GE Energy

Korangi Power
Woodward Controls Maintenance Course

2008

g
GE Energy

Korangi Power
Woodward Controls Maintenance Course
Turbine Serial Number

2008

Tab 1 Intro 01 – Intro

Tab 2 Basics 02 – Basics
Tab 3 Digital Basics 03 – Digital Basics
Tab 4 GAP Intro 04 – GAP Intro
Tab 5 MICRONET Simplex 05 – MICRONET Simplex
Tab 6 MICRONET PLUS 06 – MICRONET Plus
Tab 7 Software Tools 07 – Software Tools
Tab 8 Service Panel 08 – Service Panel
Tab 9 Sensor and Instrumentation 09 – Sensors and Instrumentation

Korangi Power, Woodward Controls Maintenance Course 1

g
Tab 1
Welcome to the Woodward Controls
Hardware Troubleshooting
Training Course For:

GE Energy
AES Engineers
Objectives of this Course…
• Recognize failed components in the turbine package
– Transducers / Actuators
– Switches / Relays
– Speed probes
• Recognize failed components in the control system
– Terminal Boards
– I/O cards
– Processor cards
• Safely replace the failed component
• Power Isolation, Grounding, etc.
• Proper downloads required when changing hardware
• Advanced troubleshooting techniques
Introduce Yourself

Name
Job Responsibility
Expectations of this Class
In Case of Emergency
In the event that an emergency situation, such as a fire, occurs at the Loveland facility and it requires
that the building to be evacuated, all employees must follow the evacuation procedure below:

Evacuate the building from the nearest exit (there are no GE employees who are expected to remain
and operate critical plant operations before they evacuate).
Quickly gather car keys and any medications to take with you.
Stay clear of all hazardous areas such as downed power lines and smoke filled rooms.
Report to the Primary Meeting (Muster) Area outside of the building. (See Attached)
Assemble quietly and avoid unnecessary conversations in order to hear role call. The Emergency
Coordinators will be taking roll to identify those who are not present and notify the fire department if
any persons are thought to be inside the building.
Remain at Evacuation Muster Area and wait for instructions from the Loveland Fire Department
and/or the Emergency Coordinators as to when the building can be re-entered and when normal
operations can be resumed.
Woodward Beginnings...
Amos Woodward
Born and raised in New England
Worked as a machinist where waterwheels were used
to power the machinery.
Each waterwheel was controlled by a mechanical
governor, although they never ran very consistently.
He continually improved these governors in his spare
time, and in 1870 he decided to start his own business
making governors for waterwheels and hydraulic
turbines.
Elmer Woodward

Followed father’s lead in the early years and

focused on hydraulic turbine governors.
Diesel engines introduced for power
generation in 1932. Elmer starts new line of
diesel governors.
1934, at age 73, developed propeller pitch
governor for aircraft engines.
• Manufactured 10,000 per month during WW II.
 Division - Historical Highlights
Amos W. Woodward
1870 Patent - Non-Compensating Water Wheel Governor
Rockford, Illinois1873
1898 Patent - Compensating Mechanical Governor
Elmer E. Woodward 1919
1933 First Diesel Engine Mechanical Governor
Fort Collins 1934 First Aircraft Propeller Governor
Holland 1955
1957 First Load Sharing Governor
England 1958
Japan 1960 First All Electric Governor
1965 First Analog Speed and Load Control
Irl C. Martin 1967
Australia 1970
1974 First Integrated Analog Control System
Calvin C. Covert
1976 First Digital Control and Digital Sequencer
Brazil 1977
1985 First 16Bit Digital Control System
1986 First Fault Tolerant Control
Singapore 1989
1990 First 32Bit Digital Control System
John A. Halbrook India 1993
1994
China 1995 New 32Bit 505H Control
New Zealand 1996
1997 Micronet TMR
1998
Jack Welch 1999
2000 GE Purchases Global Services – Creates GCS
Jeff Immelt 2001 Power Systems University
2004 PSU becomes ELC
“Prime Mover Control”
Prime Movers: Turbines Loads
• Steam • Generators
– Large • Mechanical Drives
– Utility
– Compressors
– Medium, Small
– Industrial – Pumps
– Process – Blowers
• Gas
– Industrial
– GE Frame (V, VI, etc)
– Westinghouse (171, 191, etc)
– Aero-derivative
– GE LM
– Pratt, Rolls Royce
• Hydro
“Basic Signals”
Control System
Hardwired I/O Digital Communications

– Analog I/O
9 Discrete I/O –HMI
– Temperature
– RTD’s –Pressure Switches –COI
– TC’s –Level Switches –Service Panel
– Pressure –Temperature –Engineering
– Transducers Switches Work Station
– Speed –Position Switches
– Probes
– Time
– Internal and
external
– Light Intensity
Tab 2
Governing Basics

Objective: To gain an understanding of control

fundamentals.
Safety Information

WARNING!
The engine, turbine or other type of prime mover should
be equipped with an overspeed shutdown device, that
operates independent of the prime mover control device
to protect against runaway or damage to the prime
mover with possible personal injury or loss of life should
the mechanical-hydraulic governor or electric control,
the actuator, fuel control, the driving mechanism, the
linkage, or the control device fail.
What is a Governor ???
• Governor Definition: a: An attachment to a machine
for automatic control or limitation of speed. b: A
device giving automatic control (as of pressure or
temperature).
• A governor is a device which controls the energy
source to a prime mover to control it for a specific
purpose.
• Basic governors sense speed and sometimes load of
a prime mover and adjust the energy source to
maintain the desired parameter.
• Advanced governors are often referred to as Control
Systems.
Why do we need Governors ?

Prime movers must be controlled to do useful

work. Common control parameters include:
• Speed
• Load (torque or MW)
• Pressure
• Temperature
• Valve Position
• Speed Derivative
• Pressure Derivative
• Any parameter that can be converted into a 4-20 milliamp
signal.
Speed Control: Constant Load
DESIRED
SPEED
• The driver of the car is the ACTUAL
SPEED
control or governor.
• The speed limit sign is the
desired speed setting.
• The speedometer senses actual
speed.
• The driver compares desired speed to actual speed, If they are the
same, fuel is held steady.
• If desired speed and actual speed are different, the fuel setting is
adjusted by the driver to make actual speed equal desired speed.
• Fuel is held steady until a speed or load change occurs.
Speed Control: Increased Load
SPEED
LIMIT
• The car starts up the hill, 60

load increases, speed Increase

decreases. Fuel

• The actual speed is less

than desired speed.
• Driver increases the fuel to
increase the speed, which
returns the actual speed to
the desired speed.
• Before the actual speed reaches the desired speed, the driver
reduces the fuel to prevent overshoot of speed. This is called
Compensation and is adjusted to match the response time of the
prime mover.
• It takes more fuel to pick up load than to maintain load.
Speed Control: Decreased Load

• The car starts down the hill, load

decreases, speed increases.
• Actual speed is greater than
desired speed.
• Driver decreases fuel to decrease
speed, which returns the actual
speed to desired speed.
• Before the actual speed reaches the desired speed, the driver increases
the fuel to prevent undershoot of speed. This is called Compensation and
is adjusted to match the response time of the prime mover.
Basic Control Loop

Woodward
Actuator Control
System
Energy
Source

Prime Load
Mover
Metering
Valve
Exhaust
Basic Control Loop

A basic prime mover control loop consists of the following

pieces:

• Energy/Fuel Source - Steam, Diesel, Gas, Water...

• Fuel Metering Valve - Gas Valve, Steam Valve, Gate Valve, Injector...
• Load - Generator, Compressor, Propeller...
• Control System - Governor, Electronic Control System and Actuator.
Early Mechanical Governor
Force Balance
Actual Desired
Speed Speed
Force Force
F(a) F(d)

1000 lb 1000 lb

Increase Decrease
Fuel Fuel

In the governor, Actual Speed and the Desired Speed are converted to a force that
represents their respective actions.
These forces must be balanced in order to maintain the speed/load constant.
If they are not balanced, the governor will increase or decrease fuel until they are
balanced.
Simple Flyweight System

• F(a) = Actual Measure of the Centrifugal force = Actual Speed.

• F(d) = Actual measure of the compressed speeder spring = Desired
Speed.
• F(a) = F(d) for a balanced system.
• In other words, when the force of the compressed speeder spring
equals the centrifugal force, the system is in equilibrium.
• The forces are summed together in a thrust bearing.
 Flyweights and Pilot Valve
Thrust
Bearing Speed
Adjust Output
Servo

Pilot Valve Pilot

Valve
Plunger
High
Pressure
Oil
Control Land
Control Increase
Land Fuel
Pilot Valve
Bushing Sump
Control Port Oil Pump
Pilot Valve Bushing and Porting
• Pilot Valve Bushings are
cut differently to Round
compensate for different Slot Hole
size prime movers and
prime mover responses.
• Pilot Valve Bushings are
cut with holes or slots.
Pilot Plunger
• Very tight tolerances are
required on both the pilot Valve and
valves and pilot valve Plunger Bushing
bushings for exact
controlling.
Unstable Governor
• As load is added, speed decreases. Speed
Fuel is added, increasing speed Adjust Output
Servo

until speed equals speed setpoint.

• Due to the acceleration and lag
time of the prime mover, speed
overshoots thus decreasing the Pilot
Valve
fuel. High
Pressure
• Speed decreases until speed Oil

equals speed setpoint. Control

Land
Increase
Fuel

• Due to the deceleration and lag Oil Pump

Sump

time of the prime mover, speed

undershoots thus decreasing the Prime Mover
Acceleration Actual
Speed
fuel. Load
Added
• Process is repeated remaining
SPEED

unstable or in some conditions Time

becoming more and more
unstable. Desired
Speed
Prime Mover Setpoint
Deceleration
Droop Governor

A droop governor Feedback Arm

allows the feedback

arm to increase or Output
Servo

decrease the force

on the speeder High
Pressure
Oil
spring, thus Increase
Fuel
increasing or
Sump
decreasing the speed
reference with a
Speed Setpoint

Load
change in load (fuel Added

demand) or speed.
Load
Removed

Time
Droop Curve
Droop
Definition: A
decrease in
desired speed
setpoint for an
increase in
load or output
servo position 0%
LOAD 50% 100%
(feedback).
 Droop Calculation
No Load Speed Reference - Full Load Speed Reference
% Droop = X 100
Rated Speed

Example of 5% Droop

3600 RPM (no load speed) 3600 RPM - 3420 RPM X 100 = 5% Droop
(rated speed) 3600 RPM

3420 RPM (full load speed)

0% LOAD 100%
Mechanical Load or Gen. set loaded by a Load Bank

3780 RPM 63 Hz
(no load speed)

3600 RPM 60 Hz (full load speed) 3780 RPM - 3600 RPM X 100 = 5% Droop
(rated speed) 3600 RPM

0% LOAD 100%

Generator Set Loaded to Utility Bus or Other Generator Sets

Droop Calculation
Speed Setpoint
(63 Hz) 105%
5% Droop Curve Intersection of Droop Curve
(62.4 Hz) 104%
And Actual Speed Determines
(61.8 Hz) 103% Fuel Valve Position / Load
(61.2 Hz) 102%
(60.6 Hz) 101%
(60 Hz) 100%
Actual Speed
(59.4 Hz) 99%
“Fixed” When Tied
Large system
30%
10%

20%

40%

50%

80%
60%

70%

90%
0%

100%
Fuel Valve Position / Load
 Droop Calculation
Speed Setpoint Lower Speed Setpoint
By 2.5%
3780 RPM, 63 Hz, 105% (Shifts Droop Curve) Intersection of Droop Curve
3744 RPM, 62.4 Hz, 104% And Actual Speed Determines
3708 RPM, 61.8 Hz, 103% Fuel Valve Position / Load
3720 RPM, 61.2 Hz, 102%
3636 RPM, 60.6 Hz, 101%
3600 RPM, 60 Hz, 100%
3564 RPM , 59.4 Hz, 99%

100%
40%

50%

80%

90%
10%

20%

30%

60%

70%
0%

Fuel Valve Position / Load

 Droop Calculation
Speed Setpoint
3780 RPM, 63 Hz, 105%
Increase Speed Setpoint Intersection of Droop Curve
3744 RPM, 62.4 Hz, 104% By 1% to 103.5% And Actual Speed Determines
3708 RPM, 61.8 Hz, 103% Fuel Valve Position / Load
3720 RPM, 61.2 Hz, 102%
3636 RPM, 60.6 Hz, 101%
3600 RPM, 60 Hz, 100%
3564 RPM , 59.4 Hz, 99%

Load Increases
By 20%
30%

40%

50%

60%
10%

20%

70%

80%

90%
0%

100%
Fuel Valve Position / Load
 Droop Calculation
Speed Setpoint
(63 Hz) 105%
(62.4 Hz) 104%
If System Frequency Shifts,
(61.8 Hz) 103% Load Will Shift According
To Droop Curve Intersection
(61.2 Hz) 102%
(60.6 Hz) 101%
(60 Hz) 100%
(59.4 Hz) 99%

Load Increases
By 10%
30%

40%

50%

60%
10%

20%

70%

80%

90%
0%

100%
Fuel Valve Position / Load
 Droop Calculation
Speed Setpoint
(63 Hz) 105%
5%
(62.4 Hz) 104% Dro
op C
urve
(61.8 Hz) 103%
(61.2 Hz) 102% 2% Droop
C ur v e
(60.6 Hz) 101%
(60 Hz) 100%
(59.4 Hz) 99%
30%

40%

50%

60%
10%

20%

70%

80%

90%
0%

100%
Fuel Valve Position / Load
Isochronous Definition

ISOCHRONOUS
(ISO+CHRONOS = SAME +TIME)

CONSTANT SPEED
No change in speed setting
with an change in load
Isochronous Curve

Speed / Speed Setpoint

0% LOAD 50% LOAD 100%

Pressure Compensated Governor
Pressure Compensated Governor
Response
Speed / Speed Setpoint
Speed Control Summing Junction
Speed Reference or
Desired Set - Point

Error
PID Feedback
Output Output
To To
Other Inputs Amplifier Actuator
(Load Sensor)
(Synchronizer) PID
(Droop Signal)
(Etc.)

Actual Speed

The Set-point or reference is where you would like the actual measurement to be.
Error is defined as the difference between the set-point and actual measurement
Analog Electronic Speed Control
Desired Speed
+DC Volts PID Feedback

Error Signal PID

Summing Junction

Actuator

Actual Speed
- D.C. Volts Prime Generator
Mover

Frequency
to
Voltage Converter Magnetic
Pickup
AC Sine Wave
Digital Control System Block Diagram
Setpoint (+)

PID Feedback

Summing Junction
+
Adjustable Dynamics Output To
+ Error Signal and Amplification

- Fuel Valve
-
PID
The
Thesetpoint
setpointisisthe
theonly
onlyparameter
parameteraccessible
accessibleininthe
theclosed
closed
Actual (-) loop
loopsystem.
system.
The
Thecontrol
controlwill
willforce
forcethe
theactual
actualparameter
parametertotomatch
matchthe the
setpoint
setpointby
byactuating
actuatingthethefuel
fuelvalve.
valve.
Sample Gap Speed Control Loop
Hydraulic-Mechanical vs. Electrical
Speeder Buffer
Needle
Spring Springs
Valve
Gain Reset
Rated Mechanical
Speed
Electrical
Pot

Summing
Point
Error
Signal
Actuator

Thrust Bearing Prime Generator

Mover
Flyweights

Frequency to
Voltage Converter
Magnetic
Pickup
Pilot Valve Porting
Hydraulic-Mechanical vs. Electrical
Hydraulic- Electrical
Mechanical Analog Digital

Speed Sensing Fly Weights Magnetic Pick Up or Magnetic Pick Up or

Proximity Probe Proximity Probe

Speed Setpoint
Speeder Spring Speed Potentiometer Software Ramp Block

Summing of Forces Thrust Bearing Summing Amplifier Software Add Block

Software PID Block

Stability Needle Valve Reset
Capacitor/Potentiometer Software PID Block
Gain
Buffer Springs Gain Potentiometer Software PID Block
Reaction to Error
Signal

Pilot Valve Porting PID Amplifier

Speed Sensing

• Speed of the prime mover is sensed

using Magnetic Pickups (MPU).
• An MPU generates a frequency
signal that is directly proportional to
the speed of the prime mover.
• Single pole, alternating current,
electric generator.
• Single magnet, attached to a pole
piece which is wrapped with
multiple layers of copper wire.
• The ferrous gear teeth and the magnet creates a path for the magnetic lines of force.
• Making and breaking of the flux lines induces an alternating voltage into the coil around the
pole piece.
• Each pulse is represented by a gear tooth passing by the Magnetic Pick-up.
• The Impedance of a Magnetic Pick-up is approximately 220 ohms.
 Magnetic Pick-Up’s
Magnetic Lines Ferrous Gear
of Force

1.5 V RMS Gap

Minimum
Jam Nut

s s S

MPU Brac ket Coil Pole Piece

Permanent
Magnet
• The voltage amplitude output is dependent on the air gap of the MPU. A
decrease in air gap equals an increase in voltage.
• MPU voltage must be >1.5 V RMS, at the lowest control speed.
MPU Generated Waveforms
MPU Frequency Calculation
MPU Frequency(cycles/sec) = Gear Speed(revolutions/min) x Number of Teeth
60(sec/min)
OR

Gear Speed(revolutions/min) = MPU Frequency(cycles/sec) x 60(sec/min)

Number of Gear Teeth

For a 60 Tooth Gear:

Gear Speed(revolutions/min) = MPU Frequency(cycles/sec)

MPU Generated Waveforms
The output waveform of the MPU depends on the following items:
• Speed of the gear and number of teeth.
• The air gap between the pole piece and the gear tooth.
• The dimensions of the MPU and the type of gear.
• The impedance connected across the output coil.

MPU Advances per turn:

• 16 Threads Per Inch = 0.0625 inch.
• 18 Threads Per Inch = 0.0550 inch.
• 20 Threads Per Inch = 0.0500 inch.
• 24 Threads Per Inch = 0.0415 inch.
• 28 Threads Per Inch = 0.0357 inch.
 Proximity Probes

• Proximity Probes or Proximity Switches are active devices usually used where slow rpm
or a large air gap is required. This is necessary due to the large runout of the monitored
gear and the slow speeds of large engines or turning gears on turbines. These have a
slower surface speed which an MPU cannot detect.
• Proximity probes require an external power supply, usually 24 Vdc to operate.
What is a PID ?

PID stands for Proportional, Integral, and Derivative.

Controllers use PID’s to eliminate the need for
continuous operator attention.

1 d e(t)
OUTPUT = Kc (e) + e(t) dt + D
I dt

e=error, Kc = gain, I = integral, and D = derivative settings

PID Tutorial
The Set-point or reference is where you would
like the actual measurement to be. Error is
defined as the difference between the set-point
and actual measurement.
Speed Reference or
Desired Set - Point

Feedback
Error Output
Other Inputs To Amplifier Output
(Load Sensor) PID To
(Synchronizer) Actuator
(Etc.)

Actual Speed
PID Tutorial

PID stands for Proportional, Integral, and

Derivative.
A PID amplifier is used to calculate an
appropriate response to the output based on
changes to the input.
Controllers use PID’s to eliminate the need for
continuous operator attention.
PID Tutorial

Question: Why are dynamic adjustments

necessary in a governor or control
system?
Answer: Control Systems must be
matched to the prime movers, in order for
them to operate properly.
PID Tutorial
PID Tutorial

The output of a PID controller will change

in response to a change in measurement
or set-point.
PID - Combinations of Proportional,
Integral, and Derivative will provide the
best type of process control required.
PID Tutorial

Gain - The gain is the proportional gain

term in the PID controller.
With Proportional Gain, the control output
is proportional to the error in
measurement or set-point.
PID Tutorial
Reset - The reset is the integral term in the PID controller.
With integral action, the controls output is proportional to
the amount of time the speed error is present.
It prevents slow hunting at steady state and controls the
time rate at which the speed error returns to zero after a
speed or load disturbance.
PID Tutorial

Compensation - The compensation is the

derivative term in the PID controller.
With Derivative action, the controls output is
proportional to the rate of change of the
measurement or error.
The controls output is calculated by the rate of
change of the measurement with time.
Compensation is used to avoid overshoot.
PID Tutorial
RESET
ADJUSTMENT
SPEED

GAIN
ADJUSTMENT
COMPENSATION
ADJUSTMENT

TIME
“Text Book” Dynamic Response
“Text Book” Dynamic Response

Characteristics of correctly tuned prime mover:

• Stable control at no load.
• Stable control over all load ranges.
• Minimum overshoot with no ringing or instability.
HSS - LSS

LSS = Low Signal Select. Whichever input is the

lowest, will be sent to the output.
HSS = High Signal Select. Whichever input is the
highest will be sent to the output.
These Hardware or Software algorithms allow
different channels to be in control as they are
demanded.
Only one channel can be in control at any one
time.
HSS - LSS
LSS
Speed Control
HSS
Temperature Control

Accel Control
Output
To
High Limit
Actuator

Decel Control
Low Limit
Example of Temperature Limiting LSS
Example of LSS

The two inputs on the LSS are speed and

temperature.
If the temperature input ever exceeds the
speed, then the fuel would be limited by
temperature.
Exhaust Gas Temperature, Compressor
Discharge Pressure, Manifold Air Pressure, Lube
Oil Temperature, Multiple Speeds, are examples
of LSS Inputs.
LM2500+ LSS
Example of HSS
Example of HSS

Redundant Magnetic Pickups are often

used in control systems.
Both inputs to the HSS are the same, yet
coming from different MPU’s.
If either MPU should fail and the input go
to zero, the good MPU will send its output
to the summing point.
Actuators
The part of an electronic governing system that converts the electrical
output signal of the electronics into a mechanical movement which
positions the throttle, steam valve, fuel metering valve etc.
An ACTUATOR is a hydraulic, or pneumatic, or electrical device that
converts an electrical signal to a mechanical position.
A SERVOMOTOR is a hydraulic cylinder assembly controlled by a pilot
valve and usually directly connected to the prime mover's energy-medium
control (fuel valve, steam valve, etc.).
Woodward electro-hydraulic actuators usually convert 20 -160 milliamps
to zero to ~45 degrees of rotation, or zero to one inch, depending on the
actuator.
Other manufacturers (Valtec, Vickers, Fisher, etc.) convert 4-20 milliamps
to zero to full stroke.
Proportional Actuator
Level Adjustment

Centering
Screw Increase
Fuel

Coil
+
Demand
From Governor
_
Coil
Permanent
Magnet

High Pressure
Control Oil

Control Land Control Port

To Sump
Integrating Actuator
Null Current LVDT LVDT
Adjustment Excitation Feedbac k

Centering Centering
Springs Screw
Increase
Fuel
+ Coil
Demand N N
CL
From Governor
S S
- Coil
Magnet
(-) High Pressure Oil
Power Servo
Control Pressure
CL
Control Port
Control Land
To Sump
Governor Assumptions
• Consistent fuel quality
– Steam pressure, gas pressure, BTU value, etc.
• Control of valves
– Valves must be calibrated for zero to 100 percent travel
• Linkage
– Smooth travel
– No lost motion
• Linearity
– Linear flow for zero to 100 percent travel
– Power output linear with valve position
• Consistent machine geometry
– No change in dynamic response
Tab 3
Digital Control Basics
Class Objectives

This section, the student will identify and explain the key
points on the following subjects:
• How the physical signal is brought into the GAP program.
• How the GAP value is sent to the physical world.
• The architectural layout of the GAP blocks.
• Version of GAP and Coder required for the Woodward
Control Platform.
• Gap addressing for the hardware configuration.
Getting Information Into / Out of the
Digital Control
Digital Control Basics
HMI PLC Distributive I/O

MPU / Serial/ Panel Meter

Proximity Probe Counter Ethernet
Port Actuator Coil
D/A
Thermo-couple SCADA
RTD

Transducer A/D Microprocessor Field Device

4-20 mA
Pressure
Power (WATTS)

Shutdown
START Relay
RAISE Opto Driver Alarms
Isolator
LOWER
ESD
Software
Digital Control Basics
The brain of the digital control is a microprocessor
which:
• Reads input signals.
• Makes calculations and decisions based on
application software.
• Generates output signals.
• Inputs are converted from frequency, electrical
current, or switch status to a digital representation.
• Outputs are generated by converting a digital
representation to the physical signals.
Hardware Definition

• The field device (probe, switch,

actuator, etc.) is wired directly
to the AtlasPC board’s
terminals.
• The Atlas boards are
specifically designed to
condition and filter the field
Driver
Relay

signal for use in GAP.

• The ‘Interface’ GAP Blocks
scales the signals as required.
Alarm
Analog Input Signal Conversions

4-20 mA
KW
Transdu
cer Interface Process
Field Logic Logic
Device
Analog Input Signals

Megawatt signal is wired into digital control.

A/D converter scales input signal from 4-20
milliamps to a digital value which represents
generator load.
Speed Input Signals

Frequency

Field
Device Interface Process
Logic Logic
Speed Input Signals

MPU is wired into digital control.

Sine Wave Frequency (Hz) proportional to
turbine speed is generated.
High precision frequency counter scales
input signal from Hz to turbine speed.
Discrete Input Signals
START

E-STOP

Start ESD
Button Button

Field Interface Process

Devices Logic Logic
Discrete Input Signals

Switch contacts are wired to control.

Each channel is optically isolated for protection.
The digital control reads the input status.
• Contact Closed = TRUE
• Contact Open = FALSE
Analog Output Signals

>

4-20 mA

Meter

Process Interface Field

Logic Logic Device
Analog Output Signals

D/A converter scales turbine speed (0-4000

RPM) in software to a physical 4-20 mA.
Panel meter used to indicate speed is wired
to control and is driven by the 4-20 mA
signal.
Discrete Output Signals

ALARM RELAY

>

Alarm

Driver
Relay
Process Interface
Logic Logic Field
Device
Discrete Output Signals

Relays are driven by the control’s

microprocessor.
• TRUE = Energize Relay
• FALSE = De-Energize Relay
Tab 4
 GAP™
Graphical Application Programmer
Introduction
GAP™ is a Windows™ based, high level, block-oriented
(schematic capture), programming language.
The GAP program has sophisticated algorithms and
timing control that have been rigorously proven at
Woodward. Many blocks have been in service since
1984.
Documentation is created along with the application
programming.
You don’t have to be computer programmer to
program in GAP.
Sample of a GAP Block
Category Name

Block Name

Output Fields
Input Fields

Rate Group
Block Type

Field Name: M_I_VIB.PTPTNSDDLY.DELAY

CATEGORY.BLOCK_NAME.FIELD
Sample of a GAP Block
Category Name
Block Name

Output Fields

Input Fields

Nets
Rate Group
Block Type

Field Name: M_O_CAL.FMVMAN.RAMP

CATEGORY.BLOCK_NAME.FIELD
Block Connections

NE
T

Nets connect GAP blocks on the same page

Variables are passed from the output fields to the
input fields
Block Connections

72
g e
Pa
On
k
l oc
B

74
g e
Pa
On
ck
o
Bl
Tunable / Fixed Inputs

Any analog or discrete input can be made fixed or

variable (tunable).
By putting an asterisk (*) in front of the tunable will
allow the user to tune that input.
Examples:
• *TRUE (Can be adjusted to FALSE)
• *10.0 ( -20, 100) (Can be adjusted in the range of
-20 to +100)
Tunable / Fixed Inputs
Tunable True/False

Fixed 2.0

Tunable 10.0
Min = 2.0
Max = 100.0
Rate Groups
Guaranteed “Sample Rate” For
The GAP Block
• Millisecond Units
• No Faster / No Slower
Each Rate Group (10 msec):
• Looks At Inputs
Rate Group
• Processes Them
• Updates Outputs
Rate Group Explanation
Advantages of a “Rate Group” control software structure
• Deterministic Rate Group architecture ensures that software is
executed in a timely and repeatable manner

• Six base Rate Groups (5ms, 10ms, 20ms, 40ms, 80ms, 160ms) that
can be further customized
9 All 5ms code will be executed every 5ms, no faster, no slower
9 Variable execution time blocks are avoided

• Every logic block within a Rate Group scans its inputs, processes
them accordingly, and updates its outputs every Rate Group cycle

• All I/O are synchronized within the Rate Groups in which they run
and are independent of each other, down to individual I/O channels
Rate Group Explanation

The keys to Woodward’s deterministic control system

includes:
• Synchronized I/O
• Defined Execution Order
• Real Time Operating System
Most controllers and PLCs use unsynchronized I/O handling techniques
and accept incoming information whenever it appears and output
results when they occur.
This causes “jitter” problems and may make control loops less stable.
Synchronized I/O
Synchronized I/O reduces jitter to zero allowing for faster
more stable control loops
• Deliver the newest inputs at the same known time, with
respect to the task being performed.
• Performing the task with data that is of the same age.
• Delivering the outputs at the same known time.

D/A D/A D/A

outputs outputs outputs

Task 1,2,3,.last+1 Task 1,2,3,.last+1 Task 1,2,3,.last+1

A/D A/D A/D A/D

inputs inputs inputs inputs
X time X time X time
Clock Clock Clock Clock
Tick Tick Tick Tick
Execution Order Enhances
Determinism
Being able to define the specific execution order in
which tasks are performed assures that the proper
information is used by subsequent tasks.

Task 1 Task 2 Task 8 Task 9

Task 10
Task 6 Task 7

Task 3 Task 4 Task 5

Real-Time Operating System

Real Time Operation

Guaranteed Program Execution Rates
• Programmable
• Deterministic
• Repeatable transient results independent of CPU loading
• 5ms, 10ms, 20ms, 40ms, 80ms, 160ms or ‘Free-Run’ Rate
Groups
No dynamic instability caused by microprocessor or bus load
induced timing problems
Rate Group Execution
AND

This blocks output will be true

only if all of the Boolean Input
Fields are true. Otherwise the
output of this block will be false

AND Truth Table

IN_1 IN_2 IN_x AND Output

FALSE ---------- ---------- FALSE

---------- FALSE ---------- FALSE

---------- ---------- FALSE FALSE

TRUE TRUE TRUE TRUE

---------- = This input can be true or false.

OR

This blocks output will be false only if all

of the Boolean Input Fields are false. If
any one of the inputs is true then the
output of this block will be true.

OR Truth Table (X = don’t care)

IN_1 IN_2 IN_x OR Output

FALSE FALSE FALSE FALSE
TRUE X X TRUE
X TRUE X TRUE
X X TRUE TRUE
NOT

This block negates the input

Boolean value.
ADD

This block adds the Analog Input

Fields together and outputs the
Analog result.
SUBTRACT

Output = IN_1-IN_2 or Minuend Input-

Subtrahend Input
MULTIPLY

The MULTIPLY block can be used to

perform simple multiplication of 2 or
more inputs up to a maximum of 50
input values. Output = IN_1 x IN_2.
DIVIDE

Divide block. This block performs a

divide function. It takes IN_1 and divides
it by IN_2.
Output = IN_1 / IN_2 or
dividend/divisor
A_NAME

The block allows you to name an Analog value and use that name
throughout the rest of the GAP application. A_NAME is useful for cases
where a tunable value is used as an input to more than one block in an
application. This block simplifies program flow and reduces processing
time compared to using several tunable values scattered in different
locations of the program. A_NAME can also make it easier to follow
Analog signals in the program flow.
A_COMPARE
A_SW
B_SW
RAMP

Ramp block. This block is a RAMP, it will ramp to a certain point depending on which position is selected. It will
also ramp at a certain rate depending on which rate is selected. It can be initialized to a certain value on power up,
and it has a reverse output function. The output is in units and the rates are in units/sec. The P_SEL_x inputs are
like a priority encoder, when USE_REV is FALSE, P_SEL_1 has the highest priority then P_SEL_2 and so on until
the last P_SEL_x which will have the lowest priority. The rate at which the ramp will move is determined by the
DFLT_RATE, (Default rate) R_SEL_x and R_SP_x. If there are NOT any R_SEL_x and R_SP_x then the ramp
will move at the DFLT_RATE. If an R_SEL_x and R_SP_x are being used then the ramp will move at the rate
being selected by R_SEL_x. If they are being used and NOT selected then the output will move at the
DFLT_RATE. The rates are priority encoded to, with R_SEL_1 being the highest.
PID_2

PID_2 control block. This block performs a

proportional (P), a proportional-integral (PI),
or a proportional/integral/derivative (PID)
control function.
The set point is compared to the process
input and a corrective output (scaled from 0
to 100) results from the sensed error.
LSS_BUS
The LSS_BUS block performs a low
signal select function of multiple Analog
input values. The output of the LSS_BUS
block will equal the input with the lowest
input value provided the value is not
higher than the high limit (HI_LIM) or
lower than the low limit (LOW_LIM)
inputs.
There are several Boolean outputs which
provide status of what input signal is the
lowest value and individual outputs to
indicate whether the output of the
LSS_BUS is being limited by either the
LO_LIM or HI_LIM. There is a SEL_x
output for each input signal respectively
which is set true when its corresponding
input value is the lowest value. The
Boolean output for HI_LIM limit indication
is HI_LIM_I and LO_LIM_I for the LO_LIM
limit indication.
HSS_BUS

The HSS_BUS block performs a high signal

select function of multiple Analog input values.
The output of the HSS_BUS block will equal
the input with the highest input value provided
the value is not higher than the high limit
(HI_LIM) or lower than the low limit
(LOW_LIM) inputs.
There are several Boolean outputs which
provide status of what input signal is the
highest value and individual outputs to
indicate whether the output of the HSS_BUS
is being limited by either the LO_LIM or
HI_LIM. There is a SEL_x output for each
input signal respectively which is set true
when its corresponding input value is the
highest value. The Boolean output for HI_LIM
limit indication is HI_LIM_I and LO_LIM_I for
the LO_LIM limit indication.
CURVE_2D
The CURVES_2D block is a two dimensional table
lookup block. The X_IN represents a point along the
x-axis of a simple line graph. The output represents
the y-axis value that corresponds to the specific x-
axis value. If the X_IN is less than the minimum
X_IN value in the table or greater than the maximum
X_IN value in the table, the CURVES_2D block will
extrapolate using the slope of the last two points on
the table. If a truncated output is desired, provisions
must be made in the data table to provide this
function.
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0
-20.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0
ACT

The ACT_CTRL block is the

interface to one channel of the two-
channel actuator controller module.
Each channel controls an integrating
or proportional type actuator with up
to two position feedback devices.
There are different module part
numbers for different driver current
ranges. All other operating
parameters are configured through
the ACT_CTRL block.
DELAY
LAG

Lag filter block. This

block is a lag which
outputs a lagged value of
the input according to the
LAG_TAU value. The
DERIV output field is the
rate of change of the
input.
LATCH

The latch block looks at a single Boolean

input (TRIGGER) and sets the output
(LATCH) true if the input is set true. If the
input is false and the reset (RST) is set
true, the output will return to false. If both
the input and the reset are true, the output
will remain latched true because the input
has priority over the reset
ONE_SHOT
B_ALARM

The Boolean Alarm block has the same function as a latch block but
with special features built in. There are three outputs B_ALARM,
HORN and LIGHT which can be used to indicate that an alarm has
occurred. The input can be delayed or bypassed all together. The
latching output can be reset if the input is false.
Note: The acknowledge (ACKN) input will reset the HORN output
regardless of the state of the input, but will not affect the B_ALARM or
LIGHT outputs.
EVENTLATCH

Event Latch interfaces MOE program

Boolean outputs with a serial data
communications block for
printing/downloading specified data through
a serial port. Boolean inputs set TRUE are
classified as alarm events. EVENTLATCH
outputs the state of each Boolean input,
monitors the inputs for alarm events,
generates alarm and horn outputs, outputs
a first detected alarm number,
prints/downloads event messages (optional)
and date-time stamps (optional), and stores
alarm events on an event stack for future
recall. All events and the alarm and horn
outputs are latched and the stack
maintained until a reset command is given
(the event latching function can be
disabled).
ZMINUS1

When in a Loop, the ZMINUS1 block will

break the loop at the position of the
ZMINUS1 block. For example if block 1
feeds block 2 and block 2 feeds block 3
and block 3 loops back to block1, this is a
loop. The loop must be broken by the loop
breaker blocks, ZMINUS1 or ZMINUS1_B,
and the placement of the ZMINUS1 will
determine the place the loop is broken. If
the ZMINUS1 block is inserted between
block 3 and block 1, the execution order
will be 1-2-3-z, however, if the ZMINUS1
block is inserted between block 2 and
block 3 the execution order will be 3-1-2-z.
Notice the ZMINUS1 block is always last.
GAP DESIGN LAYOUT
The different sections of GAP are to be grouped in the following order:
For Inputs:
• Hardware Definition
• Hardware Signal Processing (Redundancy Management)
• Analog Scaling
• External GAP Interface (Including A & B_NAMES)
• Control Logic
• Alarms
• Shutdowns/Trips
• Communications Logic (Modbus, Ladder Logic, etc.)
• Configure
• Service
For Outputs:
• Control Logic
• Analog Scaling
• Discrete Forcing Functions
• Hardware Signal Processing (Redundancy Management)
• Hardware Definition
GAP Computer Hot Keys
CTRL + A Append a new sheet
SHIFT + A Edit the sheet information
CTRL + B Branch to a block
SHIFT + B Zoom back
ALT + C Change to the Configure block group
CTRL + C Copy the selected items into the paste buffer
SHIFT + C Completeness check
CTRL + D Change Documentation of selected blocks
CTRL + E Format Selected Texts
CTRL + F Change Rate Group of selected blocks
SHIFT + F Zoom full
G Group select items
CTRL + G Show/Hide display grid
ALT + H Change to the Hardware block group
ALT + I Change to the Interface block group
CTRL + I Insert a new sheet
SHIFT + I Zoom in
CTRL + K Change category of selected blocks
SHIFT + K Select blocks on sheet by category
CTRL + L Branch back to last view
CTRL + M Move selected items
N Draw a net
CTRL + O Open a sheet
SHIFT + O Zoom out
GAP Computer Hot Keys
ALT + P Change to the Process block group
CTRL + R Redraw screen
SHIFT + R Resize selected items
S Start selection box
ALT + S Change to the Service block group
CTRL + S Select all items on sheet
SHIFT + S Save application
CTRL + T Add a text symbol
SHIFT + T Branch to a block (listed in order of Type)
U Start an unselection box
CTRL + U Unselect all
CTRL + V Paste the buffered items onto the current sheet
CTRL + X Cut the selected items into the paste buffer
CTRL + Z Undo the most recent undoable action
SHIFT + Z Zoom around
CTRL + 1 Change Grid Increment to 16
CTRL + 2 Change Grid Increment to 2
CTRL + 3 Change Grid Increment to 32
CTRL + 4 Change Grid Increment to 4
CTRL + 6 Change Grid Increment to 64
CTRL + 8 Change Grid Increment to 8
SHIFT + 0-9 Execute command (1-10) from 'Run' menu
"<" View block inputs (cursor must be over block)
">" View block outputs (cursor must be over block)
Arrow Down Move the cursor down one increment
CTRL + Arrow Down Scroll the screen down one increment
GAP Computer Hot Keys
SHIFT + Arrow Down Move the cursor down several increments
Arrow Left Move the cursor left one increment
CTRL + Arrow Left Scroll the screen left one increment
SHIFT + Arrow Left Move the cursor left several increments
Arrow Right Move the cursor right one increment
CTRL + Arrow Right Scroll the screen right one increment
SHIFT + Arrow Right Move the cursor right several increments
Arrow Up Move the cursor up one increment
CTRL + Arrow Up Scroll the screen up one increment
SHIFT + Arrow Up Move the cursor up several increments
ALT + Backspace Undo the most recent undoable action
Delete Delete the selected items
SHIFT + Delete Cut the selected items into the paste buffer
CTRL + End Scroll the screen one page right
Enter Finish a command / press OK
ESC Cancel a command
F1 Call up help contents menu
CTRL + F1 Call up the block help menu (if available)
CTRL + Home Scroll the screen one page left
CTRL + Insert Copy the selected items into the paste buffer
SHIFT + Insert Paste the buffered items onto the current sheet
Page Down Open the next sheet
CTRL + Page Down Scroll the screen one page down
Page Up Open the previous sheet
CTRL + Page Up Scroll the screen one page up
Tab 5
 MicroNet™
Simplex - Digital Control System
MicroNet™ Chassis

Modular Six Slot Sections

Each Section
• Cooling Fan
• High Temp Alarm
Switch - 149º F
One Section Required for
Power Supplies
Motherboard Back Plane
Bulkhead Mounted

2/
GE /
Simplex Package
Each section has:
•Fan
• Temp Switch

CPU
HD Analog

ETC....

Analog Combo
HD Discrete I/O
Power Supplies
3/
GE /
Six or Twelve Slot Chassis

4/
GE /
Motherboard
VME (Versa Modular Europe)
Compatible
Chassis Support
P.S. Terminal Block Connectors
Easily Removable
No active components
• resister networks
• capacitors
• Connectors 5/
GE /

6 - 12 layer construction.
MicroNet® Chassis
12 - Slot Chassis Only
Power Supply

Power Supply
C
P
U

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

For I/O or Transceiver Modules 6/

GE /
MicroNet™ Power Supplies

Require One Section of

Chassis
Single or Redundant
Input Voltage Options
• 18-36 VDC
• 100-150 VDC/
88-132 VAC, 47-63 Hz
• 180-264 VAC 47-63 Hz

7/
GE /
MicroNet™ Power Supplies
Each Power Supply Provides:
• 24 VDC (12 A)
MAIN MAIN • 5 VDC (20 A)
POWER POWER
SUPPLY SUPPLY • 5 VDC (Pre-charge)
Load Balancing
OK OK

INPUT FAULT INPUT FAULT Hot Replaceable

OVERTEMPERATURE OVERTEMPERATURE

POWER SUPPLY FAULT POWER SUPPLY FAULT Indication Lights

No Input Switches
+ +
-
INPUT
POWER -
INPUT
POWER Over Output Voltage Shutdown
Under Input Voltage Shutdown
Over Current Shutdown
8/

All faults/alarms are displayed

GE /

in redundant supply
Power Supply LED’s

OK - Power supply operating and no

faults present
Input Fault - Input voltage either
above or below specified range
Over Temperature - Temperature
reaches 80º C (resets at 75 º C)
Power Supply Fault - Any one of the
four power converters has shut
down.
9/
GE /
CPU Module
W D
®
RX Dedicated Fiber Optic Port for Two-Line Service
TX Panel
M
E
PCMCIA Slot - FLASH Application Downloading
M
O
R
Y Reset/Run Switch
C
A
R
D
RS-232 Serial Port
FAULT
R
Indication LED’s
E

Real Time Clock - Battery Back-up

S
E
T

J2
Motorola Processor
• 68040/68060 66 MHz
RUN
I/O LOCK
LOW VCC
• 8 MB Application Flash Memory
WATCH DOG
• 2 MB RAM
CPU

EEPROM’s - Store Tunable Variables 10 /

GE /
CPU Module
Must Be Placed In Slot 1
Motorola Processor
• 68040/68060 66 MHz
• Older CPU’s 68030
(UVPROMs)
8 MB Application Flash Memory
2 MB RAM
EEPROM’s - Store Tunable
Variables
11 /
GE /
CPU Module - Indication LED’s
FAULT
„ Blinks a distinct number of times to indicate a
specific problem.

12 /
GE /
CPU Module - Indication LED’s

FAULT
FAULT
• Blinks a distinct number of times to indicate a
specific problem. (see manual)
RUN-
RUN
• Indicates CPU is functioning properly.
I/O LOCK-
I/O
LOCK • Indicates I/O Lock has disabled all I/O.
LOW LOW VCC-
VCC • Indicates 5V power has dropped below 4.7 V
WATCH WATCH DOG-
DOG
• Indicates CPU has stopped executing the 13 /
application program. GE /
Diagnostics
Off-Line
• Memory Tests
• Duart Communication Tests
• VME Bus Tests
• Real Time Clock Tests
• Co-processor Tests
On-Line
• Memory Tests
• Application Verification
• Co-processor Tests 14 /
GE /

• Task Overrun Tests (Rate Groups)

 CPU Module - Fiber Optic Port
W
®
D Two-Line Display Connection
• Control Interface
–On-Line Tuning and Viewing
of Software
–Boot-Up Information
(Diagnostics)
• 3,000 Foot Maximum Distance

15 /
GE /
CPU Module –
Loading Application
Transfer .HEX File
• Flash Memory Card
• Ethernet
• Serial Download
Reset Control

16 /
GE /
CPU Module - Reset Switch
W
®
RX
D

“Re-Boot” or RESET Control

M
E
TX

• ↑ to RESET Control
• ↓ to RUN Control
M
O
R
Y

C
A
R
D

FAULT
R
E
S
E
T

J2

RUN
I/O LOCK
LOW VCC
WATCH DOG
17 /
GE /
CPU
CPU Module - Serial Port
W
®
D

RX

TX RS-232 Wiring Configuration Only

Used With Isolated Serial Port ONLY
M
E
M
O
R
Y

C
A
R
Download Application
D

FAULT
R
E
Baud Rate Adjustable - 110 to 57.6K
S
E

Port Filter Must Be Installed to Use

T

J2
This Port
RUN Port
I/O LOCK
LOW VCC Filter
WATCH DOG 18 /
GE /
CPU
CPU Module - Real Time Clock

Date and Time Clock

• Y2K Compliant
• 10 millisecond resolution
• Used in some GAP applications
Back-up Battery
• Not user replaceable
• Recharges when module has power
• Runs clock for at least 3 months
(without power)
19 /
GE /
 Chassis I/O Modules

Cable

I/O
Module
Field
Termination Field
Module Wiring
(FTM) 20 /
GE /
I/O Modules
W D
®
High Density Modules
• Analog Combo Module
J1 • Analog I/O Module
• Discrete I/O Module
Normal Modules
• Speed Sensor
FAULT

• Discrete In, Discrete Out

J2 • Analog In, Analog Out
• RTD, Thermocouple
• LinkNet Control Module
MPU
A I/O
• Other Specialty Modules 21 /
GE /
 MPU and Analog I/O Module
W D
®

4 Speed Sensor Inputs

J1
• MPU or Prox (wiring selected)
8 Analog Inputs
• 4-20 mA or 0-5 VDC (jumper selected)
FAULT • Self- or Loop-Powered Inputs (wiring
selected)

J2
4 Analog Outputs
• 4-20 mA
2 Analog/Actuator Outputs
MPU
A I/O • 4-20 or 20-160 mA (software selected) 22 /
GE /
MPU and Analog I/O Module
5 millisecond Update Rate
High and Low Setpoint Time
Stamping on Speed Inputs
and Analog Inputs - 5ms
resolution
16-bit Resolution on Analog
Inputs
11-bit Resolution on Analog
Outputs
Connected to Field Wires via 23 /

Field Termination Modules

GE /

(FTM’s)
MPU and Analog I/O Module
Field Termination Module -Typical Speed Sensor Wiring

Speed
Signal MPU

OR
Speed
Signal Proximity
Probe
24 /
GE /
MPU and Analog I/O Module
Field Termination Module -Typical Analog Input Wiring
+24V
0.1 A + 4-20 mA
Transducer Loop Powered
Analog In #1 - Configuration
JPR 1

0.1 A

+ 4-20 mA or
Analog In #2 Transducer 0-5 V
- Self Powered
Configuration

25 /
Independent GE /
Power Supply
MPU and Analog I/O Module
Field Termination Module -Typical Analog Output Wiring

+24V

50
25 75

0
Analog 100

Output
+
METER
- 4-20 mA
Output
26 /
GE /
MPU and Analog I/O Module
Field Termination Module -
Typical Actuator Output Wiring

27 /
GE /
Discrete I/O Module (BI48_BO24)
48 Discrete Inputs
W D
®

• 5 Millisecond Update Rate

J1
• Optically Isolated
• On-Board Processor - 1 ms Time Stamp
24 Discrete Outputs (Relay Outputs)
FAULT
• 5 Millisecond Update Rate
• Non-Isolated (Isolation provided by
relays)
J2
• Two 16 Channel Relay Boxes
OR
• One 32 Channel Relay Box
48/24 28 /
D I/O GE /
Discrete I/O Module (BI48_BO24)
Discrete Inputs
High Voltage or Low
Voltage (determined by
FTM)
• Low Voltage Threshold
– >16 VDC = “ON”
<8 VDC = “OFF”
• High Voltage Threshold
– >67 VDC = “ON”
<29 VDC = “OFF”
Internal or External 24V
Wetting Voltage 29 /
GE /

• Jumper Selectable
Discrete I/O Module (BI48_BO24)
Field Termination Module (FTM)- Typical Discrete Input Wiring -

Position Switch
Input
Input Position Switch

(+)

(-)
Jumper
Internal External Power Supply
+24V (High or Low Voltage
dependant upon FTM)
30 /
GE /
Tab 6
 MicroNet™ Plus Simplex

Programmable Control Platform

What is it?
The latest in a long line of electronic control system platform
(hardware and software) used to perform speed, load, and
process control for all types of prime movers.
Modular hardware and software that can be expanded to fit
most any size application.
A full compliment of standard MicroNet I/O modules are
available to build up a custom control system for any type or
size application.
Used for custom applications and as a basic platform for
standard products.
Electronic Controls MicroNet Plus

Migration History
2005
Motorola 5200
Based CPU
(simplex or
MicroNet redundant)
1998 on VME bus
MicroNet with MicroNet I/O
modules
TMR
1997 68040 & Pentium CPU on VME
NetCon bus with NetCon style I/O
modules
Phase A & B
1990 Triple Modular Redundant
version MicroNet with 68040 CPU

501DCS Phase A = 68020/030 Based CPU with 501DCS I/O

1985 modules
Phase B = 68030/040 Based CPU on VME bus With
Larger I/O modules with face plates

Zilog (some 68020) Based CPU

with small I/O modules
without face plates
New MicroNet™ Plus Hardware
Chassis
• Simplex or Redundant CPUs
Power Supply
• 2 slot higher power density
CPU
• Motorola 5200
RTN Expansion
• Ethernet Expansion Capabilities
MicroNet™ Plus Features
Proven Technology
New, More Powerful CPU5200 Utilizes Standard MicroNet I/O
• Motorola MPC5200 PowerPC Modules
• Seamless upgrade from simplex • User choice of simplex,
to redundant redundant, or TMR I/O
New 14-Slot VME Chassis • Hot Swappable Modules for On-
• Same Footprint as 12-slot Line Repairs
MicroNet Simplex
GAP – IEC1131-3 Functional Block
New 2-Slot Power Supply Programming Environment
• Provides additional I/O slots
• Port existing applications
RTN (Real Time Network) directly to MicroNet Plus
• Ethernet communications to
remote chassis Same Real Time, Rigid Rate Group
• Eliminates expansion chassis Execution
transceiver • Rate groups as fast as 5mS
VxWorks Operating System
• As used in other WG Controls
Powerful Service Tools
Environmental Specifications
System temperature Limits
• 0º to +50ºC (32º to 122ºF)
• Humidity up to 95% non-condensing
UL/CUL Certified
• Hazardous environments: Per NEC article 500 Class 1 Division 2 groups
A,B,C,D Temperature Code (T-3C), Pollution degree 2. CE Certified (24-32
Vdc Systems Only)
• Conforms to EMC Directive 89/336/EEC. Conformity established by test to
EN 50081-2, EN 61000-6-2 when installed in a non-EMI cabinet.
• Conforms to Low Voltage Directive 73/23/EEC. Conformity established by
testing to EN50178 1997.
Meets Lloyd’s shock, vibration, and humidity specifications
Surge: IEEE 472/ANSI 37.90a
 ™
MicroNet Plus Control Chassis
The Evolution of the Proven MicroNet Family
NEW FEATURES
• Redundant or Simplex CPU Architecture
9 Simplex CPU is located in Slot 1
• 2 slot Power Supply
9 Frees up 2 I/O slots
• Fan monitoring to detect fan failure
before temperature limit is reached
EXISTING FEATURES
• Uses standard MicroNet I/O modules
9 Module revisions must be checked for
compatibility
• Physical mounting is exactly the same as
the simplex MicroNet
 ™
MicroNet Plus Chassis
Standard Chassis - 18 Slots
• CPU’s and I/O – 14 VME Slots
9 13 I/O modules max with simplex CPU
9 12 I/O modules max with redundant CPU’s
• Power Supplies – 4 Reserved Slots
• Option of redundant or simplex Power Supplies
9 24 VDC (18-36VDC)
9 110 VAC/DC (88-132VAC, 100-150VDC)
9 230 VAC (180-264VAC)
Short Chassis – 12 Slots
• CPU’s and I/O – 8 VME Slots
9 7 I/O modules max with simplex CPU
9 6 I/O modules max with redundant CPU’s
• Power Supplies – 4 Reserved Slots
 ™
MicroNet Plus Chassis
Smart Fan speed monitoring
• 6 fans are monitored for
actual speed
• Fan fault bit is set if fan
stops rotating
9 Fan faults should be
connected to Alarm list
 ™
MicroNet Plus Chassis
Standard Chassis is 18 Slots Wide
Backplane
Chassis Support
P.S. Terminal Block Connectors
VME Compatible in I/O section
9 Electrically Isolated Data Paths
Redundant Power Supply Paths
12 Layers Thick
No active components
• resister networks
• capacitors
• connectors
Layers are isolated by ground and power planes.
 ™
MicroNet Plus Power Supply

2 Slot Power Supply

Power Inputs
• 24 VDC
• 115 VAC/125VDC
• 220 VAC
220 VDC – No longer supported
 ™
MicroNet Plus Power Supply
24 VDC 120VAC 220 VAC
125 VDC
Part Number 5466-1000 5466-1001 5466-1002
Input Voltage 18-36 VDC 88-132 VAC 180-264 VAC
100-150 VDC
Input Current 33 Amps 13.6 Amps (AC) 6.7 Amps
6 Amps (DC)
Input Power 600 W 1250 VA (AC) 1250 VA
600 W (DC)
Ambient Temp * -10 +65°C *-10 +65°C *-10 +65°C

* Reduced 5 VDC output current greater than 55°C

 ™
MicroNet Plus Power Supply
Simplex or Redundant Operation
• Simplex should be located in PS#1
On-Line replacement
• Power Supplies can be replaced on-line
• Power Supplies must be “cold” swapped
9 Turn off power to “failed” power supply
9 Disconnect input power to the power supply
9 Remove Power Supply
9 Insert new power supply
9 Connect input power
9 Turn power on to the new power supply

Phoenix Connector simplifies input power connection

Woodward Designed CPU
Woodward designed hardware and firmware
• Utilized 5200 Core CPU design
• Added peripherals required by industrial control around the 5200 core
CPU
• CPU module manufactured by Woodward
• Freedom to select what inputs went on the faceplate
• More industrialized CPU than the Xycom Pentium CPU
• Freedom to select CPU functionality
• Freedom to design fail-over mechanisms
 ™
MicroNet Plus CPU Module
CPU5200
• Simplex or Redundant operation
• Motorola MPC5200 Power PC
Microprocessor
9400 MHz
9128 MB DRAM
964 MB Flash
91.5X Computing Power of Pentium
 ™
MicroNet Plus CPU Module
CPU5200 PowerPC Module
• Two Customer Ethernet Ports
9Ports are Isolated
9Ethernet FTM is not required with 5200
9Ports must be on different domains to function as
redundant
• Two Real Time Network ports
9Dedicated for RTN expansion
9No other devices should be connected to these
networks
• Two Can Ports
9Interface to GS6 Valves and DVP Driver (Future)
• One Serial Port
9Fully isolated port
9Supports RS-232, RS-422, RS-485
 ™
MicroNet Plus CPU Module
Reset Switch = CPU hardware reset switch
Run/Reset GRN/RED LED = CPU status

2 Ethernet Ports = Communications

to external system and distributed I/O

2 Real Time Network Ports

Woodward Debug Port = Troubleshooting

USB Port - Removed on initial release of CPU
GREEN LED = CPU SYSCON
RED Fault LEDs = CPU Faults

Serial Port (RS-232, RS-485, RS-422)

= Communication port

CAN Port = Communication port

CAN Port Status

CAN Port = Communication port

CPU COMPARISON
Motorola CPU Pentium CPU Motorola 5200 CPU
(030s, 040s, 060s)
CHASSIS NetCon NetCon MicroNet Plus
MicroNet Simplex MicroNet Simplex MicroNet Simplex
COMPUTING POWER 030 – 10 mips @ 33MHz 550 mips @ 233MHz 700 mips @ 400MHz
040 – 36 mips @ 33MHz 2.5 Times the 040 1.5 times the Pentium

MEMORY 030 - 2MB RAM, 64 MB RAM 64 MB Flash

8MB FLASH 96 MB FLASH 128 MB RAM
040/060 - 8MB RAM, 8MB
FLASH
OPERATING SYSTEM Woodward XINU VenturCom/WinNT VxWorks

APPLICATION CODE GAP CODER 2.XX 3.XX GAP CODER 3.XX GAP CODER 4.XX

COMMUNICATIONS Modbus Serial UDP Modbus Serial UDP TCP/IP Modbus Serial UDP TCP/IP
ServLink Serial ServLink Serial ServLink OPC Server
Embedded OPC EGD
EGD CAN
 ™
MicroNet Plus I/O Modules
MicroNet Plus – Same Proven I/O as MicroNet Simplex
• Analog Inputs and Outputs
9 Speed MPU/Prox Inputs
9 Thermocouple and RTD Inputs
9 mA and Voltage Inputs and Outputs
9 Actuator Controller mA Output with RVDT/LVDT Feedback
• Discrete Inputs and Outputs
9 Discrete Contact Inputs
9 Relay Driver Outputs and Relay Boxes
• Communications and Network
9 LinkNet Controller
9 LinkNet Distributed I/O Modules
9 Ethernet (on CPU5200)
9 Serial I/O
9 Real Time SIO (Communications to DLE drivers)
9 Pressure Input (Comms to Honeywell DLE Pressure XDCR)
I/O Modules
Chassis

Cable

I/O
Module
Field
Termination
Module Field
(FTM) Wiring
SIO Module
The SIO (Serial In/Out) Module interfaces four serial
communication ports to the VME bus. The module manages four
serial ports. Port A(J1) and port B(J2) are RS-232 ports. Port C(J3)
and Port D(J4) are for RS-232, RS-422, or RS-485 communication
protocols. Ports C and D must be at the same baud rate when
using 38.4 Kbaud or 57.6 Kbaud.
The processor on this module is a 68030. It controls the transfer of
data between the ports and the VME bus. This module can have
as much as 4 KB of Dual-Port RAM and 64 KB of PROM.
The local memory supports the 68030 processor on this module.
The SIO module has one LED (FAULT) and no switches.
24/8 Analog Module
A 24/8 Analog module contains circuitry for twenty-four analog
inputs and eight 4-20 mA outputs. These modules have no
potentiometers and require no calibration. A module may be
replaced with another module of the same part number without any
adjustment.
The 24/8 Analog Modules come in four different configurations.
1. 24 channels of 4-20 mA inputs with 8 channels of 4-20 mA outputs (2- pole 10ms filter on
all input channels).
2. 24 channels of 4-20 mA inputs with 8 channels of 4-20 mA outputs (2- pole 10ms filter on
all input channels, except channels 23 and 24, which have 2-pole 5ms filter).
3. 12 channels of 4-20 mA inputs, 12 channels 0-5 Vdc inputs with 8 channels of 4-20 mA
outputs (2-pole 10ms filter on all input channels).

All 4-20 mA analog inputs may be used with two-wire ungrounded

(loop powered) transducers or isolated (self-powered) transducers. All
analog inputs have 200 Vdc of common mode rejection. If
interfacing to a non-isolated device, which may have the potential of
reaching over 200 Vdc with respect to the control’s common, the use
of a loop isolator is recommended to break any return current paths
producing erroneous readings.
Each board has an on-board processor for automatic calibration of
the I/O channels. Each analog input incorporates a time-stamping
feature with 5 ms resolution for two low set points and two high set
points.
24/8 Analog Module
Analog Inputs
For a 4–20 mA input signal, the 24/8 Analog Module uses a
200 ohm resistor across the input located on the 24/8
Analog Module. Each analog input channel may power its
own 4–20 mA transducer. See Figure 9-3 for analog input
connection. This power is protected with a 100 mA fuse on
each channel to prevent an inadvertent short from
damaging the module. The 24 Vdc outputs are capable of
providing 24 Vdc with ±10% regulation. The maximum
current is 0.8 A. Power connections can be made through
terminals located on the 24/8 Analog FTMs.

Analog Outputs
There are 8 analog output channels of 4–20 mA with a full
scale range of 0-25 mA. All Analog Outputs can drive a
maximum load of 600 ohms (load + wire resistance). See
Figure 9-4 for analog output connection. Each output
monitors the output source current for fault detection. All
of the analog outputs may be individually disabled. When
a channel fault or a module fault is detected, the
application program may annunciate the fault, disable the
channel and stop using data in system calculations or
control. Care should be taken to prevent ground loops and
other faults when interfacing to non-isolated devices.
34Ch High Density Versatile
Input Module (HDVIM)
This board includes no potentiometers
and requires no calibration. A Configurable
34Ch HDVIM module may be replaced with
another board of the same part number
without any adjustment. Each Configurable
34Ch HDVIM Module contains circuitry for 34
Analog inputs and two cold junction inputs. 24
of the Analog inputs may be 4– 0 mA inputs
or thermocouple inputs, and the remaining ten
Analog inputs may be 4– 0 mA inputs or RTD
inputs. The Configurable 34Ch HDVIM Module
connects to the CPU board through the VME
bus.
34Ch High Density Versatile
Input Module (HDVIM)
In a Simplex system, each 34Ch HDVIM module is
connected through two high density 62
conductor analog cables to two 34Ch HDVIM
FTMs. All inputs on the module are accessible on
the FTM, and the channels are labeled to
correspond to their software locations (e.g.,
analog input 1 on the FTM will be analog input 1
in the application software).
Loop power for the Analog inputs must be
supplied by an external supply, if needed. This
supply should be wired to terminals 40 and 81 on
each FTM. The FTM will fuse and distribute the
power to 9 sets of terminals on the FTM. The 4–
20 mA, thermocouple, or RTD configurable inputs
are selected in the GAP block software, for each
input. The GAP block configuration sets input
gain via software. The maximum wire size that
the FTM can accept is one 16 AWG or two 20
AWG wires.
48/24 Discrete Combo Module
A 48/24 Discrete Combo module contains
circuitry for forty-eight discrete inputs and
twenty-four discrete outputs. These modules
have no potentiometers and require no
calibration. A module may be replaced with
another module of the same part number
without any adjustment.
It’s configuration consists of two 24/12
Discrete FTMs (DIN rail mounted) connected to
the 48/24 Discrete Combo module via two High
Density Analog/Discrete cables.
48/24 Discrete Combo Module
Discrete Inputs
Each 48/24 Discrete Combo module accepts 48
contact inputs. The 48/24 Discrete FTM may supply
contact wetting voltage. Optionally, an external 18–
32 Vdc power source or an external 100–150 Vdc
power source can be used to source the circuit
wetting voltage. If the 24 Vdc internal power source
is used for contact wetting, a jumper is required
between FTM terminals 98 and 99. If an external
power source is used for contact wetting, the
external source’s common must be connected to the
FTM’s discrete input common, terminal 49. If 125 Vdc
contact inputs are needed, the High Voltage (125
Vdc) FTM must be used. The FTM provides a common
cage-clamp terminal connection for customer field
wiring.
Discrete Outputs
For the 48/24 Discrete Combo FTM configuration,
there are three types of relay output boxes that can
be used. These consist of the 16Ch Relay (Phoenix)
Module, 16Ch Relay Module, and the 32Ch Relay
Module (see Chapter 13 for a description of the
available modules). The relay modules connect to the
48/24 Discrete FTM through individual cables and
provide a common cage-clamp terminal connection
for customer field wiring. The discrete outputs on the
48/24 Discrete I/O module are non-isolated; the
isolation takes place in the relay boxes.
Analog Combo Module
Each High Density Analog Combo module
contains circuitry for four speed sensor inputs,
eight analog inputs, four analog outputs, and two
proportional actuator driver outputs. Each speed
sensor input may be from a magnetic pickup or
from a proximity probe, each analog input may be
4–20 mA or 0-5 V, and each actuator driver may
be configured as 4–20 mA or 20–160 mA.
This module includes no potentiometers and
requires no calibration. An Analog Combo module
may be replaced with another module of the same
part number without any adjustment.
Analog Combo Module
Speed Sensor Inputs
Any of the module’s four speed channels accepts passive magnetic pickup units (MPUs) or
proximity probes. Each speed input channel can only accept one MPU or one proximity probe.

Analog Inputs
The analog inputs may be current or voltage type dependent on the part number. All current
inputs may be used with two-wire ungrounded (loop powered) transducers or isolated (self-
powered) transducers. All analog inputs have 200 Vdc of common mode rejection. If
interfacing to a non-isolated device, which may have the potential of reaching over 200 Vdc
with respect to the control’s common, the use of a loop isolator is recommended to break any
return current paths that may produce erroneous readings. All current inputs use 200 ohm
resistors across their inputs. Each current input channel may power its own 4–20 mA
transducer. This power is protected with a 100 mA fuse on each channel to prevent an
inadvertent short from damaging the module.

Analog Outputs
The analog outputs are 4–20 mA with a full-scale range of 0–25 mA. Each output monitors the
output source current for fault detection. All of the analog outputs may be individually
disabled. When a channel fault or a module fault is detected, the application program may
annunciate the fault, disable the channel or module, and stop using the data in system
calculations or control. The Analog Combo module has four 4–20 mA current output drivers. All
analog outputs can drive a maximum load of 600 ohms (load + wire resistance). Care should
be taken to prevent ground loops and other faults when interfacing to non-isolated devices.

Actuator Outputs
The actuator outputs may be configured for 4–20 mA or 20–160 mA. Configuration is done
through the application software; no hardware modifications in the forms of jumpers or
switches are necessary. For fault detection, each output monitors the output source current
and the output return current. All of the actuator outputs may be individually disabled. When a
channel fault or a module fault is detected, the application program may annunciate the fault,
disable the channel or module, and stop using the data in system calculations or control.
34Ch High Density
Versatile Input Module (HDVIM)

This board includes no potentiometers and requires no calibration. A

Configurable 34Ch HDVIM module may be replaced with another
board of the same part number without any adjustment. Each
Configurable 34Ch HDVIM Module contains circuitry for 34 Analog
inputs and two cold junction inputs. 24 of the Analog inputs may be 4–
0 mA inputs or thermocouple inputs, and the remaining ten Analog
inputs may be 4–20 mA inputs or RTD inputs. The Configurable 34Ch
HDVIM Module connects to the CPU board through the VME bus.
Two Channel Actuator Controller

The two channel actuator controller controls an integrating

or proportional, hydromechanical or pneumatic actuator.
Each actuator may have up to two position feedback
devices. There are several versions available, and the
module part number indicates the module's maximum
output current capability. A discrete (gray) cable must be
used with this module. Do not use an analog (black) cable.
Tab 7
Woodward Software Tools

Appmanager.exe.lnk

Gap 2.17.lnk Servlink Server.lnk

Servlink OPC Server.lnk

Coder 4.02.lnk Watch Window II.lnk

Control Assistant 3.7.lnk

Software Interface Tools

Programming Tools Service Tools

GAP APP Manager

Monitor GAP
CODER MicroNet Plus
Watch Windows
Control Assistant
Software Interface Tools
The software tools can be grouped into two main
categories: Programming Tools and Service Tools.
• Programming Tools are the application tools and simulation software that
allow a control system engineer to write application software and test it.
The output of these programming tools is assembled, compiled and linked
with the Coder, and the resultant executable file is loaded into the targeted
control.
• 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.
Software Service Tool Overview
Programming Tools
• GAP
9 (Graphical Application Programmer) – Windows Based Functional Block Programming
• Coder – “C” Compiler
Service Tools
• App Manager
9 Simple application manager (application file transfer and start/stop application).
• Monitor GAP
9 Windows Based Viewer of live data on Functional Block Diagram
• Watch Window II
9 Windows Based Service tool for troubleshooting, variable monitoring and tuning.
• Control Assistant
9 Windows Based service tool for the graphical display of high speed (millisecond) data
collected by the application Data_log or real time. Tunable list management.
AppManager
AppManager allows access to control applications for transferring,
retrieving, starting, stopping and restarting.
AppManager Control List

Control
List
AppManager Application List

Application List
AppManager Status Display

Status Message Display

AppManager Status Display

Status Bar Message Display

AppManager Control Buttons

Toolbar Buttons
AppManager Toolbar

• Refresh Control List

9 Refresh Control List
ƒ Occasionally as controls come on and off the network it is
desirable to click the “Refresh Control List” button to get
an immediate update of the controls on the network.
ƒ Refreshing the Control List can also be done through the
menu; \Administer\Refresh Control List\.
AppManager Toolbar

Downloading and Running the AppManager

Application.
• Transferring Application Files
9 The AppManager’s “Transfer Application Files” command is used to move the
.OUT file to the MicroNet CPU’s non-volatile memory. To transfer an
application click on the appropriate control (Computer Name) and then click
on the “Transfer Application Files” button. A window will appear prompting
the user for the “.out” file.
9 Or use \Control\Transfer Application Files… menu option.
• Note: When the MicroNet PlusTM Control is accessed from a
new workstation or a new user, AppManager requires proper
Logon and Password validation before allowing the
application to be manipulated.
AppManager Toolbar
Retrieving Application Files
• Retrieve Application Files
9 Sometimes it is desirable to retrieve files from the control and copy it to your
local PC. One example would be a DATA_LOG file that you would want to
view using Control Assistant on your PC.
9 To retrieve a file, click on the “Retrieve Application Files” button or
\Control\Retrieve Files…\ from the menu and a window will pop up (defaults
to the applications directory) and prompt the user to select a file.
9 Multiple files can be selected at one time by the use of the “Shift” or “Control”
and the mouse.
9 The user then selects the “Open” button. Another window would pop up
prompting the user where to put the file.
AppManager Toolbar

Deleting Files from the Control

• Delete Files
• This button will bring up a window to select files to be
deleted.
9 Default file types are “.out” and “.log”
9 By default it comes up and show the applications directory where all
application files exist.
9 Using the “Shift” or “Control” key and the mouse will allow multiple files to
be deleted at the same time.
AppManager Toolbar

Control Information
• Control Information
9 Pressing the “Control Information” button
or \Control\Control Information\ menu
option, brings up a window which shows
the Footprint part numbers and
information as well as the AMService
Version.
9 It also shows the IP address and computer
name that was configured.
9 The IP Address is needed for other Service
Tool Software.
AppManager Toolbar
Starting and Stopping an Application (continued)
• Reboot the Control
–The Reboot Control command performs a soft reboot on a control.
–To Reboot an application that is running, highlight the desired
controller then press the “Reboot the Control” button or \Control\Reboot
Control from the menu. AppManager will ask for confirmation to stop
the application and reboot.
–Select “Yes” to stop and reboot the application. The Status Message
Display and Application List will indicate when the application has
stopped.
–Rebooting a control will not work if an application is running and the
stop permissive is not enabled in the GAP application.
AppManager Toolbar
Starting and Stopping an Application (continued)
• Stop Application
–To change an application that is running, highlight the running
application then press the “Stop Application” button or \Control.
AppManager will ask for confirmation to stop the application.
–Select “Yes” to stop the application. The Status Message Display
and Application List will indicate when the application has
stopped and it is removed from the Auto-Start list.
AppManager Toolbar

Starting and Stopping an Application (continued)

• Start Application
–To start an application, highlight the desired application then
press the “Start Application” button or \Control\Start Application
from the menu. AppManager will ask for confirmation to start
the application.
–Select “Yes” to Start the application. The Status Message Display
and Application List will indicate when the application has
started.
–You cannot start an application if another application is already
running.
AppManager Toolbar
Starting and Stopping an Application.
• Stop and Restart the Application.
– First, select a control from the list, the Application List (right
window) will then update.
– Next, select the application to stop and restart by highlighting it
on the Application List.
– Finally, press the Stop and Restart Application button to run the
application. If necessary, AppManager will ask for a username
and password before starting the application.
– Status information will be displayed in the Status Message
Display (the bottom window) to indicate if and when the
application software is running, as well as any fault information,
like hardware initialization failures.
– Rebooting a control will not work if the stop permissive is not
enabled in the GAP application.
AppManager Toolbar

Starting and Stopping an Application (continued)

• Auto-Start
– Once the application is running, AppManager will indicate that
the application is marked as the Auto-Start Application. This
means that if the AtlasPCTM power is cycled, or if the control
goes down for any reason, the current application will
automatically restart when the control comes back up. This
feature eliminates the need to connect to the AtlasPCTM with
AppManager every time the control is powered up to get the
application software running. When AppManager’s Start/Stop
Application command is issued to stop an application,
AppManager un-marks the application as the Auto-Start
Application.
AppManager Toolbar

Starting and Stopping an Application (continued)

• Help
– AppManager Help File.
– Search by content or keyword.
– Print option to print subject or entire help manual.
Watch Windows II

Watch Windows is a Software utility designed for Ethernet

communication with the Woodward CPU and Atlas Vx
Controllers to display all control data. From this interface,
variables can be selected for both control and monitoring
purposes.
Watch Windows is composed from three window sections.
• Main Window.
• Explorer.
• Inspector.
Watch Windows II

Main Window

Explorer Inspector
Main Window

Main Window

The Main Window is the application

controlling window.
It is used to close the application.
It is also used to control the Explorer’s visibility
and to create, control, save and restore
Inspectors.
The Main Window is composed of a tool bar
and a menu.
Explorer

The Explorer is used to browse the set of

variables, invoke commands on a
control and view properties of a control.
The Explorer is composed a set of
tabbed sheets. Each sheet is associated
Explorer
with a single control.
The sheet’s tab is labeled with the
associated control’s identifier.
Watch Windows II

Watch Window is supported on the MicroNet Plus Controller.

If a right mouse click is performed on the IP address or CPU name tab
(e.g NTM 2432) in the Explorer window, the following functions are
displayed:

• App Settings • Properties

– Load to control – Application
– Save to file – Operating System
• Lock/Unlock I/O – OPC Server
• Save Values • Add Item
Watch Windows II
Example of a “Watch Window” window with functions
displayed.
Configuration, Reset, Downloading

Right Clicking here will allow the user

to Download a new application program,
enter the configuration mode, and Save Values.
Uploading and Downloading Tunables

All tunables (variables) can be saved from one

control to a file (Save to File …) and
down-loaded to another control (Load From File)
for faster set-up.
Watch Windows II

Watch Window functions support/procedures

• Load (Configuration) from File
Function is supported however a certain procedure must be followed.
– Loading a previously saved control application settings into the
control is done by invoking the Load (Configuration) From File
command in the Explorer's Pop-up Menu. The pop-up menu is
accessed by right clicking on a control name in the Explorer.
– The system will display a prompt asking for the file name and
location. The system will then open the Control’s Configuration file
(.cfg) and load the tunable settings into the control.
– During the Configuration Load the system will not allow any other
operations to be initiated within the Explorer.
Watch Windows II

Watch Window functions support/procedures (continued).

• Save (Configuration) to File
Function is supported
– Saving a control’s configuration to a file (.cfg) is done by
invoking the “Save To File…” command in the Pop-up
Menu. The pop-up menu is accessed by right clicking on
the control name in the Explorer.
– The system will display a prompt for the file name and
location. The system will then open the Control’s
Configuration Settings file (Tunables) and save the
settings from the control.
– During the Configuration Save, the system will not allow
any other operations to be initiated within the Explorer.
Watch Windows II
Watch Window functions support/procedures (continued).
• Lock I/O & Unlock I/O
– Toggling the I/O Lock on the control is done by invoking
the Lock IO and Unlock IO commands in the Explorer's Pop-
up Menu. The popup menu is accessed by right clicking on
the control name in the Explorer. The system will display a
confirmation dialog box. If the dialog is confirmed, the
system will execute the command on the control.
• Save Values
– Saving values in the control is done by invoking the “Save Values”
command in the Explorer's Pop-up Menu. The system will execute
the command on the control.
Inspector

Inspector

The Inspector is used to monitor and edit

variables.
The Inspector is composed of a set of tabbed
sheets.
Each sheet’s tab is labeled with a user-
definable name.
The user has the ability to add and remove
sheets using menu items and/or toolbar
buttons in the Main Window.
Inspectors

Can be saved and recalled.

Can be created and modified.
Allows viewing & changing of Control’s Variables.
• Name
• Value
• Description
Multiple Inspector sheets and sheet names.
Drag and Drop to Build Inspector

Drag and Drop Variables from the Explorer

to the Inspector Sheet
Typical Inspector Sheet

10 % Change

1% Change

Editable Monitor Only Value

Variable

Configurable Variable
Typical Inspector Sheet

New Inspector Sheets

Boolean Variable
Control Assistant
Control Assistant is a custom 32bit application for Win95,
Win98, Windows NT and Windows 2000. This Woodward utility
is designed to support the following MicroNet NTTM or VX Works
Atlas features via Serial or Ethernet communications.
Tunable Maintenance. This feature supports tunable capture,
sorting, comparing vs. baseline/GAP, and saving of tunables.
Datalog Plotting. This feature supports the capture and plotting
of high-speed datalog information. See DATA_LOG for more
information in GAP Help.
Data Trending. This feature supports the trending GAP output
fields.
Control Assistant
Receiving a Tunable List
• To receive a tunable list click on ‘Transfer’ menu ‘Receive Tunable List…’
• It shows the following info.
– Category Name
– Block Name
– Block Type
– Current Value
– Initial/Default Value
– Tunable Range
– Tunable Low Limit
– Tunable High Limit
– Mode (Debug/Service/etc.)
– Very Left Column will show a “+” sign if Current value is different from
default.
Control Assistant
Control Assistant

Viewing Modifications
• To view a list of modification (current values
that differ from the initial/default values click
on the ‘View’ menu ‘Modifications’.
• This will bring up a new window showing just
the tunables that are different from the initial
value.
Control Assistant
Control Assistant

Comparing Tunable Lists

• To compare a set of tunable lists click on the
‘Edit’ menu ‘Compare’ and the below window
will pop up. The user has the ability to view
difference in tunable value, and tunable
additions/deletions to similar gap programs.
Control Assistant
Control Assistant

Tunable differences between two different

tunable lists. Example below:
Control Assistant

Tunable additions between two different

tunable lists. Example below:
Control Assistant

Tunable deletions between two different

tunable lists. Example below:
Control Assistant Data Log Display
Control Assistant

DATA_LOG block.
• For specific information on how to use the
DATA_LOG block refer to to gap help.
However in general this block is used to
capture Analog and Boolean data at whatever
rate group and for whatever length of time it
is configured for.
• Once the data is collected (in RAM), the user
can download it to the computer through the
either an Ethernet port or a serial port.
Control Assistant
Opening a Data Log
• At the completion of a “Receive Data Log”
Control Assistant will automatically open the
file and give you a window looking like this:
Control Assistant
Control Assistant
Opening a Data Log (continued)
– On the left hand side of the page are the variable
names with the corresponding gap names that
have been programmed into the Data_Log block.
– These variables can be double-clicked to be
chosen as variables to view. Other things like
variable colors can be set up.
– Once all the correct variables are setup click “OK”
and the Graphview window will appear graphing
the data you have selected.
– Cursers are then available for the users to make
measurements on the waveforms.
Control Assistant
Control Assistant Graphview Example:
Tab 8
Two Line Display (Service Panel)
Two Line Display (Service Panel)

WOODWARD GOVERNOR COMPANY

NetCon 5000 Version 2.08-11

Return to the
screen saver by
pressing exit twice
Screen Saver
Activated When
and then once.
Display is Left at
“Home” Screen
For 10 Minutes
Two Line Display (Service Panel)
D@ ACT_01.ACT_COMBO = 0.000
D A108DIO

“@” Symbol Indicates

which line is being controlled

Both Lines will update in

real-time

Pressing the”SEL” key

toggles between the two
lines
Modes of Operation

WOODWARD GOVERNOR COMPANY

NetCon 5000 Version 2.08-7

SERVICE CONFIGURE DEBUG OPSYS_FAULTS SYSTEM

MONITOR
1111 1113 1112 1114 INFORMATION
Modes of Operation
Service
Monitor
Configure
Debug
Opsys_Faults
System Information
Service Mode
WOODWARD GOVERNOR COMPANY
NetCon 5000 Version 2.08-7

SYSTEM SERVICE
MONITOR
INFORMATION 1111

Service Service Service Service More

Header 1 Header 2 Header 3 Header 4 Headers

Block 1 Block 1 Block 1 Block 1 Block 1

Block 2 Block 2 Block 2 Block 2 Block 2

More More More More More

Blocks Blocks Blocks Blocks Blocks
Service Mode
Service Menus Are Setup by Application Engineer
• Content, Order of Information, and Nomenclature
Available While Turbine/Engine is Running
Default Password is 1111
Adjusting Tunable Values:
• Use and to adjust tunable values. (1% increment or
True/False)
• To increase increment, hold down the key while adjusting. (10%
increment)
• To decrease increment, hold down the key while adjusting. (0.1%
increment)
• To directly enter a number, press , key in the number, and press
again. (Must be within 1% of number)
Monitor Mode
WOODWARD GOVERNOR COMPANY
NetCon 5000 Version 2.08-7

SERVICE CONFIGURE
MONITOR
1111 1113

Service Service Service Service More

Header 1 Header 2 Header 3 Header 4 Headers

Block 1 Block 1 Block 1 Block 1 Block 1

Block 2 Block 2 Block 2 Block 2 Block 2

More More More More More

Blocks Blocks Blocks Blocks Blocks
Monitor Mode

“READ ONLY” Mode - No Adjustments Can Be Made

Same Structure as Service Mode (Headers, Blocks)
No Password Required
Intended for personnel to view information without having
the ability to adjust parameters.
Configure Mode
WOODWARD GOVERNOR COMPANY
NetCon 5000 Version 2.08-7

CONFIGURE DEBUG
MONITOR
1113 1112

Configure Configure Configure Configure More

Header 1 Header 2 Header 3 Header 4 Headers

Block 1 Block 1 Block 1 Block 1 Block 1

Block 2 Block 2 Block 2 Block 2 Block 2

More More More More More

Blocks Blocks Blocks Blocks Blocks
Configure Mode
Used to Setup System Before Initial Operation of Control
Configure Mode is Setup by Application Engineer
Turbine/Engine Must be Shutdown Prior to Entry
Default Password for Configure Mode is 1113
To make adjustments to Configurable Values.
Directly enter any number by pressing , keying in the
desired number, and pressing again.
CAUTION: Entry into the Configure mode causes an automatic I/O lockup
which will cause the unit to shutdown. Do not enter the Configure Mode
while the turbine/engine is running.
 Debug Mode
WOODWARD GOVERNOR COMPANY
NetCon 5000 Version 2.08-7

DEBUG OPSYS_FAULTS
CONFIGURE
1112 1114

Category Alpha-Numeric Order Category

More
Categories
Alpha-Numeric Order

MORE
Block 1 FIELD FIELD FIELDS Block 1 FIELD FIELD

MORE
Block 2 FIELD FIELD FIELDS
Block 2 FIELD FIELD

More MORE More

FIELD FIELD FIELD FIELD
Blocks FIELDS Blocks
Debug Mode
Used for System Troubleshooting
Should Only Be Used by Properly Trained Personnel
Generated Automatically by GAP
View All GAP Block Output Fields and Tunable Input Fields
Default Password for Debug Mode is 1112
Short-Cut keys:

• Used to Toggle to Service Mode and Back

• To Skip to Next “Letter in Alphabet - Category/Block”

• To Skip to Previous “Letter in Alphabet -

Category/Block”
Debug Mode
D@ SPEED SETPOINT = 102.00
ACTUAL SPEED = 102.50

“D” indicates that line is

In Debug Mode
Debug Mode - Navigation
Access Categories (GAP Sheets) with and
• Categories Arranged in Alpha-Numeric Order From Left to Right
Upon Finding Correct Category, Access GAP Blocks with and
• Blocks Arranged in Alpha-Numeric Order From Top to Bottom
Upon Finding Correct Block, Access Additional Fields with and
• All Output Fields and Tunable Input Fields Can Be Accessed
If the field is tunable an asterisk (*) will be displayed before the value (i.e..
*150) the value can be changed smoothly and gradually by using either the
ADJ Up or the ADJ Down buttons.
• Note: If tunable values are adjusted they need to be saved in the
EEPROMs by pressing the CLR or EXIT twice. An alternative method to
save changed values without exiting debug mode is by pressing 99 and
the button.
Opsys_Faults Mode
WOODWARD GOVERNOR COMPANY
NetCon 5000 Version 2.08-7

DEBUG OPSYS_FAULTS SYSTEM

1112 1114 INFORMATION

Faults FT5000 System Alarms Clear Alarms

Detected Alarms Detected Detected Detected
Opsys_Faults Mode

Displays System Faults or Alarms

Permits Resetting (clearing) the List of
Detected Alarms
Default Password for Opsys_Faults Mode is
1114
System Information
WOODWARD GOVERNOR COMPANY
NetCon 5000 Version 2.08-7

OPSYS_FAULTS SYSTEM SERVICE

1114 INFORMATION 1111

Display System Change ACT_CORR Download

Information Password Block Update Tunable Values
System Information

Display System Information

Change Password
Update Act_Corr block
Download Tunable Values
System Information
Display System Information
• NetCon OS Version Number
• Name of Application
• Date of HEX File Generation
• Date of Last CDR File Save
• Information Used to Communicate with TAG Group
Change Password
• Allows User to Change Passwords for Each Mode
• Must Know Current Password to Change
• IMPORTANT! - Changed Passwords Must Be Recorded and
Logged
System Information
ACT_CORR Block Tables Update
• Used on DLE Applications - Calculation of Valve Flow
• Allows User to Download Actuator Correction Data Tables
• Default Password for ACT_CORR mode is 1115
Download Tunable Values
• Control Must Be Setup for Tunable Management
• Allows User to Download the Tunable Values from PC to
Control
• Requires WinXfer or Control Assistant Software
• Default Password for Download Tunable Values is 1116
Tab 9
LM Aeroderivative System Sensors

LM Aeroderivative System Sensors

TR0214
Rev A

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1/
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August 28, 2008
LM Aeroderivative System Sensors

What do we measure?

g GE Energy
2/
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August 28, 2008
LM Aeroderivative System Sensors

What do we measure?
•Temperature
•Humidity
•Pressure
•Level
•Speed
•Position
•Vibration
•Flow
•Flame
•Enclosure gas concentration

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3/
GE /
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LM Aeroderivative System Sensors

Briefly – Connecting to
the control system

g GE Energy
4/
GE /
August 28, 2008
LM Aeroderivative System Sensors

With an Industrial Instrumentation Transmitter……

Transmitter

Control System

Smart Transmitter
Outputs

Signal Signal
Sensor Conversion
Processing

•Thermocouple •Amplification. •4 to 20 mA (processed analog output)

•RTD •Filtering. •HART (processed digital output)
•Capacitance Cell •Linearization. •Fieldbus (processed digital output)
•Piezo Cell •Temperature compensation.
•Diagnostics.
•Analog to digital conversion.
•Processed signal output.

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GE /
August 28, 2008
LM Aeroderivative System Sensors

Without an Industrial Instrumentation Transmitter…………

Sensor Assy Input Module

Control System

Input Control System Input Module

Signal Signal
Sensor
Processing Conversion

•Thermocouple •Amplification. •Ethernet.

•RTD? •Filtering. •Fieldbus serial digital communication.
•Mag reluctance •Linearization.. •Parallel backplane digital communication.
•LVDT •Temperature compensation.
•Diagnostics.
•Analog to digital conversion.

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•Conversion to engineering units. 6/
GE /
•Processed signal output.. August 28, 2008
LM Aeroderivative System Sensors

Quick point about availability & redundancy

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Sensors

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August 28, 2008
LM Aeroderivative System Sensors

Temperature
Temperature Sensors Used Today

•Thermocouple
•RTD

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GE /
August 28, 2008
LM Aeroderivative System Sensors

Thermocouple
•A thermocouple is constructed by twisting or welding together at one end, two conductors made from
dissimilar metals.
•The voltage generated by the resulting circuit is proportional to the temperature gradient along each junction
lead, and measured at the open end of the two wires.
•System measures the difference in temperature between the ‘hot” junction and the “cold/reference” junction.
•The generated voltage is non-linear.
•The cold junction compensation is typically implemented by use of an absolute temperature sensor located
at the reference junction (RTD, thermistor).
•Thermocouples are designated as classes such as type E, K, J, N, or T based on the composition of the
two materials used to form the junction. Each type has a different temperature range/voltage response curve.
•For durability, the thermocouple junction is typically housed in a metallic tube (sheath) filled
with an insulation material (Magnesium Oxide).
a b

c
Typical thermocouple Seebeck Effect
measurement system (temperature difference
TC Isothermal Reference Reference junction Welded bare generates current flow)
junction junction junction temp sensor thermocouple junction
a

+ - Vab
J3 b
J1
- + Seebeck Voltage
J2 (Sum of voltage differences
TC Materials Copper along the wires)

Thermocouple

g GE Energy
extension wire 10 /
GE /
August 28, 2008
LM Aeroderivative System Sensors

Thermocouple
Applications
•Fuel manifold temperatures.
•Compressor discharge temperature.
•Combustor gas path temperatures.
Useful
Thermocouple Application
Type Names of Materials Range
Platinum30%
Rhodium (+) 2500 -3100F
B Platinum 6%
Rhodium (-) 1370-1700C
W5Re Tungsten

C
5% Rhenium (+) 3000-4200F Thermocouple assy
W26Re Tungsten with connection head
26% Rhenium (-) 1650-2315C
Chromel (+) 200-1650F
E
Constantan (-) 95-900C
Iron (+) 200-1400F Thermocouple terminal block
J Constantan (-) 95-760C Internal construction
Chromel (+) 200-2300F
K Alumel (-) 95-1260C
of a thermocouple probe
Nicrosil (+) 1200-2300F
N Nisil (-) 650-1260C sheath
Platinum 13% TC wire
R Rhodium (+) 1600-2640F Insulation (MgO)
Platinum (-) 870-1450C
Platinum 10%
S Rhodium (+) 1800-2640F
Platinum (-) 980-1450C
Copper (+) -330-660F
T
Constantan (-) -200-350C

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GE /
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LM Aeroderivative System Sensors

RTD
•An RTD (resistance temperature detector) is a resistor with an electrical resistance that changes in
proportion to changes in the temperature of the resistor.
•A 100 Ohm RTD per the IEC standard has a resistance of 100 ohms at 0ºC.
•PTC (positive temperature coefficient) Increase in temperature, yields an increase in resistance.
•Two common forms:
-A wire wrapped around an non-conducting insulation material.
-A metal film deposited on an electrically insulating substrate.
•The sensor film or wire is typically made of platinum due to its minimal susceptibility to contamination,
and its linearity and stability.
•The measured resistance value is typically linearized by a specialized integrated circuit, or in
microcomputer based systems, by software algorithms.
•Applied in applications using a three wire connection configuration in order to compensate for errors
created by connection lead resistance.
•Two temperature coefficients typically available ( ), one for USA standards, and one for European
standards.
Typical three wire RTD input Circuits Film Type RTD Wire Wound RTD

RTD

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12 /
GE /
August 28, 2008
LM Aeroderivative System Sensors

RTD
Applications
•Lube oil temperatures.
•Bearing temperatures.
•Enclosure temperatures.
•Ambient temperature.

Typical RTD assy

for
embedded temperature measurements RTD probe assy Thermowell RTD assy

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GE /
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Humidity
Humidity Sensors Used Today

•Transmitter assembly

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GE /
August 28, 2008
LM Aeroderivative System Sensors

Humidity Sensors
•A typical humidity sensor is an electrical transducer whose electrical output value is proportional to
water moisture in the atmosphere.
•Three common implementations:
-Capacitance - The capacitance value, proportional to humidity, of a specialized thin film
capacitor is measured. Typical “state of the art” capacitive sensors utilize
signal processing circuitry deposited on the same substrate as the capacitor.
-Resistance - Resistive sensors usually are constructed of noble (resistant to corrosion or
oxidation) metal electrodes either deposited on a substrate that is coated
with a salt, conductive polymer or acid, wire-wound electrodes on a plastic
or glass cylinder. The sensor absorbs the water vapor resulting in an
increase in electrical conductivity.
-Thermal Conductivity - Thermal Conductivity sensors measure the absolute humidity by quantifying
the difference between the thermal conductivity of dry air and that of air
containing water vapor.
•Additional electronics in the overall transmitter assembly convert the sensor signal to a typical output
of 4-20 mA for 0 to 100% relative humidity.
Note
Relative Humidity - Abbreviated as RH, relative humidity refers to the ratio (stated as a percent) of the moisture content
(actual vapor density) of air at ambient temperature and pressure compared to the saturated moisture content (saturated
vapor density) at the same temperature and pressure.
Capacitive humidity sensors Resistive humidity sensors Thermal conductivity humidity sensors

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Humidity Transmitter
Humidity transmitter assemblies

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LM Aeroderivative System Sensors

Humidity Transmitter
Applications
•Engine performance calculations.
•Air inlet system icing condition detection calculations.

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GE /
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Pressure
Pressure Sensors Used Today

•Transmitter assembly
•Switch

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Pressure Transmitter
•Typically contains an electrical transducer whose electrical output value is proportional to motion
created by the process fluid force exerted on a diaphragm. Diaphragm
Transducer
Housing
Process
Pressure “Motion”
Transducer
Coupling Media

•Three common implementations:

-Capacitance - The electrical capacitance value of a capacitor proportional to pressure is measured.
-Resistance - The resistance of a strain gauge proportional to pressure is measured.
-Resistance - The resistance of a group of piezoresistors proportional to pressure is measured.
•Capacitance or resistance is processed by onboard electronics to eliminate/reduce temperature drift,
provide linearization and convert the raw sensor signal to a typical output of 4-20 mA.
•Smart transmitters utilize a microprocessor to additionally provide diagnostics, configuration data, and
digital serial communications. Digital serial communications outputs becoming more prevalent (HART,
Foundation Fieldbus, Ethernet).
Signal processing
Typical capacitance cell piezoresisitve cell circuit
Typical silicon capacitance cell
Circuit (partial)

Voltage output is proportional

to pressure acting on
diaphragm

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LM Aeroderivative System Sensors

Pressure Transmitter
Piezo Resistive Silicon Pressure Sensor
Class 1 Div 2
High Speed Analog Pressure Transmitter Assy

Class 1 Div 2 High speed high accuracy smart

Smart Pressure transmitter Assy pressure transmitter Assy
with Local Readout

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LM Aeroderivative System Sensors

Pressure Transmitter
Applications
•Lube oil pressures.
•Compressor pressures.
•Combustor pressures.
•Hydraulic system pressures.
•Fuel pressures.
•Water/Steam injection pressures.
•Enclosure pressure.
•Inlet air pressure.
•Ambient pressure.

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LM Aeroderivative System Sensors

Pressure Switch
•Typically utilizes the motion of a diaphragm to actuate an electromechanical switch which is designed
to close or open the electrical circuit path when the pressure setpoint is reached.

Process
Pressure

•Three common implementations:

-Micro switch - Linkage from the diaphragm actuates an electromechanical switch.
-Hall Effect - The strength of a magnetic field is changed by movement of a magnet attached to the
diaphragm linkage.
-Photo Switch - Photo switch light emitter output is blocked or unblocked of by position of the
diaphragm linkage.

Pressure Switch
Pressure switch circuit Micro switch
assemblies

+ Power

Control System
Input

Power Common

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Pressure Switch
Applications
•Lube oil pressures.
•Hydraulic system pressures.
•Enclosure pressure.
•Inlet air pressure.
•Fuel pressures.
•Enclosure pressure.

Generally being replaced by pressure transmitters……..

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Level
Level Sensors Used Today

•Transmitter assembly
•Switch

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Level Transmitter
•Typically contains an electronic sensor/signal processing system that produces an electrical output value
proportional to the level of the fluid measured.
•Common implementations:
-Differential pressure – The differential pressure from the top to the bottom of the fluid containment
vessel is measured.
-Capacitance - The electrical capacitance value change with the level of the fluid of a probe assembly
immersed into the fluid is measured.
-Radar - The time delay generated by the reflection from the fluid surface of a
transmitted radar pulse is measured. The time delay is used to calculate the
material level in the vessel.
-Magnetostrictive - A current pulse injected into a magnetostrictive wire
results in strain pulse in the wire at the location where a float/magnet
assembly is floating on the fluid surface. The time delay is used to
calculate the material level in the vessel.

Differential pressure Capacitance Float Radar (Guided) Radar

LT LT LT LT

PDT

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LM Aeroderivative System Sensors

Level Transmitter
Applications
•Lube oil tank level.
Resistive/Magnetostrictive
•Hydraulic system tank level.
•Water wash tank level.

Differential pressure Radar

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LM Aeroderivative System Sensors

Level Switch
•Typically utilizes the mechanical motion of float to actuate an electrical switch that
is designed to either close or open an electrical circuit path when the level position “setpoint”
is reached.
Switch Assy
Micro switch Housing
Reed switch
Process
motion “micro” switch

Seal Switch contact leads

Linkage/Plunger
•Common implementations:
-Micro switch –mechanical plunger comes into contact with the “sensed” object and moves
the miniature electromechanical switch linkage.
-Hall Effect – The strength of a magnetic field is detected by position of a magnet attached to the
plunger linkage.
-Reed switch – The strength of a magnetic field of a moving magnet attached to the float/plunger
linkage opens or closes the reed switch contacts.

Level switch application

Level switch circuit
+ Power Float
LS
Load or
Control System Tank
Input
Power Common
LS

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Level Switch
Applications
•Lube oil tank level.
•Hydraulic system tank level.
•Water wash tank level.

Generally being replaced by level transmitters……..

Level switch assemblies

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Speed
Speed Sensors Used Today

•Magnetic Reluctance
•Proximity

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Magnetic Reluctance
•Utilizes the motion of a toothed circular ring (ferrous material) by a probe that emits a magnetic
field.
•The probe contains a permanent magnet, pole piece and a field coil. As each tooth passes near
the probe’s magnetic pole the magnetic flux lines of the system are deflected and a potential
difference (voltage) is generated by the motion of the toothed ring teeth as they change the
reluctance of the magnetic field’s path.
•The amplitude and frequency of the voltage pulses are proportional to the rotational speed of the
circular toothed ring.

Magnetic reluctance LM2500 Speed Probe

speed probe application
pole
coil
magnet

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LM Aeroderivative System Sensors

Magnetic Reluctance
Applications
•Turbine rotor speeds.

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Proximity Speed Probe

•Utilizes the measurement of motion of a toothed circular metallic ring by a probe that emits a regulated AC
magnetic field.
•The probe contains an electro magnet, signal processing electronics and a signal field coil.
•The processing enables the measurement of the distance or gap between the face of the probe and
the teeth by the effects of the changes in the magnetic field reluctance on the sensing coil signal.
•As the gap changes by rotation of the toothed wheel, the probe system will produce an output (pulse train)
that has a frequency proportional to the speed of the teeth velocity.
•Note that the processed output voltage will be constant without regard to frequency.

+V
0

Output

Excitation/Sensing
coil Output

Oscillator/ Signal
Amplifier
Driver Processor

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Proximity
Applications
•Generator rotor speed.
•Vibration system keyphasor.

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Position
Position Sensors Used Today

•Switch
•LVDT
•Resolver
•Proximity

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LM Aeroderivative System Sensors

Limit Switch
•Typically utilizes the mechanical motion of a shaft, wheel, lever to actuate an electrical switch that
is designed to either close or open an electrical circuit path when the position “setpoint” is reached.
Switch Assy
micro switch Housing
Process
Motion “micro” switch

Seal Switch contact leads

Linkage/Plunger

•Common implementations:
-Micro switch –mechanical plunger comes into contact with the “sensed” object and moves
the miniature switch linkage.
-Hall Effect – The strength of a magnetic field is changed by motion of a magnet attached to the
plunger linkage.
-Photo Switch – Photo switch light emitter output is reflected by position of the object sensed.
-Proximity Switch – A high-frequency electromagnetic alternating field is emitted at the sensing face
of the sensor. A metallic object near the sensing face generates eddy currents which changes the
loading an oscillator circuit.

Limit switch

+ Power
Load or
Control System
Input

Power Common Proximity

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35 /
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Mechanical
GE Energy Reflective
Contact
August 28, 2008
LM Aeroderivative System Sensors

Position Switch
Applications
Door switch
•Enclosure door position. CDP purge valve actuator with
integral position switch
•Shutoff/block valve position.

Valve with
external position switch
Roller Coaster
Train Location Switch

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Position Sensor
LVDT
•Utilizes the mechanical motion of a movable core, connected to the measured device to change the
coupling between a primary AC powered magnetic coil and two secondary coils.
•The secondary coil output voltages are proportional to the position of the internal core.

Secondary

AC Voltage Output
AC
Proportional to
Voltage Primary
Input Position Of Core

Secondary

Core motion

Core
linkage
LVDT Assembly

Coil Housing

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LVDT
Applications
•Engine variable inlet guide vane position.
•Engine variable bleed valve position.
•Engine variable stator vane position.

Variable stator vane actuator

with integral LVDT

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LM Aeroderivative System Sensors

Position Sensor
Resolver
•The resolver is a rotary transformer. The moving rotor consists of three coils (windings)
together with the stationary stator winding to transmit the excitation voltage to the excitation
rotor winding.
•The secondary coils output a variable alternating current (AC) voltage that is linearly
proportional to the angular displacement of the resolver shaft.

Rotor coil shaft

Reference Voltage
(excitation)

Stator coil housing

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Resolver
Applications
•Metering valve position.
•Metering valve servo motor commutation.

Metering valve assemblies

with integral dual resolvers

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Vibration
Vibration Sensors Used Today

•Accelerometer
•Proximity
•Switch

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Vibration

What is vibration?
The oscillation or repetitive motion of an object
around an equilibrium* position.

Three Types
•Linear
•Bending
•Torsion

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LM Aeroderivative System Sensors

Vibration
Accelerometer
•The accelerometer is typically implemented by applying a compressive or shear force on a
piezo-electric crystal. The force applied to the crystal generates an electrical charge across the
crystal, which is converted by a “charge amplifier” to a voltage that is proportional to acceleration.
•Typically used as dynamic sensors, that is, sensing acceleration but not static g forces.
•Other accelerometer implementation techniques:
- Moving Coil/magnet.
•The accelerometer assembly is typically mounted to rotating equipment casing or bearing housings.

Accelerometer
Accelerometer Assembly Accelerometer Assembly
(Moving coil) (Piezo)
Output = Pico-coulombs/g
Elastic rod (1x 10 – 12 amp-second)
(or spring)
Magnetic liquid
Seismic mass
Transducer plates Electromagnet
Direction of Rotating
Direction of Vibration
measured Shaft
Vibration
measured
Bearing housing
Rolling Element Bearing

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Accelerometer
Applications
•Engine vibration.
•Gearbox vibration
•Clutch vibration.
•Fan vibration.

High temperature piezo Piezo accelerometer Moving coil accelerometer Piezo accelerometer
accelerometer assembly with assembly assembly assembly
amplifier built into cable

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Vibration
Proximeter
•The proximeter is typically implemented using a technique which is similar to an inductive proximity
switch but provides a continuous analog measurement of the distance from the probe to the surface of the
shaft.
•Measures absolute distance from probe tip to shaft in static and dynamic conditions.
•Other proximity implementation techniques:
-Light (reflective distance measurement).
-Capacitive.
•Typically mounted to rotating equipment hydrodynamic bearing housings, two sensors used per bearing
to measure shaft position and produce the shaft position readout or “orbit” plot.

Distance from proximity probe to shaft

measured at two locations

The orbit represents the

path of the rotor
centerline at the lateral
position of the proximity
probes.
Oil Film Rotating
Shaft Keyphasor mark
(Clockwise rotation as
viewed from the mover…)
Bearing housing

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LM Aeroderivative System Sensors

Proximeter
Applications
•Generator vibration*.
•LMS booster vibration*.
•LMS power turbine vibration*.

g GE Energy
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Vibration Switch
•The vibration switch is typically implemented using a mechanical mass (with one or more degrees of
freedom) that is displaced by acceleration (vibration) of the equipment to which the switch is mounted.
•The displacement of the mass actuates a latching electromechanical switch that can be used to energize
a stop or trip control circuit.

Mechanical vibration switch

assembly (3 planes of motion)

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Vibration Switch
Applications
•Cooling tower fans.
•Pumps.
•Electric motors.
•Engines.
•Compressors.

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Flow
Flow Sensors Used Today

•Turbine
•Vortex
•Coriolis
•Annubar
•Orifice

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Flow
Turbine
•The turbine flow meter is a typically implemented using an impeller that rotates with a speed
proportional to the fluid flow rate. Any non-linearity in rotational speed with respect to flow
rate is typically compensated for by the measurement electronics.
•The rotational speed is measured using one of several techniques
-Magnetic reluctance probe produces voltage output (pulses) for rotation of the impeller shaft
or passage of the turbine blades.
-A permanent magnet motor assembly generates voltage proportional to the rotational
speed of the motor shaft

In line turbine Immersion turbine

flowmeter flowmeter

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Flow
Vortex
•The vortex shedding flow meter is implemented by insertion of a bar into the process fluid flow path.
The bar introduces alternating pressure gradients in the fluid. The frequency of the pressure gradients
is measured by an ultrasonic transmitter and receiver and is proportional to the flow rate of the fluid.
•Requires ~10 to 20 pipe diameters of straight piping before the meter location, and ~5 pipe diameters
after the meter.
•Mass flow rate can be obtained with the measurement of the temperature of
the fluid.

“Shedder bar” Vortex flow meter

(bluff body) assembly
Vortices induced Shedder bar
with transmitter
by “shedder bar” assembly

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Flow
Coriolis
•The Coriolis flow meter is implemented by applying an oscillating excitation force to a tube that is in
line, with the process flow. The oscillating excitation force causes the tube to vibrate, and
measurement of the phase difference (time lag) between the inlet side and the outlet side
vibrations is directly proportional to the mass of the fluid flowing through the tube.
•Unlike velocity measurement techniques, Coriolis mass flow meters provide direct mass flow
measurement. changes in temperature, pressure, density, viscosity, and flow profile in general do
not play a significant role when measuring flow with a Coriolis meter.

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Flow
Coriolis
•The fluid flowing through the tube will induce a rotation or twist to the tube because of the
Coriolis acceleration acting in opposite directions on either side of the applied force.
• When the tube is moving upward during the first half of a cycle, the fluid flowing into the
meter resists being forced up by pushing down on the tube. On the opposite side, the liquid
flowing out of the meter resists having its vertical motion decreased by pushing up on the
tube. This action causes the tube to twist. When the tube is moving downward during the
second half of the vibration cycle, it twists in the opposite direction. This twist results in a
phase difference (time lag) between the inlet side and the outlet side and this phase
difference is directly affected by the mass flow rate passing through the tube.

<1.0 mm

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Flow
Annubar
•The annubar is an “averaging pitot “tube device that provides flow rate by measurement of the difference of the
process fluid pressure on the impact ports and the pressure on the static sensing ports on the annubar.
•The annubar assembly can also contain a temperature sensor that is used for compensation of the error introduced
by temperature changes (calculation of mass flow).
Annubar

P1 P2

FLOW Impact Static

“To condition the flow pattern, need ~10 to 20 diameters (d1)

straight piping before annubar location”

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Flow
Annubar

Differential pressure
measurement
Static Flow
ports direction

Impact
port

Temperature

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Flow
Orifice
•An flow measurement orifice is typically a plate with a single round hole in the center,
mounted in line with the process fluid piping.
•Fluid flowing through the orifice, will result in a higher velocity and lower
pressure of the fluid downstream of the orifice.
•The flow rate is proportional to the resulting difference of the fluid pressures
measured across the orifice. Orifice plate

P1 P2

d1

FLOW d2

“To condition the flow pattern, need ~10 to 20 diameters (d1)

straight piping before orifice location”

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Flow
Orifice
Flow Conditioning
Standard orifice Flow conditioning orifice
(~20 upstream diameters required) (~2 upstream diameters required)

DP flow meter assemblies

with orifice and transmitter

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Flow
te?
Orifice Ra
Orifice Mass Flow Calculation for fluids - Variables Flow
c
er? Q1= upstream volumetric flow rate, m³/s e tri
m b m
lu
s Nu = mass flow rate at any point, kg/s
Vo
old Cd= coefficient of discharge, dimensionless
?
yn C= orifice flow coefficient, dimensionless (often denoted as K) ta
Re Y= expansion factor, dimensionless ra
c
o nt
A1= cross-sectional area of the pipe, m²
nac
A2= cross-sectional area of the orifice hole, m² Ve
d1= diameter of the pipe, m
d2= diameter of the orifice hole, m
β= ratio of orifice hole diameter to pipe diameter, dimensionless
te? V1= upstream fluid velocity, m/s ?
Ra V2= fluid velocity through the orifice hole, m/s s ity
n
F low P1= fluid upstream pressure, Pa with dimensions of kg/(m ·s) De
s s
Ma P2= fluid downstream pressure, Pa with dimensions of kg/(m ·s)
ρ1= upstream fluid density, kg/m³

Orifice Mass Flow Calculation for gases - Variables ip le?

c
= mass flow rate at any point, kg/s r in
C = orifice flow coefficient, dimensionless (often denoted as K) l i’ sP
l
A2 = cross-sectional area of the orifice hole, m² nou
r
? = upstream real gas density, kg/m³ Be
sity P1 = upstream gas pressure, Pa with dimensions of kg/(m ·s)
c o
Vis P2 = downstream pressure in the orifice hole, Pa with dimensions of kg/(m ·s)
M = the gas molecular mass, kg/kmol (also known as the molecular weight)
R = the Universal Gas Law Constant = 8314.5 Pa·m³/(kmol·K)

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Z = the gas compressibility factor at P1 and T1, dimensionless GE /
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Flow
Orifice

Application – DLE fuel flow

Requirements
•“High” accuracy
•“Fast” response
•“High” availability

P1A P2A

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Flow
Applications
•Turbine fuel system.
•Turbine water injection system.
•Turbine steam injection system
•LMS intercooler cooling water.

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Flame
Flame Sensors Used Today

•IR
•UV-IR

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Electromagnetic Spectrum

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Flame
Raw Sensors
•The raw sensor(s) in a flame detection system generally consists of solid state detector(s)
(photodiode(s)) or gas filled phototubes. Materials, geometry, and dimensions used to
construct the device are selected to optimize the sensor to respond to a narrow band of the
infrared range or a narrow band of the ultraviolet range of the light spectrum.

Silicon photodiode Phototube Silicon carbide photodiode

2000 nm to 5000 nm (IR) 185nm to 260 nm (UV) 210 nm to 380 nm (UV)

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Flame
IR
•The IR flame detector system utilizes solid state detector(s) (photodiode(s)) that respond to
the infrared range of the electromagnetic spectrum.
•The raw signals from the detector semiconductor(s) are typically processed to provide
rejection of false signals that do not indicate the presence of a flame (welding, sunlight,
high surface temperature objects, “flickering” ambient light).
•Can be considered as a “transmitter” as the assembly also typically provides a selection of
analog, discrete, and serial digital outputs to the control/monitoring system.

UV-IR Flame UV, UV-IR, IR Flame “Field of view” plots

Detector Assembly Detector Assembly

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Flame
UV-IR
•The UV/IR flame detector system senses energy in the short wave section of both the
ultraviolet and infrared portions of the electromagnetic spectrum.
•The signals from both sensors are analyzed for frequency, intensity and duration.
simultaneous matching of radiant energy in both the UV and IR sensors triggers an alarm
signal.
•An ultraviolet/infrared flame detector consists of an UV and single-frequency sensor, paired
together to form one unit. The two sensors individually operate but additional circuitry
processes signals from both sensors. A fire alarm is produced only when both sensor
processing systems “detect” a fire. The result is that a UV/IR system has better false alarm
rejection capabilities than either detector by itself.
•Can be considered as a “transmitter” as the assembly also typically provides a selection of
analog, discrete, and serial digital outputs to the control/monitoring system.
“Field of view” plot

UV-IR Flame
Detector Assembly

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Combustor Flame
UV

..
•Combustor flame detectors were historically implemented using a Geiger Mueller tube designed
specifically to detect UV radiation in the range of 180 nm to 260 nm.
•Recent combustor flame detectors designs utilize the solid state SiC (silicon carbide) photodiode
as the raw sensor. Silicon Carbide sensors are “naturally” sensitive to the UV radiation band
produced by the combustor flames.
•The output of the sensor assembly provides an analog measurement of the flame temperature.

Silicon carbide Model of combustor flame surface Silicon carbide

flame detector assembly temperature contours flame detector installation

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Flame
Applications
•Enclosure fire protection system.
•Turbine combustor flame detection.

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Gas
IR
•The IR combustible gas detector senses concentration levels of air/combustible gas
mixtures by measuring the level of absorption of infrared light passing through the mixture.
•The IR sensor is sensitive to radiation over the range of 2500 to 3000 nanometers. The
signals from both sensors are analyzed for frequency, intensity and duration. Simultaneous
matching of radiant energy in both the UV and IR sensors triggers an alarm signal.

IR Gas concentration
Detector Assembly

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Gas
Catalytic Bead
•The catalytic bead combustible gas detection system typically measures levels of concentration
of combustible gas/air mixtures by measuring the resistance of a heating element that is used
to heat a bead coated with catalytic material.
•When the heated catalytic bead is immersed in a combustible gas mixture, a catalyzed reaction
between the combustible gas and available oxygen in air/gas mixture generates heat and
raises the temperature of the bead and its heating element.
•The combustible gas concentration is then proportional to the resulting change in electrical
resistance of the catalytic bead’s platinum heating element.
•Two beads are normally utilized in a sensor assembly. The measurement bead is coated with
the catalyst, and the second sensor, coated with a passivation layer, is utilized as a reference
bead (does not react to the combustible gas and available oxygen in air/gas mixture).
Catalytic bead
sensor assemblies Catalytic bead
construction
Alumina bead

Catalyst Coating
Platinum wire coil

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Combustible Gas
Applications
•Enclosure fire/gas detection system.

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