting of .01 to 1 selects input dominant mode.
• A DR setting of .01 or 100 selects a PI only controller, input and feedback dominant respectively.
The change from one of these configurations to the other may have no effect during normal operation;
however, it can cause great differences in response when the governor is coming into control. (at start-up,
during a full load change, or during transfer of control from another channel).
An input dominant controller is more sensitive to the change-of-rate of its input, and can therefore prevent
overshoot of the setpoint better than a feedback dominant controller. Although this response is desirable
during a start-up or full load rejections, it can cause excessive control motions in some systems where a
smooth transition response is desired.
A controller configured as feedback dominant is more sensitive to the change-of- rate of its feedback
(LSS). A feedback dominant controller has the ability to limit the rate of change of the LSS bus when a
controller is near its setpoint but is not yet in control. This limiting of the LSS bus allows a feedback
dominant controller to make smoother control transitions than an input dominant controller.
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 1
second reduce the Integral gain term (proportional gain may need to be increased also).
On an initial start-up with the 5001, 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 5001’s PIDs to assist in determining the gain terms that provide optimum
control loop response times (Ziegler Nichols, etc.).
The figure below shows the typical response to a load change when the dynamics are optimally adjusted.


Figure 88: Typical Response to Load Change
For additional information on PID settings, refer to Appendix

D

Chapter 13 – Communications
Modbus Communications
The 5001 control can communicate with plant distributed control systems and/or CRT based operator
control panels through Modbus communication ports. There is one serial port that supports RS-232 and
RS-485 communications using ASCII or RTU MODBUS transmission protocols. There are 2 ports
available for either Modbus UDP or TCP/IP protocol which can be utilized from Ethernet port 1 or 2.
Modbus utilizes a master/slave protocol. This protocol determines how a communication network’s
master and slave devices establish and break contact, how a sender is identified, how messages are
exchanged, and how errors are detected.
Our experience has been that not all serial interfaces on

laptops or Desktop PCs work the same. Many USB-to-Serial
converters work, but some do not.
To use a 5001 Modbus port to monitor and/or operate, check the “Use Modbus” checkbox under the
Configurations menu / Communications page.
Monitor Only
The three Modbus communication ports are defaulted as read-only. As read-only ports, the 5001 can be
monitored but not controlled from an external device. By simply connecting a monitoring device,
configured to communicate through Modbus, and to the 5001’s defaulted protocol settings (parity, stop
bits, etc.), this device can be used to monitor all the 5001’s controlling parameters, modes, etc. without
affecting control.
Configuration of the protocol is found on the Communications page under both the Configuration and
Service menus. There are options for the serial settings, slave address number and a checkbox to enable
write commands from each individual link.
Monitor and Control

Once a Modbus port is configured within the 5001’s Configuration mode, the 5001 will accept RUN mode
commands from an external network master device (DCS, etc.). This allows a Modbus compatible device
to monitor and perform all 5001 RUN mode parameters and commands except for the Overspeed Test
enable, and Override Failed Speed Signal commands.
Each Modbus port is independent of the other, and can be used simultaneously. Each only must have its
own slave device address and each has its own enable write checkbox. The last command given from
any of the ports has priority or is the mode or function selected.
Modbus Communication
The 5001 control supports two Modbus transmission modes. A mode defines the individual units of
information within a message and the numbering system used to transmit the data. Only one mode per
Modbus network is allowed. The supported modes are ASCII (American Standard Code for Information
Interchange), and RTU (Remote Terminal Unit). These modes are defined in the following table.

Table 37: ASCII vs RTU Modbus
Characteristic ASCII RTU

Coding System Hexadecimal (uses ASCII printable 8-bit binary
binary characters: 0-9, A-F)
Start Bits 1 1
Data Bits per Character 7 8
Parity Even, odd, or none Even, odd, or none
Stop Bits 1, 1.5, or 2 1, 1.5, or 2
Baud Rate 110, 300, 600, 1200, 1800, 2400, 110,300, 600, 1200, 1800, 2400,
4800, 9600, 19200, 38400, or 4800, 9600, 19200, 38400, or
57600 57600
Error Checking LRC (Longitudinal Redundancy CRC (Cyclical Redundancy
Check) Check)
In the RTU mode, data is sent in 8-bit binary characters and transmitted in a continuous stream. In the
ASCII mode, each binary character is divided into two 4-bit parts (high order and low order), changed to
be represented by a hexadecimal equivalent, then transmitted, with breaks of up to 1 second possible.
Because of these differences, data transmission with the ASCII mode is typically slower (see figure
below).

Figure 89: ASCII/RTU Representation of 3
The Modbus protocol allows one master and up to 247 slaves on a common network. Each slave is
assigned a fixed, unique device address in the range of 1 to 247. With the Modbus protocol, only the
network master can initiate a transaction. A transaction consists of a request from the master to a slave
unit and the slave’s response. The protocol and Modbus device number are set in the Configuration
mode.
The 5001 control is programmed to function as a slave unit only. As a slave unit, the 5001 will only
respond to a transaction request by a master device. The 5001 can directly communicate with a DCS or
other Modbus supporting device on a single communications link, or through a multi-dropped network. If
multidropping is used, up to 246 devices (5001s or other customer devices) can be connected to one
Master device on a single network. The control address is programmed under the 5001’s communications
block and can be changed in the configuration mode, if needed.
Each message to or from a master has a defined structure called the message “frame”. A frame consists
of the slave device address, a code defining the requested data, and error checking information. See
table below.

Table 38: Modbus Frame Definition
Beginning Slave Function Data Error End of

of Frame Address Code Check Frame
Code
ASCII : 2 CHARS 2 CHARS 4 BITS 2 CHARS CR LF
8 BITS 8 BITS DATA PER 8 BITS
CHAR
RTU 3-CHAR 1 CHAR 1 CHAR 8 BITS 2 CHAR 3 CHAR
DEAD TIME 8 BITS 8 BITS DATA PER 16 BITS DEAD TIME
CHAR
The Modbus function code tells the addressed slaves what function to perform. The following table lists
the function codes supported by this control.
Table 39: Modbus Function Codes
Code Definition Reference Address

01 Read Digital Outputs (Raise/Lower and Enable/Disable Commands) 0XXXX
02 Read Digital Inputs (Status Indications/Alarms and Trips) 1XXXX
03 Read Analog Outputs 4XXXX
04 Read Analog Inputs (Speed, Setpoint, etc.) 3XXXX
05 Write Single Discrete Output (Raise/Lower and Enable/Disable 0XXXX
Commands)
06 Write Single Register (Enter Setpoint Directly) 4XXXX
08 Loopback Diagnostic Test (Subfunction 0 only) N/A
15 Write Digital Outputs 0XXXX
16 Write Analog Outputs 4XXXX
When a Modbus message is received, it is checked for any errors or invalid data. If there is invalid data in
the message, an error code is sent back to the master and the control issues an alarm message. The
error codes are defined in the following table. The exception error status and respective error codes can
be viewed on the Communication pages under the Service Menu.
If the control has not received a message for the configured time-out period, the control will alarm with an
error message, but no message is sent to the master. This time-out is defaulted to 2 seconds and only
applies to units using both monitor and control (adjustable through the Service Menu).

Table 40: Modbus Error Codes
Error Error Message Code Sent Description

Code To Master
0 No Error 0 No Error
1 Bad Modbus function 1 The specified function is not supported for this
control.
2 Bad Modbus data address 2 The Modbus value addressed is not valid for this
control.
3 Bad Modbus data value 3 Too many values requested or the on/off indicator
in
9 Bad Modbus checksum None function code 5 is invalid.
10 Bad Modbus message None Message checksum did not match.
N/A Lost Modbus link None Message could not be decoded.
Port Adjustments
Before the 5001 will communicate with the master device, the communication parameters must be
verified. These values are set in the Configure Mode and can be adjusted, if required, from the Service
Mode.
Table 41: Modbus Communication Port Adjustments
Parameter Adjustment Range

Baud Rate 110 TO 57600
Parity NONE, ODD or EVEN
Stop Bits 1 TO 2
Driver RS-232, RS-422, or RS-485
5001 Control Modbus Addresses

The Modbus communication ports in the 5001 control are programmed for unique Modbus addresses. A
complete listing of these addresses for your application is located at the end of this section in the manual.
The Modbus address listing consists of Boolean Writes, Boolean Reads, Analog Reads, and Analog
Writes. The Boolean reads and writes are also referred to as input and holding coils. The analog reads
and writes are also referred to as input registers and holding registers.
All values that can be addressed by Modbus are considered to be discrete and numeric. The discrete
values are a 1 bit binary, on or off value and the numerics are 16 bit values. Discrete values are
sometimes referred to as coils or digitals and numerics are referred to as registers or analogs. All
read/write registers are interpreted by the 5001 as signed 16 bit integer values. Since Modbus can only
handle integers, values that require a decimal point in the Modbus Master Device are multiplied by a
scaling constant before being sent by 5001. See Tables 42 and 43 for defaulted communication constants
and ranges.
The maximum number of discretes and registers that can be transmitted in one packet is dependent on
each implementation of Modbus. The following table defines these limits.

Table 42: Maximum Modbus Discrete and Analog Values
Mode Of Transmission Max Discretes Max Registers

ASCII 944 59
RTU 1188 118
Boolean Writes (Holding Coils)

Holding coils are logical signals that are both readable from and writable to the 5001 control. An example
of a Boolean write value would be raise or lower commands. A logical true denoted by the value 1 will
cause the command listed in the description to be executed. For example, if a 1 is written to address
0:0010 and this corresponded to a speed raise command, the manual speed set point will increase until a
0 is written to address 0:0010. The 5001 control supports function codes 1, 5, and 15. These correspond
to reading selected holding coils, writing to a single holding coil, and writing to multiple holding coils,
respectively. The holding coils available are listed in Table 43.
Boolean Reads (Input Coils)

Input coils are logical signals that are readable from, but not writable to, the 5001 control. An example of
a Boolean read value would be a turbine trip status indication. The input coil will have the value 1 if the
statement in the description column is true and a 0 if false. The `1:’ term in the address identifies an input
coil. The 5001 control supports Modbus function code 2, which involves reading selected input coils. The
input coils available are listed in Table 44.
Analog Reads (Input Registers)

Input registers are analog values that are readable from, but not writable to, the 5001 control. An example
of an analog read value would be turbine speed. The values of the input registers are stored internal to
the control as floating point numbers representing engineering units (kPa or rpm). The values that are
transmitted are integer values ranging from -32767 to +32767. Since Modbus can only handle integers,
values that have a decimal point are multiplied by a constant before being sent by Modbus. For example,
these input registers may be listed as the Modbus value ‘x100’ or ‘x10’ under the description heading to
denote the value is multiplied by a scaling constant. This will allow transmission of decimal parts of a unit
if this is necessary for better resolution.
The 5001 control supports Modbus function code 4, which involves reading selected input registers. The
input registers available are listed in Table 45.
Analog Writes (Holding Registers)

Holding registers are analog values that are writable to the 5001 control. These values can also be read
from by a device performing error checking. An example of an analog write value would be a direct speed
setpoint value as opposed to raise and lower commands. The values of the holding registers are also
stored in the control as numbers representing engineering units (psi or rpm). The 5001 control supports
Modbus function codes 3, 6, and 16. These correspond to reading selected holding registers, writing to a
single holding register, and writing to multiple holding registers, respectively. The holding registers
available are listed in Table 46.
The following tables give the address and description of all Boolean and analog, reads and writes:

Table 43: Boolean Write Addresses
Address Description Address Description

0:0001 Reset Peak Speed Remote Baseload Reference
0:0038
Use Modbus Level Remote Disable
0:0002
Reference? 0:0039 Remote Speed Reference Enable
0:0003 Speed/Load Raise 0:0040 Remote Speed Reference Disable
0:0004 Speed/Load Lower 0:0041 Remote Level Reference Enable
Use Modbus Speed Remote 0:0042 Remote Level Reference Disable
0:0005
Reference? 0:0043 Modbus Remote Fault #1
0:0006 Gate Manual Position Raise 0:0044 Modbus Remote Fault #2
0:0007 Gate Manual Position Lower 0:0045 Modbus Remote Fault #3
0:0008 Enable Calibrate Mode 0:0046 Modbus Remote Fault #4
0:0009 Gate Limit Raise 0:0047 Modbus Remote Fault #5
0:0010 Gate Limit Lower 0:0048 Modbus Remote Fault #6
0:0011 Governor Reset 0:0049 Modbus Remote Fault #7
0:0012 Momentary START 0:0050 Modbus Remote Fault #8
0:0013 Momentary STOP 0:0051 Modbus Remote Fault #9
0:0014 Overspeed Test Enable 0:0052 Modbus Remote Fault #10
0:0015 Not Used 0:0053 Modbus Remote Fault #11
0:0016 Not Used 0:0054 Modbus Remote Fault #12
0:0017 Speed Bias Raise 0:0055 Modbus Emergency Shutdown
0:0018 Speed Bias Lower 0:0056 Modbus Request Failover
Use Modbus Baseload Remote 0:0057 kW Droop request
0:0019
Reference? 0:0058 Actuator Droop request
0:0020 Baseload Enable 0:0059 Start Unload
0:0021 Baseload Disable 0:0060 Stop Unload
0:0022 Maintenance Mode Enable 0:0061 Send Manual Gate Demand
0:0023 Maintenance Mode Disable Manual Gate Control (Prop Valve)
0:0062
0:0024 Level Control Enable Enable
0:0025 Level Control Disable Manual Gate Control (Prop Valve)
0:0063
0:0026 Manual Gate Control Enable Disable
0:0027 Manual Gate Control Disable 0:0064 Not Used
Use ModBus Initial Baseload 0:0065 Disable Overspeed Test
0:0028
Reference? 0:0066 Disable Calibration Mode
0:0029 Blade Tilt Enable 0:0067 Reset Small System
0:0030 Blade Tilt Disable 0:0068 Set Small System
0:0031 Blade Lock Enable Manual Blade Control (Prop
0:0069
0:0032 Blade Lock Disable Valve) Enable
0:0033 Manual Blade Control Enable Manual Blade Control (Prop
0:0070
0:0034 Manual Blade Control Disable Valve) Disable
0:0035 Blade Manual Position Raise 0:0071 Not Used
0:0036 Blade Manual Position Lower 0:0072 Not Used
Remote Baseload Reference 0:0073 Not Used
0:0037
Enable 0:0074 Not Used
0:0075 Not Used

Table 44: Boolean Read Addresses

1:0001 Alm - Speed Signal #1 Trouble 1:0048 Alm - Not Used
1:0002 Alm - Speed Signal #2 Trouble 1:0049 Alm - DO #9 Readback Fault
1:0003 Alm - Speed Signal #3 Trouble 1:0050 Alm - Not Used
1:0004 Alm - Not Used 1:0051 Alm - DO #10 Readback Fault
1:0005 Alm - Not Used 1:0052 Alm - Not Used
1:0006 Alm - Not Used 1:0053 Alm - DO #11 Readback Fault
1:0007 Alm - Pond Level Signal Fail 1:0054 Alm - Not Used
1:0008 Alm - Active Power Transducer 1:0055 Alm - DO #12 Readback Fault
Fail 1:0056 Alm - Not Used
1:0009 Alm - Speed Bias Signal Fail 1:0057 Alm - DO #13 Readback Fault
1:0010 Alm - Remote Speed Reference 1:0058 Alm - Not Used
Fail 1:0059 Alm - DO #14 Readback Fault
1:0011 Alm - Gate Position Limiter Fail 1:0060 Alm - Not Used
1:0012 Alm - Remote Baseload Ref Fail 1:0061 Alm - DO #15 Readback Fault
1:0013 Alm - Net Head Signal Fail 1:0062 Alm - Not Used
1:0014 Alm - Remote Level Reference 1:0063 Alm - DO #16 Readback Fault
Fail 1:0064 Alm - Not Used
1:0015 Alm - Blade Position Limiter Fail 1:0065 Alm - DO #17 Readback Fault
1:0016 Alm - Tail Level Signal Fail 1:0066 Alm - Not Used
1:0017 Alm - Gate Minor Mismatch 1:0067 Alm - DO #18 Readback Fault
1:0018 Alm - Governor Shutdown 1:0068 Alm - Not Used
1:0019 Alm - Creep Detected 1:0069 Alm - DO #19 Readback Fault
1:0020 Alm - Blade Minor Mismatch 1:0070 Alm - Not Used
1:0021 Alm - Remote Fault #1 1:0071 Alm - DO #20 Readback Fault
1:0022 Alm - Remote Fault #2 1:0072 Alm - Not Used
1:0031 Alm - Remote Fault #11 1:0081 Alm - Speed Sensor 1 Hardware
1:0032 Alm - Remote Fault #12 Fault
1:0033 Alm - DO #1 Readback Fault 1:0082 Alm - Speed Sensor 2 Hardware
1:0034 Alm - Not Used Fault
1:0035 Alm - DO #2 Readback Fault 1:0083 Alm - Speed Sensor 3 Hardware
1:0036 Alm - Not Used Fault
1:0037 Alm - DO #3 Readback Fault 1:0084 Alm - Not Used
1:0042 Alm - Not Used 1:0089 Alm - Analog Input 1 General
1:0043 Alm - DO #6 Readback Fault Fault


1:0092 Alm - Analog Input 4 General 1:0129 Alm - Act Output 1 Hardware
Fault Fault
Fault Fault
Fault Fault
Fault Fault
1:0096 Alm - Analog Input 8 General 1:0133 Alm - Power Supply 1 Fail
Fault 1:0134 Alm - Power Supply 2 Fail
1:0097 Alm - Not Used 1:0135 Alm - Chassis Temperature Alm
1:0098 Alm - Not Used 1:0136 Alm - Chassis Fan #1 Fault
1:0103 Alm - Not Used 1:0141 Alm - Backup Cpu Fault
1:0104 Alm - Not Used 1:0142 Alm - Modbus Link #1 Fault
1:0105 Alm - Analog Output 1 HW Fault 1:0143 Alm - Modbus Link #2 Fault
1:0108 Alm - Analog Output 4 HW Fault 1:0146 Alm - Small System Detection
1:0109 Alm - Analog Output 5 HW Fault 1:0147 Alm - Left Cpu Health Not Ok
1:0110 Alm - Analog Output 6 HW Fault 1:0148 Alm - Right Cpu Health Not Ok
1:0111 Alm - LN2 - AO1 Readback Alarm 1:0149 Alm - Gate Lvdt Fail (Prop Valve)
1:0112 Alm - LN2 - AO2 Readback Alarm 1:0150 Alm - Blade Lvdt Fail (Prop
1:0113 Alm - Analog Output 1 Readback Valve)
Alm 1:0151 Alm - Gate Minor Mismatch (Prop
Alm 1:0152 Alm - Blade Minor Mismatch (Prop
Alm 1:0153 Alm - Any Force Mode Enabled
1:0116 Alm - Analog Output 4 Readback 1:0154 Alm - Not Used
Alm 1:0155 Alm - Discrete Combo #1 Card
1:0117 Alm - Analog Output 5 Readback Fault
Alm 1:0156 Alm - Not Used
1:0118 Alm - Analog Output 6 Readback 1:0157 Alm - Not Used
Alm 1:0158 Alm - Not Used
1:0119 Alm - LN1 - AO1 Readback Alarm 1:0159 Alm - Not Used
1:0120 Alm - LN1 - AO2 Readback Alarm 1:0160 Alm - Not Used
1:0121 Alm - Act Output 1 Driver Fault 1:0161 Alm - Not Used
1:0125 Alm - Act Output 1 Open Load 1:0165 Alm - Not Used
Fault 1:0166 Alm - Not Used
1:0173 Alm - Not Used


1:0198 Alm - Incomplete Stop 1:0250 Alm - Not Used
1:0199 Alm - Gate Position #1 Input Fault 1:0251 Alm - Not Used
1:0200 Alm - Gate Position #2 Input Fault 1:0252 Alm - Not Used
1:0201 Alm - Gate Position Mismatch 1:0253 Alm - Not Used
1:0206 Alm - Incomplete Start 1:0258 Alm - Not Used
1:0217 Alm - Not Used 1:0269 Shutdown - Total Speed Signal
1:0218 Alm - Not Used Failure
1:0219 Alm - Not Used 1:0270 Shutdown - Overspeed
1:0220 Alm - Not Used 1:0271 Shutdown - Incomplete Start
1:0221 Alm - Not Used Timeout
1:0222 Alm - Not Used 1:0272 Shutdown - ESD Discrete Input
1:0223 Alm - Not Used 1:0273 Shutdown - Powerup Trip
1:0224 Alm - Not Used 1:0274 Shutdown - Gate Gross Mismatch
1:0225 Alm - Not Used 1:0275 Shutdown - Blade Gross
Mismatch


1:0276 Shutdown - Gate Position 1:0320 Not Used
Feedback Fail 1:0321 Not Used
1:0277 Shutdown - Blade Pos Feedback 1:0322 Not Used
Fail 1:0323 Not Used
1:0278 Shutdown - Net Head Signal Fail 1:0324 Not Used
1:0279 Shutdown - Act Output #1 Fault 1:0325 Not Used
1:0280 Shutdown - Act Output #2 Fault 1:0326 Not Used
1:0281 Shutdown - Emergency Stop 1:0327 Not Used
1:0282 Shutdown - Not Used 1:0328 Not Used
1:0283 Shutdown - All MPU's Failed 1:0329 Not Used
Open Wire Test 1:0330 Not Used
1:0284 Shutdown - Not Used 1:0331 Not Used
1:0285 Shutdown - Remote Fault #1 1:0332 Not Used
1:0297 Shutdown - Pond or Tail Lvl Sig 1:0344 Not Used
Fail 1:0345 Not Used
1:0298 Shutdown - Gate Gross Mismatch 1:0346 Not Used
(Prop) 1:0347 Not Used
1:0299 Shutdown - Blade Gross 1:0348 Not Used
Mismatch (Prop) 1:0349 Discrete Input #1 Closed
1:0300 Shutdown - Gate LVDT Sig Fail 1:0350 Discrete Input #2 Closed
(Prop) 1:0351 Discrete Input #3 Closed
1:0301 Shutdown - Blade LVDT Sig Fail 1:0352 Discrete Input #4 Closed
(Prop) 1:0353 Discrete Input #5 Closed
1:0302 Shutdown - Trip with Unload 1:0354 Discrete Input #6 Closed
1:0303 Shutdown - Config Error 1:0355 Discrete Input #7 Closed
1:0304 Shutdown - Incomplete Stop 1:0356 Discrete Input #8 Closed
1:0305 Shutdown - Emergency Shutdown 1:0357 Discrete Input #9 Closed
Modbus 1:0358 Discrete Input #10 Closed
1:0306 "Shutdown - Configuration Mode" 1:0359 Discrete Input #11 Closed
1:0307 Not Used 1:0360 Discrete Input #12 Closed
1:0316 Not Used 1:0369 Linknet Discrete Input #1 Closed
1:0319 Not Used


1:0372 Linknet Discrete Input #4 Closed 1:0424 Linknet Discrete Output #4 Closed
1:0378 Linknet Discrete Input #10 Closed 1:0430 Linknet Discrete Output #10
1:0379 Linknet Discrete Input #11 Closed Closed
1:0385 Speed Switch #7 Closed
1:0386 Speed Switch #8 1:0434 Linknet Discrete Output #14
1:0387 Speed Switch #9 Closed
1:0388 Speed Switch #10 1:0435 Linknet Discrete Output #15
1:0389 Not Used Closed
1:0390 Not Used 1:0436 Linknet Discrete Output #16
1:0391 Not Used Closed
1:0392 Not Used 1:0437 Speed Switch #1
1:0398 Not Used 1:0443 Gate Position Switch #1
1:0404 Not Used 1:0449 Active Power Switch #1
1:0410 Not Used 1:0455 Generator Breaker Closed
1:0411 Not Used 1:0456 Emergency Shutdown Indication
1:0412 Not Used 1:0457 Raise Speed/Load
1:0413 Discrete Output #1 Closed 1:0458 Lower Speed/Load
1:0414 Discrete Output #2 Closed 1:0459 Gate Limit Raise
1:0415 Discrete Output #3 Closed 1:0460 Gate Limit Lower
1:0416 Discrete Output #4 Closed 1:0461 Creep Detector #1 Input
1:0417 Discrete Output #5 Closed 1:0462 Creep detector #2 Input
1:0418 Discrete Output #6 Closed 1:0463 Reset Input
1:0419 Discrete Output #7 Closed 1:0464 Speed Bias Raise
1:0420 Discrete Output #8 Closed 1:0465 Speed Bias Lower
1:0421 Linknet Discrete Output #1 Closed 1:0466 Manual Blade Position Raise
1:0422 Linknet Discrete Output #2 Closed 1:0467 Manual Blade Position Lower
1:0423 Linknet Discrete Output #3 Closed 1:0468 Manual Gate Position Raise
1:0469 Manual Gate Position Lower


1:0470 Local Mode Enabled 1:0508 Modbus Speed Remote
1:0471 Remote Mode Enabled Reference Enabled
1:0472 Not Used 1:0509 Modbus Level Remote Reference
1:0473 Governor Run Enabled
1:0474 Governor Stop 1:0510 Modbus Baseload Remote
1:0475 Baseload Mode Enabled Reference Enbld
1:0476 Remote Baseload Mode Enabled 1:0511 Modbus Initial Baseload Rmt Ref
1:0477 Level Control Mode Enabled Enbld
1:0478 Remote Level Control Mode 1:0512 Not Used
Enabled 1:0513 Not Used
1:0479 Position Control Mode Enabled 1:0514 General ALM Indication
1:0480 Remote Position Control Mode 1:0515 General Shutdown Indication
Enabled 1:0516 Remote Speed Reference
1:0481 Manual Gate Mode Enabled Configured
1:0482 Maintenance Gate Mode Enabled 1:0517 Remote Baseload Reference
1:0483 Calibrate Mode Enabled Configured
1:0484 Blade Tilt Enabled 1:0518 Remote Level Reference
1:0485 Blade Lock Enabled Configured
1:0486 Manual Blade Mode Enabled 1:0519 Pond Level Configured
1:0487 Speed Bias Control Mode 1:0520 Tail Level Configured
Enabled 1:0521 External Start Permissive Status
1:0488 In Control - Gate Limit 1:0522 Level Control In Head
1:0489 In Control - On-Line/Droop PID 1:0523 Use Pond/Tail Signals for Blade
1:0490 In Control - Off-Line/Isoch PID Ctrl
1:0491 Gate Limit - At 0% 1:0524 Blade Curve ALM (Revert to Fix
1:0492 Gate Limit - At 100% Curv)
1:0493 Gate Limit - At Breakaway 1:0525 Blade LSS - Auto/Manual Setpoint
1:0494 Gate Limit - At Spd-No-Load/Off- 1:0526 Blade LSS - Analog Limiter
Line Setpoint
1:0495 Gate Limit - At Max Gate Pos/On- 1:0527 Blade LSS - Internal Limiter
Line Setpoint
1:0496 Gate Limit - At Analog Gate Limit 1:0528 Turbine Stopped
1:0497 Off-Ln/Isoch Spd Ref - At Lower 1:0529 In Control - Off-Line/Load Rejec
Limit Logic
1:0498 Off-Ln/Isoch Spd Ref - Follow Actl 1:0530 In Control - On-Line/Freq Limiter
Pos PID
1:0499 Off-Ln/Isoch Spd Ref - At Start Up 1:0531 In Control - On-Line/Load Rejec
1:0500 Off-Ln/Isoch Spd Ref - At SNL Logic
Setpoint 1:0532 Blade Curve ALM (Revert to Lock)
1:0501 Off-Ln/Isoch Spd Ref - At Upper 1:0533 Blade Curve ALM (Revert to
Limit Manual)
1:0502 On-Ln/Droop Spd Ref - Follow 1:0534 Start Command
Actl Pos 1:0535 Blade Preposition Complete (one
1:0503 On-Ln/Droop Spd Ref - At Rem shot)
Stpnt 1:0536 KW Droop Selected
1:0504 On-Ln/Droop Spd Ref - At Lvl 1:0537 Enable Overspeed - Permissive
Stpnt #1
1:0505 On-Ln/Droop Spd Ref - At Lower 1:0538 Enable Overspeed - Permissive
Lim #2
1:0506 On-Ln/Droop Spd Ref - At Upper 1:0539 Enable Overspeed - Permissive
Lim #3
1:0507 Speed Fault/Overspeed Override 1:0540 Enable Overspeed - Permissive
#4


1:0541 Enable Overspeed - Permissive 1:0553 Stroke Permissive 3
#5 1:0554 Stroke Permissive 4
1:0542 Not Used 1:0555 Stroke Permissive 5
1:0543 Not Used 1:0556 Not Used
1:0544 Not Used 1:0557 Shutdown with unload in Progress
1:0545 Not Used 1:0558 Selected Droop BP0
1:0548 Not Used 1:0561 Small System Active
1:0549 Generator Unload Enabled 1:0562 Not Used
1:0550 Not Used 1:0563 Not Used
1:0551 Stroke Permissive 1 1:0564 Not Used
1:0552 Stroke Permissive 2 1:0565 Not Used
Table 45: Analog Read Addresses
Address Description Multiplier

3:0001 Last Trip Cause 1
3:0002 Gate Position (%) 100
3:0003 Gate Demand Signal (%) 100
3:0004 Gate Actuator Output (%) 100
3:0005 Gate Limit (%) 100
3:0006 Unit Speed (%) 100
3:0007 Unit Speed (rpm) 10
3:0008 Maximum Speed Since Last Start (rpm) 10
3:0009 Pond/Tail Level 10
3:0010 Pond/Tail Level Setpoint 10
3:0011 Pond/Tail Level Gate Position Setpoint 100
3:0012 Remote Speed/Gate Position Reference 100
3:0013 Speed Bias 100
3:0014 Generator Load (%) 100
3:0015 Generator Load (MW) 100
3:0016 Online/Droop Speed Reference 100
3:0017 Online/Droop PID Output 100
3:0018 Offline/Isoch Speed Reference 100
3:0019 Offline/Isoch PID Output 100
3:0020 Analog Gate Limit (%) 100
3:0021 Remote Baseload Reference (MW) 100
3:0022 Baseload Reference (MW) 100
3:0023 Analog Blade Limit (%) 100
3:0024 Blade Position (%) 100
3:0025 Blade Demand Signal (%) 100
3:0026 Blade Actuator Output (%) 100
3:0027 Analog Input #1 Value (mA) 100



3:0035 Speed Sensor 1 (rpm) 10
3:0036 Speed Sensor 2 (rpm) 10
3:0037 Not Used 10
3:0038 Not Used 10
3:0039 Analog Output #1 Value (mA) 100
3:0043 Analog Output #1A Readback Value (mA) 100
3:0047 Act Output #1 Display Value (%) 100
3:0048 Act Out #1 Readback Source Value (mA) 100
3:0049 Act Out #1 Readback Return Value (mA) 100
3:0050 Act Output #2 Display Value (%) 100
3:0051 Act Out #2 Readback Source Value (mA) 100
3:0052 Act Out #2 Readback Return Value (mA) 100
3:0053 Not Used 1
3:0054 Discrete Input 2 Configuration 1
3:0073 Not Used 1
3:0074 Discrete Output 1 Configuration - Emergency Stop 1
3:0075 Discrete Output 2 Configuration 1


3:0098 Analog Input 1 Configuration 1
3:0106 Analog Output 1 Configuration 1
3:0110 Overspeed Test Remaining Time 10
3:0111 Internal Gate Limit 100
3:0112 Internal Initial Baseload Reference 100
3:0113 Pond Level (Engineering Units) 10
3:0114 Tail Level (Engineering Units) 10
3:0115 Blade Tilt Position 100
3:0116 Starting Blade Tilt Position 100
3:0117 Blade Curves Position 100
3:0118 Manual Blade Ramp Position 100
3:0119 Internal Blade Limiter 100
3:0120 Blade Demand (LSS) 100
3:0121 Net Head Signal 10
3:0122 Analog Remote Baseload Reference 100
3:0123 Analog Remote Speed Reference 100
3:0124 Frequency Limiter PID Output 100
3:0125 Load Rejection Logic Output 100
3:0126 Analog Remote Level Reference 10
3:0127 Stopping Blade Tilt Position 100
3:0128 Load Rejection Blade Tilt Position 100
3:0129 Blade Fixed Curve Position 100
3:0130 Blade Tilt Selected 1
3:0131 Generator Frequency 100
3:0132 Speed Input #1 Config 1
3:0133 Speed Input #2 Config 1
3:0134 spare 1
3:0135 Online reference 10


3:0138 Linknet 1 Analog Output 1 Configuration 1
3:0140 Not Used 100
3:0141 Not Used 100
3:0144 Not Used 2
3:0145 Not Used 3
3:0146 Not Used 4
3:0147 Not Used 5
3:0148 Not Used 6
3:0149 Not Used 7
3:0150 Not Used 8
3:0151 Not Used 9
3:0152 Not Used 1
3:0153 Not Used 1
3:0154 Not Used 100
3:0155 Not Used 100
3:0158 Not Used 100
3:0159 Not Used 100
3:0160 Analog Output #5 Readback Value (mA) 100
3:0161 Analog Output #6 Readback Value (mA) 100
3:0162 Analog Output #1 Linknet #1 Readback Value (mA) 100
3:0164 Not Used 100
3:0165 Not Used 100
3:0166 Not Used 100
3:0167 Not Used 100
3:0168 Not Used 100
3:0169 Not Used 100
3:0170 Not Used 1
3:0171 Gate Actuator Output (mA) 100
3:0172 Blade Actuator Output (mA) 100
3:0173 Gate Position Fdbck (From Prop Valve) 100
3:0174 Blade Position Fdbck (From Prop Valve) 100
3:0175 Net Head Value for Control (EU) 10
3:0176 Linknet 1 Analog Output #1 Value (mA) 1
3:0180 Not Used 1
3:0181 Actual Droop Value 10
3:0184 Linknet Discrete Input 1 Configuration 1


Table 46: Analog Write Addresses

4:0001 MODBUS - REMOTE SPEED SETPOINT 0.01
4:0002 MODBUS - INITIAL BASELOAD SETPOINT 0.01
4:0003 MODBUS - REMOTE BASELOAD SETPOINT 0.01
4:0004 MODBUS - REMOTE LEVEL REFERENCE 0.1
4:0005 Actuator 1 Stroke Value 1
4:0006 Actuator 2 Stroke Value 1
4:0007 Net Head value 0.1
4:0008 Manual Gate Demand 0.01
Last Turbine Trip Cause

The cause of the last turbine trip (address 3:0001) is an integer that represents the Event ID found in
Table 45.

Chapter 14 – Product Support and Service Options
Product Support Options

If you are experiencing problems with the installation, or unsatisfactory performance of a Woodward
product, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact the manufacturer or packager of your system.
• Contact the Woodward Full Service Distributor serving your area.
• Contact Woodward technical assistance (see “How to Contact Woodward” later in this chapter)
and discuss your problem. In many cases, your problem can be resolved over the phone. If not,
you can select which course of action to pursue based on the available services listed in this
chapter.
OEM or Packager Support: Many Woodward controls and control devices are installed into the
equipment system and programmed by an Original Equipment Manufacturer (OEM) or Equipment
Packager at their factory. In some cases, the programming is password-protected by the OEM or
packager, and they are the best source for product service and support. Warranty service for Woodward
products shipped with an equipment system should also be handled through the OEM or Packager.
Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a global network of
independent business partners whose mission is to serve the users of Woodward controls, as described
here:
• A Full Service Distributor has the primary responsibility for sales, service, system integration
solutions, technical desk support, and aftermarket marketing of standard Woodward products
within a specific geographic area and market segment.
• An Authorized Independent Service Facility (AISF) provides authorized service that includes
repairs, repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is
an AISF's primary mission.
• A Recognized Turbine Retrofitter (RTR) is an independent company that does both steam and
gas turbine control retrofits and upgrades globally, and can provide the full line of Woodward
systems and components for the retrofits and overhauls, long term service contracts, emergency
repairs, etc.
A current list of Woodward Business Partners is available at www.woodward.com/directory.
Product Service Options

The following factory options for servicing Woodward products are available through your local Full-
Service Distributor or the OEM or Packager of the equipment system, based on the standard Woodward
Product and Service Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
Replacement/Exchange: Replacement/Exchange is a premium program designed for the user who is in

need of immediate service. It allows you to request and receive a like-new replacement unit in minimum
time (usually within 24 hours of the request), providing a suitable unit is available at the time of the

request, thereby minimizing costly downtime. This is a flat-rate program and includes the full standard
Woodward product warranty (Woodward Product and Service Warranty 5-01-1205).
This option allows you to call your Full-Service Distributor in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the unit is available at the time of
the call, it can usually be shipped out within 24 hours. You replace your field control unit with the like-new
replacement and return the field unit to the Full-Service Distributor.
Charges for the Replacement/Exchange service are based on a flat rate plus shipping expenses. You are
invoiced the flat rate replacement/exchange charge plus a core charge at the time the replacement unit is
shipped. If the core (field unit) is returned within 60 days, a credit for the core charge will be issued.
Flat Rate Repair: Flat Rate Repair is available for the majority of standard products in the field. This
program offers you repair service for your products with the advantage of knowing in advance what the
cost will be. All repair work carries the standard Woodward service warranty (Woodward Product and
Service Warranty 5-01-1205) on replaced parts and labor.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option with
the exception that the unit will be returned to you in “like-new” condition and carry with it the full standard
Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option is
applicable to mechanical products only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair, please contact your Full-
Service Distributor in advance to obtain Return Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
• Return authorization number
• Name and location where the control is installed
• Name and phone number of contact person
• Complete Woodward part number(s) and serial number(s)
• Description of the problem
• Instructions describing the desired type of repair
Packing a Control
Use the following materials when returning a complete control:

• Protective caps on any connectors
• Antistatic protective bags on all electronic modules
• Packing materials that will not damage the surface of the unit
• At least 100 mm (4 inches) of tightly packed, industry-approved packing material
• A packing carton with double walls
• A strong tape around the outside of the carton for increased strength
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.

Replacement Parts
When ordering replacement parts for controls, include the following information:
• The part number(s) (5001-XXXX) that is on the enclosure nameplate
• The unit serial number, which is also on the nameplate
Engineering Services
Madsen Controls & Engineering offers various Engineering Services for our products. For these services,
you can contact us by telephone, by email, or through the Madsen’s website.
• Technical Support
• Product Training
• Field Service
Technical Support is available from your equipment system supplier, your local Full-Service Distributor,
or from many of Madsen locations, depending upon the product and application. This service can assist
you with technical questions or problem solving during the normal business hours of the Madsen location
you contact. Emergency assistance is also available during non-business hours by phoning Madsen and
stating the urgency of your problem.
Product Training is available as standard classes at many of our locations. We also offer customized
classes, which can be tailored to your needs and can be held at one of our locations or at your site. This
training, conducted by experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product and location, from many
of our locations. The field engineers are experienced both on Woodward products as well as on much of
the non-Woodward equipment with which our products interface.
For information on these services, please contact us via telephone, email us, or use our website:
www.madsencontrols.ca


Contacting Madsen’s Support Organization

For the name of your nearest Madsen service facility, please consult our website
www.madsencontrols.ca, which also contains the most current product support and contact information.
You can also contact the Madsen Customer Service Department at one of the following Madsen facilities
to obtain information and service.
Ontario Alberta Quebec

30 Voyager Court South 5977 103A Street NW 96 Avenue Leacock
Toronto, ON Edmonton, AB Pointe-Claire, QC
M9W 5M7 T6H 2J7 H9R 1H1
Phone: (416) 907-3844 Phone: (780) 437-4673 Phone: (514) 971-2063
Nova Scotia Newfoundland & Labrador

25 Raddall Ave., Unit 2 141 Glencoe Drive
Dartmouth, NS Mount Pearl, NL
B3B 1L4 A1N 4S7
Phone: (902) 468-4736 Phone: (709) 726-6774

Technical Assistance
If you need to contact technical assistance, you will need to provide the following information. Please
write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or
the Woodward factory:
General
Your Name
Site Location
Phone number
Fax Number
Primer Mover Information
Manufacturer
Turbine Model Number
Type of Fuel (gas, steam, etc.)
Power Output Rating
Application (power generation, marine, etc.)
Control/Governor Information
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Symptoms
Description
If you have an electronic or programmable control, please have the adjustment setting positions or the
menu settings written down and with you at the time of the call.

Appendix A – Configuration Mode Worksheets
Control Part Number ________________________________
Serial Number ________________________________
Application ________________________________ Date _____________
OPERATING PARAMETERS Default Site Value

Turbine Type Francis/Kaplan
Nominal Frequency 60 Hz
Droop 5 %
Reset Clears Trip Relay? NO YES/NO
Allow Remote Control YES YES/NO
Speed Bias Signal Not Used
Primary Generator Load Signal None
Secondary Generator Load Signal None
SPEED SETPOINTS Default Site Value

Overspeed Trip 150 %
Overspeed Trip Delay 0 s
Overspeed Test Limit 160 %
Overspeed Speed Rate 2.5 %/s
Nominal Speed 1 rpm
Offline Rate 0.1 %/s
Online Rate 1 %/s
Online Remote Rate 0.8 %/s
Online Level Rate 1 %/s
Use Creep Detection NO YES/NO
Creep Speed 5 %
Dead Stop Time 60 s
Reset Creep Time 5 s
Look Again Time 5 s
SPEED SENSORS Default Site Value

Probe Type #1 MPU MPU/Active
Device Tag #1 User Text
Number of Gear Teeth #1 60
Gear Ratio #1 1
Maximum Level Speed #1 360 rpm
Failed Level Speed #1 15 rpm
Use Speed Input Channel 2 NO YES/NO
Probe Type #2 MPU MPU/Active
Device Tag #2 User Text
Number of Gear Teeth #2 60
Gear Ratio #2 1
Maximum Level Speed #2 360 rpm
Failed Level Speed #2 15 rpm

POWER SWITCHES Default Site Value

Switch #1 High Value 100 %
Switch #1 High Delay 0 s
Switch #1 Low Value 98 %
Switch #1 Low Delay 0 s
Switch #1 Invert NO YES/NO
SPEED SWITCHES Default Site Value


SPEED SWITCHES Default Site Value

GATE SWITCHES Default Site Value


GATE SWITCHES Default Site Value

TRIP RELAYS Default Site Value

All Speed Signals Failure YES YES/NO
Overspeed YES YES/NO
Incomplete Start YES YES/NO
ESD Discrete Input YES YES/NO
Power-up Trip YES YES/NO
Gross Gate Mismatch YES YES/NO
Gross Blade Mismatch YES YES/NO
Gate Position Feedback Fail YES YES/NO
Blade Position Feedback Fail YES YES/NO
Net Head Signal Fail YES YES/NO
Actuator Output #1 Fault YES YES/NO
Actuator Output #2 Fault YES YES/NO
EStop from Keypad YES YES/NO
Open Wire Test Trip YES YES/NO
Remote Fault #1 NO YES/NO
Head/Tail Level Signal Fail YES YES/NO
Gate Gross Mismatch (Prop. Valve) YES YES/NO
Blade Gross Mismatch (Prop. Valve) YES YES/NO
Gate LVDT Signal Fail (Prop. Valve) YES YES/NO
Blade LVDT Signal Fail (Prop. Valve) YES YES/NO
Trip with Unload YES YES/NO
Configuration Error YES YES/NO
Incomplete Stop YES YES/NO
Emergency Shutdown (Modbus) YES YES/NO
Configuration Mode (I/O Lock) YES YES/NO
Linknet Summary Trip YES YES/NO

BRAKE Default Site Value

Use Brake NO YES/NO
Maximum Speed to Apply brake 50 %
Brake Pulse ON Time Delay 15 s
Brake Pulse OFF Time Delay 10 s
Maximum Time to Apply Brake 60 s
COMMUNICATION Default Site Value

Ethernet IP Configuration
ENET 1 Address 172.16.100.15
ENET 1 Subnet Mask 192.168.128.20
ENET 2 Address 255.255.255.0
ENET 3 Address 255.255.255.0
ENET 4 Address 255.255.255.0
Modbus Configuration
Use Modbus NO YES/NO
Use Serial Link 1 NO YES/NO
Use Ethernet Link 2 NO YES/NO
Use Ethernet Link 3 NO YES/NO
Device Address (1-247) 1 YES/NO
Enable Write Commands NO Asci/rtu
Protocol Ascii 110-115K
Baud Rate 115200 7/8
Bits 8 1/1.5/2
Stop Bits 1 Off/odd/even
Parity OFF 232/485
Driver RS-232 YES/NO
Ethernet Protocol Ethernet TCP TCP/UDP
Device Address (1-247) 2
Enable Write Commands NO YES/NO
Ethernet Protocol Ethernet TCP TCP/UDP
Device Address (1-247) 3
Enable Write Commands NO YES/NO
ANALOG INPUT CHANNELS Default Site Value

Use Brake NO YES/NO
Maximum Speed to Apply brake 50 %

ANALOG INPUT CHANNELS

Ch Function Val@4 Val@20 Loop TAG Units Modbus Dec.
Pwrd Mult. Disp
1
2
3
4
5
6
7
8
ANALOG OUTPUT CHANNELS

Ch Function Val@4 Val@20 Ena Redbk TAG Units
Flt
1
2
3
4
5
6
ACTUATOR OUTPUT CHANNELS

Ch Function Range mA mA Dither Act Flt Trip Rev TAG Type 2-Stg
@0 @100 SD 0mA Act Cntrl Act
1
2
CONTACT INPUT CHANNELS

Ch Function Invert Logic TAG
1 Emergency Stop
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

RELAY OUTPUT CHANNELS

1 Trip Relay
2
3
4
5
6
7
8
LINKNET I/O MODULES – Channel Configuration Tables (OPTIONAL)

Node 1 – 8 channels Analog Input 4-20mA & 2 channels Analog Output 4-20mA
Ch Function Val@4 Val@20 Units Modbus Dec TAG
Mult Disp
1
2
3
4
5
6
7
8
1
2
Node 2 – 8 channels Analog Input 4-20mA & 2 channels Analog Output 4-20mA
Ch Function Val@4 Val@20 Units Modbus Dec TAG
Mult Disp
1
2
3
4
5
6
7
8
1
2

Node 3 – 8 channels RTD Input (100 or 200 ohm)

Ch Function Min Max Deg Modbus Dec Crv ohm TAG
Val Val F/C Mult Disp E/A val
1
2
3
4
5
6
7
8
For each of the Analog Input Node channels above, events can be configured if desired.
Node 1 Events
Ch Use Use Use Level 1 Inv Level 2 Inv Setpoint Delay Ena Spd
Alm1 Alm2 Trip SP SP Hysteresis Spd Hys
1
2
3
4
5
6
7
8
Node 2 Events
1
2
3
4
5
6
7
8
Node 3 Events
1
2
3
4
5
6
7
8

Node 4 – 16 channel Discrete Input (24Vdc)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Node 5 – 16 channel Discrete Output (24Vdc)

Ch Level or Function Invert Level ON Level OFF TAG
State Logic
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
When Actuator Outputs have been (In Service) Calibrated and Stroked, record values here.
Default Value in 5001

Actuator #1 mA at Minimum Position 4 mA
Actuator #1 mA at Maximum Position 20 mA
Actuator #1 Dither (mA) 0 mA
Actuator #2 mA at Minimum Position 4 mA

Actuator #2 mA at Maximum Position 20 mA
Actuator #2 Dither (mA) 0 mA

Appendix B – Service Mode Worksheets
Control Part Number ________________________________
Serial Number ________________________________
Application ________________________________ Date _____________
TURBINE START Default Site Value

Low Speed to Stable Speed 98 %
High Speed to Stable Speed 102 %
Time to Stable Speed 15 s
Time to Incomplete Start 600 s
Minimum Speed for Incomplete Start 25 s
TURBINE STOP Default Site Value

Speed to Consider Turbine Stopped 2 %
Time to Incomplete Stop 800 s
Wait Breaker Open to Start Timer NO YES/NO
Enable Incomplete Stop Trip YES YES/NO
SPEED CONTROL Default Site Value

Offline Dynamics
Proportional Gain 3.85
Integral Gain 0.03
Derivative Gain (SDR) 100
Speed-No-Load Reference (%) 100.05 %
Minimum Speed Reference 90 %
Maximum Speed Reference 110 %
Temporary Compensation 0.05
Small System
Use Small System Detection YES YES/NO
Use Speed Stable Setpoint Delay YES YES/NO
Speed Window to Activate SSD 1 %
Speed Derivative to Activate SSD 10 %
Use Breaker Status YES YES/NO
Use Timer Delay After Breaker Closes YES YES/NO
Delay 5 min
Use Disable Timer Delay NO YES/NO
Delay 10 min
Integral Gain 0.03
Online Dynamics
Integral Gain 0.25
First Control Mode When Breaker Closes Pos/kW Droop
PID Clamp Window 4 %

Load Dynamics
Integral Gain 0.15
SPEED SIGNALS Default Site Value

Override Overspeed Trip after Start 10 s
Override Timer Remaining 0 s
Deadband
Deadband Selection
Online Only
Speed Deadband 0.05 %
Speed Sensor #1 Filter 0.01
Speed Sensor #2 Filter 0.01
GATE PARAMETERS Default Site Value

Gate Configuration
Maximum Gate Limit 100 %
Breakaway Limit 25 %
Dwell Time 15 s
Speed No Load Gate Limit 15 %
Start Gate Rate 1 %/s
Stop Gate Rate 1 %/s
Load Rejection
Enable Gate Load Rejection NO YES/NO
Gate Position Value 7 %
Speed Derivative Threshold 7 %/s
Maximum Algorithm Time 7 s
Speed Threshold 110 %
POSITION/KW DROOP Default Site Value

Force gate x power curve NO YES/NO
Gate x Power Curve
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 10 %
X-3 Value 20 %
Y-3 Value 20 %
X-4 Value 30 %
Y-4 Value 30 %
X-5 Value 40 %
Y-5 Value 40 %
X-6 Value 50 %
Y-6 Value 50 %
X-7 Value 60 %
Y-7 Value 60 %
X-8 Value 70 %
Y-8 Value 70 %
X-9 Value 80 %
Y-9 Value 80 %
X-10 Value 90 %

Y-10 Value 90 %
X-11 Value 100 %
Y-11 Value 100 %
LEVEL CONTROL Default Site Value

Level Control Type Head Level
Level Setpoint Type Bumpless Transfer
Preset Value 0
Fixed Speed in Level Control NO YES/NO
Level Setpoint Raise/Lower Rate 1 EU/s
Minimum Gate Setpoint 20 %
Maximum Gate Setpoint 100 %
Level Control Window 0.5 EU
BASELOAD Default Site Value

Unload Level 1 MW
Rated Load 1 MW
Minimum Reference 1 MW
Maximum Reference 1 MW
Initial Reference 1 MW
Time to Decrease 150 s
Time to Increase 150 s
Remote Baseload
Minimum Remote Reference 1 MW
Maximum Remote Reference 1 MW
Time to Decrease 150 s
Time to Increase 150 s
BLADE PARAMETERS Default Site Value

Blade Rate 3 %/s
Blade Tilt Value 0 %
Enable Start Blade Tilt YES YES/NO
Start Blade Tilt Value 30 %
Speed to Disable Start Tilt 50 %
Enable Stop Blade Tilt YES YES/NO
Stop Blade Tilt Value 50 %
Speed to Disable Stop Tilt 25 %
Enable Blade Load Rejection YES YES/NO
Blade Load Rejection Value 100 %
Use Blade Preposition on Startup YES YES/NO
Window 5 %
Stable Time 3 s
Maximum Time 35 s

BLADE CURVE Default Site Value

Curve 1
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 2
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 3
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %

X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 4
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 5
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %

Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 6
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 7
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %

X-11 Value 100 %

Y-11 Value 100 %
Curve 8
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 9
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 10
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %

X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 11
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 12
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %

Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 13
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %
X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Curve 14
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 1 %
X-3 Value 20 %
Y-3 Value 2 %
X-4 Value 30 %
Y-4 Value 5 %
X-5 Value 40 %
Y-5 Value 10 %
X-6 Value 50 %
Y-6 Value 20 %
X-7 Value 60 %
Y-7 Value 35 %
X-8 Value 70 %
Y-8 Value 50 %
X-9 Value 80 %
Y-9 Value 66.7 %

X-10 Value 90 %
Y-10 Value 83.3 %
X-11 Value 100 %
Y-11 Value 100 %
Fixed Curve
X-1 Value 0 %
Y-1 Value 0 %
X-2 Value 10 %
Y-2 Value 10 %
X-3 Value 20 %
Y-3 Value 20 %
X-4 Value 30 %
Y-4 Value 30 %
X-5 Value 40 %
Y-5 Value 40 %
X-6 Value 50 %
Y-6 Value 50 %
X-7 Value 60 %
Y-7 Value 60 %
X-8 Value 70 %
Y-8 Value 70 %
X-9 Value 80 %
Y-9 Value 80 %
X-10 Value 90 %
Y-10 Value 90 %
X-11 Value 100 %
Y-11 Value 100 %
Net Head
Net Head Type Modbus Signal
Net Head Alarm Revert to Fixed Curve
Head Level Alarm Revert to Fixed Curve
Tail level Alarm Revert to Fixed Curve
VALVE DRIVER Default Site Value

Gate
Use Offline/Online Gain NO YES/NO
Offline Valve Gain 1
Valve Offset 0
Online Valve Gain 1
Adaptive Valve Offset Calculation
Initial Valve Offset 0
Algorithm Sample Time 15 min
Offset Maximum Step Change 0.2
Gate (Proportional Valve)
Valve Offset 0
Online Valve Gain 1

Blade
Valve Offset 0
Online Valve Gain 1
Blade (Proportional Valve)
Valve Offset 0
Online Valve Gain 1
VALVE MISMATCHES Default Site Value

Gate Mismatches
Enable Minor Mismatch YES YES/NO
Minor Mismatch Value 5 %
Minor Mismatch Alarm Delay 15 s
Enable Gross Mismatch YES YES/NO
Gross Mismatch Value 10 %
Gross Mismatch Shutdown Delay 30 s
Gate Mismatches (Proportional Valve)
Enable Minor Mismatch NO YES/NO
Enable Gross Mismatch NO YES/NO
Blade Mismatches
Enable Minor Mismatch YES YES/NO
Blade Mismatches (Proportional Valve)
Enable Minor Mismatch NO YES/NO

MANUAL/MAINTENANCE Default Site Value

Manual Gate Mode
Manual Raise/Lower Rate 0.5 %/s
Manual Gate Mode (Proportional Valve)
Manual Blade Mode
Manual Blade Mode (Proportional Valve)
CUSTOM TREND Default Site Value

Settings
Time Window 60 s
Signal 1 (Red) Not Used Selection
Y Maximum 100 Units
Y Minimum 0 Units
Width 1 Value
Show Axis YES YES/NO
Signal 1 (Green) Not Used Selection
Y Maximum 100 Units
Y Minimum 0 Units
Width 1 Value
Signal 3 (Blue) Not Used Selection
Y Maximum 100 Units
Y Minimum 0 Units
Width 1 Value
Signal 4 (Purple) Not Used Selection
Y Maximum 100 Units
Y Minimum 0 Units
Width 1 Value
Signal 5 (Orange) Not Used Selection
Y Maximum 100 Units
Y Minimum 0 Units
Width 1 Value
FIELD TOOLS Default Site Value

Step Test
Magnitude of Step Input 1 %
Step Test Length 30 s
Negative Step NO YES/NO
Gate Timer
Use Gate Timer NO YES/NO
OPERATION LOG Default Site Value

Maintenance Interval 15000 hours

SCREEN OPTIONS Default Site Value

Screen Saver Delay 4 hours
Auto Login as Operator? YES YES/NO
Operator Password wg1111
Disable Screen Saver? NO YES/NO
REAL TIME CLOCK Default Site Value

Use SNTP Synchronization NO YES/NO
SNTP IP Address 10.14.128.1
SNTP Rate 300
SNTP Timeout 300
Time Zone 0 Integer
Year 15 Integer
Month 1 Integer
Day 1 Integer
Hour 0 Integer
Minutes 0 Integer
Seconds 0 Integer
Use SNTP Synchronization NO YES/NO
COMMUNICATIONS Default Site Value

Serial Port 1
Time-out Delay 10 s
Ethernet Port 2
Time-out Delay 10 s
Ethernet Port 3
Time-out Delay 10 s

Appendix C – Password Information
General
The 5001 Series control system requires a password to be entered before access can be given to the
OPERATOR, SERVICE, CONFIGURE, or ServiceUser modes. These passwords help prevent
unauthorized or untrained personnel from accessing these modes and possibly making changes that
could cause damage to the turbine or associated process. If only selected people are to know these
passwords, remove this appendix and keep it in a separate place, apart from the manual.
To enter the login or password on the front panel display:
Navigate so the Login or Password field is highlighted (in-focus)

Press Enter on the Navigation Cross
Use the keypad to enter the text field (hold key down to scroll options)
Press Enter on the Navigation Cross – to accept your entry
Monitor User Level

There is no password required to monitor values – all navigational commands and display information is
available on all screens but no operational commands can be entered from the display. The Emergency
Stop button is always available.
“Operator” User Level Password

Login as Operator:
Login: Operator
Password: wg1111
“Service” User Level Password

Login as Service:
Login: Service
Password: wg1112
“Configure” User Level Password

Login as Configure:
Login: Configure
Password: wg1113
“ServiceUser” User Level Password

Login as ServiceUser (no autofill key available, must be entered manually):
Login: ServiceUser
Password: ServiceUser@1


Revision History

1901

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

1901

Caricato da

Copyright:

Formati disponibili

Product Manual 1901

(Revision New, 9/2019)

Flex500 Digital Control for Hydro Application

Installation and Operation Manual

Any unauthorized modifications to or use of this equipment outside its

WARNINGS AND NOTICES ............................................................................................................... 8

CHAPTER 3 – HARDWARE SPECIFICATION ..................................................................................... 23

Madsen Controls & Engineering 1

Level Control .............................................................................................................................................. 68

Madsen Controls & Engineering 2

CHAPTER 12 – 5001 OPERATION ................................................................................................ 157

Madsen Controls & Engineering 3

The following are trademarks of Woodward, Inc.:

The following are trademarks of their respective companies:

Madsen Controls & Engineering 4

Illustrations and Tables

Figure 1: 5001P Digital Control (With Display) ........................................................................................... 18

Madsen Controls & Engineering 5

Figure 52: Configuration/Woodward Links/DSLC-2.................................................................................. 149

Table 1: 5001P Part Number Options ........................................................................................................ 16

Madsen Controls & Engineering 6

Table 18: Specifications (Relay outputs) .................................................................................................... 46

Madsen Controls & Engineering 7

Warnings and Notices

The engine, turbine, or other type of prime mover should be

The overspeed shutdown device must be independent of the prime mover

To prevent damage to a control system that uses an alternator

To prevent damage to electronic components caused by

The engine, turbine, or other type of prime mover should be

Madsen Controls & Engineering 8

Be prepared to make an emergency shutdown when starting

The products described in this publication may present

IOLOCK. When a CPU or I/O module fails, watchdog logic

NOTE: Specify additional watchdog details and any

Madsen Controls & Engineering 9

An emergency switch or circuit breaker shall be included in

Authorized personnel knowledgeable of the risks posed by

Properly fuse the Power Supply MAINS according to the

Electrostatic Discharge Awareness

Electronic controls contain static-sensitive parts. Observe the

To prevent damage to electronic components caused by

Follow these precautions when working with or near the control.

Madsen Controls & Engineering 10

• Do not touch any part of the PCB except the edges.

To prevent damage to electronic components caused by

Madsen Controls & Engineering 11

Other European and International Compliance:

EAC Customs Union

Declared to Technical Regulation TR CU 020/2011 On Electromagnetic

Madsen Controls & Engineering 12

Lloyd’s: Type Approval Conditions

DNV-GL: Type Approval Conditions

Clause for application software control

Special Conditions for Safe Use

Madsen Controls & Engineering 13

Field wiring must be suitable for the following temperatures:

Madsen Controls & Engineering 14

For ATEX/IECEx installation compliance, the

Substitution of components may impair suitability

Due to the Hazardous Location Listings

Do Not Remove Covers or Connect/Disconnect

Substitution of components may impair

Properly connect the external ground lugs

Madsen Controls & Engineering 15