Anderson AV-9900 User manual

AndersonInstrumentCo.,Inc.
156AuriesvilleRd.
Fultonville,NY12072
Phone:518-922-5315
800-833-0081
www.anderson-negele.com
Instruction
Manual
Rev. 4.0
Doc. 1029
AV-9900
Field Setup
Guide
AV-9900
Microprocesor Based
HTST Recorder/Controller

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Table of Contents
1. INTRODUCTION .................................................................................................................................................3
2. KEY PRODUCT FEATURES..............................................................................................................................4
2.1. HOT PRODUCT TEMPERATURE SENSOR ........................................................................................................... 4
2.2. DIVERSION SWITCHING ................................................................................................................................... 4
2.3. DIAGNOSTIC CIRCUITRY ................................................................................................................................. 4
2.4. PEN DRIVE MECHANISM AND CHART PRINTING.............................................................................................. 5
2.5. COLD PRODUCT RECORD - CONTROL .............................................................................................................. 5
2.6. HOT WATER LOOP CONTROL .......................................................................................................................... 5
3. HARDWARE DESCRIPTIONS ..........................................................................................................................6
3.1. CHART PLATE SEAL ........................................................................................................................................ 6
3.2. SECURITY MODE SELECTION SHUNT............................................................................................................... 7
3.3. KEYPAD .......................................................................................................................................................... 8
4. USER DISPLAY....................................................................................................................................................9
4.1. SETTING CONTINUOUS DISPLAY................................................................................................................. 9
4.2. SETTING SEQUENCE DISPLAY...................................................................................................................... 9
5. PASTEURIZED MILK ORDINANCE (PMO) APPENDIX I TESTING......................................................10
5.1. AV-9900 TESTING QUICK REFERENCE ......................................................................................................... 10
5.2. METER BASED TIMING FUNCTION – CHART VERIFICATION .......................................................................... 11
5.3. TESTS 2 AND 4 - TEMPERATURE ACCURACY ................................................................................................. 13
5.3.1. Pen Calibration.......................................................................................................................................13
5.3.2. Two Point Element Calibration...............................................................................................................14
5.3.3. Chart Calibration....................................................................................................................................17
5.4. TEST 3 - TIME ACCURACY............................................................................................................................. 18
5.5. TEST 8 - THERMOMETRIC RESPONSE ............................................................................................................. 18
5.6. TEST 10 - MILK TEMPERATURE AT CUT-IN AND CUT-OUT ............................................................................ 18
5.7. TEST 11 – CONTINUOUS FLOW HOLDING TUBES – HOLDING TIME ............................................................... 19
5.7.1. LED Indicators for “Loss of Signal” and “High Flow” Alarms ............................................................19
5.7.2. Accessing Flow Alarm Setpoints .............................................................................................................21
5.7.3. Accessing Flow Controller Setpoint........................................................................................................22
5.7.4. Appendix I - Test 11.2A Mag Flow Meter Based Timing Systems Continuous Flow Holding Time......23
5.7.5. Appendix I - Test 11.2B Continuous Flow Holding Tubes – Flow alarm ...............................................23
5.7.6. Appendix I - Test 11.2C Continuous Flow Holding Tubes – Low Flow / Loss-of-Signal Alarm.............24
5.7.7. Appendix I - Test 11.2D Continuous Flow Holding Tubes – Flow Cut-In and Cut-Out........................24
5.7.8. Appendix I - Test 11.2E Continuous Flow Holding Tubes – Time Delay Relay.....................................25
5.8. TEST 15 – ELECTRO MAGNETIC INTERFERENCE FROM HAND-HELD COMMUNICATION DEVICES ................. 26
6. DEFAULT PARAMETER VERIFICATION...................................................................................................27
6.1. STLR FUNCTION SETUP ................................................................................................................................27
6.2. STLR RECORDER SETUP ............................................................................................................................... 30
6.3. CHART SETUP................................................................................................................................................ 34
7. RUN MODE PARAMETER CHANGES..........................................................................................................37
7.1. CHART KEY................................................................................................................................................... 37
7.2. DISPLAY KEY ................................................................................................................................................ 38
7.3. SCROLL KEY ................................................................................................................................................. 38

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1. Introduction
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. Additional features allow for multiple diversion set-points, recording active diversion
setpoint, cold product recording - with optional control, and hot water control.
The remainder of this publication will serve as further introduction to the features of the AV-9900, as well outlining
procedures necessary to perform the PMO Appendix I tests.

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2. Key Product Features
The AV-9900 Microprocessor Based Safety Thermal Limit Recorder incorporates many time proven features found in
earlier Anderson products. Ease of operation and high safety standards were brought together specifically to meet the
demands of the pasteurization process. Key features of the AV-9900 are as follows:
2.1. Hot Product Temperature Sensor
The Hot Product Sensor is a dual element, 1000 ohm Resistance Temperature Detector (RTD). The Primary RTD
supplies the recording - thermal limit signal input, with the Secondary RTD supplying a verification for that 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 and 1OF divisions have been met.
2.2. 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 also 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.
2.3. 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 .5 OF , no LED’s are lit. Each increment of .5OF shift 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.

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2.4. 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 within 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 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.
2.5. 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.
2.6. 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

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3. Hardware Descriptions
In performing the required testing, access will be made to various areas of the AV-9900 hardware. Specifics are
illustrated as follows:
3.1. Chart Plate Seal
Provisions have been provided for placing the Regulatory Wire Seal in the upper right corner of the chart plate. When
in place, this seal prevents unauthorized access to not only the internal wiring, but also access to the Security Mode
Shunt (see next section).
Posts For
Health Authority
Wire Seal

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3.2. Security Mode Selection Shunt
The AV-9900 is equipped with a movable shunt to allow toggling between RUN and PROGRAM modes of operation.
While in RUN mode, access is prevented to all system critical parameters (ranges, setpoint changes, etc.). Changes
may be made to display functions as well as selection of the currently active diversion setpoint. While in PROGRAM
mode, full access to all system parameters is allowed.
NOTE:Moving the Security Mode Selection Shunt to the PROGRAM position will
immediately force the unit to
DIVERT flow. If already in DIVERT flow, the unit will remain in that mode even if the hot product temperature rises
above the active setpoint.
The following diagram illustrates the location of the Security Mode Selection Shunt, in addition to the settings, RUN
or PROGRAM.

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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 Used to move through menus, or increase a value
öDOWN ARROW Used to move through menus, or decrease a value
÷LEFT ARROW Used to move through menus or digits of a parameter
øSCROLL (RIGHT
ARROW) Used to move through menus or digits of a parameter
ùESCAPE Used to cancel a flashing program prompt
úRESET Jump from within programming menus to the standard
operating screen
ûDISPLAY While in display RUN mode allows access to STLR diversion
setpoints as well as display viewing option parameters
üMODIFY Allows changes to be made to a currently displayed parameter
ýCHART Allows access to the
Change Chart Routines
þENTER Locks in changes made to a parameter

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4. User 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. This display will be utilized in selected areas of the Pasteurized Milk Ordinance
Appendix I testing.
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 testing. While in sequence mode, various parameters scroll over the screen at a timed interval.
If the unit is set to SEQUENCE display mode, the following procedure will allow the unit to be placed in continuous
mode, with the STLR temperature visible:
4.1. Setting CONTINUOUS Display
1. Operation may be done with Security Mode Shunt in either position - no
changes required.
2. Press ûkey twice - you will see:
3. Press the ökey once.
4. If CONTINUOUS is not already flashing, press the økey.
5. With CONTINUOUS flashing, press the þkey once.
6. Press the úkey once to return to the main display.
7. Press öuntil STLR INP is displayed - this is the digital display of Hot
Product Temperature.
8. You may now complete the required testing.
4.2. Setting SEQUENCE Display
1. To return the display to SEQUENCE mode, proceed as follows:
2. Operation may be done with Security Mode Shunt in either position - no
changes required.
3. Press ûkey twice - you will see:
4. Press the ökey once.
5. If SEQUENCE is not already flashing, press the økey.
6. With SEQUENCE flashing, press the þkey once.
7. Press the úkey once to return to the main display.
8. The unit is now back in standard operation.
MODIFY <->
DISPLAY PARAMETERS
MODIFY <->
DISPLAY PARAMETERS

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5. Pasteurized Milk Ordinance (PMO) Appendix I Testing
This section will provide specific procedures regarding the completion of the PMO Appendix I tests. Only AV-9900
specific information has been provided. For a detailed listing of the actual testing procedure, please refer to the
Pasteurized Milk Ordinance, Appendix I.
5.1. AV-9900 Testing Quick Reference
Test Description Variance From Printed PMO Appendix I Test
2 Recording Thermometers – Temperature
Accuracy
Pen printing not instantaneous – utilize display for test
3 Recording Thermometers – Time Accuracy Test to be started when AV-9900 prints a Major (bold)
time line, and ended when thirty minute dashed line
printed
4 Recording Thermometers – Check Against
Indicating Thermometer
Pen printing not instantaneous – utilize display for test
8 Recorder/Controller – Thermometric Response Pen printing not instantaneous – utilize display for test
10.1 Milk-Flow Controls – Milk Temperature at
Cut-In and Cut-Out; HTST Pasteurizers
Pen printing not instantaneous – utilize display for test
10.2 Milk-Flow Controls – Milk Temperature at
Cut-In and Cut-Out; HHST Pasteurizers and
Aseptic Processing Systems Using Indirect
Heating
Pen printing not instantaneous – utilize display for test
10.3 Milk-Flow Controls – Milk Temperature at
Cut-In and Cut-Out; HHST Pasteurizers and
Aseptic Processing Systems Using Direct
Heating
Pen printing not instantaneous – utilize display for test
11.1 Continuous Flow Holding Tubes – Holding
Time – HTST Pasteurizers
None – complete test as documented
11.2-A Magnetic Flow Meter Based Timing Systems
Continuous Flow Holding Time
Pen printing not instantaneous – utilize display LEDs’
#1 and #2 for test
11.2-B Continuous Flow Holding Tubes – Flow alarm Flow rate must be adjusted to go past High Flow
Setpoint. Cannot adjust High Flow Setpoint in RUN
mode as required by standard PMO test.
11.2-C Continuous Flow Holding Tubes – Low Flow /
Loss-of-Signal Alarm
Pen printing not instantaneous – utilize display LEDs’
#1 and #2 for test
11.2-D Continuous Flow Holding Tubes – Flow Cut-
In and Cut-Out
Pen printing not instantaneous – utilize display LEDs’
#1 and #2 for test
11.2-E Continuous Flow Holding Tubes – Time
Delay Relay
Pen printing not instantaneous – utilize display LEDs’
#1 and #2 for test
15 Electro Magnetic Interference From Hand-
Held Communication Devices
None – complete test as documented