Description
Core Product Summary (Brand / Model / Key Attributes)
The Woodward EM-80-3522-1009 is a dedicated driver module for the EM-80 all-electric actuator system. It forms part of the EM-80/EM-300 family of high-torque rotary actuators used on large diesel, gas and gasoline engines as well as turbines.
The 3522-1009 driver converts three-phase 400–480 Vac supply into controlled power for the brushless AC motor that drives the EM-80 planetary gearbox. The complete system delivers 40° of output rotation with a continuous torque of 91 N·m and a no-load 10–90 % slew time of 78 ms. Position command is accepted as 4–20 mA or 1–5 V; position feedback is provided as 0–5 V. The driver is designed for cabinet mounting (IP20) and operates in ambient temperatures from 0 to +55 °C.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Product type | EM-80 all-electric actuator driver |
| Part number | 3522-1009 |
| System family | EM-80 / EM-300 |
| Actuator output travel | 0–40° |
| Nominal continuous torque (EM-80) | 91 N·m (67 lb-ft) |
| Maximum torque (1 s) | 190 N·m (140 lb-ft) |
| Nominal work output (40°) | 64 J (47 ft-lb) |
| 10–90 % slew time (no load) | 78 ms |
| Driver power supply | 3-phase 400–480 Vac, 50–60 Hz |
| Rated input current | 16 A |
| Maximum output current | 24 A |
| Steady-state output current | 12 A at 45 °C |
| Command input | 4–20 mA or 1–5 V |
| Position feedback | 0–5 V |
| Driver ambient temperature | 0 to +55 °C |
| Driver weight | approx. 7 kg |
| Ingress protection (driver) | IP20 |
| Mounting | Control-cabinet installation |
Detailed Product Overview
The Woodward EM-80-3522-1009 is the electronic driver that powers and positions the EM-80 all-electric actuator. The actuator itself consists of a three-phase brushless AC servomotor coupled to a high-stiffness, low-backlash planetary gearbox. The 3522-1009 converts incoming three-phase mains power into the precise current and frequency required by the motor while closing a position loop around the resolver feedback signal.
Because the system requires neither a mechanical drive take-off nor hydraulic oil, it is particularly suitable for engines and turbines that lack these services. Typical applications include positioning of engine fuel racks, turbine fuel valves, variable-geometry mechanisms and injection-timing control. The ISO 9409 output flange simplifies linkage attachment, and break-away stops protect the mechanism during commissioning.
A single driver family (3522-1004 through 3522-1012) serves both the EM-80 and the higher-torque EM-300 actuators; only software configuration differs. PC-based setup tools allow the response, limits and diagnostics to be tailored to the application. Monitoring, alarm and diagnostic functions are available at the driver.
Engineering Selection Highlights
- Use the 3522-1009 when an EM-80 actuator (91 N·m continuous) is required and the supply voltage is 400–480 Vac three-phase.
- The driver is common to both EM-80 and EM-300; software selection determines torque and slew behaviour.
- Position demand must be supplied as 4–20 mA or 1–5 V; feedback is returned as 0–5 V.
- Maximum cable length between driver and actuator is 100 m; dedicated power and resolver cables are required.
- The driver must be installed in a control cabinet (IP20); it is not intended for direct engine mounting.
- Continuous torque and work ratings are derated above 40 °C ambient at the actuator.
- DNV, BV and ABS marine type approvals cover the 3522-100x driver series.
EM-80 3522-1009
EM-80 3522-1009
EM-80 3522-1009
System Compatibility & Integration Requirements
| Item / Dependency | Verified Compatibility or Requirement | Practical Note |
|---|---|---|
| Actuator | EM-80 (or EM-300 with software change) | Same driver hardware |
| Power supply | 3-phase 400–480 Vac, 50–60 Hz | EMI filter required |
| Position command | 4–20 mA or 1–5 V | From governing controller |
| Position feedback | 0–5 V | To governing controller |
| Cabling | Power + resolver cables | Max. 100 m between driver and actuator |
| Mounting | Control-cabinet (driver); engine bracket (actuator) | Actuator orientation within 45° of horizontal |
| Software | Woodward PC/Windows configuration tools | Required for setup and diagnostics |
Dimensions, Mounting & Connection Notes
The driver enclosure is intended for installation inside a control cabinet and carries an IP20 rating. Approximate weight is 7 kg. Two cables connect the driver to the actuator: a three-phase power cable (including protective earth) and a shielded position-sensor (resolver) cable. Maximum separation is 100 m. An EMI filter is supplied with the system to suppress conducted emissions. The actuator itself is engine-mounted via a dedicated bracket and may be oriented within 45° of horizontal.
FAQ
What is the Woodward EM-80-3522-1009?
It is the dedicated electronic driver for the EM-80 all-electric rotary actuator system used on large engines and turbines.
What torque does the EM-80 system deliver?
Continuous torque is 91 N·m; peak torque (1 second) is 190 N·m over a 40° travel range.
What power supply does the 3522-1009 require?
Three-phase 400–480 Vac, 50–60 Hz.
Can the same driver be used with the EM-300 actuator?
Yes. Hardware is identical; only the software configuration changes.
What signal interfaces are provided?
Position command: 4–20 mA or 1–5 V. Position feedback: 0–5 V.
Where is the driver mounted?
Inside a control cabinet (IP20). The actuator is mounted on the engine or turbine.
What is the maximum cable length to the actuator?
100 m for both the power and the resolver cables.
Verification & Troubleshooting Notes
- Confirm the driver part number (3522-1009) matches the EM-80 actuator software configuration.
- Verify three-phase supply voltage remains within 400–480 Vac ±10 % under all load conditions.
- Check that the EMI filter is correctly installed on the incoming power line.
- Ensure resolver and power cables are properly shielded and do not exceed 100 m.
- Use the Woodward PC configuration tool to read diagnostic and alarm status when commissioning or troubleshooting.
- Continuous torque capability is reduced when actuator ambient temperature exceeds 40 °C; consult the derating schedule in the product manual.
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