Woodward 8440-1936

2. Product Brief Introduction

3. Technical Specifications

• Rated Working Supply Voltage: 18VDC ~ 32VDC nominal 24VDC control power input, reverse polarity and transient overvoltage built-in input protection circuit
• CT Current Sampling Specification: Standard rated secondary input 5A AC current, maximum continuous overload withstand 15A short-term for 10 seconds
• Generator Frequency Adaptable Range: 45Hz ~ 65Hz, factory default calibrated for 50Hz/60Hz global standard power grid
• Overall External Dimension: Height 144mm × Width 192mm × Depth 58mm, standardized cutout dimension 138mm × 186mm for cabinet panel embedding installation
• Continuous Operating Ambient Temperature Range: -40℃ ~ +70℃; sealed long-term storage temperature: -45℃ ~ +85℃
• Allowable Working Relative Humidity: 5%~95% non-condensing full-range humidity under rated operating temperature scope
• Rated Static Power Consumption: Max total operating power 19W under full-load all-channel terminal driving condition
• Built-in Communication Hardware Ports: 1×RS232 local debugging port, 1×CANopen fieldbus port, dual-channel Modbus-RTU RS485 communication terminals, optional Ethernet Modbus TCP extended interface
• Dielectric Withstand Voltage: 2000VAC/60s isolation between power input circuit, low-voltage signal circuit and high-current CT sampling terminal without breakdown failure
• Formal Compliance Certifications: CE EN61000-6-2 EMC certification, UL1998 industrial control component certification, SIL2 functional safety partial certification
• Engine Speed Signal Input Standard: Compatible 2~10000Hz magnetic pickup speed sensor sine-wave input signal

4. Functional Features

1. Three selectable core operating modes: Auto Mains Failure (AMF), standalone island operation, multi-generator parallel grid-connected operation, one-click mode switching via front panel key operation.
2. Integrated four closed-loop control algorithm modules: engine speed PID governing, generator voltage AVR regulation, active power load sharing, reactive power equalization control for parallel gensets.
3. Complete multi-level electrical and mechanical fault protection logic including overvoltage, undervoltage, overfrequency, underfrequency, overcurrent, reverse power, engine overspeed, low oil pressure, high coolant temperature, each fault triggers classified alarm output and graded genset shutdown interlock.
4. Front panel embedded backlight LCD display plus physical operation pushbuttons for local parameter modification, running data real-time display and fault historical record checking, total storage capacity for latest 256 fault event logs with time stamp.
5. Multi-channel configurable discrete I/O terminal: 8 groups programmable digital input for auxiliary contact status collection, 6 groups relay digital output for alarm horn, solenoid valve, circuit breaker drive control, 4-channel analog input for engine auxiliary parameter collection.
6. Standard 5A CT direct access design without external signal conversion module, automatically calculates active power, reactive power, power factor, kWh cumulative energy consumption data inside controller core chip.
7. Remote centralized monitoring function via Modbus-RTU/TCP communication protocol, all running parameters, fault status and setting items readable/writable from upper PLC/SCADA/DCS host system.
8. Built-in adaptive synchronizing algorithm automatically adjusts genset speed and output voltage to match utility grid parameter before closing parallel breaker to eliminate closing impulse current.

5. Performance Parameters

• Speed regulation static precision under rated load fluctuation: ≤±0.2% of rated generator frequency
• Generator output voltage regulation accuracy: ≤±1% full rated voltage span across full load range from no-load to 100% rated loading
• Parallel synchronization closing error: Phase difference ≤3 electrical degrees, frequency difference ≤0.05Hz before breaker closing execution
• Controller overall MTBF value under standard rated industrial ambient condition: 186000 continuous running working hours
• Analog signal sampling conversion resolution: 12-bit high-precision AD conversion for all voltage/current/temperature input channels
• Relay output single contact rated load: 8A @250VAC resistive load, 8A @30VDC DC load per discrete output terminal
• Temperature drift coefficient of internal sampling circuit within rated working temperature: ≤12ppm/℃ full scale parameter variation
• Historical fault data storage retention period: Nonvolatile flash memory retains all logged data over 10 years without external backup power supply
• Communication data refresh cycle: Fixed 200ms cyclic real-time data upload to upper monitoring host via Modbus bus

6. Material Composition

1. Main Core PCB Substrate: FR-4 high-Tg flame retardant glass fiber circuit board with full immersion gold surface treatment, SMT plus through-hole hybrid component assembly process.
2. Front Panel Outer Shell: Black matte UL94-V0 flame retardant modified ABS engineering plastic with anti-UV and anti-oil surface modification treatment.
3. Rear Wiring Terminal Block Base: PA66 fire-resistant insulation engineering plastic; conductive terminal insert adopts solid nickel-plated brass material, anti-loose zinc alloy fastening screws for wire locking.
4. Internal Core Microcontroller: Industrial grade 32-bit ARM RISC single-chip processor with wide temperature range grade specification.
5. Built-in Relay Components: Silver alloy contact electromagnetic sealed relay with epoxy encapsulation for dust and moisture isolation inside PCB.
6. Passive Electronic Components: Automotive grade TVS surge suppression diodes, X7R multilayer ceramic capacitors, metal film precision fixed resistors.
7. Internal Fixed Position Parts: High temperature resistant modified nylon plastic positioning studs for anti-vibration PCB fixation inside plastic casing.

7. Structural Characteristics

1. Split integrated panel embedding structure consisting of front operation display panel and rear main control PCB assembly, fixed via rear mounting locking clips for cabinet embedded installation.
2. Internal PCB functional zoning layout: Front LCD and key control circuit concentrated on front zone, power supply and communication circuit arranged in middle area, high-current CT sampling and relay output terminal circuit placed on rear terminal region for physical isolation.
3. Front panel permanent high-temperature resistant silk-screen marking containing part number 8440-1936, terminal definition icon and function classification with anti-solvent erosion characteristic.
4. Rear terminal area partition layout classified by power supply terminal, CT sampling terminal, digital I/O terminal and communication terminal to realize classified field wiring arrangement.
5. Four peripheral fixed mounting screw holes at panel four corners for auxiliary bolt fastening after embedding into control cabinet panel cutout.
6. Small-size strip ventilation slits distributed on upper and lower casing edges for passive natural convection heat dissipation without auxiliary cooling fan configuration.

8. Working Principle

Step1: Multi-Parameter Signal Collection

Step2: Internal AD Sampling & Data Calculation

Step3: Closed-loop Regulation Operation

Step4: Synchronization Logic Calculation (Parallel Mode Only)

Step5: Fault Judgment & Protection Execution

Step6: Remote Data Interaction

9. Advantage Highlights

1. All-in-one integrated design merges speed governor, voltage regulator, synchronizer and protection relay into single unit to reduce cabinet internal spare parts quantity and overall wiring cost drastically.
2. Wide 18~32VDC control power input range adapts battery voltage fluctuation during genset startup and long-term standby operation without additional regulated power supply module.
3. Built-in complete fault historical record storage function facilitates post-failure troubleshooting and equipment maintenance analysis without extra external data logger hardware.
4. Standard global 5A CT unified sampling specification realizes seamless matching with all mainstream genset current transformer products from different manufacturers.
5. Front embedded LCD local operation design cancels mandatory external HMI configuration to save control cabinet installation space and project procurement expense.
6. Multi-protocol communication compatibility supports seamless docking with mainstream brand DCS, PLC and SCADA system for centralized unattended genset remote monitoring management.
7. Factory pre-calibrated core control algorithm enables plug-and-play replacement after field equipment failure without complicated on-site parameter readjustment work.

10. Applicable Industries

• Commercial Building Power Supply Industry: Shopping mall, high-rise office building, data center backup emergency diesel genset AMF control application
• Petrochemical Industry: Refinery, chemical plant on-site fixed gas/diesel genset parallel power generation control for process critical load backup
• Mining Industry: Underground coal mine, open-pit mineral mine mobile genset standalone and parallel running automation control
• Marine & Shipbuilding Industry: Cargo vessel, offshore platform auxiliary onboard genset grid parallel and emergency power switch control
• Municipal Infrastructure Industry: Water treatment plant, sewage pumping station, urban substation standby emergency generator set control
• Telecom Industry: Base station, central telecom machine room backup genset automatic mains failure startup and shutdown management
• Construction Engineering Industry: Large engineering construction site mobile trailer type genset parallel power distribution control

11. Model Series Affiliation

• Parent Product Series: Woodward easYgen-3000 / easYgen-3500 Full-function Genset Controller Family
• Same-series sibling standard model list:
  1. 8440-1559: Basic version single-unit AMF genset controller without parallel load sharing function
  2. 8440-1937: Enhanced multi-unit parallel controller with redundant communication expansion interface
• Compatible matching peripheral equipment: 5A specification industrial current transformer, magnetic pickup engine speed sensor, generator AVR excitation module, diesel/gas engine electronic actuator, AC grid-connected circuit breaker; Compatible upper host: Siemens, ABB, Honeywell mainstream PLC/SCADA monitoring platform

12. Installation Requirements

1. Installation Environment Rule: Must be embedded inside closed ventilated low-humidity control cabinet; installation inside high-corrosion gas, explosive classified hazardous compartment and direct outdoor open-air environment is prohibited.
2. Panel Embedding Specification: Cut cabinet panel according to standard 138mm×186mm opening dimension, insert controller body from front panel side, fasten rear fixed locking clips and four-corner auxiliary mounting screws to eliminate installation clearance gap.
3. Field Wiring Specification: High-current CT sampling wiring uses 1.5~2.5mm² copper insulated twisted pair cable; all CT secondary circuit strictly forbids open-circuit wiring during live operation per electrical safety standard.
4. Heat Dissipation Clearance Requirement: Minimum 15mm vacant gap reserved above and below controller inside cabinet for natural convection heat dissipation; no high-power heating components installed within 30mm surrounding space of controller housing.
5. Pre-installation Confirmation: Complete genset rated parameter (rated voltage, rated frequency, rated engine speed) basic configuration via front panel keys before finishing all field wiring connection.
6. Cabinet Grounding Standard: Controller dedicated PE grounding terminal connects to cabinet independent protective earth copper bus via 2.5mm² single-core grounding wire.

13. Use & Maintenance Precautions

1. Strictly forbid live plugging/unplugging any rear terminal wiring under controller powered running state; live wiring operation causes instantaneous surge voltage leading to permanent damage of internal AD sampling circuit and CPU core component.
2. Never access input voltage/current exceeding rated specification into CT and power supply terminals; over-range input directly results in internal PCB circuit burnout and controller permanent functional failure.
3. All field wiring modification operation must be executed after cutting off controller 24VDC control power supply and genset main AC output breaker to avoid accidental short-circuit triggering unplanned genset emergency shutdown.
4. Quarterly routine maintenance only uses dry lint-free cloth to wipe front panel display screen and rear terminal dust; alcohol, acetone and organic solvent direct contact with plastic casing and PCB terminals is forbidden.
5. Unused spare controllers must be sealed inside anti-static shielding bag and stored under 10℃~35℃ dry constant temperature environment; damp high-temperature open-air long-term storage is prohibited.
6. On-site fault replacement only permits original factory certified genuine Woodward 8440-1936 controller; third-party refurbished or imitation substitute products cannot be installed on critical load genset control loop.
7. Avoid high-frequency inverter, arc welding equipment installed within 40cm distance of controller installed control cabinet to prevent strong electromagnetic radiation inducing abnormal sampling data drift and false fault protection action.