Woodward 8440-1801 Rev D easYgen-350 Genset Controller

Woodward 8440-1801 Rev D easYgen-350 Genset Controller

The Woodward 8440-1801 (Revision D) is a compact genset control and automatic transfer switch (ATS) management module from the easYgen-300 Series (easYgen-350 model line). Engineered specifically for isolated prime power, emergency standby, and marine auxiliary generator automation, this microprocessor-based unit integrates engine start/stop sequencing, comprehensive AC electrical metering, mains/generator breaker interlocks, and hardware fault monitoring into a ruggedized front-panel housing.

Operating across an auxiliary DC input range of 6.5 to 32.0 VDC, Revision D features hardened input filtering to tolerate severe battery cranking dips and inductive transients typical in marine switchgear. It monitors 3-phase true RMS generator and mains voltages up to 346/600 VAC directly (eliminating external potential transformers in standard medium/low-voltage installations) alongside secondary current transformer inputs. The integrated logic executes automated open-transition breaker switching (break-before-make) with user-configurable fail-safe timers, breaker feedback confirmation, and programmable engine warm-up/cool-down curves.

Model Details

• Manufacturer: Woodward Inc.
• Series: easYgen-300 / easYgen-350 Series
• Model Identifier: easYgen-350X / 350-1
• Manufacturer Part Number (MPN): 8440-1801
• Revision Status: Rev D (Hardware/Firmware revision update with enhanced noise rejection and surge immunity)
• Product Type: Digital Generator Controller & Automatic Mains Failure (AMF) Unit

Equipment Compatibility

• Engine Interfaces:
  • Caterpillar: 3406, 3412, C9, C12, C15, C18 marine diesel generator packages.
  • Cummins: 6BT, 6CT, QSB, QSM11, KTA19, KTA38, KTA50 generating sets.
  • MAN Energy Solutions / B&W: Auxiliary GenSets using remote speed/start solenoids.
  • Volvo Penta & Scania: D9, D13, D16, DI09, DI13 series engines with external relay interfaces.
  • Wärtsilä & Yanmar: High/medium-speed auxiliary plant engines requiring automated emergency transfer.
• Governing & Actuator Systems:
  • Compatible with Woodward 2301A, 2301D, ProAct, ESD5500, Barber-Colman DYN1, Heinzmann, and GAC (Governor America Corp) electronic speed controllers via run/stop relays and speed trim loops.
• Switchgear Interfacing:
  • Direct auxiliary contact control for ABB SACE, Schneider Electric Masterpact, Eaton, and Siemens low-to-medium voltage ACBs and motorized MCCBs.

Part Number Cross-References

• Woodward Item Number: 8440-1801
• Revision Designation: 8440-1801 Rev D / 8440-1801D
• Alternative Model Names: easYgen-350, easYgen-350X, easYgen-300 Series
• Direct Function Alternates: Woodward easYgen-320 (Single Breaker only), easYgen-350-X-1

Our Engineer’s Installation Guide

1) Ground Loops and Shield Grounding

When running speed sensor wiring from a flywheel Magnetic Pickup (MPU) or 4–20 mA sender signals to the 8440-1801 terminals, utilize twisted, individually shielded pairs. Ground the drain shield at the controller end only. Never ground the shield at the engine block. Engine block ground loops introduce alternator ripple and high-voltage starter noise into the microprocessor logic, causing intermittent false overspeed trips.

2) Relay Snubbing & Inductive Flyback Protection

While the output relays on Revision D feature enhanced transient filtering, direct connection to heavy continuous solenoids (such as air shutoff flaps, run solenoids, or breaker trip coils) requires an external flyback suppression diode (1N4007 or 1N5408) installed directly across the DC coil terminals. For AC breaker coils, always wire an appropriately rated RC snubber. Failure to install local suppression will arc the internal relay contacts over extended cyclic service.

3) CT Secondary Phasing and Earthing

Ensure the current transformers (CTs) match the programmed vector orientation in the firmware. If terminal s1 (K) and s2 (L) are reversed on even one phase, the controller will read an inverse power factor and register an immediate false reverse-power (32R) trip as soon as the generator breaker closes on load. Ensure one side of each CT secondary (s2) is tied to clean plant earth at the switchboard star-point.

4) DC Power Line Routing During Crank

To safeguard against voltage starvation during cold-start cranking, never tap the 8440-1801 power input terminals directly off the starter motor junction post. Run an isolated, dedicated pair of DC conductors (minimum 1.5 mm² / 16 AWG) directly from the engine starting battery bank, protected by an in-line 2 A to 4 A fast-blow fuse.

Frequently Asked Questions

What distinguishes the 8440-1801 Rev D from earlier series revisions?

Revision D incorporates updated hardware filtering on the discrete input circuits and internal analog converters, offering superior rejection of electromagnetic interference (EMI) generated by heavy variable-frequency drives (VFDs) and marine switchboard thyristor equipment.

Can the Woodward 8440-1801 control both generator and mains circuit breakers?

Yes. Unlike the easYgen-320 variant, the 8440-1801 (easYgen-350) includes integrated control and status monitoring logic for both the Generator Circuit Breaker (GCB) and the Mains Circuit Breaker (MCB), allowing full Automatic Mains Failure (AMF) transfer switching without secondary PLC relays.

What is the maximum AC line voltage that can be connected without potential transformers?

The internal voltage measuring inputs accept line-to-line voltages up to 600 VAC (346 VAC line-to-neutral) directly. Potential transformers (PTs) are only required for applications exceeding this threshold (e.g., 3.3 kV, 6.6 kV, or 11 kV medium-voltage generator circuits).

How is the controller configured on site?

The module can be fully configured using the integrated front-panel keypad and liquid crystal display. Alternatively, comprehensive parameter file uploading, system backup, and detailed fault diagnostics can be performed by connecting a PC running Woodward configuration software via the dedicated rear serial interface.

Is this unit suitable for paralleling two generators together?

No. The easYgen-350 series (8440-1801) is engineered for isolated standby or single-unit utility transfer applications (break-before-make). For active load sharing and continuous automatic synchronizing between multiple generators, consider the Woodward easYgen-2500, easYgen-3200, or easYgen-3500 series.