Honeywell Truline DR4500A Series Addendum
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Honeywell Truline DR4500A Series Addendum

Honeywell Truline DR4500A Series Addendum

Pasteurization flow circular chart flow recorders
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DR4500A Truline Series
HTST, STLR and
Pasteurization Flow
Circular Chart Flow
Recorders
Model DR45AH – HTST (High Temperature Short Time)
Model DR45AS – STLR (Safety Thermal Limit Recorder)
Model DR45AP – Pasteurization (Flow)
Addendum
(to Product Manual
44-45-25-30)
44-45-99-08
11/05
Industrial Measurement and Control

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Summary of Contents for Honeywell Truline DR4500A Series

  • Page 1 DR4500A Truline Series HTST, STLR and Pasteurization Flow Circular Chart Flow Recorders Model DR45AH – HTST (High Temperature Short Time) Model DR45AS – STLR (Safety Thermal Limit Recorder) Model DR45AP – Pasteurization (Flow) Addendum (to Product Manual 44-45-25-30) 44-45-99-08 11/05 Industrial Measurement and Control...
  • Page 2 Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...

  • Page 3: Table Of Contents

    Table of Contents SECTION 1 – INTRODUCTION..................1 Overview....................... 1 Modifications....................2 Pasteurization Functions ................3 SECTION 2– MODEL DR45AH - HTST (HIGH TEMPERATURE SHORT TIME)..... 7 Overview....................... 7 Field Wiring....................8 Connection to System .................. 9 .ii.Configuration...................14 .ii.HTST Operation..................18 SECTION 3–...
  • Page 4 Time Delay Relay Test – Test 11-2E, PMO 2003 ........118 Differential Pressure Test – Test 9.4, PMO 2003........120 Locking and Sealing the Recorder............122 SECTION 8 – HTST PARTS ..................128 Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...
  • Page 5 Tables Table 1-1 .ii.Pasteurization Selections ................. 3 Table 1-2 Pasteurization Function Selection Procedure ..........6 Table 2-1 Setting Two Diversion Setpoints ..............11 Table 2-2 .ii.Input Versus Pen Assignments for Model DR45AH .......15 Table 2-3 Configuration Procedure ................16 Table 2-4 Future Changes..................17 Table 3-1 Setting Two Diversion Setpoints ..............27 Table 3-2...
  • Page 6 Table 7-11 Pen Configuration ..................125 Table 7-12 Flow Diversion Setpoints Check .............. 126 Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...
  • Page 7 Figures Figure 1-1 DR45AH/DR45AP/DR45AS Recorders with Pasteurization Control ... 2 Figure 2-1 DR45AH Output Connections ..............8 Figure 2-2 Pasteurizer Control Box Connection Diagram ...........13 Figure 2-3 S1 Lockout Switch Location ...............14 Figure 2-4 Diagram of .ii.Milk Pasteurization Process..........18 Figure 2-5 Simulated HTST Printed Chart..............20 Figure 3-1 DR45AS Output Connections..............24...
  • Page 8 viii Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...

  • Page 9: Section 1 - Introduction

    Section 1 – Introduction Overview Features The DR45AH - HTST, DR45AP - FLOW, and DR45AS - STLR recorder/controllers combine the broad capabilities of the Truline recorders with the special features needed to serve the milk pasteurization requirements of the dairy industry. These features address the need for sanitary protection as well as: •...

  • Page 10: Modifications

    Modifications Component Various modifications have been made to the DR4500A recorder for modification Pasteurization operation: • Two clear, low profile indicator light lenses on the door • Indicator light assembly - one red, one green light • Captive screw and bracket •...

  • Page 11: Pasteurization Functions

    Pasteurization Functions PASTEUR selections Under the “OPTIONS” Set Up group, there is a prompt labeled “PASTEUR”. The selections for this prompt are “NONE”, “HTST”, “STLR“, or FLOW”. Table 1-1 gives a brief explanation of each selection. Follow the procedure in Table 1-2 to select one of the pasteurization functions.
  • Page 12 Pasteurization Functions, Continued PASTEUR selections, continued Table 1-1 Pasteurization Selections, continued Selection How it works • PID adjustments and Time/Date/Day/Year adjustments are STLR allowed when the recorder is in the lockout mode. • A Digital Reference Thermometer can be enabled. In this mode, Input #2 is the Digital Reference The measured value of the reference (Input #2) will be the lower display default, while the upper display default will be the...
  • Page 13 Pasteurization Functions, Continued PASTEUR selections, continued Table 1-1 Pasteurization Selections, continued Selection How it works • The FLOW option allows a Hi and Lo flow setpoint to trigger a FLOW divert condition. Diversion occurs when the flow rate is below the Lo limit or above the High limit.

  • Page 14: Table 1-2 Pasteurization Function Selection Procedure

    Pasteurization Functions, Continued Selection procedure Follow the procedure in Table 1-2 to select a pasteurization function. Table 1-2 Pasteurization Function Selection Procedure Step Operation Press Action/Result Enter Until the displays read: OPTIONS set Upper Display up group SET UP Lower Display OPTIONS select Until the displays read:...

  • Page 15: Section 2- Model Dr45Ah - Htst (High Temperature Short Time)

    Section 2– Model DR45AH - HTST (High Temperature Short Time) Overview In the HTST process, milk flows from the raw milk supply tank through Introduction the plate-type heat exchanger, where it is heated to pasteurization temperature prior to entering the holding tube. The tube size ensures that the milk remains at the pasteurization temperature for the required time.

  • Page 16: Field Wiring

    Field Wiring Simplified field wiring Mount the recorder and wire the power and inputs as described in Product Manual 44-45-25-30. Refer to Figures 2-1 and 2-2 for all other field wiring. Note that additional software was added to change Loop 2-On/Off relay algorithm to use Loop 1 Control Board, thus eliminating the need for a second control board.

  • Page 17: Connection To System

    Connection to System Introduction Two relays are required to interconnect the DR45AH recorder/controller to the HTST control system. • Divert Relay Valve • Diversion Switch Relay Figure 2-2 shows this wiring. The terminals in Figure 2-2 that are designated by a box are terminal numbers in the Pasteurizer Control Box.
  • Page 18 Connection to System Continued Suitable relays The model numbers for relays suitable for this application are given below. Other equivalent relays can be used. Divert Valve Latch Relay and Socket Struthers-Dunn B255BXBP and corresponding socket* 120Vac, 2 coil latching relay: 2NO, 2NC contacts rated at 10 120Vac contacts remain in position on power failure until reset Order screw terminal socket 27390 separately.

  • Page 19: Table 2-1 Setting Two Diversion Setpoints

    Connection to System, Continued Two diversion Since the pasteurization process may include different products, two setpoints different setpoints can be assigned to control Loop 2 (pasteurization). A two deck switch is installed on the panel by the user. One set of contacts is wired to the second digital input of the HTST recorder/controller (see Figure 2-2).
  • Page 20 Connection to System, Continued Two diversion setpoints, continued Table 2-1 Setting Two Diversion Setpoints, continued Step Operation Press Action/Result Enter #1 until you see: LOWR Setpoint for DISP Upper Display Diversion The PV value Lower Display SP and the local setpoint value Enter #1 setpoint (for example:166°F) Enter #2...

  • Page 21: Figure 2-2 Pasteurizer Control Box Connection Diagram

    Connection to System, Continued Connection diagram Figure 2-2 is the Pasteurizer Control Box connection diagram for Model DR45AH. Figure 2-2 Pasteurizer Control Box Connection Diagram - Model DR45AH - Designates terminals in Pasteurizer Control Box - See Page 9 115V Divert Valve Divert Leak...

  • Page 22: Ii.configuration

    Configuration Restrictions based on Figure 2-3 shows the location of the S1 Lockout Switch on the Main Lockout switch Printed Circuit board. position When the Lockout switch is OFF (Down - Configure): • You can view and change all applicable operating parameters as described in Section 4 of this Addendum.

  • Page 23: Table 2-2 .Ii.input Versus Pen Assignments For Model Dr45Ah

    Configuration, Continued Pens vs Inputs The DR45AH Recorder/Controller can have up to 4 Analog Inputs and one Digital Input. There are four pens to which these five inputs can be assigned. Some are required while others are optional. See Table 2-2. Table 2-2 Input Versus Pen Assignments for Model DR45AH INPUT...

  • Page 24: Table 2-3 Configuration Procedure

    Configuration, Continued Configuration Place the Lockout switch (S1) in the OFF (configure) position and follow procedure the procedure in Table 2-3 to configure the DR45AH recorder/controller. ATTENTION The prompting scrolls at a rate of 2/3 seconds when the key is held in. Also, keys will move group SET UP FUNC...

  • Page 25: Table 2-4 Future Changes

    Configuration, Continued Setting the lockout After all the parameters are configured, refer to Section 5 - Tests and switch to LOCK Procedures for Model DR45AH - HTST (High Temperature Short Time) or Model DR45AS - STLR (Safety Thermal Limit Recorder). Future changes in After the Lockout Switch is placed in the ON (locked) position, the configuration...

  • Page 26: Ii.htst Operation

    3/04...
  • Page 27 Operation, Continued HTST (high Pasteurization control consists of recording the information shown on the temperature short circular chart (Figure 2-5) and implementing the following strategies: time), continued 1. The first analog input is hot water temperature which indirectly controls milk temperature in the plate heat exchanger unless the Digital Reference Temperature is selected and then Input 1 is the digital reference and optional Input 3 (if enabled) becomes the Hot Water temperature input.

  • Page 28: Figure 2-5 Simulated Htst Printed Chart

    Operation Continued HTST (high temperature short time), continued Figure 2-5 Simulated HTST Printed Chart Hot Milk (Input 2) (Pen 2) Optional Hot Water Temp (Input 1 or 3) (Pen 1) Frequency Pen Divert Event Mark (Digital Input) (Pen 3) Optional Digital Reference Temp at Diversion Valve (Input 1) (Pen 4) 22660...
  • Page 29 Operation, Continued Flow diversion On the DR45AH recorder, there is Flow Diversion Indication when Input indication 1 is programmed as a Digital Reference Temperature Indicator. When a diversion occurs, the DR45AH recorder/controller will automatically print on the chart, the temperature measured at the divert valve and then, when forward flow is resumed after the diversion, it will print the temperature again.
  • Page 30 Operation, Continued Speed of response The digital display for the Hot Milk temperature (default display on test power up) must be used when doing the speed of response test as specified by the Grade A Pasteurized Milk Ordinance, U.S. Department of Health and Human Services.

  • Page 31: Section 3- Model Dr45As - Stlr (Safety Thermal Limit Recorder)

    Section 3– Model DR45AS - STLR (Safety Thermal Limit Recorder) Overview In the Pasteurization process, milk flows from the raw milk supply tank Introduction through the plate-type heat exchanger, where it is heated to pasteurization temperature prior to entering the holding tube. The tube size ensures that the milk remains at the pasteurization temperature for the required time.

  • Page 32: Field Wiring

    Field Wiring Simplified field wiring Mount the recorder and wire the power and inputs as described in Product Manual 44-45-25-30. Refer to Figures 3-1 and 3-2 for all other field wiring. As shown in Figure 3-1, the alarm #1 relaay (Plug J4) serves as the ON/OFF relay for the diverter valve.

  • Page 33: Connection To System

    Connection to System Introduction Two relays are required to interconnect the DR45AS recorder to the STLR system. • Divert Relay Valve • Diversion Switch Relay Figure 3-2 shows this wiring. The terminals in Figure 3-2 that are designated by a box are terminal numbers in the Pasteurizer Control Box.
  • Page 34 Connection to System Continued Suitable relays The model numbers for relays suitable for this application are given below. Other equivalent relays can be used. Divert Valve Latch Relay and Socket Struthers-Dunn B255BXBP and corresponding socket* 120Vac, 2 coil latching relay: 2NO, 2NC contacts rated at 10 120Vac contacts remain in position on power failure until reset Order screw terminal socket 27390 separately.

  • Page 35: Table 3-1 Setting Two Diversion Setpoints

    Connection to System, Continued Two diversion Since the pasteurization process may include different products, two setpoints different setpoints can be assigned to control Loop 1 (pasteurization). A two deck switch is installed on the panel by the user. One set of contacts is wired to the first digital input of the STLR recorder (see Figure 3-2).
  • Page 36 Connection to System, Continued Two diversion setpoints, continued Table 3-1 Setting Two Diversion Setpoints, continued Step Operation Press Action/Result Enter #1 until you see: LOWR Setpoint for DISP Upper Display Diversion The PV value Lower Display SP and the local setpoint value Enter #1 setpoint (for example:166°F) Enter #2...

  • Page 37: Figure 3-2 Pasteurizer Control Box Connection Diagram

    Connection to System, Continued Connection diagram Figure 3-2 is the Pasteurizer Control Box connection diagram for Model DR45AS. Figure 3-2 Pasteurizer Control Box Connection Diagram - Model DR45AS - Designates terminals in Pasteurizer Control Box - See Page 27 115V Divert Valve Divert Leak...

  • Page 38: Ii.configuration

    Configuration Restrictions based on Figure 3-3 shows the location of the S1 Lockout Switch on the Main Lockout switch Printed Circuit board. position When the Lockout switch is OFF (Down - Configure): • You can view and change all applicable operating parameters as described in Section 5 of this Addendum.

  • Page 39: Table 3-2 .Ii.input Versus Pen Assignments For Model Dr45As

    Configuration, Continued Pens vs Inputs The DR45AS Recorder can have up to 4 Analog Inputs and one Digital Input. There are four pens to which these five inputs can be assigned. Some are required while others are optional. See Table 3-2. Table 3-2 Input Versus Pen Assignments for Model DR45AS INPUT...

  • Page 40: Table 3-3 Configuration Procedure

    Configuration, Continued Configuration Place the Lockout switch (S1) in the OFF (configure) position and follow procedure the procedure in Table 3-3 to configure the DR45AS recorder. ATTENTION The prompting scrolls at a rate of 2/3 seconds when the key is held in. Also, keys will move group SET UP FUNC...

  • Page 41: Table 3-4 Future Changes

    Configuration, Continued Setting the lockout After all the parameters are configured, refer to Section 6 - Tests and switch to LOCK Procedures for Model DR45AH - HTST (High Temperature Short Time) or Model DR45AS - STLR (Safety Thermal Limit Recorder). Future changes in After the Lockout Switch is placed in the ON (locked) position, the configuration...

  • Page 42: Ii.htst Operation

    3/04...
  • Page 43 Operation, Continued STLR (safety thermal Pasteurization control consists of recording the information shown on the limit recorder), circular chart (Figure 3-5) and implementing the following strategies: continued 1. The hot milk temperature is the first analog input (default display on power up) This temperature is recorded.

  • Page 44: Figure 3-5 Simulated Stlr Printed Chart

    Operation Continued STLR (safety thermal limit recorder), continued Figure 3-5 Simulated STLR Printed Chart Hot Milk (Input 1) (Pen1) Frequency Pen Divert Event Mark (Digital Input) (Pen 3) Optional Digital Reference Temp at Diversion Valve (Input 2) (Pen 4) 23136 Continued on next page Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...
  • Page 45 Operation, Continued Flow diversion On the DR45AS recorder, there is Flow Diversion Indication when Input indication 2 is programmed as a Digital Reference Temperature Indicator. When a diversion occurs, the DR45AS recorder will automatically print on the chart, the temperature measured at the divert valve and then, when forward flow is resumed after the diversion, it will print the temperature again.
  • Page 46 Operation, Continued Speed of response The digital display for the Hot Milk temperature (default display on test power up) must be used when doing the speed of response test as specified by the Grade A Pasteurized Milk Ordinance, U.S. Department of Health and Human Services.

  • Page 47: Section 4- .Ii.model Dr45Ap - Pasteurization (Flow)

    Section 4– Model DR45AP - Pasteurization (Flow) Overview The DR45AP Pasteurization Flow recorder/controller can be set up to Introduction control the flow rate in a pasteurization process. In addition to the normal divert valve control provided, by high and low flow limit setpoints, optional inputs can be set up to display and record the Raw and Pasteurized pressures in the system.

  • Page 48: Field Wiring

    Field Wiring Simplified field wiring Mount the recorder and wire the power and inputs as described in Product Manual 44-45-25-30. Refer to Figures 4-1 and 4-2 for all other field wiring. As shown in Figure 4-1, Control board #1 output is 4-20mA to the Timing Pump (Plug J1).

  • Page 49: Figure 4-1 Output Connections

    Field Wiring, Continued Output connection Figure 4-1 is a diagram of output connections for the DR45AP Model (Flow Pasteurization). Figure 4-1 Output Connections 24V Supply 24V Supply 24V Supply 24V Supply 24V Supply 24V Supply 24V Supply OPTIONAL OPTIONAL OPTIONAL from Display from Display from Display...

  • Page 50: Connection To System

    Connection to System Introduction Two relays are required to interconnect the DR45AP recorder/controller to the HTST control system. • Divert Relay Valve • Diversion Switch relay Figure 4-2 shows this wiring. The terminals in Figure 4-2 that are designated by a box are terminal numbers in the Pasteurizer Control Box.

  • Page 51: Figure 4-2 Pasteurizer Control Box Connection Diagram - Model Dr45Ap

    Connection to System, Continued Connection diagram Figure 4-2 is the Pasteurizer Control Box connection diagram for Model DR45AP. Figure 4-2 Pasteurizer Control Box Connection Diagram - Model DR45AP - Designates terminals in Pasteurizer Control Box - See Page 44 115V Divert Valve 60HZ Divert...

  • Page 52: Ii.configuration

    Configuration Restrictions based on Figure 4-3 shows the location of the S1 Lockout Switch on the Main lockout switch Printed Circuit board. position When the Lockout switch is OFF (Down - Configure): • You can view and change all applicable operating parameters as described in Section 4 of this Addendum.

  • Page 53: Table 4-1 .Ii.input Versus Pen Assignment Model Dr45Ap

    Configuration, Continued Pens vs Inputs The DR45AP Recorder/Controller can have up to 4 Analog Inputs and one Digital Input. There are four pens to which these five inputs can be assigned. Some are required while others are optional. See Table 4-1. Table 4-1 Input versus Pen Assignment Model DR45AP INPUT...

  • Page 54: Table 4-2 .Iidr45Ap.configuration Procedure

    Configuration, Continued Configuration Follow the procedure in Table 4-2 to configure the DR45AP Flow procedure recorder/controller. ATTENTION The prompting scrolls at a rate of 2/3 seconds when the key is held in. Also, keys will move group SET UP FUNC prompts forward or backward at a rate twice as fast.
  • Page 55 Step Operation Press Result Select “OPTIONS” Set Up until you see: mode Upper Display SET UP Lower Display OPTIONS Select FLOW until you see: FUNC Upper Display NONE HTST Lower Display STLR PASTEUR FLOW Press the keys to select FLOW. (Default Flow configuration is loaded when the FUNC key is pressed.
  • Page 56 Step Operation Press Result Select Forward Hysteresis until you see: FUNC Upper Display Upper Display Range: 0 to 5 % Range: 0 to 5 % Lower Display Lower Display FWD HYST FWD HYST Press the keys to select a value. Forward Flo will not begin until Limit + Hysteresis is satisfied.

  • Page 57: Table 4-3 Future Changes

    Configuration, Continued Tests and Procedures After all the parameters are configured, refer to Section 7 - Tests and Procedures for Model DR45AP - Pasteurization (Flow). Future changes in After the Lockout Switch is placed in the ON (locked) position, the configuration configuration parameters for Milk Diversion Valve control are “locked”...

  • Page 58: Ii.flow Operation

    Operation Flow The DR45AP controls the flow rate in a pasteurization process (Figure 4- The flow is controlled from the flow input from a pressure transmitter or a magnetic flowmeter in the constant flow line. The recorder/controller uses Control Output #1 (PID control and a 4– 20mA output) to control a variable speed pump which adjusts the flow rate in the system.

  • Page 59: Figure 4-4 Diagram Of Flow Milk Pasteurization Process

    3/04...
  • Page 60 Operation, Continued Flow, continued For Pasteurization Flow, DR45AP uses one analog input for flow, one digital input, one 3-mode controller and one on-off controller to control: • Process flow rate • Flow diversion valve position If controlling system back pressure, two additional analog inputs (Inputs 2 and 3) and one 3-mode, 4–20mA controller with two additional relay outputs is required.

  • Page 61: Figure 4-5 Simulated Flow Printed Chart

    Operation, Continued Flow, continued Figure 4-5 Simulated Flow Printed Chart Range 2 System Pressures Range 2 System Pressures Process Flow Rate Process Flow Rate (Input 1) (Pen 1) (Input 1) (Pen 1) Range 1 Flow Rate Range 1 Flow Rate Low Pressure Input Low Pressure Input - Raw Milk Pressure...
  • Page 62 Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...

  • Page 63: Section 5 - .Ii.parameter Configuration Tables

    Section 5 – Parameter Configuration Tables Parameter Selections Introduction The tables below list the pre-configured values that appear in the Recorder/Controller when you select “HTST”, “STLR”, or “FLOW” under configuration prompt “PASTEUR”. If you want to change any of these values, refer to Sections 6 and 7 in this addendum.

  • Page 64: Tuning 2 Group Function Prompts

    Parameter Selections, Continued Tuning 2 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display GAIN Gain 0.1 to 1000 RATE MIN Rate in minutes 0.08 to 10.00 minutes 0.00 RSET MIN Reset in minutes/repeat...

  • Page 65: Chart Group Function Prompts

    Parameter Selections, Continued Chart Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Chart Speed Selection CHRTSPD 12HR 24HR 7DAYS XHR (See prompt "HOUR/REV") HOUR/REV Hours per Revolution 6 to 744 (12 hrs for 12HR 12HR...

  • Page 66: Pen 1 Group Function Prompts

    Parameter Selections, Continued Pen 1 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Pen Record ENABLE ENABLE ENABLE ENABLE PEN 1 DISABL PEN1IN Pen Input INPUT 1, 2, 3, or 4 INPUT 1 INPUT 1 INPUT 1...

  • Page 67: Pen 2 Group Function Prompts

    Parameter Selections, Continued Pen 2 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Pen Record ENABLE ENABLE ENABLE ENABLE PEN 2 DISABL PEN2IN Pen Input INPUT 1, 2, 3, or 4 INPUT 2 INPUT 2 INPUT 2...

  • Page 68: Pen 3 Group Function Prompts

    Parameter Selections, Continued Pen 3 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Pen Record ENABLE ENABLE ENABLE ENABLE PEN 3 DISABL PEN3IN Pen Input INPUT3 DGTL1 DGTL2 DGTL1...

  • Page 69: Pen 4 Group Function Prompts

    Parameter Selections Continued Pen 4 can be used to record the diversion setpoint if desired, without the addition of another input card, by configuration. If another Process Variable is to be recorded, such as cold milk, another input card and sensor is required.

  • Page 70: Input 1 Group Function Prompts

    Parameter Selections, Continued Input 1 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Decimal Point Location XXXX None XXX.X XXX.X XXX.X DECIMAL XXX.X One XX.XX Two UNITS Temperature Units DEG F...

  • Page 71: Input 2 Group Function Prompts

    Parameter Selections, Continued Input 2 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Decimal Point Location XXXX None XXX.X XXX.X XXX.X DECIMAL XXX.X One XX.XX Two UNITS Temperature Units DEG F...

  • Page 72: Input 3 Group Function Prompts

    Parameter Selections, Continued Input 3 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Decimal Point Location XXXX None XXX.X XXX.X XXX.X DECIMAL XXX.X One XX.XX Two UNITS Temperature Units DEG F...

  • Page 73: Input 4 Group Function Prompts

    Parameter Selections, Continued Input 4 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Decimal Point Location XXXX None XXX.X XXX.X XXX.X DECIMAL XXX.X One XX.XX Two UNITS Temperature Units DEG F...

  • Page 74: Control 1 Group Function Prompts

    Parameter Selections, Continued Control 1 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Tuning Parameter Sets 1 ONLY 1 ONLY 1 ONLY 1 ONLY PID SETS 2KEYBD 2PV SW 2SP SW...
  • Page 75 Parameter Selections, Continued Control 1 Group Function Prompts, continued Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display • Time Proportional DEADBAND Output Relay Deadband Duplex: –5.0 to 25.0% • On-Off Duplex: 0.0 to 25.0% •...

  • Page 76: Control 2 Group Function Prompts

    Parameter Selections, Continued Control 2 Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display PID SETS Tuning Parameter Sets 1 ONLY 1 ONLY 2KEYBD 2PV SW 2SP SW Automatic Switchover –999.0 to 9999 SW VALUE...
  • Page 77 Parameter Selections, Continued Control 2 Group Function Prompts, continued Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display OUT HYST Output Relay Hysteresis 0.0 to 5.0 in Engineering Units FAILSAFE Failsafe Output Value 0 to 100% REM SW...

  • Page 78: Options Group Function Prompts

    Parameter Selections, Continued Options Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display INPUT 1 Input 1 Actuation DISABL ENABLE ENABLE ENABLE ENABLE Input 2 Actuation DISABL ENABLE Depends Depends...

  • Page 79: Adjust Printing Group Function Prompts

    Parameter Selections, Continued Adjust Printing Group Function Prompts Function Prompt Function Selections or HTST STLR FLOW Lower Display Name Range of Setting Setting Setting Setting Upper Display Trace Line Contrast DARK MEDIUM MEDIUM MEDIUM TRACE LN MEDIUM LIGHT GRID LN Grid Line Contrast DARK MEDIUM MEDIUM MEDIUM...
  • Page 80 Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...

  • Page 81: Section 6 - Testing Procedures For

    Section 6 – Testing Procedures for Model DR45AH - HTST (High Temperature Short Time) or Model DR45AS - STLR (Safety Thermal Limit Recorder) Overview Introduction This section contains procedures which should be done: • prior to putting the HTST Recorder/Controller or STLR Recorder into service •...

  • Page 82: Configuration Check Or Reconfiguration

    Configuration Check or Reconfiguration Application Applies to all Truline Recorder/Controllers used on continuous flow pasteurizers. Frequency Upon installation and whenever a configured value is changed. Criteria A set of configured values will be automatically entered in the Recorder/Controller when step #5 in Table 6-1 is performed. In some cases, these values may have to be changed to meet the requirements of the application.

  • Page 83: Operation

    Configuration Check or Reconfiguration, Continued Follow the procedure in Table 6-1 to allow the HTST or STLR HTST or STLR automatic configuration values to be automatically entered into memory. configuration Open the door of the recorder, open the chart plate and place the switch (S1) on the Main processor board in the OFF position.

  • Page 84: Table 6-2 Reconfiguration

    Configuration Check or Reconfiguration, Continued HTST or STLR The other configuration values on the recorder will have automatically automatic been entered when the HTST or STLR option was selected. They should configuration, be reviewed to determine that they are correct for each application. This continued can be done by pressing the SET UP key to get to a group function as indicated in the lower display and then use the FUNC key to check...
  • Page 85 Configuration Check or Reconfiguration, Continued Reconfiguration, continued Table 6-2 Reconfiguration, continued Step Operation Press Result Select any Set Up group •Successive presses of the SET UP key will sequentially display the other Set Up group titles. •You can also use the keys to scan the Set Up groups in both directions.
  • Page 86 Continued on next page Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...

  • Page 87: Figure 6-1 Communications Card Location

    They cannot operate the flow diversion valve. Technical assistance If the configuration values cannot be set or changed as described in this subsection or for other problems, contact the Honeywell Technical Assistance Center: 1-800-423-9883 3/04 Model DR45AH/AS/AP Addendum 44-45-99-08...

  • Page 88: Calibration Test

    Calibration Test Application Applies to all Truline Recorder/Controllers used in connection with continuous flow pasteurizers. Frequency Upon installation and every three months thereafter. Criteria The recorder/controller must not read higher than the corresponding indicating thermometer. This test must be conducted prior to cut-in and cut-out temperature testing.
  • Page 89 Calibration Test, Continued Procedure Table 6-3 lists the steps to perform the calibration test for HTST Models. Table 6-4 lists the steps to perform the calibration test for STLR Models. Table 6-3 Calibration Test for HTST Models Step Action Adjust the water or oil bath to a temperature approximately 2°F (1°C) above the diversion temperature.
  • Page 90 Calibration Test, Continued Procedure, continued Table 6-3 Calibration Test for HTST Models, continued Step Action Record the compensation adjustment value for the office record. Check the Digital Reference Temperature (Input 1) to make sure it reads the same as Input 2 (Hot Milk Temperature) and the standard indicating thermometer.
  • Page 91 Calibration Test, Continued Procedure, continued Table 6-4 lists the steps to perform the calibration test for STLR Models. Table 6-4 Calibration Test for STLR Models Step Action Adjust the water or oil bath to a temperature approximately 2°F (1°C) above the diversion temperature. Make sure there is sufficient agitation in the bath to maintain a uniform temperature.
  • Page 92 Calibration Test, Continued Procedure, continued Table 6-4 Calibration Test for STLR Models, continued Step Action Record the compensation adjustment value for the office record. Check the Digital Reference Temperature (Input 2) to make sure it reads the same as Input 1 (Hot Milk Temperature) and the standard indicating thermometer.

  • Page 93: Indicating Thermometers Temperature Accuracy - Test 1, Pmo 2003

    Indicating Thermometers Temperature Accuracy – Test 1, PMO 2003 Application Applies to all indicating thermometers used for measurement of milk temperature during pasteurization. Frequency Upon installation and at least once every three months. Criteria Within ±0.5°F (±0.25°C), in specified scale range. Apparatus Test thermometer meeting specifications under Appendix I, Part 1 of the Pasteurized Milk Ordinance 2003;...

  • Page 94: Recording Thermometers Temperature Accuracy - Test 2, Pmo 2003

    Recording Thermometers Temperature Accuracy – Test 2, PMO 2003 Application Applies to all recording and recorder/controller thermometers used to record milk temperatures during pasteurization. Frequency Upon installation, at least once every three months, and whenever recording pen-arm setting requires frequency adjustment. Criteria Within ±1°F (±0.5°C), in specified scale range.
  • Page 95 Recording Thermometers Temperature Accuracy – Test 2, PMO 2003, Continued Procedure, continued Table 6-6 Temperature Accuracy Test for Recording Thermometers, continued Step Action Remove the sensing element from the boiling water and immerse in the can of water whose temperature was adjusted in the previous step.

  • Page 96: Recording Thermometers Time Accuracy - Test 3, Pmo 2003

    Recording Thermometers Time Accuracy – Test 3, PMO 2003 Application Applies to all recording and recorder/controller thermometers used to record time of pasteurization. Frequency Upon installation, and at least once every three months thereafter. Criteria The recorded time of pasteurization will not exceed the true elapsed time. Apparatus A watch graduated at intervals not to exceed one minute, and accurate to within five minutes in 24 hours;...

  • Page 97: Recording Thermometers Check Against Indicating Thermometers - Test 4, Pmo 2003

    Recording Thermometers Check Against Indicating Thermometers – Test 4, PMO 2003 Application Applies to all recording and recorder/controller thermometers used to record milk temperatures during pasteurization. Frequency At least once every three months by regulatory agency, daily by plant operator. Criteria Recording thermometers will not read higher than corresponding indicating thermometer.

  • Page 98: Milk Flow Controls Milk Temperatures At Cut-In And Cut-Out - Test 10, Pmo 2003

    Milk Flow Controls Milk Temperatures at Cut-in and Cut-out – Test 10, PMO 2003 Application Applies to all recorder/controllers used in connection with HTST pasteurizers except those in which the flow diversion device is located at the end of the cooler section. Frequency Upon installation and quarterly by the regulatory agency;...

  • Page 99: Table 6-10 Adjusting The Milk Diversion Setpoint Setting

    Milk Flow Controls Milk Temperatures at Cut-in and Cut-out – Test 10, PMO 2003, Continued Corrective action If the reading is below the minimum pasteurization temperature, the cut- in and cut-out mechanism and/or the differential temperature mechanism should be adjusted to obtain proper cut-in and cut-out temperatures by repeated tests.

  • Page 100: Indicating Thermometers Thermometric Response - Test 7, Pmo 2003

    Indicating Thermometers Thermometric Response – Test 7, PMO 2003 Application Applies to all indicating thermometers located on pipelines and used for determination of milk temperatures during pasteurization. Frequency Upon installation and at least once every three months. Criteria Four seconds under specified conditions. Apparatus Test thermometer, stopwatch, water bath 10-gallon (38-liter) can, agitator, heat supply, and indicating thermometer from pasteurizer.
  • Page 101 Indicating Thermometers Thermometric Response – Test 7, PMO 2003, Continued Procedure, continued Table 6-11 Thermometric Response Test for Indicating Thermometers, continued Step Action Start stopwatch when indicating thermometer reads 19°F (11°C) below bath temperature. Stop stopwatch when indicating thermometer reads 7°F (4°C) below bath temperature.

  • Page 102: Recorder/Controller Thermometric Response - Test 8, Pmo 2003

    6.10 Recorder/Controller Thermometric Response – Test 8, PMO 2003 Application Applies to all recorder/controllers used in connection with continuous flow pasteurizers except those in which the flow diversion device is located at the end of the cooler section. Frequency Upon installation and at least once every three months thereafter. Criteria Five seconds, under specified conditions.

  • Page 103: Table 6-12 Thermometric Response Test

    6.10 Recorder/Controller Thermometric Response – Test 8, PMO 2003, Continued Procedure Table 6-12 lists the steps for testing the thermometric response of the recorder/controller. Table 6-12 Thermometric Response Test Step Action Check and, if necessary, adjust the pen-arm setting of the recording thermometer in the proper reference to agree with the indicating thermometer reading at pasteurization temperature.

  • Page 104: Locking And Sealing The Recorder

    6.11 Locking and Sealing the Recorder Application Applies to all Truline Recorder/Controllers used in connection with continuous flow pasteurizers. Frequency Upon installation, every three months thereafter, and whenever a process value is changed. Criteria The process values are configured, locked with the values determined by tests in subsections 6.3 through 6.10 inclusive, and finally the locking mechanism is sealed by the regulatory official.

  • Page 105: Figure 6-2 Dr45Ah/Dr45As Recorder With Pasteurization Control

    6.11 Locking and Sealing the Recorder, Continued Procedure, continued Figure 6-2 DR45AH/DR45AS Recorder with Pasteurization Control Continued on next page 3/04 Model DR45AH/AS/AP Addendum 44-45-99-08...

  • Page 106: Table 6-14 Chart Configuration

    6.11 Locking and Sealing the Recorder, Continued Process value check After all tests are satisfactorily completed and the seals placed in position as indicated on the previous page, the following process values shall be checked and attempts made to change them with the raise or lower keys. Check the following configuration: Chart configuration - Table 6-14 Pen Configuration - Table 6-15...
  • Page 107 6.11 Locking and Sealing the Recorder, Continued Chart configuration check, continued Table 6-14 Chart Configuration, continued Step Operation Press Result Check continue chart until you see: rotation FUNC Upper Display Lower Display CONTINUE The upper display should read “NO”. Check Optional Chart until you see: Name FUNC...

  • Page 108: Table 6-15 Pen Configuration

    6.11 Locking and Sealing the Recorder, Continued Pen configuration Follow the procedure in Table 6-15 to check the pen configuration. check Table 6-15 Pen Configuration Step Operation Press Result Select “PEN” Set up group until you see: Upper Display SET UP Lower Display Check that “PEN 2”...

  • Page 109: Table 6-16 Diversion Temperature Setpoints Check

    6.11 Locking and Sealing the Recorder, Continued Diversion temperature Follow the procedure in Table 6-16 to check the Diversion temperature setpoints check setpoints. Table 6-16 Diversion Temperature Setpoints Check Step Operation Press Result Check diversion until you see: LOWR temperature 2nd setpoint Upper Display DISP CHN 2 XX.X...

  • Page 110: Pasteurization (Flow)

    Section 7 – Tests and Procedures for Model DR45AP - Pasteurization (Flow) Overview This section contains tests and procedures which should be done: Introduction • prior to putting the Recorder/Controller into service • any time a process value is changed •...

  • Page 111: Configuration Check Or Reconfiguration

    Configuration Check or Reconfiguration Application Applies to all DR45AP Truline Recorder/Controllers used for a flow meter based timing system for Flow pasteurizers. Frequency Upon installation and whenever a configured value is changed. Criteria A set of FLOW configured values will be automatically entered in the Recorder/Controller when Step 5 in Table 7-1 is performed.

  • Page 112: Table 7-1 Automatic Flow Configuration

    Configuration Check or Reconfiguration, Continued Follow the procedure in Table 7-1 to allow the FLOW configuration Flow automatic configuration values to be automatically entered into memory. Open the door of the recorder, open the chart plate and place the switch (S1) on the Main processor board in the OFF position.

  • Page 113: Table 7-2 Reconfiguration

    Configuration Check or Reconfiguration, Continued Flow automatic The other configuration values on the recorder will have automatically configuration, been entered when the FLOW option was selected. They should be continued reviewed to determine that they are correct for each application. This can be done by pressing the SET UP key to get to a group function as indicated in the lower display and then use the FUNC key to check each value setting within that group.
  • Page 114 Configuration Check or Reconfiguration, Continued Reconfiguration, continued Table 7-2 Reconfiguration, continued Step Operation Press Result Select any Set Up group • Successive presses of the SET UP key will sequentially display the other Set Up group titles. • You can also use the [ ] [ ] keys to scan the Set Up groups in both directions.

  • Page 115: Figure 7-1 Communications Card Location

    They cannot operate the flow diversion valve. Technical assistance If the configuration values cannot be set or changed as described in this subsection or for other problems, contact the Honeywell Technical Assistance Center: 1-800-423-9883 3/04 Model DR45AH/AS/AP Addendum 44-45-99-08...

  • Page 116: Magnetic Flowmeter Systems, Continuous Flow, Holding Time Test - Test 11, Pmo 2003

    Magnetic Flowmeter Systems, Continuous Flow, Holding Time Test – Test 11, PMO 2003 Application To all high temperature short-time pasteurizers with holding time of 15 seconds or longer. Frequency Upon installation and every 6 months thereafter, whenever the seal on the speed setting is broken, any alteration is made affecting the holding time, the velocity of flow or the capacity of holding tube;...

  • Page 117: Table 7-3 Continuous Flow, Holding Time Test

    Magnetic Flowmeter Systems, Continuous Flow, Holding Time Test – Test 11, PMO 2003, Continued Procedure Table 7-3 lists the steps to run the Continuous Flow, Holding Time test. Table 7-3 Continuous Flow, Holding Time Test Step Action Examine the entire system to insure that all flow promoting equipment is operating at maximum capacity and all flow impeding equipment is so adjusted or bypassed as to provide the minimum resistance to the flow.
  • Page 118 Magnetic Flowmeter Systems, Continuous Flow, Holding Time Test – Test 11, PMO 2003, Continued Procedure, continued Table 7-3 Continuous Flow, Holding Time Test, continued Step Action Operate the pasteurizer using water at pasteurization temperature, with the flow diversion device in the forward flow position. Quickly inject 50-ml of saturated sodium chloride solution into the holder inlet.
  • Page 119 Magnetic Flowmeter Systems, Continuous Flow, Holding Time Test – Test 11, PMO 2003, Continued Procedure, continued Table 7-3 Continuous Flow, Holding Time Test, continued Step Action Compute the holding time for milk from the following formula by weight, using the average specific gravity. Compute separately for forward flow and diverted flow.

  • Page 120: Continuous Flow Holders - Flow Alarm Test - Test 11-2B, Pmo 2003

    Continuous Flow Holders – Flow Alarm Test – Test 11-2B, PMO 2003 Application Applies to all high temperature short-time pasteurizers using a magnetic Flow Meter System to replace a metering pump. Frequency Upon installation and every 6 months thereafter, whenever a seal on the Flow Recorder/Controller is broken;...

  • Page 121: Table 7-4 Continuous Flow Holders, Flow Alarm Test

    Continuous Flow Holders – Flow Alarm Test – Test 11- 2B, PMO 1993, Continued Procedure Table 7-4 lists the steps required to run the Continuous Flow, Flow Alarm test. Table 7-4 Continuous Flow Holders, Flow Alarm Test Step Action Operate the pasteurizer in forward flow, at the flow rate at which holding time was measured, using water above pasteurization temperature.

  • Page 122: Continuous Flow Holders - Loss-Of-Signal Alarm Test - Test 11-2C, Pmo 2003

    Continuous Flow Holders – Loss-of-Signal Alarm Test – Test 11-2C, PMO 1993 Application Applies to all high temperature short-time pasteurizers using a Magnetic Flow Meter System to replace a metering pump. Frequency Upon installation and every 6 months thereafter, whenever seal on the Flow Recorder/Controller is broken;...

  • Page 123: Table 7-5 Continuous Flow Holders, Loss-Of-Signal Alarm Test

    Continuous Flow Holders – Loss-of-Signal Alarm Test – Test 11-2C, PMO 1993, Continued Procedure Table 7-5 lists the steps required to run the Continuous Flow, Loss-of- Signal Alarm test. Table 7-5 Continuous Flow Holders, Loss-of-Signal Alarm Test Step Action Operate pasteurizer in forward flow, at a flow rate below the HIGH FLOW LIMIT setpoint and above the Loss-of-Signal Alarm/LOW FLOW LIMIT setpoint, using water above pasteurization temperature.

  • Page 124: Cut-In And Cut-Out Flow Points Test - Test 11-2D, Pmo 2003

    Cut-in and Cut-out Flow Points Test – Test 11-2D, PMO 1993 Application Applies to all Truline Recorder/Controllers (Model DR45AP) used on continuous flow pasteurizers for flow control using a Magnetic Flow Meter System to replace a metering pump. Frequency Upon installation and every 6 months thereafter, whenever a seal on the Recorder/Controller is broken;...

  • Page 125: Table 7-6 Cut-In And Cut-Out Flow Points Test

    Cut-in and Cut-out Flow Points Test – Test 11-2D, PMO 1993, Continued Note the flow rate setpoint on Channel 1 before starting the test so you Procedure can return to that setpoint upon completion of test. Table 7-6 lists the steps required to run the Cut-in/Cut-out Flow Points test.
  • Page 126 Time Delay Relay Test – Test 11-2E, PMO 1993 Application Applies to all high temperature short-time pasteurizers using the Magnetic Flow Meter System to replace a metering pump. Frequency Upon installation and every 6 months thereafter, whenever seal on the Flow Recorder/Controller or time delay relay enclosure is broken;...

  • Page 127: Table 7-7 Time Delay Relay Test

    Time Delay Relay Test – Test 11-2E, PMO 1993, Continued Procedure Table 7-7 lists the steps required to run the Time Delay Relay test. Table 7-7 Time Delay Relay Test Step Action Operate pasteurizer in forward flow, at a flow rate below the HIGH FLOW LIMIT setpoint and above the Loss-of-Signal/LOW FLOW LIMIT Alarm setpoint, using water above pasteurization temperature.
  • Page 128 Differential Pressure Test – Test 9.4, PMO 2003 Application Applies to all Truline Recorders/Controllers (Model DR45AP) used to control the operation of booster pumps on continuous flow pasteurizers for flow control with the Differential Pressure option displaying and recording the Raw and Pasteurized pressures in the system. Frequency Upon installation and every three months thereafter, whenever seal on the Flow Recorder/Controller is broken;...

  • Page 129: Table 7-8 Differential Pressure Test

    Differential Pressure Test, Continued Procedure Table 7-8 lists the steps required to run the Differential Pressure test. Table 7-8 Differential Pressure Test Step Operation Action Check pressure Loosen the process connections and remove the pressure from Input 2 readings at zero (Pasteurized Milk Pressure) and Input 3 (Raw Milk Pressure) sensors.

  • Page 130: Table 7-9 Setting The Lockout Switch

    Locking and Sealing the Recorder Application Applies to all Truline Recorder/Controllers used in connection with continuous flow pasteurizers. Frequency Upon installation, every 3 months thereafter, and whenever a process value is changed. Criteria The process values are configured, locked with the values determined by tests in subsections 7.3 through 7.8 inclusive, and finally the locking mechanism is sealed by the regulatory official.

  • Page 131: Figure 7-2 Dr45Ah/Dr45Ap/Dr45As Recorder With Pasteurization Control

    Locking and Sealing the Recorder, Continued Procedure, continued Figure 7-2 DR45AH/DR45AP/DR45AS Recorder with Pasteurization Control Continued on next page 3/04 Model DR45AH/AS/AP Addendum 44-45-99-08...

  • Page 132: Table 7-10 Chart Configuration

    Locking and Sealing the Recorder, Continued Process value check After all tests are satisfactorily completed and the seals placed in position as indicated on the previous page, the following process values shall be checked and attempts made to change them with the raise or lower keys. Check the following configuration: Chart Configuration - Table 7-10 Pen Configuration - Table 7-11...
  • Page 133 Locking and Sealing the Recorder, Continued Chart configuration check, continued Table 7-10 Chart Configuration, continued Step Operation Press Result Check Optional Chart until you see: Name FUNC Upper Display (chart name) Lower Display CHARTNAM You can ignore this, since no header is to be used. Check Chart Header until you see: FUNC...
  • Page 134 Locking and Sealing the Recorder, Continued Pen configuration check, continued Table 7-11 Pen Configuration, continued Step Operation Press Result Check chart high value until you see: FUNC Upper Display 50.0 Lower Display CHART2 HI The upper display should read “50.0”. Check chart low value until you see: FUNC...
  • Page 135 3/04 Model DR45AH/AS/AP Addendum 44-45-99-08...
  • Page 136 Section 8 – HTST Parts Model DR45AH/AS/AP Addendum 44-45-99-08 3/04...
  • Page 137 Index Loss-of-signal alarm test, 113 Time delay relay test, 117 Electronics Access Control, 1 Adjust Printing Group, 71 Failsafe output value, 67, 69 Automatic switchover value, 66, 68 field wiring, 8, 24, 40 , 70 Auxiliary Output Filter, 62, 63, 64, 65 Bias for remote setpoint, 66, 68 Flow, 39 Burnout, 62, 63, 64, 65...
  • Page 138 Index Remote chart activation, 57 Reset units, 67, 69 S1 Lockout Switch, 14, 30 Setpoint source, 66, 68 Setpoint tracking, 66, 68 Shed controller mode, 67, 69 Shed setpoint recall, 67, 69 Speed of response test, 22, 38 STLR, 4 STLR system, 25 Temperature units, 62, 63, 64, 65 Testing Procedures for Model DR45AH –...

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