Troubleshooting Procedures, Overview | Honeywell DR4300 instruction

DR4300 Circular Chart Recorder

7.3 Troubleshooting Procedures

7.3.1 Overview

Introduction

The troubleshooting procedures for the observable symptoms of failure are presented in the same order as they appear in Table 7-1.Each procedure includes what to do if you have that particular problem, as well as instructions for accomplishing the task, or a cross-reference to instructions elsewhere in the manual.

Equipment needed

You will need a voltmeter to troubleshoot the symptoms listed in the tables that follow.

Safety precautions

Exercise appropriate safety precautions when troubleshooting the recorder operation.

WARNING—SHOCK HAZARD	!

TROUBLESHOOTING MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS, AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. MORE THAN ONE SWITCH MAY BE REQUIRED TO DE-ENERGIZE UNIT BEFORE SERVICING.

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DR4300 Circular Chart Recorder Product Manual

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Honeywell DR4300 manual Troubleshooting Procedures, Overview

Contents

DR4300 Circular Chart Recorder Product Manual Revision I December DR4300 Circular Chart RecorderDR4300 Circular Chart Recorder Product Manual 12/03 Contacts AbstractReferences Symbol Definitions Symbol Definition Contents 141 157 DR4300 Circular Chart Recorder Product Manual Vii 161 199 203211 225 Tables DR4300 Circular Chart Recorder Product Manual 12/03 Figures Page Introduction FunctionCE conformity Europe Analog inputs Relay outputs for control and alarms Timer and totalizer optionsCommunications Analog output for control or retransmission Construction ConfigurationSelf-diagnostics Model Number Breakdown IntroductionModel number format Key numbers Model Number Table I Output Description Model No AvailabilityPen One Pen Two Instrument Power/Transmitter Power Product ConfigurationModel Number Table II Instrument Options Door Options Model Number Table III PEN 1 Options Model Number Table IV PEN 2 OptionsModel Number Table V APPROVALS/CERTIFICATES Future DR4300 Circular Chart Recorder About This Manual All models described Trouble? Pre-installation information InstallationOverview What’s in this section? Operating Limits and Condensed Specifications Operating limits Requirements 1000 ft One Pen Purple Two Pen Purple pen 1 and red penCalibrated width of 100 mm 4 inches Screw terminals 2 piece Transmitter Power Open Collector OutputModbus Communication Digital Inputs Mounting Considerations and Overall Dimensions Overall dimensionsDimensions Physical considerations How to remove knockouts for conduits Mounting MethodsIntroduction Overview Procedure Mounting Flush in Panel New Panel CutoutMounting Flush in a New Panel Cutout Step Action Do not tighten the bolt at this time Panel Mounting Recorder with NEMA4 or Heavy Duty doorDo not tighten the hex bolts at this time Panel Mounting Recorder with NEMA4 or Heavy Duty Door Side View Pipe Mounting Procedure Mounting on a 2-inch pipe Mounting on Surface of Panel or Wall Mounting Flush on a Surface of Panel or Wall Wiring Prerequisites Wiring should be performed by qualified personnelElectrical considerations Recorder grounding Taking electrical noise precautions CE conformity special conditions Europe Recommended wiring routing Recommended Wiring Routing Models Without CE Mark Recommended Wiring Routing Models With CE Mark Wire bundling recommendations Wiring Bundling CategoriesWiring diagrams Wiring Illustrations Shock Hazard Input WiringPower Wiring Procedure for Power Wiring Models Power Wiring Models Without CE Mark 10 Power Wiring Models With CE Mark Analog Input Wiring Analog Input Wiring 11 Analog Input Wiring 10 Digital Input Wiring Digital Inputs Optional 12 Digital Input Wiring 11 Communication Wiring Communication Optional 13 Communication Wiring Output Wiring Discrete Outputs Insulation of output wires 13 Relay Output Wiring 1 or 2 Pen Models Electromechanical To 30 Vac 14 Current Output Wiring Current Output 16 Current Output Wiring Transmitter Power Out 15 Transmitter Power Out Wiring 17 Transmitter Power Out Wiring TB2 Following is a list of topics covered in this section Procedure for Configuring Model without Display Configuration Recording Set UpSetting Configuration and Input Switches Configuration SwitchesS2 = Reset S3 = Lower S4 = Raise AC Power Run/Setup Switch On off off on on off off off Off = Dont care Configuration Switch S1 Input Switch S6Summary of Input Set Up Switch S6 Functions Chart Part R56 = off = on Default setting Day Any linear chart = off = on = off = on = off = on = off = on SW1 50 to 50 Even 212 24 Hr To 100 Even 116 1661-001 Day To 200 Even 131 1660-010 24 Hr Factory Configuration Day 80 to 20 Even 269 To 100 Even 238 1661-001 Day 239 IEC Alpha = 0.00391 all RTDs without an asterisk IEC Alpha = Setting SW6 Switch Off for RTD actuation Startup and Operation of Recorder without Display Overview Preparing the Recorder for Operation Preparing the Recorder for Operation Procedure for Running the Step Test Running the Optional Step TestStep Action/Result Graphic Being careful of the shock hazard at TB1 , place run Chart step patternDR4300 Circular Chart Recorder Step Action/Result Graphic Startup Procedure StartupPage Operation of Recorder with Display and Keypad Displays and indicators Operator Interface on Recorder with Display and KeypadINP OUT Key functions Configuration Recording and Output Set Up DR4300 Circular Chart Recorder Key Function Configuration Prompts Diagram prompt hierarchy REMSW1 REMSW2 Blank ToggleFor pen alignment-see of manual For field calibration-see of manual How to Get Started Configuration Tips Configuration Tips Switch Settings Safety precautions SW6 Input Switch Setting SW6 Burnout Switch Overview SW6 switch 2 OFF for RTD Location of Switches and Relays Step Operation Press Result Configuration ProcedureConfiguration Procedure DR4300 Circular Chart Recorder Step Operation Press Result Input Parameters Set Up Group Input group promptsInput Parameter Definitions Decmal 100 H*factory setting Lin factory setting Filter ExampleBias None factory setting Burnout Protection Input Failure provides most input Pen Parameters Set Up Group Pen group promptsPen Parameter Definitions CHT HI Chart Parameters Set Up Group Chart group promptsChart Parameter Definitions Chtspd Totalizer Parameters Set Up Group Control group promptsTotalizer Function Definitions Total INP EU Engineering Units of Input Signal SEC factory settingTOT EU Engineering Units of Totalized Value TOT DP Rstabl Cutoff Control Parameters Set Up Group ONE factory settingControl Parameter Definitions Outalg TIME/CURRENT Duplex Relay = Cool-Similar to Full factory settingON/OFF factory setting PROPORTIONAL-DERIVATIVE with Manual Power UP Controller Mode RECALL-ThisPROPORTIONAL-INTEGRAL-DERIVATIVE Hysteresis Output Relay only is an adjustable Control Output Direction -In what direction do Fsmode Failsafe Mode Auto Failsafe Latching Disabled When the recorder goesFailsafe Latching Enabled When the recorder goes MAN Minutes PER Repeat or Repeats PER Minute MIN factory settingMinrpm Tuning Parameters Set Up Group Two sets of PID constantsAccutune Fuzzy overshoot suppression Tuning group prompts 10 Tuning Parameter DefinitionsFuzzy Overshoot Suppression Feature Fuzzy MIN RPM Cycle Timer for Relay 1 -Use this to specify Cycle Timer for Relay 2 -This prompt will beDR4300 Circular Chart Recorder Product Manual 103 Used for cooling control 11 Setpoint Ramp Parameter Definitions Setpoint Ramp/Program Set Up GroupSetpoint ramp/program group prompts Timer Set Up Group Timer group prompts12 Timer Parameter Definitions Period 13 Alarm Parameter Definitions Alarms Set Up GroupAlarms group prompts A2S1VA A2S1TYA2S2TY From the alarm setpoint by a value equal to A2 HYS Auxiliary Output Set Up Group Auxiliary output group prompts14 Auxiliary Output Parameter Definitions Auxout Deviation Process Variable minus Setpoint 4mA VAAuxiliary Output LOW Scaling FACTOR-Use a Auxiliary Output High Scaling FACTOR-Use a Communication Set Up Group IntroductionsCommunication group prompts 15 Communication Parameter Definitions Remote Switch Digital Inputs Set Up Group Remote switch group prompts 16 Remote Switch Parameter Definitions Configuration, Startup, and Operation Recorder with DisplayDR4300 Circular Chart Recorder Product Manual 113 REMSW1 Display Parameter Set Up Group OFF factory settingLockout group prompts 17 Display Parameter Definitions Lock Out Parameter Set Up Group Set this group last18 Lockout Parameter Definitions Lock Configuration Record Sheet Keep a record DR4300 Circular Chart Recorder Product Manual 117 Recorder TAG Name 19 Limit Control Parameter Definitions Limit Control ConfigurationSpecial configuration for control and alarms DR4300 Circular Chart Recorder Product Manual 119 Startup of Recorder with Display and Keypad Preparing the Recorder for Startup 20 Preparing the Recorder for Operation 21 Procedure for Running the Step Test DR4300 Circular Chart Recorder Product Manual 121Additional automatic self-tests Step Press Action/Result DR4300 Circular Chart Recorder Step Press Action/Result Refer to if step test fails Set chart time and apply power Procedure 22 Procedure for Setting Chart Time and Applying PowerDR4300 Circular Chart Recorder Product Manual 123 Completing Preparation and Startup Diagnostic tests Tests run automatically 23 Power-Up Diagnostic TestsStatus of tests displayed Ramtst Check the displays and keys Procedure 24 Procedure for Testing the Displays and KeysKey Error message DR4300 Circular Chart Recorder Product Manual 125 Step Operation Press Action/Result Startup procedure Procedure25 Procedure for Starting the Recorder DR4300 Circular Chart Recorder Product Manual 127 Operator interface Display Operation of Recorder with Display and KeypadMonitoring Your Recorder Meaning of indicators 26 Meaning of IndicatorsIndicator Definition when lit DR4300 Circular Chart Recorder Product Manual 129 Viewing the operating parameters Contents of display 27 Lower Display Operating Parameter Labels Diagnostic Error Messages 28 Error Messages Overview Actions an operator can initiate INP Input indicatorOperator Functions DR4300 Circular Chart Recorder Product Manual 133 Procedure for selecting manual or automatic mode29 Procedure for Selecting Automatic or Manual Mode Changing the Control Setpoint Procedure 30 Procedure for Changing the Control Setpoints DR4300 Circular Chart Recorder Product Manual 135 Viewing and Changing Alarm Setpoints Introduction31 Procedure for Displaying or Changing the Alarm Setpoints FAC or FLD Selecting Factory or Field Calibration Values IntroductionPresent value 33 Procedure for Resetting Totalizer Resetting the Totalizer IntroductionReset procedure Starting the Timer Introduction 34 Procedure for Starting Timer Resetting the Limit Controller Introduction 35 Procedure for Resetting Limit ControllerDR4300 Circular Chart Recorder Product Manual 139 Limit controller operator interface 140 DR4300 Circular Chart Recorder Product Manual 141 Input and Output Calibration for Recorder with Display Input Calibration Minimum and Maximum Range Values Minimum and maximum range values RTD Equipment Needed for Calibration Input Calibration Preliminary InformationEquipment needed Disconnect the field wiring DR4300 Circular Chart Recorder Product Manual 145 Input Calibration Set Up and Wiring General Calibration Set UpDIP switch settings General set up procedure Thermocouple Inputs Using a Compensated Calibrator DR4300 Circular Chart Recorder Product Manual 147 Thermocouple Inputs Using an Ice Bath or Ice Point Reference DR4300 Circular Chart Recorder Product Manual 149 RTD Resistance Temperature Detector InputsSet Up Wiring Procedure for Calibrating RTD Inputs Millivolts, Volts and Milliamps inputs Input Calibration Procedure Calibration procedure sequenceInput Calibration Procedure Sequence DR4300 Circular Chart Recorder Product Manual 151 Repeat this procedure for the other pen, if required 10 Set Up Wiring Procedure for Current Proportional Output DR4300 Circular Chart Recorder Product Manual 153Current Output Calibration Calibrator connections 11 Procedure for Calibrating Current Output DR4300 Circular Chart Recorder Product Manual 155 Disp SET 156 Routine Maintenance DR4300 Circular Chart Recorder Product Manual 157 Replacing the Chart Procedure for Replacing the ChartChart hub Pens to the chart Replacing the Ink Cartridge Procedure for Replacing the Ink CartridgeDR4300 Circular Chart Recorder Product Manual 159 Maximizing Pen Life Maximizing Pen LifeSteps for maximizing pen life DR4300 Circular Chart Recorder Product Manual 161 Topic Types of problems Installation related problemsApplication related problems Hardware and software related problems Observable Symptoms of Failure SymptomsObservable Symptoms of Failure Symptom Subsection Troubleshooting Procedures DR4300 Circular Chart Recorder Product Manual 165 Recorder Failure TroubleshootingTroubleshooting Recorder Failure Symptoms Pen Trace Troubleshooting Troubleshooting Pen Trace Failure Symptoms DR4300 Circular Chart Recorder Product Manual 167 Chart Rotation TroubleshootingTroubleshooting Chart Rotation Failure Symptoms Troubleshooting Erratic Pen Movement Troubleshooting Erratic Pen Movement Symptoms Procedure for Pen Alignment DR4300 Circular Chart Recorder Product Manual 169Alignment of Pen at Zero and 100 % Step Action Graphic DR4300 Circular Chart Recorder Step Action Graphic Troubleshooting and Pen Alignment of Recorder with Display DR4300 Circular Chart Recorder Product Manual 171 172 Troubleshooting Aids Self Diagnostics Power up testsPower-Up Diagnostic Tests Tests run automatically View Status of Tests Procedure for Displaying the Results of Self-DiagnosticsDR4300 Circular Chart Recorder Product Manual 175 All relevant messages are displayed Error MessagesBackground Tests Error Messages Troubleshooting and Pen Alignment Recorder with DisplayConfiguration, Startup, and Operation Recorder with Display DR4300 Circular Chart Recorder Product Manual 177 P1 ERR P2 ERR DR4300 Circular Chart Recorder Product Manual 179 180 DR4300 Circular Chart Recorder Product Manual 181 Recorder with Display for instructions for Operation of Recorder with Display Subsection DR4300 Circular Chart Recorder Product Manual 183Operation of Recorder with Display Operation of Recorder with Display for procedure Troubleshooting the Keypad and Display10 Troubleshooting Keypad and/or Display Failure Symptoms Troubleshooting Relay Output 11 Troubleshooting Relay Output Failure SymptomsDR4300 Circular Chart Recorder Product Manual 185 Refer to Replacing Hardware 12 Troubleshooting External Alarm Function Failure Symptoms Troubleshooting External Alarm FunctionTroubleshooting Remote Switch Digital Input Function DR4300 Circular Chart Recorder Product Manual 187 Troubleshooting Modbus Communications14 Troubleshooting Modbus Communications 15 Procedure for Aligning Pen at Zero and Span Alignment of Pen at Zero and Span Troubleshooting and Pen Alignment Recorder with Display Step DR4300 Circular Chart Recorder Product Manual 189 190 Parts List DR4300 Circular Chart Recorder Product Manual 191 Door assembly Exploded Views Chart plate DR4300 Circular Chart Recorder Product Manual 193 Basic recorder components without options Recorder Components Upgrade PROMs DR4300 Circular Chart Recorder Product Manual 195Basic Recorder Parts Parts Not Shown Chart DR4300 Recorder Non-CE Mark Internal Cabling Diagram DR4300 Circular Chart Recorder Product Manual 197 198 Appendix a Accuracy DR4300 Circular Chart Recorder Model Product Manual 199Reference accuracy Typical Reference Accuracy Table A-1 Typical Reference Accuracy ± Degrees With Error Per 1 Degree Field Calibration Linear DR4300 Circular Chart Recorder Model Product Manual 201Types of Input Range Factory Temp Stability Actuations 202 DAY Single Range ChartsTable B-1 10-inch Single Range Chart Part Numbers DR4300 Circular Chart Recorder Chart Type Range Units 24 HR W5W26 Thermocouple 12/03 DR4300 Circular Chart Recorder Product Manual 205 RTD-PT100 a=0.00391 DR4300 Circular Chart Recorder Product Manual 207 RTD-PT100 a=0.00385 Calibration Range 24 HR Dual Range ChartsTable B-2 10-inch Dual Range Chart Part Numbers Appendix B Available 10-inch Charts Calibration Range 24 HR DR4300 Circular Chart Recorder Product Manual 209 DR4300 Circular Chart Recorder Calibration Range 24 HR Minimum purchase required DR4300 Circular Chart Recorder Product Manual 211 Appendix C Setpoint Ramp/Soak Programming and Operation Program Contents Guaranteed soak Soak segmentsStart segment number for each program End segment number for each program Drawing a Ramp/Soak Profile Ramp/soak profile example DR4300 Circular Chart Recorder Product Manual 215 Profile graphs 216 DR4300 Circular Chart Recorder Product Manual 217 Profile worksheet Setpoint Program Prompt Hierarchy Table C-1 Prompt Hierarchy and Available SelectionsEND Recycl Rpunit END STSG1 RP SG2 SP Or hour if Rpunit = EU-M Or EU-H Factory setting = Limits factory setting =SG23RP SG24SP Table C-2 Run/Monitor Functions Run/Monitor the ProgramRun/Monitor functions XX HH . MM REC.X 224 Appendix D Using Accutune DR4300 Circular Chart Recorder Product Manual 225 Starting and Stopping Tuning with Accutune Table D-1 Procedure for Starting Accutune Using Accutune with Duplex Heat/Cool Control Table D-2 Procedure for Using Accutune for Duplex ControlStep Press Action/Result Heating Tuning DR4300 Circular Chart Recorder Product Manual 227 Until the value of Setpoint 2 is at the desired value within Foreign Language Safety Instructions DR4300 Circular Chart Recorder DR4300 Circular Chart Recorder Product Manual 231 232 DR4300 Circular Chart Recorder Product Manual 233 234 DR4300 Circular Chart Recorder Product Manual 235 236 DR4300 Circular Chart Recorder Product Manual 237 238 ¹¬¸ª¸ ¸»ª¸ 240 Appendix F Honeywell Service Centers DR4300 Circular Chart Recorder Product Manual 241 242 DR4300 Circular Chart Recorder Product Manual 243 Index Ctralg parameter, 95, 100, 102, 103 current outputs DR4300 Circular Chart Recorder Product Manual 245 Knockout locations, 16 Status set up group, 175 step test DR4300 Circular Chart Recorder Product Manual 247 TB5 terminal 248 Page Industrial Measurement and Control