WESTINGHOUSE 5X00481G02

Description

Product Description

WESTINGHOUSE 5X00481G02 is a high-reliability digital input module designed specifically for Westinghouse Ovation distributed control systems (DCS), engineered to deliver precise and stable discrete signal acquisition in critical industrial processes. This equipment

specializes in capturing digital on/off signals from sensors, switches, and safety interlocks, enabling seamless data transmission to the Ovation controller for real-time process monitoring and control. Thanks to its robust construction and industrial-grade performance, WESTINGHOUSE 5X00481G02 has become a core component in power generation, nuclear energy, oil and gas, and chemical processing facilities, where uncompromised signal integrity is paramount. Implementing WESTINGHOUSE 5X00481G02 ensures consistent operation even in harsh environments, supporting safe and efficient control of boilers, turbines, reactors, and production lines. Westinghouse subjects each unit to rigorous testing, and WESTINGHOUSE 5X00481G02 

fully complies with international standards such as IEC 61131-3 and IEEE 1289, ensuring full compatibility with the Ovation DCS ecosystem. WESTINGHOUSE 5X00481G02 is highly valued for its redundant design, enhanced noise immunity, and easy integration, making it the preferred choice for mission-critical applications that demand long-term reliability and minimal downtime.

Product Parameters

• Device Type: Digital input module for WESTINGHOUSE Ovation DCS
• Compatibility: Westinghouse Ovation DCS (Version 3.x to 10.x), Ovation controllers (e.g., Ovation 1C31227G01), Westinghouse I/O chassis, Ovation Engineering Tools software, third-party safety systems (via hardwired interlocks)
• Core Functions: Discrete signal acquisition, noise filtering, signal status monitoring, channel diagnostics, fault alarm output
• Channel Configuration: 16 independent digital input channels (group isolation)
• Supported Signal Types:
  • Dry contact signals (NO/NC configurable)
  • Active digital signals (24V DC, sourcing/sinking configurable)
• Signal Processing Parameters:
  • Response Time: ≤ 1ms (typical), ≤ 3ms (maximum)
  • Input Voltage Range: 20–30V DC (operating), 5V DC (minimum detection threshold)
  • Input Current: 5–10mA per channel (active signal mode)
  • Noise Filtering: Configurable digital filters (0.1–100ms) to suppress electromagnetic interference (EMI)
• Isolation:
  • Channel-to-Channel: 500V AC (galvanic isolation)
  • Channel-to-Power: 1000V AC (reinforced isolation)
• Power Supply:
  • Input Voltage: 24V DC ±10% (from Ovation chassis)
  • Power Consumption: ≤ 8W (no load), ≤ 12W (full load)
• Environmental Specifications:
  • Operating Temperature: -40°C to +70°C (extended range)
  • Relative Humidity: 5–95% RH (non-condensing)
  • Protection Class: IP20 (for cabinet mounting)
• Physical Dimensions:
  • Size (W x H x D): 100mm x 220mm x 150mm (standard DIN rail/card rack mounting)
  • Weight: Approximately 0.9kg
• Protection Features:
  • ESD Protection: ±25kV (contact discharge), ±30kV (air discharge)
  • EMI Filtering: Complies with EN 55011/EN 55022 Class B
  • Overvoltage Protection: Up to 60V DC per channel
  • Short-Circuit Protection: Current-limiting design to prevent channel damage
• Additional Functions:
  • Status Indicators: LED lights for power, channel activity, and fault status (per channel)
  • Configuration: Via Ovation Engineering Tools software
  • Hot-Swappable: Supported with compatible Ovation chassis (no system shutdown required)
  • Diagnostics: Real-time monitoring of open circuits, short circuits, and overvoltage faults; up to 100,000 fault logs (exportable to CSV)

Advantages and Features

• Enhanced Reliability with Redundancy: WESTINGHOUSE 5X00481G02 

  

  supports chassis-level power redundancy and signal path monitoring, minimizing the risk of single-point failures in critical control loops.
• Superior Noise Immunity: Galvanic isolation and configurable digital filters ensure stable signal acquisition even in high-EMI environments (e.g., near motors, transformers, or power converters).
• Flexible Signal Compatibility: Configurable NO/NC, sourcing/sinking modes eliminate the need for additional adapters, supporting a wide range of field sensors and switches.
• Easy Integration and Maintenance: Hot-swappable design and intuitive software configuration reduce downtime during module replacement or upgrades; per-channel LEDs enable quick troubleshooting.
• Industrial-Grade Durability: Extended temperature range (-40°C to +70°C) and rugged construction ensure reliable operation in extreme conditions, such as nuclear containment areas or offshore platforms.

Application Fields and Cases

• Power Generation: Boiler Safety Interlock Monitoring — WESTINGHOUSE 5X00481G02 

  

  acquires signals from flame detectors, pressure switches, and water level sensors in coal-fired or gas-fired power plants, transmitting status data to the Ovation DCS to trigger safety shutdowns if abnormal conditions are detected. Its fast response time (≤1ms) ensures timely protection of boiler equipment.
• Nuclear Energy: Reactor Safety System Control — The module captures discrete signals from emergency shutdown switches, valve position sensors, and radiation monitors in nuclear power plants, complying with strict safety standards (e.g., 10CFR50) to support safe reactor operation. Enhanced isolation prevents signal interference in radiation-intensive environments.
• Oil and Gas: Pipeline Valve Monitoring — WESTINGHOUSE 5X00481G02 monitors the on/off status of control valves and emergency isolation valves in oil/gas pipelines, with noise filtering capabilities ensuring accurate signal acquisition despite harsh outdoor conditions (temperature fluctuations, electromagnetic interference from pumps).
• Chemical Processing: Batch Process Control — The module collects signals from flow switches, level sensors, and process interlocks in chemical reactors, enabling the Ovation DCS to sequence batch operations and stop processes if safety limits are exceeded. Its flexible configuration adapts to varying sensor types across different production lines.
• Renewable Energy: Wind Turbine Control — WESTINGHOUSE 5X00481G02 captures signals from wind direction sensors, brake switches, and gearbox temperature interlocks, supporting real-time control and safety shutdowns in wind farms. Its extended temperature range withstands extreme cold and heat in outdoor installations.

Comparison with Competitors

• Unlike competing modules with limited isolation (≤250V AC) and fixed signal modes, WESTINGHOUSE 5X00481G02 offers 500V AC channel isolation and configurable NO/NC/sourcing/sinking modes, providing greater flexibility and noise immunity.
• Competitors often have response times ≥5ms, while WESTINGHOUSE 5X00481G02 

  

  achieves ≤1ms typical response, making it better suited for high-speed safety interlock applications.
• The module’s hot-swappable design and per-channel diagnostics outperform rivals with basic fault detection, reducing maintenance time and downtime.
• Westinghouse’s 5-year warranty and global technical support exceed the 1–3-year warranties of most competitors, ensuring long-term reliability and support for critical applications.
• Compatibility with the Ovation DCS ecosystem eliminates integration issues common with third-party modules, simplifying system design and commissioning.

Selection Suggestions and Precautions

• When selecting, confirm that WESTINGHOUSE 5X00481G02 is compatible with your Ovation DCS version and chassis model; verify that the number of channels (16) meets your application requirements.
• For outdoor or high-EMI environments, use shielded twisted-pair cables (Cat 5e or higher) and ground the shield at one end to enhance noise immunity; keep wiring away from power cables (minimum separation of 30cm).
• Configure signal modes (NO/NC, sourcing/sinking) correctly via Ovation Engineering Tools to match field sensors; incorrect configuration may cause signal loss or module damage.
• Regularly check LED status indicators and fault logs to identify open circuits, short circuits, or overvoltage issues; clean module connectors periodically to prevent contact failure.
• Ensure the input voltage remains within 24V DC ±10%; use a regulated power supply to avoid voltage fluctuations that could affect signal acquisition.
• Do not exceed the maximum input current (10mA per channel) to prevent channel burnout; use current-limiting resistors for high-current active sensors.
• When replacing the module, use hot-swapping only if supported by the Ovation chassis; otherwise, shut down the relevant control loop to avoid process disruptions.

5X00481G02