WOODWARD Netcon Series Modules – 5437-672

Technical Dossier

Product Details And Specifications

WOODWARD Netcon Series Technical Notes

The WOODWARD Netcon series represents one of the most widely deployed distributed control architectures in global heavy industry. Installed across petrochemical refineries, combined-cycle power plants, nuclear auxiliary systems, and offshore platforms, the Netcon platform established WOODWARD's position as a tier-one supplier of turbine and engine control systems. Its modular backplane architecture allows field engineers to replace individual I/O, communication, and power modules without full controller shutdown, a critical requirement in continuous-process environments where unplanned outages carry six-figure hourly cost penalties. The Netcon system operates across a defined temperature range of 0–70°C ambient, with select ruggedized variants rated for extended industrial environments. Its deterministic scan cycle and redundant communication paths made it the reference architecture for gas turbine governor control from the late 1980s through the 2000s.

The Evolution of Netcon Architecture

The Netcon platform was introduced by WOODWARD in the mid-1980s as a successor to analog governor control panels. The first-generation Netcon 5000 series established the proprietary backplane bus standard and defined the physical form factor still used in legacy installations today. The second-generation Netcon architecture introduced distributed I/O expansion via the Netcon Field Terminal Module (FTM) concept, of which the 5437-672 is a primary example — enabling remote termination of field wiring up to 300 meters from the main controller chassis.

By the mid-1990s, WOODWARD expanded the Netcon ecosystem with enhanced CPU modules supporting IEC 61131-3 structured text programming, replacing earlier ladder-only configurations. Communication adapters were added to support Modbus RTU, PROFIBUS DP, and later DeviceNet, allowing Netcon controllers to integrate into plant-wide DCS environments from Honeywell, ABB, and Emerson. The platform entered its mature phase circa 2005–2010, with WOODWARD transitioning new projects to the MicroNet and ProTech platforms. As of 2026, the Netcon series is in end-of-life status; WOODWARD no longer manufactures new Netcon hardware, making third-party spare parts suppliers the primary source for ongoing maintenance and lifecycle extension.

Netcon Full Catalog & Functionalities (SKU List)

Field Terminal & I/O Modules

• 5437-672: Netcon Field Terminal Module; remote wiring termination block for distributed I/O expansion up to 300 m from main chassis.
• 5437-671: Netcon Field Terminal Module variant; alternate channel configuration for analog input termination.
• 5437-674: Netcon FTM with enhanced shielding for high-noise industrial environments.
• 5437-680: Analog Input Module; 8-channel, 4–20 mA, 12-bit resolution, field-configurable range.
• 5437-681: Analog Output Module; 4-channel, 4–20 mA, isolated outputs for actuator control.
• 5437-682: Digital Input Module; 16-channel, 24 VDC, optically isolated, for discrete field signals.
• 5437-683: Digital Output Module; 16-channel, 24 VDC relay-driven, 0.5 A per channel.
• 5437-684: RTD Input Module; 8-channel, PT100/PT1000 compatible, 3-wire configuration.
• 5437-685: Thermocouple Input Module; 8-channel, J/K/T/E type, cold-junction compensated.

CPU & Controller Modules

• 5437-700: Netcon CPU Module; primary controller, 32-bit processor, 512 KB application memory.
• 5437-701: Netcon CPU Module redundant variant; hot-standby configuration for critical turbine control.
• 5437-702: Netcon CPU with expanded memory; 1 MB application RAM, extended tag database.

Communication & Network Adapter Modules

• 5437-720: Modbus RTU Communication Adapter; RS-485, up to 115.2 kbps, master/slave configurable.
• 5437-721: PROFIBUS DP Adapter; DP-V0/V1, up to 12 Mbps, GSD file available.
• 5437-722: DeviceNet Communication Module; CAN-based, 125/250/500 kbps, 64-node support.

Power Supply Modules

• 5437-750: Netcon Power Supply Module; 24 VDC input, 5 VDC/3 A backplane output, short-circuit protected.
• 5437-751: Redundant Power Supply Module; dual-feed input, automatic failover, <10 ms switchover time.

Quality Control for the Netcon Range

WOODWARD Netcon modules present specific test challenges due to their proprietary backplane bus protocol and multi-layer PCB construction. DriveKNMS applies the following verification procedures to all Netcon inventory prior to dispatch:

• Backplane Bus Continuity Test: Each module is seated in a live Netcon test chassis and polled via the proprietary serial bus to confirm correct address response and data integrity.
• Analog Channel Calibration: All analog I/O modules (4–20 mA, RTD, thermocouple) are calibrated against NIST-traceable reference instruments. Calibration certificates are available on request.
• Digital I/O Functional Verification: Each digital input and output channel is individually exercised at rated voltage and current to confirm optocoupler and relay integrity.
• Power Supply Load Test: Power modules are tested under 100% rated load for a minimum of 30 minutes to screen for capacitor degradation and thermal drift.
• Visual and Component Inspection: All boards are inspected under 10× magnification for corrosion, cold solder joints, damaged traces, and non-original component substitutions.
• Firmware Version Logging: CPU and communication modules are connected to a WOODWARD programming interface to read and record firmware revision, ensuring compatibility documentation is shipped with each unit.