Description
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Other names for 8440-2085:
Processor Unit 8440-2085
8440-2085 Analog Unit
Input/Output Unit 8440-2085
Product Overview
Positioning: A high-end generator controller from Woodward, belonging to the easYgen-3000XT series, designed for complex parallel operation and power management, supporting coordinated control of up to 32 generator sets and 16 circuit breakers (such as MCB/GGB).
Core Functions: Supports parallel operation of multiple generator sets (up to 32 units), automatic synchronization, load sharing, circuit breaker control, engine ECU communication (supports SAE-J1939 protocol), remote monitoring (via Modbus RTU/TCP, CANopen, or Ethernet), power factor regulation, fault protection (programmable settings), etc.
Core Technical Parameters:
Communication Capabilities:
9 communication ports: 3×Ethernet (with redundancy), 3×CAN (CANopen/J1939), RS-485, USB, and interface expansion card.
Supports Modbus TCP/RTU, SAE-J1939, and other protocols, compatible with various engine ECUs (such as MTU ADEC, Volvo EMS2, Cummins, etc.).
Electrical Characteristics:
Power Input: 12/24 V DC (8-40 V DC), maximum power consumption 22W (LT low-temperature version 32W).
Voltage Measurement: Direct connection to 690 VAC, three-phase true RMS power measurement (accuracy class 1). Environmental Adaptability:
Operating Temperature: -20°C to 70°C (LT version -40°C to 70°C), Storage Temperature: -30°C to 80°C.
Altitude Adaptability: No derating operation above 4000 meters, compliant with UL 61010, CE, RoHS 2, and marine certifications (ABS, Lloyd’s Register).
Functional Expansion:
Programmable logic (LogicsManager™), HMI screen customization, alarm management.
Supports remote panel control (RP-3000XT) up to 250 meters away, user-friendly touchscreen interface.
Application Scenarios:
Key Areas:
Emergency Backup: Data centers, hospitals, commercial complexes, and other critical facilities.
Distributed Energy: Grid-connected solar/wind power, microgrids, islanded power supply (oil exploration, remote villages).
Industrial Applications: Combined heat and power (CHP), wastewater treatment, biogas power generation, marine/maritime equipment.
Isolated Operation: Independent power supply for remote areas, offshore platforms, and mobile equipment (such as leased generators).
System Upgrade: Parallel conversion of generator sets, load sharing optimization, and intelligent upgrade of switchgear.
Special Scenarios:
Demanding conditions such as low-temperature environments (-40°C), high-altitude areas, and offshore platforms.
Functional Highlights:
Parallel Control: Supports proportional load sharing (isochronous/droop mode) for up to 32 generator sets, achieving seamless grid connection, isolated operation, and black start.
Protection Mechanisms: Full parameter protection for engines/generators (overload, underfrequency, overvoltage, etc.), programmable PID control (such as heating circuits, pressure monitoring).
Intelligent Management: Automatic synchronization, circuit breaker control, soft loading/unloading, demand response (peak shaving and valley filling), remote monitoring and diagnostics.
Software Support: Woodward Toolkit configuration tool, supporting PC/laptop connection via USB/Ethernet/CAN for parameter configuration, logic programming, and system simulation.
Intelligent Control: Supports automatic/manual/test mode switching, achieving precise adjustment (e.g., speed, voltage, power factor) through a PID controller, and can configure multiple parameter sets (e.g., settings specific to mobile systems).
Communication Capabilities: Integrates CANopen, Ethernet, and Modbus RTU/TCP interfaces, supporting remote configuration (via Woodward ToolKit software) and integration with SCADA/PLC systems.
Protection Functions: Provides protection against engine/generator overload, short circuit, overvoltage/undervoltage, overfrequency/underfrequency, and high temperature, supporting programmable logic (LogicsManager™) for customized protection strategies.
Expandability: Supports I/O expansion boards (e.g., AnalogManager), redundant Ethernet, multi-language interface (including Chinese), and touchscreen operation.
Core Function Expansion Modules
AnalogManager Expansion Board: Adds analog input/output channels (e.g., 4-20mA, 0-10V), supporting connection to temperature, pressure, and flow sensors and actuators, suitable for precise process control in cogeneration (CHP), biogas power generation, and other scenarios.
Digital I/O Expansion Modules (e.g., 8440-2028): Provides 16 input/16 output channels, response time ≤1ms, compatible with Woodward 8000/8440 series, suitable for circuit breaker status monitoring, relay control, and other scenarios.
Dedicated Function Modules:
Three-Phase Bus Voltage Measurement Module: Supports Class I accuracy true RMS detection, resists harmonic interference, suitable for high-precision monitoring of power parameters.
RTD/TC Temperature Acquisition Module: Directly connects to signals such as engine cylinder head and exhaust temperature, supports J1939/CANopen protocols.
Engine ECU Communication Module: Supports SAE-J1939 and proprietary protocols such as MTU, Volvo, and Cummins, enabling engine-generator set coordinated control.
Communication and Network Module
Multi-protocol Interfaces: Integrates 3 Ethernet ports, 3 CAN ports (supporting CANopen/J1939), RS-485, USB, and interface expansion card slots. Supports Modbus RTU/TCP, SCADA system integration, and PLC linkage.
Redundant Communication Module: Redundant Ethernet design; backup links automatically take over in case of main network failure, improving system reliability; supports collaboration with the GC-3400XT group management controller to achieve parallel load sharing for multiple units (up to 248 units).
Remote Panel (RP-3500XT): Enables remote operation, alarm monitoring, and configuration up to 250 meters via the CANopen protocol; supports multiple languages including Chinese.
Protection and Logic Control Module
Programmable Logic Function (LogicsManager™): Built-in programmable engine supports customized protection strategies (such as overload, short circuit, overvoltage/undervoltage, overfrequency/underfrequency, high temperature, etc.), enabling complex logic control without an additional PLC, and can also be integrated with SCADA/PLC systems.
Engine Protection Functions: Integrates engine ECU communication, cylinder head temperature monitoring, and exhaust temperature alarms, supporting fully programmable settings.
Environmental Adaptability and Reliability Modules
Low Temperature/High Altitude Adaptation Module: The LT model supports operation from -40℃ to 70℃, suitable for extreme environments such as outdoor and offshore platforms; in high altitude mode, it supports direct 690V AC connection and operation without derating at altitudes above 4000 meters.
Redundant Power Supply and Anti-interference Design: Supports 8-40V DC wide voltage input, with built-in power filtering and anti-harmonic interference circuits to ensure stable operation under power grid fluctuations or harmonic environments.
Debugging and Maintenance Tools
Simulation and Debugging Software: The accompanying system simulation software supports offline debugging on a PC, avoiding the safety risks and fuel waste caused by repeated start-ups and shutdowns of the unit; supports firmware updates and parameter configuration via USB/Ethernet/CAN ports.
Status Monitoring Module: Integrates circuit breaker status indicator lights, alarm logs, and system update functions, supporting remote fault diagnosis and dynamic unit management (such as automatic synchronization, soft loading/unloading).
Summary
The WOODWARD EASYGEN 3500XT (8440-2085) is a high-end controller designed for complex power management systems. With its powerful parallel control capabilities, extensive communication interfaces, harsh environment adaptability, and intelligent management functions, it has become the preferred solution for data centers, industrial power generation, microgrids, and marine applications. Its modular design, programmable logic, and remote monitoring features further enhance system flexibility and reliability, meeting diverse needs from stand-alone units to large power plants.
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Model recommendation:
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admin –
Model number 8440-1936 is part of the EasyGen 3000 series that Woodward Inc produces, this controller is a generator set or a genset controller. This controller is powered by an internally isolated power supply of 12/24 Vdc. The voltage measure of your device should be 120 V or 480 V depending but they should never be reading either voltage level at the same time, if this is so then the voltage on the device will not measure correctly.
angel –
Take caution when you are using your controller, you should only have certified professionals not only operate but repair your controller, if you are using your controller and the genset it is attached to improperly it could cause potential damage to the controller and any components that it is connected to. Please only have a qualified and certified electrician perform any type of electrical work on your controller, there are hazards that can occur from electrical shock if the insulation on your device has potentially sustained damage due to the electrical shock the power supply needs to be immediately switched off.
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admin –
Core Identity: Belonging to the Woodward easYgen-3000XT series of high-end generator controllers, this product is designed for complex parallel power generation systems. It supports coordinated control of up to 32 generator sets (maximum 496 units expandable via GC-3000XT) and 16 circuit breakers (MCB/GGB/bus tie circuit breakers), making it a core component of industrial-grade power management systems.
Model Identification: Model 8440-2085 corresponds to the EASYGEN-3500XT-P1 version, compatible with 24V DC/120V AC power supplies, and suitable for industrial automation and power management systems.
Core Functions and Technical Characteristics:
Parallel Control and Protection Capabilities
Comprehensive Protection Mechanism: Integrates overcurrent, undervoltage, overvoltage, short circuit, frequency deviation (ROCOF), and mains decoupling protection. Supports programmable settings for all generator/generator parameters and complies with international certifications such as UL/cUL, CE, and BDEW.
Intelligent Logic and HMI: Built-in LogicsManager programmable logic allows for customizable control strategies (such as CHP cogeneration heating control and water/fuel level monitoring). It is paired with the RP-3000XT touchscreen remote control panel for remote operation and alarm management.
Parallel Operation: Supports multi-unit parallel operation, grid connection, peak shaving and valley filling, and emergency standby modes. Phase matching and frequency sliding synchronization technologies enable rapid load take-off (dead-zone parallel operation).
Protection Mechanism: Integrates comprehensive protection for the engine, generator, and power grid. It features three-phase true RMS power measurement (Class I accuracy), overcurrent/undervoltage/overvoltage/short-circuit protection, and supports programmable logic customization.
Communication Architecture: Equipped with 9 communication ports (3×Ethernet, 3×CAN, RS-485, USB, and expansion card slot), supporting CANopen, J1939, and Modbus TCP/RTU protocols. Optional redundant Ethernet communication enhances reliability.
Communication and Expandability
Multi-protocol Support: Integrated with 3 Ethernet ports (with redundancy), 3 CAN ports (CANOpen/J1939), RS-485, USB, and expansion card slots; compatible with Modbus RTU/TCP, SCADA systems, and third-party PLCs (such as Siemens and Rockwell).
Collaborative Control Architecture: Can work with the GC-3000XT group management controller to manage up to 496 generator sets; enables complex power distribution network control of 16-64 circuit breakers via the LS-5/LS-6XT circuit breaker controller.
Remote Diagnostics: Supports configuration and fault diagnosis via PC/laptop using Woodward ToolKit software; data synchronization is achieved via the SNTP protocol.
Hardware and Expandability
Wide Voltage Design: Supports 12/24V DC (8-40V) or 120V AC input; direct connection to a 690V AC system; operates without derating at altitudes above 4000 meters.
Extreme Environment Tolerance: Standard version operating temperature -20°C to 70°C, LT low-temperature version supports -40°C to 70°C, IP20 protection rating, storage temperature -30°C to 80°C, 95% non-condensing humidity.
Redundant Design: Dual-channel communication, redundant load sharing (achieved via Ethernet B/C network), automatic switch to backup channel in case of failure.
Intelligent Features and Compatibility
Remote Control: Remote operation via RP-3000XT touchscreen panel, supports SCADA/PLC system integration, compatible with Woodward ToolKit software for parameter configuration and fault diagnosis.
Multi-Language Support: Covers 15 languages including English, German, and Chinese, suitable for global deployment.
Certification Standards: Complies with UL 61010, CE, RoHS 2, and marine ABS/LR certifications, meeting compliance requirements of multiple industries such as power, petrochemical, and shipbuilding.
Technical Specifications
Power Requirements: 8-40V DC (24V DC typical), 120V AC optional, power consumption ≤22W (LT version ≤32W).
Measurement Accuracy: Three-phase voltage/current RMS measurement, power accuracy ±0.5%, supports monitoring of process variables such as temperature and pressure.
Communication Protocols: Supports Modbus TCP/RTU, CANopen, J1939, optional fiber optic/dual-link redundancy.
Physical Specifications: Dimensions approximately 260×180×70mm (P1 version), weight approximately 2.8kg, metal casing suitable for DIN rail or panel mounting.
Application Scenarios and Cases
Typical Applications:
Emergency Backup: Data centers, hospitals, commercial complexes, ensuring power continuity for critical facilities.
Distributed Generation: Photovoltaic/wind power complementary systems, industrial park microgrids, achieving demand response and peak-valley regulation.
Isolated Power Supply: Oil drilling platforms, remote area base stations, mobile power generation equipment, supporting independent operation in off-grid mode. Cogeneration: Biogas power generation, wastewater treatment plants, optimizing energy efficiency and carbon emission control.
Special Environments: High-altitude, low-temperature outdoor applications (e.g., polar research stations), the LT version meets extreme conditions.
Typical Cases:
Achieving generator voltage stability and dynamic load distribution in coal/gas-fired power plants.
Coordinating multiple energy inputs and load balancing in microgrid systems, improving system resilience.
Integrating with DCS/PLC systems in industrial automation to optimize power supply for production processes.
Industry Cases: Coordinating parallel operation of multiple units in coal/gas-fired power plants; achieving seamless switching between mains power and generator sets in data centers; managing complex power distribution networks in marine power systems.
Technical Parameters and Performance Indicators
Power Supply and Power Consumption: 12/24V DC (8-40V), maximum power consumption 22W (LT version 32W).
Measurement Accuracy: True RMS voltage/current detection, Class 1 power measurement accuracy, frequency measurement range 30-85Hz.
Communication Interfaces: 3×Ethernet, 3×CAN, 1×RS-485, 1×USB, expansion card slot (supports Modbus TCP/RTU).
I/O Capabilities: Multiple digital inputs/outputs (DI/DO), supports analog inputs (4-20mA), relay output contact capacity 2A@250VAC.
Environmental Certifications: CE, UL/cUL, CSA, BDEW, ABS, Lloyd’s Register, compliant with VDE AR-N4105 and other power grid standards.
Summary
The Woodward EASYGEN 3500XT is a high-reliability controller designed for complex power generation systems. It integrates advanced parallel control, protection functions, and multi-protocol communication capabilities, making it suitable for industrial, energy, and infrastructure applications with extremely high power stability requirements. Its modular design, wide environmental adaptability, and intelligent logic functions make it a core control unit for large generator power plants, microgrids, and distributed energy systems.
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