Description
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The 8440-2085 is a high-end genset controller within the Woodward easYgen-3000XT platform. It features a metal housing without an integrated display and is designed for rear-panel mounting. It is an all-in-one controller offering genset control, protection, synchronization, and load sharing, specifically designed for complex multi-unit paralleling, islanding/grid-parallel operation, and AMF (Automatic Mains Failure) with bus-tie switching applications.
Core Positioning
This controller integrates engine start/stop control, generator electrical parameter monitoring, synchronization and closing, active/reactive load sharing, genset and grid protection, and bus-tie breaker control. It supports peer-to-peer networking for paralleling, enabling multi-unit coordination without the need for an additional master controller. The P1 version focuses on complex multi-unit paralleling systems; it comes standard with redundant Ethernet communication and native support for LS-5 breaker controller expansion. It is suitable for complex, multi-bus power distribution systems in applications such as industrial backup power stations, data centers, hospitals, oil & gas facilities, and marine shore power.
Hardware and Electrical Characteristics
The unit features a ruggedized metal housing designed for internal cabinet mounting and does not include a local display, though it supports an external RP-3000XT touchscreen operator panel. The voltage sensing circuit allows for direct measurement of up to 690 Vac without external PTs, and the unit operates at altitudes up to 4,000 meters without derating. Communication interfaces include three Ethernet ports, three CAN bus ports (supporting J1939 and CANopen), RS485, and a USB debugging port. Features onboard standard digital I/O and supports expansion with LS-5/LS-6XT breaker controllers, capable of managing up to 32 generator sets and 16 generator/bus-tie breakers. The communication network supports dual-redundant Ethernet for load sharing, eliminating single points of failure and enhancing power plant reliability.
Key Functions
Generator Start/Stop Logic: Automatic/manual start and stop; supports pre-lubrication, cooling shutdown, and run-up synchronization; supports J1939 engine ECU communication to monitor engine speed, coolant temperature, oil pressure, and fault codes.
Synchronization and Load Sharing: Automatic synchronization detection; adjustment of frequency, voltage, and phase angle differences; peer-to-peer active/reactive power sharing; supports islanded paralleling, grid-parallel operation, and seamless transitions between islanded and grid-connected modes.
AMF (Automatic Mains Failure): Automatically starts the generator and closes the generator breaker upon mains voltage loss, over/under-voltage, or frequency anomalies; upon mains restoration, automatically synchronizes and switches back to mains power after a configurable delay, followed by a cooling shutdown sequence.
Peak Shaving: Limits grid power consumption during grid-parallel operation; automatically engages generators to share peak loads, thereby reducing electricity costs.
Comprehensive Protection: Generator protections include overcurrent, over/under-voltage, over/under-frequency, reverse power, over-excitation, and phase sequence faults; engine protections include overspeed, low oil pressure, and high coolant temperature; busbar protections include loss of voltage and synchronization failure; all protections are individually configurable for alarm or trip actions.
Customizable Logic: Features a built-in “Logic Manager” for programmable logic, allowing users to define interlocking conditions based on project requirements and adapt to specific on-site interlocking needs. Data Logging and Monitoring: Features event logging, fault snapshots, and trend recording; parameter configuration, online commissioning, and log export are performed using Woodward easYgen ToolKit software; supports Modbus TCP/RTU for integration with supervisory SCADA and DCS systems.
System Scalability
The unit can connect to the LS-5 circuit breaker controller to enable bus-tie control across multiple busbar sections; when paired with the GC-3000XT master controller, it supports expansion into large-scale power plant clusters comprising up to 496 units. It also supports the LS-6XT synchronizing circuit breaker controller for use in complex power distribution systems involving multiple busbar sections and multiple power sources.
Typical Application Scenarios
Industrial emergency backup power plants; dual-busbar backup power for data centers; critical load power for hospitals and rail transit; captive power plants for oil and gas platforms; combined heat and power (CHP) systems; marine main and auxiliary power plants; and microgrid islanded power generation systems.
Model recommendation:
8440-1800
8440-1925
8440-1934
8440-1546
8440-1894
8440-2096
8440-2077
8440-1809
8440-2050
8440-1878
5437-523
More……
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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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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admin –
The easYgen-3500XT (part number 8440-2085) is a high-performance parallel generator controller from Woodward, designed for OEM switchgear manufacturers, generator packagers, and system integrators. This controller integrates complete generator control and protection functions, advanced peer-to-peer parallel operation, and innovative features in a robust, aesthetically pleasing, and user-friendly interface. Its built-in LogicsManager™ programmable logic provides excellent application flexibility, typically eliminating the need for additional PLC control, and can be easily integrated with SCADA or PLC-based control systems as needed.
Core Functions:
True RMS voltage and current detection (generator, bus, and mains power), reducing sensitivity to harmonics.
CAN network communication/control with the engine ECU, supporting the standard SAE-J1939 protocol and several proprietary engine OEM protocols.
Serial Modbus RTU (slave) communication for SCADA alarms and external control.
Via Woodward ToolKit service tools are configured via PC/laptop.
Connects to the RP-3500 remote panel, enabling complete alarm, control, and configuration via the CANopen protocol, with a maximum distance of 250 meters.
Automatic synchronization: phase matching, positive/negative frequency sliding, running (dead zone) parallel operation.
Circuit breaker closing/opening control: GCB, GCB, and MCB (ATS function) or external control.
Proportional load sharing (equal or decreasing) for up to 32 generator sets, regardless of individual unit size.
Basic load, input/output control, asymmetrical load (via external basic load input).
Automatic start/stop based on load, improving generator system efficiency.
Asynchronous (induction) generator control.
Engine and generator protection functions, fully programmable settings
Typical Application Scenarios:
Emergency Backup: Data centers, hospitals, commercial and industrial facilities
Distributed Generation (DG): Utility dispatchable power for peak demand response
Islanding: Oil and gas exploration, marine, remote villages, rental/mobile equipment
Microgrids: Military, government, net-zero communities, universities
Utility Grid Connection: Peak shaving and valley filling, demand reduction
Combined Heat and Power (CHP): Wastewater treatment, biogas production/control
Switchgear Upgrade: Generator control retrofit, increasing load sharing/parallel operation capabilities
Certifications:
CE, UL/cUL, CSA, BDEW, ABS, Lloyd’s Register
This controller belongs to the easYgen-3000XT series, part number 8440-2085 corresponds to the easYgen-3500XT model, and is one of Woodward’s core products in the generator control field, widely used in various power generation systems worldwidhttps://www.weikunfadacai1.com/product/woodward-easygen-3500xt-8440-2085/e.
admin –
Brand: WOODWARD
Series: easYgen-3000XT High-End Generator Set Controller
Complete Model: easYgen-3500XT-P1
Part Number: 8440-2085
Positioning: Integrated controller for complex parallel multi-unit systems, microgrids, grid-connected/islanded systems (P1 standard version, standard basic IO, supports redundant Ethernet)
Differentiation within the series:
8440-2085 = 3500XT-P1 (Standard IO, redundant Ethernet, compatible with LS-5 circuit breaker module)
8440-2088 = 3500XT-P2 (Extended analog/transistor output, complex cogeneration) Woodward II. Core Hardware Specifications
1. Electrical and Environmental
Measurement voltage direct connection up to 690Vac, measurement range 50~650000Vac
Operating Power Supply: 12/24VDC (8~40VDC wide range)
Operating Temperature: -20℃ ~ +70℃, maximum altitude 4000m without derating
Protection & Certification: UL61010, RoHS2, marine-grade ABS/LR, marine certification Woodward2. Communication Interface (5 independent channels)
Dual Redundant Ethernet (ETH-B/ETH-C): Modbus TCP, peer-to-peer parallel, SNTP time synchronization
CANopen: Links LS-5 circuit breaker modules (up to 16 LS-5 units)
CAN J1939: Direct connection to Cummins, MTU, Volvo, MAN, Deutz, and other engine ECUs for monitoring and post-processing DPF/SCR
RS485 Modbus RTU: Interfacing with PLC/SCADA
USB: Local debugging, program download, data export
3. IO With Regulated Output
P1 version standard configuration includes isolated digital input/relay output; AVR voltage regulator and speed controller output (±10V/4-20mA/PWM)
Built-in 12-bit high-precision analog acquisition, power accuracy class 1.0, supports active/reactive/power factor closed-loop PID regulation
III. Core Functions (Core Advantages of Multi-Unit Parallel Connection)
1. Integrated Unit Control and Protection
Automatic start/stop, AMF mains power failure self-start, cold/hot engine delay
Complete engine protection: oil pressure, water temperature, cylinder temperature, overspeed, shutdown fault
Generator electrical protection: overvoltage/undervoltage, overfrequency/underfrequency, overcurrent, reverse power, loss of excitation, grounding, differential alarm
Grid protection: islanding protection, anti-islanding disconnection, loss of synchronization protection. Woodward 2. Advanced Parallel Connection and Power Management (3500XT) Key Selling Points
Peer-to-peer, master-slave parallel operation: Up to 32 units and 32 bus sections can operate in segments.
Seamless load sharing, soft loading/unloading, and open-loop/closed-loop synchronous switching.
Multi-bus tie switches and multi-mains power input line collaborative control, supporting LS-5 circuit breaker extended management.
Redundant Ethernet load sharing: No disconnection during single-network failure.
Free switching between peak shaving, grid-connected power purchase and sale, and islanded microgrid modes.
3. Programmable Logic & Expandability
LogicsManager™ built-in programmable logic: Most projects do not require an external PLC.
Customizable PID: Process regulation for waste heat boilers, CHP cogeneration, level, pressure, etc.
Customizable HMI interface, startup logo, and alarm text.
With the GC-3000XT system manager, it can be expanded to manage a cluster of 496 units (Woodward G…4). Data and Operations
Fault recording, operation log, power generation statistics, event logging
SNTP network time synchronization, remote monitoring, remote parameter modification
Supporting debugging software: easYgen Toolkit, easYview upper-level touch screen, easYsim simulation software Woodward
IV. Typical Application Scenarios
Industrial emergency power stations: Data centers, hospitals, large factories with multiple parallel backup power supplies
Microgrids/Off-grid power supply: Oil and gas platforms, mines, islands, remote villages and isolated islands
Distributed grid-connected power generation: Biogas/gas-fired CHP, photovoltaic + diesel hybrid energy storage power stations, grid peak shaving
Ships/Offshore platforms: Parallel connection of marine main and auxiliary engines, marine redundant power supply
Old power station renovation: Replacement of old parallel controllers, upgrade to intelligent load management
V. Comparison of similar series (XT) Platform)
Part Number, Model, Version, and Core Differences
8440-2081easYgen-3100XT-P1: Single unit standby, no multi-unit parallel connection.
8440-2084easYgen-3400XT-P1: Simple parallel connection, up to 8 units in parallel.
8440-2085easYgen-3500XT-P1: Complex parallel connection standard version, 32 units, redundant Ethernet, LS-5 linkage.
8440-2088easYgen-3500XT-P2: Extended IO version, adds isolation 4-20mA, transistor output, adaptable to CHP complex processes.
VI. Supporting Accessories
RP-3000XT: Remote 10-inch touchscreen operation panel.
LS-5 / LS-6XT: Circuit breaker synchronization control module.
easYview: 7/10/15 1.5-inch upper-level monitoring screen
Program debugging cables and terminal plug kits
Woodward easYgen-3500XT (8440-2085) Real-world application cases
The 8440-2085 is the standard version of the 3500XT-P1, core-compatible with 32 units in parallel operation, multi-bus segmentation, grid-connected/islanded dual-mode, and redundant Ethernet for load sharing. Below are 6 categories of real-world engineering cases, including project configuration, control challenges, and controller solutions.
Case 1: N+X Redundant Emergency Power Station for Large Supercomputing Data Center (Top-Tier Domestic IDC Park)
Project Overview
Configuration: 16 2000kW high-voltage diesel generator sets (6kV), dual-section busbars + 2 mains power inputs, 2 bus tie circuit breakers; each unit is equipped with 8440-2085 chips and LS-5 synchronous circuit breaker modules.
Power Supply Requirements: UPS zero-interruption backup; black start within 10 seconds of mains power failure + multi-unit synchronous load bearing; N+2 redundancy fault tolerance; automatic load sharing in case of single unit failure.
Control Challenges
Multiple busbar sections and complex interlocking logic between mains power/generators/bus tie circuit breakers;
Sudden impact loads (UPS full-load switching) are prone to frequency fluctuations;
Single-network failures cannot be disconnected from parallel operation; load redundancy must be evenly distributed.
3500XT (8440-2085) Solution
Dual redundant Ethernet ETH-B/C peer-to-peer parallel connection ensures stable and even distribution of active and reactive power even in the event of a single network outage.
LogicsManager features built-in custom interlocks, eliminating the need for an external PLC and handling mains power failure, bus tie-off/reconnection, and segmented isolation logic.
Built-in ROCOF, islanding protection, reverse power protection, and synchronization loss protection provide a complete set of grid-connected protection, meeting data center power supply specifications.
J1939 direct-drive Cummins high-voltage generator ECU provides real-time monitoring of aftertreatment, water temperature, and oil pressure, with graded fault alarms.
Remote RP-3000XT touchscreen provides unified monitoring with SNTP time-synchronized fault recording and remote program download capability.
Operating Results
All units synchronize and reconnect to the grid within 8 seconds after a mains power outage, with a load sharing error of <2%; zero disconnection/reconnection failures throughout the year, meeting Class A data center power supply standards.
Case 2: Off-Grid Microgrid for Deep-Sea Drilling Platform (Marine Certification Project)
Project Overview
Configuration: 6 gas turbine generator sets, dual independent busbars, the entire controller uses 8440-2085 standard, marine-grade ABS/LR certified.
Operating Conditions: Isolated operation without mains power; high-power impact loads on the top drive and mud pumps; rapid segmented isolation is required in case of main busbar failure to ensure uninterrupted power supply to the blowout preventer (BOP).
Control Challenges
High-temperature, high-humidity, and high-vibration environment at sea; 0°C but severe voltage fluctuations;
Large frequency fluctuations due to high-power load switching, requiring rapid voltage and frequency regulation;
Millisecond-level isolation is required for single-segment busbar short circuits to prevent platform-wide power loss.
Controller Advantages Delivered:
Wide temperature range -20~70℃, 690V direct measurement, marine certified for harsh marine environments;
Multi-section busbar segmented control, automatically isolating faulty busbars in conjunction with LS-5;
Fast PID speed and voltage regulation, frequency recovery <3s under 50% load impact;
Peer-to-peer parallel operation without master/slave functionality, failure of any single controller does not affect the entire station's operation;
Complete generator differential, grounding, and overcurrent protection mitigates the safety risks of power outages at sea.
Case 3: Off-Grid Solar + Diesel Hybrid Microgrid in an African Copper Mine (Energy Saving Retrofit Project)
Project Overview
Configuration: 4 x 800kW diesel generator sets (8440-2085 single unit) + 2MW solar power + energy storage converter; no external grid power, purely off-grid autonomous power supply.
Operational Objectives: Prioritize solar power output during the day, with diesel generators as backup; automatically start generators when sunlight is insufficient; start and stop generators as needed at night to reduce fuel consumption.
Key Challenges
The solar power output fluctuates greatly, and the diesel generator sets frequently switch on and off, requiring coordinated power dispatching of solar, energy storage, and diesel generators. Traditional simple controllers cannot achieve multi-energy coordination.
3500XT Implementation Logic
Modbus TCP interface with photovoltaic inverters and energy storage BMS, real-time reading of photovoltaic active power and energy storage SOC;
Built-in power scheduling logic: Reduces the number of operating units when photovoltaic power is in surplus, automatically soft-loads diesel engines during sudden photovoltaic power drops;
Load starts and stops on demand, automatically shuts down and goes into hibernation during off-peak hours, and synchronously cold-starts the black bus;
Load distribution closed-loop control, balancing output across multiple units and avoiding overload of individual units.
Project Benefits
Annual diesel fuel savings of 180,000 liters; recovery of control system upgrade investment in 2.3 years.
Case 4: Multi-Unit AMF Grid-Connected Backup Power Station for a Large-Scale Tertiary Hospital in an Urban Area
Project Overview
Configuration: Four 500kW gas turbine units, dual mains power lines (one main supply, one backup), all unit controllers are 8440-2085; primary load protection for operating rooms, ICU, and imaging equipment.
Requirements
Automatic switching to AMF mode during mains power failure; stable and synchronous grid connection after mains power restoration, with gradual unloading of the units;
High-precision equipment such as MRI and CT requires extremely high voltage waveform and frequency accuracy;
Graded fault alarm system, distinguishing between general faults and emergency shutdown faults.
Application Highlights
Smooth synchronous grid connection, soft loading/unloading, no voltage surges, protecting precision medical equipment;
Complete protection system for engine, generator, and mains power: underfrequency, overvoltage, reverse power, and loss of excitation protection;
Local + remote dual operation, complete fault event log retention, meeting hospital maintenance traceability requirements;
Built-in logic enables dual mains power switching and N+1 redundancy for parallel unit backup.
Case 5: Landfill Biogas CHP Distributed Grid-Connected Power Plant
Project Overview
Configuration: Three 1200kW biogas gas turbine units, 8440-2085 control system, grid-connected to the municipal power grid for electricity sales, waste heat for plant heating; must meet national grid connection standard VDE/IEEE1547 islanding protection.
Challenges
Unstable biogas flow, resulting in fluctuating unit output; strict compliance requirements for grid connection anti-islanding and reverse power transmission; simultaneously requiring two sets of PID controls for power generation and waste heat heating.
Controller Functionality
Built-in independent PID loop: one loop regulates generator active and reactive power for grid connection, and another loop links to waste heat boiler temperature;
Standard islanding protection (df/dt, phase offset, voltage increment protection) meets grid connection acceptance requirements;
Grid-connected power purchase and sale control allows setting forward/reverse power limits, automatically reducing load or disconnecting from the grid if limits are exceeded;
CAN J1939 is compatible with biogas-specific engines, monitoring gas concentration and combustion temperature, and automatically adjusting the air-fuel ratio.
Case 6: Old Power Plant Renovation and Replacement Project (Replacing Old 3200, EGCP3000 Models)
Project Overview
An industrial park had 8 diesel generator sets with old-style discrete synchronizers and load distribution boards, resulting in high failure rates and no remote monitoring. The entire system was replaced with the 8440-2085 complete solution.
Advantages of the Upgrade
Integrated Design: Synchronization, distribution, protection, and logic are all integrated, eliminating over 10 separate modules and simplifying control cabinet wiring by 60%.
Compatible with Existing Engine ECUs and Circuit Breakers: Only a few terminals require adaptation; no complete switchgear replacement is needed.
Dual Ethernet Redundant Communication: The original single communication network is upgraded to a fault-tolerant architecture.
LogicsManager Reuses Existing Interlocking Logic: On-site commissioning time is halved.
Unified Upper-Level SCADA Interface: Centralized monitoring of all plant unit data.
8440-2085 (3500XT-P1) Selection and Adaptation Summary
Priority: Choose 8440-2085 (P1): Standard I/O, redundant Ethernet, suitable for pure multi-machine parallel connection, data centers, mines, and offshore platforms.
For complex CHP and multiple 4-20mA process adjustments: Choose the 8440-2088 (P2 Extended I/O version) from the same series.
For single-machine/simple parallel connection of 8 units or less: Choose 3400XT. For multi-bus segmented, microgrid, and grid-connected projects with 32 units, use 3500XT 8440-2085.
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admin –
Core Positioning
This controller integrates engine start/stop control, generator electrical parameter monitoring, synchronization and closing, active/reactive load sharing, genset and grid protection, and bus-tie breaker control. It supports peer-to-peer networking for paralleling, enabling multi-unit coordination without the need for an additional master controller. The P1 version focuses on complex multi-unit paralleling systems; it comes standard with redundant Ethernet communication and native support for LS-5 breaker controller expansion. It is suitable for complex, multi-bus power distribution systems in applications such as industrial backup power stations, data centers, hospitals, oil & gas facilities, and marine shore power.
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The 8440-2085 is the P1-package version of the easYgen-3500XT—part of Woodward’s easYgen-3000XT series of genset controllers—featuring an integrated display. The easYgen-3000XT series is a high-end control platform for engine-generator system management; the 3500XT is the flagship model, specifically designed for complex applications involving paralleling, grid synchronization, and power management. It covers all operating scenarios, including islanded operation, islanded paralleling, mains paralleling, and multi-unit grid connection. The P1 package focuses on complex paralleling applications, offering redundant Ethernet communication, support for LS-5 tie-breaker controllers, and a standard I/O set.
Hardware Configuration
Mounting: Flush-mounted on the front panel; plastic housing; features a 4.3-inch backlit LCD screen and a 6-key touch keypad for direct local operation and parameter monitoring.
Dimensions: 282 × 216 × 96 mm; front panel cutout: 249 × 183 mm; weight: approx. 1.85 kg.
Ingress Protection: Front panel: IP66 (screw-fastened) / IP54 (clip-fastened); rear: IP20.
Power Supply: 12/24 VDC (allowable range: 8–40 VDC); suitable for standard battery banks or DC bus power supplies.
Operating Temperature: Standard model: -20°C to +70°C; a Low Temperature (LT) version with a heated display is also available for outdoor use down to -40°C.
Measurement and Accuracy
Comprehensive Measurement: Full measurement of voltage, current, frequency, and power for generator, mains, and busbar circuits. Features True RMS calculation and supports single-phase or three-phase systems, with independent sampling for generator and mains inputs. Voltage sensing supports direct connection up to 690 VAC (depending on order options) with a frequency range of 40–85 Hz, compatible with 50/60 Hz grids.
Current transformer inputs support 1 A or 5 A; measurement accuracy is Class 0.5; power measurement accuracy is Class 1.0, with a range of 0.5–99,999.9 kW/kvar.
Displays per-phase and average voltage, current, frequency, kW, kvar, kVA, and power factor, while accumulating kWh and kvarh.
Control Functions
This represents the core value of the 3500XT; the P1 package supports:
Synchronization and Paralleling: Synchronous closing control for generator and mains circuit breakers.
Run-up / Black Start: Black start and run-up synchronization control; supports Dead Field Paralleling.
Multi-unit Grid Paralleling: Paralleling multiple units with the mains and load sharing; supports redundant load sharing via CAN and/or Ethernet (including Ethernet Port B/C redundancy).
Load-Dependent Start/Stop: Automatic addition or removal of units based on load demand.
Import/Export Control: Bidirectional control of active power (kW) and reactive power (kvar), supporting peak-valley arbitrage and demand management.
Peak Shaving, AMF (Automatic Mains Failure) switching, and Standby Power: Standard application templates included.
Three freely configurable PID controllers: Can be used for speed/voltage biasing or process control (e.g., control loops for water temperature, oil level, or pressure in CHP applications).
Distributed Energy (Solar Function) and Critical Load Operation: Supported. Integrated AVR Voltage Regulation: Enables closed-loop generator voltage regulation when paired with a Woodward excitation module (e.g., Exciter-10).
System-Level Expansion: Manages fleets of up to 496 units via the GC-3000XT genset controller; supports bus paralleling of up to 48 members via the LS-5; controls up to 64 synchronizing breakers/manual switches and 128 complex busbar segments via the LS-6XT.
Protection Functions (ANSI Codes)
Generator Protection: Over/undervoltage (59/27), over/underfrequency (81O/81U), overload and reverse/reduced power (32/32R/32F), synchro-check (25), unbalanced load (46), instantaneous overcurrent (50), definite-time/inverse-time overcurrent (IEC 255 compliant) (51/51V), earth fault (measured earth current) (50G), power factor protection (55), phase sequence monitoring.
Engine Protection: Overspeed/underspeed (12/14), speed/frequency mismatch, D+ auxiliary excitation failure, cylinder temperature monitoring, etc.
Mains Protection: Voltage/frequency/synchro-check (59/27/81O/81U/25), phase angle jump and rotation direction, rate of change of frequency (ROCOF, df/dt) (78).
Busbar Protection: Voltage/frequency monitoring.
Communication and Expansion
Ethernet: 3 Modbus TCP (slave) interfaces; Networks B and C support redundant load sharing; supports remote control and monitoring. CAN Bus: 3 CAN interfaces (CANopen / J1939); the protocol for CAN#2 is user-configurable. Supports external expansion via CANopen for 32 digital inputs/outputs, 16 analog inputs, and 4 analog outputs (using IKD series expansion modules).
J1939 Engine Data: Directly displays and evaluates 100 analog SPNs; supports mainstream ECU protocols such as Scania S6 and MTU.
RS-485: 1 Modbus RTU slave interface for easy integration with upper-level monitoring systems.
USB: 1 serial USB interface for local configuration and debugging.
I/O Configuration: 12 isolated digital inputs (8–40 VDC), 12 configurable relay outputs (AgNi contacts), 3 analog inputs (supporting VDO sensors, Pt100/Pt1000, and resistive inputs), and 2 analog outputs (configurable for ±10 V, ±20 mA, or PWM). Typical Application Scenarios
Emergency backup power (Standby / AMF) for data centers, hospitals, airports, etc.
Multi-unit paralleling power plants and grid-parallel operation (Mains Parallel)
Combined Heat and Power (CHP / Co-Gen)
Peak shaving, load demand management, and import/export power control
Marine and offshore power distribution
Mobile / rental generator sets (Order No. 8440-2283 available with rental-specific features)
Engineer’s Note
Selection difference between P1 and P2: The P1 model focuses on complex paralleling and network redundancy; the P2 model focuses on CHP applications, offering increased onboard I/O (23 digital inputs, 22 digital outputs, 10 analog inputs, 6 analog outputs) as well as three-phase busbar voltage measurement and phase sequence monitoring. If the site requires extensive local I/O or three-phase busbar measurement, the P2 model (8440-2088) should be selected.
Configuration Tools: Woodward ToolKit software is used for parameter configuration, logic programming, and commissioning; all functions are implemented via standardized software configuration, allowing adaptation to different applications without hardware changes.
Certifications & Compliance: The product complies with relevant CE and IEC standards and supports grid-connection requirements such as VDE-4105 and VDE-4110.
Altitude Capability: The controller can operate at altitudes up to 4,000 meters without derating.
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