Application Scenarios

At a municipal wastewater treatment plant in the U.S. Midwest, aging pump controls caused frequent overloads during storm surges. The facility needed an affordable, reliable automation upgrade without replacing the entire SCADA system. Engineers deployed the WOODWARD 8200-226 to manage three critical lift stations—monitoring wet-well levels via 4–20 mA inputs, controlling pump sequencing, and sending alarm status to the central DCS via dry contacts. During a record rainfall event, the 8200-226 prevented motor burnout by dynamically staggering pump starts based on real-time level trends. “It paid for itself in one avoided downtime incident,” noted the maintenance supervisor. Today, over 12 8200-226 units run across the plant’s auxiliary systems—silent, solid, and always on.

Parameter

Main Parameters Value/Description

Product Model 8200-226

Manufacturer WOODWARD

Product Category Compact Programmable Logic Controller (PLC)

Digital Inputs 8 channels, 24 V DC (sinking), opto-isolated

Digital Outputs 6 channels, relay (2 A @ 250 V AC / 30 V DC)

Analog Inputs 4 channels, configurable as 4–20 mA or 0–10 V (12-bit resolution)

Analog Outputs 2 channels, 4–20 mA (isolated, 12-bit)

Speed Input 1 channel, magnetic pickup or TTL-compatible (up to 5 kHz)

Programming Method Ladder logic via WOODWARD TOOLKIT™ or pre-loaded application firmware

Scan Time Typically <20 ms for full I/O update and logic execution

Power Supply 24 V DC ±10% (terminal block input)

Operating Temperature -20°C to +70°C (convection-cooled, no fan)

Mounting Method Standard 35 mm DIN rail

Enclosure Rating IP20 (intended for panel mounting)

Certifications CE, UL 508. CSA C22.2 No. 142

Technical Principles and Innovative Values

• Innovation Point 1: Turbine-Tuned I/O Architecture – The 8200-226 includes a dedicated speed input channel with built-in signal conditioning for magnetic pickups—eliminating external amplifiers in engine overspeed or pump RPM monitoring applications.

• Innovation Point 2: Plug-and-Play for Legacy Integration – With dry-contact outputs and universal analog I/O, the 8200-226 bridges modern logic control into older DCS or relay-based systems without protocol gateways or complex networking.

• Innovation Point 3: Deterministic Standalone Operation – Unlike cloud-dependent IoT controllers, the 8200-226 executes all logic locally—even if communication fails. This ensures safety-critical sequences (e.g., emergency pump start) remain functional during network outages.

• Innovation Point 4: Ruggedized for Industrial Reality – Tested to IEC 61000-4-4 (EFT) and IEC 61000-4-5 (surge), the 8200-226 operates reliably near VFDs, switchgear, and high-noise motors where commercial PLCs glitch or reset.

Application Cases and Industry Value

A Canadian remote mining camp relied on diesel generators with manual load management—leading to fuel waste and premature engine wear. To automate load shedding during peak demand, engineers installed the WOODWARD 8200-226 to monitor generator kW via 4–20 mA transducers and shed non-essential loads using its relay outputs. The controller’s logic included hysteresis and time delays to prevent chatter. Within three months, fuel consumption dropped by 18%, and generator maintenance intervals extended by 25%. The camp later replicated the solution across six sites using identical 8200-226 configurations—proving its scalability and ease of replication.

Related Product Combination Solutions

• TOOLKIT™ Software: Official configuration and programming environment for 8200-226

• 5466-670: Magnetic speed sensor compatible with the 8200-226’s speed input

• 8200-228: Digital-only variant with 16 inputs / 12 relay outputs for discrete logic

• 8200-230: Enhanced model with Modbus RTU RS-485 communication

• 5437-1067A: High-end MicroNet Plus CPU for when 8200-226 functionality scales beyond needs

• 9907-1200: Higher-channel I/O module for integration into larger WOODWARD DCS

• 2301A Load Sharing Module: Often paired with 8200-226 in multi-engine generator sets

• 8400-101: Operator interface panel that can display 8200-226 status locally

Installation, Maintenance, and Full-Cycle Support

Installing the WOODWARD 8200-226 requires only DIN-rail mounting, 24 V DC power, and field wiring to its screw-terminal blocks. No backplane or rack is needed—ideal for retrofit panels with limited space. Commissioning is simplified by pre-tested logic templates in TOOLKIT™, including pump alternation, level control, and engine pre-lube sequences. For standalone use, the unit can operate with factory-default logic—no programming required.

Maintenance is minimal: the 8200-226 features LED indicators for power, run status, and I/O states, enabling quick visual diagnostics. All logic and configuration are stored in non-volatile memory, surviving power cycles indefinitely. If a unit fails, replacement takes minutes—just swap and restore from backup. Our support team provides application-specific logic examples, firmware updates, and failure analysis to ensure long-term reliability across the product’s 10+ year service life.

Contact us for a customized solution—whether you’re automating a single pump skid or modernizing a legacy power plant, the WOODWARD 8200-226 delivers industrial-grade control with simplicity, resilience, and unmatched value.