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Emerson 54e pH/ORP Photo Scanner User Manual

1. JUMPER N en EPTSTEISETSTSTSISTS ne JUMPER FIGURE 8 3 Controller Preamplifier Check 65 MODEL 54 TABLE 8 3 Troubleshooting Guide PROBLEM OR CONDITION Controller completely inoperative Controller operating but adding chemical above setpoint or not adding below setpoint or not holding setpoint Inability to standardize pH Zero Offset Err 66 PROBABLE CAUSE AND CORRECTIVE ACTION No Power Check power supply at breaker and inside controller 115 V across terminals 1 and 2 on TB3 Cut off circuit Check power supply board Electronics Failure Replace the electronics Incorrect or Changed Settings Refer to software configuration procedure and verify that control parameters are correct and entered properly Pay special attention to the TPC settings Electronics Failure Try power down and power back up to reboot the program Test alarm relays Replace electronics if necessary Incorrect standardization procedure If you are trying to adjust the pH reading by a large amount the controller may reject your standardization and will continue to display the previous value Check that your lab instrument titrations or chemical standard solutions have been used properly and are correct Sensor failure Simulate sensor in Preamp Troubleshooting Replace sensor if preamp ok Electrode coated Clean electrode as needed
2. nnne 1 1 1 General Description 5 nep GAN a E Ee 1 1 2 Description of Controls tre tlie Do dee 1 1 3 s 2 1 4 Ordering Information retient NAA 4 2 0 INSTALLATION EcL 5 2 1 Locating the Controller 5 2 2 Unpacking RE MET e ET 5 2 3 Mechanical Installation mmn 5 3 0 WIRING einge SEND Dee EUER Ehe 7 3 1 General nebat de ttiusetelade ecc teta ted 7 3 2 Power Inpu t Wiring zi esso E RARE HERR Eege 7 3 3 Analog Output Wiring 7 3 4 Alarm Relay Output Wiring 7 3 5 pH Sensor Wiring de d dud e uk da ede 9 3 6 Final Electrical Ghe eka iia ee ea os c dedere Reed 12 4 0 CALIBRATION T 14 4 1 Temperature Calibration a 15 4 2 Automatic Two Point Calibration 16 4 3 Manual Two Point 18 4 4 Single Point pH 19 4 5 Compensation Options 20 4 6 PH Slope en ET 20 4 7 Hold KO EE 21 4 8 Blue ue EN 5 0 SOFTWARE CONFIGURATION 22 5 1 Changing Alarm nennen 26
3. MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 7 CHANGING ALARM PARAMETERS continued Alarm Control Parameters Activation Method Control Mode L Exit Enter Y Activate Process Exit Alarm Setup Parameters for Normal Alarms only mm Low Setpoint 0 01 pH Delay 0 sec Exit Hysteresis 0 01 pH Delay 0 sec Relay Default None Exit Enter Nka Edit f SES 4a Menu Item Activation Method Control Mode Options Process Temperature Normal TPC Alarms 1 2 and 3 can each be configured with the options above The default options are that all three alarms are Process pH or ORP Redox and Normal not TPC This is a common configura tion and may not require changes If no changes are desired skip to step 4a To make changes in these parameters highlight the desired menu header and press Enter r4 The value now being used is displayed and the F4 key can now be pressed to Edit the item Once Edit has been pressed change the item as needed and then press Save to store the value Repeat for the other output and or items as needed 1400 to1400 2 00 to 20 00 pH 0 to 200 C 2 00 to 20 00 pH 0 to 10 C 0 99 sec None Close Open Setpoint Hysteresis Delay Relay default These parameters can be adjusted by highlighting the desired item and pressing the Edit
4. Alarm 1 control Alarm 1 setup Alarm 2 control Exit Enter Ce Alarm 2 setup Alarm 3 control Alarm 3 setup Exit ED Enter 7 Alarm 4 setup Feed limit timer Interval timer Exit 36 This section describes the options available for configuration of the alarms Alarms 1 2 and 3 can be activated on pH or ORP Redox see Appendix A or temperature One of these alarms can be setup as a feed limit timer and another alarm can be dedicated as an interval timer Alarm 4 is reserved as a fault alarm Alarms that activate on pH or ORP Redox or temperature can be con figured as on off normal or TPC These modes are described below The two alarm modes have several configuration options that are described in detail in this section 1 Beginning from the main menu move the cursor down to Program and press Enter F4 From the program menu move the cursor down using the arrow key 1 to highlight Configure and press Enter F4 Use the arrow key again to highlight Alarms as shown on the left and press Enter F4 2 There are 9 menu headers that relate to alarms Alarms 1 2 and 3 each have a control header and a setup header Alarm 4 has a sim ple setup header Configuration of a feed limit timer and an interval timer is also described here To access each header highlight the desired item and press the E
5. 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 77 This compensates for temperature related changes in the response of the glass pH electrode which would affect the pH measurement The pH temperature com pensation 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 e installing this unit for the first time changing or replacing electrodes or sensor ele ments e 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
6. The action of the reset mode depends on the propor tional band The rate at which it changes the controller output is based on the proportional band size and the reset adjustment The reset time is the time required for the reset mode to repeat the proportional action once It is expressed as seconds per repeat adjustable from 0 2999 seconds SECTION 6 0 THEORY OF OPERATION The reset mode repeats the proportional action as long as an offset from the set point exists Reset action is cumulative The longer the offset exists the more the output signal is increased The controller configured with reset continues to change until there is no offset If the offset persists the reset action eventually drives the controller output to its 10096 limit a condition known as reset windup To prevent reset windup a controller with reset mode should never be used to control a measured variable influenced by uncorrectable conditions Once the con troller is Wound up the deviation must be eliminated or redirected before the controller can unwind and resume control of the measured variable The integral time can be cleared and the windup condition quickly eliminated by manually overriding the Model 54e pH ORP s analog output using the simulate tests feature detailed in Section 5 4 Control Loop Adjustment and Tuning There are several methods for tuning PID loops includ ing Ziegler Nichols frequency response open loop step response
7. Time Period Integral vatue URY value Derivative valus LRV value Relay Default None Closed Open L Alarm Fault oft Feed Limit Disable Alarm 1 2 3 Timeout value Timer Disable AL Interval v Repeats value time value tima value Recovery time value Diagnostics Glass Imp Hi setpoint Glass imp Lo setpoint Ref imp Hi setpoint Zero offset setpoint Cal Warn setpoint imped Comp special Calibration Auto Cal Stabilize pH mV value Stabilize time value Manual Ingold DIN19267 Merck Standard Loch program Lock config pm Temp Coeli Temp Coeff Operate iso Sensor iso FIGURE 5 1 Outline of Menu Levels MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 1 CHANGING ALARM SETPOINTS S Alarm setpoints Output setpoints Simulate tests Alarm 1 setpoint Alarm 2 setpoint Alarm 3 setpoint A Exit Enter Alarm High 14 00pH Exit Enter p Setpoint 07 00 pH 26 A Exit Enter 4 Exit Edit 2 This section describes how the three alarm setpoints changed Move the cursor down by pressing the arrow key 3a 3b From the main menu move the cursor down to Program and press Enter F4 On the next display with the cursor on Alarm s
8. 5 2 Changing Output Setpoints PID 27 5 3 Changing Output Setpoints 28 5 4 Testing Outputs and Alarma a ER RR RE REA MUI Ee AA 29 5 5 Choosing Display OptiOris 5 2 et t beet pil teca eo pe e hana 31 5 6 Changing Output 33 5 7 Changing Alarm Parameters 36 5 8 On Line Diagnostics Getup 42 5 9 Auto Calibration SETUP an la edes tt ea tege dd randa 43 MODEL 54 Section 6 0 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 7 0 7 1 7 2 7 3 8 0 8 1 8 2 8 3 9 0 Appendix TABLE OF CONTENTS CONTINUED Title THEORY OF The pH Sensor Assembly aaa erede Continuous Sensor Diagnostics Interval E Alarm Rela yS ere tei He Time Proportional Control TPC Mode aan as Analog QU puts dipende ied tees AA Controller Mode PID Control SPECIAL PROCEDURES AND FEATURES Password Protection tede tie Configuring Security Solution Temperatur
9. The Model 54e pH ORP is also capable of PID control where the analog output will be proportional to the dif ference between the setpoint and the measured vari able either pH or temperature This control mode is used to modulate a pump or valve rather than to turn a device off and on MODEL 54 6 8 CONTROLLER MODE PRIORITY Your Model 54e pH ORP can function in different modes depending on both how it is configured what process conditions exist and actions an operator may have made To reconcile these possible modes there is a set priority that determines exactly what will happen to the 2 current outputs and the 4 alarm relays in the event of mul tiple modes occurring at the same time See Table 6 1 below TABLE 6 1 Controller Mode Priority Chart Priority Current Current Alarm Alarm Alarm Output 1 Output 2 Relay 1 Relay 2 Relay 3 Condition SECTION 6 0 THEORY OF OPERATION Priority is in the following order from lowest to highest normal fault timer hold feed limit test Each output or relay acts as if it is only in the state of highest priority NOTE Some of these features may not be in use for your con troller Normal Normal Normal Normal Normal Default Default Default Default Default Hold Hold Default Default Default Normal Normal pee Interval Timer Hold Mode Feed Limit Simulate tests aa Ta a a Closed Default Default Default
10. Time activated Imped activated 0 999 9 hr 1 60 0 2999 sec 0 2999 sec 0 999 sec On Off 0 2000 MOhms 0 disables 0 900 MOhms 0 disables 0 140 KOhms 0 disables 0 999 mV 0 disables 0 500 0 disables On Off Manual Standard DIN 19267 01 50 pH 0 30 sec 000 999 000 999 FACTORY SETTINGS SECTION 5 0 SOFTWARE CONFIGURATION USER SETTINGS Process Normal High 0 01 pH 0 sec None 7 pH 100 0 0 sec 0 0 30 sec 2 pH 0 pH None Fault Disable 3600 sec Disable Time activated 24 0 hr 1 120 sec 1 sec 600 sec 000 no security 000 no security 000 no security 000 no security 000 no security 000 no security 000 no security 000 no security 000 no security 000 no security ONAN WONAM NOUORWNA AD Lock Config Lock all except Calibrate Output setpoints PID Simulated Tests Alarm Setpoints and Rerange Outputs 000 999 000 no security D Solution Temperature Compensation Section 7 3 1 Temp erature Coeff icient 2 Operate Iso potential pH 3 Sensor Iso potential 0 044 to 0 028pH C 1 35 to 20 12 pH 0 14 pH 000 no security 000 no security 000 no security By changing the standard output configuration you can set up the Model 54e pH ORP to perform a wide variety of control and monitoring tasks The configuration procedures allow you to program the controller to meet the specific control and monitoring requirements of your particular
11. closed loop step response and trial and error Described in this section is a form of the open loop response method called the process reaction curve method The reaction times and control charac teristics of installed equipment and real processes are difficult to predict The Process Reaction Curve Method of tuning works well because it is based on the response of the installed system This procedure out lined in the following paragraphs can be used as a starting point for the P and I settings Experience has shown that PID controllers will do a fair job of control ling most processes with many combinations of rea sonable control mode settings 51 MODEL 54 6 0 CONTROL continued Process Reaction Curve Method A PID loop can be tuned using the Process Reaction Curve Method This method involves making a step change in the chemical feedrate usually about 50 of the pump or valve range and graphing the response of the Model 54e pH ORP reading versus time The process reaction curve graphically shows the reac tion of the process to step change in the input signal Figure 6 2 shows an example of a tuning process for a pH controller Similar results can be obtained for the conductivity controller To use this procedure with a Model 54e pH ORP and a control valve or metering pump follow the steps out lined below The Model 54e pH ORP should be wired to the control valve or metering pump You will intr
12. 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 SECTION 3 0 WIRING 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 narrow bladed 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 inter connecting wire is required The interconnecting sensor wire recommended is P N 9200273 Use of this cable provides EMI RFI protection and com plete 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 pre vent the individual sensor and shield wires from shorting All shields must be kept electrically sep arate 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 sen sor wiring to the term
13. 381 Sensor Reference chamber is contaminated Replace gel filled solution as instructed in 381 manual Defective preamplifier Check preamplifier as instructed in Preamp Troubleshooting procedure and replace if defective 381 Sensor Bad Reference If trouble still persists microjunction on reference electrode is defective Replace reference electrode SECTION 8 0 TROUBLESHOOTING FOR MORE HELP REFER TO Wiring Section 3 0 and Figure 3 1 Figure 3 1 Software Configuration Section 5 0 Simulated tests Section 5 4 Calibration Section 4 0 Section 8 2 Section 8 0 Table 8 3 is continued on the following page MODEL 54 TABLE 8 3 Troubleshooting Guide continued PROBLEM OR CONDITION Controller short spans Buffer check with 2 point calibration gives slope less than 47 mV pH lo slope error Change in pH slope value shrinking after 2 point calibration pH value locks up no change in buffers Displayed pH value not the same as grab sample of process Display reads off scale PROBABLE CAUSE AND CORRECTIVE ACTION Coated glass electrode Clean with soft cloth and clean water Service 381 Reference Junction and Solution Old glass electrode If used for more than 1 yr replace electrode Old or coated glass electrode Clean or replace glass electrode Bad RTD value See Temp Comp Troubleshooting SECTION 8 0 TROUBLESHOOTING FOR M
14. 5 5 See Section 5 5 0 9 9 darkest On Off 1 60 min Process Temp Ref Imp Normal PID 4 20 mA 0 20 mA 0 299 Sec Last value Fixed value 0 22 MA 0 22 mA Process Temp Ref Imp Normal PID 4 20 mA 0 20 mA 0 255 Sec Last value Fixed value 0 22 mA 0 22 mA Process Temp Normal TPC APPENDIX A ORP CONFIGURATION 1400 mV 1400 mV 1400 mV 1400 mV 1400 mV 0 0 C 100 0 C C mA mA English Alarm 1 Setpoint Alarm 2 Setpoint 5 On Process ORP Normal 4 20 mA 0 Sec Last value 21 mA 22 mA Temperature Normal 4 20 mA 0 Sec Last value 21 mA 22 mA Disable feature Process ORP Normal MODEL 54 pH ORP Alarm 1 Setup a Configuration b Hysteresis deadband c Delay Time d Relay Default Alarm 2 Control a Activation Method b Alarm 2 Control Mode Alarm 2 Setup a Configuration b Hysteresis deadband c Delay Time d Relay Default Alarm 3 Control a Activation Method b Alarm 3 Control Mode Alarm 3 Setup a Configuration b Hysteresis deadband c Delay Time d Relay Default Alarm 4 Control a Alarm Feed Limit Timer a Feed Limit b Timeout Value Interval Timer a Timer selection TABLE 1 ORP Settings List CHOICES Low alarm High alarm Off 0 500 mV 0 99 sec Open Closed None Process Temp Normal TPC Low alarm High alarm Off 0 500 mV 0 99 sec Open Closed None Process Temp Normal TPC Low alarm High
15. AL2 Display contrast 5 Esc Save Display contrast 5 Timeout On Timeout Value 10 min 32 AL 1 alarm 1 setpoint no units shown AL 3 alarm 3 setpoint no units shown sensor mV input GI glass impedance in Megohms RO reference offset in mV slope of glass in mV pH MS Exit Edit 4 This screen allows you to choose the items displayed on the third line left and right of the main display screen The process temperature and output 1 value in mA or are always shown on line 2 of the main display This screen allows you to make the following choices Lower Right of Main Display AL 2 alarm 2 setpoint no units shown AL 3 alarm 3 setpoint no units shown sensor mV input RI reference impedance in Kohms Out 2 Output 2 value in mA or 96 Blank nothing displayed in lower right no units shown Blank nothing displayed in lower left The Display contrast selection allows the display to be made lighter or darker Entry 0 is the lightest and 9 is the darkest The display changes as the number is changed To change any of these items use the arrow key to highlight the desired item and press Edit F4 Use the arrow keys to make the change and press Save to enter the change into memory Press Esc to abort The timeout feature works on both the display and simulated tests using the current outputs and ala
16. Observe the controller for any questionable process and to prevent injury to operating behavior and remove power if you see a problem With personnel disconnect the chemical feed the pH sensor in the process the display will show a pH pump and other external devices until the value though it may not be accurate controller is checked out programmed and calibrated 12 MODEL 54 SECTION 3 0 WIRING OPERATING RANGE CAUTION LABEL SHOWN ON SENSOR BACK VIEW e TB1 ot o PSIG PRESSURE 1 Leal GREEN 2 TEMPERATURE 2C BROWN Remove pressure and allow to cool before BLACK removal mr LL WHITE BLACK BLUE GRAY 11 WHITE GRAY RED WHITE RED WHITE CLEAR I D DRAIN MODEL LABEL INFORMATION CAUTION LABEL 1 INCH WRENCH OPENING 1 INCH NPT 2 PLACES ELECTRODE 2 REFERENCE END VIEW FIGURE 3 8 Wiring to Model 399 14 13 MODEL 54 SECTION 4 0 CALIBRATION SECTION 4 0 CALIBRATION The following procedures are described in this section Temperature Calibration Section 4 1 e Auto Buffer Two Point Calibration Section 4 2 e Manual Two Point Calibration Section 4 3 Single Point pH Calibration Section 4 4 Temperature Compensation Options Section 4 5
17. RED TEMP COMP TEMP COMP 3 JUMPER RED 87 c WHITE WHITE Si TEMP COMP AE cond T JUMPER CHH REFERENCES IN BNC CONNECTOR 8 BRAID REF g D 2 BLACK CONDUCTIVE mv IN pH COATING CH 12 ORANGE 1 NON DIAGNOSTIC pH ORP SENSOR E WITHOUT PREAMP AND SOLUTION GROUND VIEW BUT WITH PT100 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 NC REMOTE INNER DRAIN ID JUNCTION c BOX WITH I RED WHITE Z GRAY SENSOR BUS REF IN GRAY BLUE WHI TE BLACK ORANGE mV NO BLACK BROWN GREEN RED T WHITE T gt l E lale ST ING as EXTENSION CABLE 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 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 3 6 FINAL ELECTRICAL CHECK CAUTION When all wiring is completed apply power to the con To prevent unwanted chemical feed into the troller
18. after the key is pressed then the key must be pressed again to acknowledge the new event This is the only way to clear a Feed Limit Timeout 39 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 7 CHANGING ALARM PARAMETERS continued Interval Timer Setup Timer Disable Timer Time activated Interval 24 0 hr Exit Edit 2 e gt Repeats 1 Off time 1 sec Exit Edit On time 120 sec Off time 1 sec Exit sig 40 7 Menu Item Options Timer enable Disable AL1 AL2 AL3 Interval 0 999 9 hr Repeats 1 60 On time 1 2999 sec Off time 0 2999 sec Recovery 0 999 sec The Interval Timer is used to automate a relay closure sequence based on a time interval See Figure 5 2 for examples The original controller configuration disables the timer so the first step in using the timer is to select an alarm relay 1 2 or 3 which will enable the feature All parameters can be adjusted by highlighting the desired item and pressing the Edit key Once Edit has been pressed change the item as needed and then press Save to store the value NOTE The alarm relay selected for Interval Timer cannot be used for other purposes such as a process or tempera ture alarm While a timer sequence is occurring both current outputs will be placed in hold even if hold was not enabled in Section 5 6 and the other 2 alarms will be p
19. alarm Off 0 500 mV 0 99 sec Open Closed None Fault Off Disable alarm 1 alarm 2 alarm 3 0 10 800 sec Disable alarm 1 alarm 2 alarm 3 b Timer activation method Time activated Imped activated c Interval d Repeats e On Time f Off Time g Recovery Diagnostics Section 5 8 0 999 9 hr 1 60 0 2999 sec 0 2999 sec 0 999 sec 1 Diagnostics Glass and Reference On Off 4 Ref erence Imp edance High 0 140 KOhms 0 disables 5 Zero Offset Security Section 7 Lock all Lock Program Lock all except Calibrate 000 999 Lock Config Lock all except Calibrate Alarm Setpoints Rerange Outputs 000 999 0 999 mV 0 disables 000 999 SETTINGS Low 0 mV 0 sec None Process ORP Normal High 0 mV 0 sec None Process ORP Normal High 0 mV 0 sec None Fault Disable 3600 sec Disable Time activated 24 0 hr 1 120 sec 1 sec 600 sec Off 140 KOhms 60 mV 000 no security 000 no security 000 no security APPENDIX A ORP CONFIGURATION USER SETTINGS 73 MODEL 54 Accessing Calibrate Program Configure Menus Operating configuration changes are made at the levels shown in Figure A 1 Press any key from the main display to access the main menu top left Refer to Section 5 for pH measurements Level 1 Calibrate To access calibration selections from the main menu with the cursor on Calibrate press Enter F4 ORP standardization
20. and tempera ture adjustments are made at this level refer to Section A 1 and Section 3 1 for these procedures Diagnostic variables Program Exit APPENDIX A ORP CONFIGURATION Level 2 Program To access the program level from the main menu place the cursor over Program with the down arrow key Then press Enter F4 From the program level menu changes can be made to the alarm setpoints and the output setpoints Level 3 Configure To access the configure level from the main menu place cursor over Program and Enter F4 then place cursor over Configure and Enter F4 This level contains advanced selections such as alarms and diagnostics PRESS TWO ARROWS and then ENTER Alarm setpoints PRESS ENTER Exit tandardize Adjust temperature Exit CALIBRATE MENU SEC TION Buffer Calibration 4 2 4 3 Standardize pH 44 Adjust Temperature 4 1 Temp Compensation4 5 pH slope 46 ST PROGRAM MENU SEC TION Alarm setpoints 5 1 Output setpoints PID 5 2 Output setpoints Simulated tests More Enter Diagnostics Security Simulated tests Exit More CONFIGURE MENU SEC TION Display Outputs Alarms Diagnostics Security PRESS ENTER Output setpoints 5 3 Simulated tests 5 4 FIGURE A 1 Outline of Menu Levels for ORP 74 MODEL 54 pH ORP A 1 ORP CALIBRATION 7 Standardize Adjust temperature 400 mV Standardize 400 mV Exit Enter
21. arise first check other systems that affect chemical concentration Consider what may have changed in the system that can cause poor control Some causes for poor control other than controller malfunction are 1 An empty chemical drum 2 Malfunction of a chemical feed pump pump motor or motor starter 3 Water inlet or drain valves stuck or left open by operators Check flow interlocks if used A temperature control malfunction Broken or blocked chemical feed lines A A conductivity probe that has been left out of the bath 8 The level of bath is below the probe and the probe is dry 9 The probe needs to be cleaned 10 The condition of the incoming metal has changed i e temperature cleanliness speed 11 The condition of the incoming water has changed i e temperature cleanliness flow rate hardness pH 12 Unauthorized personnel have tampered with the controller settings 13 Standardizing procedure is not accurate due to a malfunctioning laboratory instrument or contami nated chemical standard solutions WARNING To prevent chemical feed into the process or injury to operating personnel disconnect or disable the chemical feed pump and other external devices while you are servicing and troubleshooting the controller MODEL 54 SECTION 8 0 TROUBLESHOOTING TABLE 8 1 Diagnostic Messages Diagnostic Messages Description of problem Cracked glass failure Br
22. change the setting to OFF to resume normal operation MODEL 54 4 7 HOLD MODE 1 00 pH Hold Mode Off eweywe A Exit Cont 7 00 pH 26 2 C 12 0mA Hold Mode Activated 4 4 8 OUTPUTS Qe Temp compensation slope Output trim L Exit Edit 2 J SES SECTION 4 0 CALIBRATION Placing the Controller on Hold for Maintenance Before performing main tenance or repair of the sensor the Controller can be placed in hold refer to Section 5 6 to enable this feature to prevent process upsets while the reading is off line This will place the current outputs into the selected default states see Section 5 6 The relays will act as selected in relay default see Section 5 7 Before removing the sensor from the process press any key and then Enter F4 When the hold mode has been enabled the hold mode screen on the left will appear prior to calibration To continue without putting the controller in hold simply press Cont F3 To put the controller in hold press Edit F4 use the arrow key to change the Off to On and press Save F4 NOTE When the Hold Mode is activated On Hold Mode Activated will always appear on the bottom line of the display Always calibrate after cleaning or repair of the pH sensor After installing the sensor back into the process always change the Hold Mode setting to O
23. fixed panel dimension reference Updated multiple drawings amp added menus Fixed setpoint example screen on page 27 Updated CE info Fixed power and weight specs on page 2 Updated recommended sensors on page 3 Added note re ordering circuit board stack on page 69 Updated Figure 1 Menu tree MODEL 54 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 II 12 0 mA AL2 14 0 26 20 0 0 e FIGURE 1 1 Main Display Screen 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 dis played in large numerals The process temperature and primary current output value are always dis played 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 k
24. forms a certification that the instruments have RMA 1 been disinfected or detoxified are required Mark the package Returned for Repair Model No _ 9 3 NON WARRANTY REPAIR The following is the procedure for returning for repair instruments that are no longer under warranty 1 Rosemount Analytical for authorization 2 Supply the purchase order number and make sure to provide the name and telephone number of the individ ual to be contacted should additional information be needed 3 Do Steps and 4 of Section 9 2 NOTE Consult the factory for additional information regarding service or repair 70 MODEL 54 APPENDIX A ORP CONFIGURATION APPENDIX A ORP CONFIGURATION QUICK STARTUP ORP The Model 54e pH ORP controller comes pre pro grammed by the factory as a pH controller In order to perform a quick startup as an ORP controller the controller must first be switched to the pre configured ORP program Most ORP sensors will look and con nect very much like pH sensors but will have a metal ring electrode over a glass shaft with a thick end instead of a thin pH glass membrane To switch to an ORP controller and perform a quick startup 1 Connect the ORP sensor to the controller Wire to controller per Figure 2 5 or 2 6 2 Apply primary power Figure 2 4 to the con troller 3 Change the controller to ORP operation Refer to Section 5 3 or A Press any key to displa
25. only option for this alarm is to enable it or to disable it To disable the alarm press Edit and use the arrow key to change Fault to Off When a fault condition exists the relay will energize and the red LED on the front display will turn on Menu Item Options Disable AL1 AL2 AL3 Timeout 0 10 800 sec Feed limit timer The controller allows configuring one of the alarms as a Feed Limit timer The Feed Limit timer prevent overfeeding of chemical reagent by automatically turning the relay off after a timeout period To enable this feature press Edit when the Feed limit is highlighted as on the left use the arrow key to select an alarm relay and then press Save Fa When a feed limit alarm has timed out a message will appear on the main display indicating Feed limit alarm1 for an alarm 1 feed limit the red LED will turn on alarm 4 will close if not turned Off the selected feed limit relay will open de energize but all other alarms and current outputs will remain unchanged i e this is not a real fault condition This condition will continue until the Ack key is pressed at which time the controller returns to normal operation and the feed limit s clock starts again See Table 6 1 Controller Mode Priority Chart for controller action in the event of several modes occurring at the same time NOTE Pressing the Ack key will acknowledge all condi tions that turn the red LED on If another event occurs
26. plant This is done by recording the desired configuration parameters on the List of Settings Form and then actually configuring them by using the keys on the controller front panel 24 MODEL 54 Accessing Calibrate Program and Configure Menus Operating configuration changes are made at the levels shown in Figure 5 1 Pressing any key from the main dis play will access the main menu top left Refer to Appendix A for ORP measurements Level 1 Calibrate To access calibration selections from the main menu with the cursor on Calibrate press Enter F4 All buffer calibration pH standardization and tem perature adjustments are made at this level refer to Section 4 0 for these procedures Buffer Calibration 2 pt calibration Standardize pH value djust Temperature value Temperature Compensationi SECTION 5 0 SOFTWARE CONFIGURATION Level 2 Program To access the program level from the main menu place the cursor over Program with the down arrow key Then press Enter F4 From the program level menu changes can be made to the alarm setpoints and the output setpoints Level 3 Configure To access the configure level from the main menu place cursor over Program and Enter F4 then place cursor over Configure and Enter F4 This level contains advanced selections such as alarms diag nostics autocal and others Temp Comp Auto Manual Manual Temp value Measure value i
27. proportional and inte gral tuning parameters Four quantities are determined from the process reac tion curve for use in the formulas time delay D time period L a ratio of these two R and plant gain C A line is drawn on the process reaction curve tangent to the curve at point of maximum rise slope as shown in Figure 6 2 The Time Delay D or lag time extends from zero time on the horizontal axis to the point where the tangent line intersects the time axis The Response Time period L extends from the end of delay period to the time at which the tangent line inter sects the 100 reaction completion line representing the process stabilization value The ratio R of the Response Time period to the Time Delay describes the dynamic behavior of the system SECTION 6 0 THEORY OF OPERATION In the example the process Delay Time D was four seconds and the Response Time period L was 12 seconds so L 12 seconds 3 D 4 seconds The last parameter used in the equations is a plant gain C The plant gain is defined as a percent change in the controlled variable divided by the percent change in manipulated variable in other words the change in the measured variable pH conductivity temperature divid ed by the percent change in the analog output signal The percent change in the controlled variable is defined as the change in the measured variable pH conductivity temperature compared to the measure
28. sensor is bad the displayed temperature will be incorrect Using manual tem perature compensation will remove all temperature related faults 63 MODEL 54 PREAMPLIFIER TROUBLESHOOTING PROCEDURE Use this procedure when diagnosing the circuit which carries the signal from the sensor There are 3 sepa rate procedures depending on where the preamplifi er is located A Preamp in a junction box Figure 8 2 1 64 Verify that the controller s preamp switch is in the sensor J box position see Figure 2 5 Remove the cover of the junction box Disconnect the BNC adapter or remove leads from 1 7 and 1 10 whichever is connect ed Install a jumper between 7 and 10 3 and 4 and 7 and 8 see Figure 8 2 The controller should now read approximately 7 pH NOTE If the controller has been calibrated with a large zero offset the pH may not be close to 7 this case standardize the con troller at 7 Section 3 4 If the controller does not read correctly after standardizing if necessary go to step B SECTION 8 0 TROUBLESHOOTING Controller preamp check Figure 8 3 Disconnect all sensor wiring from the controller at TB2 Verify that the preamp location switch is in the analyzer position and that temperature compen sation is set to manual at 25 C or 77 F see Section 3 5 Jumper TB2 3 to TB2 4 and TB2 7 to TB2 8 Jumper TB2 7 to TB2 10 to simulate 7 pH The controlle
29. the millivolt reading at the controller should be approximately that shown in Figure 8 1 Theoretical pH vs Millivolt Values Therefore one way to check the controller is to see if the incoming millivolt signal corresponds to the proc ess pH or the pH of a test buffer solution see Figure 8 1 The displayed pH value can be changed by stan dardizing but the millivolt value displayed under Diagnostic variables see Section 8 1 will always be the exact incoming value Another good check of the controller is to check the slope obtained after per form ing the two point calibration with two different buffer solutions as described in Section 3 If the controller reads correctly when the sensor is removed from the process and isolated in a container of buffer solution then the sensor and controller are most likely functioning correctly The problem is caused by something in the process such as Sensor seeing poorly mixed non homogeneous solution e Sensor located too close to chemical feed lines or heat sources Air bubbles entrained in the process or entrapped around the sensor Voltage on the process due to static electricity buildup improperly grounded recirculation pump motors or some other electrical source Aground loop caused by improper sensor wiring as outlined in Installation Section 2 e Asource of electrical noise which only takes effect when the sensor is immersed in the process Most of these
30. the other settings listed here URV is the deviation from the setpoint that results in the alarm being on all the time LRV is the deviation from the setpoint that results in the alarm being off all the time This should be set to 0 00 EXAMPLE 1 A setpoint of 6 pH with URV of 2 0 pH and LRV of 0 0 pH a time period of 30 seconds When the pH is 7 0 the relay will on 7 6 2 0 50 of the time 15 seconds each time If the set point is changed to 6 5 pH the relay will be 7 6 5 2 0 25 of the time The relay would then be on for 7 seconds and off for 23 sec onds Relay Default determines how the relay will act if there is a fault or hold condition Each alarm can be forced on Close off Open or can remain unchanged None The original configuration is None MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 7 CHANGING ALARM PARAMETERS continued CAUTION Understanding where to set the TPC parameters is not trivial and is likely to require substantial trial and error to yield acceptable results pH and ORP Redox are nonlin ear measurements and applying PID algorithms can result in unintended effects Alarm 4 Setup Alarm Fault Feed Limit Timer Setup Feed limit Disable Timeout 3600 sec Exit Edit j 7 00 pH 26 2 12 0mA Feed limit alarm 1 A Exit Eon Alarm 4 is dedicated as a fault alarm The
31. third party for resale to Buyer Resale Products shall carry only the warranty extended by the original manufacturer Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products If Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period Seller shall at its option promptly correct any errors that are found by Seller in the firmware or Services or repair or replace F O B point of man ufacture that portion of the Goods or firmware found by Seller to be defective or refund the purchase price of the defective por tion of the Goods Services All replacements or repairs necessitated by inadequate maintenance normal wear and usage unsuitable power sources unsuit able environmental conditions accident misuse improper installation modification repair storage or handling or any other cause not the fault of Seller are not covered by this limited warranty and shall be at Buyer s expense Seller shall not be obli gated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by an authorized Seller representative All costs of dismantling reinstallation and freight and the time and expenses of Seller s per sonnel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by S
32. 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 14 MODEL 54 SECTION 4 0 CALIBRATION 4 1 TEMPERATURE CALIBRATION Hold Mode Off Exit Cont Edit 2 7 Standardize pH Adjust temperature Temp compensation e Exit Enter J Adjust temp 25 1 C Exit Edit S P 4 gt 29 1 C Adjust temp 025 1 C Esc Save 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 tem perature 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 From the main display press any key and then press Enter F4 to ac
33. to the left out put 1 has been set to 10 00 mA The output will remain at 10 00 mA until either Exit or Edit see below is pressed or the test is concluded by timeout The default value for the timeout is 10 min utes so after 10 minutes the output would go back to normal oper ation To configure the timeout option see Section 5 5 If the displayed current is not the desired value press the Edit key and the next screen will allow changing the value Use the arrow keys to change the display as needed and press Test to use that value Press Esc to cancel the change in the value and contin ue simulating the previous current 29 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 4 TESTING OUTPUTS AND ALARMS continued Test alarm 1 Open Simulating alarm ES Exit Edit 4 Test alarm 1 Open 30 A Exit More Enter A 3b alarm relay is now being simulated In the example to the left alarm 1 has been set to Open This means that the relay is not ener gized i e off The alarm will remain open until either Exit or Edit is pressed or the test is concluded by timeout The default value for the timeout is 10 minutes so after 10 minutes the alarm would go back to normal operation and the display will return to the main menu To configure the timeout option see Section 5 5 If the displayed alarm action is not as desired press the Edit ke
34. 1 Control Mode Normal PID Normal 2a Output 1 Setup Normal a Current Range 4 20 mA 0 20 mA 4 20 mA b Dampening 0 299 Sec 0 Sec c Hold Mode Last value Fixed value Last value d Fixed Hold Value if c Fixed 0 22 mA 21 mA e Fault value 0 22 mA 22 mA 1 2 3 4 5 6 7 8 9 22 Continued on the following page MODEL 54 2b Output 1 Setup PID a Setpoint b Proportional c Integral d Derivative e LRV 4 mA f URV 20 mA 3 Output 2 Control a Output 2 Measurement b Output 2 Control Mode 4a Output 2 Setup Normal a Current Range b Dampening c Hold Mode d Fixed Hold Value if c Fixed e Fault value 4b Output 2 Setup PID a Setpoint b Proportional c Integral d Derivative e LRV 4 mA f URV 20 mA 5 Hold Outputs and Relays C Alarms Section 5 7 1 Alarm 1 Control a Activation Method b Alarm 1 Control Mode 2a Alarm 1 Setup Normal a Configuration b Hysteresis deadband c Delay Time d Relay Fault 2b Alarm 1 Setup TPC a Setpoint b Proportional Integral d Derivative e Time Period f LRV 100 On 9 URV 100 Off h Relay Fault Alarm 2 Control a Activation Method b Alarm 2 Control Mode 4a Alarm 2 Setup Normal a Configuration b Hysteresis deadband c Delay Time d Relay Fault 4b Alarm 2 Setup TPC a Setpoint b Proportional Integral d Derivative e Time Period f
35. 1 restricts the operator from changing the major control mode configuration by preventing access to the Program Menu The Level 1 user can do the following 1 Access Diagnostic Variables Section 8 1 2 Zero the controller in air Section 4 3 3 Enter the Temperature Slope Section 4 4 4 Change Temperature Compensation from Auto to Manual and select a temperature Section 4 7 5 Calibrating pH and Temperature readings Section 4 1 and Section 4 6 A Level 2 user can do all of the above and 1 Change control setpoints for PID current outputs Section 5 1 2 Change alarm setpoints for normal and TPC alarms Section 5 2 3 Rerange both 4 20 or 0 20 mA outputs Section 5 3 4 Manually test both outputs and all 4 alarm relays for operation A Level 3 user has total access to the Configure Menu and can make any changes that are deemed neces sary These privileges should be given only to an indi vidual who fully understands the controller the process and the potential effects of modifying the setup An individual with no password access privilege can only view the main display containing conductivity temperature current output 1 and the lower line dis play items configured in Section 5 5 NOTE You must have level 3 access to change any security code MODEL 54 SECTION 7 0 SPECIAL PROCEDURES AND FEATURES 7 2 CONFIGURING SECURITY a Alarms Security Custom
36. 2 Exit Enter A APPENDIX A ORP CONFIGURATION ORP Calibration consists of a single standardize adjustment that changes the zero offset of the controller This procedure can be done with the ORP sensor in an ORP standard solution or with the sensor left in the process and a laboratory analysis of a grab sample 1 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 at this time 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 cali bration If you don t want to engage Hold simply press F3 Cont Otherwise press F4 Edit and change the Hold Mode to On before continuing Skip to step 4 if using an ORP standard solution 2 Take a grab sample that is as close to the sensor as possible 3 Using a calibrated ORP instrument determine the ORP of the process or grab sample 4 Move the cursor to Standardize and press Enter F4 5 The number on the large display is the live process ORP reading next line displays the ORP reading when the display was accessed Press Edit F4 to perform the standardize Use the arrow 1 key to change the reading to the desired value and then press Save F4 to complete the procedure Esc F3 will cancel NOTE The sign can be changed to a sign a
37. 293 00 Enclosure Rear 9010377 Back lit Display LCD Dot Matrix 9510048 Enclosure Conduit Plug 1 2 inch NOTE Individual printed circuit boards cannot be ordered for Model 54e Replacement boards for Model 54e are assembled and calibrated as an integrated board stack 69 MODEL 54 SECTION 9 0 RETURN MATERIAL SECTION 9 0 RETURN MATERIAL 9 1 GENERAL To expedite the repair and return of instruments proper communication between the customer and the factory is important Before returning a product for repair call 1 949 757 8500 for a Return Materials Authorization RMA number 9 2 WARRANTY REPAIR The following is the procedure for returning instruments still under warranty 1 Call Rosemount Analytical for authorization 2 To verify warranty supply the factory sales order number or the original purchase order number the case of individual parts or sub assemblies the serial number on the unit must be supplied 3 Carefully package the materials and enclose your Letter of Transmittal see Warranty If possible pack the materials in the same manner as they were received 4 Send the package prepaid to Rosemount Analytical Inc Uniloc Division IMPORTANT Uniloc Division Please see second section of Return of 2400 Barranca Parkway Materials Request form Compliance with Irvine CA 92606 the OSHA requirements is mandatory for Attn Factory Repair the safety of all personnel MSDS
38. 4VDC ONLY EARTH GROUNDS 2 3 POWER WIRING GROUND DWG NO 454EPH02 FIGURE 3 1 Power Input and Relay Output Wiring for Model 54e pH ORP MODEL 54 pH ORP 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 loca tion 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 rec ommended extension cable and be careful to connect all cable leads in the junction box Sensors without pre amps that require cable extension should be wired up to the junction box P N 23555 00 as per the appropri ate 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
39. 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 Atwo 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 17 MODEL 54 SECTION 4 0 CALIBRATION 4 3 MANUAL TWO POINT CALIBRATION Standardize pH Ii ee 7s 5 2 pt calibration Adjust temperature A Exit EMEN 401 pH Calibrate point 1 Abort Cont 4 pH 04 00pH 25 C A Pt 2 T 10 01 pH Calibrate point 2 V Abort Cont 4 f ME 10 01 pH 2 pt calibration done Esc Save de 4 18 This procedure is followed if Autocal is set to Ma
40. CTION 6 0 THEORY OF OPERATION 6 1 THE pH SENSOR ASSEMBLY The pH measurement is accomplished by means of a measuring electrode usually made of glass which develops a potential directly related to the hydrogen ion concentration pH of the solution in which the elec trode is immersed A second electrode called the ref erence electrode is necessary to complete the electri cal circuit and to serve as a constant reference poten tial against which the potential of the glass electrode can be compared Together the two electrodes com prise the pH sensor The Glass Electrode The glass electrode is a thin walled bulb of glass con taining a pH buffered solution and the elements of a half cell typically silver silver chloride The glass membrane provides a means of collecting hydrogen ions so the potential can be measured The hydrogen ions on the surface of the glass membrane are in equi librium with the hydrogen ions in the solution being measured As the hydrogen ion concentration in the solution changes the concentration of hydrogen ions on the electrode changes creating a change in poten tial on the glass electrode The Reference Cell The purpose of the reference cell is to maintain a sta ble reference potential regardless of a change in sam ple pH The cell is comprised of the reference elec trode reference fill solution and porous reference junc tion The reference cell also serves to complete the voltage measuring c
41. Closed 1 Indicates the state IF that item has been configured or selected i e if it is an interval timer or a feed limit timer or it is the one being tested Condition Definitions Unconfigured or unselected items are not affected by that mode 1 Normal refers to conditions when no other mode is present 2 Fault is when the instrument has diagnosed a fault condition A fault message is displayed and the red LED will be on Interval Timer is only while the timer sequence is occurring Hold Mode is while hold is activated by the operator i e during calibration Feed Limit occurs when a feed limit timer has reached it s limit and is turned off after being on for too long Simulate tests are described in Section 5 4 Action Definitions 1 Normal is determined by process conditions or how the item has been configured Sections 5 5 5 6 Open is a deenergized alarm relay alarm off Default is the setting configured for each item if there is a fault Sections 5 5 5 6 Closed is an energized alarm relay alarm on Hold is the setting for the current output configured in Section 5 5 this could be a fixed mA value or the last normal value Prior is the state the alarm had before that mode occurred Test is the value input by the operator mA for current on or off for a relay 49 MODEL 54 6 9 CONTROL CODE 20 PID Control The Model 54e pH ORP current outputs c
42. Curve Exit Enter ES mm all mg Lock program 000 Lock config 000 Exit SES Security clearance is required at the following security gates Users without the security code will only be able to use the features indicated in parentheses Lock out all access read main screen only Lock out program features only calibration is allowed Lock out configuration features only calibration alarm setpoint and rerange output setpoints 4 and 20 mA values are allowed For convenience the level 3 security code will be accepted at levels 1 2 and the level 2 security code will be accepted at level 1 Beginning from the main menu move the cursor down to Program and press Enter F4 From the program menu move the cursor down using the arrow key 1 to highlight Configure and press Enter F4 Use the arrow key again to highlight Security as shown on the left and press Enter F4 Menu Item 1 Lock all Options 000 999 000 999 000 999 2 Lock program 3 Lock configuration The values now being used by the controller are displayed To change any of these items use the arrow key to highlight the desired item and press Edit F4 Use the arrow keys to make the change and press Save to enter the change into memory NOTES ON SECURITY a Acode of 000 disables security for that level b The security feature will not activate until the keypad has not been pressed f
43. D RTD GRAY REF BLACK mm WHITE GRAY DIGN o WHITE BLACK DIGN 4 WHITE RED RTD SENSE BLUE SOLUTION GROUND PREAMP LOCATION JUMPER MUST BE SET TO THE SENSOR OR J BOX SIDE GREEN 5 1432 OMMON gt 20 COMMON 4 ION IN Ox NO CONNECT INNER DRAIN RTD SHIELD RED RTD IN J BRAID GUARD o GRAY RE BRAID GUARD WHITE RETURN HITE RED SENSE W r DRANGE mV 4 BLUE SOLUTION GROUND o E NO CONNECTION NO CONNECTION PREAMP LOCATION JUMPER MUST BE SET TO THE ANALYZER SIDE 10 FIGURE 3 3 Sensor Wiring Diagram MODEL 54 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 junc tion box or the eleven terminals in the con troller Separate the two coaxial cables and pre pare each as follows 2a Strip back the insulating black sheath about ane a SS 1 in 2b Separate the braid from the inner black conductive sheath BLACK COAX CABLES SEE PREP BELOW 2c Solder an insulated wire to the braid 2d Strip the black conductive sheath 1 in to FIGURE 3 4 Cable Dressing expose the colored oran
44. E CONFIGURATION 5 4 TESTING OUTPUTS AND ALARMS m Alarm setpoints Output setpoints Simulated tests A Exit BUGA Test output 1 Test output 2 Test alarm 1 Y Exit Enter 4 Test alarm 2 Test alarm 3 Test alarm 4 M Exit Test output 1 10 00 mA Simulating outputt U Exit Edit 2 NN Test output 1 10 00 mA Esc Test J This section describes how the current outputs and alarm relays can be manually set for the purposes of checking devices such as valves pumps or recorders 1 3a From the main menu move the cursor down to Program and press Enter F4 On this display move the cursor to Simulated tests and press Enter F4 At this point there are six separate screens for testing each of the current outputs and each of the alarm relays Highlight the desired item by pressing the arrow keys as needed When the desired item is highlighted press Enter to continue Go to step 3a for outputs and 3b for alarms NOTE A cautionary message will appear to warn that the out put or alarm that was selected will be changed by the fol lowing action Be sure to alert plant personnel that these changes are simulated and do not represent a change in the actual process Press Enter to contin ue or Abort to cancel the simulation The output is now being simulated In the example
45. FF The instrument s current outputs may be calibrated trimmed if neces sary If either the power board or the CPU board is replaced the outputs must be calibrated To perform this procedure a calibrated meter must be connected to the output being calibrated To perform an output calibration from the main display press any key to obtain the main menu With the cursor on calibrate press Enter F4 With the cursor on Output trim press Enter F4 again Select Trim out put 1 or Trim output 2 as appropriate Press Edit F4 to select Cal point 1 4 mA expected and simulated or Cal point 2 20 mA expected and simulated Adjust the Meter value to match the reading of the calibrated meter connected to the output Press Enter F4 to complete the calibration 21 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION SECTION 5 0 SOFTWARE CONFIGURATION This section contains the following An introduction to using the configuration process AList of Settings for the controller e Step by step instructions and explanations for each parameter on the List INTRODUCTION TO CONFIGURATION The controller arrives from the factory configured and ready to operate as a pH controller Refer to Appendix A for ORP meas urements Figure 5 1 is an outline of the menu structure Before attempting any changes refer to the parameter setup list shown in Table 5 1 This table presents a brief description and the possib
46. Glass imp hi 1000 MO Glass imp lo 20 MO Exit Edit J Ref imp hi 140 Zero offset 60 m Cal warn 090 Exit Zero offset 60 mV Cal warn 0 Imped comp On Exit Edit j Edit p 42 SN This section describes the options available for configuration of the on line sensor diagnostics The controller checks the integrity of the glass electrode for pH only and the reference electrode by continuously meas uring the impedance of each The original controller configuration is with diagnostic messages turned off To enable this feature see below 1 Beginning from the main menu move the cursor down to Program and press Enter F4 From the program menu move the cursor down using the arrow key to highlight Configure and press Enter F4 Use the arrow key again to highlight Diagnostics as shown on the left and press Enter F4 2 Menu Item Option On Off 1 2000 0 disables 1 900 MO 0 disables 1 140 0 disables 1 999 mV 0 disables 1 500 0 disables On Off Related Fault Messages Diagnostics Glass impedance high setpoint Aged glass warning Glass impedance low setpoint Cracked glass failure Reference impedance high setpoint High reference imped Zero offset Zero offset err Calibration recommended Calibration warning Imped comp The values
47. H 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 19 MODEL 54 SECTION 4 0 CALIBRATION 4 5 TEMPERATURE COMPENSATION OPTIONS Adjust temperature Temp compensation pH slope Exit Enter 4 7 Temp comp Auto 025 0 C Exit Enter 9 Automatic Temperature Compensation is standard option for pH equip ment and is used in virtually all pH measurement situations If compen sation is not desired the temperature signal from the sensor can be ignored by placing the controller in the manual temperature compensa tion 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 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 hig
48. 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 cal ibration 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 calibra tion Press Abort F1 to cancel the calibration if it appears to be taking to
49. Instruction Manual 51 54epH rev G February 2006 Model 54e pH ORP pH ORP HART Analyzer Controller MODEL 54e A ROSEMOUNT Analytical SC EMERSON Process Management ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING Rosemount Analytical designs manufactures and tests its products to meet many national and international stan dards Because these instruments are sophisticated techni cal 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 and supplied with the product Inform and educate your personnel in the proper installa tion operation and maint
50. LRV 100 On g URV 100 Off h Relay Fault Continued on the following page SECTION 5 0 SOFTWARE CONFIGURATION TABLE 5 1 pH Settings List continued RANGES FACTORY SETTINGS USER SETTINGS 2 to 16 pH or 15 to 130 C 7 pH 0 299 9 100 0 0 2999 0 sec 0 299 9 0 0 2 to 16 pH or 15 to 130 C 2 pH 2 to 16 pH or 15 to 130 C 0 pH Process Temp Glass Imp Ref Imp Temperature Normal PID Normal 4 20 mA 0 20 mA 4 20 mA 0 255 Sec 0 Sec Last value Fixed value Last value 0 22 mA 21 mA 0 22 mA 22 mA 2 to 16 pH or 15 to 130 C 7 pH 0 299 9 100 0 0 2999 sec 0 sec 0 299 9 0 0 2 to 16 pH or 15 to 130 C 2 pH 2 to 16 pH or 15 to 130 C 0 pH Disable Enable 20 min timeout Disable feature Process Temp Process Normal TPC Normal Low alarm High alarm Off Low 0 5 00 pH 0 01 pH 0 99 sec 0 sec Open Closed None None 2 to 16 pH or 15 to 130 C 7 pH 0 299 9 100 0 0 2999 sec 0 sec 0 299 9 0 0 10 2999 sec 30 sec 2 to 16 pH or 15 to 130 C 2 pH 2 to 16 pH or 15 to 130 C 0 pH None Open Closed None Process Temp Process Normal TPC Normal Low alarm High alarm Off High 0 5 00 pH 0 01 pH 0 99 sec 0 sec Open Closed None None 2 to 16 pH or 15 to 130 C 7 pH 0 299 9 100 0 0 2999 0 sec 0 299 9 0 0 10 2999 30 sec 2 to 16 pH or 15 to 130 C 2 pH 2 to 16 pH or 15 to 130 C 0 pH None Open Closed None 23 MODEL 54 TABLE 5 1 pH Settings List c
51. ORE HELP REFER TO Temp Comp Troubleshooting Procedure Section 8 2 Procedure with expected RTD value resistances at temperature values Glass electrode cracked Replace glass electrode Coated glass electrode Clean glass electrode Grab sample incorrect Reevaluate sample technique and equipment Unclear which is correct Retest with new buffer solution Controller out of calibration Recalibrate per Calibration See Section 3 0 Calibration Section 4 0 Calibration Section 4 0 Calibration Section 4 0 381 Sensor Reference depleted Replace reference electrolyte as instructed in 381 manual Defective preamplifier Check preamplifier as instructed in Section 8 0 Preamp Troubleshooting Procedure and replace preamplifier if defective Electrode not in process solution Make sure sensor is in solution Wiring Section 3 0 Open circuit within glass electrode Replace glass electrode 381 Sensor Plugged reference Replace reference junction Recharge reference solution Table 8 3 is continued on the following page 67 MODEL 54 SECTION 8 0 TROUBLESHOOTING TABLE 8 3 Troubleshooting Guide continued PROBLEM OR CONDITION Display reads between 3 and 6 pH regardless of actual pH solution or sample cracked glass failure Sluggish or slow display indica tion for real changes in pH level Inability to change parameters in the c
52. SE ORDER NO NO PROCEED WITH REPAIRS INVOICE AGAINST P O NO NO CONTACT WITH ESTIMATE OF REPAIR CHARGES LETTER PHONE gt 0 I PUMI NAME ADDRESS RETURN AUTHORITY FOR CREDIT ADJUSTMENT Please check appropriate box s WRONG PART RECEIVED REPLACEMENT RECEIVED DUPLICATE SHIPMENT REFERENCE ROSEMOUNT ANALYTICAL SALES ORDER NO RETURN FOR CREDIT RETURN AUTHORIZED BY WARRANTY DEFECT 24 6047 Emerson Process Management Rosemount Analytical Inc 2400 Barranca Parkway Irvine CA 92606 USA Tel 949 757 8500 lt gt 949 474 7250 7 http www raihome com E M E RSO N eme Rosemount Analytical Inc 2001 Pre WARRANTY Seller warrants that the firmware will execute the programming instructions provided by Seller and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expira tion of the applicable warranty period Goods are warranted for twelve 12 months from the date of initial installation or eighteen 18 months from the date of shipment by Seller whichever period expires first Consumables such as glass electrodes membranes liquid junctions electrolyte o rings catalytic beads etc and Services are warranted for a period of 90 days from the date of shipment or provision Products purchased by Seller from a
53. V ORP Redox None Close Open Menu Item Set point Proportional Integral Derivative Time period URV LRV Relay Default These parameters are available for alarms that have been config ured as TPC alarms in step 3 Parameters can be adjusted using the same technique as in step 4a by highlighting the desired item and pressing the Edit key Once Edit has been pressed change the item as needed and then press Save to store the value Setpoint is usually the desired value at which the process is being controlled typically the alarm will not be on very much when the process is at this value This setpoint is also accessible in the Program Menu under Alarm Setpoints see Section 5 2 Proportional is short for Proportional Band and indicates the range over which control is being used It is the opposite of the process gain Smaller values provide tighter control Integral is the number of seconds over which deviations from the setpoint are integrated to remove continuing offsets Smaller values provide higher response Derivative is a form of control that resists all changes in readings Higher readings increase the derivative function Use caution in set ting the derivative value to prevent process oscillation Time period is the cycle time for the TPC control One cycle con sists of an energized relay on time and an deenergized relay off time The relative amounts of on time and off time depends on the reading and
54. V and LRV values the relay will be en ergized for some portion of the time period As the pH SECTION 6 0 THEORY OF OPERATION Pump on time asa of Time Period 100 10096 On pH em Time Period 100 On one On and Off cycle pH Value Where Pump is ON 100 of Period pH Value Where Pump is OFF 10096 of Period 096 On FIGURE 6 1 Time Proportional Control value approaches the setpoint the pump will be feed ing for shorter and shorter intervals and the chemicals will be allowed to mix for longer and longer intervals of the period This relationship is illustrated in Figure 6 1 The exact amount of on time and off time per period is determined by the settings for proportional integral and derivative bands The proportional band P in is a separate adjustment that narrows or widens the range of the TPC 0 100 action Smaller values are used for more control response For a setpoint of 7 pH a URV of 2 pH and 100 a pH reading of 8 would result in a relay on 8 7 2 0 100 or 50 of the time If P was changed to 50 the same relay would on 8 7 2 0 50 or 100 of the time The integral band is set in seconds and acts to increase the controller output as more time is spent away from the setpoint A smaller value in seconds will result in faster integration response Too low a value will result in excess oscillation The derivative band is set in and acts to prevent changes in
55. VP Retractable pH Model 399 Disposable pH Model Hx338 Steam Sterilizable pH Model Hx348 Steam Sterilizable pH SECTION 1 0 DESCRIPTION AND SPECIFICATIONS 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 con vention Reduction Oxidation Redox Although tem perature 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 ele
56. an be pro grammed for PID control PID control is used with a control device which is capable of varying its output from 0 to 100 percent in response to a changing sig nal in milliamps Automated control valves or vari able volume pumps are commonly used These types of devices are referred to as modulating con trol devices because of their O to 100 adjustability PID control is typically used where greater accuracy than is achievable with an on off device is required or where it is desirable to have the pump or valve on continuously or where the existing or preferred pump or valve is of the modulating type Any process control system must manually or auto matically hold the controlled variable pH conductiv ity temperature in a steady condition at selected set point values For manual control the operator looks at the value of the process variable decides whether or not it is correct and makes necessary adjustments He decides the amount direction rate of change and duration of the adjustment With auto matic control the controller does all of this The operator only adjusts the set point of the controller to the selected value of the measured variable Automatic process control such as PID is usually feedback control it eliminates the deviation between measurement and set point based on continuous updates feedback from the process itself 50 SECTION 6 0 THEORY OF OPERATION Measurement and Set Point Feedback Con
57. 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 0 14 pH The current output may be calibrated to repre sent any 1 to 14 pH span A two point calibration is made by immersing the sen sor in two different buffer solutions and entering the pH values When two buffers are used the micro processor 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 accom plished 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 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
58. ant 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 bot tom of the instrument housing which accept 1 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 discon necting 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 cur rent National and Local Electrical Codes in effect for the ins
59. asurement Control Mode Exit Enter Output Process Exit Edit 2 This section describes the options available for configuration of the out puts Each output can be configured to represent pH or ORP Redox see Appendix A temperature glass impedance or reference impedance In addition each output can be linear normal or nonlinear PID Several options for both modes of outputs can be configured This section describes the features and shows how to make modifications in the set tings 1 Beginning from the main menu move the cursor down to Program and press Enter F4 From the program menu move the cursor down using the arrow key 1 to highlight Configure and press Enter F4 Use the arrow key again to highlight Outputs as shown on the left and press Enter F4 There are 5 menu headers that relate to outputs Each output has a control header and a setup header In addition the hold feature is turned on here The hold feature is mostly used to prevent upsets dur ing buffer calibration of the pH sensor To access each header highlight the desired item and press the Enter key To select another header use the arrow keys The bottom menu header will only be highlighted if the end of the menu has been reached NOTE Always configure the control parameters BEFORE mak ing changes in the output setup Changes in the output setup in step 4 will depend on the options that h
60. ave been selected in step 3 Menu Item Options Output Measurement Process Temperature Ref Impedance Glass Impedance Control Mode Normal PID Each output can be configured with the options above The default options are that output 1 is Process pH or ORP Redox output 2 is Temperature and that both outputs are Normal not PID This is the most common configuration and may not require changes If no changes are desired skip to step 4 To make changes in these parameters highlight the desired menu header and press Enter F4 The value now being used is displayed and the F4 key can be pressed to Edit the item Once Edit has been pressed change the item as needed and then press Save to store the value Repeat for the other output and or items as needed 33 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 6 CHANGING OUTPUT PARAMETERS continued Output Setup Parameters for Normal Outputs Range 4 20 mA Dampen 0 sec Hold Last Value Exit Edit Hold Last Value Fixed Hold 21 00 mA Fault 22 00 mA S Exit Edit Output Setup Parameters for PID Outputs only Simm 7 00 pH Proportional 100 0 Integral 0 sec Exit Derivative 0 090 Range 4 20 mA Hold Last Value Exit Edit 34 4a 4b Menu Item Options 4 20mA 0 20mA 0 299 sec Last value fixed value Fixed H
61. c trodes Consult the factory for available measure ments and ranges MODEL 54 SECTION 1 0 DESCRIPTION AND SPECIFICATIONS 1 4 ORDERING INFORMATION The Model 54 Microprocessor Analyzer is housed a rugged 4X 65 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 MODEL 54e pH ORP MICROPROCESSOR ANALYZER OPTIONS 115 230 VAC 50 60 Hz Power 24 VDC Power OPTIONS HART Communications Protocol Controller Outputs PID and TPC 54e pH ORP EXAMPLE 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 MODEL 54 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 respon sible plant electrician 2 1 LOCATING THE CONTROLLER Position the Model 54e pH ORP controller to minimize the e
62. cess 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 con troller 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 com pensation highlight the Temp compensation menu item and press Enter F4 For more details see Section 4 5 Press Edit F4 with this display shown to adjust the temperature The screen below will then appear Using the arrow keys input the cor rect 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 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 th
63. cognition and stabilization 2 Menu Item Options Autocal Standard DIN 19267 Manual Stabilize pH 0 01 0 50 pH Stabilize time The values now being used by the controller are displayed To change any of these items use the arrow key to highlight the desired item and press Edit F4 Use the arrow keys to make the change and press Save F4 to enter the change into memory The pH reading must not change by more than the stabilize pH value over the stabilize time to be considered stable Using a smaller pH value and a larger time provides the best protection against calibration while the reading is still changing 43 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 9 AUTO CALIBRATION SETUP continued TABLE 5 2 Standard Buffers Buffer Value 25 Standards Referenced Buffer Composition Factory Configured 1 68 NIST DIN 19266 JIS 8802 0 05M K tetroxalate 3 56 NIST BSM KH tartrate sat d 25 C 3 78 NIST 0 05M KH citrate 4 01 NIST DIN 19266 BSM JIS 8802 0 05 KH Phthalate 4 64 BSM 0 1M HOAc 01M NaOAc 6 86 NIST DIN 19266 BSM JIS 8802 0 025M KH2PO4 0 025M 2 7 00 0 05M 0 05M 7 41 NIST JIS 8802 0 0087M 2 0 0302 KH2HPO4 9 18 NIST DIN 19266 BSM JIS 8802 0 01M Na2B40 10 01 NIST BSM JIS 8802 0 025M NaHCO3 0 025M Na3CO3 12 45 NIST DIN 19266 25 C 44 MODEL 54 pH ORP SECTION 6 0 THEORY OF OPERATION SE
64. d off control based on an alarm setpoint To prevent nuisance alarms a hysteresis deadband setting and or a time delay can be pro grammed during configuration You can configure each alarm to trigger above the setpoint as a high alarm or below the setpoint as a low alarm The operator need only raise or lower the alarm setpoint as necessary 48 SECTION 6 0 THEORY OF OPERATION 6 7 ANALOG OUTPUTS The Model 54e pH ORP controller includes a second analog output An analog output produces an electri cal current signal which varies in linear proportion to a value measured by the controller You can configure the controller to produce a 4 20 mA or 0 20 mA cur rent output proportional to pH or temperature See Section 5 6 for programming details The analog output must be scaled so that 4 or 0 mA corresponds to the low end of the scale and 20 mA cor responds to the high end The operator can scale the output as in the following example The Model 54e pH ORP is connected to a strip chart recorder with a O to 10096 scale The average value of the bath is 10 0 pH plus or minus 0 5 pH The opera tor wants to match this value with the 5096 mark on the recorder To do so the operator selects 9 5 pH as the 4 mA value and 10 5 pH as the 20 mA value by enter ing them as in Section 5 3 The chart on the recorder will display 0 when the is 9 5 or below and 100 when the pH equals 10 5 or greater this is for a 4 20 mA recorder
65. deviation from setpoint that will result in a 20 mA setpoint Highlight the desired item and press Edit and the arrow keys to change the display to the new value Example A setpoint of 6 pH with a URV of 2 and a LRV of 0 0 pH When the pH is 7 the output will be 7 6 2 0 5096 of range 12 If the setpoint is changed to 6 5 pH the output will be 7 6 5 2 0 25 of range 8 mA Press Save F4 to enter into memory or Esc F3 to abort the change The Control setpoint is typically the condition where the current output is ata minimum The P and control calculations use the setpoint to adjust the current output to the desired level based on the parameters estab lished in Section 5 6 27 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 3 CHANGING OUTPUT SETPOINTS NORMAL ONLY Alarm setpoints Output setpoints Simulated test Exit Enter Output 1 Output 2 S op Exit Enter CAUTION Current Output 1 will be affected V Exit Enter p 4 mA 0 00 pH 20 mA 14 00 pH Output 1 12 00 mA Exit Enter i Ge 4 mA 00 00 20 14 00 pH Output 1 12 00 mA Esc Save 28 This section describes how the 4 or 0 to 20 mA current outputs can be reranged Note that the current outputs can be configured to represent pH temperature glass im
66. e Uziemij przewod do metaiowego plaskownika lub obudowy Aby zachowac stopien szczelnosci obudowy stosuj niepaine wodoszczelne diawiki gravi lesioni o morte ATTENZIONE Per garantire continua protezione contro gli incendi sostituire solo con fusibili del voltaggio indicato e dell attuale potenza I fusibili sono alloggiati sotto il coperchio W celu utrzymania zabezpieczenia przed zapaleniem nalezy stosowac bezpieczniki o identycznym z oryginalnym napieciu i amperazu Bezpieczniki sa umieszczone pod ta pokrywa PERIGO POSSIBILIDADE DE TENSAO PERIGOSA remo o do fusivel ou desta tampa pode causar les es graves ou a morte IAKTTAG pin RSIK Anslutningspunkt ar jordad till chassi Anvand brands ker vattentat kabalanslutning 18 att bevara klassificering av apparatsk p HOGSPANNING KAN FOREKOMMA Avl gsnande av sakring eller skyddsk pa kan f rorsaka allvarlig skada eller d dsfall IAKTTAG F RSIKTIGHET Para manter sempre uma boa prote o contra inc ndio substituir somente fusiveis com a tens o e corrente especificadas Os fusiveis encontram se sob esta tampa For kontinuerligt skydd mot brandfara ers tt endast med specificerad s kringsstorlek och spanning MODEL 54 TABLE CONTENTS MODEL 54E PH ORP MICROPROCESSOR ANALYZER TABLE OF CONTENTS Section Title Page 1 0 DESCRIPTION AND SPECIFICATIONS
67. e Compensation TROUBLESHOOTING 11 nennen nnns Displaying Diagnostic Variables Troubleshooting Guidelines Replacement RETURN OF 5 2 2 22 Title ORP LIST TABLES Table No Title 5 1 pH Settings nde Kahandaan aa 5 2 Standard Buffers aa a AA 6 1 Controller Mode Priority 8 1 Diagnostic Messages 8 2 Quick Troubleshooting Guide 8 3 Troubleshooting Guide A 1 ORP Settings TABLE OF CONTENTS EN 54 54 NUES 55 Weiden 56 AA AA 58 YT 61 MEIN S 63 PCM 69 PEE 70 MODEL 54 Figure 1 1 2 1 2 2 2 3 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 5 1 5 2 6 1 6 2 8 1 8 2 8 3 1 TABLE CONTENTS TABLE OF CONTENTS CONTINUED LIST OF FIGURES Title Page Main Display 1 Wall MOUNTING TEE 5 Pipe Motirnitirig 5 Bn Et Ute itti ada 6 Panel MOUNTING aan bug 6 Power Input and Relay Output Wiring for Model 54e pH ORP 8 Sensor Wir
68. e Note for step 2 to turn the Hold Mode Off and then press Exit F1 15 MODEL 54 SECTION 4 0 CALIBRATION 4 2 AUTOMATIC TWO POINT CALIBRATION Standardize pH Adjust temperature Exit Enter m Hold Mode Off Exit Cont Edit 2 gt Ce n 4 2 pH Autocal buffer 1 NG Abort Cont E 64 4 02 pH Buffer 1 Wait M Abort Cont J 16 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 elec trode 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 contamina tion 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
69. e dis play to the desired setpoint and press Save F4 to enter into mem ory The plus sign can be changed to a minus sign by pressing the down arrow key To abort the change press Esc F3 to return to the previous menu MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 2 CHANGING OUTPUT SETPOINTS PID ONLY e Alarm setpoints Output setpoints Simulate tests A Exit Enter a Output 1 setpoints Output 2 setpoints Setpoint 7 00 pH 4mA 0 00 pH 20mA 2 00 pH Setpoint 06 90 pH Exit Enter 4 Exit SUD L Exit S This section describes how the two output setpoints can be changed This selection is only active if the current output control mode has been set to PID see Section 5 6 If the control mode is set to normal then Not applicable will be displayed For reranging outputs go to Section 5 3 1 From the main display press any key to obtain the main menu With the down arrow key move the cursor to Program and press Enter F4 With the cursor on Output setpoints as on the left press Enter F4 Highlight the desired Output setpoints and press Enter F4 The setpoint now being used is displayed Press Edit F4 and use the arrow keys to change the display to the new value 4 mA is the deviation from setpoint that will result in a 4 mA out 20 is the
70. e material Adherence to these procedures will expedite handling of the returned material and will prevent unnecessary additional charges for inspection and testing to determine the problem with the device If the material is returned for out of warranty repairs a purchase order for repairs should be enclosed The right people the right answers b d right now ROSEMOUNT ANALYTICAL CUSTOMER SUPPORT CENTER 1 800 854 8257 Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine 92606 USA Tel 949 757 8500 Fax 949 474 7250 http www raihome com Rosemount Analytical Inc 2006 ON LINE ORDERING NOW AVAILABLE ON OUR WEB SITE gMENT sy ROUTE PX D er http www raihome com Specifications subject to change without notice Credit Cards for U S Purchases Only a VISA ERE renge 4 4 a 4 EMERSON Process Management
71. e range of pH will dic tate 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 instru ment 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 proce dure 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 pro cedure 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 calibra tion 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 p
72. ed see Section 5 4 Simulating Alarm 1 2 3 or 4 Feed limit alarm 1 2 0r3 limit alarm 1 2 Feed limit alarm 1 2 0r3 3 Indicated alarm has been on for longer than its limit and has been turned off alarm has been on for Indicated alarm has been on for longer than its limit and has been turned off than it s limit and has been turned off Off line error messages will not initiate fault condition and will display only once The message will clear from the screen when a key is pressed 59 MODEL 54 SECTION 8 0 TROUBLESHOOTING TABLE 8 2 Quick Troubleshooting Guide SYMPTOM ACTION pH reading won t change in different buffers Clean the electrode check wiring Replace electrode Cracked glass failure 1 Replace electrode if cracked 2 Check wiring for short pH sensor has sluggish response Clean the electrode if still sluggish soak in 1 HCI for 1 hr Replace electrode if not rejuvenated by the soak Old glass warning Check sensor in buffers replace if calibration unsuccessful Lo or Hi slope error 1 Verify internal preamp switch is in the appropriate position 2 Improper buffer calibration check buffer accuracy wait for reading to stabilize 3 Clean the electrode if fault persists replace electrode 4 If new electrode doesn t resolve the fault replace preamp Calibration warning Check sensor in buffers replace if calibration unsuccessful Wait flashing contin
73. eller Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original warranty peri od or ninety 90 days whichever is longer This limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an authorized representative of Seller Except as otherwise expressly provided in the Agreement THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESS OR IMPLIED AS TO MERCHANTABILITY FIT NESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES RETURN OF MATERIAL Material returned for repair whether in or out of warranty should be shipped prepaid to Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine CA 92606 The shipping container should be marked Return for Repair Model The returned material should be accompanied by a letter of transmittal which should include the following information make a copy of the Return of Materials Request found on the last page of the Manual and provide the following thereon Location type of service and length of time of service of the device Description of the faulty operation of the device and the circumstances of the failure Name and telephone number of the person to contact if there are questions about the returned material Statement as to whether warranty or non warranty service is requested Complete shipping instructions for return of th
74. enance 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 prod uct When replacement parts are required ensure that quali fied people use replacement parts specified by Rosemount Unauthorized parts and procedures can affect the product s performance and place the safe oper ation 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 protec tive covers are in place except when maintenance is being performed by qualified persons to prevent electri cal 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 no
75. es now being used by the controller are displayed To change any of these items use the arrow key to highlight the desired item and press Edit F4 Use the arrow keys to make the change and press Save F4 to enter the change into memory WARNING Changing the measurement selection from pH to ORP or ORP to pH will reset all controller settings to factory values Press Abort F1 to cancel the change Press Cont F3 to change the measurement Refer to Appendix A for more about ORP measurements Menu Item Options Output 1 units Output 2 units Language English Frangais Espanol Deutsch ltaliano Press the arrow key three times to access this screen The current out puts can be displayed as milliamps or as percent of full scale The default is MA To change any of these items use the arrow key to highlight the desired item and press Edit F4 Use the arrow keys to make the change and press Save F4 to enter the change into memory Further menu items are available by pressing the arrow key repeatedly When the display is highlighting the item on the third line the end of the menu has been reached To back up within the menu use the up arrow key 31 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 5 CHOOSING DISPLAY OPTIONS CONTINUED Display Display right 12 Display contrast 5 ES Lower Left of Main Display Exit Edit Display left Display right
76. ess is being controlled typically the output will be 4 or 0 mA when the parameter is near the setpoint This setting can also be changed using the pro cedure in Section 5 1 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 6 CHANGING OUTPUT PARAMETERS continued ele e e o gt Fixed Hold 21 00mA Fault 22 00mA Hold Feature Setup 2 Output 2 control Output 2 setup Hold feature setup Exit Enter Hold Disable feature Exit Edit 4 E A Exit SES Um Hold mode Off Exit zu Proportional is short for Proportional Band and indicates the range over which control is being used It is the opposite of the process gain Smaller values provide tighter control Integral is the number of seconds over which deviations from the set point are integrated to remove continuing offsets Smaller values provide higher response Derivative is a form of control that resists all changes in readings Higher readings increase the derivative function Use caution in setting the derivative value to prevent process oscillation More information regarding PID control can be found in Section 7 0 Setting these parameters may require some trial and error and should be tested while the process is being supervised to prevent future upsets The rest of the PID output setup parameters are identical to those used for no
77. etpoints press Enter F4 Select the desired alarm by moving the cursor down to highlight it When the correct alarm is highlighted press Enter F4 to get to the adjustment screen In this example we have pressed the arrow key down once to access the alarm 2 setpoint NOTE There are 2 different possible screens at the next point depend ing on whether the alarm has been configured as normal or TPC normal alarm The setpoint now being used for this alarm and the kind of alarm high or low are displayed If the alarm has been turned off then off will be displayed instead of High The Enter key has now changed to the Edit key and will allow changing the setpoint once the F4 key has been pressed If the setpoint is ok then press Exit F1 After the Edit F4 key is pressed use the arrow keys to change the display to the desired setpoint and press Save F4 to enter into memory The plus sign can be changed to a minus sign by press ing the down arrow key when the is highlighted To abort the change press Esc F3 to return to the previous menu TPC alarm only When the alarm has been configured as TPC the setpoint is used for the TPC calculation of how long the alarm should stay on The Enter key has now changed to the Edit key and will allow changing the setpoint once the F4 key has been pressed If the setpoint is ok then press Exit F1 After the F4 key is pressed use the arrow keys to change th
78. eys are multifunction The active opera tion 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 will access sub menus while pressing Edit allows changing values and Save stores the values in memory Esc can be used to abort unwanted changes Exit returns to the previous screen Other labels may appear for more specialized tasks The up and down 1 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 numer ical 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 activa
79. f a pH sen sor changes with temperature which in turn changes the measured pH value The Sensor Isopotential pH Sensor ISO is the pH where the pH sensor s output does not change with temperature The Controller uses the Sensor Isopotential pH value to correct for the temperature effect on the pH sensor Except in rare instances antimony or glass on metal elec trode systems the Sensor Isopotential pH is always 7 0 pH Solution Temperature Compensation The actual pH of a solution can sometimes noticeably change with temperature This can occur in solu tions with a pH above 6 5 pH and in solutions containing weak acids bases and their salts This effect can be compensated for by entering a Temperature Coefficient Temperature Coeff which is the change in solu tion pH per degree centigrade C If there is no noticeable solution pH change with temperature or solution temperature compensation is not desired the Temperature Coefficient Temperature Coeff should be set to 0 00 Operating Isopotential pH The Operating Isopotential pH Operate ISO is the Isopotential pH which the Controller is using for overall tem perature compensation It represents a combination of both the sensor and the solution temperature compensations If no solution temperature compensation is being used Temperature Coeff 0 the Operating Isopotential pH Operate ISO is equal to the Sensor Isopotential pH Sensor ISO If there is a non zero Temperat
80. ffects 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 im mediately 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 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 FIGURE 2 1 Wall Mounting 2 3 3 Pipe Mounting 1 Attach the mounting bracket to t
81. for fault conditions that would cause an error in the meas ured pH reading If such a condition occurs the current outputs and alarm relays will act as configured in Section 5 6 and Section 5 7 the red FAIL LED on the controller panel will be lit and a diagnostic message will be displayed If more than one fault exists the display will sequence through the diagnostic messages This will continue until the cause of the fault has been cor rected or until the Ack key is pressed Troubleshooting is easy as 1 2 3 Step 1 Look for a diagnostic fault message on the dis play to help pinpoint the problem Refer to Table 8 1 for an explanation of the message and a list of the possible problems that trig gered it Step 2 Refer to the Quick Troubleshooting Guide Table 8 2 for common pH hardware problems and the recommended actions to resolve them Step 3 Follow the step by step troubleshooting approach offered in Table 8 3 to diagnose less common or more complex problems CAUTION Do not attempt to troubleshoot unless you have familiarized yourself with this manual Only trained qualified techni cians should perform these procedures Do not attempt to troubleshoot repair or modify the printed circuit cards or elec tronic components inside the controller IMPORTANT Always recalibrate the controller before returning it to service 58 Many control problems are unrelated to the pH meas urement system When problems
82. fter the numerical portion of the number has been entered by highlighting the and press ing the down arrow key Before exiting the calibration mode remember to change the hold mode setting to OFF if it was turned on in step 3 75 RETURN OF MATERIALS REQUEST IMPORTANT This form must be completed to ensure expedient factory service RETURN BILL TO amso4doco CUSTOMER USER MUST SUBMIT MATERIAL SAFETY SHEET MSDS OR COMPLETE STREAM COMPOSITION AND OR LETTER CERTIFYING THE MATERIALS HAVE BEEN DISINFECTED AND OR DETOXIFIED WHEN RETURNING ANY PROD UCT SAMPLE OR MATERIAL THAT HAVE BEEN EXPOSED TO OR USED IN AN ENVIRONMENT OR PROCESS THAT CON TAINS A HAZARDOUS MATERIAL ANY OF THE ABOVE THAT IS SUBMITTED TO ROSEMOUNT ANALYTICAL WITHOUT THE MSDS WILL BE RETURNED TO SENDER C O D FOR THE SAFETY AND HEALTH OF OUR EMPLOYEES WE THANK YOU IN ADVANCE FOR COMPLIANCE TO THIS SUBJECT mo 4oz amozmo SENSOR OR CIRCUIT BOARD ONLY Please reference where from in MODEL SER NO Column 1 PART NO 1 MODEL PART NO 2 MODEL PART NO 3 MODEL PART NO 4 MODEL PLEASE CHECK ONE REPAIR AND CALIBRATE DEMO EQUIPMENT NO EVALUATION OTHER EXPLAIN REPLACEMENT REQUIRED DESCRIPTION OF MALFUNCTION 2 3 4 R E 5 N F R R E T U R N WARRANTY REPAIR REQUESTED YES REFERENCE ORIGINAL ROSEMOUNT ANALYTICAL ORDER NO CUSTOMER PURCHA
83. ge or gray cable inside 2e Insulate the exposed black sheath and braid area to prevent shorts 3 Strip 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 SENSOR WIRING 182 XM SENSOR CABLE d SENSOR CABLE PREAMP IN SENSOR OR J BOX PREAMP IN ANALYZER TB2 C NO CONNECTION INNER INSTR 5 INNER INSTR SHLD ppa IN SHIELD RETURN WHITE 5 5 4 I WHITE RED kl IN RED dis BRAID Se NOTE PREAMP LOCATION SWITCH NOTE PREAMP LOCATION SWITCH MUST BE SET TO THE MUST BE SET TO THE SENSOR OR J BOX SIDE ANALYZER SIDE INSIDE FRONT PANEL VIEW FIGURE 3 5 Wiring for Sensors that have Solution Grounds Models 381 385 396P 396R 11 MODEL 54 SECTION 3 0 WIRING FIELD COAX CABLE PREP REMDVE BNC CONNECTOR THE BLACK CONDUCTIVE COATING MUST BE STRIPPED BACK FROM THE ORANGE INSULATOR TO AVOID SHORTING THE pH CONDUCTOR TO THE REF SHIELD COAX CABLE COAX CABLE COAX RED
84. he List of Settings Table and configuration procedures outlined in Section 5 0 As with all the settings in your Model 54e pH ORP the first step to configuration is obtaining a good under standing of how the feature works before determining the values of the settings to achieve the desired con trol This appendix provides more background for deciding on the appropriate settings Configuring the settings is done using the instructions in this appendix and Section 5 0 Software Configuration 7 1 PASSWORD PROTECTION Your Model 54e pH ORP can be programmed so that a 3 digit password must be entered before any changes in the configuration are allowed This protects your controller from tampering by unauthorized users There are three levels of password access Level 1 calibra tion only Level 2 lockout of Configure Menu and Level 3 total access Password privileges for each level are described below If password protection is not desirable you can config ure all security codes to be 000 This will leave the con troller unlocked so the configuration can be changed without entering a password The controller is shipped from the factory with the password set at 000 54 Level 1 3 Password Privileges Level 1 access is usually given to an operator who simply needs to calibrate during the course of normal operation A separate section of the manual contains operating procedures normally used by this type of per sonnel Level
85. he 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 MODEL 54 SECTION 2 0 INSTALLATION 2 3 4 Panel Mounting The controller is designed to fit into a 5 43 x 5 43 inch DIN standard 137 9 137 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 FIGURE 2 3 Panel Mounting MODEL 54 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 respon sible pl
86. hlighted 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 temper ature 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 tem perature specific faults are disabled 4 6 pH SLOPE ADJUSTMENT e E Temp compensation pH slope Output trim Exit Enter 2 a TEENA 59 16 LES Enter 20 The slope of glass electrode is normally calculated during buffer cali bration It can however be entered directly if known using this proce dure 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
87. i se stejnym jmenovitym napetim a proudem Pojistky jsou umisteny pod timto krytem AA PELIGRO VOLTAJE PUEDE ESTAR PRESENTE Cuando los fusibles esta cubierta son removidos causar severas lesiones o muerte La toma tierra debe hacerse a un contrafuerte de metal o a la caja met lica Utilice accesorios enchufes no inflamables y estancos al agua para preservar las especificaciones de la caja UBESKYTTET SPENDING Hvis sikringen eller denne p skrift tjernes kan dette medfore alvorlige kv stelser eller d d A FORSIGTIG ATENCION Para una proteccion continua contra el fuego reemplace solamente con fusibles de voltaje y corriente especificados Los fusibles se encuentran debajo de esta cubierta Brug kun sikringer med n rmere angivet sp nding og str mstyrke som sikkerhed for vedvarende beskyttelse mod brandfare Sikringerne er placeret under denne p skrift ATTENTION DANGER KAN ONDER SPANNING STAAN POSSIBILITE DE HAUTE TENSION Raccorder le tube la masse m tallique d une entretoise ou du coffret Utiliser des raccords et des bouchons tanches ininflammables afin de preserver la classification du boitier Der Analysator ist vorschriftsmaessig zu erden En cas de d montage de ce capot cu des fusibles Verwijderen van zekering of dit deksel kan dit Risques de Blessures graves ou de mort leiden tot ernstig of dodelijk letsel VOORZICHTIG ATTENTION Voo
88. ice 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 in side 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 cir cuit board Figure 3 3 The jumper is placed in the analyzer position when there is no preamp in the sen sor or junction box Generally this jumper is in the sensor position MODEL 54 SECTION 3 0 WIRING ENCL OSURE EARTH SNO CURRENT ae CURRENT 2 fano HIT D e 82 1 2 3 4 5 6 e elelele e e FOR 24VDC ONLY 1 2 24 GND VDC e elelelelele e e e e e 1 2 mm 5 6 7 8 9 10 1 12 115 NEUTRAL 230 ALARM 1 ALARM 2 ALARM 3 NC COM NG VAC L ALARM 4 IN DANGER LIVE VOLTAGES MAY BE PRESENT CURRENT OUTPUT 1 WILL CAUSE SEVERE INJURY OR DEATH HART SINGLE LOOP COMM MUL TEDROP OUTPUT AND POWER WIRING QUTPUT WIRING TB2 2 FOR 2
89. inals on the Model 54e pH ORP FAILING TO FOLLOW THESE INSTRUC TIONS WILL RESULT IN CONTROLLER MALFUNC TION FIGURE 3 2 Sensor Wiring Photo MODEL 54 RED RECEIVE OGREEN TRANSMIT PREAMP IN SENSOR DR J BOX PREAMP IN ANALYZER NO CONNECTION CLEAR RTD WHITE RTD RETURN WHITE RED RTD SENSE RED RTD IN cer WHITE CRAY DICN GRAY REF IN BLUE SQLUTION GROUND WHITE BLACK DIGN 7 BLACK mV IN d BROWN GREEN 5V NO CONNECTION INNER DRAIN RTD SHIELD WHITE RETURN E WHITE RED SENSE RED RTD IN BRAID GUARD GRAY REF IN j BLUE SOLUTION GROUND BRAID GUARD 7 RANGE mV IN NO CONNECTION NO CONNECTION 875751556 PREAMP LOCATION wen 4 5 6 7 8 9 10 11 12 Gate BIBIBIBIBIBIB FRONT PANEL SECTION 3 0 WIRING IN SENSOR PRE AMP ALYZER COMMON 4 gt COMMON Naw NO CONNECTION gt NOTE CLEAR RTD IN HITE RTD RETURN I RE
90. ing 2 11 2 ete tren aaa 9 Sensor Wiring 10 Cable Dressing 1 rendo eee de cove e ded adde 11 Wiring for Sensors that have Solution Grounds 11 Wiring for Sensors without Solution Grounds Directly to Analyzer 12 Wiring for Sensors without Solution Grounds to a Junction Box 12 Wiring to Model 399 4 13 Menu Tree Tm 25 Interval Timer Examples 41 Time Proportional 004000001 47 The Process Reaction 52 Theoretical pH vs Millivolt Values at 25 C 779 62 Junction Box Preamplifier 65 Controller Preamplifier 65 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 0 GO mm Dom P o Date 5 00 11 01 3 02 7 02 4 03 7 04 3 05 4 05 2 06 Notes 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 Added trip output infor amp
91. ircuit Within the reference elec trode a silver chloride element is surrounded by a con centrated potassium chloride solution The internal ele ment maintains electrical contact with the pH sensitive glass electrode through the porous liquid junction a multi capillary hardwood plug of the internal reference electrode The external wood reference junction and the gelled reference fill solution provide protection for the internal reference electrode to prevent contamination from harsh chemical environments The internal liquid junc tion can become blocked if the process contains any material that reacts with the filling solution to form a precipitate The double junction reference electrode is designed to avoid blocking of the internal liquid junc tion It is essentially a complete electrode within an electrode outer body using two liquid junctions A non reactive electrolyte potassium chloride gel is the filling solution in the outer body and only this solu tion is in contact with the process Clogging of the outer junction is minimized since neither potassium ions nor chloride ions form insoluble compounds with the majority of materials found in process streams Contamination of the inner junction is not likely with this configuration The Temperature Compensation Element In addition to the glass electrode and reference cell a third element required in the pH measurement system is the temperature compensation element Its
92. key Once Edit has been pressed change the item as needed and then press Save to store the value Alarm action determines whether alarm will activate when the reading exceeds the setpoint high alarm or when it drops below the setpoint low action It can also be turned off i e not used Hysteresis is a deadband that prevents deactivating a relay until the reading has dropped below the setpoint minus the hysteresis amount high alarm example Delay will delay activation and deactivation of the relay for a cer tain number of seconds Larger delays can reduce relay chatter Relay Default determines how the relay will act if there is a fault or hold condition Each alarm can be forced on Close off Open or can remain unchanged None The factory configuration is None 37 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 7 CHANGING ALARM PARAMETERS continued Alarm Setup Parameters for TPC Alarms Setpoint 07 00 pH Proportional 100 0 Integral 0 sec Exit Edit Derivative 0 0 Time period 30 sec URV 2 00 pH EN Enter j lt Exit URV 2 00 pH LRV 0 00 pH Relay default None Exit Enter j 38 4b Options 2 to 20 pH 1400 to 1400 mV ORP Redox 0 299 9 Yo 0 2999 sec 0 299 9 Yo 10 2999 sec 2 to 20 pH 1400 to 1400 mV ORP Redox 2 to 20 pH 1400 to 1400 m
93. laced in their default states Interval determines how often the timer sequence will run When set to 24 hours the sequence will run daily Repeats is the number of times the relay will activate during the sequence On time is the number of seconds the relay will stay closed on during each repeat Off time is the number of seconds the relay will stay open off between each repeat Recovery is a waiting period after the activation sequence that allows sensor readings to return to normal before outputs and alarm relays are taken out of the hold default states For more on the Interval Timer see Section 6 0 Theory of Operation NOTE The timer can be used for periodic chemical or mechan ical cleaning of a coated sensor If high reference imped ance is used to initiate the timer cycle the reference impedance set point in Section 5 8 is used MODEL 54 pH ORP SECTION 5 0 SOFTWARE CONFIGURATION 5 7 CHANGING ALARM PARAMETERS continued RELAY ACTIVATION Interval hr TIME 3 Sequence A One repeat per cycle Sequence B Two repeats per cycle RELAY ACTIVATION psa Le Off sec Time TIME gt 586 FIGURE 5 2 Interval Timer Examples 41 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 8 ON LINE DIAGNOSTICS SETUP ag Alarms Diagnostics Auto Calibration ES Exit Enter mmm Off
94. le options The factory setting is listed with a space for the user setting It is recommended that the list be carefully reviewed before any changes are made On initial configuration it is recommended that the parameters be entered in the order shown on the worksheet This will reduce the chance of accidentally omitting a needed parameter TABLE 5 1 pH Settings List ITEM CHOICES FACTORY SETTINGS USER SETTINGS PROGRAM LEVEL Sections 5 1 5 3 A Alarm Setpoints Section 5 2 1 Alarm 1 low action 0 14 pH 0 00 pH 2 Alarm 2 high action 0 14 pH 14 00 pH 3 Alarm 3 high action 0 14 pH 14 00 pH B Output Setpoints Section 5 1 5 3 1 Output 1 4 mA 0 14 pH 0 00 pH 2 Output 1 20 mA 0 14 pH 14 00 pH 3 Output 2 4 mA 15 130 C 0 0 C 4 Output 2 20 mA 15 130 C 100 0 CONFIGURE LEVEL Sections 5 5 5 9 A Display Section 5 5 Measurement type pH ORP Redox pH Resolution 0 01 pH 0 1 pH Temperature Units CIE Output 1 Units mA of full scale Output 2 Units mA of full scale Language English Frangais Espariol Deutsch ltaliano English Main display lower left See Section 5 5 Alarm 1 Setpoint Main display lower right See Section 5 5 Alarm 2 Setpoint Display contrast 0 9 9 darkest 5 10 Test Timeout On Off On 11 Timeout Value 1 60 min 10 min B Outputs Section 5 6 1 Output 1 Control a Output 1 Measurement Process Temp Glass Imp Ref Imp Process pH b Output
95. ment range the difference between the 20 mA Hi and 4 or 0 mA Lo setpoints which you determined when configuring the analog output In the example shown in Figure 6 2 The percent change in pH was pH2 pH1 8 2 7 2 pH pH Hi pH Lo 9 0 6 0 pH x 100 33 3 The change in the output signal was 6 4 milliamps 20 4 X 100 12 5 So the Plant Gain is C 33 3 2 66 12 5 Once calculated the proportional and inte gral bands can be determined as follows Proportional band P 286 Integral Time seconds per repeat 1 3 33 Dx C So for the example 286 2 65 254 3 33 4 sec 2 66 36 seconds enter these parameters use the procedure detailed in Section 5 6 53 MODEL 54 SECTION 7 0 SPECIAL PROCEDURES AND FEATURES SECTION 7 0 SPECIAL PROCEDURES AND FEATURES This section covers features of the Model 54e pH ORP controller that are used less frequently Use of the features outlined in the appendix is optional Special procedures and features outlined in this appendix include the following e Password Protection e Temperature Slope Calculation Temperature Sensor e Reference Temperature Controller Mode Priority PID Control Before using this section you should become familiar with the basic Theory of Operation of the controller as outlined in Section 6 0 the keypad functions in Section 1 0 and t
96. metalen profiel of naar metalen behuizing Gebruik onbrandbare waterdichte wartels pluggen om de beschermingsklasse te handhaven Kabelinnforing m jordes til metailavstiver eller til metalikapstingen Bruk fiammesikre og vanntette nipleriplugger siik at kapslingens tetthetsgrad opprettholdes Tubo di protezione per massa a terra con elemento di ingresso in metallo con custodia in metailo Utilizzare accessori connettori del tubo di protezione a tenuta stagna non infiammabili per assicurare i limiti di resistenza della custodis ligar a conducta de cabos terra atrav s de suporte ou inv lucro met licos Utilize bucins e acess rios ignifugos e estanques para preserva o da estanquecidade A CAUTION h NEBEZPECI ZARIZENI POD NAPETIM VAROVANI Zemnici vodic musi byt vodive spojen s kostrou pristroje Pouzivejte nehorlave vodotesne pruchodky abyste zachovali stupen kryti pristroje DANGER LIVE VOLTAGES MAY BE PRESENT When fuse or this cover is removed wili cause severe injury or death For continued protection against fire replace only with fuses of specificed voltage and current ratings Fuses are located under this cover Odstraneni pojistky nebo tohoto krytu muze zpusobit vazne zraneni nebo smrt CAUTION VAROVANI Poskozene pojistky nahrazujte pouze pojistkam
97. mitting a needed setting 71 MODEL 54 ITEM CHOICES TABLE 1 ORP Settings List ORP SETTINGS PROGRAM LEVEL Sections A 2 Alarm Setpoints Section A 2 Alarm 1 low action Alarm 2 high action Alarm 3 high action Output Setpoints Section A 3 Output 1 4 mA Output 1 20 mA Output 2 4 mA 4 Output 2 20 mA 1400 to 1400 mV 1400 to 1400 mV 1400 to 1400 mV 1400 to 1400 mV 1400 to 1400 mV 15 to 130 C 15 to 130 C CONFIGURE LEVEL Sections 5 5 5 9 Display Section 5 5 Measurement type Convention Temperature Units Output 1 Units Output 2 Units Language English Frangais Espafiol Deutsch Italiano Main display lower left Main display lower right Display contrast Tests Timeout Timeout Value Outputs Section 5 6 1 Output 1 Control Output 1 Measurement b Output 1 Control Mode Output 1 Setup a Current Range b Dampening c Hold Mode d Fixed Hold Value if c Fixed e Fault Value Output 2 Control Output 2 Measurement b Output 2 Control Mode Output 2 Setup a Current Range b Dampening c Hold Mode d Fixed Hold Value if c Fixed e Fault Value 5 Hold Outputs and Relays Disable Enable 20 min timeout Alarms Section 5 7 1 Alarm 1 Control Activation Method b Alarm 1 Control Mode Continued on the following page 72 pH ORP ORP Redox CIE mA of full scale mA of full scale See Section
98. mpensate the glass impedance for tempera ture changes This is especially important at temperature extremes NOTE The actual on line values of the sensor diagnostics are available on the controller under the Diagnostic Variables header in the main menu regardless of whether the messages have been turned on in this section 5 9 AUTO CALIBRATION SETUP Diagnostics Security e Exit Enter Autocal Standard Stabilize pH 0 01 pH Stabilize time 10 sec Exit Bey This section describes how the controller may be set up for auto calibra tion which includes automatic buffer recognition and auto stabilization Alternatively the controller may be configured to perform a manual cali bration without the automatic features 1 Beginning from the main menu move the cursor down to Program and press Enter F4 From the program menu move the cursor down using the arrow key to highlight Configure and press Enter F4 Use the arrow key again to highlight Auto Calibration as shown on the left and press Enter F4 NOTE There are three buffer groups that may be selected Automatic buffer recognition includes temperature curves from 0 to 60 C a Standard Includes NIST US BSM Britain JIS 8802 Japan and DIN 19266 Germany buffers See Table 5 2 for details b DIN 19267 1 09 4 65 6 79 9 23 12 75 c Manual for manual calibration disables automatic buffer re
99. n and off by the controller based on the control points or setpoints that you pro gram into the controller through the keypad See Section 5 7 Alarms to program the alarm relays The Model 54e pH ORP has two control modes for de vices which are turned off and on Time Proportional Control Mode TPC and Normal Mode TPC is gener ally used for chemical feed control Normal or on off mode is typically used to control external alarm lights or horns 6 5 TIME PROPORTIONAL CONTROL TPC MODE Code 20 In the TPC mode you must establish the following parameters which will determine how the Model 54e pH ORP responds to your system see Section 5 7 e Setpoint Time period point or 100 on LRV point or 0 on e Proportional Integral Derivative The setpoint is the desired value that you want to con trol at Time period is programmed in seconds and de fines the interval during which the controller compares the pH input from the sensor with the Setpoint In the TPC mode the controller divides the period up into pump on time feed time and pump off time blend time The URV setting determines how far the pH must devi ate from the setpoint to get the pump to be on for the entire period The LRV setting determines how close the pH must be to the setpoint for the pump to be off for the entire period The LRV setting should always be set at zero When the error the pH minus the setpoint is between the UR
100. n flammable closures to provide enclosure integrity in compliance with personal safety and environmental protection require ments Use NEMA 4X or IP65 conduit plugs sup plied with the instrument to maintain the ingress protection rating IP65 For safety and proper performance this instru ment must be connected to a properly grounded three wire power source Proper relay use and configuration is the responsibility of the user No external connec tion 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 C certification to EN50081 2 Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine CA 92606 USA Tel 949 757 8500 o Fax 949 474 7250 EMERSON http www raihome com Rosemount Analytical Inc 2006 Ground conduit to metal stiffener or to metal enclosure Use non flammable watertight conduit fittings piugs to preserve enclosure rating FORSIGTIG Brug uant ndelig vandt t forskruning som sikkerhed for bevaring af kapsiings klasse Jordforbindeise til metal kapsel VOORZICHTIG Aardieiding naar
101. now being used by the controller are displayed To change any of these items use the arrow key to highlight the desired item and press Edit F4 Use the arrow keys to make the change and press Save F4 to enter the change into memory Glass Imp hi warns of a glass electrode that may have exceeded it s useful life This warning level should be set higher than the new sensor s impedance For example for a new sensor with a glass impedance of 150 a setting of 400 be appropriate Glass Imp lo warns of a broken glass electrode This warning level should be set lower than the new sensor s impedance A good typical set ting would be 20 MQ Ref imp hi warns of a coated sensor This warning level should be set higher than the new sensor s reference impedance Sensors may have reference impedance values that vary considerably so it is a good idea to check each new sensor before setting this value Zero offset indicates how far the millivolt response of the sensor is from the ideal case It is updated after buffer calibration and standardization If a calibration results in a large enough offset the fault message will be dis played MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 8 ON LINE DIAGNOSTICS SETUP continued Cal warn compares the on line glass impedance with the value meas ured at the last buffer calibration This setting should be set to O dis abled Imped comp is used to co
102. nput value Glass Imped value Ret imped value Diagnostic Variables Zero Offset value pH Slope Version value Device 10 value Alarm Setpoints Alarm 1 2 amp 3 setpoint value value Setpoints Output 1 2 setpoints 29 mA value Output Trim Trim Output 1 2 Output 1 2 value Cal point value Meter value Expected value S E Test Output 1 Simulated Tests Test Output 2 Test Alarm 3 Test Alarm 4 Test Alarm 1 Test Alarm 2 Measure pH ORP Redox Resolution 0 1 0 01 Temp Units F C Output 1 MAN Output 2 MA Language English F rancais Espanol Deutse italiana Display Loft Display Right Display Contrast Timeout on off Timeout Value value Polling Address value Output 1 Controf Output 2 Control Alarm 1 2 amp 3 Control interval Timer Ref Impedance Glass Impedance Output Measurement Process Temparature Control Mode Normal P ID Setpoint value gt Range value e Dampen e Hold Last value Fixed value e Fixed Hold value Fault value Disable feature 20 min meoutt nabile feature Control Mode only Normal Mode only Activation method prosessitemp eratura Control Mode Normal TPO e Alam High Setpoint value Delay value e Hysteresis vatue Proportional value
103. nter key To select another header use the arrow keys The bottom menu header will only be highlighted if the end of the menu has been reached NOTE Always configure the control parameters BEFORE mak ing changes in the alarm setup Changes in the output setup in step 4 will depend on the options that have been selected in step 3 Alarm Modes Normal Alarm turns on when setpoint is exceeded and turns off when the reading no longer exceeds the setpoint simple high alarm example Fault Alarm turns on when controller detects a fault condition TPC Alarm turns on for a time that depends on what the reading is The time it stays on is proportional to how far the reading is from the 0 On Time point also called the setpoint time proportional control TPC Alarm turns on for a time that depends on what the reading is The time it stays on is proportional to how far the reading is from the setpoint time proportional control In addition the on time can be dependent on how long the reading has exceeded the setpoint inte gral control and how fast the reading has actually changed deriva tive control Feed limit timer When the alarm has been energized on for a long period it automatically turns off to prevent overfeeding of chemicals Interval timer Alarm is programmed to activate at various times usu ally to provide automated cleaning Useful for spray cleaning and or automatic retraction of sensors in processes
104. nual 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 min utes as the pH sensor may need to cool down to the buffer temper ature The display will flash wait while the reading is stabilizing When the pH reading is stable press Cont F3 to update the read ing Press Edit F4 and use the arrow keys to change the indicated buffer value to the correct value for the buffer at the stabilized tem perature 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 cal ibration menu 5 Remove the sensor from buffer 1 and rinse in water 6 Place the pH sensor into a beaker containing the second buffer solu tion 7 Allow the
105. o long MODEL 54 4 02 pH done E 25 C 10 02 pH Buf2 done 25 C Cont Abort Cont 64 N 10 02 pH Autocal buffer 2 A Abort Cont A 10 02pH Auto buffer cal done Cont E E SECTION 4 0 CALIBRATION 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 com pleted Aborting the calibration at this point will not change the reading of the controller 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 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
106. oduce a step change to the process by using the simulate test func tion to make the step change in the output signal The change in the measured variable conductivity pH or millivolts will be graphed as shown in Figure 6 2 Line drawn tangent to the curve a o c E 0 2 4 6 8 N SECTION 6 0 THEORY OF OPERATION This can be done by observing the reading on the Model 54e pH ORP and noting values at intervals timed with a stop watch A strip chart recorder can be used for slower reacting processes To collect the data perform the following steps 1 Let the system come to a steady state where the measured variable pH conductivity or tempera ture is relatively stable 2 Observe the output current on the main display of the controller 3 Using the simulate test manually set the controller output signal at the value which represented the stable process measurement observed in step 1 then observe the process reading to ensure steady state conditions a stable process measurement 4 Using the simulate test cause a step change in the output signal This change should be large enough to produce a significant change in the measured variable in a reasonable amount of time but not too large to drive the process out of desired limits Change in Measured Variable pH 10 12 14 16 18 20 22 24 26 28 paga L 12 4 Time Seconds FIGURE 6 2 The Process Reac
107. oint is multiplied by this factor to pro duce the output The Model 54e pH ORP s proportional mode is referred to as proportional band which is config urable from 0 to 299 For good control of a specific process the proportional band must be properly adjusted The proportional band is the percent of the analog output span the difference between the 4 or 0 mA 20 settings through which the measured variable must move to change the output from mini mum to maximum The larger the proportional band the less the controller reacts to changes in the measured variable As the proportional band is made smaller the reaction of the controller increases At 0 proportional band the proportional only controller behaves like an on off controller an alarm set at 20 Most processes require that the measured variable be held at the set point The proportional mode alone will not automatically do this Proportional alone will only stabilize the measured variable at some offset to the actual control point To control at an exact setpoint proportional plus integral mode is used Proportional Gain Plus Integral Reset For the automatic elimination of deviation Integral mode also referred to as Reset is used The propor tional function is modified by the addition of automatic reset With the reset mode the controller continues to change its output until the deviation between measure ment and set point is eliminated
108. oken or cracked glass electrode Reference electrode poisoned High reference imped 1 Coated reference electrode Sensor cleaning recommended 2 Sensor out of process Temp error high 1 Open or shorted RTD Temp error low 2 Temperature out of range Calibration warning 1 Calibration suggested due to change in glass 2 Sensor out of process Old glass warning 1 Glass electrode worn out 2 Sensor out of process Lo slope error 1 Worn out electrode Hi slope 2 Improper buffer calibration check buffer accuracy wait for stabilization in buffers 3 Plugged liquid junction coated glass Sensor line open 1 Open wire between sensor and controller 2 Distance between sensor and controller is too long Failure EEPROM 1 Defective CPU board Notify Rosemount Failure CPU if cycling power does not clear the fault Failure Factory Failure ROM Bad ROM chip on CPU board Field cal needed Output 1 and 2 need adjustment Hold mode activated All relays open and outputs set to default values DTI RN activated High input voltage input voltage Open connection from Open connection from preamplifier to controller to controller Low input voltage Open connection from glass electrode to preamplifier High reference voltage 1 Sensor not in process 2 Coated Sensor 3 Open wire between preamplifier and controller Simulating Output 1 or 2 The indicated output or alarm is being test
109. old if Output 1 hold is fixed value 0 22 00 mA 0 22 00 mA Dampen ing Fault fixed value in a fault condition These parameters can be adjusted by highlighting the desired item and pressing the Edit key Once Edit has been pressed change the item as needed and then press Save to store the value Range determines whether the 4 20mA or 0 20 mA convention is used for the current output If the range is changed be sure to rerange the outputs as described in Section 5 3 Dampening is used to time average the current output smoothing out the effect of a noisy reading Higher values provide more smooth ing Enabling the hold feature will give the user the option of placing the output in hold during the calibration sequence A fixed value places the held output at a fixed value between 0 and 22 mA Menu Item Setpoint 2 to 16 pH 1400 mV ORP Redox 15 to 120 C Temp 0 140 kQ Ref Imp Proportional 0 299 9 0 2999 sec 0 299 9 Integral Derivative The four parameters above are only available for outputs that have been configured as PID outputs in step 3 These parameters can be adjusted using the same technique as in step 4a by highlighting the desired item and pressing the Edit key Once Edit has been pressed change the item as needed and then press Save to store the value Use caution in changing the values of these parameters Setpoint is usually the desired value at which the proc
110. ontinued ITEM 5 Alarm 3 Control a Activation Method b Alarm 3 Control Mode 6a Alarm 3 Setup Normal a Configuration b Hysteresis deadband e Delay Time d Relay Fault 6b Alarm 3 Setup TPC a Setpoint b Proportional Integral d Derivative e Time Period f LRV 100 On g URV 100 Off h Relay Fault Alarm 4 Control a Alarm Feed Limit Timer a Feed Limit b Timeout Value Alarms Section 5 7 Interval Timer a Timer selection b Timer activation method Interval d Repeats e On Time f Off Time g Recovery Diagnostics Section 5 8 Diagnostics Glass and Reference Glass Imp edance High Setpoint Glass Imp edance Low Setpoint Ref erence Imp edance High Zero Offset Cal ibration Warn ing Imped ance Temperature Comp ensation Auto Calibration Section 5 9 Autocal Buffer List Selection Stabilize pH Auto Calibration Stabilization Time Auto Calibration Security Section 7 1 Lock all Lock Program Lock all except Calibrate RANGES Process Temp Normal TPC Low alarm High alarm Off 0 5 00 pH 0 99 sec Open Closed None 2 to 16 pH or 15 to 130 C 0 299 9 0 2999 0 299 9 10 2999 2 to 16 pH or 15 to 130 C 2 to 16 pH or 15 to 130 C None Open Closed Fault Off Disable alarm 1 alarm 2 alarm 3 0 10 800 sec Disable alarm 1 alarm 2 alarm 3
111. ontroller Level 1 security Lock Level 2 security Lock Level 3 security Lock Outputs do not change Hold Mode activated simulating output 1 or 2 simulating alarm 1 2 3 or 4 Red LED light is on Various fault messages shown on lower display 68 PROBABLE CAUSE AND CORRECTIVE ACTION Electrode cracked Replace electrode FOR MORE HELP REFER TO Electrode coated Clean electrode as instructed in sensor manual Password protected Section 7 0 Your controller has password protection You must enter the correct password to make changes in the controller Controller is in Hold or simulate mode Software Configuration Section 5 6 To remove from Hold press any key Calibration Section 4 7 and then press Enter F4 Press Edit F4 change On to Off and press Save F4 To stop simulation press Exit F1 When the unit has been put into Hold all outputs go to their default states Unit has gone into fault mode Section 8 0 Read the message and take action as indicated in Table 8 2 MODEL 54 SECTION 8 0 TROUBLESHOOTING 8 3 REPLACEMENT PARTS PART NUMBER DESCRIPTION 23540 05 Enclosure Front with Keyboard 23848 00 Power Supply Circuit Board Shield 23849 00 Half Shield Power Supply 23854 00 PCB CPU for Back lit Display 23969 00 PCB Calibrated board set 115 230 Vac 23969 04 PCB Calibrated board set 24 Vdc 33281 00 Hinge Pin 33286 00 Gasket Front Panel 33
112. oo low for calibration Software version Use the following procedure 1 2 From the main display press any key With the down arrow key move the cursor down to Diagnostic Variables and then press Enter F4 Diagnostic variables are displayed three at a time More variables are viewable until the cursor showing highlighted text is brought down to the bottom line Use the down arrow key to view the items on the lower screen The up arrow key can be used to return to a previously viewed item Press the Exit F1 key to return to the main menu above NOTE Many diagnostic variables can be read directly on the main dis play in the lower left or lower right positions For details see Section 5 5 61 MODEL 54 SECTION 8 0 TROUBLESHOOTING Millivolts Example A pH reading of 6 0 should yield a mV reading of 59 N Slope 59 per unit change of pH 7 0 8 0 90 100 110 120 130 140 pH FIGURE 8 1 Theoretical pH vs Millivolt Values at 25 C 77 F 62 MODEL 54 pH ORP 8 2 TROUBLESHOOTING GUIDELINES NOTE To clear any Fault message press the key If no specific error message is being displayed the fol lowing procedure can identify the specific problem The only sure way to diagnose sensor related condi tions is to isolate the pH sensor from the process im merse the sensor in a pH buffer solution and observe the controller response For any given pH value
113. 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 C 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 Ib 5 Ib 2 MODEL 54 Model 54 when configured as analyzer requires a dual glass and reference impedance pre amplifier 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 per formance 2 in a remote junction box when process temperatures exceed 80 C 176 F in submersion applications or 3 in the
114. or a short period of time the timeout value pro grammed in Section 5 5 c Ahold condition will indefinitely prolong the time out period d Security will activate immediately if power is removed from the controller and then restored e Forgotten Code Press and hold F4 Key for 5 seconds when the security screen appears and the code for that level will appear on the display 55 MODEL 54 SECTION 7 0 SPECIAL PROCEDURES AND FEATURES 7 3 SOLUTION TEMPERATURE COMPENSATION e Security Temperature Coeff Temperature sensor ES Exit Enter Operate iso 07 00 pH Sensor iso 07 00 pH 7 gt Temp coeff 000 ia 56 Exit Edit 2 This section is for advanced users only It explains how to input values for the isopotential pH and the temperature coefficient for solution temperature compensation 1 Beginning from the main menu move the cursor down to Program and press Enter F4 From the program menu move the cursor down using the arrow key to highlight Configure and press Enter F4 Use the arrow key again to highlight Temperature Coeff as shown on the left and press Enter F4 The Controller can compensate for two different temperature effects on the measured pH the temperature effect on the pH sensor and the tem perature effect on the actual pH of the process solution Sensor Temperature Compensation The millivolt output o
115. pH and temperature to stabilize as before and press Cont 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 Ifthe sensor is not at the same temperature as the buffer the cal ibration will be in error 4 fthe hold mode is ON be certain to reinstall the sensor in the process and change the setting to OFF to return to normal oper ation MODEL 54 SECTION 4 0 CALIBRATION 4 4 SINGLE POINT pH CALIBRATION Buffer calibration Standardize Adjust temperature Exit SES 4 S T 01 pH Standardize 7 01 pH Exit Enter NB d 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 read ing will drift The single point calibration re establishes the exact pH read ing Experience with your process and it s acceptabl
116. pedance or reference impedance See Section 5 6 for details on configuration 1 From the main menu move the cursor down to Program and press Enter F4 On this display move the cursor to Rerange outputs and press Enter F4 Select the desired output by moving the cursor down to highlight it When the correct output is highlighted press Enter F4 to get to the adjustment screen This message asks for confirmation of the requested change Changes in these settings may degrade process control so use cau tion when making changes Press Enter F4 to continue Otherwise press Abort F1 This screen allows changing the setpoints for output 1 A similar screen is available for output 2 The live current output now being transmitted by the controller is shown on the third line 4 Press Edit F4 to make changes the setpoints Edit key changes to a Save key and the F3 key becomes active as an Esc key Use the arrow keys to make the display read the desired val ues for the high and low current output limits When done press Save F4 to enter the changes into memory Press Esc F3 to can cel changes NOTE Outputs that have been configured as 0 20 mA in Section 5 6 will show 0 mA instead of 4 mA on the top line Outputs that are based on temperature or impedance values will show matching units such as C MQ or kQ See Section 5 6 for output config uration MODEL 54 SECTION 5 0 SOFTWAR
117. problems can be eliminated by either moving the sensor or providing proper grounding SECTION 8 0 TROUBLESHOOTING TEMPERATURE COMPENSATION CIRCUIT Troubleshooting Procedure Use this procedure to diagnose problems in the tem perature compensation circuit or as directed by the Troubleshooting Guide Table 8 3 Refer to the appro priate wiring diagram in Section 3 To check the sensor 1 Check the resistance of the RTD element at the end of the sensor lead Do not include intercon necting wire Disconnect the red lead and white lead on the end of the sensor cable 2 Checkthe resistance between the red and the white leads If values do not agree within 1 of those shown below replace the sensor see Step 4 AMBIENT TEMPERATURE 32 0 68 F 20 C 77 25 86 F 30 C 104 F 40 C 122 F 50 C Disconnect sensor leads from interconnecting wire prior to measuring resistance Values shown are only accurate when measured at the end of the cable directly attached to the sensor Allow enough time for the temperature compensation RTD embedded in the sensor to stabilize to the sur rounding temperature Temperature coefficient 0 215 ohms per F 4 Ifthe sensor is bad you can replace the sensor or you can clear the fault by switching to manual tem perature compensation as a short term solution Refer to Section 3 5 to program for manual tem perature compensation If the temperature com pensator RTD in the
118. purpose is to compensate for apparent pH changes due to the pH response of a glass electrode increasing with tem perature At values around 7 pH the variation with tem perature is zero Thus no compensation is required at 7 pH The error caused by varying temperatures is greater at high low pH values in other words as you move away from a neutral pH of 7 This compensation is done automatically by the Model 54e pH ORP unless specifically disabled The Preamp Because of the high resistance of the glass measuring electrode a preamplifier must be used to transform the extremely low level high impedance signal to a low impedance signal The Model 54e pH ORP includes a switchable preamplifier that may be used if the dis tance to the pH sensor is less than 15 feet When longer runs of cable are necessary the preamp can be located in the pH sensor itself or in a remote junction box Either design allows transmission of the pH signal long distances without suffering degradation or inter ference from outside voltage sources 6 2 CONTINUOUS SENSOR DIAGNOSTICS The Model 54e pH ORP verifies the integrity of the glass and reference segments of the pH sensor by con tinuously measuring the impedance between each segment and the solution ground 45 MODEL 54 new glass electrode has impedance of mately 200 megohms As it ages this value typically increases over time because lithium ions which car
119. r You may also get this fault if 1 sensor becomes excessively coated 2 sensor is not immersed the process Typical set points 1 1000 Megohms for old glass diagnostics 2 10 Megohms for cracked glass 3 0 Megohms for calibration warning disabled 4 40 Kohms for high reference impedance NOTE See Section 5 8 for instructions on chang ing these setpoints 46 SECTION 6 0 THEORY OF OPERATION 6 3 INTERVAL TIMER The interval timer may be used for periodic sensor cleaning or periodic process adjustment see Section 5 7 for procedure The interval timer settings are 1 Timer Enables disables the interval timer 2 Interval the time period between cycles 3 Repeats the number of relay activations per cycle 4 Ontime the time period of one relay activation 5 Off time the time period between two or more relay activations 6 Recovery the time period following the final relay activation The cycle begins at the Interval time when the Switch is turned on When the Interval time has expired the analyzer activates hold mode and the relay is activated for the On time period If the number of Repeats is greater than one the relay is deactivated for the Off time period and reactivated for the On time period for the number of relay activations selected When the final relay activation is complete the relay is deactivat ed for the Recovery time period Note that no Off time pe
120. r duurzame bescherming tegen brand uitsluitend zekeringen gebruiken met aangegeven nominale spannings en stroomwaarden De zekeringen bevinden zich onder dit deksel Afin d assurer une protection permanente contre le feu ne remplacer les fusibles que par des mod les quivalents en tension et en courant Les fusibles se trouvent derriere cette plaquette GEFAEHRLICHE ELEK TRISCHE SPANNUNG Ist die Schutzabdeckung ader die Sicherung entfernt so koennen am Geraet ernsthafte oder toedliche SPENNING KAN VJERE TIL STEDE nar sikringen eller dette deksiet fj rnes og kan fare til alvorlige skader eller d dsulykker Um die Schutzart des Geraetes sicherzustellen ist es mit den ATTENTION entsprechenden For at beskyttelse mot antennelse skal opprettholdes m sikringer bare Kabelverschraubungen Um die Gefahr von Kurzschlub und Funkenbildung zu verhindern erstattes med tilsvarende som har spesifisert spenning og str mstyrke und Blindkappen d rfen die Sicherungen nur durch solche gleicher Spannung und Sikringer er plassert under dette dekslet Stromwerte ausgetauscht werden Die Sicherungen befinden sich unter dieser Abdeckung auszuruesten NIEBEZPIECZENSTWO URZADZENIE MOZE BYC POD NAPIECIEM Gdy bezpieczniki lub ta pokrywa sa usuniete istnieje mozliwosc uszkodzenia ciala lub smierci POSSIBILE PRESENZA DI ALTA TENSIONE La rimozione del fusibile o del coperchio pu causar
121. r should now read 7 pH or O mV in ORP mode NOTE If the controller has been calibrated with a large zero offset the pH may not be close to 7 In this case standardize the con troller at 7 Section 3 4 If the controller does not read correctly after standardizing if necessary replace the con troller If a millivolt source is available it can be con nected to 2 7 and TB2 10 to simulate pH val ues Refer to Figure 8 1 for the relationship between mV and pH sample values are 172 mV for 4 pH and 172 mV for 10 pH MODEL 54 SECTION 8 0 TROUBLESHOOTING TB2 Dari oc JUMPER E 9 J BOX PREAMP d NL 000 ER RED RECEIVE 4 OGREEN TRANSMIT HART E o COMMON 8 D D De Pasa E oja M ND CONNECTION CLEAR RTO WHITE RTD RETURN H NO CONNECTION 2 3 4 WHITE RED RTD SENSE 5 6 INNER DRAIN RTD SHIELD WHITE RETURN WHITE REQ SENSE REO RTO IN BRAID GUARD GRAY REF IN BLUE SOLUTION GROUND D m o RED RID IN WHI 7 GRAY REF IN 8 BLUE SOLUTION GROUND 9 WHITE BLACK DIGN 10 BLACK mV IN 14 BROWN 12 GREEN 5V WO uH DE OU HORN NH PREAMP LOCATION SENSOR ANAL YZER HE 2 1 80 k 8 C D 12 4 8 6 7 8 9 10 11 12 KS FRONT PANEL
122. riod follows this last relay activation When the Recovery time period expires the Hold mode deacti vates and the cycle repeats beginning with the Interval time Typically the interval timer is configured with a long Interval several Repeats of fairly short On times fairly short Off times and a Recovery time which allows the process to stabilize Setting Interval to zero results in continuous pulsing and setting Off time to zero will cause a single pulse equal to On time x Repeats High reference impedance can be used to trigger timer activation In this case the interval time is used only to allow the analyzer time to determine whether the refer ence impedance has exceeded the reference imped ance setpoint If the reference impedance setpoint is exceeded the timer cycle will begin This is an ideal way to start a cleaning cycle in a dirty application Note that the hold mode supersedes the Timer State If the hold mode is on the present interval time continues to expire and once expired the interval timer is sus pended until the hold state is removed For more infor mation on Controller Mode Priority see Table 6 1 MODEL 54 6 4 ALARM RELAYS An alarm is a relay that closes a set of contact points a switch inside the controller In doing so the relay clos es an electrical circuit and turns on a device wired to the contacts The Model 54e pH ORP controller has four alarm relays The relays are turned o
123. rm relays The display timeout will return the display to the main display screen from any other screen if no key is pressed before the timeout value This is useful because the main display screen is usually the most important screen to the operator The timeout feature also allows simulating the current output and alarm actions with an automatic return to normal operation When the feature is turned on the default simulated tests see Section 5 4 for details will be completed automatically when the timeout value is reached As before to change these settings use the arrow key to highlight the desired item and press Edit F4 Use the arrow keys to make the change and press Save to enter the change into memory Press Esc to abort SECURITY CAUTION The Timeout Value is also used by the controller to acti vate security Section 7 1 After unlocking the controller by entering a security code security is not re activated unless a display timeout occurs If Timeout has been turned off here security will never re activate MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 6 CHANGING OUTPUT PARAMETERS ES Display Outputs Alarms Exit Enter Output 1 control Output 1 setup Output 2 control Exit anag Output control Output 2 setup Hold feature setup Exit Edit Output Control Parameters ED n fOutput Me
124. rmal outputs See step 4a for details 5 The Hold feature is used to prevent problems that may occur during calibration if the current outputs are used for control The feature is turned on enabled here and is specifically configured in step 4 The controller starts out with the hold feature turned off disabled To enable the Hold feature obtain the screen to the left with the hold feature setup highlighted see steps 1 and 2 for exact instructions Press Enter and the screen below will appear Press the Edit key to enable changes Options include Disable Enable and 20 minute timeout When 20 minute timeout is selected the hold mode will automatically disengage after being on for 20 minutes Selecting Enable or 20 minute timeout does not actually put the controller in hold but rather allows putting the controller in hold when calibration is conducted When the hold feature has been enabled this Hold Mode Screen will appear when the Calibrate routine is entered Possible actions are Exit which cancels the calibration Enter which enters the calibrate menu without putting the controller in hold and Edit which allows turning Hold Mode On Note that when hold has been enabled this screen requires pushing Cont to enter and leave the calibrate menu 35 MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 7 CHANGING ALARM PARAMETERS 7 Outputs Alarms Security Exit Enter ES
125. ry current in the glass are slowly depleted by the process If an electrode cracks the impedance drops sharply usually to below 5 MQ The following Diagnostic Checks are possible with the Model 54e pH ORP Cracked Glass Diagnostic One way to tell that you have a broken or cracked glass electrode is that the controller will read a constant value usually between 5 0 7 0 pH in any process or buffer The other way is to note the impedance value The controller can be configured to generate a fault when the glass imped ance drops below a setpoint When a crack occurs the controller will indicate that the electrode is broken NOTE A broken electrode may not be detected above 70 C 158 F Old Glass Diagnostic This diagnostic is used for pro gramming the high impedance limit For example if the set point is 1000 megohms and the impedance rises above this value the controller will go into a fault mode The electrode is either worn out severely coated or not immersed in the process fluid Calibration Warning Under this diagnostic you can select the percent increase in impedance before a cal ibration warning fault appears It is recommended to keep this feature disabled High Reference Impedance The reference is also continuously checked High values indicate a plugged liquid junction or a coated sensor The setpoint can be adjusted depending on the sensor used Always set this value above the value for a new clean senso
126. tallation location 3 3 ANALOG OUTPUT WIRING The analog output wiring consists of two 4 20 mA sig nals 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 pro grammed 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 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 dev
127. ted and when the time limit has been reached on a feed limit timer For more information on these subjects see Section 5 7 MODEL 54 SECTION 1 0 DESCRIPTION AND SPECIFICATIONS 1 3 SPECIFICATIONS PHYSICAL SPECIFICATIONS GENERAL Enclosure Epoxy painted aluminum NEMA 4X 65 144 X 144 132 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 Division 2 Groups B C amp D T5 Ta 50 C Dust ignition proof Class 11 Division 1 Groups E F amp G Class CSA LR34 186 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 amp 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
128. the diagnostic variables for inappropriate settings Section 5 8 3 Turn analyzer diagnostics OFF Section 5 8 4 Verify proper wiring and preamp switch position 5 Perform Systematic Troubleshooting procedures 60 MODEL 54 SECTION 8 0 TROUBLESHOOTING 8 1 DISPLAYING DIAGNOSTIC VARIABLES Calibrate Diagnostic Variables Program Input 120 mV Glass imped 300 Ref imped 8 a Zero offset 0 mV pH slope 59 02 mV pH Version pH1 01 This section explains how these helpful diagnostics be viewed 1 Electrode input in mV Used to check if the signal produced by the sensor is within acceptable limits see Figure 8 1 for typical sensor mV response at 25 C Glass impedance in MQ Used to check integrity of glass electrode Broken glass membranes will have low impedance Reference impedance in kQ Used to indicate how coated the ref erence electrode has become Coated or plugged sensors will have high values of reference impedance Zero offset in mV Indicates the deviation from the typical sensor response Figure 8 1 as of the last buffer calibration The controller compares the value at 7 pH with the ideal value of zero mV at 7 pH Slope in mV pH Indicates the sensitivity of the glass electrode This number tends to drop as a sensor ages Values below 47 are con sidered t
129. the reading This setting should generally be set to zero for pH and ORP applications 47 MODEL 54 TPC offers precise control by forcing the pump to feed chemical for shorter periods of time as you approach the desired setpoint If the process faces a large upset TPC mode forces the pump to feed chemical for longer periods of time as the process deviates further from the setpoint This action continues until the pump is feed ing all the time providing a speedy recovery from large up sets The controller can be programmed to be direct or re verse acting depending on the pH or temperature value selected for URV For example if the controller is direct acting based on pH such as in caustic chemical addition control the pH will rise as chemical is added so the URV value will be below the LRV i e below zero As the pH rises toward the control point value the pump will be on for gradually less time Conversely if the controller is reverse acting based on pH such as in acid addition for control the pH will drop as acid is added and the URV value will be positive The pH will fall toward the control point value and the pump will be on for gradually less time Complete TPC configuration is explained and typical settings for these parameters are listed in Section 5 0 After startup the operator needs to adjust only the 0 On to maintain the desired chemical concentration 6 6 NORMAL MODE Normal mode is on an
130. tion Curve 52 MODEL 54 6 0 CONTROL continued 5 The reaction of the system when graphed will resemble Figure 6 2 showing a change in the measured variable over the change in time After a period of time the process delay time the meas ured variable will start to increase or decrease rapidly At some further time the process will begin to change less rapidly as the process begins to sta bilize from the imposed step change It is important to collect data for a long enough period of time to see the process begin to level off to establish a tan gent to the process reaction curve 6 When sufficient data has been collected return the output signal to its original value using the simulate test function Maintain the controller in this manual mode until you are ready to initiate automatic PID control after you have calculated the tuning con stants Once these steps are completed the resulting process reaction curve is used to obtain information about the overall dynamics of the system It will be used to cal culate the needed tuning parameters of the Model 54e pH ORP controller NOTE The tuning procedure outlined below is adapted from Instrumentation and Process Measurement and Control by Norman A Anderson Chilton Co Radnor Pennsylvania 1980 Information derived from the process reaction curve will be used with the following empirical formulas to predict the optimum settings for
131. trol The Model 54e pH ORP controller is given two items of information measurement and set point The con troller reacts to the difference in value of these two signals and produces an analog output signal to eliminate that difference As long as the difference exists the controller will try to eliminate it with the output signal When measurement and set point are equal the condition of the controller is static and its output is unchanged Any deviation of measurement from set point will cause the controller to react by changing its output signal PID Control Mode Combinations All PID controllers have several control modes which can be used in various combinations proportional plus integral reset proportional plus derivative rate and a combination of proportional P integral 1 and derivative D Each control mode produces response to the deviation of measurement from set point that is the result of a specific characteristic of the deviation and each control mode is separately adjustable D the derivative or rate mode is seldom used in water treatment and is beyond the scope of this manual MODEL 54 6 0 CONTROL continued Proportional Mode Gain The simplest control is proportional Proportional may also be referred to as sensitivity or gain Although these terms may refer to a different version of proportional the control function is still fundamentally the same the error from set p
132. uously won t stabilize Readjust stabilization pH or time for Auto Cal Section 5 9 during Auto Buffer Calibration Clean the sensor and retry Auto Cal in buffers Try a Manual Buffer Calibration see Section 5 9 for configuration Calibrates in buffers but not in the process Verify process reading to be correct Possible ground loop Make sure that the shield wires do NOT touch grounded metal Process noise Incorrect temperature reading Standardize the temperature Suspected temp compensation problem Verify sensor s RTD resistance vs temperature Temp error high Verify temperature reading to be correct Temp error low Display segments missing Replace Display board Analyzer locks up won t respond Replace CPU board Erratic display and relays chattering Check alarm set points configuration Sections 5 2 5 7 Analyzer not responding to key presses Verify and clean ribbon cable connection on CPU board Key press gives wrong selection Replace enclosure door keyboard assembly Wrong or no current output 1 Verify that output is not being overloaded max load is 600 ohms 2 Rerange outputs Section 3 3 3 Replace Power board No display or indicators Verify that the removable fuse module is securely seated Alarm relay closure problems Check Power board Power board cut off Replace the Power board Sensor diagnostics faults keep appearing 1 Calibrate sensor in buffers replace if unsuccessful 2 Check
133. ure Coefficient Temperature Coeff being used the Controller automatically calculates the Operating Isopotential pH Operate ISO from the following relation Operate ISO Sensor Iso Temperature Coeff X 298 16 Conversely if an Operating Isopotential pH is known for a particular solu tion the Controller will automatically calculate the corresponding Temperature Coefficient Example High Purity water with Ammonia being measured with a normal pH sensor Sensor Isopotential pH of 7 0 pH has a Temperature Coefficient of 033pH per C and an Operating Isopotential pH of 16 84 MODEL 54 SECTION 7 0 SPECIAL PROCEDURES AND FEATURES 7 3 SOLUTION TEMPERATURE COMPENSATION continued 2 Menu Item Options d N Temp coeff 000 Temperature coefficient 0 044 to 0 028 pH C 0 00 for Operate iso 07 00 pH most applications SEN Operating isopotential 1 35 to 20 12 pH 7 00 for most Sensor ISO 07 00 pH Isopotential pH applications Exit Edit Sensor isopotential 0 14 pH 7 00 for most applications G 44 The values now being used by the controller are displayed change any of these items use the arrow key to highlight the desired item and press Edit F4 Use the arrow keys to make the change and press Save to enter the change into memory 57 MODEL 54 SECTION 8 0 TROUBLESHOOTING SECTION 8 0 TROUBLESHOOTING The Model 54e pH ORP automatically searches
134. y and the next screen will allow changing it Use the arrow keys to change the display as needed and press Test to enter the change Press Esc to cancel the change in the value and con tinue simulating the previous action NOTE Alarm relays may be simulated in the energized Closed position or the de energized Open position MODEL 54 SECTION 5 0 SOFTWARE CONFIGURATION 5 5 CHOOSING DISPLAY OPTIONS qum Outputs Alarms ES Exit fMeasure pH Resolution 0 01 Temp Units Exit Enter J WARNING This change resets analyzer to factory settings ES Cont 2 G gt Output 1 mA Language English C Exit Edit j gt Display left Display right AL2 Display contrast 5 V Exit Edit Measure pH Resolution 0 01 Temp Units C A Exit SES This section describes the options available for the changing of engineering units and variables on the main display 1 From the main menu move the cursor down to Program and press Enter F4 From the program menu move the cursor down using the arrow key to highlight Configure and press Enter F4 The first configuration menu is displayed With the cursor on Display press Enter F4 Menu Item Options Measure pH ORP Redox 0 01 0 1 Resolution pH only Temperature units The valu
135. y the main menu Move cursor until Program is highlighted Press Enter F4 Highlight Configure and press Enter F4 Highlight Display and press Edit F4 Use the arrow key to change Measure from pH to ORP and press Save F4 Warning screen appears press Cont F3 Complete the ORP standardize instructions Preset alarm and output settings are listed below If these values are unacceptable refer to Section A 1 for a detailed configuration proce dure For a summary of the complete factory set tings see Table A 1 Alarm 1 low alarm 1400mV Alarm 2 high alarm 1400 Alarm 3 high alarm 1400 Output 1 4mA setpoint 1400 Output 1 20mA setpoint 1400mV CONFIGURING THE CONTROLLER Configuration of the ORP settings can be done at any time after the controller has been set to ORP mode step 3 in Quick Startup on the left Procedures for these operations follow the ORP Standardization instructions in this appendix Before attempting any changes refer to the configu ration setup list shown in Table A 1 This table pres ents a brief description and the configurable items The factory setting is also given with a space for the user setting It is recommended that the list be care fully reviewed before any changes are made On initial configuration it is recommended that the settings be entered in the order shown on the work sheet This will reduce the chance of accidentally o

Emerson 54e pH/ORP Photo Scanner User Manual

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