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Woodward 5441-661 Relay Interface Module
Woodward 5441-661
Product Positioning
Woodward 5441-661 is a relay interface module under the Woodward Speed Control series. It is mainly used for closed-loop speed regulation of rotational machinery such as engines, gas turbines, and generator sets, controlling parameters like speed, power, or fuel flow.
Core Functions
- Provides 1 A (5 A/10 A optional) relay output, compatible with 24 VDC/120 VAC control signals.
- Supports multi-channel I/O combinations, enabling direct digital/analog signal interaction with Woodward main controllers (e.g., 5501-467, 5466-316) or on-site PLCs.
Key Technical Parameters
| Parameter | Specification |
|---|---|
| Input Voltage | 24 VDC |
| Output Current | 5 A (standard) / 10 A (high-power version) |
| Output Channel | Single relay interface |
| Operating Temperature | –40 ℃ ~ +85 ℃ |
| Protection Class | IP65 (dustproof and waterproof) |
| Dimensions | Approximately 70 mm × 35 mm × 25 mm (compact type) |
| Weight | Approximately 60 g |
| Communication Interface | RS-485 (Modbus/TCP) or fieldbus |
| Power Supply Method | Direct connection to 24 VDC power supply of the main control cabinet |
Structure and Composition
- Housing: Made of metal or high-strength plastic, complying with IP65 protection standards.
- Relay Unit: Adopts electromagnetic relays with silver alloy contact materials to ensure high reliability and low contact resistance.
- Power Module: Equipped with an internal voltage stabilization circuit, converting external 24 VDC to the voltage required by the relay coil.
- Signal Interface: Comes with terminal blocks or DIN-rail interfaces for easy on-site wiring.
- Communication Board: RS-485/Modbus interface board, supporting remote monitoring and parameter downloading.
- Heat Sink: Provides passive heat dissipation during high-power operation to ensure long-term stable performance.
Typical Application Fields
- Gas Turbine/Steam Turbine Speed Regulation: Cooperates with Woodward main control systems to achieve precise closed-loop control of speed and fuel flow.
- Generator Sets: Used for generator speed protection, load distribution, and automatic start-stop.
- Marine Engines: Provides reliable speed control in marine and offshore operations.
- Industrial Automation: Works with PLCs to realize speed/power linkage control of large machinery.
- Renewable Energy Systems: Power regulation and protection for wind power and photovoltaic inverters.
Installation Points
- Fixing Method: Adopt DIN-rail installation, ensuring the module is placed horizontally for easy later maintenance.
- Power Wiring: Use cables conforming to IEC 60320 standards, ensuring correct power polarity to avoid reverse connection.
- Signal Wiring: Use shielded wires or twisted pairs for relay output terminals to prevent electromagnetic interference.
- Grounding: The housing must be reliably grounded to meet safety specifications.
- Heat Dissipation: Install in a well-ventilated cabinet, and add auxiliary heat sinks if necessary.
Maintenance and Troubleshooting
Maintenance Items
| Maintenance Item | Recommended Cycle | Key Check Points |
|---|---|---|
| Visual Inspection | Monthly | Integrity of the housing, tightness of wiring, and dust accumulation on the heat sink |
| Electrical Testing | Every 6 months | Relay coil resistance, contact resistance, and whether the power supply voltage is within the rated range |
| Communication Verification | Quarterly | RS-485 signal integrity, Modbus address conflicts, and parameter backup |
| Function Verification | Annually | Conduct a complete closed-loop speed regulation test through the main controller to confirm response time and threshold settings |
Common Faults and Solutions
- Relay Failure to Operate: Check the coil voltage and whether the relay contacts are stuck; replace the relay unit if necessary.
- Communication Failure: Confirm the RS-485 terminal resistance, check for damage to the bus cable, and reconfigure communication parameters.
- Overheating Alarm: Check if the heat sink is blocked, confirm whether the ambient temperature exceeds the rated upper limit, and add a fan if necessary.
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