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Help CenterWOODWARD 8200-1100 Distributed I/O Module
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I. Overview
WOODWARD 8200-1100 is a digital control module, with its core positioning as an industrial-grade full-process precision control and safety protection unit for compressors. Integrated with core functions including anti-surge control, performance optimization, load regulation and fault diagnosis, this module adopts a modular hardware design and advanced digital algorithms. It can realize the full-cycle control of compressor startup, operation and shutdown, effectively avoiding risks such as surge and overload. It serves as a core control component to ensure the stable and efficient operation of compressors in fields such as petrochemical industry, natural gas processing and industrial refrigeration.
Featuring wide working condition adaptability and flexible expandability, this product supports the independent operation control of single compressors. It is compatible with Woodward ToolKit service tools and mainstream industrial communication protocols, and can be seamlessly integrated into various industrial control systems. Through precise closed-loop control and a comprehensive safety protection mechanism, it not only optimizes compressor operation efficiency and reduces energy consumption, but also improves equipment operation reliability, meeting the professional requirements for compressor control in harsh industrial scenarios.
II. Core Features
Integrated Anti-surge Control (ASC): Built-in dedicated anti-surge control logic, supporting three types of compressor maps including P2=F(flow), P2/P1=F(flow) and H=F(flow). It can be configured with up to 10 surge points. Through the three-layer protection mechanism of Surge Limit Line (SLL), Surge Control Line (SCL) and Boost Line, it accurately identifies surge risks and triggers protective actions such as valve quick-opening and minimum limit to avoid equipment damage.
Multi-dimensional Performance Optimization Control (PFC): Integrated with main PID and dual-limit PID control units, it can precisely regulate process parameters such as compressor suction/discharge pressure and flow. It supports sequence control of valve positions during startup/shutdown phases, adapts to throttle valve, Inlet Guide Vane (IGV) and speed regulation, and also supports remote setpoint (4-20mA) input to achieve both local and remote control.
Reliable Signal Redundancy and Fault Diagnosis: Key signals (flow, pressure, temperature) support dual-sensor redundant configuration, effectively avoiding misjudgment caused by single-sensor failure. It has a complete self-diagnosis function, which can real-time monitor the module hardware status and the integrity of input/output signals, and intuitively feed back fault types through fault codes, providing a basis for quick troubleshooting.
Wide Working Condition Adaptability and Strong Environmental Tolerance: Adopting industrial-grade component packaging and electromagnetic shielding design, it can withstand a wide temperature range of -40℃~85℃, with excellent vibration and electromagnetic interference resistance performance. It can adapt to harsh industrial field conditions such as heavy dust, high humidity and voltage fluctuations, ensuring long-term stable operation.
Flexible Configuration and System Compatibility: Supports parameter configuration, logic debugging and data export through service tools, with built-in multiple industrial communication interfaces to achieve seamless linkage with DCS and PLC systems. It supports switching among three operation modes: automatic, manual backup and full manual, adapting to control requirements under different working conditions.
III. Technical Parameters
| Parameter Name | Specification |
|---|---|
| Product Model | WOODWARD 8200-1100 |
| Product Type | Digital Control Module (Dedicated for Axial/Centrifugal Compressors) |
| Power Supply Input | 9-30V DC, with reverse polarity protection and overvoltage protection functions |
| Operating Temperature | -40℃~85℃ (-40°F~185°F) |
| Storage Temperature | -40℃~90℃, non-condensing |
| I/O Interface Specification | AI: 8 channels of 4-20mA (supporting loop power supply); AO: 6 channels of 4-20mA; DI: 20 channels of 24Vdc; Relay Output: 8 channels of Form-C |
| Actuator Output | 2 channels of dedicated output (optional 4-20mA/20-200mA), suitable for valve driving |
| Anti-interference Performance | EMI immunity complies with ISO 11452 standard, 100 V/m (200~1000 MHz) |
| Vibration Resistance Level | 6 Gs (40Hz~2000Hz), 20 Gs shock (45Hz frequency) |
| Control Mode | Automatic mode, manual backup mode, full manual mode |
IV. Working Principle
The core working principle of the WOODWARD 8200-1100 module is a closed-loop control process of signal collection - logic calculation - control output - feedback calibration - safety protection, focusing on the full-cycle operation control of compressors. Through the coordination of various functional units, it achieves precise control and risk avoidance. The specific working process can be divided into five core stages:
Stage 1: Signal Collection and PreprocessingThe module receives monitoring signals from flow, pressure and temperature sensors through multi-channel AI interfaces. The signals are processed by built-in filter circuits and electromagnetic isolation components to eliminate interference clutter and achieve electrical isolation. Meanwhile, redundant signals are compared and verified to ensure the stability and accuracy of input signals, providing reliable data support for control calculation.
Stage 2: Logic Calculation and Status JudgmentThe preprocessed signals are transmitted to the control unit. Combined with preset compressor map parameters, surge thresholds, performance control targets and current operation mode, comprehensive calculation is performed through PID algorithm and anti-surge logic to judge whether the compressor has surge risks, whether parameters deviate from the set values, and clarify the regulation direction and protection requirements.
Stage 3: Control Output and Equipment RegulationAccording to the calculation results, the module sends control signals through AO interfaces and dedicated actuator output interfaces to adjust throttle valve opening, IGV angle or speed, realizing precise regulation of parameters such as suction/discharge pressure and flow. If surge precursors are detected, anti-surge actions are triggered immediately to quickly open protective valves and suppress surge occurrence.
Stage 4: Feedback Calibration and Parameter OptimizationReal-time collection of adjusted equipment status signals through sensors forms closed-loop feedback, dynamically adjusting control parameters to eliminate deviations and ensure process parameters are stable within the set range. During startup/shutdown phases, valve positions are automatically controlled according to preset sequences to ensure smooth startup and shutdown of equipment and avoid impact damage.
Stage 5: Fault Diagnosis and Safety ProtectionThe module real-time monitors its own hardware status, the integrity of input/output signals and compressor operation parameters. If sensor faults, signal abnormalities, surge risks or module hardware faults are detected, alarms are given immediately through fault codes, and preset protection strategies (such as switching to manual mode, cutting off dangerous actions) are triggered at the same time, and fault information is fed back to the main control system to ensure equipment safety.
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