Description
System Role and Integration
The 5X00062G01 serves as the precision analog control interface within the Ovation Distributed Control System architecture, functioning as the critical output stage that translates digital controller commands into physical current signals for field actuators. As a HART Analog Output (HAO) Electronics Module, it mounts in standard Ovation I/O bases and operates in conjunction with the 5X00063G01 Personality Module to create a complete eight-channel analog output solution capable of driving both standard 4-20mA devices and HART-enabled smart field instruments.
This module occupies a pivotal position in closed-loop control strategies, receiving digital setpoint values from the Ovation controller via the I/O bus and converting them into precise current loop signals. The integrated HART modem capability distinguishes this module from basic analog outputs, allowing bidirectional digital communication over the same two-wire connection used for the analog signal. This enables remote configuration of smart valve positioners, access to diagnostic information from field devices, and asset management integration without additional communication wiring.
Core Functionality and Signal Handling
The module provides eight multiplexed analog output channels, each capable of sourcing 4-20mA into loads ranging from 230 to 700 ohms. A 16MHz microcontroller manages the D/A conversion process and HART communication protocol, employing a 14-bit digital-to-analog converter to achieve 0.25% accuracy over the full operating temperature range. The multiplexed architecture updates each channel once every 24 milliseconds, providing sufficient responsiveness for most process control loops while optimizing component costs.
HART communication is implemented through frequency-shift-keyed (FSK) sine wave signals superimposed on the 4-20mA analog output without interfering with the primary control signal. An array of internal switches enables the HART digital data to overlay the analog current, allowing the Ovation system to communicate with compatible field devices at 1200 baud while maintaining the integrity of the control loop. The module supports both point-to-point HART configurations (single device per channel) and multidrop configurations (multiple devices addressed digitally on a single channel).
The 5X00062G01 derives its loop power from a shared +24VDC auxiliary supply distributed to all eight channels, with the personality module providing user-serviceable fusing for each output channel. This common power architecture simplifies field wiring while maintaining individual channel protection.
Platform Heritage and Operational Benefits
As a component of the Emerson Ovation platform originally developed by Westinghouse, the 5X00062G01 benefits from extensive deployment in power generation, petrochemical, and water treatment applications where precise analog control determines process efficiency and safety. The module’s 1000V AC/DC isolation between field channels and controller logic ensures that ground faults or high common-mode voltages in field wiring cannot propagate to damage sensitive controller electronics or create safety hazards.
Integration with Emerson’s AMS Suite: Device Manager enables centralized asset management, allowing maintenance personnel to configure, calibrate, and diagnose HART field devices from the control room without requiring handheld communicators in the field. The electronic ID information stored in onboard EEPROM facilitates automatic module recognition and configuration verification, reducing commissioning errors and ensuring that replacement modules are properly integrated into the control strategy.
WESTINGHOUSE 5X00062G01
Part 4: Technical Specifications
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Model Number: 5X00062G01
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Manufacturer: Westinghouse Electric Corporation (Emerson Ovation product line)
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Product Type: HART Analog Output Electronics Module (HAO EMOD)
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Number of Channels: 8 multiplexed analog output channels
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Output Signal: 4–20 mA with HART superimposed (Bell 202 FSK)
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D/A Resolution: 14 bits
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Channel Update Rate: 24 mS per channel (each channel updated once every 24mS)
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Accuracy Over Temperature: ±0.25% of span (20mA) across full operating range
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Reference Accuracy (@25°C): ±0.1% of full scale @ 99.7% confidence
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Output Loading: 230 Ω minimum to 600 Ω typical (700 Ω maximum)
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Output Compliance: 20 mA @ 21.6 VDC into 700 Ω load
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Output Impedance: 250 Ω
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HART Protocol: HART 5/6/7 compatible, 1200 baud FSK modulation
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Isolation: 1000 VAC/VDC for 1 minute (channel-to-logic); No isolation between channels
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Common Mode Rejection: 120 dB @ DC or nominal line frequency ±0.5%
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Normal Mode Rejection: 60 dB @ 50/60 Hz ±0.5% (when properly configured)
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Diagnostics: Open loop detection, 8 Pass/Fail status bits in data register 0xC
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Power Consumption (Main): 24 VDC, 1.2W typical, 2.5W maximum
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Power Consumption (Auxiliary): 24 VDC, 6W typical, 7.2W maximum
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Microcontroller: 16 MHz for A/D, D/A conversion and HART interface control
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Memory: EEPROM for electronic ID and configuration data storage
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Operating Temperature: 0°C to 60°C (32°F to 140°F)
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Storage Temperature: -25°C to 70°C
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Humidity: 0% to 95% RH (non-condensing)
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Personality Module: Requires 5X00063G01 (HAO PMOD) for complete functionality
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Compatible Systems: Emerson Ovation DCS, AMS Suite: Device Manager
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Dimensions: 160 mm × 100 mm × 60 mm (6.3 in × 3.9 in × 2.4 in)
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Weight: 0.9 kg (2.0 lbs) with packaging; 0.3 kg (0.65 lbs) module only
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Mounting: Standard Ovation I/O base or DIN rail compatible
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Field Wiring: Braid-shielded cable grounded at cabinet entry point
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Certifications: CE Mark variants available (non-CE version designated as standard)
WESTINGHOUSE 5X00062G01
Part 5: Core Features & Customer Value
HART Communication Integration: The superimposed HART digital communication capability enables bidirectional data exchange with smart field devices without additional wiring. For maintenance engineers, this means remote access to valve positioner diagnostics, automatic configuration of transmitter ranges, and online device verification from the control room—eliminating the need for handheld communicators in hazardous areas and reducing exposure to high-voltage switchgear or chemical process units.
High-Resolution 14-Bit D/A Conversion: The 14-bit resolution provides 16,384 discrete output levels across the 4-20mA range, delivering control precision sufficient for tight regulatory loops such as distillation column reflux control or combustion air flow modulation. This granularity enables fine adjustments that minimize process variability and improve product quality compared to lower-resolution alternatives.
1000V Isolation and Noise Immunity: The robust isolation barrier between field circuits and controller logic prevents ground loop currents and protects against high-voltage transients common in power plant switchyards and motor control centers. Combined with 120dB common-mode rejection, this ensures signal integrity when driving field devices located hundreds of feet from the control cabinet, eliminating the need for external signal isolators in most applications.
Open Loop Diagnostics: The module continuously monitors output current flow and reports open circuit conditions (broken wires, disconnected devices) via status registers. For control engineers, this provides immediate notification of field wiring failures before they impact process control, enabling predictive maintenance and reducing the frequency of manual loop verification checks during outages.
Multiplexed Architecture Cost Optimization: By multiplexing eight channels through shared D/A conversion and HART modem circuitry, the module achieves significant cost savings per channel compared to discrete single-channel designs. This economy allows facilities to implement comprehensive analog control strategies—controlling dozens of valves and drives—without excessive I/O hardware costs, particularly beneficial in large-scale power plant distributed control retrofits.
Part 6: Typical Applications
Control Valve Positioning with Smart Diagnostics: The 5X00062G01 is extensively deployed in oil and gas processing, petrochemical refining, and power generation to control smart valve positioners. The 4-20mA signal provides the position command while the HART overlay enables retrieval of valve travel history, friction analysis, and predictive maintenance alerts. In refinery distillation units, this capability allows operators to identify sticky valves or packing degradation before they cause product quality excursions or safety incidents.
Variable Speed Drive Control: In water treatment facilities and HVAC systems, the module provides analog speed references to variable frequency drives (VFDs) while using HART communication to monitor drive status, energy consumption, and fault conditions. The 700-ohm load capability accommodates the input impedance of most industrial drives without additional load resistors, simplifying panel wiring.
Reactor Temperature and Pressure Control: Chemical processing plants utilize the module to drive control valve actuators on reactor cooling water, steam injection, and pressure relief systems. The 24mS update rate provides responsive control for moderately fast processes, while the high isolation ensures safe operation in classified hazardous areas where intrinsically safe barriers may be required for field wiring.
Turbine Auxiliary Control: Within power generation turbine control systems, the module regulates auxiliary steam valves, lubricating oil temperature control valves, and hydrogen seal oil pressure regulators. The HART capability supports valve partial stroke testing required for safety instrumented systems (SIS), allowing automated testing of emergency shutdown valves without process interruption.
Water Treatment Chemical Dosing: In municipal and industrial water treatment, the module controls chemical metering pump stroke adjusters and chlorine dosing valves. The 14-bit resolution enables precise chemical feed rates essential for maintaining water quality standards while minimizing chemical consumption costs. Open loop diagnostics alert operators to pump failures or line blockages before water quality parameters drift out of specification.
