Description
Key Technical Specifications
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Model Number: 5X00226G02
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Manufacturer: Emerson (formerly Westinghouse)
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Module Type: OCR 400 Series I/O Interface Carrier
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Mounting: DIN rail (EN 60715 compliant) for secure installation in control cabinets
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LocalBus Power: +5 VDC at 1.4 A (supplies power to plugged-in I/O cards)
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Fieldbus Power: 9–32 VDC at 12 mA per port (supports field devices with varying voltage requirements)
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Operating Voltage: 12–24 VDC (wide range for compatibility with industrial power systems)
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Operating Temperature: –20°C to +50°C (suitable for most industrial environments)
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Certifications: UL/CUL (US/Canada), CE (EU), FCC Class B (electromagnetic compatibility)
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Communication Protocols: Modbus RTU/ASCII, DeviceNet, Profinet (seamless integration with Ovation and third-party systems)
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Dimensions: 12.7 cm × 6.2 cm × 16.2 cm (compact form factor for cabinet installation)
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Weight: 0.34 kg (lightweight for easy handling during maintenance)
WESTINGHOUSE 5X00226G02
Field Application & Problem Solved
In industrial automation—from power plants to chemical refineries—field devices (e.g., temperature sensors, pressure transmitters, control valves) require a reliable interface to connect to DCS/PLC systems. The biggest challenge with legacy I/O setups is finding a solution that balances flexibility (support for multiple signal types) with ease of installation (minimal wiring and configuration). Traditional I/O modules often require custom wiring and are difficult to maintain, leading to downtime and increased labor costs.
The 5X00226G02 solves this by acting as a modular I/O carrier that supports plug-in analog and discrete I/O cards. You’ll find it in:
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Power generation: Connecting boiler temperature sensors (RTDs) and turbine pressure transmitters (4–20 mA) to Ovation DCS for real-time monitoring.
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Chemical/petrochemical: Interfacing with reactor level sensors (ultrasonic) and valve positioners (digital outputs) for process control.
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Manufacturing: Linking conveyor belt speed sensors (encoders) and robotic arm actuators (digital inputs) to PLC systems for automation.
Its core value is modularity and ease of use. The DIN-rail mounting allows for quick installation and removal, while the plug-in I/O cards eliminate the need for custom wiring. The fieldbus power supply supports a wide range of field devices, reducing the need for additional power supplies. This modularity also simplifies maintenance—if an I/O card fails, you can replace it without shutting down the entire system.
Installation & Maintenance Pitfalls (Expert Tips)
1. Incorrect DIN Rail Mounting
A common rookie mistake is not securing the module properly to the DIN rail. Always use the provided mounting clips and ensure the module is seated firmly on the rail. Loose mounting can cause the module to vibrate loose, leading to intermittent connections—we once had a client lose communication with a field device because the module was not mounted correctly.
2. Ignoring Fieldbus Power Requirements
The 5X00226G02’s fieldbus power supply supports 9–32 VDC, but you must verify the voltage requirements of your field devices. Connecting a 24 VDC device to a 12 VDC supply will cause it to malfunction—always check the device’s datasheet before connecting. We fixed a recurring valve malfunction in a paper mill by correcting the fieldbus voltage.
3. Poor Wiring of I/O Cards
When plugging in analog or discrete I/O cards, always follow the wiring diagram in the Ovation documentation. Incorrect wiring (e.g., reversing the polarity of a 4–20 mA signal) will cause the module to misinterpret the signal—we once spent hours troubleshooting a faulty temperature reading only to find the wiring was reversed.
4. Forgetting to Configure the Module
The 5X00226G02 requires configuration via the Ovation Developer Studio to enable communication protocols (e.g., Modbus) and set channel scaling. Always verify the configuration before powering up the module—we had a client skip this step, and the module did not communicate with the DCS, leading to a 2-hour downtime.
WESTINGHOUSE 5X00226G02
Technical Deep Dive & Overview
The 5X00226G02 is a modular I/O interface carrier designed exclusively for Emerson’s Ovation OCR 400 series. It acts as a bridge between the Ovation DCS/PLC system and field devices, enabling seamless data exchange. Here’s how it works:
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Mounting & Power: The module is mounted on a DIN rail in the control cabinet. The LocalBus power supply (+5 VDC) powers the plugged-in I/O cards, while the fieldbus power supply (9–32 VDC) powers the field devices.
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I/O Card Integration: Plug-in analog (e.g., 4–20 mA) and discrete (e.g., digital inputs) I/O cards are inserted into the module. The module’s backplane connects the I/O cards to the Ovation system via the LocalBus.
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Communication: The module supports multiple communication protocols (Modbus, DeviceNet, Profinet) to integrate with Ovation and third-party systems. The Ovation Developer Studio is used to configure the module’s communication settings.
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Data Exchange: Field devices send signals (e.g., temperature, pressure) to the I/O cards via the fieldbus. The module converts these signals to digital data and sends them to the Ovation DCS/PLC via the LocalBus. The DCS/PLC processes the data and sends commands back to the field devices via the module.
What sets the 5X00226G02 apart is its modularity and compatibility. The plug-in I/O cards allow you to customize the module for your specific application, while the support for multiple communication protocols ensures seamless integration with existing systems. The DIN-rail mounting and hot-swappable I/O cards also simplify maintenance—you can replace a faulty card without shutting down the system.
Final Notes
The 5X00226G02 is a workhorse module for industrial automation. Its combination of modularity, ease of installation, and compatibility makes it ideal for mission-critical applications where reliability is non-negotiable. Whether you’re upgrading a legacy system or building a new one, this module will provide the flexible, reliable I/O interface you need—just remember to follow the installation tips to avoid common pitfalls.
