PMCS-B- 0011-17 (Revision New, 08/2018) FLEX500-HF Digital Turbine Control - Hydro Francis 32-Bit processor Based Digital Control Integrated Graphical operator control panel Real time trending Trip and event recorder Remote view QT interface option Field configurable though QT interface APPLICATION The Flex500-HF controls Hydro turbines driving electrical generators. Its configurable program provides control of Francis turbines (one actuator applications). The Flex500-HF provides the electronic brains to control the turbine s hydraulic control system and auxiliary functions, and operates as either a stand-alone unit governor or in conjunction with a plant s Distributed Control System (DCS). DESCRIPTION The Flex500-HF contains a fixed number of inputs and outputs. The inputs and outputs can be programmed to meet specific customer s requirements. It also provides several user selectable features including: starting, stopping, gate/blade positioning, speed control, load control, pond level control, and automatic-manual/local remote operation. A first-out indication feature for system shutdowns reduces troubleshooting time. The menu driven software allows program configuration of the control for a specific application. The Flex500-HF is a fully digital electronic control, and uses a 32-bit MPC 5125 to perform all of its control functions. The microprocessor control package consists of printed circuit boards in an enclosure designed to be mounted within a system control panel. Removable terminal blocks allow for easy wiring and installation. COMMUNICATIONS The Flex500-HF includes an 8-inch (20 cm) graphical front panel screen and related keypad. It provides monitoring and operational information. System configuration is done through QT Interfacing software. The display presents easy-to-follow instructions in plain English expressed in engineering units. Discrete and analog input and output signals can be wired directly to the Flex500-HF to control the unit externally. Fast, accurate on-board I/O channels Deterministic scan rates as fast as 5ms LinkNet HT Distributed I/O capability Modbus serial & ethernet communications Level Control Capability (pond or tail) Creep Detection Brake function Integral Overspeed Protection Designed to meet IEEE 125, IEEE-1207, IEC 61362 Gate Limit Functionality Bumpless control mode transfer
The Flex500-HF can communicate directly with HMI based operator control panels and/or the plant s DCS through four Ethernet ports using Modbus TCP or OPC communication protocols, or via one serial Modbus port. The single serial port supports RS-232 or RS-485 communications using ASCII or RTU Modbus protocols. The discrete and analog input and output signals can also be hard-wired directly to a DCS if required by the application. Communications between the Flex500-HF control and a plant DCS can also be performed through hardwired connections. FLEXIBILITY The Flex500-HF is field configurable via QT interface software, allowing site engineers to configure the control to their specific application, and to make future control configuration changes. On-line tunables are available to allow set point adjustments while a unit is running. Inputs and Outputs are programmable as required by the application or interface. FEATURES Feed forward control Remote analog setpoints for Speed, Gate, Level, Power, and Manual Control Isochronous loadsharing via Woodward DSLC-2 Gate limit Selectable start mode (auto/manual) Selectable actuator outputs (4-20mA/20-160mA) Dual speed inputs Creep detection option (available with proximity probes) Local/remote control Wide speed setting range option (85% - 110%) Generator breaker logic Bumpless control mode transfer Level switches for: Speed, Gate Position and Gate Limit. Selectable brake operation Dynamics for each control mode First-out indication of shutdowns Real time clock indicated Alarms and Trips log Four Ethernet and One Serial independent Modbus communications ports System configuration via QT interface SYSTEM PROTECTION Integral Overspeed Protection Logic First-out Indication (1 individual Shutdown input) Bumpless transfer between control modes Local/Remote Control priority and selection Fail-safe Shutdown Logic CONTROL Speed for Droop and Isochronous Position (with Speed Droop) for Gate Set Point, Power (KW Droop), and Pond Level (Tailrace or Forebay) Manual Gate Limit FUNCTIONALITY Speed/Frequency control including Isochronous and Droop Modes Auxiliary control modes for Power, Level, Gate Position Integrated manual control ADD-ON I/O POINTS OPTION Optionally users can increase the number and type of input and output signals to/from the Flex500-HF controller by utilizing and connecting three Woodward s LINKnet HT distributed I/O modules (DI, DO and AIO) to the Flex500 s CAN communication ports.
CONTROL SPECIFICATIONS INPUTS Power LV models = 18 32 Vdc HV models = 88 264 Vac & 90 150 Vdc Speed 2 Passive MPUs or 2 Active Proximity probes (usable for PT interface Input) (0.5 32 000 Hz) Discrete Inputs 20 configurable contact inputs (optionally, additional inputs can be added via distributed I/O modules) Analog Inputs 8 Configurable 4 20 ma Inputs (optionally, additional inputs can be added via distributed I/O modules) OUTPUTS Actuator Drivers 2 Actuator Outputs (4-20mA or 20-160mA) Discrete Outputs 8 configurable relay outputs (2 relays rated for 24 Vdc @ 5 A, 6 relays rated for 24 Vdc @ 2 A) (optionally, additional outputs can be added via distributed I/O modules) Analog Outputs 6 (4-20mA) Programmable (optionally, additional outputs can be added via distributed I/O modules) COMMUNICATION Serial 1 Modbus (ASCII or RTU) Comm Ports (RS232, RS422 or RS485 compatible) Ethernet 4 ports (Modbus TCP or OPC protocols) CAN 4 ports (CANopen protocol)
OPERATING CONDITIONS 25 to +65 C ambient air temperature range Humidity: Lloyd s ENV2 test #1 Dry Heat: Lloyd s ENV3 Salt Fog: US MIL-STD-810 method 509.2 procedure 1 Shock: meets US MIL-STD-810C, method 516.2-1, procedure 1B Vibration: Lloyd s ENV2 test #1 Pollution Resistance Particulate Pollution Resistance: IEC 664-1 Pollution Degree 2 (Normally only nonconductive pollution occurs. IEC 60068-2-60:1995 Part 2.60 Methods 1 and 4 (Flowing Mixed Gas Corrosion Test). Gaseous Pollution Resistance: Module conformal coating withstands NO2, CO2, SO2, and H2S gases. Will withstand levels typical of telecommunications and computer installations as defined by Battelle Labs Class III (between IEC60721-3-3 classification 3C1 and 3C2, light industrial to urban industrial, heavy traffic). REGULATORY COMPLIANCE European Compliance for CE Marking: These listings are limited to only those units bearing the CE Marking. EMC Directive: 89/336/EEC COUNCIL DIRECTIVE ATEX Directive: 94/9/EEC COUNCIL DIRECTIVE Zone 2, Category 3, Group II G EEx na II T3 X Other International Compliance: GOST R: Certified for use in explosive atmospheres within the Russian Federation per GOST R certificate POCC US. ГБ04.B01002 as 2ExnAIIT3X. C-Tick (ACA/RSM): North American Compliance: UL: Declared to Australian Radiocommunications Act of 1992 and the New Zealand Radiocommunications Act of 1989. UL Listed for Class I, Division 2, Groups A, B, C, and D. T3A at +60 C Ambient (rear enclosure provided) and T3B at +65 C Ambient (rear enclosure omitted) for use in Canada and the United States. UL File E156028. Marine Compliance: Lloyd s Register (LR): FRANCIS TURBINE APPLICATION Environmental Category ENV3, Lloyd s Register Type Approval Test Specification Number 1, July, 2013.
FRANCIS TURBINE APPLICATION Models Part Numbers Flex500-HF - Panel Mount - OCP, LV CFL0001SS Flex500-HF - Panel Mount - OCP, HV CFL0002SS Flex500-HF - Bulkhead, LV CFL0003SS Flex500-HF - Bulkhead, HV CFL0004SS Flex500-HF RemoteView - Software License 5501-0205 For more information contact: PM Control Systems Pte Ltd Tel: (65) 6779 2822 Fax: (65) 6777 6301 Email: sales@pmcontrol.com.sg