LMI DP5000-6A, DP5000-1B, DP5000-3B, DP5000-6B, DP5000-01B Instruction Manual

Instruction

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Liquitron™ DP5000 Series

Manual Manual

Manual

Manual Manual

pH Controller

For file reference, please record the following data:

Model No:

Serial No:

Installation Date:

Installation Location:

When ordering replacement parts for your LMI Controller or accessory, please include
the complete Model Number and Serial Number of your unit.

201 Ivyland Road

Ivyland, PA 18974 USA

TEL: [phone]

FAX: [phone]

http://www.Imipumps.com

Replaces same of Rev. F 4/01

1756.G 2/06

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Contents

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1.0 Introduction ..................................................................................................................................................... 3

2.0 Unpacking ........................................................................................................................................................ 3

3.0 Installation ........................................................................................................................................................ 4

3.1 Mounting the Electronic Enclosure ................................................................................................... 4

3.2 Electrical Installation ........................................................................................................................ 6

3.2.1 Terminal Board Signal Description........................................................................................ 7

3.2.2 Field Wiring Instructions (Optional 4-20 mA Output) .......................................................... 8

3.3 pH Adjustment Pump(s) .................................................................................................................... 9

3.4 Keypad and Display .......................................................................................................................... 9

4.0 Operation........................................................................................................................................................ 10

4.1 Default Settings ............................................................................................................................... 10

4.1.1 Proportional Mode ............................................................................................................... 11

4.1.2 On/Off Mode ........................................................................................................................ 12

4.2 Alarms ............................................................................................................................................. 13

4.3 Calibration (Viewing Last Calibration Data) ..................................................................................15

4.4 New Calibration .............................................................................................................................. 15

4.5 Pump Timers and Solenoid Valve Control ..................................................................................... 17

4.6 Advanced Menu .............................................................................................................................. 20

5.0 Maintenance .................................................................................................................................................... 21

5.1 pH Electrode and Cable .................................................................................................................. 21

6.0 Troubleshooting .............................................................................................................................................. 21

6.1 Error Messages ................................................................................................................................ 22

7.0 DP5000 Specifications.................................................................................................................................... 23

8.0 Program Log ................................................................................................................................................... 25

9.0 Parts List ....................................................................................................................................................... 26

10.0 Exploded View ............................................................................................................................................... 27

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1.0 Introduction

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The Liquitron™ DP5000 Series pH Controllers are designed for a variety of industrial pH applications including metal
finishing, water treatment, printed circuit board manufacturing and waste treatment.

The DP5000 is a microprocessor-based pH controller with a backlit customized display and tactile keypad for ease of
programming. The DP5000 allows independent programming of control methods (‘ON/OFF’ or ‘PROPORTIONAL’) for
acid (Pump A) or base (Pump B) dosage. Independent high and low pH alarms may be set with activation of the ‘Alarm
relays.’ A third relay output is available for activating a solenoid valve or other devices.

The controller is compatible with any pH electrode that generates a mV signal and allows incorporation of platinum 1000 W
automatic temperature compensation (ATC) elements. Two point or single point pH calibrations may be performed. Timer
functions for pump ‘Run’ time and solenoid ‘Delay’ times can be programmed to operate a solenoid pump valve. An
‘Advanced Menu’ allows selection of special features such as a ‘Point 3’ (inflection point) for the control profiles of the
acid or alkali pumps for finer control. The DP5000 features continuous non-volatile memory back-up, voltage selection,
pre-amplifier outputs, flow and level switch inputs as standard. 4-20 mA recorder output is optional.

2.0 Unpacking

Your carton will contain the items shown in Figure 1. Please notify the carrier immediately if there are any signs of damage
to the controller or its parts. Contact your LMI Distributor if any of the parts are missing.

There is a number label on the inside cover of the unit; for easy reference, you should note the model and serial numbers
on the front cover of this instruction manual.

Quick Reference Guide

DP5000 pH Controller

User Manual

Figure 1: Unpacking Items

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3.0 Installation

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Pre-Installation

!

Be sure that the unit has a plug and voltage code compatible with the power source that you intend to use.

CAUTION

Environment

The housing is corrosion and spray resistant but should not be subjected to excessive spray or ambient temperature over
122° F (50° C). Never immerse the unit.

Installation

The DP5000 Controller should be mounted on a solid, stable surface. pH adjustment pumps should be installed following
the manufacturer’s recommendations. For installations requiring longer cables, consult your distributor. The electrode
installation will vary, depending on the process used. In general, the temperature electrode and pH electrode should be
mounted together, and placed far enough downstream from the source of pH adjusting solution that sufficient mixing may
occur, but close enough to eliminate hydraulic lag time of response. Refer to the typical installation diagrams on the
following page.

3.1 Mounting the Electronic Enclosure

The DP5000 control module is supplied with integral wall mounting flanges. It should be hung with the display at eye level,
on a vibration-free structure, in a location where liquids will not be splashed on it. All four (4) top-mounting holes should
be used for structural stability. The control module requires the following clearances:

Figure 2: Minimum Clearances

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Figure 3A: Typical In-Line Installation

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Figure 3B: Typical Batch Installation

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3.2 Electrical Installation

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Electrical Connections

!

CAUTION

Electrical installation of the DP5000 Series pH Controllers consists of plugging the control module into a proper line outlet.
Based on model number, the following voltages and receptacles are required:

To reduce the risk of electrical shock, the control or metering pump must be plugged into a ground outlet with

ratings conforming to the data on the control panel. It must be connected to a good ground. DO NOT USE

ADAPTERS! All wiring must conform to local electrical codes.

DP5000-1A DP5000-3A DP5000-6A DP5000-01A
DP5000-1B, DP5000-3B DP5000-6B DP5000-01B

115 V, 60 Hz 230 V, 50 Hz, 230 V, 50 Hz 115 V, 60 Hz
USA Cord DIN Cord AUS/NZ Cord No Cord

DP5000-2A DP5000-5A DP5000-7A DP5000-02A
DP5000-2B DP5000-5B DP5000-7B DP5000-02B

230 V, 60Hz 230 V, 50 Hz 230 V, 50Hz 230 V, 50/60Hz
USA Cord UK Cord SWISS Cord No Cord

Connect the pH adjustment pump(s) to the terminal strip for ‘ON/OFF’ control (connect to receptacles directly for 115 V
models) or to cables for ‘PROPORTIONAL’ control. Connect the pH electrode to the BNC connector on the right side of
the control module. Take care not to twist or strain the wires. If equipped, connect the ATC cable (1000 Ω at 32° F
[0° C]) through the cable gland below the BNC connector to the terminal strip. You may optionally connect an alarm,
solenoid, flow switch and low level switch. You may also connect the mA connections (with the option fitted). The ± 5
V supply for electrode pre-amplification is also accessed on the terminal strip. There is a 500 Ω maximum resistance
for 4-20 mA option (refer to Figures 4 and 5).

(Either option is available)

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Figure 4: Electrode and Pump Connections

Voltage Selection Switch

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Fuse #2

Fuse #1

See Detail A

TB1 TB3

Live

10

120V/230V

9

8

7

Neutral

6

5

4

3

2

1

Solenoid

Alarm 1

Alarm 2

Pump A

Pump B

NC

NO

NC

NO

NC

NO

NO

NO

115V

TB2

Detail A

8

7

6

5

4

3

2

1

Output
Pump B

Output
Pump A

Output
Fault

Remote
off

TB4

Tem p

Tem p

+ 5V

- 5V

GND

GND

12

11

10

9

8

7

6

5

4

3

2

1

GND

Output

4-20mA

PreAmp

Power

Tem p
Input

Low Level

Flow

12

11

10

9

8

7

6

5

4

3

2

1

Figure 5: Terminal Strip

3.2.1 Terminal Board Signal Description

Terminal blocks are TB1-TB4 from left to right, and Pin 1 is at the bottom of each terminal block.

TB1 Terminal Strip

TB1 Pin 1-Pin 3 ............. Earth connection (one for input power connection)

TB1 Pin 4-Pin 9 ............. Neutral power connection (one for input power connection)

TB1 Pin 10 .................... AC Mains live input

TB2 Terminal Strip

TB2 Pin 1 ...................... Form A contact closed when Pump B (base) is ON

TB2 Pin 2 ...................... Form A contact closed when Pump A (acid) is ON

TB2 Pin 3-4 ................... Form C contact activated, (if programmed) when pH is within programmed limits

(solenoid pump)

TB2 Pin 5-6 ................... Form C contact activated when Alarm Setpoint 2 exceeded (powered output contacts)

TB2 Pin 7-8 ................... Form C contact activated when Alarm Setpoint 1 exceeded (powered output contacts)

TB3 Terminal Strip

TB3 Pin 1-2 ................... Opto isolated input - low or short stops pumps (OFF on display)(Remote OFF)

TB3 Pin 3-4 ................... Opto isolated output - low when alarm condition exists

TB3 Pin 5-6 ................... Opto isolated output - pulse train to drive Pump A

TB3 Pin 7-8 ................... Opto isolated output - pulse train to drive Pump B

TB3 Pin 9-10 ................. Spare, not programmed

TB3 Pin 11-12 ............... Spare, not programmed

TB4 Terminal Strip

TB4 Pin 1-2 ................... Opto isolated input - flow switch input (add jumper if no flow switch is used)

TB4 Pin 3-4 ................... Opto isolated input - level switch input (add jumper if no level switch is used)

TB4 Pin 5-6 ................... Spare, not programmed

TB4 Pin 7-8 ................... Temperature input (from platinum RTD probe) (polarity sensitive)

TB4 Pin 9-10 ................. Power voltage source for preamp

TB4 Pin 11-12 ............... 4-20 mA output proportional to pH (programmable limits) (optional) (polarity sensitive)

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3.2.2 Field Wiring Instructions

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Typical US field installation would include a 6 ft (2 m) AC cord wired and two (2) 1 ft (30 cm) AC receptacles (‘ON/OFF’
mode) or two (2) 10 ft (3 m) pump drive cables (‘PROPORTIONAL’ mode) installed. A BNC receptacle would be installed
for the pH probe.

Connect the two (2) pumps appropriately. Install the probe, run the cable back to the controller and attach to BNC receptacle.
If the probe is farther than 25 ft (7.6 m) from the controller, a pre-amp may be desirable to reduce noise effects. If this is
the case, run +5 V/-5 V as required by your preamp. Current draw must not be greater than 10 mA.

If a flow switch and/or low-level tank switch is available, run wires to the controller - entering through one of the spare
cable ports. Remove the appropriate jumper(s) and attach the external wires. Polarity does not matter. Wire size #20-22
is adequate.

Alarm relays 1 and 2 are provided to signal an out of tolerance condition externally. These are Form C contacts, providing
a common, a normally open and a normally closed connection.These terminals provide power output.

A solenoid drive relay is provided that can be connected to drain a tank when the pH is within programmed limits. This
form C contact provides a common, a normally open and a normally closed connection. A delay can be programmed after
initially entering this programmed zone, to allow conditions to settle within the tank. The duration of solenoid ON time
is separately programmable. Wire size #16-18 is adequate. These terminals provide output power (main voltage).

The optional 4-20 mA PCB provides a fully programmable 4-20 mA output based on the pH readings. The optional PCB
plugs into the back of the computer pc board, as shown in Figure 6.

Figure 6: Circuit Board

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3.3 pH Adjustment Pump(s)

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There are two (2) versions of the DP5000, one is the ‘ON/OFF’ Output and the second is ‘PROPORTIONAL’ Output.

The On/Off Output DP5000 pH Controller will operate any pH adjustment pump(s) which operate on the same line voltage
as the controller itself. Combined continuous controlled load must not exceed 4A @ 115 V or 2A @ 230 V. To ensure
efficient control, the pumps should be capable of delivering at least 150% of the maximum pumping requirement. Install
and calibrate the pumps according to the manufacturer's recommendations.

The Proportional Output DP5000 pH Controller will operate any LMI A9, A7, B9, B7, C9, C7, E7 or L7 pump, or any
other pump which operates by providing direct proportional response to a modulated pulse input signal. The pumps must
be set to the ‘external’ control mode. To ensure efficient control, the pumps should be capable of delivering at least 150%
of the maximum pumping requirement. Install and calibrate the pumps according to the manufacturer’s recommenda­tions.

3.4 Keypad and Display

The DP5000 pH Controller menu allows the user to input all the variables necessary to customize the controller for the
application. The keypad is used for all programming (see Figure 7).

Figure 7: Keypad

Keys:

This key is used to set up the control profile for the acid dosing pump. (Holding the key for five (5) seconds
will allow priming of Pump A) (Factory setting 90 SPM).

This key is used to set up the control profile for the base (alkali) dosing pump. (Holding key for five (5)
seconds will allow priming of Pump B) (Factory setting 65 SPM).

This key is used to program the high and low alarm points and hysteresis (ON/OFF mode). It also allows
programming of the mA output when installed.

This key is used to program ‘run times’ for Pumps A and B, ‘delay times’ 1 and 2 for actuating and controlling
a solenoid valve (when programmed ‘ON’ in the advanced features menu). This key also allows setting of
the ‘manual temperature’ and the controller response rate ∆ pH. If pump run time is over 11:01 hours, the
run time is disabled. The pump will not be stopped and will run continuously.

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