Woodward Atlas-II 8273-552 User manual

ProductManual 26415
(RevisionG, 1/2019)
Original Instructions
Atlas-II™ Digital Control
Installation and OperationManual
Released

General
Precautions
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.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
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
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.
Proper Use
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
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.
Translated
Publications
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
translation was made. Be sure to check manual 26455, Customer Publication
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 Out-of-date translations are marked with .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—A bold, black line alongside the text identifies changes in this publication since the
last revision.
Woodward reserves the right to update any portion of this publication atany time. Information provided by Woodw ard is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken. Manual 26415
Copyright © Woodward, Inc. 2007 - 2019
All Rights Reserved
Released

Manual 26415 Atlas-II Digital Control
Woodward 1
Contents
IOLOCK. Whena 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 ..................................................................................................................6
ELECTROSTATIC DISCHARGE AWARENESS........................................................................................7
REGULATORY COMPLIANCE...............................................................................................................8
CHAPTER 1. GENERAL INFORMATION...............................................................................................11
Information.......................................................................................................................................11
Atlas-II Control Description................................................................................................................11
Control Versions...............................................................................................................................12
Control Accessories..........................................................................................................................16
CHAPTER 2. INSTALLATION..............................................................................................................17
Introduction ......................................................................................................................................17
General Installation...........................................................................................................................17
Shipping Carton................................................................................................................................17
Mounting..........................................................................................................................................17
Environmental Specifications.............................................................................................................18
Non-Marine Enclosure Application Information....................................................................................22
Marine Enclosure Application Information...........................................................................................23
General Enclosure Application Information .........................................................................................24
Input Power......................................................................................................................................28
Maintenance.....................................................................................................................................30
Application Guidelines.......................................................................................................................30
CHAPTER 3. POWER SUPPLY BOARD...............................................................................................34
General Description..........................................................................................................................34
Troubleshooting Guide......................................................................................................................35
CHAPTER 4. SMARTCORE CPU A5200 BOARD ...............................................................................37
General Description..........................................................................................................................37
Released

Manual 26415 Atlas-II Digital Control
Woodward 2
SmartCore CPU A5200 Board Operation............................................................................................48
CHAPTER 5. ANALOG COMBO BOARD .............................................................................................62
General Description..........................................................................................................................62
Specifications...................................................................................................................................63
Analog Combo Board Operation ........................................................................................................67
Troubleshooting Guide......................................................................................................................72
General Description..........................................................................................................................74
Physical...........................................................................................................................................74
Hazardous Live ................................................................................................................................74
PowerSense Board Operation ...........................................................................................................80
Power Calculations...........................................................................................................................88
Troubleshooting Guide......................................................................................................................95
CHAPTER 7. 12-CHANNEL RELAY MODULE......................................................................................97
General Information ..........................................................................................................................97
Relay Information .............................................................................................................................98
Shielding..........................................................................................................................................98
Board Status Lights...........................................................................................................................98
Wiring..............................................................................................................................................98
CHAPTER 8. DLE SERIAL COMMUNICATION BOARD.......................................................................100
General Information ........................................................................................................................100
Application Developer Information....................................................................................................103
CHAPTER 9. PC104 PROFIBUS INTERFACE....................................................................................104
Introduction ....................................................................................................................................104
Profibus Software and Hardware Requirements................................................................................104
Hardware for End Users..................................................................................................................104
Software for Application Developers................................................................................................. 109
CHAPTER 10. PRODUCT SUPPORT AND SERVICE OPTIONS ............................................................110
Product Support Options .................................................................................................................110
Product Service Options..................................................................................................................110
Returning Equipment for Repair.......................................................................................................111
Replacement Parts .........................................................................................................................112
Engineering Services......................................................................................................................112
Contacting Woodward’s Support Organization ..................................................................................112
Technical Assistance ......................................................................................................................113
APPENDIX A. .................................................................................................................................114
ACRONYMS AND GLOSSARY OF TERMS .........................................................................................114
Acronyms.......................................................................................................................................114
APPENDIX B. .................................................................................................................................116
WIRING DIAGRAMS ........................................................................................................................116
APPENDIX C. FLASH CODES ..........................................................................................................121
REVISION HISTORY........................................................................................................................124
DECLARATIONS .............................................................................................................................125
The following aretrademarks of Woodward, Inc.:
Atlas-II
AtlasPC
DSLC
GAP
Woodward
Released

Manual 26415 Atlas-II Digital Control
Woodward 3
The following are trademarks of their respective companies:
Beldfoil (Belden Inc.)
DeviceNet (Open DeviceNet Vendor Association, Inc.[ODVA])
Modbus (Schneider Automation Inc.)
VxWorks (WindRiver Systems, Inc.)
Illustrations and Tables
Figure 1-1. Atlas-II, Example Module Layout.......................................................................................13
Figure 1-2a. Physical Dimensions......................................................................................................14
Figure 1-2b. Physical Dimensions......................................................................................................15
Figure 2-1. ScrewConnection Terminal Block Used on A5200 SmartCore Board..................................19
Figure 2-2. Spring Clamp Terminal Block ...........................................................................................19
Figure 2-3. Wiring Fixed Terminal ......................................................................................................20
Figure 2-4. Fixed Terminals...............................................................................................................20
Figure 2-5. Descriptions of Main Cabinet Cabling Options ...................................................................25
Figure 3-1. Atlas-II Power Supply Board (601-1008)............................................................................34
Figure 3-2. Discrete Output Wiring Example .......................................................................................36
Figure 4-1. SmartCore CPU A5200 board, Connectors........................................................................37
Figure 4-2. Block Diagram—Atlas-II SmartCore CPU A5200 Board......................................................39
Figure 4-3. SmartCore CPU A5200 Communications Ports (SIO1, SIO2) .............................................41
Figure 4-4. CPUService Port (mini-DIN6F) ........................................................................................41
Figure 4-5. CANCommunication Ports...............................................................................................42
Figure 4-6. CAN Network Multidrop....................................................................................................42
Table 4-4. CAN Cable Specification...................................................................................................43
Figure 4-7. MPU Minimum Input Magnitude in Vrms............................................................................44
Figure 4-8. MPU Maximum Input Magnitude in Vrms...........................................................................45
Figure 4-8. MPU Typical Input Impedance Magnitude and Phase.........................................................45
Figure 4-9. Wiring Example–MPU Interface to the SmartCore Board....................................................49
Figure 4-10. Wiring Example–Open Collector Proximity Probe to the SmartCore CPU A5200 Board ......49
Figure 4-11a. Wiring Example–4–20 mA Input Interface to the SmartCore CPU A5200 Board ...............50
Figure 4-11b. Wiring Example–4–20 mA Input Interface using External Loop Power .............................50
Figure 4-12. Wiring Example–Analog Output Interface to the SmartCore CPU A5200 Board..................51
Figure 4-13. Wiring Example–Actuator Output Interface to the SmartCore CPU A5200 Board................52
Figure 4-14. Wiring Example–Discrete Input Interface to the SmartCore CPU A5200 Board ..................53
Figure 4-15. Serial #1–RS-232 Pinouts ..............................................................................................54
Figure 4-16. Serial #1–RS-422 Pinouts ..............................................................................................54
Figure 4-17. Serial #1–RS-485 Pinouts ..............................................................................................55
Figure 4-18. Serial #2–RS-232 Pinouts ..............................................................................................55
Figure 4-19. Serial #2–RS-422 Pinouts ..............................................................................................56
Figure 4-20. Serial #2–RS-485 Pinouts ..............................................................................................56
Figure 4-21. Wiring Example–RS-232 Interface to the SmartCore CPU A5200 Board............................57
Figure 4-22. Wiring Example–RS-422 Interface to the SmartCore CPU A5200 Board............................57
Figure 4-23. Wiring Example–RS-485 Interface to the SmartCore CPU A5200 Board............................57
Figure 4-24. Wiring Example–Alternate Multipoint Wiring.....................................................................57
Figure 5-1. Atlas-II Analog Combo Board Connections........................................................................62
Figure 5-2. Atlas-II Analog Combo Board Block Diagram.....................................................................63
Figure 5-3. Minimum MPU Voltage ....................................................................................................66
Figure 5-4. Wiring Example–MPU Interface to the Analog Combo Board..............................................68
Figure 5-5a. Wiring Example–Analog Input Interface...........................................................................69
Figure 5-5b. Wiring Example–Analog Input Interface with External Loop Power ....................................69
Figure 5-6. Wiring Example–4–20 mA Input Interface..........................................................................69
Figure 5-7. Wiring Example–RTD Input Interface ................................................................................70
Figure 5-8. Wiring Example–Analog Output Interface..........................................................................71
Figure 6-1. Terminal Block Covers.....................................................................................................75
Figure 6-2. PowerSense Board Connections ......................................................................................76
Figure 6-3. PowerSense Board Block Diagram ...................................................................................77
Released

Manual 26415 Atlas-II Digital Control
Woodward 4
Figure 6-4. Wiring Example–Wye Connected System..........................................................................82
Figure 6-5. Wiring Example–Wye Connected System..........................................................................83
Figure 6-6. Example Wiring–Wye Connected System..........................................................................84
Figure 6-7. Wiring Example–Delta Connected System.........................................................................85
Figure 6-8. Wiring Example–Delta Connected System.........................................................................86
Figure 6-9. Wiring Example–CT Interface to the PowerSense Board ....................................................89
Figure 6-10. Wiring Example–CT Interface to the PowerSense Board ..................................................90
Figure 6-11. Wiring Example–Speed Bias Output Interface..................................................................91
Figure 6-12. Wiring Example–Speed Bias Output Interface..................................................................92
Figure 6-13. Wiring Example–Voltage Bias Output Interface................................................................93
Figure 6-14. Wiring Example–Voltage Bias Output Interface................................................................93
Figure 6-15. Wiring Example–LONInterface to the PowerSense Board................................................94
Figure 7-1. 12-Channel Relay Module................................................................................................97
Figure 7-2. 12-Channel Relay Module Wiring Diagram........................................................................99
Figure 8-1. DLE Connections...........................................................................................................100
Figure 8-2. Terminator Locations .....................................................................................................101
Figure B-1. SmartCore CPUA5200 board Connections.....................................................................116
Figure B-2. Analog Combo Board Connections.................................................................................117
Figure B-3. PowerSense Board Connections....................................................................................118
Figure B-4. 12-Channel Relay Module Connections ..........................................................................119
Figure B-5. DLE Connections..........................................................................................................120
Figure D-1. Board Address Numbers................................................................................................123
Table 1-1. Atlas-II Modules................................................................................................................12
Table 1-2. VxWorks Atlas-II ItemNumbers .........................................................................................12
Table 2-1. Shield Termination Combinations.......................................................................................26
Table 2-1. Power Supply Requirements .............................................................................................29
Table 3-1. Specifications...................................................................................................................35
Table 4-1. SmartCore CPU A5200 LED Names and Descriptions ........................................................40
Table 4-2. Ethernet Port Pinout..........................................................................................................41
Table 4-3. CAN Network Cable Specifications ....................................................................................42
Table 4-5. Recommended Bulk Cable Manufactures and Part Numbers...............................................43
Table 4-6. Digital Speed Sensor Inputs ..............................................................................................43
Table 4-7. MPU Inputs ......................................................................................................................44
Table 4-8. Proximity Probe Inputs ......................................................................................................46
Table 4-9. Analog Inputs ...................................................................................................................46
Table 4-10. Analog Outputs...............................................................................................................47
Table 4-11. Actuator Outputs.............................................................................................................47
Table 4-12. Discrete Inputs................................................................................................................48
Table 4-13. Serial I/O........................................................................................................................48
Table 4-14. SmartCore CPU A5200 Failure Codes..............................................................................59
Table 5-1 Analog Combo Failure .......................................................................................................71
Table 6-1. Specifications...................................................................................................................78
Table 6-2. PT/CT Accuracy Table ......................................................................................................80
Table 6-3. PowerSense Failure Codes ...............................................................................................94
Table 8-1. Termination Resistors and Pin Connections......................................................................102
Table 8-2. DLE Failure Codes..........................................................................................................102
Table 9-1. Electrical and Technical Specifications.............................................................................104
Table 9-2. Profibus—Type A Cable..................................................................................................105
Table 9-3. Profibus—Type B Cable..................................................................................................105
Table 9-4. Bulk Cable Manufactures and Part Numbers ....................................................................105
Table 9-5. Belden Profibus Cable.....................................................................................................105
Table 9-6. Recommended Profibus Cable Connector ........................................................................106
Table 9-7.Alternate Profibus Connectors ..........................................................................................106
Table 9-8. Profibus—Siemens RS-485 Bus Connector / Plastic .........................................................106
Table 9-9. Profibus—Siemens RS-485 Bus Connector / Metal...........................................................106
Table 9-10. I/O Connector Pinout.....................................................................................................107
Table 9-11. Allen-Bradley FlexI/O ...................................................................................................108
Table 9-12. Automation Direct Terminator I/O...................................................................................108
Released

Manual 26415 Atlas-II Digital Control
Woodward 5
Table C-1. SmartCore CPU A5200 Failure Codes.............................................................................121
Table C-2 Analog Combo Failure Codes ..........................................................................................121
Table C-3. PowerSense Failure Codes.............................................................................................121
Table C-4. DLE Failure Codes.........................................................................................................122
Released

Manual 26415 Atlas-II Digital Control
Woodward 6
Warnings and Notices
Important Definitions
This is the safety alert symbol 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.
Overspeed /
Overtemperature /
Overpressure
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,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Personal Protective
Equipment
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 at hand. Equipment that should be considered includes but is
not limited to:
Eye Protection
Hearing Protection
Hard Hat
Gloves
Safety Boots
Respirator
Always read theproper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start-up
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
property damage.
Released

Manual 26415 Atlas-II Digital Control
Woodward 7
Electrostatic Discharge Awareness
Electrostatic
Precautions
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
contact while handling the control).
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. Wearcotton 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 circuitboard (PCB) from the control cabinet unless absolutely necessary.
If youmust 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.
Whenreplacing 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 fromthe control cabinet,
place it in the antistatic protective bag.
External wiring connections for reverse-acting controls are identical
to those for direct-acting controls.
Released

Manual 26415 Atlas-II Digital Control
Woodward 8
Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.
EMC Directive:
Declared to Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014 on the harmonization of the laws of the
Member States relating to electromagnetic compatibility. (EMC)
ATEX –Potentially
Explosive
Atmospheres
Directive:
Directive 2014/34/EU on the harmonization of the laws of the Member
States relating to equipment and protective systems intended for use in
potentially explosive atmospheres.
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 of
Shipping:
Rules for Conditions of Classification, Part 1 - 2017 Steel Vessels Rules 1-
1-4/7.7,1-1-A3, 1-1-A4, which covers the following: 2017 Steel Vessels
Rules: 4-2-1/7.3, 4-2-1/7.5.1, 4-9-3/11.9, 4-9-5/17, 4-9-6/23, & 4-9-8/13
Table 1 & 2 (as appropriate)
Det Norske Veritas:
DNV GL Rules for Classification - Ships and Offshore Units
DNV GL Rules for Classification - High-Speed and Light Craft
Temperature Class B, Humidity Class B, Vibration Class A, and EMC
Class A.
Lloyd’s Register of
Shipping:
LR Type Approval Test Specification No. 1, 2002 for Environmental
Categories ENV1, ENV2, and ENV3
Special Conditions For Safe Use:
This Equipment is Suitable For Use inClass I, Division 2, Groups A, B, C, D or Non-Hazardous Locations
Only.
This equipment issuitable for use inEuropean 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 requiredfor 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
Wiringmust be in accordance with North American Class I, Division 2, or European Zone 2, Category 3
wiring methods as applicable, and inaccordance with the authority having jurisdiction.
Released

Manual 26415 Atlas-II Digital Control
Woodward 9
A fixed wiring installation is required and a switch or circuitbreaker 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 circuitbreaker shall not
interrupt the protective earth conductor.
Do not connect more than one main power supply to any one fuse or circuitbreaker.
Protective Earth Grounding isrequired 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 astandard 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.
The Atlas-II Actuator and Analog outputs are intended to drive loads
that are isolated from protective earth, like actuators and meters.
Released

Manual 26415 Atlas-II Digital Control
Woodward 10
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 theappropriate sections for more details.)
Released

Manual 26415 Atlas-II Digital Control
Woodward 11
Chapter 1.
General Information
Information
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/Ointerfaces
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 isprogrammed to the specificneeds 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 programhas been generated
and loaded into the Atlas-II control, the user canview 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 canbe connected using optional communication modules that
support Profibus and DLE Communications.
The hardwareplatform isbased onthe industry-standardPC/104bus structure.Inthe Atlas-II control, the
backplane is the SmartCore board. The PC/104 modules are “stacked” onto the SmartCore board in order
to add I/Oor other functionality.Eachof the stacked modules has an on-boardDIP switch that is positioned
to the unique address of that particularmodule. The Atlas-II control uses asecond stack called the Power
Bus Stack.This stack isused primarilyfor power-related I/O.The controlruns on low-voltage DCpower
(18–32 Vdc).Atlas-II fieldwiringis accomplished via terminal blocks that plug intothe control modules.
Released

Manual 26415 Atlas-II Digital Control
Woodward 12
Control Versions
The Atlas-II control provides a flexible platform that canbe structured into a wide variety of configurations
of I/Oand communications. The required number of I/O modules and the types of communication
modules that are requiredwill depend entirely on the specific application scenario. Table 1-1 shows the
various modules that are available.
Table 1-1. Atlas-II Modules
Atlas-II Module List
Power Supply
SmartCore CPU A5200
PowerSense
Analog Combo I/O
DLE Communications
Profibus
Table 1-2. VxWorks Atlas-II Item Numbers
Atlas-II
Item
Number
Operating
System
Atlas-II
A5200
Power-
Sense
Analog
Combo
DLE
Com
Profibus
Cooling
Fan
Description
8273-552
VxWorks
1
2
2
X
ATLAS II, 2 X 5, A5200, LV, 2
COMBO, 2 PROFIBUS
8273-553
VxWorks
1
1
1
ATLAS II, 2 X 4, A5200, LV, 1
COMBO, 1 DLE
8273-555
VxWorks
1
3
X
ATLAS II, 2 X 4, A5200, LV, 3 COMBO
8273-556
VxWorks
1
1
1
ATLAS-II, 3 X 4, A5200, LV, PSENSE,
1 COMBO
8273-557
VxWorks
1
1
2
X
ATLAS-II, 3X4 A5200, PSENSE, LV, 2
COMBO
8273-560
VxWorks
1
3
1
X
ATLAS-II, 2X5, A5200, LV, 3 COMBO,
1 PROFIBUS
8273-562
VxWorks
1
1
2
1
X
ATLAS II, 3 X 5, A5200, PSENSE, LV,
2 COMBO, 1 PROFIBUS
8273-565
VxWorks
1
1
ATLAS-II, 2 X 2, A5200, LV, 1 COMBO
8273-570
VxWorks
1
1
1
X
ATLAS-II, 2 X 4, A5200, LV, 1
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
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 canbe substituted. Figure 1-1 shows a “maximum” example
configuration (5 levels high).
Released

Manual 26415 Atlas-II Digital Control
Woodward 13
Figure 1-1. Atlas-II, Example Module Layout
Released

Manual 26415 Atlas-II Digital Control
Woodward 14
Figure 1-2a. Physical Dimensions
Released

Manual 26415 Atlas-II Digital Control
Woodward 15
Figure 1-2b. Physical Dimensions
Released

Manual 26415 Atlas-II Digital Control
Woodward 16
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 programloading, 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.
Released

Manual 26415 Atlas-II Digital Control
Woodward 17
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
Whenselecting alocation for mounting the Atlas-II control, consider the following:
Protect the unit fromdirectexposure to water or to a condensation-prone environment.
The control is designed 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 fromradiant heat sources.
Do not install the unit or its connecting wires near inductive, high-voltage, or high-current devices. If
this isnot 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.
Wheninstalling on a generator set package, provide vibration isolation.
Shipping Carton
Before unpacking the control, refer to the inside front cover and page 4i of this manual for WARNINGS
and CAUTIONS. Be carefulwhen 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.
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.
Released

Manual 26415 Atlas-II Digital Control
Woodward 18
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 3.4and 4.5 kg (7.5and 10 pounds). A minimum of 25 mm (1 inch)of clear space around the
outer surfacesof 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 specifiedambient temperature of
–40 to +70 °C(–4 to +158 °F) with forcedconvection 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).
Continuousoperationwithinsufficient airflow or higher operating
temperatureswilllead toreducedreliability 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 isrecommended 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.
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.
Released