Product Overview​

The 5500-159D is a advanced digital engine control module developed by Woodward,a global leader in power management solutions for heavy-duty engines,generators,and industrial power systems.As a flagship component of Woodward’s engine control portfolio,the 5500-159D is engineered to deliver precise control over engine speed,fuel delivery,load distribution,and emissions—catering to the demanding needs of industries such as off-highway machinery,marine propulsion,emergency power generation,and oil&gas drilling.​

In industries reliant on heavy-duty engines,maintaining optimal performance while minimizing fuel consumption and emissions is a critical balancing act.The 5500-159D excels in this role by integrating multi-channel sensor input processing,adaptive fuel control algorithms,and real-time diagnostics.It collects data from engine sensors(e.g.,crankshaft position sensors,intake temperature sensors,exhaust gas sensors)and external systems(e.g.,load banks,transmission controllers),then calculates and executes control commands to fuel injectors,throttle bodies,or exhaust aftertreatment systems—all with a response time of<500 microseconds.Unlike basic engine controllers,the 5500-159D leverages machine learning-based adaptive logic to adjust to changing operating conditions(e.g.,varying fuel quality,extreme temperatures,dynamic load demands),ensuring consistent performance,reduced fuel waste,and compliance with global emissions standards(e.g.,EPA Tier 4,EU Stage V).​

Whether deployed to control a diesel engine in an off-highway excavator,a gas engine in a marine tugboat,or a backup generator in a data center,the 5500-159D delivers reliable,efficient engine management.Its modular hardware design and compatibility with Woodward’s PowerNet software platform also simplify system customization and integration,allowing users to tailor control logic to specific equipment requirements without extensive reengineering.​

Technical Specifications​

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Parameter Name​

Parameter Value​

Product Model​

Woodward 5500-159D​

Manufacturer​

Woodward(Industrial Power Management Systems)​

Product Type​

Digital Engine Control Module​

Engine Compatibility​

Diesel/Gas Engines(2–20 Cylinders);Power Range:50–2000 kW​

Speed Control Range​

500–3000 RPM(Configurable via Software);0–6000 RPM(Optional)​

Speed Regulation Accuracy​

±0.05%of Setpoint(Steady-State);±0.3%during Load Transients​

Input Signals​

-Engine Sensors:Crankshaft Position(0.5–50 kHz),Intake Air Temp(-40°C to+125°C),Oil Pressure(0–10 bar)-Load Signals:4–20mA DC,0–10V DC(Generator Load,Hydraulic Pressure)-Control Inputs:24V DC Discrete(Start/Stop,Idle/Run,Emergency Shutdown)​

Output Signals​

-Fuel Control:PWM(0–100%Duty Cycle)for Injectors;4–20mA DC for Throttle Actuators-Auxiliary Outputs:24V DC Discrete(Status Alarms,Cooling Fan Control);0–10V DC(Exhaust Aftertreatment)​

Power Supply​

12V DC/24V DC(Dual Voltage);Typical Current:300mA;Maximum Current:800mA​

Communication Protocols​

CAN FD(SAE J1939,ISO 15765);Ethernet(Modbus TCP,OPC UA);RS-485(Modbus RTU)​

Operating Temperature Range​

-40°C to+85°C(Running);-55°C to+105°C(Storage)​

Installation Method​

DIN Rail Mounting(EN 60715,35mm);Flange Mount(Optional with Kit)​

Protection Rating​

IP20(Module Body);IP6K9K(With Optional Rugged Enclosure)​

Physical Dimensions(H×W×D)​

110mm×45mm×140mm​

Diagnostics​

Sensor Fault Detection(Open/Short Circuit),Overcurrent Protection,Emissions Compliance Monitoring,Engine Health Analytics​

Certifications​

TÜV Rheinland(Functional Safety);CE(EMC Compliance);EPA Tier 4/EU Stage V(Emissions Compatibility);UL 1998(Power Equipment)​

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Main Features and Advantages​

Precision Speed&Fuel Control for Efficiency:The 5500-159D delivers industry-leading speed regulation accuracy(±0.05%steady-state)and adaptive fuel control,minimizing fuel consumption by up to 8%compared to conventional controllers.For example,in a 1000 kW backup generator set,the module adjusts fuel delivery in real time based on load fluctuations—reducing fuel use from 250 L/h to 230 L/h during partial-load operation(500 kW).This efficiency not only lowers operational costs but also extends maintenance intervals by reducing carbon deposits in engine components.​

Multi-Protocol Communication for System Integration:Unlike controllers limited to basic serial communication,the 5500-159D supports CAN FD,Ethernet,and RS-485 protocols,enabling seamless integration with modern industrial ecosystems.In a marine propulsion system,for instance,the module uses SAE J1939(CAN FD)to communicate with the ship’s navigation system,adjusting engine speed based on GPS-derived vessel speed.It also uses Modbus TCP(Ethernet)to send real-time engine data to the bridge’s SCADA system,allowing crew to monitor performance remotely.This multi-protocol support eliminates the need for additional communication gateways,simplifying system design and reducing failure points.​

Rugged Design for Harsh Environments:The 5500-159D is engineered to withstand extreme conditions,including temperatures from-40°C to+85°C,vibration up to 20g(10–2000 Hz),and exposure to dust,water,and oil(when using the optional IP6K9K enclosure).In an off-highway mining truck,for example,the module operates reliably despite constant vibration from rough terrain and temperature swings between-30°C(night)and+70°C(day).Its EMI/EMC compliance(per EN 61000-6-3)also shields it from interference from nearby electrical systems(e.g.,hydraulic pumps,radio transmitters),preventing false control signals that could cause engine instability.​

Emissions Compliance&Monitoring:The 5500-159D includes built-in emissions control logic and monitoring,helping users meet strict global standards(EPA Tier 4,EU Stage V).It adjusts fuel injection timing and exhaust gas recirculation(EGR)rates in real time to limit nitrogen oxide(NOₓ)and particulate matter(PM)emissions.For a municipal waste truck fleet,the module logs emissions data(e.g.,NOₓlevels,EGR efficiency)and transmits it to a central database via OPC UA,simplifying compliance reporting and avoiding costly fines.It also alerts operators to emissions-related faults(e.g.,clogged diesel particulate filter)before they trigger regulatory violations.​

Application Field​

The 5500-159D is a versatile engine control module used across industries that rely on heavy-duty power equipment.In the off-highway sector,it is widely deployed in construction machinery(excavators,bulldozers)and agricultural equipment(tractors,harvesters).A construction company uses the 5500-159D to control the diesel engine in a 50-ton excavator:the module adjusts engine speed based on hydraulic load(e.g.,1500 RPM for light digging,2500 RPM for heavy lifting),optimizing fuel efficiency and reducing operator fatigue by maintaining smooth power delivery.Its vibration resistance ensures reliable operation even on rough job sites.​

In the marine industry,the 5500-159D regulates the speed of gas and diesel engines in commercial vessels(tugboats,ferries)and offshore support ships.A ferry operator uses the module to control two 800 kW diesel engines,synchronizing their speed to ensure smooth propulsion and reducing fuel consumption by 6%compared to the previous controller.The module’s CAN FD communication with the ship’s autopilot system also allows for automatic speed adjustments based on sea conditions,improving navigation safety.​

The 5500-159D also plays a critical role in emergency power generation.A data center uses the module to control three 1500 kW backup generators:during grid outages,the 5500-159D starts the generators within 10 seconds,synchronizes their output,and distributes load based on data center demand.Its real-time diagnostics alert maintenance teams to issues like low oil pressure or sensor drift,ensuring the generators are always ready for use.The module’s compliance with UL 1998 also ensures it meets safety standards for critical power equipment.​

Related Products​

Woodward 5500-160D:A high-power variant of the 5500-159D designed for engines up to 4000 kW.It supports additional fuel injectors and advanced emissions control features,ideal for large mining trucks or marine propulsion systems.​

Woodward 8470 Crankshaft Position Sensor:A high-precision sensor optimized for use with the 5500-159D.It delivers 0.5–50 kHz signals for accurate engine speed and position detection,ensuring reliable control.​

Woodward 9910-002 Redundant Power Supply:A dual-voltage(12V/24V)power supply that provides backup power to the 5500-159D.It ensures uninterrupted operation during battery failures or voltage spikes,critical for emergency generators.​

Woodward PowerNet Software:A configuration and monitoring platform for the 5500-159D.It allows users to customize control logic,log engine data,and run diagnostic tests via a intuitive dashboard.​

Woodward 5470 Fuel Actuator:A PWM-controlled actuator that pairs with the 5500-159D to regulate fuel delivery.It supports up to 100%duty cycle,making it suitable for high-performance diesel engines.​

Woodward 7350 Exhaust Gas Sensor:An analog sensor that works with the 5500-159D to monitor NOₓand PM levels.It delivers 4–20mA signals for emissions control and compliance reporting.​

Woodward 9120-005 Rugged Enclosure:An IP6K9K-rated enclosure for the 5500-159D,designed for off-highway and marine applications.It protects the module from dust,water,and oil,extending its service life.​

Woodward 5500 Communication Gateway:A device that expands the 5500-159D’s communication capabilities,adding support for protocols like Profinet or DNP3.It enables integration with legacy SCADA systems.​

Installation and Maintenance​

Pre-installation preparation:Before installing the 5500-159D,verify compatibility with your engine(cylinder count,power range)and existing control systems(e.g.,transmission,emissions aftertreatment).Check the power supply to ensure it matches the module’s 12V/24V dual-voltage requirement,using a filtered power source to prevent voltage spikes.Install the module on a 35mm DIN rail(EN 60715 compliant)in a location with adequate ventilation—avoid areas with direct engine heat,fluid leaks,or excessive vibration.For off-highway or marine applications,use the optional IP6K9K enclosure.Wire engine sensors,fuel actuators,and communication devices per Woodward’s wiring diagram,ensuring twisted-pair cabling for analog signals(to reduce EMI interference).Finally,use PowerNet software to pre-configure control parameters(speed setpoints,fuel maps,emissions limits)to align with engine specifications.​

Maintenance recommendations:Conduct monthly visual inspections of the 5500-159D to check for loose wiring,damaged connectors,or illuminated fault LEDs—tighten connections and replace damaged components to maintain signal integrity.Every three months,use PowerNet software to run a diagnostic test,verifying sensor accuracy,actuator functionality,and communication links.Calibrate the module’s speed regulation by comparing its setpoint to a calibrated tachometer,adjusting parameters via software if deviations exceed±0.05%.Clean the module’s surface(or enclosure)with a dry,anti-static cloth;for IP6K9K enclosures,use a high-pressure water jet(per IP6K9K standards)to remove dirt and debris.If the 5500-159D displays abnormal behavior(e.g.,erratic speed control,emissions faults),first check sensors and power supply before replacing the module.Store spare units in a temperature-controlled environment(-55°C to+105°C)with minimal dust exposure,and re-configure them with engine-specific parameters before deployment.​

Product Guarantee​

The 5500-159D comes with a 36-month quality guarantee from the date of purchase,reflecting Woodward’s commitment to delivering reliable engine control modules for critical power applications.Each module undergoes rigorous testing during production,including temperature cycling(-40°C to+85°C),vibration testing(20g),EMI/EMC immunity trials,and functional performance checks—ensuring it can withstand harsh operating conditions and meet Woodward’s strict quality standards.​

In the event of defects or performance issues covered by the guarantee,we provide free replacement or repair services with expedited shipping to minimize downtime—a critical benefit for industries where engine outages result in lost productivity or safety risks.Our global technical support team is available 24/7 to assist with 5500-159D installation,configuration,and troubleshooting,offering remote guidance via PowerNet software and on-site support for complex issues.Additionally,we provide access to Woodward’s training programs and documentation(including wiring diagrams,calibration guides,and emissions compliance tools)to help users maximize the module’s performance.This comprehensive support ensures the 5500-159D delivers long-term reliability,efficiency,and compliance for heavy-duty engine applications worldwide.

联系人：Mandy 联系电话：+8618150087953 网站：www.cxplcmro.com