Woodward 8440-1934 Genset Control for Complex Breaker Applications

Model 8440-1934 is a front-panel flush-mounting controller featuring a 5.7-inch color graphical display and soft keys, ideal for applications requiring intuitive operation and full system visualization. This controller supports networking of up to 32 generator sets with automatic sequencing and can integrate up to 16 Woodward LS-5 Series synchronizers and load sharing controllers to enable complex power management with multiple mains and bus breakers.

The easYgen-3500 provides comprehensive protection for generators, engines, and mains. It supports isolated operation, island parallel operation, mains parallel operation, multi-unit mains parallel operation, peak shaving, import/export control, cogeneration (CHP), and distributed generation. Its modular software structure and rich I/O capabilities allow users to flexibly configure breaker logic, PID process controls, ECU communication, and remote monitoring via FlexApp™, LogicsManager™, DynamicsLCD™, and FlexCAN™ technologies.

Model 8440-1934 is equipped with 5 A CT inputs, suitable for industrial standard current transformers. It holds international certifications including UL/cUL, GOST-R, CSA, LR (Lloyd's Register), and ABS (American Bureau of Shipping), making it suitable for marine, oil & gas, data centers, hospitals, and other critical industrial facilities.

Key Features & Benefits

• Full LS-5 Integration: Communicate directly with up to 16 Woodward LS-5 Series breaker protection and control devices. Visualize the status of each LS-5 on the color display for complete system overview.

• Flexible Breaker Control (FlexApp™): Configure support for no breaker, GCB (generator circuit breaker), GCB+MCB (mains circuit breaker), GGB (generator group breaker), and multiple modes for LS-5 interaction.

• Advanced Synchronization:

  • Slip frequency / phase matching synchronization

  • Run-up synchronization: Multiple generators can quickly take load after starting, avoiding transformer inrush currents.

  • Configurable VT ratios and vector group adjustment to accommodate different transformer connections.

• Multiple Operating Modes: Auto, Stop, Manual, Load Test, No-Load Test (selectable via discrete inputs).

• Load Transfer Features: Open transition, closed transition, interchange, soft loading / soft unloading, mains parallel.

• Remote Setpoint Control: Adjust speed, frequency, voltage, active power, reactive power, and power factor setpoints via analog inputs or communication interface.

• Freely Configurable PID Controllers: Up to 3 PID loops for heating circuit control (CHP), water level, fuel level, pressure, or other process variables.

• Extensive ECU Support: Supports Scania S6, MTU ADEC ECU7/8, Volvo EMS2 & EDC4, Deutz EMR2, MAN MFR/EDC7, SISU EEM, Cummins, and Woodward E3 ECUs.

• J1939 Data Visualization: Display and evaluate up to 100 J1939 analog values (supported SPNs) in plain text.

• I/O Expansion Capability: Via CANopen, connect Woodward IKD 1 or Phoenix Contact IL Series expansion modules to add up to 32 discrete inputs / 32 discrete outputs and 16 analog inputs / 4 analog outputs.

• Multi-Language Interface: Multiple languages built-in, switchable from the front panel.

• Comprehensive Protection Functions: ANSI-based protection for generator (voltage/frequency, overload, reverse power, unbalanced load, overcurrent, ground fault, power factor, phase rotation, etc.), engine (overspeed/underspeed, speed/frequency mismatch, D+ excitation failure, etc.), and mains (voltage/frequency, phase shift, phase rotation, ROCOF, etc.).

• High-Accuracy Measurement: True RMS three-phase voltage/current measurement, voltage accuracy Class 1, current linear range up to 3× rated.

• Event Logging & Metering: 300 time-stamped event records (FIFO), battery-backed real-time clock (≥6 years); active/reactive energy metering; operating hours, start counter, maintenance counter.

Application Modes & Breaker Control (FlexApp™)

The easYgen-3500 supports multiple breaker configuration modes via FlexApp™ technology. Users can select the appropriate mode based on project requirements:

Operating Modes

The controller supports the following operating modes, selectable via front-panel soft keys or discrete inputs:

• Auto: Automatically start/stop generators and control breakers based on preset logic.

• Stop: Immediately stop the engine and open GCB.

• Manual: Operator manually controls start/stop and breaker open/close.

• Load Test: Test generator load capability during parallel operation.

• No-Load Test: Test engine and generator without connecting load.

Protection Functions (ANSI Codes)

The easYgen-3500 provides comprehensive protection, including but not limited to:

Additional protections include phase rotation, D+ excitation failure, speed/frequency mismatch, etc.

Communication & Integration Capabilities

• LS-5 Integration: Communicate with up to 16 LS-5 devices via CAN bus; visualize status of each LS-5 for complex bus tie and mains breaker management.

• J1939 ECU Support: Supports major engine ECUs (Scania, MTU, Volvo, Deutz, MAN, SISU, Cummins, Woodward E3, etc.); read up to 100 analog values (e.g., oil pressure, coolant temperature, fuel consumption); remote start/stop and alarm management.

• CANopen Expansion: Connect Woodward IKD 1 or Phoenix Contact IL Series I/O expansion modules to add 32 discrete inputs / 32 discrete outputs and 16 analog inputs / 4 analog outputs.

• Modbus RTU: Communicate with SCADA, PLC, or DPC software via RS-232 or RS-485.

• Remote Control: Remotely adjust speed, frequency, voltage, active power, reactive power, and power factor setpoints via analog inputs (0-10V or 4-20mA).

Configuration & Software

• PC Configuration Software: ToolKit software (included), connects via RS-232 serial port.

• Front Panel Configuration: Direct parameter editing via DynamicsLCD™ color graphical interface and soft keys – no PC required.

• Multi-Level Password Protection: Prevents unauthorized parameter changes.

• Multi-Language Switching: Supports English, German, French, Italian, Spanish, Portuguese, Russian, Turkish, Chinese, Japanese, etc.

Metering & Logging

• Energy Metering: Active energy (kWh), reactive energy (kvarh).

• Counters: Operating hours, start counter, maintenance interval counter.

• Event Recorder: 300 events, FIFO, with real-time timestamp (battery backup ≥6 years).

Model & Ordering Information

Accessories: Screw and clamp kits are delivered with the unit. Spare connector kits: P/N 8928-7371 (for front-panel units), P/N 8923-1314 (for back-panel units).

Installation & Dimensions

Front-Panel Mounting (Plastic Housing)

• External Dimensions: 282 mm (W) × 217 mm (H) × 99 mm (D)

• Cutout Dimensions: 249 [+1.1] mm × 183 [+1.0] mm

• Fastening: Clip fastening (front IP54) or screw fastening (front IP66)

• Wiring: Screw/plug terminals, suitable for 2.5 mm² wire

Back-Panel Mounting (Metal Housing) – for reference

• Dimensions: 250 mm × 227 mm × 84 mm

• Protection Rating: IP20

• Weight: Approx. 2,150 g