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DR4500A Classic Series Circular Chart Recorder With or Without

1. 82 4 3 Parameters Set Up Group 86 4 4 Chart Parameters Set Up 88 4 5 Total Parameters Set Up 89 4 6 Control Parameters Set Up Group ssssssssssssseee eee 91 4 7 Tuning Parameters Set Up 100 4 8 Setpoint Ramp Set Up enne 103 49 Timer Set Up eene nennen 105 4 10 Alarms Set Up Groupen a 106 4 11 Auxiliary Output Set Up 109 4 12 Modbus Communications Set Up 111 4 13 Options Set Up Group nennen 112 4 14 Lockout Parameters Set Up Group 114 Sis Operation ideti etm mmu 115 OVervieW pts 115 5 24 Pr parationsz e eta eee ien iN 116 5 3 Staneu pecs scout eue RR Ee 118 54 Monitoring Your Recorder ssssssseeeee emen nemen 121 5 5 Operator FUnctlofis cente etae reed te tene Yet o da RO RR a o e Ran 128 56 Operating Modes ute ere te berti
2. 163 6 7 Setpoint Program Segments Set Up 165 6 8 Setpoint Program Event Set Up 168 6 9 Run Monitor the Program ssseseee 172 7 Input GallDIalor iu sett dudes ta etr Inm oe neta eri Ert 175 7 1 nette I 175 7 2 Restoring Factory Calibration 176 7T 3 Minimum and Maximum Range Values sse 178 7 4 Preliminary Informations t irt cie three nete e 178 7 5 Calibration Set Up and Wiring for PV 181 1 6 Galibration Procedure io ice tuae elc Ga PR ds 190 8 Output Calibration done onion iind 193 8 1 OVeEVIOW apesan eaae ciun debi 193 8 2 Current Proportional Output Aux Out 2 and Calibration 194 8 3 Position Proportional Output Calibration sss 196 8 4 A Auxiliary Output Calibration emm 199 9 Troubleshooting Service Su d ose pened mean met Sie merde 201 9 1 rl as 201 9 27 Troubleshooting Aids vite ierit teet P anie vienen eas 203 9 3 Self Diaghostics bet oue eb ded tc B e haa En dede tds 205 9 4 Visual Failure Symptoms
3. 129 5 4 pee tes ebd ee eee 131 5 8 Single Setpoint Ramp ssssssssssseseeeeee eere 133 5 9 Using Two Sets of Tuning Constants PID 136 57101 Using Accutune lI itcr c eder E 139 5 11 Alarm Setpolnts 2 pee te ta ed e eee Gt hel ge wed etd Pe aue 142 5 12 Digital Input Option Remote Switching eee 143 5 13 Resetting and Displaying Totalizer Value 144 5 14 Monitoring the External Event Operation 146 5 15 eC e de tk ie dee etd ee 146 5 16 Routine Maintenant ssaa eaa eA aE nennen merenti 147 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual vii May 2013 5 17 Installing Replacing Chart ssseem eme 148 6 Setpoint Ramp Soak Programming and Operation 149 6 1 OVERVIEW e e eu 149 6 2 Setpoint Program Contents ersero aa ea Ea E emnes 151 6 3 Drawing a Ramp Soak Profile ssssss eem 154 6 4 Entering the Setpoint Program Data sse 159 65 SPRAMP 1 and SP RAMP2 Set Up 161 6 6 Setpoint Program Profiles Set Up Group
4. RTD Be sure W1 MA jumper is in position Be sure W3 jumper W1 on the input board is in position T C on the input board Thermocouple Compensated extension wires Calibrator Connector plug J2 for 22090 inputs 1 or 2 Figure 7 4 Calibration set up diagram for Thermocouple inputs using a compensated calibrator method 184 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Input Calibration Calibration Set Up and Wiring for PV Inputs Thermocouple inputs using the ambient temperature method Refer to Figure 7 5 and wire the recorder according to the procedure given in Table 7 8 Table 7 8 Set up wiring procedure for Thermocouple inputs using the ambient temperature method Step Action 1 Connect the copper wire to the Precision Millivolt Source see Figure 7 5 2 Connect the other end of the copper wire to the clamp type terminals in the plug for the applicable input connector J2 3 dri the plug into the input connector J2 on the applicable circuit board for input 1 or input 2 Adjust calibration voltages to compensate for measured ambient temperature scd L Calibration source Copper wires FD 0 Ambient temperature method Connector plug J2 for inputs 1 or 2 TUN Be sure W1 MA jumper is in position Be sure W3 jumper W1 on the input board is in position T C on the input board Figure 7 5 Calibrati
5. 00 00 to 99 59 SG17RAMP Ramp 00 00 to 99 59 or 0 to 999 SEG5RAMP Ramp 00 00 to 99 59 SEG18SP Soak SP Within SP or 0 to 999 limits SEG6 SP Soak SP Within SP SG18TIME Soak Time 00 00 to 99 59 limits SEG6TIME Soak Time 00 00 to 99 59 SG19RAMP Ramp 00 00 to 99 59 or 0 to 999 SEG7RAMP Ramp 00 00 to 99 59 SEG20SP Soak SP Within SP or 0 to 999 limits SEG8 SP Soak SP Within SP SG20TIME Soak Time 00 00 to 99 59 limits SEG8TIME Soak Time 00 00 to 99 59 SG21RAMP Ramp 00 00 to 99 59 or 0 to 999 SEG9RAMP Ramp 00 00 to 99 59 SEG22SP Soak SP Within SP or 0 to 999 limits SEG10SP Soak SP Within SP SG22TIME Soak Time 00 00 to 99 59 limits SG10TIME Soak Time 00 00 to 99 59 SG23RAMP Ramp 00 00 to 99 59 or 0 to 999 SG11RAMP Ramp 00 00 to 99 59 SEG24SP Soak SP Within SP or 0 to 999 limits SEG12SP Soak SP Within SP SG24TIME Soak Time 00 00 to 99 59 limits SG12TIME Soak Time 00 00 to 99 59 SG25RAMP Ramp 00 00 to 99 59 or 0 to 999 166 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Segments Set Up Group Prompt Function Range Your Prompt Function Range Your selection selection SEG26SP Soak SP Within SP SG31RAMP Ramp 00 00 to 99 59 limits or 0 to 999 SG26TIME Soak Time 00 00 to 99 59 SEG32SP Soak SP Within SP limits SG27RAMP Ramp 00 00 to 99 59 SG
6. Para reduzir o risco de choque el ctrico que pode causar danos corporais seguir todas as normas de seguran a contidas nesta documenta o Este s mbolo avisa o utilizador sobre um eventual perigo de choque quando s o acess veis voltagens sob tens o perigosas Terminal de protec o de terra Fornecido para liga o do condutor do sistema da protec o de terra Om e Se este equipamento for usado de modo n o especificado pelo fabricante a protec o fornecida pelo equipamento pode n o ser adequada e Nao se deve substituir qualquer componente ou pe a que n o seja explicitamente especificado como substitu vel pelo nosso revendedor e Toda a cablagem deve estar de acordo com os c digos el ctricos locais e deve ser realizada por pessoal experiente devidamente autorizado e terminal de terra deve ser ligado antes de ser feita qualquer outra cabelagem e desligado em ultimo lugar e Recomenda se um comutador na fonte de alimenta o principal pr ximo do equipamento ESPECIFICAGOES DO EQUIPAMENTO Voltagem 102 a 132 Vac 204 a 264 Vac Frequ ncia 49 61 Hz 59 61 Hz Pot ncia ou consumo de corrente 9 Watts max CONDI ES AMBIENTAIS N o operar o instrumento na presen a de liquidos ou vapores inflam veis A opera o de qualquer instrumento el ctrico em tal ambiente constitui um perigo para a seguran a Temperatura Ambiente 15 a 55 C Humidade 10 a 90 RH Vibra o 0 a 70 Hz aceler
7. Prompt Description Range Your selection SPP EVNT Access to events N A N A SEG1 EV Event status NONE ALARM1 ALARM2 ALARM3 ALARM4 ALARM5 ALARM6 SEG2 EV Event status Same SEG3 EV Event status Same SEG4 EV Event status Same SEG5 EV Event status Same SEG6 EV Event status Same SEG7 EV Event status Same SEG8 EV Event status Same SEG9 EV Event status Same SEG10 EV Event status Same SEG11 EV Event status Same SEG12 EV Event status Same SEG13 EV Event status Same SEG14 EV Event status Same SEG15 EV Event status Same SEG16 EV Event status Same SEG17 EV Event status Same SEG18 EV Event status Same SEG19 EV Event status Same SEG20 EV Event status Same SEG21 EV Event status Same SEG22 EV Event status Same SEG23 EV Event status Same SEG24 EV Event status Same SEG25 EV Event status Same SEG26 EV Event status Same 170 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Event Set Up Group Prompt Description Range Your selection SEG27 EV Event status Same SEG28 EV Event status Same SEG29 EV Event status Same SEG30 EV Event status Same SEG31 EV Event status Same SEG32 EV Event status Same SEG33 EV Event status Same SEG34 EV Event status Same SEG35 EV Event status Same SEG36 EV Event status Same ReleaseK DR4500A Classic Series Circular Chart Recorder With or
8. 100PCT CURRENT DUPLEX RANGE FULL enables the normal control current output to provide duplex heat control over 0 100 output change and the relay output to provide cool control Repeat this procedure for CONTROL 2 configuration Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 99 Configuration Parameter Definitions Tuning Parameters Set Up Group 4 7 Tuning Parameters Set Up Group Introduction Tuning consists of establishing the appropriate values for the tuning constants you are using so that your recorder responds correctly to changes in process variable and setpoint You can start with predetermined values but you will have to watch the system to see how to modify them There are two Tuning groups available Tuning group prompts Table 4 6 lists all the function prompts in the Tuning 1 and Tuning 2 setup group and their definitions Table 4 6 Tuning group prompt definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection FUZZY FUZZY OVERSHOOT SUPPRESSION FEATURE DISABL DISABLE Disables fuzzy overshoot suppression ENABLE ENABLE The recorder will use fuzzy logic to suppress or mimimize any overshoot that may occur as a result of the existing tuning parameters It does NOT change the parameters ACCUTUNE ACCUTUNE 11 demand tuning algorithm DISABL DISABLE Disables ACCUTUNE
9. ERR ERR CAL2 ERR BATT LOW Troubleshooting Refer to STATUS TESTS in Section 9 Troubleshooting Service to identify and correct the problem Check the displays and keys Use the procedure in Table 5 4 to run the display and key test Table 5 4 Procedure for testing the displays and keys Press Result SET Release the keys The recorder runs a display test All the displays will UP light for 8 seconds then you will see and hold in then press Upper Display KEYS FUNC Lower Display TRY ALL at the same time Press each key to see if it When the key is pressed the lower display indicates the name of the works key pressed Key Pressed Lower Display SET UP SET UP FUNC FUNCTION LOWR DISP LWR DISP MAN AUTO AUTO MAN CHART CHART A INCRMENT v DECRMENT RUN HOLD RUN HOLD Note MAN AUTO or RESET is shown but not both fno key is pressed for 25 seconds the test times out and the recorder exits the key test e If any test fails go to subsection 9 3 Self Diagnostics for more information Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 119 May 2013 Operation Start up Key error When a key is pressed and the prompt KEY ERROR appears in the lower display it will be for one of the following reasons e parameter not available not in Set Up mode press SET UP key first key malfun
10. For alphanumeric entries the display will cycle from blank left to right with highlighting increased brightness of each digit The value of each digit can be changed only when it is highlighted Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 89 May 2013 Configuration Parameter Definitions Total Parameters Set Up Group Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection RATE RATE OF INTEGRATION This selection allows you to select the desired rate of integration It must match scaling of input units EXAMPLE GPM must use MINUTE PPH must use HOUR SECOND SECOND EU Engineering Units per second MINUTE MINUTE EU per minute HOUR HOUR EU per hour DAY DAY EU per day M DAY M DAY Millions of Units per day multiplier 106 x input SCALER 1 TOTALIZER SCALE FACTOR this selection allows 10 you to select a scale factor that is a Multiplier for the 100 totalizer display It affects only the display 1000 10000 e The desired factor is applied to the calculated value 100000 to extend the maximum flow range that can be 1E6 displayed e Scaler selection does not affect the totalization value printed on the chart EXAMPLE e 1E6 equals 1 times 106 1 000 000 RSETABLE NO LOCAL LOCAL TOTALIZER RESET Allows the totalizer value to be reset to zero via the display keypad EXT SW1 EXTERNAL SWITCH 1 Allows the
11. As required These parts are also included in the miscellaneous hardware kit 30755980 003 226 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Parts List Exploded Views Additional recorder components associated with options Figure 10 4 is an exploded view of the recorder components associated with options Table 10 4 is a list of the associated part numbers 22098 o 2v N N Figure 10 4 Recorder components associated with options Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 227 May 2013 Parts List Exploded Views Table 10 4 Recorder parts associated with options Recommended inti Spare Parts per Quantity Key Part Number Description per Unit 10 100 1 30754922 501 Control Output 1 or 2 PCB 1 5 1 30754922 502 For FM Approved Output PCB 30755306 501 Control Output Relay 1 relay 30755306 601 Control Output Relay 5 relays 2 K 30756140 001 Alarm output digital input PCB kit 1 3 30755119 501 Ribbon cable 34 conductor See Note 3 1 3 1 4 30755127 502 Light accessory kit 1 5 K 30749598 501 Kit of 5 Bulbs General Instruments 1828 or 1 equivalent 6 30732192 502 Spacer 1 4 7 K 30756141 003 Input PCBs optional second input 5 1 2 8 K 30755980 004 Battery Duracell DL2450 or equivalent 1 3 1 9 Original Main board w o
12. Functional Earth N minimize electrical noise and transients that may adversely affect the system supplementary bonding of the recorder enclosure to a functional earth ground using a 3 4 braided copper conductor is required A terminal on the rear of the recorder is provided for this connection CE conformity special conditions Europe Braid shielded cable is required for all Input I O and Output Relay cables All recorder cable shield wires except the RS485 Modbus communications cable shield must be connected to a low impedance earth ground at the recorder This can be done by bussing the shields to an earth ground point or by connecting the shields to the conduit entry fittings if they are in electrical contact with the enclosure conductive coating In either case the shields shall not extend into the recorder enclosure The cable shields shall also be connected to a low impedance earth ground at the farthest end of the cable through a 0 0047 uF capacitor See each of the individual wiring diagrams Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 27 May 2013 Installation Wiring Prerequisites For the RS485 Modbus communications cable Alpha XTRA Guard I cable Alpha P N 5121C is required At the recorder end the communications cable shield must be unconnected and must not extend into the recorder enclosure The shield of the communications cable must be connect
13. reset the totalizer externally switch display the totalizer value Resetting the totalizer Follow the procedure in Table 5 27 to reset the totalizer value Table 5 27 Procedure for resetting the totalizer Step Operation Press Action Result 1 Access the Totalizer Set SET Until you see Up group UP Upper Display SET UP Lower Display TOTAL 1 or TOTAL 2 2 Allow Totalizer Reset FUNC You will see once Upper Display Ex XXX Lower Display a value FUNC You will see again Upper Display NO Lower Display RSET TOT Aor V Change NO to YES in the upper display ATTENTION Function prompt RSETABLE must be set to LOCAL 3 Return to normal LOWR Returns to normal operation operation DISP External totalizer reset The totalizer can be reset to 0 from external switch 1 or external switch Z2 Refer to Subsection 3 9 Totalizer Set Up Group and set function prompt RSETABLE to EXT SWI or EXT SW2 144 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Resetting and Displaying Totalizer Value Displaying the totalizer value Follow the procedure in Table 5 28 to display the totalizer value Table 5 28 Procedure for displaying the totalizer value Step Operation Press Action Result 1 Alternating Totalizer LOWR Until you see Display DISP Upper Display PV VALUE Lower Display t
14. sssssssssessessesee ener 190 Table 8 1 Set up wiring procedure current proportional output Aux Out 2 and 3 sse 194 Table 8 2 Current proportional output Aux Out 2 and 3 calibration procedure sse 195 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual xi May 2013 Table 8 3 Table 8 4 Table 8 5 Table 9 1 Table 9 2 Table 9 3 Table 9 4 Table 9 5 Table 9 6 Table 9 7 Table 9 8 Table 9 9 Table 9 10 Table 9 11 Table 9 12 Table 9 13 Table 9 14 Table 9 15 Table 9 16 Table 9 17 Table 9 18 Table 9 19 Table 9 20 Table 10 1 Table 10 2 Table 10 3 Table 10 4 Table 10 5 xii Position proportional output calibration procedure sss 197 Set up wiring procedure for auxiliary output ener eene nenne 199 Auxiliary output calibration procedure enne 200 Procedure for identifying the software version essen eene rennes 204 dn eri P E T 205 Procedure for displaying the device status sse eene 206 tea E EE re th eo ERE tre e Ew ERE Un 207 Visual failure Symptoms tee ct teg c Ue e Yo E e Au UEM ee t et e re e etg tt 211 Procedure 41 Troubleshooting recorder failure symptoms 212 Procedure 42 Troubleshooting pen trace failure symptoms sesssssssesseeeeeeneee 213 Procedure 43 Troubleshooting
15. Required for CE Mark Conformity Kit supplied Part No 51197612 502 contains two ferrite filters More than one kit may be supplied Install inside of case See Figure 2 11 VIEW A From transmitter with power L 01 pF source 0047 pF Plug J2 EN Capacitor ATTENTION The DR4500A4 Recorder inputs are protected from overvoltage by a protection diode The wake up pulse on 4 Transmitter the ST3000 m ay not be recognized by the transmitter due to power 24 Vdc this clam ping action It may be necessary to add 100 ohms of Plug J11 additional loop resistance so the transmitter and SFC can communicate Cable Shield 4 VIEW B From y transmitter n receiving 24 Vdc power from recorder ko d Plug J2 i E PN Ferrite filter Figure 2 14 4 20 mA input wiring 36 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Input Wiring Procedures 0 10 Volt dc inputs You can wire input 1 or 2 for 0 10 Volt dc actuations The polarity for inputs 1 and 2 is identical The prerequisites are Model Number Table 1 3X00 X300 ATTENTION Calibrate the recorder to achieve the stated accuracy Refer to Section 7 Input Calibration Refer to Figure 2 15 and follow the procedure in Table 2 14 to wire 0 10 Vdc inputs Table 2 14 0 10 Volt dc input wiring Step Acti
16. SW SW VALUE Automatic Switchover Value 999 0 to 9999 0 00 SP SOURC Setpoint Source 1 LOCAL 1 LOCAL REMOTE 2 LOCAL OUT 2 available for Control 1 only NOTE If you select REMOTE then RSP will be on Input 2 RATIO Ratio for Remote Setpoint 20 00 to 20 00 1 0 BIAS Bias for Remote Setpoint 999 0 to 9999 in engineering units 0 SP TRACK Setpoint Tracking NONE NONE RSP POWER UP Power Up Controller Mode MANUAL MANUAL Recall A LSP A RSP AM SP AM LSP SP HILIM High Setpoint Limit 999 0 to 9999 500 SP LOLIM Low Setpoint Limit 999 0 to 9999 0 ACTION Control Output Direction DIRECT REVRSE REVRSE OUTHILIM High Output Limit 5 0 to 105 0 of output 100 0 OUTLOLIM Low Output Limit 5 0 to 105 0 of output 0 DROPOFF Controller Dropoff Value 5 0 to 105 0 of output 0 0 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 67 May 2013 Configuration Control Set Up Group Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting DEADBAND Output Relay Deadband e Time Proportional Duplex 2 0 5 0 to 25 0 e On Off Duplex 0 0 to 25 0 e Position Proportional 0 5 to 5 0 OUT HYST Output Relay Hysteresis 0 0 to 5 0 of PV Span 0 5 FAILSAFE Failsafe Output Value 0 to 100 50 REM SW Remote Switching NONE TO 2SP TUNE NONE Digital Input TO MAN TO DIR TIMER TO LSP RN HLD MAN KEY Manual Mode Key Selecti
17. Table 5 15 Procedure for switching between setpoints Step Operation Press Action Result 1 Switch between setpoints FUNC Alternately select Local setpoint 1 and Remote setpoint or switch between the 2 Local Setpoints LOWR Press appropriate key until you see the desired setpoint DISP indicated ATTENTION KEY ERROR appears in the lower display if the remote setpoint or second local setpoint is not configured as a setpoint source or if you attempt to change the setpoint while a setpoint ramp is enabled 2 Change the Local Aor V The REMOTE setpoint cannot be changed at the setpoint value keyboard Setpoint selection indication Table 5 16 shows how the indicators react and what the displays show for each type of setpoint Table 5 16 Setpoint selection indication RSP Indicator Upper Display Using Local Setpoint Using Remote Setpoint Using 2 Local Setpoint OFF PV ON Note 1 PV ON Note 2 Note 3 PV Lower Display SP and the Local Setpoint Source RSP and Remote Setpoint Value 2SP and the 2nd Local Setpoint Value To Change Setpoint Value Press or V Cannot change the value at the keyboard Note 1 RSP blinks when RSP is reached using Digital Input Note 2 RSP solid for 2nd Setpoint Note 3 RSP blinks for 2nd setpoint activated by Digital Input 132 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manua
18. 136 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Using Two Sets of Tuning Constants PID Values Table 5 20 Procedure for setting switchover values Step Operation Press Action Result 1 Select switchover value FUNC Until you see function assuming you Upper Display The switchover value are still in Set Up Lower Display SW VALUE group CONTROL Aor V Select the switchover value in the upper display Set Tuning constant values for each set There are specific tuning constants that must be set for each set The procedure in Table 5 21 shows you how to access these constants and change their values Table 5 21 Procedure for setting tuning constant values Step Operation Press Action Result 1 Select Tuning Set Up SET Until you see group UP Upper Display SET UP Lower Display TUNING 2 Select the tuning FUNC Successively displays the following constants constants Upper Display Tuning constant value Lower Display PROPBD or GAIN RATEMIN RSETMIN or RSETRPM PROPBD2 or GAIN2 RATE2MIN RSET2MIN or RSET2RPM PIDSET1 will be used when PV or SP whichever is selected is greater than the switchover value PIDSET2 will be used when PV or SP whichever is selected is less than the switchover value Aor V Change the value of any of the above listed prompts in the lower display Rel
19. L1 00 Time remaining Timer function 0 00 Time elapsed in Timer function TUNEXxXXX Accutune ll indicator 1 or 2 ATTENTION The lower display can be configured to scroll through the operating parameters MAN e Alternately selects AUTO AUTO Lower display automatically displays setpoint value in engineering units MAN Lower display automatically indicates output in 96 CHART e Used to stop recording operation and move pen to outer limit for chart change RUN e Alternate action switch initiates or holds the Setpoint Ramp or Setpoint Program HOLD e n configuration mode restores the original value or selection if you do not want to enter a change you are making to a parameter A e Increases the setpoint output or configuration values displayed e Used to step through the items in each function while in configuration mode plus adjust control variables in the lower display v e Decreases the setpoint output or configuration values displayed e Used to step through the items in each function while in configuration mode plus adjust control variables in the lower display 4 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Overview Set up Tasks 1 3 Set up Tasks Major set up tasks As shown in Figure 1 2 there are four major tasks that you must complete to Set Up the DR4500A recorder for operation For easy reference the secti
20. Operatot interface ore hati ei etat eee tete t lta oes 122 sos hee ire e teet tate tese pde ba ons 124 Ramp Soak profile examples eh hetero ee ene ae ees e CENE 154 Location of the input connections on the input boards sssssssssseeeeeenmene 179 Location of jumper positions W1 MA W3 on the input boards sene 181 Calibration set up diagram for Thermocouple inputs using an 183 Calibration set up diagram for Thermocouple inputs using a compensated calibrator method 184 Calibration set up diagram for Thermocouple inputs using the ambient temperature method 185 Calibration set up diagram for RTD 1 nennen eren nnne enne 186 Calibration set up diagram for Radiamatic Millivolts and Volts inputs except 0 10 Volts 187 Calibration set up diagram for 0 10 Volt enne nnns 188 Calibration set up diagram for 4 20 MA inputs ener 189 Test equipment connections for calibrating current proportional output sss 194 Test equipment connections for calibrating auxiliary output esses 199 Mechanical Alignment of Pens cccesccesecsseesseeseesseeeeceecnsccesecsaecaaecaaecaeecaeeeseeeeeseeseseaeeeeesereseeneenaes 219 Figure 10 1 Door assembly A E E 222 Figur
21. SW TWO SETS SP AUTOMATIC SWITCHOVER when the setpoint is GREATER than the value set at prompt SW VALUE Switchover Value the recorder will use Gain Rate Reset and Cycle e When the setpoint is LESS than the value set at prompt SW VALUE the recorder will use Gain 2 Rate 2 Reset 2 and Cycle 2 e Other prompts affected SW VALUE SW VALUE 999 0 to 9999 AUTOMATIC SWITCHOVER VALUE this is the value of process variable or setpoint at which the recorder will switch from Tuning Constant Set 2 to Set 1 Only appears when PID SETS selections 2PV SW or 2SP SW are selected SP SOURC SETPOINT SOURCE this selection determines what your setpoint source will be One local or Two local Toggled by the SETPOINT SELECT key 1LOCAL LOCAL SETPOINT the setpoint entered from the keyboard or from the setpoint program REMOTE REMOTE SETPOINT a signal is brought in through the second input printed circuit board connector J2 and used as the control setpoint e f you select REMOTE Input 2 is automatically assigned as your RSP source for CONTROL 1 there is no remote setpoint for CONTROL 2 e Ratio and Bias can be applied to the remote setpoint Mutually exclusive with 2 Local setpoints e Other prompts affected RATIO BIAS 2LOCAL OUT2 TWO LOCAL SETPOINTS this selection lets you switch between two local setpoints Mutually exclusive with Remote setp
22. and change it if required 3 Check the motor cable plug connection Visually examine the plug and reset it at connector J7 on the main printed circuit board 4 Replace the chart motor Refer to the instructions included with the replacement part 5 Call Technical Assistance Center 1 800 423 9883 USA and Canada Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 213 Troubleshooting Service Troubleshooting Procedures Table 9 9 Procedure 4 Troubleshooting erratic pen movement symptoms N WARNING Do not lubricate the plastic gears on the chart and pen motors Step What to do How to do it or where to find the data Check the sensor and lead wires for continuity Check the connections Replace the sensor lead wires as needed Tighten the connections Check the pen and input configuration data Refer to Section 3 Configuration Replace the servo plate assembly Refer to the instructions included with the replacement part Call Technical Assistance Center 1 800 423 9883 USA and Canada Table 9 10 Procedure 5 Troubleshooting pen failure symptoms Step WARNING Do not lubricate the plastic gears on the chart and pen motors What to do How to do it or where to find the data Check the sensor and lead wires for continuity Check the connections Check the pen arm for secure mechanical
23. esse emen 211 9 5 Troubleshooting Procedures ssssssseee ene 212 9 6 Pen Alignment ipn epe team pet ed RES 218 Vii DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K Release K May 2013 10 Fats amp et eal pe nea eene 221 10 1 as tke P DR 221 102 Exploded VIeWS ee tees due ERU ave 222 10 3 Miscellaneous Hardware Kit Contents 229 10 4 Internal Cabling Data Without 230 10 5 Internal Wiring Diagram Options Only 231 A Foreign Language Safety Instructions 233 DA2I 605 7e M scan ead eased daa 234 BIBIT 235 EM EM 236 ER2I 6057 5 5 attestato eire taf 236 GE2GOD 0 d ere fpi idR o tetur ree 238 GR2IFGO5 7 i tte EAD in titel dmt 239 IT21 6057 tite e M 240 2126057 aie ean S au 241 2 6 05 242 Sigel 243 Sl PARU EE 244 jr GE RPP 245 Release K DR4500A Classic Series Circular Chart Rec
24. 106 4 11 A Auxiliary Output Set Up Group 109 4 12 Communications Set Up Group 111 4 13 Options Set Up Group 112 4 14 Lockout Parameters Set Up Group 114 Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 81 Configuration Parameter Definitions Input Parameters Set Up Group 4 2 Input Parameters Set Up Group Introduction These are the parameters required for input 1 or 2 temperature units decimal location actuation transmitter characterization high and low range values in engineering units input compensation filter and burnout Input group prompts Table 4 1 lists all the function prompts in the Input 1 or 2 setup group and their definitions Table 4 1 Input group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection Input n n 1 2 ENABLE DISABLE parameter DECIMAL DECIMAL POINT LOCATION This selection determines where the decimal point appears in the display XXXX None XXX X One Place XX XX Two Places X XXX Three Places NOTE Auto ranging will occur when one decimal position has been selected and the value increases above 999 9 but auto ranging will not similarly occur when two decimal positions are selected UNITS TEMPERATURE UNITS This selection will be indicated on the PV display If you select EU go to prompt ENGUNITS DEGF Degrees Fahrenheit DEG C Degrees Cel
25. 5 or 6 AXS2 VAL Setpoint 2 value of alarm 1 2 3 4 5 or 6 Aor V Change any alarm setpoint value you select in the upper display 3 Return to normal LOWR Returns to normal operation operation DISP 142 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Digital Input Option Remote Switching 5 12 Digital Input Option Remote Switching Introduction The digital input option detects the state of external contacts wired to 1t On contact closure the recorder responds according to how each digital input is configured e Make your selection under Set Up group CONTROLI or CONTROL2 function group prompt REM SW see Subsection 3 10 Table 3 7 or Subsection 4 6 Table 4 5 Action on contact closure Table 5 26 lists the configuration prompt selections the Action on Contact Closure and the display indication for each selection available REM SW Selections Table 5 26 Digital input option action on contact closure Display Indication Action on Contact Closure None None No Digital Input selection To MAN MAN blinks Puts the recorder into manual mode contact open returns the recorder to former mode unless AUTO MAN key is pressed while digital input is active To LSP To 2SP RSP blinks RSP blinks Puts the recorder into local setpoint 1 switches out of remote When cont
26. 63 Burnout protection 87 Index Calibration procedure 192 Calibration set up 184 0 10 Volt inputs 190 4 20 mA inputs 191 Millivolts and Volts inputs except 0 10 Volts 189 RTD inputs 188 Thermocouple inputs using a compensated calibrator method 186 Thermocouple inputs using an ice bath 185 Thermocouple inputs using the ambient temperature method 187 CE Conformity Europe 1 CE Conformity special conditions 7 CE conformity special conditions Europe 27 Chart high range value 88 Chart lamp 149 Replacing 149 Chart low range value 88 Chart plate assembly parts 225 Chart speed selection 65 Chart time line 120 CHN indicator 130 Circuit breaker 30 Communications station address 75 113 Condensed specifications 8 Configuration procedure 60 Configuration prompts 56 Configuration tips 59 Control algorithm 68 98 Control output direction 67 96 Controller dropoff value 67 96 Current proportional output calibration 196 201 Current simplex 100 Current relay duplex 100 Current time duplex range 68 Customer support 205 Cycle time heat 104 Cycle time 2 cool 104 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 245 May 2013 Deadband 68 96 Gain 103 Decimal point location 62 84 Gain 2 104 Deviation 114 Gain units 68 Deviation bargraph 126 Grid line contrast 122 Deviation recording action 76 Deviation setpoint value 76 114 H
27. Action 1 Connect the copper wire to the calibration source see Figure 7 7 2 Connect the other end of the copper wire to the clamp type terminals in the plug for the applicable input connector J2 3 dd the plug into the input connector J2 on the applicable circuit board for input 1 or input 2 Calibration source Copper wires HO 22093 z ls TIC gt Ore B Plug J2 Be sure W1 MA Be sure W3 jumper jumper is in position is in position T C W1 on the input board on the input board Figure 7 7 Calibration set up diagram for Radiamatic Millivolts and Volts inputs except 0 10 Volts Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 187 May 2013 Input Calibration Calibration Set Up and Wiring for PV Inputs 0 10 Volt inputs Refer to Figure 7 8 and wire the recorder according to the procedure given in Table 7 11 Table 7 11 Set up wiring procedure for 0 10 Volt inputs Step Action 1 Connect the copper wire to the calibration source see Figure 7 8 2 Connect the other end of the copper wire to the clamp type terminals in the plug for the applicable input connector J2 3 e the plug into the input connector J2 on the applicable circuit board for input 1 or input 2 Calibration source Copper wires N Dr QD eg 22094 z 9 T C D OOO O RTD Plug J2 Be sure W1 MA Be sure W3
28. Classic Recorder Consult Model Selection Guide for information 2 Includes reference junction calibration of 0 01 degrees using standard ice bath method of calibration Factory calibration at reference 1 2 F Note that factory calibration may vary by as much as 10 microvolts or 0 3 ohms for RTDs which means recalibration may be required to achieve stated accuracy 3 The RH calculation is inoperative when temperature goes below 32 F 0 C or above 212 F 100 C However the dry bulb temperature will be monitored to 103 F 75 C Accuracy stated is for Classic Series Recorder only and does not include remaining system accuracies 12 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Model Number Interpretation 2 2 Model Number Interpretation Model number The model number interpretation is shown in Figure 2 1 Write the model number into the spaces provided and compare it to the model number interpretation This information will also be useful when you wire your recorder The example on the next page will help you to decode the model Key Number Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 bfrlalsla LLL L LL LELI L EEELLLI le Key Number 17 1 Pen Recorder Hardware Options 2 2 Pen Recorder 0 Gray door Glass window 1 Gray door Acrylic window E Gray door Glass window and keypa
29. Configuration Pen Set Up Group 3 7 Pen Set Up Group Introduction The functions listed in this group deal with how to configure pen 1 or pen 2 The procedure for configuring each pen is the same The prompts shown in Table 3 4 show PEN 1 e Repeat the process for pen 2 e Press the SET UP key until PEN 2 appears in the display Function prompts Table 3 4 lists all the function prompts in the PEN Set Up groups Table 3 4 Pen 1 or 2 group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting PEN 1 Pen Record ENABLE ENABLE DISABL PEN1IN Pen Input INPUT1 OUTPT1 SETPT2 INPUT 1 INPUT2 OUTPT2 DGTL1 RH SETPT1 DGTL2 CHART1HI Chart High Range Value 999 0 to 9999 302 0 CHART1LO Chart Low Range Value 999 0 to 9999 292 0 PEN1ON Pen Chart Position for ON 0 to 10096 91 0 Event PEN1OFF Pen Chart Position for OFF 0 to 10096 93 0 Event Repeat this procedure for PEN 2 64 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Chart Set Up Group 3 8 Chart Set Up Group Introduction The functions listed in this group deal with the parameters that must be set to assure proper chart function CAUTION Before making any configuration changes to the Chart Set Up group place the recorder in Chart Hold Press the CHART key to stop the chart rotatio
30. Definitions Pen Parameters Set Up Group 4 3 Pen Parameters Set Up Group Introduction The functions listed in this group deal with how to configure pen 1 or pen 2 The procedure for configuring each pen is the same The prompts shown in Table 4 2 show PEN 1 e Press the SET UP key until PEN 1 or PEN 2 appears in the display Pen 1 or 2 group prompts Table 4 2 lists all the function prompts in the Pen 1 or Pen 2 set up groups and their definitions Table 4 2 Pen 1 or 2 group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection PENn ENABLE PEN RECORD This selection lets you enable or DISABL disable the pen channel record n 1 or 2 e Remember the lower display prompt could read PEN2 PENnIN PEN INPUT What do you want the pen to record n 1 or 2 INPUT 1 INPUT 1 records Input 1 INPUT 2 INPUT 2 records Input 2 RH RELATIVE HUMIDITY records in RH It initiates an external calculation for measuring relative humidity INPUT 1 IN TYP must be configured for 100 PT INPUT 2 IN TYP must be configured for 100 RH The RH prompt only appears when RELHUMID prompt in the OPTIONS group is configured as YES OUTPT1 OUTPUT 1 records Output 1 OUTPT2 OUTPUT 2 records Output 2 SETPT1 SETPOINT 1 records Setpoint 1 SETPT2 SETPOINT 2 records Setpoint 2 DGTL1 DIGITAL 1 INPUT records EVENT pen function on contact closure across digital 1 input DGT
31. Device status 208 Diagnostic error messages 128 Hardware kit contents 231 Diagnostic tests 120 Heavy Duty door mounting 22 Digital inputs 45 High output limit 67 96 Dimensions 16 High range value 63 86 Direct acting control 96 High setpoint limit 67 Display test 121 Hours per revolution 90 Displaying totalizer value 147 Hysteresis 68 96 110 Displays 3 Ice bath 182 Electrical alignment 221 Indicators 3 Electrical noise 27 Input 1 actuation type 62 Emissivity 63 Input actuation type 85 Engineering units 84 Input compensation 63 87 Error message Input out of range 212 BATT LOW See Input terminals 181 BATTERY 211 Inputs CAL TEST 210 0 5 Vdc 33 CAL1 ERR 210 Radiamatic mV 33 CAL2 ERR 210 RTD 33 CONFTEST 209 Thermocouple 33 EE FAIL 211 Installation FACT CRC 210 Operating limits 8 FAILSAFE 209 Preinstallation information 7 INxFAIL 211 Installing chart 150 PV LIMIT 211 Internal cabling 232 RAM TEST 209 RV LIMIT 211 J Error message prompts 209 Error messages 128 Jumper positions 183 Event pen function 148 Event pen operation 148 K F Key test 121 Knockout locations 17 Factory calibration 178 Failsafe 207 L Failsafe output value 68 Failure symptoms 205 Local setpoint 133 Ferrite filter locations CE Mark 29 Local setpoint 94 Field wiring 180 Lockout 77 116 Filter 63 87 Low flow cutoff selection 63 Low output limit 67 96 Low range value 63 87 Low setpoint limi
32. It allows the operation of a second ON OFF output There is a deadband between the operating ranges of the two inputs and an adjustable overlap hysteresis of the on and off states of each output Both Deadband and Hysteresis are separately adjustable With no relay action the controller will read 50 e Other prompts affected OUT HYST and DEADBAND 96 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Control Parameters Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition CONT1ALG continued Release K May 2013 PIDA NOTE PID A should not be used for Proportional only action that is no integral reset action Instead use PD MR with rate set to 0 PID A is normally used for three mode control This means that the output can be adjusted somewhere between 100 and 0 It applies all three control actions Proportional Integral 1 and Derivative D to the error signal Proportional Gain regulates the controller s output in proportion to the error signal the difference between Process Variable and Setpoint Integral Reset regulates the controller s output to the size of the error and the time the error has existed The amount of corrective action depends on the value of proportional Gain Derivative Rate
33. Key error When a key is pressed and the prompt KEY ERROR appears in the lower display it will be for one of the following reasons e parameter not available notin Set Up mode press SET UP key first e key malfunction do keyboard test operation e individual key locked out Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 59 May 2013 Configuration Configuration Procedure 3 5 Configuration Procedure Introduc Procedu tion Each of the Set Up groups and their functions are preconfigured at the factory The factory settings are shown in the Set Up group tables that follow this procedure If you want to change any of these selections or values follow the procedure in Table 3 2 This procedure tells you the keys to press to get to any Set Up group and any associated Function parameter prompt If you need a detailed explanation of any prompt refer to Section 4 Configuration Parameter Definitions re Follow the procedure listed in Table 3 2 to access the Set Up groups and Function prompts n TIP The prompting scrolls at a rate of 2 3 seconds when the SET UP or FUNC key is held in Also A V keys will move group prompts forward or backward at a rate twice as fast Table 3 2 Configuration procedure Step Operation Select Set Up mode Press SET UP Result Upper Display SET UP Lets you know you are in the configuration mode and a Se
34. MA and W3 for the particular sensor being used refer to the wiring connection drawings in this section for each individual setting Refer to Figure 7 2 for the location of jumper positions W1 MA and W3 on these circuit boards and the status of these jumpers for each type of input sensor Main board Input board Position RTD Position T C MA Linear Position MA Position W1 Status of jumper plugs 1 Install W1 MA plug in position W1 for thermocouple RTD Radiamatic mV 0 5 Vdc 0 10 Vdc inputs 2 Install W1 MA plug in position MA for 4 20 mA inputs 3 Install plug in W3 according to your input type 21443 Figure 7 2 Location of jumper positions W1 MA and W3 on the input boards Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 181 May 2013 Input Calibration Calibration Set Up and Wiring for PV Inputs Thermocouple input calibration methods You can calibrate for a thermocouple input using one of three methods e using an ice bath e using a compensated calibrator or by measuring the ambient temperature at the input terminals and subtracting the voltage contribution of the input terminal junction General set up procedure Table 7 5 lists the general set up procedure for all methods of calibration Do this procedure and then refer to the set up procedure and diagram for your specific input Table 7 5 General set up procedure Step Action Set u
35. Product Manual 111 May 2013 Configuration Parameter Definitions Options Set Up Group 4 13 Options Set Up Group Introduction The Options Set Up Group lets you enable or disable some of the options that are available on the DR4500 You can select the power frequency select relative humidity as a measurement and a atmospheric pressure compensation select deviation recording action and set the desired deviation setpoint Options group prompts Table 4 13 lists all the function prompts in the Option set up group and their functions Table 4 13 Option group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection REJ FREQ 60HZ REJECTION FREQUENCY be sure that this selection 50HZ agrees with the line voltage frequency HF REJ ENABLE HIGH FREQUENCY REJECTION This selection DISABL allows high frequency noise rejection It is used to quiet noisy pens or PV ATTENTION For fast processes it will cause additional lag RELHUMID NO RELATIVE HUMIDITY allows you to activate or YES deactivate the RH calculation algorithm e You must select 100RH input type for two inputs to measure RH It requires two 100 ohm RTD inputs so INPUT 2 must be enabled for this prompt to appear e Also you must select RH for PEN2IN which represents the wet bulb temperature when input 2 is selected ATMPRES 590 to 800 mmHg ATMOSPHERIC PRESSURE COMPENSATION This prompt on
36. Refer to Figure 8 2 and wire the recorder according to the procedure given in Table 8 4 Table 8 4 Set up wiring procedure for auxiliary output Step Action 1 With the power off door open and the chart plate swung out tag and disconnect field wiring from the plug in connector J2 on the auxiliary output PCB see Figure 8 2 Observing polarity connect a milliammeter s leads to the plug for connector J2 3 Close the chart plate apply power and allow the recorder to warm up 15 minutes before you calibrate Control output uncos PEE SUR PCR 1 Py i Milliammeter 2222 d Plug J2 auxiliary output Control output 2 PCB mc 1927 2722 NOM S ANG Keel _ 22818 Figure 8 2 Test equipment connections for calibrating auxiliary output Procedure Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 199 May 2013 Output Calibration Auxiliary Output Calibration The procedure for calibrating the Auxiliary Output is listed in Table 8 5 Make sure LOCKOUT in the Set Up group is set to NONE See Section 3 Configuration Also AUX OUT must NOT be disabled Table 8 5 Auxiliary output calibration procedure Step Operation Press Action Result 1 Enter Calibration Mode SET Until you see UP Upper Display CALIB Lower Display AUX OUT 2 Calibrate 0 96 FUNC You will see Upper Display a va
37. SP Local Setpoint 1 Also current setpoint of SP Ramp or SP Ramp Soak Program SPN Current setpoint for setpoint rate applications 2SP Local Setpoint 2 where remote setpoint does not apply RSP Remote Setpoint when configured 2IN Value of Channel 2 input when available DEV PV deviation from setpoint 999 9 maximum EU Engineering units that PV represents when available RH RH value in percent 96 when available PIDSETx Tuning Parameter Set x 1 or2 RAMP The time minutes remaining in the setpoint ramp RA The time minutes remaining in the SP Ramp segment SK The time minutes remaining in the SP Soak segment RECYC The number of recycles remaining to be run in the Setpoint Program 0 00 Time remaining in Timer function 0 00 Time elapsed in Timer function Accutune II indicator X Loop number 1 or 2 XXX ON or OFF Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 125 May 2013 Operation Monitoring Your Recorder Prompt Description Totalization value upper display shows TCHN1 or 2 for totalization value 1 or 2 You can press Aor V to change the value of this parameter Diagnostic error messages 126 The DR4500A runs background tests to verify data and memory integrity If there is a malfunction an error message will blink in the lower display In the case of more than one simultaneous malfunction or
38. Sequentially press the LOWR DISP key to scroll through the displays and light the appropriate CHN indicator for controller related values 128 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Operating Modes 5 6 Operating Modes Available modes The recorder can operate in any of three basic modes e Manual e Automatic with Local Setpoint e Automatic with Remote Setpoint Manual and Automatic with Local setpoint are standard features and Automatic with Remote Setpoint is optional Mode definitions Table 5 10 Operating mode definitions Operating Mode Definition MANUAL When switched to manual mode the recorder holds its output at the last value used during automatic operation and stops adjusting the output for changes in setpoint or process variable Instead you adjust the output by changing the value shown in the lower display See Selecting Modes AUTOMATIC with LOCAL SETPOINT In automatic local mode the recorder operates from the local setpoint and automatically adjusts the output to maintain the setpoint at the desired value In this mode you can adjust the setpoint See Setpoints AUTOMATIC with REMOTE SETPOINT In automatic remote mode the recorder operates from the setpoint measured at input 2 Adjustments are available to ratio this input and add a constant bias before it is applied to the cont
39. Set Up Group 4 14 Lockout Parameters Set Up Group Introduction These are the parameters that you will set to lockout any unauthorized changes to the recorder s configuration and calibration prompts n ATTENTION Configuration can also be locked using S1 switch on the main printed circuit board Refer to Subsection 2 9 Configuration Lockout Switch The chart plate can be sealed using a lead seal to provide a positive indication that the electronics and configuration lockout switch may have been accessed Set this group last Because this group contains functions that have to do with security and lockout we recommend that you configure this group last after all the other configuration data has been loaded Lockout group prompts Table 4 14 lists all the function prompts in the Lockout set up group and their definitions Table 4 14 Lockout group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection LOCKOUT LOCKOUT applies to one of the functional groups Configuration Calibration Tuning Adaptive Tune DO NOT CONFIGURE UNTIL ALL CONFIGURATION IS COMPLETE NONE No Lockout all groups read write CALIB CALIB All are available for read write except for the Calibration group CONF Tuning SP Ramp and program groups are read write All other groups are read only Calibration group is not available MAX MAX Calibration group not available A
40. Solutions ask ssc honeywell com iv DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Symbol Definitions The following table lists those symbols used in this document to denote certain conditions Symbol Definition This CAUTION symbol on the equipment refers the user to the Product Manual for additional information This symbol appears next to required information in the manual WARNING PERSONAL INJURY Risk of electrical shock This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 VDC may be accessible Failure to comply with these instructions could result in death or serious injury ATTENTION Electrostatic Discharge ESD hazards Observe precautions for handling electrostatic sensitive devices Protective Earth PE terminal Provided for connection of the protective earth green or green yellow supply system conductor Functional earth terminal Used for non safety purposes such as noise immunity improvement NOTE This connection shall be bonded to protective earth at the source of supply in accordance with national local electrical code requirements Earth Ground Functional earth connection NOTE This connection shall be bonded to Protective earth at the source of supply in accordance with national and local electrical code requirements Chassis Ground Identifies a connection to the chas
41. Table 6 7 Segment event relay operation enne 169 Table 6 8 Run Monitor functions cere a eee rte todo deoa a ese ctore eo esee Eee a 172 Table 7 1 Restormg factory calibration ore EE eR e eise i desee Hee eque dtes sev 176 Table 7 2 Voltage and resistance equivalents for 0 and 100 range values eene 178 Table 7 3 Disconnect the field wirttig i eee Te SERERE Ue ER te see 179 Table 7 4 Equipinent needed ss cc euo ete ente i vestire D eget tans 179 Table 7 5 General set up proc dUt sssi rsa er a 182 Table 7 6 Set up wiring procedure for Thermocouple inputs using an ice bath ssseeeeee 183 Table 7 7 Set up wiring procedure for Thermocouple inputs using a compensated calibrator method 184 Table 7 8 Set up wiring procedure for Thermocouple inputs using the ambient temperature method 185 Table 7 9 Set up wiring procedure for RTD 186 Table 7 10 Set up wiring procedure for Radiamatic Millivolts and Volts inputs except 0 10 Volts 187 Table 7 11 Set up wiring procedure for 0 10 Volt nennen 188 Table 7 12 Set up wiring procedure for 4 20 MA inputs esses 189 Table 7 13 Calibration procedure sequence
42. Upper Display The final setpoint value value Lower Display FINAL SP 6 Aor V Change the upper display value to the desired final setpoint value Setting Range within the setpoint limits Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 133 May 2013 Operation Single Setpoint Ramp Running the setpoint ramp Running a setpoint ramp includes starting holding viewing the ramp time ending the ramp and disabling it Procedure Table 5 18 lists the procedure for running the setpoint ramp Table 5 18 Procedure for running a setpoint ramp Step Operation Press Action Result 1 Put the controller into MAN Until A indicator is ON and you will see automatic mode AUTO Upper Display H and the PV value Lower Display SP and the present setpoint value 2 Set Start SP or V Until the start setpoint value you desire is indicated in the lower display Upper Display H and the PV value Lower Display SP and the start setpoint value 3 Start the ramp RUN You will see HOLD Upper Display R and the PV value Lower Display SP and a changing setpoint value NOTE The value in the lower display will be increasing or decreasing toward the final setpoint value The PV value in the upper display and the pen trace will also change 4 Hold the ramp at the RUN This holds the ramp at the current setpoint value current va
43. With or Without Control Product Manual Release K May 2013 About This Document Revision Information Document Name Document ID Revision Publication Date DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 44 45 25 35 K May 2013 References The following list identifies all documents that may be sources of reference for material discussed in this publication Document Title Doc ID How to Apply Digital Instrumentation in Severe Electrical 51 52 05 01 Noise Environments Modbus RTU Serial Communications User Manual 51 52 25 66 Modbus RTU Serial Communications user Manual 51 52 2569 Configuration Interface for DR4500 Supplement to 51 52 25 66 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual May 2013 Support and Contact Information For Europe Asia Pacific North and South America contact details refer to the back page of this manual or the appropriate Honeywell Solution Support web site Honeywell Corporate www honeywellprocess com Honeywell Process Solutions www honeywellprocess com circular chart recorders Training Classes http www automationccollege com Telephone and Email Contacts Area Organization Phone Number United States and 1 800 343 0228 Customer Service Canada Honeywell Inc 1 800 423 9883 Global Technical Support Global Email Support Honeywell Process
44. Without Control Product Manual 171 May 2013 Setpoint Ramp Soak Programming and Operation Run Monitor the Program 6 9 Run Monitor the Program Introduction Make sure all the SP PROG function prompts under the Set Up group SP RAMP have been configured with the required data e An appears in the upper display indicating that the program is in the HOLD state If an does not appear go to the SP Program configuration procedure and enable the program instead of disabling n ATTENTION For recorders with two controllers both enabled remember that any controller related values displayed correspond with the lighted CHN indicator 1 means that the values apply for Controller 1 and 2 means that the values apply for Controller 2 Run Monitor functions Table 6 8 lists all the functions required to run and monitor the program Table 6 8 Run Monitor functions Function Press Result Run State RUN Initiates the setpoint program HOLD changes to in the upper display indicating that the program is running PV value and pen trace tracks the ramp soak profile Hold State RUN Holds the setpoint program HOLD e An appears in the upper display indicating that the program is in the HOLD state e The setpoint holds at the current setpoint Press again to continue to run External Hold If Remote Switching Digital Input Option is present on your recorder
45. a single local setpoint source a remote setpoint source or two local setpoints Table 5 13 Procedure for selecting the setpoint source Step Operation Press Action Result 1 Enter set up mode SET Until the displays read UP Upper Display SET UP Lower Display CONTROL 2 Display local setpoint FUNC Until the displays read source selections Upper Display Setpoint source selections 1LOCAL 2LOCAL REMOTE Lower Display SP SOURCE 3 Select the desired source or V Select the desired setpoint source in the upper display 4 Return to control LOWR Controller assumes normal control DISP Changing the local setpoints Use the procedure in Table 5 14 to change either local setpoint value Table 5 14 Procedure for changing the local setpoint Step Operation Press Action Result 1 Select the setpoint LOWR Until you see DISP Upper Display PV value Lower Display SP or SP2 and the local setpoint value 2 Change the value Aor V Change the local setpoint to the value at which you want the process maintained The deviation bargraph indicates PV deviation from setpoint Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 131 May 2013 Operation Setpoints Switching between setpoints You can switch between Local and Remote setpoints or between two Local setpoints when configured Use the procedure in Table 5 15 to switch between setpoints
46. alarm each message will be shown in succession A list of error messages is contained in Table 5 8 If any of these error messages occur refer to Section 9 Troubleshooting Service for information to correct the failure Table 5 8 Error messages Prompt Description EE FAIL Unable to write to nonvolatile memory FAILSAFE Failsafe INP1FAIL Two consecutive failures of input 1 integration INP2FAIL Two consecutive failures of input 2 integration INP1 RNG Input out of range INP2 RNG PV LIMIT PV 10 out of range RV LIMIT Remote Variable out of range Note RV input 2 x ratio bias CNFG ERR Configuration data is in error CAL1 ERR Working CAL TEST failure Control Output 1 Input 1 Input 2 CAL2 ERR Working CAL TEST failure Control Output 2 BATT LOW Battery failure DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Monitoring Your Recorder Alarm and tuning messages Alarms 3 through 6 and Accutune II for Control Loops 1 and 2 are indicated in the lower display In the case of more than one simultaneous diagnostic or alarm message each message will be shown in succession Table 5 9 Alarm and tuning messages Prompt Description ALARM 3 Indicates an alarm 3 action ALARM 4 Indicates an alarm 4 action ALARM 5 Indicates an alarm 5 action ALARM 6 Indicates an alarm 6 action TUNING 1 Indicates A
47. assembly Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 223 May 2013 Parts List Exploded Views Table 10 2 Chart plate assembly parts Recommended Key Part Number Description Spare Parts per Quantity per Unit 10 100 1 K 30755980 002 No 2 pen arm two pen model only 1 5 1 2 K 30755980 002 No 1 pen arm 1 5 1 3 30754957 501 Membrane switch keypad 1 5 1 4 K 30756150 001 Chart Hub Kit 1 3 2 5 30735489 007 No 1 puple pen cartridge six pack 2 5 1 6 30735489 002 No 2 red pen cartridge six pack 2 5 1 7 30756113 501 Chart motor includes Chart Hub Kit 1 3 1 8 30757571 501 Display PCB includes key no 9 1 5 1 9 See above Ribbon cable display included with key no 8 1 3 1 10 K 30755980 002 Spring tension 1 11 30756114 501 Servo motor assembly 1 3 1 12 Servo plate assembly includes key no 11 1 2 1 30754975 501 1 pen model 30754975 502 2 pen model 13 Chart plate 1 30754977 501 1 pen model 30754977 502 2 pen model 30754977 511 1 pen model CE Mark 30754977 512 2 pen model CE Mark 224 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Parts List Exploded Views Basic recorder components without options Figure 10 3 is an exploded view of the basic recorder components Table 10 3 15 a list of the associated pa
48. assembly component While troubleshooting is straightforward we recommend that only trained service technicians repair the recorder What s in this section The following topics are covered in this section Topic See Page 9 1 Overview 201 9 2 Troubleshooting Aids 203 9 3 Self Diagnostics 205 9 4 Visual Failure Symptoms 211 9 5 Troubleshooting Procedures 212 9 6 Pen Alignment 218 Types of problems Instrument performance can be adversely affected by installation and application problems as well as hardware problems We recommend that you investigate the problems in the following order e Installation related problems e Application related problems e Hardware and software related problems and use the information presented in this section to solve them If a replacement of any part is required follow the instructions shipped with the replacment part Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 201 Troubleshooting Service Overview Installation related problems Read the Installation section in this manual to make sure the DR4500A has been properly installed The installation section provides information on protection against electrical noise connecting external equipment to the recorder and shielding and routing external wiring n ATTENTION System noise induced into the recorder will result in diagnostic error messa
49. attachment to the servo shaft Check the servo cable plug connection J6 on the main printed circuit board Replace the sensor lead wires as needed Verify and tighten the input connections Verify that the flat head screw that attaches the pen arm to the plastic servo gear on the servo shaft is tight Visually examine the plug and reseat it Replace the servo plate Refer to the instructions included with the replacement part Call Technical Assistance Center 1 800 423 9883 USA and Canada Table 9 11 Procedure 6 Troubleshooting keyboard and or display failure symptoms Step What to do How to do it or where to find the data 1 Run a Key Test to check the operation of the keys and displays Refer to Section 5 Operation for procedures on running a key test Replace the membrane switch keyboard and or display printed circuit board as required Refer to the instructions included with the replacement part 214 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Troubleshooting Procedures Table 9 12 Procedure 7 Troubleshooting current proportional output failure symptoms Step What to do How to do it or where to find the data 1 Be sure the recorder is configured for Refer to Section 3 Configuration Make sure current output OUT ALG selec
50. by making a new cutout or using an existing cutout with a filler plate see Table 2 4 Use the mounting kit supplied Adequate access space must be available at the back of the panel for installation and servicing activities The overall dimensions and panel cutout requirements for mounting the recorder are shown in Figure 2 3 Overall dimensions Figure 2 3 shows the overall dimensions for mounting the recorder millimeters Dimensions inches Standard DR4500 Reference 20 3 17 5 0 255 D 321 D 0 69 F 752 196 14 6 us e 77 Short wing latch e TET oJ oO H 5 163 5 4 18 Double bit latch tdg Left side view 2 Bottom view 9 ale gr Surface mounting 322 355 12 7 14 Front view Back view NEMA4X DR4500 322 12 7 17 5 Reference s 321 9 69 F TA 203 08 23 o 3 Panel cutout all models 438 lo Bottom view i 17 25 Surface mounting 321 12 6 9 i 2 pll 387 gt 406 i 15 25 42 La m 43 Front view Back view 142 4 5 6 S Figure 2 3 Overall dimensions 16 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Mounting Methods 2 4 Mounting Methods Introduction There are several methods available for mounting
51. can be changed for purposes of tweaking the calibration Procedure The procedure for calibrating the position proportional output control output is listed in Table 8 3 e Make sure LOCKOUT in the Set Up group is set to NONE See Section 3 Configuration Also CONTROL 1 2 must be enabled in the Control Set Up group e Make sure CONT ALG PID A and OUT ALG POSITN in the Control Set Up group 196 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Output Calibration Position Proportional Output Calibration Table 8 3 Position proportional output calibration procedure Step Operation Press Action Result 1 Enter Calibration Mode SET Until you see UP Upper Display CALIB Lower Display POS PROP 2 Set Motor Traverse Time FUNC Until you see NOTE This is the time it Upper Display a value takes the motor to travel Lower Display MTR TIME from 0 to 100 95 Aor V Until the proper motor stroke time is reached see the motor specs or measure the time e Range of setting 5 to 255 Seconds 3 Select Automatic or FUNC Until you see Manual Calibration Upper Display DISABL Lower Display POS PROP e You can calibrate the control output manually or let the recorder calibrate the control output automatically e In the Automatic Calibration Mode DO AUTO the control relays automatically move the motor in the proper d
52. chart rotation failure symptoms 213 Procedure 4 Troubleshooting erratic pen movement symptoms essere 214 Procedure 5 Troubleshooting pen failure symptoms essen 214 Procedure 6 Troubleshooting keyboard and or display failure symptoms 214 Procedure 77 Troubleshooting current proportional output failure 215 Procedure 48 Troubleshooting position proportional output failure symptoms 215 Procedure 49 Troubleshooting relay output failure symptoms sse 216 Procedure 410 Troubleshooting current time or time current failure 216 Procedure 11 Troubleshooting the auxiliary output esee 217 Procedure 412 Troubleshooting external alarm function failure symptoms 217 Procedure 413 Troubleshooting Modbus communications failure 217 Pen 1 purple and Pen 2 red Mechanical Alignment eseeseeeeereennennn 218 Set the chart time line procedure csset ede eere PRU RUE Ee rede de e eed 220 Door assembly parts tede diet pede re eR e ee ede eee de RE deed 222 Chart plate assembly parts tese ee GE Re ee er e dei e e Ee edd 224 Basic recorder parts without options sessi enne enini
53. contact wa W4 contact Alarm No 2 w2 W1 contac 1 W2 N O contact 3 Position when shipped N C with power off or Alarm indicator light on Ferrite Filter Fair Rite P N 0443164151 or equivalent Required for CE Mark Conformity Kit Part No 51197612 502 contains two ferrite filters Part No 51197612 508 contains 8 ferrite filters Install inside of case See Figure 2 11 Capacitor Kit 51197755 001 Install capacitors as shown in figure 22085 terminals 2 and 4 are the by non switched connections to Cable Shield i Digital inputs an SPST relay Selectable for P Vice normally open or normally _ _ _ 4 closed as required PIN 3 2nd Control Loop Digital 2 2 This relay supplies a dry En T PIN 2 1st Control Loop Digital 1 contact closure User must PIN 4 Recorder Supplied supply appropriate power LL Volt S connections for his external device Plug J3 for Digital Inputs This relay has a resistive load rating of 1A 120 Vac pm Load calculation example 0047 uF ju Capacitor Supply voltage gt for example 115 Vac _ must equal a number less Resistance of customer than 1 amps controlled device Figure 2 19 Alarm output or digital input wiring 46 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Option Wiring Procedures Additio
54. contacts in an and or fashion so that both contacts or either contact initiates the configured action Tighten the screws to secure the wires Install the wired plug into J3 10 Remove the unwired plug from J4 11 Run the alarm output wires through the desired knockout 12 For CE Mark conformity e install the ferrite filter as shown in Figure 2 11 e install the shield capacitors as shown in Figure 2 19 13 Strip insulation from the end of each wire 14 Loosen the screws in plug J4 terminals and position the plug as you would to plug it into J4 15 Insert the wires for the alarm devices into the appropriate screw clamps as shown refer to Figure 2 19 Tighten the screws to secure the wires 16 17 Locate the jumper positions W1 W2 and W3 WA on the printed circuit board Reposition the jumpers as shown in Figure 2 19 for the desired relay control action The recorder is shipped with the W1 and W3 in N C positions Install the wired plug into J4 Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 45 Installation Option Wiring Procedures External Load Alarm outputs Powe 4 Cable Shield CUP Al 1 arm Relay Load Ce No Alarm 2 Relay Load o _ P NE 0047 uF Capacitor E 7 WA Alarm No 1 W3
55. controller 1 and OUT2ALG applies for controller 2 Selections are model dependent For example current output models cannot be configured for Time Proportioning Simplex Output TIME RELAY SIMPLEX type of output using one SPDT relay Its normally open NO or normally closed NC contacts are selected by positioning an internal jumper e Other prompts affected OUT HYST e Controller 1 uses Relay 3 and overrides control of relay by Alarm 3 Controller 2 uses Relay 5 and overrides control of relay by Alarm 5 CURRNT CURRENT SIMPLEX type of output using one 4 to 20 mA signal that can be fed into a positive or negative grounded load of 0 to 1000 ohms The signal can be recalibrated for any desired range from 3 25 to 21 mA for O to 100 output POSITN POSITION PROPORTIONAL SIMPLEX type of output using two SPDT relays and a motor which has a 100 to 1000 ohms feedback slidewire e Other prompt affected DEADBAND e Controller 1 uses Relays and 4 and overrides control of relays by Alarms 3 and 4 Controller 2 uses Relays 5 and 6 and overrides control of relays by Alarms 5 and 6 TIME D RELAY DUPLEX type of output using two SPDT relays Its normally open NO or normally closed NC contacts are selected by positioning an internal jumper see Installation section e Other prompts affected DEADBAND e Controller 1 uses Relays and 4 and overrides control of relays by Alarms 3
56. filter 0 FILTER FOR INPUT a software digital filter is provided for the input to smooth the input signal You can configure the first order lag time constant from 1 to 120 seconds If you do not want filtering enter O BURNOUT NONE UP DOWN BURNOUT PROTECTION SENSOR BREAK provides most input types with upscale or downscale protection if the input fails e Not available for inputs 0 5V 0 10V or 4 20 mA NO BURNOUT Failsafe output applied for failed input UPSCALE BURNOUT will make the indicated PV signal increase when a sensor fails and flash the upper display DOWNSCALE BURNOUT will make the indicated PV signal decrease when a sensor fails and flash the upper display NOTE For no Burnout that is None to function properly on a linear input there must be a dropping resistor directly across the input terminals that is not remote then the unit can detect the zero voltage that occurs when the 4 20 mA line is opened EMISSIV 01 to 1 00 EMISSIVITY is a correction factor applied to the Radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be emitted if the target were a perfect radiator Available only for Radiamatic inputs Repeat the procedure for INPUT 2 configuration Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 85 Configuration Parameter
57. in the position labeled MA this connects an internal 250 ohm resistor across the 4 20 mA input terminals on J2 Refer to Figure 2 14 for location of jumper Locate jumper W3 and make sure the jumper is in the proper position for your input type see Figure 2 14 Locate connector J2 on the printed circuit board for input 1 refer to Figure 2 14 Remove the unwired plug from J2 Run the input wires through the desired knockout DO NOT bundle them with the power wires oc For CE Mark conformity e Install the ferrite filter as shown in Figure 2 11 e Install the capacitors as shown in Figure 2 14 Strip insulation from the end of each wire Loosen the screws in plug J2 terminals and position the plug as you would to plug it into J2 For transmitters with power Insert the wires into the appropriate screw clamps and tighten the screws to secure the wires e For transmitters which require power Remove the unwired plug from J11 then wire the transmitter power to J11 and the input to J2 Tighten the screws in the plugs to secure the wires 11 Insert the wired plug into J2 and J11 as applicable 12 Repeat steps 2 through 11 for input 2 printed circuit board as applicable Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 35 Installation Input Wiring Procedures Fal Rie P N OHBIGHISI orequiabit
58. information 6 Strip insulation from the end of each wire 7 Loosen the screws in plug J3 terminals and position the plug as you would to plug it into J3 8 Insert the wires for the communications option into the appropriate screw clamps as shown refer to Figure 2 22 Tighten the screws to secure the wires 9 Install the wired plug J3 into J3 connector on the communications board REFERENCE Refer to Documents 51 52 25 66 and 51 52 25 69 for a complete description of RS485 Modbus Communications Option DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Option Wiring Procedures Ferrite Filter 24801 Fair Rite P N 0443164151 or equivalent Required for CE Mark Conformity Kit supplied Part No 51197612 502 contains two ferrite filters More than one kit may be supplied Install inside of case See Figure 2 11 Communication wire must be Alpha XTRA Guard Cable Alpha P N 5121C Communications master 120 Ohm Resistor Place 120 Ohm Resistor on last device between Tx Rx and Tx Rx Notes To other 1 The shield of the RS485 Modbus Communications cable is not communications connected at the recorder end and should not extend into the instruments recorder enclosure The shield of the communication cable Maximum 15 should be connected to earth ground at the farthest end on the cable 2 For non CE Mar
59. listed in Table 2 1 when you install your recorder Table 2 1 Operating limits and condensed specifications Condition Specifications Ambient Temperature 32 to 131 F 0 to 55 C Relative Humidity 5 to 90 RH at 40 C 104 F Vibration Frequency 0 to 200 Hz Acceleration 0 2g Mechanical Shock Acceleration 5g Duration 30 ms Power 102 to 132 Vac 50 60 Hz 204 to 264 Vac 50 60 Hz Power Consumption 20 watts maximum Digital Indication Accuracy 1 digit Minimum Input Span Input Impedance Range is fully configurable with span limitation of the operating range selected 4 20 mA dc 250 ohms 0 10 Vdc 200K ohms All others 10 Megohms Source Impedance RTD 100 ohms per lead maximum Span Step Response Time Sampling Rate 6 seconds maximum with no filtering Each input sampled 3 times a second Input Filter Software Single pole low pass section with selectable time constants off to 120 seconds Digital Displays Vacuum fluorescent alphanumeric A six digit display dedicated to the process variable Alternate information displayed during configuration mode An eight digit display shows key selected operating parameters Also provides guidance during configuration Indicators Channel PV display CHN 1 or 2 Alarm status ALM 1 2 Controller Output OUT 1 2 Remote Setpoint RSP Temperature unit F or C or Engineering Units Control
60. main printed circuit board Replace the transformer and tighten the screws Connect the lead wires to the main printed circuit board 7 Call Technical Assistance Center 1 800 423 9883 USA and Canada 212 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Troubleshooting Procedures Table 9 7 Procedure 2 Troubleshooting pen trace failure symptoms WARNING Do not lubricate the plastic gears on the chart and pen motors Step What to do How to do it or where to find the data 1 Check the sensor for the proper type and Verify the input configuration data and operation its ability to function of the sensor 2 Recalibrate the recorder Refer to Section 7 Input Calibration For thermocouple input be sure to confirm cold junction temperature calibration 3 Replace the servo plate assembly Refer to the instructions included with the replacement part 4 Call Technical Assistance Center 1 800 423 9883 USA and Canada Table 9 8 Procedure 3 Troubleshooting chart rotation failure symptoms WARNING Do not lubricate the plastic gears on the chart and pen motors Step What to do How to do it or where to find the data 1 Check the chart installation Be sure the drive pin on the hub is in the drive hole on the chart 2 Check the configured chart speed value Refer to Section 3 Configuration
61. nni nnns 226 Recorder parts associated with options nnns 228 Miscellaneous hardware kit nee tete gere e oet e Lot RR ep E oe de eo doces 229 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Figure 1 1 Figure 1 2 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 2 19 Figure 2 20 Figure 2 21 Figure 2 22 Figure 2 23 Figure 3 1 Figure 5 1 Figure 5 2 Figure 5 3 Figure 6 1 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Figure 8 1 Figure 8 2 Figure 9 1 Figures Operator interface sii Heec e REIR HE tate Rte dee HEC e ede t ded e REA HE des 3 Set up tasks ienn a 5 Model number interpretation ecciesie ia EE E eE R deseen 13 DR4500A recorder hardware components versus table 1 15 Overall dimensions tree Pede dete te oe T Hn ee Ee Oe GERI GI EE Fe PRESE 16 How knockouts eet se detenti dnt Eaton te aL Eden a Peta ees 17 Mounting Flush in a New Panel Cutout essssssssssesesseeee eee enne nnn 18 Mounting in a panel using universal fil
62. or Tuning 2 group function prompts sse enne nnns 69 Table 3 9 SP Ramp 1 or 2 group function prompts sess nennen nennen 70 Table 3 10 Timer group function prompts en rennen enne 71 Table 3 11 Priority of functions that operate relays 72 Table 3 12 Alarms group function eene nnnm ener nnn trennen 73 Table 3 13 Auxiliary output group function prompts sess nennen nenne 74 Table 3 14 Modbus communications group function prompts esses 75 Table 3 15 Options group function prompts eee ener enne innen entities 76 Table 3 16 Lockout group function enne ener nnne nnne nennen 77 Table 4 1 Input group definitions eene 82 Table 4 2 Pen 1 or 2 group 2 86 Table 4 3 Chart parameters group 88 Table 4 4 Totalizer group definitions cc cccceeccesscessceeseeseeesecseceaecseecaeeeneeeaecseessecesesneseeseeeesaecsaecseecaeeeaeseneeeeeenrenes 89 Table 4 5 Control 1 or 2 group definitions ceeeecceesceseceeecesecseceeecaeecaeeeaeeeecceseeneccseceseesesesaeceecaeeeaeeeaeenaeeeeeees 91 Table 4 6 Tuning group prompt definitions ee
63. power is lost during execution of a program upon power up the recorder will use the last setpoint value prior to the beginning of the setpoint program The program is placed in hold at the beginning The Manual Auto mode will be as configured under POWER in the CONTROL group Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 149 May 2013 Setpoint Ramp Soak Programming and Operation Overview What s in this section This section contains the following information Topic See Page 6 2 Setpoint Program Contents 151 6 3 Drawing a Ramp Soak Profile 154 6 4 Entering the Setpoint Program Data 159 6 5 SP RAMP1 and SP RAMP2 Set Up Group 161 6 6 Setpoint Program Profiles Set Up Group 163 6 7 Setpoint Program Segments Set Up Group 165 6 8 Setpoint Program Event Set Up Group 168 6 9 Run Monitor the Program 172 150 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Contents 6 2 Setpoint Program Contents What you will configure You will configure all the data that is relevant to each ramp and soak segment for a given setpoint versus time program profile The recorder will prompt you through the sequence of segments and associated functions These prompts and functions are described below Recycle number The recycle number allows the program
64. printing 9 Be sure the chart hub assembly is pushed onto the motor shaft so that it is flush with the chart plate 146 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Routine Maintenance 5 16 Routine Maintenance Introduction The DR4500A recorder does not require any periodic maintenance as such But you will have to replace the ink cartridge and replace the chart and optional chart lamp as required A CAUTION Do not lubricate the plastic gears on the chart and pen motors Changing the ink cartridge Follow the procedure in Table 5 30 to clean the pen tip A CAUTION Be careful not to move the pen arm s during this procedure The top arm is pen 1 purple cartridge and the bottom arm is pen 2 red cartridge Table 5 30 Changing the ink cartridge Step Action 1 Open the recorder door Pull the pen lifter up in order to raise the pen from the chart Unclip and remove the ink cartridge from the pen arm Remove the protective cap from the pen tip on the new cartridge and open its clip Slide the new cartridge onto the pen arm and close its clip Push the pen lifter down to lower the pen tips to the chart oc AJOJN Close the door and resume normal operation Replacing a burned out chart lamp optional Follow the procedure in Table 5 31 to replace a burned out chart lamp Table 5 31 Replacing a
65. regulates the controller s output in proportion to the rate of change of the error The amount of corrective action depends on the value of proportional Gain PID B PID B unlike the PID A equation the controller gives only an integral response to a setpoint change with no effect on the output due to the gain or rate action and it gives full response to PV changes Otherwise controller action is as described for the PID A equation See note on PID A PD MR PD WITH MANUAL RESET is used whenever integral action is not wanted for automatic control The equation is computed with no integral contribution The MANUAL RESET which is operator adjustable is then added to the present output to form the controller output Switching between manual and automatic mode will not be bumpless e f you select PD with Manual Reset you can also configure the following variations PD Two Mode control P Single Mode control Set Rate D and or Reset Time I to 0 e Other prompts affected MAN RSET DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 97 Configuration Parameter Definitions Control Parameters Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition OUT1ALG The OUTPUT ALGORITHM lets you select the type of output you want ATTENTION If the recorder has two controllers both enabled OUT1ALG applies for
66. the No 2 pen arm so that its right tip aligns with the inside circumference of the inner most circle in the center of the chart Tighten the screw 8 Replace the No 1 pen arm lockwasher and screw but leave the screw slightly loose 9 Move the No 1 pen arm so that its right tip aligns with the inside circumference of the inner most circle in the center of the chart Tighten screw 218 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Pen Alignment Figure 9 1 is a graphic view of the mechanical alignment of pens Push sector gear for Push sector gear for pen 2 bottom pen 1 top pen down pen up for zero setting for zero setting 22096 Figure 9 1 Mechanical Alignment of Pens Electrical alignment If the group prompt LOCKOUT has been configured for CALIB or selection you will not be able to access PEN 1 or PEN 2 group prompt for electrical alignment See Section 3 Configuration to set LOCKOUT to NONE n ATTENTION PEN 1 and PEN 2 must be aligned separately However the keystroke sequence is the same for both pens but the prompts change from PEN 1 to PEN 2 Be sure that the number of the pen displayed in the prompt agrees with the number of the pen being aligned If you only have a one pen recorder the PEN 2 prompts do not apply Align the pens electrically as shown in Table 9 20 R
67. the order of their appearance The list includes the name of the prompt the range of setting or selections available and the factory setting It allows you to quickly find a parameter and obtain the available range or selection you require Parameter explanations or definitions If you need a detailed explanation of any prompt listed refer to Section 4 Configuration Parameter Definitions This section lists the set up and function prompts the selections or range of settings that you can make for each plus a detailed explanation or definition of each parameter Configuration record sheet Located in subsection 3 19 is a Configuration Record Sheet When you make your configuration selections record them on this sheet Then you will have a record of how the recorder was configured Set up the recorder in this order e Inputs Display will be correct e Pens e Chart e Alarms e Control e Tuning e Other functions as needed 58 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Configuration Tips 3 4 Configuration Tips Introduction Listed below in Table 3 1 are some tips that will help you enter the configuration data more quickly Table 3 1 Configuration tips Function Tip Displaying groups Use the SET UP key to display the Set Up groups The group titles are listed in this section in the order that they appear in the rec
68. to 2240 18 to 1227 0 234 mV 22 277 mV RTD IEC 0 00385 1000 300 to 900 184 to 482 25 180 274 960 1000 RH 130 to 392 90 to 200 64 300 175 840 5000 300 to 900 184 to 482 125 900 1374 800 Milliamps 4 to 20 mA 4 mA 20 mA Millivolts 0 to 10 mV 0 mV 10 mV 10 to 50 mV 10 mV 50 mV Volts 0 to 5 Volts 0 Volts 5 Volts 0 to 10 Volts 0 Vols 10 Volts Radiamatic RH 1400 to 3400 760 to 1871 0 99 mV 57 12 mV Range values for thermocouples are based on a cold junction temperature of 32 F 0 C These values must be adjusted for the actual cold junction temperature when using the ambient temperature method for calibrating thermocouple inputs Resistor network 30755232 002 must be installed in inputs 1 and 2 when using this range see set up diagram for details 7 4 Preliminary Information Disconnect the field wiring 178 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Input Calibration Preliminary Information Depending on which input 1 or 2 you are going to calibrate tag and disconnect any field wiring connected to the input terminals on the input boards inside the recorder Reference Figure 7 1 and follow the procedure in Table 7 3 Table 7 3 Disconnect the field wiring Step Action 1 Remove the operating power from the recorder 2 Open the door on the recorder 3 Loosen the slotted cap screw on the right
69. to recycle a specified number of times from beginning to end e Range 0 to 99 Guaranteed soak A SOAK DEV soak deviation parameter is provided If its value is not zero then soaking will be frozen for each segment until the difference plus or minus between PV and SP is less than or equal to the value of SOAK DEV There are no guaranteed soaks whenever SOAKDEV 0 In this case soak segments start timing soak duration as soon as the soak setpoint is first reached regardless of where the process variable remains relative to the soak setpoint during the duration of the segment The decimal location corresponds to input 1 decimal selection Profile number The profile number specifies which of up to six profiles will run Up to 6 profiles can be configured out of any even number of consecutive segments from the 36 segments configured Program state The program state selection determines the program state after completion The selections are DISABL program is disabled HOLD program on hold Recovery If Recovery is enabled the setpoint program will continue from where it left off after the last power down Program End State This determines the status of the recorder upon completion of the profile The selections are LAST SP hold at the last setpoint in the program e FSAFE Manual mode Failsafe Output Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 151 May 2
70. vor allen anderen Kabeln angeschlossen und zuletzt abgeklemmt werden e In der Nahe der Ausr stung mu ein Schalter in der Hauptstromversorgung vorhanden sein AUSR STUNGSDATEN Netzspannung 102 bis 132 Vac oder 204 bis 264 Vac Frequenz 49 51 Hz 59 60 Hz Nennleistung 9 watts max UMGEBUNGSBEDINGUNGEN Betreiben Sie das Ger t nicht in Gegenwart entflammbarer Fl ssigkeiten oder D mpfe Der Betrieb elektrischer Ger te in solchen Umgebungen stellt ein Sicherheitsrisiko dar Temperatur Umgebung 15 bis 55 C Feuchtigkeit 10 bis 90 RH Vibration 0 bis 70 Hz Beschleunigung 0 1 g ANBRINGUNG DER AUSR STUNGEN Der Regler mu in ein Pult eingebaut sein damit der Bediener nicht zu oft auf die hinteren Anschl sse zugreifen muB 238 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Foreign Language Safety Instructions GR21 6057 GR21 6057 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 239 May 2013 NORME DI SICUREZZA IT21 6057 Per ridurre 1 rischi di scariche elettriche che potrebbero causare alle persone seguire tutte le precauzioni circa la sicurezza indicate in questa documentazione Questo simbolo avverte del pericolo di scossa elettrica nelle aree in cui sono accessibili conduttori sotto tensione Terminale di protezione verso terra Previsto per il collegamento del conduttore di protezione vers
71. your recorder They are e Flush in Panel new panel cutout e Flush in Panel using an existing panel cutout using universal filler plate kit using cutout made for Kent Model 105M e Flush in Panel for recorders with NEMA4 Door e Ona2 inch Pipe e Surface of panel or wall Procedures for each method follow Choose the one that meets your mounting requirements Use the associated dimension drawings for reference How to remove knockouts for conduits Before you mount the recorder remove the appropriate knockouts in the bottom and or sides of the recorder case for wire entry via 1 2 12 7mm conduits Refer to Figure 2 4 for knockout locations n ATTENTION The knockouts are really plugs that you just have to push out to remove Side View Bottom View O Xx 21405 Figure 2 4 How to remove knockouts Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 17 May 2013 Installation Mounting Methods Mounting flush in panel New panel cutout Refer to Figure 2 5 and follow the procedure in Table 2 3 to make a new cutout in a panel and mount your recorder in the cutout Table 2 3 Mounting flush in a new panel cutout Step Action 1 At the appropriate location make a square cutout in the panel measuring 12 7 0 060 inches by 12 7 0 060 inches 322 58 1 52 by 322 58 1 52 millimeters See Figure 2 3 2 Orient the recorder case properly and slide it
72. 0 1 Door assembly Table 10 1 Door assembly parts 21452C Recommended Key Part Number Description Spare Parts per Quantity per Unit 10 100 1 Door Assembly 1 Note 30754955 501 Blue with glass window and latch 3 30754955 504 Blue with acrylic window and latch 30754955 505 Gray with glass window and latch 30754955 506 Gray with acrylic window and latch 30754955 507 Black with glass window and latch 30754955 508 Black with acrylic window and latch 51452435 501 NEMAAX Door with Acrylic window 51452435 502 NEMAAX Door with Glass window 30756548 501 Stainless Steel Door with Glass window 30756548 501 Stainless Steel Door with Acrylic window 1 1 K 30755980 001 Hinge Pin Note 1 2 1 2 K 30755980 001 Retaining Ring Note 1 2 1 3 51309609 503 Latch Lock Assembly Kit 1 3 1 1 3A 30755980 006 Key kit for keyed latch or lock 51452208 503 NEMAAX Latch Kit 51404929 501 External Keypad Upgrade Kit not shown 1 NOTE 1 For Door 30754955 50X K denotes that these parts are included in the miscellaneous hardware kit 30755980 001 For all other doors the parts are included with applicable door assembly 222 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Parts List Exploded Views Chart plate Figure 10 2 is an exploded view of the Chart Plate Assembly Table 10 2 15 a list of the associated part numbers Figure 10 2 Chart plate
73. 0 to 1371 C NIC TC NIC Nicrosil Nisil thermocouple 0 to 2372 F 178 to 1300 C RTC R thermocouple 0 to 3100 F 18 to 1704 C STC S thermocouple 0 to 3100 F 18 to 1704 C TTCH T thermocouple high 300 to 700 F 184 to 371 C TTCL T thermocouple low 200 to 500 F 129 to 316 C WTCH W5W26 thermocouple high 0 to 4200 F 18 to 2316 C WTCL W5W26 thermocouple low 0 to 2240 F 18 to 1227 C 100 PT 100 Ohm RTD 300 to 1200 F 184 to 649 C 500 PT 500 Ohm RTD 300 to 900 F 184 to 482 100 RH 100 Ohm RTD 130 to 392 F 90 to 200 C 4 20mA 4 to 20 Milliamps 0 10mV 0 to 10 Millivolts 10 50m 10 to 50 Millivolts 0 5 V 0 to 5 Volts 0 10 V 0 to 10 Volts RADIAM Radiamatic 1400 to 3400 F 760 to 1871 LINEAR Linear 999 9 to 9999 SQROOT Square Root 999 9 to 9999 These selections appear only with XMITTER prompt which appears only if a linear type is configured input type Go to prompt XMITTER to characterize the input Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 83 May 2013 Configuration Parameter Definitions Input Parameters Set Up Group Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection XMITTER TRANSMITTER CHARACTERIZATION This selection lets you instruct the recorder to characterize a linear input to represent a nonlinear one e NOTE Prompt only appears when a linear actuation
74. 0 x 18 56 Yes Fisher and Porter Model 51 1100 13 75 17 31 Foxboro Model 40 14 38 x 17 06 Yes Kent Model 105M 13 6 x 13 46 No Partlow Model ER 13 5 x 12 69 No Taylor Model 76J 13 78 x 16 5 Yes No adaptation is required use procedure for Flush in Panel New Panel Cutout Use procedure for Cutout made for Kent Model 105M Adapter plate dimensions The dimensions of the adapter plate part number 30755134 are 16 5 x 19 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 19 May 2013 Installation Mounting Methods Mounting flush in panel using universal filler plate kit Refer to Figure 2 6 and follow the procedure in Table 2 5 to mount your recorder in an existing cutout using the Universal Filler Kit Table 2 5 Mounting flush in a panel using universal filler kit Step Action 1 Lay the recorder face down on a clean work surface and position the universal filler plate as shown in Figure 2 6 2 Measure the height of the existing panel cutout 3 Refer to Figure 2 6 Position the support brackets supplied with the kit so that the distance from the top of the window in the filler plate to the right angle of the support brackets is just less than the height of the existing panel cutout 4 Secure brackets with two 10 32 x 1 4 inch screws provided in the kit by inserting them through the holes in the filler plate into the tapped scre
75. 013 Setpoint Ramp Soak Programming and Operation Setpoint Program Contents Profile Start and Profile End These selections let you specify the segments that will comprise each of the 6 profiles The first segment must be a ramp odd numbered segment and the last segment must be a soak even numbered Ramp unit The ramp unit selection determines the engineering units for the ramp segments The selections are e TIME Hours Minutes EU H DegreesSHour OR EU M Degrees Minute Ramp time or rate segments A ramp segment is used to change the setpoint to the next soak setpoint value in the program e Ramps are odd numbered segments Segment 1 will be the initial ramp e Ramps are specifed in terms of either TIME Hours Minutes Range 0 99 hrs 59 min Or EU M Degrees Minute Range 0 to 999 EU H Degrees Hour The selection of time or rate is made at prompt RAMP UNIT Set this prompt before entering any Ramp information n ATTENTION Entering 0 will imply an immediate step change in setpoint to the next soak Soak segments A soak segment is a combination of soak setpoint value and a soak duration time e Soaks are even numbered segments e Segment 2 will be the initial soak value and soak time e The soak setpoint range value must be within the setpoint high and low range limits in engineering units Specify the setpoint range with SP HI and SP LO in the control group as described in Section 4 e
76. 2 CONTROL2 ENABLE TUNING 2 FUZZY DISABL PID SETS 1ONLY ACCUTUNE DISABL SW VALUE 0 0 AT ERR Read only SP SOURC 1LOCAL PROP BD 1 0 RATIO 1 0 or BIAS 0 GAIN 1 0 SP TRACK NONE RATE MIN 0 00 POWER UP MANUAL RSET MIN 1 0 SP HILIM 500 or SP LOLIM 0 RSET RPM 1 0 ACTION REVRSE MAN RSET 0 0 OUTHILIM 100 0 CYCSEC 20 0 OUTLOLIM 0 PROP BD2 1 0 DROPOFF 0 0 DEADBAND 2 0 GAIN 2 40 Bu d 0 5 RATE2MIN 0 00 Ba ae a0 RSET2MIN 1 0 REM SW2 NONE ENABLE PBorGAIN GAIN JG MINorRPM MIN CONT2ALG PIDA SP RAMP1 SP RAMP DISABL OUT2ALG CURRENT TIME MIN 0 4 20 RNG 50PCT FINAL SP 100 0 TUNING 1 FUZZY DISABL See BISSBE ACCUTUNE BEEN DISABL EU HR DN m SP PROG DISABL RECYCLES or SOAK DEV SAIN 1 9 PROFILE RATE MIN 0 00 STATE _ RSET MIN 1 0 RECOVERY or RSET RPM 1 0 eRe ee MAN RSET od SPRAMP2 RAMP DISABL CYCSEC 20 0 PROP BD2 1 0 TIME MIN 2 of FINAL SP 100 0 GAIN 2 1 0 EUIHR UP RATE2MIN 0 00 EU HR DN 1 0 SP PROG DISABL RSET2RPM 1 0 SON DEY CYC2SEC 20 0 PROFILE __ STATE RECOVERY PROG END PROFILES PRx STRT PRx END RAMPUNIT SYNC 1 2 SPP SEGS SEGxRAMP SEGx SP SEGxTIME SPP EVNT SEGx EV Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 79 May 2013 Configuration Configuration Record Sheet Group Function Value or Factory Group Function Value or Facto
77. 3 13 Timer Set Up Group Introduction The Timer gives a countdown or elapsed time after which Relay 1 energizes If Timer 1s enabled it has exclusive control over Relay 1 Alarm 1 will not control the relay Function prompts Table 3 10 lists all the function prompts in the TIMER Set Up group Table 3 10 Timer group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting TIMER Timer Enable Disable ENABLE DISABL DISABL PERIOD Timeout Period 0 00 to 99 59 0 START Start Initiation RHKEY RHKEY ALARM2 LDISPLAY Timer Display TREM TREM ET RESET Timer Reset Control RHKEY RHKEY ALARM 1 REPEAT ON TIME Timer Repeat Mode 1 SEC On Time 2 SEC 3 SEC 4 SEC 5 SEC INCRMENT Timer Count Increment MINUTE MINUTE SECOND Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 71 May 2013 Configuration Alarms Set Up Group 3 14 Alarms Set Up Group Introduction This data deals with the Alarms function that is available with your recorder e There are six alarms available Each alarm has two setpoints e You can configure each of these two setpoints to alarm on various recorder parameters There are two alarm output selections high or low e You can also configure the two setpoints to alarm on the same event and to alarm both high and low if desired An adjustable hysteresis of 0 0
78. 3 CHART To disable the chart drive function and return to normal operation 5 3 Start up Preparation Before start up there are two tasks to perform e Install or replace the circular chart as described in 5 16 Routine Maintenance e sure that the configured settings for the current time and wake time time at which recording begins are correct Note that the recorder is awake during start up to verify interaction with the process During start up you should verify the interaction between your process and the DR4500A recorder to be sure that your process can tolerate some upsets during this procedure Diagnostic tests When power is applied the recorder will run four diagnostic tests Table 5 3 lists the four diagnostic tests Table 5 3 Power up diagnostic tests Prompt on Lower Display Condition RAM TEST Check RAM CONFTEST configuration checksum Check nonvolatile memory CAL TEST working calibration Check calibration BATTERY Check the battery 118 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Start up Test failures If control is enabled and one or more of these tests fail the recorder will go to the Failsafe Manual Mode and FAILSAFE will flash in the lower display If control is not configured the self test failures will be displayed periodically as other error messages are presently displayed
79. 32TIME Soak Time 00 00 to 99 59 or 0 to 999 SEG28SP Soak SP Within SP SG33RAMP Ramp 00 00 to 99 59 limits or 0 to 999 SG28TIME Soak Time 00 00 to 99 59 SEG34SP Soak SP Within SP limits SG29RAMP Ramp 00 00 to 99 59 SG34TIME Soak Time 00 00 to 99 59 or 0 to 999 SEG30SP Soak SP Within SP SG35RAMP Ramp 00 00 to 99 59 limits or 0 to 999 SG30TIME Soak Time 00 00 to 99 59 SEG36SP Soak SP Within SP limits SG36TIME Soak Time 00 00 to 99 59 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 167 May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Event Set Up Group 6 8 Setpoint Program Event Set Up Group Introduction Segment events are used to activate relays by means of alarms There are six alarms and six corresponding relays Alarm 1 controls Relay 1 Alarm 2 controls Relay 2 etc When the setpoint program reaches the segment the segment event triggers the alarm which triggers the relay The relay stays on for the duration of the segment There are no alarm conditions to be satisfied that is when the event goes on the alarm goes on How to trigger a relay with a segment event 1 Program the segment event with the alarm corresponding with the desired relay 2 Program that alarm as type EVENT It is not necessary to program any alarm parameters other than the alarm type Do not program other functions that have higher priority control of the relay See Durin
80. 4 Run the output wires through the desired knockout 5 For CE Mark conformity e Install the ferrite filter as shown in Figure 2 11 e Install the 0047yF capacitor as shown in Figure 2 16 6 Strip insulation from the end of each wire 7 Loosen the screws in plug J1 terminals and position the plug as you would to plug it into J1 8 Observing the polarity insert the wires into the appropriate screw clamps as shown refer to Figure 2 16 Tighten the screws to secure the wires 9 Install the wired plug into J1 10 Locate jumper position W6 W7 on the bottom left portion of the board Make sure W7 position is selected for 4 20 mA output 11 Repeat steps 2 through 10 for control output 2 printed circuit board as applicable n ATTENTION Be sure that the 4 20 mA current output is aligned Refer to subsection 8 2 Current Proportional Output Calibration The 4 20 mA output can be used as a retransmission output if it is not used as a control output Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 39 May 2013 Installation Output Wiring Procedures Control Output 1 2 PCB Current Output Select Jumper W7 Relay or Current Output W7 Control Output 1 PCB or Auxiliary Output 2 Control Output 2 PCB or Auxiliary Output 3 Ferrite Filter Fair Rite P N 0443164151 or equivalent Controller load Requir
81. 44 Configuration TIPS eet tree trei ete alate antes 59 3 5 Configuration Procedure PESE ees 60 3 6 4nput Set Up GrOUp i eee e ee eid e de 62 3 4 PenSetUp Group p nde LR Re P ER Re pA ERR IRE 64 3 8 Chart Set Up Group rene nnn sn nennen a nnne 65 3 9 Totalizer Set Up Group 66 3 10 Control Set enne ei deem edes 67 3 41 Tuning Parameters Set Up 69 3 12 SP Ramp Set Up 70 3 19 Timer Set Up GIOUp z Ft pete roi eet quete eda eee erase 71 3 14 Alarms Set p GOUD eie 72 3 15 Auxiliary Output Set Up Group ssssssssseeeeene enne 74 3 16 Modbus Communications Set Up 75 vi DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 3 17 Options Set Up Group ui Ree HE een 76 3 18 Lockout Set Up Group ede teet erdt dete teint atten 77 3 19 Configuration Record eene 78 4 Configuration Parameter Definitions 81 4 OVetvIOW uus 81 4 2 Input Parameters Set Up
82. AL 1 CONTROL 2 Sameas CONTROL 1 TUNING 1 or or GAIN RSET RPM or or RSET2RPM GAIN 2 56 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Configuration Prompts Set Up Group Function Prompts SP ENABLE SPRANP TMEMN SP RAMP2 Same as SP RAMP1 PROFILES SPP SEGS SPP EVNT ALARM 1 eve wersc sisca H ALARM 2 ALARM 3 ALARM 4 Same as ALARM 1 ALARM 5 ALARM 6 AUX OUT COMM OPTIONS 8EFREG RELAUWD ATWPRES DEVIATION DEVSETPT SCROLL LOCKOUT LOCKOUT ADJUST For printing adjustments see Troubleshooting Service section of manual CALIB For field calibration see Calibration section of manual STATUS Displayed on test failure only Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 57 May 2013 Configuration How To Get Started 3 3 How To Get Started Read the configuration tips Read subsection 3 4 Configuration Tips which will help you to easily and quickly configure your recorder Read configuration procedure Read subsection 3 5 Configuration Procedure which tells you how to access the Set Up groups and the function parameters within each of these groups that are shown in the Prompt Hierarchy in Figure 3 1 Set Up groups The Set Up groups and function parameters are listed in
83. CAL SETPOINT TRACKS RSP REMOTE SETPOINT IN AUTO if configured when the recorder transfers out of remote setpoint the last value of the remote setpoint RSP is inserted into the local setpoint POWER UP POWER UP CONTROLLER MODE RECALL this selection determines which mode and setpoint the recorder will use when the it restarts after a power loss Select one from below MANUAL e MANUAL LSP at power up the recorder will use manual mode with the output value displayed ALSP AUTOMATIC LOCAL SETPOINT at power up the recorder will return to the automatic mode and will use the local setpoint for control A RSP e AUTOMATIC REMOTE SETPOINT at power up the recorder will return to the automatic mode and will use the remote setpoint for control AM SP LAST MODE LAST SETPOINT used before power down AM LSP e LAST MODE LAST LOCAL SETPOINT on power down SP HILIM 999 0 to 9999 input units SETPOINT HIGH LIMIT this selection prevents the local and remote setpoints from going above the value selected here The setting must be equal to or less than the upper range of input 1 and input 2 Input 2 when configured for remote setpoint will be restricted to this upper limit Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 93 Configuration Parameter Definitions Control Parameters Set
84. Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Input Calibration Restoring Factory Calibration Step Operation Press Action Result Aor V Until you see Upper Display 0 10V Lower Display INn TYPE ATTENTION If you are already using a 0 10V input change to a 0 5V input type FUNC Until the upper display rolls through the input types and returns to Upper Display 0 10V Lower Display INn TYPE 2 A V Until you change the input selection in the upper display cont back to the proper selection You will see Upper Display Original input selection that matches your type of sensor Lower Display INn TYPE To commit press FUNC before pressing LOWR DISP 3 Return to normal LOWR To return to Normal operating mode operating mode DISP The factory calibration will be restored If the problem is not corrected contact the Honeywell Technical Assistance Center 1 800 423 9883 USA and Canada CAUTION A restored factory calibration overwrites any previous field calibration done for the input Be sure to protect any field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration See the Section 3 Configuration for specific instructions to set the lockout Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 177 May 2013 Input Calibration Minimum and Maximum Range Val
85. Daughterboard 1 5 1 See 51404561 502 RS485 Comms only Note 51404561 503 RS485 Comms 4 20 mA Aux Output 4 Current Main board with Daughterboard 51404561 504 RS485 Comms only 51404561 505 RS485 Comms 4 20 mA Aux Output 10 30754919 501 Mother board 1 3 0 1 PARTS NOT SHOWN K 30757301 001 Configuration Lockout Hardware 1 NOTE 3 Part included with alarm output digital input PCB kit 30756140 001 Includes connectors and standoffs as required Note 4 Processor Board change occurred approximately September 2009 See Diagram below for daughter board Main board with Daughter board Daughter board 228 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Parts List Miscellaneous Hardware Kit Contents 10 3 Miscellaneous Hardware Kit Contents Kit contents Table 10 5 lists the kit contents of miscellaneous hardware kit part number 30755980 TAB Table 10 5 Miscellaneous hardware kit Quantity Part Description Tab 001 Tab 002 Tab 003 Tab 004 Tab 005 Tab 006 Pen lifter retainer Screw 10 32 3 4 Ig O ring Spring tension Hinge pin NIAJ A Retaining ring Pen arm 1 classic Pen arm 2 classic Latch without lock Latch pin Latch gasket Card guide 4 position connector 3 position connector 3 position connector CE Mark 2 position
86. EN ASENNUS Piirturi on asennettava paneeliin siten ett per liitimille j riitt v sti CONSIGNES DE SECURITE FR21 6057 236 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Foreign Language Safety Instructions FR21 6057 Pour r duire tout risque de d charge lectrique qui pourrait provoquer une l sion corporelle respectez toutes les consignes de s curit de cette documentation Ce symbole avertit l utilisateur d un risque lectrique potentiel lorsqu il peut avoir acc s des l ments sous tension Borne de mise la terre Destin e au raccordement du conducteur de mise la terre de l alimentation e Sil quipement est utilis dans un but non sp cifi par le constructeur la protection fournie avec cet quipement peut tre affect e e Aucun composant ou pi ce ne doit tre remplac s il n est pas explicitement sp cifi comme tel par le constructeur e Tous les c blages doivent tre conformes aux normes locales et doivent tre r alis s par un personnel autoris et exp riment e borne de masse doit tre raccord e avant tout autre c blage et d branch e en dernier e Jl est obligatoire de connecter cet appareil sur une ligne poss dant un moyen de coupure pr s de l appareil CARACTERISTIQUES DE L EQUIPEMENT Tension 102 132 Vac ou 204 264 Vca d alimentation Fr quence 49 51 59 61 Hz Puissance
87. ETS NUMBER OF TUNING PARAMETER SETS this selection lets you choose one or two sets of tuning constants gain rate and reset 1 ONLY ONE SET ONLY only one set of tuning parameters is available Configure the values for Gain proportional band Rate Reset Time Cycle Time if time proportional is used 2KEYBD TWO SETS KEYBOARD SELECTABLE two sets of tuning parameters can be configured and can be selected at the operator interface e Press LOWR DISP key until you see PID SET1 or PID SET2 to switch between sets Configure the values for Gain Rate Reset Cycle Time Gain 2 Rate 2 Reset 2 Cycle 2 Time 2PV SW TWO SETS PV AUTOMATIC SWITCHOVER when the process variable is GREATER than the value set at prompt SW VALUE Switchover Value the recorder will use Gain Rate Reset and Cycle Time The active PID SET can be read in the lower display e When the process variable is LESS than the value set at prompt SW VALUE the recorder will use Gain 2 Rate 2 Reset 2 and Cycle 2 Time The active PID SET can be read in the lower display e Other prompts affected SW VALUE Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 91 May 2013 Configuration Parameter Definitions Control Parameters Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition PID SETS continued 25
88. Gal Min The control setpoint will be limited by the range of units selected here 84 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Input Parameters Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition INn LO n 1 or 2 999 9 to 9999 or 999 to 9999 in Engineering units INPUT LOW RANGE VALUE in engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization e Otherwise this is a read only display of the low range value for the selected T C or RTD input including transmitter characterization if applicable e Scale the input signal to the display value you want for 0 See example on previous page The control setpoint for Input will be limited by the range of units selected here CUTOFF n n 1 or 2 0 to 10096 of Input Range LOW FLOW CUTOFF Lets you set a value in percent of range below which the applicable totalizer does not increment ATTENTION Prompt appears only if totalizer option is present in the recorder BIAS n nz1 2 999 9 to 9999 INPUT COMPENSATION used to compensate the input for drift of an input value due to deterioration of a sensor or some other cause select the value you want on the input FILTER n n 1 or 2 0 to 120 seconds No
89. Honeywell DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Doc No 44 45 25 35 Release K Last Revision Date May 2013 Honeywell Field Solutions Notices and Trademarks Copyright 2013 by Honeywell Release May 2013 WARRANTY REMEDY Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship Contact your local sales office for warranty information If warranted goods are returned to Honeywell during the period of coverage Honeywell will repair or replace without charge those items it finds defective The foregoing is Buyer s sole remedy and is in lieu of all other warranties expressed or implied including those of merchantability and fitness for a particular purpose Specifications may change without notice The information we supply is believed to be accurate and reliable as of this printing However we assume no responsibility for its use While we provide application assistance personally through our literature and the Honeywell web site it is up to the customer to determine the suitability of the product in the application Honeywell Process Solutions 1860 West Rose Garden Lane Phoenix Arizona 85027 www honeywellprocess com DR4500 is a trademark of Honeywell Modbus is a registered trademark of Modicon Other brand or product names are trademarks of their respective owners ii DR4500A Classic Series Circular Chart Recorder
90. II ENABLE ENABLE TUNEXOFF will be displayed as a status message Use the Increment or Decrement key to toggle status to TuneON New PID parameters will be entered automatically when tuning is complete AT ERR NONE ACCUTUNE ERROR CODES Read Only IDFL ABRT RUN 100 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Tuning Parameters Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition PROP BD or GAIN 0 1 to 100096 or 0 1 to 1000 PROPORTIONAL BAND is the percent of the range of the measured variable for which a proportional recorder will produce a 100 change in its output GAIN is the ratio of output change 96 over the measured variable change 96 that caused it _ 100 PB where PB is the proportional band in e Ifthe PB is 20 then the Gain is 5 Likewise a 3 change in the error signal SP PV will result in a 15 change in the recorder s output due to proportional action If the gain is 2 then the PB is 5096 e Used with control algorithm PID A or PID B Defined as HEAT Gain on Duplex models for variations of Heat Cool applications e The selection of Proportional Band or Gain is made in the control parameter group under prompt PBorGAIN RATE MIN 0 08 to 10 00 minutes 0 08 or less OFF RATE action affects the recorder s output
91. L2 DIGITAL 2 INPUT records EVENT pen function on contact closure across digital 2 input CHARTnHI 999 0 to 999 CHART HIGH RANGE VALUE Enter a value that corresponds with the chart high range value for n 1 or 2 pen 1 pen 2 CHARTnLO 999 0 to 999 CHART RANGE LOW VALUE Enter a value that corresponds with the chart low range value for n 1 or 2 pen 1 pen 2 CHART HI minus CHART LO equals Chart Range must be whole number 2 or greater 86 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Pen Parameters Set Up Group Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection PENnON 0 to 100 PEN CHART POSITION FOR ON EVENT This is the event marker configuration using digital inputs n 1 or 2 Select the chart position where pen 1 pen 2 is to mark trace occurrence of an ON event Prompt only appears if DGTL1 or 2 is selected as pen 1 pen 2 input PENnOFF 0 to 10096 PEN CHART POSITION FOR OFF EVENT This is the event marker configuration using digital inputs n 1 or 2 Select the chart position where pen 1 pen 2 is to mark trace occurrence of an OFF event e Prompt only appears if DGTL1 or 2 is selected as pen 1 pen 2 input Repeat this procedure for PEN 2 configuration Release K May 2013 DR4500A Classic Series Circular Chart Reco
92. LMI indicator can also mean the Interval Timer has timed out Alarms 3 6 are indicated by a message on the lower display See Table 5 9 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 123 May 2013 Operation Monitoring Your Recorder Reading the deviation bargraph In addition to the indicators a bargraph containing 21 bars displays Process Variable PV deviation from Setpoint SP n ATTENTION When CHN 1 indicator is lit the bargraph display applies for Controller 1 It applies for Controller 2 when CHN 2 indicator is lit Sequentially press the LOWR DISP key to light the appropriate CHN indicator 1 or 2 and view the corresponding controller displays e The green on control bar lights when the PV is within 1 of setpoint e The 10 small green bars above the on control bar light for each positive deviation up to 10 and the 10 below light for each negative deviation down to 10 If the process deviation is greater than 1096 the on control bar and the specific small green bars light Figure 5 3 shows how the deviation bargraph works 1 to 10 small green deviation bars Green on control bar 1 to 10 small green deviation bars 21424 Figure 5 3 Deviation bargraph 124 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Monitoring Your Recor
93. Lower Display ZERO VAL Aor V Until the desired zero value is reached in the upper display Upper Display desired zero value Lower Display ZERO VAL 7 Set 100 value FUNC The recorder stores the 0 value and you will see Upper Display existing span calibration value in counts approximately 1500 Lower Display SPAN VAL Aor V Until the desired span value is reached in the upper display Upper Display desired span value Lower Display SPAN VAL For manual calibration the motor does not move from its position prior to the start of position proportional calibration 8 Exit the Calibration Mode FUNC The recorder stores the 100 value LOWR To exit the calibration mode DISP or SET UP 198 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Output Calibration Auxiliary Output Calibration 8 4 Auxiliary Output Calibration Introduction Calibrate the recorder so that the auxiliary output provides the proper amount of current over the desired range e The recorder can provide an auxiliary output current range of from 3 1 to 21 milliamperes and can be calibrated at 4 mA for 0 of output and 20 mA for 100 of output or any other values between 3 1 and 21 mA Equipment needed You will need a standard shop type milliammeter with whatever accuracy is required capable of measuring 0 to 20 milliamps Calibrator connections
94. N 51309355 tab CN xn LL LL 120 Vac 240 Vac Fair Rite P N 0443164151 or equivalent Required for CE Mark Conformity Kit supplied Part No 51197612 502 contains two ferrite filters More than one kit may be supplied Install inside of case See Figure 2 11 Y js 120 or 240 Vac Figure 2 12 AC line power wiring 32 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Input Wiring Procedures Thermocouple RTD Radiamatic mV or 0 5 Vdc inputs You can wire input 1 or 2 for thermocouple RTD Radiamatic mV or 0 5 Vdc actuations The polarity for inputs 1 and 2 is identical The prerequisites are e Model Number Table 1 1X00 X100 n ATTENTION For thermocouple or RTD inputs calibrate the recorder to achieve the stated accuracy Refer to Section 7 Input Calibration Refer to Figure 2 13 and follow the procedure in Table 2 12 to wire Thermocouple RTD Radiamatic mV 0 5 inputs Table 2 12 Thermocouple RTD Radiamatic mV or 0 5 Vdc input wiring Step Action 1 Open the recorder door Loosen the captive screw in the chart plate and swing the plate out 2 Locate connector J2 on the printed circuit board for input 1 refer to Figure 2 13 3 Remove the unwired plug from J2 4 Run the input wires through the desired knockout DO NOT bundle them with the power wires 5 For CE Mark conformity e Install th
95. NE NO DIGITAL INPUT SELECTION TO MAN TO MANUAL contact closure selects Manual mode TO LSP TO LOCAL SETPOINT contact closure selects the local setpoint TO 2SP TO LOCAL SETPOINT 2 contact closure selects local setpoint 2 TO DIR TO DIRECT ACTION contact closure selects Direct Control Action RN HLD RUN HOLD contact closure suspends setpoint Ramp Program Contact open resumes TUNE AUTOTUNE contact closure initiates Autotune TIMER TIMER starts the timer if enabled The Timer can also be started by the RH KEY or ALARMA These parameters are found under the Timer set up group MAN KEY MANUAL MODE KEY SELECTION make selection to enable or disable the Manual Mode selection through the MAN AUTO key ENABLE ENABLE allows you to use the MAN AUTO key to select Manual Mode DISABL DISABLE disables the MAN AUTO key PB or GAIN PROPORTIONAL BAND UNITS select one of the following for the Proportional P term of the PID algorithm PB PCT e PROPORTIONAL BAND selects units of percent proportional band for the P term of the PID algorithm where PB 100 FS GAIN GAIN e GAIN selects the unitless term of gain for the P term of the PID algorithm where must be used with settings of TIME D TIME DUPLEX or TI GAIN 100 FS CUR TIME CURRENT Release DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 95 May 2013 Configuration Parameter Defi
96. Ohr 30 min Recycles SOAKDEV Deviation Value 0 SEG9RAMP Ramp 9 0 PROFILE Number of 1 SEG10 SP Soak SP 10 400 profile to run STATE Program HOLD SG10TIME Soak Time 10 Ohr 30 min State at end RECOVERY Program ENABLE SG11RAMP Ramp 11 3hr 30min resumes after power interruption PROGEND SP value after LAST SP SEG12 SP Soak SP 12 200 last segment SPPSEGS Settings for SEG12TIME Soak Time 12 Ohr 30 min segments PR1 STRT Profile 1 Start 1 SEG1 EV Event 1 NONE Seg PR1 END Profile 1 End 12 SEG2 EV Event 2 ALARM1 Seg RAMPUNIT Ramp Units TIME SEG3 EV Event 3 NONE SEG1 RAMP Ramp 1 1 hr SEG4 EV Event 4 ALARM1 SEG2 SP Soak SP 2 300 SEG5 EV Event 5 NONE SEG2TIME Soak Time 2 1hr 30 min SEG6 EV Event 6 ALARM1 SEG3RAMP Ramp 3 1hr SEG7 EV Event 7 NONE SEG4 SP Soak SP 4 400 SEG8 EV Event 8 ALARM1 SEG4TIME Soak Time 4 1 hr SEG9 EV Event 9 NONE SEG5RAMP Ramp 5 1hr 30 min SEG10 EV Event 10 ALARM1 SEG6 SP Soak SP 6 250 SEG11 EV Event 11 NONE SEG6TIME Soak Time 6 SEG12 EV Event 12 ALARM1 Reminder There are up to 36 segments available for inclusion in a profile The above example uses only the first 12 Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 155 Setpoint Ramp Soak Programming and Operation Drawing Ramp Soak Profile Profile graphs Draw your six ramp soak profiles on the graphs below and fill in the associated informa
97. One XX XX Two X XXX Three UNITS Temperature Units DEGF DEGF DEGC XXXXX make selection at prompt ENGUNITS ENGUNITS Engineering Units 0 to 9 AtoZ T Y blank IN1TYPE Input 1 Actuation Type B TC TTCL 100 PT ETCH WTCH or ETCL WTCL 0 5 V J TCH 100 PT with Control JTCL 500 PT K TCH 100 RH KTCL 4 20 mA NNM TC 0 10 mV NIC TC 10 50m RTC 0 5 V S TC 0 10 V TTCH RADIAM 62 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Input Set Up Group Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting XMITTER Transmitter Characterization B TC S TC Linear E TC H T TCH ETCL TTCL J TCH W TC H JTCL WTCL KTCH 100 PT KTCL 500 PT NNM TC H 100 RH NIC TC LINEAR RTC SQROOT Set IN1 HI and IN1 LO IN1 HI Input 1 High Range Value 999 0 to 9999 900 linear inputs only in engineering units IN1LO Input 1 Low Range Value 999 0 to 9999 300 linear inputs only in engineering units CUTOFF 1 Low Flow Cutoff Selection 0 to 100 of input range 0 INPTCOMP Input Compensation 999 9 to 9999 0 FILTER 1 Input 1 Filter 0 to 120 seconds 0 BURNOUT Burnout Protection NONE UP UP DOWN EMISSIV Emissivity 01 to 1 00 01 Repeat this procedure for INPUT 2 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 63 May 2013
98. P Until you see Lower Display UseSPn This is the prompt used to select the setpoint If it is not USESP1 use or switch to USESP1 4 DISP Until you see Lower Display TUNExOFF 10 2 If TUNExOFF tune off does not appear then Accutune is not enabled 5 A to toggle to Lower Display TUNExON 10 2 me Tuning will begin and the lower display will flash TUNING The output will cycle between 50 and 100 or high output limit v When tuning has been completed the lower display will again show TUNExOFF The Heat tuning parameters are entered for the first set of PID constants in the Tuning Set Up group 140 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Using Accutune II Release K May 2013 Step Press Action Result Cooling Tuning 6 DISP Until you see Setpoint 2 Lower Display SP nnn 7 A Until the value of Setpoint 2 is at the desired value within the Cooling zone or 8 DISP Until you see Lower Display Use SP1 9 A to toggle to 5r Lower Display Use SP2 10 DISP Lower Display TUNExOFF 1 2 11 to toggle to 5E Lower Display TUNExON 1 2 Tuning will begin and the lower display will flash TUNING The v output will cycle between 0 and 50 or low output limit When tuning has been completed the lower display will again show TUNEXOFF The Cool tuning parameters are entered for th
99. R4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 23 Installation Mounting Methods Mounting on a 2 inch pipe Refer to Figure 2 9 and follow the procedure in Table 2 8 to mount your recorder on a 2 inch pipe Table 2 8 Pipe Mounting Procedure Step Action 1 Using the eight plastite screws supplied with the pipe mounting bracket kit attach the two mounting brackets flat side against the case to the back of the recorder Refer to Figure 2 9 for location 2 Position the recorder with brackets on the 2 inch pipe 3 Install the U bolts around the pipe and through the bracket holes Secure with lockwashers and hex nuts provided Pipe Mounting J Bracket i Plastite Bb e screw t 24224 Figure 2 9 Pipe Mounting Brackets 24 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Mounting Methods Mounting on surface of panel or wall Refer to Figure 2 10 and follow the procedure in Table 2 9 to mount your recorder on a surface panel or wall ATTENTION You must supply three 3 screws for attaching the mounting hardware brackets and support hook to panel or wall Table 2 9 Mounting flush on a surface of panel or wall Step Action Using two flat head 10 32 x 1 4 inch screws supplied with the recorder fasten the support hook into the recess at the back of the
100. Radiamatic mV or 0 5 Vdc _ 01 pF Capacitor mV or Volt source sod x f Be sure that thermocouple extension Plug J2 As 0047 pF wire matches thermocouple type EEEE AEN OESE Capacitor Keep resistance of all wires equal t NOTE For T C or RTD input calibrate 8 dE t recorder to achieve stated accuracy 1 See Section 7 Input Calibration Use 18 gauge copper wire for lengths up to 150 feet Fortwo wire RTD jumper terminal 1 to 3 Figure 2 13 Thermocouple RTD Radiamatic mV or 0 5 Vdc input wiring 34 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Input Wiring Procedures 4 20 mA inputs and transmitter power You can wire input 1 or 2 for 4 20 mA actuations The polarity for inputs 1 and 2 is identical The prerequisites are Model Number Table 1 1X00 X100 ATTENTION Connector J11 on the main processor printed circuit board can be used to provide 24 Vdc power to up to two field transmitters without power which are supplying the 4 20 mA input signals to the recorder 1 2W 24 Vdc 50 mA available Refer to Figure 2 14 and follow the procedure in Table 2 13 to wire 4 20 mA inputs Table 2 13 4 20 mA input wiring Step Action Open the recorder door Loosen the captive screw in the chart plate and swing the plate out Be sure that the jumper MA W1 is installed
101. Soak time is the duration of the soak and is determined in TIME Hours Minutes Range 0 99 hrs 59 min Segment Events Each segment can be programmed to trigger an alarm which in turn deenergizes the associated relay The selected alarm must be programmed as an event type for this to occur Selections are ALARM 1 ALARM 6 152 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Contents Segment events will not trigger a relay if that relay is configured with one of these higher priority functions e Control loop output e Interval timer e Alarm type other than Event See During alarm conditions an alarm will deenergize its associated relay unless a higher priority function has been configured for that relay See Table 3 11 If you want the alarm to control the relay do not configure a higher priority function Table 3 11 Digital input remote operation Program can be placed in RUN or HOLD state through a remote dry contact connected to optional digital input terminals The Control Loop parameters REM SW and REM SW2 parameters must be configured as RN HLD to support this function The valid states of the contacts are e RUN contact closure places program in HOLD state HOLD contact open places program in RUN state Release K DR4500A Classic Series Circular Chart Recorder With or Without C
102. Suppression ENABLE ACCUTUNE Accutune II for Control Loop DISABL DISABL ENABLE AT ERR Accutune Error Codes No message under normal conditions Read Only message displayed if tuning has been manually aborted PROP BD Proportional Band 0 1 to 1000 1 0 or or GAIN Gain 0 1 to 1000 RATE MIN Rate in minutes 0 00 to 10 00 minutes 0 00 RSET MIN Reset in minutes repeat 0 02 to 50 00 1 0 or or RSET RPM Reset in repeats minute 0 02 to 50 00 1 0 MAN RSET Manual Reset 100 to 10096 output 0 0 PROP BD2 Proportional Band 2 0 1 to 100096 5 0 or or GAIN 2 Gain 2 0 1 to 1000 RATE2MIN Rate 2 in minutes 0 08 to 10 00 minutes 0 00 RSET2MIN Reset 2 in minutes repeat 0 02 to 50 00 0 2 RSET2RPM Reset 2 in repeats minute 0 02 to 50 00 0 2 CYC SEC Cycle Time Heat 1 to 120 seconds 20 0 Electromechanical Relays CYC2 SEC Cycle Time 2 Cool 1 to 120 seconds 20 0 Electromechanical Relays Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 69 May 2013 Configuration SP Ramp Set Up Groups 3 12 SP Ramp Set Up Groups The Setpoint Ramp 1 or 2 Set Up groups let you configure two setpoint ramps Each group SP RAMPI and SP RAMP 2 can be configured one of three ways ramp rate or setpoint program Setpoint Ramp Setpoint will ramp between the current local setpoint and a final setpoint over a time interval SP RAMP Setpoint Rate The Setpoint Ramp Set Up group also contains the function parameters that let yo
103. Ter vermindering van het gevaar van elektrische schokken die lichamelijk letsel kunnen veroorzaken dient u alle veiligheidsaanwijzingen in dit dokument te volgen Dit symbool waarschuwt de gebruiker voor een potentieel schokgevaar wanneer toegang bestaat tot onderdelen die onder gevaarlijke spanning staan Beschermende aarde aansluiting Bestemd voor aansluiting van de aardingsdraad van de voeding PS gt e Indien de apparatuur wordt gebruikt anders dan door de fabrikant gespecificeerd kan de bescherming die de apparatuur biedt ongedaan worden gemaakt e Alleen die onderdelen mogen worden vervangen die door de fabrikant als uitwisselbaar zijn aangemerkt e Alle bedrading moet in overeenstemming zijn met de lokale elektriciteiseisen en moet aangelegd worden door geauthoriseerd ervaren personeel e De aardingsdraad moet worden aangesloten v rdat alle andere bedrading wordt aangesloten en als laatste worden verbroken e Het verdient aanbeveling een netschakelaar aan te brengen vlakbij het instrument APPARATUUR VOORWAARDEN Voedingsspanning 102 tot 132 Vac 204 to 264 Vac Frequentie 49 tot 51 Hz 59 tot 61 Vermogen of 9 watts max stroomvermogen OMGEVINGSCONDITIES Gebruik het instrument niet in de aanwezigheid van ontvlambare vloeistoffen of dampen Het gebruik van elk elektrisch instrument in een dergelijke omgeving vormt een gevaar voor uw veiligheid Temperatuur In bedrijf 15 tot 55 C Vochtigheid 10 tot 90 RH Tr
104. To select new segment RUN To begin running at new segment HOLD or LOWR To retain the old segment DISP Viewing the number of LOWER Until you see les left in th DISP S Upper Display R and the PV value Lower Display RECYC XX Remaining cycles O to 99 This number includes the current partially completed cycle End Program When the final segment is completed the R in the upper display either changes to if configured for HOLD state or disappears if configured for DISABL of setpoint programming e The recorder operates at the last setpoint in the program in automatic or will be in manual mode at the failsafe output Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 173 May 2013 Setpoint Ramp Soak Programming and Operation Run Monitor the Program This page has been intentionally left blank 174 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 175 7 Input Calibration 7 1 Overview SHOCK HAZARD WARNING Disregard of these instructions may cause injury or death INPUT CALIBRATION MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE CALIBRATION Introduction This section describes the field calibration procedures for inputs 1 and 2 All DR4500A
105. UT 2 This represents the value of the configured range of input 2 PROCESS VARIABLE 1 Represents the value of the Process Variable for Loop 1 PV Input 1 Bias DEV 1 DEVIATION 1 PROCESS VARIABLE MINUS SETPOINT Represents 100 to 100 of the selected PV span in engineering units for Loop 1 FOR EXAMPLE Type T Thermocouple PV range PV span Deviation range If PV and SP then Deviation Display Auxiliary Output 300 to 700 F 1000 1000 to 1000 F 500 F 650 F 150 F 42 5 NOTE A deviation of 0 F yields an auxiliary output of 50 OUT 1 OUTPUT 1 Represents the displayed controller output in percent for Loop 1 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 109 May 2013 Configuration Parameter Definitions Auxiliary Output Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition AUX OUT SP 1 continued SETPOINT 1 Represents the value of the setpoint in units of PV for Loop 1 PV 2 PROCESS VARIABLE 2 Represents the value of the process variable for Loop 2 DEV 2 DEVIATION 2 PROCESS VARIABLE MINUS SETPOINT Represents 100 to 100 of the selected PV span for Loop 2 See Example at DEV 1 OUT 2 OUTPUT 2 Represents the displayed controller output in percent for Loop 2 SP 2 SETPOINT 2 Represents the
106. Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition SP LOLIM 999 0 to 9999 inputs units SETPOINT LOW LIMIT this selection prevents the local and remote setpoints from going below the value selected here The setting must be equal to or greater than the lower range of input 1 and input 2 Input 2 when configured for remote setpoint will be restricted to this lower limit ACTION OUTHILIM CONTROL OUTPUT DIRECTION in what direction do you want the recorder output to go when the process variable increases DIRECT DIRECT ACTING CONTROL the recorder s output increases as the process variable increases REVRSE 5 0 to 105 0 of output REVERSE ACTING CONTROL the recorder s output decreases as the process variable increases HIGH OUTPUT LIMIT this is the highest value of output beyond which you do not want the recorder automatic output to exceed Use 0 to 100 for time proportional output type OUTLOLIM 5 0 to 105 096 of output LOW OUTPUT LIMIT this is the lowest value of output below which you do not want the recorder automatic output to exceed Use 0 to 100 for time proportional output type DROPOFF 5 to 105 0 of output CONTROLLER DROPOFF VALUE select an output value that below which the recorder output will dropoff to the low output limit value set in prompt OUT LOLIM DEADBAND 5 0
107. a o 0 1 g INSTALA O DO EQUIPAMENTO O Registrador deve ser montado num painel para limitar o acesso do operador aos terminais traseiros 242 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Foreign Language Safety Instructions SP21 6057 NORMAS DE SEGURIDAD SP21 6057 Para reducir el riesgo de choque el ctrico el cual podr a causar lesiones personales seguir todas las indicaciones de este documento Este s mbolo previene al usuario de un riesgo potencial de descarga cuando se puede acceder a corrientes de tensi n peligrosas Terminal de tierra de protecci n Proporcionado para la conexi n de la tierra de protecci n del conductor del sistema de alimentaci n Om e Si el equipo es utilizado de forma no especificada por el fabricante la protecci n suministrada con el mismo podr a resultar da ada e reemplazar ning n componente o parte no explicitamente especificado por el suministrador e Todo el cableado debe realizarse de acuerdo con las normas el ctricas locales y debe ser realizado por personal experimentado e FEl terminal de tierra debe ser conectado antes que cualquier otro cable y desconectado el ultimo e Se recomienda la instalaci n de un interruptor de la alimentaci n principal cerca del equipo DATOS ELECTRICOS DEL EQUIPO Tensi n de 102 a 132 Vac 204 a 264 Vac alimentaci n Frecuencia 49 5 Hz 59 61 Hz Potencia o 9
108. ackground test failure error messages 210 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Visual Failure Symptoms 9 4 Visual Failure Symptoms Introduction In addition to the error message prompts there are visual failure symptoms that can be identified by noting the erratic recorder functions Symptoms Compare your symptoms with those shown in Table 9 5 and refer to the troubleshooting procedure indicated to correct the problem Table 9 5 Visual failure symptoms Symptom Troubleshooting Procedure Recorder will not operate 1 Recorder operation is normal but pen trace is incorrect Chart rotates at wrong speed or will not rotate pen indication correct 2 3 Pen remains at high end of range when input signal is low 4 Pen does not move when input signal changes 5 6 A key does not respond and or a display does not light Displayed output does not agree with controller output Current Proportional Output Type 7 Position Proportional Output Type 8 Single or Dual Relay Output Type 9 Duplex Current Time or Time Current Proportional Output Type 10 Auxiliary Output Type 11 External Alarm Function does not operate properly 12 Modbus Communications Failure 13 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 211 May 2013 Troubleshooting Service T
109. act opens the recorder returns to former operation unless the FUNC key is pressed while digital input is active Puts the recorder into local setpoint 2 To DIR None Selects direct controller action transfer if in reverse RN HOLD H blinks in upper display Suspends setpoint program or setpoint ramp e Keyboard takes priority over external switch for RUN HOLD function e Contact open runs the program or ramp e If initially in the HOLD state close then open the contact to remotely start the SP ramp or program TUNE TUNING x Initiates Accutune Keyboard operation If a particular mode or parameter is selected by the contact closure using the keyboard to select the same parameter ensures that the selected mode will be maintained after the remote digital switch is reopened Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 143 Operation Resetting and Displaying Totalizer Value 5 13 Resetting and Displaying Totalizer Value Introduction If the totalizer is enabled and has been configured to allow resetting you can reset the current totalizer value as follows Refer to Section 3 Configuration under Set up prompt TOTAL 1 for Input 1 or TOTAL 2 for Input 2 to enable the totalizer function and allow the totalizer to be reset e Refer to the procedures that follow to reset the totalizer locally
110. al Output Aux Out 2 and 3 Calibration Procedure The procedure for calibrating the Current Proportional Output is listed in Table 8 2 Make sure LOCKOUT in the Set Up group is set to NONE See Section 3 Configuration Also CONTROL 1 2 must be enabled and OUT ALG must be set to CURRNT in the Control Set Up group n ATTENTION Follow this procedure when calibrating Auxiliary Output 2 or 3 Make sure LOCKOUT in the Set Up group is set to NONE and AUX OUT must NOT be disabled in the Auxiliary Output group Table 8 2 Current proportional output Aux Out 2 and 3 calibration procedure Step Operation Press Action Result 1 Enter Calibration Mode SET Until you see UP Upper Display CALIB Lower Display CURRENT 2 Calibrate 0 FUNC You will see Upper Display a value approximately 380 Lower Display ZERO VAL Aor V Until the desired O output is read on the milliammeter Use the values shown below depending on the action of your recorder 4mA For4to 20 mA Direct Action 20 mA For 4 to 20 mA Reverse Action 3 Calibrate 100 FUNC Stores the 0 value and you will see Upper Display a value approximately 1890 Lower Display SPAN VAL Aor V Until the desired 100 output is read on the milliammeter Use the values shown below depending on the action of your recorder 20 mA For 4 to 20 mA Direct Action 4mA For 4 20 mA Reverse Action 4 Exit the C
111. al Release K May 2013 193 8 Output Calibration 8 1 Overview SHOCK HAZARD WARNING Disregard of these instructions may cause injury or death OUTPUT CALIBRATION MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE CALIBRATION Introduction This section describes the field calibration procedures for the following types of outputs e Current Output Position Proportional Output e Auxiliary Output n ATTENTION Calibration for Control Outputs 1 and 2 is identical except for the particular printed circuit board involved What s in this section This section contains the following topics Topic See Page 8 1 Overview 193 8 2 Current Proportional Output Aux Out 2 and 3 Calibration 194 e Introduction 194 e Equipment needed 194 e Calibrator connections 194 e Calibration Procedure 195 8 3 Position Proportional Output Calibration 196 e Position proportional control 196 e Equipment needed 196 e Connections 196 e Auto mode vs manual mode 196 e Displayed values 196 e Calibration Procedure 196 8 4 Auxiliary Output Calibration 199 e Introduction 199 e Equipment needed 199 e Calibrator connections 199 e Calibration Procedure 199 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 193 May 2013 Output Calibration Current Pr
112. alibration Mode FUNC The recorder stores the span value LOWR To exit the calibration mode DISP or SET UP Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 195 May 2013 Output Calibration Position Proportional Output Calibration 8 3 Position Proportional Output Calibration Position proportional control When the DR4500A Recorder has a position proportional control output calibrate the recorder so that the increase and decrease relays operate properly with respect to the position of the external feedback slidewire Equipment needed None Connections Leave all field wiring connected to the plugs in connectors J2 and J5 on the appropriate control output printed circuit board Apply power and allow the recorder to warm up 15 minutes before you calibrate Auto mode vs manual mode There are two ways in which to calibrate Position Proportional control AUTO mode or MANUAL mode Rules for auto mode vs manual mode The auto mode selection must be done at least once before the manual mode will operate properly Failure to use the auto mode procedure will prevent the recorder from going into automatic control mode Displayed values During the auto mode calibration procedure the values being displayed are used only to indicate if the motor is still traveling To view the actual calibration value use the manual mode after the auto mode is completed These values
113. and 4 Controller 2 uses Relays 5 and 6 and overrides control of relays by Alarms 5 and 6 CUR TI CURRENT RELAY DUPLEX RELAY HEAT is a variation of duplex with current active for 0 to 50 output tuning set 2 and relay active for 50 to 100 output tuning set 1 e Other prompts affected 4 20 RNG DEADBAND e Controller 1 uses Relay and overrides control of relay by Alarm 3 Controller 2 uses Relay 5 and overrides control of relay by Alarm 5 98 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Control Parameters Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition OUT1ALG continued TI CUR RELAY CURRENT DUPLEX RELAY COOL is similar to CUR TI except that current is active for 50 to 100 and relay is active for 0 to 50 e Other prompts affected 4 20 RNG DEADBAND e Controller 1 uses Relay 4 and overrides control of relay by Alarm 4 Controller 2 uses Relay 6 and overrides control of relay by Alarm 6 4 20 RNG CURRENT DUPLEX RANGE ALGORITHM used with Output Algorithm selections CUR TI or TI CUR 50 PCT CURRENT DUPLEX RANGE SPLIT enables the normal control current output to provide its full range for 5096 output change e If CUR TI duplex was selected the current output provides cool control
114. anual 139 May 2013 Operation Using Accutune II Using Accutune with Duplex Heat Cool Control can be done for applications using Duplex Heat Cool control During tuning Accutune II assumes SP 1 will cause a Heating demand and then the calculated tuning parameters will be automatically entered as the first set of PID constants Likewise it assumes tuning at Local SP 2 will cause a Cooling demand and the cooling parameters will be entered as the second set of PID constants Procedure After TUNE has been enabled in the Tuning Set Up group as described in section 4 use the procedure in Table 5 24 to start tuning Note that control group parameter SP SOURC must be set to 2LOCAL to enable the second setpoint To abort tuning in progress press the MAN AUTO key to take the recorder out of Auto mode The message AbRT abort will be displayed as the value of Tuning Set Up group parameter ERR The tuning parameters will retain the values they had at the start of the Accutune operation Table 5 24 Procedure for using Accutune for duplex control Step Press Action Result Heating Tuning 1 DISP Until you see Setpoint 1 Lower Display SP nnn 2 A Until the value of Setpoint 1 is at the desired value within the Heat zone or Make sure the recorder is in Auto mode indicator lit v If not use the MAN AUTO key to put the unit in Auto 3 DIS
115. ard selected e Automatically switched when a predetermined Process Variable value is reached e Automatically switched when a predetermined Setpoint value is reached The following procedures show you how to e Select two sets e Set the switchover value e Set tuning constant value for each set e Switch between two sets via the keyboard without automatic switchover n ATTENTION For recorders with two controllers both enabled remember that any controller related values displayed correspond with the lighted CHN indicator 1 means that the values apply for Controller 1 and 2 means that the values apply for Controller 2 Select two sets The procedure in Table 5 19 tells you how to select two sets of tuning constants Table 5 19 Procedure for selecting two sets of tuning constants Step Operation Press Action Result 1 Select Control Set Up SET Until you see group UP Upper Display SET UP Lower Display CONTROL 2 Select FUNC You will see PID SETS function Upper Display Available selections are 1 ONLY 1 set of constants 2 KEYBD 2 sets keyboard selectable 2 PVSW 2 sets auto switch at PV value 2 SPSW 2 sets auto switch at SP value Lower Display PIDSETS A or V Select the type of PID set Set switchover value If you select 2 PVSW or 2 SPSW you must set a value at which the sets will switch over The procedure in Table 5 20 shows you how to set this value
116. aximizing Pen Life 146 5 16 Routine Maintenance 147 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 115 Operation Preparation 5 2 Preparation Introduction After the DR4500A recorder is installed and configured there are a few preparation tasks to perform prior to start up These tasks include e installing the chart e setting the time line and e changing the chart hub if necessary Refer to Table 5 1 for these procedures In some instances it may be necessary to tune the controller portion see Subsection 5 3 Start up e align the pens electrically see Section 9 Troubleshooting Service e recalibrate the input see Section 7 Input Calibration Install replace chart Table 5 1 lists the steps required to install replace the chart Refer to Figure 5 1 and follow the procedure Table 5 1 Install replace chart Step Action 1 Open the recorder door Remove power if it is applied 2 Pull the pen lifter up in order to raise the pen s from the chart 3 If there is a chart already installed remove the chart from the hub and retaining clips 4 Install the new chart so that its edges are under the four retaining clips and its small alignment hole is over the alignment pin on the hub 5 e f your chart hub looks like one of these and requires a smaller hub size Setscrew 2 2 b For a unscrew the hex head set screw and open the latch F
117. ber for which the event applies AxS2 VAL Value in engineering units ALARM x SETPOINT 2 VALUE this is the value at which you want the alarm type chosen in prompt AxS2TYPE to actuate e The details are the same as AxS1 VAL AxS1TYPE ALARM x SETPOINT 1 TYPE select what you want Setpoint 1 of Alarm 1 to represent It can represent any of the Inputs Relative Humidity Deviation loop 1 or 2 Output loop 1 or 2 and if you have a model with communications you can configure the recorder to alarm on SHED If you have setpoint programming you can alarm when a segment goes ON or OFF loop 1 or 2 An alarm can also be set to activate if a totalizer value has exceeded a configured alarm value NONE NO ALARM IN 1 INPUT 1 IN 2 INPUT 2 RH RELATIVE HUMIDITY DEV loop 1 LOOP 1 DEVIATION OUT loop 1 LOOP 1 OUTPUT DEV2 loop 2 LOOP 2 DEVIATION OUT2 loop 2 LOOP 2 OUTPUT EVENT EVENT ON SP PROGRAMMING TOTAL 1 TOTALIZER TO ALARM ON TOTAL 2 TOTALIZER TO ALARM ON AxS2TYPE Same as AxS1TYPE ALARM x SETPOINT 2 TYPE select what you want Setpoint 2 of Alarm x to represent The selections are the same as AxS1TYPE Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 107 May 2013 Configuration Parameter Definitions Alarms Set Up Group Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection ALARM x SETPOINT 1 STATE select wheth
118. bus Communications DISABL DISABL MODBUS Com ADDR Communications Station 1 to 99 1 Address BAUD Communications Baud Rate 300 9600 600 1200 2400 4800 9600 19200 38400 XMT DLAY Transmit Delay NONE NONE in milliseconds 10MSEC 20MSEC 30MSEC 40MSEC 50MSEC DBL BYTE Double Byte Order FP B FP FP BB FPL FP LB Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 75 May 2013 Configuration Options Set Up Group 3 17 Options Set Up Group Introduction This data deals with various options that are available with your recorder If your recorder does not have any of these options the prompts will not appear Function prompts Table 3 15 lists all the function prompts in the Option Set Up group Table 3 15 Options group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting REJ FREQ Rejection Frequency 50HZ 60HZ 60HZ HF REJ High Frequency Rejection ENABLE ENABLE DISABL RELHUMID Relative Humidity NO NO YES ATMPRES Atmospheric Pressure 590 to 800 mmHg Compensation DEVIATION Deviation Recording Action NONE NONE SETPNT CHAN1 DEVSETPT Deviation Setpoint Value 999 0 to 9999 0 SCROLL Lower Display Scroll NONE NONE 1 SEC 2 SEC 3 SEC GRANDTOT Grand Totalizer ENABLE DISABL DISABL 76 DR4500A Classic Series Circular Chart Recorder With or W
119. ccutune II in progress for Control Loop 1 TUNING 2 Indicates Accutune II in progress for Control Loop 2 n ATTENTION An active alarm will always provide an indication on the display but may not control its associated relay that is a higher priority function such as a control loop or timer may have control of the relay Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 127 May 2013 Operation Operator Functions 5 5 Operator Functions Actions an operator can initiate An operator can do the following Change the Control Mode Auto Man Adjust the Output Manually Change the Setpoint Switch between Setpoints Run or Disable a Setpoint Ramp Run or Disable a Setpoint Program Switch between Two Sets of PID Values Run or Disable Control Loop Tuning Check the Alarm Setpoints Display and Reset the Totalizer Close a Remote Switch Monitor External Event Pen Operation Run a Key Test Note that some actions depend upon how the recorder was configured and the features supplied on your particular recorder model Refer to the following pages for functions and procedures CHN indicator Remember for recorders with two controllers both enabled any controller related values displayed including control mode correspond with the lighted CHN indicator 1 means that the values apply for Controller 1 and 2 means that the values apply for Controller 2
120. chart lamp Step Action 1 Open the recorder door and remove power 2 Unscrew and remove the hood from the lamp assembly 3 Push the bayonet type lamp in and turn it counterclockwise to remove it from the socket 4 Reverse step 3 and install the replacement lamp General Instrument type 1828 or equivalent in the socket Replace the hood on the lamp assembly 6 Close the door and apply the power Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 147 May 2013 Operation Installing Replacing Chart 5 17 Installing Replacing Chart Installing replacing chart procedure Follow the procedure in Table 5 1 to install replace the chart A CAUTION Store replacement charts in a dust resistant location Otherwise accumulated dust on the chart may cause excessive pen tip abrasion which can shorten expected pen life In addition you may want to air purge the case if the recorder is mounted in an extremely dusty environment 148 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 149 6 Setpoint Ramp Soak Programming and Operation 6 1 Overview Introduction As an option the recorder can support the programming of a 36 segment setpoint program containing 18 ramp segments and 18 soak segments In a ramp segment the setpoint value is changed as specified during configuration The ramp is configu
121. ck information Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 217 Troubleshooting Service Pen Alignment 9 6 Pen Alignment Mechanical alignment CAUTION Align pens mechanically as shown in Table 9 19 and then electrically as described in Table 9 20 Never attempt to manually force the pen arms from the front since this will damage the pen mechanism n ATTENTION Be sure the shipping sponge is installed on the pen tip whenever the recorder is moved or stored Table 9 19 1 purple and Pen 2 red Mechanical Alignment Step Action 1 Refer to Figure 9 1 ATTENTION If you only have a one pen recorder steps for pen 2 red do not apply 2 Turn off power open the door and lift the pen lifter up 3 Unclip and remove the purple and red ink cartridges from pen 1 and 2 arms to provide a better view of tips of arms 4 Push the No 1 pen sector gear down so that its uppermost teeth mesh with teeth on the motor shaft gear 5 Push the No 2 pen sector gear up until it is at the top of the slot in the servo plate 6 For the 2 Pen Recorder Remove the screw and lockwasher holding the No 1 pen arm to the servo shaft Slightly loosen the screw holding the No 2 pen arm to the servo shaft For the 1 Pen Recorder Slightly loosen the screw holding the No 1 pen arm to the servo shaft and skip to Step 8 7 Move
122. connector NINININI Fuse 0 5 A 250 V 20 Batteries 3 0 V Lithium Button Cell Key for latch or lock Key for Heavy Duty Door Keyed latch Noise Suppression Kit 120VAC 51404594 501 Noise Suppression Kit 220VAC 51404594 502 Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 229 Parts List Internal Cabling Data Without Options 10 4 Internal Cabling Data View of internal cabling Without Options Figure 10 5 is a view of the internal cabling for the DR4500A Classic Series Recorder 9 position keyboard cable 4 conductor cable Chart motor Chart Plate Light option 2 wire pair us Mother board 2 wire cable_y gray pair Chassis ground 2 wie 7 2 wire purple pair Main transformer orange 2 wire pair black pair 4 conductor cabld 4 conductor cable L 2 wires black Pen 1 drive Pen 2 drive Chart drive Alarm digital inputs 2 22099 Figure 10 5 Internal cabling for DR4500A Classic recorder 230 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Parts List Internal Wiring Diagram Options Only 10 5 Internal Wiring Diagram Options Only View of internal option wiring Figure 10 6 is a view of the internal wiring diagram options only fo
123. contact closure places the recorder in the HOLD state if the setpoint program is running e The in the upper display blinks ATTENTION The keyboard takes priority over external switch for the RUN HOLD function e Contact reopening runs program Guaranteed Soak If a non zero value has been entered for SOAK DEV a Soak Segment will be suspended until deviation SP PV is less than SOAK DEV will appear in the upper display during Soak Deviation Hold 172 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Run Monitor the Program Function Press Result Viewing the present LOWR Until you see ramp or soak segment DISP n mberand ya Upper Display R and the PV value Lower Display For Ramp segments RA XX XX jl Ramp Time Hours Minutes or Ramp Rate Degrees Minute Indicates Ramp segment Segment Number odd only For Soak segments SK XX XX Time remaining in segment in Hrs Minutes including current partially completed minute Indicates Soak segment Segment Number even only Skipping segments LOWR Until you see Upper Display R and the PV value Lower Display XX XX Ramp Segment SK XX XX Soak Segment RUN To hold the SP Program HOLD e H appears in the upper display indicating that the program is in the HOLD state Aor V
124. ction perform keyboard test Start up procedure Use the procedure listed in Table 5 5 to start up the recorder Open the recorder door Apply power and wait for the recorder to run its power up tests n ATTENTION e If FAILSAFE starts blinking in the lower display refer to Section 9 for troubleshooting data e For recorders with two controllers both enabled be sure the CHN 1 indication is lit for steps 2 6 If CHN 1 is not lit sequentially press the LOWR DISP key until 1 is lit when OUT is displayed Table 5 5 Procedure for starting up the recorder Step Description Press Action 1 Pen check For RECORDER ONLY models just check that the pen is operating and skip to step 6 2 Select manual mode MAN Until MAN indicator is ON AUTO The recorder is in manual mode and the Output OUT in percent is displayed in the lower display 3 Adjust the output Aor V Adjust the output value and ensure that the final control element is functioning correctly Upper Display shows the PV value Lower Display shows OUT and the output value in 96 Make sure the pen trace on the chart corresponds to the change in output 4 Tune the recorder SET Make sure the recorder has been configured properly UP and all the values and selections have been recorded on the Configuration Record Sheet To tune your recorder automatically see section 5 10 Using Accutune Refer to Set Up group TUNING 1 or TUNING 2
125. ctivates the relay for 1 to 5 seconds ON TIME 1 SEC Relay 1 on time when timer is in repeat mode 2 SEC 3 SEC 4 SEC 5 SEC INCRMENT MINUTE Selects the units of the timer SECOND Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 105 May 2013 Configuration Parameter Definitions Alarms Set Up Group 4 10 Alarms Set Up Group Introduction An alarm is an indication that an event that you have configured for example Process Variable has exceeded one or more alarm limits There are six alarms available each with two setpoints You can configure each of these two setpoints to alarm on various controller parameters There are two alarm output selections high and low You can configure each setpoint to alarm either high or low These are called single alarms You can also configure the two setpoints to alarm on the same event and to alarm both high and low An adjustable hysteresis of 0 0 to 100 0 is configurable for each alarm setpoint Priority of functions that operate relays During alarm conditions an alarm will deenergize its associated relay unless a higher priority function has been configured for that relay See Table 3 11 If you want the alarm to control the relay do not configure a higher priority function Table 4 9 Priority of functions that operate relays Relay Relay is controlled by in order of priority 1 3 Timer function 4 A
126. d F Gray door Acrylic window and keypad 5 Blue door Glass window 6 Blue door Acrylic window Input Actuation L Black door Glass window 0 None 9 Black door Acrylic window 1 T C RTD Radiamatic mV 0 5V 4 20mA 4 door Glass window 3 0 10 Vdc R NEMAAX door Acrylic window 0 Standard door latch External Output A Keyed latch 00 None K Door lock with key 10 1 Control Output 0 No illumination 11 2 Control Outputs L Configuration lockout Chart plate seal M Configuration Lockout Chart plate seal Illumination N Chart illumination 0 Noapprovals 6 0 1 Control Output with FM Approval K CE Mark 6 6 2 Control Outputs with FM Approval L UL CSA certification M CE Mark FM approval N CE Mark UL CSA certification P UL listing CSA certification 0 None R FM approved Class 1 Div 2 Groups A B C D Auxiliary 4 20 mA Output U UL listing CSA certification FM approval RS485 Modbus RTU 0 1 0 Tag 4 RS485 Modbus RTU plus Auxiliary Output T Customer I D Tag 30 characters maximum 0 Standard Pen B Certificate of Conformance F3391 C Custom Calibration Test Report F3399 0 None D Certificate of Conformance 1 0 Tag 1 2 Alarm Outputs 2 Digital In
127. dard Caribbean Blue Black or Gray Approval Bodies U L approval depending on model CSA approval Consult Model Selection Guide for information FM approved for Class Div 2 Groups A B C D areas depending on model Weight 13 2 Ibs 6 kg Mounting Panel pipe or surface mounted Some adapter kits available for existing panel cutouts OPTIONS Alarm Output Two four or six relays available Relays 3 through 6 available if not used for control outputs Relay Contact Ratings First Relays Resistive Load 1A 120 Vac 1 2A 240 Vac Relays 3 through 6 Resistive Load 5A 120 Vac 2 5A 240 Vac Digital Input 20 Vdc source for external dry contact or isolated solid state contacts Selects one configured input Totalizers One or two totalizers depending on model Eight digit totals with multiplier on digital display Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 11 May 2013 Installation Overview Condition Specifications RS485 Modbus RTU Communications Baud rate 300 600 1200 2400 4800 9600 19200 38400 Protocol RS485 Modbus Communications Length of Link 4000 ft 1 219 m maximum Link Characteristics Two wire multidrop Miscellaneous e FM Approved 4 20 mA Control Output e AUL and FM approved NEMA4X door e Door Lock e External Keypad e Chart Illumination e ULL List
128. der Viewing the operating parameters The upper display 15 a six character display four of which show the value of the PV during normal operation The lower display is an eight character display During normal operation you can view various operating parameters Press the LOWR DISP key to scroll through the operating parameters listed in Table 5 7 The lower display shows only those parameters and their values that apply to your specific model and the way in which it was configured You can configure the lower display to scroll through the items in Table 5 7 at an interval of 1 2 or 3 seconds Refer to subsection 3 17 Options Set Up group function prompt SCROLL to make your selection Pressing the LOWR DISP key will freeze the lower display at the presently viewed item pressing it again will advance to the next item and scrolling will resume Pressing V while pressing LOWR DISP will scroll backwards For recorders with two controllers both enabled remember that any controller related values displayed correspond with the lighted CHN indicator 1 means that the values apply for Controller 1 and 2 means that the values apply for Controller 2 Table 5 7 Lower display key parameter prompts Prompt Description OUT Output Value in Percent 96 Note that the output can only be adjusted through the raise lower keys when the controller in manual mode
129. dures 45 2 9 Lockout Switch Configuration 54 Pre installation information If the recorder has not been removed from its shipping carton inspect the carton for damage and remove the recorder Inspect the unit for any obvious shipping damage and report any damage due to transit to the carrier Make sure a bag containing mounting hardware is included in the carton with the recorder Check that the model number shown on the chart plate agrees with what you have ordered CE Conformity special conditions Europe Shielded twisted pair cables are required for all Analog I O Process Variable RTD Thermocouple dc millivolt low level signal 4 20 mA and relay output circuits Supplementary bonding of the recorder enclosure to a local ground using 3 4 braided copper conductor is required Ferrite suppression filters see Subsection 2 5 for Wiring Prerequisites shall be installed on all cables connected to the recorder controller The cable shield drain wire at the cable load end requires connection through a 0 0047uf capacitor to ground Refer to document 5 52 05 01 How to Apply Digital Instrumentation in Severe Electrical Noise Environments for additional installation guidance Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 7 May 2013 Installation Overview Operating limits and condensed specifications We recommend that you review and adhere to the operating limits
130. e second set of PID constants in the Tuning Set Up group DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 141 Operation Alarm Setpoints 5 11 Alarm Setpoints Introduction An alarm consists of a relay contact and an operator interface indication The alarm relay is de energized if Alarm Setpoint 1 or Setpoint 2 is exceeded e The alarm relay is energized when the monitored value goes into the allowed region by more than the hysteresis e There are twelve alarm setpoints two for each alarm e The type and state High or Low is selected during configuration see Section 3 Configuration for details n ATTENTION An active alarm will always provide an indication on the display but may not control the relay that is a higher priority function such as a control loop or timer may have control of the relay Procedure for displaying the alarm setpoints The procedure for displaying and changing the alarm setpoints is listed in Table 5 25 Table 5 25 Procedure for displaying or changing the alarm setpoints Step Operation Press Action Result 1 Access the Alarm Set Up SET Until you see group UP Upper Display SET UP Lower Display ALARM X 1 2 3 4 5 6 2 Access the Alarm FUNC Successively displays the alarm setpoints and their Setpoint Values values Upper Display The alarm setpoint value Lower Display AXS1 VAL Setpoint 1 value of alarm 1 2 3 4
131. e 10 2 Chart plate assembly 4 csset ei eee e e Pe e HF Tee dede 223 Figure 10 3 Basic recorder components without options c cesccesccsseeeecesecseecseeeseeenceseeeseeeaeeeeeeeeeeeeeneeeeeneenaes 225 Figure 10 4 Recorder components associated with options essen eene enne 227 Figure 10 5 Internal cabling for DR4500A Classic eene 230 Figure 10 6 Internal diagram for DR4500A Classic recorder options only eee 231 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual xiii May 2013 xiv DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 1 Overview 1 1 Introduction Function The DR4500A Classic Series recorder combines the simplicity of pen drawn analog traces with the sophistication of microprocessor controlled functions This combination results in a user configurable recorder that is easily adapted to meet a variety of application requirements from blast furnace to laboratory In addition to recording analog traces the Classic Series recorder continuously displays process variable values in the selected engineering units Both one pen and two pen models accept inputs from any one of a variety of sensors or transmitters within the configurable range limits Also models are available with one or two digital controllers to ge
132. e K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 37 Installation Input Wiring Procedures Ferrite Filter P N 0443164151 orequbak it Required for CE Mark Conformity Kit Part No 51197612 502 contains two ferrite filters Part No 51197512 508 contains 8 ferrite filters Install inside of case See Figure 2 11 Capacitor Kit 51197755 001 Install capacitors as shown in figure 0 10 Vdc source f foe fet 9 modified NOTE Calibrate recorder to achieve stated accuracy See Section Input Calibration Loi 0047 pF Capacitor Figure 2 15 0 10 Volt dc input wiring 38 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Output Wiring Procedures 2 7 Output Wiring Procedures 4 20 mA control output wiring You can wire control output 1 or 2 for 4 20 mA output The prerequisites are e Model Number Table 2 6X X6 Refer to Figure 2 16 and follow the procedure in Table 2 15 to wire 4 20 mA control outputs Table 2 15 4 20 mA control output wiring Step Action 1 Open the recorder door Loosen the captive screw in the chart plate and swing the plate out 2 Locate connector J1 near the top of the control output 1 printed circuit board refer to Figure 2 16 for location 3 Remove the unwired plug from J1
133. e control loop status Diagnostic error messages signal detection of malfunctions in certain internally monitored data Alarm and tuning messages indicate alarms in effect and control loops being tuned Operator interface Release K May 2013 The indicators and displays on the operator interface let you see what 1s happening to your process and how the recorder is responding Figure 5 2 is a view of the operator interface A description of the displays and indicators is included DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 121 Operation Monitoring Your Recorder Indicates temperature units of PV Upper Display six characters e Normal operation Displays process variable PV for selected channel e Configuration mode Displays selection or Alarm condition exists for alarm 1 or 2 when lit PV displayed is for channel 1 or 2 Remote setpoint or 2nd setpoint is active when lit Blinks when 2nd setpoint or remote setpoint is obtained through remote switch Control relay 10r2 is ON when lit Lower Display eight characters Normal operation Displays selectable operating parameters and values Configuration mode Displays function group and parameters Figure 5 2 122 4500 Classic Series Circular Chart Recorder With or Without Control Product Manual parameter value Indicates controller mode MAN Manual e A Aut
134. e enne nennen nre en nnne 100 Table 4 7 Setpoint Ramp 1 or 2 group definitions ssssessessseeeeeeeeeeeenen nenne ennemis 103 Table 4 8 Timer group definitions eere nennen enne nennen tenete 105 Table 4 9 Priority of functions that operate relays sess 106 Table 4 10 Alarms group definitions eere enne nnne trennen nennen nnne nre nnns 107 Table 4 11 Auxiliary output group 109 Table 4 12 Modbus communications group definitions essere 111 4 13 Option group definitions 5 essere e tete 112 x DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Table 4 14 Lockout group definitions essere 114 Table 5 1 Xnstall replace charta acest ee ette RT ER ER OC ENG e e uet es cents 116 Fable 5 2 Setthe charttime line procedure sese rtt ette o eie tere E louse rei tege E egets 118 Table 5 3 Power up diagnostic tests eren tote ee e et e e e c ee tO ee ee tenet 118 Table 5 4 Procedure for testing the displays and keys sssssssssssesseeeeeeeeeeen nennen 119 Table 5 5 Procedure for starting up the recorder sss eene ener 120 Table 5 6 Meaning of 1ndicators usto e s e INNER 123 Table 5 7 Lower display key
135. e ferrite filter as shown in Figure 2 11 e Install a 01uF capacitor across the J2 terminals and a 0047 uF capacitor at the sensor end of the input wiring as shown in Figure 2 13 6 Locate jumper position MA W1 and make sure the jumper is in the W1 position See Figure 2 13 for the jumper positions 7 Locate jumper position W3 and make sure the jumper is in the proper position for your input type See Figure 2 13 for the jumper positions 8 Strip insulation from the end of each wire 9 Loosen the screws in plug J2 terminals and position the plug as you would to plug it into J2 10 Insert the wires into the appropriate screw clamps for the applicable input type See Figure 2 13 for specific input actuation plug wiring Tighten the screws to secure the wires 11 Insert the wired plug into J2 12 Repeat steps 2 through 11 for input 2 printed circuit board as applicable Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 33 May 2013 Installation Input Wiring Procedures Fair Rite P N 0443164151 or equivalent Required for CE Mark Conformity Kit supplied Part No 51197612 502 contains two ferrite filters More than one kit may be supplied Install inside of case See Figure 2 11 SS Cable Shield Thermocouple ge D 9 4 ye A 30756141 003 Input PWA DR4500A D1 pF Capacitors fr Fem fr
136. e function prompt you have selected e See subsection 3 4 Configuration Tips for instructions to increase or decrease value quickly e Change the value or selection to meet your needs Ifthe display flashes you are trying to make an unacceptable entry 6 Enter the value or selection FUNC e This key selects another function prompt or SET e This key selects another Set Up group UP The value or selection you have made will be entered into memory after another key is pressed 7 Exit configuration LOWR This exits configuration mode and returns the recorder to DISP the same state it was in immediately preceding entry into the Set Up mode It stores any changes you have made Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 61 May 2013 Configuration Input Set Up Group 3 6 Input Set Up Group Introduction This data deals with various parameters required to configure input 1 or input 2 Function prompts Table 3 3 lists all the function prompts in the INPUT 1 Set Up group Repeat the process for input 2 e Press the SET UP key until INPUT 2 appears in the display Table 3 3 Input group function prompts Selections or Range of Setting Function Prompt Function Name Factory Lower Display Upper Display Setting INPUT 1 Input 1 Actuation DISABL ENABLE ENABLE DECIMAL Decimal Point Location XXXX None XXX X XXX X
137. e next setpoint value in the program x 1 3 5 35 0 to 999 Rate Ramps are odd number segments Segment 1 will be the initial ramp time e This selection of time or rate is made at prompt RAMPUNIT ATTENTION Entering 0 implies an immediate step change in setpoint to the next soak SEGx SP Within the setpoint high and low The soak segment s setpoint value range limits in engineering units x 2 4 6 36 SEGxTIME 0 99 hrs 59 min The soak segment s duration x 2 4 6 36 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 165 May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Segments Set Up Group Setpoint program segments worksheet Use this worksheet to keep a record of your setpoint segment settings Prompt Function Range Your Prompt Function Range Your selection selection SPPSEGS Settings for NA NA SG13RAMP Ramp 00 00 to 99 59 segments or 0 to 999 SEG1RAMP Ramp 00 00 to 99 59 SEG14SP Soak SP Within SP or 0 to 999 limits SEG2 SP Soak SP Within SP SG14TIME Soak Time 00 00 to 99 59 limits SEG2TIME Soak Time 00 00 to 99 59 SG15RAMP Ramp 00 00 to 99 59 or 0 to 999 SEG3RAMP Ramp 00 00 to 99 59 SEG16SP Soak SP Within SP or 0 to 999 limits SEG4 SP Soak SP Within SP SG16TIME Soak Time 00 00 to 99 59 limits
138. e or Factory Prompt prompt Selection Setting Prompt prompt Selection Setting INPUT 1 INPUT ENABLE TOTAL 2 Value E0 GAL DECIMAL XXX X RSET TOT NO UNITS DEGF TOTAL 2 DISABL ENGUNITS TOTAL EU GAL IN1 TYPE 100PT RATE SECOND XMITTER LINEAR SCALER 1 IN1 HI 900 RSETABLE NO IN1 LO 300 INHIBIT NONE GUTOPE 0 CONTROL 1 CONTROL1 ENABLE n h kaa PID SETS 1ONLY BURNOUT UP p VALUE 0 0 EMISSIV 01 SP SOURC 1LOCAL INPUT 2 RATIO 1 0 BIAS 0 ee Rial ee SP TRACK NONE UNITS XXX X POWER UP MANUAL ENGUNITS DEGF SPHILIM LAST IN2 TYPE __ SPLOLIM 0 ACTION REVRSE XMIT TER dd OUTHILIM 100 0 IN2 HI LINEAR IN2 LO 900 OUTLOLIM 0 CUTOFF 2 300 DROPOFF 0 0 0 DEADBAND 2 0 BIAS n 2 OUT HYST 0 5 FILTER 2 n 1 2 FAILSAFE 50 PEN BURNOUT 0 REM SW NONE EMISSIV UP MAN KEY ENABLE RENIN 01 PBorGAIN GAIN MINorRPM MIN CHART1HI INPUT1 CONT1ALG PIDA CHART1LO 302 0 OUT1ALG CURRENT BEN PEN1ON 292 0 4 20 RNG 50PCT PEN1OFF 91 0 93 0 PEN2IN CHART2HI INPUT2 CHART2LO PEN2ON 2 91 0 93 0 CHRTSPD HOUR REV XHR TOTAL 1 LINEARIZ 12 Value RSET TOT E0 GAL TOTAL 1 NO TOTAL EU DISABL RATE GAL SCALER SECOND RSETABLE 1 INHIBIT NO NONE 78 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Configuration Record Sheet Group Function Value or Factory Group Function Value or Factory Prompt prompt Selection Setting Prompt prompt Selection Setting CONTROL
139. e the recorder s output two full cycles between 0 and 100 or low and high output limits while allowing only a very small process variable change above and below the setpoint during each cycle e Accutune works for all control algorithms except ON OFF e The recorder must be in Auto mode e Accutune works for integrating processes Enable disable Accutune using the Tuning Set Up group TUNE parameter described in Section 4 Detailed instructions for using Accutune follow Starting and Stopping Tuning with Accutune After TUNE has been enabled in the tuning set up group as described in Section 4 use the procedure in Table 5 23 to start tuning To abort tuning in progress press the MAN AUTO key to take the recorder out of Auto mode The message AbRT abort will be displayed as the value of tuning set up group parameter AT ERR The tuning parameters will retain the values they had at the start of the Accutune operation Table 5 23 Procedure for starting Accutune II Step Press Action Result 1 DISP Until you see Lower Display TUNExOFF 1 2 If TUNExOFF tune off does not appear then Accutune is not enabled 2 A to toggle to or Lower Display TUNExON 1 2 Tuning will begin and the lower display will flash TUNING v When tuning has been ompleted the lower display will again show TUNEXOFF Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product M
140. e value of SOAKDEV soak time is frozen There are no guaranteed soaks if SOAKDEV 0 PROFILE 1to6 PROFILE used by Setpoint Program This can also be set or changed when viewed in the lower display and the current profile is in the HOLD state STATE DISABLE Determines the state of the program after it completes HOLD the final program segment cycles If you select DISABL you must enable the program through the function prompt before you can run the program again If you select HOLD you can run the program again by pressing the RUN HOLD key RECOVERY ENABLE This mode when enabled will allow the SP Program to DISABL continue from the point at which the power was removed when there is a power interruption PROG END ENABLE Determines the status of the control output after the DISABL program is run If you select LASTSP the recorder controls to the last setpoint value which becomes the LSP For FSAFE selection the recorder is switched to manual mode and to the selected failsafe output value Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 161 May 2013 Setpoint Ramp Soak Programming and Operation SP 1 and SP RAMP2 Set Up Group SP RAMP1 and SP RAMP2 worksheet Use this worksheet to make a record of your SP RAMPI and SP RAMP settings Prompt Description Range Your selection SP RAMP1 Accesses prompts f
141. ease K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 137 May 2013 Operation Using Two Sets of Tuning Constants PID Values Switch between two sets via the keyboard without automatic switchover This procedure is operational only if 2 PID SETS was configured at CONTROL set up group The procedure in Table 5 22 shows you how to switch from one set to another Table 5 22 Procedure for switching PID sets from the keyboard Step Operation Press Action Result 1 Access the PID set LOWR Until you see display DISP Upper Display The PV value Lower Display PIDSETX 1 2 Aor V Change PIDSET1 to PIDSET2 or vice versa 138 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Using Accutune II 5 10 Using Accutune Il Introduction Accutune II provides foolproof trouble free on demand tuning in the recorder No knowledge of the process is required at start up The operator simply enters the desired setpoint and initiates the tuning The recorder immediately starts controlling to the setpoint while it identifies the process calculates the tuning constants and enters them into the tuning set up group and begins PID control with the correct tuning parameters This works with any process including integrating type processes and allows retuning at a fixed setpoint The tuning sequence will cycl
142. ection 8 4 Auxiliary Output Calibration 5 Replace the Auxiliary Output printed Refer to the instructions included with the circuit board replacement part Table 9 17 Procedure 12 Troubleshooting external alarm function failure symptoms Step What to do How to do it or where to find the data 1 Be sure all the alarm configuration data Refer to Section 3 Configuration is correct 2 Check the applicable alarm relay jumper Refer to Section 3 Configuration position 3 Check the field wiring Refer to Section 2 Installation 4 Check that the applicable alarm relay Alarms can be triggered either by actuates properly depending on ALARM TYPE configuration selection e reconfiguring the value of the trip points AnSnVAL or e connecting a signal generator to the input and setting the generator level beyond the trip point values Table 9 18 Procedure 13 Troubleshooting Modbus communications failure symptoms Step What to do How to do it or where to find the data 1 Check the field wiring and termination Refer to Figure 2 21 in Section 2 Installation in resistor this manual 2 Make sure the Modbus Communications Open the recorder door and chart plate and board is properly installed in the inspect the board Refer to Figure 10 4 for recorder location of the board 3 Run a Loopback test Refer to Modbus Communications manuals 51 52 25 66 and 51 52 25 69 for loopba
143. ed for CE Mark Conformity 0 1000 ohms Kit Part No 51197612 502 contains two ferrite filters Part No 51197612 508 contains 8 ferrite filters Install inside of case See Figure 2 11 z ds Capacitor Capacitor Kit 51197755 001 Install capacitors as shown in figure Figure 2 16 4 20 mA control output wiring or Aux Out 2 and 3 wiring 40 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Output Wiring Procedures Position proportional control output wiring You can wire control output 1 or 2 for position proportional output The prerequisites are Model Number Table 2 10 or 11 Refer to Figure 2 17 and follow the procedure in Table 2 16 to wire position proportional control output ATTENTION Be sure to calibrate the position proportional control output so that the increase and decrease relays operate properly with respect to the position of the external feedback slidewire Refer to Section 8 Output Calibration in this manual Table 2 16 Position proportional control output wiring Step Action Open the recorder door Loosen the captive screw in the chart plate and swing the plate out Locate connector J2 and J5 on the control output 1 printed circuit board refer to Figure 2 17 for location and remove the unwired plug from J2 and J5 Locate jumper positions W2 W3 and W4 W5 below connector J5 on the printed circuit board Re
144. ed to earth ground at the farthest end of the cable See the option wiring procedure for the RS485 Communications Card Inside of the enclosure the user must install ferrite suppression filters and capacitors on all wires connected to the recorder Fair Rite Products Corp part number 0443164151 or equivalent shall be installed as shown in Figure 2 11 to Figure 2 22 one filter for each circuit group Cable with an outer jacket diameter larger than 6 7 mm 0 264 in may require the outer Jacket to be removed to fit the required one turn in the filter or the selection of a different cable Permissible wire bundling Table 2 10 shows which wire functions should be bundled together Table 2 10 Permissible wiring bundling Bundle No Wire Functions 1 Line power wiring Earth ground wiring Control relay output wiring Line voltage alarm wiring Analog signal wire such as Input signal wire thermocouple 4 to 20 mA etc 4 20 mA output signal wiring Slidewire feedback circuit wiring Digital input signals Communications 4 20 mA auxiliary output Low voltage alarm relay output wiring Low voltage wiring to solid state type control circuits Identify your wiring requirements 28 To determine the appropriate diagrams for wiring your recorder refer to the model number interpretation in this section The model number of the recorder can be found on the chart plate DR4500A Classic Series Circ
145. elease K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 219 May 2013 Troubleshooting Service Pen Alignment Table 9 20 Set the chart time line procedure Step Press Action Result 1 Open the door apply power and wait for the recorder to run its power up tests 2 SET Until you see UP Upper Display ALIGN Lower Display PEN 1 3 FUNC You will see Upper Display ALIGN Lower Display PEN 10 The pen moves to an internal stop then backs away and stops Aor V To move the pen to the zero position on the chart inner position of chart ATTENTION You can position the pen over 100 steps Those steps are relative units only Step 0 0 is the innermost position on the chart and step 1200 is the highest circumference position 4 FUNC You will see Upper Display ALIGN Lower Display PEN 100 The value adjusted in Step 3 is entered into memory Aor V To raise or lower the value in the upper display up to 1200 move the pen to the highest chart range value outer circumference printed on the chart 5 Repeat steps 2 through 4 for pen 2 or press LOWR DISP key to return to normal operation and enter the span value into memory 220 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Parts List Overview 10 Parts List 10 1 Overview Introduction This section provides the replacement parts li
146. ept the Modbus RS485 communications cable should be tied to earth ground at the recorder end and to earth ground through a 0047uF Capacitor at the other end of the cable An example of shield wiring to an external ground bus bar is shown in Figure 2 11 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 29 May 2013 Installation Input Wiring Procedures Mother PCB Ferrite Beads Fair Rite 0443164151 Honeywell Part Processor Number 51197612 Board or Steward 28B2024 0A0 quantity 5 Number 1 amp 2 Alarm Digital Control Output Washer Quantity 5 Relays Alarm Relays Inputs 1 2 Current Output 1 E C Slidewire 1 Main Digital Inputs 1 amp 2 Auxiliary Output Modbus RS485 Transmitter Power Communications Az External Ground Bus Bar Shield Wiring 4 Recorder grounding rear of case Use 3 4 inch braided copper conductor To Earth Ground 2 Use cable fitting to support wiring and hold in place Place the washer on the inside of the recorder between the case and the fastening nut to protect the recorder conductive case coating 3 Ferrite filter location Cable with an outer jacket diameter larger than 6 7 mm 0 264 in may require the outer jacket to be removed to fit the required one turn in the filter or the selection of a different cable in Figure 2 11 Ferrite filter locations and shield wiring CE Mark AC line power Refer
147. er you want the alarm type chosen in prompt AxS1TYPE to alarm high or low or the beginning or end of a segment in setpoint Ramp Soak programming AxS1HL HI HI ALARM Relay coil is de energized when the PV is above the setpoint LO LO ALARM Relay coil is de energized when the PV is below the setpoint AxS1SCAL 1 MULTIPLIER FOR ALARM TYPE TOTAL 10 SELECTION the alarm is only a high value Enter a 100 scaler of from 1 to 1000000 1000 10000 Base value x multiplier 2 alarm setpoint value 100000 1E6 ALARM x SETPOINT 2 STATE select whether you want the alarm type chosen in prompt AxS2TYPE to alarm high or low or the beginning or end of a segment in setpoint Ramp Soak programming AxS2HL HI HI ALARM LO LO ALARM AxS2SCAL 1 MULTIPLIER FOR ALARM TYPE TOTAL 10 SELECTION the alarm is only a high value Enter a 100 scaler of from 1 to 1000000 1000 10000 Base value x multiplier alarm setpoint value 100000 1E6 ALx HYST 0 0 to 100 096 of span or full ALARM HYSTERESIS an adjustable hysteresis is output as appropriate provided on each alarm such that when the alarm is OFF it activates at exactly the alarm setpoint when the alarm is ON it will not deactivate until the variable is 0 0 to 100 0 whatever has been set away from the alarm setpoint e Configure the hysteresis of the alarms based on INPUT signals as a of input range span e Configure the hysteresis of the alarm based on OUTPUT signals as a of the
148. ero RSETABLE must be set to LOCAL NO YES NO TOTAL 1 Totalizer 1 DISABL INPUT1 INPUT2 DISABL TOTAL EU Total Engineering Units 0 to 9 AtoZ T blank GAL RATE Rate of Integration SECOND MINUTE HOUR DAY M DAY Millions of Units per Day SECOND SCALER Totalizer Scale Factor 1 10000 10 100000 100 1E6 1 000 000 1000 RSETABLE Totalizer Reset NO LOCAL EXTSW1 EXTSW2 Total will be set to 0 on closure of the assigned external switch NO INHIBIT Totalizer Inhibit Repeat this procedure for INPUT 2 66 NONE S1 OPEN S1 CLOSE 52 OPEN S2 CLOSE DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual NONE Release K May 2013 Configuration Control Set Up Group 3 10 Control Set Up Group Introduction This data deals with various parameters required to effectively control your process Function prompts Table 3 7 lists all the function prompts in the CONTROL 1 or CONTROL 2 Set Up group You can enable the Control groups in the Option group Table 3 7 Control 1 or Control 2 group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting CONTROL1 Control Loop 1 DISABL ENABLE ENABLE PID SETS Tuning Parameter Sets 1 ONLY 1 ONLY 2KEYBD 2PV SW 25
149. et Up Group Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection TIME MIN 0 to 255 minutes SETPOINT RAMP TIME Enter the number of minutes desired to reach the final setpoint A ramp time of 0 implies an immediate change of setpoint Example of SP Ramp Settings TL _ SP 120 0 255 I Time 3 21421 FINAL SP Within SP limits SETPOINT RAMP FINAL SETPOINT Enter the value desired for the final setpoint The recorder will operate at the setpoint set here when ramp is ended SP RATE SETPOINT RATE Lets you configure a specific rate of option change for any local setpoint change SP RAMP and SP PROG must be disabled ENABLE ENABLE SETPOINT RATE Allows the SP rate feature DISABL DISABLE SETPOINT RATE Disables the setpoint rate EU HR UP 0 to 9999 in Engineering Units RATE UP Value for SP Rate selection per hour EU HR DN 0 to 9999 in Engineering Units RATE DOWN Value for SP Rate selection per hour SP PROG SETPOINT RAMP SOAK PROGRAM option Available only with recorders that contain this option SP RAMP and SP RATE must be disabled ENABLE For reasons of convenience the information for the DISABL prompts when SP PROG is enabled are included in Section 6 Setpoint Ramp Soak Programming Option 104 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Defini
150. f case See Figure 2 11 Capacitor Kit 51197755 001 Install capacitors as shown in figure No 5 amp 6 Alarm outputs PCB W3 4W2 21466C Plug J5 Cable Shield External Load Power Supply Alarm No 5 1 1 Sf o W2 contact W3 contact Alarm No 6 LI IL Alarm 6 o o Relay Load W4 N O contact o W5 N C contact m L o 0047 uF Ferrite filter qe apacitor Figure 2 20 Alarm outputs 3 4 5 and 6 wiring 49 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual May 2013 Installation Option Wiring Procedures RS485 Modbus communications wiring 50 RS485 Modbus Communications is an option available on the DR4500A recorder The prerequisites are Model Number Table 3 3XX or 4AXX Refer to Figure 2 21 and follow the procedure in Table 2 21 to wire the RS485 Modbus communications option Table 2 21 RS485 Modbus communications wiring Step Action 1 Open the recorder door Loosen the captive screw in the chart plate and swing the plate out 2 Locate connector J3 on the RS485 Modbus communications option printed circuit board refer to Figure 2 21 for location 3 Remove the unwired plug from J3 4 Run the communications option wires through the desired knockout 5 For CE Mark conformity e Install the ferrite filter as shown in Figure 2 11 e Refer to Figure 2 21 for shield
151. full scale output range Repeat this procedure for Alarm 2 Alarm 3 Alarm 4 Alarm 5 Alarm 6 configuration 108 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Auxiliary Output Set Up Group 4 11 Auxiliary Output Set Up Group Introduction This provides a milliampere output representing any of twelve control parameters Input 1 2 PV 1 2 Deviation 1 2 Output 1 2 Setpoint 1 2 The display for auxiliary Output viewing will be in engineering units for all but output Output will be designated in percent Timer group prompts Table 4 11 lists all the function prompts in the Auxiliary Output setup group and their definitions Table 4 11 Auxiliary output group definitions Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition AUX OUT DISABL AUXILIARY OUTPUT SELECTION provides an mA output representing any of twelve control parameters The display for Auxiliary Output viewing will be in engineering units for all but output Output will be designated in percent 96 e Other prompts affected by these selections 4 mA VAL and 20mA VAL NO AUXILIARY OUTPUT IN 1 INPUT 1 This represents the configured range of input 1 FOR EXAMPLE Type J Thermocouple 0 to 1600 F O F display 0 output 1600 F display 100 output IN 2 PV 1 INP
152. g alarm conditions an alarm will deenergize its associated relay unless a higher priority function has been configured for that relay See Table 3 11 If you want the alarm to control the relay do not configure a higher priority function 3 Table 3 11 Setpoint Program Event group prompts Table 6 6 lists all the function prompts in the Setpoint Program Event setup group and their definitions Table 6 6 Setpoint program event group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection SEGx EV NONE Configured event will be active during the segment All ALARM1 ALARM2 ALARMS others will be inactive x 1 36 ALARMA ALARM5 ALARM6 Example of how a segment event works For example to have Segment 1 energize Relay 1 e Program SEGI EV as ALARMI e Program AISITYPE or AIS2TYPE as EVENT Do not program the Timer function Relay 1 namely Timer For alarm programming information see section 4 10 168 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Event Set Up Group To ensure control of relay by segment event To make sure a segment event operates the associated relay observe the requirements below Table 6 7 Segment event relay operation requirements Relay Relay is controlled by in order of
153. g to the recommendations fpecie eria Ks Tale given in this table for that particular Failsafe will be displayed in rotation errorMessage with other failure messages except BATTERY only if control is enabled RAM TEST Power up RAM failure 25 Cycle power Note 1 26 Check Device Status page 206 to see if error clears 277 If error doesn t clear replace the main printed circuit board CONFTEST Power up Configuration data is in error 28 Check all the configuration prompts Note 1 for accuracy e See Section 3 Configuration for selections and limits 29 Change any configuration item check Device Status to see if CONFTEST PASS return configuration item to original value e See Section 3 Configuration for instructions to change a configuration item Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 207 May 2013 Troubleshooting Service Self Diagnostics Lower Display Indication Test Group Reason for Failure How to Correct the Problem CNFG ERR Background Configuration data is in error 30 Check all the configuration prompts for accuracy e See Section 3 Configuration for selections and limits 3 Change any configuration item then return it to the original value e See Section 3 Configuration for instructions to change a configuration item CAL TEST Note 1 CAL1 ERR Power up Background The working calibrati
154. ges recurring If the diagnostic error messages can be cleared it indicates a soft failure and is probably noise related If system noise is suspected completely isolate the recorder from all field wiring Use calibration sources to simulate PV and check all recorder and control functions that is Pen functions Chart Trace Gain Rate Reset Output Alarms etc Application related problems Review the application of the recorder then if necessary direct your questions to the local sales office Hardware and software related problems Use the troubleshooting error message prompts and recorder failure symptoms to identify typical failures which may occur in the recorder Follow the troubleshooting procedures to correct them 202 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Troubleshooting Aids 9 2 Troubleshooting Aids Self diagnostics The DR4500A recorder runs self diagnostic tests to monitor the recorder s general health The tests are divided into three main groups and will produce an error message when failed An error message can occur e at power up run when power is cycled off and on e during continuous background tests while in normal operation and e when the Status Tests are requested by the operator Table 9 4 lists all the error message prompts that you could see the reason for the failure and how to correct the pr
155. gment for Program 1 RAMP1 to RAMP35 PR1 END End Segment for Program 1 SOAK2 to SOAK36 PR2 STRT Start Segment for Program 2 RAMP1 to RAMP35 PR2 END End Segment for Program 2 SOAK2 to SOAK36 PR3 STRT Start Segment for Program 3 RAMP1 to RAMP35 PR3 END End Segment for Program 3 SOAK2 to SOAK36 PR4 STRT Start Segment for Program 4 RAMP1 to RAMP35 PR4 END End Segment for Program 4 SOAK2 to SOAK36 PR5 STRT Start Segment for Program 5 RAMP1 to RAMP35 PR5 END End Segment for Program 5 SOAK2 to SOAK36 PR6 STRT Start Segment for Program 6 RAMP1 to RAMP35 PR6 END End Segment for Program 6 SOAK2 to SOAK36 RAMPUNIT Ramp Type TIME EU MIN EU HR SYNC 1 2 Synchronizes Profile for Control Loops ENABLE 1 and 2 DISABL 164 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Segments Set Up Group 6 7 Setpoint Program Segments Set Up Group Introduction You can configure up to 36 ramp and soak segments Setpoint program segments group prompts Table 6 5 lists all the function prompts in the Setpoint Program Segments setup group and their definitions Lower Display Table 6 5 Setpoint program segments group definitions Upper Display Parameter Definition Prompt Range of Setting or Selection SEGxRAMP 0 99 hrs 59 min Time A ramp segment is the time it takes to change the setpoint to th
156. guration Prompts 56 3 3 How To Get Started 58 3 4 Configuration Tips 59 3 5 Configuration Procedure 60 3 6 Input Set Up Group 62 3 7 Pen Set Up Group 64 3 8 Chart Set Up Group 65 3 9 Totalizer Set Up Group 66 3 10 Control Set Up Group 67 3 11 Tuning Parameters Set Up Group 69 3 12 SP Ramp Set Up Groups 70 3 13 Timer Set Up Group 71 3 14 Alarms Set Up Group 72 3 15 A Auxiliary Output Set Up Group 74 3 16 Modbus Communications Set Up Group 75 3 17 Options Set Up Group 76 3 18 Lockout Set Up Group 7 3 19 Configuration Record Sheet 78 Prompts To assist you in the configuration process there are prompts that appear in the upper and lower displays These prompts let you know what group of configuration data set up prompts you are working with and also the specific parameters function prompts associated with each group Figure 3 1 shows an overview of the prompt hierarchy Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual May 2013 Configuration Configuration Prompts 3 2 Configuration Prompts Diagram prompt hierarchy Figure 3 1 shows an overview of the DR4500A Set Up prompts and their associated Function prompt read from left to right Figure 3 1 DR4500A prompt hierarchy Set Up Group Function Prompts INPUT 2 Same as INPUT 1 PEN PEN 2 Same as PEN 1 CHART gt HOURIREV _LINEARIZ TOTAL 1 TOTAL 2 Same as TOT
157. he ambient temperature method 187 Release K May 2013 Sales and Service For application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ASIA PACIFIC EMEA NORTH AMERICA SOUTH AMERICA TAC hfs tac Phone 80012026455 or 44 Honeywell Process Solutions Honeywell do Brazil amp Cia support honeywell com 0 1202645583 Phone 1 800 423 9883 Phone 55 11 7266 1900 Ausirsfis 44 0 1344 655554 1 800 343 0228 55 11 7266 1905 Honeywell Limited Email Sales sc cp apps Email Sales ask Email Sales ask Phone 61 7 3846 1255 com ssc honeywell com or ssc honeywell com or ee TAC hfs tac TAC his tac oe com BUTS WES support honeywell com Toll Free Fax support honeywell com 1300 36 04 70 China PRC Shanghai Honeywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 Singapore Honeywell Pte Ltd Phone 65 6580 3278 Fax 65 6445 3033 South Korea Honeywell Korea Co Ltd Phone 822 799 6114 Fax 822 792 9015 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 249 May 2013 Honeywell Honeywell Process Solutions 1860 West Rose Garden Lane 44 45 25 35 Rev K Phoenix Arizona 85027 May 2013 www honeywellprocess com 2013 Honeywell International Inc
158. he output voltage to the slidewire Put the voltmeter across the slidewire terminals at connector J2 on the control output printed circuit board and check that the slidewire voltage varies with the motor position 6 Be sure that the output relays are Put the recorder into manual mode and adjust the actuating properly If they are not check output manually above and below the present the field wiring then go to step 4 If they value Listen for the click of the relays One relay are go to step 7 should click when the output is adjusted higher and the other should click when the output is adjusted lower than the present value Observe OUT 1 and 2 indicators on the front display 7 Check the control relay jumper position Refer to Section 3 Configuration 8 Replace the control output printed circuit Refer to the instructions included with the board replacement part 9 Recalibrate the position proportional Refer to Section 8 Output Calibration output Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 215 Troubleshooting Service Troubleshooting Procedures 216 Table 9 14 Procedure 9 Troubleshooting relay output failure symptoms Step What to do How to do it or where to find the data 1 Be sure the recorder is configured for Refer to Section 3 Configuration Make sure relay output OUT ALG selection TIME 2 Be sure all t
159. he recorder and control Refer to Section 3 Configuration related data is correct Check the Tuning Algorithm and Control data 3 Check that the applicable output relay Put the recorder into manual mode and adjust the actuates properly If it does go to step 4 output manually to raise or lower the PV around the setpoint Listen for the click of the relay as the PV moves in either direction Observe OUT 1 or 2 indicator on the front display 4 Check the control relay jumper positions Refer to Section 3 Configuration 5 Check the field wiring Refer to Section 2 Installation 6 Replace the control output printed circuit Refer to the instructions included with the board replacement part Table 9 15 Procedure 10 Troubleshooting current time or time current failure symptoms Step What to do How to do it or where to find the data 1 Be sure the recorder is configured for Refer to Section 3 Configuration Make sure current time time current output OUT ALG selection TI CUR or CUR TI 2 Be sure all the recorder and control Refer to Section 3 Configuration related data is correct Check the tuning algorithm and control data 3 Check that the applicable output relay Put the recorder into manual mode and adjust the actuates properly If it does go to step 4 output manually to raise or lower the PV around If it does not check the field wiring then the setpoint Listen for the click of the relay as
160. his exits from the configuration mode DISP 160 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation SP 1 and SP RAMP2 Set Up Group 6 5 SP RAMP1 and SP RAMP2 Set Up Group Introduction There is a SP RAMP set up group for each control loop Use the prompts to select the settings for each loop s program SP RAMP Prompts Table 6 3 lists all the function prompts for SP RAMP configuration in the order of their appearance These prompts are available when SP PROG is enabled in the S PRAMP set up group described in Section 4 All parameters may be changed while the program is disabled or in HOLD Table 6 3 SP RAMP prompts and available selections Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection SPPROG SETPOINT PROGRAMMING This must be set to ENABLE for the setpoint program feature to work and for the associated operating parameters to be displayed SP RAMP and SP RATE must be disabled See Section 4 DISABL DISABL Disables Setpoint Programming ENABLE ENABLE Enables Setpoint Programming RECYCLES 0 to 99 RECYCLES Enter the number of times the program selected for execution will be repeated SOAKDEV 99 9 to 99 9 engineering units SOAK DEVIATION Enter the acceptable deviation from setpoint during a soak cycle If the PV differs from the setpoint by more than th
161. hown in Figure 2 20 7 Strip insulation from the end of each wire 8 Loosen the screws in plug J5 terminals and position the plug as you would to plug it into J5 9 Insert the wires for the alarm devices into the appropriate screw clamps as shown Refer to Figure 2 20 Tighten the screws to secure the wires 10 Install the wired plug into J5 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 4T May 2013 Installation Option Wiring Procedures Alarm 5 and 6 output wiring You can wire 5 and 6 Alarm outputs The prerequisites are e Model Key Number DR45A2 e Model Number Model Table 2 X1 X6 If control output is 4 20 mA then the relays on the control card are available for use as alarms Refer to Figure 2 20 and follow the procedure in Table 2 20 to wire Alarm 5 and Alarm 6 outputs Table 2 20 Alarm 5 and Alarm 6 output wiring Step Action 1 Open the recorder door Loosen the captive screw in the chart plate and swing the plate out 2 Locate connector J5 on the 4 20 mA control output printed circuit board to wire relays 5 and 6 Refer to Figure 2 20 for location 3 Remove the unwired plug from J5 4 Locate jumper position W2 W3 and W4 W5 below connector J5 on the printed circuit board Note that you may want to remove the plug in output printed circuit board for better access to jumpers Be sure to tag and remove all the plug connections to
162. iblf g c 37 Tabl 2 15 4 20 mA coritrol output wiring o teet eerte ee ghee aw ek 39 Table 2 16 Position proportional control output wiring 41 Tabl 2 17 Relay control output E 43 Table 2 18 Alarm output or digital input 45 Table 2 19 Alarm 3 and Alarm 4 output wiring esee ener eerie 47 Table 2 20 Alarm 5 and Alarm 6 output wiring esses 48 Table 2 21 RS485 Modbus communications wiring esses eene 50 Table 2 22 4 20 mA auxiliary output Witing oionn eere ener nennen nnne 52 Tabl 3 1 Configur tion tps esee ro TH EUR cece shone SOIN CHEESE TEN NU Uer E 59 Table 3 2 Configuration procedure sessssssssessesseseeeee eene enne nennen nnne innen ennt enin nnne nenne 60 Table 3 3 Input group function prompts ener 62 Table 3 4 Pen 1 or 2 group function prompts ssssssssseeeeeeeeenenenen eee entren enne nennen nennen nennen nnns 64 Table 3 5 Chart group function prompts 65 Table 3 6 Totalizer group function prompts enne nennen enne nennen enne nene 66 Table 3 7 Control 1 or Control 2 group function ener nnne 67 Table 3 8 Tuning 1
163. icates PV is within 1 of control setpoint e Next small bar will light if PV is between 1 but less than 2 in deviation e f PV is equal to or greater than 10 deviation the green bar plus all ten small green bars will light Operator interface Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual May 2013 Overview Operator Interface Key functions Table 1 1 shows each key on the operator interface and defines its function Table 1 1 Function of keys Key Function SET e Places the controller in the Configuration Set Up group select mode Sequentially UP displays Set Up groups and allows the FUNC key to display individual functions in each Set Up group FUNC e Used in conjunction with the SET UP key to select the individual functions of a selected Configuration Set Up group e Used to toggle between SP1 and SP2 e Used during field calibration procedure LOWR e Selects an operating parameter to be shown in the lower display DISP OUT Output Value SP Local Setpoint 1 SPN Current setpoint for setpoint rate applications 2SP Local Setpoint 2 RSP Remote Setpoint 2IN Input 2 DEV Deviation EU PV Engineering Units RH RH Value PIDSETX Tuning Parameter Set X 1 or 2 RAMP Minutes remaining in Setpoint Ramp RA Minutes remaining in SP Prog Ramp SK Minutes remaining in SP Prog Soak RECYC Number of recycles left in SP Program
164. ikoen for elektrisk st t og mulige personskader Dette symbolet advarer brukeren om tilgjengelige terminaler med farlige spenninger og en potensiell fare for elektrisk st t Jordingsterminal kabelen for jording av systemet skal tilknyttes til denne terminalen Of gt e Dersom utstyret benyttes pa en mate annerledes enn spesifisert av produsent kan utstyrets beskyttelsesgrad forringes e Ingen komponenter eller deler skal skiftes ut dersom de ikke er uttrykkelig spesifisert som utskiftbare av din forhandler e Det er p krevet med en hovedstremsbryter i n rheten av utstyret e All kabling ma utfores 1 henhold til gjeldende forskrifter og installeres av autoriser og erfaren installator e Jord ma tilknyttes for all annen kabling og frakobles sist UTSTYRSPESIFIKASJONER Stremtilforsel 102 til 132 Vac 204 til 264 Vac Nettfrekvens 49 5 Hz 59 61 Hz Kraftforbruk 9 watts max OMGIVELSER Instrumentet ma ikke opereres i n rheten av lettantennelige v sker eller gasser Bruk av elektriske instrumenter i slike omgivelser utgjor en sikkerhetsrisiko Temperatur omgivelse 15 til 55 C Fuktighet 10 til 9096 HR Vibrasjon 0 til 70 Hz akselerasjon 0 1 g UTSTYRSINSTALLASJON Pass p montere panelene regulatoren slik at berering av terminalene p baksiden forhindres Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 241 May 2013 INSTRUCOES DE SEGURANCA PO21 6057
165. illing 0 tot 70 Hz versnelling 0 1 g MONTAGE VAN DE APPARATUUR De recorder moet worden gemonteerd in een paneel om de toegankelijkheid tot de achterste aansluitpunten te beperken Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 235 May 2013 TURVALLISUUSMAARAYKSET FI21 6057 Noudata t m n ohjeen kaikkia turvaohjeita valtt aksesi s hk tapaturman vaaraa T m merkki varoittaa k ytt j s hk iskun vaarasta paikassa miss voi koskettaa vaarallisia j nnitteit Suojamaaliitin Kytke maadoitsjohdin t h n liittimeen Om e Jos laitetta k ytet n olosuhteissa joihin sit ei ole suunniteltu k ytt turvallisuus voi heikenty e Ala vaihda mit n komponettia tai osaa jota valmistaja ei ole m ritellyt k ytt j n vaihdettavaksi e Asennus ja johdotus on teht v paikallisten varmuusm r ysten mukaisesti valtuutetun s hk asentajan toimesta e Ensimm iseksi on kytkett v suojamaa liitin ja viimeiseksi irroittettava e Laitteen l heisyyteen suositellaan asennettavaksi verkkokytkin LAITTEEN VAATIMUKSET Sy tt j nnite 102 132 Vac 204 264 Vac Taajuus 49 51 Hz 59 61 Hz Teho 9 watts K YTT OLOSUHTEET l k yt laitetta paikassa jossa on syttyvi nesteit tai kaasuja koska laitteen k ytt aiheuttaa r j hdysvaaran L mp tila ymp r iv 15 55 Kosteus 10 90 RH T rin 0 70 Hz Kiihtyvyys 0 1 g LAITTE
166. ing FM Approval CSA CE Conformity e Control with Accutune II Tuning capability e Glass or Acrylic Window e Configuration Lockout Switch e Customer ID Tag 30 characters maximum CE Conformity Europe Product Classification Enclosure Rating Installation Category Overvoltage Category Pollution Degree EMC Classification Method of EMC Assessment Declaration of Conformity This product is in conformity with the protection requirements of the following European Council Directives 73 23 EEC the Low Voltage Directive and 89 336 EEC the EMC Directive Conformity of this product with any other CE Mark Directive s shall not be assumed Class 1 Permanently connected Panel Surface Mounted Industrial Control Equipment with protective earthing grounding EN 61010 1 Panel Surface Mounted Equipment IP 54 ref IEC 529 Category Il Energy consuming equipment supplied from the fixed installation Local level appliances and Industrial Control Equipment EN 61010 1 Pollution Degree 2 Normally non conductive pollution with occasional conductivity caused by condensation ref IEC 664 10 Group 1 Class A ESM Equipment EN 55011 emissions Industrial Equipment EN 50082 2 immunity Technical File TF Document 51197635 000 EC Alpha 0 00385 Q Q C Registered Trademark General Electric Co 1 Not all controller outputs are available on all models of the
167. into the cutout from the front of the panel Support the recorder as shown in steps 3 and 4 3 Refer to Figure 2 5 From the back of the panel attach a mounting bracket to each side of the recorder case using a 1 4 20 x 1 2 inch hex screw and a lockwasher for each bracket mounting hardware supplied with recorder Leave the screws slightly loose so you can adjust the brackets 4 While holding the recorder firmly against the panel slide each bracket against the back of the panel and tighten the screws Hex screw 1 4 20 x 1 2 inch and washer Figure 2 5 Mounting Flush in a New Panel Cutout 18 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Mounting Methods Reference data for existing panel cutouts Refer to Table 2 4 to determine whether the existing panel cutout can be used Use the procedure for mounting with the universal filler kit unless otherwise noted Table 2 4 Reference data for mounting DR4500A in existing panel cutouts Manufacturer Instrument Dimensions of Existing Need Universal Filler Panel Cutout inches Plate Kit 30755134 001 Blue Color 30755134 002 Gray Color Honeywell Model AR100 DR4200 127 x 12 7 No Honeywell Class 15 15 8 x 172 Yes Honeywell Class 45 13 12 x 17 12 Yes Badger Meter Model Micro Chart 14 25 x 17 88 Yes Bristol Models 4330 500 Classes 1 2A 3B and 5 3 5
168. into the ice bath 3 Connect the other end of the thermocouple extension wires to the clamp type terminals in the plug for the applicable input connector J2 4 Reinstall the plug into the input connector J2 on the applicable circuit board for Input 1 or Input 2 Calibration source Containers of crushed ice Thermocouple extension wires 0 Connector plug J2 for inputs 1 2 Copper wires 22089 RTD Be sure W1 MA jumper is in position W1 on the input board Be sure W3 jumper is in position T C on the input board Figure 7 3 Calibration set up diagram for Thermocouple inputs using an ice bath Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 183 Input Calibration Calibration Set Up and Wiring for PV Inputs Thermocouple inputs using a compensated calibrator method Refer to Figure 7 4 and wire the recorder according to the procedure given in Table 7 7 Table 7 7 Setup wiring procedure for Thermocouple inputs using a compensated calibrator method Step Action 1 Connect the thermocouple extension wire to the Precision Compensated Calibrator see Figure 7 4 2 Connect the other end of the thermocouple extension wires to the clamp type terminals in the plug for the applicable input connector J2 3 Reinstall the plug into the input connector J2 on the applicable circuit board for Input 1 or Input 2
169. ion 0 100 on the chart When the switch closes the pen tracks at the configured ON position 0 100 on the chart and tracks at this position until the switch is opened Thus the Event Pen record makes it easy to monitor the on off operation of an external event 5 15 Maximizing Pen Life Steps for maximizing pen life Table 5 29 lists nine steps that will help to maximize the life of your chart pen Table 5 29 Maximizing pen life Step Action 1 Store the chart paper in a cool clean dry place where the temperature does not exceed 40 C 104 F and the humidity is below 65 RH 2 Do not expose the pen tip and chart paper to abrasive chemicals or dust that cause excessive pen wear 3 If the recorder is used in a dusty atmosphere provide a positive clean air purge to minimize dust particle accumulation on the chart paper 4 Periodically clean the pen arm using a cotton swab dipped in alcohol This is more important when the recorder is located in a dusty environment and no clean air purge is used 5 Never let the pen tip ride on the chart plate when the paper is not present Use the pen lifter to raise the arm when changing the paper 6 Keep the door closed while recording 7 Always insert the pen arm tip into the shipping sponge when storing or shipping the recorder 8 Be sure that the chart paper lays flat against the chart plate Any ripple in the paper will cause light pen
170. irection e f desired however the motor may be manually positioned to 0 and 100 positions Disconnect the relay wires DO MAN In the Manual Calibration Mode DO MAN the motor does not move Instead the existing 0 and 100 96 values may be changed with the or V keys Aor V Select automatic or manual calibration Upper Display DO AUTO or DO MAN Lower Display POS PROP e If you select DO AUTO go to step 4 e f you select DO MAN go to step 6 ATTENTION When calibration is terminated this selection reverts to DISABL 4 DO AUTO FUNC The decrement relay is turned on to move the motor to Set 0 value 0 position Upper Display counts of feedback slidewire 0 to 2047 Lower Display ZERO VAL e When the motor stops the display should stop counting go to the next step Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 197 May 2013 Output Calibration Position Proportional Output Calibration Step Operation Press Action Result 5 Set 100 value FUNC The increment relay is turned on to move the motor to 100 position Upper Display counts of feedback slidewire 0 to 2047 Lower Display SPAN VAL e When the motor stops the display should stop counting then go on to step 8 6 DO MAN FUNC You will see Set 0 value Upper Display existing zero calibration value in counts approximately 100
171. is selected at prompt IN1 e FOR EXAMPLE If input 1 is a 4 to 20 mA signal but the signal represents a type K thermocouple select K TC H and the recorder will characterize the 4 to 20 mA signal so that it is treated as a type K thermocouple input high range BTC B Type Thermocouple ETCH E Type Thermocouple High ETCL E Type Thermocouple Low JTCH J Type Thermocouple High JTCL J Type Thermocouple Low K TC H K Type Thermocouple High KTCL K Type Thermocouple Low NNM H NNM NiNiMo Type Thermocouple High NIC TC NIC Nicrosil Nisil Thermocouple RTC R Type Thermocouple S TC S Type Thermocouple TTCH T Type Thermocouple High TTCL T Type Thermocouple Low W TC H W5W26 Type Thermocouple High WTCL W5W26 Type Thermocouple Low 100 PT 100 Ohm RTD 500 PT 500 Ohm RTD 100 RH 100 Ohm RTD LINEAR Linear Range SQROOT Extracts Square Root INn HI 999 9 to 9999 INPUT HIGH RANGE VALUE in engineering units is displayed for all inputs but can only be configured for n 1 or 2 or linear or square root transmitter characterization 999 to 9999 Otherwise this is a read only display of the higher range value for the selected T C or RTD input including engineering units transmitter characterization if applicable e Scale the 1 input signal to the display value you want for 100 EXAMPLE Actuation Input 4 to 20 mA Process Variable Flow Range of Flow 0 to 250 Gal Min High Range display value 250 Then 20 mA 250
172. ision calibrator e Two containers of crushed ice Thermocouple Inputs e A calibrating device with 0 02 accuracy for use as a Ambient Temperature signal source such as a millivolt source e Two insulated copper leads for connecting the calibrator to the recorder Thermocouple Inputs e Acalibrating device with temperature compensation and Compensated Calibrator 0 02 accuracy for use as a signal source e Thermocouple extension wire that corresponds with the type of thermocouple that will be used with the recorder input RTD Resistance Thermometer e Aresistance decade box with 0 02 accuracy capable Device of providing stepped resistance values over a minimum range of 0 to 1400 ohms with a resolution of 0 01 ohm e Three insulated copper leads for connecting the decade box to the controller Radiamatic Milliampere Millivolt and calibrating device with 0 02 accuracy for use as a Volts Inputs signal source e Two insulated copper leads for connecting the calibrator to the controller 180 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Input Calibration Calibration Set Up and Wiring for PV Inputs 7 5 Calibration Set Up and Wiring for PV Inputs Jumper positions Before starting the calibration activity check that the jumper plugs on the applicable input circuit board are installed in the proper jumper position in WI
173. ith configurable chart speed through the keyboard The microprocessor uses the configured chart range data as well as the input data to determine the proper pen position The stepper motor accurately positions the pen drive without damping thus eliminating the need for slidewire feedback gearing and drive cables A configurable deviation recording function lets users show graphically the difference between a reference input and a process variable input Users can designate the channel 1 input or enter a deviation setpoint value as the reference input Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 1 May 2013 Overview Introduction Digital controller The DR4500A recorder includes an integral microprocessor based PID controller with two loops of control A variety of output types including a duplex variation for heat cool applications lets you select the output that is right for your final control element You can configure the control action as On Off PID A PID B or PD with manual reset English language prompts guide you through the entry of all the controller s configurable parameters Construction The DR4500 recorder is housed in a molded case which can be panel or surface mounted A glass or acrylic windowed door protects the internal components while allowing easy access to the chart and operator interface An optional external keypad that allows operator selections w
174. ithout Control Product Manual Release K May 2013 Configuration Lockout Set Up Group 3 18 Lockout Set Up Group Introduction These are the parameters that you will select to lockout any unauthorized changes to the recorder s configuration and calibration prompts Function prompt Table 3 16 lists all the function prompts in the Lockout Set Up group Table 3 16 Lockout group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting LOCKOUT Lockout NONE CALIB CALIB CONF MAX n ATTENTION Configuration can also be locked using S1 switch on the main printed circuit board Refer to Subsection 2 9 Configuration Lockout Switch The chart plate can be sealed using a lead seal to provide a positive indication that the electronics and configuration lockout switch may have been accessed This feature also includes the special screw and plate that provide for the lead seal capability for sealing the chart plate Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual May 2013 77 Configuration Configuration Record Sheet 3 19 Configuration Record Sheet Keep a record Enter the value or selection for each prompt on this sheet so you will have a record of how your recorder was configured Group Function Value or Factory Group Function Valu
175. ithout opening the door is available Circuitry is partitioned on printed circuit boards for ease of service Power input and output wiring connect to terminations inside the case Knockouts in the sides and bottom of the case accept conduit connections for convenient wire entry 2 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Overview Operator Interface 1 2 Operator Interface Operator interface Figure 1 1 shows the operator interface and defines the displays and indicators The function of the keys is described in Table 1 1 Indicates temperature Upper Display six characters units of PV Normal operation Displays process variable PV for selected channel e Configuration mode Displays selection or Alarm condition parameter value exists for alarm 1 Indicates controller mode or 2 when lit MAN Manual e A Automatic Key Pad Key Functions PV displayed is for channel 1 or 2 FC MA zem Remote setpoint or 2nd setpoint is active when lit SET RUN UP HOLD Blinks when 2nd 22074 setpoint or remote Control relay setpoint is 1or2 18 ON M obtained through when lit Bargraph deviation 10 of span remote switch Lower Display eight characters Normal operation Displays selectable operating parameters and values Configuration mode Displays function group and parameters Figure 1 1 Center green bar ind
176. ive load rating of 5A 120 Vac for example 115 Vac must equal a Load calculation example CResitancciof customer 7 number less than 5 amps controlled device Figure 2 18 Relay control output wiring 44 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Option Wiring Procedures 2 8 Option Wiring Procedures Alarm output and digital input wiring You can wire 1 and 2 Alarm Outputs and Digital Inputs The prerequisites are Model Number Table 3 1 Refer to Figure 2 19 and follow the procedure in Table 2 18 to wire alarm outputs or digital inputs The alarm output is a dry contact closure Table 2 18 Alarm output or digital input wiring Step Action Open the recorder door Loosen the captive screw in the chart plate and swing the plate out Locate connector J3 and J4 on the alarm output digital input printed circuit board refer to Figure 2 19 for location Remove the unwired plug from J3 Run the digital input wires through the desired knockout For CE Mark conformity install the ferrite filter as shown in Figure 2 11 Strip insulation from the end of each wire Loosen the screws in plug J3 terminals and position the plug as you would to plug it into J3 CO Insert the wires for the digital inputs into the appropriate screw clamps as shown refer to Figure 2 19 Note that you can wire the
177. jumper Resistor assembly part no 30755232 002 jumper is in position is in position T C is furnished with the recorder W1 on the input board on the input board Figure 7 8 Calibration set up diagram for 0 10 Volt inputs 188 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Input Calibration Calibration Set Up and Wiring for PV Inputs 4 20 mA inputs Refer to Figure 7 9 and wire the recorder according to the procedure given in Table 7 12 Table 7 12 Set up wiring procedure for 4 20 mA inputs Step Action 1 Connect the copper wire to the calibration source see Figure 7 9 2 Connect the other end of the copper wire to the clamp type terminals in the plug for the applicable input connector J2 3 e the plug into the input connector J2 on the applicable circuit board for input 1 or input 2 Calibration source Copper wires 4 20 mA 5 PE s 10 i E MM 22305 Be sure W1 MA jumper is in Plug J2 E P position MA this connects Be sure W3 jumper 2500 resistor internal on is in position T C PCB across inputs terminals on the input board Figure 7 9 Calibration set up diagram for 4 20 mA inputs Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 189 May 2013 Input Calibration Calibration Procedure 7 6 Calibration Procedure Introduction Apply powe
178. k applications use shielded twisted pair cables Optional communication Belden 4271 Twinax or equivalent Figure 2 21 RS485 Modbus communications wiring Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 51 May 2013 Installation Option Wiring Procedures 4 20 mA auxiliary output wiring You can wire an auxiliary output for 4 20 mA The prerequisites are Model Number Table 3 1XX or 4XX Refer to Figure 2 22 and follow the procedure in Table 2 22 to wire 4 20 mA auxiliary output Table 2 22 4 20 mA auxiliary output wiring Step Action Open the recorder door Loosen the captive screw in the chart plate and swing the plate out Locate connector J2 near the bottom of the auxiliary output printed circuit board refer to Figure 2 22 for location Remove the unwired plug from J2 Run the output wires through the desired knockout For CE Mark conformity install the ferrite filter as shown in Figure 2 11 Strip insulation from the end of each wire Loosen the screws in plug J2 terminals and position the plug as you would to plug it into J2 Observing the polarity insert the wires into the appropriate screw clamps as shown refer to Figure 2 22 Tighten the screws to secure the wires Install the wired plug into J2 l O Nj ATTENTION Be sure that the 4 20 mA auxiliary output is aligned Refe
179. l Press or V Release K May 2013 Operation Single Setpoint Ramp 5 8 Single Setpoint Ramp Configuring the setpoint ramp You can configure a single setpoint ramp to occur between the current local setpoint and a final local setpoint over a time interval of from 1 to 255 minutes You can RUN or HOLD the ramp at any time Procedure Table 5 17 lists the procedure for configuring the Setpoint Ramp 1 or 2 parameters The procedure for Setpoint Program is in Section 6 Setpoint Ramp Soak Programming Option Table 5 17 Procedure for configuring a single setpoint ramp Step Operation Press Action Result 1 Select SP RAMP 1 or SET Until you see SP RAMP 2 Set Up UP group Upper Display SET UP Lower Display SP RAMP X 10 2 2 Select Setpoint Ramp FUNC Until you see function Upper Display DISABL Lower Display SP RAMP X 3 Enable Setpoint Ramp A Until you see Upper Display ENABLE Lower Display SP RAMP X NOTE You cannot change the current local setpoint if the setpoint ramp function is enabled Make sure SP PROG is disabled 4 Set the Ramp Time FUNC Until you see Upper Display The ramp time in minutes Lower Display TIME MIN V Change the upper display value to the number of minutes in which you want the final setpoint to be reached Setting Range 1 to 255 minutes NOTE Entering 0 implies an immediate step change to the final SP 5 Set the Final Setpoint FUNC
180. l gasket onto the rear flange of the recorder case Install five 448 32 x 3 4 screws on each of the four mounting brackets so the ends of the screw threads are flush with the face of the bracket NOTE Screw heads to be flange side of brackets Insert the case with gasket into the panel opening Position the bracket so that the tabs on the end of the bracket slide into the holes in the case Secure the four brackets with 1 4 20 x 5 8 long bolts and lockwashers one to the top bottom and each side of the case Tighten the bolts Start to tighten the 8 32 x 3 4 screws on a bracket Tighten the end screws first then those toward the middle until all five screws have a 5 to 8 Ib in of torque applied Do the same to both the other three brackets When completed all twenty screws should have a 5 to 8 Ib in of torque applied This assures that the case and panel gaskets are adequately sealed against the panel 22 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Mounting Methods Pan Head Screw 8 32 x 3 4 inch 1 4 20 x 5 8 inch Hex Head Bolt 1 4 20 x 5 8 inch Hex Head Bolt 1 4 20 x 5 8 inch Pan Head Screw 8 32 x 3 4 inch Side View NOTE Mounting brackets attaching hardware and panel gasket are included in kit 30755065 503 Figure 2 8 Panel Mounting Recorder with NEMA4X Door Release K May 2013 D
181. l outputs ATTENTION Relay 2 is used for time proportional control Table 2 17 Relay control output wiring Step Action 1 Open the recorder door Loosen the captive screw in the chart plate and swing the plate out 2 Locate connector J5 on the control output 1 printed circuit board refer to Figure 2 18 for location 3 Remove the unwired plug from J5 4 Locate jumper positions W2 W3 and W4 W5 below connector J5 on the printed circuit board Remove plug in output 1 printed circuit board for better access to the jumpers Be sure to tag and remove all the plug connections to the printed circuit board before removing it Position the jumpers as shown in Figure 2 18 for desired relay contact action Locate jumper position W6 W7 on the bottom left portion of the board Make sure W7 position is selected for relay control output then reinstall the printed circuit board 5 Run the relay load wires through the desired knockouts 6 For CE Mark conformity e Install the ferrite filter as shown in Figure 2 11 e Install the shield capacitor as shown in Figure 2 18 7 Strip insulation from the end of each wire 8 Loosen the screws in plug J5 terminals and position the plug as you would to plug it into J5 9 Insert the relay wires and relay power into the appropriate screw clamps for single or duplex action as shown refer to Figure 2 18 tighten the screws to secure the wires 10 Install the wired p
182. larm 1 2 Alarm 2 only 3 5 Controller 1 output algorithms Relay Simplex Position Proportional Relay Duplex Current Relay Duplex 6 Alarm 3 4 7 Controller 1 output algorithms Position Proportional Relay Duplex Current Relay Duplex 8 Alarm 4 5 9 Controller 2 output algorithms Relay Simplex Position Proportional Relay Duplex Current Relay Duplex 10 Alarm 5 6 11 Controller 2 output algorithms Position Proportional Relay Duplex Current Relay Duplex 12 Alarm 6 106 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Alarms Set Up Group Alarms group prompts Table 4 10 lists all the function prompts in the Alarms setup group and their definitions These prompts repeat for all 6 alarms To configure an alarm for a setpoint program segment event program either type AxS1TYPE or AXS2TYPE as EVENT It is not necessary to configure any other alarm prompts Table 4 10 Alarms group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection AxS1 VAL Value in engineering units ALARM x SETPOINT 1 VALUE this is the value at which you want the alarm type chosen in prompt AxS1TYPE to actuate The value depends on what the setpoint has been configured to represent NO setpoint is required for Communications SHED For SP Programming the value is the segment num
183. lay Indication EE FAIL Background Unable to write to nonvolatile 39 Check the accuracy of the parameter memory Any time you change a and re enter parameter and it is not accepted you will see EE FAIL 40 Try to change something in configuration 41 Call Customer Support 1 800 423 9883 USA and Canada INTFAIL Background Two consecutive failures of input 1 42 Be sure the range and actuation are IN2FAIL integration for example cannot configured correctly make analog to digital conversion 43 Check the input source 44 Recalibrate Refer to Section 7 Input Calibration 45 Replace the input card 46 Call Customer Support 1 800 423 9883 USA and Canada BATTERY Power up or Battery test failure 47 Replace battery Status 48 Call Customer Support BATT LOW Background 1 800 423 9883 USA and Canada PV LIMIT Background Process Variable is out of range 49 Be sure pen input configuration is correct 10 of range 50 Check the displayed PV value to see if itis outside input limits 51 Call Customer Support 1 800 423 9883 USA and Canada RV LIMIT Background The result of the formula shown 1 Make sure the input signal is correct below is beyond the range of the remote variable 2 Make sure the ratio and bias settings are correct RV INP2 X RATIO BIAS 3 Go to CONTROL prompt REMOTE SOURCE and change REMOTE to 1LOCAL Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 209 May 2013 Trouble
184. ler s mode A or MAN Deviation Bargraph 21 segment color coded deviation bargraph Green large On Control Green small Deviation to 10 of PV Controller Modes of Operation 8 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Manual Operation Automatic with local setpoint Automatic with remote setpoint Release K May 2013 Installation Overview Condition Specifications Transmitter Supply Voltage 22 to 26 Vdc at input terminals 50 mA dc at 24 Vdc Controller Output Optional e Output can be field calibrated between 3 1 to 21 0 mA On Off or Time Proportional One SPST electromechanical relay Control action can be set for direct or reverse N O or N C contact selectable On Off Duplex or Time Proportional Duplex Two SPST electromechanical relays Control action can be set for direct or reverse N O or N C contact selectable Current Proportional 21 mA maximum into a negative or positive grounded or non grounded load of 0 to 1000 ohms Output range can be set between 4 and 20 mA and as direct or reverse action Resolution 10 bits Accuracy 0 5 full scale FM Approved Output optional e Position Proportional Two SPST electromechanical relays operate motor having a 100 ohm to 1000 ohm slidewire Current Time Duplex and Time Current Duplex Variation of time proportional duplex for Heat Cool applications Ti
185. ler kit esee enne 20 Mounting in a panel using Kent Model 105M cutout sese ene 21 Panel Mounting Recorder with NEMA4X enne enne nennen 23 Pipe Mounting Brackets oett REI oie ots es es e ERRORES EE ene 24 Mounting flush on a surface of panel or wall sese 26 Ferrite filter locations and shield wiring CE Mark sss 30 AC line power Winge iei so ede TUR SATB LU RIEN TED 32 Thermocouple RTD Radiamatic mV or 0 5 Vdc input wiring ssssessseeeseesessreresseseesersrrseeseeresersees 34 4 20 m WITITIB t rU 36 0s10 Volt dc Input uote Ee a Re 38 4 20 mA control output wiring or Aux Out 2 and 3 wiring 40 Position proportional control output wiring sees enne eren nnne nnns 42 Relay control output wiring c rr RC RC ERR EUER I TETTE DERE 44 Alarm output or digital input wiring sess ener nnne eren enne 46 Alarm outputs 43 4 5 and tert sete AI ER econ Ee tee E dee edens 49 RS485 Modbus communications amp 51 4 20 mA auxiliary output wirlng sese nnne tren enn nennen nnne nnns 53 ST Iockoutswitcli location ini e erede teet ede bd 54 DR4500A prompt hierarchy i ata bite e ae de e pede RO e a purs 56 Basic tecording componetits 5 si d etate eee e pr a ede a pde te ues 117
186. ll other groups are Read only ATTENTION Do not leave in NONE Lockout 114 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 115 5 Operation 5 1 Overview Introduction This section gives you all the information necessary to monitor and operate your recorder and for performing routine maintenance tasks In this section assume that the recorder has been properly installed and configured and that the inputs are properly calibrated Some of the procedures in this section are required only initially and some are required only randomly as conditions dictate Once the recorder 15 up and running required operation actions are infrequent and straightforward Review the Operator Interface Display and Keypad descriptions shown in Section 1 Overview What s in this section This section contains the following topics Release K May 2013 Topic See Page 5 1 Overview 115 5 2 Preparation 116 5 3 Start up 118 5 4 Monitoring Your Recorder 121 5 5 Operator Functions 128 5 6 Operating Modes 129 5 7 Setpoints 131 5 8 Single Setpoint Ramp 133 5 9 Using Two Sets of Tuning Constants PID Values 136 5 10 Using Accutune II 139 5 11 Alarm Setpoints 142 5 12 Digital Input Option Remote Switching 143 5 13 Resetting and Displaying Totalizer Value 144 5 14 Monitoring the External Event Operation 146 5 15 M
187. lts of the tests PASS or FAIL in the following order RAM TEST CONFTEST CAL TEST FACT CRC BATTERY e Identify the problem from the error message and correct the failure as shown under Lower Display Indication in Table 9 4 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Self Diagnostics Error message prompts The messages listed in Table 9 4 may appear during the power up test or status test or they may blink in the lower display as the result of ongoing background tests that verify data and memory integrity In the case of more than one simultaneous malfunction in the background tests the failure messages will be displayed in rotation Table 9 4 lists the error message the test group that prompted the message the reason for the failure and how to correct the problem Table 9 4 Error message prompts Lower Test Group Reason for Failure How to Correct the Problem Display Indication FAILSAFE Status or This error message shows whenever 23 Run through the Device Status Note 1 Background the recorder goes into a failsafe check page 206 to determine the Note 2 mode of operation This will happen reason for the failsafe indication if control is enabled and i 24 Identify the other failure message in e a power up test fails the display and correct the problem ific back d test fail accordin
188. lue approximately 750 Lower Display ZERO VAL Aor V Until the desired O 4 mA output is read on the milliammeter 3 Calibrate 100 96 FUNC Stores the 0 value and you will see Upper Display a value approximately 3650 Lower Display SPAN VAL Aor V Until the desired 100 20 mA output is read on the milliammeter 4 Exit the Calibration Mode FUNC The recorder stores the span value LOWR To exit the calibration mode DISP or SET UP n ATTENTION The calibration for Auxiliary Outputs 2 and 3 follows the procedure for calibrating the current proportional output refer to Subsection 8 2 200 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 201 9 Troubleshooting Service 9 1 Overview SHOCK HAZARD WARNING Disregard of these instructions may cause injury or death TROUBLESHOOTING MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE SERVICING Introduction This section explains how to troubleshoot the DR4500A recorder using self diagnostic test results and error messages as well as some visual failure symptoms Using an optimum replacement unit repair philosophy trouble is traced to a printed circuit board PCB hardware assembly level rather than to an individual PCB hardware
189. lue HOLD Press again to continue run A KEY ERROR prompt appears if RUN HOLD key is pressed while SP RAMP is disabled 5 View the remaining ramp LOWR Until you see time DISP Upper Display R or H and the PV value Lower Display RAMP XXXM time remaining 6 End the ramp When the final setpoint is reached the R changes to H in the upper display and the recorder operates at the new setpoint ATTENTION Any time the local setpoint is different from the final setpoint value and the RUN HOLD key is pressed the ramp will start again 134 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Single Setpoint Ramp Step Operation Press Action Result 7 Disable the setpoint ramp SET Until you see function UP Upper Display SET UP Lower Display SP RAMP X FUNC You will see Upper Display ENABLE Lower Display SP RAMP X A You will see Upper Display DISABL Lower Display SP RAMP X 8 Return to normal LOWR Returns to normal operating mode operating mode DISP Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 135 May 2013 Operation Using Two Sets of Tuning Constants PID Values 5 9 Using Two Sets of Tuning Constants PID Values Introduction You can use two sets of tuning constants for single output types and choose the way they are to be switched The sets can be e Keybo
190. lug into J5 11 Repeat steps 2 through 10 for control output 2 printed circuit board as applicable Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 43 Installation Output Wiring Procedures Control output 111 2 Relay No 1 s W2 N O contact W3 contact Relay No 2 W4 N O contact W5 N C contact Position when shipped N O with power applied I and OUT indicator light off W7 Relay or Current Output Ferrite Filter Cable Shield External Load f power supply ius Relay 1 load Vo Q o N Heat o H a Relay 2 N Cooling So o H Fair Rite P N 0443164151 or equivalent Required for CE Mark Conformity Kit Part No 51197612 502 contains two ferrite filters Part No 51197612 508 contains 8 ferrite filters Install inside of case See Figure 2 11 Capacitor Kit 51197755 001 Install capacitors as shown in figure Relay 2 is used for time proportional duplex Capacitor Also used for 3 position step See Figure 2 17 oe as Plug J5 see Notes ds T ess HE 1 J5 terminals 2 and 4 are the non switched connections to an SPST relay Selectable for normally open or normally closed as required 2 This relay supplies a dry contact closure User must supply appropriate power connections for his external device Supply voltage 3 This relay has a resist
191. ly appears if you select YES at RELHUMID prompt previously Select the desired compensation DEVIATION DEVIATION selects deviation recording action NONE e NONE No deviation recording SETPNT e SETPNT Records deviation from setpoint CHAN1 e CHAN1 Pen 1 records the difference between Input 1 and Input 2 DEVSETPT 999 0 to 9999 DEVIATION SETPOINT VALUE sets the desired 112 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual deviation setpoint value for deviation recording e This prompt only appears if SETPNT was selected at prompt DEVIATION previously Release K May 2013 Configuration Parameter Definitions Options Set Up Group Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection SCROLL LOWER DISPLAY SCROLL The lower display will automatically change to the next item as if the LOWR DISP key had been pressed at the interval selected NONE NONE Disables the scroll function 1 SEC 1 SEC One second intervals 2 SEC 2 SEC Two second intervals 3 SEC 3 SEC Three second intervals GRANDTOT ENABLE GRAND TOTALIZER When enabled it prints on the DISABL chart the sum of ALL the enabled totalizers as TOTAL XXXXXXXXXXX Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 113 May 2013 Configuration Parameter Definitions Lockout Parameters
192. mbrytare for n str mmen rekommenderas STR MF RS RJNING Sp nning 102 a 132 Vac 204 a 264 Vac Frekvens 49 51 Hz 59 61 Hz Effekt eller 9 watts max m rkstr m OMGIVNINGSVILLKOR Anv nd ej instrumentet i n rhet av br nnbara v tskor eller gaser Anv ndandet av instrumenteti s dant milj r en direkt s kerhetsrisk Temperatur Omgivande 15 till 55 C Fuktighet 10 till 90 RH Vibration 0 till 70 Hz acceleration 0 1 g INSTALLATION Instrumentet skall monteras i en panel eller 1 en l da f r att undvika att personalen kommer 1 ber ring med bakre inkopplingsplintar 244 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 0 10 Volt dc inputs 37 0 10 Volt inputs 190 4 4 20 mA auxiliary output wiring 52 4 20 mA control output wiring 39 4 20 mA input wiring 35 4 20 mA inputs 191 AC line power 30 Accutune Il 141 Alarm hysteresis 73 110 Alarm messages 129 Alarm outputs 45 Alarm setpoints 144 Alarms group definitions 109 Atmospheric pressure compensation 76 114 Automatic calibration mode 199 Automatic local mode 131 Automatic mode Return to 132 162 Selecting 131 Automatic remote mode 131 Automatic switchover 93 Automatic switchover value 67 94 Auxiliary Output 73 74 B Basic recorder components without options 227 Battery test failure 211 Baud rate 75 Bias 95 Bias for remote setpoint 67 Burnout
193. me proportional output heat or cool is a SPST electromechanical relay Current proportional output heat or cool is a 4 20 mA signal that can be fed into a negative or positive grounded load of 0 to 1000 ohms and is operational over 50 of range or the entire range Time Proportional Relay Resolution 4 4 mSec Relay Contact Ratings Resistive Load 5A 120 Vac 2 5A 240 Vac Inductive Load 50 VA 120 Vac or 240 Vac Cycle Time 1 to 120 seconds Current Proportional Resolution 10 bits Accuracy 0 5 full scale Auxiliary Output Optional Output can be field calibrated between 3 1 to 21 0 mA 21 mA dc maximum into a negative or positive grounded load of 0 to 1000 ohms The range can be set between 0 to 21 mA It can be configured to represent any one of 10 control parameters Input 1 2 PV1 2 Deviation 1 2 Output 1 2 Setpoint 1 2 Auxiliary Output 2 and Auxiliary Output 3 use Control Current Output 1 and Control Current Output 2 if Control OUTALG is not set to CURRENT Resolution 12 bits over 0 to 21 mA Accuracy 0 2 of full scale Temperature Stability 0 03 F S C Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual May 2013 Installation Overview Types of Input Range Reference Accuracy Temp Stability Actuations S n Degrees Error Per 1 F c t F Degree AT Thermoco
194. method 186 Thermocouple inputs using an ice bath 185 Thermocouple inputs using the ambient temperature method 187 Totalizer 66 Totalizer group definitions 91 Totalizer reset 66 67 Totalizer scale factor 66 Totalizer value 146 Displaying 147 Resetting 146 Trace line contrast 122 Transmitter characterization 63 86 Troubleshooting procedures 214 Ttransmitter power 35 Tuning constants 138 Tuning group prompt definitions 102 Tuning messages 129 Tuning parameter sets 67 93 Two local setpoints 94 Two sets of tuning constants 138 V Visual failure symptoms 205 213 Voltage equivalent 180 248 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Wire bundling 28 Wiring 0 10 Vdc inputs 37 0 5 Vdc inputs 33 4 20 mA auxiliary output 52 4 20 mA control output 39 4 20 mA inputs See AC line power See Electrical noise precautions 27 mV inputs 33 Position proportional control output 41 Radiamatic inputs 33 Relay control output 43 RS485 Modbus communications 50 RTD inputs 33 Shields 29 Thermocouple inputs 33 Transmitter power See Wire bundling 28 Wiring the recorder 29 Wiring for PV inputs 184 0 10 Volt inputs 190 4 20 mA inputs 191 Millivolts and Volts inputs except 0 10 Volts 189 RTD inputs 188 Thermocouple inputs using a compensated calibrator method 186 Thermocouple inputs using an ice bath 185 Thermocouple inputs using t
195. move plug in output 1 printed circuit board for better access to the jumpers Be sure to tag and remove all the plug connections to the printed circuit board before removing it Position the jumpers as shown in Figure 2 17 for desired relay contact action Locate jumper position W6 W7 on the bottom left portion of the board Make sure position W6 is selected for position proportioning then reinstall the printed circuit board Run the feedback slidewire and motor drive wires through the desired knockouts For CE Mark conformity e install the ferrite filter as shown in Figure 2 11 e install the shield capacitors as shown in Figure 2 17 Strip insulation from the end of each wire Loosen the screws in plug J2 terminals and position the plug as you would to plug it into J2 Insert the wires from the motor s feedback slidewire into the appropriate screw clamps as shown refer to Figure 2 17 Tighten the screws to secure the wires Loosen the screws in plug J5 terminals and position the plug as you would to plug it into J5 10 Insert the wires for the motor into the appropriate screw clamps as shown refer to Figure 2 17 Tighten the screws to secure the wires 11 Install the wired plug into J2 and J5 as applicable 12 Repeat steps 2 through 11 for Control Output 2 printed circuit board as applicable Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Cont
196. ms 300 to 900 184 to 482 0 20 0 11 0 05 10 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Overview Types of Input Range Reference Accuracy Temp Stability Actuations S m e Degrees Error Per 1 F c F Degree AT Linear Milliamperes dc 4 to 20 0 1096 0 004 Millivolts dc 0 to 10 0 0596 0 004 F 10 to 50 0 05 0 004 F Volts dc 1 to 5 can be 0 0596 0 004 F calibrated 0 to 5 0 to 10 0 10 0 004 F Relative Humidity Platinum 100 ohm Wet Dry Bulb Wet Dry Input 130 to 392 90 to 200 0 30 0 03 0 03 Measured Dry Bulb Range Reference Temp Stability RH n n Accuracy 53 to 104 F 12 to y RH 0 to 20 103 to 212 75 to 100 296 RH 0 11 RH F 20 to 100 35 to 40 2to4 2 RH 0 11 RH F gt 40 to 100 gt 4 to 38 1 RH 0 06 RH F 100 to 212 38 to 100 1 RH 0 03 RH F Condition Specifications Case Molded foamed Noryl with gasketed door A UL and FM approved NEMA4X door is also available Pen Disposable fiber tip ink cartridge line length per cartridge more than 1000 ft 305 m One pen Purple Two pens Purple and red Chart 12 inch 304 8 mm diameter chart with standard preprinted markings and a calibrated width of 4 62 inches 117 5 mm Wiring Connections Terminals inside the case Color Case Black Door stan
197. n Press again after configuration entry is made Function prompts Table 3 5 lists all the function prompts in the Chart Set Up group Table 3 5 Chart group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting CHRTSPD Chart Speed Selection 8HR XHR 12HR 24HR 7DAYS XHR See prompt HOUR REV HOUR REV Hours per Revolution 1 to 744 12 appears only if XHR is selected above LINEARIZ Linearization LINEAR NONLIN Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 65 May 2013 Configuration Totalizer Set Up Group 3 9 Totalizer Set Up Group Introduction The functions listed in this group deal with the calculation and display of the total flow volume as measured by input 1 total 1 or input 2 total 2 The displayed value is 8 digits with a configurable scale factor Function prompts Table 3 6 lists all the function prompts in the TOTAL 1 Set Up group Repeat the process for input 2 e Press the SET UP key until TOTAL 2 appears in the display Table 3 6 Totalizer group function prompts Function Prompt Lower Display Function Name Selections or Range of Setting Upper Display Factory Setting Actual Current Totalized Value View Current Totalized Value Current Scale Factor Example E1 GPM E0 GAL RSET TOT Reset Totalizer to Z
198. n this group deal with the calculation and display of the total flow volume as measured by Input 1 Total 1 or Input 2 Total 2 The displayed value is eight digits with a configurable scale factor Totalizer 1 and 2 group prompts Table 4 4 lists all the function prompts in the Totalizer 1 and 2 Set Up group and their definitions Table 4 4 Totalizer group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection Actual Current Current scale factor VIEW CURRENT TOTALIZED VALUE this selection totalized value lets you view the current totalized value Example E1 GPM In the example shown E1 represents exponential value of total total times 101 GPM represents total engineering units selected See SCALER and TOTAL EU function prompts in this group for selections RSETTOT YES RESET TOTALIZER TO ZERO this selection lets NO you reset the totalizer to zero e Selecting YES will reset the totalizer to zero Function prompt RSETABLE must be set to LOCAL TOTAL1 DISABL TOTALIZATION FOR INPUT 1 OR 2 this selection TOTAL 2 INPUT 1 allows you to select the input to Totalizer 1 or 2 INPUT 2 e Not DISABL allows selection of the rest of the prompts associated with totalization TOTAL EU 0 to 9 TOTAL ENGINEERING UNITS this selection allows AtoZ you to make up to 3 selections to create a unit identifier that the total represents
199. nal alarm wiring information The DR4500 has the ability to provide for Alarm outputs 3 4 5 and 6 Follow the procedures listed below to wire No 3 and No 4 Alarm Outputs and No 5 and No 6 Alarm Outputs Alarms 3 and 4 output wiring You can wire 3 and 4 Alarm Outputs The prerequisites are Model Number Model Table 2 1X 6X If control output is 4 20 mA then the relays on the control card are available for use as alarms Refer to Figure 2 20 and follow the procedure in Table 2 19 to wire Alarm 3 and Alarm 4 outputs Table 2 19 Alarm 3 and Alarm 4 output wiring Step Action 1 Open the recorder door Loosen the captive screw in the chart plate and swing the plate out 2 Locate connector J5 on the 4 20 mA control output printed circuit board to wire relays 3 and 4 Refer to Figure 2 20 for location 3 Remove the unwired plug from J5 4 Locate jumper position W2 W3 and W4 W5 below connector J5 on the printed circuit board Note that you may want to remove the plug in output printed circuit board for better access to jumpers Be sure to tag and remove all the plug connections to the printed circuit boards before removing it Position the jumpers as shown for the desired relay contact action and reinstall the printed circuit board 5 Run the alarm output wires through the desired knockout 6 For CE Mark conformity e Install the ferrite filter as shown in Figure 2 11 e Install the capacitors as s
200. nerate controlled output signals to operate valves dampers heating elements etc for process control CE Conformity Europe Indicated models of this product are in conformity with the protection requirements of the following European Council Directives 73 23 EEC the Low Voltage Directive and 89 336 EEC the EMC Directive Conformity of this product with any other CE Mark Directive s shall not be assumed Deviation from the installation conditions specified in this manual and the special conditions for CE conformity in Section 2 1 may invalidate this product s conformity with the Low Voltage and EMC Directives n ATTENTION The emission limits of EN 61326 are designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment Operation of this equipment in a residential area may cause harmful interference This equipment generates uses and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 meters 98 feet to the antenna e In special cases when highly susceptible apparatus is used in close proximity the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment Microprocessor controlled recording and printing Both the chart and the pen are driven by stepper motors which are controlled by the microprocessor w
201. nitions Control Parameters Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition MINorRPM RESET UNITS selects units of minutes or repeat per minutes for the term of the PID algorithm 20 Repeats per Minute 0 05 Minutes per Repeat RPM REPEATS PER MINUTE the number of times per minute that the proportional action is repeated by reset MIN MINUTES PER REPEAT the time between each repeat of the proportional action by reset CONT1ALG The CONTROL ALGORITHM lets you select the type of control that is best for your process ATTENTION If the recorder has two controllers both enabled CONT1ALG applies for controller 1 and CONT2ALG applies for controller 2 ON OFF ON OFF is the simplest control type The output can be either ON 100 or OFF 0 The Process Variable PV is compared with the setpoint SP to determine the sign of the error ERROR PV SP The ON OFF algorithm operates on the sign of the error signal e In Direct Acting Control when the error signal is positive the output is 10096 and when the error signal is negative the output is 096 If the control action is reverse the opposite is true An adjustable overlap Hysteresis Band is provided between the on and off states e Other prompts affected OUT HYST DUPLEX ON OFF is an extension of this algorithm when the output is configured for Duplex
202. nsert e the green wire into the first screw clamp from the right e the white wire L2 into the second screw clamp from the right and e the black wire L1 into the third screw clamp from the right Tighten the screws to secure the wires CAUTION To avoid damaging the recorder be sure that you install the power wires into the correct screw clamps Make sure the fuse block is installed properly for the given supply rating 120 or 240 Vac The fuse is in the 120 Vac location from the factory 9 Make sure the fuse block is installed in the proper location Refer to Figure 2 12 for fuse block location e 120 Vac Fuse block in location F2 e 240 Vac Fuse block in location F1 10 Dress the wires as slack as possible This keeps the noise signal on these wires from bypassing built in suppression Also do not bundle any low level signal wires with the power wires Refer to Table 2 10 for permissible wire bundling e Refer to document 51 52 05 01 for additional information concerning noise interference prevention 11 Insert the wired plug into J10 WARNING Input line voltage will be present on the instrument ground plane if safety ground is not attached personal injury and product damage could result Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 31 May 2013 Installation Input Wiring Procedures Fuse Block on Main PC Board PLUG J10 P
203. ntil you see Upper Display DISABL Lower Display SP PROG If you see Upper Display ENABLE Lower Display SP RAMP or Upper Display ENABLE Lower Display SP RATE you must disable them SP PROG and its subordinate prompts are not visible unless SP RAMP and SP RATE are disabled Once they are disabled press FUNC until you see SP PROG 3 Enable SP PROG A or V Until you see Upper Display ENABLE Lower Display SP PROG 4 Select the functions FUNC Upper Display shows current value for each prompt Lower Display shows individual function prompts within the setpoint program group e Successive presses of the FUNCTION key sequentially displays all the functions and their values or selections e Using the FUNCTION key follow the prompts shown in Sections 6 5 6 6 and 6 7 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 159 May 2013 Setpoint Ramp Soak Programming and Operation Entering the Setpoint Program Data Step Operation Press Action Result 5 Change the value or Aor V This changes the value or selection in the upper selection of a function display If the display blinks you are trying to select an prompt unacceptable value 6 Enter value or selection FUNC This enters the value or selection and goes to another into memory prompt e Repeat steps 4 and 5 for each function you want to change 7 Exit configuration LOWR T
204. o terra del sistema di alimentazione e Selostrumento viene utilizzato in modo diverso dalla specifica del costruttore la protezione fornita dallo strumento pu essere diversa e Non sostituire alcun componente o parte non specificato esplicitamente come ricambio dal vostro fornitore e Tutti i cablaggi devono essere in accordo con i regolamenti locali e devono essere eseguiti da personale esperto ed autorizzato e lterminale di massa deve essere collegato prima di ogni altro filo e scollegato per ultimo e necessario che sia presente un interruttore nell alimentazione principale accanto all apparecchio ALIMENTAZIONE APPARECCHIATURA Tensione di Da 102 a 132 Vac da 204 a 264 Vac alimentazione Frequenza 49 51 Hz 59 61 Hz Potenza o corrente 9 watts max CONDIZIONI AMBIENTALI Non far funzionare l apparecchio in presenza di liquidi o gas infiammabili in quanto questo potrebbe essere estremamente pericoloso Temperatura Ambiente da 15 a 55 C Umidit relativa Da 10 a90 UR Vibrazioni Da 0 a 70 Hz accelerazione 0 1 g INSTALLAZIONE DELL APPARECCHIO Il apparecchio deve essere montato su un pannello per limitare l accesso ai terminali posteriori 240 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Foreign Language Safety Instructions NO21 6057 SIKKERHETSKRAV NO210 6057 F lg alle retningslinjene i dette dokumentet slik at du reduserer ris
205. oblem Visual failure symptoms Other failures may occur that deal with the power pen functions chart rotation output or alarms Refer to the visual failure symptom in Table 9 5 to determine what is wrong and the troubleshooting procedures to use to correct the problem Check Installation If a set of symptoms still persists refer to Section 2 Installation and ensure proper installation and proper use of the recorder in the system Customer support If you cannot solve the problem using the troubleshooting procedures listed in this section get the model number and serial number from the label on the chart plate and software version see Determining the software version then call Customer Support Phone Number 1 800 423 9883 USA and Canada If it is determined that a hardware problem exists and the recorder is still within the two year warranty a replacement recorder will be shipped with instructions for returning the defective unit Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 203 May 2013 Troubleshooting Service Troubleshooting Aids Determining the software version Table 9 1 lists the procedure for identifying the software version number Table 9 1 Procedure for identifying the software version Step Operation Press Action Result 1 Select STATUS SET Until you see Set Up Group UP Upper Display READ Lower Display STATUS 2 Read the sof
206. oint Only for Loop 1 Setpoint is the output of Control Loop 2 RATIO 20 00 to 20 00 RATIO used when input 2 operates as a remote setpoint prompt REMOTE e This ratio value can be applied to the remote setpoint It establishes the correct relationship between the remote setpoint and the input 2 signal applied according to the formula below under Bias e Input 2 must be enabled 92 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Control Parameters Set Up Group Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition BIAS 9999 to 9999 engineering units BIAS used when input 2 operates as a remote setpoint prompt REMOTE e Bias together with ratio establishes the correct relationship between the remote setpoint and the input 2 signal applied according to the formula REMOTE SETPOINT IN2 VALUE RATIO BIAS NOTE IN2 VALUE Actual engineering units e All values must be within configured setpoint high and low limits e Input 2 must be enabled SP TRACK SETPOINT TRACKING the local setpoint can be configured to track the remote setpoint as listed below NONE NO TRACKING if local setpoint tracking is not configured the LSP will not be altered when transfer from RSP to LSP is made RSP LSP LO
207. oint 2 Value Value in engineering units 95 AxS1TYPE Alarm 1 Setpoint 1 Type NONE IN 1 IN 1 Input 1 IN 2 Input 2 RH Relative Humidity PV Process Variable Loop 1 DEV Loop 1 Deviation OUT Loop 1 Output DEV2 Loop 2 Deviation OUT2 Loop 2 Output EVENT SP Programming Segment Event TOTAL 1 Totalizer to Alarm On TOTAL 2 Totalizer to Alarm On AxS2TYPE Alarm 1 Setpoint 2 Type Same as A1S1TYPE IN 1 AxS1HL Alarm 1 Setpoint 1 State LO Low Alarm LO H I High Alarm AxS1SCAL Alarm 1 Setpoint 1 Scaling 1 10000 1 Multiplier for Totalizer 10 100000 Selection 100 1E6 1000 AxS2HL Alarm 1 Setpoint 2 State LO HI HI AxS2SCAL Alarm 1 Setpoint 2 Scaling 1 1 Multiplier for Totalizer 10 Selection 100 1000 10000 100000 1E6 ALx HYST Alarm Hysteresis 0 0 to 100 0 of Input Span as appropriate 0 1 Repeat this procedure for ALARM 2 ALARM 3 ALARM 4 ALARM 5 ALARM 6 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 73 May 2013 Configuration Auxiliary Output Set Up Group 3 15 Auxiliary Output Set Up Group Introduction The auxiliary output will supply a 4 20mA output scaled to one of four operating parameters Input Output Setpoint or Deviation This current 1s supplied from a separate option card AUX OUT 2 and AUX OUT 3 use CONTROL CURRENT OUT 1 and CONTROL CURRENT OUT 2 if CONTROL OUT ALG is not set to CURRENT Function prom
208. omatic Key Pad Key Functions LOWR MAN FUNC DISP AUTO CHART SET RUN UP HOLD 22074 Bargraph deviation 10 of span Center green bar indicates PV is within 1 of control setpoint e Next small bar will light if PV is between 1 but less than 2 in deviation e f PV is equal to or greater than 10 deviation the green bar plus all ten small green bars will light Operator interface Release K May 2013 Operation Monitoring Your Recorder Meaning of indicators During normal operation the indicators will light for the reasons shown in Table 5 6 Table 5 6 Meaning of indicators Indicator Definition when lit ALM 1 2 Alarm condition exists for alarm 1 or 2 1 2 PV displayed is for channel 1 or 2 RSP Remote Setpoint when available or 2nd setpoint is active OUT 12 Control relay 1 or 2 is ON A or MAN Indicates the mode of operation A Automatic MAN Manual F or C or blank Indicates the temperature units of PV F Fahrenheit C Celsius R or H or G or blank Indicates the state of the setpoint ramp or program if enabled in upper display R Run Hold Guar Soak blank Disabled T Totalizer LIMIT Alternately displayed with limit SP value in lower display when limit in lower display condition exists KEY ERR in lower display Indicates parameter not available not in set up mode or key malfunction A
209. ompts REFERENCE Refer to Documents 51 52 25 66 and 51 52 25 69 for a complete description of the RS485 Modbus Communications Option Table 4 12 lists all the function prompts in the Modbus Communications set up group and their functions Table 4 12 Modbus communications group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection ComSTATE DISABL DISABL Disables the communications option MODBUS MODBUS Allows Modbus communication prompts Com ADDR 1 to 99 COMMUNICATIONS STATION ADDRESS This is a number that is assigned to the recorder that is to be used with the communications option BAUD BAUD RATE is the transmission speed in bits per second 300 300 Baud 600 600 Baud 1200 1200 Baud 2400 2400 Baud 4800 4800 Baud 9600 9600 Baud 19200 19200 Baud 38400 38400 Baud XMT DLAY NONE TRANSMIT DELAY This is the approximate time 10MSEC delay between receipt of Modbus request message and 20MSEC start of response message in addition to message 30MSEC processing time 40MSEC 50MSEC DBL BYTE DOUBLE REGISTER BYTE ORDER The transmitted or received order of the 4 bytes comprising an IEEE floating point value The default order is EXP MH MM ML or 0123 for reference FPB 0123 Big Endian FP BB 1032 Big Endian Byte Swapped FPL 3210 Little Endian FPLB 2301 Little Endian Byte Swapped Release K DR4500A Classic Series Circular Chart Recorder With or Without Control
210. on Open the recorder door Loosen the captive screw in the chart plate and swing the plate out Locate connector J2 on the printed circuit board for input 1 refer to Figure 2 15 Remove the unwired plug from J2 and replace it with the modified 4 screw plug from the bag of accessories supplied with the recorder Run the input wires through the desired knockout DO NOT bundle them with the power wires For CE Mark conformity e Install the ferrite filter as shown in Figure 2 11 e Install the 01uF capacitor and the 0047uF capacitor as shown in Figure 2 15 Strip insulation from the end of each wire Loosen the screws in plug J2 terminals and position the plug as you would to plug it into J2 Using the 30755232 002 100K ohm voltage divider connector kit supplied in the bag of accessories insert the wires into the appropriate screw clamps Tighten the screws to secure the wires Install the wired plug into J2 Since J2 has only three receptacles one of the modified plug connectors is designed to slide outside J2 when the plug is installed 10 Locate jumper position W3 and make sure the jumper is in the proper position for your input type See Figure 2 15 for the location 11 Locate jumper position MA W1 and make sure the jumper is in the W1 position See Figure 2 15 for the location 12 Repeat steps 2 through 11 for input 2 printed circuit board as applicable Releas
211. on ENABLE ENABLE DISABL PB or GAIN Proportional Band or Gain PB PCT GAIN Units GAIN MIN orRPM Reset Units RPM repeats per minute MIN MIN minutes per repeat CONT1 ALG Control Algorithm ON OFF PID A PID A PID B PD MR OUT1 ALG Output Algorithm TIME TIMED CURRENT CURRNT CUR TI POSITN TI CUR 4 20RNG Current Time Duplex Range 100PCT FULL 50PCT CUR D 50 PCT SPLIT Note GAIN must be used with OUTPUT ALG settings of TIME D TIME DUPLEX or TI CUR TIME CURRENT Repeat this procedure for CONTROL 2 68 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Tuning Parameters Set Up Group 3 11 Tuning Parameters Set Up Group Introduction These Tuning Set Up groups contain the Function parameters that will allow your recorder to respond correctly to changes in process variable or setpoint You can start with predetermined values but you will have to watch your process to determine how to modify them Function prompts Table 3 8 lists all the function prompts in the Tuning 1 or Tuning 2 Set Up groups How the Control Set Up group is configured determines which prompts will appear Table 3 8 Tuning 1 or Tuning 2 group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting FUZZY Fuzzy Overshoot DISABL DISABL
212. on constants in the recorder are in error Working CAL TEST failure Control 1 Input 1 Input 2 32 Change to a different input type e See Section 3 Configuration 33 Check Device Status page 206 to see if FACT PASS e If PASS return to original input type e If FAlL field calibrate Refer to Section 7 Input Calibration 34 Change to a different input type e See Section 3 Configuration 35 Check Device Status page 206 to see if FACT CRC PASS e If PASS return to original input type e If FAlL field calibrate Control Output 1 Input 1 or Input 2 Refer to Section 7 Input Calibration and Section 8 Ouiput Calibration CAL2 ERR Background Working CAL TEST failure Control 2 Output 36 Field calibrate Control Output 2 e Refer to Section 8 Output Calibration FACT CRC Check Device Status See page 206 Factory set input constants have been changed due to the change in input type 37 Check background test error message being displayed 38 Recalibrate Input or Output e Refer to Section 7 Input Calibration or Section 8 Output Calibration 208 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Self Diagnostics Lower Test Group Reason for Failure How to Correct the Problem Disp
213. on numbers for each task are shown 1 Determine your recorder s hardware components and See Section 2 software functions 2 Mount the recorder flush in a panel or on the surface See Section 2 of a panel or a wall 3 Connect the power and input output wiring See Section 2 4 Follow the simple keystroke sequences and English language prompts to See Sections 3 amp 4 configure the functional characteristics of your recorder Ready for Operation 22075 Figure 1 2 Set up tasks Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual May 2013 Overview Set up Tasks 6 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 2 Installation 2 1 Overview Introduction Installation of the DR4500A Recorder consists of mounting and wiring the recorder according to the instructions given in this section Read the preinstallation information check the model number interpretation and become familiar with your model selections then proceed with installation What s in this section This section contains the following information Topic See Page 2 1 Overview 7 2 2 Model Number Interpretation 13 2 3 Mounting Considerations and Overall Dimensions 16 24 Mounting Methods 17 2 5 Wiring Prerequisites 27 2 6 Input Wiring Procedures 29 2 7 Output Wiring Procedures 39 2 8 Option Wiring Proce
214. on set up diagram for Thermocouple inputs using the ambient temperature method Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 185 May 2013 Input Calibration Calibration Set Up and Wiring for PV Inputs RTD Resistance Thermometer Device inputs Refer to Figure 7 6 and wire the recorder according to the procedure given in Table 7 9 Table 7 9 Set up wiring procedure for RTD inputs Step Action 1 Connect the copper wire to the calibration source see Figure 7 6 2 Connect the other end of the copper wire to the clamp type terminals in the plug for the applicable input connector J2 3 e the plug into the input connector J2 on the applicable circuit board for input 1 or input 2 Decade box Copper wires Spes ws ww Plug J2 22092 Be sure W1 MA Be sure W3 jumper jumper is in position is in position RTD W1 on the input board on the input board Figure 7 6 Calibration set up diagram for RTD inputs 186 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Input Calibration Calibration Set Up and Wiring for PV Inputs Radiamatic millivolts and volts inputs except 0 10 Volts Refer to Figure 7 7 and wire the recorder according to the procedure given in Table 7 10 Table 7 10 Set up wiring procedure for Radiamatic Millivolts and Volts inputs except 0 10 Volts Step
215. onfigured and any test except BATTER Y fails FAIL appears momentarily in the upper display then a display test is run after which the controller goes into manual mode and you will see Upper Display PV value Lower Display FAILSAFE blinking Refer to Device Status next page to determine which tests have failed and how to correct them All applicable error messages are displayed in rotation If CONTROL is not configured FAILSAFE will not display ERR CALI ERR CAL2 ERR or BATT LOW will display whether FAILSAFE does or not Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 205 May 2013 Troubleshooting Service Self Diagnostics Device status When required the results of the power up tests can be checked to determine the reason the recorder has gone to Failsafe The following procedure in Table 9 3 tells you how to display the results of the latest tests run Table 9 4 lists the tests the reason for the failure and how to correct the problem Table 9 3 Procedure for displaying the device status Step Operation Press Action Result 206 Select STATUS SET Until you see Set Up Group UP Upper Display READ Lower Display STATUS Read the status tests FUNC Until you see results Upper Display NO or YES YES indicates a failure Lower Display FAILSAFE e Successive presses of the FUNC key will display the resu
216. ontrol Product Manual 153 May 2013 Setpoint Ramp Soak Programming and Operation Drawing a Ramp Soak Profile 6 3 Drawing a Ramp Soak Profile Ramp soak profile example 154 Before you perform the actual configuration we recommend that you draw your Ramp Soak profiles in the space provided on the blank graphs and fill in the associated information on the worksheet An example of a Ramp Soak Profile using the first twelve segments for Profile 1 is shown in Figure 6 1 Start setpoint in this example is at 200 F Assume each soak segment is desired to trigger an event Assume you are configuring the program to be used by Control Loop SP RAMP1 4444 40898 10 44 EEENEE EEE ENG E LG Ashea LL T seee L1 LLL TE TT INU LLL Time Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Figure 6 1 Ramp Soak profile example DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Drawing a Ramp Soak Profile Table 6 1 Parameter settings for example 12 step profile Prompt Function Segment Value Prompt Function Segment Value SP RAMP1 Settings for SEG7RAMP Ramp 7 2hr 30min Control Loop 1 ramp SP PROG Enables SP ENABLE SEG8 SP Soak SP 8 500 prompts RECYCLES Number of 2 SEG8TIME Soak Time 8
217. oportional Output Aux Out 2 and 3 Calibration 8 2 Current Proportional Output Aux Out 2 and 3 Calibration Introduction Calibrate the recorder so that the output provides the proper amount of current over the desired range The recorder can provide an output current range of from 3 1to 21 mA and can be calibrated at 4 mA for 0 of output and 20 mA for 100 96 of output or any other values between 3 1 and 21 mA Equipment needed You will need a standard shop type milliammeter with whatever accuracy is required capable of measuring 0 to 20 milliamps Calibrator connections Refer to Figure 8 1 and wire the recorder according to the procedure given in Table 8 1 Table 8 1 Set up wiring procedure current proportional output Aux Out 2 and 3 Step Action 1 With the power off door open and the chart plate swung out tag and disconnect field wiring from the plug in connector J1 on the appropriate control output PCB see Figure 8 1 2 Observing polarity connect a milliammeter s leads to the plug for connector J1 3 Close the chart plate apply power and allow the recorder to warm up 15 minutes before you calibrate 1 PCB 2 PCB a len tt Plug J1 current output 22095 Figure 8 1 Test equipment connections for calibrating current proportional output 194 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Output Calibration Current Proportion
218. or Control Loop 1 s N A N A profile SP PROG Enables SP Program prompts ENABLE ENABLE DISABLE RECYCLES Number of Recycles 0 99 SOAK DEV Deviation Value 0 0 99 PROFILE Number of profile to run 1 6 STATE Program State at end DISABL HOLD RECOVERY Program resumes after power ENABLE interruption DISABLE PROG END SP value after last segment LASTSP FSAFE SP RAMP2 Accesses prompts for Control Loop 2 s N A N A profile SP PROG Enables SP Program prompts ENABLE ENABLE DISABLE RECYCLES Number of Recycles 0 99 SOAK DEV Deviation Value 0 0 99 PROFILE Number of profile to run 1 6 STATE Program State at end DISABL HOLD RECOVERY Program resumes after power ENABLE interruption DISABLE PROG END SP value after last segment LASTSP FSAFE 162 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Profiles Set Up Group 6 6 Setpoint Program Profiles Set Up Group Introduction You can configure up to six profiles each profile contains a subset of the 36 segments Each profile starts with a ramp segment and ends with a soak segment Each control loop uses one of these profiles They can use the same profile too The profiles can be synchronized to RUN HOLD together Setpoint program profiles group prompts Table 6 4 lists all the function prompts in the Setpoint Program Profiles setup group and their definition
219. or a and b pull the hub off the motor shaft Replace with the smaller hub shown below Use hub from Honeywell hub kit 30756150 001 Continued 116 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Preparation Step Action 5 e f your chart hub looks like this and requires a smaller hub size then just pull the adapter hub off the chart hub to expose the smaller diameter hub Save the adapter hub for future use Figure 5 1 shows the location of the basic recording components Captive Screw or Lockout Screw and plate 2 Engraved time index Removable chart hub Zero position of pen arm 22087 Figure 5 1 Basic recording components Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 117 May 2013 Operation Start up Set the Chart Time Line Table 5 2 lists the steps required to set the chart time line Table 5 2 Set the chart time line procedure Step Press Action Result 1 Apply power and wait until the recorder runs its power up tests 2 CHART To enable the chart drive function A To drive the chart forward or v To drive the chart backward until current chart time line aligns with engraved time index on the chart plate To increase forward drive speed press and release the key while holding in the W key
220. order Displaying Use the FUNC key to display the individual parameters under each group The functions prompts are listed in the order of their appearance in each group Scrolling To get to a Set Up group prompt more quickly hold the SET UP key in To get to a function prompt more quickly hold the FUNC key in The display will scroll through the parameters ATTENTION The prompting scrolls at a rate of 2 3 seconds when the SET UP or FUNC key is held in Also A V keys will move group prompts forward or backward at a rate twice as fast Changing values When Changing the value of a parameter you can adjust a more significant quickly digit in the upper display by holding in one key A or V and pressing the other A or W at the same time e The adjustment will move one digit to the left e Press the key again and you will move one more digit to the left Restoring to the When you change the value or selection of a parameter while in Set Up mode original value and decide not to enter it press RUN HOLD once the original value or selection will be recalled Exiting Set Up mode To exit Set Up mode press the LOWR DISP key This returns the display to the same state it was in immediately preceding entry into the Set Up mode Timing out from Set If you are in Set Up mode and do not press any keys for one minute the Up mode recorder will time out and revert to the mode and display that was being used prior to entry into Set Up mode
221. order With or Without Control Product Manual May 2013 Tables Table E nction of keys agito ett OU tnter p iut 4 Table 2 1 Operating limits and condensed specifications essere 8 Table 2 2 Procedure to access components cceecceescesscesscesecesecsecseecseeeseeeseeseeeeeeeesseeaeceseeseceeecseecseeeseseneeneeeneeeas 14 Table 2 3 Mounting flush in a new panel cutout sees enne nennen 18 Table 2 4 Reference data for mounting DR4500A in existing panel cutouts 19 Table 2 5 Mounting flush in a panel using universal filler kit enne 20 Table 2 6 Mounting flush in a panel using Kent Model 105M cutout eesssssseeeeeeneeereeenen enne 21 Table 2 7 Procedure for Mounting Recorder with NEMAAX Door 22 Table 2 8 Pipe Mounting Procedure esie etcetera tiae estie ede eee a aT i 24 Table 2 9 Mounting flush on a surface of panel or wall sse enne 25 Table 2 10 Permissible wiring enne nennen nennen 28 Table 2 11 line power wiring iet erede er te edente e ee HE Tei eee see e HL RE RT Res 31 Table 2 12 Thermocouple RTD Radiamatic mV or 0 5 Vdc input wiring 33 Table 2 13 4 20 mA put wirIfig os e Rete SuSE e ER RSS EET NGA CAISSE RU ES EE e RI E EAE RR URS 35 Table 2 14 0 10 Volt de W
222. otal value ATTENTION When two totalizers are configured notice that channels 1 and Z2 totalizer values are alternately displayed 2 Display Channel 1 V Until CHN 1 indicator lights totalizer Upper Display 1tPV VALUE Lower Display total value 8 digits maximum 3 Display Channel 2 Aor V Until CHN 2 indicator lights totalizer Upper Display 2tPV VALUE Lower Display total value 8 digits maximum 4 Return to Alternating and V You will see Display simultaneously Upper Display SCAN Lower Display total value 8 digits maximum After the keys are released the upper display alternately shows 1 2 PV values while lower display shows 1 2 totalization values 5 Return to Normal PV LOWR Returns to normal PV display Display DISP Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 145 May 2013 Operation Monitoring the External Event Operation 5 14 Monitoring the External Event Operation Event pen function If Function prompt PEN 1IN under Set up prompt PEN 1 has been configured as DGTL1 or DGTL2 the pen channel operates as an event pen and tracks the remote contact switch closure by way of the digital 1 or digital 2 input wired to the alarm output digital input printed circuit board Event pen operation When the switch opens the pen for the channel tracks at the configured OFF posit
223. ou 9 watts max courant CONDITIONS AMBIANTES Ne jamais utiliser cet quipement en pr sence de liquides ou vapeurs inflammables L utilisation de tout instrument lectrique dans un tel environnement pourrait pr senter un risque pour la s curit Temp rature Ambiante 15 55 C Humidit 10 90 HR Vibration Fr quence 0 70 Hz Acc l ration 0 1 g INSTALLATION DE L EQUIPEMENT Cet appareil doit tre mont dans un panneau pour limiter l acc s aux bornes arri res par l op rateur Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 237 May 2013 SICHERHEITSHINWEISE GE21 6057 Befolgen Sie alle Sicherheitshinweise in diesen Unterlagen um das Risiko eines Stromschlags zu verringern der zu K rperverletzung f hren kann Dieses Symbol warnt den Benutzer vor eventueller Ber hrungsgefahr wo lebensgef hrliche Spannungen zug nglich sein k nnen Sch tzende Erdung F r den Anschluf der sch tzenden Erdung der Versorgungssystemleitung Dp e Bei Benutzung der Ausr stungen auf nicht vom Hersteller angegebene Art und Weise kann der von der Ausr stung gewahrleistete Schutz beeintr chtigt werden e Ersetzen Sie keine Komponente oder Teil die das nicht ausdr cklich vom Lieferanten als ersetzbar angegeben ist e Die gesamte Verkabelung mu den rtlichen Normen entsprechen und von zugelassenem erfahrenem Personal durchgef hrt werden e Die Erde mu
224. our particular thermocouple from the 100 value For example for a Type J Thermocouple and input temperature of 68 F From 50 059 mV Subtract 1 019 mV To yield 49 040 mV Type J 1600 F Type J 68 F calibrator output for INn SPAN Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 191 Input Calibration Calibration Procedure Step Operation Press Action Result 4 Check the Cold Junction FUNC The calculations for zero and span are now stored and Temperature you will see WARNING Upper Display The cold junction temperature at The the rear terminals accuracy of the recorder is directly affected by the Lower Display C J TEMP accuracy of this value Change this value only if e The value in the upper display is in the tenths of a the zero and span degree It is the current reading of the temperature calibration procedures did as measured at the thermocouple terminals not bring the recorder that is at J2 and recognized by the recorder ithin th ified e When using the Ice Bath method this value should be the terminal ambient temperature You can change this value if it is in error using the A or Y key 5 Exit the Calibration Mode LOWR The recorder stores the calibration constants and exit DISP calibration mode or SET UP 192 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manu
225. p and connect the calibrator to the input plug for the applicable input circuit board in your recorder according to the particular input sensor being used Refer to the following figures for corresponding set up diagrams Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Thermocouple inputs using an ice bath Thermocouple inputs using a compensated calibrator Thermocouple inputs using the ambient temperature method RTD Resistance Thermometer Device inputs Radiamatic mV and Volts except 0 10 Volts inputs 0 10 Volts input 4 20 mA inputs Route leads for example copper leads or thermocouple extension wires through a conduit hole in the recorder case so that you will be able to close the chart plate Close the chart plate after you have completed the applicable calibration set up 182 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Input Calibration Calibration Set Up and Wiring for PV Inputs Thermocouple inputs using an ice bath Refer to Figure 7 3 and wire the recorder according to the procedure given in Table 7 6 Table 7 6 Set up wiring procedure for Thermocouple inputs using an ice bath Step Action 1 Connect the copper leads to the calibration source see Figure 7 3 2 Connect a length of thermocouple extension wire to the end of each copper lead and insert the junction points
226. parameter prompts cccccsceeseessceseceseesecenecseecseecaeeeeeeeeeseceseenseeeseseesaeenseenseenaeenaes 125 Table 5 8 Efr r messages i accetta ue ROSE TER CUBE NER noes eee tie E We qe CEPR EG 126 Table 5 9 Alarm and tuning messages 127 Table 5 10 Operating mode definitions esses ener nn nennen nnne 129 Table 5 11 Changing operating modes sesssssssssssesseseeeeeenne ener nnne enne 129 Table 5 12 Procedure for selecting automatic or manual mode sse 130 Table 5 13 Procedure for selecting the setpoint 131 Table 5 14 Procedure for changing the local nennen 131 Table 5 15 Procedure for switching between setpoints 132 Table 5 16 Setpoint selection indication essssssssessessesees 132 Table 5 17 Procedure for configuring a single setpoint ramp sse eene 133 Table 5 18 Procedure for running a setpoint ramp eene 134 Table 5 19 Procedure for selecting two sets of tuning constants 136 Table 5 20 Procedure for setting switchover 1 2 137 Table 5 21 Procedure for setting tuning constant values sssssssssseseeseeeeeeenee nennen ene
227. priority Requirements for operation of relay by segment event 1 13 Timer function Do not configure Timer 14 Alarm 1 e Configure Alarm 1 type Event 2 Alarm 2 Configure Alarm 2 type Event 3 15 Controller 1 output algorithms Relay Simplex e Do not configure Controller Position Proportional Relay Duplex 1 with these output Current Relay Duplex algorithms 16 Alarm 3 e Configure Alarm type Event 4 17 Controller 1 output algorithms Position Do not configure Controller Proportional Relay Duplex Current Relay 1 with these output Duplex algorithms 18 Alarm 4 e Configure Alarm 4 type Event 5 19 Controller 2 output algorithms Relay Simplex Do not configure Controller Position Proportional Relay Duplex 2 with these output Current Relay Duplex algorithms 20 Alarm 5 e Configure Alarm 5 type Event 6 21 Controller 2 output algorithms Position Do not configure Controller Proportional Relay Duplex Current Relay Duplex 22 Alarm 6 2 with these output algorithms Configure Alarm 6 type Event Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 169 Setpoint Ramp Soak Programming and Operation Setpoint Program Event Set Up Group Setpoint program event worksheet Use this worksheet to make a record of the segment event settings
228. pts Table 3 13 lists all the function prompts in the Auxiliary Output Set Up group Table 3 13 Auxiliary output group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting AUX OUT 1 Auxiliary Output DISABL SP 1 DISABL Representation IN 1 PV2 IN 2 DEV 2 PV 1 OUT 2 DEV 1 SP 2 OUT 1 4 mA VAL Low Scaling Factor Low scale value to represent 4 mA 0 0 20mA VAL High Scaling Factor High scale value to represent 20 mA 100 0 Repeat this procedure for AUX OUT 2 and AUX OUT 3 74 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Modbus Communications Set Up Group 3 16 Modbus Communications Set Up Group Introduction This data deals with the Communications option that is available with your recorder This option allows the recorder to be connected to a host computer via the Modbus protocol If your recorder does not have this option the prompts will not appear n ATTENTION Refer to Documents 51 52 25 66 and 51 52 25 69 for a complete description of the RS485 Modbus Communications Option Function prompts Table 3 14 lists all the function prompts in the Modbus Communications Set Up group Table 3 14 Modbus communications group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting ComSTATE Mod
229. puts E Customer Calibration 1 0 Tag External Interface 7 Product Configuration Software Options 0 None A Totalization Input 1 B Math Only E Totalization Inputs 1 amp 2 Figure 2 1 Model number interpretation Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 13 May 2013 Installation Model Number Interpretation Example of model number decoding Assume that the model number on the label is DR45A2 1300 10 001 A IKNOTO 0 Using the table code definitions from Figure 2 1 this recorder has the following features and options e 2 input type with thermocouple RTD Radiamatic mV 0 5 Vdc or 4 20 mA input for channel 1 e 0 10 Vdc input for channel 2 e One controller output e Alarm output digital input capability e Totalization for input 1 e Gray door with acrylic window e Door lock e No approvals e Chart illumination e Customer LD tag Location of hardware components 14 After you decode your recorder s model number refer to Figure 2 2 to match table selections with the location of actual recorder hardware components This will help you to determine applicable input output wiring requirements as well as identify appropriate software functions to be configured later To access and view the actual components inside your recorder follow the procedure in Table 2 2 Table 2 2 Procedure to access component
230. r Definition Prompt Range of Setting or Selection PROP BD2 0 1 to 100096 PROPORTIONAL BAND 2 or GAIN 2 RATE 2 and or or RESET 2 parameters are the same as previously GAIN 2 0 1 to 1000 described for Heat except that they refer to the cool 7 zone tuning constants duplex models or the second RATE2MIN 0 08 to 10 00 minutes set of PID constants whichever is pertinent 0 08 or less OFF RSET2MIN 0 02 to 50 00 RSET2RPM CYC SEC 1 to 120 seconds CYCLE TIME HEAT determines the length of one time proportional output relay cycle Defined as HEAT cycle time for Heat Cool applications e Electromechanical relays CYC2 SEC 1 to 120 seconds CYCLE TIME 2 COOL is the same as above except it applies to Duplex models as the cycle time in the COOL zone of Heat Cool applications or for second set of PID constants e Electromechanical relays 102 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Setpoint Ramp Set Up Group 4 8 Setpoint Ramp Set Up Group Introduction The Setpoint Ramp 1 and 2 Set Up groups contain the Function parameters that enable you to configure two setpoints Each setpoint SP RAMP 1 and SP RAMP 2 can be configured only one of three ways ramp rate or setpoint program Single Setpoint Ramp Setpoint will ramp between the current local setpoint and a final setpoint over a time interval of up to 255 minutes SP RAMP Setpoin
231. r and allow the recorder to warm up for one hour before you calibrate e Please read Set Up Wiring before beginning the procedure e Make sure LOCKOUT is set to NONE see Section 3 Configuration The calibration procedure for inputs 1 and 2 are identical The displays indicate the input number CAUTION For milliampere inputs be sure the current source is at zero before switching on the calibrator Do not switch the calibrator on off while it is connected to the recorder s input n ATTENTION For linear inputs avoid step changes in input signal Vary calibration source signal smoothly from initial value to final 10096 value Calibration procedure sequence The calibration procedure sequence for all inputs is listed in Table 7 13 Table 7 13 Calibration procedure sequence Step Operation Press Action Result 1 Enter Calibration Mode SET Until you see UP Upper Display CALIB Lower Display INPUT n n 10r2 FUNC You will see Upper Display DISABL Lower Display CAL INn n 10r2 A The calibration sequence is enabled and you will see Upper Display BEGIN Lower Display CAL INn 2 Calibrate 0 FUNC You will see Upper Display APPLY Lower Display INn ZERO 1 2 e Adjust your calibration device to an output signal equal to the 096 range value for your particular input sensor see Table 7 2 for Voltage or Resistance equivalents e Wait 30 seconds then go to
232. r enne 137 Table 5 22 Procedure for switching PID sets from the keyboard sse 138 Table 5 23 Procedure for starting Accutune II enne 139 Table 5 24 Procedure for using Accutune for duplex control essen 140 Table 5 25 Procedure for displaying or changing the alarm setpoints essere 142 Table 5 26 Digital input option action on contact 1 143 Table 5 27 Procedure for resetting the totalizer sss eee 144 Table 5 28 Procedure for displaying the totalizer value essen enne 145 Table 5 29 Maximizing pen life menn iie eene rie ER E e Ree oleo Ee 146 Table 5 30 Changing the ink cartridge sese ener enne nnne enne 147 Table 5 31 Replacing chart lamp eee eet tee ee dee eee eee ee redeo Renee 147 Table 6 1 Parameter settings for example 12 step profile sssssssssseseeeseeeeeeeeneennenerenennen rennen 155 Table 6 2 Setpoint program data entry procedure enne enne enne 159 Table 6 3 SP RAMP prompts and available selections eese enne 161 Table 6 4 Setpoint program profiles group definitions essere ene 163 Table 6 5 Setpoint program segments group 165 Table 6 6 Setpoint program event group definitions esses eene enne 168
233. r the DR4500A Classic Recorder 9 position keyboard cable TABLE 1 No T1 of Destination Leads Cond Board Control Output 1 Control Output 2 Auxiliary Output Modbus RS485 No PURPLE 2 Communications Connection Auxiliary Output Modbus RS485 Communications Processor Card Conn Designation on Destinaton Bd Display board Chart motor 2 wire light Main transformer Female Conn GRN WHT BLK RED Chart Plate Dual Connector L Te T1 See Table 1 for connections 2 wire pair Processor card Jig 1 34 cond ribbon cable Alarm digital inputs jo Ground Control Output 1 Control Output 2 22819 2 wire gray pair Main transformer Figure 10 6 Internal diagram for DR4500A Classic recorder options only Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 231 May 2013 Parts List Internal Wiring Diagram Options Only 232 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 A Foreign Language Safety Instructions Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 233 SIKKERHESKRAV DA21 6057 For at undg elektrisk st d med mulighed for personskade skal alle sikkerhedsbestemmelser i denne manual felges noje Dette symbol advarer brugeren om en poten
234. r to subsection 8 4 Auxiliary Output Calibration TIP The 4 20 mA output on the control output board can also be set up for an Auxiliary retransmission output if it is not being used for a control output This requires model selection option Table Il 10 60 66 TIP Auxiliary output 2 and Auxiliary output 3 use Control current output 1 and Control current output 2 if Control OUT ALG is not set to CURRENT 52 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Option Wiring Procedures Auxiliary Output Modbus Comm Printed Wiring Board D EP p eH Ferrite Filter Fair Rite P N 0443164151 or equivalent Required for CE Mark Conformity Kit Part No 51197612 502 contains two ferrite filters Part No 51197612 508 contains 8 ferrite filters Install inside of case See Figure 2 11 Capacitor Kit 51197755 001 Install capacitors as shown in figure 4 20 mA auxiliary Controller load 0 1000 ohms Figure 2 22 4 20 mA auxiliary output wiring n ATTENTION Refer to Figure 2 16 for Auxiliary Output 2 and Auxiliary Output 3 wiring Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 53 May 2013 Installation Lockout Switch Configuration 2 9 Lockout Switch Configuration Introduction The configuration can be locked using S1 switch located nex
235. rder With or Without Control Product Manual 87 Configuration Parameter Definitions Chart Parameters Set Up Group 4 4 Chart Parameters Set Up Group Introduction The functions listed in this group deal with how the chart will be set up CAUTION Before making any configuration changes to the Chart Set Up group place the recorder in Chart Hold Press the CHART key to stop the chart rotation Press again after configuration entry is made Chart group prompts Table 4 3 lists all the function prompts in the chart parameters setup group and their definitions Table 4 3 Chart parameters group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection CHRTSPD CHART SPEED This is the time it will take to drive the chart one complete revolution 8HR 8 Hour revolution 12HR 12 Hour revolution 24HR 24 Hour revolution 7DAYS 7 Day revolution XHR X hour revolution make Hours per Revolution selection at prompt HOUR REV HOUR REV 1 to 744 Hours HOURS PER REVOLUTION Set the desired chart speed Appears only if XHR was selected at prompt CHRT SPD LINEARIZ LINEAR LINEARIZATION NONLIN 88 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Total Parameters Set Up Group 4 5 Total Parameters Set Up Group Introduction The functions listed i
236. re for selecting automatic or manual mode Step Operation Press Action Result 1 Selecting automatic MAN Until A indicator is ON mode AUTO The recorder regulates its output to maintain the PV at the desired setpoint Upper Display shows the PV value Lower Display shows SP and the setpoint value The deviation bargraph indicates the PV deviation from the setpoint 2 Selecting manual mode MAN Until MAN indicator is ON AUTO The recorder holds its output at the last value used during automatic operation and stops adjusting the output for changes in setpoint or process variable Upper Display shows the PV value Lower Display shows OUT and the output value in 96 The deviation bargraph indicates the PV deviation from the setpoint 3 Adjust the output in V Adjust the output value while in manual mode manual mode Upper Display shows the PV value Lower Display shows OUT and the output value in 96 4 Return to automatic MAN A indicator appears indicating automatic mode mode AUTO 130 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Setpoints 5 7 Setpoints Introduction You can configure the following setpoints for the DR4500A recorder e A single local setpoint e 2 local setpoints A local setpoint and a remote setpoint These setpoints can be toggled by the FUNC key Selecting the setpoint source Use the procedure in Table 5 13 to select
237. recorder case as shown in Figure 2 10 Using 1 4 20 x 1 2 inch hex screws and lockwashers attach a mounting bracket to each side of the case Leave the screws slightly loose so as to permit some adjustments of the brackets On the panel mark the locations for the three holes as shown by the hole pattern in Figure 2 10 Using a drill of appropriate size for user supplied screws drill a hole in the front of the panel for the eye of the support hook Insert the screws for the support hook into the panel allowing the screw head to protrude approximately 5 16 inch Hang the recorder support hook on the screw Make sure that the locations for the other two holes marked in step three are correct If not make sure that the recorder is aligned vertically and use the brackets as templates to mark the proper locations Remove the recorder from the panel and drill the other two holes Hang the recorder on the screw by the support hook and insert the other two user supplied screws through the brackets into the panel Tighten the two hex screws that attach the brackets to the case Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 25 Installation Mounting Methods 26 Hole Pattern Reference m NOTE millimeters These screws must be supplied by inches user all other mounting hardware is supplied with recorder 163 32 6 430 Fig
238. recorders are factory calibrated prior to shipment It should not therefore be necessary to recalibrate the recorder when it is initially installed However you must recalibrate the input if any one of the conditions summarized below applies e The thermocouple or RTD input must meet published accuracy rates Note that the factory calibration at reference is 1 2 F plus 10 microvolts for thermocouples or 40 3 ohms for RTDs Specifications 44 45 03 15 e You are using a 0 10 Vdc input Recalibration is necessary because the resistor network used for this input has a tolerance of 1 095 e You have cause to believe that the recorder is out of calibration e You must perform regularly scheduled or periodic recalibration based on your own needs e You have performed specific servicing activities such as replacement of an input PCB n ATTENTION Replacing a main PCB does not normally require recalibration since a new main PCB is already factory calibrated whereas an input PCB is not e You have changed the input type through configuration which results in the loss of the previous field calibration but restores factory calibration See subsection 7 2 Restoring Factory Calibration paragraph that follows Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 175 May 2013 Input Calibration Restoring Factory Calibration What s in this section This section contains the follo
239. red in terms of ramp time or ramp rate depending on how you have configured the RAMPUNIT parameter During a soak segment the setpoint is held at the specified value For each control loop you can build up to 6 profiles using any number of consecutive segments of the program Odd numbered segments are always ramp segments Even numbered segments are always soaks These ramp and soak segments can be used in up to six programs You designate the beginning and end segments to determine where the program will start or stop e Every profile must start with a ramp segment and end on a soak segment e Control Loop must have Setpoint Source set to ILOCAL e Control Loop 1 uses SP RAMPI Control Loop 2 uses SP RAMP2 SP RAMPI and SP RAMP2 are the prompts under which the setpoint program is configured e Recorder must be set to use SP1 setpoint 1 e Only contiguous segments can be used by a profile e There can be overlap between programs For example Profile 1 could use Segments 1 2 3 4 5 and 6 Profile 2 could be configured to begin with Segment 5 and end with Segment 8 This section contains instructions for setting up a setpoint program and for executing the program at runtime Note that Section 4 contains instructions for using the setpoint ramp or setpoint rate The SPRAMP setpoint ramp and SPRATE setpoint rate parameters described in Section 4 must be set to DISABL disabled if a setpoint program is to be used n ATTENTION If
240. rol Product Manual 41 Installation Output Wiring Procedures Control output 111 2 PCB 1w2 Relay No 1 ne w3 W2 contact 4 W3 contact Relay No 2 i4 WA N O contact A iws W5 contact G 4 4 W6 Position i i i Proportional W6i 5 Output W7 22083 Qr T l OPEN Motor s feedback slidewire 1002 Ferrite Filter D 2 to 10002 TL CLOSED ee m Not required for z A D i Three Position A Step Control xe XN M Plug J2 d 0047 uF EZ Capacitor Fair Rite P N 0443164151 __ Cable Shield or equivalent Required for CE Mark Conformity Kit Part No 51197612 502 contains two ferrite filters Part No 51197612 508 contains 8 ferrite filters Install inside of case See Figure 2 11 Capacitor Kit 51197755 001 Install capacitors as shown in figure CCW Motor power supply Siona o H Je 0047 UF R Capacitor iA OPEN CW ER dere Lj EM jos 0 Figure 2 17 Position proportional control output wiring 42 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Output Wiring Procedures Relay control output wiring You can wire control output 1 or 2 for relay output including Time proportional applications The prerequisites are Model Number Table 2 1X or X1 Refer to Figure 2 18 and follow the procedure in Table 2 17 to wire relay contro
241. rol equation See subsection 3 10 Control Set Up Group What happens when you change modes Table 5 11 explains what happens to the recorder when you switch from one mode to another Table 5 11 Changing operating modes Operating Mode Definition Manual to Automatic Local Setpoint The local setpoint is usually the value previously stored as the local setpoint Manual or Auto Local to Automatic Remote SP The second input value with ratio and bias applied is used to calculate the control setpoint Automatic Remote SP to Manual or Auto Local Setpoint If configured for RSP Tracking when the recorder transfers out of remote setpoint the last value of the control setpoint is inserted into the local setpoint If RSP tracking is not configured the local setpoint will not be altered when the transfer is made See subsection 3 10 Control Set Up Group SP TRACK Selecting manual or automatic mode Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 129 Operation Operating Modes An alternate action switch places the recorder in automatic or manual mode of operation e Switching between manual and automatic will be bumpless except when the PD MR algorithm is selected e Table 5 12 includes procedures for selecting automatic or manual mode and changing the output while in manual Table 5 12 Procedu
242. roubleshooting Procedures 9 5 Troubleshooting Procedures Introduction The troubleshooting procedures for the Visual Failure Symptoms are listed in numerical order as they appear in Table 9 5 Each procedure lists what to do 1f you have that particular failure and how to do it or where to find the data needed to accomplish the task Progressive steps provide aid in finding and fixing the problem Equipment needed You will need the following equipment in order to troubleshoot the symptoms listed in the tables that follow DC Milliammeter mAdc e Calibration sources T C mV Volt etc e Voltmeter Table 9 6 Procedure 1 Troubleshooting recorder failure symptoms Step What to do How to do it or where to find the data 1 Check the fuse on the main printed Replace if defective circuit board 2 Check the supply voltage Measure the line voltage across J10 on the Main printed circuit board 3 Check the connections to J10 on the Refer to subsection 2 6 Input Wiring main printed circuit board Procedures Figure 2 12 AC Line Power Wiring 4 Check the transformer leadwire Refer to Figure 10 5 in Section 10 Parts List connections to the main printed circuit board 5 Check the system for brown outs heavy Refer to Section 2 Installation load switching etc and conformance to installation instructions 6 Replace the transformer Disconnect the transformer lead wires from the
243. rt numbers 3 4 14 21454 Figure 10 3 Basic recorder components without options Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 225 May 2013 Parts List Exploded Views Table 10 3 Basic recorder parts without options Recommended Key Part Number Description Spare Parts per Quantity per Unit 10 100 1 30754982 502 Main Transformer 1 3 1 2 51309355 501 Main PCB 1 5 1 3 K 30756141 003 Input PCB input 1 or 2 1 3 4 See Note 2 3 position connector 2 5 See Note 2 2 position connector 1 6 K 30755980 005 Fuse Wilkman 19374 041K 500 ohm or equal 1 7 30754924 502 Case 1 51452182 502 Case NEMA 4 PARTS NOT SHOWN See Note 2 Card guides for Input PCBs 2 51197612 502 Ferrite Filter Package of 2 CE Mark 1 51197755 001 Capacitor Kit 01mfd 12 per kit CE Mark 30755232 502 0 10 Vdc Input Divider input PCBs 30756461 002 250 ohm Resistor Assembly K 30755065 501 Mounting Kit standard 1 K 30755065 502 Mounting Kit Heavy Duty K 30755065 503 Mounting Kit NEMA4X K 30755134 002 Gray Universal Filler Plate Kit K 30755011 001 Filler Panel Kit for replacing Servoline recorder K 30757205 008 Kit to Upgrade Add Totalization to Inputs 1 and 2 for Classic Recorder 5 51197657 502 Panel Mounting Gasket Kit 1 NOTE 2 These parts are included with applicable PCB kits as required
244. ry Prompt prompt Selection Setting Prompt prompt Selection Setting TIMER TIMER DISABL ALARM 5 551 VAL 90 PERIOD 0 01 A5S2 VAL 95 START KEY A5S1TYPE INPUT1 LDISPLAY TREM A5S2TYPE INPUT1 RESET KEY A5S1 HL Lo ON TIME A5S1SCAL 1 INCRMENT MIN A5S2 HL HI A5S2SCAL 1 ALARM 1 A1S1 VAL 90 AL5 HYST 0 1 A1S2 VAL 95 A1S1TYPE INPUT1 ALARM 6 A6S1 VAL 90 A1S2TYPE INPUT1 A6S2 VAL 95 A1S1HL LO A6S1TYPE INPUT1 A1S1SCAL 1 A6S2TYPE INPUT1 A1S2HL HI A6S1HL LO A1S2SCAL 1 A6S1SCAL 1 AL1 HYST 0 1 A6S2 HL HI A6S2SCAL 1 ALARM 2 A281 VAL 90 AL6 HYST 0 1 252 VAL 95 A2S1TYPE INPUT1 AUX OUT AUX OUT DISABL A2S2TYPE INPUT1 4 mA VAL 0 0 A2S1 HL LO 20mA VAL 100 0 A2S1SCAL 1 A2S2 HL HI AUX OUT2 AUX OUT2 DISABL A2S2SCAL 1 4 mA VAL2 0 0 AL2 HYST 0 1 20mA VAL2 100 0 ALARM 3 A3S1 VAL 90 AUX OUT3 AUX OUT3 DISABL A3S2 VAL 95 4 mA VAL3 0 0 A3S1TYPE INPUT1 20mA VAL3 100 0 A3S2TYPE INPUT1 A3S1HL LO COMM ComSTATE DISABL A3S1SCAL 1 Com ADDR 1 A3S2HL HI BAUD 9600 A3S2SCAL 1 XMT DLAY NONE AL3 HYST 0 1 DBL BYTE FPB ALARM 4 451 VAL 90 OPTIONS REJ FREQ 60 452 VAL 95 HF REJ ENABLE A4S1TYPE INPUT1 RELHUMID NO A4S2TYPE INPUT1 ATMPRES RD A4S1 HL LO DEVIATION NONE A4S1SCAL 1 DEVSETPT 0 A4S2 HL HI SCROLL NONE A4S2SCAL 1 GRANDTOT DISABL AL4 HYST 0 1 LOCKOUT LOCKOUT CALIB XXXX 80 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Overview 4 Configuration Parameter Definition
245. s Step Action 1 Turn the latch on the recorder door and swing the door open 2 Loosen the captive screw on the right hand side of the chart plate and swing the chart plate out 3 Reverse the steps to close the chart plate and door DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Mounting Considerations and Overall Dimensions View of hardware components Figure 2 2 shows the location of the actual hardware components for key number DR45A1 or DR45A2 Key Number DR45A1 Key Number DR45A2 Mother PCB for control and Control output 1 PCB Alarm output digital input PCB selected options Table Il 1X 6X Table III XX1 Auxiliary Output PCB Table Ill 1XX or Modbus RS485 Communications PCB Table Ill 3XX or Modbus RS485 Communications Auxiliary Output PCB Table 11 4XX Main processor board common Control Output 2 PCB Table Il X1 X6 Ww Input PCB s Table XX00 0 1 3 Refer Model Selection Guide 22077 Figure 2 2 DR4500A recorder hardware components versus table selections Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 15 May 2013 Installation Mounting Considerations and Overall Dimensions 2 3 Mounting Considerations and Overall Dimensions Physical considerations The recorder can be mounted in a panel
246. s Table 6 4 Setpoint program profiles group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection PRx STRT RAMP1 RAMP 35 You can configure up to 6 profiles PR1 PR6 Each profile contains a subset of the 36 ramp and soak segments configured later PRx STRT designates the number of the first segment of the profile It must be a ramp segment odd number PRx END SOAK2 SOAK36 This designates the number of the last segment of the profile It will be a soak segment even number RAMPUNIT TIME Hours Minutes This determines the engineering units for the ramp segments EU MIN Engineering Units Minute EU HR Engineering Units Hour SYNC 1 2 ENABLE Synchronizes the profiles for Control Loops 1 and 2 DISABL This means that a Both SP programs will RUN or HOLD simultaneously b A Guaranteed Soak Hold on one profile will cause the other profile to HOLD for the duration of the Guaranteed Soak Hold Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 163 May 2013 Setpoint Ramp Soak Programming and Operation Setpoint Program Profiles Set Up Group Setpoint program profiles worksheet Use this worksheet to keep a record of your setpoint program profile settings Prompt Description Range Your selection PROFILES Settings for profiles NA NA PR1 STRT Start Se
247. s 4 1 Overview Introduction This section provides information for all the user configurable control parameters listed in the configuration section If you aren t familiar with these parameters this section gives you the parameter prompt the selection or range of setting that you can make and a definition of how each parameter setting affects recorder performance It will also refer you to any other prompts that might be affected by your selection Parameter groups and prompts The control information is found in three configuration groups which are accessed by the SET UP key e Each of these groups contains prompts viewed in the lower display which deal with functions that are pertinent to that particular group These are accessed by pressing the FUNC key e The selections or values are listed in the upper display Refer to Section 3 Configuration for step by step instructions What s in this section The table below lists the topics that are covered in this section They are listed in the order of their appearance in the recorder Topic See Page 4 1 Overview 81 4 2 Input Parameters Set Up Group 82 4 3 Pen Parameters Set Up Group 86 4 4 Chart Parameters Set Up Group 88 4 5 Total Parameters Set Up Group 89 4 6 Control Parameters Set Up Group 91 4 7 Tuning Parameters Set Up Group 100 4 8 Setpoint Ramp Set Up Group 103 4 9 Timer Set Up Group 105 4 10 Alarms Set Up Group
248. shooting Service Self Diagnostics Lower Test Group Reason for Failure How to Correct the Problem Display Indication INTRNG Background Input out of range The process input 52 Make sure the range and actuation IN2RNG is outside the range limits are configured properly 53 Check the input source 54 Restore the factory calibration c Disconnect the wiring from the terminals on plug J2 on the input board see Figure 2 13 Place a jumper across these terminals The controller should read room temperature if it is configured for a thermocouple input d If it does not read room temperature see Section 3 Configuration and change the prompt the INPUT 1 group to another type of thermocouple e After the change press FUNC key then the LOWR DISP key The controller should read the correct room temperature If it does not the unit has an input failure f Repeat step b This time switch the INTTYP back to the originally selected thermocouple g Repeat step c The controller is restored with factory calibration h Remove the jumper and reconnect the thermocouple to plug J2 55 Field calibrate See Section 7 Input Calibration 56 Replace the input card 57 Call Customer Support 1 800 423 9883 USA and Canada NOTE 1 Will appear in STATUS Set Up Group See procedure for displaying the test results on page 206 NOTE 2 Will also appear in rotation with other b
249. side of the chart plate and open the chart plate 4 Depending on the input 1 or 2 you are going to calibrate remove the wired plug from the input connector J2 on the applicable circuit board See Figure 7 1 for the location of the circuit boards and input connectors 5 Tag and disconnect the field wiring installed in the applicable input connector plug Mother board for options Main board Alarm output digital input board optional J2 on input 1 board 22088 J2 on input 2 board optional Figure 7 1 Location of the input connections on the input boards Equipment needed Table 7 4 lists the equipment required to calibrate the specific types of inputs listed in the table You will need a medium size bladed screwdriver for general use and a small size bladed screwdriver for use with the screws on the connector plugs Table 7 4 Equipment needed Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 179 May 2013 Input Calibration Preliminary Information Type of Input Equipment Needed Thermocouple Inputs A calibrating device with 0 02 accuracy for use as a Ice Bath signal source such as a millivolt source e Thermocouple extension wire that corresponds with the type of thermocouple that will be used with the recorder input e Two insulated copper leads for connecting the thermocouple extension wire from the ice baths to the prec
250. sis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Contents de IY ELON led 1 1 1 On e 1 12 Operator Interfaces lone edo det dee nau he a dee 3 Ads TL asKs nitet theo 5 2 NUTS ah el Da 7 2 T SOVOIVIGW actae exce rtt rte 7 22 Model Number Interpretation sssssssssssseeeeem 13 2 3 Mounting Considerations and Overall Dimensions 16 24 Mounting Methods ditate iin dei ede Hin O 17 2 5 Wiring Prerequisites 2 t ttu b t ttu entres 27 2 6 Input Wiring Procedures innen ettet netten edente ttai 29 2 Output Wiring enm mene 39 2 8 Option Wiring Procedures ineen a EEEE ENE emm enm 45 2 9 Lockout Switch Configuration sssseee eme 54 3 Configuration AAA te At te torto AR Ere ARE rot Rer 55 3 11 Pee udo dede 55 3 2 Configuration Prompts deel in e et er e eed eta er di 56 9 39 HowTo Get Started e 58 3
251. sius EU Engineering Units ENGUNITS ENGINEERING UNITS Make up 5 selections to create unit identifier 0 to 9 AtoZ For example create unit identifier H2O by selecting T an H from A to Z a 2 from 0 to 9 an from A to Z sm e For alphanumeric entries the display will cycle from left to right with highlighting increased brightness of each digit The value of each digit can be changed only when it is highlighted 82 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Input Parameters Set Up Group Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection INn TYPE INPUT ACTUATION TYPE This selection determines what actuation you are going to use for input one Be n 1 or 2 sure that the values configured for high and low chart range soak setpoint alarm setpoint etc are within the measuring range for the selected actuation type BTC B thermocouple 105 to 3300 F 41 to 1815 ETCH E thermocouple high 454 to 1832 F 270 to 1000 C ETCL E thermocouple low 200 to 1100 F 129 to 593 C JTCH J thermocouple high 0 to 1600 F 18 to 871 C JTCL J thermocouple low 20 to 770 F 7 to 410 C KTCH K thermocouple high 320 to 2500 F 196 to 1371 C KTCL K thermocouple low 20 to 1000 F 29 to 538 C NNM TC NNM NiNiMo thermocouple 32 to 2500 F
252. step 3 190 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Input Calibration Calibration Procedure Step Operation Press Action Result cont Using Ambient Temperature Method ATTENTION If you are using the Ambient Temperature method to calibrate a thermocouple input be sure to measure the temperature at the input terminals and subtract the equivalent millivolt value for your particular thermocouple from the 0 value just prior to doing calibration For example for a Type J Thermocouple and input temperature of 68 F From 0 885 mV Subtract 1 019 mV To yield 1 904 mV Type J 0 F Type J 68 F calibrator output for INn ZERO Calibrate 100 FUNC You will see Upper Display APPLY Lower Display INn SPAN 10 2 Adjust your calibration device to an output signal equal to the 100 range value for your particular input sensor see Table 7 2 for voltage or resistance equivalents wait 30 seconds and If Then you are calibrating a Go to thermocouple input step 4 you are calibrating other thana Goto thermocouple input step 5 Using Ambient Temperature Method ATTENTION If you are using the Ambient Temperature method to calibrate a thermocouple input be sure to measure the temperature at the input terminals and subtract the equivalent millivolt value for y
253. sts for the DR4500A Clasic Series Recorder Most parts are supplied on an optimum replacement unit basis that is part numbers are given for complete printed circuit boards rather than for individual PCB components The figures that follow are exploded views of the DR4500A recorder Each part is labeled with a key number and the key numbers are listed in tables with associated part number Also included for your reference are an Internal Cabling drawing Figure 10 5 and an Internal Wiring Diagram Figure 10 6 for options only When ordering parts be sure to specify your recorder s serial and model numbers on nameplate as well as the part identification What s in this section This section contains the following topics Topic See Page 10 1 Overview 221 10 2 Exploded Views 222 Figure 10 1 Door assembly 222 Figure 10 2 Chart plate assembly 223 Figure 10 3 Basic recorder components without options 225 Figure 10 4 Recorder components associated with options 227 10 3 Miscellaneous Hardware Kit Contents 229 10 4 Figure 10 5 Internal Cabling Data 230 10 5 Figure 10 6 Internal Wiring Diagram Options Only 231 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 221 May 2013 Parts List Exploded Views 10 2 Exploded Views Door assembly Figure 10 1 is an exploded view of the Door Assembly Table 10 1 is a list of the associated part numbers Figure 1
254. t 67 May 2013 Foreign Language Safety Instructions SW21 6057 Maintenance 149 Manual calibration mode 199 Manual mode 131 Adjusting output 132 133 161 162 Selecting 132 Manual reset 103 Minutes per repeat 98 Monitoring your recorder 123 Motor traverse time 199 Mounting Overall dimensions 16 Mounting methods 17 2 inch pipe 24 Flush in panel 18 20 Flush in panel 21 Heavy Duty door 22 Surface 25 ON OFF algorithm 98 Operating limits 8 Operating modes 131 Operating parameters 127 Operator functions 130 Operator interface 3 123 Output algorithm 68 100 Output wiring for alarms 3 and 4 47 Output wiring for alarms 5 and 6 48 P Parts lists 223 PD with manual reset 99 Pen Set Up group 64 tip 149 Physical considerations 16 PIDA 99 PID B 99 PID sets 140 Pipe mounting 24 Position proportional control output wiring 41 Position proportional output calibration 198 Position proportional simplex 100 Power supply mains 30 Power up controller mode recall 67 95 Power up diagnostic tests 120 Power up tests 207 Prompt hierarchy 56 Proportional band 103 Proportional band 2 104 Proportional band units 97 R Radiamatic millivolts and volts inputs except 0 10 Volts 189 Ramp soak program 106 Rate 2 104 Rate action 103 Rate of integration 66 92 Ratio 94 Ratio for remote setpoint 67 Recorder components associated with op
255. t Rate The Setpoint Ramp Set Up group also contains the function parameters that let you configure a specific rate of change for any local setpoint change SP RATE It includes selections for Rate Up and Rate Down Setpoint Program Also included under this group are prompts for configuring a 36 segment Setpoint program SP PROG The prompts and instructions for Setpoint programming are presented in the Section 6 Setpoint Ramp Soak Programming Option e You can start and stop ramp program using the RUN HOLD key Setpoint Ramp Program group prompts Table 4 7 lists all the function prompts in the Setpoint Ramp 1 or 2 setup group and their definitions When you enable the ramp type SP RAMP SP RATE SP PROG the other two types are hidden from the display Table 4 7 Setpoint Ramp 1 or 2 group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection SP RAMP SINGLE SETPOINT RAMP Make selection to enable or disable the setpoint ramp function Make sure you configure a ramp time and a final setpoint value SP PROG and SP RATE must be disabled ENABLE ENABLE SETPOINT RAMP Allows you to start the setpoint ramp in automatic mode DISABL DISABLE SETPOINT RAMP Disables the setpoint ramp Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 103 May 2013 Configuration Parameter Definitions Setpoint Ramp S
256. t Up group title is being displayed in the lower display Lower Display INPUT 1 This is the first Set Up group title Select any Set Up group SET UP e Successive presses of the SET UP key will sequentially display the other Set Up group titles shown in the prompt hierarchy in Figure 3 1 e You can also use the A V keys to scan the Set Up groups in both directions e Stop at the Set Up group title which describes the group of parameters you want to configure Then proceed to the next step Select a Function parameter FUNC Upper Display Shows the current value or selection for the first function prompt of the particular Set Up group that you have selected EXAMPLE ENABLE DISABLE Lower Display Depends on what is selected in Set Up group Shows the first function prompt within that Set Up group EXAMPLE INPUT 1 Select other Function parameters FUNC e Successive presses of the FUNC key will sequentially display the other function prompts of the Set Up group you have selected e Stop at the function prompt that you want to change then proceed to the next step 60 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Configuration Procedure Step Operation Press Result 5 Change the value or A v e These keys increment or decrement the value or selection selection that appears for th
257. t to the microprocessor U17 on the main printed circuit board Restrictions based on lockout switch position Figure 2 23 shows the location of the S1 lockout switch on the main printed circuit board When the lockout switch is OFF Down Configure e You can view and change all applicable operating parameters as described in Section 4 Configuration Parameter Definitions When the lockout switch is ON Up Locked e Most parameters for the recorder are locked and the parameters may not be changed except for Tuning 1 and Tuning 2 parameters Main Printed Wiring Board Right Side S1 Lockout Switch UP ON Locked DOWN OFF Configure 22709 Figure 2 23 S1 lockout switch location n ATTENTION Lockout can also be configured under set up group LOCKOUT See Subsection 3 18 This feature also includes the special screw and plate that provide the lead seal capability for sealing the chart plate 54 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 3 Configuration 3 1 Overview Introduction Configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish configure pertinent control data best suited for your application What s in this section The table below lists the topics that are covered in this section Topic See Page 3 1 Overview 55 3 2 Confi
258. the go to step 5 PV moves in either direction Observe OUT 1 or 2 indicator on the front display 4 Check the control relay jumper positions Refer to Section 3 Configuration 5 Check the current proportional output Put the recorder in manual mode and manually adjust the output from 0 to 10096 4 20 mA Use a milliammeter across the terminals in connector J1 on the control output printed circuit board to verify the output 6 Recalibrate the current output Refer to Section 8 Output Calibration 7 Replace the control output printed circuit Refer to the instructions included with the board replacement part DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Troubleshooting Procedures Table 9 16 Procedure 11 Troubleshooting the auxiliary output Step What to do How to do it or where to find the data 1 Be sure the controller is configured for Refer to Subsection 3 15 Auxiliary Output Set Auxiliary Output Up Group Make sure AUX OUT is enabled and the correct parameter is chosen Check the High and Low Scale values 2 Check the field wiring Refer to Section 2 Installation 3 Check the output Use a milliammeter at connection J2 on the Auxiliary Output printed circuit board to determine the correct output based on your representation of 4 mA and 20 mA 4 Recalibrate the Auxiliary Output Refer to Subs
259. the back of the recorder case ATTENTION If the panel is more than 1 4 inch thick substitute 10 32 x 1 2 inch long screws for the 3 8 inch long screws supplied with the recorder 2 While supporting the recorder insert it through the panel cutout and orient the case so that the threaded inserts at the bottom of the case align with the holes drilled in the panel 3 From the rear of the panel insert two 10 32 pan head screws of appropriate length into threaded inserts in the recorder case 4 From the back of the panel attach a mounting bracket to each side of the recorder case using a 1 4 20 x 1 2 inch hex screw and a lockwasher for each bracket mounting hardware supplied with recorder Leave the screws slightly loose so you can adjust the brackets 5 While holding the recorder firmly against the panel slide each bracket against the back of the panel and tighten the screws Cutout for Kent model 105M 7 Drill two 3 1 2 1 4 inch holes 21408 Figure 2 7 Mounting in a panel using Kent Model 105M cutout Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 21 May 2013 Installation Mounting Methods Panel mounting recorder with NEMA4X door Refer to Figure 2 8 and follow the procedure in Table 2 7 to panel mount your recorder if it has a NEMAAX door Table 2 7 Procedure for Mounting Recorder with NEMA4X Door Step Action Place the pane
260. the printed circuit boards before removing it Position the jumpers as shown for the desired relay contact action and reinstall the printed circuit board 5 Run the Alarm output wires through the desired knockout 6 For CE Mark conformity e Install the ferrite filter as shown in Figure 2 11 e Install the capacitors as shown in Figure 2 20 7 Strip insulation from the end of each wire 8 Loosen the screws in plug J5 terminals and position the plug as you would to plug it into J5 9 Insert the wires for the alarm devices into the appropriate screw clamps as shown Refer to Figure 2 20 Tighten the screws to secure the wires 10 Install the wired plug into J5 48 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Option Wiring Procedures Wiring for alarm outputs 3 4 5 and 6 Cable Shiel External Load and no 3 amp 4 alarm outputs PCB Al No 3 Ferrite filter W2 NO contact j _ Power Supply W3 N C contact LL A Alarm 3 Alarm No 4 Relay Load W4 N O contact W5 contact Agi 4 bo r 1W2 Baan 2j WP 4 20 mA control output Plug J5 p L 0047 HF Capacitor Fair Rite P N 0443164151 or equivalent Required for CE Mark Conformity Kit Part No 51197612 502 contains two ferrite filters Part No 51197612 508 contains 8 ferrite filters Install inside o
261. tiel bereringsfare s fremt der kan v re adgang til den livsfarlige netspzending Beskyttende jordterminal Terminalen er forberedt for og skal forbindes til beskyttelses jordledning i henhold til steerkstromsberkendtgorelsen DK Om e Hvis udstyret ikke bruges som specificeret i manualen kan den beskyttelse udstyret yder blive nedsat eller forsvinde Eerstat kun komponenter som udtrykkeligt er specificeret som udskiftelige 1i manualen e Alle ledningsforbindelser skal f lge st rkstr msberkendtg relsen DK og udf res af autoriseret erfarent personel e Den beskyttende jordterminal skal forbindes f rst af alle forbindelser og fjernes som den sidste e Det anbefales jvf st rkstr msberkendtg relsen at der installeres en afbryder til frosyningssp ndingen n r udstyret UDSTYRS SPECIFIKATIONER Str mforsyning 102 til 132 Vac 204 til 264 Vac Frekvens 49 til 51 Hz 59 til 61 Hz Nominel effekt 9 watts max OMGIVELSES SPECIFIKATIONER Placer ikke udstyret i n rheden af brandbare v sker eller dampe Temperatur Rumtemperatur 15 til 55 C Fugtighed 10 til 90 RH Vibration 0 til 70 Hz acceleration 0 1 g UDSTYRS INSTALLATION Skriveren skal monteres i en tavle for at forhindre adgang til bagterminaler 234 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Foreign Language Safety Instructions DU21 6057 VEILIGHEIDSVEREISTEN DU21 6057
262. tion CURRENT 2 Check the field wiring Refer to Section 2 Installation 3 Be sure all the recorder and control Refer to Section 3 Configuration related data is correct Check the tuning algorithm and control data 4 Check the output Put the recorder into Manual Mode and raise lower the output manually from 096 to 10096 4 20 mA Use a milliammeter at connection J1 on the control output printed circuit board 5 Recalibrate the current proportional Refer to Section 8 Output Calibration output 6 Replace the control output printed circuit Refer to the instructions included with the board replacement part Table 9 13 Procedure 8 Troubleshooting position proportional output failure symptoms Step What to do How to do it or where to find the data 1 Be sure the recorder is configured for Refer to Section 3 Configuration Make sure position proportional output OUT ALG selection POSITN 2 Check the field wiring Refer to Section 2 Installation 3 Check the output Put the recorder into manual mode and adjust the output manually to drive the motor from 096 to 100 4 Check whether the motor drives in both Refer to Section 8 Output Calibration for motor directions If it does go to step 5 If the slidewire calibration Refer to the motor motor drives in one direction only check instructions the slidewire If the motor does not drive in either direction check the motor 5 Check t
263. tion in the worksheets that follow in the next sections This will give you a permanent record of your program and will assist you when entering the ramp and soak values Profile 1 Profile 2 Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 156 Setpoint Ramp Soak Programming and Operation Drawing a Ramp Soak Profile Profile 3 Profile 4 157 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Drawing a Ramp Soak Profile Profile 5 N A o o Profile 6 158 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Setpoint Ramp Soak Programming and Operation Entering the Setpoint Program Data 6 4 Entering the Setpoint Program Data Introduction The procedure listed in Table 6 2 tells you what keys to press and what prompts you will see when entering the setpoint program data Follow the prompts in Sections 6 5 6 6 and 6 7 when selecting the functions for setpoint programming n ATTENTION Make sure SP RAMP and SP RATE are disabled first Table 6 2 Setpoint program data entry procedure Step Operation Press Action Result 1 Select SP PROG Group SET Until you see UP Upper Display SET UP Lower Display SP RAMPn 1 2 2 Access SP PROG FUNC U
264. tions 229 RECYCL parameter 163 Rejection frequency 73 76 114 Relative humidity 76 114 Relay control output wiring 43 Relay duplex 100 Relay current duplex 101 Remote setpoint 94 Remote switching 145 Repeats per minute 98 Replace the chart 118 Replacing chart 150 Reset 103 Reset 2 104 Reset units 68 98 Resetting totalizer value 146 Resistance equivalent 180 Restoring factory calibration 178 Reverse acting control 96 RS485 Modbus communications wiring 50 RSP 134 RTD inputs 188 S Safety Requirements for Electrical Equipment 27 Self diagnostics 205 Setpoint high limit 95 Setpoint low limit 96 Setpoint Program Data entry 161 event setup 170 overview 151 ramp setup 163 run monitor functions 174 segment setup 165 167 Setpoint ramp 105 Configuring 135 Running 136 Setpoint ramp final setpoint 106 Setpoint ramp time 106 Setpoint selection indication 134 Setpoint source 67 94 133 Setpoint tracking 67 95 Set up tasks 5 Shield wiring 29 Single setpoint ramp 105 135 SOKDEV parameter 163 Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 247 May 2013 SPPROG parameter 163 Start up 122 Stylus 122 Support and Contact Information iv Suppression filters 29 Switchover value 138 T Telephone and Email Contacts iv Temperature units 62 84 Thermocouple inputs using a compensated calibrator
265. tions Timer Set Up Group 4 9 Timer Set Up Group Introduction The Timer gives a countdown or elapsed time after which Relay 1 energizes If Timer 1s enabled it has exclusive control over Relay 1 that is Alarm 1 will not control the relay Timer group prompts Table 4 8 lists all the function prompts in the Timer setup group and their definitions Table 4 8 Timer group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection TIMER ENABLE Lets you enable or disable the timer option DISABL PERIOD 0 00 to 99 59 Configures the length of the timeout period from 0 to 99 hours 59 minutes START RH KEY Selects whether the Timer starts with the keyboard ALARM 2 Run Hold key or Alarm 2 The Timer can also be started by a discrete input REM SW or REM SW2 These prompts are found under the Control Set Up Group LDISPLAY Select whether time remaining TREM or elapsed time ET is displayed for the timer option The time is shown on the lower display in hh mm format along with a rotating clock character TREM Time remaining If the clock rotation is clockwise elapsed time is indicated OF 00 ET Elased time If the clock rotation is counterclockwise time left is indicated TH L1 00 RESET RH KEY Selects whether the Timer resets with the keyboard ALARM 1 Run Hold key or Alarm 1 REPEAT In Repeat Mode the timer restarts immediately upon timeout and a
266. to ensure that the proper selections for PROP BD or GAIN RATE MIN and RSET MIN or RSET RPM have been entered 120 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Operation Monitoring Your Recorder Step Description Press Action 5 Enter the local setpoint LOWR Until you see DISP Upper Display shows the PV value Lower Display SP and the local setpoint value Aor V Adjust the local setpoint to the value at which you want the process variable maintained The local setpoint cannot be changed if the Setpoint Ramp function is enabled or appears in the upper display 6 Select automatic mode MAN Until A indicator is ON AUTO The recorder is in Automatic mode The recorder will automatically adjust the output to maintain the process variable at setpoint as tracked by the pen trace if the recorder is properly tuned 7 Start up Controller 2 LOWR Until 2 is lit when OUT is displayed DISP For recorders with two controllers both enabled repeat steps 2 6 for controller 2 but be sure CHN 2 indicator is lit instead of CHN 1 8 Exit Start up Close the door and monitor the operation 5 4 Monitoring Your Recorder Introduction Besides the historical chart record you can monitor the recorder s indicators and displays to get an instantaneous view of various process conditions and of th
267. to 100 0 is configurable for each alarm Priority of functions that operate relays 72 During alarm conditions an alarm will deenergize its associated relay unless a higher priority function has been configured for that relay See Table 3 11 If you want the alarm to control the relay do not configure a higher priority function Table 3 11 Priority of functions that operate relays Relay Relay is controlled by in order of priority 1 1 Timer function 2 Alarm 1 2 Alarm 2 only 3 Controller 1 output algorithms Relay Simplex Position Proportional Relay Duplex Current Relay Duplex 2 Alarm 3 4 1 Controller 1 output algorithms Position Proportional Relay Duplex Current Relay Duplex 2 Alarm4 5 1 Controller 2 output algorithms Relay Simplex Position Proportional Relay Duplex Current Relay Duplex 2 Alarm 5 6 1 Controller 2 output algorithms Position Proportional Relay Duplex Current Relay Duplex 2 Alarm 6 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Alarms Set Up Group Function prompts Table 3 12 lists all the function prompts in the Alarms Set Up group Table 3 12 Alarms group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting AxS1 VAL Alarm 1 Setpoint 1 Value Value in engineering units 90 AxS2 VAL Alarm 1 Setp
268. to 25 0 0 to 25 0 0 5 to 5 0 DEADBAND is an adjustable gap between the operating ranges of output 1 and output 2 in which neither output operates positive value or both outputs operate negative value It is the difference between the nominal trip points of relay 1 and relay 2 Time Duplex On Off Duplex Position Proportional OUT HYST 0 0 to 5 0 of PV span HYSTERESIS OUTPUT RELAY ONLY is an adjustable overlap of the ON OFF states of each control output This is the difference between the value of the process variable at which the control outputs energize and the value at which they de energize Only applicable for ON OFF control FAILSAFE 0 to 100 FAILSAFE OUTPUT VALUE the output level used when you have communications SHED or when NO BURNOUT is configured and input 1 fails The Local Setpoint will automatically adjust itself to be within the setpoint limit range For example if SP 1500 and the SP HILIM is changed to 1200 the new Local Setpoint will be 1200 94 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Control Parameters Set Up Group Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection REM SW REMOTE SWITCHING DIGITAL INPUT contact REM SW2 closure enables one of the following NO
269. to Figure 2 12 and follow the procedure in Table 2 11 to connect the AC line power WARNING Be sure that the line voltage is OFF before connecting the power wires to the recorder or personal injury could result This equipment is suitable for connection to 120 240 Vac 50 60 Hz power supply mains It is the user s responsibility to provide a switch and non time delay North America quick acting high breaking capacity Type F Europe 1 2 A 250 V fuse s or circuit breaker as part of the installation The switch or 30 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Input Wiring Procedures circuit breaker shall be located in close proximity to the recorder within easy reach of the OPERATOR The switch or circuit breaker shall be marked as the disconnecting device for the recorder Table 2 11 AC line power wiring Step Action 1 Open the recorder door Loosen the captive screw in the chart plate and swing the plate out 2 connector J10 on the bottom edge of the main printed circuit board Refer to Figure 3 Remove the unwired plug from J10 4 Run the power wires separately through second conduit from the right 5 For CE Mark conformity install the ferrite filter as shown in Figure 2 11 6 Strip insulation from the end of each wire 7 Loosen the screws in plug J10 terminals and position the plug as you would to plug it into J10 8 I
270. totalizer to be set to zero upon switch 1 closure Digital Input 1 EXT SW2 EXTERNAL SWITCH 2 Allows the totalizer to be set to zero upon switch 2 closure Digital Input 2 INHIBIT The totalizer will be inhibited while the configured action is true NONE S1 OPEN External SW1 open inhibits totalizer S1 CLOSE External SW1 closed inhibits totalizer S2 OPEN External SW2 open inhibits totalizer S2 CLOSE External SW2 closed inhibits totalizer Repeat the configuration for TOTAL 2 90 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Control Parameters Set Up Group 4 6 Control Parameters Set Up Group Introduction The functions listed in this group deal with how the DR4500A will control the process including number of tuning parameter sets setpoint source ratio bias tracking power up recall setpoint limits output direction and limits deadband and hysteresis control algorithm output algorithm and the current duplex range There are two control groups Control group prompts Table 4 5 lists all the function prompts in the Control 1 or Control 2 set up groups and their definitions Table 4 5 Control 1 or 2 group definitions Lower Display Upper Display Parameter Definition Prompt Range of Setting or Selection CONTROL 1 ENABLE CONTROL 1 allows you to enable or disable control DISABL loop 1 PID S
271. tware FUNC Until you see version Upper Display Software Version Number Lower Display VERSION Please give this number to the Customer Support person It will indicate which version of DR4500A you have and help them determine a solution to your problem Troubleshooting The troubleshooting procedures are divided into two parts e Self Diagnostics Error Message Prompts and e Visual Failure Symptoms If a Failed indication is given for one of the power up tests and or an error message prompt blinks in the lower display refer to the Self Diagnostic error message prompts If erratic operation is observed refer to the Visual Failure symptoms In either case run the status tests to verify the status of the recorder s basic self diagnostic tests 204 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Troubleshooting Service Self Diagnostics 9 3 Self Diagnostics Power up tests When the recorder is powered up four tests are run by the DR4500A software to ensure memory integrity As the tests run the displays appear as shown in Table 9 2 Table 9 2 Power up tests Lower Display Upper Display RAM TEST PASS or FAIL CONFTEST configuration checksum PASS or FAIL CAL TEST working calibration PASS or FAIL BATTERY PASS or FAIL Battery test failure does not cause a failsafe Failsafe e f control is c
272. u configure a specific ramp rate up and ramp rate down SP RATE These rates are used when the local setpoint is manually changed Setpoint Program Also included under this group are prompts for configuring a Setpoint program SP PROG The prompts and instructions for Setpoint programming are presented in the Section 6 Setpoint Ramp Soak Programming Option Function prompts Table 3 9 lists all the function prompts in the SP RAMP 1 or SP RAMP 2 Set Up group Configure each ramp separately When you enable the ramp type SP RAMP SP RATE SP PROG the other two types are hidden from the display Table 3 9 SP Ramp 1 or 2 group function prompts Function Prompt Function Name Selections or Range of Setting Factory Lower Display Upper Display Setting SP RAMP Single Setpoint Ramp DISABL DISABL Selection ENABLE TIME MIN Single Setpoint Ramp Time 0 to 255 minutes 0 FINAL SP Single Setpoint Ramp Final Enter a value within the setpoint limits 100 0 Setpoint SP RATE Setpoint Rate DISABL DISABL ENABLE EU HR UP Rate up value SP Rate 0 to 9999 0 enabled in units per hour EU HR DN Rate down value SP Rate 0 to 9999 0 enabled in units per hour SP PROG Setpoint Programming DISABL DISABL Refer to Section 6 ENABLE Only one of these can be enabled at a time 70 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Timer Set Up Group
273. ues 7 3 Minimum and Maximum Range Values Select the range values You should calibrate the recorder for the minimum 0 and maximum 100 range values of your particular sensor e f your recorder has two or more inputs calibrate each input separately Select the voltage or resistance equivalent for 0 and 10096 range values from Table 7 2 use these values when calibrating your recorder Table 7 2 Voltage and resistance equivalents for 0 and 100 range values Sensor Type PV Input Range Range Values Thermocouples F C 0 68 F 20 C 100 B 105 to 3300 41 to 1816 0 mV 0 003 mV 13 763 mV E 454 to 1832 270 to 1000 9 835 mV 1 192 mV 76 358 mV E low 200 to 1100 129 to 593 6 471 mV 44 547 mV J 0 to 1600 18 to 871 0 885 mV 1 019 mV 50 059 mV J low 20 to 770 7 to 410 0 334 mV 22 397 mV K 320 to 2500 196 to 1371 5 822 mV 0 798 mV 54 845 mV K low 20 to 1000 29 to 538 1 114 mV 22 251 mV NiNiMoly 32 to 2500 0 to 1371 0 001 mV 1 458 mV 71 330 mV NIC Nicrosil Nisil 0 to 2372 17 8 to 1300 0 461 mV 0 525 mV 47 502 mV R 0 to 3100 18 to 1704 0 089 mV 0 111 mV 20 275 mV S 0 to 3100 18 to 1704 0 092 mV 0 113 mV 17 993 mV T 300 to 700 184 to 371 5 341 mV 0 789 mV 19 095 mV T low 200 to 600 129 to 316 4 149 mV 15 769 mV W5W26 0 to 4200 18 to 2315 0 234 mV 0 062 mV 37 066 mV W5W26 low 0
274. ular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Input Wiring Procedures 2 6 Input Wiring Procedures Wiring the recorder Using the information contained in the model number select the appropriate wiring diagrams from the figures listed below and wire the recorder accordingly Wiring Requirements Refer to Ferrite Filter Locations Figure 2 11 AC Line Power Figure 2 12 Thermocouple RTD Radiamatic mV or 0 5 Vdc Inputs Figure 2 13 4 20 mA Inputs Figure 2 14 0 10 Vdc Inputs Figure 2 15 4 20 mA Current Outputs or Auxiliary Outputs 2 and 3 Figure 2 16 Position Proportional Control Outputs Figure 2 17 Relay Control Outputs Figure 2 18 Time Proportioning Alarm 1 and 2 Outputs and Digital Inputs Figure 2 19 Alarm Outputs 3 4 5 and 6 Figure 2 20 RS485 Modbus Communications Figure 2 21 Auxiliary Output Figure 2 22 Ferrite filter locations CE Mark Inside of the enclosure install ferrite suppression filters on all wires connected to the recorder Fair Rite Products Corp part number 0443164151 or equivalent shall be installed as shown in Figure 2 11 one filter for each circuit group Cable with an outer jacket diameter larger than 6 7 mm 0 264 in may require the outer jacket to be removed to fit the required one turn in the filter or the selection of a different cable Shield Wiring The shield wires of all cables exc
275. uples 105 to 3300 41 to 1816 B 105 to 150 41 to 66 42 00 23 00 2 00 150 to 500 66 to 260 14 00 7 70 2 00 500 to 1000 260 to 538 3 00 1 70 0 50 1000 to 3300 538 to 1815 1 50 0 80 0 20 E 454 to 1832 270 to 1000 454 to 202 270 to 130 18 00 10 00 0 70 202 to 1832 130 to 1000 1 00 0 55 0 35 E low 200 to 1100 129 to 593 0 50 0 30 0 20 J 0 to 1600 18 to 871 0 40 0 22 0 06 J low 20 to 770 7 to 410 0 20 0 11 0 04 K 320 to 2500 196 to 1371 320 to 0 196 to 18 1 25 0 70 0 18 0 to 2500 18 to 1371 0 60 0 35 0 09 K low 20 to 1000 29 to 538 0 30 0 16 0 05 NNM Ni Ni Moly 32 to 2500 0 to 1371 32 to 500 0 to 260 0 75 0 40 0 09 500 to 2500 260 to 1371 0 50 0 30 0 07 NIC Nicrosil Nisil 0 to 2372 18 to 1300 1 0 0 55 0 01 R 0 to 3100 18 to 1704 0 to 500 18 to 260 2 00 1 10 0 25 500 to 3100 260 to 1704 1 00 0 55 0 13 S 0 to 3100 18 to 1704 0 to 500 18 to 260 2 00 1 10 0 23 500 to 3100 260 to 1704 1 00 0 55 0 13 T 300 to 700 184 to 371 0 60 0 35 0 07 T low 200 to 600 129 to 316 0 40 0 22 0 07 W5W26 0 to 4200 18 to 2315 0 to 600 18 to 316 1 40 0 77 0 17 600 to 3600 316 to 1982 1 30 0 70 0 17 3600 to 4200 1982 to 2315 1 60 0 90 0 29 W5W26 low 0 to 2240 18 to 1227 0 to 600 18 to 316 1 10 0 60 0 14 600 to 2240 316 to 1227 1 00 0 55 0 10 Radiamatic 1400 to 3400 760 to 1871 1 00 0 55 0 10 RTD Platinum 100 ohms 300 to 900 184 to 482 0 40 0 22 0 05 500 oh
276. ure 2 10 Mounting flush on a surface of panel or wall DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Support hook Release K May 2013 Installation Wiring Prerequisites 2 5 Wiring Prerequisites Taking electrical noise precautions Electrical noise is composed of unabated electrical signals which produce undesirable effects in measurements and control circuits Digital equipment is especially sensitive to the effects of electrical noise Your recorder has built in circuits to reduce the effect of electrical noise from various sources If there is a need to further reduce these effects e Separate External Wiring separate connecting wires into bundles see Table 2 10 and route the individual bundles through separate conduits or metal trays e Use Suppression Devices for additional noise protection you may want to add suppression devices at the external source appropriate suppression devices are commercially available e REFERENCE For additional noise information refer to document number 51 52 05 01 Electrical considerations The recorder is considered rack and panel mounted equipment per EN 61010 1 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements Recorder grounding dih PROTECTIVE BONDING grounding of this recorder shall be in accordance with National and local electrical codes
277. value of the setpoint in units of PV for Loop 2 4 mA VAL Low Scale Value AUXILIARY OUTPUT LOW SCALING FACTOR Use within the range of the selected a value in engineering units for all selections above variable to represent 4 mA except Output Use value in percent 96 for Output Output can be between 5 and 105 20mA VAL High Scale Value AUXILIARY OUTPUT HIGH SCALING FACTOR Use within the range of the selected variable to represent 20 mA a value in engineering units for Input 1 Input 2 Process Variable Deviation and Setpoint Use a value in percent 96 for Output Output can be between 5 and 105 When Deviation is selected only one operating parameter will be entered This value represents the deviation level that will produce 20 mA output Zero deviation will produce a center scale 12 mA output A negative deviation equal in magnitude to the Auxiliary Output High Value will produce a low end 4 mA output Repeat for AUX OUT 2 and AUX OUT 3 110 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Configuration Parameter Definitions Modbus Communications Set Up Group 4 12 Modbus Communications Set Up Group Introduction This option allows the DR4500A to be connected to a host computer via the Modbus protocol Up to 99 addresses and a maximum of 15 units can be configured over this link Communications group pr
278. w holes in the recorder case 5 Insert the recorder into the cutout from the front of the panel as shown in Figure 2 6 6 Refer to Figure 2 6 From the back of the panel attach a mounting bracket to each side of the recorder case using a 1 4 20 x 1 2 inch hex screw and a lockwasher for each bracket mounting hardware supplied with recorder Leave the screws slightly loose so you can adjust the brackets 7 While holding the recorder firmly against the panel slide each bracket against the back of the panel and tighten the screws NOTE Universal filler plate and attaching Universal hardware are included in kt 30755134 xxx filler plate Universal upport brackets Mounting brackets supplied Support brackets with recorder included in kit 30755134 xxx Figure 2 6 Mounting in a panel using universal filler kit 20 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release K May 2013 Installation Mounting Methods Mounting flush in panel using cutout made for Kent Model 105M Refer to Figure 2 7 and follow the procedure in Table 2 6 to mount your recorder in an existing cutout using the cutout made for Kent Model 105M Table 2 6 Mounting flush in a panel using Kent Model 105M cutout Step Action 1 Drill two 1 4 inch holes in the back of the panel as shown in Figure 2 7 These holes are for 10 32 screws to be inserted from back of panel into threaded inserts in
279. watts max corriente CONDICIONES AMBIENTALES No operar con el instrumento en presencia de liquidos o gases inflamables La operaci n de cualquier equipo el ctrico en tal ambiente constituye un riesgo contra la seguridad Temperatura Ambiente 15 a 55 Humedad 10 90 RH Vibraci n 0a 70 Hz acceleraci n 0 1 g INSTALACION DEL EQUIPO Este equipo debe ser montado en un panel para limitar al operador el acceso a los terminales traseros Release K DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 243 May 2013 SAKERHETSFORESKRIFTER SW21 6057 F r att reducera riskerna av elektriska chocker som kan orsaka personskador f lj alla s kerhetsf reskrifter 1 denna dokumentation Denna symbol varnar anv ndaren for risk for elchock vid tillf llig tkomst av spanningsforande del Anslutning av skyddsjord Avsedd f r anslutning av elsysternets skyddsjordsledare Om e Om utrustningen anv nds ett s dant s tt att det inte innefattas av tillverkarens specifikation kan de inbyggda s kerhetsfunktionerna ventyras e Ers tt aldrig n gon komponent eller del som inte ar specificerad som ers ttningsbar av tillverkaren e Allledningsdragning m ste utf ras 1 enlighet med lokala best mmelser och skall utf ras av beh rig personal med erfarenhet av s dant arbete e Skyddsjordsanslutningen skall anslutas f re alla andra anslutningar och losskopplas sist e str
280. whenever the deviation is changing and affects it more when the deviation is changing faster e Used with control algorithm PID A or PID B Defined as HEAT Rate on Duplex models for variations of Heat Cool applications RSET MIN or RSET RPM 0 02 to 50 00 RSET MIN RESET IN MINUTES REPEAT RSET RPM RESET IN REPEATS MINUTE RESET adjusts the recorder s output in accordance with both the size of the deviation SP PV and the time it lasts The amount of the corrective action depends on the value of Gain The Reset adjustment is measured as how many times proportional action is repeated minute e Used with control algorithm PID A or PID B Defined as HEAT Reset on Duplex models for variations of Heat Cool applications e The selection of minutes per repeat or repeats per minute is made in the control parameters group under prompt MINorRPM MAN RSET 100 to 100 in output MANUAL RESET is only applicable if you have control algorithm PD WITH MANUAL RESET Because a proportional recorder will not necessarily line out at setpoint there will be a deviation offset from setpoint This eliminates the offset and lets the PV line out at setpoint Release K May 2013 DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual 101 Configuration Parameter Definitions Tuning Parameters Set Up Group Lower Display Upper Display Paramete
281. wing topics Topic See Page 7 1 Overview 175 7 2 Restoring Factory Calibration 176 7 3 Minimum and Maximum Range Values 178 7 4 Preliminary Information 178 7 5 Calibration Set Up and Wiring for PV Inputs 181 7 6 Calibration Procedure 190 7 2 Restoring Factory Calibration How to restore it The factory calibration constants for all the input actuation types that can be used with the DR4500A recorder are stored in its nonvolatile memory Thus you can quickly restore the Factory Calibration for a given input actuation type by simply configuring the actuation type through the INI TYPE or IN2 TYPE prompt to another type and then changing it back to the original type See Table 7 1 for the procedure ATTENTION be field calibrated This procedure applies only for factory installed inputs Any input that was field installed must Procedure Table 7 1 lists the procedure for restoring factory calibration Table 7 1 Restoring factory calibration Step Operation Press Action Result 1 Enter Input Setup Group SET Until you see UP Upper Display SET UP Lower Display INPUT n n 10r2 2 Change input type FUNC Until you see Upper Display Note the input type in the upper display Make sure that the selection matches the type of sensor that is connected to the input in your application Write it down if necessary Lower Display INn 1 2 176 DR4500A Classic Series

DR4500A Classic Series Circular Chart Recorder With or Without

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