Engineering Service Tools

Control Assistant Service Tool — Windows-based trend viewing tool used to view high-speed datalog captures or perform other useful utilities (program compare functions, etc.; see product specification 03201).

AppManager Service Tool — Windows-based tool used to upload and download GAP and GUI (graphical user interface) based application programs, retrieving datalog files, and starting/stopping the programs.

Control Specifications

INPUTS

• Power:

  • LV models = 18–32 Vdc

  • HV models = 88–264 Vac & 90–150 Vdc

• Speed:

  • 2 MPU and 2 Prox with Prox Power

• Discrete Inputs:

  • 20 configurable contact inputs (optionally, additional inputs can be added via distributed I/O modules)

• Analog Inputs:

  • 8 Configurable 4–20 mA Inputs (optionally, additional inputs can be added via distributed I/O modules)

OUTPUTS

• Valve/Actuator Drivers:

  • 2 actuator outputs, 4–20 mA or 20–200 mA

• Discrete Outputs:

  • 8 configurable relay outputs (2 relays rated for 24 Vdc @ 5 A, 6 relays rated for 24 Vdc @ 2 A) (optionally, additional outputs can be added via distributed I/O modules)

• Analog Outputs:

  • 6 programmable 4–20 mA outputs (optionally, additional outputs can be added via distributed I/O modules)

COMMUNICATIONS

• Ethernet:

  • 4 ports (Modbus TCP or OPC protocols)

• Serial:

  • 1 Modbus port (ASCII or RTU) comm ports (RS-232 or RS-485 compatible)

• CAN:

  • 4 ports (CANopen protocol)

Real-Time Operating System (RTOS)

The Flex500 controller’s structured scan rate and synchronized software-to-I/O architecture enforce fast, deterministic, and completely repeatable dynamic behavior. Thorough and extensive FFT testing has proven that screw-to-screw response times are exactly the same for every scan rate, regardless of what is happening elsewhere in the controller. PLCs make use of a less rigid scan rate and synchronization structures that can introduce dynamic instability as the processor becomes busy or code is added or removed.

Communications

The Flex500 control can communicate directly with plant Distributed Control Systems and/or touch-screen operator control panels through four Ethernet ports using Modbus TCP or OPC communication protocols, or via one serial Modbus port. The included serial port supports either RS-232 or RS-485 communications and can be configured to use ASCII or RTU Modbus protocols. Communications between the Flex500 control and a plant DCS can also be performed through hardwired connections.

Advantages over PLCs:

• Purpose built for turbines, engines, & compressors (deterministic response, special purpose algorithms, etc.)

• Rated for installation in hazardous and high temperature locations (skid mountable)

• Integrated graphical operator control panel reduces installation and support costs

• Scalable with Woodward distributed I/O modules designed for hazardous and high temperature locations

• Open architecture allows users with the right security level to perform software program changes as needed

• PLC based logic and related operator control panel screens can easily be added as needed

• All modules protected by sulfur/corrosive-resistant conformal coating

• Full control redundancy (Power, CPU, inputs, outputs, on-line programming) - dual redundant systems

• Simple to replace a controller or make program changes while turbine is on-line running normally

• Entire plants can standardize on one control system for all of their turbines, compressors, and, engines
  (difference is software program only)