BY ALTRONIC

Series XI
Control Panel

Operations
Guide
FORM EXACTA XI-OG 9-03
 Contents Series XI Control Panel
Operations Guide BY ALTRONIC

Contents
Foreword
Contents
Figures and Tables List
1. Introduction
1.1 Monitoring
1.2 Shutdowns, Alarms and Annunciation
1.3 Sequential Control
1.4 Capacity Control
1.5 Data Capture
1.6 Communications
1.7 Programming
1.8 Modbus
1.9 Compressor Control Interface
1.10 Special Functions
1.10.1 Control Panel Software
1.10.2 AGA Calculations
1.11 Data Capture
1.11.1 Downloading
1.11.2 Trending Data
1.11.3 First-In Shutdown Data
1.12 Programming
1.13 Summary of Features
2. System Layout
2.1 System Drawing
2.2 Computer Module
2.3 Analog Board
2.4 Discrete Board
2.5 Converter Board
3. Basic Operation
3.1 Main Run Mode Screen
3.2 Typical Panel Layout
3.3 Using the Keyboard
3.4 Multi-Screen Scrolling
3.5 Adjusting Screen Contrast

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Exacta Series XI Control Panel—Operations Guide Contents

3.6 Keyboard Functions

Reset
Start
Crank
Stop
Auto Stop
Control Keys
Slide Valve Control
Enter/Exit
Up Down
Menu
Remote/Local
Prelube
History
Messages
Inputs
Outputs
Timers and Settings
Typical Timers and Settings Parameters
3.7 Entering Alphabetical Data with the 21-Key Keyboard Software Version 11.07F5
and earlier
3.7.1 Key Functions
3.7.2 The Character List
3.7.3 Example of a Name Entry
3.8 Entering Alphabetical Data with the 21-Key Keyboard Software Version 11.07F6
and Later
3.8.1 The Character List
3.8.2 Example of a Name Entry
4. Control Sequences
4.1 Typical Engine-Driven Reciprocating Unit—Control Sequences
4.1.1 Typical Startup Sequence
Startup Notes
4.1.2 Typical Shutdown Sequence
4.1.3 Subroutines
Auto Slowdown
Manifold Pressure Override
Remote Idle
Engine Jacket Water/Oil Temperature Override and the Blowdown Valve
4.2 Typical Engine-Driven Screw Unit—Control Sequence Changes
4.3 Typical Electric Drive—Control Sequence Changes
5. Setting System Parameters
5.1 Test Mode
5.2 Shutdowns and Alarms
5.3 Changing Passwords

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Exacta Series XI Control Panel—Operations Guide Contents

5.4 Controlling Unit Variables

5.4.1 Process Control theory
5.4.2 PID Control Theory
5.4.3 Tuning PID Control
6. Calibration
6.1 Determining the Software Version
6.2 Calibration Procedure
6.2.1 Opening Procedure
6.2.2 Freezing the Input
6.2.3 Check Jumpers
6.2.4 Check Span Settings
6.2.5 Calibrating
4 to 20 mA Channels
Thermocouple Temperature Channels
RTD Temperature Channels
0 to 5 V Channels
6.2.6 Final Loop Checkout
6.2.7 Adding an Offset
6.2.8 Using Entered Calibration Points
7. Air:Fuel Ratio Control
8. Troubleshooting
9. Communications
9.1 Requirements and Settings
9.2 How to Set Up the Port and Log On
9.3 How to Download Reports
9.4 How to Upload Binary Files (Code)
9.5 How to Download Binary Files (Code)
9.6 How to Log on by Modem to Download Reports
9.7 HyperTerminal TM Help Files
Appendix A Master Controller
A1 Master Controller Inputs
A2 Master Controller Setpoints
A3 Master Controller PIDs
A4 Master Controller Overview
A5 Master Controller Operation
A5.1 Example
A5.2 Notes
A6 Panel Indications
Index

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 Foreword Series XI Control Panel
Operations Guide BY ALTRONIC

This manual provides basic information on operating, parameter setting, calibration,

installation, and troubleshooting, to assist the operator with proper use of the Series XI
Control Panel.
A companion manual Series XI Programming Guide is available for technicians and more
knowledgeable operations personnel.

About this Manual

Throughout the manual, a number of margin icons and writing conventions are used as shown:

Identifies a cross-reference to another section of this manual, possibly followed underneath by

ª
text explaining the reference.

Identifies a cross-reference to another external manual, possibly followed underneath by text

©
explaining the reference.

Identifies actions which could cause system malfunction or operator induced errors (not safety

 related). It may have a message following.

Calls attention to an important area of text. It may have a message following.

2 Identifies required communication with with Altronic Controls or your authorized Exacta
 integrator.

R Identifies text written for optional equipment.

You will also find text in ARIAL font, small capitals, for menu names, messages, etc. Panel
actions required from the operator are shown like this:
Choose [1], ENTER
In this example, the operator is expected to press a “1” key to make the identified menu
choice.
Italics is used on each introductory page, and to identify the names of other documents within
text. Bold is used to highlight certain important items.

2 Start When showing procedures, this column will tell you which keys to press.
If a key indicator has only a number or letter, it is being used to make a choice, not its
2
programmed function (label).

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 Figures Series XI Control Panel
and Tables Operations Guide BY ALTRONIC
List

Figures and Tables List

Figures
# Title Section, Page
1–1 Sample Lookout™ Interface ................................................................. 1, 5
1–2 Typical Control Panel™ Display ........................................................... 2, 4
1–3 AGA Calculation Data Entry ................................................................ 1, 7
1–4 AGA Calculation resulty ....................................................................... 1, 5
1–5 Typical downloaded Data Set ................................................................ 1, 8
1–6 Typical Trending Data Graph ................................................................ 1, 9
1–7 Typical First-In Shutdown Data Graph ................................................. 1, 9
1–8 Sample Program .................................................................................. 1, 10

2–1 Cabinet .................................................................................................. 1, 2

2–2 Behind the Board Cover ....................................................................... 1, 3
2–3 Port Layout on Series XI Module ......................................................... 1, 3

3–1 Main Run Mode Screen ........................................................................ 3, 2

3–2 Typical Panel Layout ............................................................................. 3, 3
3–3 Key Functionality .................................................................................. 3, 4
3–4 Scrolling Through Screens .................................................................... 3, 5
3–5 Menu Screen ......................................................................................... 3, 6
3–6 Contrast Adjust Screen ......................................................................... 3, 6
3–7 Start Screen (Engine-Driven) ................................................................ 3, 7
3–8 Start Screen (Electric Drive) ................................................................ 3, 7
3–9 Master PID ........................................................................................... 3, 9
3–10 Bypass Control ...................................................................................... 3, 9
3–11 Menu Screen ....................................................................................... 3, 10
3–12 Pass word Screen ............................................................................... 3, 10
3–13 Program Menu Screen ........................................................................ 3, 11
3–14 History Menu Screen .......................................................................... 3, 11
3–15 First-In Shutdowns Screen .................................................................. 3, 12
3–16 Sample First In Shutdown Detail Display ............................................ 3, 12
3–17 Event History Screen .......................................................................... 3, 12
3–18 Messages Screen ................................................................................ 3, 13
FORM EXACTA XI-OG 9-03 1 of 2
Series XI Control Panel—Operations Guide Figures List

Figures (Continued)
# Title Section, Page
3–19 Inputs Menu screen ............................................................................. 3, 14
3–20 Shutdowns and Alarms Screen ........................................................... 3, 14
3–21 Shutdown Parameter Entry Screen ..................................................... 3, 15
3–22 Analog Inputs Screen .......................................................................... 3, 15
3–23 Discrete Inputs Screen ........................................................................ 3, 15
3–24 Analog Outputs Screen ....................................................................... 3, 16
3–25 Discrete Outputs Screen ..................................................................... 3, 16
3–26 Discrete Outputs Screen ..................................................................... 3, 17
3–27 Timers and Settings Screen ................................................................. 3, 17
3–28 Shutdown and Alarms Screen ............................................................. 3, 17
3–29 Changing Settings Screen .................................................................... 3, 18
3–30 Name Screen ...................................................................................... 3, 20

5–1 Main Run mode Screen with Test Mode Active ................................... 5, 2
5–2 Shutdown Selected but Not in Test Mode ............................................. 5, 2
5–3 Shutdown Selected but Not in Test Mode ............................................. 5, 3

6–1 Inputs Menu Screen .............................................................................. 6, 3

6–2 Analog Inputs Screen ............................................................................ 6, 3
6–3 Password Entry Screen ......................................................................... 6, 3
6–4 Analog Input (Calibration) Screen ........................................................ 6, 4
6–5 Jumpers and Connections ...................................................................... 6, 6

8–1 Troubleshooting Chart ................................................................ 8, 2 to 8, 4

Tables
# Title Section, Page
1–1 Modbus Information .............................................................................. 1, 4
6–1 Jumper Settings ..................................................................................... 6, 5

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 Chapter
Series XI Control Panel
1 Operations Guide BY ALTRONIC

Introduction
This Chapter introduces the Series XI control panels. It provides
an explanation of the purpose and capabilities of the system,
including:
• monitoring
• shutdowns/alarms and annunciation
• sequential control
• capacity control
• communications, Modbus, remote interface
• data capture, downloading and graphing
• AGA calculations
• programming
• summary of features.
This Chapter provides an overview for a typical Exacta control
2 panel. Since the actual configuration is variable to suit the
customer’s needs and choice of options, specific details may be
different than described.

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Exacta Series XI Control Panel–Operations Guide Chapter 1—Introduction

1.0 Introduction
The fully configurable Series XI Gas Compressor Control System has been developed as an
“all-in-one” solution for controlling gas compressors and associated site equipment. This
makes it ideal for new or retrofit packages. It performs all standard control functions, plus it
has several unique features.
The system can be configured for large or small compressors, screw or reciprocating, with
engine or electric drivers.

1.1 Monitoring
The Series XI monitors temperatures, pressures, levels and other signals, through ‘smart’
analog and discrete I/O boards. The system can handle a maximum of 192 I/Os. Each analog
board contains 16 channels that can be individually configured to accept different input types:
• 4 to 20 mA
• 0 to 5 V
• discrete (switched)
• thermocouple Type J and K
• resistive temperature devices (RTDs)
• resistive.
The controller has a 40 character by eight line backlit display, allowing simultaneous display
of many values.
<Up> and <Down> keys can be used to scroll between display screens if there are more inputs
to be viewed than one screen can handle.

1.2 Shutdowns, Alarms and Annunciation

One of the main functions of any control system is to perform shutdowns and alarms. The
Series XI uses the industry standard Class A, B, C, and D designations, with individual timers
on all Class B’s and C’s (programmable default setting). In addition, the system can be
configured to add a delay to the shutdown or alarm, to debounce and eliminate nuisance
shutdowns. An unlimited number of shutdowns and alarms can be added on any analog
channel, which include the normal high and low shutdowns and alarms plus:
• differentials
• calculated shutdowns
• time delayed shutdowns
• out of range.
For example, a calculated shutdown would calculate the dew point of acid gas and then
shutdown and purge the unit if the gas temperature ever goes below the calculated curve.

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Exacta Series XI Control Panel–Operations Guide Chapter 1—Introduction
The Series XI annunciates the “first-in shutdown” and lists all other shutdowns and alarms,
1 Reset which must be acknowledged by the operator pushing <RESET>. The system records the date
and time when any shutdown or alarm occurs and stores this for future reference. In addition,
it takes a snapshot of all the temperatures, pressures and other analog values when a first-in
shutdown occurs, and also records data for 39 intervals back in time (usually 1 second apart).

If a compressor stalls, it is desirable to have historical data, so you can determine the real
cause. The Exacta computer saves 40 first-in shutdown data sets, to always ensure a complete
history.

1.3 Sequential Control

The control system performs the sequence of starting, loading and stopping the compressor
unit. The Series XI can handle all the pre-lubes, purges, cranking sequences, warm up cycles,
loading, stopping and post-lubes. In addition, it can control the valves associated with these
functions. The sequenced steps can be programmed to work from both time and temperature
data.

1.4 Capacity Control

The Series XI fully handles the loading and unloading of the compressor with up to 15 PID
controllers that are built into the unit. This includes controlling the:
• speed of the engine
• inlet suction valve
• auto and startup bypass valves
• slide valve on a screw-type compressor.
The built-in master controller allows the control of four inputs simultaneous with four
different outputs. This allows for control of suction pressure, discharge pressure, and manifold
pressure (or amperage on electric drives) with one quick and easy setting for each. The
system will automatically control to the input closest to it’s setpoint.

1.5 Data Capture

The Series XI automatically records all the temperatures, pressures and other analog inputs at
regular intervals. The computer keeps a minimum of 1400 of these records in memory at any
given time. If recorded at 15-minute intervals, 14 day’s worth of data can be stored (52 days if
recorded once every hour, etc.). The operator can view this data, and scroll back and forth
through time, to determine how well the unit is operating.
As mentioned previously, for diagnosing problems, the system continuously captures 40
records of data, usually at one second intervals, and can store data for 40 separate shutdowns
in its memory. This data can be downloaded and put into a spreadsheet or SCADA system,
and then graphed to do trending and performance calculations.

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1.6 Communications
The Series XI has built-in RS232 and RS485/422 ports. All that is needed to communicate
with the system is a simple terminal program like Procomm Plus™ or Microsoft Terminal™
or HyperTerminal™. The Series XI can be linked to a SCADA system by using the Modbus
protocol. The transmission medium can be direct, modem, FM transmitter, MSat satellite, or
any other comparable method.

1.7 Programming
The Series XI combines all the programming and flexibility of a programmable logic
controller with the ease and simplicity of a dedicated controller. The object-oriented
programming language and state engine allows programming of very complex processes. The
parameter setting capabilities allow quick and easy programming of specific functions like
shutdowns, alarms, pre-lube, post-lube, crank sequences, etc.

1.8 Modbus
The information in Table 1–1 can be read or written to the Exacta Series XI Computer.

Table 1–1
Modbus Information
Item Read/Write
analog inputs read only
analog outputs read / write
discrete inputs read / write
discrete outputs read / write
PID setpoints read / write
PID Auto/Manual read / write
shutdown and alarm setpoints read / write
shutdown and alarm status read only
engine RPM read only
first-in shutdown read only
hour meter read only

The unit can be started, stopped, and reset remotely. Other functions can be performed by
forcing discrete inputs ON.
The data can be formatted in any of the following forms, assuming that the data can fit in a
specific format. For example, analog values cannot be formatted as bytes or bit mapped.
• bit mapped (discrete inputs and outputs only)
• byte
• short word (2 Bytes)
• long word (4 Bytes)
• IEEE Single Floating Point (4 Bytes)
• IEEE Double Floating Point (8 Bytes)
Modbus RTU can be connected to either communications port (RS232 or RS485). Selectable
from 2400 to 19200 Baud, 8 Bit, No Parity (N 8 1).

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1.9 Compressor Control Interface

An optional graphical user interface software can be used to enhance its existing remote
monitoring and control capabilities. In addition to the standard Exacta features, this software
provides an interactive GUI interface, graphing, and a permanent data log. Figure 1–1 shows
a sample screen.

Figure 1–1
Sample Lookout Interface

1.10 Special Functions

1.10.1 Control Panel Software

Control Panel displays a combination of analog inputs, shutdowns, alarms, recorded history
and events. It can be viewed on a laptop or PC computer using inexpensive software like
Procomm Plus™, Microsoft Terminal™ or HyperTerminal™. Figure 1–2 shows a typical
display.

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Exacta Series XI Control Panel–Operations Guide Chapter 1—Introduction

Figure 1–2
Typical Control Panel Display

1.10.2 AGA Calculations

As an optional feature, the EXACTA Series XI is capable of performing AGA 3 and AGA 8
flow calculations. The calculations are based on the latest editions of AGA Report No. 3, Part
3—Natural Gas Applications and AGA Report No. 8.—Compressibility Factors of Natural
Gas & Other Related Hydrocarbon Gases. Parameters can be set either through a HMI
interface or from the EXACTA panel itself.

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Exacta Series XI Control Panel–Operations Guide Chapter 1—Introduction
Figure 1–3 and 1–4 show a typical AGA Calculation.

Figure 1–3
AGA Calculation Data Entry

Figure 1–4
AGA Calculation Result

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1.11 Data Capture

1.11.1 Downloading
The Series XI computer captures data by taking a snapshot at regular intervals. This data can
be transferred to a PC and loaded into any spreadsheet. The column headers on the
spreadsheet are downloaded with the data. The sample data shown to the left was downloaded
over Satellite (MSat). Figure 1–5 shows a typical downloaded data set.

Engine Engine Engine

#1 #1 #2 #3 Engine Compres Manifold Gas Coolant Engine Oil #1
Suction Discharge Discharge Discharge Oil sor Oil Air Detection Fire Inlet Tempera Tempera 24 Volt Suction
Date Time Pressure Pressure Pressure Pressure Pressure Pressure Pressure #1 Detection Temp ture ture Input RPM Temp
May 6/96 10:35:00 16 70 267 817 76 61 5 0 4 115 144 175 25.8 1730 62
May 6/96 10:50:00 16 67 262 815 76 58 4 0 4 115 147 181 25.6 1730 64
May 6/96 11:05:00 16 65 258 813 76 57 4 0 4 115 149 185 25.6 1729 67
May 6/96 11:20:00 15 66 259 814 77 53 4 0 4 115 144 177 25.8 1730 69
May 6/96 11:35:00 15 65 257 814 77 61 4 0 4 114 143 177 25.8 1730 69
May 6/96 11:50:00 15 64 255 814 77 58 4 0 4 114 144 177 25.8 1730 70
May 6/96 12:05:00 14 63 253 813 76 54 4 0 4 115 145 179 25.8 1730 70
May 6/96 12:20:00 14 62 253 812 77 62 4 0 4 114 143 177 25.8 1730 71
May 6/96 12:35:00 14 62 253 812 77 61 4 0 4 113 143 177 25.8 1729 71
May 6/96 12:50:00 14 61 251 811 77 55 4 0 4 113 142 176 25.9 1728 70
May 6/96 13:05:00 13 60 250 813 77 58 4 0 4 114 144 179 25.8 1730 71
May 6/96 13:20:00 13 62 253 817 77 55 4 0 4 113 142 176 25.9 1730 70
May 6/96 15:35:00 13 59 246 813 77 54 4 0 4 112 140 176 25.9 1729 72
May 6/96 15:50:00 12 57 245 811 77 53 3 0 4 112 143 181 25.8 1731 73
May 6/96 16:05:00 12 58 246 811 77 58 3 0 4 111 140 176 26 1731 73
May 6/96 16:20:00 12 58 246 812 77 61 4 0 4 111 140 176 26 1729 73
May 6/96 16:35:00 12 58 245 809 77 58 3 0 4 111 140 176 26 1730 73
May 6/96 16:50:00 12 58 245 809 77 59 3 0 4 111 140 176 26 1731 73
May 6/96 17:05:00 12 58 246 808 78 53 3 0 4 111 140 176 26 1731 73
May 6/96 17:20:00 12 58 244 806 77 63 3 0 4 111 139 176 26 1731 73
May 6/96 17:35:00 12 58 243 804 77 62 3 0 4 111 140 176 26 1729 74
May 6/96 17:50:00 12 58 243 803 77 54 3 0 4 111 139 176 26 1729 73
May 6/96 18:05:00 12 58 244 803 77 53 3 0 4 111 140 176 26 1730 73
May 6/96 18:20:00 12 57 242 801 78 62 3 0 4 111 139 176 26 1730 74
May 6/96 18:35:00 12 57 242 799 78 57 3 0 4 110 139 176 26 1730 73
May 6/96 18:50:00 12 57 240 798 77 55 3 0 4 110 139 176 26 1729 74
May 6/96 19:05:00 12 57 241 797 78 58 3 0 4 110 139 176 26 1730 74
May 6/96 19:20:00 15 66 259 801 78 61 4 0 4 110 139 177 26 1730 73

Figure 1–5
Typical Downloaded Data Set

1.11.2 Trending Data

Once loaded into a spreadsheet. The data can then be graphed to show trends. The cylinder
temperature graph in Figure 1–6 was taken over a period of three weeks. (The spikes indicate
daily temperature changes.)

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Cylinder and Packing Temperatures

300

250

200
Temperatures (F)

150

Discharge Temp Cyl #2

100 Discharge Temp Cyl #4
Discharge Temp Cyl #1
Discharge Temp Cyl #3
#1 Packing Temp
50
#2 Packing Temp
#3 Packing Temp
#4 Packing Temp
0
May 14/96

May 7/96

May 7/96

May 8/96

May 9/96

May 9/96

May 10/96

May 10/96

May 11/96

May 12/96

May 12/96

May 13/96

May 14/96

May 14/96

May 15/96

May 16/96

May 16/96

May 17/96

May 18/96

May 18/96

May 19/96

May 20/96

May 20/96

May 21/96
18:23:41

17:31:26

23:35:23

14:39:18

22:43:14

13:47:09

19:51:05

10:54:55

18:58:52

10:02:49

16:06:47

15:14:41
3:20:00

9:27:29

0:27:29
9:21:05

8:35:23

7:43:14

4:51:05

1:54:55

1:02:49

9:10:44

0:10:44

6:18:38
Date & Tim e

Figure 1–6
Typical Trending Data Graph

1.11.3 First-in Shutdown Data

40 intervals of data before a shutdown can be downloaded into a spreadsheet. The data can
then be graphed to make it easy to diagnose the cause of the shutdown. Figure 1–7 shows a
typical first-in shutdown data graph.

Low Engine Oil Pressure

2000 80

1800
70

1600
60
1400
#3 Discharge Pressure
RPM 50
1200
#1 Suction Pressure
1000 Engine Oil Pressure 40
Engine Manifold Air Pressure
800
30

600
20
400

10
200

0 0
13:51:08 13:51:10 13:51:12 13:51:14 13:51:16 13:51:18 13:51:20 13:51:22 13:51:24 13:51:26 13:51:28 13:51:30 13:51:32 13:51:34 13:51:36 13:51:38 13:51:40 13:51:42 13:51:44 13:51:46
Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr
16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96 16/96

Data & Time

Figure 1–7
Typical First -In Shutdown Data Graph
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1.12 Programming
The printout in Figure 1–8 shows an example of the shutdown and alarm list. Additional
information on analog inputs, PID settings, discrete inputs and outputs, plus configuration
information, can also be printed directly from the Series XI or downloaded onto a laptop or
PC.
Exacta Series XI
Electric Motor
Sample Program

Programming
Date: Mar 14, 96
Time: 9:00 AM

Shutdown and Alarm List

Dev Name Tag Type Class Mode Wired Delay Channel Diff Set Point
—————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————

1 Low Suction Pressure PT-105 Analog B 120 Sec Low Shutdown 0.0 Sec 1 75
2 High Suction Pressure PT-105 Analog B 120 Sec High Shutdown 0.0 Sec 1 700
3 Low Oil to Suction Differential PT-112 Diff B 15 Sec Low Shutdown 0.0 Sec 2 1 345
4 High Discharge Pressure PT-200 Analog A High Shutdown 0.0 Sec 3 2000
5 High Discharge Gas Temperature Alarm TE-116 Analog A High Alarm 0.0 Sec 4 90
6 High Discharge Gas Temp Shutdown TE-116 Analog A High Shutdown 5.0 Sec 4 100
7 High Lube Oil Temp Alarm TE-115 Analog A High Alarm 0.0 Sec 5 700
8 High Lube Oil Temp. Shutdown TE-115 Analog A High Shutdown 0.0 Sec 5 80
9 Suction Scrubber High Level LSHH-101 Discrete A Shutdown NC 0.0 Sec 2107
10 High Vibration - Compressor VSHH-107 Discrete A Shutdown NC 0.0 Sec 2108
11 High Vibration - Motor VSHH-109 Discrete A Shutdown NO 0.0 Sec 2109
12 Oil Separator Low Temp - Alarm TE-210 Analog B 120 Sec Low Alarm 0.0 Sec 11 55
13 Oil Seperator Low Temp - Shutdown TE-210 Analog B 120 Sec Low Shutdown 0.0 Sec 11 52
14 Economizer - High Liquid Level LSHH-220 Discrete B 20 Sec Shutdown NC 0.0 Sec 2112
15 Propane Injection Low Pressure PDLL-228 Discrete A Shutdown NC 0.0 Sec 2113
16 High Gas Level Alarm CM-100 Discrete A Alarm NC 0.0 Sec 1103
17 High Gas Level Shutdown CM-100 Discrete A Shutdown NC 0.0 Sec 1104
18 Motor Stopped ZSO-108 Discrete B 20 Sec Shutdown NO 0.0 Sec 1102
19 Remote Stop Discrete A Shutdown NC 0.0 Sec 1108
20 ESD (Emergency Shutdown) HS-108 Discrete A Shutdown NC 0.0 Sec 1101

Analog and Discrete Inputs

Num Name Device Type Decimals High Calibration Low Calibration Filter Degree Accuracy
—————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————

1 Suction Pressure 2101 4 - 20 MA 0 862 61855 0 12732 1 3 16

2 Compressor Oil Pressure 2102 4 - 20 MA 0 2100 61728 0 12701 1 3 16
3 Discharge Pressure 2103 4 - 20 MA 0 2100 61247 0 12604 1 3 16
4 Discharge Temperature 2104 RTD 0 110 29264 0 20482 1 5 16
5 Lube Oil Temperature 2105 RTD 0 70 26016 0 20488 1 5 16
6 Slide Valve Potentiometer 2106 Voltage 1 100.0 60000 0.0 4000 1 3 16
7 High Liquid Level - Suction Scrubber 2107 Discrete 0 100 65535 0 0 1 7 16
8 High Vibration - Compressor 2108 Discrete 0 100 65535 0 0 1 7 16
9 High Vibration - Motor 2109 Discrete 0 100 65535 0 0 1 7 16
10 Economizer Pressure 2110 4 - 20 MA 0 2100 61026 0 11783 1 1 16
11 Oil Seperator Temperature 2111 RTD 0 110 28688 0 20512 1 5 48
12 Economizer - High Liquid Level 2112 Discrete 0 100 65535 0 0 1 7 16
13 Propane Injection - Low Pressure 2113 Discrete 0 100 65535 0 0 1 5 16
14 Economizer Level 2114 4 - 20 MA 0 1000 60976 0 11751 1 3 16
15 Motor Current 2115 4 - 20 MA 1 80.0 61775 0.0 12708 1 3 16

Analog Outputs

Num Name Device Type Decimals High Span Low Span

—————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————————

1 Bypass Valve I/P 2101 4 - 20 MA 2 20.00 65535 4.00 0

2 Suction Valve I/P 2102 4 - 20 MA 2 20.00 65535 4.00 0
3 Spare 2103 4 - 20 MA 2 20.00 65535 4.00 0
4 Spare 2104 4 - 20 MA 2 20.00 65535 4.00 0

Figure 1–8
Sample Program

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1.13 Summary of Features

• built-in gas compressor programming
• AGA 3 and AGA 8 gas flow calculations (optional)
• customized programming for individual requirements
• customized diagnostic messages
• up to 192 discrete inputs or outputs (relay, triac or transistor)
• up to 128 analog inputs (RTDs, T/C’s, 4 to 20mA, voltage, or resistive)
• up to 32 analog outputs (4 to 20 mA)
• high speed pulse inputs (e.g., RPM monitoring)
• built-in PID and time proportional control (up to 15 loops)
• shutdowns and alarms for discrete, analog and differentials
• rated for Class 1, Div. 2
• Non-incendive discrete inputs, analog inputs and outputs
• 33.6 K modem, capable of paging and faxing through land line or cell phone
(optional)
• one RS232 port, one RS485/422 port, and one parallel port
• extensive memory for trending, first-in shutdowns, and event monitoring
• data capture, on line
• air:fuel ratio control (optional)

FORM EXACTA XI-OG 9-03 11 of 11

 Chapter
Series XI Control Panel
2 Operations Guide BY ALTRONIC

System Layout

This Chapter provides a system drawing of the required

components of the Series XI Control Panel. It also provides
drawings of the computer module and the I/O boards.
• system drawing
• computer module
• analog board
• discrete board
• converter board

FORM EXACTA XI-OG 9-03 1 of 6

 SPECIFICATIONS:

FORM EXACTA XI-OG 9-03

SYSTEM POWER: 24 VDC, 120 W MAX.

HAZARDOUS AREA CLASSIFICATION: CLASS I, DIV. 2 GROUPS C & D

691400-1 COMPUTER CONTROL MODULE

PANEL GROUND DISPLAY: BACKLIT 40 X 8 LCD

PANEL
GROUND
(8-32)

AMBIENT TEMP RANGE: -30°C TO 70°C (-22°F TO 158°F)

B (+)

B
24 VDC POWER INPUT

A
A (COM) 10SL-4P CONNECTOR (M)
ENCLOSURE: POWDER COATED STEEL

A = COM, B = +24 V
24 VDC INPUT POWER
CW3702-2 DC-DC CONVERTER

INPUT: 18 TO 36 VDC, 995 mA MAX.

OUTPUT: +5, +15, -15, 20 WATT MAX.

1 2 3
CW2810-1 16 CHANNEL ANALOG I/O BOARD
4 5 6
7 8 9 INPUTS: 16 INDIVIDUALLY SELECTABLE
- TYPE J OR K THERMOCOUPLES
Exacta Series XI Control Panel–Operations Guide

0 A B - 4-20 mA (BUILT IN 200 O RESISTORS)

- 0-5 VOLT

SERIAL NO.
C D E - RESISTIVE
- 100 O, 3 OR 4 WIRE

Altronic, Inc. Girard, Ohio

F G H
PLATINUM RTD (EXCITATION FROM CW2810-1 BOARD)
I J K

PART NO.
ALTRONIC EXACTA XI COMPUTER MODULE
OUTPUTS: 4 EA. 4-20 mA

CW4495-1 12/12 I/O DISCRETE BOARD

INPUTS: 12 ISOLATED DIGITAL DISCRETE

N/O OR N/C
CW3702-2
EXACTA EXACTA DC-DC
OUTPUTS: 12 ISOLATED DIGITAL DISCRETE
MODEM RS232 RS485 PARALLEL
PORT 2 PORT 1 24 VDC IN
CONVERTER 100 V MAX., 3 AMP MAX.

RPM: 1 EA. ZERO CROSSING

+5 -15 +15
OUT
2.5 V PEAK MIN.
15 V PEAK MAX.
CW2810-1 CW4495-1
IN EXACTA EXACTA
ANALOG DISCRETE
I/O BOARD I/O BOARD
IN OUT IN OUT MIX OR MATCH
UP TO 4 TOTAL I/O ON

RS232 PORT (DB9 M)

FIG. 1 SYSTEM DRAWING, SERIES XI

EACH EXACTA PORT

RS485/422 PORT (DB9 M)

EXACTA PORT #2 (DB9 F)
EXACTA PORT #1 (DB9 F)

PARALLEL PORT (DB25 F)

MODEM CONNECTION (RJ11)

FROM ANALOG SENSORS FROM DISCRETE SWITCHES
TO CONTROL DEVICES TO DISCRETE OUTPUTS
RPM INPUT

CW2810-1 CW4495-1
IN EXACTA EXACTA
ANALOG DISCRETE
I/O BOARD I/O BOARD
IN OUT IN OUT MIX OR MATCH
UP TO 4 TOTAL I/O ON
EACH EXACTA PORT

FROM ANALOG SENSORS FROM DISCRETE SWITCHES

TO CONTROL DEVICES TO DISCRETE OUTPUTS
Chapter 2—System Layout

2 of 6
RPM INPUT
Exacta Series XI Control Panel–Operations Guide Chapter 2—System Layout

FIG. 2 691400-1 COMPUTER CONTROL MODULE

EXACTA SERIES XI

GROUND
PANEL
PANEL
GROUND

24 VDC INPUT POWER

A = COM, B = +24 V
B (+)

B
A
A (COM)
24 VDC
POWER INPUT

1 2 3
4 5 6
7 8 9

ALTRONIC EXACTA XI COMPUTER MODULE

0 A B

SERIAL NO.

Altronic, Inc. Girard, Ohio

C D E
F G H
I J K
PART NO.

EXACTA EXACTA
MODEM RS232 RS485 PARALLEL
PORT 2 PORT 1
(DB9 M)

(DB9 M)

(DB25 F)
(RJ11)

(DB9 F)

(DB9 F)
MODEM

RS232 PORT

EXACTA PORT #2

EXACTA PORT #1
RS485/422 PORT

PARALLEL PORT

FORM EXACTA XI-OG 9-03 3 of 6

 ANALOG INPUTS ANALOG OUTPUTS

FORM EXACTA XI-OG 9-03

-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+ -+-+-+-+
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4
abababababababababababababababab 3 +- abababab
2
1
3 JUMPER
2
1 PINS
+15V
ANALOG INPUT SELECTION JUMPERS COM
CH1 J40 J41
Exacta Series XI Control Panel–Operations Guide

16 Channel Analog PCB

RTD
EXACTA PORTS
EXCITATION
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
(1 mA)

IN OUT
CH16
Exacta Port from Exacta Port
Previous Unit to Next Unit

MALE FEMALE

EXACTA PORTS
FIG. 3 CW2810-1 16 CHANNEL ANALOG BOARD
Chapter 2—System Layout

4 of 6
FORM EXACTA XI-OG 9-03
DISCRETE INPUTS DISCRETE INPUTS

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
- + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - + - +

F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12

OUTPUT FUSES
Exacta Series XI Control Panel–Operations Guide

1 2 3 4 5 6 7 8 9
10
11
12

OUTPUT LED'S

RPM+
RPM-
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 12X12IO-RPM

EXACTA IN EXACTA OUT

RPM

MALE FEMALE

EXACTA PORT IN EXACTA PORT OUT

FIG. 4 CW4495-1 12-12 I/O DISCRETE BOARD
Chapter 2—System Layout

5 of 6
Exacta Series XI Control Panel–Operations Guide Chapter 2—System Layout

FIG. 5 CW3702-2 DC-DC CONVERTER

OUTPUT

COM
COM
+15

-15
+5
+5

CONN2

CONVERTER
DC/DC

POWER FUSE
POWER LED
F2

CONN1
+VIN
-VIN

POWER
INPUT
COM

+24 VDC

FORM EXACTA XI-OG 9-03 6 of 6

 Chapter
Series XI Control Panel
3 Operations Guide BY ALTRONIC

Basic Operation
This chapter is designed to provide the operator with the basic
skills and knowledge necessary to properly use the Series XI
Control Panel. Later chapters cover setup, sequencing, and PID
control details.
Information in this chapter includes:
• main Run Mode screen explanation
• typical panel layout
• using the keyboard
• multi-screen scrolling
• adjusting the contrast
• keyboard functions for each key
• entering alphabetical information.

FORM EXACTA XI-OG 9-03 1 of 21

Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

3. Basic Operation

3.1 Main Run Mode Screen

During normal operation, and when the computer is first turned on, the Main Run Mode
screen will be displayed (after some initialization screens are cycled through).
Figure 3–1 shows a sample Main Run mode screen with labels pointing out its features. This
screen shows the most important unit parameters, and provides an hour meter, real-time clock
with date, and a message line for important messages.
When the Series XI is displaying the Main Run Mode screen (or its auxiliary screens), the
values on the screen are the current readings taken from the end devices. These are displayed
in engineering units, and the units are shown.

Date
Screen Title
Input Name
The computer
Whenever
has a Identifies
possible,
real-time each input
screens have
clock that being
their title
displays the displayed.
displayed.
time and date.

Messages
March 6/97 Run Mode 2:18 PM
Displays High Engine Temperature-Alarm
programmable Time
messages Suction Discharge Manif Eng JW RPM
describing 45PSI 950PSI 12”hg 165F 1156 Updates the
what is time each
happening Eng Oil Comp Oil Power Gas Det Hour minute.
within the system 185F 130F 23V 0.2% 850
or shutdowns/
alarms.

Unit of
Hour Meter
Measure
Input Reading Displays the
Displays
number of
information in
Displays the hours the unit
engineering
current reading has been run.
units with the
of analog inputs. This hour
units shown
meter is
after the
resettable.
reading.

Figure 3–1
Main Run Mode Screen

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Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

3.2 Typical Panel Layout

Real Time March 6/97 Run Mode 2:18 PM Scrollable

Clock High Engine Temperature-Alarm
Screens
Suction Discharge Manif Eng JW RPM
45PSI 950PSI 12”hg 165F 1156

Eng Oil Comp Oil Power Gas Det Hour

185F 130F 23V 0.2% 850
Event Resetable
Messages Hour Meter
1 Reset 2 Start 3 Stop
Master Load Bypass Speed
4 Control 5 Control 6 Control

Louver Suction
7 Control 8 Prelube 9 Control

Eng Units of Hot

Remote/ Auto
Measure 0 Local A Crank B Stop Keys
Enter
C History D Messages E Exit

Timers/
F Status G Outputs H Settings

LED I Up J Down K Menu Advanced

Feedback Functions

Figure 3–2
Typical Panel Layout

Figure 3–2 shows a typical panel layout. Although the 21-key keyboard is fully
programmable, certain functions will usually be present on engine-driven units:
• Reset
• Start
• Stop
• Master Load Control
• Crank
• Auto Stop
• History
• Messages
• Enter/Exit
• Status (may also be labelled as Inputs)
• Outputs
• Timers and Settings
• Up
• Down
• Menu

FORM EXACTA XI-OG 9-03 3 of 21

Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

3.3 Using the Keyboard

Each of the 21 keys has three elements: an LED indicator, a small square containing a number
or letter and a larger rectangle for the custom label. The number/letter and label act as a single
pushbutton (see Figure 3–3).

Enter Custom Label

LED E Exit

Letter Identifier
Figure 3–3
Key Functionality
While the key is pressed, the LED will illuminate. It will normally go out as soon as the key
is released. If it doesn’t go out, the computer is performing some function, an error has
occurred, or, in some cases it may be programmed to stay on or flash. For example, LED for
key <1>, Reset, will normally be programmed to flash whenever a shutdown occurs and it will
continue to flash until the problem has been cleared and the key is pushed.
The small squares (0 through 9 and A through K) are used to enter your choices (or data) after
the computer requests it. Whenever the computer asks for a number or word, press the
appropriate keys to enter it.
In addition, each key can also be programmed to perform a special function whenever the
computer is in Run Mode (normal operation). For example, the <E> key is used to enter
information or acknowledge an action.

3.4 Multi-Screen Scrolling

The functions of all of the common keys are explained in Section 3.6; however, the <UP>,
<DOWN>, and <EXIT/ENTER> keys are used for basic navigation as explained in the following.
It is often inadequate, or not possible, to put all necessary information on one screen at the
same time. The Series XI has the ability to distribute the information on several screens which
you can scroll through using the <UP>, <DOWN> and <ENTER/EXIT> keys, as shown in Figure
3–4.
The <UP> key will display the next screen in the string. The <DOWN> key will bring you back
to the previous screen. The <ENTER/EXIT> key will always return you to the Main Run Mode
screen. Note that the actual information shown on your system will depend on the
programming, application, and the end devices used.

FORM EXACTA XI-OG 9-03 4 of 21

Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

June 23/99 Run Mode 2:18 PM

Ramping Speed To Minimum Load

Suction Disch(th2&4) Disch(th1&3) RPM

1047kpa 2411kpa 7787kpa 1156

JW Out Gas Fire Volts Manif Hour

87C 0% 4.0ma 23V 23”hg 850

I Up J Down

June 23/99 Run Mode 2:18 PM

Compressor Running
Enter
Process Temperatures E Exit
Suct Stg 1 41C Disch Stg 1 (2): 141C
Suct Stg 2 49C Disch Stg 1 (4): 142C
Disch Stg 2 (3): 145C
Final: 55C Disch Stg 2 (1): 140C

I Up J Down

June 23/99 Run Mode 2:18 PM

Compressor Running
Temperatures Enter
Eng Manifold Air: 29C E Exit
Eng JW Out: 97C
Eng JW In: 73C
Eng Oil: 75C
Comp Oil: 64C

I Up J Down

June 23/99 Run Mode 2:18 PM

Compressor Running
Enter
Engine Pyrometer E Exit
1R: 212C 5R: 203C 1L: 218C 5L: 216C
2R: 218C 6R: 207C 2L: 222C 6L: 208C
3R: 222C 3L: 216C
4R: 206C 4L: 214C

Figure 3–4
Scrolling Through Screens

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Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

3.4 Adjusting Screen Contrast

The type of display used in the Series XI has a small degree temperature sensitivity (darker
when warmer), and is also subject to varying light levels within the unit. This means it may
be necessary to adjust the contrast periodically to suit the operating conditions.
This is a very easy process:
K Menu (a) With any Run Mode screen showing, press <MENU>.
The Menu screen, (Figure 3–5) will be displayed.

Mar 15/03 I6 Menu 8:50 AM

[1] Program Mode [4] Display Modes

[2] History Menu [6] Software Version
[3] Contrast Adjust

[E] Exit

Figure 3–5
Menu Screen
3 (b) Choose [3], CONTRAST ADJUST, by pressing the “3” key.
The Contrast adjust screen (Figure 3–6) will be displayed

Jun 24/99 Contrast Adjust 8:03 AM

Contrast Adjust (150 - 250): 176

[I] Darker [J] Lighter [K] Adjust [E]xit

Figure 3–6
Contrast Adjust Screen
I Up (c) Choose and hold the [I], UP, key to make the screen darker or [J], DOWN, to make it
J Down lighter.
OR
K Choose [K], Adjust.
The value desired from 150 to 250 can then be typed in.
Enter
E Exit (d) Press <ENTER/EXIT> to save the changes and return to the Main Run Mode screen.

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Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

3.6 Keyboard Functions

This Section is based on a typical keyboard layout (Figure 3–2). Some keys may be
different or missing, or perform differently, depending on the program for your unit.
This Section is intended only as a guide to basic operation for a typical unit.

When the compressor is running and a shutdown occurs, the LED for the <RESET> key will
1 Reset
flash to indicate that a shutdown has occurred. (The LED will also flash when the system is
first turned on.) The second line of the screen will show the “first in” fault, such as the HIGH
ENGINE JACKET WATER TEMPERATURE, and the system is taken out of Run Mode.
Press <ENTER/EXIT> to get back to Run Mode. Note that the <RESET> key only works as
a reset in Run Mode.
After a shutdown, before you can restart the unit, all faults have to be cleared on the unit, and
you have to press <RESET> to reset the system. If the LED still flashes after <RESET> is
pressed, another fault (or multiple faults) still remain(s). After all faults are cleared, pressing
<RESET> will stop the flashing and bring up an OK TO START message.
To show all the current faults press <MESSAGES>. To determine when the fault occurred press
<HISTORY>, then choose [2], EVENT HISTORY.

2 Start <START> is used to initiate the starting sequence of the compressor. This key will not initiate
a start until all shutdown faults have been cleared and the <RESET> LED has stopped flashing.
The screen will display an OK TO START message on the Run Mode screen.
After pressing <START>, the start screen will be displayed. Figure 3–7 shows the Start screen
for an engine-driven compressor, and Figure 3–8 shows the Start screen for an electric-drive
compressor.

Aug 16/99 Run Mode 8:10 AM

Start Using: [1] Auto Crank

[2] Manual Crank
[3] Exit (Cancel Start)

Figure 3–7
Start Screen (Engine-Driven)

Aug 16/99 Run Mode 8:10 AM

Action On Selection

Perform Action: [1] Yes

[2] No

Figure 3–8
Start Screen (Electric Drive)

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Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

For engine-driven units, choosing [1], AUTO CRANK, initiates the automated start sequence
described in Chapter 4. Choosing [2], MANUAL CRANK, initiates that same sequence, except
that you will have to manually press the <CRANK> key when the message OK TO CRANK
appears. Choosing [3], EXIT, aborts the start.
For electric-drive units, Choosing [1], YES, will begin the automated start sequence, and
choosing [2], NO, will abort the start.
As stated above, when doing a start from the control panel the <RESET> must be pressed first.
In the case of a remote start, the system will automatically do a reset then a start.
Usually the first functions performed after pressing <START> are the purge and partial
pressurization steps, followed by prelube cycles.

On an engine-driven unit, pressing <CRANK> at any time when the unit is not running will
A Crank
manually crank the engine. The manual key is locked out whenever the unit is above 75 rpm.
This key is used during a manual startup or to test the cranking system.

<STOP> is normally used to perform a fast shutdown (partially-sequenced) of the compressor.

3 Stop After pressing the <STOP> key, the <RESET> key will start to flash even if there is no fault.
This requires the operator to press <RESET> before restarting the compressor.
If you do not have an <AUTO STOP> key, the <STOP> key may be programmed to perform a
controlled shutdown sequence instead of a fast shutdown. The fast shutdown would be
accomplished by pressing the red <Stop> button on the panel.
A non-sequenced Emergency Shutdown option is also available and is actuated from ESD
pushbuttons on the panel and at other locations.

Auto This key is programmed to perform a controlled shutdown sequence. Typically it will only
B Stop work if the unit is operating above the adjustable IDLE RPM. Pressing this key will turn the
Master PID Control to OFF, and gradually ramp the speed down while opening the Bypass
Valve on a reciprocating compressor or unloading the slide valve on a screw-type compressor.
Once the unit reaches the adjustable MINIMUM LOAD RPM, the controller will ramp the unit
down to IDLE RPM for an adjustable length of time, then shut it down and perform post lube
operations. This sequence of events depends on your unit’s configuration.
The <RESET> key must still be pressed after this type of shutdown.

FORM EXACTA XI-OG 9-03 8 of 21

Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

4
Master Load The Master Load Control is used to adjust the set points used by the control system to load the
Control
compressor. This screen can also be used to toggle the Master PID between Auto and
Manual. For a more detailed explanation of Master Load Control See Appendix A.

Mar 15/03 Master PID 8:17 AM

Mode: Auto Off
PV Name Setpoint PV
[1] Suction Pressur 100kpa 166kpa
[2] Discharge Press 1900kpa 596kpa
[3] Engine Manifold 15.0inHg -52.8inHg

[E]xit [H]Manual [F]Setpoint [K]PIDs

Figure 3–9
Master PID
Bypass The <BYPASS CONTROL>, <SPEED CONTROL>, <SUCTION CONTROL>, and <LOUVER CONTROL>
5 Control keys are all used to make changes to their respective PID’s (Chapter 5 explains PID’s and
Speed some important precautions). As an example, Figure 3–10 shows the screen that appears
6 Control
when <BYPASS CONTROL> key is pressed. (All the PID screens are identical except for the
9 Suction name in the top left hand corner. The information displayed is dependent on the type of
Control
compressor.)
Louver
7 Control

Bypass Control Slide Suction

Off 22.1% 166 kpa
Input: Master Control Discharge
Output: Bypass Valve 596 kpa
Input SetPoint Output PID RPM
166kpa 2kpa 0% Auto 1800

[F]SetPoint [G]Output [H]Manual [K]Menu

Figure 3–10
Bypass Control
These keys are used to switch between auto and manual and make adjustments to the setpoint
or output. In Auto mode, this screen is used to adjust the setpoint of the appropriate PID. In
Manual mode, this screen is used to adjust the 4 to 20 mA output signal which controls the
PID. To toggle back and forth between Auto mode and Manual mode press the <H> and
answer YES to the SWITCH TO MANUAL or SWITCH TO AUTO question. If the LED is on for this
button the PID is in Manual. Normally, the Bypass Valve and Speed Control setpoints are
controlled from the Master PID and cannot be modified from these screens unless the Master
PID is in Manual.
The setpoint or output can be adjusted either with the <UP> or <DOWN> keys, or by typing the
value directly.
To use the <UP> or <DOWN> keys, push and hold one of the keys until the desired value has
been reached.
To type a value directly, choose [F], SETPOINT, to select the setpoint, or push the [G], OUTPUT,
key to select Output, and then type the desired value on the key board.
Press the <D> button to enter a decimal. Once the value has been typed push <E> to enter
the value into the controller.

FORM EXACTA XI-OG 9-03 9 of 21

Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

7
Slide Valve The <SLIDE VALVE CONTROL> is a special pulsed PID used to control the slide valve on screw-
Control
type compressors. This type of PID can only be forced with the <OUTPUTS> key (described
later) or from special <MANUAL LOAD> or <MANUAL UNLOAD> keys programmed into controllers
for screw-type units.

Enter
The <ENTER/EXIT> key is one of the most important keys on the keyboard.
E Exit
Whenever a number or name is typed, this key must be pressed to tell the system to “enter”
the information.
The <ENTER/EXIT> key is also used to “exit” from a screen or menu back to a previous screen
or menu.

The <UP> key is used for several different functions. When using it to adjust a setpoint, it will
I Up
increase the value of the setpoint as long as the key is being pressed. When using it in
conjunction with the screens under the <INPUTS>, <MESSAGES>, or <HISTORY> keys, it is used
to move on to the next input or page of information.
Please note that if the Output High Limit value is lower than the Output Low Limit value,
the <UP> and <DOWN> keys will have a reverse action when manually forcing outputs from
a PID key. That is, the <UP> key will cause the output to ramp down and the <DOWN> key
will cause the output to ramp up.

The <DOWN> key is very similar to the <UP> key. When using it to adjust a setpoint it will
J Down decrease the value of the setpoint as long as the key is being pressed. When using it in
conjunction with the screens under the <INPUTS>, <MESSAGES>, or <HISTORY> keys, it is used
to move on to the previous input or page of information.
The <MENU> key is used to enter PROGRAM MODE. When this key is pressed the system will
K Menu display the menu shown in Figure 3–11. When [1], PROGRAM MODE, is chosen, the system will
ask for a password as shown in Figure 3–12 (see Chapter 5 for information on passwords).
The correct level of password is required to enter the program mode. After entering the
password, the Program Menu screen as shown in Figure 3–13 will be displayed.

Mar 15/03 I6 Menu 8:50 AM

[1] Program Mode [4] Display Modes

[2] History Menu [6] Software Version
[3] Contrast Adjust

[E] Exit

Figure 3–11
Menu Screen

Mar 15/03 SXI 11.08.6 2:04 PM

Access Number: 30454

Enter Password:

[E] Enter [C] Clear

Figure 3–12
Password Screen
FORM EXACTA XI-OG 9-03 10 of 21
Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

Aug 27/99 L1 Program Menu 8:03 AM

[1] Compressor Menu [7] AGA Menu

[2] Set Up Menu [8] Counters
[3] Query Menu [9] Control Panel
[4] Print Reports [A] Run Mode Test
[5] Program Keyboard [I] Software Version
[6] Advanced Program

Figure 3–13
Program Menu Screen
From some screens, for example certain PID screens, analog input screens, or timers and
settings, <MENU> also allows access to a more detailed setup.

The <MENU> key also allows access to the <HISTORY>, <CONTRAST ADJUST>, <DISPLAY
MODES> AND <SOFTWARE VERSION>. The <HISTORY> key is discussed later in this Section.
<CONTRAST ADJUST> was discussed earlier in Section 3.4. <Display Modes> is used to set
the units of measure for display purposes (either Metric or English).

Remote/ The <REMOTE/LOCAL> key is used when a SCADA host system is connected to the panel
0 Local through modbus communications. Such a connection allows remote control of the system and
remote setting of various parameters.
When REMOTE is chosen, the system will allow changes to setpoints remotely by the host
computer. When LOCAL is chosen, the host cannot make any changes or control the unit, and
the host will receive the setpoint entered on the system panel as its new setpoint. The system
must be in LOCAL to allow changes to be made directly from the system panel, otherwise the
host will override the system with its own setpoints.
The system may be programmed to ask PERFORM ACTION, [1] YES, [2], NO, or it may simply
toggle the system on pushing the button. The LED for REMOTE/LOCAL will typically be ON in
REMOTE .

8 Prelube The <PRELUBE> key enables the operator to manually prelube the engine and/or compressor.
Pushing this key turns on the prelube pump(s). (The system may be programmed to ask
PERFORM ACTION, [1] YES, [2], NO.) The pumps will run for a preset length of time (adjusted
under <TIMERS AND SETTINGS>) and then turn to OFF. If programmed, pushing the button
again while the pumps are running will also turn them to OFF.

This key will display the screen shown in Figure 3–14.

C History

To select one of the options on the menu, press the numbered key shown in [ ] brackets.
Select [E], EXIT, to exit.

Aug 17/99 History Menu 8:03 AM

[1] First in Shutdowns

[2] Event history
[3] Captured data

[E] Exit

Figure 3–14

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Exacta Series XI Control Panel–Operations Guide Chapter 3—Basic Operation

History Menu Screen

[1] FIRST IN SHUTDOWNS, will display a list of shutdowns in reverse order of occurrence, as
shown in Figure 3–15. The system will display five shutdowns at one time.
To scroll to the next five shutdowns, press <F>. Push <E> to return to the History Menu
screen. To get more details about any one shutdown, enter its number.

Aug 17/99 Select Shutdown 8:23 AM

[1] High Jacket Water Temp 11:36:04

[2] Low Engine Oil Pressure Aug 10/99
[3] High Discharge Pressure Jul 1/99
[4] Low Compressor Oil Level Jun 4/99
[5] Low Engine Oil Level May 21/99
[E] Exit [F] Forward

Figure 3–15
First In Shutdowns Screen
When selecting more detail, the system displays the main Run Mode screen at the time that the
shutdown occurred. A sample screen is shown in Figure 3–16. It is possible to scroll to the
other detail screens by using the <UP> and <DOWN> keys, as described earlier in this Section.
In addition, it is possible to move back in time by using the <B> key. As the <B> key is
pressed, the time will start going backwards typically at one-second intervals. The index will
increase in value at the same time. The <F> key can be used to go forward in time. The index
reads zero at the time of the last shutdown. The system keeps 40 time-slots worth of data for
each shutdown.

Date of Time of Index

Shutdown Shutdown Number

Cause of Date: Aug 17/99 11:36:04 0

Shutdown High Jacket Water Temp

Suction Disch1 Disch2 RPM

1047kpa 2490kpa 8456kpa 1156

JW Out Gas Fire Volts Manifold Hour

95C 0% 4.0ma 23.0 24”hg 1850

Figure 3–16
Sample First In Shutdown Detail Display
The second option on the History Menu is [2], EVENT HISTORY. This option displays all current
and previous shutdowns (not just first in) and other events in reverse chronological order,
showing the date and time when they occurred, as shown in Figure 3–17. This screen also
shows other events such as when the compressor was started.

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Device Start time Stop Time

High Diff Stg 1 Press
Sep 21/98 16:06:04 Sep 21/97 20:52:32
High Diff Stg 1 Press - Alarm
Sep 21/98 16:06:04 Sep 21/97 20:52:32
2401 Start button
Sep 21/98 14:20:12
[I] Next Page [J] previous Page [E]xit

Figure 3–17
Event History Screen
This screen shows both a start time and stop time. The stop time tells when the event ended or
the fault was cleared. For shutdowns, the fault must be cleared and then <RESET> must be
pressed before the stop time and date are set. The <I> key is used to scroll to the next set of
three events on the screen, and the <I> key can be used to scroll back to the previous screen.
The <E> key is used to exit to the History Menu. The system will store 385 events in memory.
The third option on the History Menu is [3], CAPTURED DATA. This option displays a screen
similar to Figure 3–16, but will not show a shutdown cause. Once again the <B> key and the
<F> key can be used to scroll back and forth through time. The <UP> and <DOWN> keys can
be used to scroll between screens. The time interval is typically set to 15 minutes and will
show temperatures and pressures, regardless of whether the compressor is running or not.
Typically the Computer will store a minimum of 2 weeks worth of data when set to a 15-
minute interval. Captured data is generally used when graphing trends by downloading to a
spreadsheet (See Chapter 8).

The <MESSAGES> key displays a screen showing all the current messages being written to the
D Messages
screen including shutdowns and alarms affecting the compressor. This screen shows four
items at one time, as shown in Figure 3–18. If there are more than four messages the screen
will show the [I], MORE MESSAGES, option at the bottom of the screen. To display the next four
messages press the <I> key. When the last page of messages is displayed, pressing the <I>
key again will cause the first page of messages to be re-displayed. The system displays the
messages in order of priority and then a ‘first in’ order. Since all shutdowns have the same
priority, they will be shown in ‘first in’ order.

Aug 17/99 Show Messages 2:00 PM

Push Reset Button To Clear

VSHH-206 High Vibration - Engine
TSHH-227 High Oil Temperature - Engine
LSLL-233 Low Level - Jacket water

[E] Exit [I] More Messages

Figure 3–18
Messages Screen

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This key will display the Status Menu screen shown in Figure 3–19. This screen allows you to
F Status
Inputs
view the status of various items. To select one of the options on the menu, press the number
key shown in brackets beside the option. Press <E> to exit back to Run Mode.
F Inputs
Mar 15/03 Status Menu 2:09 PM

[1] Shutdowns: 10 [5] Analog Inputs

[2] Alarms: 0 [6] Discrete Inputs
[3] Faults: 2 [7] Analog Outputs
[4] Shutdown List [8] Discrete Outputs

[E] Exit

Figure 3–19
Status Menu Screen
Choosing OPTIONS [1 - 4], SHUTDOWNS, ALARMS, FAULTS AND SHUTDOWN LIST, on the Inputs
Menu will display shutdowns and alarms, up to four at a time, showing their current status.
Figure 3–20 shows a typical screen. Push the number beside a specific shutdown or alarm to
see the detail screen. The screen shows if the input is currently faulty or healthy, and for
analog or differential shutdowns it will display the current reading and the setpoint. The delay
time, zero with a healthy input, will start counting down when the shutdown or alarm goes from
healthy to faulty. When the timer reaches zero the shutdown or alarm will take affect.

Mar 15/03 Shutdowns 3:05 PM

[1] Slide Valve High - Cannot S Fault

[2] Suction Scrubber Level High Fault
[3] Compressor Oil Level Low Fault
[4] Engine Oil Level Low Fault

[J] More [E] Exit

Dev Type Class Mode Wired Delay Chann

26 Analog D HH NC 0.5 2113
Slide Valve High - Cannot Sta ZE-201

Status: Fault Value: 22.1%

Delay: 0.0 Set Point: 10.0%

[1] Test [K] Menu

Figure 3–20
Shutdowns and Alarms Screen
The <UP> and <DOWN> keys can be used to scroll forward and backward, four shutdowns /
Alarms at a time. The <1> key is used to enter Test Mode. See Chapter 5 for an
explanation.
For the particular shutdown or alarm being displayed, the <K> key is used to display the
Shutdown Parameter Entry Screen shown in Figure 3–21. This screen allows you to quickly
change parameters . The system will ask for an appropriate password (Figure 3–12) before
ª allowing access to this menu.
By choosing an option from this screen, all the parameters for the particular shutdown or alarm
Refer to Chapter
can be accessed to enter changes. If an option is not applicable for the particular shutdown or
5 for more details.
alarm, the screen will display a message. To make a change, choose the parameter, type in the

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new information on the screen that is displayed (or in some cases toggle between the options
given) and choose <ENTER> to lock in your change. This is explained further in Chapter 5.

Dev Type Class Mode Wired Delay Chann

1 Analog C OS LL NC 5.0 2101
Low #1 Suction Pressure 46C
Setpoint: 2960

[A] Mode [D] Setpoint

[B] Class [F] Delay Timer
[C] Class Timer [G] Wired N/O N/C

Figure 3–21
Shutdown Parameter Change Screen
Choosing [5], ANALOG INPUTS, will display the Analog Inputs screen (Figure 3–20). Four inputs
will be displayed on the screen. To scroll to the next four inputs, press the <UP> key. Press
<DOWN> to scroll back through the previous screens. Exit back to the Input Menu by pressing
the <EXIT> key. Pushing the number beside the input will display the calibration screen (see
Chapter 6).

Aug 27/99 Analog Inputs 8:04 AM

[1] Engine Induction Air Tem 46C

[2] Engine Manifold Pressure 23”hg
[3] Engine JW Outlet Temp. 79C
[4] Engine JW Inlet Temp. 57C

[I] Next [J] Previous [E] Exit

Figure 3–22
Analog Inputs Screen
Choosing [6], DISCRETE INPUTS, on the Inputs Menu shows the status of four discrete inputs as
shown in Figure 3–23. Closed means that the contacts on the input are closed which is
normally the healthy position. Open means that the contacts are open. The <UP> and
<DOWN> keys can be used to scroll forward and backward, four inputs at a time.

Aug 27/99 Discrete Inputs 8:04 AM

[1] 1101 Engine Coolant Level Closed

[2] 1102 Engine Oil Level Closed
[3] 1103 Compressor Oil Level Closed
[4] 1104 Compressor Lube Flow Closed

[I] Up [J] Down [E] Exit

Figure 3–23
Discrete Inputs Screen

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Choosing [7], ANALOG OUTPUTS, on the Inputs Menu shows the status of four analog outputs as
shown in Figure 3–24. The <UP> and <DOWN> keys can be used to scroll forward and
backward, four outputs at a time.

Mar 15/03 Analog Outputs 2:36 PM

Governor 0%
Suction Valve 0%
Bypass Valve 0%
Backpressure Valve 0%

[J] More [E] Exit

Figure 3–24
Analog Outputs Screen

Choosing [8], DISCRETE OUTPUTS, on the Inputs Menu shows the status of eight Discrete
outputs as shown in Figure 3–25. The <UP> and <DOWN> keys can be used to scroll forward
and backward, eight outputs at a time. Please see the <Outputs> button below for overriding
outputs.

Mar 15/03 Outputs 2:40 PM

Load Solenoid Off Engine Lube Pu Off

Unload Solenoi Off Crank Solenoid Off
Fuel Valve Off Balance Soleno Off
Comp Lube Pump Off Panel Power On

[I] Up [J] Down [E] Exit

Figure 3–25
Discete Outputs Screen

G Outputs The <OUTPUTS> key is used to force discrete (switch) outputs to ON or OFF. This is very
useful when checking out the equipment to see if it is wired up and functioning correctly. To
switch an output to ON or OFF, press the <OUTPUTS> key. This will bring up a screen similar to
the one shown in Figure 3–26 (the screen shows eight outputs at a time). Use the <F> key to
scroll to the next screen and the <B> key to scroll back to the previous screen.

Select the output desired by choosing the corresponding number. A ‘<‘ will display on the right
side of the one selected. Choose [K], TOGGLE, to change (toggle) the output state to ON or
OFF. Choose [H], MOMENTARY, to momentarily switch to ON or OFF, while the key is held.
Option [G], AUTO, was set up to toggle between Auto Mode (enable programming) and Manual
Mode (disable programming); however, this feature has not been activated. The program will
still show an “M” in front of the ON or OFF (see “[6] Blowdown V MOff” in Figure 3–26)
when the output has been put in the Manual Mode, but this has no effect.

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Aug 27/99 Outputs 8:04 AM

[1] Fuel Gas On <[5] BC Drain Off

[2] Crank Off [6] Blowdown V MOff
[3] Eng Prelub Off [7] SU Bypass Off
[4] BC Fill Off [8] ESD Block Off

[H]Momentary [K]Toggle [F]orward [G]Auto

Figure 3–26
Discrete Outputs Screen

The <TIMERS/SETTINGS> key is used to change parameter settings for various control
Timers/
H Settings functions. This menu will vary for each compressor depending on the type of compressor and
the options associated with the compressor. A typical menu is shown in Figure 3–27. When
one of the options is selected, the system will ask for an appropriate password (Figure 3–12).
This password will then be good for one hour and will not need to be re-entered each time.

Aug 27/99 Timers & Settings 8:13 AM

[1] Shutdowns/Alarm [6] Dump Timers

[2] Prelube Settings [7] Purge Timers
[3] Crank Settings [8] Load Settings
[4] Warm Up [9] Test
[5] Post Lube
[E] Exit

Figure 3–27
Timers and Settings Screen

When one of the options is selected from the Timers and Settings Menu (<1> in the example)
the system will display a list of four numbered parameters as shown in Figure 3–28. Scroll
through the list using the keys shown at the bottom of your screen to find the specific
parameter you want.
To change a parameter press the number to the left of your choice. Pressing the <1> key in
the example causes the system to go into number edit mode as shown in Figure 3–29. The
new setpoint value can be typed. Pressing the <ENTER> key will cause the system to accept
any changes. The [A], UNDO, option can be selected at any time up until the <ENTER> key is
pressed.

Aug 27/99 Shutdowns & Alarms 8:30 AM

[1] 20% LEL Alarm 20%

[2] Low Suct Stg 1 Pres - Alarm 1100kpa
[3] High Disch Stg 1 (2, 4) Pres 4830kpa
[4] High Disch Stg 1 (2, 4) Pres 4750kpa

[F] Next Page [E] Exit

Figure 3–28
Shutdown and Alarms Screen

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Aug 27/99 Shutdowns & Alarms 8:30 AM

[1] 20% LEL Alarm 22 20%

[2] Low Suct Stg 1 Pres - Alarm 1100kpa
[3] High Disch Stg 1 (2, 4) Pres 4830kpa
[4] High Disch Stg 1 (2, 4) Pres 4750kpa
[E] Enter [B] Backup [F] Forward
[C] Clear [A] Undo [D] Decimal

Figure 3–29
Changing Settings Screen

Typical Timers and Settings Parameters

[1] Shutdowns & Alarms - This is a sample of the setpoints for the analog inputs
[1] 20% LEL Alarm 20%
[2] Low Suct Stg 1 Pres - Alarm 1100kpa
[3] High Disch Stg 1 (2,4) Pres 4830kpa
[4] High Disch Stg 1 (2,4) Pres - Alarm 4750kpa
[5] High Disch Stg 2 (1,3) Pres 9300kpa
[6] High Eng Oil Temp - Alarm 100C
[7] High Disch Stg 2 (1,3) Pres - Alarm 9200kpa
[8] High Eng JW Out Temp 99C
[9] High Disch Stg 1(2) Temp 160C
[A] UV Fire Detection 49.0

[2] Prelube Settings - These settings control the Prelube Cycle

[1] Engine Prelube 20.0 Sec - Set to Zero for No Prelube
[2] Engine Prelube Press 3.0 psi - Set to Zero for No Pressure
Test
[3] Comp Prelube Time 20.0 Sec - Set to Zero for No Prelube
[3] Comp Prelube Press 10.0 psi - Set to Zero for No Pressure
Test
[3] Crank Settings
[1] Crank On Time 14.0 Sec - The Engine will Crank for this
Time
[2] Crank Off Time 4.0 Sec - The Time between Cranks
[3] Crank Time Out 120.0 Sec - Quits Crank Sequence after
this time
[4] Crank Cut Out 200 RPM - Cuts out the Crank Solenoid
[4] Warm Up
[1] Min Time 30.0 Sec - Minimum Warm Up Time
[2] Maximum Time 600.0 Sec - Maximum Warm Up Time
[3] JW Temperature 150 F - Temperature Permissible

[5] Post Lube

[1] Eng Post Lube 10.0 Sec - Set to zero for no Post Lube
[2] Comp Post Lube 0.0 Sec - Set to zero for no Post Lube

[6] Blow Case - Blow Case Control Parameters

[1] BC Drain Delay 4.0 Sec
[2] Blow Time 120.0 Sec
[3] BC Fill Delay 2.0 Sec

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[7] Purge Timers
[1] Start Purge 2.0 Sec - Delay before turning on fuel
[2] Stop Purge 0.0 Sec - Delay before turning off ignition

[9] Load Settings

[1] Minimum Load RPM 1200 RPM - RPM will never go below this
speed while loaded

3.7 Entering Alphabetical Data with the 21-Key Keyboard

Software Version 11.07F5 and Earlier

3.7.1 Key Functions

When the computer asks for a name or other non-programmed data, the functions of some
keys change to the following:
Key Action
1 change to next character in the list
2 change to previous character in the list
3 toggle between upper and lower case
4 insert a capital J (half way in the character string)
F move the cursor forward one position
B move the cursor back one position
C clear the entire line
D delete the current character
A insert a space
E enter the changes made

(There may be a menu set at the bottom of the screen to help with this process, but it will not
show all these keys.)

3.7.2 The Character List

When entering characters, typing them will not work, and they are not all available on the
keyboard. Instead, you must use a special keyboard process.
When you press the [1] or [2] keys, the current character will change up or down in the
following continuous sequence:

(space)!”#$%&*+,-./0123456789:;< = >? @
ABCDEFGHIJKLMNOPQRSTUVWXYZ[ ]^_’
abcdefghijklmnopqrstuvwxyz
3.7.3 Example of a Name Entry
(a) When the computer is asking for a name, the cursor will be flashing at the entry point
(current character comes after).

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(b) Use the [1] key to scroll up to the character you want (holding it down will scroll
rapidly through the list; pressing it momentarily will advance one-at-a-time through
the list).
Use the [2] key to scroll the other way if you go past the one you want.
Use the [3] to change the current character from upper to lower case or back again (it
toggles with each keystroke), or alternatively scroll to the character you want using
[1] or [2].
Use the [4] key to immediately go to a capital J, about ½ way through the list.
(c) When you have the character you want, use the [F] key to move to the next character
(the [B] key will take you back one character if you miss or want to go back).
(d) When you get to the end of the word, press [A] to insert a space, then continue with
the next character.
(e) The [C] will clear the current line if you get messed up, and the [D] key will delete the
current character only.
(f) When the name is correct, push [E] to enter the name into the computer.

3.8 Entering Alphabetical Data with the 21-Key Keyboard

Software Version 11.07F6 and Later
The 21-key keyboard makes it easy to enter numerical data when requested by the computer
by simply pressing the numbers.
Occasionally while you work with the menus, you will be asked to enter names or data which
is not just numerical. Entering alphabetical data, is slightly more complicated since each
character has to be entered and adjusted separately.
The Custom Name screen (Figure 3–30) will appear to let you do this. This Section shows
how to proceed with entering names, etc., using the 21-key keyboard.

Jan 20/99 1 Custom Name 10:00 AM

Ignition

1ABC 2DEF 3GHI 4JKL 5MNO 6PQR 7STU 8VWX

9YZ# F:Fw B:Bk A:In I:Up J:Dn K:Cap D:el

Figure 3–30
Name Screen

3.8.1 The Character List

When entering characters, typing them directly will not work, and they are not all available
anyway. Instead, you must use a special keyboard process.
When you press the <1> to <9> keys, the current character will cycle through the four
characters shown at the bottom of the name menu for each key. For Example <2> scrolls
through 2DEF.

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If you press <I>, the current character will scroll through the following list in sequence each
time the key is pressed. Pressing <J> scrolls the list in a reverse direction.

(space)!”#$%&*+,-./0123456789:;< = >? @
ABCDEFGHIJKLMNOPQRSTUVWXYZ[ ]^_’
abcdefghijklmnopqrstuvwxyz
When you have the character you want, use the <F> key to move to the next character. The
<B> key will take you back one character if you miss one or want to go back.
The <D> key will delete the current character.
The <K> key toggles all future characters between an upper and a lower case (capital and
small) letter or symbol.

3.8.2 Example of a Name Entry

(a) When the computer is asking for a name, the cursor will be flashing at the entry point
(current character).
(b) Use the appropriate <1> through <9> key to scroll up to the first character you want.
Or you could scroll through the entire list using <I> (holding it down will scroll
rapidly through the list; pressing it momentarily will advance one-at-a-time through
the list).
Use the <J> key to scroll the other way if you go past the one you want.
Use the <K> to change the current character (and those entered later) from upper to
lower case or back again (it toggles with each keystroke), or alternatively scroll to the
character you want.
(c) When you have the character you want, use the <F> key to move to the next character
(the <B> key will take you back one character if you miss or want to go back).
(d) When you get to the end of the word, press <A> to insert a space, then continue with
the next character.
(e) The <C> will clear the current line if you get messed up, and the <D> key will delete
the current character only.
(f) When the name is correct, press <E> to enter the name into the computer and revert to
the previous menu.

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 Chapter
Series XI Control Panel
4 Operations Guide BY ALTRONIC

Control Sequences
This chapter is designed to provide the operator with knowledge of
the control sequences that are programmed into the Series XI
Control Panel.
Some changes to the sequences in this Chapter will occur,
depending on the programming of the individual panel; however,
the typical sequencing for a typical panel is included.
Information in this chapter includes:
Engine-Driven Reciprocating Compressor
• typical startup sequence
• typical shutdown sequence
• subroutines
– auto slowdown
– manifold pressure override
– remote idle
– engine jacket water/oil temperature override.
Typical Engine-Driven Screw Unit—Control Sequence Changes
Typical Electric Drive—Control Sequence Changes

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4. Control Sequences
The Series XI Control system is used to monitor, control, and protect the drive and compressor
package. All shutdowns, alarms, startup and shutdown sequences, as well as speed, bypass,
and suction control are performed by the control system. This includes prelube sequence, auto
crank sequence, engine warm up, loading, auto cooldown, and automatic depressurization on
shutdown.

ª Password protected adjustable timers and analog settings are accessible from the <TIMERS AND
SETTINGS> key (See Chapters 3 and 5). This allows easy access to the various timers and
Chapter 3 settings for changing most parameters.
describes the
basic operation
and Chapter 5 4.1 Typical Engine-Driven Reciprocating Unit—
provides details
on setting Control Sequences
parameters.
4.1.1 Typical Start-Up Sequence
Any time the unit is shutdown (either due to a shutdown, or pushing the <STOP> or
2 <AUTO STOP> key, or receiving a remote shutdown or stop command) the system goes to
State 1–Shutdown.

State 0–Initializing
(1) Power is switched to ON.
(2) The Series XI Controller:
(a) records the power loss
(b) initializes I/O boards (software Versions 11.07F6 and earlier)
(c) switches ESD TEST subroutine to ON
(d) switches PID’s for louvre control to ON (if applicable).
(3) Advances to State 1.
(4) The ESD TEST subroutine monitors the fire, gas and H2S detection systems, and the
ESD pushbuttons.
If any of these are tripped, the controller stops the unit, opens the blowdown valve,
and closes the block valves.

State 1–Shutdown
(1) The controller immediately switches all the discrete outputs, except the ignition and
blowdown valve, to OFF.
(2) Turns the ignition OFF after the STOP PURGE TIMER elapses (typically 3 Seconds).
(3) Forces the analog (variable) outputs to a value of ‘0’ which effectively:
(a) closes the suction valve
(b) opens the bypass valve
(c) forces the governor to minimum speed (providing the governor is set up
properly).
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(4) Turns all the PID control loops, except the louvre controls, to OFF.
(5) Activates the logic for separator and scrubber dump control.
(6) Turns output OFF for suction and discharge block valves (they close).
(7) Uses an AUTO BLOWDOWN routine to open the blowdown valve until the discharge
pressure is below MAXIMUM START PRESSURE.
(8) Switches the BEACONS AND FANS subroutine to ON.
This activates the beacons whenever fire, gas or H2S detection alarms, and turns the
exhaust fan ON whenever gas or H2S detection alarms. If the alarm condition clears,
the beacons and exhaust fan is deactivated.
(9) Checks to see if POST LUBE SEQUENCE is active.
If so, continues to energize the post lube timers; if not, de-energizes post lube pumps.
(10) Waits for the <RESET> key to be pressed and no shutdowns to be active; then proceeds
to State 2.
Any time there are active shutdowns; the LED beside the <RESET> key will be
flashing. (Clear the shutdown cause, press <ENTER> to get to Run Mode, then
<RESET> to get to State 2.)
(11) Turns output for blowdown valve ON (it closes).

State 2–OK to Start Compressor

(1) LED beside <RESET> key is OFF.
(2) Message OK TO START COMPRESSOR is displayed.
(3) To start the unit, push the <Start> key.
(4) A choice of [1], AUTO START, [2], MANUAL START, or [3], EXIT, will be displayed.
Typically the AUTO START is selected; however, if MANUAL START is selected, the
operator will have to manually push the <Crank> key, once the unit is ready to crank
(explained in more detail later).
(4) As soon as option [1], AUTO START, or [2], MANUAL START is made, advances to the
State 3.

State 3–Pressurize/Depressurize (Optional)

R (1) The controller opens the main suction ESD valve.
(2) Typically the blowdown valve and purge valves are used to either depressurize or
pressurize the unit.
(3) If the discharge pressure is above MAXIMUM START PRESSURE, the discharge block
valve is closed, the suction control valve is closed (after 10 seconds), and the
blowdown valve opens until the discharge pressure is below MAXIMUM START
PRESSURE.
(4) If the discharge pressure is below MINIMUM START PRESSURE, the purge valves and
blowdown valve are opened for 120 seconds. After 120 seconds, the blowdown valve
is closed. Waits for discharge pressure to get above MINIMUM START PRESSURE, then
closes the purge valves.

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(6) Waits until the discharge pressure is above MINIMUM START PRESSURE and below
MAXIMUM START PRESSURE, then opens the discharge block valve.
(7) If this is not achieved within 600 seconds, returns to State 1.
(8) Advances to State 4.

State 4–Prelubing
(1) The controller energizes the engine and compressor prelube pumps.
(2) Both pumps run for a minimum of the MINIMUM PRELUBE TIME (typically 10 seconds).
(3) Waits for the engine oil pressure to be greater than ENGINE OIL PERM
(typically 5 kPa) and the compressor oil pressure to be greater than COMPRESSOR OIL
PERM (typically 21 kPa).
(4) If this is not achieved within the PRELUBE FAIL TIME (120 seconds), returns to State 1.
(5) Advances to the State 5.

State 5–OK to Crank

If [2] MANUAL CRANK was chosen in State 2:
(1) The controller waits for the <CRANK> key to be pressed.
The Crank button is a momentary switch so as soon as it is released the crank solenoid
will be turned off.
(2) The operator has the ability to manually determine the CRANK ON TIME and TIME
BETWEEN CRANKS, and the MESSAGE OK TO CRANK is displayed, but otherwise the
same sequence as [1], AUTO START in the following is used.
If [1], AUTO START was chosen in State 2:
(1) Energize the Crank Failure Timer (typically 120 Seconds)
(2) Initiate the AUTO CRANK SEQUENCE:
(a) show message AUTO CRANK SEQUENCE
(b) energize the crank solenoid
(c) wait for 20 RPM; then go to State 6.
If this does not happen within the CRANK FAILURE TIME, de-energize crank
solenoid and go back to State 1.

State 6–Engine Cranking and Fuel

(1) Energize the ignition.
(2) After the FUEL DELAY TIMER has expired (typically 3 seconds) energize the fuel gas
solenoid.
The fuel gas solenoid gets energized when the speed is above 50 RPM and de-
energized when the speed is less than 30 RPM.
(3) Crank the engine for the CRANK ON TIME (typically 30 seconds).
If the engine does not start; de-energize the crank solenoid for the TIME BETWEEN
CRANKS (typically 5 seconds).

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(4) Continue this cycle until the CRANK FAILURE TIME (typically 120 seconds) is exceeded
(returns to State 1) or until the unit starts (continues).
(5) Crank sequence remains energized until the speed exceeds the RPM CRANK CUT OUT
(typically 250 RPM).
(6) Once the engine speed exceeds the UNDERSPEED setpoint (typically 600 RPM) the
system advances to State 7.
The UNDERSPEED is configured in the speed setup, which can only be accessed while
in [1], PROGRAM MODE, under the <MENU> key.

State 7–Engine Warm Up Cycle

(1) The controller starts the MAXIMUM WARM UP TIMER (typically a minimum of 720
seconds).
(2) Activates Run Status and locks off the <CRANK> key.
(3) Waits for the MINIMUM WARM UP TIMER (typically 30 seconds) to expire, and then
waits for the engine JW temperature to exceed the WARM UP TEMPERATURE (typically
60°C).
At this time, energizes a SUCTION STARTUP PID (low setpoint) to ensure minimal
suction pressure is maintained.
(4) Once both the minimum time and temperature have been achieved, starts to load up
the unit in State 8.
If the WARM UP TEMPERATURE has not been achieved within the period of the MAXIMUM
WARM UP TIMER, advance to State 8.
This warm up delay is to allow sufficient warm up time, but the maximum time is
limited to allow for very cold temperatures, where an unloaded unit may never reach
the WARM UP TEMPERATURE. In some programs this is disabled to ensure adequate
warm up gets completed.

State 8–Compressor Running

(1) Locks off <PURGE> AND <CRANK> keys, energizes logic for MANIFOLD PRESSURE
OVERRIDE (optional) and arms the POST LUBE SEQUENCE.
(2) Assuming all the PID controllers are in Auto Mode, the unit will start to load.
If in Manual mode the operator must manually ramp engine speed.
(3) Displays message RAMPING SPEED.
(4) The controller, first ramps up the engine speed to MINIMUM LOAD RPM (typically
1000 RPM on a 1200 RPM rated engine).
This is done by energizing a SPEED RAMP PID with a setpoint high enough to ramp up
the speed over the MINIMUM LOAD RPM. This PID typically has a low gain and no
derivative to gradually ramp up the speed.

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(5) Once the MINIMUM LOAD RPM is achieved:

(a) de-energize SPEED PID
(b) energize SUCTION CONTROL PID

R (c) energize MANIFOLD PRESSURE OVERRIDE PID (optional)

(c) energize MASTER PID
(d) de-energize SUCTION STARTUP PID.
(6) The SUCTION CONTROL PID has a built in ramp to gradually ramp the setpoint from the
current suction pressure to the setpoint in the PID.
This only occurs when the PID is first switched to ON. The time period for this ramp
is usually 2 minutes.
(7) The MASTER PID is set up so that as long as the suction pressure is above the SUCTION
PRESSURE OVERRIDE and the final discharge pressure is below the DISCHARGE
PRESSURE OVERRIDE the unit controller gradually closes the bypass valve, and ramps
the speed up to full-rated RPM.
(8) Once the bypass valve is 100% closed, the MASTER PID adds an offset value to the
DISCHARGE PRESSURE OVERRIDE and subtracts an offset value from the SUCTION
PRESSURE OVERRIDE only on the Bypass PID.
This is to prevent the SPEED PID and the BYPASS PID from fighting each other.
(9) If a shutdown occurs, returns to State 1.
(10) Both the pressure overrides are adjustable from the <MASTER LOAD CONTROL> key.
This is explained in detail in Appendix A.

Startup Notes:

- Ensure suction control valve setpoint is a minimum of 50 kPa

higher than the MASTER PID suction pressure setpoint.

- MASTER PID suction setpoint MUST be lower than suction control

valve setpoint at all times for unit to load.

- Recommended minimum 10% difference between the two

setpoints.

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4.1.2 Typical Shutdown Sequence

The Series XI Controller has the conventional Class A, B, and C shutdowns. Class A
shutdowns are always active. Class B shutdowns get activated after the unit is up and running
and the Class B timer has expired (typically 120 seconds). Class C shutdowns are only active
once the initial setpoint has cleared; for example, the Low Suction Pressure shutdown
becomes active once the suction pressure climbs above the setpoint. In the Series XI
controller, Class C shutdowns can also have an overriding timer, such that if the value does not
exceed the shutdown setpoint within a certain time, the timer will activate the alarm or
shutdown.
The sequence for a shutdown is as follows:
(1) Any time the unit is shutdown due to a logic triggered shutdown, or by someone
pushing the < STOP> or <AUTO COOLDOWN> keys, the system goes to State 1, the
Shutdown State.
(2) The controller switches all the discrete outputs to OFF immediately, except the ignition
and the blowdown valve.
The ignition is deactivated after the STOP PURGE TIMER has elapsed.
(3) Forces the analog (variable) outputs to a value of zero.
This effectively closes the suction valve, opens the bypass valve, and forces the
governor to minimum speed (providing the governor is set up properly).
(4) Deactivates all the PID control loops except the louvre controls.
(5) Uses an AUTO BLOWDOWN routine to open the blowdown valve until the suction
pressure is below the MAXIMUM START PRESSURE.
(6) Initiates a postlube sequence if the unit was in the loading or run state.
This sequence turns on the lube pumps until the POST LUBE TIMER has expired
(typically 120 seconds).
Under the <TIMERS AND SETTINGS> key, the operator can adjust the POST LUBE TIMER from the
Post Lube menu, the STOP PURGE TIMER from the Purge Timers menu, and the MAXIMUM START
PRESSURE from the Start Pressures menu.

4.1.3 Subroutines

Auto Slowdown
The Auto Slowdown sequence is used to gradually unload the compressor package and let it
run unloaded for several minutes before shutting down the package. It is initiated by pushing
the <AUTO SLOWDOWN> key and answering [1], YES, when the controller asks if you want to
perform the action. The controller performs the following actions when the AUTO SLOWDOWN
is initiated:
(1) Switches the MASTER PID to OFF.
(2) Ramps down the speed to MINIMUM LOAD RPM.
(3) Gradually opens the bypass valve.
(4) Gradually closes the suction valve.

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(5) Once the bypass valve is fully open and the suction valve is fully closed, the controller
slows the engine down to idle speed.
(6) Waits for approximately 3 minutes and then shuts down the unit (refer to Section
4.1.2, above).

R Manifold Pressure Override

The MANIFOLD PRESSURE OVERRIDE sequence uses the suction control valve to control
manifold pressure.
On a V-type engine, there are both Left and Right MANIFOLD PRESSURE OVERRIDE PIDs. Four
setpoints are used: LEFT MANIFOLD PRESSURE OVERRIDE On; LEFT MANIFOLD PRESSURE
OVERRIDE Off; RIGHT MANIFOLD PRESSURE OVERRIDE On, and; RIGHT MANIFOLD PRESSURE
OVERRIDE Off. These are all adjusted from the Manifold Overrides menu under the <TIMERS
AND SETTINGS> key.

The control setpoint for these MANIFOLD PRESSURE OVERRIDE PID’s are usually set very close
or equal to the MANIFOLD PRESSURE OVERRIDE On setpoints. This prevents cycling back and
forth between suction pressure control and manifold pressure control. On an inline engine
there is only one MANIFOLD PRESSURE OVERRIDE PID and two corresponding setpoints.
The controller performs the following actions:
(1) Whenever the left or right manifold pressure exceeds the MANIFOLD PRESSURE
OVERRIDE On setpoint, the controller deactivates the main suction PID and activates
either the Right or Left MANIFOLD PRESSURE OVERRIDE PID, depending which of the
manifold pressures exceeded the setpoint.
(2) A message will appear on the display stating either Left or Right MANIFOLD OVERRIDE,
depending which override is active.
(3) When the manifold pressure drops below the MANIFOLD PRESSURE OVERRIDE Off
setpoint for the corresponding MANIFOLD PRESSURE OVERRIDE PID, the controller
deactivates the MANIFOLD PRESSURE OVERRIDE PID (right or left) and activates the
SUCTION CONTROL PID.
R Remote Idle
The REMOTE IDLE sequence is used to gradually unload the compressor package and let in run
unloaded (on full bypass) until the REMOTE IDLE is turned off. The unit will gradually load up
and go back to normal operating condition when the REMOTE IDLE is turned off. The REMOTE
IDLE sequence is initiated remotely via the RS485 using the Modbus RTU protocol.
The controller performs the following actions when the REMOTE IDLE is initiated:
(1) Deactivates the MASTER PID control.
(2) Ramps the speed down to MINIMUM LOAD RPM.
(3) Gradually opens the bypass valve.
(4) Gradually closes the suction valve.

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(5) Once the bypass valve is fully open and the suction valve is fully closed, slows the
engine to idle speed.
(6) Waits until the REMOTE IDLE is deactivated and then essentially reverses the REMOTE
IDLE process to load the engine up again.
This involves ramping the speed up to the MINIMUM LOAD RPM, activating the MASTER
CONTROL PID (closes the bypass valve and ramps the engine speed to FULL RPM
unless a suction or discharge override exists), and turning on the SUCTION CONTROL
PID.

Engine Jacket Water/Oil Temperature Override and the Blowdown Valve

R This sequence is used in some remote locations to automatically reduce the engine speed when
the engine jacket water or oil temperature exceeds the JW TEMP HIGH or ENG OIL TEMP HIGH
setpoints respectively.
The controller performs the following actions:
(1) If one of the above setpoints is exceeded the controller puts the SPEED CONTROL PID
in MANUAL and use a separate PID to reduce the engine speed to 1100 RPM (unless the
engine speed is already less than 1100 RPM).
(2) Waits for 5 minutes and checks the engine JW and oil temperature again.
(3) If either one is still above its respective setpoint, reduces the engine speed to
1000 RPM.
(4) Five minutes later, checks the engine JW and oil temperature again, and if they are
below the high setpoints, the unit will continue to run at 1000 RPM until both the
temperatures are below the JW TEMP LOW or ENG OIL TEMP LOW setpoints
respectively.
(5) If the either temperature exceeds the high setpoints at any time after the five minutes
in Step (4) has expired, initiates an AUTO SLOWDOWN sequence.
To ramp the unit back up to full speed, the controller essentially reverses the above process:
(1) When the temperatures are below the JW TEMP HIGH or ENG OIL TEMP HIGH setpoints
respectively, the controller first checks the engine speed.
(2) If the speed is already above 1050 RPM, deactivates the JW/OIL TEMPERATURE
OVERRIDE and puts the speed control back into AUTO.
The MASTER PID now takes over the speed control and ramps it up to full speed
(unless a suction or discharge override exists).
(4) If the engine speed is below 1050 RPM, the controller ramps the speed up to
1100 RPM, waits 5 minutes, and monitors the temperatures.
As long as they both remain below the setpoints, deactivates the JW/OIL TEMPERATURE
OVERRIDE and puts the SPEED CONTROL PID back into AUTO.
The MASTER PID now takes over the speed control and ramps it up to full speed
(unless a suction or discharge override exists).

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4.2 Typical Engine-Driven Screw Unit—

Control Sequence Changes
With screw-type compressors, the most noticeable difference is in the load/unload sequences.
The slide valve is forced to <10% before a start sequence is allowed.
During the start up sequence, typically the bypass valve is forced closed in the warm up state.
After the engine is warmed up, the controller proceeds to the COMPRESSOR RUNNING state.
During the LOADING sequence, the slide valve is ramped to a fully loaded position, the speed is
ramped to full RPM, and the bypasss valve is kept in the closed position.
In the override condition, one of these unload sequences will occur:
• Unload slide valve, ramp speed down to MINIMUM LOAD RPM, and open the bypass
valve.
• Ramp speed down to MINIMUM LOAD RPM, unload the slide valve, and open the
bypass valve.

4.3 Typical Electric Drive—Control Sequence

Changes
With an electric drive, the load/unload sequence is simplified dramatically. In the load
sequence, the slide valve is forced to <10% before a start sequence is allowed (if applicable).
The prelube, cranking, and warm up states are all removed.
As soon as the <Start> key is pressed, the controller displays a message PERFORM ACTION [1],
YES, [2], NO. If [1], YES, is chosen, the controller sends a signal to the MCC to start the drive
motor. Once the motor is started, the load sequence is initiated in similar fashion to an engine
drive.
During a shutdown, the motor contacts are opened, the bypass valve is opened, the postlube
sequence is initiated (if applicable) and (in a screw compressor) the slide valve is unloaded.

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 Chapter
Series XI Control Panel
5 Operations Guide BY ALTRONIC

Setting System Parameters

This chapter is designed to provide the operator with information
about setting up the Series XI Control Panel.
Information in this chapter includes:
• test mode
• shutdowns and alarms
• changing passwords
• controlling unit variables (PIDs).

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5.1 Test Mode

Test Mode is used to check shutdowns with the compressor running. One or more shutdowns
can be under test at any time. When a shutdown is in Test Mode it is still possible to move
around the various screens, adjust setpoints, manually adjust the engine speed, and so on.
When Test Mode is activated, a COUNT DOWN TIMER starts at 1200 seconds (20 minutes) and
counts down until it reaches zero. If this timer reaches zero, all shutdowns in Test Mode will
revert to normal operation.
When any shutdowns are under test, the main Run Mode screen of the controller will display
TEST MODE instead of RUN MODE, as shown in Figure 5–1. As mentioned above, a resettable
COUNT DOWN TIMER is shown where the time of day is normally displayed. This display
shows the amount of time left before the current shutdowns under test are reactivated. If any
2 shutdowns are still faulty when the timer reaches zero the compressor will shut down.
The timer can be extended back to 1200 seconds (20 minutes) at any time by selecting [G],
RESET, from the screen shown in Figure 5–3.

J un 23/ 99 Te st Mod e 550 Sec

L ow E ngi ne O il Le vel Wh ile R unn ing

Suct ion D is ch( 1) Dis ch (2) RPM

1047 kpa 2 41 1kp a 778 7k pa 11 5 6

J W Ou t Gas F ire V olt s Ma nif Ho u r

87C 0% 4 .0m a 24V 23 ”hg 18 5 0

Figure 5–1
Main Run Mode Screen with Test Mode Active
F Status
Inputs
(a) Select a shutdown by choosing AND OF OPTIONS [1-4], SHUTDOWNS, ALARMS, FAULTS
AND SHUTDOWN LIST, under the <STATUS> OR <INPUTS> key.
F Inputs
(See Section 3.6 page 14 for details on the <STATUS> key.)
I Up (b) When this option is chosen, the controller shows a list of up to four shutdowns or
alarms. Use the <Up> and <Down> keys on the keyboard to show more.
J Down
(c) Select the number beside the desired shutdown to display the detail screen.
(d) Choose [1], TEST, to switch the selected shutdown to Test Mode.

Dev Type Class Mode Wired Delay Chann

7 Analog A HH NC 2.0 2103
Discharge Pressure High PT-204

Status: Healthy Value: 596kpa

Delay: 2.0 Set Point: 2172kpa

[1] Test [K] Menu

Figure 5–2
Shutdown Detail (Not in Test Mode)

1 (e) If [1], TEST, is chosen, the controller will ask OK TO GO INTO TEST MODE, [1], YES, or
[2], NO.
2
(f) Choose [1], YES to switch the current shutdown into Test Mode.

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1
(g) If the shutdown is an analog input the Computer will ask FREEZE ANALOG INPUT: [1]
YES or [2] NO. Answering Yes will cause the analog input to be frozen at the current
2 value.
The controller will now show the COUNT DOWN TIMER as shown in Figure 5–3. It is
now possible to move to the next shutdown and place it into Test Mode. Only those
shutdowns with the COUNT DOWN TIMER shown are in Test Mode.

Dev Type Class Mode Wired Delay Chann

7 Analog A HH NC 2.0 2103
Discharge Pressure High PT-204
Count
Down Status: Healthy Value: 596kpa
Delay: 2.0 Set Point: 2172kpa
Timer Test: 1191
[1] Test [2] Reset [K] Menu

Figure 5–3
Shutdown in Test Mode
1 (h) To exit out of Test Mode choose [1], TEST, and answer [1], YES.
Do this for each shutdown until none of them display the COUNT DOWN TIMER.
Alternately, wait until the timer counts down to zero.

CAUTION

Placing shutdowns in Test Mode in effect disables the shutdown.

Do not Leave a shutdown in Test Mode on an unattended unit,

and remember to monitor the shutdowns’ conditions
when they are in Test Mode.

5.2 Shutdowns and Alarms

One of the main functions of the control system is to perform shutdowns and alarms. The
Series XI Controller uses standard A, B, C, D and E Classifications, with individual timers
that include a programmable default setting on all Class B shutdowns and alarms. In addition,
a delay can be added to the shutdown or alarm to debounce and eliminate nuisance shutdowns.
An unlimited number of shutdowns and alarms can be added on any channel, which includes
the normal High and Low Shutdowns and Alarms, plus Differentials, Time Delayed
Shutdowns, and Calculated Shutdowns. An example of a calculated shutdown would be to
calculate the dewpoint of acid gas, and then shutdown and purge the unit if the gas
temperature ever goes below the dewpoint curve.

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The controller annunciates the “First In Shutdown” and lists all other shutdowns and alarms
which must be acknowledged and reset by the operator by pressing <RESET>. The controller
also records the date and time when any shutdown or alarm occurs, and stores this for future
reference. In addition, the controller takes a snap shot of all the temperatures, pressures and
other signals at the moment when a first in shutdown occurs. The controller records these
values for forty intervals before the shutdown occurs, usually one second apart, in order to give
a true picture of the shutdown cause. If a compressor stalls, it is desirable to go back in time
to find the real cause.
The following describes some of terminology used:
Type: This refers to the source type of the shutdown or alarm.
• Discrete Discrete input
• Analog Analog input
• Differential Difference between two analog inputs
• Calculated Calculated from one or more inputs (special calculations
programmed in C code)
Mode: Selects either Shutdown or Alarm plus High or Low.
• High High (HH) High Shutdown
• High (H) High Alarm
• Low (L) Low Alarm
• Low Low (LL) Low Shutdown
Class: Controls how the shutdown is armed or reset.
Class A Enabled at all times; for example, low engine jacket water
level. Resets with the <RESET> key after condition cleared.
Class B Enabled after the bypass timer times out following a start
sequence; for example, engine oil pressure, which takes a
certain amount of time to build up. Resets with the <RESET>
key after condition cleared.
Class C Enabled after the input point is initially satisfied following a
start sequence. An example is low suction pressure. It must
increase above its shutdown setpoint before it is armed.
Resets with the <RESET> key after condition cleared. A
maximum timer can also be programmed to shut down/alarm
if the condition is not cleared at the end of the timed period.
Class D Must be satisfied to start. Bypassed after start during normal
operation.
Class E Must be satisfied to start, but is bypassed for a timed period
after start.
Class Timer: Classes B, C and E have an arming delay timer.
Delay Timer: Debounce delay time. The amount of time after a
change from healthy to faulty or faulty to healthy before
being recognized.
Wired NC/NO: Discrete devices can be connected with their contacts
normally closed or normally open.

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Channel: The I/O channel associated with the input. Two channels are
required for differentials.

Setpoint: Used by analogs, differentials and calculated shutdowns to

determine the shutdown or alarm point.

Status: Either Healthy or Faulty

5.3 Changing Passwords

System access to specific functions and menu selections is password-protected.
On startup, whenever the operator requests a change, or if the PROGRAM MODE is entered, a
password will be requested.
Three levels of password are available:
Level 3 permits viewing only.
Level 2 permits changing basic setpoints commonly adjusted in the field.
Level 1 allows full access to setpoints, calibrations, programming, etc.
The Level 1 password allows access to set up Level 2 and Level 3 passwords.
Passwords are set under the PROGRAM MODE. When the PROGRAM MODE is entered, a screen
will come up asking for a password to proceed. Enter your password (must be Level 1) to
access PROGRAM MODE. If you want to change/setup passwords, use the following procedure.
If the password is forgotten or a technician needs a temporary password for diagnostics, a one-
time password may be obtained by choosing [K], MENU, then [1], PROGRAM MODE, and
recording the number displayed on the screen. Phone Altronic Controls or your authorized
Exacta integrator with the access number and the technician will give you a one-time password
for Level 1, 2 or 3.
To change passwords:
K Menu
(a) Press [K], MENU.
1
(b) Choose [1], PROGRAM MODE.
2 (c) Choose [2], SET UP MENU.

6 (d) Choose [3], CHANGE PASSWORD.

The controller will ask, CHANGE PASSWORD, [1], YES or [2], NO.
1
(e) Answer [1], YES, and the controller will ask if ARE YOU SURE, [1], YES or [2], NO.
1 (f) Answer [1], YES, again.

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5.4 Controlling Unit Variables (PIDs)

This section describes the method used to control unit variables (called “process variables”) at
their control setpoint. See Section 3.6 if you want to change settings, display information, etc.

5.4.1 Process Control Theory

There are three basic elements to any process control system (called “control loop”):
• process variable
• control variable
• control setpoint.
The variable that we want to control is called the “process variable”. It is the input to the
control loop; for example, the unit suction pressure.
The variable that we use to control the process variable is called the “control variable”. It is
the output from the control loop; for example, the inlet control valve position.
By changing the control variable (inlet control valve position) we will see a change in the
measured process variable (unit suction pressure). Opening the valve further will increase the
unit suction pressure; closing it will decrease the unit suction pressure.
The actual value at which the control loop attempts to control the process variable is called the
“control setpoint”. The control setpoint is entered into the control panel and remains at the
entered value until it is changed manually by an operator.
For example, if we want the unit suction pressure to be controlled at a value of 1400 kPa, the
control setpoint is entered as 1400 kPa.
When the process variable is not at the control setpoint, the control loop will change the
control variable until the process variable is at the control setpoint.
If the process variable is at the control setpoint, the control variable remains constant at its last
value.
A control loop uses proportional-integral-derivative (PID) control logic to change the control
variable in response to changes in the process variable or control setpoint.

5.4.2 PID Control Theory

PID control continuously compares the process variable to the control setpoint and calculates
an “error” value:

Error = Process Variable – Control Setpoint

The error is used to calculate the value of the “control variable”.
The control variable is made up of three components:

Control Variable = Proportional Control + Integral Control + Derivative Control

PID control is developed from complex mathematics. Full explanation is beyond the scope of
this manual, but the theory can be simplified, as in the following subsections.

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Proportional Control
The proportional component of the control variable is the main output of PID control. It
calculates an output amount that is proportional to the error. The larger the error, the larger
the proportional component will be, in an attempt to make the process variable equal to the
control setpoint. Proportional control alone cannot eliminate all of the error.

Integral Control
The integral control component is proportional to both the error and the length of time the error
exists. The larger the error and the longer the error exists, the larger the integral component
will be, in an attempt to make the process variable equal to the control setpoint.
The integral control component is used to eliminate all remaining error.

Derivative Control
The derivative control component is proportional to the rate of change of the error. The faster
the process variable moves away from the control setpoint, the larger the derivative control
component will be, in an attempt to quickly return the process variable to equal the control
setpoint.

5.4.3 Tuning PID Control

In PID control, there is a gain setting for each of the three types of control. Determining the
appropriate values for each of these gains is referred to as “tuning” a controller. With a
properly tuned PID controller, the process variable will be maintained at the control setpoint
during steady-state (normal) conditions. The PID controller will also react quickly to return
the process variable to the control setpoint when disturbances occur (such as sudden load
changes).
Refer to the Series XI Programming Guide for details.

CAUTION

It is recommended that all changes,

except adjusting the setpoints or output as described in Section 3,
be done by a qualified instrument technician.
Wrong settings can easily cause faulty operation or
unit malfunction/damage.

NOTE

When a Suction Control Valve is controlling suction pressure,

the Master PID acts as an override. In this case the setpoint
for the Master PID should always be lower than the setpoint for
the Suction Control Valve PID setpoint. Similarly if there is a
Discharge Back Pressure Control Valve
the Master PID setpoint should always be set higher
than the Discharge Control Valve PID setpoint.

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 Chapter
Series XI Control Panel
6 Operations Guide BY ALTRONIC

This Chapter provides the recommended procedure to calibrate

analog loops for the Series XI control panels. It gives an explanation
of the general operating and checking procedures, followed by
detailed procedures for each type of loop, including:
• 4 to 20 mA
• thermocouple
• RTD
• 0 to 5 V.
Special topics on adding an offset and using entered calibration
points are included at the end of the document.
The first step in this procedure is determining the software version.
Newer versions of software (Version 11.07E and higher) have an
improved (easier) calibration procedure, as defined in this document.
Older versions can use similar procedures, but the access to
calibration and key choices are slightly different, as defined in the
operating manual supplied with the unit.

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6.1 Determining the Software Version

See the notes on Page 1.
To determine which version of software is installed in your unit, use the following procedure:
K Menu (a) Press the <Menu> key, [K].
(b) Choose [6], Software Version.
The software version will be displayed.

6.2 Calibration Procedure

Analog end devices should be calibrated or checked periodically to guarantee accuracy and
reliability. Basically the Series XI requires two known points to calibrate any device. This
will require hand pumps, and a calibrated gauge to calibrate pressure inputs; and a
thermocouple simulator or RTD simulator to calibrate temperature inputs.
With pressures, the two calibration points are typically the zero and full span. With
temperatures, these two points usually are 0°C (32°F) and some higher point close to the
maximum operating temperature. (The temperatures can still go above and below these
values.)
There are six basic steps to a calibration:
1. Open and select a channel.
2. Freeze the input.
3. Check the jumpers.
4. Check the span settings.
5. Calibrate high and low ends.
6. Check loop and end device operation.
The subsequent sections provide procedures for each of these six steps.
A linear offset may be added to the calibration if the loop is off by a similar amount at both
the high and low points.
6.2.1 Opening Procedure
Use the following steps to start the calibration procedure.
F Status
Inputs
(a) From the Run Mode screen, press the [F], STATUS OR INPUTS, button.
F Inputs The Series XI will display the Input Menu screen (Figure 6–1).

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Mar 15/03 Status Menu 2:09 PM

[1] Shutdowns: 10 [5] Analog Inputs

[2] Alarms: 0 [6] Discrete Inputs
[3] Faults: 2 [7] Analog Outputs
[4] Shutdown List [8] Discrete Outputs

[E] Exit

Figure 6–1
Status Menu Screen

(b) Choose [5], ANALOG INPUTS.

The Series XI will display an Analog Inputs screen, similar to Figure 6–2.

Mar 15/03 Analog Inputs 4:24 PM

[1] Engine Oil Pressure 150kpa

[2] Engine Manifold Pressure 10.8inHg
[3] Gear Box Oil Pressure 35kpa
[4] Discharge Gas Temperatur 7C

[J] More [I] Previous [E] Exit

Figure 6–2
I Up Analog Inputs Screen
(c) Choose [I], UP or [J], DOWN to scroll through the inputs until the desired one is
J Down
displayed.
? (d) Choose the input desired by entering the number associated with the text.
The Series XI will ask for a technician level password (Figure 6–3).

Jun 11/99 SXI 11.07F3 12:09 PM

Access Number: 75770

Enter Password:

[E] Enter [C] Clear

Figure 6–3
Password Entry Screen
E
Enter (e) Type the password and press <ENTER/EXIT>.
Exit
The Series XI will display the Analog Inputs screen (Figure 6–4) for the input selected.

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Exacta Series XI Control Panel–Operations Guide Chapter 6—Calibration

Suction Pressure
In: 6012kpa [A] H: 10342 [D] 61754
ADC: 41024 [C] L: 0 [G] 12244
Name Class Mode SetP Stat
[1] Low Suction Pr C 0 LL 100 H
[2] Suction Pressu A SD H
[3] High Suction P - HH 6000 H
[9]CalMode[H]Tog ADC [J]Force[K]Offset

Figure 6–4
Analog Input (Calibration) Screen
This screen shows the current analog value in engineering units, with the ADC value
underneath, at the left-hand side of lines 2 and 3. The high and low span settings, in
both engineering units and ADC values, are on the right-hand side of lines 2 and 3. The
screen also shows the alarm and shutdown setpoints associated with the channel on lines
5, 6 and 7. (These can be chosen and adjusted from the calibration screen, but are not
part of calibration procedure). The choices on this screen are explained in the calibration
procedures which follow.
6.2.2 Freezing the Input

CAUTION

Forcing an input disables the protection

provided by the control system.
It is the technician’s responsibility to always monitor the unit
for safe values, until forcing is removed.
During calibration, to avoid entering alarms or shutting down the unit, the technician would
normally freeze the input being calibrated. Use the following procedure to do this:
J (a) Choose [J] to force the input.
The Series XI will display the upcoming forced value and ask if you want to FORCE
2 INPUT? ‘Forcing’ an input will put all alarms, shutdowns, PIDs, and
programming into a bypassed mode.
1 (b) Choose [1], YES, to force the input or [2], NO, to return to the Analog Inputs screen
2 chosen in Section 6.1 without freezing the input.
(c) If you chose [1], YES, in the previous step, the Series XI will give you two choices.
1 Choose [1], FREEZE AT CURRENT VALUE, to freeze the input at the currently displayed
value.
2 Choose [2], FORCE A SPECIFIC VALUE, to force the input to a specific value by
E
Enter entering the value wanted and pressing <ENTER/EXIT>.
Exit

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Exacta Series XI Control Panel–Operations Guide Chapter 6—Calibration

(d) The Series XI will revert to the Analog Inputs screen chosen earlier, but the value will
remain frozen.
An indication of freezing is given by an “F” displayed at the top right of Line 1 and in
front of the value displayed in the Run Mode screens.
The calibration screen will continue to show the real values from the end device,
provided it is connected and operating.
(e) To remove the forcing, either:
Enter
E Exit
• power down and restart the panel
• exit out of the Analog Input screen chosen in Step (e) and the Series XI will
J
ask UNFREEZE INPUT? Choose [1], YES.
1 • choose [J] and the Series XI will ask UNFREEZE INPUT? Choose [1], YES.
6.2.3 Check Jumpers
Appropriate jumpers on the analog board need to be set for input devices to work properly.
Normally these would not require changing unless the device type changes (or someone
intentionally changes them). The jumpers are plastic push-on devices which connect
across two protruding pins. Table 6–1 and Figure 6–5 show the jumpers and settings for
the various types of inputs.

Table 6–1
Jumper Settings For CW1704-3 (or earlier)
Device Type Jumper Setting
Thermocouples Type J and K None
RTDs and Resistive None
4 to 20 mA and 0 to 20 mA 1 and 2
Voltage 2 and 3
Discrete None

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Exacta Series XI Control Panel–Operations Guide Chapter 6—Calibration

1 2 3

Jumper
(Shown in None Jumper Pin Orientation
Position)

Analog
Input
Wiring

Figure 6–5
Jumpers and Connections
6.2.4 Check Span Settings
Normally the span settings are preset during programming and would not require changing.
The settings are displayed on the Analog Input (Calibration) screen (Figure
6–4). If changes need to be made, use this procedure.
A (a) Choose [A] or [C] to select the high or low span setting, respectively.
C The chosen setting will have a flashing cursor over the engineering units.
(b) Type in the span setting desired (the cursor will indicate the next digit to be
E
Enter entered).
Exit
(c) Once the correct value is showing, press <ENTER/EXIT>.
1 For all non-zero numbers, the Series XI will ask you if THE VALUE IS [1], POSITIVE,
[2], NEGATIVE ? at the bottom of the screen.
2
(d) Make your choice and the screen will revert to the Analog Input (Calibration)
screen (Figure 6–4), using the new span setting.

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Exacta Series XI Control Panel–Operations Guide Chapter 6—Calibration

6.2.5 Calibrating

4 to 20 mA Channels
After selecting and freezing the input, and checking the jumpers and span settings (if necessary),
use the following procedure to calibrate a 4 to 20 mA channel.

NOTE
This procedure assumes correct operation of the end
device and field wiring. That is, the device output is
approximately 4 mA when the lower process value is
applied and 20 mA with the upper process value, and that
the device is linear.

This can be determined from the ADC values indicated on

the panel. The ADC value should be approximately 12 000
for a 4 mA signal and 62 000 for a 20 mA signal from the
transmitter. If the ADC values vary excessively, then a full
end-device calibration should be completed before
continuing with this calibration procedure.
(a) Isolate the end device from the process.
(b) Apply the lower span process value to the end device.
The screen should show the low span setting as the current value in engineering units.
(c) If not, choose [G] and the current ADC value will be inserted for the lower span ADC
G value.
(d) Connect an accurate calibrator and/or simulator to the end device for the channel.
(e) Apply the correct upper span process value to the end device.
The screen should show the upper span setting as the current value in engineering units.
(f) If not, choose [D] and the current ADC value will be inserted for the upper span ADC
value.
D
(g) Complete final loop checkout described on Page 10.

Thermocouple Temperature Channels

After selecting and freezing the input, and checking the jumpers and span settings (if necessary),
use the following procedure to calibrate a thermocouple channel.

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NOTE
This procedure assumes correct operation of the
thermocouple end device and field wiring. That is, the
thermocouple mV output corresponds with published
thermocouple tables.

If the mV output does not correspond a full end device

checkout should be completed before continuing with this
calibration procedure.
(a) Connect a thermocouple calibrator at the field end in place of the thermocouple.
This will calibrate and test the integrity of the temperature measurement loop.
(b) Set the calibrator to simulate the lower span value.
The screen should show the low span setting as the current value in engineering units.
(c) If not, choose [G] and the current ADC value will be inserted for the lower span ADC
G
value.
(d) Set the calibrator to simulate the upper span value.
The screen should show the upper span setting as the current value in engineering units.
(e) If not, choose [D] and the current ADC value will be inserted for the upper span ADC
value.
D (f) Complete final loop checkout described on Page 10.

RTD Temperature Channels

After selecting and freezing the input, and checking the jumpers and span settings
(if necessary), use the following procedure to calibrate an RTD channel.

NOTE
This procedure assumes correct operation of the RTD
end device and field wiring. That is, the RTD’s resistance
corresponds with published RTD tables.

If the resistance does not correspond a full end device

verification should be completed before continuing with
this calibration procedure.
(a) Connect an RTD calibrator at the field end in place of the RTD.
If it is not possible or practical to connect to the field end, the RTD calibrator may
be connected to the terminals in the panel.
This will calibrate and test the integrity of the temperature measurement loop.
(b) Choose [9], CALMODE.

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9 This places the RTD input channel into a special calibration mode to correctly activate
the excitation voltage for the channel.
 (c) Set the calibrator to simulate the lower span value.
The screen should show the low span setting as the current value in engineering units.
G (c) If not, choose [G] and the current ADC value will be inserted for the lower span ADC
value.
(d) Set the calibrator to simulate the upper span value.
The screen should show the upper span setting as the current value in engineering units.
D (e) If not, choose [D] and the current ADC value will be inserted for the upper span ADC
value.
Enter (f) Press <ENTER/EXIT> to exit from the calibration screen to deactivate calibration mode.
E Exit
(g) Complete final loop checkout described on Page 10.

 0 to 5 V Channels
After selecting and freezing the input, and checking the jumpers and span settings (if necessary),
use the following procedure to calibrate a 0 to 5 V channel (usually a pressure transducer).

NOTE
This procedure assumes correct operation of the end
device and field wiring. That is, the device output is
approximately 0.5 Vdc when the lower process value is
applied and 4.5 Vdc with the upper process value, and that
the device is linear.

This can be determined from the ADC values indicated on

the panel. The ADC value should be approximately
6 000 for a 0.5 Vdc signal and 56 000 for a 4.5 Vdc signal
from the transmitter. If the ADC values vary excessively,
then a full end-device calibration should be completed
before continuing with this calibration procedure.
(a) Isolate the end device from the process.
(b) Connect an accurate calibrator and/or simulator to the end device for the channel.
(c) Apply the lower span process value to the end device.
The screen should show the low span setting as the current value in engineering units.

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G (d) If not, choose [G] and the current ADC value will be inserted for the lower span ADC
value.

(e) Apply the correct upper span process value to the end device.
The screen should show the upper span setting as the current value in engineering units.
D (f) If not, choose [D] and the current ADC value will be inserted for the upper span ADC
value.
(g) Complete final loop checkout described following.

6.2.6 Final Loop Checkout

(a) Reconnect the end device.
The screen should indicate the current process conditions.
(b) If the indicated engineering value does not correspond with the current process
conditions, a complete end-device and field wiring checkout should be completed.
(If the error is small and linear, an offset could be used, see below.)
(c) After loop integrity has been verified, unfreeze the input as described on Page 5 of
this Chapter.

6.2.7 Adding an Offset

If the calibration is off at both the lower and upper ends by a similar small amount (linear
offset) then the operator can enter an offset value by pressing the [K], OFFSET, key, and
entering the desired current value. (There is no way to tell later if an input has been
offset.)
K (a) Choose [K], OFFSET
The Series XI will ask SET SPECIFIC INPUT VALUE [1], YES, [2], NO?
1 (b) Choose [1] and type the current value desired in engineering units.
(c) Press <ENTER/EXIT>.
Enter
E Exit
The Series XI will ask if THE VALUE IS [1], POSITIVE, [2], NEGATIVE ? at the bottom
1
of the screen.
(d) Make your choice and the screen will revert to the Analog Input (Calibration)
2 screen, using the offset setting for the current value.
6.2.8 Using Entered Calibration Points
During a calibration, entering a specific calibration value (ADC units) instead of using the
H
value sent by the device, can be accomplished with the [H], TOG ADC, key.
(a) Follow the normal procedure, but before choosing [D] or [G], choose [H], TOG

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ADC.
The Series XI will display an “S” at the top-right of the screen.
G (b) Choose [D] or [G] as per the normal procedure.
A flashing cursor will indicate to enter the digits in ADC, instead of automatically
D
accepting the device’s value.
(c) Type in the desired ADC value and press <ENTER/EXIT>.
Enter
E Exit (d) Proceed with the rest of the calibration.

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 Chapter
Series XI Control Panel
7 Operations Guide BY ALTRONIC

Air:Fuel Ratio Control

Please refer to the publication:

Series XI—Air:Fuel Ratio Control

Operation and Installation Manual

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 Chapter
Series XI Control Panel
8 Operations Guide BY ALTRONIC

Troubleshooting
This Chapter contains a troubleshooting chart for the Series
XI controller.

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Exacta Series XI Control Panel–Operations Guide Chapter 8—Troubleshooting

Problem Possible Cause Solutions

Magnetic pickup broken Check magnetic pickup for damage or metal filings.

Broken cable or loose

Check cable for continuity. Check cable ends and terminations.
terminations
RPM not reading
15Vdc missing from Check voltage from pin #3 to pin #5, using pin #3 as reference
12X12 I/O board (ground).

Ensure correct analog channel has been selected and that the
RPM setup not correct
program points to the correct discrete point.

Ensure that there is 24Vdc supply at the transmitter.

Signal from transmitter
less than 4mA
Gas detection reading Ensure that the transmitter is connected correctly to the input channel
negative 24% (signal leg connected to the B terminal and 0Vdc to the A terminal).

Using industry standard calibration equipment simulate 4-20mA signal

Faulty Analog input card
directly to card and monitor gas detection indication.

Signal from transmitter Check conductor terminations at both ends. Ensure the signal line is
reversed connected to the B terminal of the input channel.

Jumper on analog card installed incorrectly. Jumper should be

installed on pins #1and #2.
4 to 20mA input not
Gas detection reads
correctly set up on Analog input is not set at 4 to 20mA in the controller.
over range
analog card
Analog input setup as 4 to 20mA (10ohm) in the controller with a 4 to
20mA (200ohm) installed.

Using industry standard calibration equipment simulate 4-20mA signal

Faulty analog input card
directly to card and monitor gas detection indication.

Ensure the sensor type for that channel has been set at 4 to 20mA.
Gas detection reads
Sensor type incorrect
incorrectly
Calibrate gas detector.

Open thermocouple or Check thermocouple with a calibrator. Check conductor terminations

conductors (open circuit) at both ends.
Temperature reads over
range Using industry standard calibration equipment simulate appropriate
Faulty Analog input card thermocouple (K or J) signal directly to card and monitor temperature
indication.

Temperature decreases Thermocouple wired Correct the connections. Ensure the conductors are connected with
as heat is applied backwards the correct polarity from the thermocouple to the analog input board.

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Exacta Series XI Control Panel–Operations Guide Chapter 8—Troubleshooting

Problem Possible Cause Solutions

Loose connections Check and tighten all terminals.

Thermocouple wire not Replace non-thermocouple wire with the correct type of thermocouple
used throughout the loop wire.
Temperature readings
are erratic Using industry standard calibration equipment simulate appropriate
Faulty analog input card thermocouple (K or J) signal directly to card and monitor temperature
indication.

Bad thermocouple Replace thermocouple.

Open connections Check connections and circuits for open curcuit.

Single pressure channel

Needs calibrating Calibrate using hand pump. See calibration in Chapter 6.
reading negative

Span settings
Confirm span settings in controller match. Transmitter calibrated span.
mismatched

5 or 15Vdc fuse blown

Measure voltage on the fuse and change if required.
Multiple pressure or shortened to frame
channels reading
negative Using industry standard calibration equipment simulate a 4-20mA
Faulty analog input card
signal directly to card and monitor pressure indication.

Calibration Check calibration.

Pressure reading too Wires shorted (causes

Check wiring and terminations.
high reading pegged high)

Using industry standard calibration equipment simulate 4-20mA signal

Faulty analog input card
directly to card and monitor pressure indication.

24Vdc supply conductor Remove both field wires from terminals and resistance conductor to
shortened to ground ground.

Single discrete reads

Defective end device Check end divice.
faulty continuously

Jumper across field terminals and monitor discrete input status on

Defective discrete input
pannel.

24Vdc common wire

Multiple discrete inputs
connected to the 12X12 Check wiring and terminations.
faulty
I/O board is loose

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Exacta Series XI Control Panel–Operations Guide Chapter 8—Troubleshooting

Problem Possible C ause Solutions

C onductor shorted to
C heck wi ri ng at termi nati ons.
ground
Si ngle di screte i nput
reads healthy D efecti ve end devi ce C heck end devi ce.
conti nuously
Remove fi eld wi res from termi nals and/or from board termi nals and
D efecti ve di screte i nput
moni tor di screte i nput status on panel.

Voltage not present at

Analog cards do not C heck voltages on Exacta port at pi ns #1, #5, #9, wi th respect to pi n
Exacta port on analog
i ni ti ali ze #3 as reference (ground).
card

C ontroller i s i n a screen
Push <Enter/Exi t> key.
whi ch i s blank

C ontroller screen i s No power, blown fuse,

C heck 24Vdc power supply, fuses and wi ri ng.
blank or black loose connecti ons

C ontrast needs adjusti ng Adjust contrast.

D ate and ti me wrong Set date and ti me accordi ng to C hapter 5.

Swi tch to Auto. Use the <Outputs> key to check for letter "M" before
Output i n manual mode the words "On" or "Off". Push the number besi de the output and then
Si ngle output channel not <G> to toggle back to Auto mode.
worki ng
Fuse blown or loose C heck the fuse on the 12X12 I/O board. C heck the wi ri ng and the
connecti on termi nati ons.

C heck the 24Vdc mai n fuse i n the pannel. C heck the 24Vdc wi re that
Multi ple outputs not Fuse blown or loose
runs from the fuse to the 12X12 I/O board. C heck the 24Vdc common
worki ng connecti on
that runs to each output end devi ce.

Engi ne crank speed i s

less than the mi ni mum
C heck the RPM whi le cranki ng. See "RPM not Readi ng" i f no RPM i s
requi red purge value.
readi ng.
Fuel solenoi d not Approx 30-50 (vari es
energi zi ng wi th engi ne type)

Output not worki ng See "Si ngle Output C hannel not Worki ng."

Manual crank selected

Push <Stop> then <Start> and select [1], Auto C rank.
on start
No C rank si gnal
Output not worki ng See "Si ngle Output C hannel not Worki ng".

Engi ne crank speed less

than mi ni mum requi red
C heck RPM whi le cranki ng. See "RPM not Readi ng" i f no RPM
purge value. Approx 30-
readi ng.
50 (vari es wi th engi ne
Igni ti on not energi zi ng
type)

Output not worki ng See "Si ngle Output not Worki ng."

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Problem Possible Cause Solutions

Solenoid valve not Output in Manual, fuse or

See "Single Output Channel not Working."
responding wiring

Power down and then up to reset.

Analog board in
calibration mode
Analog valves frozen See Chapter 6, Section 6.2.5 on page 5 to unfreeze.

Using industry standard calibration equipment simulate appropriate

Faulty analog input card
signal directly to card and monitor analog indication.

Unit cranks but it does Check the RPM while cranking. See "RPM not Reading" if no RPM
No RPM detection
not start reading.

Push <Messages> key to determine the cause and check them one at
Shutdowns not cleared
a time.

Cannot clear Class Shutdown improperly set

See Chapter 5, Section 5.2, page 3 of 7.
Shutdowns up

See "Single Discrete Input Reads Faulty Continuously" or "Multiple

Defective discrtete input
Discrete Inputs Faulty."

Bypass control valve in

Push <Bypass Control> key and choose [H], Auto and answer [1], Yes.
Manual (LED On)
Bypass valve not
opening on High Master load control in Push <Master Load Control> key and choose [H], Auto and answer [1],
discharge or Low Manual (LED On) Yes.
suction
Place Master Controller, bypass controller, and speed controller into
Master laod controller
manual. Then place all controllers back into automatic. (Specific
locked up
sequence not required).

Speed controller in
Push <Speed Control> key and choose [H], Auto and answer [1], Yes.
Manual (LED On)

Speed not decreasing Master load control in Push <Master Load Control> key and choose [H], Auto and answer [1],
during high discharge or Manual (LED On) Yes.
Low suction conditions
Place Master Controller, bypass controller, and speed controller into
Master load controller
manual. Then place all controllers back into automatic. (Specific
locked up
sequence not required).

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 Chapter
Series XI Control Panel
9 Operations Guide BY ALTRONIC

Communications
UPLOADING INSTRUCTIONS
DOWNLOADING INSTRUCTIONS
DOWNLOADING REPORTS

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Exacta Series XI Control Panel-Operations Guide Chapter 9-Communications

A1 Requirements and Settings

Requirements
The requirements to permit logging onto the Exacta Computer are as follows:
1. A remote computer, either laptop or desktop running Windows 3.11™,
Windows 95/98™ or Windows ME/XP™ with a terminal emulation program such
as Hyperterminal™ or Procomm Plus™, or Windows Terminal™.
If not running Windows, you will require some other communication program such
as Procomm™.
2. An Exacta computer to PC serial interface cable, Part #CW1642.
The pin-out of this cable is:
Exacta PC
2 TXD 2 RXD
3 RXD 3 TXD
4 RTS 8 CTS
5 CTS 7 RTS
6 DSR 4 DTR
7 GND 5 GND
8 DCD - -
9 DTR 6 DSR
3. A Level 1 password from Altronic Controls or your Exacta integrator (usually
owner or distributor only) for uploading/downloading binary files (code) or a Level
2 password for downloading reports.
Exacta Settings
To change or check the settings on the Exacta computer follow the steps on page 3.
The Exacta computer has one RS232 and one RS485/RS482 port located on the bottom
of the unit. The RS232 port is the 9-pin D connector furthest to the right when looking at
the back of the controller. The RS485 is the 2nd port from the right when looking at the
back of the controller. Figure A-1 shows these ports.
This document covers using the RS 232 port to communicate with the Exacta Series XI,
which is the most common method. Special procedures and hardware (RS232/RS485
Convertor) are required to communicate using the RS485 port. Please contact Altronic
Controls or your Exacta integrator if for some reason the RS232 port cannot be used.

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Series XI Ports

Modem
Port 1 Port 2 Parallel RS485 RS232

Front Panel
This Side
Figure A-1

A2 How to Set Up the Port and Log On

Before you can log on with a PC, the settings for the port to be used must be configured
properly. The port settings on the PC’s communication port should be configured as
follows:
• 19,200 Baud
• No Parity
• 8 Bits
• 1 Stop Bit
• Transfer Protocol X Modem
• No software or hardware flow control.
If necessary, the port settings can be changed by following Steps (a) to (j) following:
K Menu 1. Press the [K] or <MENU> key on the Exacta’s keyboard.
1 2. Select option [1], PROGRAM MODE, by pressing <1>.
Enter
E Exit
3. Enter your password (Level 2 required) and press <E>, ENTER.
2 4. Choose [2], SET UP MENU.

2 5. Choose either [2] or [3], depending on which port you will be logging into.
3

F 6. The Port Settings screen (Figure A-2) will appear, and by pushing the <F> on the
Exacta keyboard, you will be asked the following: DEFAULT SETTINGS? [1], YES, or [2],
1 NO.
7. Select [1], YES. This will configure the port to the proper settings for logging on.

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Port Settings Screen

[0] State: ON [6]Device: Computer

[1] Baud: 9600 [7]Type: VT100
[2] Parity:None [8]Display:One
[3] Size: 8 [9]Exacta Link
[4] Stop Bits:1 [A]Test RS232
[5] HS: DTR CTS [B]Echo Mode

Figure A-2
8. Connect the Exacta to PC cable between the two computers, ensuring the cable is
oriented properly. One end is marked To Exacta the other To PC.
9. Start up your terminal emulation program. Ensure the cable is connected to the correct
com port on the PC. Typically com 1.
A. Select Connect using: Direct to Com x (x being the RS232 port being used).
B. Set communication parameters to 19200, 8,N,1, No Flow Control to match the
Exacta Series XI Computer.
C. Select Properties then Settings then Emulation and make it VT100.
(Hyperterminal’s help files are provided at the end of this document for your convenience
in the field.)
10. Press <ENTER> or <RETURN> on the PC, 3 times. The Exacta Series XI splash screen
will appear on the PC for a few seconds, changing to ENTER PASSWORD. Enter your
password and press <ENTER>, the PC will show the Exacta Series XI Program Menu.
Step 10 completes the procedure for logging onto the EXACTA computer.

A3 How to Download Reports

This procedure is used to print reports; for example, captured data, history, or modbus
table. Reports are first transferred from the Exacta to the PC.
1. Connect and log on to the unit from the PC as described above.
2. After entering your password, press <ENTER> or <RETURN>. You will now be at the
Program Menu on the PC.
3. Choose [4], PRINT REPORTS.
4. The next screen gives you the option of which file you want to download.
5. Select the file you want to download between:
[1] Programming
[2] I/O Summary
[3] Power Loss
[4] Record History
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[5] Capture Data (In this case PRINT CAPTURE D ATA appears; answer YES or NO. ARE
YOU SURE appears; answer YES or NO. You will be asked to select DATA SET A or B. If A
is chosen the computer will ask for the shutdown you want to download. Then the Print
Menu appears - (See Figure A-3.)
[6] Modbus Table.

Print Menu Screen

[1] Start Print

[2] Port: Download
[3] Mode: CR & LF
[4] Length: 0

Figure A-3

6. Ensure the [2], PORT, and [3], MODE, settings are as shown on the screen (Figure A-3).
7. Select [1], START PRINT. The message PRINTING will be displayed. If Capture Data was
chosen SENDING DATA will appear.
8. Follow the emulation software’s procedures for receiving a text file (a pop-up window
will appear to show data transfer.) Hyperterminal’s help files are provided at the end of
this document for your convenience in the field.
Step eight completes the process for downloading a report.

NOTE
There is a limited time (about 60 Sec.) to start this or the download will fail.
XModem is the recommended protocol. Give the file an appropriate name, version number
and extension. We recommend that ‘.txt’ be used as an extension since this is reconizable
by most text viewing programs and word processing packages.
When [5], Data Capture, is selected the computer gives you a choice between [1], DATA
SET A (first-in shutdowns) or [2], DATA SET B (standard trending data normally set to
every 15 minutes). If [1] is selected, the list of shutdowns will appear. Choose one of
them and proceed.

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Sample Download Using Hyperterminal™

1. After entering your password, press the <ENTER> key. You will then be at the Program
Menu.
2. Select [4], PRINT REPORTS.
3. Select the report you would like to print. In this example we will be selecting option [1],
PROGRAMMING. The screen will change to the Print Menu Screen (Figure A-3).
4. Option [2], PORT, should be set to DOWNLOAD. If it requires changing, choose [2] until it
changes to DOWNLOAD. Once this is completed press the <1> to start the print and the
screen will change to PRINTING.
5. Move your mouse to the Transfer Menu, and select RECEIVE FILE. A screen will appear
allowing you to select a folder.
6. Click on <BROWSE> and select the appropriate drive and file folder.
7. Click on <OK> and then <RECEIVE> and type a file name. An appropriate name would
be Sitename-Prog.txt. After entering the name, press the <RECEIVE> button, to begin
capturing the text to a file. When the capture is complete the screen will change back to the
Report Menu screen.

A4 How to Upload Binary Files (Code)

This procedure is used to upload binary files (code) from the PC or laptop to the Exacta
Series XI.
1. Connect and log on to the unit from the PC as described in section A2.
2. After entering your password, Choose [2], SET UP MENU.
3. Choose [7], UP LOAD.
4. Choose [1], PROGRAMMING.
5. Answer [1], YES, to the next two questions displayed.

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Exacta Series XI Control Panel-Operations Guide Chapter 9-Communications

The Save Calibrations screen (Figure A-4) will be displayed.

Save Calibrations Screen

[1] Save Calibrations: [1] Yes

[2] No

Figure A-4
NOTE
Option [1] YES saves the calibrations already in the Exacta Series XI. Only choose [1]
when all end devices were previously calibrated and you are sure you want these
values saved.
[2] NO overwrites with new calibrations from the new programming.

6. Follow the emulation software’s procedures for sending a file, choosing the file you
want to upload. XModem is the recommended protocol.
7. Select a file with an appropriate name, version number and extension. Exacta’s
standard extensions are as follows:
.txt Reports (Cannot be Uploaded)
.ep Exacta Program
.el Link file (Modbus)
.er Record History
.ec Capture File
Step seven completes the process for uploading binary files.

NOTE
EVERY TIME A NEW PROGRAM IS UPLOADED it is highly recommended to power
down and up to properly re-initialize the controller with the new programming.
If you encounter difficulties or have questions, please don’t hesitate to call Altronic
Controls or your Exacta integrator.

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Exacta Series XI Control Panel-Operations Guide Chapter 9-Communications

A5 How to Download Binary Files (Code)

This procedure is used to download programming from the Exacta Series XI to a PC or
laptop.
1. Connect and log on to the unit from the PC as described in Section A2.
2. After entering your password, Choose [2], SET UP MENU.
3. Choose [8], DOWN LOAD.
4. Choose [1], PROGRAMMING.
5. Answer [1], YES, to the next two questions displayed.
6. Follow the emulation software’s procedures for receiving a file, choosing the one you
want to download. XModem is the recommended protocol.
7. Give the file an appropriate name, version number and extension. Exacta’s standard
extensions are as follows:
.txt Reports (Cannot be Uploaded)
.ep Exacta Program
.el Link file (Modbus)
.er Record History
.ec Capture File

If you encounter difficulties or have questions, please don’t hesitate to call Altronic
Controls or your Exacta integrator.

A6 How to Log On by Modem to Download Reports

An optional modem is available with the Exacta Series XI Computer. This modem allows
access to the Exacta from a remote location. This feature is used for troubleshooting
problems with the site, as well as viewing information, uploading and downloading files,
and changing some control setpoints (with an appropriate password). In the procedure
below you will find a detailed step-by-step procedure for dialling into the sites and
downloading the appropriate reports. The following procedure is for Hyperterminal™
found in all Windows 95™ and above operating systems.
1. Run the Hyperterminal™ program by clicking on the Windows <START> button.
2. Move the mouse to the Program Menu, a new screen will appear.
3. Move the mouse to the Accessories Group, then click on the Hyperterminal™ file. A
screen to enter a name and pick an icon will appear. After one or two seconds, a screen
will appear with the file name and number to be dialled.

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Exacta Series XI Control Panel-Operations Guide Chapter 9-Communications

4. Type a suitable name and press <OK> (assign an icon if you wish). A phone number
screen will appear.
5. Type in the correct phone number and press <OK>.
6. Press <DIAL>. You will then see a window displaying the status.
7. Once the call has been connected you will see the Enter Password screen. You have
made a successful connection.
Step seven completes the process for logging on by modem to download reports.

A7 Hyperterminal™ Help Files

To set up a new connection

1. On the FILE MENU, click NEW CONNECTION.

2. Type a name that describes the connection, click THE APPROPRIATE IICON, and the click
OK.
3. Enter the information for the call, and then click OK.
4. To dial the call, click DIAL.

To call a remote computer

1. On the File Menu, click OPEN, and the double-click THE CONNECTION you want to use.
2. Click DIAL.

To change the port settings for a modem connection

1. On the File menu, click Open.

2. Right-click THE CONNECTION you want to change, and then click PROPERTIES.
3. Click the CONNECT TO TAB, and then click CONFIGURE.
4. Click the CONNECTION TAB.

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Exacta Series XI Control Panel-Operations Guide Chapter 9-Communications

5. Click PORT SETTINGS, and the makethe changes.

6. Click ADVANCED to change settings such as flow control and error correction.
NOTE
The changes that you make to the port settings afffect only this connection.

To change the settings for making a call

1. In the HyperTerminal folder, double-click THE CONNECTION you want to change.
2. On the FILE MENU, click PROPERTIES.
3. Click the CONNECT TO TAB , and then make the changes you want.
4. To change settings, such as the terminal type, click the SETTINGS TAB, and then make the
changes you want.

To send a file to a remote computer

1. On the TRANSFER MENU, click SEND FILE.
2. In the FILENAME, type the path and name of the file you want to send.
3. Click SEND.

NOTE
You can change the protocol you use to send the file by clicking the one you want in
PROTOCOL.
You can also send a text file to a remote computer by clicking SEND TEXT FILE on the
TRANSFER MENU.
In most cases, you need to prepare the file-transfer software on the remote computer to
receive the file. For more information, contact the administrator of the remote computer.

To receive a file from a remote computer

1. Use the software on the remote computer to send (download) the file to your computer.
2. On the TRANSFER MENU, click RECEIVE FILE.
3. Type the path of the folder in which you want to store the file.
4. In USE RECEIVING PROTOCOL, click the protocol the remote computer is using to send
your file.

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Exacta Series XI Control Panel-Operations Guide Chapter 9-Communications

To save a HyperTerminal session to a file

1. On the TRANSFER MENU, click CAPTURE TEXT.

2. Type a descriptive file name, or click BROWSE to select the path and file name, and then
click START.

NOTE
You can also send the session text directly to a printer by clicking the TRANSFER MENU, and
then clicking CAPTURE TO PRINTER. When you end the call, the text will be sent to your
default printer.

To adjust the HyperTerminal window size

1. On the VIEW MENU, click FONT.
2. In SIZE, enter A POINT SIZE, using larger numbers to increase the size of the terminal
window or smaller numbers to decrease it.
3. To adjust the HyperTerminal window to the size of the terminal window, right-click in
THE TERMINAL WINDOW, and then click SNAP.

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 Appendix
Series XI Control Panel
A Operations Guide BY ALTRONIC

Master Controller
This Appendix explains the functionality and operation of the
Master Controller.

FORM EXACTA XI-OG 9-03 1 of 8

A1 Master Controller Inputs
The master controller (MC) can accept up to four analog inputs; the RANGES for which are designated by the
configuration applied to each analog input. For example:
Suction Pressure 4 to 20 mA Span 0 to 6895 kPa
Discharge Pressure 4 to 20 mA Span 0 to 6895 kPa
Manifold Pressure 4 to 20 mA Span 0 to 250 In.H20
Unit Flow Mapped Span 0 to 250 103m3
Upon initial configuration of the MC, each input will be assigned an ACTION based upon what the process variable
(PV) will do during normal unit operation. This ACTION dictates to the MC the corrective action required to keep
all PVs within the setpoints (SP) input by operator. For example:
Suction Pressure Action during normal loading – decrease Offsets subtracted from SP
Discharge Pressure Action during normal loading – increase Offsets added to SP
Manifold Pressure Action during normal loading – increase Offsets added to SP
Unit Flow Action during normal loading – increase Offsets added to SP
In the MC these actions are input as either LOW (for decreasing action) or HIGH (for increasing action). The offsets
are either added or subtracted from the actual setpoint for the controllers that are not being acted on (explained in
more detail later).

A2 Master Controller Setpoints

Each input will then be assigned a SETPOINT (in engineering units, not percentage). This allows for easier setpoint
input by the operator, as no unit conversion is required. For example:
Suction Pressure Setpoint = 90 kPa
Discharge Pressure Setpoint = 1750 kPa
Manifold Pressure Setpoint = 190 In.H20
Unit Flow Setpoint = 185 103m3
Each setpoint will then be assigned as OFFSET value (discussed later). This value is also input in Engineering
units during initial MC configuration. For example:
Suction Pressure Offset = 15 kPa
Discharge Pressure Offset = 50 kPa
Manifold Pressure Offset = 50 In.H20
Unit Flow Offset = 15 103m3

A3 Master Controller PIDs

The MC can be configured to change the setpoint on up to four controllers (PIDs). For example:
Bypass Valve Controller
Governor Controller
Slide Valve Controller
The order these controllers are configured is important as it determines the order they will manipulated during the
loading/unloading of the compressor (further discussion follows).

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Exacta Series XI Control Panel–Operations Guide Appendix A—Master Controller

A4 Master Controller Overview

Suction
Pressure

MASTER Bypass
Controller
Controller
Discharge S
Pressure E
I
T
N
P
P Speed
O
U Controller
I
T
Manifold N
S
Pressure T
S

Slide
Controller

Unit Flow

A5 Master Controller Operation

During normal operation there will only be one controller being manipulated to maintain the inputs within setpoint.
This is accomplished through the use of the previously configured OFFSETS, as shown below, and the order which
the controllers are configured to sequence.

A5.1 Example
Suppose a screw-type unit is 100% loaded, RPM is at 100%, and the bypass valve is 100% closed. The suction
pressure has decreased to the setpoint value in the MC—90kPa. As shown below, the first controlled device will
be the slide valve. To accomplish this, the MC will subtract the offset value from the actual setpoint and will
place this in the two controllers not being manipulated. In this case the speed and bypass controllers. The slide
valve controller will receive the actual setpoint and will manipulate the slide valve to maintain suction at setpoint.
As the suction pressure continues to decrease the slide valve will continue to unload to attempt to maintain
suction pressure at setpoint. The slide will continue to unload until it reaches 0%, or until the desired suction
pressure is obtained:

FORM EXACTA XI-OG 9-03 3 of 8

 Suction
90 kPa
Pressure

MASTER 75 kPa Bypass

Controller
Controller 100%
S
E
I
T
N 75 kPa
P Speed
P
O Controller
U
I 100%
T
N
S
T
S
90 kPa Slide
Controller
0 - 100%

At this point the MC will calculate the setpoint to the slide valve, by adding the offset value to the current process
value (suction pressure). It will place the actual setpoint (90 kPa) into the next controller, in this case the speed
controller, and the setpoint in the bypass controller will remain the same:

Suction 90 kPa
Pressure

MASTER 75 kPa Bypass

Controller
Controller 100%
S
E
I
T
N
P
P 90 kPa Speed
O Controller
U
I 0 - 100%
T
N
S
T
S PV + Offset
(kPa) Slide
Controller
0%

Now the speed will be manipulated to attempt to maintain suction pressure at the setpoint of 90 kPa. With the
offsets applied to the controllers as shown above it is clear how the MC sequences the controllers. The only time
more than one controller will be changing its controlled variable will be if the suction pressure was to decrease
rapidly below the actual setpoint minus the offset. For our example 75 kPa. At this point both speed and bypass
valve would be reacting to changes in suction pressure:

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Exacta Series XI Control Panel–Operations Guide Appendix A—Master Controller

Suction <75 kPa

Pressure

MASTER 75 kPa Bypass

Controller
Controller 0 - 100%
S
E
I
T
N
P
P 90 kPa Speed
O Controller
U
I 0 - 100%
T
N
S
T
S PV + Offset
(kPa) Slide
Controller
0%

Now, if the suction pressure began to increase, the unit would begin loading. Starting with the controller currently
being controlled and sequencing through the controllers. For example, if the speed is being manipulated to maintain
suction at 90 kPa the setpoints in the three controllers would be as follows:

Suction 90 kPa
Pressure

MASTER 75 kPa Bypass

Controller
Controller 100%
S
E
I
T
N
P
P 90 kPa Speed
O Controller
U
I 0 - 100%
T
N
S
T
S PV + Offset
(kPa) Slide
Controller
0%

The speed would continue to increase to attempt to maintain suction pressure at 90 kPa. Once the speed
controller output increased to 100%, the next controller, in this case the slide valve controller, would now get the
actual setpoint and the speed controller would get a setpoint equal to the actual minus the offset value as shown
following:

FORM EXACTA XI-OG 9-03 5 of 8

 Suction >90 kPa
Pressure

MASTER 75 kPa Bypass

Controller
Controller 100%
S
E
I
T
N
P
P 75 kPa Speed
O Controller
U
I 100%
T
N
S
T
S
90 kPa Slide
Controller
0 - 100%

The same sequencing will occur for discharge, manifold and flow.
For example, using the same initial conditions—slide 100%, speed 100% and bypass 100% closed. If the
Manifold pressure increases above setpoint the MC would insert the setpoint for the manifold pressure into the
slide controller. The speed and bypass valve controllers would receive the manifold pressure setpoint plus the
offset for the manifold pressure. As previously described, the same sequencing will occur to attempt to control
the manifold pressure at setpoint.

240 "H20 Bypass

MASTER Controller
Controller 100%
S
E
I
N T
P 240 "H20 Speed
P
O Controller
U
I 100%
T
Manifold
190 "H20 S
N
T
Pressure S
190 "H20 Slide
Controller
0 - 100%

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Exacta Series XI Control Panel–Operations Guide Appendix A—Master Controller

A5.2 Notes
It is important to remember the remaining analog inputs, although not currently being controlled, will still be
monitored and will become the controlling variable if required.
The tuning of the MC is accomplished through the tuning of each separate control loop. This gives the capability
of apparent dynamic tuning based upon the item being manipulated. For example, the speed loop can be tuned
much differently than the bypass controller to maintain good stable control.
From the description above, it becomes apparent why you cannot change the setpoints directly in the speed or
bypass controllers. They must be changed from the MC.

A6 Panel Indications
The following is a MC screen representation. From the data shown, it can be said that currently all conditions are
satisfied. However, the MC is designed to look at the PV that is closest to setpoint on a percentage basis. Below
you can see an asterisk beside the Suct Stg 1 Press. This means that currently suction is closest to setpoint.

Aug 9/99 Master PID 8:30 AM

Mode: Auto
PV Name Setpoint PV
*[1] Suct Stg1 Press 200 322
[2] Disch Stg 2 (2) 7400 4600
[3] Eng Manifold Pre 750 435

[E]xit [H]Manual [F]Setpoint [K]PIDs

The next example shows the load on the unit has increased and now the Eng Manifold Press is selected as current
because it’s closest to setpoint.

Aug 9/99 Master PID 8:30 AM

Mode: Auto
PV Name Setpoint PV
[1] Suct Stg1 Press 200 322
[2] Disch Stg 2 (2) 7400 4600
*[3] Eng Manifold Pre 750 704

[E]xit [H]Manual [F]Setpoint [K]PIDs

In both of the above cases the selection of a setpoint; that is, Suction or Manifold, does not indicate the control
panel is unloading the unit based upon that controlled variable. To check this, pressing the [K] PIDs button will
bring up the next screen as shown following.
This screen indicates by the asterisk the controller that is currently attempting to control the unit. For the above
example, you can see that speed is selected by the position of the asterisk, however, the output to governor is at
100%. This confirms the previous statement.

Aug 9/99 Master PID 8:34 AM

PV: 322
PID Name Setpoint Output
Bypass Control 122 100
*Speed Control ) 200 100

[E]Exit

FORM EXACTA XI-OG 9-03 7 of 8

For the next screen capture the suction pressure has now decreased below setpoint. It is selected as the PV to be
controlled. This is indicated by position of the asterisk.

Aug 9/99 Master PID 8:30 AM

Mode: Auto
PV Name Setpoint PV
*[1] Suct Stg1 Press 200 195
[2] Disch Stg 2 (2) 7400 4600
[3] Eng Manifold Pre 750 704

[E]xit [H]Manual [F]Setpoint [K]PIDs

We can see that some corrective action should be taking place; for example, RPM reducing or Bypass Valve
opening. To determine what is currently being manipulated to attempt to control suction at setpoint pressing the
[K] PIDs button will bring up the following screen.

Aug 9/99 Master PID 8:34 AM

PV: 195
PID Name Setpoint Output
Bypass Control 0 100
*Speed Control 200 82

[E]Exit

This time we can see the speed controller has begun to reduce the output to the governor in an attempt to control
the suction pressure at setpoint. This output will be reduced until the engine has reached Minimum Load RPM.
At this time control will now be switched to the next controller in the list. For this example the bypass control.
The screen will now look as follows. The asterisk beside the bypass control indicates it is the controller currently
being manipulated to attempt to control suction.

Aug 9/99 Master PID 8:34 AM

PV: 195
PID Name Setpoint Output
*Bypass Control 200 96
Speed Control 200 62

[E]Exit

You can see the output to the governor has decreased to 62%, which should correspond with the Minimum Load
RPM. The bypass has now begun to reduce output to the bypass valve in an attempt to control suction at setpoint.
If the suction were to increase back above setpoint the bypass would be the first to increase output. When it
reached 100%, the Speed would then begin to increase. This order will always be the same unless either the speed
or bypass has been placed into Manual mode. If any controller is in Manual the MC will ignore it.

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 Index Series XI Control Panel
Operations Guide BY ALTRONIC

Index
Topic Section, Page Topic Section, Page

capacity control 1, 3
A capturing data 1, 3 &8
adding an offset, calibration 6, 10 changing passwords 5, 5
adjusting screen contrast 3, 6 check
AGA calculations 1, 6 jumpers, calibration 6, 5
air:fuel ratio control (see Air:Fuel Ratio Control span settings, calibration 6, 6
Operation and Installation manual) checkout, calibration 6, 10
alarms and shutdowns, parameters 5, 3 communications (see also Series XI Upload/Download
alarms, annunciation and shutdowns, 1, 2 Procedure, or Series XI Programming Guide
annunciation, alarms and shutdowns, 1, 2 communications 1, 4
auto slowdown subroutine 4, 7 compressor control interface 1, 5
auto stop key 3, 8 control keys 3, 9
control
B capacity 1, 3
basic operation 3, 1 interface, compressor 1, 5
adjusting screen contrast 3, 6 sequences 4, 2
entering alphabetical data engine-driven reciprocating unit 4, 2
software 11.07F5 and earlier 3, 18 typical electric drive—changes 4, 10
software 11.07F6 and later 3, 19 typical engine-driven screw unit—changes 4, 10
keyboard functions 3, 7 sequence subroutines 4, 7
main run mode screen 3, 2 auto slowdown 4, 7
multi-screen scrolling 3, 4 engine jacket water/oil temperature override
typical panel layout 3, 3 and the blowdown valve 4, 8
using the keyboard 3, 3 manifold pressure override 4, 8
blowdown valve subroutine 4, 8 remote idle 4, 8
sequential 1, 3
controller, master A, 1
C inputs A, 2
calculations, AGA 1, 6 operation A, 3
calibration 6, 1 overview A, 3
determining the software 6, 2 panel indications A, 7
procedure 6, 2 PIDs A, 2
adding an offset 6, 10 setpoints A, 2
calibrating 6, 7 controlling unit variables 5, 6
check jumpers 6, 5 PID control theory 5, 6
check span settings 6, 6 process control theory 5, 6
final loop checkout 6, 10 tuning PID control 5, 7
freezing the input 6, 4 contrast, adjusting screen 3, 6
opening 6, 2 crank key 3, 8
using entered calibration points 6, 11
calibrating 6, 7
4 to 20 mA channels 6, 7
thermocouple temperature channels 6,7
RTD temperature channels 6, 8
0 to 5 V channels 6, 9

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Exacta Series XI Control Panel—Operations Guide Index

Topic Section, Page Topic Section, Page

D H
data history key 3, 11
capture 1, 3 &8
downloading 1, 8
I, J
first-in shutdown 1, 9 inputs key 3, 13
trending 1, 8 inputs, master controller A, 2
determining the software 6, 2 introduction 1, 2
down key 3, 10 capacity control 1, 3
downloading data 1, 8 communications 1, 4
compressor control interface 1, 5
data capture 1, 3 &8
E modbus 1, 4
engine jacket water/oil temperature override subroutine 4, 8 monitoring 1, 2
entered calibration points, using 6,11 programming 1, 4 &10
enter/exit key 3, 9 shutdowns, alarms and annunciation 1, 2
entering sequential control 1, 3
alphabetical data special functions 1, 5
software 11.07F5 and earlier 3, 18 summary of features 1, 11
software 11.07F6 and later 3, 19
names 3, 19 jumpers check, calibration 6, 5

F K, L
4 to 20 mA channels, calibrating 6, 7 keyboard
features, summary of 1, 11 functions 3, 7
final loop checkout, calibration 6, 10 auto stop 3, 8
first-in shutdown data 1, 9 control keys 3, 9
freezing an input, calibration 6, 4 crank 3, 8
functions down 3, 10
keyboard 3, 7 enter/exit 3, 9
auto stop 3, 8 history 3, 11
control keys 3, 9 inputs 3, 13
crank 3, 8 menu 3, 10
down 3, 10 messages 3, 13
enter/exit 3, 9 outputs 3, 15
history 3, 11 prelube 3, 11
inputs 3, 13 remote/local 3, 11
menu 3, 10 reset 3, 7
messages 3, 13 start 3, 7
outputs 3, 15 stop 3, 8
prelube 3, 11 slide valve control 3, 9
remote/local 3, 11 timers and settings 3, 16
reset 3, 7 typical parameters 3, 17
start 3, 7 up 3, 10
stop 3, 8 using 3, 3
slide valve control 3, 9
timers and settings 3, 16 layout, system 2, 1
typical parameters 3, 17
up 3, 10
special 1, 5
AGA calculations 1, 6
Control Panel software 1, 5

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Exacta Series XI Control Panel—Operations Guide
Index

Topic Section, Page Topic Section, Page

prelube key 3, 11
M process control theory 5, 6
main run mode screen 3, 2 procedure, calibration 6, 1
manifold pressure override subroutine 4, 8 calibrating
master controller A, 1 adding an offset 6, 10
inputs A, 2 calibrating 6, 7
operation A, 3 check jumpers 6, 5
overview A, 3 check span settings 6, 6
panel indications A, 7 final loop checkout 6, 10
PIDs A, 2 freezing the input 6, 4
setpoints A, 2 opening 6, 2
menu key 3, 10 using entered calibration points 6, 11
messages key 3, 13 determining the software 6, 2
modbus 1, 4 programming 1, 4 &10
monitoring 1, 2
multi-screen scrolling 3, 4
R
remote idle subroutine 4, 8
N, O remote/local key 3, 11
name entry 3, 19 reset key 3, 7
RTD temperature channels, calibrating 6, 8
offset, adding during calibration 6, 10 run mode, main screen 3, 2
opening procedure, calibration 6, 2
operation,
basic 3, 1 S
adjusting screen contrast 3, 6 scrolling 3, 4
entering alphabetical data sequential control 1, 3
software 11.07F5 and earlier 3, 18 sequences
software 11.07F6 and later 3, 19 control 4, 2
keyboard functions 3, 7 engine-driven reciprocating unit 4, 2
main run mode screen 3, 2 typical electric drive—changes 4, 10
multi-screen scrolling 3, 4 typical engine-driven screw unit—changes 4, 10
typical panel layout 3, 3 shutdown 4, 7
using the keyboard 3, 3 startup 4, 2
master controller A, 3 startup notes 4, 6
outputs key 3, 15 setpoints, master controller A, 2
overview, master controller A, 3 setting system parameters 5, 1
changing passwords 5, 5
controlling unit variables 5, 6
P shutdowns and alarms 5,3
panel test mode 5,2
layout, typical 3, 3 settings and timers, key 3, 16
indications, master controller A, 7 typical parameters 3, 17
parameters, setting 5, 1 shutdown sequence 4, 7
changing passwords 5, 5 shutdowns and alarms, parameters 5, 3
controlling unit variables 5, 6 shutdowns, alarms and annunciation 1, 2
shutdowns and alarms 5, 3 slide valve control key 3, 9
test mode 5, 2 software
passwords, changing 5, 5 Control Panel 1, 5
PID control determining 6, 2
tuning 5, 7 span settings check, calibration 6, 6
theory 5, 6
PIDs, master controller A, 2

FORM EXACTA XI-OG 9-03 3 of 4

Exacta Series XI Control Panel—Operations Guide Index

Topic Section, Page Topic Section, Page

special functions 1, 5
AGA calculations 1, 6
Control Panel software 1, 5
start key 3, 7
startup sequence 4, 2
startup notes 4, 6
stop key 3, 8
subroutines, control sequences 4, 7
auto slowdown 4, 7
engine jacket water/oil temperature override
and the blowdown valve 4, 8
manifold pressure override 4, 8
remote idle 4, 8
summary of features 1, 11
system layout 2, 1

T
temperature channels, calibrating
RTD 6, 8
thermocouple 6,7
theory
PID control 5, 6
process control 5, 6
thermocouple temperature channels, calibrating 6,7
timers and settings key 3, 16
typical parameters 3, 17
trending data 1, 8
troubleshooting 8, 1
tuning PID control 5, 7
typical panel layout 3, 3

U, V
unit variables, controlling 5, 6
PID control theory 5, 6
process control theory 5, 6
tuning PID control 5, 7
up key 3, 10
using
entered calibration points 6,11
the keyboard 3, 3

Z
0 to 5 V channels, calibrating 6, 9

FORM EXACTA XI-OG 9-03 4 of 4