BTU XT-70 User manual

Manual XT-003.5 Copyright BTU
Ventilation 2013

3
FORWARD
The new XT Series Control Panel from BTU Ventilation is built from the groun up for the 21st century farm
manager. Simplicity of operation, combine with sophisticate on-boar ata analysis an internet communica-
tions make this a control panel of the future.
STANDARD FEATURES:
• Twelve temperature sensors
• Three humi ity sensors
• One CO
2
sensor
• Fresh air oor pulse or irectional control
• Centrally istribute time, outsi e air temperature an outsi e air humi ity to multiple panel complexes
• Ethernet panel-to-panel networking
• Pulse humi ity control
• Infinite CO
2
control in refrigeration an cooling mo e
• Refrigeration capacity control
• Fan frequency rive on-boar controller
• In ivi ual frequency setting for each mo e
• Automatic pile temperature ifferential control
• All outputs are plug-in soli state mo ules for noise isolation
• All 4-20mA outputs are optically isolate
• All RS-485 communications are optically isolate
• Buil ing cavity control on-boar
• Manual - Off - Auto (MOA) switches for all outputs
• View multiple fan houses using a single graphical user interface
• Select from a number of ifferent user interface options
• Flexible Heat mo e, with pulse output
• Setpoint ramping
INDUSTRY FIRSTS:
• On-boar embe e web server
• No special PC programs require for remote monitoring an control
• Use any web browser on a PC, laptop, PDA or cell phone to monitor an control your storage
• Secure Socket Layer (SSL) for secure access
• Alarms an aily up ates via e-mail or text messaging.
• File Allocation Table (FAT) file system. All ata ownloa e irectly into a sprea sheet or atabase.
• Integrate all refrigeration information an controls into same atabase an user interface.
• Integrate smart oor controls to i entify in ivi ual oor controls an for accurate oor position.
• Designe for multiple fan house applications. Uses one user interface for a itional fan houses.
• Single boar esign, multi-layer for noise rejection.
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XT-70 Control Panel 3

Page
XT Sensors
1.1 Input And Output Specifications ………………………………………………. 6
Main Components
2.1 XT HMI ……………………………………………………………………………. 7
2.2 XT Control Module …………………………………………………………….. 8
Networking
3.1 Typical Ethernet Network Connections ……………………………………. 8
XT Operation And Alarm modes
4.1 Operational Modes ……………………………………………………………. 9
4.2 Secondary Modes ……………………………………………………………… 12
XT HMI Operation
5.1 Main Home Screen …………………………………………………………….. 14
5.2 Status Screen ………………………………………………………………….. 15
5.3 Password Screen ……………………………………………………………… 18
5.4 Pile temperature Screen …………………………………………………….. 19
5.5 Time Clock ……………………………………………………………………… 20
5.6 Outside Air Control ……………………………………………………………. 21
5.7 Deviation Alarms ………………………………………………………………. 24
5.8 Setpoint Ramp Control ……………………………………………………….. 25
5.9 Fan Speed Control …………………………………………………………….. 26
5.10 Humidity Control ………………………………………………………………. 28
5.11 Miscellaneous ………………………………………………………………….. 30
5.12 Virtual Switches Option Screen …………………………………………….. 32
5.12 Switch & Output Screen ………………………………………………………. 33
5.13 Fresh Air Door Status …………………………………………………………. 34
5.14 Test Mode ……………………………………………………………………….. 36
5.15 Graphing Module ……………………………………………………………….. 37
5.16 Activity og ……………………………………………………………………… 38
5.17 Refrigeration Interface ………………………………………………………… 39
5.18 E2 Memory Setup ………………………………………………………………. 40
E2 Parameters
6.1 E2 Definitions …………………………………………………………………… 41
XT Web Interface
7.1 Web Interface ………………………………………………………………….. 50
7.2 Web Refrigeration Interface ………….…………………………………….. 51
7.3 Web Setpoints ………………..……………………………………………….. 51
7.4 Web Java Control …....……....……………………………………………….. 53
7.5 Web Java Pile Temps …...…..……………………………………………….. 54
7.6 Web Java Run Time Clock ………………………………………………….. 54
7.7 Web Java Outside Air Control ……………………………………………… 55
7.8 Web Java Temperature Dev Alarm ………………………………………… 55
7.9 Web Java Setpoint Ramp ……………………………………………………. 56
7.10 Web Java Fan Speed Control ……………………………………………….. 56
7.11 Web Java Humidity Control …………………………………………………. 57
7.12 Web Java Miscellaneous …………………………………………………….. 57
7.13 Web Java Switch Control ……………………………………………………. 58
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5
Page
7.14 Web Java Door control ………………………………………………………. 58
7.15 Web Java Refrigeration Control ……………………………………………. 59
7.16 Web Java Records ……………………………………………………………. 59
XT Field wiring
8.1 120 VAC Field wiring ………………………………………………………….. 60
8.2 ow voltage Field wiring ……………………………………………………… 62
ONION CONTRO S
9.0 Onion Basics …………………………………………………………………… 64
9.1 Cure sequence ………………………………………………………………… 64
9.2 Cooling sequence ……………………………………………………………... 65
9.3 Onion Flow Chart ..…………………………………………………………….. 67
Appendix A: XT Records Interface …….……………………………………………. 69
Appendix B: XT Diagnostics Port …….……………………………………………... 77
Appendix C: XT Purge Cycles …..…….……………………………………………... 79
Appendix D: XT Warming Mode ……………………………………………………… 85
Appendix E: XT Sensor Measurements .…………………………………………... 86
Appendix F: XT CO
2
Management ….………………………………………………... 89
Appendix G: XT Potato Dehumid …..….……………………………………………... 96
Appendix H: XT HMI Records …………………………………………………………. 97
Appendix I: Sweet Potato Operation ………………………………………………... 98
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XT Analog Inputs:
• Plenum 1 F 2250 ohm
• Plenum 2 F 2250 ohm
• Outsi e Air F 2250 ohm
• Return F 2250 ohm
• Pile 1 F 2250 ohm
• Pile 2 F 2250 ohm
• Pile 3 F 2250 ohm
• Pile 4 F 2250 ohm
• Pile 5 F 2250 ohm
• Pile 6 F 2250 ohm
• Pile 7 F 2250 ohm
• Pile 8 F 2250 ohm
• Outsi e Humi % 4-20mA
• Plenum Humi % 4-20mA
• Return Humi % 4-20mA
• CO2 ppm 4-20mA
XT Digital Inputs:
• Fan proving Dry contact
• Cell pump proving Dry contact
• Refrigeration Fail Dry contact
• Remote Stan by Dry contact
• Spare
• Spare
• Spare
• Spare
• Low Temp SPDT contact
• Air Restrict Dry contact
• Start / Stop Dry contact
XT Sensors: The XT panel can accept a number of ifferent input sensors an has ten soli state 3
amp outputs. In a ition, there are two analog outputs that are 0-20mA or 0-10VDC. The fresh air
oors are controlle by two relay outputs.
XT Analog Outputs:
• Freq Drive 0-20mA / 0-10VDC
• Refrigeration 0-20mA / 0-10VDC
XT Digital Outputs:
• Re light 3A 120VAC SS
• Yellow light 3A 120VAC SS
• Fan / Green light 3A 120VAC SS
• Evap cooling pump 3A 120VAC SS
• Humi ifier pump 1 3A 120VAC SS
• Humi ifier pump 2 3A 120VAC SS
• Heater 3A 120VAC SS
• Aux 1 3A 120VAC SS
• Aux 2 3A 120VAC SS
• Cavity heater 3A 120VAC SS
• Door open 12VDC/relay
• Door close 12VDC/relay
Note - The Aux 1, Aux 2, an cavity heater can be set to be interlocke with the Start / Stop
switch, mechanical Low Temp an Air Restriction evices or to operate in epen ently.
1.1

7
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XT Panel Main Components
G70 HMI (Human Machine Interface) color touch screen: The XT panel has many options for user inter-
faces. The stan ar interface is a G70 an is a 320 x 240 color touch screen. An optional G75, 640 x 480 lar-
ger color touch screen, is also available. Active touch buttons are either labele or shown as raise buttons.
Pressing one of these buttons will pro uce a keypa for entering a new value.
The sole purpose of the HMI is to provi e a frien ly user interface to the XT control car . One HMI can commu-
nicate with multiple XT panels an more than one HMI can communicate with the same XT panel. The HMI is
not necessary for the XT panel to run. A PC with the appropriate software can also act as an HMI. Ethernet is
use for the communications connection between the HMI an XT panel. With the high spee of the internet, it
is now possible to locate the HMI screen almost anywhere.
HMI Hot Keys: The HMI has a number of hot keys use to go irectly to a screen verses using the FWD> an
<BWD keys. For example, pressing the label TEMP SP on the home screen will irectly bring up the Tempera-
ture Setpoint Ramp screen. Pressing the <HOME> key on any screen will go irectly back to the first general
screen (the home screen).
2.1

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XT-70 Control Panel 8
XT Control Module: The XT control mo ule was esigne for economics, ease of installation, manufacturing
an flexibility. Each outputs on the XT mo ule has a MOA (Manual-Off-Auto) switch an an LED in icator asso-
ciate with it. By incorporating the MOA switches as part of the panel, it allows for a very compact mo ule an
also allows the microprocessor to rea full switch status. The mo ule also inclu es a refrigeration control poten-
tiometer for use in manual mo e. This allows a justment of the output of the refrigeration for testing purposes.
At all times, the low temperature an air restriction safeties, along with the Start/Stop switch, supervise the out-
puts. The Aux 1, Aux 2 an Cavity outputs can be set for supervision or act in epen ently of the Start/Stop
switch an system safeties.
Typical Ethernet Network Connections
XT Panel 01
XT Panel 02
Router
INTERNET
Remote PC
Remote HMI
Local HMI
Local PC
2.2
3.1

9
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XT-70 Control Panel 9
XT Modes: The XT Panel operates in two mo es: the main operation mo e an a secon ary mo e. Depen -
ing on the setup of the alarms, it is possible to continue running in an alarm mo e.
For example, for a cell pump failure, the secon ary mo e woul in icate a cell pump failure, sen out the alarm,
in icate an alarm (a blinking re light) but continue to run in Cooling or Refrigeration. Wetbulb calculation woul
be shut off.
4.1 XT Modes of Operation
MAIN OPERATIONA
MODES
SECONDARY
MODES
Main Operation Modes:
Shutdown: Shut own is activate by the Stop/Start switch set to the Stop position.
Standby: Stan by can only be activate with the time clock set to stan by or
with no outsi e cooling available uring Cooling mo e.
Cooling: Cooling mo e can only be activate with outsi e cooling air available
an time clock set to either Cooling or Refrigeration mo e.
Refrig: Refrigeration mo e will be activate when cooling air is not available
an the time clock is set for Run or Ref Only.
Timed: Time Run will be activate when the time clock is set to Run, there
is no outsi e cooling air available an the refrigeration switch is set to
Off.
Remote Stop: Remote stop is activate with the Stop button from either the HMI
touchscreen or web interface.
Test: The Test mo e is a special mo e that allows remote testing of all out-
puts. This is activate from either the HMI or the web interface.
ow Temp: The low temp alarm is triggere by the backup low temp safety
thermostat. It can only be reset with the Start/Stop switch.
Air Restriction: The Air Restriction alarm is triggere by the air pressure ifferential
switch. It can only be reset with the Start/Stop switch.
Parameter Fail: The Parameter fail is triggere by an out-of-range setting on one of the
critical parameters. If setpoint is < 32.0 or > 76.7, the alarm is trig-
gere . If target is < 32.0 or > 76.7, the alarm is triggere . If pile iff
selection > 8, the alarm is triggere . If Start ifferential > 50 or < -50,
the alarm is triggere .

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Comm Fail: Loss of communication between the Rabbit an P1 processor for more
than three minutes. An internal comms bus failure is serious.
Power Fail: Loss of 110VAC control power.
Remote Standby: Remote Stan by is activate by a contact closure across input IN4.
Typically use for off-peak power, ripple control or refrig efrost.
Alarm Standby: Any alarm con ition that was set to shut own the system.
Cure: This mo e is a Onion mo e. This mo e is use when the fresh air
oors are being use to cure the onions.
Burner: This mo e is a Onion mo e. This mo e is use when the burner is
being use to cure the onions.
Fan Fail: The fan input IN1 i not get a close contact within the fan fail timer
perio . There is a programmable timer associate with this alarm.
Fan Off: The fan MOA switch is in the Off position.
Warming: The virtual warming switch in in the Auto position. In Warming mo e,
the oors will open whenever the OSA is greater than the start tem-
perature an will warm the plenum air up to the setpoint. The PID is
running in a reverse mo e, opening the oors whenever the plenum is
too col . When OSA is less than the start temperature the system will
run in Cooling. The time clock must be set to Cooling for the Warming
mo e to operate.
Cooling / Purge: The system is in Cooling an the return air heaters are being use to
force the fresh air oors open. This cycle has been triggere by time
an not the CO2 sensor.
Refrig / Purge: The system is in Refrigeration an the fresh air oors are open to the
max oor setting. This cycle has been triggere by time an not the
CO2 sensor.
Timed / Purge: The system is in Time an the time purge cycle is active. At the
esignate time, the fresh air oor will open to the max oor setting
an purge for the programme time. This cycle has been triggere by
time an not the CO2 sensor.
Refrig / AR : The system is in Refrigeration an the ARL (ambient reverse loa ing) is
active. The Fresh air oors are being use to bring in fresh air an keep
the refrigeration running at a minimum setting.
Cooling / CO2: The system is in Cooling an the CO
2
level is above The CO2 setpoint.
The return air heaters are active to help open the oors an purge the
CO
2
.

11
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XT-70 Control Panel 11
Refrig / CO2: The system is in Refrigeration an the CO
2
level is above CO2 setpoint.
The fresh air oors are being use to purge the CO
2
.
Door Defrost: The system is in Cooling an the fresh air oor efrost has been
triggere . The oors are close an the return air is being use to
efrost them. This shoul only be use uring extreme times of col
Outsi e air.
Heat: This mo e is use to turn on return air heaters when the system is
running in Cooling, the oors are close an the plenum temperature
has rop below the Setpoint minus the heat ifferential.
Cooling / Dehumid: The system is in a normal Cooling mo e an has etecte high
humi ity. In Onion mo e, the burner is on low fire to bring in more fresh
air. In Potato mo e, the return air heater is use to ehumi ify.
Refrig / Dehumid: This is an Onion mo e. The system is in a normal Refrigeration mo e
an the burner is being run on low fire.

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XT-70 Control Panel 12
Secondary Modes:
None: There are no secon ary mo es currently active.
Ramp: The setpoint an target are ifferent values an the system is in the
Ramp mo e. The Ramp mo e can ramp the setpoint up or own.
Fan Manual: The fan MOA switch is in the Manual position. The system will run as
normal.
Cell Pump Fail: The Cell Pump Fail will trigger when the cell MOA switch is turne to
Auto an the Cell pump input (IN2) is off. There is a programmable
elay timer (CPF_timer) associate with this alarm..
Refrig Fail: The Refrig Fail Alarm will trigger when the refrigeration MOA switch is
turne to Auto, the refrigeration input (IN3) is off an the system is in
Refrigeration mo e. The system will continue to run in Cooling mo e if
outsi e cooling is available.
Plen Sensor Fail: The Plenum Sensor Fail alarm is triggere by a programmable iffer-
ence between Plen 1 an Plen 2. There is a programmable timer
Associate with this alarm.
OSA Sensor Fail: The Outsi e Air Sensor Fail alarm is triggere by an out-of-range out-
si e air sensor. There is a programmable timer associate with this
alarm.
Fan Boost: The fan boost has programmable parameters that allow you to specify
certain intervals for the fans to spee up stir the air an then go back to
original spee . On the initial change the fans will spee up 5% per
Minute. On termination the fans will change imme iately to the original
spee .
ow Dev: The Low Dev alarm will trigger when the plenum temperature rops
below the low ev setting, the timer has expire an the fans are run-
ning. There is a programmable timer associate with this alarm.
High Dev: The High Dev alarm will trigger when the plenum temperature rises
above the high ev setting, the timer has expire an the fans are
running. There is a programmable timer associate with this alarm.
OSH Sensor Fail: The Outsi e Humi ity Sensor Fail alarm is triggere by a out-of-range
outsi e humi ity sensor. There is a programmable timer
associate with this alarm.
ow Humidity: The Low Humi ity alarm is triggere when the plenum humi ity level
rops below the low humi ity setting. The system must be in a vali
operating mo e. There is a programmable timer associate with this
alarm.
High CO2: The High CO
2
alarm is triggere by a CO
2
level greater than the high
CO
2
setting. The system must be in a vali operating mo e. There is a
programmable timer associate with this alarm.
4.2

13
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XT-70 Control Panel 13
Pile Humid Fail: This is an Onion alarm. The program has etecte a failure with one
of the two pile humi ity sensors. There is a programmable timer
associate with this alarm.
Pile Temp Fail: This is an Onion alarm. The program has etecte a failure with one of
the four pile sensors that are being use . See the sensor configuration
to etermine which sensors are being use . There is a programmable
timer associate with this alarm.

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HMI Operation:
Main Home Screen:
The home screen will show the status of up to ten XT panels. Each of the panels are up ate every secon .
The panel name is unique to each panel an can be set up with the web interface. To get to the main screen of
any panel, press the PANEL name button. This will isplay the in ivi ual screens for a panel on the HMI. Press-
ing the <HOME> button from the home screen will take the HMI back to this screen.
Touchscreen:
The touchscreen can be activate by using your finger or any type of plastic stylus. Using a finger will leave
prints an oil on the isplay screen. Care shoul be use when cleaning the screen not to scratch it. A clean
soft cloth an a mil glass cleaner shoul be use to clean the screen, .
5.1

15
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HMI Status Screen:
TEMP SP: Plenum temperature setpoint. To change the setpoint, press the yellow button A pop-up key-
boar will be isplaye . Type in the esire setpoint with or without a ecimal place. Only one
ecimal place can be entere . Press Enter to sen the new
value or press Cancel to go back to the main screen. The
range of the setpoint is 33.0 to 80.0 egrees F. A value outsi e
this range will cause a Parameter Fail alarm.
HUMID SP: Plenum Humi ity Setpoint. The humi ity setpoint has a range
from 0 to 100 %. To change the setpoint, press the blue but-
ton. A pop-up keyboar will be isplaye . Type in the esire
value. The value can be a number with zero or one ecimal
places.
CO
2
SP: CO
2
Setpoint. This is the upper limit for the CO
2
level in the storage. The best location for the
CO
2
sensor is in the return air of the storage. The CO
2
Setpoint has a range of 0 to 10000 ppm.
To change the CO
2
setpoint, press the green button. A pop-up keyboar will be isplaye . The
value is a whole number only.
OUTSIDE T: This is the outsi e air temperature in egrees F.
OUTSIDE H: This is the outsi e humi ity.
DOOR OPEN: This isplays the amount of fresh air that is being brought into the storage. It is a value from 0
to 100 percent. This is a important value an will be active in the Refrig/CO2 mo e.
5.2
Note - to make any change to a system parameter, the Unlocked button must be green. See .3
on how to lock and unlock the system.

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HMI Status Screen:
FAN: This is the current percentage of fan spee if variable frequency rives are use . This
value will change epen ing on the current system mo e.
P ENUM T: The plenum temperature is measure using two plenum sensors locate close together.
These two sensors are average an isplaye as Plenum T. The reason for two
sensors is to etect a sensor failure. If the ifference between the two sensors is above
a preset limit, the system will shut own an isplay a plenum sensor alarm.
P ENUM H: Plenum Humi ity. This value is use for the storage humi ity control.
CO
2
: This is the CO
2
level in ppm. This rea ing is taken in the return air an is a goo
in icator of the CO
2
level in the buil ing. This rea ing is also use for the CO
2
control.
RETURN T: The return air temperature is locate above the pile an is a goo in icator of the
amount of heat coming out of the pile or of the average pile temperature.
START T: Start Temperature. Start temperature is a calculate value use to etermine when out-
si e cooling is available. For outsi e cooling air to be available, the outsi e air temp
must be below the start temperature.
REFRIG EVE : Refrigeration level is the current refrigeration operation level from 0 to 100 %.
DAI Y: Actual run time since 12:00 Noon. The aily run time is cleare each ay at noon.
TOTA : Total run time of the system. At any time, press the TOTAL button to change the time to
zero or to a preset value.
This button will return to the previous screen.
This button will a vance to the next screen.
This button will return to the main home screen.
The Locke button will keep the keyboar locke an will not allow any changes to the
setpoints. When the Locke key is presse , a keyboar will appear. Type in the user-
name an passwor separate by a perio .
Once the correct user name an passwor is entere , the key will change to
UnLocke . To lock the system again, press the UnLocke key.
This button will a vance to the real time graphs mo ule an the activity log.
<BWD
FWD>
<HOME>
ocked
Un ocked
GRAPHS

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HMI HOT KEYS:
Hot keys allow the user to jump to any of the screens irectly without using the FWD> an <BWD buttons. The
labels for each of the parameters on the main screen are hot keys.
TEMPERATURE RAMP SETPOINT SCREEN
HUMIDITY CONTROL SCREEN
CO2 CONTROL AND MISC SCREEN
OUTSIDE AIR CONTROL SCREEN
FRESH AIR DOOR CONTROL SCREEN
FAN SPEED CONTROL
TEMPERATURE DEVIATION SCREEN
REFRIGERATION CONTROL SCREEN
RUN TIME CLOCK SCREEN
STOP
START
This button will force the system into a Remote Stop mo e. The Remote Stop will
reset all alarms an act just like the local Start/Stop switch.
Once the STOP button has been presse an the system goes into Remote Stop
mo e, the STOP button will then isplay START. Press it once again an the sys-
tem will resume normal operation.

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HMI Passwor Screen:
5.3 Password Screen:
A vali username an passwor must be entere to unlock the system. There are three levels of passwor pro-
tection within the XT program. Three ifferent passwor s can be entere . All passwor information can only be
entere using the XT web interface. The username an passwor can not be change from the HMI, only from
the web interface.
evel 1 View only User is authorize to view only.
evel 2 Control User is authorize to view an to make control parameter
changes.
evel 3 Configure User is authorize to view, to make control parameter changes
an to make system configuration changes.
Web Interface
User Authorization
Screen

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HMI PILE TEMPERATURES:
Each of the pile temperatures are isplaye as a bar graph an in a win ow. The bar graph allows easy com-
parison between all of the pile temperatures. If the system is operating a cavity, some of the pile sensors may
be esignate as cavity sensors.
The line graph shows the plenum an return temperatures for one hours.
Each pile sensor can be in ivi ually name . This is one through the web interface an can be one remotely
by the ealer. When the names of the pile sensors are change , the names will appear on all of the recor s an
also on the web pages.
5.4

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HMI TIME CLOCK:
The XT panel runtime clock is use to esignate how the panel is to run. It is the heart of the system an will
etermine the amount of runtime your storage will get each 24 hours. The time clock provi es a visual ai on
how the panel is set up. If the AM button is presse , the isplay will show the PM settings for the time clock.
Pressing the PM button will isplay the AM settings. Each colore block esignates a half hour increment. The
AM time clock starts at mi night an goes to noon. The PM time starts at noon an goes to mi night. To change
a time, press one of the four mo e buttons first an then press the esire 30 minute block. Mo es can be
change by pressing the mo e button at any time an then the 30 minute blocks. When one, press the pro-
gram button. Pressing the cancel button iscar s any changes
Once the mo e is chosen, press the SET ALL button to save the changes to all time clock slots.
STANDBY
The STANDBY hours in the time clock will force the system to turn off. The fans an all
other evices will be in the Off mo e.
COO ING
COOLING hours in the time clock will allow the system to run only when there is cooling air
available. This mo e will not run refrigeration or a time run. If COOLING hours are pro-
gramme an there is no cooling air available, the system will go into Stan by mo e.
5.5