Woodward 5441-693

Description

Key Functions

• Engine Speed Control — Maintains setpoint speed under varying load conditions
• Load Sharing / Droop Control — Enables parallel operation of multiple generators with accurate load distribution
• Overspeed Protection — Automatically shuts down the engine if speed exceeds a preset safety limit
• Under-Speed Protection — Trips the engine if speed drops below a minimum threshold
• Fuel Limiting — Restricts maximum fuel delivery to prevent engine damage
• Starting Control — Manages crank and run fuel quantities during engine start sequences
• Governor Alarm Outputs — Provides relay contacts for alarm and shutdown signaling

Technical Specifications

Actuator Output Specifications

Communication Interfaces

Drop / Isochronous Modes

Protection Features

• Overspeed Shutdown — Configurable trip point, adjustable delay (0 to 30 seconds)
• Underspeed Shutdown — Configurable trip point, adjustable delay
• Overspeed Alarm — Relay output activates before trip point
• Fail-Safe Operation — On loss of speed signal, output drives to safe position (fuel cut or full fuel depending on configuration)
• Loss of Actuator Feedback Alarm — Detects open/short circuit in actuator coil
• Supply Voltage Monitoring — Low voltage and high voltage alarm thresholds configurable

Material Composition

Structural Features

• DIN rail mountable (35 mm top-hat rail)
• Front-accessible terminal blocks for wiring
• Membrane keypad with LCD display for local configuration
• LED status indicators (Power, Run, Alarm, Fault)
• Configurable via front panel or remote via Modbus/CAN

Working Principle

The 5441-693 receives a frequency signal from a magnetic pickup sensor mounted on the engine flywheel or gear. The internal microcontroller converts the frequency to engine RPM and compares it to the setpoint speed. The error signal is processed through a PID (Proportional-Integral-Derivative) control algorithm. The controller outputs a PWM signal to the fuel actuator, adjusting fuel rack position to minimize the speed error. For load sharing, the controller adjusts the speed setpoint based on the load reference input, creating a controlled droop characteristic.

Advantages and Highlights

• Fully Digital Architecture — No mechanical linkages, no wear parts in the controller
• High Precision — Speed regulation within ±0.1% of setpoint
• Fast Response — Sub-100 ms transient response
• Remote Configuration — Full parameter set via Modbus RTU or Woodward CAN
• Wide Input Compatibility — Supports MPU, variable reluctance, and Hall-effect speed sensors
• Redundant Protection — Multiple independent overspeed and underspeed protection channels
• Compact Footprint — Fits in standard DIN rail enclosures
• Long Service Life — No mechanical fatigue, MTBF exceeds 50,000 hours

Applicable Industries

• Power Generation — Diesel and gas generator sets (standby, prime, continuous)
• Marine Propulsion — Auxiliary and main engine governors
• Oil and Gas — Compressor drivers, pump drivers, wellhead power units
• Mining — Diesel generator sets for underground and surface operations
• Rail — Auxiliary power units (APUs)
• Industrial — Any diesel/gas engine requiring electronic speed control

Compatible Actuator Models (Woodward)

Installation Requirements

• Mount on 35 mm DIN rail in a location free from excessive vibration and direct heat sources
• Maintain minimum 50 mm clearance on all sides for ventilation
• Route speed sensor cable away from high-current power cables (minimum 150 mm separation)
• Use shielded twisted-pair cable for speed signal (minimum 0.5 mm² cross-section)
• Ground the controller chassis to the engine block ground point
• Supply voltage must be filtered; use a 24 VDC regulated supply with less than 5% ripple
• Torque all terminal connections to 1.2 Nm (10.6 in-lbs)

Usage Precautions

• Do not exceed the maximum supply voltage of 32 VDC — permanent damage will occur
• Do not reverse the polarity of the power supply — internal fuse will blow
• Verify speed sensor air gap is within 0.3 mm to 1.5 mm (0.012″ to 0.060″) before startup
• Perform a no-load speed calibration after initial installation
• Do not operate the unit in environments exceeding +85°C ambient temperature
• Replace the conformal coating if the PCB is exposed to chemical solvents
• Perform a functional test of all protection relays every 6 months
• Do not modify the firmware using unauthorized tools — this voids the warranty
• The unit contains no user-serviceable components — contact Woodward for repairs

Model Series Cross-Reference

Certifications and Compliance

• CE Marking — Conforms to EU Machinery Directive 2006/42/EC
• UL Listed — File E147353 (for North American installations)
• CSA Certified — File LR78161
• DNV GL Type Approval — For marine applications
• Lloyd’s Register — Approved for marine generator sets
• ATEX — Not rated for hazardous area use (use 5441-Ex variants for ATEX zones)

Part Number Breakdown

Warranty

• Standard Warranty: 24 months from date of shipment
• Extended Warranty: Available up to 60 months (Woodward Protect program)

Document Reference Numbers