DR4500 Circular Chart Recder Replacement Kit Instruction Replacement Addition of Control Output Printed Circuit Board Assembly 30754922-501 (Universal Outputs) Assembly 30754922-502 (4-20 ma Output Only - FM Approval) Assembly 30754922-503 (CE Mark) Fm: 44-45-33-12C Effective: 9/96 Supersedes: 44-45-33-12B, 8/96 Summary Enclosed with this instruction is a new Control Output printed circuit board f your DR4500 Recder (Classic Truline models). Table of contents This instruction contains the following infmation: Topic See Page 1.0 Introduction 2 2.0 Replacing Existing Control Output Printed Circuit Board 3 3.0 Adding 4-20 ma Control Output 6 3.1 Calibrating 4-20 ma Output 7 4.0 Adding Position Proptional Control Output 9 4.1 Calibrating Position Proptional Control Output 11 5.0 Adding Relay Control Output 14 6.0 Application Notes 16 9/96 Replacement Kit Instruction #44-45-33-12C 1 of 20
1.0 Introduction Overview This instruction covers the replacement of an existing control output printed circuit board (Subsection 2.0) and the addition of one of the following control output printed circuit boards: 4 to 20 ma Output (Subsection 3.0) Position Proptional Output (Subsection 4.0) Relay Output (Subsection 5.0) Common causes of failure Two of the most common causes of failure of this card are: Excessive load on the output board relays Supply Voltage (Example 115 Vac) Resistance of Customer Controlled Device = Must equal a number less than 5 (Amps) Noise damage to the slidewire circuit (Position Proptional Output) See Application Notes in this instruction - Subsection 6.0. Limitations Only one control output is available on any of the DR4500A recders except on the DR45AT and DR45AP recder which can have two control outputs. The DR45AH HTST and DR45AS STLR recders come standard with one control output since this is necessary f this application; therefe, this unit cannot be upgraded to add any control outputs. The Setpoint Programming feature has been made a standard part of the control output option on the DR45AT and DR45AR recders and no longer is specified separately as was the case with the DR450T DR450R Recders. The DR4500A recder cannot be upgraded with the FM approved control output in the field since additional facty tests are required to attach the FM logo. If you are adding a Control Output and the recder does not have Communications option a Third Fourth Input, you will need to der a Motherboard, Part Number 30754919-501. WARNING Never access components inside the case with the power applied. CAUTION When handling electronic assemblies, care should be taken to avoid damage by electrostatic discharge. Use a wrist strap connected to an earth ground befe removing the suspect board withdrawing the replacement from its container and installing it into the recder. 2 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
2.0 Replacing an Existing Control Output Printed Circuit Board Removing and replacing an existing control output board Follow the steps listed in Table 1 to remove and replace an existing control output printed circuit board. The procedure assumes that the chart do is open, the chart plate is swung out, and the power is removed. Table 1 Removing and Replacing an Existing Control Output PCB Step Action 1 Tag and disconnect all the cable plugs from the applicable control output printed circuit board. Secondary Transfmer Leads (2-wire connect) = Brown Control Output #1/ Orange Control Output #2 at J4 on the Control Output Board. 2 Note the ientation of the output printed circuit board in the card guides, and unplug it from the motherboard. (Control Output #1=J5; Control Output #2 = J1 on motherboard) 3 Compare the position of the relay contact jumpers on the old printed circuit board with those on the new printed circuit board and change as required. W2 W3 W4 W5 Relay No. 1 W2 = N.O. contact W3 = N.C. contact Relay No. 2 W4 = N.O. contact W5 = N.C. contact 4 Locate W6/W7 jumper(if present) near connect J3 and position the jumper f your specific output: W6 W7 Position W7 Relay W6 Current W6 5 Orient the new control output printed circuit board as noted in Step 2, slide it into the card guides and press down firmly to seat the connect onto the motherboard. 6 Connect the cable plugs as tagged in step 1 to the connects on the control output printed circuit board. If required, refer to the following drawings: 4 to 20 ma Output Table 2, Step 10 Position Proptional Table 5, Step 9 Relay Output Table 7, Step 10 Model DR45AW Flow Figure 2-1, Page 4 Model DR45AH HTST Figure 2-2, Page 4 Model DR45AP Pasteurization Figure 2-3, Page 5 Model DR45AS STLR Figure 2-4, Page 5 7 If the control output is current position proptional type, you may want to check the calibration. Refer to Tables 3 and 4 (Current) Table 6 (Position Prop) in this instruction. Continued on next page 9/96 Replacement Kit Instruction #44-45-33-12C 3 of 20
2.0 Replacing an Existing Control Output Printed Circuit Board, Continued Model DR45AW cable connections Figure 2-1 is a diagram of the output connections f Model DR45AW. Figure 2-1 Model DR45AW PULSE #1 OUTPUT PULSE #2 OUTPUT PULSE OUTPUT CARD Plug J5 INPUT 4 INPUT 3 22772 Model DR45AH cable connections Figure 2-2 is a diagram of the output connections f Model DR45AH. Figure 2-2 Model DR45AH Plug J1 4-20 ma output + #4 #3 #2 #1 + Air I/P Transducer Supply Plug J5 ON / OFF Control to Diverter Valve Diversion Switch Hot Water Valve 22773 Continued on next page 4 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
2.0 Replacing an Existing Control Output Printed Circuit Board Continued Model DR45AP cable connections Figure 2-3 is a diagram of the output connections f Model DR45AP. Figure 2-3 Model DR45AP Control #1 Plug J1 4-20mA Output + #3 #4 #2 #1 Control #1 Plug J5 Timing Pump + RELAY 1 ON / OFF Control to Diverter Valve with Configurable Time Delay Control #2 Plug J1 4-20 ma output + + System Back Pressure Pump Control #2 Plug J5 RELAY 1 Booster Pump Control On/Off Control (DP Low Limit) RELAY 2 High Pressure Limit Alarm 22774 Model DR45AS cable connections Figure 2-4 is a diagram of the output connections f Model DR45AS. Figure 2-4 Model DR45AS Plug J4 Alarm outputs ON / OFF Control to Diverter Valve #4 #3 #2 #1 Plug J3 Frequency Pen Input Digital Input 2 9/96 Replacement Kit Instruction #44-45-33-12C 5 of 20
3.0 Adding 4-20 ma Control Output Installation procedure Follow the steps listed in Table 2 to add the 4-20 ma control output printed circuit board. The procedure assumes that the chart do is open, the chart plate is swung out, and the power is removed. Table 2 Adding a 4-20 ma Control Output PCB Step Action 1 Install the new card guides supplied with the kit into proper location on the motherboard located in the left hand side of the case. Control Output 1 J5 on Motherboard Control Output 2 J1 on Motherboard (See Figure below f Output card location.) CAUTION Install the guides with a steady downward pressure. Excessive rocking will destroy its latch. 2 Locate the W6/W7 jumper near connect J3. Make sure W6/W7 jumper on the output card is in location W6 f 4-20 ma output. 3 Slide the new control output board into the card guides and press down firmly to seat the connect onto the motherboard. 4 Connect the 2-wire connect lead from the transfmer on the mother board to the Control output board at J4: Brown to Control Output #1 board Orange to Control Output #2 board 5 Locate connect J1 near the top of the control output #1 printed circuit board (refer to Figure below f location). 6 Remove the unwired plug from J1. 7 Run the output wires through the desired knockout. 8 Strip 1/4-inch maximum of insulation from the end of each wire. 9 Loosen the screws in plug J1 terminals and position the plug as you would to plug it into J1. 10 Observing the polarity, insert the wires into the appropriate screw clamps as shown. Tighten the screws to secure the wires. 4-20 ma output + Control output #1 PCB Controller load 0-1000 ohms Plug J1 _ Control output #2 PCB Motherboard 11 Install the wired plug into J1. 12 Repeat steps 1 through 11 f control output #2 printed circuit boards as applicable. 13 Make sure that the 4-20 ma current output is calibrated. Refer to Subsection 3.1. 22752 6 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
3.1 4-20 ma Current Proptional Output Calibration Introduction Calibrate the recder so that the output provides the proper amount of current over the desired range. The recder can provide an output current range of from 2 to 21 milliamperes and can be calibrated at 4 ma f 0% of output and 20 ma f 100% of output any other values between 2 and 21 ma. Equipment needed You will need a standard shop type milliammeter, with whatever accuracy is required, capable of measuring 0 to 20 milliamps. Calibrat connections Refer to Table 3 and wire the recder accding to the procedure given. Table 3 Set Up Wiring Procedure Current Proptional Output Step Action 1 With the power off, do open, and the chart plate swung out; tag and disconnect field wiring from the plug in connect J1 on the appropriate control output PCB (see Figure below). 2 Observing polarity, connect a milliammeter s leads to the plug f connect J1. Plug J1 (current output) Milliammeter + Control output #1 PCB Control output #2 PCB - Motherboard 22756 3 Close the chart plate: apply power and allow the recder to warm up 15 minutes befe you calibrate. Continued on next page 9/96 Replacement Kit Instruction #44-45-33-12C 7 of 20
3.1 4-20 ma Current Proptional Output Calibration, Continued Calibration procedure Table 4 The procedure f calibrating the Current Proptional Output is listed in Table 4. Make sure LOCKOUT in the Set Up group is set to NONE.. Current Proptional Output Calibration Procedure Step Description Press Action/Result 1 Enter Calibration Mode 2 Calibrate 0% SET UP until you see CALIB CURRENT You will see: ZERO VAL (approximately 380) a value Until the desired 0% output is read on the milliammeter. Use the values shown below depending on the action of your recder. 4 ma F 4 to 20 ma Direct Action 20 ma F 4 to 20 ma Reverse Action 3 Calibrate 100% Stes the 0% value and, you will see: a value SPAN VAL (approximately 1890) Until the desired 100% output is read on the milliammeter. Use the values shown below depending on the action of your recder. 20 ma F 4 to 20 ma Direct Action 4 ma F 4 to 20 ma Reverse Action 4 Exit the Calibration Mode The recder stes the span value. LOWR DISP To exit the calibration mode. 8 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
4.0 Adding Position Proptional Control Output Installation procedure Follow the steps listed in Table 5 to add the Position Proptional control output printed circuit board. The procedure assumes that the chart do is open, the chart plate is swung out, and the power is removed. Table 5 Adding a Position Proptional Control Output PCB Step Action 1 Install the new card guides supplied with the kit into proper location on the motherboard located in the left hand side of the case. Control Output 1 J5 on Motherboard Control Output 2 J1 on Motherboard (See Step 9 f Output card location.) CAUTION Install the guides with a steady downward pressure. Excessive rocking will destroy its latch. 2 Befe you install the control output board, locate connect J2 and J5 on the control output #1 printed circuit board (refer to Step 10 f location). 3 Locate jumper positions W2/W3 and W4/W5 near connect J5 on the printed circuit board. Position the jumpers as shown below f desired relay contact action. Nmally, the W2 and W4 - N.O. contacts are used f mot control. W2 W3 W4 W5 Relay No. 1 W2 = N.O. contact W3 = N.C. contact Relay No. 2 W4 = N.O. contact W5 = N.C. contact 4 Locate jumper positions W6/W7 near connect J3. Make sure jumper W6/W7 position is W7 f position proptional output. W6 W7 5 Slide the new control output board into the card guides and press down firmly to seat the connect onto the motherboard. 6 Connect the 2-connect lead from the transfmer on the mother board to the Control output board at position J4. Brown to Control Output #1 board Orange to Control Output #2 board 7 Run the feedback slidewire and mot drive wires through the desired knockouts. 8 Strip 1/4-inch maximum of 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. Table continued on next page 9/96 Replacement Kit Instruction #44-45-33-12C 9 of 20
4.0 Adding Position Proptional Control Output, Continued Installation procedure, continued Table 5 Step Adding a Position Proptional Control Output PCB, continued Action 10 Insert the wires from the mot s feedback slidewire into the appropriate screw clamps as shown. Tighten the screws to secure the wires. Control output #1 PCB Control output #2 PCB Motherboard 1 2 3 OPEN CLOSED Mot s feedback slidewire 100 to 1000 Plug J2 Connect shield to ground at one end only Plug J5 Relay 1 Relay 2 OPEN (CW) N Mot CLOSED (CCW) power supply H 22754 11 Loosen the screws in plug J5 terminals and position the plug as you would to plug it into J5. 12 Insert the wires f the mot into the appropriate screw clamps as shown above. Tighten the screws to secure the wires. 13 Install the wired plug into J2 and J5, as applicable. 14 Repeat Steps 1 through 13 f Control Output #2 printed circuit boards as applicable. 10 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
4.1 Position Proptional Output Calibration Position proptional control When the DR4500A Recder has a position proptional control output, calibrate the recder so that the open and close relays operate properly with respect to the position of the external feedback slidewire. Equipment needed None Connections Leave all field wiring connected to the plugs in connects J2 and J5 on the appropriate control output printed circuit board. Apply power and allow the recder to warm up 15 minutes befe you calibrate. Auto mode vs manual mode There are two ways in which to calibrate Position Proptional control: AUTO mode MANUAL mode. Rules f auto mode vs manual mode The auto-mode selection must be done at least once befe the manual mode will operate properly. Failure to use the auto-mode procedure will prevent the recder from going into automatic control mode. Displayed values During the auto-mode calibration procedure, the values being displayed are used only to indicate if the mot is still traveling. To view the actual calibration value, use the manual mode after the automode is completed. These values can be changed f purposes of fine tuning the calibration. Continued on next page 9/96 Replacement Kit Instruction #44-45-33-12C 11 of 20
4.1 Position Proptional Output Calibration, Continued Procedure Table 6 The procedure f calibrating the position proptional output is listed in Table 6. Make sure LOCKOUT in the Set Up group is set to NONE. Position Proptional Output Calibration Procedure Step Description Press Action 1 Enter Calibration Mode SET UP CALIB until you see POS PROP 2 Set Mot Traverse Time Note: This is the time it takes the mot to travel from 0 to 100%. Until you see: MTR TIME a value Until the proper mot stroke time is reached (see the mot specs measure the time). Range of setting = 5 to 255 Seconds 3 Select Automatic Manual Calibration until you see: DISABLE POS PROP You can calibrate the control output manually let the recder calibrate the control output automatically. In the Automatic Calibration Mode (DO AUTO), the control relays automatically move the mot in the proper direction. If desired, however, the mot may be manually positioned to 0% and 100% positions. Disconnect the relay wires. DO MAN. In the Manual Calibration Mode (DO MAN) the mot does not move. Instead, the existing 0% and 100% values may be changed with the keys. Select automatic manual calibration. DO AUTO POS PROP DO MAN If you select DO AUTO, go to step 4 If you select DO MAN, go to step 6 ATTENTION When calibration is terminated, this selection reverts to DISABL. Table is continued on next page 12 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
4.1 Position Proptional Output Calibration, Continued Table 6 Position Proptional Output Calibration Procedure, continued Step Description Press Action 4 DO AUTO Set 0% value 5 Set 100% value 6 DO MAN Set 0% value The close relay is turned on to move the mot to 0% position. counts of feedback slidewire (0 to 2047) ZERO VAL When the mot stops, the display should stop counting; go to the next step. The open relay is turned on to move the mot to 100% position. counts of feedback slidewire (0 to 2047) SPAN VAL When the mot stops, the display should stop counting, then, go on to step 8. You will see: ZERO VAL (approximately 100) The existing zero calibration value in counts. Until the desired zero value is in the upper display. The desired zero value ZERO VAL 7 Set 100% value 8 Exit the Calibration Mode The recder stes the 0% value and you will see: The existing span calibration value in counts SPAN VAL (approximately 1500) Until the desired span value is in the upper display. The desired span value SPAN VAL F manual calibration, the mot does not move from its position pri to the start of position proptional calibration. The recder stes the 100% value. 9/96 Replacement Kit Instruction #44-45-33-12C 13 of 20
5.0 Adding Relay Control Output Installation procedure Follow the steps listed in Table 7 to add the Relay control output printed circuit board. The procedure assumes that the chart do is open, the chart plate is swung out, and the power is removed. Table 7 Adding a Relay Control Output PCB Step Action 1 Install the new card guides supplied with the kit into proper location on the motherboard located in the left hand side of the case. Control Output 1 J5 Control Output 2 J1 (See Figure in Step 10 f Output card location.) CAUTION Install the guides with a steady downward pressure. Excessive rocking will destroy its latch. 2 Befe you install the control output board, locate connect J5 on the control output #1 printed circuit board (refer to Step 11 f location). 3 Remove the unwired plug from J5. 4 Locate jumper positions W2/W3 and W4/W5 below connect J5 on the printed circuit board. Position the jumpers as shown below f desired relay contact action. W2 W3 W4 W5 Relay No. 1 W2 = N.O. contact W3 = N.C. contact Relay No. 2 W4 = N.O. contact W5 = N.C. contact 5 Locate jumper positions W6/W7 near connect J3. Make sure jumper W6/W7 position is W6 f relay control output. W6 W7 6 Slide the new control output board into the card guides and press down firmly to seat the connect onto the motherboard. 7 Connect the 2-connect lead from the transfmer on the mother board to the Control output board at J4 position. Brown to Control Output #1 board Orange to Control Output #2 board 8 Run the relay load wires through the desired knockouts. 9 Strip 1/4-inch maximum of insulation from the end of each wire. 10 Loosen the screws in plug J5 terminals and position the plug as you would to plug it into J5. Table continued on next page 14 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
5.0 Adding Relay Control Output, Continued Installation procedure, continued Table 7 Step Adding a Relay Control Output PCB, continued Action 11 Insert the relay wires and relay power into the appropriate screw clamps f single duplex action as shown below. Tighten the screws to secure the wires. Control output #1 PCB Control output #2 PCB Plug J5 Heat Relay 1 load Relay 2 load Cooling External Load power supply N H N H NOTE: Relay 2 is used f time proptional duplex Motherboard 22753 12 Install the wired plug into J5. 13 Repeat steps 1 through 12 f Control Output #2 printed circuit board as applicable. 9/96 Replacement Kit Instruction #44-45-33-12C 15 of 20
6.0 Application Notes Introduction One of the common causes of Position Proptional Output card failure is excessive noise on the slidewire circuitry. You can check out the Position Proption circuitry on the DR4500 recder by following the procedure in Table 7. Checkout procedure Table 7 Table 7 lists the steps required to check out the Position Proption circuitry. Checkout Procedure Step Operation Press Result 1 Configure the recder f Time Duplex output with ON/OFF control action SET UP until you see: SET UP SET UP CONTROL1 CONTROL2 until you see: CONTxALG x =1 2 use until you see: OUTxALG x =1 2 ON-OFF PID-A PID-B PD+MR 3PSTEP to select ON-OFF TIME CURRNT POSITN TIME D CUR TI TI CUR use to select TIME D 2 Check the relay jumpers Ensure that the relay jumpers on the Output card are in the nmally open position (jumper in W2 and W4). W2 W3 W4 W5 Relay No. 1 W2 = N.O. contact W3 = N.C. contact Relay No. 2 W4 = N.O. contact W5 = N.C. contact Jumper to W7 W6 W7 Table continued on next page 16 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
6.0 Application Notes, Continued Checkout procedure, continued Table 7 Checkout Procedure, continued Step Operation Press Result 3 Select Manual Mode 4 Set the controller output to 100% MAN AUTO LOWR DISP until MAN indicat is ON in the upper right hand cner of the display. until the OUT prompt appears in the lower display along with a value. until the controller output is at 100%. 5 Check Relay #1 and valve action ATTENTION If the valve is already in the fully open position, press the key until the controller output in the lower display goes to 0% and the mot travels toward the closed position, then move the output to 100%. Observe that Relay #1 turns ON and drives the valve to the fully OPEN position. Relay #1 is the relay connected to terminals 1 and 2 on J5, the four position connect on the output card. Measure the voltage across the two Relay #1 screw terminals on J5 using an AC Voltage range. If the relay is turned ON, the AC voltage across the two screw terminals should be close to zero. If this condition is met go to Step 7. If this condition is not met, go to Step 6. 6 Troubleshoot the relay 1. Remove power from the control relays and check that the relays are fully seated into the socket. 2. Verify that the field wiring is crect. 3. If the relay is defective, der 30754499-005, Control Output Relay Kit (2 relays per kit). 4. Call TAC # f assistance. 1-800-423-9883 USA 1-800-461-0013 Canada 7 Set the controller output to 0% LOWR DISP until the OUT prompt appears in the lower display along with a value. until the controller output is at 0%. ATTENTION If the valve is already in the fully closed position, press the key until the controller output in the lower display goes to 100% and the mot moves toward the open position, then move the output to 0%. Table continued on next page 9/96 Replacement Kit Instruction #44-45-33-12C 17 of 20
6.0 Application Notes, Continued Checkout procedure, continued Table 7 Checkout Procedure, continued Step Operation Press Result 8 Check Relay #2 and valve action Observe that Relay #2 turns ON and drives the valve to the fully CLOSED position. Relay #2 is the relay connected to terminals 3 and 4 on J5, the four position connect on the output card. Measure the voltage across the two Relay #2 screw terminals on J5 using an AC Voltage range. If the relay is turned ON, the AC voltage across the two screw terminals should be close to zero. If this condition is met go to Step 10. If this condition is not met, go to Step 9. 9 Troubleshoot the relay 1. Remove power from the control relays and check that the relays are fully seated into the socket. 2. Verify that the field wiring is crect. 3. If the relay is defective, der 30754499-005, Control Output Relay Kit (2 relays per kit). 4. Call TAC # f assistance. 1-800-423-9883 USA 1-800-461-0013 Canada 10 Check the Voltage on J2 Use a DVM to measure the voltage between the first and middle terminals of J2, the three position connect on the output card. This Voltage should typically be 1.250 Volts dc. The range of acceptable Voltage values is between 1.125 Vdc and 1.375 Vdc. If this condition is met go to Step 12. If this condition is not met, go to Step 11. 11 Troubleshoot J2 1. Verify that the two wire power connect at J4 on the Output card is securely in place. 2. Call TAC # f assistance. 1-800-423-9883 USA 1-800-461-0013 Canada 12 Check 0% Output Voltage Move the output to 0% and measure the voltage between the middle and bottom terminal on J2. This Voltage should be between 0 Volts dc and 0.2 Volts dc. If this condition is met go to Step 14. If this condition is not met, go to Step 13. 13 Troubleshoot 0% Voltage 1. Verify that the field wiring is crect. 2. Call TAC # f assistance. 1-800-423-9883 USA 1-800-461-0013 Canada Table continued on next page 18 of 20 Replacement Kit Instruction #44-45-33-12C 9/96
6.0 Application Notes, Continued Checkout procedure, continued Table 7 Checkout Procedure, continued Step Operation Press Result 14 Check 100% Output Voltage 15 Troubleshoot 100% Output Voltage 16 Configure the recder f Position Proptional Output SET UP Move the output to 100% and measure the voltage between the middle and bottom terminal on J2. This Voltage should be between 1.0 Volts dc and the Voltage measured in Step 10. If this condition is met go to Step 16. If this condition is not met, go to Step 15. 1. Verify that the field wiring is crect. 2. Call TAC # f assistance. 1-800-423-9883 USA 1-800-461-0013 Canada until you see: SET UP SET UP CONTROL1 CONTROL2 until you see: OUTxALG x =1 2 TIME CURRNT POSITN TIME D CUR TI TI CUR use to select POSITN 17 Calibrate the recder Complete the Calibration Procedure shown in Subsection 3.1 of this Instruction. Use DO MAN procedure. The 0% value should be between 100 and 400, If not enter 300. The 100% value should be between 1000 and 1800, if not enter 1500. Complete the calibration procedure in the manual using DO AUTO. If the Position Proptioning Output is still not functioning properly, call TAC # f assistance. 1-800-423-9883 USA 1-800-461-0013 Canada 9/96 Replacement Kit Instruction #44-45-33-12C 19 of 20
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