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3. Key Technical Specifications
| Parameter | Value |
|---|---|
| Power Supply | 12/24 VDC (6–36 VDC) |
| Intrinsic Consumption | Max. 3 W |
| Discrete Inputs | 8, galvanically isolated |
| Input Voltage Range | 6–32 VDC (rated 12/24 VDC) |
| Input Resistance | Approx. 6.8 kΩ |
| Relay Outputs | 8, potential-free Form C |
| Relay Contact Rating (GP) | 2 A @ 250 VAC / 2 A @ 24 VDC |
| Communication | Isolated CAN bus |
| Operating Temperature | –20 °C to +70 °C (typical) |
| Storage Temperature | –40 °C to +85 °C |
| Humidity | 95 % RH, non-condensing |
| Weight | Approx. 4.0 lbs (1.81 kg) |
4. Product Introduction
The Woodward 8440-2028 is the IKD1 digital I/O expansion board that adds eight isolated discrete inputs and eight Form C relay outputs to easYgen-3000, GCP-31/32, and compatible genset controllers. It communicates over isolated CAN bus and supports cascading multiple units for larger I/O counts.
Engineers use it when the base controller runs out of discrete points for alarms, breaker status, start/stop sequencing, or auxiliary equipment. Configuration of input names, alarm classes, NO/NC polarity, and delays is handled through the host controller’s relay manager or a direct configuration cable. The module draws a maximum of 3 W and operates from a standard 12/24 VDC supply.
5. Troubleshooting Quick Reference
| Symptom | Possible Cause | Relevance to this Part | Quick Check Method | Recommendation |
|---|---|---|---|---|
| No LEDs / module dead | Power supply missing or reversed | ✅ High | Measure 6–36 VDC at power terminals with multimeter | Verify polarity and fuse before replacing module |
| Inputs not reported to controller | CAN address or baud mismatch | ✅ High | Confirm Node ID and 250 kBaud setting match host | Reconfigure via DPC cable or host software |
| Specific input LED stays off | Wiring polarity or open circuit | ✅ Medium | Apply known 12/24 VDC signal and watch LED | Check field wiring and input configuration (NO/NC) |
| Relays fail to energize | Host not commanding outputs | ✅ Medium | Force output from controller software | Verify relay manager mapping in host controller |
| Intermittent CAN communication | Termination or wiring fault | ✅ High | Check CAN-H/CAN-L continuity and termination | Add proper 120 Ω termination if missing |
| Module works but host shows alarms | Firmware or parameter mismatch | ❌ Low | Compare configuration files | Reload parameters from known-good backup |
If the problem persists after these checks, capture diagnostic logs, photos of terminal wiring and LEDs, and contact technical support.
8440-2028
8440-2028
6. Frequently Asked Questions (FAQ)
Q: How many 8440-2028 modules can I connect to one easYgen or GCP controller?
A: Multiple units can be cascaded on the same CAN bus. The exact maximum depends on the host controller’s capacity and Node ID assignments—typically several modules are supported. Always leave margin for bus loading and check the host manual for the current limit.
Q: Is the 8440-2028 hot-swappable?
A: No. Power down the module and the CAN bus before connecting or removing it. Hot-plugging risks damaging the isolated interfaces or corrupting the bus.
Q: What is the difference between New Original / New Surplus and a factory-new unit from Woodward?
A: New Original / New Surplus units are genuine Woodward parts that were never installed in service. They are typically from excess inventory or project cancellations. They carry a full functional test and our warranty, but packaging or documentation may differ slightly from current production stock.
Q: Do I need special software to configure the inputs and outputs?
A: Basic configuration (names, delays, NO/NC, alarm classes) is done through the host controller’s relay manager. For extensive or batch configuration, a Direct Configuration Cable (DPC) and PC software are available and recommended.
Q: What happens if the CAN baud rate is set wrong?
A: The module will not communicate. Default for most easYgen/GCP applications is 250 kBaud. Confirm the host setting and reconfigure the IKD1 if necessary before blaming the hardware.
Q: Are the relay contacts rated for inductive loads?
A: The published ratings are general-purpose (resistive). For inductive loads (contactors, solenoids), derate or add external suppression. Check the exact contact material (AgCdO) and apply proper snubbers if needed.
Q: Can I use this module with non-Woodward PLCs?
A: The CAN interface follows standard messaging that some third-party controllers can talk to, but full parameter mapping and display integration are designed for Woodward hosts. Verify protocol details and Node ID usage before attempting integration.
