EMERSON 1X00416H03 (Model Alias: WH5D-2FF) Product Description

I. Product Overview

The Emerson 1X00416H03 (designated as Model Alias WH5D-2FF) is a high-performance single-output power module of the Emerson Ovation DCS system. It was originally designed by Westinghouse and manufactured by Emerson, providing high-reliability, redundant isolation 24V DC power for controllers, I/O modules, and field instruments within the Ovation system cabinets. It is the core power supply unit of the system. This module optimizes power density and heat dissipation structure based on the 1X00416H02 model, adopts industrial-grade rugged design, wide temperature operating range, and intelligent temperature-controlled fans, and is suitable for high-reliability, high-density I/O power supply scenarios in critical process industries such as power, chemical, oil and gas, and metallurgy, ensuring the long-term uninterrupted operation of the DCS system and avoiding system shutdown and production interruption caused by power failures. 

II. Core Functions

Global wide-range AC input + high-power 24V DC output, providing strong and stable power supply

Supports 100–240V AC ultra-wide voltage input (50/60Hz, ±20% voltage fluctuation tolerance), compatible with global industrial power grids, suitable for environments with unstable on-site voltages; provides a single 24V DC output, rated at 25A, peak at 26.5A, total power at 630W, capable of simultaneously powering multiple sets of controllers, high-density I/O modules, and on-site instruments, with output voltage accuracy of ±1%, ripple ≤ 50mV (peak-to-peak), load regulation rate ≤ 0.5%, linear regulation rate ≤ 0.1%, featuring automatic voltage stabilization and linear regulation capabilities, ensuring stable voltage at the load end and protecting precision electronic equipment.

Redundant parallel + seamless switching, eliminating single-point failures

Supports dual-module redundant parallel connection, compatible with the same model or 1X00416H01/02; when the main module fails, the standby module automatically takes over the load with zero switching time, without interrupting system operation; built-in intelligent current sharing circuit, balanced distribution of dual-module loads, extending the overall machine service life, completely eliminating power supply single-point failures, ensuring 24/7 uninterrupted operation of the system.

Multiple electrical isolation + comprehensive protection, strong anti-interference capability

Adopts input-output and output-ground dual electrical isolation design, with isolation strength of 1500V AC/1min, blocking ground potential difference, common-mode interference and transient shock; built-in overvoltage, undervoltage, overcurrent, short circuit, reverse polarity, surge suppression, ESD protection, overheat protection multiple protection circuits, automatic current-limiting protection when output short-circuits, automatic recovery after fault removal; complies with EN 61000-6-1/2/3/4, CE, UL 508, RoHS, CSA standards, capable of withstanding strong electromagnetic sources from inverter, large-power motors, etc., protecting the module and the downstream load safely.

Intelligent temperature control cooling + efficient low-power design, wide temperature long-term operation

Built-in intelligent temperature control cooling fan, automatically adjusting speed according to internal temperature, balancing both cooling efficiency and noise control; adopts efficient switching power supply architecture, conversion efficiency up to 98%, low full-load power consumption, less heat generation, energy-saving; operating temperature range **-40℃ to + 75℃** (full load without derating), storage temperature -40℃ to + 85℃, relative humidity 0%–95% RH (non-condensing); withstands vibration (5g rms, 10–500Hz) and shock (30g, 11ms half-sine wave), mean time between failures (MTBF) ≥ 1000,000 hours, suitable for outdoor, mining, chemical, metallurgical and other extreme industrial environments, with stable and reliable long-term operation. 

LED status indication + remote diagnosis, precise and efficient operation

Panel equipped with high-brightness LED indicators for power, operation, fault, and output status, intuitively displaying input power supply, output voltage, fan operation and alarm status; supports Ovation system remote health monitoring and in-depth fault diagnosis, capable of uploading 10+ types of fault codes and status information such as input abnormalities, output overvoltage/undervoltage, overcurrent, overheat, fan failure, etc., real-time monitoring of module key parameters by the background, precise fault location, significantly reducing troubleshooting and repair time. 

Online hot-swappable + standardized installation, flexible and convenient deployment

Compatible with Ovation standard I/O rack DIN rail / 19-inch standard rack installation, supports online hot-swappable replacement, no system downtime,不影响 other modules and load operation， effectively reducing downtime losses； Metal reinforcement shell + three-proof coating (waterproof, salt fog resistant, corrosion resistant, in accordance with MIL-STD-810 standard), structurally solid, easy to install and maintain.

III. Technical Specifications

(1) Input Parameters

Input voltage: 100–240V AC (±20%), 50/60Hz

Input current: ≤7A (full load, 240V AC input)

Input surge: in accordance with EN 61000-4-5 standard

Input isolation: 1500V AC/1min (input-output)

Surge current: ≤30A (maximum)

(2) Output Parameters

Output channels: single channel 24V DC

Output voltage: 24V DC (±1%)

Output current: rated 25A, peak 26.5A

Total output power: rated 600W, peak 630W

Ripple noise: ≤50mV (peak-to-peak)

Load regulation rate: ≤0.5% (0–100% load)

Isolation: 1500V AC/1min (output-ground)

(3) Electrical Protection Parameters

Overvoltage protection: protection when input ≥ 265V AC or output ≥ 28V DC

Undervoltage protection: protection when input ≤ 90V AC or output ≤ 20V DC

Overcurrent protection: limit current limiting protection when output ≥ 115% rated current for a limited time

Short-circuit protection: automatic current limiting when output short-circuits, automatic recovery after fault removal

Overheating protection: reduction of capacity when internal temperature ≥ 85℃, shutdown when ≥ 95℃

Insulation resistance: ≥10MΩ (500V DC)

(4) Environmental Parameters

Operating temperature: –40℃ to + 75℃ (full load without capacity reduction)

Storage temperature: –40℃ to + 85℃

Relative humidity: 0%–95% RH (non-condensing)

Anti-vibration: 5g rms, 10Hz–500Hz

Anti-shock: 30g, 11ms half-sine wave

EMC performance: in accordance with EN 61000-6-1/2/3/4, CE, UL 508, CSA, RoHS

Protection level: IP20 (module body)

Three-proof performance: waterproof, salt fog resistant, corrosion resistant (MIL-STD-810)

(5) Physical Parameters

Size: 400mm×205mm×103mm (width × height × depth)

Weight: approximately 3.18kg

Material: aluminum alloy reinforced shell, military-grade PCB board + three-proof coating

Installation method: DIN rail installation / 19-inch standard rack installation

Certification: CE, UL 508, RoHS, CSA

Origin: USA

IV. Product Features

High power density, strong power supply capacity

Single channel 24V DC output, rated 600W, peak 630W, rated current 25A, sufficient power supply capacity, suitable for medium-sized Ovation DCS systems and high-density I/O stations, can simultaneously meet the power supply requirements of controllers, multiple I/O modules and field instruments, flexible load distribution, high stability.

Redundant seamless switching, extremely high reliability

Support dual-module redundant parallel connection, automatic takeover of load with zero switching time, built-in intelligent current equalization circuit, load balanced distribution, completely eliminating power supply single-point failure, ensuring 24/7 continuous operation of the system, significantly reducing downtime risks and losses.

Wide temperature reinforcement durability, suitable for harsh working conditions

–40℃ to + 75℃ ultra-wide operating temperature range, metal reinforced shell + three-proof coating, strong anti-vibration and anti-shock ability, MTBF ≥ 100 million hours, long-term operation with extremely low failure rate, suitable for strict industrial environments such as power, chemical, oil and gas, metallurgy, etc. Efficient and intelligent heat dissipation, energy conservation and environmental protection

98% ultra-high conversion efficiency, low heat generation and low power consumption under full load; intelligent temperature-controlled fan automatically adjusts speed according to temperature, balancing between heat dissipation efficiency and low noise, energy conservation, and reduction of operating costs.

Hot-swappable + remote diagnosis, efficient and convenient operation and maintenance

Support online hot-swappable replacement, no need for downtime, significantly reducing maintenance time and lowering maintenance costs; LED status indicator lights intuitively display operating status, remote diagnosis can precisely locate faults, facilitating rapid troubleshooting and repair.

High standard compatibility, flexible deployment

Standard DIN rails / 19-inch rack installation, compatible with Ovation standard cabinets and I/O racks, ready for immediate use; compatible with Ovation's full range of controllers, I/O modules, and system versions, with strong versatility, allowing for direct replacement of 1X00416H01/02 equivalent power modules, suitable for different scale and configuration Ovation DCS system projects.

VII. Application Scope

Power industry: Ovation DCS system main control cabinets, remote I/O stations for controllers, I/O modules, transmitters, actuators, etc., providing stable 24V DC power supply for controllers, I/O modules, transmitters, actuators, etc., suitable for strong electromagnetic interference, high temperature, and vibration conditions, ensuring continuous and stable power generation process.

Chemical industry: main control cabinets for petrochemical, fine chemical, and coal chemical plants, providing power supply for control systems and non-explosive on-site instruments, suitable for explosion-proof, humid, salt spray, and corrosive gas environments, ensuring continuous production and avoiding power failure-induced process interruptions.

Oil and gas industry: Ovation system cabinets for oil and gas extraction platforms, long-distance pipeline stations, and refining and chemical plants, providing power supply for control systems and on-site equipment in extreme temperatures, sandstorms, and salt spray environments, with strong ability to resist harsh environments, ensuring safety in oil and gas production and transportation.

Metallurgical industry: steel and non-ferrous metal smelting Ovation automation system cabinets, providing power supply for controllers, I/O modules, and detection instruments in high-temperature, dust, and strong electromagnetic interference environments, compatible with metallurgical continuous production scenarios, ensuring stable smelting process.

Other industrial scenarios: Ovation DCS system main control cabinets and remote control stations for large-scale water treatment, papermaking, cement, and pharmaceutical industries, providing power supply for electronic equipment related to process parameter collection and equipment control, compatible with long-distance, strong interference, and harsh conditions, supporting stable system operation.

VII. Installation and Maintenance

(1) Installation Requirements

Installation location: Installed on Ovation standard I/O rack DIN rails or 19-inch rack, installed firmly and vibration-proof; reserve ≥100mm of space above and below the module, and ≥50mm of space on the left and right for heat dissipation, away from strong heat sources and strong electromagnetic sources (such as frequency converters, large-power motors), ensuring smooth ventilation.

Installation specifications: Use standard snap fasteners or rack fixing parts for installation, ensuring good contact between the module and the backplane; when installing, wear anti-static wristbands to avoid damage to electronic components due to static electricity; when installing multiple modules in parallel, the spacing should be ≥50mm to ensure heat dissipation and signal isolation; when redundant installation is performed, the spacing between the two modules should be ≥100mm to facilitate maintenance and heat dissipation.

Cable connection specifications: Input side uses compliant AC power cables, firmly connected without loosening, with clear distinction between live, neutral, and ground wires; output side uses multi-strand copper core DC cables, correct positive and negative polarity connections, avoiding reverse polarity; all connection terminals should be tightened with a torque control of 1.5–2.0N・m to prevent loosening and overheating; cable arrangement should be neat, away from strong electromagnetic interference sources, and avoid excessive bending.

(2) Maintenance Points Regular inspection: Monthly checks on the module's appearance, LED status indicator lights, cooling fan operation status, and connection terminals, confirming normal input and output voltages, no overheating, abnormal noises, or looseness; review the DCS system diagnostic log to identify potential issues such as input abnormalities, output fluctuations, and fan failures.

Cleaning and maintenance: Quarterly use a dry soft cloth or low-pressure compressed air to wipe the module surface, cooling fan, and ventilation ports, removing dust and oil stains to prevent dust accumulation from affecting heat dissipation and insulation performance; in high-dust environments, the cleaning cycle can be shortened to once a month; do not use corrosive cleaning agents or liquids for direct wiping.

Troubleshooting: When the output is abnormal, first check if the input voltage is normal and if the wiring is loose, then check if the load is short-circuited or overloaded; when the fan stops rotating, check the fan power supply or replace the fan; when the module fails, perform an online hot-swappable replacement operation, and after replacement, verify the output voltage and load operation status.

Replacement precautions: Support online hot-swapping, no need to shut down for replacement; first disconnect the input switch of the faulty module, remove the wiring, then remove the module, install the new module and restore the wiring, close the input switch, confirm that the module starts normally and the output is stable; the old module should be stored according to specifications to avoid damage from static electricity and moisture.

VII. Order Information

Product model: 1X00416H03 (also known as: WH5D-2FF)

Brand: Emerson (艾默生)

Series： Ovation DCS System 1X Series High Power Power Module

Input specifications： 100–240V AC， 50/60Hz

Output specifications： 24V DC， rated 25A/600W， peak 26.5A/630W

Packaging： Original anti-static packaging， including installation manual， certificate of conformity， and connection terminals

Warranty： 12 months original factory warranty， providing global technical support and after-sales maintenance