Woodward 5501-381

Product Brief Introduction

• Woodward 5501-381 is factory calibrated plug-in switching power supply exclusively designed for Woodward MicroNet TMR triple redundant turbomachinery control chassis, responsible for converting input AC power into stable DC working bus voltage for all CPU, I/O and communication modules installed inside TMR chassis.
• This product supports hot-swap online replacement under full system live running state without interrupting continuous power supply of entire TMR control rack, which is core redundant power configuration for critical non-stop power generation equipment control cabinet.
• Every finished unit passes full-load aging test, input surge withstand test, insulation voltage test and four-channel fault indicator functional inspection before factory delivery; each single module carries exclusive serialized production number for full lifecycle spare part traceability management.
• It matches standard MicroNet TMR 14-slot VME backplane chassis, maximum two identical 5501-381 modules can be deployed inside one single TMR chassis for dual redundant power parallel backup configuration.

3. Technical Specification

• Rated AC input voltage: 220VAC, allowable input fluctuation range: 187VAC ~ 242VAC
• Input rated frequency range: 47Hz ~ 63Hz industrial universal AC frequency band
• Max rated input apparent power: 1250VA, maximum input rated current: 6.7A
• Input overcurrent protection configuration: built-in 10A time-delay type input fuse at AC input terminal
• DC output rated specification: DC24V stabilized bus output, continuous rated output current: 30A per single module
• AC input power hold-up time: 1 full AC cycle under rated 220VAC input condition during instantaneous power dip
• Overall outer dimension: 203.2mm(L) ×152.4mm(W) ×50.8mm(H)
• Net single module weight: 0.70kg excluding external connecting cable
• Protection grade after cabinet installation: IP20 compliant with IEC60529 standard
• Continuous working ambient temperature range: -40℃ ~ +70℃; storage extreme temperature range: -55℃ ~ +85℃
• Working relative humidity scope: 5%RH ~95%RH non-condensing environment without corrosive gas accumulation
• EMC certification standard: CE, UL508, ISO9001 factory certification fully passed
• Vibration resistance index: comply with IEC60068-2-6 standard, withstand 3g RMS vibration within 10Hz~500Hz frequency range during continuous operation

4. Functional Features

1. Built-in full-isolation switching power conversion circuit, completes AC220V to stabilized DC24V conversion and electrical isolation between input AC side and control cabinet DC bus side to cut common-mode ground interference path.
2. Front panel equipped with four independent status LED indicator lamps, separately marked Input Fault, Power Fault, Overtemperature and System OK for real-time running status visualization monitoring.
3. Standard VME64X rear plug connector structure supports hot-plug disassembly and replacement; internal instant surge suppression circuit automatically stabilizes bus voltage during module plugging action to avoid system undervoltage trip.
4. Internal dual-level overvoltage, overcurrent and overtemperature three-stage protection circuit; corresponding protection action triggers automatic cut-off of power output once any abnormal operating parameter exceeds rated threshold.
5. Built-in parallel current-sharing control circuit, two pieces of 5501-381 modules can run in parallel redundant mode inside one TMR chassis with balanced load current distribution automatically assigned between dual power units.
6. Embedded passive EMI filter at AC input terminal to filter high-frequency clutter and power-frequency harmonic interference transmitted from factory AC power grid side.
7. Reserved external fault dry-contact signal output terminal on module side for connecting cabinet DCS remote fault alarm system to realize remote abnormal state upload.
8. Surface reserved white label marking area for manual filling of equipment unit number and installation slot number for later maintenance management work.

5. Performance Parameter

• DC output voltage precision: ±0.5%FS under rated full-load 30A output and 25℃ standard ambient condition
• Output long-term continuous drift: ≤0.04%FS per 24-hour full-load uninterrupted running under constant-temperature environment
• Parallel current sharing deviation between dual redundant modules: ≤3% of rated single-module output current under random load change condition
• Input power hold-up characteristic: DC output voltage maintains above DC21.6V within one AC cycle after sudden AC input power loss at rated operating status
• Insulation resistance between AC input circuit and DC output circuit: ≥1500MΩ tested with DC500V megohmmeter under normal ambient
• Withstand voltage value between input and output: AC2000V/1min no breakdown and no creepage discharge phenomenon
• Module overtemperature protection trigger threshold: internal core temperature reaches +85℃ to activate automatic output shut-off protection
• AC input surge withstand capacity: withstand 2kV instantaneous surge pulse at input port per IEC61000-4-5 standard without internal component damage

6. Material Composition

Core PCB Circuit Board

• Substrate material: FR-4 TG150 high-temperature flame retardant epoxy glass fiber board, 6-layer laminated PCB structure; power layer copper foil thickness 35μm, signal layer copper foil thickness 18μm, board surface adopts lead-free HASL anti-oxidation coating.

Outer Metal Housing & Heat Dissipation Radiator

• Outer shielding shell: cold-rolled SPCC steel plate with black matte electrophoretic anti-corrosion coating, plate thickness 1.2mm; built-in radiator fin: extruded aluminum alloy with natural oxidation surface treatment for power tube heat dissipation.

Connector & Conductive Components

• Rear VME plug connector plastic base: UL94-V0 grade glass fiber filled PA66 nylon; internal contact pins: phosphor bronze with 0.8μm full gold plating for anti-oxidation stable conduction.
• AC input terminal conductive inserts: H62 brass raw material with nickel plating surface anti-corrosion treatment; fixed assembly screws: SUS304 stainless steel fasteners.

Internal Electronic Components

• Main switching power tube: industrial wide-temperature grade IGBT power device; input filter capacitor: high-temperature aluminum electrolytic capacitor and polypropylene film capacitor combination; protection components: SMD TVS diode, organic PTC resettable fuse and bimetallic overtemperature cut-off switch.

7. Structural Characteristics

1. Overall split three-section compact structure: front panel indicator section, middle internal circuit and radiator section, rear VME plug connector section, three parts fixed with evenly distributed stainless steel anti-loose screws into integrated whole unit.
2. Front panel four LED lamps arranged in horizontal equidistant layout with corresponding silk-screen fault function identification text printed directly on panel surface.
3. Bottom side reserved integrated limit guide rail structure matching MicroNet TMR chassis VME slot track to ensure vertical smooth plug-in without lateral deflection during installation.
4. Upper and lower shell surfaces designed with dense strip-shaped ventilation slot for natural convection heat dissipation of internal power heating components.
5. Side wall reserved independent AC wiring terminal small window with removable plastic dust baffle to block foreign dust falling into internal wiring terminal space when unused.
6. Internal PCB fixed with high-temperature insulating plastic support pillars to maintain fixed safe clearance between circuit board and metal shell to avoid accidental short-circuit caused by metal debris falling.

8. Working Principle

1. External site AC220V industrial power source connects module AC input terminal via shielded power cable; input AC signal first passes built-in EMI filter to eliminate grid clutter interference before entering rectifier and switching conversion circuit.
2. Internal high-frequency switching circuit converts alternating current into stable DC24V direct current after isolation transformation, then outputs to TMR chassis backplane power distribution bus via rear VME connector pins.
3. When two 5501-381 modules work in parallel redundant state, onboard current-sharing circuit automatically distributes chassis total load current evenly between two power units; single faulty module exits output automatically while the other module bears full chassis load without DC bus voltage collapse.
4. Four real-time detection circuits separately monitor input voltage state, internal power circuit working condition, core temperature and output voltage; corresponding LED lamp lights up immediately once any monitored parameter exceeds normal rated range to indicate specific fault category.
5. Internal three-stage protection circuit activates instant shut-off of DC output when short-circuit, overcurrent or overtemperature abnormal condition occurs to prevent back-end chassis loaded control modules from overvoltage burnout damage.
6. External dry-contact fault signal outputs switch state change synchronously along with internal fault triggering for transmitting abnormal alarm signal to upper-level DCS monitoring system to realize remote fault early warning.

9. Advantage Highlights

1. Exclusive customized design for Woodward MicroNet TMR control chassis realizes zero dimensional and electrical compatibility error during VME slot plug-in assembly, eliminating non-original power adapter matching hidden danger.
2. Full hot-swap function realizes single faulty power module online replacement without entire control system power outage, greatly improving uninterrupted operation reliability of power station core control equipment.
3. Built-in multi-stage integrated protection circuit omits extra external overcurrent protection accessory configuration, simplifies cabinet internal power wiring layout and reduces peripheral fault points.
4. Wide-temperature grade raw material selection enables stable continuous operation from -40℃ to +70℃ without additional cabinet forced cooling fan under standard industrial control cabinet environment.
5. Dual-module parallel current-sharing redundant mode fully satisfies TMR triple redundant control system high-reliability power supply design requirement for critical power generation unit.
6. Complete factory serial number traceability system guarantees spare part inventory accurate matching and after-sale replacement consistency for all on-site running equipment.
7. Standard front-panel multi-indicator design shortens on-site fault positioning time and reduces maintenance difficulty during equipment daily inspection work.

10. Applicable Industries

• Thermal & Gas Power Generation Industry: Steam turbine, heavy-duty gas turbine, large diesel generator set MicroNet TMR control cabinet core redundant power supply configuration.
• Oil & Gas Industry: Offshore oil platform large centrifugal compressor control rack, natural gas pipeline pressurization unit TMR turbomachinery control system power matching.
• Marine Propulsion Industry: Large ocean-going cargo vessel main engine TMR governor control cabinet, marine auxiliary gas turbine control system power supply assembly complying with DNV-GL marine standard.
• Petrochemical Refining Industry: Refinery cracking furnace blower, large reciprocating compressor safety interlock TMR control cabinet internal power supply configuration.
• Hydropower Equipment Industry: Large hydro-turbine TMR governor control cabinet core power backup unit installation and application.
• Industrial Heavy Engine Industry: Large industrial gas engine and turbocharger test bench redundant control system dedicated power module matching.

11. Model Series Classification

• Base standard model: 5501-381 (Factory default standard AC220V input bare power module without attached external wiring harness)
• Derivative variant 1: 5501-381-C (PCB full conformal coating customized model for high-humidity coastal and chemical corrosive gas environment)
• Derivative variant 2: 5501-381-K (Complete set model with factory pre-terminated AC input power cable and terminal plug accessory)
• Derivative variant 3: 5501-381-110 (Custom modified AC110V input version for North America and Japan local industrial power grid specification)

12. Installation Requirements

1. Cabinet pre-installation environment standard: Install inside IP43 and above sealed industrial control cabinet; keep installation slot over 120mm spacing away from cabinet internal high-power transformer and AC contactor strong magnetic field components.
2. VME slot plug-in specification: Align module bottom guide rail with chassis slot inner track, push module horizontally along track until rear VME connector fully locks into backplane socket with audible locking sound; prohibit forced lateral prying during plugging to avoid connector pin bending deformation.
3. AC power wiring rule: Use shielded three-core power cable for AC220V input wiring; cable shielding layer single-end connects cabinet PE protection ground bar with copper wire gauge ≥2.5mm².
4. Pre-power-on inspection requirement: After module installation and wiring completion, use multimeter to confirm no short-circuit between AC input live line and ground terminal before switching on cabinet AC total power supply.
5. Dual redundant installation regulation: When deploying two 5501-381 modules inside single TMR chassis, arrange two modules at non-adjacent slot positions to avoid mutual heat accumulation affecting heat dissipation efficiency.
6. Post-install preheating specification: Power on module and maintain continuous 30min preheating period to stabilize internal switching circuit temperature before formal system commissioning and load test.
7. Cabinet ventilation constraint: Keep chassis surrounding ventilation space unblocked without baffle or foreign object covering module upper and lower heat dissipation slots.

13. Usage Precautions

1. Electrostatic protection regulation: Wear certified anti-static wristband reliably connected to cabinet PE ground bar when pulling out module or opening shell for internal component inspection; bare-hand direct contact with PCB circuit and gold-plated connector pins is strictly forbidden to prevent electrostatic breakdown internal power device.
2. Live operation restriction: Prohibit live disassembly of module AC input wiring under powered running state; hot-swap replacement only allows pulling module out from VME slot after confirming front panel OK lamp is in normal bright state.
3. Daily maintenance specification: Clean module surface accumulated dust every six months with dry compressed air at maximum 0.3MPa air pressure; avoid high-pressure air direct blowing to internal electrolytic capacitor solder joint area.
4. Overload operation constraint: Strictly control single module continuous output current not exceeding rated 30A; prohibit long-term overloading running beyond rated output parameter range.
5. Spare module storage standard: Store idle spare modules inside original factory anti-static shielding carton under 15℃~25℃ dry constant-temperature warehouse environment, far away from corrosive chemical reagent and high dust concentration space.
6. Fault disposal criterion: Cut off corresponding AC input power supply immediately once abnormal overheating, burnt smell or frequent fault lamp flicker occurs during operation; unauthorized disassembly of module shell and modification of internal original circuit layout are prohibited, contact Woodward official after-sales engineer for professional maintenance.
7. Long-term idle equipment management: If control cabinet stops running over 60 consecutive days, cut off all 5501-381 modules AC input power; place desiccant bags inside cabinet and fully close cabinet door to prevent internal PCB damp condensation corrosion.