Category: Industry Trends

Features and Functionality

Application programming is done on the PCM112 using Woodward’s MotoHawk application software

tool.

MotoHawk is a rapid control system development tool that allows control engineers

to quickly create control software directly in Simulink diagrams.

The software runs on any electronic control module that supports MotoHawk.

Working directly in the Simulink environment, application developers can convert application models

into files that can be programmed directly into Woodward production hardware in a single build step.

MotoHawk provides an advanced programming environment for users with control system expertise

but not necessarily specific embedded programming skills.

Once an application has been generated and loaded into the PCM112 controller via the CAN port, the

users can view variables and tune the controller using appropriate service interface

tools such as Woodward’s ToolKit or MotoTune.

Connections to other devices (such as diagnostic tools) are accomplished

through other CAN ports available on the controller.

The required information flow is programmed into the controller via MotoTune or ToolKit.

The PCM112 controller consists of a rigid printed circuit board that is attached to an aluminum enclosure

using thermally conductive adhesive and then closed and sealed with an aluminum cover.

Connections to the controller are made via three automotive style sealed connectors.

The controller can be mounted directly to the engine or frame using vibration isolators.

The 8923-2241 includes the 1751-6685 module and mounting kit.

Expandability

The MicroNet TMR platform is expandable into additional expansion chassis as required by the system

size, and will support any mix of I/O, including networked and/or distributed I/O. Redundant “Real-Time

Ethernet” networks are utilized between main and expansion chassis to ensure a fast and reliable

communications. Expansion chassis are available in 6-, 8-, 12-, or 14-slot models. This TMR architecture

allows all remote I/O points to be automatically shared with each kernel CPU, increasing system

robustness and availability.

Woodward also offers a suite of software service-tools to

simplify system troubleshooting and service. These tools

provide high-speed (5 milliseconds) operational and

analytical information such as graphical display of operating

data, historical trending, event logging, X-Y plotting, system

overviews, calibration pages, and other functions.

Communications

The MicroNet TMR platform’s open-architecture allows

users to easily interface with plant DCSs, HMIs, and

distributed I/O devices for system operation, as well as

control programming and service. Multiple

communication ports and protocols are available for

system communications, allowing users to select their

desired communication method and level of

communication redundancy. MicroNet-to-DCS

communications have been performed and qualified with

all major DCS vendors. The following communication

ports are available for use:

• Ethernet ports (10/100 BaseT)

• RS-232/-422/-485 Serial ports

• LON network for LinkNet® Distributed I/O Modules

Protocols Supported:

• Modbus® * (Serial or Ethernet)

• Ethernet TCP/IP & UDP

• OPC (OLE for Process Control)

• Printer Drivers, Modems, Data Loggers

Woodward also offers a suite of software service-tools to

simplify system troubleshooting and service. These tools

provide high-speed (5 milliseconds) operational and

analytical information such as graphical display of operating

data, historical trending, event logging, X-Y plotting, system

overviews, calibration pages, and other functions.

Programming

The MicroNet TMR control system provides an

IEC1131-3 environment for programming. Application

code is generated by use of Woodward’s GAP™

Graphical Application Programming environment or

Woodward’s Ladder Logic programming environment.

• Function Block Programming — through Woodward GAP

• Sequential Function Chart Programming — through

Woodward GAP

• Ladder Logic Programming — through Woodward

Ladder Logic Programmer

The MicroNet TMR operating system, together with

GAP, produces a very powerful control environment

designed for control and protection of turbines and

compressors. Woodward’s unique scan rate structure

ensures that control functions will execute

deterministically at defined scan rates, with critical

control loops able to be processed within 5 milliseconds.

Accurate speed and speed acceleration and

deceleration rates are sensed using a sampling rate of

100 microseconds. These ultra-fast sampling and

response rates allow the controller to adequately

respond to system transients, failures, or safety events.

Fault Tolerance

Each of the MicroNet TMR controller’s kernel sections

individually monitors all input data, performs all

application calculations, and generates all output values

and responses. This control’s architecture allows it to

operate with any single point of failure, without shutting

down. Architected for reliability and safety, the system’s

CPU fault tolerance logic of 3-2-0 allows the control to

function normally with any CPU module failed or

removed, and ensures a safe shutdown with multiple

CPU failures. An analog I/O fault tolerance logic of 3-2

1-0 allows the control to function normally with any one

or two analog modules failed or removed. A discrete I/O

fault tolerance logic of 3-2-1-0 allows the control to

function normally with any one or two discrete modules

failed or removed. A power supply fault tolerance logic of

2-1-0 allows the control to function normally with any one

power supply failed or removed.

Each kernel CPU module runs the identical software

program, in “lock-step” with the other two CPUs. All

inputs from each kernel are distributed to the other two

kernels. For each sensed input, each CPU compares its

read value with the value the other two CPUs read

before outputting a signal to the application software. All

CPUs use the same voted input signals in the same

application calculations to generate the same outputs.

All output values are then exchanged between kernels,

the results are voted, and the appropriate value is output.

MicroNet TMR features include:

IEC61508 SIL-3 certified

Network-safe CPUs

Simplex or redundant CPU configurations

VME-based (full and narrow chassis)

Real-time multitasking VxWorks® operating system

Woodward’s proven Graphical Application Programmer (GAP) software and support tools

Deterministic update rates as fast as 5 milliseconds

Improves control system availability and reliability

SNTP-compliant for time synchronization

Expandable with redundant real-time networks in CAT-5 or fiber optic configurations

Ethernet communications

Simplex or dual power

Modular I/O

Events are timestamped to 1 millisecond

Hot-swap modules for in-line maintenance

MicroNet TMR features include:

Speed and load control

Temperature and process control

Combustion control

Anti-surge control

System sequencing and package assist control

Tight load rejection performance

Sophisticated DLE fuel control algorithms

Initial surge detection

Long-term naval program

Alarm + shutdown communications

Operating Conditions:

Temperature (0 to 55) °C / (32 to 131) °F Ambient Air Temperature Range

Shock US MIL-STD-810C, Method 516.2-1. Procedure 1B

Vibration Lloyd’s ENV2 Test #1

Emissions * EN61000-6-4

Immunity * EN61000-6-2

Achilles Level 1 Certification

Certifications * CE, UL/cUL, CSA (Class I, Zone 2), LR for ENV1 and ENV2. ABS, GOST

Other international compliance (using MicroNet safety modules) TÜV certified to IEC 61508 Part 1-7.

Functional Safety of Electrical/Electronic/Programmable Systems, Electronic Safety-Related Systems

Available inputs and outputs include

 Magnetic pickups (MPUs) and proximity probes

 Discrete I/O

 Analog inputs/outputs

 Thermocouple inputs

 Resistance Temperature Devices (RTD)

 Proportional and integrated actuator drives (integrated AC and DC position inputs)

 Ethernet and serial communications

 Distributed analog, discrete, thermocouple and RTD I/O available with LinkNet HT

Woodward’s MicroNet TMR (Triple Modular Redundancy) controller is a customizable digital control

platform that reliably controls and protects steam, gas turbine and compressor trains.

These are system-critical applications where safety issues can arise or cause significant economic loss.

This triple power supply structure provides maximum protection against single or multiple points of

hardware failure.

The controller’s dedicated TMR® Discrete I/O Module is designed for critical discrete circuits.

The module accepts discrete inputs and distributes them to each individual core section,

as well as outputs relay contacts to drive discrete application logic.

The module’s special TMR® outputs utilize a six-relay configuration and integrated potential fault

detection logic that allows any one or two relays to fail without affecting the integrity of the output

contacts.

This configuration allows routine relay testing and in-circuit repair without compromising output or

system integrity.

Designed from the ground up as a turbine control system, the MicroNet TMR® controller’s actuator

drive module is available with the use of single or dual redundant coils,

Proportional or integral turbine valve servos with AC or DC feedback position sensors using single or dual

redundant coils.

The MicroNet TMR® controller can accommodate any combination of Woodward MicroNet I/O modules

and LinkNet HT distributed I/O to provide maximum application flexibility.

Description

The MicroNet TMR® control platform features a ruggedized rackmount chassis

with in-line replaceable I/O modules and triple modular architecture for 99.999% availability.

This triple modular redundancy-based system consists of three independent cores

(A, B, and C) housed in the platform’s compact chassis.

Each core section includes its own CPU, CPU power supply, and up to four I/O modules,

which can be used for simplex I/O, redundant I/O, triple redundant I/O, or any combination of

redundancy.

I/O can be expanded via a system expansion chassis or the ruggedized LinkNet HT Distributed I/O.

The platform’s high-density modules and integrated application software reduce

troubleshooting time by providing first-out indication of monitored system events.

These specialized modules can time stamp discrete events in 1 millisecond and analog events in 5

milliseconds.

The MicroNet TMR® utilizes two power supplies, each supplying power to the controller from a separate

power source.

Within each power supply are three independent power converters, one each for the CPU and I/O

sections.

This triple power supply structure provides maximum protection against single or multiple points of

hardware failure.

The controller’s dedicated TMR® Discrete I/O Module is designed for critical discrete circuits.