Description
Product Overview
The Woodward 3522-1005 is a high-performance digital actuator controller designed for precise positioning of hydraulic and pneumatic actuators in critical industrial applications. As part of Woodward’s 3500 series of control solutions, this advanced module provides closed-loop control for valves, dampers, and other final control elements in power generation, oil & gas, and heavy industrial processes. The 3522-1005 combines 32-bit processor technology with Woodward’s proven control algorithms to deliver ±0.1% positioning accuracy even in demanding operating conditions. Its ruggedized design features military-grade connectors and conformal-coated electronics, ensuring reliable operation in environments with extreme temperatures (-40°C to +85°C), vibration (up to 5G), and electrical noise. The module supports multiple feedback types including LVDT, RVDT, and potentiometer signals, making it adaptable to various actuator configurations. With built-in diagnostics and predictive maintenance capabilities, the Woodward 3522-1005 helps minimize unplanned downtime while optimizing control loop performance.
Technical Specifications
| Parameter Name | Parameter Value |
| Product Model | 3522-1005 |
| Manufacturer | Woodward |
| Product Type | Digital Actuator Controller |
| Control Accuracy | ±0.1% of full scale |
| Position Feedback | LVDT/RVDT (2-20V AC), Potentiometer (0-10V DC) |
| Output Drive | ±100mA (servo), 4-20mA (analog) |
| Control Algorithms | PID with adaptive gain, Feedforward |
| Response Time | <20ms (position update) |
| Communication | Modbus RTU, CANopen, Ethernet/IP (optional) |
| Power Supply | 24V DC (18-36V range) |
| Power Consumption | 6W typical |
| Operating Temp. | -40°C to +85°C |
| Vibration Resistance | 5G (10-500Hz) |
| Protection Rating | IP65 (panel-mounted) |
| Certifications | UL, CE, ATEX (optional) |
WOODWARD 3522-1005
Main Features and Advantages
Precision control architecture: The Woodward 3522-1005 utilizes dual-channel feedback processing with automatic sensor validation, ensuring continuous operation even during transducer faults. Its adaptive PID algorithms automatically compensate for changing load conditions and mechanical wear.
Robust connectivity options: Standard Modbus RTU and CANopen interfaces enable seamless integration with existing control systems, while an optional Ethernet/IP module (3522-1005-ETH) provides high-speed data exchange for Industry 4.0 applications.
Advanced diagnostics: Built-in actuator performance trending monitors parameters like friction, spring rate, and response time to predict maintenance needs. The controller’s embedded web server provides real-time health status without additional software.
Safety-focused design: The 3522-1005 features configurable fail-safe positions and redundant power inputs, meeting SIL 2 safety requirements for critical applications. Its military-spec connectors ensure reliable signal transmission in high-vibration environments.
Application Field
The Woodward 3522-1005 excels in applications requiring precise actuator control:
Power Generation: Governor valve control for steam and gas turbines
Oil & Gas: Position control for pipeline choke valves and compressor surge valves
Chemical Processing: Precise dosing valve control for batch processes
Water Treatment: Flow control valves for large water distribution systems
Marine: Throttle valve control for ship propulsion systems
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WOODWARD 3522-1005
Related Products
3522-1006: High-current version (±500mA drive)
3522-1004: Basic version without comms
3502-1000: I/O expansion module
UG-8/UG-10: Hydraulic actuators
L-series LVDTs: Compatible position feedback sensors
ProAct DCS: Distributed control system integration
Installation and Maintenance
Pre-installation preparation: Verify actuator compatibility and feedback sensor specifications. Ensure proper shielding for analog signal cables (twisted pair with overall shield). Allocate sufficient clearance for heat dissipation (minimum 50mm around unit).
Maintenance recommendations: Perform quarterly closed-loop response tests using Woodward’s ACT-100 test software. Inspect connectors annually for corrosion in humid environments. Monitor friction trends via built-in diagnostics to predict packing wear. The 3522-1005 supports hot firmware updates via Modbus during operation.
Product Guarantee
Woodward provides a 3-year warranty for the 3522-1005, covering all components including connectors and firmware. Each unit undergoes 500-hour burn-in testing with full functional validation. Lifetime technical support includes control loop optimization services and legacy system migration assistance. Calibration certifications are NIST-traceable with annual recalibration recommended for critical applications.
