Product Manual 26415

(Revision F, 10/2014)
Original Instructions

Atlas-II™ Digital Control

Control Part Numbers 8273-552, -553, -555, -556,

-557, -560, -562, -565, -570, -571, -584, -586

Installation and Operation Manual

 Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.

This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:
www.woodward.com/publications

The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative
to get the latest copy.

Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
Proper Use modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.

If the cover of this publication states "Translation of the Original Instructions"

please note:
The original source of this publication may have been updated since this
Translated translation was made. Be sure to check manual 26455, Customer Publication
Publications Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.

Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 26415
Copyright © Woodward 2007–2014
All Rights Reserved
Manual 26415 Atlas-II Digital Control

Contents

IOLOCK. When a CPU or I/O module fails, watchdog logic drives it into an
IOLOCK condition where all output circuits and signals are driven to a known
de-energized state as described below. The System MUST be designed such that
IOLOCK and power OFF states will result in a SAFE condition of the controlled
device.

 CPU and I/O module failures will drive the module into an IOLOCK state.
 CPU failure will assert an IOLOCK signal to all modules and drive them into
an IOLOCK state.
 Discrete outputs / relay drivers will be non-active and de-energized.
 Analog and actuator outputs will be non-active and de-energized with zero
voltage or zero current.

The IOLOCK state is asserted under various conditions including:

 CPU and I/O module watchdog failures
 PowerUp and PowerDown conditions
 System reset and hardware/software initialization
 Entering configuration mode

NOTE: Additional watchdog details and any exceptions to these failure states
are specified in the related CPU or I/O module section of the manual.

WARNINGS AND NOTICES ........................................................................... VI

ELECTROSTATIC DISCHARGE AWARENESS .................................................VII
REGULATORY COMPLIANCE ...................................................................... VIII
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Atlas-II Control Description .....................................................................................1
Control Versions .....................................................................................................2
Control Accessories................................................................................................6
CHAPTER 2. INSTALLATION.......................................................................... 7
Introduction .............................................................................................................7
General Installation.................................................................................................7
Shipping Carton ......................................................................................................7
Mounting .................................................................................................................8
Environmental Specifications .................................................................................8
Electrical Connections ............................................................................................9
Grounding .............................................................................................................11
Non-Marine Enclosure Application Information ....................................................13
Marine Enclosure Application Information ............................................................14
General Enclosure Application Information ..........................................................15
Input Power ..........................................................................................................20
Maintenance .........................................................................................................22
Application Guidelines ..........................................................................................22
CHAPTER 3. POWER SUPPLY BOARD ......................................................... 27
General Description ..............................................................................................27
Specifications .......................................................................................................28
Troubleshooting Guide .........................................................................................28

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Contents

CHAPTER 4. SMARTCORE CPU A5200 BOARD ..........................................31

General Description ..............................................................................................31
Hardware Specifications .......................................................................................38
SmartCore CPU A5200 Board Operation .............................................................42
Troubleshooting Guide .........................................................................................53
CHAPTER 5. ANALOG COMBO BOARD ........................................................56
General Description ..............................................................................................56
Specifications........................................................................................................57
Analog Combo Board Operation ..........................................................................62
Troubleshooting Guide .........................................................................................67
CHAPTER 6. POWERSENSE BOARD ............................................................69
General Description ..............................................................................................69
Features................................................................................................................69
Physical ................................................................................................................69
Hazardous Live .....................................................................................................69
Specifications........................................................................................................73
PowerSense Board Operation ..............................................................................76
Power Calculations ...............................................................................................84
Troubleshooting Guide .........................................................................................91
CHAPTER 7. 12-CHANNEL RELAY MODULE ................................................93
General Information ..............................................................................................93
Relay Information..................................................................................................94
Shielding ...............................................................................................................94
Board Status Lights ..............................................................................................94
Wiring ....................................................................................................................94
CHAPTER 8. DLE SERIAL COMMUNICATION BOARD....................................96
General Information ..............................................................................................96
Application Developer Information........................................................................99
CHAPTER 9. PC104 PROFIBUS INTERFACE...............................................100
Introduction .........................................................................................................100
Profibus Software and Hardware Requirements ................................................100
Hardware for End Users .....................................................................................100
Software for Application Developers ..................................................................105
CHAPTER 10. PRODUCT SUPPORT AND SERVICE OPTIONS .......................107
Product Support Options ....................................................................................107
Product Service Options .....................................................................................107
Returning Equipment for Repair .........................................................................108
Replacement Parts .............................................................................................109
Engineering Services ..........................................................................................109
Contacting Woodward’s Support Organization ..................................................109
Technical Assistance ..........................................................................................110
APPENDIX A. ACRONYMS AND GLOSSARY OF TERMS ...............................111
Acronyms ............................................................................................................111
Glossary of Terms ..............................................................................................112
APPENDIX B. WIRING DIAGRAMS..............................................................113
APPENDIX C. FLASH CODES ....................................................................118

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Contents

APPENDIX D. BOARD ADDRESSES ........................................................... 120

REVISION HISTORY .................................................................................. 121
DECLARATIONS ....................................................................................... 122

Illustrations and Tables

Figure 1-1. Atlas-II, Example Module Layout .........................................................3

Figure 1-2a. Physical Dimensions ..........................................................................4
Figure 1-2b. Physical Dimensions ..........................................................................5
Figure 2-1. Screw Connection Terminal Block Used on A5200 SmartCore Board 9
Figure 2-2. Spring Clamp Terminal Block ............................................................10
Figure 2-3. Fixed Terminals..................................................................................11
Figure 2-4. Descriptions of Main Cabinet Cabling Options ..................................17
Figure 3-1. Atlas-II Power Supply Board (601-1008) ...........................................27
Figure 3-2. Discrete Output Wiring Example ........................................................29
Figure 4-1. SmartCore CPU A5200 board, Connectors .......................................31
Figure 4-2. Block Diagram—Atlas-II SmartCore CPU A5200 Board....................33
Figure 4-3. SmartCore CPU A5200 Communications Ports (SIO1, SIO2) ..........35
Figure 4-4. CPU Service Port (mini-DIN6F) .........................................................36
Figure 4-5. CAN Communication Ports ................................................................36
Figure 4-6. MPU Minimum Input Magnitude in Vrms ...........................................38
Figure 4-7. MPU Maximum Input Magnitude in Vrms ..........................................39
Figure 4-8. MPU Typical Input Impedance Magnitude and Phase ......................39
Figure 4-9. Wiring Example–MPU Interface to the SmartCore Board .................43
Figure 4-10. Wiring Example–Open Collector Proximity Probe to the SmartCore
CPU A5200 Board ...........................................................................43
Figure 4-11a. Wiring Example–4–20 mA Input Interface to the SmartCore CPU
A5200 Board ....................................................................................44
Figure 4-11b. Wiring Example–4–20 mA Input Interface using External Loop
Power ...............................................................................................45
Figure 4-12. Wiring Example–Analog Output Interface to the SmartCore CPU
A5200 Board ....................................................................................45
Figure 4-13. Wiring Example–Actuator Output Interface to the SmartCore CPU
A5200 Board ....................................................................................46
Figure 4-14. Wiring Example–Discrete Input Interface to the SmartCore CPU
A5200 Board ....................................................................................47
Figure 4-15. Serial #1–RS-232 Pinouts................................................................48
Figure 4-16. Serial #1–RS-422 Pinouts................................................................48
Figure 4-17. Serial #1–RS-485 Pinouts................................................................49
Figure 4-18. Serial #2–RS-232 Pinouts................................................................49
Figure 4-19. Serial #2–RS-422 Pinouts................................................................50
Figure 4-20. Serial #2–RS-485 Pinouts................................................................50
Figure 4-21. Wiring Example–RS-232 Interface to the SmartCore CPU A5200
Board ...............................................................................................51

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Illustrations and Tables

Figure 4-22. Wiring Example–RS-422 Interface to the SmartCore CPU A5200

Board ...............................................................................................51
Figure 4-23. Wiring Example–RS-485 Interface to the SmartCore CPU A5200
Board ...............................................................................................51
Figure 4-24. Wiring Example–Alternate Multipoint Wiring ....................................51
Figure 5-1. Atlas-II Analog Combo Board Connections .......................................56
Figure 5-2. Atlas-II Analog Combo Board Block Diagram ....................................57
Figure 5-3. Minimum MPU Voltage ......................................................................61
Figure 5-4. Wiring Example–MPU Interface to the Analog Combo Board ...........62
Figure 5-5a. Wiring Example–Analog Input Interface...........................................63
Figure 5-5b. Wiring Example–Analog Input Interface with External Loop Power 64
Figure 5-6. Wiring Example–4–20 mA Input Interface .........................................64
Figure 5-7. Wiring Example–RTD Input Interface ................................................64
Figure 5-8. Wiring Example–Analog Output Interface ..........................................66
Figure 6-1. Terminal Block Covers .......................................................................70
Figure 6-2. PowerSense Board Connections .......................................................71
Figure 6-3. PowerSense Board Block Diagram....................................................72
Figure 6-4. Wiring Example–Wye Connected System .........................................78
Figure 6-5. Wiring Example–Wye Connected System .........................................79
Figure 6-6. Example Wiring–Wye Connected System .........................................80
Figure 6-7. Wiring Example–Delta Connected System ........................................81
Figure 6-8. Wiring Example–Delta Connected System ........................................82
Figure 6-9. Wiring Example–CT Interface to the PowerSense Board ..................85
Figure 6-10. Wiring Example–CT Interface to the PowerSense Board ................86
Figure 6-11. Wiring Example–Speed Bias Output Interface ................................87
Figure 6-12. Wiring Example–Speed Bias Output Interface ................................88
Figure 6-13. Wiring Example–Voltage Bias Output Interface ...............................89
Figure 6-14. Wiring Example–Voltage Bias Output Interface ...............................89
Figure 6-15. Wiring Example–LON Interface to the PowerSense Board .............90
Figure 7-1. 12-Channel Relay Module .................................................................93
Figure 7-2. 12-Channel Relay Module Wiring Diagram........................................95
Figure 8-1. DLE Connections ...............................................................................96
Figure 8-2. Terminator Locations .........................................................................97
Figure B-1. SmartCore CPU A5200 board Connections ....................................113
Figure B-2. Analog Combo Board Connections .................................................114
Figure B-3. PowerSense Board Connections.....................................................115
Figure B-4. 12-Channel Relay Module Connections ..........................................116
Figure B-5. DLE Connections .............................................................................117
Figure D-1. Board Address Numbers .................................................................120

Table 1-1. Atlas-II Modules.....................................................................................2

Table 1-2. VxWorks Atlas-II Item Numbers ............................................................2
Table 2-1. Power Supply Requirements ...............................................................21
Table 4-1. Ethernet Port Pinout ............................................................................35
Table 4-2. SmartCore CPU A5200 Failure Codes ...............................................53
Table 5-1 Analog Combo Failure..........................................................................67
Table 6-1. PowerSense Failure Codes ................................................................90
Table 8-1. DLE Failure Codes ..............................................................................98
Table 9-1. Profibus—Type A Cable ....................................................................101
Table 9-2. Profibus—Type B Cable ....................................................................101
Table 9-3. Belden Profibus Cable.......................................................................102
Table 9-4. Profibus—Siemens RS-485 Bus Connector / Plastic ........................102
Table 9-5. Profibus—Siemens RS-485 Bus Connector / Metal .........................103
Table 9-6. I/O Connector Pinout .........................................................................103

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Illustrations and Tables

Table C-1. SmartCore CPU A5200 Failure Codes .............................................118

Table C-2 Analog Combo Failure Codes ...........................................................118
Table C-3. PowerSense Failure Codes ..............................................................118
Table C-4. DLE Failure Codes ...........................................................................119

The following are trademarks of Woodward, Inc.:

Atlas-II
AtlasPC
DSLC
GAP
Woodward

The following are trademarks of their respective companies:

Beldfoil (Belden Inc.)
DeviceNet (Open DeviceNet Vendor Association, Inc. [ODVA])
Modbus (Schneider Automation Inc.)
VxWorks (Wind River Systems, Inc.)

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Warnings and Notices

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

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

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.

The products described in this publication may present risks that

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

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
Start-up property damage.

On- and off-highway Mobile Applications: Unless Woodward's control

functions as the supervisory control, customer should install a
system totally independent of the prime mover control system that
Automotive monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
Applications
control with possible personal injury, loss of life, or property damage.

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To prevent damage to a control system that uses an alternator or

battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Battery Charging
Device

Electrostatic Discharge Awareness

Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
 Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
Electrostatic contact while handling the control).
Precautions  Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
 Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.

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Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.

EMC Directive: Declared to 2004/108/EC COUNCIL DIRECTIVE of 15

December 2004 on the approximation of the laws of the
Member States relating to electromagnetic compatibility
and all applicable amendments.

ATEX - Potentially Declared to 94/9/EC COUNCIL DIRECTIVE of 23 March

Explosive 1994 on the approximation of the laws of the Member
Atmospheres States concerning equipment and protective systems
Directive: intended for use in potentially explosive atmospheres.
Zone 2, Category 3, Group II G, Ex nA IIC T3 X

North American Compliance:

These listings are limited only to those units bearing the UL identification.

UL: UL Listed for Class I, Division 2, Groups A, B, C, & D,

T3C at 70C surrounding air temperature. For use in
Canada and the United States.
UL File E156028
The 16-channel relay interface modules are suitable for
ordinary or non-hazardous locations only.

Marine Compliance

American Bureau ABS Rules 2006 SVR 4-2-1/7.3, 7.5.1, 7.9.3/17,

of Shipping 4-9-4/23, 4-9-7/Table 9

Det Norske Veritas Standard for Certification No. 2.4, 2006: Temperature
Class B, Humidity Class B, Vibration Class A, and EMC
Class A

Lloyd’s Register LR Type Approval Test Specification No. 1, 2002 for

of Shipping Environmental Categories ENV1, ENV2, and ENV3

Special Conditions For Safe Use:

This Equipment is Suitable For Use in Class I, Division 2, Groups A, B, C, D or
Non-Hazardous Locations Only.

This equipment is suitable for use in European Zone 2, Group IIC environments.

This equipment is intended to be installed in a metal cabinet or enclosure to

provide protection against the entry of dust or water and to protect against
mechanical impact. For ATEX compliance, a minimum ingress protection rating
of IP54 is required for the enclosure.

For ATEX compliance, this equipment must be protected externally against

transient disturbances. Provisions shall be made to prevent the power input from
being exceeded by transient disturbances of more than 40% of the rated voltage

Wiring must be in accordance with North American Class I, Division 2, or

European Zone 2, Category 3 wiring methods as applicable, and in accordance
with the authority having jurisdiction.

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Manual 26415 Atlas-II Digital Control
A fixed wiring installation is required and a switch or circuit breaker shall be
included in the building installation that is in close proximity to the equipment and
within easy reach of the operator and that is clearly marked as the disconnecting
device for the equipment. The switch or circuit breaker shall not interrupt the
protective earth conductor.

Do not connect more than one main power supply to any one fuse or circuit
breaker.

Protective Earth Grounding is required by the input PE terminal (see Chapter 2,

Installation).

Ground leakage current exceeds 3.5 mA.

For Communications wires, use wires with a temperature rating of at least 5 °C

above surrounding ambient. All others use wires with a temperature rating of at
least 10 °C above surrounding ambient.

The Atlas-II A5200 board contains a single cell primary battery. This battery is
not to be charged and is not customer replaceable.

Control is suitable for installation in pollution degree 2 environments.

Unmarked inputs are classified as permanently connected IEC measurement

Category I. To avoid the danger of electric shock, do not use inputs to make
measurements within measurement categories II, III, or IV. See individual inputs
for additional information on transient overvoltage input ratings.

EXPLOSION HAZARD—Do not connect or disconnect while circuit is

live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2 applications.

RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I,
applications Division 2.

The Atlas-II is designed for installation in a standard metal cabinet. If

the cabinet door is open or Atlas-II is not installed in a metal cabinet,
some degraded performance can occur on RTD and thermocouple
inputs in the presence of radio wave energy. Radio wave energy may
be from transmitters such as cell phones or push to talk radios.
This degraded performance is in the form of a slight change in the
accuracy of the RTD and thermocouple input measured temperature.
It is recommended that operation of such radio wave devices be kept
more than 3 m (10 ft) from the Atlas-II control. This will prevent
performance degradation. Installation of the Atlas-II control in a
metal enclosure, as intended, will also prevent performance
degradation.

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The Atlas-II Actuator and Analog outputs are intended to drive loads
that are isolated from protective earth, like actuators and meters.

The Atlas-II is protected from indirect lighting strikes. However,

during a lighting strike to protective earth (PE), or similar transient
events, if the Actuator or Analog outputs are connected to earth-
referenced devices, the device may significantly reduce performance
of the Atlas-II.
Protective earth connections separated by a significant distance (>30
m) can see a large voltage difference due to transient surge events.
The non-isolated device may cause a ground fault with significant
current flow through the analog signal lines, causing signal input
measurement errors beyond Analog I/O to occur.
Adding an isolator between the Atlas-II and its analog loads will
solve this issue. Alternatively adding clamping circuitry, like Metal
Oxide Varistors (MOV) or Transient Voltage Suppression (TVS)
diodes, from chassis to signal lines at both ends will also solve this
issue. (See the appropriate sections for more details.)

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Chapter 1.
General Information

Introduction
This manual describes the Woodward Atlas-II Digital Control. It provides a variety
of useful information for the user ranging from simple basic descriptions to
detailed information on wiring, specifications, and functionality. Included are:
 General information on the Atlas-II platform and available versions
 A physical description of the control hardware
 A description of all Atlas-II modules
 A listing of accessories that may be used with the platform
 Information on Atlas-II communications and distributed I/O interfaces
 Installation and maintenance
 Troubleshooting information
 For information on programming, networking, and communication protocols,
refer to the software manual provided with the control.

Atlas-II Control Description

The Atlas-II digital control platform fits a wide range of prime mover applications.
These include small mechanical-drive units with a minimum of complexity on up
to large two-shaft gas turbine generator sets that require unit sequencing and
load control. The Atlas-II control is programmed to the specific needs of the
prime mover and its driven load.

At the heart of the Atlas-II control is a 32-bit microprocessor that runs a powerful
Real Time Operating System. This operating system is specifically designed to
control the proper timing of all application code so that dynamic performance of
the final control system is absolutely guaranteed. Each piece of the application
code is “scheduled” under a Rate Group structure that ensures execution of the
code at a predetermined time.

Application programming is accomplished via Woodward’s GAP Graphical

Application Program. GAP is a pictures-to-code system that provides a high-level
programming environment for users who have control expertise but do not have
specific programming skills. Once the application program has been generated
and loaded into the Atlas-II control, the user can view variables and tune the
control with a variety of Woodward service tools. Connection to other devices,
such as an HMI, is accomplished by means of serial Modbus or Ethernet ports on
the control. The desired information flow is programmed into the control via GAP.
If required, distributed I/O can be connected using optional communication
modules that support Profibus and DLE Communications.

The hardware platform is based on the industry-standard PC/104 bus structure. In

the Atlas-II control, the backplane is the SmartCore board. The PC/104 modules
are “stacked” onto the SmartCore board in order to add I/O or other functionality.
Each of the stacked modules has an on-board DIP switch that is positioned to the
unique address of that particular module. The Atlas-II control uses a second stack
called the Power Bus Stack. This stack is used primarily for power-related I/O. The
control runs on low-voltage DC power (18–32 Vdc). Atlas-II field wiring is
accomplished via terminal blocks that plug into the control modules.

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Control Versions
The Atlas-II control provides a flexible platform that can be structured into a wide
variety of configurations of I/O and communications. The required number of I/O
modules and the types of communication modules that are required will depend
entirely on the specific application scenario. Table 1-1 shows the various
modules that are available.

Atlas-II Module List

 Power Supply
 SmartCore CPU A5200
 PowerSense
 Analog Combo I/O
 DLE Communications
 Profibus

Table 1-1. Atlas-II Modules

Atlas-II
Item Operating Atlas-II Power- Analog DLE Cooling
Number System A5200 Sense Combo Com Profibus Fan Description
ATLAS II, 2 X 5, A5200, LV, 2
8273-552 VxWorks 1 2 2 X
COMBO, 2 PROFIBUS
ATLAS II, 2 X 4, A5200, LV, 1
8273-553 VxWorks 1 1 1
COMBO, 1 DLE
8273-555 VxWorks 1 3 X ATLAS II, 2 X 4, A5200, LV, 3 COMBO
ATLAS-II, 3 X 4, A5200, LV, PSENSE,
8273-556 VxWorks 1 1 1
1 COMBO
ATLAS-II, 3X4 A5200, PSENSE, LV, 2
8273-557 VxWorks 1 1 2 X
COMBO
ATLAS-II, 2X5, A5200, LV, 3 COMBO,
8273-560 VxWorks 1 3 1 X
1 PROFIBUS
ATLAS II, 3 X 5, A5200, PSENSE, LV,
8273-562 VxWorks 1 1 2 1 X
2 COMBO, 1 PROFIBUS
8273-565 VxWorks 1 1 ATLAS-II, 2 X 2, A5200, LV, 1 COMBO
ATLAS-II, 2 X 4, A5200, LV, 1
8273-570 VxWorks 1 1 1 X
COMBO, 1 PROFIBUS
8273-571 VxWorks 1 2 ATLAS-II, 2 X 4, A5200, LV, 2 COMBO
8273-584 VxWorks 1 ATLAS II, 2 X 2, A5200, LV
8273-586 VxWorks 1 1 ATLAS-II, 3 X 2, A5200, LV, PSENSE

Table 1-2. VxWorks Atlas-II Item Numbers

NOTE—Depending on the configuration, the control may or may not contain a

fan. See Table 1-2 above.

Figure 1-1 shows diagrammatically the physical arrangement of the modules in

the Atlas-II control hardware. The hardware uses two stacked-bus arrangements
to provide the required structure. The Power Bus Stack is used for the power-
related I/O as well as the discrete output drivers. The PC/104 Stack is used
primarily for the signal I/O, the main processor, and communications modules. All
configurations contain a SmartCore CPU A5200 module that spans both the
Power Bus Stack and the PC/104 Stack. If real power sensing is required in the
application, a PowerSense module is stacked above the SmartCore module and
also spans both bus stacks. If a PowerSense module is not specified, then an
additional Analog I/O module can be substituted. Figure 1-1 shows a “maximum”
example configuration (5 levels high).

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Figure 1-1. Atlas-II, Example Module Layout

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Figure 1-2a. Physical Dimensions

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Figure 1-2b. Physical Dimensions

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Atlas-II Digital Control Manual 26415

Control Accessories
The Atlas-II digital control platform is designed to interface with several
Woodward service tools and commercial software products. Available tools are
listed below with a brief description of their functionality:
 Monitor GAP—An Ethernet connection to the control allows on-line GAP
monitoring, debug, and tunable configuration.
 Watch Window—Provides an Ethernet or serial connection to the control to
allow 1) initial configuration of the unit; 2) monitoring and tuning of system
variables; and 3) management of configuration and setpoints.
 Control Assistant—Ethernet connection to the control for Tunable
Management, viewing of high-speed data captures, and other useful utilities.
 Application Manager—Ethernet access to the control for program loading,
network configuration and support, and system diagnostics.
 HMI (Human Machine Interface)—Commercially available HMI programs
interface to the Atlas-II control through Ethernet or serial connections to
provide operator access and control of the application machinery.

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Manual 26415 Atlas-II Digital Control

Chapter 2.
Installation

Introduction
This chapter provides the general information for mounting location selection,
installation, and wiring of the Atlas-II control. Hardware dimensions, ratings, and
requirements are given for mounting and wiring the control in a specific
application.

General Installation
When selecting a location for mounting the Atlas-II control, consider the
following:
 Protect the unit from direct exposure to water or to a condensation-prone
environment.
 The control is deigned for installation in a protective metal enclosure such
as a standard cabinet with ingress protection rating of IP54.
 A standard “EMC” cabinet is required when installing into a Marine Type
Approval applications.
 Provide an ESD strap inside the cabinet for handling the equipment and
plugging/unplugging the connectors.
 The operating range of the Atlas-II control is –40 to +70 °C
(–40 to +158 °F) except when the Profibus module is used. See the
Environmental Specifications for more details.
 Provide adequate ventilation for cooling. Shield the unit from radiant heat
sources.
 Do not install the unit or its connecting wires near inductive, high-voltage, or
high-current devices. If this is not possible, shield both the system
connecting wires and the interfering devices or wires.
 Allow adequate space around the unit for servicing and wiring.
 Do not install where objects can be dropped on the terminals.
 Ground the chassis for proper safety and shielding.
 When installing on a generator set package, provide vibration isolation.

Shipping Carton
Before unpacking the control, refer to the inside front cover and page vi of this
manual for WARNINGS and CAUTIONS. Be careful when unpacking the control.
Check for signs of damage such as bent or dented panels, scratches, and loose
or broken parts. If any damage is found, immediately notify the shipper.

The Atlas-II control was shipped from the factory in an anti-static foam lined
carton. This carton should always be used for transport of the control or for
storage when the control is not installed.

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Atlas-II Digital Control Manual 26415

Mounting
Figure 1-2 shows the Atlas-II control layout and mounting pattern. The Atlas-II
digital control is to be mounted in an appropriate enclosure for the installed
environment. This equipment is designed for installation within a control room
panel or cabinet.

This equipment is intended to be installed in a metal cabinet or

enclosure to provide protection against the entry of dust or water
and to protect against mechanical impact. For ATEX compliance, a
minimum ingress protection rating of IP54 is required for the
enclosure.

The standard Atlas-II package must be mounted to allow sufficient room for
wiring access. Eight front panel mounting holes permit secure mounting.
Depending on its configuration, the Atlas-II weighs between 3.4 and 4.5 kg (7.5
and 10 pounds). A minimum of 25 mm (1 inch) of clear space around the outer
surfaces of the Atlas-II is adequate for ventilation, however approximately 75 mm
(3 inches) of space may be required for wiring, depending on wire size.

Environmental Specifications
Operating Temperature
The Atlas-II Control Platform operates in a specified ambient temperature of
–40 to +70 °C (–4 to +158 °F) with forced convection cooling. When the Atlas-II
contains a single Profibus module, the operating temperature is limited to –20 to
+60 °C (–4 to +140 °F). When the Atlas-II contains (2) Profibus modules, the
operating temperature is limited to –20 to +55 °C (–4 to +131 °F).

Continuous operation with insufficient airflow or higher operating

temperatures will lead to reduced reliability and possible damage to the
control.

Storage Temperature
The Atlas-II Control Platform is designed to be stored without applied power at
the temperature range of –40 to +85 °C (–40 to +185 °F). Any unit with Profibus
is limited to –20 to +70 °C (–4 to +158 °F).

Component life is adversely affected by high-temperature, high-humidity

environments. Room temperature storage is recommended for long life. If the
unit is to be stored for a long period of time, operating power must be applied at
least for one hour every 18 to 24 months.

Shock
The Atlas-II Control Platform was designed to meet the shock requirements
specified by MIL-STD-810C procedure 516.2, procedure 1 (30g, 11 millisecond
half sine pulse). During Shock, relay bounce shall be limited to less than 100 ms.

Vibration (Sinusoidal)
The Atlas-II Control Platform was designed and tested to meet Lloyd’s Test
Specification No. 1, 2002, Vibration Test 1. The Vibration test profile includes 3–
16 Hz, ±1 mm and 16–150 Hz, ±1.0g.

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Manual 26415 Atlas-II Digital Control
Audible Noise Emission
The Atlas-II Control Platform does not emit an audible noise above 70 dBA as
measured 1 meter away, with or without a fan.

Enclosure Protection
In order to meet Zone 2 European Group IIC, the Atlas-II Control must be
mounted in an enclosure that meets or exceeds IP 54.

Altitude
The Atlas-II Control Platform is designed to operate up to 3000m / 9800 feet.

Electrical Connections
Most of the Atlas-II control’s terminal blocks are designed to be removed
by hand. The Atlas-II Control uses two different styles of pluggable terminal
blocks: Screw Connection (limited to the A5200 SmartCore board) and
“CageClamp”.

The pluggable terminal blocks on the SmartCore CPU A5200 board all utilize the
Screw Connection style terminal blocks (see Figure 2-1 for torque and
screwdriver requirements). The Screw Connection terminal blocks accept wires
from 0.08–1.5 mm² (28–16 AWG). Two 0.8 mm² (18 AWG) wires or three 0.3
mm² (22 AWG) wires can be easily installed in each terminal.

The pluggable terminal blocks on the modules (other than the A5200 SmartCore)
are screwless, CageClamp style blocks. The spring clamp can be actuated by
using a standard 2.5 mm (3/32 inch) flat bladed screwdriver (see Figure 2-2).
These terminal blocks accept wires from 0.08–1.1 mm² (28–18 AWG). Two 0.5
mm² (20 AWG) wires or three 0.3 mm² (22 AWG) wires can be easily installed in
each terminal.

Most of the Atlas-II control’s terminal blocks are designed to be removed by

hand. After Atlas-II input power is disconnected, the terminal blocks can be
removed one at a time by pulling them straight out. Be careful not to pull the plug
out at an angle, as this will fracture the end terminal. Wires for the all the
pluggable I/O terminal blocks should be stripped at 8 mm (0.3 inch).

Torque range for screws of Screw

Connection Terminal Blocks:
0.22–0.25 N·m (1.95–2.21 lb-in).

Screwdriver blade: 0.4 X 2.5 mm

(0.016 X 0.10 inch)
Screwdriver available as Woodward
PN 8992-005

Figure 2-1. Screw Connection Terminal Block Used on A5200 SmartCore Board

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Atlas-II Digital Control Manual 26415

Method #1 Method #2
Free Hand (holds spring open) Bench (momentarily opens
spring while force is applied)

Figure 2-2. Spring Clamp Terminal Block

The Atlas-II fixed terminal blocks used for the power supply input accept wires
from 0.08–1.1 mm² (28–18 AWG). Two 0.5 mm² (20 AWG) wires or three 0.3
mm² (22 AWG) wires can be easily installed in each terminal. Wires for the fixed
mounted power terminals should be stripped 5 mm (0.2 inch).

Wiring Fixed Terminal

Do not tin (solder) the wires that terminate at the Atlas-II terminal
blocks. The spring-loaded CageClamp terminal blocks are designed
to flatten stranded wire, and if those strands are tinned together, the
connection loses surface area and is degraded.

EXPLOSION HAZARD—Do not connect or disconnect while circuit is

live unless area is known to be non-hazardous.

RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.

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Manual 26415 Atlas-II Digital Control
All AC wiring for voltages and currents is done with fixed screw barrier blocks
rather than pluggable terminal blocks. The fixed screw barrier blocks accept
wires terminated into terminal lugs for #6 screws.

Figure 2-3. Fixed Terminals

Grounding
Protective Earth (PE) must be connected to the termination point on the backside
of the unit next to the label with the symbol to reduce the risk of electric shock.
This connection will be made using a thread-forming screw (M4 x 6 mm). The
conductor providing the connection shall have a properly sized ring lug and wire
larger than or equal to 3.3 mm² (12 AWG).

The unit also needs low impedance grounding to earth, e.g. the cabinet or
enclosure used. The low impedance ground can be accomplished by one or
more of the following:
 A short 15 cm (6 inch) protective earth wire
 A 1.3 cm (0.5 inch) wide flat hollow braid less than 1 m long
 A 1.3 cm (0.5 inch) wide flat tin or lead/tin plated copper strap less than 1 m long
 The use of the eight mounting bolts and paint breaking washers.

Do not connect chassis ground or PE ground to signal common.

Safety Ground Wire Installation

 Safety wires must be routed against the grounded cabinet structure. Locate
safety ground wire 150 mm (6 inches) from unshielded cabling and 75 mm
(3 inches) from shielded cabling inside the cabinet, and 150 mm (6 inches)
from any I/O cabling exiting the cabinet.

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Atlas-II Digital Control Manual 26415

Recommended Grounding Practices

Providing the proper ground for the Atlas-II control is important. Improper
connection of the control chassis to the protective earth / building ground plane
may lead to stray currents between the reference point for the AC signal sources
(current and voltage transformers), and the reference point for the sensing inputs
on the Atlas-II control. Differences in potential between these two points results
in equalizing current flow which then produces unacceptably high common mode
voltages. Common mode voltages may result in improper readings for the
sensed AC inputs, or even damage to the Atlas-II control in extreme cases. To
minimize this problem, it is necessary to provide a low resistance path between
the AC signal reference point, and the chassis of the Atlas-II control. Typically
this point is the designated ground for the generator set and related instrument
transformers.

Shields and Grounding

All signal lines except PT/CT, relay outputs, contact inputs, and power supply
wiring should be shielded to prevent picking up stray signals from adjacent
equipment.

Shielding of PT/CT, relay outputs, contact inputs, and power supply

wires inside the metal enclosure is required for Marine Type
Approval installation applications. Relay outputs, contact inputs, and
power supply wiring do not normally require shielding for other
installations, but may be shielded if desired.

All shielded cable must be twisted conductor pairs. The Atlas-II control is
designed with shield terminations to earth ground at the control. An individual
shield termination to earth is provided at the terminal block for each of the signals
requiring shielding. Do not tin (solder) or attempt to tin the braided shield for
connection into the terminal block. Wire exposed beyond the shield should be as
short as possible, not exceeding 50 mm (2 inches).

If intervening terminal blocks are used in routing a signal, the shield should be
continued through the terminal block. If shield grounding is desired at the
terminal block, it should be AC coupled to earth. All shield terminations not at the
Atlas-II or entry into its metal enclosure should be AC coupled to earth through a
capacitor. (A 1000 pF, 500 V capacitor is typically sufficient. The intent is to
provide a low impedance path to earth for the shield at frequencies of 150 kHz
and higher.)

Multiple, spread out, direct or high capacitance connections of a shield to earth

should be avoided. Multiple connections risks high levels of low frequency
ground current, like 50/60 Hz, flowing within the shield.

Shield termination can be a deterministic process. AC shield connections

(capacitors) may be dictated at the control, instead of the direct earth connection
provided. Typically, shields at signal inputs are connected directly to earth, and
shields at signal outputs are AC-coupled to earth or floating. See Woodward
application notes 50532, Interference Control in Electronic Governing Systems,
and 51204, Grounding and Shield Termination, for more information.

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Manual 26415 Atlas-II Digital Control

Shielded Wire Preparation

Where shielded cable is required, cut the cable to the desired length and prepare
the cable as instructed below.
1. Strip outer insulation from both ends, exposing the braided or spiral wrapped
shield. Do not cut the shield or nick the wire inside the shield.
2. Using a sharply pointed tool, carefully spread the strands of the braided
shield to form a hole.
3. Pull inner conductor(s) out of the shield. If the shield is the braided type, twist
it to prevent fraying.
4. Remove 6 mm (1/4 inch) of insulation from the inner conductors.
5. Connect wiring and shield as shown in plant wiring diagram.
6. If a shield connection is not required or desired, fold back and secure or
remove the excess shield as needed.

General Wiring Guidance

For noise suppression reasons, it is recommend that all low-current wires be
separated from all high-current wires and high-voltage be separated from low-
voltage.

Input power ground terminal, not power return, should also be wired to earth
ground.

Installations with severe electromagnetic interference (EMI) may require

additional shielding precautions, such as wire run in conduit or double shielding.
Contact Woodward for more information.

Shields from the control to its loads or inputs can be directly grounded to earth at
both ends, if the cable length is sufficiently short to prevent ground loop current in
the shield (e.g. within a single cabinet).

Enclosure Installations: If the control is installed in a metal enclosure, as

intended, shielded I/O must be AC or DC terminated directly to the cabinet (earth
ground) at the entry to the cabinet, as well as at the control shield pins.

Specifics are provided in each individual installation section.

Non-Marine Enclosure Application Information

Cabinet Structural Grounding
 The cabinet needs to be a six-sided metal enclosure.
 Do not use cabinet doors with windows—doors should be solid metal.
 The enclosure floor and/or top panels must provide holes for cable entry.
 Top and bottom cable entry areas must be restricted in size. Cable entry
aperture sizes should be minimized to the extent possible, the largest
dimension of any aperture (hole) is no greater than 152 mm (6 inches). This
is particularly important when RF transmitters, like push to talk radios or cell
phones, can be located near the cable access areas.
 An enclosed metal cable area or cable way joining to the cabinet may be
thought of as part of the enclosure; If it has no holes larger than 152 mm
(6 inches) and no RF transmitters can be present with in it. This allows larger
holes in the enclosure cable access plate. The enclosed cableway effectively
becomes part of the enclosure.
 The cabinet enclosure frame and device mounting areas must be bonded
(grounded) together.
 The frame shall be electrically connected at each structural interface
(<2.5 mΩ).

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Atlas-II Digital Control Manual 26415
 Mounting plates shall be electrically connected to structural frame (<2.5 mΩ).
 4 corners minimum—4 corners + 2 mid-points preferred.
 Doors must be electrically connected to the main structural frame (<2.5 mΩ).
 1 place minimum, 3 places preferred, use of 25 mm (1 inch) wide bond
straps is preferred.
 Optimally install bond straps at the locations that cables cross the door
hinge. If no cables cross the hinge point, locate straps to break up the
size of gaps or openings in the metal structure to door interface.
 Cover panels shall be electrically connected to structural frame (<10 mΩ).
 1 place minimum, 2 places preferred (placed at opposite corners).
 Floor and top panels must be electrically connected to structural frame (<2.5
mΩ).
 1 place minimum, 4 places at the corners is preferred.
 DIN rails must be electrically connected to structural frame (<2.5 mΩ).
 Once every 12”, use a minimum of 2 screws to bond a DIN rail to cabinet
frame or mounting panel.
 The cabinet must provide a shield termination point for cables as they enter
the enclosure. Shielded I/O must be AC or DC terminated directly to the
cabinet (earth ground) at the entry to the cabinet, as well as to the Atlas-II
shield pins.

The grounding section covers how to create shield terminations and

when to ground shields: directly to earth or indirectly to earth
through a capacitor. There must be one earth ground.

Marine Enclosure Application Information

Cabinet Structural Grounding
 The cabinet needs to be a six-sided EMI shielded metal enclosure. The
interior surfaces must be conductive and coated with corrosion protection
treatments.
 Do not use cabinet doors with windows—doors should be solid metal.
 The enclosure floor and/or top panels must provide holes for cable entry.
 Top and bottom cable entry areas must be restricted in size. Cable entry
aperture sizes should be minimized to the extent possible, the largest
dimension of any aperture (hole) is no greater than 152 mm (6 inches). This
is particularly important when RF transmitters, like push to talk radios or cell
phones, can be located near the cable access areas.
 The cabinet/enclosure frame and device mounting areas must be bonded
(grounded) together.
 The frame shall be electrically connected at each structural interface (<2.5
mΩ).
 Mounting plates shall be electrically connected to structural frame (<2.5 mΩ).
 4 corners minimum, 4 corners + 2 mid-points preferred.
 Doors must be electrically connected to the main structural frame (<2.5 mΩ)
and must be mounted to contact an EMI gasket all the way around the
perimeter when the door is closed.
 Bond strap 1 place minimum, 3 places preferred, use of 25 mm (1 inch)
wide bond straps is preferred.
 Optimally, install bond straps at the locations that cables cross the door
hinge. If no cables cross the hinge point, locate straps to break up the
size of gaps or openings in the metal structure.

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Manual 26415 Atlas-II Digital Control
 Cover panels shall be electrically connected to structural frame (<10 mΩ)
and must be mounted to contact an EMI gasket all the way around the
perimeter when the panel is mounted.
 Bond strap 1 place minimum, 2 places (placed at opposite corners)
preferred.
 Floor and top panels must be electrically connected to structural frame (<2.5
mΩ) and must be mounted to contact an EMI gasket all the way around the
perimeter when the panel is mounted.
 Bond strap 1 place minimum, 4 places preferred.
 DIN rails must be electrically connected to structural frame (<2.5 mΩ).
 Once every 12”, use a minimum of 2 screws to bond a DIN rail to cabinet
frame or mounting panel.
 The cabinet must provide a shield termination point for cables as they enter
the enclosure. Shielded I/O must be AC or DC terminated directly to the
cabinet (earth ground) at the entry to the cabinet, as well as at the Atlas-II
shield pins.
 All cables that have sections going outside the cabinet must be shielded from
the cabinet entry/exit point to the cable end point inside the cabinet. Cables
normally unshielded may limit the shield to just the section inside the cabinet,
with shield terminations to the cabinet at each end.

The grounding section covers how to create shield terminations and

when to ground shields: directly to earth or indirectly to earth
through a capacitor. There must be one earth ground.

General Enclosure Application Information

Cable Entry Locations
 Cable shield termination hardware must be installed at cable entry points.
 Cable shield terminations must be electrically connected to structural frame
and shall allow direct grounding (<2.5 mΩ) or AC grounding of cable shields
as specified.
 Route each of the shielded cable types separately, by type. A minimum of 5
cm (2 inches) between types should be maintained.
 Maintain unshielded cables within 0-10 mm (0.0-0.4 inches) of the enclosure
metal mounting panels, frame rails, etc, until they get close to the Atlas-II.
Approximately 152-203 mm (6-8 inches) near the Atlas-II may be moved
away from the enclosure ground by as much as needed to get to the
connector.
 The cable shielding of shielded cables performs better if the shielded cables
follow the same routing instructions given for unshielded cables, however this
is not required.
 Atlas-II cable shields termination pins, except for CAN shield, are designed
connected directly to chassis. If this direct connection is used, cables at the
cabinet’s cable entry point should also be directly connected to the cabinet.
 All signal lines going outside the cabinet must be shielded while inside the
cabinet to prevent picking up stray signals.

Shielding of PT/CT, relay outputs, contact inputs, and power supply

wires inside the metal enclosure is required for Marine Type
Approval installation applications. Relay outputs, contact inputs, and
power supply wiring do not normally require shielding for other
installations, but may be shielded if desired.

Woodward 15
Atlas-II Digital Control Manual 26415

The grounding section covers how to create shield terminations and

when to ground shields: directly to earth or indirectly to earth
through a capacitor. There must be one earth ground.

Equipment Zoning (Segregation)

Separate the equipment types inside the enclosure/cabinet, as possible:
 Analog equipment area
 Discrete I/O equipment areas
 Shielded I/O area
 Un-shielded I/O area
 Power
 AC mains PT & CT monitoring area
 Light Industrial EMC compliant equipment area
 Monitor/kybd/pointing device (HMI if applicable)
 Other equipment area
 Maintain a minimum or 6” of separation between equipment type areas

Light Industrial equipment is defined as equipment that is designed

and tested to comply with European Union (EU) directives (e.g.
EN61000-6-1 and EN61000-6-3) for Light Industrial environments.
Industrial compliant equipment is designed and tested for the EU
directives for Heavy Industrial environments (e.g., EN61000-6-2 and
EN61000-6-4).

Third Party Hardware Located Inside the Cabinet

 Use only CE Compliant or Marine Type Approved devices
CE Compliant to Light Industrial Levels
 Locate cables (to and from Light Industrial) away from all I/O cables that
enter or exit the cabinet by 305 mm (12 inches)
 Locate cables (to and from Light Industrial) away from all other cables
not going outside the cabinet, separated by greater than 150 mm (6
inches).
CE Complaint to Industrial Levels
 Locate based on zoning restrictions

Installation of Other Equipment, Fans, Meters, etc.

Shield Termination Schemes
 Follow general guidance above and see Application Note 51204 for this
information.

Input Power Routing and Filtering

 Input power coming inside the cabinet from outside it or going outside the
cabinet from inside it must be routed separately from all other circuits as it
enters the cabinet and while inside the cabinet.

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Manual 26415 Atlas-II Digital Control
 If input power feeding the Atlas-II is ever outside the cabinet, it must be
routed separately from all other circuits as it enters the cabinet and while
inside the cabinet. Marine Type Approval applications also require input
power that leaves the cabinet to be shielded while inside the cabinet. Shield
termination at the cabinet entry point and just before the device input.
 Route Atlas-II power coming from outside the cabinet along the left side of
middle, at the back of the cabinet. Route it directly against the mounting
panel. All other I/O and internal cabling must be kept more than 152 mm (6
inches) away.
 Input power must route directly to controls that are “Industrial” compliant.
 Input power that must route to controls that are “Light Industrial” compliant
must be filtered with a minimum of 20 dB filtering.
 Input power that must be routed near other cabling will be filtered prior to the
point the cables follow a common path. Filter with a 20 dB filter.

Cabinet Cabinet Cabinet

Atlas-II Atlas-II Atlas-II

Field Iterim Field Field

Device Device Device Device

Interim Device: Isolator, Relay Box, FTM, etc.

Field Device: Actuator, Valve, Sensor, Meter, Profibus Head, etc.

Figure 2-4. Descriptions of Main Cabinet Cabling Options

Shielded Cable Routing & Shield Termination

Do not connect chassis ground or PE ground to signal common.

Field Device not in Cabinet, No Interim Device (Figure 2-4)

 Use shielded cable from Atlas-II to field device (Isolator, FTM, Analog Driver,
indicator meter, etc).
 Route the cable from Atlas-II to the cabinet exit point with the cable against
cabinet metal structure.
 AC or DC ground the cable shield at entry point to cabinet and at the Atlas-II
shield termination pin.
 If the I/O cable is AC grounded or floated at the field device end of the cable,
it must be directly ground at the cabinet and Atlas-II shield termination pin.
 If the I/O cable is directly grounded (DC coupled) at the field device end of
the cable, it should be ground with a capacitor (AC ground) at the cabinet.
AC ground it both at the Atlas-II shield pin and at the cable entry point into
the cabinet.

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Atlas-II Digital Control Manual 26415
 Two separate I/O cable shields:
 If over braided (two shields), directly ground over braid shield to cabinet
and shield pin—directly connect inner braids at field device termination
point. The inner braid must have at least one point directly grounded to
earth.

Field Device not in Cabinet, with Interim Device in the Cabinet (Figure 2-4)
 Locate interim device away from unshielded discrete areas > 152 mm (6
inches).
 Use shielded cable from Atlas-II to field device (Isolator, FTM, Analog Driver,
indicator meter, etc.)
 Route the cable from Atlas-II to the interim device with the cable against
cabinet metal structure.
 The interim device must have one AC shield and one DC shield connection.
The following are the shield termination combinations, starting from outside
the cabinet and working to the Atlas-II.

Interim Interim
Field Cabinet Device Device
Device Entry Out In Atlas-II Status
DC AC AC DC DC Allowed / Preferred
AC AC AC DC DC Allowed
AC AC AC DC AC Allowed /
Not Preferred
AC DC DC AC DC Allowed /
Not Preferred
AC DC DC AC AC Allowed /
Not Preferred
DC AC or DC AC AC or Not allowed
DC DC
DC DC DC AC AC or Not allowed
DC

 Two separate I/O cable shields:

 If over braided (two shields), directly ground over braid shield to cabinet
& shield pin—directly connect inner braids at field device termination
point. The inner braid must still have at least one point directly grounded
to earth.

Field Device in Cabinet, No Interim Device (Figure 2-4)

 Locate field device away from unshielded discrete areas > 152 mm (6
inches).
 Use shielded cable from Atlas-II to field device (Isolator, FTM, Analog Driver,
indicator meter, etc.)
 Locate field device as close to I/O cable entry point as possible.
 Route the I/O cable against cabinet metal wall from entry point to field
device.
 Ground the I/O cable shield directly at both ends.
 If over braided (two shields), directly ground over braid shield to
cabinet—directly connect inner braids at field device termination point.
The inner braid must have at least one point directly grounded to earth.
 If single shield, ground the shield to the cabinet and/or shield pin at both
ends.

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Manual 26415 Atlas-II Digital Control

Unshielded Cable Routing & Termination

Field Device not in Cabinet, No Interim Device (Figure 2-4)
 Route the I/O cable against the metal cabinet wall, from cabinet entry point to
the Atlas-II.
 Limit the length of unshielded I/O cable inside the cabinet. Lengths over 915
mm (36 inches) are too long.
 If lengths greater than 915 mm (36 inches) are required, special
considerations should be used to separate this unshielded wiring from other
circuits and minimize electromagnetic coupling into or from the cable.
 Do not let other cables within 305 mm (12 inches) of unshielded cables if
they are parallel for greater than 610 mm (24 inches).
 Do not let other cables within 150 mm (6 inches) of unshielded cables if they
are parallel for less than 610 mm (24 inches).

Field Device not in Cabinet, with Interim Device in the Cabinet (Figure 2-4)
 Locate unshielded field devices > 152 mm (6 inches) away from other field
devices.
 Locate field device as close to I/O cable entry point as possible.
 Route the I/O cable against the metal cabinet wall, from cabinet entry point to
the interim device.
 Route the I/O cable against the metal cabinet wall, from the interim device to
the Atlas-II.
 Limit the length of unshielded I/O cable inside the cabinet. Lengths over 915
mm (36 inches) are too long.
 If lengths greater than 915 mm (36 inches) are required, special
considerations should be used to separate this unshielded wiring from other
circuits and minimize electromagnetic minimize electromagnetic coupling into
or from the cable.
 Do not let other cables within 305 mm (12 inches) of unshielded cables if
they are parallel for greater than 610 mm (24 inches).
 Do not let other cables within 150 mm (6 inches) of unshielded cables if they
are parallel for less than 610 mm (24 inches).

Field Device in Cabinet, No Interim Device (Figure 2-4)

 Locate field device as close to I/O cable entry point as possible.
 Route the I/O cable against the metal cabinet wall, from cabinet entry point to
the Atlas-II.
 Limit the length of unshielded I/O cable inside the cabinet. Length over 915
mm (36 inches) is too long and may couple.
 If lengths greater than 915 mm (36 inches) are required, special
considerations should be used to separate this unshielded wiring from other
circuits and minimize electromagnetic minimize electromagnetic coupling into
or from the cable.
 Do not let other cables within 305 mm (12 inches) of unshielded cables if
they are parallel for greater than 610 mm (24 inches).
 Do not let other cables within 150 mm (6 inches) of unshielded cables if they
are parallel for less than 610 mm (24 inches).

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Atlas-II Digital Control Manual 26415

Input Power
The Atlas-II control requires a nominal voltage source of 18 to 32 Vdc. Input
power requirements vary depending on the control version. Table 2-1 contains
information for the maximum configuration.

Power must be applied to the Atlas-II control at least 60 seconds

prior to expected use. The control must have time to do its power up
diagnostics to become operational. Failure of the diagnostics will
disable control function.

The Atlas-II power supply board must have the input power removed
before installing or removing.
This Equipment is Suitable For Use in Class I, Division 2, Groups A,
B, C, D or Non-Hazardous Locations Only.
This equipment is suitable for use in European Zone 2, Group IIC
environments.
Wiring must be in accordance with North American Class I, Division
2, or European Zone 2, Category 3 wiring methods as applicable, and
in accordance with the authority having jurisdiction.
Do not connect more than one main power supply to any one fuse or
circuit breaker.
For Communication wires, use wires with a temperature rating of at
least 5C above surrounding ambient. All others use wires with a
temperature rating of at least 10C above surrounding ambient.

For ATEX compliance, this equipment must be protected externally

against transient disturbances. Provisions shall be made to prevent
the power input from being exceeded by transient disturbances of
more than 40% of the rated voltage.

The power supply output supplying the Atlas-II must be of a low impedance type
for proper operation of the control. DO NOT power a control from a high voltage
source containing dropping resistors and zener diodes. If batteries are used for
operating power, an alternator or other battery-charging device is necessary to
maintain a stable supply voltage.

To prevent damage to a control system that uses an alternator or

battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.

If an alternator is used to charge batteries supplying the Atlas-II

power, the alternator must be a suppressed/clamped type or have
external load dump transient suppression. The Atlas-II does not have
sufficient energy handling capability to suppress a full alternator
load dump.

Significant inrush currents are possible when current is applied to the Atlas-II
control. The magnitude of the inrush current depends on the power source
impedance, so Woodward cannot specify the maximum inrush current. Time-
delay fuses or circuit breakers must be used to avoid nuisance trips.

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Manual 26415 Atlas-II Digital Control

Input Power Wiring

Protective earth ground (PE) must be connected to the chassis at the termination

point on the unit labeled with . The power supply grounding

terminals should also be connected to earth to ensure grounding of the power
supply printed circuit boards. The grounding conductor must be the same size as
the main supply conductors or the combined PT wires, whichever is larger.

The control’s power supplies are not equipped with input power
switches. For this reason, a fixed wiring installation is required and a
switch or circuit breaker shall be included in the building installation
that is in close proximity to the equipment and within easy reach of
the operator and that is clearly marked as the disconnecting device
for the equipment. The switch or circuit breaker shall not interrupt
the protective earth conductor.

It is expected that the installation of this equipment will include over current
protection between the power source and the Atlas-II control. This over current
protection may be accomplished by series connection of properly rated fuses or
circuit breakers. Branch circuit protection of no more than 250% of the maximum
Atlas-II power supply input current rating must be provided. See Table 2-1 for
maximum recommended fuse ratings. This value meets the 250% UL listing
requirements. The use of properly sized UL class CC, J, T, G, RK1, or RK5 fuses
meet the requirements for branch circuit protection. Do not connect more than
one Atlas-II control to any one fuse. Use only the wire size specified in Table
2-1 or equivalent metric size which meets local code requirements. Time delay
fuses should be used to prevent nuisance trips.

Table 2-1 provides the power supply holdup time specification; which is the time
the supply will continue to operate within specification after its input power is
interrupted. This information may be useful in specifying uninterruptible power
supply (UPS) systems.

Input Voltage Fuse

Range (Current Rating) Fuse (I2t Rating) Wire Size* ** Holdup Time
18–32 Vdc** 9A >800 2/4 mm² 8 ms
12/14 AWG
Table 2-1. Power Supply Requirements

* 4 mm² (12 AWG) is the largest wire gauge size that may be
connected to the control power input terminal blocks.

** The minimum input voltage allowed is 18 V at the power input of

the control. The length, size of wire, and load current will determine
the minimum supply output voltage. The minimum supply voltage
measured at the source should always be greater than 18 V.
Example: two (source and return) 20 foot (6 m) lengths of 14 AWG (2
mm²) wire carrying 1.2 A (maximum rated current) will result in a
voltage drop from source output to control power input of approx.
0.16 volts. The resulting supply voltage from the example must be
greater than 18.16 volts.

*** A fuse or circuit breaker shall not interrupt the protective earth
conductor.

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Atlas-II Digital Control Manual 26415

Input Power Wiring Diagram

The power supply and ground connections are located on the power supply
board (see also Recommended Grounding Practices).

AtlasPC
Power Supply Board
3

Optional Common
- System
Ground
2
Switching
Power 24V
Supply +
1

Maintenance
The only part of the Atlas-II control system that may require user maintenance is the
cooling fan (Woodward part number 1886-439). In the event that the fan must be
replaced, please use the following procedure to remove a faulty fan from the chassis:
 Use a #2 Phillips screwdriver
 Power down the control to avoid overheating or other hazards.
 Disconnect fan wires from terminal block. Cut the tie-wrap supporting the
wires to the cover.
 Remove, the four retaining screws holding the fan and guard to the cover.
 Remove fan and guard from unit.
 Remove guard from faulty fan
 Install new fan of same size and flow rate.
 Reinstall fan (flow arrows should point "OUT")
 Reinstall fan guard with the 4 screws. Torque screws to 0.1 N·m (1 lb-in)
max to avoid damage to the flange of fan.
 Trim leads to a reasonable length.
 Connect RED wire to the + fan terminal and BLACK wire to - fan terminal.
 If desired strain relief leads to cover with a new tie-wrap.

Application Guidelines
The following items are general guidelines intended to educate the system
integrator on potential installation and application issues that might arise when
the Atlas-II controller is applied.

The Atlas-II platform must use Coder 4.05 or higher.

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Manual 26415 Atlas-II Digital Control

Analog Inputs
The readback output on the AO_420_ATL block can be used to detect a fault
condition associated with the analog output. The readback output is available on
all analog output channels associated with the Atlas-II main board (A5200). The
readback fault output can also be used to monitor the analog outputs. It is
intended to detect a gross fault in the actual current versus current setpoint. Note
that the readback output does not have the same specifications as the analog
output. The readback function is intended as a gross check only. It is also
recommended that application software have filtering to use multiple rate groups
for readback indication before enunciating a fault.

Two of the connectors used for the analog inputs are identical. It is possible for
the end user to connect the wrong connector to the wrong input. The terminals
are numbered to minimize the chance of this happening however it is possible.
The system integrator should take precautions to ensure that it is easy to view
the terminal labels or design other methods to allow the user to easily identify the
correct cable for each connector.

Analog Input cables are shielded, and shields should be terminated directly at the
Atlas-II end and the cabinet entry/exit point.

Actuator Outputs
The actuator outputs on the Atlas-II main board have readback monitoring on
both the source side of the current driver circuit and the return side of the circuit.
The readback outputs can fault. These outputs can be used to monitor the
current loop associated with the actuator for open circuit conditions. These
monitoring inputs are intended to be used to detect a gross error in the actuator
driver current loop. It is also recommended that application software have filtering
to use multiple rate groups for readback indication before enunciating a fault.

Analog Output cables are shielded, and shields may be terminated directly
(preferred) or via AC coupling at the Atlas-II end and the cabinet entry/exit point.

Discrete Inputs
Two of the connectors used for the discrete input connections are identical. It is
possible for the end user to connect the wrong connector to the wrong input. The
terminals are numbered to minimize the chance of this happening however it is
possible. The system integrator should take precautions to ensure that it is easy
to view the terminal labels or design other methods to allow the user to easily
identify the correct cable for each connector.

Discrete Input cables are only required to be shielded for Marine Type Approval
applications, and shielding may be limited to the cabinet interior. Cable shields
should be terminated directly at the Atlas-II end and the cabinet entry/exit point.

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Atlas-II Digital Control Manual 26415

CAN Network
The connectors used for the CAN network connections are identical. It is possible
for the end user to connect the wrong connector to the wrong input. The
terminals are numbered to minimize the chance of this happening however it is
possible. The system integrator should take precautions to ensure that it is easy
to view the terminal labels or design other methods to allow the user to easily
identify the correct cable for each connector.

The CAN Network’s cables are shielded, and the shield should only be directly
terminated to earth at one point. The Atlas-II’s CAN shield pins are AC coupled to
earth and the shield may be direct connected (preferred) or AC coupled at the
Atlas-II end and the cabinet entry/exit point depending on the rest of the network.

Serial Ports
The connectors used for the serial port connections are identical. It is possible for
the end user to connect the wrong connector to the wrong input. The terminals
are numbered to minimize the chance of this happening however it is possible.
The system integrator should take precautions to ensure that it is easy to view
the terminal labels or design other methods to allow the user to easily identify the
correct cable for each connector.

Serial port cables are shielded and should be terminated directly at the Atlas-II
end and the cabinet entry/exit point. Take care with the shield termination at the
field device end.

Ethernet Connectors
The Atlas-II has four Ethernet connectors that are arranged in one connector.
The physical spacing between connectors is limited. This can create the situation
where it is easy to connect the wrong cable to the connector. Another
consideration is that the Ethernet cables are located on the side of the controller
which was not used for connections on the original AtlasPC. In certain
installations, the space to access these connectors may be limited.

To mitigate the risk the system integrator should implement an Ethernet cable
labeling process to allow the user to easily identify which Ethernet cable
connects to each Ethernet port. The Atlas-II also has application level checks
that the system integrator should be aware of when designing a system.

At the GAP application level there are functions available to monitor the Ethernet
ports. The following functions can be implemented depending on the application
requirements.

Ethernet Status Block (ENET_STAT)

 Monitors the number of packets received and transmitted by each physical
Ethernet port.
 Provides diagnostic information about the low level Ethernet interface.

Modbus Communications
 Each Modbus interface block has a link error output that should be
monitored in the GAP application and appropriate action taken when a link
error occurs.
 The link error will not go FALSE unless the cables are connected properly.

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Manual 26415 Atlas-II Digital Control
EGD Communications
 The EGD interface block has a link error output that should be monitored in
the GAP application and appropriate action taken when a link error timeout
is detected.
 The link error will not go FALSE unless the cables are connected properly.

Ethernet Based Distributed IO

 Distributed IO interfaces will have a timeout diagnostic similar to the link
error function on the communication blocks. The application programmer
must ensure that the timeouts and action taken, when a timeout is detected,
is appropriate for the application requirements.

Woodward Service Tools

 Woodward service tools will only work when the laptop is connected to
Port1.

Ethernet port cables are shielded. Cable shields are terminated directly at the
Atlas-II end and the cabinet entry/exit point. An Ethernet Field Termination
Module (FTM), available from Woodward, may be used to break the shield path
between the field device and the Atlas-II.

Speed Sensor Ports

Speed Sensor port cables are shielded. Cable shields are terminated directly at
the Atlas-II end and the cabinet entry/exit point. Refer to the SmartCore CPU
A5200 module for additional information and wiring requirements.

Installation Functional Check Guidelines

In general all IO points should be functionally tested prior to starting the prime
mover. The IO points should be checked for ground loops and other possible
sources of noise as well as isolation from other power sources that are not
related to the specific IO circuit. These installation guidelines are given as
general guidelines only. The system integrator / end user are responsible for
understanding the application and defining a field checkout procedure that
addresses the requirements of the system being installed.

When performing IO checkout, appropriate safety precautions must

be taken to ensure that the devices being tested are properly locked
out or that a safety issue is not created.

Analog Inputs
 The field signal should be validated to ensure that the correct field signal is
connected to the correct analog input channel. It is recommended that this
validation is done by viewing the field signal in the GAP application.
 Example: If the analog input comes from a pressure transducer then a
pressure tester could be used to vary the analog output that is being
input to the Atlas. This signal can then be verified to be correct in the
GAP application.

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Atlas-II Digital Control Manual 26415
Analog Outputs
 Analog output values should be forced from the Atlas-II controller and
verified at the receiving device. Outputs should be checked at min and max
current values (4 – 20 ma).
 Example: If the analog output is used to drive an indicator then the
output should be forced to several values and the indicator should be
monitored to ensure that the indicator is connected to the correct analog
output as defined by the GAP application.
 Verify that the total loop resistance is less than the specification limit defined
in the hardware manual.

Discrete Inputs
 The field contacts should be operated to ensure that the correct field device
is connected to the correct discrete input on the Atlas-II.
 Example: If the discrete input tells the Atlas-II that a certain motor is
running then the motor should be operated and the input should be
viewed in the GAP software to ensure that software “sees” the change of
state.
 Verify that only the 24Vdc wetting voltage is connected to the discrete
inputs.
 Check for AC by measuring all inputs from the input terminals to chassis
ground.
 Check the discrete input common with respect to other power supply
commons to ensure that the discrete inputs are isolated from other
power supplies that are not used with the discrete inputs.

Discrete Outputs
 The discrete outputs should be forced and the resulting signal should be
confirmed at the field device.
 Example: If the discrete output is input to another PLC then the output
should be forced from the GAP logic and verified in the PLC logic. If the
output drives a field device such as a motor starter then the output
should be forced and verified at the motor starter. Note: Before forcing
outputs to field devices verify that all necessary safety precautions are in
place.

Ethernet Connections
 The Ethernet connections should be removed one at a time and expected
faults should be verified in the Atlas-II software and also in the other device.
 Example: If port 2 is connected to an HMI using the Modbus TCP
protocol then removing the Ethernet cable connected to port 2 should
cause a Link Error in the GAP application and a comm. fault in the HMI
application.
 Note: Due to the identical design of the Ethernet ports and the potential
for similar cables, labeling is important to ensure that the user can easily
identify which cable goes to each connector.

CAN Connections
 The CAN network connections should be verified to ensure that the correct
networks are connected to the correct connector.
 Note: Due to the identical design of the two CAN ports and the potential for
similar cables, labeling is important to ensure that the user can easily
identify which network is connected to the CAN connectors.

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Manual 26415 Atlas-II Digital Control

Chapter 3.
Power Supply Board

General Description
The Atlas-II power supply contains the power supply and twelve discrete output
driver channels. The discrete outputs are low-side drivers having short circuit and
thermal shutdown protection. The discrete output drivers are not isolated from
each other, and are powered by an external +12 Vdc or +24 Vdc. They are
isolated from the internal power supplies of the Atlas-II Control platform.

Input power connections are made to the power supply through terminals on the
front of the power supply.

The Atlas-II power supply board must have the input power removed
before installing or removing.
This equipment is suitable for use in Class 1, Division 2, Groups A,
B, C, and D, Zone 2, Group IIC, or non-hazardous locations only.
Wiring must be in accordance with Class I, Division 2 or Zone 2
wiring methods and in accordance with the authority having
jurisdiction.

855-741B
02-11-21

Figure 3-1. Atlas-II Power Supply Board (601-1008)

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Atlas-II Digital Control Manual 26415

Specifications
Power Supply Input (Power Supply Board)
Range 18–32 Vdc
Input Current 2.7 A @ 24 Vdc
3.61 A @ 18 Vdc
Input Power less than 65 W at 70 °C
Interrupt Time Holdup 8 ms @ >/= 24 V
Efficiency 70% minimum over operating input
voltage range
Reverse Polarity Protection 56 V
Input Wiring Constraints The Atlas-II control platform must be
wired such that no other device receives
power from the wiring between the
Atlas-II Control Platform and the power
supply source.

Discrete Output Drivers (Power Supply Board)

Number of channels 12
Type Low-side driver with short circuit and
overvoltage protection
Current drive rating 200 mA
Discrete Output Supply Voltage 9–32 V

Power Supply Monitoring Circuit (Power Supply Board)

LVdc Maximum voltage measured 35 Vdc
Resolution in volts 0.15 Vdc
Maximum Error due to temperature change 1.0 Vdc
Maximum Error due to load change 1.0 Vdc
Total maximum error at 25 °C 1.2 Vdc
(over 15 to 35 V range)

Electric Shock
The Atlas-II control platform shall not present an electrical shock hazard to the
operator or maintenance personnel when used in a normal manner per the
National Electrical Code Handbook, ANSI/NFPA 70 HANDBOOK-1990. Safety is
ensured by certification through the safety agencies specified in the “Regulatory
Compliance” section of this document.

Troubleshooting Guide
Power Supply Checks
The following is a troubleshooting guide for checking areas, which may present
difficulties. If these checks are made prior to contacting Woodward for technical
assistance, system problems can be more quickly and accurately assessed.
 Is the input voltage within the control’s specified input voltage range
(measured at control power supply input)?
 Is the input power free of switching noise or transient spikes?
 Is the power circuit dedicated to the Atlas-II control only?

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Manual 26415 Atlas-II Digital Control

Discrete Output Checks

The Atlas-II power supply contains twelve discrete output driver channels. The
discrete outputs are low-side drivers having short circuit and thermal shutdown
protection. The discrete output drivers are not isolated from each other, and are
powered by an external +12 Vdc or +24 Vdc. They are isolated from the internal
power supplies of the Atlas-II Control platform.
 Is the input power within the range of 9–32 V?
 Is the input free of switching noise or transient spikes?
 Is the power circuit dedicated to the control only?
 Are the individual discrete output lines current limited by external series
connected components (example: relay coils) to <200 mA?

+ -

855-745
00-01-25 KDW

Figure 3-2. Discrete Output Wiring Example

(Discrete Output Interface Wiring to the Power Supply Board)

Configuration Notes
 Refer to Figure 3-2 for discrete output wiring.
 Discrete outputs are not normally shielded, however may be shielded and
are required to be shielded for Marine Type Approval applications.
o When shielding cables, shield at least from the Atlas-II to the cabinet
entry/exit point. Terminate the shield directly to the cabinet at the
entry/exit point and Atlas-II.
 The discrete output commons are tied together, so each power supply board
accepts only one voltage source.
 Power for the discrete outputs must be externally supplied, the external
supply must be capable of supplying a voltage between 9–32 V while
supplying up to 2.5 A. As specified in the Input Power Wiring Section,
branch circuit protection of no more than 250% of the maximum rated
current of the load (Discrete Output power input current plus 12 times the
maximum Discrete Output channel current) shall be provided. Fuse current
rating should not exceed 6.25 A (time delay fuses are recommended).

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Atlas-II Digital Control Manual 26415
 Chapter 7 contains a relay module that can be used with these discrete outputs.

Shielding of relay (discrete) output wires inside the metal enclosure

is required for Marine Type Approval installation applications. Relay
outputs do not normally require shielding for other installations, but
may be shielded if desired.

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Manual 26415 Atlas-II Digital Control

Chapter 4.
SmartCore CPU A5200 Board

General Description
The SmartCore CPU A5200 board contains 4 Ethernet communication ports as
well as circuitry for 2 speed sensor inputs, 6 analog inputs, 4 analog outputs, 2
proportional actuator drivers, 2 CAN communication ports, 2 isolated serial ports,
1 debug serial port (isolated), and 24 discrete inputs. Each speed sensor input
may be either from a magnetic pick-up or a proximity probe. Analog input and
output circuits are 4–20 mA. The actuator driver outputs may be configured as
either 4–20 mA or 20–220 mA. The user serial ports are configurable as RS-232,
RS-422, or RS-485.

Figure 4-1. SmartCore CPU A5200 board, Connectors

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Features
 5 ms update rate
 On-board processor for automatic calibration of the I/O channels
 PowerPC 5200, low power version
 64 MB DDR-266 MHz, DRAM
 8/16 bit PC/104 Interface (ISA bus)

Communications
 (4) RJ45 10/100 Base-TX Ethernet
 (2) isolated CAN ports
 (2) isolated and configurable RS-232 / RS-422 / RS485 Serial ports, 115.2K
baud max
 (1) isolated RS-232 Debug Service Port

Hardware I/O
 (24) Discrete inputs
 (2) Speed Sensor Inputs (MPU / Proximity), 16 bit minimum resolution
 (6) Analog inputs have 16 bit resolution
 (4) Analog outputs have 15 bit resolution
 (2) Actuator outputs with 15 bit resolution

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Block Diagram
The Atlas-II boards connect to each other through either the PC/104 bus
connectors or the power bus connectors. All of the boards are held together and
to the chassis, by bolts. The SmartCore CPU A5200 board is the size of two
analog boards.

Smartcore A5200
Two Serial
Speed J11 Debug
PC104 BUS
Inputs TB8 Port
MPU or
PROX

PC104 PC104 PC104 Actuator

Three Buffer ADDRESS DATA CTRL Out 1-2
RCVR XCVR XCVR XCVR Analog
Analog TB7 Out 1-4
Inputs
4-20mA
TB12 Serial
FPGA Power
Port 2
PC104 BUS Bus

Three CONTROLLER XCVR

Analog TB6 A/D
Converter
Inputs
4-20mA 32MHz
DISC
IN
RCVR

CAN 2 TB5 TB11 Serial

64MB FLASH
Port 1
ADDRESS DATA
File System, On-Board BUFFERS BUFFERS
Reserved Boot Sectors

TB4
CAN 1

Power
Four
64MByte Bus
DDR SDRAM MOTOROLA TB10 Analog
Eight (high) Outputs
Digital TB3 MPC5200 4-20 mA
Inputs
64MByte
DDR SDRAM
(low)

Eight RESET*
Digital TB2
Inputs LOCAL PWR Two
MONITOR
Ethernet
5.0V_FAIL TB9 Actuators
Controller LOCAL
3.3V_FAIL POWER 4-20 or
Four
10/100
2.5V_FAIL SUPPLY 20-200mA
1.8V_FAIL
Eight 1.5V_FAIL
Digital TB1 1.2V FAIL
Inputs

Ethernet 1-4

Figure 4-2. Block Diagram—Atlas-II SmartCore CPU A5200 Board

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Module Configuration
Hardware Configuration. This module is factory configured as module 1 of the
Atlas platform. No user hardware configuration is necessary.

Network Configuration. Ethernet port #1 can be re-configured for the customer

network as desired. See the on-site Network Administrator to define an
appropriate I/P address configuration for port #1. Please note that each Ethernet
port is required to be on a separate domain.

This module has been factory configured with fixed Ethernet IP

addresses of:
 Ethernet #1 = 172.16.100.20, Subnet Mask = 255.255.0.0
 Ethernet #2 = 192.168.128.20, Subnet Mask = 255.255.255.0
 Ethernet #3 = 192.168.129.21, Subnet Mask = 255.255.255.0
 Ethernet #4 = 192.168.130.22, Subnet Mask = 255.255.255.0

Network Configuration Utility (AppManager)

Woodward's AppManager software can be used to load GAP Control software,
monitor diagnostic faults, and configure Network settings. The AppManager utility
can be downloaded from www.woodward.com/software. A PC to Atlas-II
connection must be made using an Ethernet cable and Ethernet port #1.

 Locate the Atlas-II ControlName on the chassis and highlight it using

AppManager.
 To VIEW the IP address configuration, select menu option CONTROL -
CONTROL INFORMATION. Look for the Ethernet adapter addresses under the
Footprint Description.
 To CHANGE the IP address configuration, select menu option CONTROL -
CHANGE NETWORK SETTINGS.

Module Indicators (LEDs)

The SmartCore CPU A5200 module has the following LEDs.

LED Name Description

CPU FAULT (RED)—Active upon reset and flashes CPU fault
FAULT
RD FAULT codes as necessary.
RUN (GREEN)—Active GREEN after the CPU Operating system is
GR RUN RUN loaded and running.

LINK ACTIVE (GREEN)—A valid Ethernet connection to another

G LINK LINK device exists
ETH TX/RX (YELLOW)—Active YELLOW when data is transmitted or
Y TX/RX TX/RX
received.
CAN LED’s
GR CAN #1, #2 CAN #1, #2 (GREEN/RED)—Active GREEN or RED when data is
RD transmitted or received through CAN port #1 or #2.

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10/100 BaseT Ethernet Ports

There are four 10/100 BaseT Ethernet Ports (RJ45) available to the application
software. These ports are full duplex, auto switching, and do not require the use
of an Ethernet shield box.

Max cable length is 30 meters. Double shielded, Cat 5 Ethernet

cables (SSTP) are required for customer installations.

Connector Signal Mnemonic

RJ45F Shielded RJ45 female
receptacle

1 RX+
2 RX-
3 TX+
4 --
5 --
6 TX-
7 --
8 --
Shield Chassis EARTH

Table 4-1. Ethernet Port Pinout

RS-232/422/485 Serial Ports

Two isolated, pluggable RS-232 / 422 / 485 serial ports (SIO1, SIO2) are
available for customer use and can be configured by the GAP software
application. The baud rate is selectable from 300 baud to 115.2 kBaud. Shielded
cable is required when connecting to the CPU module’s serial port. Using
shielded cable will help ensure the robustness of the serial communications.

Pin 1 – RS-232 Transmit

Pin 2 – RS-232 Receive
1
Pin 3 – Signal Ground
Pin 4 – RS-485/422 Receive (+)
10 Pin 5 – Termination Resistor (+)
Pin 6 – Termination Resistor (–)
Pin 7 – RS-485/422 Receive (–)
Pin 8 – RS-422 Transmit (+)
Pin 9 – RS-422 Transmit (–)
Pin 10 – Chassis EARTH

Figure 4-3. SmartCore CPU A5200 Communications Ports (SIO1, SIO2)

RS-232 Service Port

An isolated RS-232 service port is located near one corner of the A5200 CPU
module. This port is for VxWorks operating system use only and cannot be
configured for application software use. The communication settings are fixed at
38.4 kBaud, 8 data bits, no parity, 1 stop-bit, and no flow control.

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 Atlas-II Digital Control Manual 26415
For debug use, a null-modem cable and 5450-1065 Serial Adapter cable (PS2M
to DB9F) is required to attach this port to a PC. This port is to be used by trained
Field Service personnel only!

Shielded cable is required when connecting to the Service Port. Using shielded
cable will help ensure the robustness of the serial communications.

Pin 1 – RS-232 Receive

Pin 2 – RS-232 Transmit
Pin 3 – Signal Ground
Pin 4 – Not Used
Pin 5 – Signal Ground
Pin 6 – Not Used
Connector Shell – Chassis EARTH

Figure 4-4. CPU Service Port (mini-DIN6F)

CAN Communication Ports

Two CAN ports (5 pin pluggable connectors, screw down) are available for
communication with Woodward Valves and other CAN devices. A maximum of
15 Woodward valves configured for operation in the 10 ms rate group may be
used.

Pin 1 – not used

5 Pin 2 – CAN High (white)
1
Pin 3 – CAN Shield (14Meg + AC coupled to EARTH)
Pin 4 – CAN Low (blue)
Pin 5 – CAN Signal Ground (black)

Figure 4-5. CAN Communication Ports

CAN networks must include 120Ω terminations at each end of the trunk line.
Drop cables connecting a device to the trunk line should be as short as possible
and less than 6 meters. It is recommended to design the network to be less than
100 meters with a max cumulative drop length of less than 39 meters.

Network Speed Max Trunk Length Max Trunk Length Max Drop Max Cumulative
(Thick cable) (Thin cable) Length Drop Length
500 Kbps 100 m 100 m 6m 39 m
250 Kbps 250 m 100 m 6m 78 m
125 Kbps 500 m 100 m 6m 156 m

CAN
Valve Valve
Device
Pigtail Drop Cable
TB TB TB

...
5417-1117 (1m)
or Similar Thick Pigtail Drop
Cable 5417-1117
Termination 7/8" Tee or Similar Termination
Resistor (F) F 1635-1463 F F F Resistor (male)
1635-1465 1635-1464
Thick Trunk Cable
Atlas-II M F
5417-1113 (3m) or Similar
M F M F M F

EARTH Ground the overall cable

braid at the cabinet exit point

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Manual 26415 Atlas-II Digital Control

CAN Cable Specification

Thick cable is preferred and recommended for all uses. Most CAN / DeviceNet
cable is not rated for temperatures above 80 °C so be careful during installation
to avoid hot routing areas. Always use shielded cables for improved
communications in industrial environments.

Impedance: 120Ω 10% at 1MHz

DC resistance: < 7ohms per 1000 ft.
Cable capacitance: 12 pF/ft at 1kHz
Propagation delay 1.36 ns/ft (maximum)
Data Pair: 19 strands, 1.0 mm² corresponds to 18 AWG, individually tinned, 3 twists/foot
Power Pair: 19 strands, 1.5 mm² corresponds to 15 AWG, individually tinned, 3 twists/foot
Drain / Shield Wire: 19 strands Tinned Copper shielding braid or shielding braid and foil
Cable type: twisted pair cable. 2x2 lines
Bend Radius: 20x diameter during installation or 7x diameter fixed position
Signal attenuation: 0.13 dB/100 ft @ 125 kHz (maximum)
0.25 dB/100 ft @ 500 kHz (maximum)
0.40 dB/100 ft @ 1000 kHz (maximum)

Recommended Bulk Cable

Cable manufacturer Turck and Belden are widely available in North America.
Turck, Lumberg, and Lapp Cable products are available in Europe. All cables
below are suitable for DeviceNet trunk and drop cabling. Be aware that cable
vendors may not use the same wire colors on individual conductors.

*Note: Turck and Lumberg can also provide custom length cordsets with connectors.
Manufacturer part number Website
Belden 3082A DeviceNet Thick Cable–Grey www.belden.com
Belden 3083A DeviceNet Thick Cable–Yellow www.belden.com
Lapp Cable 2710-250 Unitronic DeviceNet Thick www.lappcable.com
Lumberg STL 613 www.lumbergusa.com
Turck Type 575, DeviceNet Thick Cable – Grey www.turck.com

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Atlas-II Digital Control Manual 26415

Hardware Specifications
Digital Speed Sensor Inputs
Number of channels 2, selectable as MPU or proximity probe, by terminal block wiring
and correct software switches
Input frequency 100–25 000 Hz (MPU), 0.5-25 000 Hz (Prox)
(25 kHz is the max reading available using the TSS_ATL GAP
block)
Input frequency (max) 25 000 Hz
Resolution Dependent on frequency, 16 bit minimum at maximum speed
Accuracy Less than ±0.08% full scale from –40 to +85 °C internal temperature
Shielded cable is required when connecting to the Digital Speed Sensor Inputs.

MPU Inputs
Input magnitude (min) See Figure 4-6
Input magnitude (max) See Figure 4-7
Input impedance (typ) See Figure 4-8
Input impedance (min) 1450 Ohm at 1 Vrms and 100 to 25 000 Hz input
Input impedance (min) 450 Ohm at 14.6 Vrms and 100 to 300 Hz input
Input impedance (min) 1450 Ohm at 14.6 Vrms and 301 to 25 000 Hz input
Isolation voltage 500 Vac minimum, each channel is isolated from all other channels
and from the Atlas-II platform

When choosing to wire either a MPU or proximity speed input, make

sure the unused MPU/PROX(+) terminal block input is shorted to
MPU/PROX (–).

MPU Minimum Input Magnitude

4
Minimum Input Magnitude (Vrms)

3.5

2.5

1.5

0.5

0
10 100 1000 10000 100000

Frequency (Hz)

Figure 4-6. MPU Minimum Input Magnitude in Vrms

To convert to V peak to peak, multiply by 2.828.

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Manual 26415 Atlas-II Digital Control

MPU Maximum Input Magnitude

21.0
20.6

Maximum Input Magnitude (Vrms)

20.0

19.0
18.3
18.0

17.0
16.8
16.0 15.9
14.9
15.0 14.6

14.0
10 100 1000 10000 100000

Frequency (Hz)

Figure 4-7. MPU Maximum Input Magnitude in Vrms

To convert to V peak to peak, multiply by 2.828.

MPU Input Impedance Magnitude and Phase

Typ Impedance Magnitude at 14.6 Vrms Input Typ Impedance Magnitude at 14.6 Vrms Input
Typ Impedance Magnitude at 1 Vrms Input Typ Impedance Phase at 14.6 Vrms Input
Typ Impedance Phase at 14.6 Vrms Input Typ Impedance Phase at 1 Vrms Input
10000 90
80
70
60
3066 50
2427 40
40 2001
28 30
1718
1503 1498 1553
1470 26 25 20
Impedance (Ohms)

23

Phase (Deg)
1216 17 10
10
1000 9 0
1 1
600 -10
-20
-30
-40
-50
-60
-70
-80
100 -90
10 100 1000 10000 100000
Frequency (Hz)

Figure 4-8. MPU Typical Input Impedance Magnitude and Phase

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 Atlas-II Digital Control Manual 26415

Proximity Probe Inputs

Voltage threshold /duty cycle at 5 kHz at 16 Vin, duty cycle = 3.5–96.5%
at 24 Vin, duty cycle = 3.5–96.5%
at 28 Vin, duty cycle = 3.5–96.5%
Voltage threshold /duty cycle at 25 kHz at 16 Vin, duty cycle = 17.5-82.5%
at 24 Vin, duty cycle = 17.5-82.5%
at 28 Vin, duty cycle = 17.5-82.5%
Input threshold (V low) < 8 Vdc
Input threshold (V high) > 16 Vdc
Input voltage (V high range) 16–28 Vdc
Minimum Input Resistance (Ohm) @ 8V 37730
Minimum Input Resistance (Ohm) @ 16V 7160
Minimum Input Resistance (Ohm) @ 28V 4190
Available power none
Isolation 500 Vac minimum, each channel is isolated from
all other channels and from the Atlas-II platform
Input frequency 0.5–25 000 Hz

 A derivative output is provided to the application software. Generally, the

derivative error increases with frequency input. The typical six-sigma
performance with input frequencies < 5000 Hz is better than 8 Hz/s. The
typical six-sigma performance with input frequencies > 5000 Hz is better
than 24 Hz/s. Note: Field wiring may introduce additional signal error due to
cable length, cable routing, and other sources.
 No proximity probe power is provided.

When choosing to wire either a MPU or proximity speed input, make

sure the unused MPU/PROX(+) terminal block input is shorted to
MPU/PROX (–).

Analog Inputs
Number of channels 6
Input type 4–20 mA , (full scale = 24 mA)
Max. input current > 23 mA
Max. input voltage 24V @ 25 C
Common mode rejection 80 dB minimum
Input common mode range ±40 V minimum
Safe input common mode volt ±40 V minimum
Input impedance 211 Ω (±1.3%)
Anti-aliasing filter (ch1-4) 2 poles at 10 ms
Anti-aliasing filter (ch5-6) 2 poles at 5 ms
Resolution Greater than 16 bits
Accuracy @ 25 °C less than ±0.1% of full scale
Temp Drift 171 ppm/°C, maximum (1.1% of full scale, 0.275 mA)
30 ppm/°C, typical (0.20% of full scale, 0.05 mA)
I/O Latency 1 ms
Shielded cable is required when connecting to the Analog Inputs.

 Loop power for the analog inputs is NOT available.

 Only 4–20 mA inputs are supported. This is a change from the previous
SmartCore module that allowed both current and voltage inputs.

oExternal loop powered transducers must be individually protected

with a 100 mA fuse on each channel.

40 Woodward
Manual 26415 Atlas-II Digital Control

Analog Outputs
Number of channels 4
Output type 4–20 mA outputs, non-isolated, (full scale = 25mA)
Common Mode Voltage 15 Vdc ±10%
Max current output 25 mA ±5%
Min. load resistance 0Ω
Max load resistance 300 Ω at 22 mA
Resolution 15 bits of full scale
Accuracy @ 25 °C less than ±0.1% of full scale
Readback Accuracy @ 25 °C ±1% of full scale
Temperature Drift 140 PPM/°C, maximum (±0.23 mA)
70 ppm/°C, typical (±0.45% of full scale, 0.1125 mA)
Shielded cable is required when connecting to the Analog Outputs.

Actuator Outputs
Number of channels 2
Actuator Type Proportional, non-isolated,
Output Type 4-20 or 20-200 mA, software selectable
(full scale = 31 mA or 233 mA)
Isolation None
Max current output 27 mA +10% (4-20 mA range)
218 mA +10% (20-200 mA range)
Min. load resistance 10 Ω
Max load resistance 300 Ω at 22 mA (4-20 mA range)
40 Ω at 200 mA (20-200 mA range)
Resolution 15 bits of full scale
Accuracy @ 25 °C less than ±0.1% of full scale
0.029 mA (4-20 mA range)
0.220 mA (20-200 mA range)
Readback Accuracy @ 25 °C 1.0 % of full scale
Temperature Drift 140 PPM/°C maximum
0.26 mA maximum (4-20 mA range)
2.00 mA maximum (20-200 mA range)
70 ppm/°C typical 0.45% of full scale,
0.13 mA (4-20 mA range)
1.00 mA (20-200 mA range)
Readbacks Actuator source and return currents
Dither Current 25 Hz, fixed duty cycle, software variable amplitude
Shielded cable is required when connecting to the Actuator Outputs.

Discrete Inputs
Number of channels 24
Input type Optically isolated discrete input
Input thresholds < 8 Vdc = “OFF”
> 16 Vdc = “ON”
Input current 3 mA @ 24 Vdc
Contact voltage 24 Vdc isolated output (100 mA max, internally protected)
Max input voltage 28 Vdc
Isolation voltage 500 Vac, all channels are isolated from the Atlas-II platform
Shielded cable is only required when connecting to the Discrete Inputs and it is a
Marine Type Approval installation.

 For EMC compliance, the on-board, isolated, +24 Vdc supply is

recommended for use as power to contacts, 100 mA maximum.
 All channels are common to each other. Isolation is with respect to the
Atlas-II platform and other I/O types.

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Atlas-II Digital Control Manual 26415

Serial I/O
Number of channels 3 isolated ports, 115.2K max
Channel configuration 1 - RS-232 Debug Port (PS2 style, mini-DIN6F connector)
2 - RS-232/RS-485/RS-422 software configurable, terminal block
connections
Termination Resistor Located on the board and are accessible via field wiring. Termination
resistors are provided for RS-485 and RS-422 Receive.
Isolation Voltage 500 Vdc
Shielded cable is required when connecting to the Serial I/O.

SmartCore CPU A5200 Board Operation

This board includes no potentiometers and requires no field calibration.

Speed Sensor Inputs

The MPU and proximity probe inputs are read and the speed is provided to the
application program. A derivative output is also provided. The speed sensor
inputs are filtered by the SmartCore CPU A5200 board with the filter time
constant being selectable in GAP software between 5 and 160 ms. Eight
milliseconds should be acceptable for most turbine applications, while 16
milliseconds may be necessary for very slow speed applications. The speed
range is selected in the application software and determines the maximum speed
that the board will detect. The control output of the software will detect a
minimum speed of one fiftieth of the speed range. This allows detection of failed
speed sensors to help prevent overspeed due to slow update times at very low
speeds. The monitor output of the GAP block will read down to 0.5 Hz,
regardless of the speed range. An application may use any combination of
accepted MPU and proximity probes, and any combination of speed ranges.

The SmartCore CPU A5200 board uses speed sensing probes mounted on a
gear connected or coupled to the turbine’s rotor to sense turbine rotor speed.
Either of the A5200 board’s speed channels accept passive magnetic pickup
units (MPUs) or proximity probes.

It is not recommended that gears mounted on an auxiliary shaft coupled to the

rotor be used to sense speed. Auxiliary shafts tend to turn more slowly than the
rotor (reducing speed sensing resolution) and have coupling gear backlash,
resulting in less than optimum speed control. For safety purposes, it is also not
recommended that the speed sensing device sense speed from a gear coupled
to a generator or mechanical drive side of a system’s rotor coupling.

42 Woodward
Manual 26415 Atlas-II Digital Control

Atlas

MPU+
+ Passive
55
MPU
Jumpered
PROX+
56

-
57

GND
(isol)
58

Figure 4-9. Wiring Example–MPU Interface to the SmartCore Board

A proximity probe may be used to sense very low speeds. With a proximity
probe, speed can be sensed down to 0.5 Hz. When interfacing to open collector
type proximity probes, a pull-up resistor is required between the supplied
proximity probe voltage and the proximity probe input to the SmartCore CPU
A5200 board.

Atlas Atlas
Active
+V Pickup
Jumper Jumper
55 55 Active
+V Pickup

56 56

57 57

58 58

PNP Type NPN Type

Figure 4-10. Wiring Example–Open Collector Proximity Probe to the SmartCore

CPU A5200 Board

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Atlas-II Digital Control Manual 26415
Configuration Notes
 Refer to Figures 4-9 and 4-10 for speed sensor wiring.
 Each speed input channel can only accept one MPU or one proximity probe.
 Proximity probe power is not provided.
 Proximity probes only—External pull-up resistors are required when
interfacing to open collector type proximity probes.
 If the proximity probe inputs are used, the corresponding MPU inputs must
be jumpered as shown.

Speed Sensor Input Software Configuration Limitations

 (TxMxR)/60 must be < 25 000 Hz
T = gear teeth
M = (overspeed test limit setting x 1.2)
R = gear ratio

Analog Inputs
The analog inputs accepts a 4-20 mA current signal and may be used with two-
wire ungrounded (loop powered) transducers or isolated (self-powered)
transducers. All Analog inputs have greater than 40 Vdc of common mode
rejection. If interfacing to a non-isolated device, which may have the potential of
reaching over 40 Vdc with respect to the control’s common, the use of a loop
isolator is recommended to break any return current paths, which could produce
erroneous readings.

For a 4–20 mA input signal, the SmartCore CPU A5200 board uses a 211 Ω
resistor across the input.

Atlas

+ 4-20 mA
+ 38
Transducer Self
Powered

-
37

39

Figure 4-11a. Wiring Example–4–20 mA Input Interface to the SmartCore CPU

A5200 Board

44 Woodward
Manual 26415 Atlas-II Digital Control

(+) Loop Power

Atlas
100 mA Fuse
+ 4-20 mA
38 Transducer Loop
Powered

37 (-) Loop Power

39

Figure 4-11b. Wiring Example–4–20 mA Input Interface using External Loop

Power

Configuration Notes
 Refer to Figures 4-11a,b for analog input wiring.
 All 4-20 mA inputs have an input impedance of 211 Ω.
 Loop power is NOT provided by the Atlas control, it must be sourced
externally.

External loop powered transducers must be individually protected

with a 100 mA fuse on each channel.

Analog Outputs
The analog outputs are 4–20 mA with a full scale range of 0–25 mA. The
SmartCore CPU A5200 board has four analog outputs.

Atlas

+15 Vdc

69 +
A

4-20 mA
70

71

Figure 4-12. Wiring Example–Analog Output Interface to the SmartCore CPU

A5200 Board

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Atlas-II Digital Control Manual 26415
Configuration Notes
 Refer to Figure 4-12 for analog output wiring.
 Only 4–20 mA signals are output.
 See the specifications section for the maximum analog output load.
 Care should be taken to prevent ground loops and other faults when
interfacing to non-isolated devices.
 Each output provides readback capability that can be used to detect field
wiring or device faults as needed.
 The analog outputs have a 15 V common mode voltage, with respect to
Atlas-II control common.

Avoid misconnection of the Analog Output (+) to the Actuator Output

(–). This will damage internal components, making the control
inoperable.

Signal Isolators should be used when connecting to non-isolated

field devices greater than 30 meters away.
Beware of Analog and Actuator output connections to non-isolated
field devices that are located greater than 30 meters away from the
Atlas-II Control. Ground potentials between different locations can be
severe enough under certain EMC/Surge events to cause control
malfunction.

Actuator Outputs
The (2) proportional actuator driver outputs are software configurable as either 4-
20 mA or 20-200 mA with a full scale range of 0–31 mA or 0-233 mA. Each driver
output provides both current source and return readbacks that can assist in
troubleshooting and detection of field wiring or device failures.
Atlas

+15 V
Source
Current
Readback

63 + Proportional
Actuator
Return
Current 64
Readback

65

Figure 4-13. Wiring Example–Actuator Output Interface to the SmartCore CPU

A5200 Board

Configuration Notes
 Refer to Figure 4-13 for actuator output wiring.
 4–20 mA or 20-200 mA signals are output.
 See the specifications section for the maximum actuator output load.

46 Woodward
Manual 26415 Atlas-II Digital Control
 Care should be taken to prevent ground loops and other faults when
interfacing to non-isolated devices.
 Application software selects the actuator type, the output range, and the
dither amount.
 Each output provides readback capability that can be used to detect field
wiring or device faults as needed.

Avoid misconnection of the Analog Output (+) to the Actuator Output

(–). This will damage internal components, making the control
inoperable.

Signal Isolators should be used when connecting to non-isolated

field devices greater than 30 meters away.
Beware of Analog and Actuator output connections to non-isolated
field devices that are located greater than 30 meters away from the
Atlas-II Control. Ground potentials between different locations can be
severe enough under certain EMC/Surge events to cause control
malfunction.

Discrete Inputs
The SmartCore CPU A5200 board accepts 24 discrete inputs. Contact wetting
voltage may be supplied by the SmartCore CPU A5200 card. Optionally, an
external 18–28 Vdc power source can be used to source the circuit wetting voltage.

Atlas

1
Dry
Contact

+24V 25
(isol)
GND
(isol)
26

Figure 4-14. Wiring Example–Discrete Input Interface to the SmartCore CPU

A5200 Board

Configuration Notes
 Refer to Figure 4-14 for discrete input wiring.
 The discrete input commons are tied together, so each SmartCore CPU
A5200 board accepts only one voltage source, which can be internally or
externally supplied.
 All contact inputs accept dry contacts.
 If an external power supply is used, it must be rated to 28 Vdc max from
Class 2 type source for North America (SELV type source for applications
outside North America). Power supply outputs must be fused with
appropriately sized fuses (a maximum, current rating of 100  V, where V is
the supply’s rated voltage, or 5 A, whichever is less).
 The 24 V isolated contact power is protected by a 0.3 A poly switch that is
rated for 0.1A continuous use. This may not prevent interruption in control
operation due to a short in the field wiring, but should protect the control from
damage. The poly switch will reset itself when the short condition is resolved.
Woodward 47
Atlas-II Digital Control Manual 26415
 If unused (floated) Discrete Inputs have an extended cable length attached
for future use, they must be ignored in software. Events such as large
transient pulses near the unused cable can cause them to momentarily
toggle.
 Marine Type Approval installations require Discrete Input cabling inside the
cabinet to be shielded if it leaves the cabinet.

Serial I/O
The SmartCore CPU A5200 accepts (2) user serial I/O connections. Both isolated
ports are configurable for RS-232, RS-422, or RS-485. RS-232 is specified to 50
feet (15 m) while RS-485 and RS-422 are specified to 4000 feet (1219 m).

Serial #1 - RS-232

Atlas
90

Isolated
+5V

RS 232C Isolated
Transceiver Ground
83

RXB COM
82 TXB
RXB
TXB
81 Twisted RS 232
Pair Device

Figure 4-15. Serial #1–RS-232 Pinouts

Serial #1 - RS-422

Atlas
90

RS 422
Transceiver 89
422R
422T +
+ 88 Twisted
+
Pairs
422R 87
+ 422T
+
243 RS 422
86 Device
SIG GND
140
Isolated
+5V 85 Jumpers to
243 use optional
termination
84 resistor
+

83

Isolated 82
Ground

81

Figure 4-16. Serial #1–RS-422 Pinouts

48 Woodward
Manual 26415 Atlas-II Digital Control
Serial #1 - RS-485

Atlas
90

RS 485
Transceiver 89

- 88 Twisted
Pair
+ 87 -

+
243 RS 485
86 Device
SIG GND
140
Isolated
+5V 85
Jumpers to
243
use optional
termination
84
resistor
+

83

82
Isolated
Ground
81

Figure 4-17. Serial #1–RS-485 Pinouts

Serial #2 - RS-232

Atlas
100

Isolated
+5V

RS 232C Isolated
Transceiver Ground
93

RXB COM
92 TXB
RXB
TXB
91 Twisted RS 232
Pair Device

Figure 4-18. Serial #2–RS-232 Pinouts

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Atlas-II Digital Control Manual 26415
Serial #2 - RS-422

Atlas
100

RS 422
Transceiver 99
422R
422T +
+ 98 Twisted
+
Pairs
422R 97
+ 422T
+
243 RS 422
96 Device
SIG GND
140
Isolated
+5V 95 Jumpers to
243 use optional
termination
94 resistor
+

93

Isolated 92
Ground

91

Figure 4-19. Serial #2–RS-422 Pinouts

Serial #2 - RS-485

Atlas
100

RS 485
Transceiver 99

- 98 Twisted
Pair
+ 97 -

+
243 RS 485
96 Device
SIG GND
140
Isolated
+5V 95 Jumpers to
243 use optional
termination
94 resistor
+

93

92
Isolated
Ground

91

Figure 4-20. Serial #2–RS-485 Pinouts

50 Woodward
Manual 26415 Atlas-II Digital Control

Figure 4-21. Wiring Example–RS-232 Interface to the SmartCore CPU A5200

Board

ATLAS RS422 Device

(Isolated) 4000 feet max (1200m)

422T 422R TERM 422T 422R TERM

+ + + + + +

VIS-161
**Shield to be hard grounded at 1 end only and optionally AC coupled at other devices. 31JAN08

Figure 4-22. Wiring Example–RS-422 Interface to the SmartCore CPU A5200

Board

ATLAS RS485 Device RS485 Device

(Isolated)

RS485 TERM RS485 TERM RS485 TERM

+ - + - + - + - + - + -

VIS-162
**Shield to be hard grounded at 1 end only and optionally AC coupled at other devices. 31JAN08

Figure 4-23. Wiring Example–RS-485 Interface to the SmartCore CPU A5200

Board

Figure 4-24. Wiring Example–Alternate Multipoint Wiring

(without a separate signal ground wire for the SmartCore CPU A5200 board)

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Atlas-II Digital Control Manual 26415
Configuration Notes
 RS-232. Refer to Figure 4-21 for RS-232 wiring. The transmit data (TXD),
receive data (RXD), and signal ground (SIG GND) must be properly
connected as shown. In addition the shield (SHLD) should be connected in
at least one location.
 RS-422. Refer to Figure 4-22 for RS-422 wiring. The transmit data pairs
(422T+ and 422T-), receive data pairs (422R+ and 422R-), and signal
ground (SIG GND) must be properly connected as shown. In addition, the
shield (SHLD) should be connected in at least one location. Only the
receiver at each end of the network should be terminated with a resistor.
 RS-485. Refer to Figure 4-23 for RS-485 wiring. The data lines (485+ and
485–) and signal ground (SIG GND) must be properly connected as shown.
In addition, the shield (SHLD) should be connected in at least one location.
The unit at each end of the network should be terminated with a resistor.
 Termination Resistors. The Atlas-II has termination resistors (TERM RES)
built into the SmartCore CPU A5200 board that can be jumpered-in as
required for RS422 and RS485 communication networks.
 The serial ports must be properly configured in the application software for
the appropriate communication parameters.

Reference Grounds
 The serial ports are individually isolated from each other, and from the rest
of the Atlas-II control. The RS-422 and RS-485 specifications state that a
ground wire is needed if there is no other ground path between units. The
preferred method for isolated ports is to include a separate wire in the
ground cable that connects the circuit grounds together.
 Non-isolated nodes may not have a signal ground available. If signal ground
is not available, use the alternate wiring scheme of connecting all circuit
grounds of isolated nodes to the shield, and connecting the shield to earth
ground at a non-isolated node.

Troubleshooting and Tuning

The SmartCore CPU A5200 module runs off-line and on-line diagnostics that
display troubleshooting messages through the debug Service Port and
AppManager. Off-line diagnostics run automatically on power-up and upon reset.
On-line diagnostics run during normal Control System operation when the GAP
application is active. More information on diagnostics tests, subsequent LED
flash codes, and serial port messages is contained in the VxWorks manual.

Fault Detection (Board Hardware)

Each SmartCore CPU A5200 board has a red fault LED that is turned on when
the system is reset. During initialization of a board, which occurs after every CPU
reset, the CPU turns the Fault LED on. The CPU then tests the board using
diagnostic routines built into the software. If the diagnostic test is not passed, the
LED remains on or blinks. If the test is successful, the LED goes off. If the fault
LED on a board is illuminated after the diagnostics and initialization have been
completed, the SmartCore CPU A5200 board may be faulty.

52 Woodward
Manual 26415 Atlas-II Digital Control
A table of the CPU fault LED flash codes is shown below:

Failure Flash Code

RAM Test Failure 1, 4
Real Time Clock Test Failure 2, 2
Floating Point Unit Test Failure 2, 3
Flash Test Failure 2, 4
HD1 Flash Test Failure 2, 5
I2C Bus Test Failure 2, 6
Module Installed in wrong slot 2, 7
Main Chassis CPU switch must be set to 0 3,5
Remote RTN Rate Group 5 Slip 3, 7
Remote RTN Rate Group 10 Slip 3, 8
Remote RTN Rate Group 20 Slip 3, 9
Remote RTN Rate Group 40 Slip 3, 10
Remote RTN Rate Group 80 Slip 3, 11
Remote RTN Rate Group 160 Slip 3, 12

Table 4-2. SmartCore CPU A5200 Failure Codes

Fault Detection (I/O)

In addition to detecting board hardware faults, the application program may
detect I/O faults.
 Analog Input Faults—The application software may set a high and low latch
set point to detect input faults.
 Speed Sensor Input Faults—The application software may set a high and
low latch set point to detect input faults.
 Serial Port Faults—The system monitors the serial communications on the
serial ports for various communication errors.
 Microcontroller Faults—The system monitors a software watchdog, a
hardware watchdog, and a software watchdog on the PC/104 bus
communications. All outputs are shutdown in the event of a microcontroller
fault.

Troubleshooting Guide
Speed Sensor Inputs
MPUs—If a magnetic pickup input is not functioning properly, verify the following:
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Measure the input voltage on the terminal block. It should be greater than 1
Vrms.
 Verify that the signal waveform is clean and void of double zero crossings.
 Verify that no signal return to ground connections exist and that the 60 Hz
signal resulting from ground loops is absent.
 Measure the frequency. Frequency should be in the range of 100 Hz to 25
kHz.
 Check the wiring. Look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
 Check the software configuration to ensure that the input is configured
properly.

After verifying all of the above, the Atlas-II should be returned for service.

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Proximity Probes—If a proximity probe input is not functioning properly, verify
the following:
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Measure the input voltage on the terminal block. It should be in the range of
16–28 V peak, and the duty cycle should be within the specified range for
the input voltage.
 Verify that the signal waveform is clean and void of double zero crossings.
 Verify that no signal return to ground connections exist and that the 60 Hz
signal resulting from ground loops is absent.
 Measure the frequency. Frequency should be in the range of 0.5 Hz to 3
kHz.
 Check the wiring. Look for a loose connection at the terminal blocks and
disconnected or misconnected cables. If an open collector probe is used,
check to ensure that the pull-up resistor is installed properly.
 Check the software configuration to ensure that the input is configured
properly.
 Verify that the corresponding MPU input is jumpered.

After verifying all of the above, the Atlas-II should be returned for service.

Analog Inputs
If an Analog input is not functioning properly, verify the following:
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Measure the input voltage on the terminal block. It should be in the range of
0–5 V.
 Verify that there are no or minimal AC components to the analog input
signal. AC components can be caused by improper shielding or grounding.
 Check the wiring. If the inputs are reading 0 or the engineering units that
correspond to 0 mA, look for a loose connection at the terminal blocks and
disconnected or misconnected cables. If the unit is a 4–20 mA input, check
for proper jumper installation on the terminal block.
 If all of the inputs are reading high, check that the power is not connected
across the input directly.
 Check the software configuration to ensure that the input is configured
properly.
 If the input is loop powered, ensure that power is provided externally, the
Atlas control does not provide this power.

After verifying all of the above, the Atlas-II should be returned for service.

Analog Outputs
If an Analog output is not functioning properly, verify the following:
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Check the load resistance, ensure that it is less than the specification limit
for the output current.
 Check to ensure that the load wiring is isolated.
 Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
 Disconnect the field wiring and connect a resistor across the output. If the
output is correct across the resistor, there is a problem with the field wiring.

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Manual 26415 Atlas-II Digital Control
 Check the software configuration to ensure that the output is configured
properly.

After verifying all of the above, the Atlas-II should be returned for service.

Proportional Actuator Outputs

If an Actuator output is not functioning properly, verify the following:
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Check the load resistance, ensure that it is less than the specification limit
for the output current.
 Check to ensure that the load wiring is isolated.
 Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
 Disconnect the field wiring and connect a resistor across the output. If the
output is correct across the resistor, there is a problem with the field wiring.
 Check the software configuration to ensure that the output is configured
properly.

After verifying all of the above, the Atlas-II should be returned for service.

Discrete Inputs
If a discrete input is not functioning properly, verify the following:
 Measure the input voltage on the terminal block. It should be in the range of
18–28 Vdc.
 If an external wetting voltage source is used, check the voltage source is
referenced to the A5200 wetting voltage’s common.
 Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
 Check the software configuration to ensure that the input is configured
properly.

After verifying all of the above, the Atlas-II should be returned for service.

Serial I/O
If a serial port is not functioning properly, verify the following:
 Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
 Check to be sure that termination resistors are properly installed where
needed on the network.
 Check the software configuration to ensure that the input is configured
properly.
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.

After verifying all of the above, the Atlas-II should be returned for service.

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Chapter 5.
Analog Combo Board

General Description
Each Analog Combo board contains circuitry for two speed sensor inputs, fifteen
analog inputs, one cold junction, and two Analog outputs. The first eleven analog
inputs may be 4–20 mA inputs or thermocouple inputs, and the remaining four
analog inputs may be 4–20 mA inputs or RTD inputs.

Features

 5 ms update rate
 On-board processor for automatic calibration of the I/O channels
 Analog inputs have 15 bit resolution
 Analog outputs have 12 bit resolution
 First 11 analog inputs are software configurable 4–20 mA or thermocouple
(in pairs)
 Last 4 analog inputs are software configurable 4–20 mA or RTD
(individually)
 First 11 analog inputs are isolated as a group, from the other inputs, and
from control common
 Last 4 analog inputs are isolated as a group, from the other inputs, and from
control common
 A cold junction measurement is provided on the board

855-740
02-2-22

Figure 5-1. Atlas-II Analog Combo Board Connections

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Physical
The Atlas-II Analog Combo board connects to the CPU board through the
PC/104 bus. It does not connect to the Atlas-II power bus directly, it requires a
SmartCore CPU A5200 board for this purpose.

Dualport
PC/104 Interface PC/104 Interface
RAM
Signals and Decode Logic Memory

Board Address
Dip Switches BDM
Port
Speed
Speed Sensor Sensing
Inputs (2) Circuitry 32.768 kHz
MC68332 Crystal
Microcontroller
Isolated Watchdog
Optocouplers & LED

Flash memory
256 Kbyte
Two16-bit
Thermocouple or 4- Mux & 4-channel Isolation
20mA Inputs (15) Input cfg. Serial A/D Circuits EEPROM
converters non-
volatile
memory

One16-bit
RTD or 4-20mA 8-channel Isolation Analog Out 4-20mA Analog
Input cfg. Serial A/D Circuits
Inputs (4) circuitry Outputs (2)
Converter
VIS-003
00-01-18 KDW

Figure 5-2. Atlas-II Analog Combo Board Block Diagram

Specifications
Thermocouple/4–20 mA Analog Inputs
Number of channels 11
Input type 4–20 mA, type J or type K, thermocouple
(required)
Max. input current 24 mA if configured for 4–20 mA
Max. input voltage ±72.8 mV for thermocouples inputs
Thermocouple Range Type E:–9.83 mV (–267.68 °C/–449.82 °F) to
72.8 mV (952.60 °C/1746.68 °F)
Type J:–8.09 mV (–209.72 °C/–345.50 °F) to
69.55 mV (1199.94 °C/2191.89 °F)
Type K:–6.45 mV (–263.95 °C/–443.11 °F) to
54.88 mV (1371.81 °C/2501.26 °F)
Type N:–4.34 mV (–263.14 °C/–441.65 °F) to
47.51 mV (1299.92 °C/2371.86 °F)
Type R:–0.22 mV (–48.27 °C/–54.89 °F) to
21.10 mV (1767.88 °C/3214.18 °F)
Type S:–0.23 mV (–48.60 °C/–55.48 °F) to
18.69 mV (1767.76 °C/3213.97 °F)
Type T:–6.25 mV (–265.71 °C/–446.28 °F) to
20.87 mV (399.97 °C/751.95 °F)
Common mode rejection –80 dB minimum for analog inputs
–96 dB typical for analog inputs
–110 dB minimum for thermocouple inputs
–120 dB typical for thermocouple inputs
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Input common mode range ±11 V minimum
Safe input common mode volt ±40 V minimum
Input impedance 103 Ω (±1%) for 4–20 mA inputs
Anti-aliasing filter 2 poles at 10 ms (channel 11 has 2 poles at 5
ms)
Resolution 15 bits
Accuracy
Thermocouple Input Accuracy @ 25C (%)
Range
T/C type
< 25 °C > 25 °C < 300 °C > 300 °C
Typ Max Typ Max Typ Max Typ Max
E or K 0.15 0.45 0.075 0.25
J 0.10 0.30 0.05 0.20
N 0.15 0.60 0.10 0.30
R or S 0.15 0.50 0.10 0.30
T 0.50 1.50 0.15 0.60

Terminal block wiring must use multi-stranded wires to provide best results.
Due to the clamping action of the spring-loaded terminal blocks, lower level
signals (like TC and RTD inputs) are susceptible to glitches when using
single “solid-core” wiring.

The Atlas may experience degraded performance of the thermocouple (TC)

inputs of the Analog Combo cards from ~900 MHz to 1.1 GHz at field
strengths greater than 10 V/m. Fields of 10–20 V/m degrade the steady-state
performance from a 0.25% tolerance to a 1.2% tolerance. Installation of the
Atlas in a metal cabinet will minimize this degradation.

4–20 mA Input Accuracy @ 25C (%)

Input type Typ Max
4–20 mA 0.05 0.10

The Atlas may experience degraded performance of these 4–20 mA inputs of

the Analog Combo cards from 410 MHz to 450 MHz at field strengths greater
than 10 V/m. Fields of 10–20 V/m degrade the steady-state performance from
a 0.1% tolerance to a 0.36% tolerance. Installation of the Atlas in a metal
cabinet will minimize this degradation.

Temperature Drift
Max % Error
Max Drift Max Drift over 25 °C Delta
Input Type Full Scale Degree C/C µa/°C) (% of full scale)
E 999.4 °C 0.22472989 0.56
J 1200 °C 0.29615393 0.62
K 1370 °C 0.43528413 0.79
N 1300 °C 0.46956505 0.90
R 1760 °C 1.43793547 2.04
S 1756 °C 1.62240259 2.31
T 399 °C 0.32912099 2.06
4–20 mA 25 mA 4 µA 0.40

For thermocouple inputs, the Max % Error example is calculated for a

25 °C delta using the full scale for the corresponding thermocouple
type. For the 4–20 mA inputs, the Max % Error example is calculated
for a 25 °C delta using the 25 mA full scale.

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Manual 26415 Atlas-II Digital Control
CJ update time 5 ms
Latency 1 ms for odd channels and 3 ms for even
numbered channels
Failure detection Open wire detection provided for thermocouples
Isolation All input channels are isolated from the rest of
the Atlas-II platform to 500 Vac, however they
are not isolated from each other. The inputs are
differential, with a high impedance between
channels.
CJ accuracy ±3 °C worst case at 25 °C, (±1 °C typical at 25
°C) uncalibrated
±1 °C worst case at 25 °C, (±0.5 °C typical at 25
°C) calibrated
±4 °C over the full temperature range (–40 to
+85 °C) uncalibrated
±2 °C over the full temperature range (–40 to
+85 °C) calibrated
 Loop power for the analog inputs must be supplied by an external supply, if
needed.
 4–20 mA, or type J or K T/C is selected in the GAP block software, for each
input. GAP configuration sets input gain via software.
 Maximum wire size, one 16 AWG (1.5 mm²), or two 20 AWG (0.5 mm²)
wires. Wires must be shielded.
 Channels 1–10 must be configured in pairs, that is, channels 1 and 2, 3 and
4, etc., must both be configured as 4–20 mA inputs or must both be
configured as thermocouple inputs.
 Any “unused” channel of a pair, Channels 1–10, must have its input shorted
to prevent measurement errors on the “in-use” channel of the pair.

External loop powered transducers must be individually protected

with a 100 mA fuse on each channel.

RTD/4–20 mA Analog Inputs

Number of channels 4
Input type 100 or 200 Ω 3-wire
Max. input current 24 mA, if configured for 4–20 mA
Max. input resistance 781 Ω, if configured for RTD
RTD range European Curve (Type 385):
100 Ω RTD: 18.49 Ω (–200 °C/–328 °F) to
390.48 Ω (850 °C/1562 °F)
200 Ω RTD: 37.04 Ω (–200 °C/–328 °F) to
533.10 Ω (457 °C/854.6 °F)
American Curve (Type 392):
100 Ω RTD: 59.57 Ω (–100 °C/–148 °F) to
269.35 Ω (457 °C/854.6 °F)
200 Ω RTD: 119.14 Ω (–100 °C/–148 °F) to
538.70 Ω (457 °C/854.6 °F)
Common mode rejection –80 dB minimum for analog inputs
–96 dB typical for analog inputs
–96 dB minimum for RTD inputs
–115 dB typical for RTD inputs
Input common mode range ±11 V minimum
Safe input common mode volt ±40 V minimum
Input impedance 103 Ω (±1%) for 4–20 mA inputs
Anti-aliasing filter 2 poles at 10 ms
Resolution 15 bits

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Accuracy
RTD and 4–20 mA Input Accuracy @ 25 °C (%)
Input type Typ Max
100 Ω American and European, 200 Ω American 0.05 0.10
200 Ω European 0.10 0.20
4–20 mA 0.05 0.10

Temp Drift
Temperature Drift
Input Type Typ (ppm/°C) Typ error (%) Max (ppm/°C) Max error (%)
100 Ω European Curve 30 0.20 290 1.89
100 Ω American Curve 50 0.33 290 1.89
200 Ω European Curve 20 0.13 290 1.89
200 Ω American Curve 20 0.13 290 1.89
4–20 mA 105 0.68 160 1.04

Terminal block wiring must use multi-stranded wires to provide best

results. Due to the clamping action of the spring-loaded terminal
blocks, lower level signals (like TC and RTD inputs) are susceptible
to glitches when using single “solid-core” wiring.

For RTD inputs, percent error is for full scale for 65 degree delta (25
to –40 °C). For 4–20 mA inputs, percent error is for 25 mA full scale
input for 65 degree delta (25 to –40 °C).

Update time 5 ms
I/O Latency 1 ms
Isolation All input channels are isolated from the rest of
the Atlas-II platform to 500 Vdc, however inputs
are not isolated from each other.
 Loop power for the Analog inputs must be supplied by an external supply if
needed.
 4–20 mA, or RTD is selected in the GAP block software, for each input.
GAP configuration sets input gain via software.
 Maximum wire size, one 16 AWG (1.5 mm²), or two 20 AWG (0.5 mm²)
wires. Wires must be shielded.

External loop powered transducers must be individually protected

with a 100 mA fuse on each channel.

Digital Speed Sensor Inputs

Number of channels 2, MPU only
MPU Inputs:
Input frequency 100—24 950 Hz
Minimum input amplitude See Figure 5-3.
Maximum input amplitude 70 V peak-to-peak
Input impedance >550 Ω
Isolation voltage 500 Vac, each channel is isolated from all other
channels, and from the Atlas-II platform
Resolution dependent on frequency, 13 bit minimum at
maximum speed
Accuracy less than ±0.08% of full scale from –40 to +85
°C internal temperature

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4.0

3.5

Minimum MPU Magnitude (Volts RMS)

3.0

2.5

2.0

1.5

1.0

0.5

0
100 10000 15000 20000 25000 30000

Frequency (Hz)

Figure 5-3. Minimum MPU Voltage

 A derivative output is provided. The inherent noise on this output, due to

resolution, increases with frequency. At 1000 Hz, it can be as much as 2.5
Hz/s. At 5000 Hz, it can be as much as 12.5 Hz/s. At 10 kHz, it can be as
much as 25 Hz/s. At 20 kHz, it can be as much as 80 Hz/s. Typically, at
3600 Hz, noise on the MPU signal due to wiring runs, will make the noise
contribution due to resolution, insignificant.
 Maximum wire size, one 16 AWG (1.5 mm²), or two 20 AWG (0.5 mm²)
wires. Wires must be shielded and the shield terminated to the shield pin
and cabinet entry/exit point.

Analog Outputs
Number of channels 2
Output type 4–20 mA outputs, non-isolated
Current output 4–20 mA
Max current output 25mA ±5%
Isolation 0 Vdc
Min. load resistance 0Ω
Max load resistance 300 Ω at 22 mA
Resolution 12 bits
Accuracy less than ±0.1% of full scale at 25 °C (after
software calibration)
Temperature drift 140 ppm/°C, maximum, =0.23 mA
70 ppm/°C, typical (0.45% of full scale),
=0.11375 mA
 0–1 mA OUTPUTS ARE NOT SUPPORTED, WITHOUT A GREATER THAN 4
BIT LOSS OF RESOLUTION. RESULTING RESOLUTION WOULD BE 7 BITS.
 Common mode voltage is 15 Vdc.
 Maximum wire size, one 16 AWG (1.5 mm²), or two 20 AWG (0.5 mm²)
wires. Wires must be shielded.
 When interfacing to non-isolated devices, an isolator should be used
between the Atlas-II and the device.

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Analog Combo Board Operation

This board includes no potentiometers and requires no field calibration.

Speed Sensor Inputs

The MPU inputs are read and the speed is provided to the application program. A
derivative output is also provided. The speed sensor inputs are filtered by the
Analog Combo board, and the filter time constant is selectable at 8 milliseconds
or 16 milliseconds. Eight milliseconds should be acceptable for most turbine
applications, sixteen milliseconds may be necessary for very slow speed
applications. The speed range is selected in the application software and
determines the maximum speed that the board will detect. The control output of
the software will detect a minimum speed of one fiftieth of the speed range. This
allows detection of failed speed sensors to help prevent overspeed due to slow
update times at very low speeds. The monitor output of the GAP block will read
down to .5 Hz, irrespective of the speed range. An application may use any
combination of accepted MPUs, and any combination of speed ranges.

The Analog Combo board uses speed sensing probes mounted on a gear
connected or coupled to the turbine’s rotor to sense turbine rotor speed. Any of
the board’s speed channels accept passive magnetic pickup units (MPUs) or
proximity probes. It is not recommended that gears mounted on an auxiliary shaft
coupled to the rotor be used to sense speed. Auxiliary shafts tend to turn more
slowly than the rotor (reducing speed sensing resolution) and have coupling gear
backlash, resulting in less than optimum speed control. For safety purposes, it is
also not recommended that the speed sensing device sense speed from a gear
coupled to a generator or mechanical drive side of a system’s rotor coupling.

Atlas

+ Passive
57
MPU

58

GND
(isol) 59

Figure 5-4. Wiring Example–MPU Interface to the Analog Combo Board

Configuration Notes
 Refer to Figure 5-4 for speed sensor wiring.

Speed Sensor Input Software Configuration Limitations

(TxMxR)/60 must be < 25 000 Hz
T = gear teeth
M = (overspeed test limit setting x 1.2)
R = gear ratio

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Analog Inputs
The Analog inputs may be current or temperature inputs. The first 11 inputs can
be thermocouple inputs, and the other 4 inputs can be RTD inputs. The software
must be configured for the correct input type. This allows the Analog Combo card
to use the applicable hardware calibration values, and to configure the
appropriate hardware gains. The first 10 inputs must be configured in pairs, that
is, channels 1 and 2 must both be thermocouples or must both be 4–20 mA
inputs. Channels 11–15 may be configured individually.

All 4–20 mA inputs may be used with two-wire ungrounded (loop powered)
transducers or isolated (self-powered) transducers. All Analog inputs have 11
Vdc of common mode rejection. If interfacing to a non-isolated device, which may
have the potential of reaching over 11 Vdc with respect to the control’s common,
the use of a loop isolator is recommended to break any return current paths,
which could produce erroneous readings.

RTD inputs must be configured to use either the European or American curve.
200 Ω RTDs are limited to the maximum temperature on the American curve,
even when the European curve is used. The RTD source current is 2 ma, and the
RTD sense input should be tied to the negative side of the RTD, at the RTD.

See the specifications section for supported thermocouple types. The cold
junction sensor is provided on the Atlas-II Analog Combo board. If the actual cold
junction in the field wiring occurs elsewhere, the temperature of that junction
must be brought into the control as a thermocouple, RTD, or 4–20 mA input, and
the application software must be configured to use the appropriate cold junction
temperature.

The first 11 analog inputs are isolated as a group from control common, earth
ground, and the other 4 analog inputs. The last 4 analog inputs are also isolated
as a group from control common, earth ground, and the first 11 analog inputs.
For a 4–20 mA input signal, the Analog Combo board uses a 100 Ω resistor
across the input.

Atlas

+ Thermocouple
1
Transducer or 4-20 mA
Analog - Transducer
Input #1
2

Figure 5-5a. Wiring Example–Analog Input Interface

(to the Analog Combo Board for 4–20 mA
and thermocouple inputs on inputs 1–11)

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(+) Loop Power
Atlas
100 mA Fuse
+ 4-20 mA
1 Transducer Loop
Powered
Analog
Input #1
2 (-) Loop Power

Figure 5-5b. Wiring Example–Analog Input Interface with External Loop Power

Atlas

+ 4-20 mA
35 Transducer Loop
- Powered

Analog
36
Input #12

37

38

Figure 5-6. Wiring Example–4–20 mA Input Interface

(to the Analog Combo Board for inputs 12–15)

Atlas

sense
Analog 35
Input #12

(-)
36 RTD

AC
Current (+)
Source 37

38

Figure 5-7. Wiring Example–RTD Input Interface

(to the Analog Combo Board for inputs 12–15)

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Configuration Notes
 Refer to Figures 5-5, 5-6, and 5-7 for analog input wiring.
 4–20 mA inputs are supported, 0–5 V inputs are not.
 The application software must be configured to match the input type used,
that is, 4–20 mA, 100 Ω RTD, k-type thermocouple, etc.

External loop powered transducers must be individually protected

with a 100 mA fuse on each channel.

RTDs

 Only 100 and 200 Ω RTDs are supported.

 RTD inputs can use the European or American curve. 200 Ω RTDs are
limited to the maximum temperature on the American curve, even when the
European curve is used.
 The RTD source current is 2 mA.
 The RTD sense input should be tied to the negative side of the RTD, at the
RTD.

Thermocouples

 See the specifications section for supported thermocouple types.

 The cold junction sensor is provided on the Atlas-II Analog Combo board. If
the actual cold junction in the field wiring occurs elsewhere, the temperature
of that junction must be brought into the control as a thermocouple, RTD, or
4–20 mA input, and the application software must be configured to use the
appropriate cold junction temperature.
 The thermocouple and cold junction input units (°C or °F) should be
consistent in the application software.

4–20 mA Inputs

 All 4–20 mA inputs have an impedance of 100 Ω.

 No loop power is provided.

External loop powered transducers must be individually protected

with a 100 mA fuse on each channel.

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Analog Outputs
The Analog outputs are 4–20 mA with a full scale range of 0–24 mA. The Analog
Combo board has four Analog outputs.

Atlas +V

51 + 4-20 mA
Output
On earlier versions of the
52 Analog Combo board, the cable
#1 shield termination went directly
to earth.
53

Figure 5-8. Wiring Example–Analog Output Interface

(to the Analog Combo Board)

Configuration Notes
 Refer to Figure 5-8 for analog output wiring.
 Only 4–20 mA signals are output.
 See the specifications section for the maximum analog output load.
 Care should be taken to prevent ground loops and other faults when
interfacing to non-isolated devices.
 The output does not contain fault detection. If it is necessary to detect
failures, then the device that is driven by the Analog output, for example an
actuator driver, must contain reference failure detection.
 The Analog outputs have a 15 V common mode voltage, with respect to
Atlas-II control common.
 +V is 15 V

Avoid misconnection of the Analog Output (+) to the Actuator Output

(–). This will damage internal components, making the control
inoperable. This applies only when a SmartCore CPU A5200 board is
installed in the control.

Fault Detection (Board Hardware)

Each Analog Combo board has a red fault LED that is turned on when the
system is reset. During initialization of a board, which occurs after every CPU
reset, the CPU turns the Fault LED on. The CPU then tests the board using
diagnostic routines built into the software. If the diagnostic test is not passed, the
LED remains on or blinks. If the test is successful, the LED goes off. If the fault
LED on a board is illuminated after the diagnostics and initialization have been
completed, the Analog Combo board may be faulty or may have the address DIP
switches configured incorrectly. The DIP switch setting must match the module
address set in the GAP application program.

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Number of LED Flashes Failure
1 Microprocessor failure
2 Bus, address, any unexpected exception error
5 Failure during EE test or erasing
7 Kernel software Watchdog count error
12 Failure during CPU Internal RAM test
13 Dual port RAM error

Table 5-1 Analog Combo Failure

Fault Detection (I/O)

In addition to detecting board hardware faults, the application program may
detect I/O faults.
 Analog Input Faults—The application software may set a high and low latch
set point to detect input faults. For thermocouple inputs, open wire detection
is provided.
 Speed Sensor Input Faults—The application software may set a high and
low latch set point to detect input faults.
 Microcontroller Faults—The system monitors a software watchdog, a
hardware watchdog, and a software watchdog on the PC/104 bus
communications. All outputs are shutdown in the event of a microcontroller
fault.

Troubleshooting Guide
Speed Sensor Inputs
If a magnetic pickup input is not functioning properly, verify the following:
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Measure the input voltage on the terminal block. It should be greater than
that shown in Figure 5-3.
 Verify that the signal waveform is clean and void of double zero crossings.
 Verify that no signal return to ground connections exist and that the 60 Hz
signal resulting from ground loops is absent.
 Measure the frequency. Frequency should be in the range of 100 Hz - 25
kHz.
 Check the wiring. Look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
 Check the software configuration to ensure that the input is configured
properly; check the hertz to rpm ratio, and the maximum speed.

After verifying all of the above, the Atlas-II should be returned for service.

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Analog Inputs
If an Analog input is not functioning properly, verify the following:
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Measure the input voltage on the terminal block. It should be in the range of
0–5 V for 4–20 mA inputs. RTD inputs have a 2 mA current source.
Thermocouple inputs should have the appropriate millivolt signal.
 Verify that there are no or minimal AC components to the Analog Input
signal. AC components can be caused by improper shielding or grounding.
Thermocouple inputs are extremely sensitive to signal fluctuations.
 Check the wiring. For a 4–20 mA input if the input is reading 0 or the
engineering units that correspond to 0 mA, look for a loose connection at the
terminal blocks and disconnected or misconnected cables.
 For RTD inputs, check for proper connection of the sense line.
 For thermocouple inputs, check for proper cold junction location.
 If the input is reading high, check that the power is not connected across the
input directly.
 Check the software configuration to ensure that the input is configured
properly. Ensure that the proper RTD or thermocouple type is selected, if
applicable.

After verifying all of the above, the Atlas-II should be returned for service.

Analog Outputs
If an Analog output is not functioning properly, verify the following:
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Check the load resistance, ensure that it is less than the specification limit
for the output current.
 Check to ensure that the load wiring is isolated.
 Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
 Disconnect the field wiring and connect a resistor across the output. If the
output is correct across the resistor, there is a problem with the field wiring.
 Check the software configuration to ensure that the input is configured
properly.

After verifying all of the above, the Atlas-II should be returned for service.

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Chapter 6.
PowerSense Board

General Description
Each PowerSense board contains the circuitry for two sets of three phase AC
voltage (PT) and AC current (CT) inputs, as well as a speed bias output, a
voltage bias output, and a LON communications port.

Features
 On-board processor for automatic calibration of the I/O channels
 PT and CT inputs provide fundamental as well as harmonic information
 PT and CT inputs are sampled at high speed, then the RMS value is
updated every 50 ms (which is 3 cycles at 60 Hz)
 PT and CT inputs and bias outputs have 12 bit resolution
 PT inputs are software configurable for 70 V, 120 V, or 240 V ranges
 Each set of PT and CT inputs is isolated from the rest of the board and
chassis
 5 ms update rate for speed and voltage bias outputs
 Speed bias output is software configurable for 4–20 mA, 0–5 V, PWM, or ±3
V output
 Speed Bias output is isolated from the rest of the board
 Voltage Bias output is software configurable for 4–20 mA, ±1 V, ±3 V, and
±9 V
 Voltage bias output is isolated from the rest of the board
 The LON port is isolated from the rest of the board

Physical
The Atlas-II PowerSense board connects to the CPU board through the PC/104
bus. It connects to the power supply, through the Atlas-II power bus. It requires a
SmartCore CPU A5200 board or a Pentium CPU board as a master controller. The
master controller is responsible for all application level tasks such as protective
relaying, load share, and controlling the voltage and speed bias outputs.

Hazardous Live
The following circuits are classified as Hazardous Live because they carry potential
shock hazardous voltages during normal operation or under single fault conditions:
 potential transformer (PT) inputs
 current transformer (CT) inputs
 voltage bias outputs

HIGH VOLTAGE—Do not contact the above inputs and outputs

during system operation when such circuits are live. Possible
serious personal injury or death could result.

HIGH VOLTAGE—Before disconnecting the secondary terminals of

the current transformer or the connections of the current transformer
at the control, ensure that the transformer is short-circuited.

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HIGH VOLTAGE—To prevent risk of electric shock, make sure that

the terminal block covers are installed on the above inputs before
operation (see Figure 6-1).

Terminal Block

Figure 6-1. Terminal Block Covers

These inputs and outputs are provided with 500 V of dielectric isolation from
chassis ground. In addition, these inputs/outputs are isolated from safety extra-
low voltage (SELV) circuits (such as serial communication, PC/104 circuits) by
optoisolators or transformers provided with double insulation and 3 kVac of
dielectric isolation.

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Figure 6-2. PowerSense Board Connections

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PC/104 Interface PC/104 Interface Dualport RAM LON MIP/DPS LON

LON Channel 1
Signals and decode logic memory Interface Transceiver

Board Address
Dip Switches

Dualport RAM
memory
BDM Port

Zero-phase
crossing 5 MHz
dectectors Crystal
MC68332 Microcontroller
Isolated Watchdog
Optocouplers

Flash Memory
12-bit
Generator AC Sample & 8-channel Isolation
Inputs(6) Hold Serial A/D circuits EEPROM non-
converter volatile
memory

12-bit
Bus Sample & 8-channel Isolation Isolation
AC Inputs(3) Serial A/D circuits circuits
Hold
converter

Speed bias
Speed bias Output
circuitry

Voltage bias Voltage Bias

Circuitry Output
VIS-002
01-4-26

Figure 6-3. PowerSense Board Block Diagram

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Specifications
Utility and Generator PT Voltage Inputs
Input Voltage (Typical) 77, 120, 240/277 Vac, transducers externally
powered.
Max. Input Voltage 300 Vac
Input Current 3 mA maximum
Input Frequency 45—70 Hz
Common Mode Voltage ±450 Vdc minimum
Common Mode Rejection Ratio –63 dB minimum
Measurement Category CAT III

PT Temp Drift
(Vrange =
70/120/240 Vrms) –40 to +85 °C Any 40 °C change
Typical (1σ): < 0.4 % of Vrange < 0.3% of Vrange
0.28V, 70V scale 0.21V, 70V scale
0.48V, 120V scale 0.36V, 120V scale
0.96V, 240V scale 0.72V, 240V scale
Max (3σ): < 1.2 % of Vrange < 0.8% of Vrange
0.84V, 70V scale 0.56V, 70V scale
1.44V, 120V scale 0.96V, 120V scale
2.88V, 240V scale 1.92V, 240V scale

Input Impedance 400 kΩ or greater

Isolation see HAZARDOUS LIVE section above

Utility and Generator CT Current Inputs

Input Current 5 A rms full scale
Max Transient Input Current 7.07 A rms
Input Frequency 45—70 Hz
Common Mode Voltage ±250 Vdc minimum
Common Mode Rejection Ratio –63 dB minimum
Measurement Category CAT III
Accuracy see PT/CT Accuracy Table

CT Temp Drift
(FullScale = 5 Arms) –40 to +85 °C Any 40 °C change
Typical (1σ): < 0.4% or 20.0 mA < 0.3% or 15.0 mA
Max (3σ): < 1.2% or 60.0 mA < 0.8% or 40.0 mA

Input Impedance 0.030 Ω

Isolation see HAZARDOUS LIVE section above

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Speed Bias Output

Number of channels 1
Current output option 4–20 mA selected by software switch and wiring
Max current output 25mA ±5%
Voltage output options 0–5 V (5 V max ±5%), ±3 V (±3V limit ±5%), 500 Hz
PWM, selected by software switch and wiring
Isolation 500 Vac
Max load resistance 300 Ω at 24 mA for 4–20 mA output, infinite for V
outputs
Min load resistance 0 Ω for current output, 450 Ω for ±3 V output, 1kΩ for
0–5 V output, PWM output.
Resolution 11 bits, except for PWM output
Accuracy less than ±0.1% of full scale @ 25 °C or
±0.006 V for ±3 V output
±0.005 V for 0–5 V output
±0.025 mA for 4–20 mA output

TempDrift
(4–20 mA, FS = 25 mA) –40 to +85 °C Any 40 °C change
Typical (1σ): < 0.5% or 0.125 mA < 0.3% or 0.075 mA
Max (3σ): < 1.2% or 0.30 mA < 0.8% or 0.20 mA

Temp Drift
(±3V range) –40 to +85 °C Any 40 °C change
Typical (1σ): < 0.3% or 18.0 mV < 0.2% or 12.0 mV
Max (3σ): < 0.7% or 42.0 mV < 0.5% or 30.0 mV

TempDrift
(0–5 V range and PWM) –40 to +85 °C Any 40 °C change
Typical (1σ): < 0.1% or 5.0 mV < 0.1% or 5.0 mV
Max (3σ): < 0.2% or 10.0 mV < 0.2% or 10.0 mV

 Options: 4–20 mA, 0–5 V, ±3V, PWM- 5V- 500 Hz. Both the GAP block field and the
wiring must be changed to switch between current and voltage outputs. Only the
GAP block field must be changed to switch between the voltage outputs.

Voltage Bias Output

Number of channels 1
Current output option 4–20 mA selected by software switch and wiring
Max current 25mA ±5%
Voltage output options ±1, ±3, ±9 V selected by software switch and wiring
Max Voltage ±9V ±5%
Isolation see HAZARDOUS LIVE section above
Max load resistance 300 Ω at 24 mA for 4–20 mA output, infinite for V
output
Min load resistance 7kΩ for ±9V output, 0 Ω for 4–20 mA output
Resolution 11 bits for ±9V, >9 bits for ±3V, >7 bits for ±1V
Accuracy less than ±0.1% of full scale @ 25 °C or
±0.018V for ±1V, ±3V, ±9V output
±0.025 mA for 4–20 mA output

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Manual 26415 Atlas-II Digital Control
TempDrift
(4–20 mA, FS = 25 mA) –40 to +85 °C Any 40 °C change
Typical (1σ): < 0.5% or 0.125 mA < 0.3% or 0.075 mA
Max (3σ): < 1.2% or 0.30 mA < 0.8% or 0.20 mA

Temp Drift
(±9V range) –40 to +85 °C Any 40 °C change
Typical (1σ): < 0.3% or 54.0 mV < 0.3% or 54.0 mV
Max (3σ): < 0.6% or 108.0 mV < 0.5% or 90.0 mV

Temp Drift
(±3V range) –40 to +85 °C Any 40 °C change
Typical (1σ): < 0.9% or 54.0 mV < 0.9% or 54.0 mV
Max (3σ): < 1.8% or 108.0 mV < 1.5% or 90.0 mV

TempDrift
(±1V range) –40 to +85 °C Any 40 °C change
Typical (1σ): < 2.7% or 54.0 mV < 2.7 % or 54.0 mV
Max (3σ): < 5.4% or 108.0 mV < 4.5% or 90.0 mV

 options: 4–20 mA, ±1V, ±3V, ±9V; software and wiring selectable. Both the GAP
block field and the wiring must be changed to switch between current and voltage
outputs. Only the GAP block field must be changed to switch between the voltage
outputs.

PT/CT Accuracy Table

Accuracy with Default Filter
Metering Item
Values of 0.67
0.25% or 0.175 V, 70 Vac scale
Voltage 0.25% or 0.3 V, 120 Vac scale
0.25% or 0.6 V 240 Vac scale
Current 0.25% or 12.5 mA
0.5% or 1.75 VA, 70 V scale
Power 0.5% or 3.0 VA, 120 V scale
0.5% or 6.0 VA, 240 V scale
0.003 PF
Power Factor Across entire range of 0.5 lead to
0.5 lag
Frequency 0.08% of 60 Hz or 0.048 Hz
Synchronizing 0.25% or 0.00157 rad or 0.9°
1% or 50 mA for current
1% or 0.7 V, 70 Vac scale
Harmonics 2-7
1% or 1.2 V, 120 Vac scale
1% or 2.4 V, 240 Vac scale
2% or 100 mA for current
2% or 1.4 V, 70 Vac scale
Harmonics 9, 11, 13
2% or 2.4 V, 120 Vac scale
2% or 4.8 V, 240 Vac scale
0.5% or 25 mA for current
Negative Phase
0.5% or 0.35 V, 70 Vac scale
Sequence Voltage or
0.5% or 0.6 V, 120 Vac scale
Current
0.5% or 1.2 V, 240 Vac scale
Typical Temperature <0.4% of Vrange for any 40 °C
Drift for voltage inputs change
Typical Temperature <0.4% or 20.0 mA for any 40 °C
Drift for current inputs change
* Accuracy values at 25 °C with no harmonics

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PowerSense Board Operation

This board includes no potentiometers and requires no field calibration.

A PowerSense board may be replaced with another board of the same part
number without any physical adjustment.

When the PowerSense card is used for synchronizing, the GAP

application must be configured so that the timing is correct for the
characteristics of the PTCT_ATL and SYNCHRO blocks.
1) The rate group for both blocks must be set to "10".
2) Disable the synchronizer and verify that the
SYNCHRO.SYNC_DIS is <TRUE>.
3) Enable the PTCT_ATL.SMPL_TYPE by tuning to <TRUE>.
4) Delay 200 ms.
5) After the 200 ms delay, tune the SYNCHRO.SYNC_DIS to
<FALSE>.
Please see the GAP help for further details on the remaining
functionality of these blocks.

PT Voltage Inputs
The PT inputs are designed to sense three phase voltage. All features of the
three phase voltage for the generator are exactly duplicated for the mains inputs.
The ‘A’ phase voltage inputs of each set (generator and mains) are used for
frequency measurement and synchronizing. The fundamental magnitude and
phase information is calculated, in addition to the magnitude and phase of each
harmonic. All harmonics are calculated, up to the 7th harmonic, as well as the
9th, 11th, and 13th harmonics. In addition the PT voltage inputs are used in
conjunction with the CT current inputs for power calculation purposes. All voltage
calculations are performed using algorithms in accordance with IEEE 1459-2000.

Individual fundamental and harmonic voltage inputs are provided. A negative

phase sequence voltage input, and a THD voltage input are also provided.

Three hardware ranges are provided and are selected by the application
software. The nominal inputs for these ranges are 70 V, 120 V, and 240 V. Using
the 70 V range, the lowest voltage that will be sensed it 26.67 V, using the 120 V
range the lowest voltage is 40 V, and using the 240 V range the lowest voltage is
80 V.

PT ratio and gain inputs are provided, to allow field configuration of the PT
scaling. The PT ratio will scale all three PT inputs by the same ratio. There is a
separate gain input provided for each PT input (3 for the generator and 3 for the
mains) that is provided to allow for compensation of potential transformer turns
ratio inaccuracies.

The PT inputs, have adjustable software filters. All PT inputs are updated every 3
cycles. With an input of 60 Hz, this equates to 50 ms.

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The hardware does not require three phases for voltage calculations, the
application can configure the module for single phase, and all functionality will be
modified accordingly. The single phase input that must be provided is the A
phase. The application can also configure the module for a “Y” or “delta” line
configuration, and the calculations will compensate appropriately. If the physical
connections are to a wye connected generator or load, the input to PowerSense
should also be wye connected (line-to-neutral). If the physical connections are to
a Delta connected generator or load (no neutral present), the input to
PowerSense should also be Delta connected (line-to-line). ). The “Y” or “delta”
configuration applies to the entire set of PT and CTs, it is not possible to
configure the PTs for “Y”, and the CTs for “delta”, or vice versa. However, the
configuration may differ between PT/CT 1 and PT/CT 2 (or gen and mains in a
typical configuration).

Configuration Notes
 Refer to Figures 6-4 through 6-8 for PT wiring.
 When using the 3 different PT ranges, 70 V, 120 V, and 240 V, the physical
input must be the correct voltage AND the application software must
configure the PT/CT block for the correct voltage range.
 When using a single phase input, the PT input used must be phase A, and
the application software must configure the PT/CT block for “single phase”
operation.
 The application software must configure the PT/CT block for the correct
system frequency 50Hz or 60 Hz, as well as for the correct rotation,
clockwise or counterclockwise.
 See the GAP help, for information on application software configuration
variables.
 The terminal block screws should be torqued to 8 – 10 lb-in (0.9038782 -
1.129848 Nm).
 Marine Type Approval installations require cabling to be shielded if it leaves
the cabinet. PT wires may be shielded as a single group and the shield may
be conduit or similar.

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AtlasPC
B
31 C
1A
PH A

32

33
1A
PH B

34

35
1A
PH C

36

Load Bus

7
1A
PH A

9
1A
PH B

10

11
1A
PH C

12
VIS-152a
01-4-26

Figure 6-4. Wiring Example–Wye Connected System

(PT Interface wired L-N to the PowerSense Board)

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AtlasPC
B
31 C
1A
PH A

32

33
1A
PH B

34

35
1A
PH C

36

Load Bus

7
1A
PH A

9
1A
PH B

10

11
1A
PH C

12

VIS-152b
01-4-26

Figure 6-5. Wiring Example–Wye Connected System

(wired L-N to PowerSense with potential transformers used to step the voltage
down to a level within the capability of the PowerSense inputs)

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AtlasPC
B
31 C

1A
PH A

32

33
1A
PH B

34

35
1A
PH C

36

Load Bus

7
1A
PH A

9
1A
PH B

10

11 1A

PH C

12

VIS-152c
01-4-26

Figure 6-6. Example Wiring–Wye Connected System

(wired L-L to PowerSense with potential transformers used to step the voltage
down to a level within the capability of the PowerSense inputs; the ground on the
b-phase input is optional.)

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AtlasPC
B C

31
1A
PH A

32

33
1A
PH B

34

35
1A
PH C

36

Load Bus

7
1A
PH A

9
1A
PH B

10

11
1A
PH C

12 VIS-152d
01-4-26

Figure 6-7. Wiring Example–Delta Connected System

(PT Interface wired L-L to the PowerSense Board)

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AtlasPC
B C

31
1A
PH A

32

33
1A
PH B

34

35
1A
PH C

36

Load Bus

7
1A
PH A

9
1A
PH B

10

11 1A

PH C
VIS-152-e
12 01-4-26

Figure 6-8. Wiring Example–Delta Connected System

(wired L-L to PowerSense with potential transformers used to step the voltage
down to a level within the capability of the PowerSense inputs; the ground on the
B-phase input is optional.)

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Generator Current Inputs

The CT inputs are designed to sense three phase current inputs. The ‘A’ phase
current inputs of each set are used for phase calculations. The fundamental
magnitude and phase information is calculated, in addition to the magnitude and
phase of each harmonic. All harmonics are calculated, up to the 7th harmonic, as
well as the 9th, 11th, and 13th harmonics. In addition the CT current inputs are
used in conjunction with the PT voltage inputs for load calculation purposes. All
current calculations implement algorithms in accordance with IEEE 1459-2000.

Individual fundamental and harmonic CT inputs are provided. A negative phase

sequence current input and a THD current input are also provided.

The CT inputs are rated at 5A and function down to 50 mA. For optimum
accuracy in the usable range, it is recommended to use 5 A secondary CTs with
PowerSense (not 1A secondary CTs). Take care to avoid secondary currents
greater than 7 Arms, as this will cause damage.

CT ratio and gain inputs are provided, to allow field configuration of the CT
scaling. The CT ratio will scale all three CT inputs by the same ratio. There is a
separate gain input provided for each CT input (3 for the generator and 3 for the
mains) that is provided to allow for compensation of current transformer turns
ratio inaccuracies.

The CT inputs have adjustable software filters. All CT inputs are updated every 3
cycles. With an input of 60 Hz, this equates to 50 ms.

The hardware does not require three phases for current calculations, the
application can configure the module for single phase, and all functionality will be
modified accordingly. The single phase input that must be provided is the A
phase. The application can also configure the module for a “Y” or “delta” line
configuration, and the calculations will compensate appropriately. If the physical
connections are to a wye connected generator or load, the input to PowerSense
should also be wye connected (line-to-neutral). If the physical connections are to
a Delta connected generator or load (no neutral present), the input to
PowerSense should also be Delta connected (line-to-line). ). The “Y” or “delta”
configuration applies to the entire set of PT and CTs, it is not possible to
configure the PTs for “Y”, and the CTs for “delta”, or vice versa. However, the
configuration (line type and single or three-phase) may differ between PT/CT 1
and PT/CT 2 (gen and mains in most systems).

HIGH VOLTAGE—Before disconnecting the secondary terminals of

the current transformer or the connections of the current transformer
at the control, ensure that the transformer is short-circuited.

Configuration Notes
 Refer to Figures 6-9 and 6-10 for CT wiring.
 When using only one CT, rather than 3, the CT must be phase A, and the
application software must configure the PT/CT block for “single phase” operation.
 The application software must configure the PT/CT block for the correct
system frequency 50 Hz, or 60 Hz, as well as for the correct rotation,
clockwise or counterclockwise.
 See the GAP help, for information on application software configuration variables.
 The terminal block screws should be torqued to 8–10 lb-in (0.9–1.1 Nm).
 Marine Type Approval installations require cabling to be shielded if it leaves
the cabinet. CT wires may be shielded as a group and the shield may be
conduit or similar.

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Power Calculations
Individual and total watts, VARs, VA, and power factor inputs. A negative phase
sequence voltage input and a THD voltage input are also provided.

All power calculations implement algorithms in accordance with IEEE 1459-2000.

The power inputs have adjustable software filters. All power inputs are updated
every 3 cycles. With an input of 60 Hz, this equates to 50 ms.

The hardware does not require three phases for load calculations, the application
can configure the module for single phase, and all functionality will be modified
accordingly. The single phase input that must be provided is the A phase. The
application can also configure the module for a “Y” or “delta” line configuration,
and the calculations will compensate appropriately. If the physical connections
are to a wye connected generator or load, the input to PowerSense should also
be wye connected (line-to-neutral). If the physical connections are to a Delta
connected generator or load (no neutral present), the input to PowerSense
should also be Delta connected (line-to-line). The “Y” or “delta” configuration
applies to the entire set of PT and CTs, it is not possible to configure the PTs for
“Y”, and the CTs for “delta”, or vice versa.

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AtlasPC
B
C
25

PH A

26

27

PH B

28

29

PH C

30

Load Bus

PH A

PH B

PH C

VIS-152f
01-4-26

CT grounds optional

Figure 6-9. Wiring Example–CT Interface to the PowerSense Board

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AtlasPC
B C

25

PH A

26

27

PH B

28

29

PH C

30

Load Bus

PH A

PH B

PH C

VIS-152g
01-4-26

CT grounds optional

Figure 6-10. Wiring Example–CT Interface to the PowerSense Board

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Speed Bias Output

The Speed Bias output is configurable for 4–20 mA with a full scale range of 0–
24 mA, or as a ±3 V, 0–5 V, or PWM voltage output. When used as a PWM
output, the PWM frequency is 500 Hz. Configuring the output requires wiring and
application software configuration. This output is isolated from the rest of the
control system, to prevent ground loops when connecting the PowerSense board
to other controls.

Configuration Notes
 Refer to Figures 6-11 and 6-12 for Speed Bias Output wiring. Wires must be
shielded.
 The Speed Bias output must be configured for the correct type, 4–20 mA or
the voltage type in the application software.
 See the specifications section for the maximum output load.
 The output does not contain fault detection. If it is necessary to detect
failures, then the device that is driven by the analog output, for example an
actuator driver, must contain reference failure detection.
 The output cannot be used as a voltage output and a current output at the
same time.

Atlas
19

+15 Vdc
(isol) 20

21 +
SC
4-20 mA
interface to
22
speed control

23

24

GND
(isol)

Figure 6-11. Wiring Example–Speed Bias Output Interface

(to the PowerSense Board configured for 4–20 mA)

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Atlas
19

20

21

22

23 +
SC
±3, 0-5, PWM
interface to
24
speed control
GND
(isol)

Figure 6-12. Wiring Example–Speed Bias Output Interface

(to the PowerSense Board configured for ±3 V, 0–5 V, or PWM)

Voltage Bias Output

The Voltage Bias output is configurable for 4 - 20 mA with a full scale range of 0 -
24 mA, or as a 1, 3V, or 9V voltage output. Configuring the output requires
wiring and application software configuration. This output is isolated from the rest
of the control system to prevent ground loops when connecting the PowerSense
board to other controls. The voltage outputs are configured in the software,
therefore the 9V output has about 3 times better accuracy and resolution than
the 3V output, which has about 3 times better accuracy and resolution than the
1V output.

Configuration Notes
 Refer to Figures 6-13 and 6-14 for Voltage Bias Output wiring. Wires must
be shielded.
 The Voltage Bias output must be configured for the correct type, 4–20 mA or
the voltage type, in the application software.
 See the specifications section for the maximum output load.
 The output does not contain fault detection. If it is necessary to detect
failures, then the device that is driven by the analog output, for example an
actuator driver, must contain reference failure detection.
 The output cannot be used as a voltage output and a current output, at the
same time.

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Atlas
+15 Vdc
(isol)

13 +
VR
4-20 mA
interface to
14
voltage regulator

15

16

GND
17
(isol)

18

Figure 6-13. Wiring Example–Voltage Bias Output Interface

(to the PowerSense Board configured for 4–20 mA)

Atlas
13

14

15 +
VR
±1, ±3, ±9,
16 interface to
voltage regulator
GND
(isol)
17

18

Figure 6-14. Wiring Example–Voltage Bias Output Interface

(to the PowerSense Board configured for ±1 V, ±3 V, or ±9 V)

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LON Channel
The PowerSense board has one LON channel.

Figure 6-15. Wiring Example–LON Interface to the PowerSense Board

Configuration Notes
 Refer to Figure 6-15 for LON channel wiring. Wire must be shielded.
 The LON network must be terminated with load terminating resistors.
 The LON channel is DSLC/MSLC and EGCP-3 compatible. It may only be
used with specified Woodward equipment.

Fault Detection (Board Hardware)

Each PowerSense board has a red fault LED that is turned on when the system
is reset. During initialization of a board, which occurs after every CPU reset, the
CPU turns the Fault LED on. The CPU then tests the board using diagnostic
routines built into the software. If the diagnostic test is not passed, the LED
remains on or blinks. Table 6-1 below explains what a blinking LED indicates.
The LED will blink the appropriate number of times, rest for one second, then
blink again in repetition. If the test is successful, the LED goes off. If the fault
LED on a board is illuminated after the diagnostics and initialization have been
completed, the PowerSense board may be faulty or may have the address DIP
switches configured incorrectly. The DIP switch setting must match the module
address set in the GAP application program. It cannot be the same address used
by any other card on the PC/104 bus. These are factory set at the time the
system is built.

Number of LED Flashes Failure

Off No failure, system OK
Solid Module in initialization mode
1 Hardware watchdog, CPU clock failure, reset fail
2 Unexpected Exception Error
3 RAM test failure
5 EEPROM failure
7 Kernel Watchdog Timeout
10 System Error
11 Board Identification Error
12 TPU RAM failure
13 Dual Port RAM test failure
14 QSM or ADC Initialization failure
15 Self test status failure
20 Invalid A/D converter selected
21 QSPI timeout
24 ADC auto calibration time-out

Table 6-1. PowerSense Failure Codes

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Fault Detection (I/O)—In addition to detecting board hardware faults, the
application program may detect I/O faults, by comparing values against each
other at specific operating points. For example, if phases A and C are reading
correctly, and phase B is significantly different, the application could annunciate a
problem with phase B.

Microcontroller Faults—The system monitors a software watchdog, a hardware

watchdog, and a software watchdog on the PC/104 bus communications. All
outputs are shutdown in the event of a microcontroller fault or watchdog
detection.

Troubleshooting Guide
PT Inputs
If a PT input is not functioning properly, verify the following:
 Measure the voltage and frequency on the terminal block, to ensure that
they are correct.
 Check the wiring. Look for a loose connection at the terminal blocks and for
disconnected or misconnected cables.
 Check the PT range configuration in the application software, to ensure that
it corresponds to the rated voltage at the input.
 Check the system frequency configuration in the application software, to
ensure that 50Hz or 60 Hz is selected, as appropriate.
 Check the “3 phase” configuration in the application software. In single
phase mode, phases B and C will be set to 0.
 Check the A phase signal. B and C phase PTs will not read correctly without
the A phase PT. If the A phase frequency is unstable, B and C readings will
be unstable.
 Verify the settings to the PT/CT block in the application software.
 Verify the settings for wye or delta (L-N or L-L) match the actual wiring
 Verify proper grounding. Incorrect grounding practices may cause
inaccurate voltage readings.

After verifying all of the above, the Atlas-II should be returned for service.

CT Inputs
If a CT input is not functioning properly, verify the following:
 Measure the current and frequency on the terminal block, to ensure that
they are correct.
 Check the wiring. If the input is reading 0, look for a shorted connection at
the terminal blocks and for misconnected cables.
 Check the system frequency configuration in the application software, to
ensure that 50Hz or 60 Hz is selected, as appropriate.
 Check the “3 phase” configuration in the application software, in single
phase mode phases B and C will be set to 0.
 Check the A phase PT signal, CT phases A, B, and C will not read correctly
without the A phase PT. If the A phase PT frequency is unstable the CT
readings will be unstable.
 Verify the settings to the PT/CT block, in the application software.
 Verify the settings for wye or delta (L-N or L-L) match the actual wiring
 If the CT common is not grounded, try grounding it to eliminate offsets in the
readings. Be sure to ground it in the same location as the other system
grounds following good, accepted grounding practices.

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After verifying all of the above, the Atlas-II should be returned for service.

HIGH VOLTAGE—Before disconnecting the secondary terminals of

the current transformer or the connections of the current transformer
at the control, ensure that the transformer is short-circuited.

Speed and Voltage Bias Outputs

If a speed or voltage output is not functioning properly, verify the following:
 Check to make sure that the output is wired to the correct terminals, 4–20
mA connections are different from voltage output connections.
 Check that the cable is shielded and the shield is properly grounded per the
shields and grounding section in Chapter 2.
 Check the load resistance, ensure that it is less than the specification limit
for the output current.
 Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
 Disconnect the field wiring and connect a resistor across the output. If the
output is correct across the resistor, there is a problem with the field wiring.
 Check the software configuration to ensure that the output is configured
properly.

After verifying all of the above, the Atlas-II should be returned for service.

LON Channel
If the LON channel is not functioning properly, verify the following:
 Check the network wiring, it should be low capacitance cable.
 The cable length should not exceed the maximum allowed cable length.
 Check to make sure that termination networks are installed on the ends of
the network.
 Check the software configuration.

After verifying all of the above, the Atlas-II should be returned for service.

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Chapter 7.
12-Channel Relay Module

General Information

Figure 7-1. 12-Channel Relay Module

The Atlas system has 12 relay drivers on the power supply board. For customers
that do not wish to wire their own discrete relays, Woodward can provide an
integrated 12-channel relay module with cable harness that is certified for use in
ordinary, hazardous, and marine locations.

The module is DIN rail mounted. Approximate dimensions are 254 mm long, 76
mm wide, and 64 mm tall (10 inches long, 3 inches wide, and 2.5 inches tall).

 Relay Module, Item Number 5441-699

 Cable, Item Number 5417-747

This equipment has been evaluated as EEx nC IIC T3 equipment under DEMKO
Certificate No. 03 ATEX 0328750 U. Each device is suitable for use in Zone 2
explosive atmospheres. Device must be installed in a minimum IP54 enclosure
as defined in IEC60529 and EN60529. This certification applies only to products
bearing the DEMKO identification and the marking:

II 3G.

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Relay Information
Each relay has one set of normally open contacts and one set of normally closed
contacts. The relay contact ratings are:
5 A at 28 Vdc resistive
0.1 A at 125 Vdc resistive
3 A at 120 Vac resistive
2 A at 120 Vac inductive
0.241 hp—120 Vac motor
0.112 hp—28 Vdc motor
0.5 A at 120 Vac tungsten

Shielding
There is a terminal on the module labeled “SHLD”. A wire should be connected
between this terminal and a good local system ground. Alternatively, a ground
wire can be crimped to the bare shield wire at the Atlas end of the cable and then
tied to the chassis ground stud of the Atlas. If this shield wire is not used at the
Atlas end of the cable, it should be trimmed back to the insulation jacket of the
cable.

Board Status Lights

The module is equipped with twelve yellow LEDs to indicate when each relay has
been energized, and one green LED to indicate that there is external power to
the module. For proper operation, the green LED must be lit any time the Atlas
system is being used.

Wiring
The relay module requires an external 18 to 32 Vdc power supply and a wiring
harness. One end of this cable has been stripped back several inches, and
individual wires are labeled with the terminal numbers of the appropriate
terminals used on the Atlas power supply board. Refer to the following plant
wiring diagram and the power supply chapter of this manual for more details.

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Figure 7-2. 12-Channel Relay Module Wiring Diagram

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Chapter 8.
DLE Serial Communication Board

General Information
The Atlas system can be provided with a DLE serial communications board. The
DLE board has six ports—three RS-422 ports for communication with Honeywell
pressure transducer modules, and three RS-485 ports for use with Woodward LQ
series and EM series drivers. All ports are special purpose and are not designed
for general communication functions.

Refer to manuals 85555 (Smart Pressure Transducer) and 26159 (EM/LQ Digital
Driver) for more information about the transducer and driver modules used with
the board.

For proper operation the end user will need a properly shielded cable, network
terminations, and a program that has been written for their application.

TOP BOTTOM

855-766
02-8-20

Figure 8-1. DLE Connections

Connectors
The connectors used with the DLE board come as part of a connector kit that
ships with each Atlas control. If you are missing the connector kit, contact your
sales representative.

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RS-485 Cables
There are two options for cabling used with the RS-485 ports depending on the
length of the cable run required:
 Standard shielded, twisted-pair for cables up to 30 m (100 ft)
 0.3 mm² (22 AWG) low capacitance (36 pF/m or 11 pF/ft) cable for cables
up to 120 m (400 ft)

The characteristic impedance of any cable selected should be near 120 Ω for
best performance. Refer to your cable manufacturer for more information on
characteristic impedance of cables.

The wiring must be one continuous cable between nodes, and must meet the
requirements of EIA RS-485 for 500 kbps except that Woodward recommends
that the maximum cable lengths be cut in half because typical prime mover
installations have high levels of electrical interference.

RS-422 Cables
Use 20 AWG low capacitance cable such as Belden 89207A up to 150 m (500
ft). The characteristic impedance of any cable selected should be near 120 Ω.

Many customers are used to thinking of RS-422 and RS-485 as two-

wire networks with shield, but the transceivers used on this board
require a third “signal common” wire to ensure best performance in
noisy environments. Please be sure to allow for this when ordering
cable.

Termination
To achieve best performance with serial communication networks, it is necessary
to terminate the network to prevent interference caused by signal reflections. For
this reason, all ports on the DLE board are equipped with built-in network
termination resistors.

Customers using the pressure transducer ports (RS-422) and the driver ports
(RS-485) will be communicating with a single device, so the termination resistors
will always need to be installed on each operating port.

Figure 8-2. Terminator Locations

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The termination resistors are connected by inserting jumper wires on the external
plug in connectors. Jumper the following pins to connect the termination resistors
as needed on the ports that you are using.

Comm Port # Connect Pins

1 7 to 8 and 9 to 10
2 17 to 18 and 19 to 20
3 27 to 28 and 29 to 30
4 52 to 54 and 51 to 53
5 42 to 44 and 41 to 43
6 32 to 34 and 31 to 33

Shielding
Shielded cable is required between the Atlas-II and any other devices.
Unshielded cables and improperly shielded cables will very likely lead to
communication problems and unreliable control operation.

The shield must always be AC-coupled (connected through a capacitor) at one

end and connected directly to earth on the opposite end for proper operation.
The DLE board has been constructed so that the Shield/Drain connection can be
either AC-coupled or directly connected to the Atlas chassis ground which must
be tied to earth. Devices connected to the opposite end of the cable must provide
for the opposite shield connection. For instance, if the AC-coupled connection is
used on the DLE, the other end of the shield must be connected directly to earth.

Board Status Lights

The board is equipped with two LEDs labeled H and D to provide feedback from
the board. The LED labeled H indicates operation of the Honeywell portion of the
board, and LED labeled D indicates operation of the driver side of the board.
During normal operation, the LEDs will light as soon as power is applied and will
eventually turn off as the application starts running. This can take up to four
minutes, depending upon the size of the application. If the board fails its own self
test or failures are detected during normal operation, the LEDs will flash in
particular coded patterns which will repeat periodically.

LED and
Number of
Flashes Failure
H1 RAM test fail (this test is done only at boot and application start)
H2 exception error
H3 dual port test fail (this test is done only at boot and application start)
H4 watchdog timeout
H7 kernel watchdog timeout
D1 RAM test fail (this test is done only at boot and application start)
D2 exception error
D3 dual port test fail (this test is done only at boot and application start)
D3 module watchdog timeout
D7 kernel watchdog timeout

Table 8-1. DLE Failure Codes

Some users may not use both the RS-422 and RS-485 ports in their
application. In this case, one LED will stay on all the time. This only
signifies that one side of the board is not being used. It is not a
failure unless a flash code appears.

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Application Developer Information

Many end users will be purchasing pre-programmed Atlas units and

will not need the information in this section. The information below is
aimed at programmers using the GAP programming tool provided by
Woodward.

Application developers must use version 3.04 or later of the GAP

programming tool when using a DLE board.

DLE Address Configuration

The DLE serial communications board is always configured to use address 10 in
Atlas systems. This is done because this board is a 16-bit board (versus 8-bit for
everything else) and it consumes two address spaces in the stack. To simplify
things, the board is factory-configured to be at address 10 to avoid address
conflicts with other boards, and there are warnings enabled in the coder in the
event that someone accidentally sets it incorrectly.

Driver Limitations
Each driver port (RS-485) can support only a single driver. The LM and EQ
series drivers have been built so that they can complete a communications
transaction in 5 milliseconds.

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Chapter 9.
PC104 Profibus Interface

Introduction
This chapter has been divided into two sections, Hardware for End Users, and
Software for Application Developers. The hardware section is aimed at
customers that are applying the Atlas-II in a permanent installation. The software
section is for customers that are developing software for the Atlas-II control.

Profibus Software and Hardware Requirements

 Atlas-II with Profibus Module
 Profibus Master Configuration Tool
 Profibus Diagnostic Utilities
 Profibus slave device GSD file(s)
 GAP Programming Tool 4.04 or later
 Profibus Cables and Connectors
 Slave Interface and Modules
 Device Memory Maps and Scaling (Manuals)
 Woodward Interface Tools

Hardware for End Users

Profibus Module
The Profibus hardware module used on the Atlas-II control system is a PC/104
form factor ApplicomIO PC104-DPIO board, equipped with one Profibus port,
capable of handling Profibus-DP (Distributed Peripherals) protocol in both Master
(Class1, Class2) and Slave modes up to 12Mbps. This module operates on the
PC104 bus and has a PC104 pass through connector to allow use with multiple
PC104 modules depending on the Atlas configuration.

Electrical and Technical Specifications

Processor: Intel 80386EX, 24 MHz
Memory: 4 Mbyte DRAM, 512 K flash memory
Network Speeds Supported: 9600 kbps to 12 Mbps
Interface: RS-485 with 500 Vdc galvanic isolation
Interface Connector: Isolated DB9F I/O connector
Power: 4.0 W max (3.75 W typical)

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Interface Cables and Connectors

The Profibus network is a balanced transmission line corresponding to the
standard EIA RS-485, terminated at both ends. The Profibus standard EN50170
defines two variations of the bus cable for Profibus-FMS and Profibus-DP.
Profibus Type A cable is preferred and recommended for all uses.
 Type A—recommended for high transmission speeds (> 500 kBaud) and
permits doubling of the network distance in comparison to Type B.
 Type B—should only be used at low baud rates and low requirements on
the network distances.

Impedance: 135 up to 165 Ω at a frequency of 3 to 20 MHz

Cable capacitance: < 30 pF/m
Core diameter: > 0.34 mm², corresponds to 22 AWG
Cable type: twisted pair cable. 1x2 or 2x2 or 1x4 lines
Resistance: < 110 Ω/km
Signal attenuation: max. 9 dB over total length of line section
Shielding: CU shielding braid or shielding braid and foil

Table 9-1. Profibus—Type A Cable

Impedance: 135 up to 165 Ω at a frequency of > 100 kHz

Cable capacitance: typ. < 60 pF/m
Core diameter: > 0.22 mm², corresponds to 24 AWG
Cable type: twisted pair cable. 1x2 or 2x2 or 1x4 lines
Signal attenuation: max. 9 dB over total length of line section
Shielding: CU shielding braid or shielding braid and foil

Table 9-2. Profibus—Type B Cable

Recommended Bulk Cable

Cable manufacturer Belden is widely available in North America, and Siemens is
available in Europe. These manufacturers are listed in the table below. Neither
manufacturer has any exclusive rights to Profibus cable, and other suitable
alternatives are available from other manufacturers. Both cables below are rated
as suitable for Profibus cabling and may also be used for drop cabling.
Alternative cables may not use the same color coding on the individual
conductors.

Manufacturer Part Number Website

Belden 3079A Profibus Cable www.belden.com
Siemens Profibus-DP, STD, 6XV1830- www.ad.siemens.de/simatic
0EH10

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The cable specification below is provided for convenience and is typical for the
Profibus industry.

Belden 3079A Profibus

Cable

Weight: 57 lbs/1,000 ft (~85 kg/1000 m)

Ratings: NEC PLTC CL2 CMG CEC CMG
Conductor: #22 AWG solid high conductivity Cu (~0.3 mm²)
Insulation: Cellular Polyethylene
Tested: 300 MHz
Nom. O.D.: 0.315" (8.00 mm)
Shield: Beldfoil, 100% coverage
Jacket: Purple or Gray, PVC, optional blue intrinsically safe
Impedance: 150 Ω
Velocity Of Prop. : 78% (nom.)
Mutual Capacitance: 9.0pF/ft (nom.) (~30 pF/m)
Attenuation: 0.27 dB/100 ft @ 0.2 MHz (~0.89 dB/100 m)
0.67 dB/100 ft @ 4.0 MHz (~2.20 dB/100 m)
1.37 dB/100 ft @ 16.0 MHz (~4.49 dB/100 m)
3.75 dB/100 ft @ 100 MHz (~12.30 dB/100 m)
6.52 dB/100 ft @ 300 MHz (~21.39 dB/100 m)
Standard Lengths: 1000, 2000, and 3600 ft (~305, 610, and 1097 m)

Table 9-3. Belden Profibus Cable

Profibus Cable Connectors

The typical Profibus cable connector is a sub-D 9-pin male connector. The
following products are provided for reference.

Recommended Connector
Manufacturer Part Number Website
Siemens Bus Connector 6ES7 972-0BA11-0XA0 www.ad.siemens.de/simatic

Alternate Connectors
Manufacturer Part Number Website
ERNI Erbic PROFIBUS Connectors www.erni.com
Siemens Bus Connector 6GK1500-0EA02 www.ad.siemens.de/simatic
Phoenix Contact SUBCON Profibus Connector–2744348 www.phoenixcon.com

Profibus Connector Specifications

The following connectors are typical for Profibus and are provided for reference.

Name: Bus Connector www.ad.siemens.de/simatic

Mfr: Siemens
P/N: 6ES7 972-0BA11-0XA0
Connector: DB9M
Transmission Rate: 12 Mbits/s
Shielding: Plastic case with internal shld clamp
Bus Termination: Terminating resistor slide switch
Cable Ports: (2) for daisy chain use, 90 exit
Cable Connection: 4 Internal screw terminal blocks
Dim (WxHxD): 15.8 mm x 54 mm x 34 mm

Table 9-4. Profibus—Siemens RS-485 Bus Connector / Plastic

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Name: Bus Connector www.ad.siemens.de/simatic
Mfr: Siemens
P/N: 6GK1500-0EA02
Connector: DB9M
Transmission Rate: 12 Mbits/s
Shielding: Metal case with internal shld clamp
Bus Termination: Terminating resistor slide switch
Cable Ports: (2) for daisy chain use
Cable Connection: 4 Internal screw terminal blocks
Dim (WxHxD): 15 mm x 57 mm x 39 mm

Table 9-5. Profibus—Siemens RS-485 Bus Connector / Metal

Profibus Connector Pinout

Connector Signal Mnemonic

DB9F Shielded DB9 female receptacle

1 --
2 --
3 RxD/TxD—P
4 --
5 GND
6 +5 V
7 --
8 RxD/TxD—N
9 --
Shell / Shield Chassis / Earth Ground

Table 9-6. I/O Connector Pinout

Profibus Network Construction

Profibus networks, in some installations, have been constructed over large
distances and may even go between two or more buildings. The Profibus
network is specified/intended to have a low impedance galvanic connection of
cable shield grounds at each device and across the network, counter to this.

Due to the galvanic shield connection, if the Profibus network is designed longer
than 30 m (99 feet), there may be substantial potential differences between the
ground reference connections at each end. This affect is especially apparent
during lightning strikes to earth near one end of a long network, because shields
are referenced to earth ground.

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Isolators must be used if the network is NOT a local, relatively short (>30 m)
network shields connected to the same reference by low impedance galvanic
connections. Isolators must be placed between sections of the network further
than 30 m apart. Isolators must provide galvanic isolation to the signals, shield,
and reference connections. This prevents potentially substantial equalizing
currents from flowing in the cable shields and reference signal wires. Equalizing
currents can (and will) disrupt communications or in extreme cases cause
equipment damage. (All though isolated, cable shields should be connected
across the isolator via an AC connection (capacitor) to maintain RF shielding
effectiveness. Typically 0.001 to 0.1 µF capacitors rated at 500 – 2000 V, may be
used depending on the application and these capacitors are often built into the
isolator.)

Profibus Slave Hardware

The Atlas-II control system can control Profibus slave modules from many
different manufacturers. With the exception of Woodward-manufactured devices,
Woodward makes no expressed or implied statement of suitability of these
devices. It is the user’s responsibility to ensure EMC compliance of their system,
if necessary, by using distributed modules that are CE compliant. The following
Profibus slave hardware has been tested with the Atlas-II control to confirm
functionality only.

1) All Woodward devices designed for Profibus

2) Allen-Bradley Flex I/O

Part Number Description

3170-PDP I/O Network Interface for Profibus (Slave) (ProSoft Technologies)
1794-IB16 Discrete Input (Sink)
1794-OV16 Discrete Output (Sink)
1794-OW8 Discrete Output (Relay)
1794-IE8/B Analog Input (Current)
1794-OE4/B Analog Output (Current)
1794-IT8 Thermocouple Input
1794-CJC2 Cold Junction
1794-IR8 RTD Input
1794-TB3S Terminal Base
1794-TB3TS Terminal Base

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3) Automation Direct Terminator I/O

Part Number Description

T1K-01AC Power Supply
T1K-01DC Power Supply
T1H-PBC Profibus Interface
T1K-08ND3 Discrete Input (Sink)
T1K-16ND3 Discrete Input (Sink)
T1K-16TD1 Discrete Output
T1K-08TRS Discrete Output (Relay)
T1F-16AD-1 Analog Input (Current)
T1F-16DA-1 Analog Output (Current)
T1F-14THM Thermocouple Input
T1K-08B-1 Terminal Base
T1K-16B-1 Terminal Base

Software for Application Developers

It is possible to disrupt an existing Profibus network by attaching an

improperly configured device. To prevent problems on your existing
Profibus network, read this chapter before connecting the Atlas-II
Profibus port to a network.

Many end users will be purchasing pre-programmed Atlas-II units

and will not need the information in this section. The information
below is aimed at programmers using the GAP programming tool
provided by Woodward. The information provided here covers the
basics. For more detail, refer to Woodward software manual 26336,
Woodward VxWorks Real Time Operating System.

The information in this section is intended for customers that create their own
GAP programs for the Atlas-II platform and who are using a Profibus network.

Programmers will need the following:

 ApplicomIO configuration software CD-ROM (supplied with the Atlas-II
control)
 GSD file(s) for slave module(s)
 Device memory maps and scaling (manuals)
 GAP Programming Tool 4.04 or later to create the application (This can be
downloaded from our website: www.woodward.com/software)
 For more information on these and additional software tools mentioned in
this chapter, see Woodward software manual 26336 (VxWorks RTOS).

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The Atlas-II control is configured to communicate with a Profibus network by
performing the following steps:

1. Verify that the Atlas contains a Profibus module.

2. Determine slave and I/O modules to be used.
3. Determine order of I/O modules.
4. Obtain GSD file(s).
5. Create Profibus Configuration using the Profibus Configuration Tool.
6. Review the Profibus slave manuals and understand the hardware
addressing.
7. Create GAP application that reads and writes to the Profibus I/O.
8. Transfer Configuration files and GAP application to Atlas-II control.
9. Start GAP application.

Profibus Software Configuration (Configuration)

The Profibus network is configured using a Profibus Configuration Tool provided
on CD-ROM with the Atlas-II control (ApplicomIO 2.2 Console). This tool
supports defining the Atlas-II Profibus board as a master or slave device. For
master operation, the slave devices are defined and configured by importing their
GSD files and assigning network addresses. Once the Profibus I/O configuration
is completed, it must be downloaded to the Atlas-II control and stored with the
GAP application.

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Chapter 10.
Product Support and Service Options

Product Support Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
 Consult the troubleshooting guide in the manual.
 Contact the manufacturer or packager of your system.
 Contact the Woodward Full Service Distributor serving your area.
 Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In many cases, your
problem can be resolved over the phone. If not, you can select which course
of action to pursue based on the available services listed in this chapter.

OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.

Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
 A Full Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on Woodward's
behalf. Service (not new unit sales) is an AISF's primary mission.
 A Recognized Turbine Retrofitter (RTR) is an independent company that
does both steam and gas turbine control retrofits and upgrades globally, and
can provide the full line of Woodward systems and components for the
retrofits and overhauls, long term service contracts, emergency repairs, etc.

A current list of Woodward Business Partners is available at

www.woodward.com/directory.

Product Service Options

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

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

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
 return authorization number;
 name and location where the control is installed;
 name and phone number of contact person;
 complete Woodward part number(s) and serial number(s);
 description of the problem;
 instructions describing the desired type of repair.

Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.

To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

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Replacement Parts
When ordering replacement parts for controls, include the following information:
 the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
 the unit serial number, which is also on the nameplate.

Engineering Services
Woodward offers various Engineering Services for our products. For these services,
you can contact us by telephone, by email, or through the Woodward website.
 Technical Support
 Product Training
 Field Service
Technical Support is available from your equipment system supplier, your local Full-
Service Distributor, or from many of Woodward’s worldwide locations, depending
upon the product and application. This service can assist you with technical
questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business
hours by phoning Woodward and stating the urgency of your problem.
Product Training is available as standard classes at many of our worldwide
locations. We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product
and location, from many of our worldwide locations or from one of our Full-
Service Distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface.
For information on these services, please contact us via telephone, email us, or
use our website: www.woodward.com.

Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service facility,
please consult our worldwide directory at www.woodward.com/directory, which
also contains the most current product support and contact information.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
Products Used in Products Used in Products Used in Industrial
Electrical Power Systems Engine Systems Turbomachinery Systems
Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany ------ +49 (711) 78954-510 India --------------- +91 (129) 4097100
Kempen---- +49 (0) 21 52 14 51 India --------------- +91 (129) 4097100 Japan---------------+81 (43) 213-2191
Stuttgart - +49 (711) 78954-510 Japan---------------+81 (43) 213-2191 Korea ---------------+82 (51) 636-7080
India --------------- +91 (129) 4097100 Korea ---------------+82 (51) 636-7080 The Netherlands--+31 (23) 5661111
Japan---------------+81 (43) 213-2191 The Netherlands--+31 (23) 5661111 Poland -------------- +48 12 295 13 00
Korea ---------------+82 (51) 636-7080 United States -----+1 (970) 482-5811 United States -----+1 (970) 482-5811
Poland -------------- +48 12 295 13 00
United States -----+1 (970) 482-5811

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Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:

General
Your Name

Site Location

Phone Number

Fax Number

Prime Mover Information

Manufacturer

Turbine Model Number

Type of Fuel (gas, steam, etc.)

Power Output Rating

Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Control/Governor #2

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Control/Governor #3

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Symptoms
Description

If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.

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Appendix A.
Acronyms and Glossary of Terms

Acronyms
ADC Analog-to-Digital Converter
AWG American Wire Gauge (metric equivalent is mm²)
CE The CE marking is a European proof of conformity and is also
described as "passport" that allows manufacturers and exporters
to circulate products freely within the EU. The letters "CE"
(French for "Conformité Européenne") indicate that the
manufacturer has satisfied all assessment procedures specified
by law for its product.
CPU Central Processing Unit. Executes the GAP application program.
CT Current Transformer. Used to measure the generator or bus
current.
dc Direct Current
EEPROM Electrically Erasable and Programmable Read Only Memory
EMC Electromagnetic Conformity
EMI Electromagnetic Interference
GAP Graphical Application Program
I/O Input/Output
LED Light Emitting Diode
LON Local Operating Network
MFT Minor Frame Timer. Used by the CPU for scheduling execution
of the software.
MPU Magnetic Pick-Up
MTBF Mean Time Between Failures
PC Personal Computer
PCB Printed Circuit Board
PT Potential Transformer. Used to measure the generator or bus
voltage.
PWM Pulse Width Modulated
RAM Random Access Memory
RG Rate Group. Defines how often software is executed.
RTD Resistance Temperature Device
RXD Receive Data Line
SRAM Static Random Access Memory
SSTP Shielded-Shielded Twisted Pair (or Double Shielded Ethernet
Cables)
THD Total Harmonic Distortion
TXD Transmit Data Line
V/I Voltage-to-Current converter

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Glossary of Terms
Analog Input—A 4–20 mA or 0–5 V input on the SmartCore CPU A5200 board,
and a thermocouple, RTD or 4–20 mA input on the Analog Combo board.
Analog Output—A 4–20 mA output, usually the full range is 0–24 mA.
Atlas-II Analog Combo board—An Atlas-II board with an analog format that
connects to the Atlas-II SmartCore CPU A5200 board or PowerNet board,
through the PC/104 interface. It contains 15 analog inputs, 2 speed sensor
inputs, and 2 Analog outputs.
Atlas-II Chassis—A combination of pieces required to hold the boards together,
and may optionally include a keyboard and display.
Atlas-II Pentium CPU board—An Atlas-II board with a Pentium processor, for
applications with a single Ethernet connection.
Atlas-II Platform—The combination of boards, a power supply, and a chassis,
that can be combined to compose a variety of controls for a variety of
applications. The boards must have either a PC/104 connection, or a
proprietary power bus connection, and meet certain packaging constraints.
Atlas-II Power Supply board—An Atlas-II board with primary power supply and
12 discrete outputs.
Atlas-II SmartCore CPU A5200 board—An Atlas-II board with 6 analog inputs,
4 analog outputs, 2 actuator outs, 2 speed sensor inputs, 24 discrete inputs,
4 ethernet, 2 can, and 2 serial communication ports. This board includes
both the PC/104 and the power bus connections, allowing it to function as a
backplane.
Backplane—A board that ties other boards together electrically. Atlas-II needs
either the SmartCore CPU A5200 board, or the PowerNet board, to connect
the power bus voltages to the PC/104 bus.
Discrete Input—An input used for switches or other contacts, that registers only
two states, open or closed.
Discrete Output—Output drivers used for driving relays that register only two
states, high or low.
Serial Port—A connection for RS-232, RS-422, or RS-485.
Speed Sensor Input—An MPU or proximity probe input on the SmartCore CPU
A5200 board, and a MPU only input on the Analog Combo board.

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Appendix B.
Wiring Diagrams

Figure B-1. SmartCore CPU A5200 board Connections

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855-740
02-2-22

Figure B-2. Analog Combo Board Connections

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Figure B-3. PowerSense Board Connections

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Figure B-4. 12-Channel Relay Module Connections

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TOP BOTTOM

855-766
02-8-20

Figure B-5. DLE Connections

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Appendix C.
Flash Codes

Failure Flash Code

RAM Test Failure 1, 4
Real Time Clock Test Failure 2, 2
Floating Point Unit Test Failure 2, 3
Flash Test Failure 2, 4
HD1 Flash Test Failure 2, 5
I2C Bus Test Failure 2, 6
Module Installed in wrong slot 2, 7
Main Chassis CPU switch must be set to 0 3,5
Remote RTN Rate Group 5 Slip 3, 7
Remote RTN Rate Group 10 Slip 3, 8
Remote RTN Rate Group 20 Slip 3, 9
Remote RTN Rate Group 40 Slip 3, 10
Remote RTN Rate Group 80 Slip 3, 11
Remote RTN Rate Group 160 Slip 3, 12

Table C-1. SmartCore CPU A5200 Failure Codes

Number of LED Flashes Failure

1 Microprocessor failure
2 Bus, address, any unexpected exception error
5 Failure during EE test or erasing
7 Kernel software Watchdog count error
12 Failure during CPU Internal RAM test
13 Dual port RAM error

Table C-2 Analog Combo Failure Codes

Number of LED Flashes Failure

Off No failure, system OK
Solid Module in initialization mode
1 Hardware watchdog, CPU clock failure, reset fail
2 Unexpected Exception Error
3 RAM test failure
5 EEPROM failure
7 Kernel Watchdog Timeout
10 System Error
11 Board Identification Error
12 TPU RAM failure
13 Dual Port RAM test failure
14 QSM or ADC Initialization failure
15 Self test status failure
20 Invalid A/D converter selected
21 QSPI timeout
24 ADC auto calibration time-out

Table C-3. PowerSense Failure Codes

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LED and
Number of
Flashes Failure
H1 RAM test fail (this test is done only at boot and application start)
H2 exception error
H3 dual port test fail (this test is done only at boot and application start)
H4 watchdog timeout
H7 kernel watchdog timeout
D1 RAM test fail (this test is done only at boot and application start)
D2 exception error
D3 dual port test fail (this test is done only at boot and application start)
D3 module watchdog timeout
D7 kernel watchdog timeout

Table C-4. DLE Failure Codes

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Appendix D.
Board Addresses

Board address numbers are necessary in GAP to identify the location of each
board. Below are the possible combinations.

Figure D-1. Board Address Numbers

* NOTES—

All board addresses are factory configured.

When a DLE board is used, its address will always be 10.

Up to (2) Profibus modules may be used. Profibus communication

board(s) are configured differently and do not have the same type of
board number.

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Revision History

Changes in Revision F—
 Clarified third Features bullet (page 69)

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Declarations

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124 Woodward
 We appreciate your comments about the content of our publications.
Send comments to: [email protected]

Please reference publication 26415F.

PO Box 1519, Fort Collins CO 80522-1519, USA

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Phone +1 (970) 482-5811  Fax +1 (970) 498-3058

Email and Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.