Woodward Vertex Compressor Control System: Function, Application, and Installation Details

Woodward Vertex Compressor Control System: Function, Application, and Installation Details

Summary

The Woodward Vertex compressor control system is an advanced digital controller designed specifically for centrifugal and axial compressors, providing comprehensive anti surge control, performance control, and load distribution functions. This article provides a detailed introduction to the core functions, hardware specifications, installation guide, and operation configuration process of the system based on its official manual (35072V1_C. pdf), aiming to provide comprehensive technical references for engineers, technicians, and operations personnel.

System Overview and Functional Features

The Woodward Vertex control system is an integrated compressor control solution suitable for single-stage or two-stage compressor applications. The system supports three operating modes: automatic mode, manual mode with backup protection, and fully manual mode, ensuring safe and stable operation under various working conditions.

1.1 Core Control Functions

Anti surge control (ASC): Real time monitoring of the operating point of the compressor, preventing the compressor from entering the surge zone by adjusting the anti surge valve.

Performance Control (PFC): Control the inlet pressure, outlet pressure, or flow rate of the compressor by adjusting the inlet guide vanes, throttle valves, or speed set points.

Load distribution control: When multiple compressors are running in parallel, the load of each unit is coordinated through Ethernet communication to maintain system pressure balance.

Quenching control: used for temperature control in refrigeration cycles, by adjusting the quenching valve to inject liquid refrigerant to control the suction temperature.

1.2 System Features

Built in 12 configurable PID controllers, supporting multiple control logic combinations.

Support redundant input signals (such as flow, pressure, temperature) to enhance system reliability.

Equipped with online valve testing function (VertexDR only), valve response testing can be performed during operation.

Support distributed I/O expansion (RTCnet nodes), flexible expansion of input and output channels.

Provide rich communication interfaces: Ethernet CAN、RS-232/RS-485， Supports Modbus protocol.

Hardware specifications and environmental adaptability

2.1 Hardware Configuration

Power input: Supports low voltage DC (18-36 Vdc) or high voltage AC/DC (88-264 Vac/90-150 Vdc).

Communication interface: 4 Ethernet ports, 4 CAN ports, and 1 RS-232/RS-485 port.

Input/output channels:

2 speed sensor inputs (MPU/proximity probe)

8 analog inputs (4-20 mA)

6 analog outputs (4-20 mA)

2 actuator outputs (4-20 mA/20-200 mA)

20 discrete inputs

8 relay outputs (Form-C)

Optional display: 8.4-inch LCD touch screen, supporting multilingual interface.

2.2 Environmental adaptability

Working temperature: The version with a monitor ranges from -30 ° C to+70 ° C; the version without a monitor ranges from -40 ° C to+70 ° C.

Protection level: IP20 (body), installed in cabinets with IP54 or above, can meet the requirements for use in hazardous areas.

Certification standards: Complies with international explosion-proof and industrial standards such as ATEX, IECEx, CSA, etc.

Installation and Wiring Guide

3.1 Installation location selection

The control unit should be installed vertically, ensuring that the ventilation openings are located at the top and bottom.

Avoid direct exposure to water or condensation environments.

Stay away from high voltage and high current equipment to prevent electromagnetic interference.

3.2 Wiring Requirements

It is recommended to use shielded cables for all signal lines (except for power and discrete I/O).

The shielding layer should be grounded at one end to avoid forming a grounding circuit.

Use multiple stranded wires and prohibit welding of wire ends to ensure good contact with the spring clamp.

The power grounding wire must be connected to the PE terminal, and the cross-sectional area of the wire must not be less than 4 mm ² (12 AWG).

3.3 Network Configuration

Default IP address:

Ethernet port 1:172.16.100.15

Ethernet port 2:192.168.128.20

Ethernet port 3:192.168.129.20 (for load distribution communication)

Ethernet port 4:192.168.130.20 (for redundant communication)

Woodward AppManager tool can be used for network settings and software updates.

Control Algorithm and Operating Logic

4.1 Anti surge control principle

The system calculates in real-time the distance between the operating point of the compressor (based on actual flow rate and manifold) and the preset surge control line to determine whether the anti surge valve needs to be opened. The calculation formula for the operating point is as follows:

Operating Point= H p(Q A) 2

among which

QA is the actual suction flow rate

Hp is a polyhedral head

4.2 Surge detection and recovery

The system supports multiple surge detection methods:

Flow derivative

Pressure derivative

Velocity derivative

Minimum traffic detection

Surge line crossing detection

Once surge is detected, the system will initiate the surge recovery program, quickly open the anti surge valve, and activate the "minimum surge position" protection to prevent the compressor from repeatedly entering surge.

4.3 Performance Control and Load Allocation

The performance controller can achieve pressure or flow control through PID regulation.

The load distribution function allows multiple Vertex controllers to communicate through Ethernet, coordinate the output of each compressor, and maintain stable pressure in the common main pipe.

Operation interface and user permissions

5.1 Operation panel

Vertex provides an intuitive graphical user interface that supports navigation keys, soft keys, and hard key operations. Users can use the interface to:

Running status monitoring

parameter adjustment

fault diagnosis

View data records

5.2 User Permission Levels

Operator level: Only allows viewing of operational status and basic operations.

Service level: capable of calibration, parameter tuning, and forced output.

Configuration level: Can enter configuration mode and modify system parameters (password required).

Fault diagnosis and maintenance

6.1 Common fault codes

The system provides fault diagnosis information through LED indicator lights and software interface, such as:

CPU malfunction (red constantly on)

RAM test failed (flash code 2,1)

Watchdog not enabled (flashing code 2,10)

6.2 Maintenance Suggestions

Perform calibration verification every 24-36 months.

The backup equipment is powered on for 3 hours every 24-36 months to activate the electrolytic capacitor.

The battery life of the real-time clock is about 10 years and needs to be checked regularly.

Application cases and typical configurations

The Vertex control system is suitable for various compressor application scenarios, including:

Single stage single valve compressor

Double stage double valve compressor

Multiple parallel compressor systems

Quenching control in refrigeration cycle

The system can be flexibly configured according to actual process requirements, supporting customized control logic and I/O expansion.