Woodward Vertex User manual

Product Manual 35072V1
(Revision -, 4/2018)
Original Instructions
V
ertex Digital Control
for Performance and Compressor Control
Volume 1
Installation, Operation, and Configuration Manual
Manual 35072 consists of 3 volumes (35072V1, 35072V2, & 35072V3).
Released

General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual
26455 , Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
the publications page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual
26455 , Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions— A bold, black line alongside the text identifies changes in this publication since the
last revision.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 35072V1
Copyright © Woodward, Inc. 2018
All Rights Reserved
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Contents
WARNINGS AND NOTICES ............................................................................................................... 6
ELECTROSTATIC DISCHARGE AWARENESS...................................................................................... 8
REGULATORY COMPLIANCE ............................................................................................................ 9
ABBREVIATIONS ........................................................................................................................... 12
CHAPTER 1. GENERAL INFORMATION ............................................................................................ 13
Introduction ................................................................................................................................................. 13
Part Number Options .................................................................................................................................. 13
General Installation and Operating Notes and Warnings ........................................................................... 14
Controller Overview..................................................................................................................................... 15
Vertex Inputs and Outputs .......................................................................................................................... 22
Optional Distributed I/O............................................................................................................................... 27
Keypad and Display .................................................................................................................................... 28
Watchdog Timer/CPU Fault Control ........................................................................................................... 30
CHAPTER 2. INSTALLATION ........................................................................................................... 31
Introduction ................................................................................................................................................. 31
Shipping Carton .......................................................................................................................................... 31
General Installation ..................................................................................................................................... 31
General Wiring Guidance............................................................................................................................ 32
CHAPTER 3. HARDWARE SPECIFICATIONS..................................................................................... 34
Vertex Description and Features ................................................................................................................ 34
Environmental Specifications...................................................................................................................... 35
Maintenance Info and Recommendations .................................................................................................. 35
Electromagnetic Compatibility (EMC) ......................................................................................................... 36
Outline Drawing for Installation ................................................................................................................... 36
Input Power Specification............................................................................................................................ 40
Visual Indicators (LED’s) & CPU Configuration .......................................................................................... 41
Communications (Ethernet) ........................................................................................................................ 41
Communications (CAN) .............................................................................................................................. 43
Communications (RS-232/RS-485) ............................................................................................................ 45
Communications (Service Ports) ................................................................................................................ 46
Hardware - Terminal Blocks & Wiring ......................................................................................................... 46
Hardware - Speed Sensor Inputs................................................................................................................ 49
Hardware - Analog Inputs (4-20 mA) .......................................................................................................... 50
Hardware - Analog Outputs (4-20 mA) ....................................................................................................... 51
Hardware - Actuator Outputs ...................................................................................................................... 52
Hardware - Discrete Inputs ......................................................................................................................... 53
Hardware - Relay Outputs........................................................................................................................... 54
Troubleshooting Fault Codes...................................................................................................................... 55
Troubleshooting & Commissioning checks ................................................................................................. 55
CHAPTER 4. MANUAL NETWORK SETUP ........................................................................................ 59
Factory Set IP Addresses for the Control ................................................................................................... 59
Factory Set Network Passwords................................................................................................................. 59
Network setup instructions for the control................................................................................................... 60
CHAPTER 5. DISTRIBUTED I/O EXPANSION .................................................................................... 63
Network Wiring Considerations................................................................................................................... 63
CHAPTER 6. CONTROL DESCRIPTION ............................................................................................ 65
Introduction ................................................................................................................................................. 65
Anti-Surge Control....................................................................................................................................... 66
Anti-Surge Control 2.................................................................................................................................. 104
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Commands................................................................................................................................................ 106
Train Commands....................................................................................................................................... 106
Performance Control ................................................................................................................................. 107
Load Sharing Control ................................................................................................................................ 117
CHAPTER 7. CONFIGURATION PROCEDURES ............................................................................... 126
Program Architecture ................................................................................................................................ 126
Display Modes and User Levels ............................................................................................................... 126
Configuring the Vertex .............................................................................................................................. 127
Exiting the Configure Mode....................................................................................................................... 167
Calibration/Stroking Procedure ................................................................................................................. 174
CHAPTER 8. VERTEX OPERATION................................................................................................ 176
Software Architecture................................................................................................................................ 176
Power-Up Screen...................................................................................................................................... 177
Control Mode Architecture ........................................................................................................................ 178
User Login Levels ..................................................................................................................................... 179
Navigation ................................................................................................................................................. 180
Page Organization .................................................................................................................................... 181
Stop Key.................................................................................................................................................... 196
Alarm Summary ........................................................................................................................................ 196
Shutdown Summary.................................................................................................................................. 203
Manual Dynamic Adjustments of Anti-surge, Performance, Limiter 1, Limiter 2, Load Sharing, and
Pressure Override PID Controls ............................................................................................................... 205
CHAPTER 9. COMMUNICATIONS................................................................................................... 208
Modbus Communications.......................................................................................................................... 208
Port Adjustments....................................................................................................................................... 211
Vertex Control Modbus Addresses ........................................................................................................... 211
CHAPTER 10. PRODUCT SUPPORT AND SERVICE OPTIONS .......................................................... 238
Product Support Options........................................................................................................................... 238
Product Service Options ........................................................................................................................... 238
Returning Equipment for Repair ............................................................................................................... 239
Replacement Parts.................................................................................................................................... 240
Engineering Services ................................................................................................................................ 240
Contacting Woodward’s Support Organization ......................................................................................... 240
Technical Assistance ................................................................................................................................ 241
APPENDIX A. VERTEX CONFIGURATION MODE WORKSHEETS ...................................................... 242
REVISION HISTORY ..................................................................................................................... 262
DECLARATIONS .......................................................................................................................... 263
The following are trademarks of Woodward, Inc.:
ProTech
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)
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Illustrations and Tables
Figure 1-1. Vertex Compressor Control (With Display) .............................................................................. 13
Figure 1-2. Vertex Compressor Control (Without Display) ......................................................................... 14
Figure 1-1. Typical One Section Compressor Application .......................................................................... 16
Figure 1-2. Typical Two Section Compressor Application .......................................................................... 16
Figure 1-3. Load Sharing Compressor Application..................................................................................... 17
Figure 1-4. Overview of ASC Functionality Notes ...................................................................................... 18
Figure 1-5. Overview of ASC Functional Block Diagram ............................................................................ 19
Figure 1-6. Overview of Performance Control Block Diagram.................................................................... 20
Figure 1-7. Overview of Load Share Control Block Diagram...................................................................... 20
Figure 1-9. Vertex Keypad and Display ...................................................................................................... 28
Figure 3-1. Functional Block Diagram (Vertex Control) .............................................................................. 34
Figure 3-2. Vertex Outline Drawing............................................................................................................. 37
Figure 3-3. Vertex Outline Drawing............................................................................................................. 39
Figure 3-3. COM1 Example RS-485 wiring................................................................................................. 45
Figure 3-5. CPU Service Port (3 pin, 2 mm) ............................................................................................... 46
Figure 3-3. Vertex Back Cover Label.......................................................................................................... 46
Figure 3-4. Vertex Back Cover Label.......................................................................................................... 47
Figure 3-5. Vertex Terminal Block Connectors ........................................................................................... 48
Figure 3-6. Speed Sensor Block Diagram .................................................................................................. 50
Figure 3-7. Analog Input – Self-Powered Block Diagram ........................................................................... 51
Figure 3-8. Analog Input – Loop-Powered Block Diagram ......................................................................... 51
Figure 3-9. Analog Output Block Diagram .................................................................................................. 52
Figure 3-10. Actuator Output Block Diagram .............................................................................................. 53
Figure 3-11. Discrete Input Block Diagram ................................................................................................. 53
Figure 3-12. Relay Output Block Diagram .................................................................................................. 54
Figure 4-1. Network Setup Flowchart ......................................................................................................... 60
Figure 4-2. Network Cable Connections ..................................................................................................... 62
Figure 5-1. Daisy Chain Network (preferred) .............................................................................................. 63
Figure 5-2. Trunk and Daisy Chain Network............................................................................................... 63
Figure 6-1. Typical Compressor Application ............................................................................................... 66
Figure 6-2. Surge Cycle .............................................................................................................................. 67
Figure 6-3. Stonewall .................................................................................................................................. 68
Figure 6-4. Standard Compressor Map ...................................................................................................... 69
Figure 6-6. Process Control Diagram ......................................................................................................... 70
Figure 6-9. Compressor Map S_PV Regions.............................................................................................. 72
Figure 6-9. Mode Select.............................................................................................................................. 73
Figure 6-10. Manual Setting of Anti-Surge Valve ....................................................................................... 74
Figure 6-11. On-Line Detection................................................................................................................... 75
Figure 6-12. Anti-Surge Functions .............................................................................................................. 77
Figure 6-13. Surge Detection and Counter ................................................................................................. 78
Figure 6-14. Surge Recovery and Surge Minimum Position (SMP) ........................................................... 79
Figure 6-15. Anti-Surge Valve Response to a Surge.................................................................................. 80
Figure 6-16. Boost....................................................................................................................................... 81
Figure 6-17. Compressor Map Margin and Region .................................................................................... 81
Figure 6-18. Anti-Surge PID........................................................................................................................ 82
Figure 6-19. Rate Controller PID ................................................................................................................ 83
Figure 6-20. Automatic Gain Compensation............................................................................................... 84
Figure 6-21. Anti-Surge Decoupling............................................................................................................ 85
Figure 6-22. Effect of Valve Layout on Adjacent Stage Decoupling Amounts............................................ 86
Figure 6-23. Pressure Override Control...................................................................................................... 88
Figure 6-24. Auxiliary Control Variables ..................................................................................................... 89
Figure 6-25. Analog 4–20 mA Input Signal Filtering and Failure Monitoring .............................................. 90
Figure 6-26. Valve Position Freeze Routine ............................................................................................... 91
Figure 6-27. Valve Overstroke .................................................................................................................... 92
Figure 6-28. Valve Dither ............................................................................................................................ 92
Figure 6-29. Valve Characterization ........................................................................................................... 93
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Figure 6-30. Boost Response with Pre-Pack.............................................................................................. 94
Figure 6-31. Gas Properties Calculations ................................................................................................... 95
Figure 6-32. Input Signal Configure and Failure Response........................................................................ 96
Figure 6-33. Two Section Compressor with One ASV.............................................................................. 105
Figure 6-34. Performance Control Overview ............................................................................................ 107
Figure 6-36. Mode Select.......................................................................................................................... 109
Figure 6-37. Performance PID Overview .................................................................................................. 110
Figure 6-38. Limiter 1 PID Overview......................................................................................................... 113
Figure 6-39. Limiter 2 PID Overview......................................................................................................... 115
Figure 6-40. Load Sharing Functional Block Overview............................................................................. 117
Figure 6-41. Two Compressors Supplied by a Common Suction Header................................................ 118
Figure 6-42. Load Share (LS) Implementation.......................................................................................... 119
Figure 6-43. Load Share Communication Overview................................................................................. 124
Figure 6-44. Load Share Communication Status...................................................................................... 125
Figure 7-1. Initial HOME Screen (unit not configured).............................................................................. 127
Figure 7-2. Configuration Menu – Configuration Mode (Edit) ................................................................... 129
Figure 8-1. Software Architecture ............................................................................................................. 176
Figure 8-2. Vertex Splash Screen............................................................................................................. 177
Figure 8-3. Boot-up to HOME Screen....................................................................................................... 178
Figure 8-4. Control Mode Architecture...................................................................................................... 179
Figure 8-5. Mode Screen .......................................................................................................................... 179
Figure 8-6. Navigation Cross .................................................................................................................... 180
Figure 8-7. Service Menu showing “Compressor 1 Control” IN-Focus..................................................... 181
Figure 8-8. Configuration Menu – Operation Mode (View only) ............................................................... 182
Figure 8-9. Configuration Menu – Configuration Mode (Edit) ................................................................... 182
Figure 8-10. Overview Screen .................................................................................................................. 183
Figure 8-11. ASC Control Popup .............................................................................................................. 184
Figure 8-12. ASC Demands Screen ......................................................................................................... 184
Figure 8-13. ASC Demands Screen ......................................................................................................... 185
Figure 8-14. ASC Compressor Map Screen ............................................................................................. 186
Figure 8-15. ASC Control Dynamics Screen ............................................................................................ 187
Figure 8-16. Performance Control Screen ................................................................................................ 188
Figure 8-17. Performance Sequencing Screen......................................................................................... 189
Figure 8-18. Performance Valve Demand Screen.................................................................................... 190
Figure 8-19. Controllers Screen................................................................................................................ 191
Figure 8-20. Analog Input Summary Screen............................................................................................. 192
Figure 8-21. Contact Input Summary Screen ........................................................................................... 193
Figure 8-22. Analog Output Summary Screen.......................................................................................... 194
Figure 8-23. Relay Output Summary Screen............................................................................................ 195
Figure 8-24. Actuator Driver Summary Screen......................................................................................... 196
Figure 8-25. ALARM Screen..................................................................................................................... 197
Figure 8-26. Shutdown Summary Screen................................................................................................. 204
Figure 8-27. ASC Dynamics Adjustment Screen ...................................................................................... 206
Figure 9-1. ASCII/RTU Representation of Three...................................................................................... 209
Figure 9-2. Modbus Frame Definition ....................................................................................................... 210
Table 1-1. Vertex (with display) Part Number Options ............................................................................... 13
Table 1-2. Vertex (without display) Part Number Options .......................................................................... 14
Table 1-1. Selectable functions for 4-20mA Analog Inputs......................................................................... 22
Table 1-2. Selectable functions for Discrete Inputs .................................................................................... 23
Table 1-3. Selectable functions for 4-20mA Analog Outputs...................................................................... 25
Table 1-4. Selectable functions for Relay Output States ............................................................................ 26
Table 1-5. Selectable functions for Relay Output Level switches............................................................... 26
Table 1-6. Available (programmed) distributed I/O Nodes ......................................................................... 27
Table 3-1. Environmental Specifications..................................................................................................... 35
Table 3-2. Specifications (LV)..................................................................................................................... 40
Table 3-3. Specifications (HV) .................................................................................................................... 40
Table 3-4 Input Power Connector Pinout.................................................................................................... 40
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Table 3-5 Ethernet Ports #1-4 (10/100) ...................................................................................................... 42
Table 3-6. CAN Specifications .................................................................................................................... 43
Table 3-7. CAN Connector Pinout .............................................................................................................. 43
Table 3-8. Belden YR58684, bulk cable (Woodward PN 2008-1512) ........................................................ 44
Table 3-9. COM1 Serial Port Connector ..................................................................................................... 45
Table 3-10. Specifications (MPU/PROX) .................................................................................................... 49
Table 3-11. Specifications (AI).................................................................................................................... 50
Table 3-12. Specifications (AO) .................................................................................................................. 51
Table 3-13. Specifications (ACT) ................................................................................................................ 52
Table 3-16. Specifications (DI).................................................................................................................... 53
Table 3-15. Specifications (Relay outputs) ................................................................................................. 54
Table 3-16. CPU Fault LED Flash Codes ................................................................................................... 55
Table 4-1. Factory set IP addresses for the Vertex CPU............................................................................ 59
Table 4-2. Factory set account names and passwords for newer controls ................................................ 59
Table 5-1. Useful Woodward Part Numbers at the Time of Writing............................................................ 64
Table 6-1. Compressor Train Control Types............................................................................................... 65
Table 6-1. Valve Characterization Percentages ......................................................................................... 93
Table 6-2. Temperature Fallback Strategy ................................................................................................. 97
Table 6-3. Discharge Pressure Fallback Strategy ...................................................................................... 97
Table 6-4. Suction Pressure Fallback Strategy .......................................................................................... 98
Table 6-5. Fallback Strategy on Flow Failure ............................................................................................. 98
Table 6-6. Action on Flow Failure ............................................................................................................... 98
Table 6-7. Typical Discharge Coefficients ................................................................................................ 101
Table 7-1. Mode Access by User Level .................................................................................................... 126
Table 7-2. Configuration Modes and Descriptions.................................................................................... 129
Table 7-3. Configure Menu Descriptions .................................................................................................. 130
Table 7-4. Configuration Error Messages ................................................................................................. 168
Table 8-1. ALARM Messages ................................................................................................................... 197
Table 8-2. Shutdown Messages ............................................................................................................... 204
Table 9-1. ASCII vs RTU Modbus............................................................................................................. 209
Table 9-2. Modbus Function Codes.......................................................................................................... 210
Table 9-3. Modbus Error Codes................................................................................................................ 210
Table 9-4. Modbus Communication Port Adjustments ............................................................................. 211
Table 9-5. Maximum Modbus Discrete and Analog Values...................................................................... 211
Table 9-6. Boolean Write Addresses ........................................................................................................ 212
Table 9-7. Boolean Read Addresses ........................................................................................................ 215
Table 9-8. Analog Read Addresses .......................................................................................................... 228
Table 9-9. Analog Write Addresses .......................................................................................................... 236
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Warnings and Notices
Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
IMPORTANT - Designates an operating tip or maintenance suggestion.
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure to turn off the charging device
before disconnecting the battery from the system.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
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Personal Protective
Equipment
The products described in this publication may present risks that
could lead to personal injury, loss of life, or property damage. Always
wear the appropriate personal protective equipment (PPE) for the job
at hand. Equipment that should be considered includes but is not
limited to:
Eye Protection
Hearing Protection
Hard Hat
Gloves
Safety Boots
Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
IOLOCK. When a CPU or I/O module fails, watchdog logic drives it into
an IOLOCK condition where all output circuits and signals are driven to
a known de-energized state as described below. Design the System
such that IOLOCK and power OFF states will result in a SAFE condition
of the controlled device.
CPU and I/O module failures will drive the module into an IOLOCK
state
CPU failure will assert an IOLOCK signal to all modules and
expansion racks to drive them into an IOLOCK state.
Discrete outputs / relay drivers will be non-active and de-
energized
Analog and Actuator outputs will be non-active and de-energized
with zero voltage or zero current.
The IOLOCK state is asserted under various conditions including
CPU and I/O module watchdog failures
Power Up and Power Down conditions.
System reset and hardware/software initialization
Entering configuration mode
NOTE: Specify additional watchdog details and any exceptions to
these failure states in the related CPU or I/O module section of the
manual.
Emergency
Disconnecting
Device
An emergency switch or circuit breaker shall be included in the
building installation that is in close proximity to the equipment and
within easy reach of the operator. The switch or circuit breaker shall be
clearly marked as the disconnecting device for the equipment. The
switch or circuit breaker shall not interrupt the Protective Earth (PE)
conductor.
Risk of Calibration
and Checkout
Authorized personnel knowledgeable of the risks posed by live
electrical equipment should only perform the calibration and checkout
procedure.
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Fuse Power Supply
Mains
Properly fuse the Power Supply MAINS according to the NEC/CEC or
Authority Having Final Jurisdiction per the Input Power
Specifications.
Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715 , Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Follow these precautions when working with or near the control.
1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not store
static electric charges as much as synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.
If you must remove the PCB from the control cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the components with conductive
devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
SOFTWARE
An unsafe condition could occur with improper use of the software
tools used with the Vertex control. Only trained personnel should
have access to these tools.
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Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking. Refer to DoC for applicability by
part number.
EMC Directive: Declared to Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014 on the harmonization of the laws of the Member
States relating to electromagnetic compatibility. (EMC)
ATEX – Potentially
Explosive
Atmospheres
Directive:
Declared to Directive 2014/34/EU on the harmonization of the laws of the
Member States relating to equipment and protective systems
intended for use in potentially explosive atmospheres.
Zone 2, Category 3, Group II G, Ex ic nA IIC T4 X Gc IP20
Low Voltage
Directive:
Declared to Directive 2014/35/EU on the harmonization of the laws of the
Member States relating to the making available on the market of electrical
equipment designed for use within certain voltage limits.
Other European and International Compliance:
IECEx: Ex ic nA IIC T4 Gc T4 Certificate: IECEx CSA 15.0020X
IEC 60079-0: 2011 – Explosive Atmospheres – Part 0 Equipment General
Requirements
IEC 60079-11: 2011 – Explosive Atmospheres – Part 11 Equipment Protection
by Intrinsic Safety “i”
IEC 60079-15: 2010 – Explosive Atmospheres – Part 15: Equipment protection
by type of protection “n”
North American Compliance:
These listings are limited only to those units bearing the CSA identification.
Units bearing only the CSA identification are restricted for use only in Ordinary Locations in North
America.
Units bearing the CSA identification in addition to the marking indicating Class I, Div 2, Groups A, B, C
and D are acceptable for use in North American Hazardous Locations.
CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T4 at 70 °C surrounding air
temperature. For use in Canada and the United States.
CSA Certificate 70006135
This product is certified as a component for use in other equipment. The final combination is subject to
acceptance by the authority having jurisdiction or local inspection.
Special Conditions for Safe Use
The Vertex Compressor Control shall not be installed in areas exceeding Pollution Degree 2 as defined in
IEC 60664-1 and Overvoltage Category II.
The controls containing a LCD and Keypad must be mounted in a vertical position with air vents located
at the top and bottom of the unit. The Bulkhead mount control can be mounted in a vertical or horizontal
position. Regardless of the mounting orientation, the air temperature surrounding the control cannot
exceed 70˚C.
A fixed wiring installation is required. Field wiring must be in accordance with North American Class I,
Division 2 (CEC and NEC), or European Zone 2, Category 3 wiring methods as applicable, and in
accordance with the Local Inspection Authority having jurisdiction. On high voltage versions of the control
the interior of the enclosure shall not be accessible in normal operation without the use of a tool.
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A switch or circuit breaker shall be included in the building installation that is in close proximity to the
equipment and within easy reach of the operator. The switch or circuit breaker shall be clearly marked as
the disconnecting device for the equipment. The switch or circuit breaker shall not interrupt the Protective
Earth (PE) conductor.
Field wiring must be suitable for the following temperatures:
Power Input rated minimum of +95˚C.
All remaining connections; +10˚C above highest ambient temperature.
Protective Earth Grounding of the Vertex Compressor Control connection to the PE terminal is required.
Hazardous Locations
The Low Voltage ATEX Vertex Compressor Control is suitable for use in Class I, Div 2, Gas, Groups A, B,
C, and D & European Zone 2, Group IIC environments
The risk of electrostatic discharge is reduced by permanent installation of the Vertex, proper connection
of the equipotential ground lugs, and care when cleaning. Verify that the area is non-hazardous prior to
the device being cleaned or wiped off.
The Real Time Clock Battery located on the CPU board is not to be recharged and is not user
replaceable. Contact a Woodward Authorized Service Center if replacement service is needed.
The controls with an LCD and Keypad must be installed in an area or enclosure providing adequate
protection against high impact. (4 Joules and 7 Joules) The control is rated for 2 Joules impact.
The Vertex Bulkhead control must be installed in an area or enclosure that protects the control from any
impact.
ATEX/IECEx locations require that the Vertex Control with a keypad and display be installed in a cabinet
or enclosure coded Ex nA or Ex e that provides a minimum IP54 ingress protection per IEC 60529 for the
rear of the control. The front bezel, keypad and display have been tested and are rated IP54 while the
rear of the control is rated IP20 due to the ventilation slots required for heat dissipation. The installer shall
ensure that the maximum surrounding air temperature in the enclosure does not exceed the rated
temperature of +70˚C.
The Vertex Bulkhead Control without the front panel display or keyboard must be installed in a cabinet or
enclosure coded Ex nA or Ex e that provides a minimum IP54 ingress protection per IEC 60529. The
installer shall ensure that the maximum surrounding air temperature in the enclosure does not exceed the
rated temperature of +70˚C.
Transient Protection for the Vertex is to be provided externally by the end user at the supply terminals of
the control. The transient protection device is to be set at a level not exceeding 140% of the maximum
rated peak voltage of 36Vdc.
Explosion Hazard
For ATEX/IECEx installation compliance, the input voltage shall be
limited to 36 Vdc. When selecting an external power supply to supply
the Control, it shall be ATEX/IECEx approved for Zone 2 Group IIC,
Category 3G Applications.
Explosion Hazard
Due to the Hazardous Location Listings associated with this product,
proper wire type and wiring practices are critical to the operation.
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Electric Shock
To reduce the risk of Electrical Shock the Protective Earth (PE) must
be connected to the PE terminal on the enclosure. The conductor
providing the connection must have a properly sized ring lug and wire
gauge equal to or larger than 4mm² (12AWG).
Explosion Hazard
ENCLOSURE REQUIREMENT—
ATEX/IECEx Zone 2, Category 3G applications require the final
installation location provide a minimum IP-54 ingress protection
enclosure against dust and water per IEC 60529. The enclosure must
be coded Ex nA or Ex e.
Explosion Hazard
Do Not Remove Covers or Connect/Disconnect electrical connectors
unless power has been switched off or the area is known to be non-
hazardous
Explosion Hazard
Substitution of components may impair suitability for Class 1, Division
2, or Zone 2.
Explosion Hazard
Properly connect the external ground lugs shown on the installation
drawing to ensure equipotential bonding. This will reduce the risk of
electrostatic discharge in an explosive atmosphere. Perform cleaning
by hand or water spray while the area is non-hazardous to prevent an
electrostatic discharge in an explosive atmosphere.
Explosion Hazard
MOUNTING
Controls containing a LCD and Keypad must be mounted in a vertical
position. The installer shall ensure the maximum surrounding air
temperature of the control does not exceed 70˚C at the final location.
Explosion Hazard
Class I, Div 2 Groups A, B, C, D and Zone 2, Group IIC applications
require the input voltage to the relay contacts not exceed 32Vac rms
or 32Vdc.
Risque d'explosion
Ne pas enlever les couvercles, ni raccorder / débrancher les
prises électriques, sans vous en assurez auparavant que le
système a bien été mis hors tension; ou que vous situez
bien dans une zone non-explosive.
Risque d'explosion
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2
et/ou Zone 2.
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Risque d'explosion
Ne pas utiliser les bornes d’essai du block d’alimentation ou
des cartes de commande à moins de se trouver dans un
emplacement non dangereux.
Safety Symbols
Direct Current
Alternating Current
Both Alternating and Direct Current
Caution, risk of electrical shock
Caution, refer to accompanying documents
Protective conductor terminal
Frame or chassis terminal
Abbreviations
AS Anti-Surge
ASC Anti-Surge Control
GAP Graphical Application Programmer
OP Operating Point
PFC Performance Controller
SCL Surge Control Line
SLL Surge Limit Line
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Chapter 1.
General Information
Introduction
This manual describes the Woodward Vertex Digital Compressor Control for use with one or two section
compressors (axial and centrifugal). The option charts below shows the part numbers and the differences
between the models. Volume 1 of this manual describes the control, provides installation instructions,
defines hardware specifications, and explains the configuration (programming) and operating procedures.
Volume 2 includes notes on applying the control to specific applications and Service mode information.
Volume 3 includes a detailed commissioning procedure. This manual does not contain instructions for the
operation of the complete compressor system. For compressor or plant operating instructions, contact the
plant-equipment manufacturer.
Part Number Options
Table 1-1 lists models with an integrated display. Models with display are panel mounted and include a
color graphical display that has the capability of customization to unique compressor, OEM, and customer
requirements.
Table 1-1. Vertex (with display) Part Number Options
Part Number Power
8200-1370 LVDC (18-36 Vdc) Ordinary Location Compliance
8200-1371 AC/DC (88-264 Vac or 90-150 Vdc) Ordinary Locations Compliance
8200-1372 ATEX Compliance LVDC (18-36 Vdc)
Figure 1-1. Vertex Compressor Control (With Display)
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Table 1-2 lists models without an integrated display. These models are a bulkhead-mounted version of
the Vertex. Configured without a display, the Vertex without a display is ideal for remote environments.
Table 1-2. Vertex (without display) Part Number Options
Part Number Power
8200-1380 LVDC (18-36 Vdc) Ordinary Location Compliance
8200-1381 AC/DC (88-264 Vac or 90-150 Vdc) Ordinary Locations Compliance
8200-1382 ATEX Compliance LVDC (18-36 Vdc)
Figure 1-2. Vertex Compressor Control (Without Display)
General Installation and Operating Notes and Warnings
The Standard Low Voltage and High Voltage Controls are suitable for use in ordinary locations only. The
Low Voltage ATEX Control is suitable for use in Class I, Division 2, Groups A, B, C, and D or Class I,
European Zone 2, Group IIC environments or non-hazardous locations.
These listings are limited only to those units bearing the certification identification.
Field wiring must be stranded copper wire rated at least 75 °C for operating ambient temperatures
expected to exceed 50 °C.
Peripheral equipment must be suitable for the location in which it is used.
Wiring must be in accordance with North American Class I, Division 2, or European Zone 2 wiring
methods as applicable, and in accordance with the authority having jurisdiction.
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Controller Overview
General Description
The Vertex Compressor Control is field programmable which allows a single design to be used in many
different control applications and reduces both cost and delivery time. It uses a built in graphical user
interface (GUI) with multi-lingual menu driven screens to instruct site engineers on configuring the control
to a specific compressor application. The Vertex can be configured to operate as a stand-alone unit or in
conjunction with a plant’s Distributed Control System.
The Vertex control has 12 PID controllers that can affect the controlled operation of the compressor.
1. Anti-Surge PID Stage 1
2. Suction Pressure Override Stage 1
3. Discharge Pressure Override Stage 1
4. Rate Control PID Stage 1
5. Anti-Surge PID Stage 2
6. Suction Pressure Override Stage 2
7. Discharge Pressure Override Stage 2
8. Rate Control PID Stage 2
9. Performance Control PID
10. Performance Limiter 1 PID
11. Performance Limiter 2 PID
12. Load Sharing PID
Depending on the configuration of the Vertex, these PIDs may be used or not used. Please refer to the
Block diagrams listed later in this chapter to fully understand PID relationships.
Anti-Surge Control
The Vertex can be applied to protect one or two section compressor trains from surge. The control is
configured with the OEM provided compressor performance map which describes the Surge Limit Line. A
Surge Control Line with a configured margin away from the Surge Limit Line is generated. The controller
continuously monitors the current operating point of the compressor and compares it with the Surge
Control Line to determine if opening of the Anti-surge valve is necessary. The Vertex control protects
against surge by modulating one or two Anti-Surge Valves (or blow-off valve) while keeping process
conditions within acceptable limits.
Performance Control
The Vertex has a Performance Controller (PFC) which is commonly configured to drive suction/discharge
throttle valves, Inlet Guide Vane position, or speed control setpoint. When configured, this control function
is used to control compressor suction pressure, compressor discharge pressure, compressor flow, or any
process variable related to compressor flow or load. This control function compares an analog input
signal to an internal setpoint and, depending on the programmed configuration, positions the compressor
throttle valve, inlet guide vanes, torque converter, and/or motor speed (VFD) to accomplish the desired
control.
Figure 1-1 shows an example of a compressor application with a typical 1-section, 1-valve compressor
train. Figure 1-2 shows an example of a compressor application with a typical 2-section, 2-valve
compressor train.
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Figure 1-1. Typical One Section Compressor Application
Figure 1-2. Typical Two Section Compressor Application
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Load Sharing Control
When multiple compressor trains are given the task of controlling a common process variable, such as
suction header pressure or discharge header pressure, multiple Vertex control units can be connected
together to equally share the load across multiple compressor trains. The Vertex can load share between
two, three, four, or five compressor trains. The load sharing algorithm works with the performance
controller outputs to maintain the common process variable (suction or discharge header pressure) and to
balance the load between the compressors.
Figure 1-3. Load Sharing Compressor Application
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Functional Block Diagrams
An overview of the anti-surge and capacity control functions is shown in Figure 1-5. Use this diagram to
match the ASC’s control features to the site-specific application. Many of the features of the ASC are
configurable or optional. Later in this manual, more detailed functional block descriptions will be given for
each control feature. The functional diagram in Figure 1-4 is identical for additional sections of anti-surge
control.
Figure 1-4. Overview of ASC Functionality Notes
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