WOODWARD 8440-2058

الوصف

The Woodward 8440-2058 is a specific part number that identifies an easYgen-2000 Series genset controller. More precisely, it’s commonly associated with the easYgen-2300-5/P2 model. This is a powerful and versatile controller designed for comprehensive management and protection of generator sets in a variety of applications, including sophisticated paralleling operations.

WOODWARD 8440-2058: easYgen-2300-5/P2 Genset Controller

The Woodward 8440-2058 easYgen-2300-5/P2 is a member of Woodward’s easYgen-2000 series, a line of robust and feature-rich controls for extensive generator set management. It’s engineered to provide flexible control and protection for both the engine and the generator, with advanced communication capabilities. The “P2” designation indicates a package that specifically supports advanced paralleling and communication features.

Product Overview

• Product Type: Generator Set Controller (Genset Controller)
• Manufacturer: Woodward
• Series: easYgen-2000 Series (specifically easYgen-2300-5/P2)
• Function: This controller provides extensive control, monitoring, and protection functions for generator sets. It’s designed for automatic start/stop, precise generator voltage and frequency control, and monitoring of numerous engine and generator parameters. Its “P2” designation signifies its capability for sophisticated paralleling applications.

Key Features

• Comprehensive Control: Manages complete engine operation (e.g., start/stop logic, pre-glow/purge control, warm-up/cool-down cycles for diesel/gas engines) and generator output (voltage, frequency).
• Integrated Display: Features a built-in display screen (typically a backlit LCD) for showing status indicators, operational data, and alarm messages. Some sources indicate this model has a resistive current voltage of 1.00 and reactive power display of +70 and -50 kVAR.
• Extensive I/O: Equipped with numerous configurable terminals for connecting a wide range of sensors and actuators, allowing for adaptable system integration in complex setups. It often supports 5A CT inputs.
• Electronic Engine Support: Capable of communicating directly with electronic engine ECUs (Electronic Control Units) via CAN bus (J1939), enabling detailed monitoring and control of engine parameters for various manufacturers.
• Generator Metering: Provides accurate measurement of 3-phase generator voltage, current, power (kW, kVA, kVAr), and frequency, with true RMS sensing.
• Advanced Protection Functions: Offers comprehensive protection for both the engine (e.g., overspeed, low oil pressure, high temperature) and the generator (e.g., over/under voltage, over/under frequency, overcurrent, reverse power, phase sequence, voltage-restrained overcurrent monitoring – ANSI 51V).
• Sophisticated Communication: Designed for advanced interface capabilities, including:
  • CANopen: For peer-to-peer load sharing and synchronization among multiple gensets (up to 16 units in island operation).
  • J1939: For engine ECU communication.
  • Modbus RTU: For integration with PLCs, HMIs, and SCADA systems.
  • Modem Support: For remote control and programming via PC using Woodward’s ToolKit software.
• Event Log: Stores a detailed event log with a real-time clock for diagnostic purposes and troubleshooting.
• High Configurability: Highly configurable via PC software (such as Woodward’s ToolKit-SC) or directly from the front panel, with multi-level password protection.
• Load-Dependent Start/Stop: Integrated logic for optimizing fuel efficiency by managing the number of online gensets based on changing load demands, even with mixed-sized engines.

Detailed Description

The easYgen-2000 series, including the 8440-2058, was a core product in Woodward’s portfolio for sophisticated generator control. These controllers are renowned for their robust design, comprehensive feature set, and strong communication capabilities, making them suitable for demanding industrial and commercial power generation applications. They excelled not only in managing individual generator sets but also in complex systems requiring synchronized load sharing among multiple gensets, whether in island mode or paralleling with the utility grid.

It’s worth noting that some units from the easYgen-2000 series might have experienced LCD display performance issues (e.g., blank screen, abnormal contrast, flickering, or non-working keypads). This was detailed in Woodward Service Bulletin 37987 (Revision A, 06/2024), which attributed the issue to a specific non-standard soldering process. This problem primarily affected the HMI and not the core control functionality, and in some cases, cleaning corrosion on display terminals could resolve it.

Applications

The Woodward 8440-2058 easYgen-2300-5/P2 controller was commonly used in a wide range of power generation applications requiring advanced control and paralleling capabilities, including:

• Standby/Emergency Power Systems: Controlling gensets that provide backup power for commercial, industrial, and critical facilities during grid outages, often with Automatic Mains Failure (AMF) functionality.
• Prime Power Applications: Managing gensets that serve as the primary power source in remote or off-grid locations, potentially with load sharing.
• Peak Shaving and Import/Export Control: Optimizing energy costs by running gensets during peak demand periods or controlling power flow to and from the utility.
• Co-generation / CHP (Combined Heat and Power): Integrating gensets into systems that produce both electricity and useful heat.
• Load Sharing Applications: Synchronizing and sharing load among multiple generator sets in island or parallel-to-grid operations.
• Marine Applications: For controlling generator sets on vessels or offshore platforms.

Obsolescence and Replacement Options

It’s crucial to be aware of the current status of the 8440-2058:

• Obsolescence (End-of-Life): The easYgen-2000 series, including the 8440-2058, has been officially designated as inactivated (End-of-Life) by Woodward. This means that direct sales and new production of this specific part number are discontinued. This decision is primarily due to the obsolescence of internal components. A Last Time Buy (LTB) period for these controls concluded on January 23, 2015, with final shipments occurring by April 22, 2015.
• Limited Support: While some third-party repair and refurbishment services may still offer support for these units, direct support and new unit availability from Woodward are severely limited. Any repair services provided directly by Woodward for these older models are typically on a declining support schedule, with repairs based on parts availability becoming the norm.
• Recommended Replacements: Woodward has introduced newer, more advanced generations of genset controllers to replace the easYgen-2000 series. The recommended modern replacements typically include:
  • easYgen-3000XT Series: This series is the direct successor and offers enhanced features, improved connectivity (including robust Ethernet), advanced control algorithms, and a more modern user interface. It’s designed to handle a wide range of single-unit and paralleling applications, effectively covering and expanding upon the capabilities of the easYgen-2000 series. Examples of models within this series that could be suitable include the easYgen-3200XT (e.g., 8440-2082) or easYgen-3500XT-P2 (e.g., 8440-2088), depending on the specific paralleling and I/O requirements.
  • easYgen-1000 Series (newer variants): For simpler single-unit AMF applications that don’t require extensive paralleling features, newer models within the easYgen-1000 series might also be suitable, depending on the specific feature set required.
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