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The Flex500 control system represents a new generation of turbine and engine control

Flex500 is an industrial hardware platform that offers robust, low-cost control for a wide variety of turbine, engine, and compressor applications. The platform’s real-time operating system and dedicated inputs and outputs provide deterministic performance for key prime mover control functionality. Its 0.5 ms I/O scan times, high accuracy, and software program synchronization make it ideal for use

in controlling and protecting critical high speed rotating equipment. 

Use the Flex500’s custom programmed hardware platform for prime mover control applications such as:

  • Gas turbines
  • Compressor control and protection
  • Gas and diesel engines
  • Steam turbines
  • Hydro turbines

 Optional Operator Control Panel (OCP)

The Flex500 controller’s optional user-friendly front panel serves as both a programming station and operator control panel (OCP). This front panel allows engineers to access and program the unit to specific plant requirements and lets plant operators easily start/stop the turbine and enable/disable any control mode. Password security is used to protect all unit program mode settings. The controller’s 5” graphical display allows operators to view actual and setpoint values from the same screen, simplifying turbine operation.

Distributed Control System (DCS) System

Designed to function as a distributed control system, Woodward-based RTCnet™ and/or LINKnet HT distributed I/O modules can be used in conjunction with the Flex500 platform to expand the number and type of input and output signals as required by the specific application.

Ethernet, serial and CAN communication ports, and the related Modbus® TCP/IP and CANopen protocols also make this platform ideal for functioning as part of an overall plant DCS or as a standalone controller. Four Ethernet ports and four CAN ports allow for the network flexibility and redundancy necessary for today’s critical control system architectures.

Flex500 features include:

  • Optional integrated graphical operator control panel
  •  Fast, accurate on-board I/O channels
  •  Combines real time control with PLC programming
  •  Deterministic scan rates as fast as 5 ms
  •  Distributed I/O capability
  •  Compliant with time synchronization protocol SNTP
  •  Networked control
  •  4 Ethernet ports
  •  4 CANopen ports
  •  RTCnet compatible
  •  Low cost alternative to a general purpose PLC
  •  Sulfur-resistant conformal coating
  • Certified for Hazardous Locations

Specifications include:


  • Power:  LV models: 18-32 Vdc / HV models: 88-264 Vac & 90-150 Vdc
  • Speed: 2 passive MPUs or 2 active proximity probes (0.5-32,000 Hz)
  • Discrete Inputs: 20 configurable contact inputs*
  • Analog Inputs: 8 configurable 4-20 mA inputs*



  •  Valve/Actuator Drivers: 2 actuator outputs, 4-20 mA or 20-200 mA
  •  Discrete Outputs: 8 configurable relay outputs
    (2 relays rated for 24 Vdc @ 5 A, 6 relays rated for 24 Vdc @ 2 As)*
  • Analog Outputs: 6 programmable 4-20 mA outputs*



  • Ethernet: 4 ports (Modbus TCP or OPC protocols)
  • Serial: 1 Modbus port (ASCII or RTU) comm ports
    (RS-232 or RS-485 compatible)
  •  CAN: 4 ports (CANopen protocol)

           (*) Optionally, additional inputs can be added via distributed I/O modules


  • Ambient Air Temperature Range: -25 °C to +65 °C (-13 °F to 149 °F)
  • 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 non-conductive 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)

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