Rosemount Analytical 54e Operating Manual
Model 54e pH/ORP
pH/ORP HART®Analyzer/Controller
Instruction Manual
51-54epH/rev.G
February 2006
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures, and tests its
products to meet many national and international standards. Because these instruments are sophisticated technical products, you must properly install, use, and maintain
them to ensure they continue to operate within their normal
specifications. The following instructions must be adhered
to and integrated into your safety program when installing,
using, and maintaining Rosemount Analytical products.
Failure to follow the proper instructions may cause any one
of the following situations to occur: Loss of life; personal
injury; property damage; damage to this instrument; and
warranty invalidation.
• Read all instructions prior to installing, operating, and
servicing the product. If this Instruction Manual is not the
correct manual, telephone 1-800-654-7768 and the
requested manual will be provided. Save this Instruction
Manual for future reference.
• If you do not understand any of the instructions, contact
your Rosemount representative for clarification.
• Follow all warnings, cautions, and instructions marked on
and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
• Install your equipment as specified in the Installation
Instructions of the appropriate Instruction Manual and
per applicable local and national codes. Connect all
products to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to
install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by
Rosemount. Unauthorized parts and procedures can
affect the product’s performance and place the safe operation of your process at risk. Look alike substitutions may
result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is
being performed by qualified persons, to prevent electrical shock and personal injury.
WARNING
ELECTRICAL SHOCK HAZARD
Making cable connections to and servicing this
instrument require access to shock hazard level
voltages which can cause death or serious injury,
therefore, disconnect all hazardous voltage
before accessing the electronics.
Relay contacts made to separate power sources
must be disconnected before servicing.
Electrical installation must be in accordance
with the National Electrical Code (ANSI/NFPA-
70) and/or any other applicable national or local
codes.
Unused cable conduit entries must be securely
sealed by non-flammable closures to provide
enclosure integrity in compliance with personal
safety and environmental protection requirements. Use NEMA 4X or IP65 conduit plugs supplied with the instrument to maintain the ingress
protection rating (IP65).
For safety and proper performance this instrument must be connected to a properly grounded
three-wire power source.
Proper relay use and configuration is the
responsibility of the user. No external connection to the instrument of more than 60VDC or
43V peak allowed with the exception of power
and relay terminals. Any violation will impair the
safety protection provided.
Do not operate this instrument without front
cover secured. Refer installation, operation and
servicing to qualified personnel.
WARNING
This product is not intended for use
in the residential, commercial or
light industrial environment per
certification to EN50081-2.
Emerson Process Management
Liquid Division
2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: (949) 757-8500
Fax: (949) 474-7250
http://www.raihome.com
© Rosemount Analytical Inc. 2006
MODEL 54e pH/ORP TABLE OF CONTENTS
MODEL 54E PH/ORP
MICROPROCESSOR ANALYZER
TABLE OF CONTENTS
Section Title Page
1.0 DESCRIPTION AND SPECIFICATIONS ................................................................ 1
1.1 General Description................................................................................................. 1
1.2 Description of Controls ............................................................................................ 1
1.3 Specifications........................................................................................................... 2
1.4 Ordering Information................................................................................................ 4
2.0 INSTALLATION....................................................................................................... 5
2.1 Locating the Controller ............................................................................................ 5
2.2 Unpacking and Inspection ....................................................................................... 5
2.3 Mechanical Installation ............................................................................................ 5
3.0 WIRING ................................................................................................................... 7
3.1 General.................................................................................................................... 7
3.2 Power Input Wiring .................................................................................................. 7
3.3 Analog Output Wiring .............................................................................................. 7
3.4 Alarm Relay Output Wiring...................................................................................... 7
3.5 pH Sensor Wiring .................................................................................................... 9
3.6 Final Electrical Check.............................................................................................. 12
4.0 CALIBRATION ........................................................................................................ 14
4.1 Temperature Calibration .......................................................................................... 15
4.2 Automatic Two-Point Calibration ............................................................................. 16
4.3 Manual Two-Point Calibration.................................................................................. 18
4.4 Single-Point pH Calibration ..................................................................................... 19
4.5 Compensation Options ............................................................................................ 20
4.6 pH Slope Adjustment............................................................................................... 20
4.7 Hold Mode ............................................................................................................... 21
4.8 Trim Outputs............................................................................................................ 21
5.0 SOFTWARE CONFIGURATION ............................................................................. 22
5.1 Changing Alarm Setpoints....................................................................................... 26
5.2 Changing Output Setpoints (PID only) .................................................................... 27
5.3 Changing Output Setpoints (Normal) ...................................................................... 28
5.4 Testing Outputs and Alarms .................................................................................... 29
5.5 Choosing Display Options ....................................................................................... 31
5.6 Changing Output Parameters.................................................................................. 33
5.7 Changing Alarm Parameters ................................................................................... 36
5.8 On-Line Diagnostics Setup...................................................................................... 42
5.9 Auto Calibration Setup ............................................................................................ 43
i
Section Title Page
6.0 THEORY OF OPERATION...................................................................................... 45
6.1 The pH Sensor Assembly........................................................................................ 45
6.2 Continuous Sensor Diagnostics .............................................................................. 45
6.3 Interval Timer........................................................................................................... 46
6.4 Alarm Relays ........................................................................................................... 47
6.5 Time Proportional Control (TPC) Mode................................................................... 47
6.6 Normal Mode ........................................................................................................... 48
6.7 Analog Outputs........................................................................................................ 48
6.8 Controller Mode Priority........................................................................................... 49
6.9 PID Control .............................................................................................................. 50
7.0 SPECIAL PROCEDURES AND FEATURES.......................................................... 54
7.1 Password Protection................................................................................................ 54
7.2 Configuring Security ................................................................................................ 55
7.3 Solution Temperature Compensation ...................................................................... 56
8.0 TROUBLESHOOTING ............................................................................................ 58
8.1 Displaying Diagnostic Variables .............................................................................. 61
8.2 Troubleshooting Guidelines..................................................................................... 63
8.3 Replacement Parts .................................................................................................. 69
9.0 RETURN OF MATERIALS...................................................................................... 70
Appendix Title Page
A ORP CONFIGURATION.......................................................................................... 71
LIST OF TABLES
Table No. Title Page
5-1 pH Settings List .................................................................................... 22
5-2 Standard Buffers ................................................................................... 44
6-1 Controller Mode Priority Chart .............................................................. 49
8-1 Diagnostic Messages ........................................................................... 59
8-2 Quick Troubleshooting Guide ............................................................... 60
8-3 Troubleshooting Guide ......................................................................... 66
A-1 ORP Settings List ................................................................................. 72
ii
MODEL 54e pH/ORP TABLE OF CONTENTS
TABLE OF CONTENTS (CONTINUED)
iii
MODEL 54e pH/ORP TABLE OF CONTENTS
TABLE OF CONTENTS (CONTINUED)
LIST OF FIGURES
Figure No. Title Page
1-1 Main Display Screen............................................................................. 1
2-1 Wall Mounting....................................................................................... 5
2-2 Pipe Mounting....................................................................................... 6
2-3 Panel Mounting..................................................................................... 6
3-1 Power Input and Relay Output Wiring for Model 54e pH/ORP............. 8
3-2 Sensor Wiring Photo............................................................................. 9
3-3 Sensor Wiring Diagram ........................................................................ 10
3-4 Cable Dressing ..................................................................................... 11
3-5 Wiring for Sensors that have Solution Grounds ................................... 11
3-6 Wiring for Sensors without Solution Grounds Directly to Analyzer....... 12
3-7 Wiring for Sensors without Solution Grounds to a Junction Box .......... 12
3-8 Wiring to Model 399-14 ........................................................................ 13
5-1 Menu Tree ............................................................................................ 25
5-2 Interval Timer Examples ....................................................................... 41
6-1 Time Proportional Control..................................................................... 47
6-2 The Process Reaction Curve................................................................ 52
8-1 Theoretical pH vs. Millivolt Values at 25°C (77°F)................................ 62
8-2 Junction Box Preamplifier Check.......................................................... 65
8-3 Controller Preamplifier Check............................................................... 65
A-1 Outline of Menu Levels for ORP ........................................................... 74
About This Document
This manual contains instructions for installation and operation of the Model 54epH
pH/ORP HART Analyzer/Controller. The following list provides notes concerning all
revisions of this document.
Rev
. Level Date Notes
0 5/00 This is the initial release of the product manual. The manual
has been reformatted to reflect the Emerson documentation
style and updated to reflect any changes in the product offering.
0 11/01 Added trip output infor & fixed panel dimension reference.
A 3/02 Updated multiple drawings & added menus.
B 7/02 Fixed setpoint example screen on page 27.
C 4/03 Updated CE info.
D 7/04 Fixed power and weight specs on page 2.
E 3/05 Updated recommended sensors on page 3.
F 4/05 Added note re ordering circuit board stack on page 69.
G 2/06 Updated Figure 1, Menu tree.
1
MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
1.1 GENERAL DESCRIPTION
The Model 54e pH/ORP analyzer/controller monitors
and controls pH in chemical processes used in many
industries. This manual's sections and appendices
cover the system's configuration, calibration, and
maintenance, and provides a troubleshooting guide.
All adjustments to the current outputs, alarm relays,
and calibration of the pH and temperature inputs can
be made using the controller's membrane keypad.
1.2 DESCRIPTION OF CONTROLS
Figure 1-1 shows a diagram of the main display
screen. Similar diagrams are used throughout this
manual. The primary variable is continuously displayed in large numerals. The process temperature
and primary current output value are always displayed on the second line of the main display
screen. The third line can be configured to read
several different items, as desired. In this case, it is
displaying setpoints for alarms 1 and 2.
The F1-F4 keys are multifunction. The active operation for that key is displayed as a label just above
each function key as needed. For example, F1 is
usually labeled Exit and F4 may be labeled Edit,
Save, or Enter. Pressing Enter 4 will access submenus, while pressing Edit allows changing values
and Save stores the values in memory. Esc 3 can
be used to abort unwanted changes. Exit 1 returns
to the previous screen. Other labels may appear for
more specialized tasks.
The up t and down b keys are used to:
1. Move the cursor (shown in reverse video) up and
down on the menu screens.
2. Scroll through the list of options available for the
field shown in reverse video. When the last
item of a menu has been reached, the cursor
will rest on the third line of the display. If the
cursor is on the second line, there are more
items to see with the down arrow key.
3. Scroll through values when a highlighted numerical value is to be set or changed.
The right and left keys are used to move the cursor
to the next digit of a number.
Green LEDs (labeled 1, 2, and 3) indicate when
alarm relays 1, 2, and 3 are energized. The fourth
relay indicates a fault condition. When a fault
occurs, the red LED (labeled FAIL) lights up, a
descriptive error message is displayed, and the
action of the outputs and relays will be as described
in Section 5.6 and Section 5.7 under fault value
(e.g. 22 mA).
The red LED also indicates when the interval timer
routine is activated and when the time limit has been
reached on a feed limit timer. For more information
on these subjects, see Section 5.7.
FIGURE 1-1. Main Display Screen
7.00
pH
26.2°C. 12.0 mA
AL1: 0.0 AL2: 14.0
MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
1.3 SPECIFICATIONS
PHYSICAL SPECIFICATIONS - GENERAL
Enclosure: Epoxy-painted aluminum, NEMA 4X (IP65), 144 X 144 X 132 mm, DIN size (5.7 X 5.7 X 5.2 in.)
Front Panel: Membrane keyboard with tactile feedback and user selectable security. Light gray, blue and white
overlay. Light gray enclosure, dark gray bezel
Display: Back-lit dot matrix LCD (7.0 x 3.5 cm), blue on gray-green. The display contrast is compensated for
ambient temperature.
Process Variable Character Height: 16mm (0.6 in.)
Electrical Classification:
Class I, Division 2, Groups A, B, C, & D.
T5 Ta=50°C. Dust ignition proof: Class II, Division 1, Groups E, F, & G; Class III.
CSA-LR34186:
Max. relay contact rating: 28 Vdc; 110 Vac;
230 Vac; 6 amps resistive
FM: Max. relay contact rating: 28 Vdc resistive
150 mA - Groups A & B;
400 mA - Group C;
540 mA - Group D
Power:
Code -01: 100 - 127 VAC, 50/60 Hz ± 6%, 6.0 W
200 - 253 VAC, 50/60 Hz ± 6%, 6.0 W
Code -02: 20 - 30 VDC, 6.0 W
Current Outputs:
Output 1: pH, ORP, temperature, glass impedance, or reference impedance.
Output 2: pH, ORP, temperature, glass impedance, or reference impedance.
Each output is galvanically isolated, 0-20 mA
or 4-20 mA into 600 ohms maximum load at 115/230 Vac or
24 Vdc (Code -02) or 550 ohms maximum load at 100/200 Vac. Output 1 includes digital signal 4-20 mA
superimposed HART (Code -09 only).
RFI/EMI: EN-61326
LVD (Code -01 only): EN-61010-1
Ambient Temperature:
0 to 50°C (32 to 122°F)
NOTE:
The analyzer is operable from -20 to 60°C
(-4 to 140°F) with some degradation in display
performance.
Relative Humidity: 95%, non condensing
Alarms:
Relay 1 - Process, Interval*, or Time Proportional Control (code -20)
Relay 2 - Process, Interval*, or Time Proportional Control (code -20)
Relay 3 - Process, Interval*, or Time Proportional Control (code -20)
Relay 4 - Sensor/analyzer and process fault alarm
Each relay has a dedicated LED on the front panel.
*maximum of one interval timer
Relay Contacts: Relays 1-3: Epoxy sealed form A contacts, SPST, normally open
Relay 4: Epoxy sealed form C, SPDT
Resistive
Inductive
28 Vdc 5.0 Amps 3.0 Amps
115 Vac 5.0 Amps 3.0 Amps
230 Vac 5.0 Amps 1.5 Amps
Weight/Shipping Weight: 1.8 kg/2.3 kg (4 lb/5 lb)
2
MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
The Model 54e when configured as a pH analyzer,
requires a dual (glass and reference) impedance preamplifier (patent pending). This preamp converts the
high impedance pH glass electrode signal to a low
impedance signal. The preamplifier may be located in
one of three areas: 1) in the pH sensor for best performance, 2) in a remote junction box when process
temperatures exceed 80°C (176°F) in submersion
applications, or 3) in the analyzer when the distance
between the pH sensor and the analyzer is 4.5 meters
(15 feet) or less.
The Model 54e pH measures over the full range of 014 pH. The current output may be calibrated to represent any 1 to 14 pH span.
A two-point calibration is made by immersing the sensor in two different buffer solutions and entering the
pH values. When two buffers are used, the microprocessor automatically calculates the electrode slope
which is used for self-diagnostics. The electrode slope
can be read on the display and manually adjusted. A
one-point process standardization is easily accomplished by entering the pH value of a grab sample.
ANALYZER SPECIFICATIONS @ 25°C
Measurement Range: 0 to 14 pH
Output Scale Expansion: Zero suppression: up to 13
pH units
Span: Any pH from 1 to 14
Accuracy: ± 0.01 pH
Repeatability: ± 0.01 pH
Stability: ± 0.01 pH/month, non-cumulative
Temperature Coefficient: Input: ± 0.003 pH/°C
Output: ± 0.006 pH/°C
Temperature Compensation
: Pt 100 or Pt 1000 RTD,
Automatic or Manual
–15 to 120°C (5 to 248°F)
RECOMMENDED SENSORS:
Model 320B Flow Through pH
Model 320HP High Purity pH
*Model 328A Steam Sterilizable pH
*Model 370 and 371 EuroSenz pH
Model 381+ Insertion/Submersion/Flow Through pH
*Model 389 Disposable pH
*Model 396/VP Disposable pH
Model 396P/VP Disposable pH
Model 396R/VP Retractable pH
Model 397 Quik Disconnect pH
Model 398/VP Insertion/Submersion pH
*Model 398R/VP Retractable pH
*Model 399 Disposable pH
*Model Hx338 Steam Sterilizable pH
*Model Hx348 Steam Sterilizable pH
The Model 54e when configured as an ORP
analyzer, measures over a range of -1400 mV to
+1400 mV in either the American convention
(Oxidation Reduction Potential), or the European convention (Reduction Oxidation-Redox). Although temperature compensation is not used for ORP
measurements, the process temperature is measured
and displayed. Temperature measurement is made by
an RTD located in the sensor assembly.
ANALYZER SPECIFICATIONS @ 25°C
Measurement Range: –1400 to +1400 mV
Output Scale Expansion: Zero suppression: up to
±1300 mV
Span: Any ORP range from 100 to 2800 mV
Accuracy: ± 1.0 mV
Repeatability: ± 1.0 mV
Stability: ± 1.0 mV/month, non-cumulative
Temperature Coefficient: Input: ± 0.2 mV/°C
Output: ± 0.4 mV/°C
Temperature Measurement: –15 to 120°C (5 to 248°F)
Pt 100 or Pt 1000 RTD
RECOMMENDED SENSORS:
Model 330 Flow Through ORP
*Model 371 EuroSenz ORP
Model 381+ Insertion/Submersion/Flow Through ORP
*
Model 389 Disposable ORP
Model 396P Disposable ORP
Model 396R Retractable ORP
Model 398 Insertion/Submersion ORP
Model 398VP Insertion/Submersion with VP 6.0 connector
Model 398R Retractable ORP
Model 398RVP Retractable ORP with VP 6.0 connector
The Model 54e when ordered for ISE capability,
is suitable for use with a number of ion-selective electrodes. Consult the factory for available measurements and ranges.
3
MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
4
1.4 ORDERING INFORMATION
The Model 54e pH/ORP Microprocessor Analyzer is housed in a rugged, NEMA 4X (IP65) epoxy- painted cast
aluminum enclosure. Standard features include a back-lit dot-matrix liquid crystal display, sensor diagnostics,
dual isolated outputs, and four relays. The analyzer can measure pH or ORP as configured by the user. For ISE
capability, please consult the factory.
CODE OPTIONS
01 115/230 VAC, 50/60 Hz Power
02 24 VDC Power
MODEL
54e pH/ORP MICROPROCESSOR ANALYZER
CODE OPTIONS
09 HART Communications Protocol
20 Controller Outputs - PID and TPC
ACCESSORIES
PART NO. DESCRIPTION
2002577 Wall and two inch pipe mounting kit
23545-00 Panel mounting kit
23554-00 Cable glands, kit (Qty 5 of PG 13.5)
9240048-00 Stainless steel tag (specify marking)
54e pH/ORP -01 -20 EXAMPLE
5
MODEL 54e pH/ORP SECTION 2.0
INSTALLATION
SECTION 2.0
INSTALLATION
This section is for installation of the controller.
WARNING
All electrical installation must conform to the
National Electrical Code, all state and local
codes, and all plant codes and standards for
electrical equipment. All electrical installations
must be supervised by a qualified and responsible plant electrician.
2.1 LOCATING THE CONTROLLER
Position the Model 54e pH/ORP controller to minimize
the effects of temperature extremes and to avoid
vibration and shock. Locate the controller away from
your chemical process to protect it from moisture and
fumes.
Select an installation site that is more than 2 ft from
high voltage conduit, has easy access for operating
personnel, and is not exposed to direct sunlight.
2.2 UNPACKING AND INSPECTION
Inspect the exterior of the shipping container for any
damage. Open the container and inspect the controller
and related hardware for missing or damaged parts.
If there is evidence of damage, notify the carrier immediately. If parts are missing, contact Rosemount
Analytical customer support.
2.3 MECHANICAL INSTALLATION
2.3.1 Mounting the Controller
The Model 54e pH/ORP controller may be supplied
with a mounting bracket accessory. If you use the
mounting bracket on wall or pipe installations, avoid
mounting on pipes which vibrate or are close to the
process. The bracket may be modified to mount the
controller on I-beams or other rigid members. You can
also fabricate your own bracket or panel mount the
controller using the bracket as an example.
2.3.2 Wall or Surface Mounting:
1. Mount the bracket to the controller using the sup-
plied four screws as shown in Figure 2-2.
2. Mount controller mounting bracket to wall using
any appropriate fastener such as screws, bolts,
etc (see Figure 2-1 below).
2.3.3 Pipe Mounting:
1. Attach the mounting bracket to the rear of the con-
troller and tighten the four screws as shown in
Figure 2-2.
2. Place supplied U bolts around the mounting pipe
and through the pipe mounting bracket and
mounting bracket. Tighten the U bolt nuts until the
controller is securely mounted to the pipe.
FIGURE 2-1. Wall Mounting
6
FIGURE 2-2. Pipe Mounting
MODEL 54e pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-3. Panel Mounting
2.3.4 Panel Mounting:
The controller is designed to fit into a 5.43 x 5.43 inch (DIN standard 137.9 x137.9 mm) panel cutout (Figure 2-3).
Installation requires both front and rear access.
1. Install the controller as shown in Figure 2-3. Insert the instrument enclosure through the front of the panel
cutout and align the panel mounting brackets as shown.
2. Insert two mounting bracket screws through each of the two mounting brackets and into the tapped holes in
the rear of the controller enclosure and tighten each screw.
3. Insert four panel mounting screws through each hole in the mounting brackets. Tighten each screw until the
mounting bracket holds controller firmly in place. To avoid damaging the controller mounting brackets, do not
use excessive force.
MODEL 54e pH/ORP SECTION 3.0
WIRING
SECTION 3.0
WIRING
3.1 GENERAL
WARNING
All electrical installation must conform to the
National Electrical Code, all state and local
codes, and all plant codes and standards for
electrical equipment. All electrical installations
must be supervised by a qualified and responsible plant electrician.
NOTE
Wire only the analog and alarm outputs
required for your application. Be sure to read
the warning at the beginning of Section 2.0.
The Model 54e pH/ORP has five access holes in the bottom of the instrument housing which accept ½-in. strain
relief connectors or conduit fittings. Be sure to seal any
unused access holes. As you face the front of the unit,
the rear openings are for input power, and alarm relay
signals. The opening on the front left is for sensor wiring
only (DC). The front right is for analog output wiring.
NOTE
For best EMI/RFI protection, the output cable
should be shielded and enclosed in an earth
grounded, rigid, metal conduit. Connect the
output cable's outer shield to the earth ground
connection on TB2 (Figure 3-1)
3.2 POWER INPUT WIRING
Figure 3-1 depicts the wiring detail for the Model 54e
pH/ORP. Code -01: connect AC power to TB3, termi-
nals 1 and 2 for 115 VAC (terminals 2 and 3 for 230
VAC). Code -02: connect DC power to TB3 terminals 1
and 2. Connect earth ground to the nearby ground lug.
A good earth ground is essential for proper operation of
the controller. Be sure to provide a means of disconnecting the main power to the controller.
CAUTION
Do not apply power to the controller until all
electrical connections are made.
WARNING
Electrical connections to this equipment
must be made in accordance with the current National and Local Electrical Codes in
effect for the installation location.
3.3 ANALOG OUTPUT WIRING
The analog output wiring consists of two 4-20 mA signals: output one from terminals 4 and 5, output 2 from
1 and 2 on TB2, as shown in Figure 3-1. These signals
can be used for chart recorder, computer monitoring, or
PID control output. The analog outputs can be programmed for 4-20 mA or for 0-20 mA, direct or reverse
acting. Current output 1 includes superimposed HART
(code -09 only).
3.4 ALARM RELAY OUTPUT WIRING
The controller has 3 "dry" alarm relay contacts which are
normally open. Alarm 1 is across terminals 4 and 5 on
TB3. This alarm is typically used to control the pump in a
chemical feed system. Alarm 2 across terminals 6 and 7
on TB3 is usually used to operate a light or horn as a
means of alerting the chemical process operator when
pH/ORP is outside the control range. Alarm 3 is across
terminals 8 and 9 on TB3. All 3 of these alarms may be
activated on pH/ORP or temperature. They can also be
used to control other pumps or valves provided they are
programmed to do so. Refer to Section 5.0 to set up these
functions.
All three alarm contacts on the Model 54e pH/ORP are
rated for a maximum of 3 A (1.5A, 230 VAC, inductive
load). If your associated pump or valve exceeds this,
use a separate contact or relay rated for the external
device.
To use a contact output to control a pump, valve, or
light, the contact must be wired into a circuit together
with a source of power for the device to be controlled.
The power can be jumpered from the main power into
the controller and the circuit can be wired as shown on
the wiring diagrams, Figure 3-1.
PREAMPLIFIER SELECTION
The pH sensor signal requires a preamplifier at some
point in the measuring circuit. The preamp can be inside the sensor, in the junction box, or in the controller.
To allow for these options, the Model 54e pH/ORP has
a jumper selectable preamp mounted on the CPU circuit board (Figure 3-3). The jumper is placed in the
"analyzer" position when there is no preamp in the sensor (or junction box). Generally, this jumper is in the
"sensor" position.
7
8
MODEL 54e pH/ORP SECTION 3.0
WIRING
FIGURE 3-1. Power Input and Relay Output Wiring for Model 54e pH/ORP
DWG. NO. REV.
454EPH02 D
9
MODEL 54e pH/ORP SECTION 3.0
WIRING
pH SENSOR COMPATIBILITY
The following sensors contain solution grounds:
Models 381+, 385+, 396P, 396R
The use of these sensors will allow both glass and ref-
erence diagnostics.
Figure 3-3 shows how these sensors should be wired.
Note that wiring connections depend on whether the
sensor (or junction box) has a preamp or not. If the
sensor (or j-box) has a preamp, then the preamp location jumper is moved accordingly and wiring connected
as on the left of Figure 3-3. Otherwise, the jumper is
moved to the "analyzer" position and wiring for TB1 is
connected as on the right hand side.
Junction box (P/N 23550-00) wiring for sensors that
contain a preamp is strictly point to point. All sensor
leads are run to the junction box and carried through by
the extension cable (P/N 9200273). Only use this recommended extension cable and be careful to connect
all cable leads in the junction box. Sensors without preamps that require cable extension should be wired up
to the junction box (P/N 23555-00) as per the appropriate sensor instruction manual.
The following sensors do not contain solution grounds
but are compatible with the Model 54e pH/ORP:
Models 389-02-54, 396-54, 397-54, 399-09
Sensors without solution grounds must be wired differ-
ently (see Figure 3-6). Diagnostics will only be possible
on the glass electrode side of the sensor.
When extending cable, the junction box with preamp
(P/N 23555-00) must be used. See Figure 3-7 for
wiring details.
3.5 pH SENSOR WIRING
Be sure that the pH sensor has been properly installed
and mounted. Wire the sensor to the junction box (if so
equipped) and/or Model 54e pH/ORP according to
Figures 3-5 through 3-7, or use the wiring diagram
drawing included inside the controller. Use a narrowbladed screwdriver to facilitate sensor wiring (see
Figure 3-2).
The wiring diagrams show connections between
the Model 54e pH/ORP and the junction box used
where distance from the sensor to the controller
exceeds the integral sensor cable length and interconnecting wire is required. The interconnecting
sensor wire recommended is P/N 9200273. Use of
this cable provides EMI/RFI protection and complete sensor diagnostics (for sensors so
equipped). The maximum interconnecting wire
length is 500 ft.
IMPORTANT
All interconnecting sensor cable ends must be
properly dressed, as shown in Figure 3-4, to prevent the individual sensor and shield wires from
shorting. All shields must be kept electrically separate all the way back to the terminals on the Model
54e pH/ORP. Check that there is no continuity
between the shield wires and any other sensor
conductors or shields prior to connecting the sensor wiring to the terminals on the Model 54e
pH/ORP. FAILING TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN CONTROLLER MALFUNCTION.
FIGURE 3-2. Sensor Wiring Photo
MODEL 54e pH/ORP SECTION 3.0
WIRING
10
FIGURE 3-3. Sensor Wiring Diagram
DWG. NO. REV.
454EPH01 C
MODEL 54e pH/ORP SECTION 3.0
WIRING
To prepare the cable for sensor wiring:
1. Use only the cable specified. Figure 3-4 shows
the 10 conductor cable with 3 shields
(9200273).
2. Strip back the PVC jacket 4 in. or far enough to
access the eleven screw terminals in the junction box, or the eleven terminals in the controller. Separate the two coaxial cables and prepare each as follows:
2a. Strip back the insulating black sheath about
1½ in.
2b. Separate the braid from the inner black
conductive sheath.
2c. Solder an insulated wire to the braid.
2d. Strip the black conductive sheath 1 in. to
expose the colored (orange or gray) cable
inside.
2e. Insulate the exposed black sheath and braid area to prevent shorts.
3. Strip ¼ in. of insulation on each conductor for terminal mounting. Insulate the exposed foil shields with heat
shrink sleeves or electrical tape. Be sure that heat shrink overlaps the exposed metal end where the foil shield
has been cut. Shields must not be shorted together. The sensor will not work if foil shields or drain wires are
not electrically isolated from each other.
FIGURE 3-4. Cable Dressing
FIGURE 3-5. Wiring for Sensors that have Solution Grounds (Models 381+, 385+, 396P, 396R)
INSIDE FRONT PANEL VIEW
11
MODEL 54e pH/ORP SECTION 3.0
WIRING
3.6 FINAL ELECTRICAL CHECK
When all wiring is completed, apply power to the controller. Observe the controller for any questionable
behavior and remove power if you see a problem. With
the pH sensor in the process, the display will show a pH
value (though it may not be accurate).
CAUTION
To prevent unwanted chemical feed into the
process and to prevent injury to operating
personnel, disconnect the chemical feed
pump and other external devices until the
controller is checked out, programmed, and
calibrated.
FIGURE 3-7. Wiring for Sensors Without Solution Grounds to a Junction Box (Models 389-02-54, 396-54, 399-09)
NOTES:
1. Interconnecting wire maximum length is 500 ft. Use PN 9200273 (no substitutes). Shields must be insulated from each other at all
cable ends. Connect to junction box as shown.
2. If distance to controller is short, the junction box is not required. Connect sensor leads directly to controller.
FIGURE 3-6. Wiring for Sensors Without Solution Grounds Directly to Analyzer (Models 389-02-54,
396-54, 397-54, 399-09). For wiring to a junction box, see Figure 3-7.
12
MODEL 54e pH/ORP SECTION 3.0
WIRING
FIGURE 3-8. Wiring to Model 399-14
13
14
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
SECTION 4.0
CALIBRATION
The following procedures are described in this section:
• Temperature Calibration (Section 4.1)
• Auto Buffer (Two-Point) Calibration (Section 4.2)
• Manual Two-Point Calibration (Section 4.3)
• Single-Point pH Calibration (Section 4.4)
• Temperature Compensation Options (Section 4.5)
• pH Slope Adjustment (Section 4.6)
• Hold Mode (Section 4.7)
INTRODUCTION
Calibration is the process of adjusting or standardizing
the controller to a lab test (such as free acid titration) or
a calibrated laboratory instrument, or standardizing to
some known reference (such as a commercial pH
buffer). Calibration ensures that the controller shows
an accurate, and therefore, repeatable reading of pH or
temperature.
Since pH measurements are affected by temperature,
the Model 54e pH/ORP reads the temperature at the
sensor and compensates for the changing temperature
by referencing all pH measurements to 25°C (77 °F).
This compensates for temperature-related changes in
the response of the glass pH electrode which would
affect the pH measurement. The pH temperature compensation does not account for changes in chemical
activity which affect the actual pH value of the solution
being measured. See Section 7.0 for information on
solution temperature compensation.
To ensure the controller's accuracy, it is important to
perform all the calibration procedures provided in this
section if you are:
• installing this unit for the first time
• changing or replacing electrodes or sensor elements
• troubleshooting
IMPORTANT
Before attempting to calibrate, inspect the
pH sensor assembly. It must be clean,
undamaged and free from cracks or other
signs of leakage or wear.
WARNINGS
Before performing any of these procedures, be sure to disable or disconnect the chemical feed pumps or
other external devices (see placing controller in hold, Section 4.7)
Perform the calibration procedures in this section only in the order they are given.
Do not attempt to calibrate the controller if the fault LED is lit or the display is showing fault messages.
4.1 TEMPERATURE CALIBRATION
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
This procedure is used to ensure an accurate temperature measurement
by the temperature sensor. It enables the controller to display process
temperature accurately as well as to compensate for the effect of temperature on the pH reading when the temperature in your process
changes. The following steps should be performed with the sensor in the
process or in a grab sample near the operating temperature.
1. Check the controller temperature reading (main display) to make sure
the sensor has acclimated to the process temperature. Compare the
controller temperature to a calibrated temperature reading device.
Proceed to the next step if the reading requires adjustment.
2. From the main display, press any key and then press Enter (F4) to
access the Calibrate menu.
NOTE
The hold mode screen (top left) will appear if the hold mode was
enabled in Section 5.6. Activate hold mode by pressing Edit (F4),
using the arrow key to change Off to On, and then pressing
Save(F4). The hold mode holds the outputs and relays in a fixed
state to avoid process upsets to a control system. The message
"Hold Mode Activated" will always be displayed when the controller is in hold. To leave the hold mode in it's current state,
press Cont(F3).
Press the arrow key twice to bring up the screen to the left and
then press Enter (F4).
NOTE
(To verify that the controller is using automatic temperature compensation, highlight the "Temp compensation" menu item and
press Enter (F4). For more details, see Section 4.5)
3. Press Edit (F4) with this display shown to adjust the temperature. The
screen below will then appear. Using the arrow keys, input the correct temperature value and press Save (F4). The controller will enter
the value into memory. To abort the change, press Esc (F3).
Afterwards, to continue with buffer calibration, go to Section 4.2 or
4.3, otherwise press Exit (F1) three times for the main display.
NOTE
If hold mode was turned ON, be certain to install the sensor back
in the process and change the setting to OFF to resume normal
operation before leaving the controller. The screen on the top left
will appear again before the main display is shown. Follow the
same routine as in the Note for step 2 to turn the Hold Mode Off
and then press Exit (F1).
7.00 pH
Hold Mode: Off
Exit Cont Edit
25.1 °C
Adjust temp: +025.1 °C
Esc Save
Standardize pH
Adjust temperature
Temp compensation
Exit Enter
25.1 °C
Adjust temp: 25.1 °C
Exit Edit
15
16
4.2 AUTOMATIC TWO-POINT CALIBRATION
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
The two-point calibration is performed when the controller is initially
installed and whenever elements of the sensor assembly or controller are
replaced. The two-point calibration re-establishes the slope of the electrode. This is necessary because the slope (mV/pH change) decreases
as the glass pH electrode ages.
Buffer calibration uses measurements of two solutions to calculate the
slope (efficiency) and the zero offset of the pH sensor.
Obtain two pH buffer solutions with different pH values. They should be
at least 2 pH units apart. Unopened buffers have a shelf life of about a
year and should generally not be reused because of possible contamination.
Before taking readings, clean and rinse the sensor (if necessary). Shake
the sensor down to remove air bubbles from the glass electrode tip. Place
the sensor into the first buffer solution. Verify and adjust the temperature
(Section 4.1), if necessary.
The controller is set at the factory for automatic calibration. If this feature
has been disabled (Section 5.9), see Section 4.3 for manual calibration.
Auto calibration includes automatic buffer recognition (factory set buffers
are 4.01, 7.00, and 10.01 pH) and a stabilization check. The stabilization
feature eliminates errors caused by changes in temperature and
response time of the glass electrode. To change these settings, refer to
Section 5.9.
1. From the main display, press any key to obtain the main menu. With
the cursor on "Calibrate", press Enter (F4). With the cursor on "Buffer
calibration", press Enter (F4) again.
NOTE
The hold mode screen (top left) will appear if the hold mode was
enabled in Section 5.6. Activate hold mode by pressing Edit (F4),
using the arrow key to change Off to On, and then pressing
Save(F4). The hold mode holds the outputs and relays in a fixed
state to avoid process upsets to a control system. To leave the
hold mode in it's current state, press Cont (F3).
2. With the sensor in the first buffer, press Cont (F3). To cancel the calibration, press Abort (F1).)
The word "Wait" flashes until the sensor is stabilized.
The controller is waiting for the pH reading to stabilize within the
parameters established in Section 5.9. If the controller appears to be
locked at this stage, the reading is not stable enough. Increase the
stabilize pH and/or decrease the stabilize time and retry the calibration.
Press Abort (F1) to cancel the calibration if it appears to be taking too
long.
7.00 pH
Hold Mode: Off
Exit Cont Edit
4.02 pH
Buffer 1 -- “Wait”
Abort Cont
4.02 pH
Autocal buffer 1
Abort Cont
Buffer calibration
Standardize pH
Adjust temperature
Exit Enter
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
3. A screen like the one on the left will appear after stabilization.
Use the arrow keys to select the correct buffer.
If the correct buffer does not appear, refer to Section 5.9 and select
a buffer group that includes the desired buffers. As usual, to cancel
the calibration, press Abort (F1).
When the correct buffer is shown, remove the sensor from buffer 1,
rinse and gently dry it. Press Cont (F3) to continue.
NOTE
The calibration calculation does not occur until buffer 2 is completed. Aborting the calibration at this point will not change the
reading of the controller.
4. This screen appears immediately after pressing the Cont key in
step 3.
Place the sensor into the second buffer. Press Cont (F3) to proceed.
The word "Wait" flashes (as before) until the sensor is stabilized.
Press Abort (F1) to cancel the calibration if the process is taking too
long. (see step 2).
5. A screen like the one on the left will appear after stabilization. Use the
arrow keys to select the correct buffer, and press Cont (F3). If
the correct buffer does not appear, refer to Section 5.9 and select a
buffer group that includes the desired buffers. As usual, to cancel the
calibration, press Abort (F1).
This completes the calibration. The controller has now recalculated
the slope and the zero offset of the sensor.
CALIBRATION NOTES
1. A two-point calibration should always be followed by a sin-
gle-point calibration (see Section 4.4).
2. After a buffer calibration, the electrode slope value can be
checked to see if the electrode is aging.
3. If the sensor is not at the same temperature as the buffer the cal-
ibration will be in error.
NOTE
If hold mode was turned ON, be certain to install the sensor back
in the process and change the setting to OFF to resume normal
operation before leaving the controller. The hold mode screen
will appear again before the main display is shown. Follow the
same routine as in the Note for step 1 to turn the Hold Mode Off
and then press Exit (F1).
4.02 pH
Buf1 done: 4.01 @25°C
Abort Cont
10.02 pH
Buf2 done: 10.01 @25°C
Abort Cont
10.02 pH
Auto buffer cal done
Abort Cont
10.02 pH
Autocal buffer 2
Abort Cont
17
18
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
This procedure is followed if Autocal is set to "Manual" in Section 5.9.
Buffer values are entered manually and no stabilization check is used.
1. From the main display, press any key to obtain the main menu. With
the cursor on "Calibrate", press Enter (F4). With the cursor on "2-pt
Calibration", press Enter (F4) again.
NOTE
The Hold Mode screen may appear if the feature was enabled in
Section 5.6. Changing the Hold Mode to ON holds the outputs in
a fixed state, and avoids process upsets during calibration.
2 . Place the sensing portion of the pH sensor into a beaker containing
the first buffer solution. The large displayed pH shows the actual pH.
3. Allow the pH and temperature to stabilize. This may take several minutes, as the pH sensor may need to cool down to the buffer temperature. The display will flash “wait’ while the reading is stabilizing.
When the pH reading is stable, press Cont (F3) to update the reading. Press Edit (F4) and use the arrow keys to change the indicated
buffer value to the correct value for the buffer at the stabilized temperature. The pH values at various temperatures are written on the
label of most buffer bottles.
4. Press Pt 2 (F3) to enter Buffer 1 into memory and proceed to buffer
2 (pt. 2) calibration.
NOTE
Press Abort (F1) to cancel buffer calibration and return to the calibration menu.
5. Remove the sensor from buffer 1 and rinse in water.
6. Place the pH sensor into a beaker containing the second buffer solution.
7. Allow the pH and temperature to stabilize (as before) and press Cont
(F3). The display will flash “wait’ while the reading is stabilizing.
8. Enter the correct value for buffer 2 as described in step 3 and press
Save (F4) to complete the calibration. Reinstall the sensor.
CALIBRATION NOTES
1. A two-point calibration should always be followed by a sin-
gle-point calibration (see Section 4.4)
2. After a buffer calibration, the electrode slope value can be
checked to see if the electrode is aging.
3. If the sensor is not at the same temperature as the buffer the cal-
ibration will be in error.
4. If the hold mode is ON, be certain to reinstall the sensor in the
process and change the setting to OFF to return to normal operation.
4.3 MANUAL TWO-POINT CALIBRATION
2-pt calibration
Standardize pH
Adjust temperature
Exit Enter
4.01
pH
Pt. 1: 04.00pH 25°C
Pt 2 Edit
4.01
pH
Calibrate point 1
Abort Cont
10.01 pH
Calibrate point 2
Abort Cont
10.01 pH
2-pt calibration done
Esc Save
4.4 SINGLE-POINT pH CALIBRATION
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
A single-point calibration (standardization) should always be performed
following a two-point calibration. It may have to be performed as often as
once a day to ensure that the sensor is accurately reading pH. As the
glass electrode or the porous reference plug fouls and ages, the pH reading will drift. The single-point calibration re-establishes the exact pH reading. Experience with your process and it's acceptable range of pH will dictate how often the single-point calibration will have to be performed. The
procedure is most easily performed on-line by determining the pH of a
process grab sample with a laboratory instrument. This value can then be
entered into the Model 54e pH/ORP to make it agree with the lab instrument.
Many processes have effects on on-line sensors that cause them to read
slightly different than grab samples measured with laboratory electrodes.
Standardizing the controller allows both readings to agree. This procedure does not calculate the sensor slope.
1. Take a grab sample that is as close to the sensor as possible.
2. Using a calibrated pH instrument with automatic temperature com-
pensation, determine the pH of the process or grab sample (as close
to actual process temperature as possible). Continue with this procedure if an adjustment is needed.
3. From the main display, press any key to obtain the main menu. With
the cursor on "Calibrate", press Enter (F4).
NOTE
The Hold Mode screen may appear if the feature was enabled in
section 5.6. Changing the Hold Mode to ON holds the outputs in
a fixed state, and avoids process upsets during calibration.
Remember to change the Hold Mode back to OFF when calibration is completed.
4. Move the cursor (using the down arrow key) from "Buffer Calibration"
(or 2-pt calibration) to "Standardize" and press Enter (F4).
5. The pH reading in large numbers is the live process pH reading. The
next line displays the pH reading when this screen was first
accessed. Press Edit (F4) to perform the standardize.
Use the arrow keys to change the second line standardize value to
the correct pH and press Save (F4) to complete the procedure. Esc
(F3) will cancel.
The pH reading in the large display will change to the new value and
the zero offset number will be recalculated.
NOTE
Before exiting the calibration mode, remember to change the
hold mode setting to OFF (if it was turned on in step 3).
Buffer calibration
Standardize
Adjust temperature
Exit Enter
4.01 pH
Standardize: +07.00 pH
Esc Save
7.01 pH
Standardize: 7.01 pH
Exit Enter
19
20
4.5 TEMPERATURE COMPENSATION OPTIONS
4.6 pH SLOPE ADJUSTMENT
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
Automatic Temperature Compensation is a standard option for pH equipment and is used in virtually all pH measurement situations. If compensation is not desired, the temperature signal from the sensor can be
ignored by placing the controller in the manual temperature compensation mode.
Manual mode allows the input of a fixed value that will be used instead of
the sensor value. The manual temperature value need only be entered if
the temperature compensation setting is manual. In this case, a value
may be entered between -15 and 120°C (5 and 248°F).
To change these settings, obtain the top screen by pressing Enter (F4)
when Calibrate is highlighted in the main menu and then press the arrow
key. Press Enter (F4) again to obtain the lower screen. Highlight the
desired item and press Edit (F4) and change the value as needed.
Options are Auto or Manual temperature compensation and the temperature values listed above. Press Save (F4) to save the change. Esc (F3)
will cancel the change.
NOTE
When the temperature compensation setting is manual, all temperature specific faults are disabled.
The slope of the glass electrode is normally calculated during buffer calibration. It can, however, be entered directly (if known) using this procedure. A new electrode has a slope of about 59 mV/pH but as it ages the
slope will decrease. A slope value below 47 mV/pH unit is a sign of an
aged electrode and is not considered adequate for calibration. The pH
slope can also be viewed on the diagnostic variables screen.
Use the procedure in Section 4.5 to obtain the screen to the left with "pH
slope" highlighted. Press Enter (F4) to display the slope value now being
used. Press Edit (F4) for editing and then change the value as needed.
Save the new value with Save (F4).
Acceptable slope values are between 45.0 and 60.0 mV/pH.
NOTE
Before exiting the calibration mode, if the Hold Mode is ON, be
certain to change the setting to OFF to resume normal operation.
Adjust temperature
Temp compensation
pH slope
Exit Enter
Temp comp: Auto
Manual temp:
025.0°C
Exit Enter
pH slope: 59.16 mV/pH
Exit Enter
Temp compensation
pH slope
Output trim
Exit Enter
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