Woodward 5466-1035 MicroNet Plus CPU5200 Processor Module

Key Features

  • Dual – Mode Operation: Runs in simplex for cost – effective small – scale systems or redundant mode for high – availability critical applications, with automatic failover in redundant setups.
  • Integrated Data Storage: 64 MB flash memory retains firmware, application code, and event logs during power loss; 128 MB RAM enables fast program execution and real – time control loops.
  • Real – Time Monitoring: The real – time clock timestamps all events (alarms, trips, mode changes) for post – incident analysis and compliance reporting.
  • Hot – Swappable Redundancy: In redundant mode, the standby CPU automatically takes over within milliseconds if the primary CPU fails, with no process interruption.
  • VMEbus Compatibility: The on – board FPGA provides VMEbus master/slave functionality to interface with all MicroNet I/O modules (discrete, analog, speed, temperature).
  • Secure Configuration: The service port uses password – protected access to prevent unauthorized changes to control logic and parameters.
  • Firmware Upgradability: Flash memory supports in – field firmware updates via the service port or Ethernet for feature enhancements and bug fixes.
  • Hazardous Area Rating: CSA Class 1, Division 2 certification allows deployment in petrochemical, offshore, and other hazardous industrial environments.
Category:
Description

Technical Specifications

Parameter Details
Processor Motorola MPC5200 32 – bit PowerPC, 400 MHz clock speed
Memory 128 MB DDR RAM (program execution), 64 MB flash memory (firmware & data storage)
Power Supply 80 – 150 Vac/dc (nominal 110 Vac/125 Vdc), 25 W max power consumption
Operating Modes Simplex (stand – alone) or redundant (dual – CPU hot – standby)
Redundant Slot Placement Slot 8 (7 – slot chassis) or Slot 14 (14 – slot chassis) for second CPU
Communication Ports 1×10/100 Base – T Ethernet (general – use), 1×RS – 232 service port (configuration/debug)
Real – Time Clock 10 ms resolution, non – user – replaceable battery (3 – month backup without power)
I/O Interface VMEbus master/slave via on – board FPGA; supports MicroNet I/O modules (discrete, analog, specialty)
Operating Temperature -25°C to 60°C (-13°F to 140°F); storage: -40°C to 85°C (-40°F to 185°F)
Certifications CSA Class 1, Division 2; Lloyds ENV2 vibration compliant; EMI/EMC industrial standards compliant
Physical Dimensions 461 mm (H) × 265 mm (W) × 59 mm (D) (VME – compatible form factor)
Weight Approx. 1.8 kg (4 lb)
Speed Sensing Input 1 – 30 Vac (for magnetic pickup integration with MicroNet I/O)
Output Capability Supports 24 Vdc, 16 A discrete outputs via paired I/O modules

Functional Capabilities

  • Control Logic Execution: Runs custom Coder programming language code for turbine/generator speed, load, and combustion control.
  • Redundant Synchronization: In redundant mode, CPUs sync data and status in real – time to ensure consistent operation during failover.
  • Event & Data Logging: Captures up to 10,000 time – stamped events, including process variables, alarms, and trip conditions for compliance.
  • Diagnostics & Self – Test: Performs continuous self – checks on CPU, memory, and communication ports; triggers alarms for hardware/software faults.
  • I/O Module Management: Controls and monitors all connected MicroNet I/O modules, including discrete inputs/outputs, analog transducers, and speed pickups.
  • Ethernet Connectivity: Enables Modbus RTU/TCP communication for SCADA integration and remote monitoring.

Application Scenarios

  • Gas & Steam Turbines: Primary control for turbine speed, load, and fuel flow in power generation plants, refineries, and industrial facilities.
  • Diesel/Gas Engines: Manages engine start/stop, fuel injection, and emission control in marine propulsion and backup generator sets.
  • Compressors & Pumps: Controls speed and discharge pressure for centrifugal compressors in natural gas pipelines and petrochemical plants.
  • Cogeneration (CHP) Systems: Coordinates generator – grid synchronization and load distribution for combined heat and power applications.
  • Marine Power Systems: Redundant control for shipboard main propulsion engines and auxiliary power generators.
  • Retrofit Projects: Direct replacement for legacy MicroNet CPUs (e.g., 5466 – 1034) to extend system life without full hardware replacement.
  • Critical Process Control: Used in pulp/paper mills and steel plants for rotating machinery control where downtime is costly.

Configuration & Maintenance

  • Programming: Configured via the RS – 232 service port using Woodward Coder software (v5.04 or earlier) for logic development and parameter tuning.
  • Redundant Setup: Requires matching 5466 – 1035 CPUs; auto – detects redundant mode on power – up and initiates synchronization.
  • Failover Testing: Supports manual failover tests to validate redundant operation without disrupting machinery.
  • Firmware Update: Load new firmware via the service port or Ethernet; redundant CPUs update sequentially to avoid downtime.
  • Spare Replacement: Hot – swappable in redundant mode; replaces faulty CPU without system shutdown or process interruption.
  • Status Monitoring: Front – panel LEDs indicate power, CPU status, redundancy mode, and communication health for quick troubleshooting.

Replacement & Obsolescence Notes

  • Non – Preferred Status: Not recommended for new systems; Woodward recommends P1020 – based CPUs (e.g., 5466 – 1160) for new installations.
  • Spare Availability: Fully supported for repairs and spare parts orders to maintain legacy MicroNet Plus systems.
  • Migration Path: Can be upgraded to P1020 CPUs with compatible firmware and minimal chassis reconfiguration.
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