EMERSON 5X00226G04 | Ovation I/O Power Supply | Obsolete Distributed Control Spare Parts
EMERSON 5X00226G04 | Ovation I/O Power Supply | Obsolete Distributed Control Spare Parts - Image 2
EMERSON 5X00226G04 | Ovation I/O Power Supply | Obsolete Distributed Control Spare Parts - Image 3

EMERSON 5X00226G04 | Ovation I/O Power Supply | Obsolete Distributed Control Spare Parts

  • Model: 5X00226G04
  • Brand: Emerson (formerly part of Westinghouse/ABB Ovation lineage)
  • Core Function: 24 VDC redundant power supply module for Ovation distributed control system I/O racks
  • Lifecycle Status: Obsolete (discontinued)
  • Procurement Risk: High (no new production, limited refurbished inventory, extended lead times)
  • Critical Role: Provides regulated power to I/O modules in remote or local I/O chassis; failure causes loss of all connected field signals and outputs
Category: SKU: EMERSON 5X00226G04

Description

Key Technical Specifications (For Spare Parts Verification)

  • Product Model: 5X00226G04
  • Manufacturer: Emerson Automation Solutions (Ovation product line)
  • System Family: Ovation™ Distributed Control System (DCS)
  • Module Type: Redundant 24 VDC power supply for I/O racks
  • Input Voltage: Typically 100–240 VAC, 50/60 Hz (dual-input for redundancy)
  • Output Rating: 24 VDC nominal, ～10 A continuous (verify nameplate)
  • Redundancy Support: Hot-swappable, load-sharing with paired unit
  • Mounting: Slide-in carrier for standard Ovation I/O chassis (e.g., 5X00220-series backplane)
  • Diagnostic Features: LEDs for AC OK, DC OK, redundancy status, and fault indication
  • Form Factor: Full-height I/O slot (occupies one module position in rack)

System Role and Downtime Impact

The 5X00226G04 is a foundational component in Emerson Ovation I/O subsystems, commonly deployed in fossil fuel, nuclear, and combined-cycle power plants, as well as water/wastewater facilities. It supplies stable 24 VDC power to analog and digital I/O modules that interface with field instruments—such as transmitters, solenoid valves, and motor starters. In redundant configurations, two units share the load; if one fails, the other assumes full capacity without interruption.
However, if both units fail—or if a single non-redundant installation experiences a fault—all downstream I/O modules lose power. This results in loss of process visibility (analog inputs go to zero or bad status) and loss of actuation capability (digital outputs de-energize). In safety-critical applications, this can trigger automatic plant trips or force manual intervention under degraded conditions. Recovery requires physical replacement and system re-synchronization, often during unplanned outages with high operational cost.

 

Reliability Analysis and Common Failure Modes

Although designed for industrial environments, the 5X00226G04 is vulnerable to long-term stress from heat, dust, and electrical transients. Common failure modes include:
  • Electrolytic capacitor aging: Internal bulk capacitors dry out over time, reducing hold-up time and causing premature shutdown during minor voltage sags.
  • Fan failure (if equipped): Some variants include cooling fans; bearing wear leads to overheating and thermal shutdown.
  • Input rectifier or switching transistor degradation: Results in output voltage droop, ripple increase, or complete no-output condition.
  • Backplane connector fatigue: Repeated thermal cycling loosens pin contact, causing intermittent power delivery.
Design limitations include lack of remote health monitoring (beyond local LEDs) and dependence on clean AC input—units in harsh electrical environments often fail prematurely without surge protection.
Recommended preventive actions:
  • Perform annual infrared thermography to detect hot spots
  • Verify output voltage stability under load during maintenance outages
  • Clean ventilation slots and ensure adequate rack airflow
  • Maintain at least one tested spare with matching revision (G04 suffix critical for compatibility)
EMERSON 5X00226G04

EMERSON 5X00226G04

Lifecycle Status and Migration Strategy

The 5X00226G04 belongs to an earlier generation of Ovation hardware. While Emerson continues to support the Ovation platform, this specific power supply model has been superseded by newer variants (e.g., 5X00226G05 or integrated chassis power in Ovation Evo). Official manufacturing has ceased, and new units are unavailable.
Continued use carries risk: refurbished units may have unknown service life, and mismatched revisions can cause compatibility issues with backplane firmware or diagnostics.
Short-term strategies include:
  • Qualifying third-party repair vendors for capacitor/fan replacement
  • Implementing external UPS or power conditioning to reduce stress
  • Stocking verified spares with documented test reports
Long-term, facilities should consider migration within the Ovation ecosystem:
  • Upgrading to Ovation Evo I/O chassis, which feature integrated, higher-efficiency power supplies with enhanced diagnostics
  • Consolidating legacy racks into modern enclosures during planned outages
  • Leveraging Emerson’s migration services for seamless integration without full DCS replacement
Such upgrades preserve existing control logic while improving power reliability, cybersecurity posture, and lifecycle sustainability—turning an obsolete component into an opportunity for infrastructure modernization.

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