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STANDARD OPERATING PROCEDURE &

BASIC TROUBLESHOOTING OF
ALTRONIC MIDAS HMI & EXACTA21 PLC
A. INTRODUCTION OF
MIDAS HMI
WHAT IS MIDAS ????...........

MIDAS is Monitored Information Devices And


Systems, provides a system touch screen that
delivers centralized access to critical
information in parallel with the individual
Overview
5.The standard MIDAS system includes pre-
configured system display screens, individual
Altronic product databases, and the
MIDASBuilder-Crimson3 system software to do
simple custom screen development.
Overview

1.Each MIDAS system


incorporates a 10.4" panel
mounted LCD for critical
engine and
compressor/process data
collection and monitoring.
2.MIDAS provides a central
point for key control panel
information while
maintaining direct access
to individual in-panel
instruments and controls.
Overview
3.MIDAS acts as a communications
hub/protocol converter for a single
connection from the plant (unit) to the PC

Display of MIDAS HMI Workstation Monitor at CPS


Mechanic Office
Overview
4.MIDAS is compatible with all serial
communications-capable of Altronic
products and another suitable products
manufactured by others.
Overview
5.MIDAS incorporates full-
featured, user-configurable
system data logging and
export.
6.An integral CompactFlash
card reader offers expanded
capability.
Overview
7.MIDAS display incorporates a
full-featured math library
capable of advanced
calculations
8.Certified UL-C for use in Class
I, Division 2, Groups A,B, C
and D hazardous areas.
C. MIDAS HMI
Screen Structure
and
Functionality
MIDAS HMI Buttons
#1
#1 -- Unit
Unit
Overview
Overview
#2 - Sequence
Control

#3
#3 -- Engine
Engine

#4
#4 -- Compressor
Compressor

#5
#5 -- Trending
Trending
#6
#6 -- F1
F1
(Compact
(Compact Flash
Flash
Status)
Status)

#7
#7 -- F2
F2 (IP
(IP
Configuration)
Configuration)
#8 -- Main
#8 Main Menu
Menu
MIDAS Button #1 - Unit
Overview
The MIDAS Unit Overview
screen displays start-
stop engine and
compressor squence
Screen includes
Reset, Step start, Auto start,
Cooldown Stop, Sudden stop
Buttons
Engine hours & RPM
Critical engine & compressor
temperatures and process
pressures
Alarm/shutdown indicators
Log sheet button for data operator
reading
MIDAS Button #2 - Squence
Controller
The MIDAS Squence
Controller screen
emulates much of the
display and control
functionality of the
monitoring and control
system in the Exacta21 &
MIDAS Panel
Screen includes
Purging Squence
Prelube Squence
Auto Start Squence
Warm-up Squence
RPM Setting
Vavlve Squence fail
MIDAS Button #3 -
Engine
The MIDAS ENGINE screen
displays prime mover-
specific parameters
typically the engine
driving the process
Screen includes
Engine Layout and speed
All major prime mover-related
temperatures and pressures
engine, cylinder, turbocharger,
manifold, etc.
Run timer and engine hours
Offers a comprehensive
view of the engine
MIDAS Button #4 -
Compressor
The MIDAS Compressor
screen displays critical
parameters from multiple
instruments and controls
specific to the process of
compressor
Screen includes
Engine and compressorstatus and
speed
All major process-related
temperatures, pressures, Valves
position and levels
Offers a comprehensive view
of the compressor
MIDAS Button #5 -
TRENDING
The MIDAS Exhaust &
Discharge temperature
screen allows the user to
simultaneously monitor a
number of Engine exhaust
and discharge
temepratures, etc.
Effective in detecting
abnormal conditions or
trends over extended
time periods
MIDAS Button #6 (F1)- Compact
Flash Status
The MIDAS Compact flash
status screen displays
External memory status
Screen includes
Compact flash status
Compact flash disk size
Compact flash free memory
Compact flash percent free
storage
Eject Card Button
Format Card Button
MIDAS Button #7 (F2) - IP
Configuration
The MIDAS IP Configuration
screen displays Internet
Protocol address of MIDAS
on the altronic control panel
Screen includes
Current IP Address
Current subnet mask
Current default gateway
Device MAC Address for
Apple_Machintosh operating
system
MIDAS display brightness
MIDAS display contrast
MIDAS Button #8 - Main
Menu
The MIDAS Main Menu
screen displays the menu
buttons
Screen includes
Unit Overview
Sequence Controller
Engine
Compressor
Master PID
Shutdown & Alarm Set-point
Digital Status
Alarm
Log of
MIDAS SCREEN - SHUTDOWN &
ALARM SETPOINTS
MIDAS SCREEN - DIGITAL
STATUS
MIDAS SCREEN - MASTER PID
CONTROL
MIDAS SCREEN - VIBRATION
MONITOR
D. MIDAS HMI
TROUBLESHOOTING
1. SERIAL COMMUNICATION (RS232 or
RS485)
PROBLEM POSSIBLE CAUSES POSSIBLE SOLUTIONS
Values show ---- Port settings do not match. Check that the port settings of the MIDAS Builder device match the
target device (i.e. Baud, Parity, etc.).
Incorrect target device Check that the target device address in Midas Builder Crimson (in
address. communications on the Exacta PLC symbol) matches the target
device address setup.
Incorrect cable. Check the cable part number or cabling to match your protocol.

Incorrect communication Check if the cable is connected to the right communication port.
port.
If the above is correct, check that the protocol settings are on the right
communication port in MIDAS Builder.
Communication port Although unlikely, check the communication port connector pins on
connector pins the MIDAS device in case some are bent inward resulting in a bad
contact with the cable.
bent inward.
Incorrect tag mapping. Check that the tag is mapped to an existing register in the target
device.
Values blink Incorrect tag mapping on Delete tags one after another and download in-between. When the
between one of the values on the screen stop blinking, the last deleted tag was mapped
incorrectly or accessed an unknown register in the target device.
the data and ---- tags on the display.
Communications times-out. Increase the Slave Response or Device Timeout on the
communication port or
target device in MIDAS Builder.
D. MIDAS HMI
TROUBLESHOOTING
1. RS-485 SERIAL COMMUNICATION (Sample
Case)

ERROR RS-485 SERIAL NORMAL RS-485 SERIAL


COMMUNICATION COMMUNICATION
D. MIDAS HMI
TROUBLESHOOTING
2. ETHERNET COMMUNICATION
PROBLEM POSSIBLE CAUSES POSSIBLE SOLUTIONS

Values show ---- Incorrect target device IP address. Check the target device IP address in MIDAS builder (in communications on
the EXACTA21 PLC symbol) to match the target device IP address setup.

Incorrect cable or wrong Check the LED on the Crimson device Ethernet port. If none are lit, there
connection. are no connections. Check the cable or that the Ethernet port is enabled in
MIDAS Builder Crimson, see below.
Ethernet port disabled. Check that the Ethernet port in Crimson is enabled.

MIDAS Builder Crimson and target


devices are in a different address
domain.

a If no routers are present on the Check that the target device IP address and Crimson device IP address are
different but in the same domain. (For example, both start with the same
network. three
first numbers; ex: 192.168.0.xxx if the mask is 255.255.255.0).

b If a router is present on the Check the MIDAS Builder Crimson device Ethernet port gateway address to
match the router IP address.
network.
Incorrect tag mapping. Check that the tag is mapped to an existing register in the target device.
Values blink Incorrect tag mapping on one of Delete tags one after another and download in-between. When the values
between the tags on the display. on the screen stop blinking, the last deleted tag was mapped incorrectly or
accessed an unknown register in the target device.
the data and ----
Communications times-out. Increase the Slave Response or Device Timeout on the communication port
or
target device in MIDAS Builder Crimson.
D. MIDAS HMI
TROUBLESHOOTING
2. ETHERNET COMMUNICATION
PROBLEM POSSIBLE CAUSES POSSIBLE SOLUTIONS
Internet Browser Web Server not enabled. Check that the Web Server in MIDAS Builder Crimson is
says enabled.
Cannot display Ethernet port disabled or Check that the Ethernet port in MIDAS Builder Crimson is
the Ethernet enabled and has a correct
web page settings issue. IP address.
Incorrect MIDAS Builder Check that the IP address in the browser matches MIDAS Builder
Crimson device IP Crimsons Ethernet IP address.
address.
Incorrect PC IP Address. Check the PC Ethernet Settings for a valid IP address.
D. MIDAS HMI
TROUBLESHOOTING
2. ETHERNET COMMUNICATION (Sample
Case)

ERROR ETHERNET NORMAL ETHERNET


COMMUNICATION COMMUNICATION
Exacta21 Control
Systems
Exacta21 Control
Products
The Altronic Exacta Series 21
Controller system includes
the necessary hardware and
program for the referenced
gas compressor application.
Exacta 21-based gas
compressor control panels in
operation throughout the
United States, Canada, and
internationally,
Over 3,000 applications of the same
controller in service in
Hardware and software are well-
developed, recently modernized, and
stable
Ideal for moderate to high-
specification control
applications as an alternative
to a PLC
Exacta21 Control -
Benefits
Configuration software is embedded
within the controller, eliminating the need
for expensive software purchases and
upgrades
Designed and constructed for harsh and
hazardous environments
Like all Altronic products, the Exacta 21controller is suitable
for service in extreme temperature conditions (low and high)
Local password protection of critical
setpoints and other parameters
Easily produces effective, usable data
reports of operating condition
System is expandable and can accept up
to (8) back panel-mounted I/O cards
Why an Exacta21 instead of
a PLC?
Designed from day one for gas
compression control service
The Exacta is not an empty sheet of paper
System is configured not programmed
allowing for simple field adjustments
Reliability
3000+ Systems in daily service
Hardware stability
The Exacta line has been continually
maintained and upgraded
Converted to surface-mount technology in
2007
Screen Preview of EXACTA21
Configuration
The Exacta21 Control
The Exacta 21 is capable of
being applied to virtually
any size compressor or
prime mover
Advanced monitoring and
control capabilities are
available, including:
Pre/post-lube
Auto or manual start
Warmup
Compressor loading/valve control
Safety shutdown, alarm
annunciation and monitoring
Fast or auto-cool-down
Auto-depressurization (unloading)
The Exacta21 Control
Comprehensive
control capability is
achieved through the
use of up to fifteen
(15) PID control loops
Speed setpoint control
Capacity control - screw and
reciprocating compressors
Suction valves
Bypass valves
Slide valves (screw)
Cooling louver controls
Other desired control loops
The Exacta21 Control
Altronic
EXACTA21 Major
components:
- Altronic EXACTA
COMPUTER/DISPLAY UNIT
- Altronic EXACTA SMART
ANALOG I/O BOARD
- Altronic EXACTA SMART
DISCRETE I/O BOARD
The Exacta21 Control
There are four Exacta 21 I/O board assemblies
Sixteen (16) Channel Analog I/O Board
(16x16) P/N: 691404-1
Individually selectable for J or K TCs,
4-20mA/0-5 volt resistive, RTDs as inputs,
PLUS four (4) 4-20mA Outputs

Sixteen (16) Channel Analog Input Board


(16x0) P/N: 691404-2
Identical to above, but excludes any outputs

Twelve (12) Channel Digital I/O Board


(12x12) P/N: 691405-1
Isolated digital discrete (N/O or N/C), PLUS
twelve (12) isolated digital discrete outputs

Twelve (12) Channel Digital Input Board


(12x0) P/N: 691405-2
Identical to above, but excludes any outputs
The Exacta21 Control
Local and
remote
communications
done via ModBus
RTU (Remote
Terminal Unit)
EXACTA21

RS-485
Serial Communication
The Exacta21 Control
Exacta standard
with 21
character
programmable
"hotkeys" is
dedicated to
control functions
of individual
Displays all critical operating
data on a single screen
User-friendly interface
The Exacta21 Control
Sample
Screen Layout
and Keyboard
Reset Start
Stop
History Outputs
Crank
Up Messages
Auto Stop
Down Enter/Exit
Menu
Timers and Settings
Master Load Control
Status (may also be labeled
as Inputs)
EXACTA21 DISPLAY
Troubleshooting
Exercise for
Troubleshooting
Exacta21 and Midas not
connected
1. Make sure the RS-485 Serial
Communication connected
2. Do the configuration on exacta21:
- Press the button K [menu)
- Select [1] Program Mode
- Type the password and press ENTER
to advance to the Program Menu
Exercise for
Troubleshooting
Exacta21 and Midas not
connected
- Press [2] Set Up Menu

- Select [3] Set Up RS-485


- Make sure all the configuration is correct