Product Core Brief
- Model: 1X00416H01 (alias WH5-2FF, legacy Westinghouse Ovation part)
- Brand: Emerson (Former Westinghouse)
- Series: Ovation Q-Line Chassis Power Infrastructure
- Core Function: Plug-in AC-DC power supply delivering dual isolated 24VDC rails to Ovation controller and IOP rack backplanes
- Product Type: Hot-swappable rack-mounted industrial switching power supply
- Key Specs: 85–264VAC universal input | 500W total output | MAIN 24VDC 12A / AUX 24VDC 8A | redundant diode OR-ing
- Note: New original surplus unit; direct replacement for aging WH5-2FF power shelves in power plant Ovation DCS racks
Key Technical Specifications
| Parameter | Value |
|---|---|
| AC Input Range | 85–264 VAC, 50/60Hz, max 8A inrush |
| Total Continuous Output Power | 500W maximum combined load |
| MAIN Output Rail | 24VDC, 12A continuous (controller backplane) |
| AUX Auxiliary Rail | 24VDC, 8A continuous (IOP I/O backplane) |
| Redundancy Support | Built-in diode OR-ing for parallel redundant power pairing |
| Hot-Swap Compatibility | Safe removal/insertion with rack power energized |
| Overload Protection | 1.5x nominal peak current for 4s minimum, auto-recovery post fault |
| Short-Circuit Protection | Constant current foldback limiting, no permanent damage on sustained shorts |
| Hold-Up Time | >20ms at full rated 500W load during AC dropouts |
| Cooling | Internal axial cooling fan with filter grille |
| Operating Temperature | -40°C to +70°C operational; -40°C to +85°C storage |
| Environmental Rating | ISA S71.04 G3 corrosive gas resistant, PCB conformal coating |
| Physical Dimensions | 470mm L × 160mm W × 90mm D; net weight 4.6kg |
| Hazardous Certifications | FM Class I Div2, ATEX Ex ec IIC Gc (Zone 2 cabinet installation only) |
| Enclosure Rating | IP20 internal cabinet use, metal shielded housing |
Product Introduction
This plug-in switching supply converts universal AC mains into two segregated 24VDC power domains for Ovation DCS racks. The MAIN rail feeds critical controller processing hardware, while the isolated AUX rail powers all IOP I/O backplanes to isolate field wiring faults from core control logic.Integrated diode redundancy lets two identical units run in parallel without external OR-ing modules. Hot-swap capability eliminates full rack shutdown during power supply failure replacement, a critical feature for continuous boiler and turbine control systems in thermal power plants.
QA & Testing SOP
- Incoming Inspection: Cross-reference unit serial number against OEM factory batch logs; inspect AC input connector, DC terminal pins, and fan assembly for corrosion or deformation. Reject units with cracked metal housings or clogged fan grilles.
- Live Full-Load Testing: Mount to Ovation Q-Line chassis, feed 120VAC / 240VAC mains via Fluke 115 multimeter. Load both DC rails to combined 500W rated output for 24 hours; log voltage stability and fan thermal rise.
- Redundancy & Fault Stress Test: Pair two units in parallel to validate seamless load sharing; force DC output short circuits to verify foldback current limiting without shutdown of the opposite rail.
- Status Indicator Verification: Confirm INPUT, MAIN, AUX LED status lights activate correctly under nominal, overload, and loss-of-input AC conditions.
- Final QC & Packaging: Blow fan and PCB surfaces with dry nitrogen to remove industrial dust; seal unit in static-shield bag with printed test report capturing full-load runtime voltage ripple data.
Installation Pitfalls & Guide
❗ ESD Damage Risk: Ungrounded contact with internal PCB traces destroys OR-ing diodes and switching MOSFETs; full rack power outage labor costs exceed $2,800. Always attach a grounded anti-static wrist strap to cabinet safety ground before handling the unit.❗ Zone 0/1 Hazardous Area Misuse: The supply only carries Div2 safety certification. Installing it in Zone 0 or Zone 1 flammable gas cabinets voids all safety approvals and creates ignition hazards.❗ Uneven Redundant Load Sharing: Mismatched firmware revision units paired in parallel create unbalanced current draw, triggering premature overload faults under peak I/O loading. Match identical model revision numbers for redundant deployments.❗ Clogged Fan Filter Neglect: Accumulated plant dust blocks airflow; internal overheating reduces service life and initiates thermal shutdown during high-load turbine startup transients. Schedule quarterly filter cleaning.❗ AC Input Undersizing: Branch circuit breakers sized below 10A trip during cold-start inrush current; calculate combined inrush draw for all rack power supplies before sizing upstream protection.
4-Step Replacement Guide
- Pre-install: Confirm redundant standby power supply is online and carrying partial rack load; photograph AC input wiring and DC MAIN/AUX terminal terminations for rebuild reference. Hot-swap is permitted in safe zone cabinets.
- Removal: Toggle front panel power switch to OFF; unlock chassis slide latches, pull the unit straight outward horizontally to avoid stressing internal wiring harnesses.
- Install: Slide the new unit fully into Q-Line chassis until latches lock; reconnect AC mains and two DC output terminals per pre-install photos; toggle front power switch to ON.
- Power-on Test: Monitor MAIN and AUX rail voltage via Ovation diagnostic console for 2 continuous hours; simulate brief AC dropout to verify >20ms hold-up and zero controller scan interruption.
FAQ
Q: Can a single unit run a full Ovation rack with both controller and 8-slot IOP carrier?A: Only if combined total DC load stays below 500W. Heavy analog output or FOUNDATION Fieldbus IOP racks require dual redundant WH5-2FF supplies to avoid overload tripping during peak process transients.Q: Does hot-swapping this unit disrupt controller or IOP operation?A: When paired with a second redundant power supply, load transfers seamlessly with no loss of 24VDC rail voltage. Single-supply racks require a full rack shutdown before removal.Q: What fault patterns indicate a failed unit?A: Persistent MAIN/AUX LED fault lights, voltage sag under moderate load, fan stall noise, automatic thermal shutdown at normal ambient cabinet temperatures, or inability to share load in redundant parallel configurations.Q: Can this supply be used outside Ovation Q-Line rack chassis?A: Not recommended. The slide-in mechanical keying and dedicated DC terminal harness are engineered exclusively for Ovation rack backplanes; standalone mounting requires custom wiring voiding OEM safety certifications.Q: What warranty coverage applies to new surplus stock?A: A 12-month limited warranty covers switching PCB, fan assembly, and diode OR-ing circuit factory defects. Damage from ESD mishandling, clogged fan overheating, AC overvoltage surges, or deployment in unapproved hazardous zones is excluded from coverage.Q: What is the difference between 1X00416H01 and 1X00416H03 variants?A: 1X00416H01 = standard WH5-2FF 500W dual rail supply; 1X00416H03 is a low-power 300W single-rail variant for small auxiliary I/O subracks and cannot replace the 500W unit for full controller racks.
