Honeywell DR4500A User manual

Honeywell Field Solutions
DR4500A Classic Series Circular Chart
Recorder With or Without Control
Product Manual
Doc. No.: 44-45-25-35
Release: M
Last Revision Date: April 2017

ii DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release M
April 2017
Notices and Trademarks
Copyright 2017 by Honeywell
Release M –April 2017
WARRANTY/REMEDY
Honeywell warrants goods of its manufacture as being free of defective materials and faulty
workmanship. Contact your local sales office for warranty information. If warranted goods are
returned to Honeywell during the period of coverage, Honeywell will repair or replace without
charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all other
warranties, expressed or implied, including those of merchantability and fitness for a particular
purpose. Specifications may change without notice. The information we supply is believed to be
accurate and reliable as of this printing. However, we assume no responsibility for its use.
While we provide application assistance personally, through our literature and the Honeywell web
site, it is up to the customer to determine the suitability of the product in the application.
Honeywell Process Solutions
1250 W Sam Houston Pkwy S
Houston, TX 77042
DR4500 is a trademark of Honeywell
Modbus is a registered trademark of Modicon
Other brand or product names are trademarks of their respective owners.

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About This Document
Revision Information
Document ID
44-45-25-35
Document Name
DR4500A Classic Series Circular Chart Recorder With or Without Control Product
Manual
Revision #
Publication Date
L
February 2017, (Daughterboard info updated in parts list)
M
April 2017, Range values table (7.2) updated, Aux Output only spare part added
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
51-52-05-01
Modbus® RTU Serial Communications User Manual
51-52-25-66
Modbus® RTU Serial Communications user Manual
Configuration Interface for DR4500
Supplement to 51-52-25-66
51-52-25-69

iv DR4500A Classic Series Circular Chart Recorder With or Without Control Product Manual Release M
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Support and Contact Information
For Europe, Asia Pacific, North and South America contact details, refer to the back page of this manual or
the appropriate Honeywell Solution Support web site:
Honeywell Corporate: www.honeywellprocess.com
Honeywell Process Solutions: https://www.honeywellprocess.com/*
Honeywell Circular Recorders: https://www.honeywellprocess.com/circular-chart-recorders/
Telephone and Email Contacts
Area
Organization
Phone Number
United States and
Canada
Honeywell Inc.
1-800-343-0228 Customer Service
1-800-423-9883 Global Technical Support
Global Email
Support
Honeywell Process Solutions
[email protected]m

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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
PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a
potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4
Vpeak, or 60 VDC may be accessible. Failure to comply with these instructions
could result in death or serious injury.
ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for
handling electrostatic sensitive devices
Protective Earth (PE) terminal. Provided for connection of the protective earth (green
or green/yellow) supply system conductor.
Functional earth terminal. Used for non-safety purposes such as noise immunity
improvement. NOTE: This connection shall be bonded to protective earth at the
source of supply in accordance with national local electrical code requirements.
Earth Ground. Functional earth connection. NOTE: This connection shall be bonded to
Protective earth at the source of supply in accordance with national and local electrical
code requirements.
Chassis Ground. Identifies a connection to the 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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Contents
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.....................................................................................56
3.3 How To Get Started.........................................................................................58
3.4 Configuration Tips ...........................................................................................59
3.5 Configuration Procedure .................................................................................60
3.6 Input Set Up Group..........................................................................................62
3.7 Pen Set Up Group...........................................................................................64
3.8 Chart Set Up Group.........................................................................................65
3.9 Totalizer Set Up Group....................................................................................66
3.10 Control Set Up Group......................................................................................67
3.11 Tuning Parameters Set Up Group...................................................................69
3.12 SP Ramp Set Up Groups ................................................................................70
3.13 Timer Set Up Group ........................................................................................71
3.14 Alarms Set Up Group ......................................................................................72
3.15 Auxiliary Output Set Up Group........................................................................74
3.16 Modbus Communications Set Up Group.........................................................75

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3.17 Options Set Up Group.....................................................................................76
3.18 Lockout Set Up Group.....................................................................................77
3.19 Configuration Record Sheet............................................................................78
4. Configuration Parameter Definitions................................................81
4.1 Overview..........................................................................................................81
4.2 Input Parameters Set Up Group......................................................................82
4.3 Pen Parameters Set Up Group .......................................................................86
4.4 Chart Parameters Set Up Group.....................................................................88
4.5 Total Parameters Set Up Group......................................................................89
4.6 Control Parameters Set Up Group..................................................................91
4.7 Tuning Parameters Set Up Group.................................................................100
4.8 Setpoint Ramp Set Up Group........................................................................103
4.9 Timer Set Up Group ......................................................................................105
4.10 Alarms Set Up Group ....................................................................................106
4.11 Auxiliary Output Set Up Group......................................................................109
4.12 Modbus Communications Set Up Group.......................................................111
4.13 Options Set Up Group...................................................................................112
4.14 Lockout Parameters Set Up Group...............................................................114
5. Operation.......................................................................................115
5.1 Overview........................................................................................................115
5.2 Preparation....................................................................................................116
5.3 Start-up..........................................................................................................118
5.4 Monitoring Your Recorder .............................................................................121
5.5 Operator Functions........................................................................................128
5.6 Operating Modes...........................................................................................129
5.7 Setpoints........................................................................................................131
5.8 Single Setpoint Ramp....................................................................................133
5.9 Using Two Sets of Tuning Constants (PID Values) ......................................136
5.10 Using Accutune II ..........................................................................................139
5.11 Alarm Setpoints.............................................................................................142
5.12 Digital Input Option (Remote Switching) .......................................................143
5.13 Resetting and Displaying Totalizer Value .....................................................144
5.14 Monitoring the External Event Operation ......................................................146
5.15 Maximizing Pen Life ......................................................................................146
5.16 Routine Maintenance ....................................................................................147

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5.17 Installing/Replacing Chart .............................................................................148
6. Setpoint Ramp/Soak Programming and Operation........................149
6.1 Overview........................................................................................................149
6.2 Setpoint Program Contents...........................................................................151
6.3 Drawing a Ramp/Soak Profile .......................................................................154
6.4 Entering the Setpoint Program Data .............................................................159
6.5 SP RAMP1 and SP RAMP2 Set Up Group...................................................161
6.6 Setpoint Program Profiles Set Up Group ......................................................163
6.7 Setpoint Program Segments Set Up Group..................................................165
6.8 Setpoint Program Event Set Up Group.........................................................168
6.9 Run/Monitor the Program..............................................................................172
7. Input Calibration.............................................................................175
7.1 Overview........................................................................................................175
7.2 Restoring Factory Calibration........................................................................176
7.3 Minimum and Maximum Range Values.........................................................178
7.4 Preliminary Information .................................................................................180
7.5 Calibration Set Up and Wiring for PV Inputs.................................................182
7.6 Calibration Procedure....................................................................................191
8. Output Calibration..........................................................................194
8.1 Overview........................................................................................................194
8.2 Current Proportional Output/Aux Out 2 and 3 Calibration.............................195
8.3 Position Proportional Output Calibration.......................................................197
8.4 Auxiliary Output Calibration...........................................................................200
9. Troubleshooting / Service ..............................................................202
9.1 Overview........................................................................................................202
9.2 Troubleshooting Aids.....................................................................................204
9.3 Self Diagnostics.............................................................................................206
9.4 Visual Failure Symptoms...............................................................................212
9.5 Troubleshooting Procedures .........................................................................213
9.6 Pen Alignment...............................................................................................219

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10.Parts List........................................................................................222
10.1 Overview........................................................................................................222
10.2 Exploded Views.............................................................................................223
10.3 Miscellaneous Hardware Kit Contents ..........................................................230
10.4 Internal Cabling Data –Without Options.......................................................232
10.5 Internal Wiring Diagram –Options Only........................................................233
A. Foreign Language Safety Instructions ...........................................235
DA2I-6057 ................................................................................................................236
DU2I-6057 ................................................................................................................237
FI2I-6057 ..................................................................................................................238
FR2I-6057.................................................................................................................238
GE2I-6057 ................................................................................................................240
GR2I-6057................................................................................................................241
IT2I-6057 ..................................................................................................................242
NO2I-6057................................................................................................................243
PO2I-6057 ................................................................................................................244
SP2I-6057.................................................................................................................245
SW2I-6057................................................................................................................246
Index ...................................................................................................247

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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 NEMA4X 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......................................................................................................................................59
Table 3-2 Configuration procedure............................................................................................................................60
Table 3-3 Input group function prompts....................................................................................................................62
Table 3-4 Pen 1 or 2 group function prompts............................................................................................................64
Table 3-5 Chart group function prompts ...................................................................................................................65
Table 3-6 Totalizer group function prompts..............................................................................................................66
Table 3-7 Control 1 or Control 2 group function prompts.........................................................................................67
Table 3-8 Tuning 1 or Tuning 2 group function prompts..........................................................................................69
Table 3-9 SP Ramp 1 or 2 group function prompts...................................................................................................70
Table 3-10 Timer group function prompts ................................................................................................................71
Table 3-11 Priority of functions that operate relays ...................................................................................................72
Table 3-12 Alarms group function prompts...............................................................................................................73
Table 3-13 Auxiliary output group function prompts................................................................................................74
Table 3-14 Modbus communications group function prompts..................................................................................75
Table 3-15 Options group function prompts..............................................................................................................76
Table 3-16 Lockout group function prompts.............................................................................................................77
Table 4-1 Input group definitions..............................................................................................................................82
Table 4-2 Pen 1 or 2 group definitions ......................................................................................................................86
Table 4-3 Chart parameters group definitions ...........................................................................................................88
Table 4-4 Totalizer group definitions........................................................................................................................89
Table 4-5 Control 1 or 2 group definitions................................................................................................................91
Table 4-6 Tuning group prompt definitions.............................................................................................................100
Table 4-7 Setpoint Ramp 1 or 2 group definitions ..................................................................................................103
Table 4-8 Timer group definitions...........................................................................................................................105
Table 4-9 Priority of functions that operate relays ...................................................................................................106
Table 4-10 Alarms group definitions.......................................................................................................................107
Table 4-11 Auxiliary output group definitions........................................................................................................109
Table 4-12 Modbus communications group definitions ..........................................................................................111
Table 4-13 Option group definitions .......................................................................................................................112