Grieve Corporation DR4500A Installation Manual

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Page 1

DR4500A Truline Circular Chart

Recorder With or Without Control

Product Manual

Doc. No.: 44-45-25-30

Release: L

Last Revision Date: 8/02

Industrial Measurement and Control

Page 2

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.

Notices and Trademarks

Release L - August, 2002

Industrial Measurement and Control

Honeywell

1100 Virginia Drive

Ft. Washington, PA 19034

DR4500 Truline is a U.S. registered trademark of Honeywell.

Other brand or product names are trademarks of their respective owners.

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About This Document

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 Noise Environments

Modbus® RTU Serial Communications User Manual 51-52-25-66

Modbus® RTU Serial Communications User Manual Configuration Interface for DR4500

51-52-05-01

51-52-25-69

Contacts

World Wide Web

The following lists Honeywell’s World Wide Web sites that will be of interest to our customers.

Honeywell Organization WWW Address (URL)

Corporate

Industrial Measurement and Control

Telephone

Organization Phone Number

http://www.honeywell.com

http://www.honeywell.com/imc/

United States and Canada Honeywell

Release L DR4500A Truline Circular Chart Recorder With or Without Control Product Manual iii 8/02

1-800-423-9883 Tech. Support 1-888-423-9883 Q&A Faxback (TACFACS) 1-800-525-7439 Service

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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: 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.

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 chassis 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.

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1. Overview ........................................................................................... 1

1.1 Introduction ........................................................................................................1

1.2 Operator Interface..............................................................................................3

1.3 Set-up Tasks......................................................................................................5

2. Installation ......................................................................................... 7

2.1 Overview............................................................................................................7

2.2 Model Number Interpretation...........................................................................13

2.3 Mounting Considerations and Overall Dimensions .........................................16

2.4 Mounting Methods ...........................................................................................17

2.5 Wiring Prerequisites.........................................................................................27

2.6 Input Wiring Procedures ..................................................................................29

2.7 Output Wiring Procedures ...............................................................................39

2.8 Option Wiring Procedures ...............................................................................45

2.9 Lockout Switch Configuration ..........................................................................54

3. Configuration................................................................................... 55

3.1 Overview..........................................................................................................55

3.2 Configuration Prompts.....................................................................................57

3.3 How To Get Started.........................................................................................60

3.4 Configuration Tips............................................................................................61

3.5 Configuration Procedure..................................................................................62

3.6 Input Set Up Group..........................................................................................64

3.7 Pen Set Up Group ...........................................................................................66

3.8 Chart Set Up Group.........................................................................................67

3.9 Time Set Up Group..........................................................................................69

3.10 Totalizer Set Up Group ....................................................................................70

3.11 Input Algorithm Set Up Group .........................................................................72

3.12 Control Set Up Group ......................................................................................73

3.13 Tuning Parameters Set Up Group ...................................................................75

3.14 SP Ramp Set Up Groups ................................................................................76

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3.15 Timer Set Up Group ........................................................................................77

3.16 Alarms Set Up Group ......................................................................................78

3.17 Auxiliary Output Set Up Group ........................................................................80

3.18 Modbus Communications Set Up Group .........................................................81

3.19 Options Set Up Group .....................................................................................82

3.20 Event Message Configuration .........................................................................83

3.21 Lockout Set Up Group .....................................................................................86

3.22 Adjust Printing..................................................................................................87

3.23 Configuration Record Sheet ............................................................................88

4. Configuration Parameter Definitions................................................ 93

4.1 Overview..........................................................................................................93

4.2 Input Parameters Set Up Group ......................................................................94

4.3 Pen Parameters Set Up Group........................................................................98

4.4 Chart Parameters Set Up Group ...................................................................100

4.5 Time Parameters Set Up Group....................................................................103

4.6 Total Parameters Set Up Group....................................................................104

4.7 Input Algorithm Set Up Group .......................................................................106

4.8 Control Parameters Set Up Group ................................................................109

4.9 Tuning Parameters Set Up Group .................................................................119

4.10 Setpoint Ramp Set Up Group........................................................................122

4.11 Timer Set Up Group ......................................................................................124

4.12 Alarms Set Up Group ....................................................................................125

4.13 Auxiliary Output Set Up Group ......................................................................128

4.14 Modbus Communications Set Up Group .......................................................130

4.15 Options Set Up Group ...................................................................................131

4.16 Event Message Set Up Group.......................................................................133

4.17 Lockout Parameters Set Up Group ...............................................................134

4.18 Printing Characteristics Adjustments.............................................................135

5. Operation ...................................................................................... 137

5.1 Overview........................................................................................................137

5.2 Start-up ..........................................................................................................138

5.3 Monitoring Your Recorder .............................................................................142

5.4 Operator Functions........................................................................................148

5.5 Operating Modes ...........................................................................................149

5.6 Setpoints........................................................................................................151

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5.7 Single Setpoint Ramp....................................................................................153

5.8 Using Two Sets of Tuning Constants (PID Values).......................................156

5.9 Using Accutune II...........................................................................................159

5.10 Alarm Setpoints .............................................................................................162

5.11 Three Position Step Control Algorithm ..........................................................163

5.12 Digital Input Option (Remote Switching)........................................................164

5.13 Resetting and Displaying Totalizer Value......................................................165

5.14 Monitoring the External Event Operation ......................................................167

5.15 Maximizing Pen Life.......................................................................................168

5.16 Routine Maintenance.....................................................................................169

5.17 Installing/Replacing Chart..............................................................................170

5.18 Chart Operation .............................................................................................171

6. Setpoint Ramp/Soak Programming and Operation .......................173

6.1 Overview........................................................................................................173

6.2 Setpoint Program Contents ...........................................................................175

6.3 Drawing a Ramp/Soak Profile .......................................................................178

6.4 Entering the Setpoint Program Data..............................................................183

6.5 SP RAMP1 and SP RAMP2 Set Up Group ...................................................185

6.6 Setpoint Program Profiles Set Up Group ......................................................187

6.7 Setpoint Program Segments Set Up Group ..................................................189

6.8 Setpoint Program Event Set Up Group .........................................................192

6.9 Run/Monitor the Program ..............................................................................196

7. Input Calibration ............................................................................ 199

7.1 Overview........................................................................................................199

7.2 Restoring Factory Calibration ........................................................................200

7.3 Minimum and Maximum Range Values.........................................................202

7.4 Preliminary Information..................................................................................203

7.5 Calibration Set Up and Wiring for PV Inputs .................................................205

7.6 Calibration Procedure....................................................................................214

7.7 Printing Characteristics Adjustments.............................................................217

8. Output Calibration .........................................................................219

8.1 Overview........................................................................................................219

8.2 Current Proportional Output/Aux Out 2 and 3 Calibration.............................220

8.3 Position Proportional and Three Position Step Output Calibration ..............222

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8.4 Auxiliary Output Calibration ...........................................................................225

9. Troubleshooting / Service.............................................................. 227

9.1 Overview........................................................................................................227

9.2 Troubleshooting Aids.....................................................................................229

9.3 Self Diagnostics.............................................................................................231

9.4 Visual Failure Symptoms...............................................................................237

9.5 Troubleshooting Procedures .........................................................................238

10. Parts List .................................................................................... 245

10.1 Overview........................................................................................................245

10.2 Exploded Views .............................................................................................246

10.3 Miscellaneous Hardware Kit Contents ..........................................................252

10.4 Internal Cabling Data .....................................................................................253

10.5 Internal Wiring Diagram – Options Only........................................................254

A. Model DR45AR .............................................................................255

A.1 Overview........................................................................................................255

A.2 Hardware Identification..................................................................................256

A.3 Fo Reset Configuration..................................................................................258

A.4 Options Configuration....................................................................................259

A.5 Operations Additions .....................................................................................261

A.6 Configuration Worksheet Additions ...............................................................262

B. Security Lockout............................................................................ 263

B.1 Overview........................................................................................................263

C. Foreign Language Safety Instructions........................................... 265

DA2I-6056 ................................................................................................................266

DU2I-6056 ................................................................................................................267

FI2I-6056 ..................................................................................................................268

FR2I-6056.................................................................................................................269

GE2I-6056 ................................................................................................................270

GR2I-6056 ................................................................................................................271

IT2I-6056 ..................................................................................................................272

NO2I-6056 ................................................................................................................273

PO2I-6056 ................................................................................................................274

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SP2I-6056.................................................................................................................275

SW2I-6056................................................................................................................276

Index ...................................................................................................277

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Tables

Table 1-1 Function of Keys .........................................................................................................................................4

Table 2-1 Operating Limits and Condensed Specifications.........................................................................................8

Table 2-2 Procedure to Access Components .............................................................................................................14

Table 2-3 Mounting Flush in a New Panel Cutout ....................................................................................................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.............................................................................. 20

Table 2-6 Mounting Flush in a Panel Using Kent Model 105M Cutout....................................................................21

Table 2-7 Procedure for Mounting Recorder with Heavy Duty Door .......................................................................22

Table 2-8 Pipe Mounting Procedure..........................................................................................................................24

Table 2-9 Mounting Flush on a Surface (of Panel or Wall).......................................................................................25

Table 2-10 Permissible Wiring Bundling..................................................................................................................28

Table 2-11 AC Line Power Wiring............................................................................................................................31

Table 2-12 Thermocouple, RTD, Radiamatic, mV, or 0–5 Vdc Input Wiring ..........................................................33

Table 2-13 4-20 mA Input Wiring............................................................................................................................. 35

Table 2-14 0-10 Volt dc Input Wiring.......................................................................................................................37

Table 2-15 4-20 mA Control Output Wiring.............................................................................................................39

Table 2-16 Position Proportional Control Output Wiring .........................................................................................41

Table 2-17 Relay Control Output Wiring..................................................................................................................43

Table 2-18 Alarm Output or Digital Input Wiring.....................................................................................................45

Table 2-19 Alarm 3 and Alarm 4 Output Wiring ......................................................................................................47

Table 2-20 Alarm 5 and Alarm 6 Output Wiring ......................................................................................................48

Table 2-21 RS485 Modbus Communications Wiring................................................................................................50

Table 2-22 4-20 mA Auxiliary Output Wiring..........................................................................................................52

Table 3-1 Configuration Tips ....................................................................................................................................61

Table 3-2 Configuration Procedure ........................................................................................................................... 62

Table 3-3 Input Group Function Prompts.................................................................................................................. 64

Table 3-4 Pen 1, 2, 3, 4 Group Function Prompts .....................................................................................................66

Table 3-5 Chart Group Function Prompts .................................................................................................................67

Table 3-6 Time Group Function Prompts ..................................................................................................................69

Table 3-7 Totalizer Group Function Prompts............................................................................................................ 70

Table 3-8 Input Algorithm Group Function Prompts ................................................................................................72

Table 3-9 Control 1 or Control 2 Group Function Prompts.......................................................................................73

Table 3-10 Tuning 1 or Tuning 2 Group Function Prompts ......................................................................................75

Table 3-11 SP Ramp 1 or 2 Group Function Prompts...............................................................................................76

Table 3-12 Timer Group Function Prompts...............................................................................................................77

Table 3-13 Priority of functions that operate relays ..................................................................................................78

Table 3-14 Alarms Group Function Prompts............................................................................................................. 79

Table 3-15 Auxiliary Output Group Function Prompts.............................................................................................80

Table 3-16 Modbus Communications Group Function Prompts ...............................................................................81

Table 3-17 Options Group Function Prompts............................................................................................................82

Table 3-18 Event Message Group Function Prompts................................................................................................83

Table 3-19 Lockout Group Function Prompts...........................................................................................................86

Table 3-20 Adjust Group Function Prompts..............................................................................................................87

Table 4-1 Input Group Definitions ............................................................................................................................ 94

Table 4-2 Pen 1, 2, 3, or 4 Group Definitions............................................................................................................98

Table 4-3 Chart Parameters Group Definitions ....................................................................................................... 100

Table 4-4 Time Parameters Group Definitions........................................................................................................103

Table 4-5 Totalizer Group Definitions ....................................................................................................................104

Table 4-6 Input Algorithm Group Definitions ......................................................................................................... 106

Table 4-7 Control 1 or 2 Group Definitions ............................................................................................................109

Table 4-8 Tuning Group Prompt Definitions...........................................................................................................119

Table 4-9 Setpoint Ramp 1 or 2 Group Definitions.................................................................................................122

Table 4-10 Timer Group Definitions....................................................................................................................... 124

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Table 4-11 Priority of functions that operate relays .................................................................................................125

Table 4-12 Alarms Group Definitions..................................................................................................................... 126

Table 4-13 Auxiliary Output Group Definitions .....................................................................................................128

Table 4-14 Modbus Communications Group Definitions........................................................................................130

Table 4-15 Option Group Definitions......................................................................................................................131

Table 4-16 Event Message Group Definitions.........................................................................................................133

Table 4-17 Lockout Group Definitions ................................................................................................................... 134

Table 4-18 Printing Characteristics Adjustment Procedure.....................................................................................136

Table 5-1 Power Up Diagnostic Tests..................................................................................................................... 138

Table 5-2 Procedure for Testing the Displays and Keys .........................................................................................139

Table 5-3 Procedure for Starting Up the Recorder ..................................................................................................140

Table 5-4 Meaning of Indicators .............................................................................................................................143

Table 5-5 Lower Display Key Parameter Prompts..................................................................................................145

Table 5-6 Error Messages........................................................................................................................................ 146

Table 5-7 Alarm and tuning messages.....................................................................................................................147

Table 5-8 Operating Mode Definitions....................................................................................................................149

Table 5-9 Changing Operating Modes.....................................................................................................................149

Table 5-10 Procedure for Selecting Automatic or Manual Mode............................................................................150

Table 5-11 Procedure for Selecting the Setpoint Source .........................................................................................151

Table 5-12 Procedure for Changing the Local Setpoint ..........................................................................................151

Table 5-13 Procedure for Switching Between Setpoints .........................................................................................152

Table 5-14 Setpoint Selection Indication.................................................................................................................152

Table 5-15 Procedure for Configuring a Single Setpoint Ramp ..............................................................................153

Table 5-16 Procedure for Running a Setpoint Ramp ...............................................................................................154

Table 5-17 Procedure for Selecting Two Sets of Tuning Constants ........................................................................156

Table 5-18 Procedure for Setting Switchover Values..............................................................................................157

Table 5-19 Procedure for Setting Tuning Constant Values.....................................................................................157

Table 5-20 Procedure for Switching PID Sets from the Keyboard..........................................................................158

Table 5-21 Procedure for Starting Accutune II........................................................................................................159

Table 5-22 Procedure for Using Accutune for Duplex Control...............................................................................160

Table 5-23 Procedure for Displaying or Changing the Alarm Setpoints .................................................................162

Table 5-24 Procedure for Displaying the 3PSTEP Motor Position .........................................................................163

Table 5-25 Digital Input Option Action on Contact Closure...................................................................................164

Table 5-26 Procedure for Resetting the Totalizer....................................................................................................165

Table 5-27 Procedure for Displaying the Totalizer Value.......................................................................................166

Table 5-28 Maximizing Pen Life.............................................................................................................................168

Table 5-29 Cleaning the Pen Tip.............................................................................................................................169

Table 5-30 Replacing a Chart Lamp........................................................................................................................169

Table 5-31 Installing/Replacing the Chart...............................................................................................................170

Table 5-32 Remote Chart Modes.............................................................................................................................172

Table 6-1 Parameter settings for example 12-step profile .......................................................................................179

Table 6-2 Setpoint program data entry procedure ...................................................................................................183

Table 6-3 SP RAMP prompts and available selections ...........................................................................................185

Table 6-4 Setpoint Program Profiles Group Definitions .........................................................................................187

Table 6-5 Setpoint Program Segments Group Definitions ......................................................................................189

Table 6-6 Setpoint Program Event Group Definitions.............................................................................................192

Table 6-7 Segment Event relay operation requirements ..........................................................................................193

Table 6-8 Run/Monitor Functions ........................................................................................................................... 196

Table 7-1 Restoring Factory Calibration .................................................................................................................200

Table 7-2 Voltage and Resistance Equivalents for 0 % and 100 % Range Values..................................................202

Table 7-3 Disconnect the Field Wiring....................................................................................................................203

Table 7-4 Equipment Needed..................................................................................................................................204

Table 7-5 General Set Up Procedure ....................................................................................................................... 206

Table 7-6 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath ..................................................207

Table 7-7 Set Up Wiring Procedure for Thermocouple Inputs Using a Compensated Calibrator Method..............208

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Table 7-8 Set Up Wiring Procedure for Thermocouple Inputs Using the Ambient Temperature Method.............. 209

Table 7-9 Set Up Wiring Procedure for RTD Inputs...............................................................................................210

Table 7-10 Set Up Wiring Procedure for Radiamatic, Millivolts, and Volts Inputs (except 0-10 Volts) ................211

Table 7-11 Set Up Wiring Procedure for 0–10 Volt Inputs .....................................................................................212

Table 7-12 Set Up Wiring Procedure for 4–20 mA Inputs ......................................................................................213

Table 7-13 Calibration Procedure Sequence............................................................................................................214

Table 8-1 Set Up Wiring Procedure Current Proportional Output/Aux Out 2 and 3...............................................220

Table 8-2 Current Proportional Output/Aux Output 2 and 3 Calibration Procedure ............................................... 221

Table 8-3 Position Proportional and 3 Position Step Output Calibration Procedure ...............................................223

Table 8-4 Set Up Wiring Procedure Auxiliary Output ............................................................................................225

Table 8-5 Auxiliary Output Calibration Procedure..................................................................................................226

Table 9-1 Identifying the software version.............................................................................................................. 230

Table 9-2 Power-up tests .........................................................................................................................................231

Table 9-3 Displaying the test results........................................................................................................................232

Table 9-4 Error message prompts............................................................................................................................233

Table 9-5 Visual failure symptoms..........................................................................................................................237

Table 9-6 Procedure #1—Troubleshooting recorder failure symptoms...................................................................238

Table 9-7 Procedure #2—Troubleshooting pen trace failure symptoms .................................................................239

Table 9-8 Procedure #3—Troubleshooting chart rotation failure symptoms...........................................................239

Table 9-9 Procedure #4—Troubleshooting chart rotation failure symptoms...........................................................240

Table 9-10 Procedure #5—Troubleshooting pen failure symptoms........................................................................240

Table 9-11 Procedure #6—Troubleshooting keyboard and/or display failure symptoms .......................................240

Table 9-12 Procedure #7—Troubleshooting current proportional output failure symptoms...................................241

Table 9-13 Procedure #8—Troubleshooting position proportional output failure symptoms .................................241

Table 9-14 Procedure #9—Troubleshooting relay output failure symptoms...........................................................242

Table 9-15 Procedure #10—Troubleshooting current/time or time/current failure symptoms ................................ 242

Table 9-16 Procedure #11—Troubleshooting the auxiliary output .........................................................................243

Table 9-17 Procedure #12—Troubleshooting external alarm function failure symptoms.......................................243

Table 9-18 Procedure #13—Troubleshooting Modbus communications ................................................................243

Table 10-1 Door assembly parts..............................................................................................................................246

Table 10-2 Chart plate assembly parts.....................................................................................................................247

Table 10-3 Basic recorder parts without options ..................................................................................................... 249

Table 10-4 Recorder parts associated with options .................................................................................................251

Table 10-5 Miscellaneous hardware kit...................................................................................................................252

Table A-1 Fo RESET group function prompts........................................................................................................258

Table A-2 Options group function prompts, continued from Section 3/Table 3-17 ................................................259

Table A-3 Option group definitions, continued from Section 4/Table 4-15............................................................ 260

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Figures

Figure 1-1 Operator Interface ...................................................................................................................................... 3

Figure 1-2 Set-up Tasks...............................................................................................................................................5

Figure 2-1 Model Number Interpretation ..................................................................................................................13

Figure 2-2 DR4500A Recorder Hardware Components Versus “Table” Selections ................................................. 15

Figure 2-3 Overall Dimensions .................................................................................................................................16

Figure 2-4 How to Remove Knockouts ..................................................................................................................... 17

Figure 2-5 Mounting Flush in a New Panel Cutout ...................................................................................................18

Figure 2-6 Mounting in a Panel Using Universal Filler Kit ......................................................................................20

Figure 2-7 Mounting in a Panel using Kent Model 105M Cutout.............................................................................21

Figure 2-8 Panel Mounting Recorder with Heavy Duty Door...................................................................................23

Figure 2-9 Pipe Mounting Brackets...........................................................................................................................24

Figure 2-10 Mounting Flush on a Surface (of Panel or Wall) ...................................................................................26

Figure 2-11 Ferrite Filter Locations and Shield Wiring (CE Mark)..........................................................................30

Figure 2-12 AC Line Power Wiring ..........................................................................................................................32

Figure 2-13 Thermocouple, RTD, Radiamatic, mV, or 0–5 Vdc Input Wiring.........................................................34

Figure 2-14 4-20 mA Input Wiring............................................................................................................................36

Figure 2-15 0-10 Volt dc Input Wiring...................................................................................................................... 38

Figure 2-16 4-20 mA Control Output Wiring (or Aux Out #2 and #3 Wiring) .........................................................40

Figure 2-17 Position Proportional Control Output or Three Position Step Wiring....................................................42

Figure 2-18 Relay Control Output Wiring................................................................................................................. 44

Figure 2-19 Alarm Output or Digital Input Wiring ...................................................................................................46

Figure 2-20 Alarm outputs #3, 4, 5, and 6 wiring......................................................................................................49

Figure 2-21 RS485 Modbus Communications Wiring .............................................................................................. 51

Figure 2-22 4-20 mA Auxiliary Output #1 Wiring....................................................................................................53

Figure 2-23 S1 Lockout Switch Location..................................................................................................................54

Figure 3-1 DR4500A Prompt Hierarchy ...................................................................................................................57

Figure 5-1 Operator Interface .................................................................................................................................. 142

Figure 5-2 Deviation Bargraph................................................................................................................................144

Figure 6-1 Ramp/Soak Profile Example..................................................................................................................178

Figure 7-1 Location of the Input Connections on the Input Boards ........................................................................ 203

Figure 7-2 Location of Jumper Positions W1/MA and W3 on the Input Boards.....................................................205

Figure 7-3 Calibration Set Up Diagram for Thermocouple Inputs Using an Ice Bath.............................................207

Figure 7-4 Calibration Set Up Diagram for Thermocouple Inputs Using a Compensated Calibrator Method........ 208

Figure 7-5 Calibration Set Up Diagram for Thermocouple Inputs using the Ambient Temperature Method .........209

Figure 7-6 Calibration Set Up Diagram for RTD Inputs .........................................................................................210

Figure 7-7 Calibration Set Up Diagram for Radiamatic, Millivolts, and Volts Inputs (except 0-10 Volts) ............211

Figure 7-8 Calibration Set Up Diagram for 0–10 Volt Inputs .................................................................................212

Figure 7-9 Calibration Set Up Diagram for 4–20 mA Inputs ..................................................................................213

Figure 8-1 Test Equipment Connections for Calibrating Current Proportional Output...........................................220

Figure 8-2 Test Equipment Connections for Calibrating Auxiliary Output.............................................................225

Figure 10-1 Door assembly .....................................................................................................................................246

Figure 10-2 Chart plate assembly ............................................................................................................................ 247

Figure 10-3 Basic recorder components without options ........................................................................................248

Figure 10-4 Recorder components associated with options.....................................................................................250

Figure 10-5 Internal cabling for DR4500A Truline recorder...................................................................................253

Figure 10-6 Internal diagram for DR4500A Truline recorder – options only..........................................................254

Figure A-1 DR45AR with one input........................................................................................................................256

Figure A-2 DR45AR with two to four inputs .......................................................................................................... 257

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1.1 Introduction

Function

The DR4500A Truline Recorder is a one to four-channel microprocessor-based circular chart recorder. Its "one-pen" stylus printhead produces up to four analog traces and prints alphanumeric chart data on a blank heat-sensitive chart. All four traces share the same time line reference which the Truline prints. This eliminates the error caused by pen alignment offsets in conventional pen designs. Since the Truline prints the chart and generates the analog traces at the same time, there is no error due to variations in chart size caused by changes in temperature and humidity.

In addition to printing chart records, the Truline recorder alternately displays process variable values for all channels in the selected engineering units.

Models with up to four input channels accept inputs from any one of a variety of sensors or transmitters within the configurable range limits.

The Truline is also available with one or two independent digital controllers and setpoint programmers.

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.

1. Overview

Deviation from the installation conditions specified in this manual, and the special conditions for CE conformity in Subsection 2.1, may invalidate this product’s conformity with the Low Voltage and EMC Directives.

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 printhead are driven by stepper motors controlled by the microprocessor with configurable chart speed through the keypad.

You can configure various "printed" chart data such as range marking in engineering units, digital values for process variables, and trace identification. This data plus printed time lines and engineering units of scale eliminate the need to maintain an inventory of a variety of preprinted charts.

The Truline recorder uses a dot fill technique from a microprocessor algorithm to produce a continuous analog trace of a process variable.

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Overview Introduction

Digital controller

The DR4500A recorder controller includes an integral microprocessor-based, single or dual loop PID controller with optional setpoint program. 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. Accutune II lets you automatically tune your loops.

You can configure the control action as On-Off, PID-A, PID-B, PD with manual reset, or Three Position Step. English language prompts guide you through the entry of all the controller's configurable parameters.

Construction

The DR4500A recorder is housed in a molded case which can be panel or surface mounted. A glass or acrylic windowed door (A UL and FM approved NEMA4X door is also available )protects the internal components while allowing easy access to the chart and operator interface. An optional external keypad that allows operator selections without 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.

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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 units of PV Upper Display - six characters

PV displayed is for channel 1, 2, 3, or 4

Alarm condition exists for alarm 1 or 2, when lit.

ALM

CHN

Remote set point or 2nd set point is active, when lit. Blinks when 2nd setpoint or remote setpoint is attained through remote switch

RSP

OUT

12 FC

1234

Operator Interface

Normal operation - Displays process variable (PV) for selected channels. Configuration mode - Displays selection or parameter value.

Indicates controller mode: MAN = Manual

Keypad / Key functions

A = Automatic

MAN

FUNC

LOWR

DISP

MAN

AUTO

CHART

SET

RUN

HOLD

Overview

Control relay 1 or 2 is ON, when lit.

Lower Display - eight characters

• Normal operation - Displays selectable operating parameters and values. Indicates diagnostic error messages, alarm condition for alarms 3-6, Accutune in progress.

• Configuration mode - Displays function group and parameters.

Bargraph - deviation (±10% of span) Center green bar indicates PV is within ±1% of control setpoint Next small bar will light if PV is between ±1% but less than ±2% in deviation. If PV is equal to or greater than ±10% deviation, the green bar plus all ten small green bars will light.

Figure 1-1 Operator Interface

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Overview Operator Interface

Key functions

Table 1-1 shows each key on the operator interface and defines its function.

Key Function

Table 1-1 Function of Keys

SET

FUNC

LOWR

DISP

• Places the controller in the Configuration Set Up group select mode. Sequentially

displays Set Up groups and allows the FUNC key to display individual functions in each Set Up group.

• Used in conjunction with the SET UP key to select the individual functions of a

selected Configuration Set Up group.

• Used to toggle between SP1 and SP2.

• Used during field calibration procedure.

• Selects an operating parameter to be shown in the lower display:

OUT = Output Value (estimated motor position for 3 Position Step) SP = Local Setpoint 1 SPN = Current setpoint for setpoint rate applications 2SP = Local Setpoint 2 RSP = Remote Setpoint 1IN = Input 1 (if Loop 1 is a derived PV) 2IN = Input 2 3IN = Input 3 4IN = Input 4 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

= Time remaining in Timer function

= Time elapsed in Timer function

TUNExXXX = Accutune II indicator. x = 1 or 2

ATTENTION

The lower display can be configured to scroll through the operating

parameters.

MAN

AUTO

• Alternately selects:

AUTO Lower display automatically displays setpoint value in engineering units. MAN Lower display automatically indicates output in %.

CHART

• Used to stop printing operation and move pen to outer limit for chart change.

Display will revert to date and time.

RUN

• Alternate action switch initiates or holds the Setpoint Ramp or Setpoint Program.

HOLD

• In configuration mode, restores the original value or selection if you do not want to

enter a change you are making to a parameter.

▲

▼

• Increases the setpoint, output, or configuration values displayed.

• Decreases the setpoint, output, or configuration values displayed.

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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 section numbers for each task are shown.

START

Determine your recorder's hardware components and software functions

Mount the recorder flush in

2. a panel, or on the surface of a panel or a wall

Overview

Set-up Tasks

See Section 2

Connect the power and input/output wiring.

Follow the simple keystroke

See Section 2

sequences and English language prompts to

See Sections 3 & 4

"configure" the functional characteristics of your recorder.

Ready for Operation

For Model DR45AR, also see Appendix A

21402

Figure 1-2 Set-up Tasks

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Overview Set-up Tasks

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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:

2.1 Overview 7

2.2 Model Number Interpretation 13

2. Installation

Topic See Page

2.3 Mounting Considerations and Overall Dimensions 16

2.4 Mounting Methods 17

2.5 Wiring Prerequisites 27

2.6 Input Wiring Procedures 29

2.7 Output Wiring Procedures 39

2.8 Option Wiring Procedures 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)

Braid 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 a 3/4” braided copper conductor, is required. Ferrite suppression filters and capacitor filters (see Subsection 2.5 for Wiring Prerequisites) shall be installed on all cables connected to the recorder/controller.

Refer to document 51-52-05-01, How to Apply Digital Instrumentation in Severe Electrical Noise Environments, for additional installation guidance.

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Installation Overview

Operating limits and condensed specifications

We recommend that you review and adhere to the operating limits listed in Table 2-1 when you install your recorder.

Table 2-1 Operating Limits and Condensed Specifications

Condition Specifications

Ambient Temperature

Relative Humidity

Vibration Frequency Acceleration

Mechanical Shock Acceleration Duration

Power

Power Consumption

Digital Indication Accuracy

Minimum Input Span

Input Impedance

Source Impedance

Sampling Rate

Input Filter

Digital Displays

Indicators

Deviation Bargraph

Controller Modes of Operation

Transmitter Supply Voltage

32 °F to 131 °F (0 °C to 55 °C)

5 % to 90 % RH at 40 °C (104 °F)

0 to 200 Hz

0.2 g

5 g 30 ms

102 Vac to 132 Vac 50/60 Hz 204 Vac to 264 Vac 50/60 Hz

20 VA maximum

1 digit

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

RTD: 100 ohms per lead maximum

Each input sampled 3 times a second (1 or 2 inputs); 3 times in 2 seconds (3 or 4 inputs).

Software: Single pole low pass section with selectable time constants (off to 120 seconds).

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.

Channel PV display (CHN 1, 2, 3, or 4) Alarm status (ALM 1, 2) Controller Output (OUT 1, 2) Remote Setpoint (RSP) Temperature unit (F or C) or Engineering Units Controller’s mode (A or MAN)

21 segment, color coded deviation bargraph: Green (large) = On Control Green (small) = Deviation to ± 10 % of PV

Manual Operation Automatic with local setpoint Automatic with remote setpoint

22 Vdc to 26 Vdc at input terminals (50 mA dc at 24 Vdc)

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Condition Specifications

Controller Output1 (Optional)

Auxiliary Output (Optional)

Installation

Overview

• 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 dc 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)

• Position Proportional and Three Position Step

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. Time 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: 5 A @ 120 Vac, 2.5 A @ 240 Vac Inductive Load: 50 VA @ 120 Vac or 240 Vac Cycle Time: 1 second to 120 seconds Current Proportional: Resolution: 10 bits Accuracy: 0.5 % full scale

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 12 control parameters. Resolution: 12 bits over 0 to 21 mA Accuracy: 0.2 % of full scale Temperature Stability: 0.03 % F.S./°C

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Installation Overview

Actuations

Thermocouples3 B

E (low)

J (low)

K (low)

NNM (Ni Ni Moly)

NIC (Nicrosil-Nisil)

T (low)

W5W26

W5W26 (low)

°F °C ± °F ± °C

105 to 3300

105 to 150 150 to 500 500 to 1000 1000 to 3300

–454 to 1832 –454 to –202 –202 to 1832

–200 to 1100 –129 to 593

0 to 1600 –18 to 871

20 to 770 –7 to 410

–320 to 2500

–320 to 0 0 to 2500

–20 to 1000 –29 to 538

32 to 2500

32 to 500 500 to 2500

0 to 2372 –18 to 1300

0 to 3100

0 to 500 500 to 3100

0 to 3100 0 to 500 500 to 3100

–300 to 700 –184 to 371

–200 to 600 –129 to 316

0 to 4200

0 to 600 600 to 3600 3600 to 4200

0 to 2240 0 to 600 600 to 2240

Range Reference Accuracy Types of Input

41 to 1816

41 to 66 66 to 260 260 to 538 538 to 1815

–270 to 1000 –270 to –130 –130 to 1000

–196 to 1371

–196 to –18 –18 to 1371

0 to 1371

0 to 260 260 to 1371

–18 to 1704 –18 to 260 260 to 1704

–18 to 1704

–18 to 260 260 to 1704

–18 to 2315

–18 to 316 316 to 1982 1982 to 2315

–18 to 1227 –18 to 316 316 to 1227

Radiamatic 1400 to 3400 760 to 1871

RTD Platinum

100 ohms 200 ohms (high)5 200 ohms (low)

500 ohms

–300 to 900 32 to 752 32 to 392 –300 to 900

–184 to 482 0 to 400 0 to 200 –184 to 482

Temp Stability ±

Degrees Error Per 1

Degree ∆T

42.00

14.00

3.00

1.50

18.00

1.00

23.00

7.70

1.70

0.80

10.00

0.55

2.00

0.50

0.20

0.70

0.35

0.50 0.30 0.20

0.40 0.22 0.06

0.20 0.11 0.04

1.25

0.60

0.70

0.35

0.18

0.09

0.30 0.16 0.05

0.75

0.50

0.40

0.30

0.09

0.07

1.0 0.55 0.01

2.00

1.00

2.00

1.00

1.10

0.55

1.10

0.55

0.25

0.13

0.23

0.13

0.60 0.35 0.07

0.40 0.22 0.07

1.40

1.30

1.60

1.10

1.00

0.77

0.70

0.90

0.60

0.55

0.17

0.29

0.14

0.10

1.00 0.55 0.10

0.40

0.30

0.20

0.22

0.16

0.12

0.11

0.05

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Installation

Overview

Actuations

Linear

Milliamperes dc

Millivolts dc

Volts dc

Relative Humidity Platinum 100 ohm

Wet/Dry Bulb*

Wet/Dry Input

% RH4

Range Reference Accuracy Types of Input

°F °C ± °F ± °C

4 to 20

0 to 10 10 to 50

1 to 5 (can be calibrated 0 to 5) 0 to 10

–130 to 392

—

–90 to 200

0.10 %

0.05 %

0.10 %

0.30

Dry Bulb Range Measured

% RH

0 to <20 20 to 100

°F °C

–103 to 212 35 to 40 >40 to 100 100 to 212

–75 to 100 2 to 4 >4 to 38 38 to 100

—

0.03

Reference

Accuracy

2 % RH 2 % RH 1 % RH 1 % RH

Temp Stability ±

Degrees Error Per 1

Degree ∆T

0.004 %/°F

0.03

Temp. Stability 53 °F to 104 °F/

12 °C to 40 °C

0.11 % RH/°F

0.11 %RH/°F

0.06 % RH/°F

0.03 % RH/°F

Condition Specifications

Case Molded, foamed-Noryl** with gasketed door.

A UL and FM approved NEMA4X door is also available.

Chart

Wiring Connections

12-inch (304.8 mm) diameter chart. Plain thermal-sensitive paper.

Terminals inside the case.

Color Case: Black

Door (standard): 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 I, Div. 2, Groups A, B, C, D areas depending on model.

Weight

13.2 lbs (6 kg)

Mounting Panel, 2-inch pipe, or surface mounted. Some adapter kits available for existing panel

cutouts.

OPTIONS

Alarm Output Two, four, or six relays available.

Relay Contact Ratings: First Relays, Resistive Load: 1 A @ 120 Vac, 1/2 A @ 240 Vac Relays 3 through 6, Resistive Load: 5 A @ 120 Vac, 2.5 A @ 240 Vac

Digital Input +20 Vdc source for external dry contact or isolated solid state contacts. Selects one

configured input.

Totalizers One to four totalizers depending on model.

Eight digit “totals” with multiplier on digital display; 14 digit totalization printout on chart.

RS485 Modbus RTU Communications

Baud rate: 300, 600, 1200, 2400, 4800, 9600,19,200, 38,400 Protocol: RS485 Modbus RTU Communications Length of Link: 4000 ft (1,219 m) maximum Link Characteristics: Two-wire, multidrop

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Installation Overview

Condition Specifications

Calculations

Miscellaneous

calculation available on DR45AR, Math function.

• FM Approved 4-20 mA Control Output

• A UL and FM approved NEMA4X door

• Door Lock

• External Keypad

• Chart Illumination

• U.L. Listing, CSA Approval, FM Class I Div. 2

• Control with Accutune II Tuning capability

• Math

• Glass or Acrylic Window

• Configuration Lockout Switch

• Customer ID Tag (30 characters maximum)

• Pulse output counter alarm function on DR45AW model

CE Conformity (Europe) 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.

Product Classification Class 1: Permanently connected, Panel/Surface Mounted Industrial Control Equipment

with protective earthing (grounding). (EN 61010-1)

Enclosure Rating

Installation Category (Overvoltage Category)

Panel/Surface Mounted Equipment, IP 54. (ref. IEC 529)

Category II: Energy-consuming equipment supplied from the fixed installation. Local level appliances, and Industrial Control Equipment. (EN 61010-1)

Pollution Degree Pollution Degree 2: Normally non-conductive pollution with occasional conductivity

caused by condensation. (ref. IEC 664-10

EMC Classification Group 1, Class A, ESM Equipment (EN 55011, emissions),

Industrial Equipment (EN 50082-2, immunity)

Method of EMC

Technical File (TF)

Assessment

Declaration of

Document #51197639-000

Conformity

*IEC Alpha (α) = 0.00385 Ω/Ω/°C

**Registered Trademark—General Electric Co.

Not all controller outputs are available on all models of the Truline Recorder.

Consult Model Selection Guide for information.

Not all Input Actuations are available on all models of the Truline Recorder.

Consult Model Selection Guide for information.

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.

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.

Only available with Model DR45AR.

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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.

Table 1 Table 2 Table 3 Table 4 Table 5Key Number

DR45A 00

Key Number

Standard Recorder

Relay expansion Recorder

Flow Recorder

HTST

Pasteurization Recorder - Flow

Safety Thermal Limit Recorder

Input Actuation (Note 1) 0

None

T/C, RTD, Radiamatic , mV, 0–5V, 4–20mA

0–10 Vdc

External Output 0 0

= None

1 0

= 1 Control Output

1 1

= 2 Control Outputs

4 0

= 1 Control w/SP Programming

4 4

= 2 Controls w/SP Programming

5 0

= Pulse Output

6 0

= 1 Control Output with FM Approval

6 6

= 2 Control Outputs with FM Approval

External Interface 0 – –

= None

1 – –

= Auxiliary 4-20 mA Output

3 – –

= RS485 Modbus RTU**

4 – –

= RS485 Modbus RTU ** plus Auxiliary Output

– 0 –

= Standard Pen

– 1 –

= Abrasion Resistant Pen

– – 0

= None

– – 1

= 2 Alarm Outputs/2 Digital Inputs

– – 2

= 4 Alarm Outputs/2 Digital Inputs

– – 3

= 6 Alarm Outputs/2 Digital Inputs

– – 4

= 1 Alarm/1 Timer/2 Digital Inputs **

**Only available with key number DR45AT, AR, AW

––––– –

Hardware Options

0 - - - - 1 - - - - E - - - - F - - - - 5 - - - - 6 - - - - -

L - - - - 9 - - - - P - - - - R - - - - S - - - - -

- 0 - - - -

- A - - - -

- K - - - -

- - 0 - - -

- - L - - -

- - M - - -

- - N - - -

- - - 0 - -

- - - K - -

- - - L - -

- - - M - -

- - - N - -

- - - P - -

- - - R - - FM approved - Class 1, Div. 2, Groups A, B, C, D

- - - U - -

- - - - 0 -

- - - - T -

- - - - B -

- - - - C -

- - - - D -

- - - - E -

- - - - - 0

- - - - - 1

Gray door / Glass window

Gray door / Acrylic window

Gray door / Glass window and keypad

Gray door / Acrylic window and keypad

Blue door / Glass window

Blue door / Acrylic window

Black door / Glass window

Black door / Acrylic window

NEMA4X door / Glass window

NEMA4X door / Acrylic window

NEMA4X HTST door

Standard door latch

Keyed latch

Door lock with key

No illumination

Configuration lockout / Chart plate seal

Configuration Lockout / Chart plate seal / Illumination

Chart illumination

No approvals

CE Mark

CE Mark + UL + CSA certification

CE Mark + FM approval

CE Mark + UL + FM / CSA certification

UL listing + CSA certification

UL listing + CSA certification + FM approval

No I.D. Tag

Customer I.D. Tag (30 characters maximum)

Certificate of Conformance (F3391)

Custom Calibration / Test Report (F3399)

Certificate of Conformance + I.D. Tag

Customer Calibration + I.D. Tag

None

Product Configuration

Installation

Table 6

Software Options 0

= None

= Totalization , Input 1

= Math Only

= Totalization , Inputs 1 & 2

= Fo Sterilization Calculation

= Totalization , Inputs 1, 2, 3, & 4

= Totalization , Input 1 + Math

= Totalization , Input 1 and 2 + Math

= Totalization, Input 1, 2, 3, 4 + Math

NOTE 1: Every DR4500A recorder has all the available inputactuations stored in its nonvolatile memory and can accept up to 4 inputs which must be specified sequentially in 1–4 entries in Table 1. Therefore, you can easily change the input actuation in the field by re-wiring input connections, changing the input jumper position, and reconfiguring the input type, as applicable.

Figure 2-1 Model Number Interpretation

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Installation Model Number Interpretation

Example of model number decoding

Assume that the model number on the label is

DR45AT - 1300 - 44 - 001 - A - 1KN0T0 - 0

Using the table code definitions from Figure 2-1, this recorder has the following features and options:

• 2-input type with thermocouple, RTD, Radiamatic, mV, 0-5 Vdc or 4-20 mA input for channel 1

• 0-10 Vdc input for channel 2

• Two controllers with setpoint programming capability

• Alarm output / digital input capability

• High speed pen

• Totalization for input 1

• Gray door with acrylic window

• Door lock

• Chart illumination

• Customer I.D. tag

• No approvals

Location of hardware components

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 Components

Step Action

1 Turn the latch on the recorder door and swing the door open.

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.

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Page 29

View of hardware components

Figure 2-2 shows the location of the actual hardware components for key number DR45AT. If key number is DR45AR, see Appendix A for internal views.

Key Number: DR 45AT*

* If Key number is DR45AR, see Appendix A for internal views.

Installation

Model Number Interpretation

"One-Pen" stylus printhead

Mother PCB (for #3, #4 inputs, control and selected options)

Control output #2 PCB **Table II - X1,

X4, X6

Control output #1 PCB **Table II - 1X, 4X, 6X

#2 #1

Auxiliary Output PCB **Table III - 1XX OR RS485/422 Modbus Communications PCB **Table III - 3XX OR Auxiliary Output and RS485/422 Modbus Com PCB **Table III - 4XX

Alarm output/ digital input PCB **Table III - XX1

Main Processor Board

Input PCB's

**Table I - XXXX x = 0,1, or 3

** Refer to Model Selection Guide

21404

Figure 2-2 DR4500A Recorder Hardware Components Versus “Table” Selections

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Page 30

Installation

Mounting Considerations and Overall Dimensions

2.3 Mounting Considerations and Overall Dimensions

Physical considerations

The recorder can be mounted in a panel 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.

321

12.6

ottom view

millim e te rs

in ch e s

Reference

20.3

0.8

321

12.6

419

16.5

163

6.4

196

7.7

Surface mounting

14.6

370

181

7.1

Dime ns ions :

Standard DR4500

17.5

0.69

Short wing latch :

ouble bit latch :

e ft side view

14.5 .57

.19

NEMA4X DR4500

17.5

0.69

ottom view

321

12.6

106

4.2

Reference

20.3

0.8

321

12.6

106

4.2

142

322

355

5.6

11.0 .43

5.6

ron t vie w

387

15.25

ron t vie w

EMA4

438

17.25

Surface mounting

zzzzz

ack vie w

ack view

322

12.7

anel cutout (all models)

Figure 2-3 Overall Dimensions

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Page 31

2.4 Mounting Methods

Introduction

There are several methods available for mounting your recorder.

• Flush in Panel (new panel cutout)

• Flush in Panel (using an existing panel cutout)

− using universal filler plate kit

− using cutout made for Kent Model 105M

• Flush in Panel for recorders with NEMA4 Door

• On a 2-inch Pipe

• On 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

Installation

Mounting Methods

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" (12.7 mm) conduits. Refer to Figure 2-4 for knockout locations.

ATTENTION

The knockouts are really plugs that you just have to push out to remove.

Side View

Bottom View

21405

Figure 2-4 How to Remove Knockouts

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Page 32

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

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.

Orient the recorder case properly and slide it into the cutout from the front of the panel. Support the recorder as shown in steps 3 and 4.

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.

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

21406

Figure 2-5 Mounting Flush in a New Panel Cutout

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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

Honeywell/Model AR100*, DR4200 12.7 x 12.7 No*

Honeywell/Class 15 15.8 x 17.2 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 3.56 x 18.56 Yes

Fisher and Porter/Model 51-1100 13.75 x 17.31 Yes

Dimensions of Existing

Panel Cutout (inches)

Need Universal Filler

Plate Kit 30755134-001 Blue Color 30755134-002 Gray Color

Installation

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 L DR4500A Truline Circular Chart Recorder With or Without Control Product Manual 19 8/02

Page 34

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

Lay the recorder face down on a clean work surface and position the universal filler plate as

shown in Figure 2-6.

Measure the height of the existing panel cutout.

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.

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 screw holes in the recorder case.

Insert the recorder into the cutout from the front of the panel as shown in Figure 2-6.

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.

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 hardware are included in kit 30755134-xxx

Universal filler plate

Height of cutout in panel

Figure 2-6 Mounting in a Panel Using Universal Filler Kit

Universal filler plate

Support brackets

Tapped screw holes

Mounting brackets (supplied with recorder)

21407

Support brackets (included in kit 30755134-xxx

20 DR4500A Truline Circular Chart Recorder With or Without Control Product Manual Release L 8/02

Page 35

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

Drill two 1/4-inch holes in the back of the panel as shown in Figure 2-7. These holes are for 1032 screws to be inserted from back of panel into threaded inserts in the back of the recorder case.

Installation

Mounting Methods

ATTENTION

screws for the 3/8-inch long screws supplied with the recorder.

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.

From the rear of the panel, insert two 10-32 pan head screws of appropriate length into threaded inserts in the recorder case.

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.

While holding the recorder firmly against the panel, slide each bracket against the back of the panel and tighten the screws.

If the panel is more than 1/4-inch thick, substitute 10-32 x 1/2-inch long

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

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Page 36

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 NEMA4X door.

Table 2-7 Procedure for Mounting Recorder with NEMA4X Door

Step Action

1 Place the panel gasket onto the rear flange of the recorder case.

Install five #8-32 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.

3 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 lb-in of torque applied. Do the same to both the other three brackets.

When completed all twenty screws should have a 5 to 8 lb-in of torque applied. This assures that the case and panel gaskets are adequately sealed against the panel.

22 DR4500A Truline Circular Chart Recorder With or Without Control Product Manual Release L 8/02

Page 37

Installation

Mounting Methods

Slot

Bracket (4)

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

Slot

Hex Head Bolt 1/4-20 x 5/8 inch

Slot

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

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Page 38

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.

Step Action

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.

Install the U-bolts around the pipe and through the bracket holes. Secure with lockwashers and hex nuts provided.

Table 2-8 Pipe Mounting Procedure

Washer

Hex Nut

Pipe Mounting Bracket

Plastite Screw

Rear of Case

U-bolt

24224

Figure 2-9 Pipe Mounting Brackets

24 DR4500A Truline Circular Chart Recorder With or Without Control Product Manual Release L 8/02

Page 39

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 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.

Installation

Mounting Methods

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.

7 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.

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Page 40

Installation Mounting Methods

181.36

7.14

Hole Pattern Reference:

196.22

7.725

millimeters

inches

These screws must be supplied by user; all other mounting hardware is supplied with recorder.

369.6

14.550

163.32

6.430

18.03

0.710

Figure 2-10 Mounting Flush on a Surface (of Panel or Wall)

NOTE:

Support hook

21409

26 DR4500A Truline Circular Chart Recorder With or Without Control Product Manual Release L 8/02

Page 41

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:

• Separate External Wiring - separate connecting wires into bundles (see Table 2-10) and route the individual bundles through separate conduits or metal trays.

• Use Suppression Devices - for additional noise protection, you may want to add suppression devices at the external source; appropriate suppression devices are commercially available.

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.

Installation

Wiring Prerequisites

Recorder grounding

PROTECTIVE BONDING (grounding) of this recorder shall be in accordance with National and local electrical codes.

Functional earth

To 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.

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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 connected 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.

Bundle No. Wire Functions

Table 2-10 Permissible Wiring Bundling

1 • Line power wiring

• Earth ground wiring

2 Analog signal wire, such as:

3 • Low voltage alarm relay output wiring

Identify your wiring requirements

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.

• Control relay output wiring

• Line voltage alarm wiring

• 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 wiring to solid state type control circuits

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Page 43

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

Installation

Input Wiring Procedures

Relay Control Outputs – 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 #1 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, except the RS485 communications cable, should be tied to earth ground at the recorder end and to earth ground through a .0047 µF 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.

Figure 2-18

Release L DR4500A Truline Circular Chart Recorder With or Without Control Product Manual 29 8/02

Page 44

Installation Input Wiring Procedures

Mother PCB

Control Loop 1 and Loop 2 Output Relays Alarm Relays

RS485/422 Modbus Communications

External Ground Bus Bar

Current Output 1 & 2 Slidewire 1 & 2 Auxiliary Output

Number 1 & 2 Alarm/ Digital Inputs

Transformer

A.C. Main

Shield Wiring

Processor

Board

Digital Inputs 1 & 2 Transmitter Power

Hex Nut

Ferrite Filter

Cable Fitting

Inputs 1–4

Washer

To Earth Ground

1 Recorder Grounding, rear of case - Use 3/4 inch braided copper conductor.

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.

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.

Figure 2-11 Ferrite Filter Locations and Shield Wiring (CE Mark)

AC line power

Refer 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 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.

23685

30 DR4500A Truline Circular Chart Recorder With or Without Control Product Manual Release L 8/02

Page 45

Installation

Input Wiring Procedures

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.

Locate connector J10 on the bottom edge of the main printed circuit board. (Refer to Figure 2-12.)

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 Insert

• the green wire (G) into the first screw clamp from the right,

• the white wire (L2) into the second screw clamp from the right, and

• the black wire (L1) into the third screw clamp from the right.

Tighten the screws to secure the wires.

CAUTION

into the correct screw clamps. Make sure the fuse block is installed properly for the given supply rating –– 120 Vac or 240 Vac. The fuse is in the 120 Vac location from the factory.

Make sure the fuse block is installed in the proper location. Refer to Figure 2-12 for fuse block location.

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.

• Refer to document 51-52-05-01 for additional information concerning noise interference

prevention.

To avoid damaging the recorder, be sure that you install the power wires

• 120 Vac – Fuse block in location F2

• 240 Vac – Fuse block in location F1

11 Insert the wired plug into J10.

WARNING

ground is not attached; personal injury and product damage could result.

Input line voltage will be present on the instrument ground plane if safety

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Page 46

Installation Input Wiring Procedures

#2 #1

Fuse Block on Main PC Board

P/N51309355-tab

120 Vac

240 Vac

Required for CE Mark Conformity— 14 AWG Braided Wire to AC supply

PLUG J10

ground

L1 L2

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.

120 or 240 Vac

Figure 2-12 AC Line Power Wiring

Fair-Rite P/N 0443164151

or equivalent

21410B

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Page 47

Thermocouple, RTD, Radiamatic, mV, or 0-5 Vdc inputs

You can wire input 1, 2, 3, or 4 for thermocouple, RTD, Radiamatic, mV, or 0-5 Vdc actuations.

The polarity for inputs #1, #2, #3, and #4 is identical.

The prerequisites are:

• Model Number - Table 1 = 1XXX, X1XX, XX1X, XXX1

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, or 0–5 Vdc inputs.

Table 2-12 Thermocouple, RTD, Radiamatic, mV, or 0–5 Vdc Input Wiring

Step Action

Installation

Input Wiring Procedures

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:

• Install the ferrite filter as shown in Figure 2-11.

• Install a .01 µF capacitor across the J2 terminals and a .0047 µF capacitor at the

sensor end of the input wiring as shown in Figure 2-13.

Locate jumper position MA/W1 and make sure the jumper is in the W1 position. (See Figure 2-13 for the location.)

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 locations.)

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.

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, 3, and 4 printed circuit boards as applicable.

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Installation Input Wiring Procedures

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.

Thermocouple

.01 µF

Capacitors

Plug J2

RTD

Cable Shield

.0047 µF

Capacitor

MA/W1 Jumper position on input

T/C

board

#2#1

21411B

W3 Jumper

Positions

Thermocouple

Linear

RTD

T/C

RTD

T/C

RTD

.01 µF

Capacitors

Plug J2

Radiamatic, mV, or 0-5 Vdc

.01 µF Capacitor

Plug J2

NOTE: For T/C or RTD input, calibrate recorder to achieve stated accuracy. See Section 7 - Input Calibration.

Figure 2-13 Thermocouple, RTD, Radiamatic, mV, or 0–5 Vdc Input Wiring

•

.0047 µF

Capacitor

RTD

.0047 µF

Capacitor

TYPE W1/MA W3

T/C, Linear

RTD

mV or Volt source

Be sure that thermocouple extension

• wire matches thermocouple type

•

Keep resistance of all wires equal Use 18 gauge copper wire for lengths up to

• 150 feet. For two wire RTD, jumper terminal 1 to 3.

•

T/C

RTD

34 DR4500A Truline Circular Chart Recorder With or Without Control Product Manual Release L 8/02

Page 49

4-20 mA inputs and transmitter power

You can wire input 1, 2, 3, or 4 for 4–20 mA actuations.

The polarity for inputs #1, #2, #3, and #4 is identical.

The prerequisites are:

• Model Number - Table 1 = 1XXX, X1XX, XX1X, XXX1

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

Installation

Input Wiring Procedures

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 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 position W3 and make sure the jumper is in the proper position for your input type (see Figure 2-14 for the location).

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.

For CE Mark conformity, install the ferrite filter as shown in Figure 2-11 and 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.

ATTENTION

protection diode. The wake-up pulse on the ST3000 may not be recognized by the transmitter due to this clamping action. It may be necessary to add 100 ohms of additional loop resistance so the transmitter and SFC can communicate.

• 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.

Insert the wired plug into J2 and J11 as applicable.

The DR4500A Recorder inputs are protected from overvoltage by a

Release L DR4500A Truline Circular Chart Recorder With or Without Control Product Manual 35 8/02

Repeat steps 2 through 11 for input 2, 3, and 4 printed circuit boards as applicable.

Page 50

Installation Input Wiring Procedures

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.

VIEW A - From transmitter with power

.01 µF

4-20 mA

Cable Shield

Plug J2

ATTENTION

from overvoltage by a protection diode. The wake up pulse on the ST3000 may not be recognized by the transmitter due to this clamping action. It may be necessary to add 100 ohms of additional loop resistance so the transmitter and SFC can communicate.

The DR4500A Recorder inputs are protected

Cable Shield

VIEW B - From

4-20 mA

transmitter receiving 24Vdc power from recorder

Plug J2

Ferrite filter

Figure 2-14 4-20 mA Input Wiring

.0047 µF

Capacitor

.0047 µF

Capacitor

4 - 20 mA source

Xmtr

MA/W1 Jumper position on input board

TYPE W1/MA W3

4-20mA

#2 #1

M/A

Transmitter power (24 Vdc)

Plug J11

21412B

W3 Jumper

Positions

Linear/MA

T/C

RTD

T/C

36 DR4500A Truline Circular Chart Recorder With or Without Control Product Manual Release L 8/02

Page 51

0-10 Volt dc inputs

You can wire input 1, 2, 3, or 4 for 0–10 Volt dc actuations.

The polarity for inputs #1, #2, #3, and #4 is identical.

The prerequisites are:

• Model Number - Table 1 = 3XXX, X3XX, XX3X, XXX3

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.

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 2-15).

Installation

Input Wiring Procedures

Table 2-14 0-10 Volt dc Input Wiring

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.

5 For CE Mark conformity:

• Install the ferrite filter as shown in Figure 2-11.

• Install the .01 µF capacitor and the .0047 µF capacitor as shown in Figure 2-15.

6 Strip insulation from the end of each wire.

7 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.

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, 3, and 4 printed circuit boards as applicable.

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Installation Input Wiring Procedures

Ferrite Filter

Fair-Rite P/N 0443164151

or equivalent

#2 #1

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.

100K

.01 µF

Plug J2

100K

(modified)

NOTE: Calibrate recorder to achieve stated accuracy. See Section 7 - Input Calibration.

MA/W1 Jumper

Cable Shield

0-10 Vdc source

.0047 µF

Capacitor

position on input board

TYPE W1/MA W3

Linear

Figure 2-15 0-10 Volt dc Input Wiring

21413B

W3 Jumper

Positions

Linear/MA

W1 T/C

T/C

RTD

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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:

• Model Number - Table 2 = 10, 40, 44, 60, or 66

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.

Locate connector J1 near the top of the control output #1 or #2 printed circuit board (refer to Figure 2-16 for location).

3 Remove the unwired plug from J1.

4 Run the output wires through the desired knockout.

Installation

Output Wiring Procedures

For CE Mark conformity, install the ferrite filter as shown in Figure 2-11 and the .0047 µF 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.

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.

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.

TIP

The 4-20 mA output can be used as a retransmission output if it is not used as a control output.

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Installation Output Wiring Procedures

#2 #1

Control Output #1-2 PCB Current Output Select Jumper

W7 = Relay or Current Output

Control Output #1 PCB

Auxiliary Output #2

Control Output #2 PCB

Auxiliary Output #3

Ferrite Filter

21414

4-20 mA output

Plug J1

Cable Shield

Controller load 0-1000 ohms

.0047 µF

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 of case. See Figure 2-11.

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)

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Position proportional or 3-position step control output wiring

You can wire control output 1 or 2 for position proportional or 3 position step output.

The prerequisites are:

• Model Number Key = DR45AT

• Model Number - Table 2 = 10, 40, or 44

Refer to Figure 2-17 and follow the procedure in Table 2-16 to wire position proportional or 3 position step control outputs.

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.

Slidewire input is not required for 3 position step control but can be used for motor position indication.

Table 2-16 Position Proportional Control Output Wiring

Step Action

Installation

Output Wiring Procedures

1 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).

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 2-17 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 (not required for 3 position step) and motor drive wires through the desired knockouts.

5 For CE Mark conformity:

• install the ferrite filter as shown in Figure 2-11

• install the shield capacitors as shown in Figure 2-17.

6 Strip insulation from the end of each wire.

7 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.

9 Loosen the screws in plug J5 terminals and position the plug as you would to plug it into J5.

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.

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Installation Output Wiring Procedures

Control output #1-2 PCB

Relay No. 1

W2 = N.O. contact

W3 = N.C. contact

Relay No. 2

W4 = N.O. contact

W5 = N.C. contact

W6 = Position

Proportional Output

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.

Figure 2-17 Position Proportional Control Output or Three Position Step Wiring

Plug J5

Relay 1

Relay 2

Plug J2

Cable Shield

.0047 µF

Capacitor

#2 #1

OPEN

CLOSED

.0047 µF

Capacitor

OPEN (CW)

CLOSED (CCW)

Control output #1 PCB

Control output #2 PCB

Motor's feedback slidewire 100 to 1000

(Not required for Three Position Step Control)

Motor power supply

21415

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Relay control output wiring

You can wire control output 1 or 2 for relay output including Time proportional and 3 position step applications.

The prerequisites are:

• Model Number - Table 2 = 10, 40, 60, 11, 44, 66

Refer to Figure 2-18 and follow the procedure in Table 2-17 to wire relay control outputs.

ATTENTION

Relay #2 is used for time proportional control. Relay 2 can also be used for 3 position step control (see Figure 2-17).

Step Action

1 Open the recorder door. Loosen the captive screw in the chart plate and swing the plate out.

Installation

Output Wiring Procedures

Table 2-17 Relay Control Output Wiring

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.

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.

For CE Mark conformity:

- install the ferrite filter as shown in Figure 2-11.

- 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.

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 plug into J5.

11 Repeat steps 2 through 10 for control output #2 printed circuit board as applicable.

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Installation Output Wiring Procedures

Control output #1-2 PCB

Relay No. 1

W2 = N.O. contact

W3 = N.C. contact

Relay No. 2

W4 = N.O. contact

W5 = N.C. contact

Position when shipped N.O. with power applied and out indicator light off.

W7 = Relay or Current Output

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.

*Relay 2 is used for time proportional duplex. Also used for 3 position step. See Figure 2-17.

Plug J5 (see Notes)

#2 #1

Cable Shield

.0047 µ F

Capacitor

Relay 1 load

Heat

Relay 2 load

Cooling

External Load power supply

Control output #1 PCB

Control output #2 PCB

Notes:

J5 terminals 2 and 4 are the non-switched connections to an SPST relay. Selectable for normally open or normally closed as required.

This relay supplies a dry contact closure. User must supply appropriate power connections for his external device.

This relay has a resistive load rating of 5A @ 120 Vac Load calculation example:

Figure 2-18 Relay Control Output Wiring

44 DR4500A Truline Circular Chart Recorder With or Without Control Product Manual Release L 8/02

Supply voltage (for example: 115 Vac)

Resistance of customer controlled device

must equal a

number less than 5 amps

21416

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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 = XX1

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.

Installation

Option Wiring Procedures

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.

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 contacts in an

or either contact initiates the configured action. Tighten the screws to secure the wires.

Install the wired plug into J3.

Remove the unwired plug from J4.

Run the alarm output wires through the desired knockout.

For CE Mark conformity:

• install the ferrite filter as shown in Figure 2-11

• install the shield capacitors as shown in Figure 2-19.

Strip insulation from the end of each wire.

Loosen the screws in plug J4 terminals and position the plug as you would to plug it into J4.

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.

Locate the jumper positions W1/W2 and W3/W4 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.

and/or fashion, so that both contacts

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Installation Option Wiring Procedures

External Load Power Supply

Alarm #1 Relay Load

Alarm #2 Relay Load

.0047 µF Capacitor

Ferrite Filter

Fair-Rite P/N 0443164151

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.

or equivalent

Cable Shield

Alarm outputs

Plug J4 (see Notes)

Alarm No. 1

W3 = N.C. contact

W4 = N.O. contact

Alarm No. 2

W1 = N.C. contact

W2 = N.O. contact

#2 #1

Position when shipped N.C. with power off or Alarm indicator light on.

Notes:

1. J4 terminals 2 and 4 are the nonswitched 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.

3. This relay has a resistive load rating of 1 A @ 120 Vac Load calculation example:

Supply voltage (for example: 115 Vac)

Resistance of customer controlled device

Cable Shield

Digital inputs

PIN 3 - 2nd Control Loop + Digital 2

PIN 2 - 1st Control Loop + Digital 1

PIN 1 - Recorder Supplied Voltage Source

Plug J3

for Digital Inputs

.0047 µF Capacitor

must equal a number less than 1 amps

Figure 2-19 Alarm Output or Digital Input Wiring

21417

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Additional 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, 4X, 6X*

*If control output is 4-20 mA, then the relays on the control card are available for use as alarms on all models except DR45AH/AS/AP models.

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

Installation

Option Wiring Procedures

1 Open the recorder door. Loosen the captive screw in the chart plate and swing the plate out.

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.

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:

• install the ferrite filter as shown in Figure 2-11

• 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.

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.

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Installation Option Wiring Procedures

Alarms 5 and 6 output wiring

You can wire #5 and #6 Alarm outputs.

The prerequisites are:

• Model Number - Model Table 2 = X1, X4, X6*

*If control output is 4-20 mA, then the relays on the control card are available for use as alarms on all models except DR45AH/AS/AP models.

Refer to Figure 2-20 and follow the procedure in Table 2-20 to wire Alarm 5 and Alarm 6 outputs.

Step Action

1 Open the recorder door. Loosen the captive screw in the chart plate and swing the plate out.

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.

Table 2-20 Alarm 5 and Alarm 6 Output Wiring

5 Run the Alarm output wires through the desired knockout.

6 For CE Mark conformity:

• install the ferrite filter as shown in Figure 2-11

• 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.

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.

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Wiring for alarm outputs #3, 4, 5, and 6

Alarm No. 3 W2 = N.O. contact

W3 = N.C. contact Alarm No. 4 W4 = N.O. contact W5 = N.C. contact

W3 W2

Ferrite filter

Cable Shield

Installation

Option Wiring Procedures

External Load Power Supply

Alarm #3 Relay Load

Alarm #4 Relay Load

4 - 20 mA control output and no. 3 & 4 alarm outputs

W5 W4

PCB

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.

No. 5 & 6 Alarm outputs PCB

W3 W2

Plug J5

.0047 µF

Capacitor

#2 #1

21466

External Load Power Supply

W5 W4

Alarm No. 5 W2 = N.O. contact

Plug J5

Cable Shield

Alarm #5 Relay Load

W3 = N.C. contact

Alarm No. 6

W4 = N.O. contact

Alarm #6 Relay Load

W5 = N.C. contact

Ferrite filter

.0047 µF

Capacitor

Figure 2-20 Alarm outputs #3, 4, 5, and 6 wiring

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Installation Option Wiring Procedures

RS485 Modbus communications wiring

RS485 Modbus Communications is an option available on the DR4500A recorder.

The prerequisites are:

• Model Key Number - All models except DR45AH/AP/AS

• Model Number - Table 3 = 3XX or 4XX

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.

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

• Install the ferrite filter as shown in Figure 2-11.

• Refer to Figure 2-21 for shield 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.

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.

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Ferrite Filter

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 I Cable (Alpha P/N 5121C)

Plug J3

See

Note 2

Communications master

Tx+/ Rx+

SHLD

See

Note 1

Installation

Option Wiring Procedures

#2 #1

Tx–/ Rx–

120 Ohm

Resistor

Place 120 ohm resistor on last device, between Tx+/Rx+ and Tx–/Rx–.

Notes:

1. The shield of the RS485 Modbus Communications cable is not connected at the recorder end and should not extend into the recorder enclosure. The shield of the communication cable should be connected to earth ground at the farthest end on the cable.

2. For non-CE Mark applications, use shielded twisted pair cables (Belden 4271 Twinax or equivalent).

Optional communication

communications instruments (Maximum 15)

21418G

Figure 2-21 RS485 Modbus Communications Wiring

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Page 66

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.

Step Action

1 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).

3 Remove the unwired plug from J2.

4 Run the output wires through the desired knockout.

5 For CE Mark conformity, install the ferrite filter as shown in Figure 2-11.

Table 2-22 4-20 mA Auxiliary Output Wiring

6 Strip insulation from the end of each wire.

7 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.

9 Install the wired plug into J2.

ATTENTION

Be sure that the 4-20 mA auxiliary output is aligned. Refer 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 II = 10, 40, 44, 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”.

and #3 wiring.

Refer to Figure 2-16 for Aux Out #2

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4-20 mA auxiliary output

Installation

Option Wiring Procedures

Auxiliary Output PCB

#2 #1

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.

Ferrite Filter

Fair-Rite P/N 0443164151

or equivalent

Controller load 0-1000 ohms

Plug J2

.0047 µF Capacitor

22841G

Figure 2-22 4-20 mA Auxiliary Output #1 Wiring

ATTENTION

Refer to Figure 2-16 for Auxiliary Output 2 and Auxiliary Output 3 wiring.

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Installation Lockout Switch Configuration

2.9 Lockout Switch Configuration

Introduction

The configuration can be locked using S1 switch located next 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):

• 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):

• Most parameters for the recorder are locked and the parameters may not be changed except for

Tuning 1 and Tuning 2 parameters and adjustments to time/date/day/year.

Main Printed

U17

J17

U19

Wiring Board (Right Side)

S1 Lockout Switch

UP (ON) Locked

DOWN (OFF) Configure

C50

R42

R43

R45

C56

C55

R47

22709

Figure 2-23 S1 Lockout Switch Location

ATTENTION

Lockout can also be configured under set up group “LOCKOUT”. See Subsection 3.21.

This feature also includes the special screw and plate that provide the lead seal capability for sealing the chart plate. This feature is normally used with DR45AH model recorders.

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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.

3.1 Overview 55

3.2 Configuration Prompts 57

3.3 How to Get Started 60

3.4 Configuration Tips 61

3.5 Configuration Procedure 62

3.6 Input Set Up Group 64

3.7 Pen Set Up Group 66

3.8 Chart Set Up Group 67

3.9 Time Set Up Group 69

3.10 Totalizer Set Up Group 70

3.11 Input Algorithm Set Up Group 72

3.12 Control Set Up Group 73

3.13 Tuning Parameters Set Up Group 75

3.14 SP Ramp Set Up Group 76

3.15 Timer Set Up Group 77

3.16 Alarms Set Up Group 78

3.17 Auxiliary Output Set Up Group 80

3.18 Modbus Communications Set Up Group 81

3.19 Options Set Up Group 82

3.20 Event Message 83

3.21 Lockout Set Up Group 86

3.22 Adjust Printing 87

3.23 Configuration Record Sheet 88

3. Configuration

Topic See Page

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Page 70

Configuration Overview

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.

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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

Configuration

Configuration Prompts

FO RESET

INPUT 1

INPUT 2 INPUT 3 INPUT 4

PEN 1

PEN 2 PEN 3 PEN 4

CHART

RESET FO

ENABLE DECIMAL UNITS ENGUNITS IN1 TYPE XMITTER IN1 HI

IN1 LO CUTOFF 1 INPTCOMP FILTER1 BURNOUT EMISSIV

Same as INPUT 1

ENABLE PEN 1 IN CHART1HI CHART1LO PEN1ON PEN1OFF MAJORDIV

MINORDIV RNG1TAG

Same as PEN 1

CHRTSPD HOUR/REV TIME DIV MINORDIV CONTINUE CHARTNAM HEADER

REM CHRT

Only with key number DR45AR, see Appendix A

TIME

TOTAL 1

TOTAL 2

INP ALG

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MINUTES HOURS DAY MONTH YEAR DAY WAKE MIN

WAKE HR WAKE DAY WAKE MON

(Value) RSET TOT TOTAL 1 TOTAL EU RATE SCALER RSETABLE

INHIBIT

Same as TOTAL 1

INP ALG COEFF PV HIGH PV LOW RATIO A BIAS A RATIO B

BIAS B RATIO C BIAS C POLYNOM C0 VALUE C2x10-1 C3x10-3

C4x10-5 C5x10-7

Page 72

Configuration Configuration Prompts

Set Up Group Function Prompts

CONTROL 1

CONTROL 2

TUNING 1

TUNING 2

SP RAMP1

ENABLE PID SETS SW VALUE SP SOURC RATIO BIAS SP TRACK

POWER UP PWR OUT SP HILIM SP LOLIM ACTION OUT HILIM OUT LOLIM

DROPOFF DEADBAND OUT HYST FAILSAFE REM SW MAN KEY PBorGAIN

MINorRPM CONT1ALG OUT1ALG 4-20 RNG

Same as CONTROL 1

FUZZY ACCUTUNE AT ERR

PROP BD2

GAIN 2

Same as TUNING 1

ENABLE SP RAMP TIME MIN FINAL SP

RATE2MIN

SP RATE EU/HR UP EU/HR DN

SP PROG RECYCLES SOAK DEV PROFILE STATE RECOVERY

RSET2MIN

RSET2RPM

PROP BD

GAIN

CYC SEC CYC2SEC

RATE MIN

RSET MIN

RSET RPM

MAN RSET

SP RAMP2

PROFILES

SPP SEGS

SPP EVNT

TIMER

ALARM 1

ALARM 2 ALARM 3 ALARM 4 ALARM 5 ALARM 6

Same as SP RAMP1

PRx STRT PRx END RAMPUNIT SYNC 1+2

SEGxRAMP SEGx SP SEGxTIME

SEGx EV

TIMER PERIOD START LDISPLAY RSET ON-TIME INCRMENT

A1S1 VAL A1S2 VAL A1S1TYPE A1S2TYPE A1S1 H L A1S1SCAL A1S2 H L

A1S2SCAL AL1 HYST

Same as ALARM 1

PROG END

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Set Up Group Function Prompts

Configuration

Configuration Prompts

AUX OUT

COMM

OPTIONS

EVNT MSG

LOCKOUT

ADJUST

CALIB

STATUS

AUX OUT 4 mA VAL 20mA VAL AUX OUT 2 4 mA VAL 20mA VAL AUX OUT 3

4mA VAL 20 mA VAL

ComSTATE Com ADDR BAUD XMT DLAY DBL BYTE

REJ FREQ HF REJ RELHUMID ATMPRES DEVIATION DEVSETPT SCROLL

GRANDTOT

EVENT 1 MESSAGE1 POSITION1 EVENT 2 MESSAGE2 POSITION2 EVENT 3

MESSAGE3 POSITION3 EVENT 4 MESSAGE4 POSITION4 EVENT 5 MESSAGE5

POSITION5 EVENT 6 MESSAGE6 POSITION6

PASSWORD

TRACE LN GRID LN PEN TYPE

For field calibration—see Calibration section of manual

VERSION FAILSAFE* RAM TEST CONFTEST CAL TEST COMMTEST FACT CRC

If key number is DR45AR, see Appendix A for Fo calculation prompts.

LOCKOUT CHANGE

BATTERY

*Displayed on test failure only

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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 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 3.23 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:

• Inputs (Display will be correct)

• Pens (Trace will agree with display)

• Chart

• Alarms

• Control

• Tuning

• Other functions as needed

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3.4 Configuration Tips

Introduction

Listed below in Table 3-1 are some tips that will help you enter the configuration data more quickly.

Function Tip

Configuration

Configuration Tips

Table 3-1 Configuration Tips

Displaying groups

Displaying functions

Scrolling

Changing values quickly

Restoring to the original value

Exiting Set Up mode

Timing out from Set Up mode

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 recorder.

Use the FUNC key to display the individual parameters under each group. The prompts are listed in the order of their appearance in each group.

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

UP or FUNC key is held in. Also, [▲] [▼] keys will move group prompts

forward or backward at a rate twice as fast.

When Changing the value of a parameter, you can adjust a more significant digit in the upper display by holding in one key [▲] or [▼] , and pressing the other [▲] or [▼] at the same time.

• The adjustment will move one digit to the left.

• Press the key again and you will move one more digit to the left.

When you change the value or selection of a parameter while in Set Up mode and decide not to enter it, press RUN/HOLD once, the original value or selection will be recalled.

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.

If you are in Set Up mode and do not press any keys for one minute, the recorder will time out and revert to the mode and display that was being used prior to entry into Set Up mode.

The prompting scrolls at a rate of 2/3 seconds when the SET

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:

• parameter not available

• not in Set Up mode, press SET UP key first

• key malfunction, do keyboard test (operation)

• individual key locked out

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Configuration Configuration Procedure

3.5 Configuration Procedure

Introduction

• 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.

Procedure

Follow the procedure listed in Table 3-2 to access the Set Up groups and Function prompts.

TIP

The prompting scrolls at a rate of 2/3 seconds when the SET UP or FUNC key is held in. Also, [▲] [▼] keys will move group prompts forward or backward at a rate twice as fast.

Table 3-2 Configuration Procedure

Step Operation Press Result

1 Select Set Up mode SET

2 Select any Set Up group SET

Select a Function parameter

Select other Function parameters

FUNC

Upper Display: SET UP—Lets you know you are in the configuration mode and a Set Up group title is being displayed in the lower display.

Lower Display: INPUT 1—This is the first Set Up group title.

• 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.

• You can also use the [▲] [▼] keys to scan the Set Up

groups in both directions.

• Stop at the Set Up group title which describes the

group of parameters you want to configure. Then proceed to the next step.

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”

• Successive presses of the FUNC key will sequentially

display the other function prompts of the Set Up group you have selected.

• Stop at the function prompt that you want to change,

then proceed to the next step.

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Configuration Procedure

Step Operation Press Result

Configuration

6 Enter the value or selection

Change the value or selection

▲ or ▼

FUNC

7 Exit configuration LOWR

SET

DISP

• These keys increment or decrement the value or

selection that appears for the function prompt you have selected.

• See Subsection 3.4 Configuration Tips for instructions

to increase or decrease value quickly.

• Change the value or selection to meet your needs.

• If the display flashes, you are trying to make an

unacceptable entry.

• This key selects another function prompt.

• This key selects another Set Up group.

The value or selection you have made will be entered into memory after another key is pressed.

This exits configuration mode and returns the recorder to the same state it was in immediately preceding entry into the Set Up mode. It stores any changes you have made.

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Configuration Input Set Up Group

3.6 Input Set Up Group

Introduction

This data deals with various parameters required to configure input 1, input 2, input 3, or input 4.

Function prompts

Table 3-3 lists all the function prompts in the “INPUT 1” Set Up group. Repeat the process for each input you want to set up.

• Press the SET UP key until INPUT 2, INPUT 3, or INPUT 4 appears in the display.

Function Prompt

Lower Display

Function Name

Table 3-3 Input Group Function Prompts

Selections or Range of Setting

Upper Display

Factory

Setting

INPUT 1

DECIMAL

UNITS

ENGUNITS

IN1 TYPE

Input 1 Actuation

Decimal Point Location

Temperature Units

Engineering Units

Input 1 Actuation Type

DISABL ENABLE

XXXX None XXX.X One XX.XX Two X.XXX Three

DEG F DEG C XXXXX (make selection at prompt "ENGUNITS")

0 to 9 A to Z + – \ (blank)

B TC W TC H E TC H W TC L E TC L 100 PT J TC H 200 HI* J TC L 200 LO* K TC H 500 PT K TC L 100 RH NNM TC 4-20 mA NIC TC 0-10 mV R TC 10-50m S TC 0-5 V T TC H 0-10 V T TC L RADIAM

ENABLE

XXX.X

DEG F

100 PT or 0-5 V with Control

*DR45AR only

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Configuration

Input Set Up Group

Function Prompt

Lower Display

XMITTER

IN1 HI

IN1 LO

CUTOFF 1

INPTCOMP

FILTER 1

BURNOUT

Function Name

Transmitter Characterization

Input 1 High Range Value (linear inputs only)

Input 1 Low Range Value (linear inputs only)

Low Flow Cutoff Selection 0 to 100 % of input range 0

Input Compensation –999.9 to 9999. 0

Input 1 Filter 0 to 120 seconds 0

Burnout Protection

Selections or Range of Setting

Upper Display

B TC T TC H E TC H T TC L E TC L W TC H J TC H W TC L J TC L 100 PT K TC H 500 PT K TC L 100 RH NNM TC H LINEAR* NIC TC SQROOT* R TC S TC

*Set “IN1HI” and “IN1LO”

–999.0 to 9999. in engineering units

NONE UP DOWN

Factory

Setting

Linear

900

-300

EMISSIV

Emissivity .01 to 1.00 .01

Repeat this procedure for INPUT 2, INPUT 3, and INPUT 4.

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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, pen #2, pen #3, or pen #4. The procedure for configuring each pen is the same. The prompts shown in Table 3-4 show PEN 1.

• Repeat the process for each pen you want to set up.

• Press the SET UP key until PEN 2, PEN 3, or PEN 4 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, 2, 3, 4 Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Factory

Setting

PEN 1 (or PEN 2, PEN 3, PEN 4)

PEN1IN (or PEN2IN, PEN3IN, PEN4IN)

CHART1HI (or CHART2HI, CHART3HI, CHART4HI)

CHART1LO (or CHART2LO, CHART3LO, CHART4LO)

PEN1ON (or PEN2ON, PEN3ON, PEN4ON)

PEN1OFF (or PEN2OFF, PEN3OFF, PEN4OFF)

MAJORDIV

Pen Record ENABLE

DISABL

Pen Input INPUT1 RH SETPT2

INPUT2 OUTPT1 DGTL1 INPUT3 OUTPT2 DGTL2 INPUT4 SETPT1 PV1

Chart High Range Value –999.0 to 9999 302.0

Chart Low Range Value –999.0 to 9999 292.0

Pen Chart Position for ON Event

Pen Chart Position for OFF Event

Major Chart Divisions 2 to 10 10

0 to 100 % 91.0

0 to 100 % 93.0

ENABLE

INPUT 1

MINORDIV

RNG1TAG

Minor Chart Division 2 to 10 10

Range 1 Tag Name 0 to 9

A to Z + – / (blank)

RNG 1

Repeat this procedure for PEN 2, PEN 3, and PEN 4.

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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 rotation. 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

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Configuration

Chart Set Up Group

Factory

Setting

CHRTSPD

HOUR/REV

TIME DIV

MINORDIV

CONTINUE

CHARTNAM

HEADER

Chart Speed Selection

Hours per Revolution (appears only if "XHR" is selected above)

Time Division 8 to 24 time periods 24

Minor Time Division

Continue Chart Rotation

Chart Name

Header for Chart

8HR 12HR 24HR 7DAYS XHR (See prompt "HOUR/REV")

6 to 744 (12 hrs for abrasion resistant pen) NOTE: Below 8 hrs chart speed (24 hrs chart speed with abrasion resistant pen), printing may be degraded.

Four Eight

YES NO

0 to 9 A to Z + – / (blank)

YES NO

XHR

Four

TRULIN

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Configuration Chart Set Up Group

Function Prompt

Lower Display

REM CHRT

Function Name

Remote Chart Activation

Selections or Range of Setting

Upper Display

NONE EXT SW1 EXT SW2 ALARM 1 ALARM 2 TIME (See “WAKE MIN”, “WAKE HOUR”, “WAKE DAY”, “WAKE MON” in Time Set Up group.) ALARM 3 ALARM 4 ALARM 5 ALARM 6

Factory

Setting

NONE

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3.9 Time Set Up Group

Introduction

The functions listed in this group deal with the parameters that let you configure the real time that will appear on the chart.

Function prompts

Table 3-6 lists all the function prompts in the “Time” Set Up group.

Function Prompt

Lower Display

Function Name

Table 3-6 Time Group Function Prompts

Selections or Range of Setting

Upper Display

Configuration

Time Set Up Group

Factory

Setting

MINUTES

HOURS

DAY

MONTH

YEAR

DAY

WAKE MIN

WAKE HR

WAKE DAY

WAKE MON

Real Time in Minutes Chart Speed Selection

Real Time in Hours 0 to 23

Real Time in Days 1 to 31

Real Time in Months 1 to 12

Real Time in Years 0 to 99

Day of the Week Chart Name

Wake Minutes 0 to 59 0

Wake Hour 0 to 23 0

Wake Day 0 to 31 0

Wake Month 1 to 12 1

0 to 59

MONDAY TUEDAY WEDDAY THRDAY FRIDAY SATDAY SUNDAY

Set to local time

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Configuration Totalizer Set Up Group

3.10 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 3-7 lists all the function prompts in the “TOTAL 1” Set Up group. Repeat the process for each input you want to set up.

• Press the SET UP key until TOTAL 2 appears in the display.

Table 3-7 Totalizer Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Factory

Setting

Actual Current Totalized Value

RSET TOT

TOTAL 1 TOTAL 2

TOTAL EU

RATE

SCALER

View Current Totalized Value

Reset Totalizer to Zero (RSETABLE must be set to “LOCAL”)

Totalizer 1 Totalizer 2

Total Engineering Units

Rate of Integration

Totalizer Scale Factor

Current Scale Factor Example: E1 GPM

NO YES

DISABL, INPUT1, PV1, INPUT2, INPUT 3, INPUT 4, E TIME

0 to 9 A to Z + – / (blank)

SECOND MINUTE HOUR DAY M/DAY (Millions of Units per Day)

1 10 100 1000 10000 100000 1E6 (1,000,000)

E0 GAL

DISABL

GAL

SECOND

RSETABLE

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Totalizer Reset

NO LOCAL EXTSW1* EXTSW2* TIME

*Total will be set to “0” on closure of the assigned external switch.

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Configuration

Totalizer Set Up Group

Function Prompt

Lower Display

INHIBIT

Repeat this procedure for INPUT 2.

Function Name

Totalizer Inhibit

Selections or Range of Setting

Upper Display

NONE S1 OPEN S1 CLOSE S2 OPEN S2 CLOSE

Factory

Setting

NONE

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Configuration Input Algorithm Set Up Group

3.11 Input Algorithm Set Up Group

Introduction

Input Algorithm set up group lets you calculate a process variable (PV1) using Inputs 1, 2, and 3. Input 1 is represented by ‘A’, Input 2 by ‘B’, Input 3 by ‘C’.

Function prompts

Table 3-8 lists all the function prompts in the Input Algorithm Set Up group.

Table 3-8 Input Algorithm Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Factory

Setting

INP ALG

COEFF

PV HIGH

PV LOW

RATIO A

BIAS A

RATIO B

BIAS B

RATIO C

BIAS C

POLYNOM

Input Algorithm

Coefficient K 0.000 to 1000.0 1.0

Calculated PV High Limit –999 to 9999 0.0

Calculated PV Low Limit –999 to 9999 0.0

Ratio for Input 1 –20.00 to 20.00 1.0

Bias for Input 1 –999 to 9999 0.0

Ratio for Input 2 –20.00 to 20.00 1.0

Bias for Input 2 –999 to 9999 0.0

Ratio for Input 3 –20.00 to 20.00 1.0

Bias for Input 3 –999 to 9999 0.0

Polynomial characterizer

NONE A+B+C (Summer)

√A*B/C (Square Root Multiplier/Divider) √A*B*C (Square Root Multiplier)

A*B/C (Multiplier/Divider) A*B*C (Multiplier) (A–B)*C (Difference Multiply) HI SELECT LO SELECT

NONE, INPUT 1, INPUT 2, INPUT 3, INPUT 4

NONE

C0 VALUE

C1 VALUE

C2x10-1

C3x10-3

C4x10-5

C5x10-7

Polynomial coefficient CO –99.99 to 99.99 0

Polynomial coefficient C1 –9.999 to 9.999 0

Polynomial coefficient C2 –9.999 to 9.999 0

Polynomial coefficient C3 –9.999 to 9.999 0

Polynomial coefficient C4 –9.999 to 9.999 0

Polynomial coefficient C5 –9.999 to 9.999 0

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3.12 Control Set Up Group

Introduction

This data deals with various parameters required to effectively control your process.

Function prompts

Table 3-9 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 3-9 Control 1 or Control 2 Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Configuration

Control Set Up Group

Factory

Setting

CONTROL1

PID SETS

SW VALUE

SP SOURC

RATIO

BIAS

SP TRACK

POWER UP

Control Loop 1

Tuning Parameter Sets

Automatic Switchover Value –999.0 to 9999 0.00

Setpoint Source

Ratio for Remote Setpoint –20.00 to 20.00 1.0

Bias for Remote Setpoint –999.0 to 9999 in engineering units 0

Setpoint TrackingTotalizer Scale Factor

Power Up Controller Mode Recall

DISABL ENABLE

1 ONLY 2KEYBD 2PV SW 2SP SW

1 LOCAL REMOTE 2 LOCAL OUT 2 (available for Control 1 only)

NOTE: If you select “REMOTE,” Input #3 is automatically assigned as your RSP source for control #1; Input #4 is assigned for control #2. However, if the unit has only 2 inputs, then RSP will be on Input 2.

NONE RSP

MANUAL A LSP A RSP AM SP AM LSP

ENABLE

1 ONLY

1 LOCAL

NONE

MANUAL

PWR OUT

SP HILIM

SP LOLIM

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Power Up Output

High Setpoint Limit –999.0 to 9999. 500

Low Setpoint Limit –999.0 to 9999. 0

LAST FAIL SF

NOTE: This prompt will appear only if “3PSTEP” is selected at function prompt “CONT ALG”.

LAST

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Configuration Control Set Up Group

Function Prompt

Lower Display

ACTION

OUTHILIM

OUTLOLIM

DROPOFF

DEADBAND

OUT HYST

FAILSAFE

Function Name

Control Output Direction

Selections or Range of Setting

Upper Display

DIRECT

Factory

Setting

REVERSE

REVRSE

High Output Limit –5.0 to 105.0 % of output 100.0

Low Output Limit –5.0 to 105.0 % of output 0

Controller Dropoff Value –5.0 to 105.0 % of output 0.0

Output Relay Deadband

• Time Proportional Duplex:

2.0

–5.0 to 25.0 %

• On-Off Duplex:

0.0 to 25.0 %

• Position Proportional

0.5 to 5.0 %

Output Relay Hysteresis 0.0 to 5.0 % of PV Span 0.5

Failsafe Output Value

0 to 100 % 50

For 3 Position Step Control:

0.0

100PCT Set motor position to 100 % output position

0PCT Set motor to 0 % output position

REM SW or REM SW2

MAN KEY

PB orGAIN

MIN orRPM

CONT1 ALG or CONT2 ALG

OUT1 ALG or OUT2 ALG

(appears if not 3PSTEP above)

4–20RNG

Remote Switching (Digital Input)

Manual Mode Key Selection

Proportional Band or Gain Units

Reset Units

Control Algorithm

Output Algorithm

Current/Time Duplex Range (CUR D)

NONE TO 2SP TUNE TO MAN TO DIR TIMER TO LSP RN/HLD

ENABLE DISABL

PB PCT GAIN

R P M (repeats per minute) M I N (minutes per repeat)

ON-OFF PD+MR PID-A 3PSTEP* PID-B

*not applicable for model DR45AR

TIME* TIME D* CURRNT CUR TI* POSITN* TI CUR*

*not applicable for Model DR45AR

100PCT (FULL) 50 PCT (SPLIT)

NONE

ENABLE

GAIN

MIN

PID-A

CURRENT

50PCT

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3.13 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 3-10 lists all the function prompts in the Tuning 1 or Tuning 2 Set Up groups. How the “Algorithm” and “Control” Set Up groups are configured determines which prompts will appear.

Table 3-10 Tuning 1 or Tuning 2 Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Tuning Parameters Set Up Group

Upper Display

Configuration

Factory

Setting

FUZZY

ACCUTUNE

AT ERR

PROP BD

GAIN

RATE MIN

RSET MIN or RSET RPM

MAN RSET

PROP BD2

GAIN 2

RATE2MIN

RSET2MIN

Fuzzy Overshoot Suppression

Accutune II for Control Loop

Accutune Error Codes No message under normal conditions

Proportional Band or Gain

Rate in minutes 0.00 to 10.00 minutes 0.00

Reset in minutes/repeat or Reset in repeats/minute

Manual Reset –100 to 100 % output 0.0

Proportional Band 2 or Gain 2

Rate 2 in minutes 0.08 to 10.00 minutes 0.00

Reset 2 in minutes/repeat

DISABL ENABLE

Read Only message displayed if tuning has been manually aborted

0.1 to 1000 %

0.1 to 1000

0.02 to 50.00

0.1 to 1000 %

0.1 to 1000

0.02 to 50.00

DISABL

––

1.0

5.0

0.2

RSET2RPM

CYC SEC

CYC2 SEC

Reset 2 in repeats/minute

Cycle Time (Heat) Electromechanical Relays

Cycle Time 2 (Cool) Electromechanical Relays

0.02 to 50.00

1 to 120 seconds 20.0

0.2

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Configuration SP Ramp Set Up Groups

3.14 SP Ramp Set Up Groups

The Setpoint Ramp 1 or 2 Set Up groups let you configure 2 setpoint ramps. Each group (SP RAMP1 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 you 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 and Operation.

Function prompts

Table 3-11 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.

Function Prompt

Lower Display

SP RAMP*

TIME MIN

FINAL SP

SP RATE*

EU/HR UP

EU/HR DN

SP PROG*

*Only one of these can be enabled at a time.

Table 3-11 SP Ramp 1 or 2 Group Function Prompts

Function Name

Single Setpoint Ramp Selection

Single Setpoint Ramp Time 0 to 255 minutes 0

Single Setpoint Ramp Final Setpoint

Setpoint Rate

Rate up value (SP Rate enabled)

Rate down value (SP Rate enabled)

Setpoint Programming (Refer to Section 6)

Selections or Range of Setting

Upper Display

DISABL ENABLE

Enter a value within the setpoint limits 100.0

DISABL ENABLE

0 to 9999 in units per hour

DISABL ENABLE

Factory

Setting

DISABL

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3.15 Timer Set Up Group

Introduction

The Timer gives a countdown or elapsed time, after which Relay 1 energizes. If Timer is enabled, it has exclusive control over Relay 1; Alarm 1 will not control the relay.

Function prompts

Table 3-12 lists all the function prompts in the TIMER Set Up group.

Table 3-12 Timer Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Configuration

Timer Set Up Group

Factory

Setting

TIMER

PERIOD

START

LDISPLAY

RESET

ON-TIME

INCRMENT

Timer Enable/Disable

Timeout Period 0:00 to 99:59 0

Start Initiation

Timer Display

Timer Reset Control

Timer Repeat Mode On-Time

Timer Count Increment

ENABLE DISABL

RHKEY ALARM2 TIME

TREM ET

RHKEY ALARM1 REPEAT

1 SEC 2 SEC 3 SEC 4 SEC 5 SEC

MINUTE SECOND

DISABL

RHKEY

TREM

RHKEY

MINUTE

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Configuration Alarms Set Up Group

3.16 Alarms Set Up Group

Introduction

This data deals with the Alarms function that is available with your recorder.

• There are six alarms available. Each alarm has two setpoints.

• You can configure each of these two setpoints to alarm on various recorder parameters. There are two

alarm output selections, high or low.

• 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 % to 100.0 % is configurable for each alarm.

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 3-13. If you want the alarm to control the relay, do not configure a higher priority function.

Table 3-13 Priority of functions that operate relays

Relay Relay is controlled by (in order of priority)

1. Timer function

2. Alarm 1

2 Alarm 2 only

1. Controller 1 output algorithms Relay Simplex,

Position Proportional, Relay Duplex, Current/Relay Duplex

2. Alarm 3

1. Controller 1 output algorithms Position

Proportional, Relay Duplex, Current/Relay Duplex

2. Alarm 4

1. Controller 2 output algorithms Relay Simplex,

Position Proportional, Relay Duplex, Current/Relay Duplex

2. Alarm 5

1. Controller 2 output algorithms Position

Proportional, Relay Duplex, Current/Relay Duplex

2. Alarm 6

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Function prompts

Table 3-14 lists all the function prompts in the Alarms Set Up group.

Function Prompt

Lower Display

Table 3-14 Alarms Group Function Prompts

Function Name

Selections or Range of Setting

Upper Display

Configuration

Alarms Set Up Group

Factory

Setting

AxS1 VAL

AxS2 VAL

AxS1TYPE

AxS2TYPE

AxS1 H L

AxS1SCAL

Alarm 1, Setpoint 1 Value Value in engineering units 90

Alarm 1, Setpoint 2 Value Value in engineering units 95

Alarm 1, Setpoint 1 Type

Alarm 1, Setpoint 2 Type Same as A1S1TYPE IN 1

Alarm 1, Setpoint 1 State

Alarm 1, Setpoint 1 Scaling Multiplier for Totalizer Selection

NONE IN 1 (Input 1) IN 2 (Input 2) IN 3 (Input 3) IN 4 (Input 4) 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) TOTAL 3 (Model DR45AW only) TOTAL 4 (Model DR45AW only)

LO (Low Alarm) H I (High Alarm)

1 10000 10 100000 100 1E6 1000

IN 1

AxS2 H L

AxS2SCAL

ALx HYST

Alarm 1, Setpoint 2 State

Alarm 1, Setpoint 2 Scaling Multiplier for Totalizer Selection

Alarm Hysteresis 0.0 to 100.0 % of Input Span as appropriate 0.1

LO H I

1 10 100 1000 10000 100000 1E6

Repeat this procedure for ALARM 2, ALARM 3, ALARM 4, ALARM 5, ALARM 6.

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Configuration Auxiliary Output Set Up Group

3.17 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 is 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 prompts

Table 3-15 lists all the function prompts in the Auxiliary Output Set Up group.

Table 3-15 Auxiliary Output Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Factory

Setting

AUX OUT 1

4 mA VAL

20mA VAL

Repeat this procedure for AUX OUT 2 and AUX OUT 3.

Auxiliary Output Representation

Low Scaling Factor Low scale value to represent 4 mA 0.0

High Scaling Factor High scale value to represent 20 mA 100.0

DISABL PV 2 IN 1 DEV 2 IN 2 OUT 2 PV 1 SP 2 DEV 1 IN 3 OUT 1 IN 4 SP 1

DISABL

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3.18 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.

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 3-16 lists all the function prompts in the Modbus Communications Set Up group.

Table 3-16 Modbus Communications Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Configuration

Modbus Communications Set Up Group

Factory

Setting

ComSTATE

Com ADDR

BAUD

XMT DLAY

DBL BYTE

Modbus Communications

Communications Station Address

Communications Baud Rate

Transmit Delay (in milliseconds)

Double Byte Order

DISABL MODBUS

1 to 99 1

300 600 1200 2400 4800 9600 19200 38400

NONE 10MSEC 20MSEC 30MSEC 40MSEC 50MSEC

FP B FP BB FP L FP LB

DISABL

9600

NONE

FP B

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Configuration Options Set Up Group

3.19 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 3-17 lists all the function prompts in the Option Set Up group.

Table 3-17 Options Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Factory

Setting

REJ FREQ

HF REJ

RELHUMID

ATMPRES

DEVIATION

DEVSETPT

SCROLL

GRANDTOT

Rejection Frequency

High Frequency Rejection

Relative Humidity

Atmospheric Pressure Compensation

Deviation Recording Action

Deviation Setpoint Value –999.0 to 9999 0

Lower Display Scroll

Grand Totalizer

50HZ 60HZ

ENABLE DISABL

NO YES

590 to 800 mmHg ––

NONE SETPNT CHAN1

NONE 1 SEC 2 SEC 3 SEC

ENABLE DISABL

60HZ

ENABLE

NONE

DISABL

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3.20 Event Message Configuration

Introduction

This Set Up group allows you to specify an event message to be printed on a designated area of the chart when triggered by a specific selectable actuation.

Function prompts

Table 3-18 lists all the function prompts in the “Event Message” Set Up group.

Table 3-18 Event Message Group Function Prompts

Function Prompt

Lower Display

Function Name

Event Message Configuration

Selections or Range of Setting

Upper Display

Configuration

Factory

Setting

EVENT1

MESSAGE1

POSITON1

EVENT 2

Event 1 Trigger

Message for Event 1 (up to six characters)

Chart Position for Message 1 Printing

Event 2 Trigger

NONE EXTSW1 EXTSW2 ALARM1 ALARM2 ALARM3 ALARM4 ALARM5 ALARM6

0 to 9 A to Z + – / (blank)*

0 to 100 % 87.3

NONE EXTSW1 EXTSW2 ALARM1 ALARM2 ALARM3 ALARM4 ALARM5 ALARM6

NONE

EVENT1

NONE

MESSAGE2

POSITON2

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Message for Event 2 (up to six characters)

Chart Position for Message 2 Printing

0 to 9 A to Z + – / (blank)*

0 to 100 % 85.5

EVENT2

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Configuration Event Message Configuration

Function Prompt

Lower Display

EVENT 3

MESSAGE3

POSITON3

EVENT 4

Function Name

Event 3 Trigger

Message for Event 3 (up to six characters)

Chart Position for Message 3 Printing

Event 4 Trigger

Selections or Range of Setting

Upper Display

NONE

Factory

Setting

NONE EXTSW1 EXTSW2 ALARM1 ALARM2 ALARM3 ALARM4 ALARM5 ALARM6

0 to 9

EVENT3 A to Z + – / (blank)*

0 to 100 % 83.6

NONE

NONE EXTSW1 EXTSW2 ALARM1 ALARM2 ALARM3 ALARM4 ALARM5 ALARM6

MESSAGE4

POSITON4

EVENT 5

MESSAGE5

Message for Event 4 (up to six characters)

Chart Position for Message 4 Printing

Event 5 Trigger

Message for Event 5 (up to six characters)

0 to 9

EVENT4 A to Z + – / (blank)*

0 to 100 % 80.0

NONE

NONE EXTSW1 EXTSW2 ALARM1 ALARM2 ALARM3 ALARM4 ALARM5 ALARM6

0 to 9

EVENT5 A to Z + – / (blank)*

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Configuration

Event Message Configuration

Function Prompt

Lower Display

POSITON5

EVENT 6

MESSAGE6

POSITON6

Function Name

Chart Position for Message 5 Printing

Event 6 Trigger

Message for Event 6 (up to six characters)

Chart Position for Message 6 Printing

Selections or Range of Setting

Upper Display

0 to 100 % 78.2

NONE EXTSW1 EXTSW2 ALARM1 ALARM2 ALARM3 ALARM4 ALARM5 ALARM6

0 to 9 A to Z + – / (blank)*

0 to 100 % 76.9

Factory

Setting

NONE

EVENT6

*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.

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Configuration Lockout Set Up Group

3.21 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. You must know the password in order to change the Lockout configuration.

Function prompt

Table 3-19 lists all the function prompts in the Lockout Set Up group.

Table 3-19 Lockout Group Function Prompts

Function Prompt

Lower Display

Function Name

Selections or Range of Setting

Upper Display

Factory

Setting

PASSWORD

LOCKOUT

CHANGE

This feature also includes the special screw and plate that provide for the lead seal capability for sealing the chart plate.

Lockout Password

Lockout

Change Password

ATTENTION

Configuration can also be locked using S1 switch on the main printed circuit board. Refer to Subsection 2.9 –Lockout Switch Configuration.

Select up to 4 alphanumeric characters (++++ is factory default password)

For more information on password security, refer to Appendix B.

NONE CALIB +CONF MAX

0 to 9 A to Z

XXXX

CALIB

XXXX

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