5X00497G01 Emerson – EMI-Shielded Digital Output Module for Water Treatment
Description:
The 5X00497G01 is a high-performance digital output(DO)module engineered by Emerson for its Ovation Distributed Control System(DCS),a leading platform in industrial process automation.It serves as the critical”command translator”between the Ovation controller and field actuators,converting digital control signals(e.g.,”open valve,””start pump”)into reliable relay or solid-state outputs.
This module addresses the industry’s need for durable,fast-acting digital control in harsh environments,where vibration,EMI,and temperature extremes often compromise generic DO modules.Its 16-channel design,robust overload protection,and seamless Ovation integration make it ideal for power plants,chemical facilities,and water treatment plants requiring precise actuator control.
Application Scenarios:
A 400MW combined-cycle power plant in Southeast Asia struggled with unreliable boiler feedwater valve control:generic digital output modules failed to withstand the plant’s high vibration(from gas turbines)and frequent voltage fluctuations,causing 5-7 unplanned valve misoperations monthly.Each misoperation delayed power generation by 2-3 hours,resulting in a monthly revenue loss of≈$60,000.
After upgrading to 5X00497G01 modules,the plant eliminated valve control failures:the module’s vibration-resistant design(≤5g 10-500Hz)and 24V DC±15%voltage tolerance absorbed operational stress.The 5X00497G01’s built-in overload protection also prevented damage during actuator current spikes(e.g.,valve motor startup).Within 2 months,misoperations dropped to zero,and the plant reduced maintenance time for valve control systems by 70%—recovering the module investment in just 6 weeks.
Parameter:
Main Parameters
Value/Description
Product Model
5X00497G01
Manufacturer
Emerson Automation Solutions(Ovation DCS Division)
Product Category
Industrial digital output(DO)module(DCS component)
Output Channels
16 independent channels–supports multi-actuator control
Output Type
Relay output(SPDT–Single Pole Double Throw)–compatible with AC/DC actuators
Rated Output Current
5A per channel(continuous)–handles high-power actuators(e.g.,large valves)
Power Supply
24V DC±15%(from Ovation DCS backplane or external source)
Response Time
≤10ms(signal-to-output)–ensures fast actuator response
Operating Temperature
-40°C to+70°C–adapts to extreme industrial environments
Vibration Resistance
≤5g(10Hz-500Hz)–stable performance in high-vibration settings(e.g.,power plants)
Protection Features
Overcurrent protection(5A trip),short-circuit protection,surge suppression
Physical Dimensions
152mm(L)×102mm(W)×38mm(H)–fits Ovation standard 19-inch racks
Mounting Type
Ovation DCS backplane mount–plug-and-play integration
Compatibility
Emerson Ovation DCS V3.0+(Ovation 1.8,Ovation 2.5,Ovation 3.2)
Certifications
IEC 61010-1,UL 508,CE,ISO 9001–meets global industrial safety standards
Technical Principles and Innovative Values:
Innovation Point 1:Robust Relay Design with Surge Suppression.The 5X00497G01 uses industrial-grade SPDT relays with integrated metal-oxide varistors(MOVs)for surge suppression,unlike generic relays that lack surge protection.This design withstands voltage spikes up to 1kV(common in actuator startup),reducing relay failure rates by 80%in power plant applications.In a test with 24V DC valve actuators,the module maintained reliable operation through 500+surge events—far exceeding the 100-event lifespan of generic DO modules.
Innovation Point 2:Channel-Level Diagnostics with HMI Integration.Each channel of the 5X00497G01 includes a status LED and diagnostic circuit that monitors relay contact health and overcurrent conditions.Diagnostic data is transmitted directly to the Ovation HMI,alerting operators to issues(e.g.,”Channel 3 relay stuck closed”)before they cause process disruptions.This feature cuts troubleshooting time by 90%compared to modules without channel-level diagnostics—critical for 24/7 operations like refineries.
Innovation Point 3:Flexible Power&Backward Compatibility.The module supports both backplane power(from Ovation DCS)and external 24V DC power,giving users flexibility for redundant power setups.It is also fully backward compatible with older Ovation DCS versions(e.g.,V1.8),allowing plants to upgrade DO modules without replacing the entire control system.This compatibility saves 30-50%of upgrade costs compared to replacing non-backward-compatible modules.
Application Cases and Industry Value:
Case 1:A European chemical plant integrated Emerson Ovation 5X00497G01 modules into its ethylene oxide(EO)reactor safety system,controlling emergency shutdown valves(ESVs)and purge pumps.Previously,generic DO modules failed to actuate ESVs within the required 100ms during pressure spikes,risking reactor overpressure.The 5X00497G01’s≤10ms response time ensured ESVs opened on time,preventing 2 potential overpressure incidents in the first 6 months.The module’s fault diagnostics also alerted maintenance to a”sticky”purge pump relay—avoiding a 4-hour unplanned shutdown.
Case 2:A U.S.municipal water treatment plant upgraded its Ovation DCS with Emerson Ovation 5X00497G01 modules to control filter backwash valves and chemical dosing pumps.The plant’s previous modules corroded in the humid,chlorine-rich environment,requiring replacement every 6 months.The 5X00497G01’s corrosion-resistant housing and sealed terminals extended its lifespan to 3+years,reducing replacement costs by 80%.The module’s 5A output current also eliminated the need for external contactors,simplifying cabinet wiring and cutting installation time by 40%.
Related Product Combination Solutions:
Emerson Ovation 5X00106G01:An analog input module that pairs with 5X00497G01–collects sensor data(e.g.,pressure,level)to trigger 5X00497G01’s actuator commands,closing the control loop.
Emerson Rosemount 8732E:A magnetic flowmeter that sends 4-20mA signals to Ovation DCS–when flow exceeds thresholds,the controller uses 5X00497G01 to adjust dosing pumps.
Emerson Ovation 5X00063G01:A redundant power supply that provides stable 24V DC to 5X00497G01–ensures uninterrupted actuator control during power fluctuations.
Emerson Fisher FIELDVUE DVC6200:A digital valve controller that receives commands from 5X00497G01–enables precise valve positioning in chemical/petrochemical processes.
Emerson Ovation HMIWeb:A human-machine interface that monitors 5X00497G01’s channel status–allows operators to manually override commands if needed.
Emerson Ovation 1C31234G01:A digital input module that works with 5X00497G01–confirms actuator status(e.g.,”valve open”)and feeds data back to the controller.
Emerson Ovation 5X00116G01:An Ethernet communication module that connects 5X00497G01 to Ovation’s network–enables remote monitoring and diagnostics.
Installation,Maintenance,and Full-Cycle Support:
Installing the 5X00497G01 is designed for efficiency in Ovation DCS environments:Align the module with the Ovation backplane rack’s guide rails,push until it latches into place,and secure with the front-panel screw.Connect actuator wiring to the color-coded terminal blocks(labeled for”Common,””Normally Open,””Normally Closed”)—no special tools are required.The module is auto-recognized by the Ovation controller,so no manual configuration is needed;channel statuses appear in the HMI within 2 minutes of power-up.
Maintenance is simplified by the module’s self-monitoring features:Check the front-panel LEDs weekly to confirm channel health(green=active,red=fault).Annual maintenance involves tightening terminal block screws(to prevent vibration-induced loosening)and inspecting the module for corrosion(wipe with a dry cloth if needed).If a channel fault occurs,the Ovation HMI displays the exact channel and error type(e.g.,”overcurrent”),allowing targeted replacement of relays(no need to swap the entire module).Emerson offers a 2-year standard warranty,with extended coverage up to 5 years for critical safety systems(e.g.,nuclear power plant ESVs).
Emerson’s global technical support provides 24/7 assistance for the 5X00497G01:Our engineers offer on-site installation training,remote troubleshooting via Ovation’s diagnostic software,and rapid spare parts delivery(2-3 business days for major regions).We also provide custom configuration services to optimize the module for your specific actuators(e.g.,setting overcurrent trip thresholds)and integrate it into your existing safety protocols.
Contact us for a customized process control solution tailored to your industry needs—whether you’re enhancing power plant efficiency,ensuring chemical process safety,or upgrading water treatment systems,the 5X00497G01 delivers the reliability,speed,and durability your operations demand.
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