ANDERSON-NEGELE AV-9900 User manual

Anderson Instrument Co., Inc.
156 Auriesville Rd.
Fultonville, NY 12072
Phone: [phone]
www.anderson-negele.com
Instruction
Manual
Rev. 3.0
Doc. 1029
AV-9900
Microprocesor Based
HTST Recorder/Controller

1. General Information
1.1. How to Use This Service Manual
In order to facilitate easier start-up and commissioning, the AV-9900 has been pre-programmed at the
factory. Before attempting installation, changes, or additions to the unit it is recommended that this manual
be thoroughly reviewed. Many common operations have been thoroughly outlined in the Quick Start -
How To section. For more detailed explanations of commands, the Menu Options and Setup section
provides command options and descriptions.
Chapter 1 Description Features
Chapter 2 Unpacking Wiring
Chapter 3 Operation
Chapter 4 Shortcuts
Chapter 5 Function Setup Menu - programming
Chapter 6 Controller Setup Menu - programming
Chapter 7 Configuration Menu - programming
Chapter 8 Test routines
Chapter 9 Calibration routines
Chapter 10 Model and Revision info
Chapter 11 Chart Operation
Appendix I Warranty
ñNOTE: The service manual contains notes that point out key information. When
reviewing a section, be sure to stop and review all notes.
ôCAUTION: The caution symbol will alert the user/installer to functional or safety
hazards which may effect the operation of the equipment, or create a safety
hazard for the individual. Be sure to read each of these notations.
For additional service/set-up questions you may call your authorized Anderson Distributor. In addition,
you may reach Anderson Technical Services directly at the following numbers:
Phone: [phone] or 800-833-0081
Fax: [phone] or 800-726-6733
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1.2. AV-9900 Description
The AV-9900 High Temperature Short Time Controller provides all USPHS required functions associated
with recording pasteurized product temperature, signaling the flow diversion valve (F.D.V.), and recording
the Flow Diversion Valve position. Addition features allow for multiple diversion set-points, recording
active setpoint, cold product recording - with optional control, and hot water control.
1.3. AV-9900 Features
1.3.1. Hot Product Temperature Sensor
The Hot Product Sensor is a dual element, 1000ohm Resistance Temperature Detector (RTD). The
Primary RTD supplies the recording - thermal limit signal input, with the Secondary RTD supplying a
verification signal.
Sensors are available with a wide variety of sanitary connections featuring a 5-1/2” or 7-1/4” probe length.
Provision for the Health Authority Seal on the stainless steel conduit housing provides separate servicing of
the probe, and ease of installation. Overall response characteristics allow for cable runs of up to 500 feet.
Chart ranges are programmable, and are factory set to meet all Pasteurized Milk Ordinance (PMO)
requirements. In addition, criteria of 12 hour rotation, linear, and 1OF divisions have been met.
1.3.2. Diversion Switching
Diversion set-point circuitry provides for up to five selectable cut-in/cut-out temperatures. User
configurable parameters exist for displaying the active set-point. The current set-point is recorded to the
chart for verification at time of cut-in. Diversion set-point values are easily modifiable upon breaking the
Health Authority Seal, and entering the system program mode. In addition to restricting access to the
Run/Program shunt jumper, the chart plate seal prevents modifications to circuit boards and input/output
wiring connections.
Flow Diversion Valve position is indicated by red and green lights on the chart plate, in addition to being
recorded by an event pen on the outside area of the chart. The event pen position is outward for forward
flow on all diversion set-points. Selection of the current diversion set-point is accomplished via the front
mounted user keypad and display. Five function keys become active, allowing the user to choose the
desired set-point.
1.3.3. Diagnostic Circuitry
The AV-9900 provides fail-safe operation via internal self-diagnostics of the Hot Product Probe input
signals. The Primary RTD input signal is continually referenced against the Secondary RTD signal. The
result is indicated on a series of LED’s, located just above the user display, and labeled Sensor Balance. If
both RTD elements are in agreement by less than .5OF , no LED’s are lit. Each increment of .5OF error
will light an LED. At the point at which the elements differ greater than 2OF , the AV-9900 will go into
automatic divert. In addition, the user display will indicate that a Probe Failure has taken place. Until a
replacement Hot Product Probe is installed, the unit will not allow a forward flow condition to take place.
1.3.4. Pen Drive Mechanism and Chart Printing
The pen drive mechanism is similar to a dot-matrix print device in that a series of dots are placed down
onto the paper chart. This mechanism is fully alpha-numeric capable allowing printing of ranges, units,
alarm’s, etc. to the chart. All four pens are housed with a small pen cartridge in a straight line
arrangement. As a result, all data printed to the chart is on the same time line. No lag exists from pen to
Revision 3.0 Section 1 2

pen as with typical felt pen type recorders. Chart ranges and scales are factory programmed, per applicable
PMO requirements, but may easily be re-ranged in the field. Charts are plain paper, and pre-printed only
with circular ring divisions. Division spacing meets PMO requirements. User defined scales and chart
ranges are printed in one of four available colors.
1.3.5. Cold Product Record - Control
The AV-9900 may be configured to receive an input from an RTD, or mA transmitter, measuring the Cold
Product temperature as it exits the pasteurization loop. This function may be specified at time of order, or
upgraded in the field at a later date. A factory set, field modifiable scale has been programmed for the
recording pen. Data will be recorded in color allowing easy interpretation when reviewing chart
information.
An additional option exists for controlling the Cold Product Cooling within the AV-9900. An optional
PID Loop Control function can be specified at time of order, or upgraded at a later date in the field. This
function will receive its input from the same probe measuring the Cold Product temperature. In turn, a
desired set-point may be programmed, with output signals interfacing to the cooling loop. The PID, or
control functions, will vary the resulting output signal based on rising above or falling below the desired
Cold Product set-point.
1.3.6. Hot Water Loop Control
The AV-9900 may be configured to receive an input from an RTD, or mA transmitter, measuring the Hot
Water Loop temperature. This function may be specified at time of order, or upgraded in the field at a later
date. In turn, a desired set-point may be programmed, with output signals interfacing to the Hot Water
Loop. The PID, or control functions, will vary the resulting output signal based on rising above or falling
below the desired Hot Water set-point.
If various products are being processed, up to five Hot Water Controllers are available (one for each STLR
diversion set-point). Each controller may have it’s own set-point and PID tuning parameters. When the
operator selects a new STLR diversion set-point, the corresponding Hot Water Controller is automatically
selected. Again, Hot Water Control set-points and PID tuning parameters would have been pre-
programmed
1.3.7. Safety Flow Limit Record - Control
The AV-9900 may be configured to receive an input from a Sanitary Flow Meter for the purpose of
controlling the pasteurization loop flow rate via Meter Based Timing. This function may be specified at
time of order, or upgraded in the field at a later date. A factory set scale has been programmed for the
recording pen per FDA (Food & Drug Administration) guidelines. Data will be recorded in color allowing
easy interpretation when reviewing chart information. In addition to the recorded flow rate on the chart, an
event pen is also present on the outer chart area. This event pen indicates when the system has gone below
“Loss of Signal” setpoint, “High Flow” setpoint or is in proper flow. These alarm conditions directly
switch on-board mechanical relays. Contacts of the relays interface with the Legal Flow Control unit,
allowing for auto system divert in the event of an alarm condition.
An optional PID Loop Control function can be specified at time of order, or upgraded at a later date in the
field. This function will receive its input from the same flow meter signal feeding the recording pen. In
turn, a desired set-point may be programmed, with output signals interfacing to the pump controlling the
system flow rate. The PID, or control functions, will vary the resulting output signal based on rising above
or falling below the desired Flow Rate set-point.
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2. Installation
The following section details mounting, installation, and wiring details for the AV-9900 Series HTST
Controller.
ôCAUTION: Be sure to thoroughly read the material in this section prior to installation. Data
tags for voltage and wiring are located inside the unit, viewable upon swinging
the chart plate forward.
2.1. Unpacking
Remove the instrument and pen cartridge assembly from the shipping container and inspect for any damage
due to transit. If damage has occurred, report and file a claim with the carrier immediately. All packing
and shipping materials should be secured as proof of damage.
ñNOTE:Charts, pen cartridge, and included service manual are enclosed in a cardboard
box within the container holding the unit. Be sure to secure these items before
discarding shipping material.
Select a location for the instrument which is accessible, clean, well lighted and free from excessive
vibrations and wide variations in temperature. The instrument should be mounted vertically on a rigid
support (either wall mount or panel mount). Be sure to observe all local wiring codes.
2.2. Mounting
Wall Mount: Brackets supplied provide holes for ¼” machine bolts or
No. 14 wood screws.
Panel Mount: Four countersunk locations provided for ¼” machine bolts. Accessible by
swinging open door and chart plate - located on upper and lower lip of
case. Installer required to complete hole penetration through case
Dimensions
A = 16.77”
B = 12.6”
C = 14.12”
D = 7.747”
E = 5.24”
Panel Cutout
12.7” x 12.7”
Figure 1 - Case Dimensions
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2.3. Circuit Board Identification / Locations
The following diagram shows the locations of circuit boards within the AV-9900. Case cutouts have been
provided for wire entry, and are located at the base of the unit. In order to eliminate interference, be sure to
isolate signal cables from power cables when entering recorder.
ôCAUTION: To prevent moisture entry, or damage to components, DO NOT cut
case penetrations in sides or top of unit.
Power Supply
HTST
Termination
Board
Input
Boards MA Output
Boards
Transmitter Power Suppl
y
Boar
d
Motherboard
Figure 2 - Board Layout
Note: Boards present will be determined by model ordered.
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2.4. AC Power Wiring
G
N
N
L
L
GND
Jumper Wires
Power Supply
F1F2
110 VAC: F1 & F2 = 3 amp
220 VAC: F1 & F2 = 1.5 amp
7
65
4
3
2L2
TB1
HTST
Termination Board
Fuses
110 VAC / 220 VAC (As Per Order)
Review Instrument Data Tag
Prior To Makin
g
Field Connections
ô CAUTION:
Figure 3 - Power Wiring
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2.5. Signal Input and Output Wiring
The following sections illustrate wiring connections for the signal inputs and outputs. Prior to performing
termination’s, be sure to review each section as installed components will vary based on the configuration
ordered.
CAUTION: Disconnect power to the instrument to prevent electrical shock or
component damage.
2.5.1. Legal Controls Wiring
Wiring to the legal controls (FDV, Differential Pressure Switch, etc.) is accomplished on the HTST
Termination Board. The terminal strip wiring utilizes the conventional HTST numbering system for ease
of setup.
Figure 4 - Legal Field Wiring
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2.5.2. Input Card General Information
The first step in making wiring termination’s is to identify the functions that are present within the unit.
The data tag on the inside of the unit will show the
Matrix Order Number . A complete product matrix,
showing all options, has been supplied under the Specifications section of this manual. Once functions that
are present have been identified, the following sections will guide the installer through wiring connections
and termination’s.
STLR Function Always present
Hot Water Function First available option
Cold Product Function Second available option
SFLR Function Third available option
Depending on the features ordered there will be either One, Two, or Three stacked input cards. Unless
specified at time of order, all programming and jumper selections have been pre-set at the factory.
Note: The following chart outlines board locations for
Input’s only.
Board Location LEFT Input Channel RIGHT Input Channel
First (Furthest In) Hot Product / Input 1
(ALWAYS - Cannot change)
Hot Product / Input 2
(ALWAYS - Cannot change)
Second (Stacked on top of first) Input 3 (mA or RTD) Input 4 (mA or RTD)
Third (Stacked on top of second) Input 5 (mA or RTD) Not present
Each input card has a set of jumpers which determine the location within the instrument (Board one, two,
or three). For ease of wiring, it may be necessary to remove cards. Locating JU13 and JU14, near the top
of each card, will indicate which position they should be re-installed into the unit.
Jumper
JU13 Jumper JU14
Board 1
Board 2
Board 3
Board
Position
Input 1 Input 2
Input 3 Input 4
Input 5 Not Used
TOP
MID or TOP
BOTTOM
Figure 5 - Input Card Details
Revision 3.0 Section 2 5

2.5.3. Hot Product Probe Input Board Wiring
The Hot Product Probe will always terminate at the bottom (furthest in) input card. The wiring terminal
block of this board has been color coded so as to differentiate it from the remaining cards. Termination’s
to the Hot Product Probe are as follows:
JU15 JU16
JU2 JU5
JU3
JU6
JU7 JU8
BLUE
BLACK
BROWN
WHITE
RED
GREEN
TB1 TB2
Figure 6 - Hot Product Input Card Wiring
All conditioning jumpers have been pre-set at the factory. Proper positions have been noted on the above
diagram.
2.5.4. Hot Product Probe Wiring
The Hot Product Sensor is provided with dual removable plugs and a specified amount of six conductor
shielded cable. If wires are removed for installation purposes, they must be re-wired properly.
CAUTION: Anderson does not recommend splicing of signal cable. The possibility will exist for
corrosion, leading to intermittent connection or loss of signal. If cable length is insufficient, it is
recommended that a new, longer, cable be utilized.
VIBRATION DAMPENER - DO NOT DISCARD: A small black rubber puck was shipped with the Hot
Product Probe. It is inside the conduit housing of the sensor, and must be removed for wiring. This puck
prevents terminal blocks from coming loose in high vibration applications. RE-INSTALL upon
completion of probe wiring.
Once all wiring has been completed, a
Health Autho ity Seal must be placed from the cap (hole provided)
around the seal-tight grommet. This will prevent unauthorized entry into the Hot Product Probe.
r
Revision 3.0 Section 2 6

BL BK BN
GRW
Primary RTD: G = Green (Return)
R = Red (Common)
W = White (Common)
Secondar
y
RTD: BL = Blue (Return)
BK = Black (Common)
BN = Brown (Common)
Removable
Plugs
Seal-Tight
Grommet
Figure 7 - Hot Product Probe Wiring
2.5.5. RTD Input Board Wiring
Each half (right or left) of the remaining input cards may be set for either RTD or mA inputs. You should
first determine which input you will be working with (Cold Product or Hot Water), it’s type (RTD or mA),
and finally which terminal it wires to. The following diagram illustrates the wiring and configuration
jumper positions for both an RTD wired to the LEFT or RIGHT of an input card.
Green Green
Red Red
White White
TB1
JU15 JU16
JU2 JU5
JU3
JU6
JU7 JU8
TB2
Figure 8 - RTD Input Card Wiring
All conditioning jumpers have been pre-set at the factory. Proper positions have been noted on the above
diagram.
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2.5.6. mA Input Board Wiring
Each half (right or left) of the remaining input cards may be set for either RTD or mA inputs. You should
first determine which input you will be working with (Cold Product or Hot Water), it’s type (RTD or mA),
and finally which terminal it wires to. The following diagram illustrates the wiring and configuration
jumper positions for both a 4-20 mA input wired to the LEFT or RIGHT of an input card.
NOTE: Before completing wiring, determine whether mA input from sensor is Powered or Un-powered.
This can be accomplished by placing a meter (DC Volts position) across the two sensor leads. If a voltage
is observed, the signal is said to be Powered. Wiring can go directly to the mA input of the associated
card. If NO voltage is present, a loop power supply must be utilized. If AV-9900 ordered with
Transmitter Power Supply option, refer to next section for wiring. If external, customer supplied, power
supply to be utilized, final wiring termination’s will be as follows:
TB1
JU15 JU16
JU2 JU5
JU3
JU6
JU7 JU8
TB2
Figure 9 - mA Input Card Wiring
All conditioning jumpers have been pre-set at the factory. Proper positions have been noted on the above
diagram.
Revision 3.0 Section 2 8

2.5.7. Transmitter Power Supply Wiring
If supplied with the transmitter power supply option, connections will be located near top of unit. Refer to
the circuit board locations diagram for assistance in locating the board. Wiring connections to a transmitter
will be as follows:
Two Wire
Transmitter
Transmitter
Power
Supply
Transmitter
Power
Supply
T wo Wire
Transmitter
--
-
-
-
-
T
TB B12
Figure 10 - Transmitter Power Supply Wiring
2.5.8. mA Retransmission Output Board Wiring
Refer to the circuit board locations diagram for assistance in locating the mA retransmission board.
Retransmission signals are utilized as outputs from either the Cold Product PID Loop Controller or the Hot
Water Loop Controller. They are powered signals, with wiring as follows:
TB1 TB2
mA Retransmission
or
Out to I:P Transducer
or
Out to Variable Frequency
Motor Drive
mA Retransmission
or
Out to I:P Transducer
or
Out to Variable Frequenc
y
Motor Drive
+ + + +
Figure 11 - mA Retransmission Output Wiring
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2.6. Relay Output Wiring
Refer to the circuit board locations diagram for assistance in locating the relay board. Wiring is as follows:
NO
COM
NC NO
COM
NC NO COM NC NO COM NC
RELAY 1 RELAY 2 RELAY 3 RELAY 4
Figure 12 - Relay Board
NOTE: If ordered with Safety Flow Limit Record function, Relay 1 and Relay 2 will be pre-configured
to act as the flow alarms. Details are as follows:
•Relay 1 = SFLR Alarm 1 = “Loss of Signal” alarm
Wire to COM and NO terminals for failsafe operation
•Relay 2 = SFLR Alarm 2 = “High Flow” alarm
Wire to COM and NO terminals for failsafe operation
Relay contacts interface with Legal Flow Control unit found in system. For proper operation, these relays
MUST be utilized. Proper system function is not possible utilizing external “Loss of Signal” and “High
Flow” relays.
2.7. Chart Plate Health Authority Seal
A through hole lug and post have been provided for installing the Health Authority Seal. They are located
in the upper right corner of the chart plate.
Posts For
Health Authority
Wire Seal
Figure 12 - Health Authority Seal
Revision 3.0 Section 2 10

3. Instrument Operation
The AV-9900 is a fully microprocessor driven instrument, and posses many options for customizing
operation and output. This section will detail specifics relating to overall operation of the unit.
3.1. Installation of pen cartridge assembly
Remove the pen cartridge assembly from its shipping container. With mounting tab on the bottom, slide
the pen cartridge assembly (item #2) into the print actuator (item #1).
Figure 1 - View of Chart Plate
Revision 3.0 Section 3 1

3.2. Recording Chart Identification
ó STOP: The AV-9900 uses only one style chart. Be sure Chart Number 00215401 is being
utilized. HTST ONLY is printed around the center hub for ease of identification.
Charts are installed by simply loosening the knurled lug located at the end of the print arm assembly. This
will allow the entire assembly to swing forward. The chart may then be installed, taking care to slip edges
underneath the plastic retainer clips. Swing the pen arm assembly closed, and tighten the knurled lug.
3.3. Keypad
Located on the front chart plate of the unit is the USER KEYPAD. From here, access to the
program parameters can be gained. A description of each of the keys is as follows:
õUp Arrow Key: Used to move through menus, or increase a value
öDown Arrow Key: Used to move through menus, or decrease a value
÷Left Arrow Key: Used to move through menus or digits of a parameter
øScroll (Right Arrow) Key: Used to move through menus or digits of a parameter
ùEscape Key: Used to cancel a flashing program prompt
úReset Key: Will jump from within programming menus to the standard operating display
ûDisplay Key: Allows access to display menu options, STLR setpoints and additional
menus as activated
üModify Key: Allows changes to be made to a currently displayed parameter
ýChart Key: Allows access to the Change Chart Routines (Run mode) and Chart
parameters (Program mode)
þEnter Key: Locks in changes made to a parameter
Revision 3.0 Section 3 2

3.4. User Display
Figure 2 - Keypad / Display
Also located on the front chart plate is the User Display. From here, data such as a digital readout
of the STLR temperature value may be viewed.
Two options exist for the display; CONTINUOUS DISPLAY and SEQUENCE DISPLAY.
When in continuous mode, the selected parameter is viewable at all times on the display. This is
the required mode for completion of the Appendix I Pasteurized Milk Ordinance testing. While in
sequence mode, various parameters scroll over the screen at a timed interval.
3.4.1. Display - Continuous Mode
1. Operation may be done with Security Mode Shunt in either position - no changes
required.
2. ÿûkey twice - you will see: MODIFY <->
DISPLAY PARAMETERS
3. ÿökey once.
4. If CONTINUOUS is not already flashing, ÿøkey.
5. With CONTINUOUS flashing, ÿþkey once.
6. ÿúkey once to return to the main display.
7. ÿöuntil STLR INP is displayed - this is the digital display of Hot Product
Temperature.
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3.4.2. Display - Sequence Mode
1. Operation may be done with Security Mode Shunt in either position - no changes
required.
2. ÿûkey twice - you will see: MODIFY <->
DISPLAY PARAMETERS
3. ÿökey once.
4. If SEQUENCE is not already flashing, ÿøkey.
5. With SEQUENCE flashing, ÿþkey once.
6. ÿúkey once to return to the main display.
3.4.3. Sensor Balance LED’s
Located directly above the blue user feedback display are the Sensor Balance LED’s. The Anderson Hot
Product Temperature probe utilized for the STLR input contains two resistance temperature detector
elements. These elements provide the temperature input to the STLR portion of the system. A continuous
check is made between the two elements.
Match to < .5 OF shift = No LED’s lit - operation allowed
>= .5
OF to < 1 OF shift = 1 LED lit - Forward Flow allowed
>= 1
OF to < 1.5 OF shift = 2 LED’s lit - Forward Flow allowed
>= 1.5OF to < 2 OF shift = 3 LED’s lit - Forward Flow allowed
>= 2
OF shift = 4 LED’s lit - NO Forward Flow allowed
Display shows: *** WARNING ***
SENSOR BALANCE FAILURE
Possible causes for a sensor balance failure are:
•Shorted elements - failed probe
•Broken / unattached wires
The Sensor Balance Failure display will be shown until the error condition is rectified. Even if proper
temperatures are met, the unit will send a signal to the Flow Diversion valves to authorize forward flow.
Revision 3.0 Section 3 4