Woodward 5466-419 Industrial Fuel Control Module

Name: WOODWARD 5466-419 Industrial Fuel Control Module
SKU: 19153
Price: 1199.00 USD
Availability: InStock

1. Product Description

Woodward 5466-419 is an industrial-grade fuel control module designed by Woodward specifically for precise fuel flow regulation in engines, turbines, and combustion systems. It acts as the “fuel adjustment core” of the system, mainly compatible with diesel engines, gas engines, and industrial turbines (e.g., power generation engines, marine main engines, oilfield pump turbines). It is widely used in scenarios that require stable fuel supply to maintain equipment performance, such as generator set fuel control, marine engine speed stabilization, and industrial boiler combustion optimization.

Its core function is to “receive speed, pressure, or load signals from the equipment control system, compare them with the set values, and output a 4-20mA control signal to drive fuel valves (e.g., fuel injectors, throttle valves). This adjusts fuel flow in real time to ensure the equipment operates at the target speed or load; it also has fault protection functions (e.g., over-speed, low fuel pressure) to prevent damage from abnormal fuel supply.” For example, in a diesel generator set, when the load increases (from 50% to 100%), the generator speed drops slightly. The module detects this speed change, outputs a signal to increase the fuel valve opening, and raises fuel flow—stabilizing the speed back to the rated 1500rpm (for 50Hz power) within 1 second.

Its practical advantages are particularly prominent in fuel control scenarios:

Precise flow regulation: The output signal accuracy is ≤±0.5% FS, and the response time is ≤200ms. It can accurately adjust fuel flow even with frequent load changes, avoiding excessive fuel consumption or insufficient power caused by imprecise control.

Wide compatibility: It supports 24V DC power supply (common in industrial equipment) and accepts multiple input signals (e.g., 0-10V speed signals, 4-20mA load signals). It can connect to Woodward or third-party control systems without additional adapters.

Industrial reliability: It uses a wide-temperature design (-40℃~+70℃) to adapt to harsh environments like high-temperature engine rooms or cold outdoor oilfields. It has anti-vibration (10-2000Hz) and anti-electromagnetic interference (EMI) capabilities, with a Mean Time Between Failures (MTBF) exceeding 80,000 hours—ensuring long-term stable operation.

Easy use & maintenance: It has a compact DIN rail-mounted design (fits standard control cabinets) and is equipped with status indicator lights (e.g., “PWR” for power on, “FAULT” for errors). Maintenance staff can quickly identify issues; parameter setting only requires a basic handheld controller (no complex software).

For example, in an oilfield gas injection pump system driven by a gas engine, Woodward 5466-419 receives the pump pressure signal (4-20mA, corresponding to 0-10MPa). When the injection pressure drops to 8MPa (below the set 9MPa), the module outputs a signal to increase the engine’s fuel valve opening—boosting engine power and raising the pump pressure back to 9MPa. This ensures stable oilfield gas injection efficiency.

2. Key Technical Parameters

Parameter Category	Details
Application Scenarios	Diesel/gas engines, industrial turbines, generator sets, marine main engines, oilfield pumps
Input Signals	– Control signals: 0-10V DC (speed/load), 4-20mA DC (pressure/flow)- Feedback signals: 4-20mA DC (fuel flow/valve position)
Output Signals	– Control signal: 4-20mA DC (drives fuel valves, max load ≤500Ω)- Alarm signal: 1 set of relay contacts (AC 250V/5A, for fault alerts)
Control Performance	– Signal accuracy: ≤±0.5% FS- Response time: ≤200ms- Control mode: PID closed-loop control (built-in, no extra programming)
Operating Environment	– Temperature: -40℃~+70℃- Relative Humidity: 5%~95% (non-condensing)- Vibration: 10-2000Hz, 50m/s² acceleration- Protection Level: IP20 (must be installed in a control cabinet)
Power Supply	– Input Voltage: 24V DC (±15%, 12V DC optional)- Power Consumption: Typical 8W, Maximum 12W- Protection: Over-voltage (≥30V DC), over-current, short-circuit protection
Fault Protection	– Over-speed protection (triggers when speed ≥115% rated value)- Low fuel pressure alarm (triggers when pressure ≤20% set value)- Valve stuck detection (alerts if valve position feedback is abnormal)
Dimensions & Weight	– Dimensions: 120mm×80mm×35mm (L×W×H, DIN rail mounting)- Weight: Approximately 250g
Certifications	CE, UL, IEC 61010-1 Industrial Safety Standard, SAE J1939 (for automotive/marine engines)

3. System Integration Instructions

Woodward 5466-419 is the “core fuel adjustment unit” for engines/turbines. Its integration must follow industrial fuel system installation rules:

Installation Steps (Including Safety Precautions):

1. Shut down the equipment (e.g., engine, turbine) and cut off the fuel supply (close the main fuel valve) to avoid fire risks from fuel leaks during installation.

1. Mount the module: Fix it on a DIN rail in the control cabinet, away from high-temperature components (e.g., engine exhaust pipes) or strong interference sources (e.g., frequency converters). Reserve a 5cm ventilation gap to prevent overheating.

1. Connect power: Use a 24V DC power cable (2.5mm² copper wire) to connect the module’s power terminals. Confirm positive (+) and negative (-) polarities—reverse connection will damage the module. Add a 3A fuse in the power circuit for protection.

1. Connect input/output signals:

- - Connect the control signal (e.g., engine speed sensor’s 0-10V signal) to the module’s input terminal. Use shielded twisted-pair cables to reduce EMI.

- - Connect the module’s 4-20mA output terminal to the fuel valve actuator. Ensure the actuator’s impedance (≤500Ω) matches the module’s output load.

1. Set parameters: Use a Woodward handheld controller (e.g., Woodward Toolkit) to set the rated speed (e.g., 1500rpm), fuel pressure range (e.g., 5-10MPa), and alarm thresholds (e.g., over-speed 1725rpm).

1. Test the system:

- - Power on the module and check the “PWR” light (should be on). Use a signal generator to simulate a speed drop (e.g., from 1500rpm to 1400rpm) and confirm the module outputs a signal to increase fuel flow.

- - Start the equipment and run it at 50% load. Gradually increase the load to 100% and check if the module stabilizes the speed/load within the set range.

1. Test protection functions: Simulate low fuel pressure (e.g., input a 4mA pressure signal) and confirm the module triggers an alarm (the “FAULT” light turns on) and cuts off the fuel valve signal if needed.

Daily Maintenance Points:

- Check the power voltage monthly (ensure it stays within 20.4V~27.6V).

- Clean the module’s terminals every quarter to remove dust or oil—this prevents poor contact.

- Calibrate the output signal every 6 months: Use a standard current meter to verify that a 4mA input corresponds to the minimum fuel flow and 20mA to the maximum.

- Back up parameters (e.g., speed set values) to a handheld controller—this avoids reconfiguration if the module is replaced.

- If the “FAULT” light is on: First check the fuel valve’s wiring and position feedback. If the issue persists, use the controller to read fault codes (e.g., “E01” for over-speed, “E02” for low pressure).

For example, in a marine diesel main engine system, after integrating Woodward 5466-419:

The module receives the engine speed signal (0-10V, 0-1800rpm) and outputs a 4-20mA signal to the fuel injector.

When the ship needs to accelerate (speed from 1200rpm to 1500rpm), the bridge control system sends a speed signal to the module. The module increases the fuel injector’s opening, raising fuel flow and engine speed to 1500rpm within 1.5 seconds.

If the engine over-speeds (≥1710rpm), the module triggers an alarm and reduces fuel flow—preventing engine damage.

4. Recommended Related Models in the Same Series

Model	Core Differences & Application Scenarios
Woodward 5466-420	Dual-Fuel Control Type: Supports both diesel and gas fuel systems (switches fuel types via input signals). Suitable for dual-fuel generators or marine engines (reduces fuel costs by using gas).
Woodward 5466-421	High-Power Adaptation Type: Output signal load increases to ≤1000Ω (drives large fuel valves for high-power turbines, e.g., 10MW+ industrial turbines).
Woodward 5466-422	Explosion-Proof Type: Certified with ATEX Zone 2 (for flammable environments like oilfields or chemical plants). Has an IP65 protective housing (resists dust and splashes).
Woodward 5466-423	Wide-Temperature Type: Operating temperature range extends to -55℃~+85℃. Suitable for cold regions (e.g., northern oilfields) or high-temperature boiler systems.
Woodward 5466-424	Communication-Enhanced Type: Adds an RS485 interface (Modbus-RTU protocol) for remote monitoring. Allows parameter adjustment via a PC (e.g., for centralized control of multiple generator sets in a power plant).
Woodward 5466-425	Low-Power Type: Power consumption reduces to 5W (typical). Suitable for battery-powered small equipment (e.g., portable diesel pumps or small generators).
Woodward 5466-426	Redundant Type: Uses dual power supplies and dual output channels. If one channel fails, the other takes over (no interruption). Suitable for critical systems (e.g., nuclear power plant backup generators).
Woodward 5466-427	Economic Type: Fixes key parameters (e.g., 1500rpm speed, 4-20mA fuel range) to lower costs. Suitable for standardized equipment (e.g., mass-produced small generators).