LMI LIQUITRON DP5000 Series User manual

LIQUITRON™
DP5000 Series pH Controller
Instruction Manual
Manual No : 1756
Rev. : J
Rev. Date : 5/2019

iInstruction Manual
1.0 INTRODUCTION ....................................................................... 1
2.0 UNPACKING .......................................................................... 2
3.0 INSTALLATION ........................................................................ 3
3.1 PRE-INSTALLATION .............................................................. 3
3.2 ENVIRONMENT ................................................................. 3
3.3 INSTALLATION .................................................................. 3
3.4 MOUNTING THE ELECTRONIC ENCLOSURE ......................................... 3
3.5 ELECTRICAL INSTALLATION....................................................... 5
3.5.1 Electrical Connections ........................................................... 5
3.5.2 Terminal Board Signal Description .................................................. 8
3.5.3 Field Wiring Instructions .......................................................... 9
3.6 pH ADJUSTMENT PUMP(S)....................................................... 10
3.7 KEYPAD AND DISPLAY .......................................................... 10
4.0 OPERATION ......................................................................... 12
4.1 DEFAULT SETTINGS ............................................................ 12
4.1.1 Proportional Mode.............................................................. 13
4.1.2 ON / OFF Mode................................................................ 14
4.2 ALARMS ...................................................................... 16
4.3 CALIBRATION (VIEWING LAST CALIBRATION DATA) .................................. 17
4.4 NEW CALIBRATION ............................................................. 17
4.5 PUMP TIMERS AND SOLENOID VALVE CONTROL TIMERS ............................. 19
4.5.1 Pump Run Time ............................................................... 19
4.5.2 Solenoid Delay Pump Valve Time .................................................. 19
4.5.3 Setting Timers................................................................. 20
4.5.4 Solenoid Valve Control .......................................................... 20
4.5.5 Display Key................................................................... 21
4.6 ADVANCED MENU .............................................................. 22
5.0 MAINTENANCE ....................................................................... 23
5.1 pH ELECTRODE AND CABLE ..................................................... 23
6.0 TROUBLESHOOTING .................................................................. 24
6.1 ERROR MESSAGES............................................................. 24
7.0 DP5000 SPECIFICATIONS .............................................................. 25
8.0 PROGRAM LOG ...................................................................... 27
9.0 PARTS LIST ......................................................................... 28
10.0 EXPLODED VIEW .................................................................... 29
TABLE OF CONTENTS

ii Instruction Manual
LIST OF ILLUSTRATIONS
FIGURE 1. Unpacking Items .................................................................. 2
FIGURE 2. Minimum Clearances .............................................................. 3
FIGURE 3A. Typical In-Line Installation ......................................................... 4
FIGURE 3B. Typical Batch Installation .......................................................... 4
FIGURE 4. Electrode and Pump Connections .................................................... 6
FIGURE 5. Terminal Strip .................................................................... 7
FIGURE 6. Circuit Board..................................................................... 9
FIGURE 7. Keypad ........................................................................ 10
FIGURE 8. ON / OFF Control ................................................................ 12
FIGURE 9. Proportional .................................................................... 12
FIGURE 10. Pump A Control Prole ........................................................... 13

1Instruction Manual
SECTION 1 - INTRODUCTION
The LIQUITRON™ DP5000 Series pH Controllers
are designed for a variety of industrial pH
applications including metal finishing, water
treatment, printed circuit board manufacturing and
waste treatment.
The LIQUITRON™ DP5000 is a microprocessor-
based pH controller with a backlit customized
display and tactile keypad for ease of programming.
The DP5000 allows independent programming of
control methods (‘ON / OFF’ or ‘PROPORTIONAL’)
for acid (Pump A) or base (Pump B) dosage.
Independent high and low pH alarms may be set
with activation of the ‘Alarm relays.’ A third relay
output is available for activating a solenoid valve
or other devices.
The controller is compatible with any pH electrode
that generates a mV signal and allows incorporation
of platinum 1000 W automatic temperature
compensation (ATC) elements. Two point or single
point pH calibrations may be performed. Timer
functions for pump ‘Run’ time and solenoid ‘Delay’
times can be programmed to operate a solenoid
pump valve. An ‘Advanced Menu’ allows selection
of special features such as a ‘Point 3’ (inection
point) for the control proles of the acid or alkali
pumps for finer control. The DP5000 features
continuous non-volatile memory back-up, voltage
selection, pre-amplier outputs, ow and level
switch inputs as standard. 4-20 mA recorder output
is optional.

2Instruction Manual
SECTION 2 - UNPACKING
Your carton will contain the items shown in
Figure 1. Please notify the carrier immediately if
there are any signs of damage to the controller or
its parts. Contact your LMI®Distributor if any of the
parts are missing.
DP5000 pH Controller
DP5000
Quick Reference Guide
Quick Reference Guide
Liquitron DP5000 Series
pH Controller
Instruction Manual
Version 5.2
User Manual
Figure 1. Unpacking Items
There is a number label on the inside cover of
the unit; for easy reference, you should note the
model and serial numbers on the front cover of this
instruction manual.

3Instruction Manual
SECTION 3 - INSTALLATION
3.1 PRE-INSTALLATION
BE SURE THAT THE UNIT HAS A
PLUG AND VOLTAGE CODE
COMPATIBLE WITH THE POWER SOURCE THAT YOU INTEND
TO USE.
3.2 ENVIRONMENT
The housing is corrosion and spray resistant but
should not be subjected to excessive spray or
ambient temperature over 122°F (50°C). Never
immerse the unit.
3.3 INSTALLATION
The LIQUITRON™ DP5000 Controller should
be mounted on a solid, stable surface. pH
adjustment pumps should be installed following the
manufacturer’s recommendations. For installations
requiring longer cables, consult your distributor.
The electrode installation will vary, depending on
the process used. In general, the temperature
electrode and pH electrode should be mounted
together, and placed far enough downstream from
the source of pH adjusting solution that sufcient
mixing may occur, but close enough to eliminate
hydraulic lag time of response. Refer to the typical
installation diagrams on the following page.
3.4 MOUNTING THE ELECTRONIC
ENCLOSURE
The LIQUITRON™ DP5000 control module is
supplied with integral wall mounting anges. It
should be hung with the display at eye level, on a
vibration-free structure, in a location where liquids
will not be splashed on it. All four (4) top-mounting
holes should be used for structural stability. The
control module requires the following clearances:
2” (51mm)
10” (254mm) 4” (102mm)
8” (203mm)
Figure 2. Minimum Clearances

4Instruction Manual
pH ELECTRODE
FLOW
FLOW
LMI
PUMP
LMI
PUMP
Optional
Preamp.
and Cable
DP5000
pH CONTROLLER
ACID
SOLUTION
BASE (ALKALAI)
SOLUTION
pH
ELECTRODE
BASE (ALKALAI)
SOLUTION
ACID
SOLUTION
LMI
PUMP
DP5000
pH CONTROLLER
LMI
PUMP
BATCH TANK EFFLUENT
INFLUENT
OPTIONAL
PREAMPLIFIER
Figure 3A. Typical In-Line Installation
Figure 3B. Typical Batch Installation

5Instruction Manual
3.5 ELECTRICAL INSTALLATION
3.5.1 Electrical Connections
TO REDUCE THE RISK OF
ELECTRICAL SHOCK, THE
CONTROL OR METERING PUMP MUST BE PLUGGED INTO A
GROUND OUTLET WITH RATINGS CONFORMING TO THE DATA
ON THE CONTROL PANEL. IT MUST BE CONNECTED TO A
GOOD GROUND. DO NOT USE ADAPTERS. ALL WIRING MUST
CONFORM TO LOCAL ELECTRICAL CODES.
SECTION 3 - INSTALLATION
INCORRECT CORRECT
Electrical installation of the DP5000 Series pH
Controllers consists of plugging the control module
into a proper line outlet. Based on model number,
the following voltages and receptacles are required:
Model Number voltage Receptacles
DP5000-1A
DP5000-1B 115 V, 60 Hz USA Cord
DP5000-01A
DP5000-01B 115 V, 60 Hz No Cord
DP5000-2A
DP5000-2B 230 V, 60Hz USA Cord
DP5000-02A
DP5000-02B 230 V, 50/60Hz No Cord
DP5000-3A
DP5000-3B 230 V, 50 Hz DIN Cord
DP5000-5A
DP5000-5B 230 V, 50 Hz UK Cord
DP5000-6A
DP5000-6B 230 V, 50 Hz AUS / NZ Cord
DP5000-7A
DP5000-7B 230 V, 50Hz SWISS Cord
Connect the pH adjustment pump(s) to the
terminal strip for ‘ON / OFF’ control (connect to
receptacles directly for 115 V models) or to cables
for ‘PROPORTIONAL’ control. Connect the pH
electrode to the BNC connector on the right side
of the control module. Take care not to twist or
strain the wires. If equipped, connect the ATC cable
(1000 Ω at 32°F (0°C)) through the cable gland
below the BNC connector to the terminal strip. You
may optionally connect an alarm, solenoid, ow
switch and low level switch. You may also connect
the mA connections (with the option tted). The
± 5 V supply for electrode pre-amplication is also
accessed on the terminal strip. There is a 500 Ω
maximum resistance for 4-20 mA option (refer to
Figures 4 and 5).

6Instruction Manual
*Proportional
10ft (3m)
*ON / OFF
12in (304.8mm)
pH Electrode
(BNC Connector)
Output Wiring
for Options
Power Cord
6ft (1.8m)
BOTTOM VIEW Input / Output
Wiring for Options
Base Pump Output*
Acid Pump Output*
Power Cord
Figure 4. Electrode and Pump Connections

7Instruction Manual
Voltage Selection Switch
Fuse #2
Fuse #1
See Detail A
Detail A
TB1 TB4
TB3
TB2
SCREWDRIVER
SCREWDRIVER
WIRE
WIRE
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
Live
Neutral
Alarm 1
Temp
Temp
TX
RX
+5V
-5V
Alarm 2
Solenoid
Pump B
120V/230V
Terminal Strip Wiring
NO
NC
NO
NC
NO
NO
NO
NC
Output
4-20mA
Output
AUX
Output
Pump B
PreAmp
Power
Temp
Input
Low Level
Flow
Output
Pump A
Remote
OFF
Output
Fault
GND
GND
GND
Figure 5. Terminal Strip

8Instruction Manual
SECTION 3 - INSTALLATION
3.5.2 Terminal Board Signal Description
Terminal blocks are TB1-TB4 from left to right, and
Pin 1 is at the bottom of each terminal block.
TB1 Terminal Strip
TB1 Pin 1-Pin 3 Earth connection (one for input power connection)
TB1 Pin 4-Pin 9 Neutral power connection (one for input power
connection)
TB1 Pin 10 AC Mains live input
TB2 Terminal Strip
TB2 Pin 1 Form A contact closed when Pump B (base) is ON
TB2 Pin 2 Form A contact closed when Pump A (acid) is ON
TB2 Pin 3-4 Form C contact activated, (if programmed) when
pH is within programmed limits (solenoid pump)
TB2 Pin 5-6 Form C contact activated when Alarm Setpoint 2
exceeded (powered output contacts)
TB2 Pin 7-8 Form C contact activated when Alarm Setpoint 1
exceeded (powered output contacts)
TB3 Terminal Strip
TB3 Pin 1-2 Opto isolated input - low or short stops pumps
(OFF on display)(Remote OFF)
TB3 Pin 3-4 Opto isolated output - low when alarm condition
exists
TB3 Pin 5-6 Opto isolated output - pulse train to drive Pump A
TB3 Pin 7-8 Opto isolated output - pulse train to drive Pump B
TB3 Pin 9-10 Spare, not programmed
TB3 Pin 11-12 Spare, not programmed
TB4 Terminal Strip
TB4 Pin 1-2 Opto isolated input - ow switch input
(add jumper if no ow switch is used)
TB4 Pin 3-4 Opto isolated input - level switch input
(add jumper if no level switch is used)
TB4 Pin 5-6 Spare, not programmed
TB4 Pin 7-8 Temperature input (from platinum RTD probe)
(polarity sensitive)
TB4 Pin 9-10 Power voltage source for preamp
TB4 Pin 11-12 4-20 mA output proportional to pH
(programmable limits) (optional) (polarity sensitive)

9Instruction Manual
SECTION 3 - INSTALLATION
3.5.3 Field Wiring Instructions
Typical US field installation would include a
6 ft (2 m) AC cord wired and two (2) 1 ft (30 cm)
AC receptacles (‘ON / OFF’ mode) or two (2) 10 ft
(3 m) pump drive cables (‘PROPORTIONAL’ mode)
installed. A BNC receptacle would be installed for
the pH probe.
Connect the two (2) pumps appropriately. Install
the probe, run the cable back to the controller and
attach to BNC receptacle. If the probe is farther
than 25 ft (7.6 m) from the controller, a pre-amp
may be desirable to reduce noise effects. If this is
the case, run +5 V/-5 V as required by your preamp.
Current draw must not be greater than 10 mA.
If a ow switch and / or low-level tank switch is
available, run wires to the controller - entering
through one of the spare cable ports. Remove
the appropriate jumper(s) and attach the external
wires. Polarity does not matter. Wire size #20-22
is adequate.
Alarm relays 1 and 2 are provided to signal an
out of tolerance condition externally. These are
Form C contacts, providing a common, a normally
open and a normally closed connection. These
terminals provide power output.
A solenoid drive relay is provided that can be
connected to drain a tank when the pH is within
programmed limits. This form C contact provides
a common, a normally open and a normally closed
connection. A delay can be programmed after
initially entering this programmed zone, to allow
conditions to settle within the tank. The duration
of solenoid ON time is separately programmable.
Wire size #16-18 is adequate. These terminals
provide output power (main voltage).
The optional 4-20 mA PCB provides a fully
programmable 4-20 mA output based on the pH
readings. The optional PCB plugs into the back of
the computer pc board, as shown in Figure 6.
4-20mA Option Board
Figure 6. Circuit Board

10 Instruction Manual
SECTION 3 - INSTALLATION
3.6 pH ADJUSTMENT PUMP(S)
There are two (2) versions of the DP5000, one
is the ‘ON / OFF’ Output and the second is
‘PROPORTIONAL’ Output.
The ON / OFF Output DP5000 pH Controller will
operate any pH adjustment pump(s) which operate
on the same line voltage as the controller itself.
Combined continuous controlled load must not
exceed 4A @ 115 V or 2A @ 230 V. To ensure
efcient control, the pumps should be capable of
delivering at least 150% of the maximum pumping
requirement. Install and calibrate the pumps
according to the manufacturer’s recommendations.
The Proportional Output DP5000 pH Controller
will operate any LMI®AA9, AA7, B9, B7, C9, C7
and E7 pump, or any other pump which operates
by providing direct proportional response to a
modulated pulse input signal. The pumps must
be set to the ‘external’ control mode. To ensure
efcient control, the pumps should be capable of
delivering at least 150% of the maximum pumping
requirement. Install and calibrate the pumps
according to the manufacturer’s recommendations.
3.7 KEYPAD AND DISPLAY
The DP5000 pH Controller menu allows the user to
input all the variables necessary to customize the
controller for the application. The keypad is used
for all programming (see Figure 7).
BASE
ACID
PUMP B
ALARMS
mA
- TIMERS - CALIBRATE
HOLD 5 SEC
MENU
RUN
EDIT
DISPLAY
PUMP A
LQUITRON™ DP5000
LMI
Figure 7. Keypad
Keys:
This key is used to set up the control
prole for the acid dosing pump. (Holding
the key for ve (5) seconds will allow
priming of Pump A) (Factory setting
90 SPM).
This key is used to set up the control
prole for the base (alkali) dosing pump.
(Holding key for ve (5) seconds will
allow priming of Pump B) (Factory setting
65 SPM).
This key is used to program the high
and low alarm points and hysteresis
(ON / OFF mode). It also allows
programming of the mA output when
installed.
ACID
PUMP A
BASE
PUMP B
ALARMS
mA

11Instruction Manual
SECTION 3 - INSTALLATION
This key is used to program ‘run times’
for Pumps A and B, ‘delay times’
1 and 2 for actuating and controlling a
solenoid valve (when programmed ‘ON’
in the advanced features menu). This
key also allows setting of the ‘manual
temperature’ and the controller response
rate Δ pH. If pump run time is over 11:01
hours, the run time is disabled. The
pump will not be stopped and will run
continuously.
This key when pressed will display
details of the last successful electrode
calibration. (Holding this key for five
(5) seconds will allow entry into a new
calibration procedure (single or two
point)).
- TIMERS -
CALIBRATE
HOLD 5 SEC
Pressing this key will cause the display
to alternate showing various settings.
(Holding the key for ve (5) seconds will
allow entry to the ‘advanced features’
menu).
This key is used for starting and stopping
(run or edit) the pumps and changing
set points in the controller. It changes
the mode of the controller from ‘RUN’
to ‘OFF.’
These keys are used to change
values on the display.
Simultaneously pressing these
two (2) keys will lock the keypad
to prevent casual tampering.
Pressing them a second time will
unlock the keypad. (Wait ve (5)
seconds between locking and
unlocking).
DISPLAY
RUN
EDIT
ALARMS
mA

12 Instruction Manual
SECTION 4 - OPERATION
4.1 DEFAULT SETTINGS
In the default mode, as shipped from the factory
without any extended features programmed in
the ‘menu’, the controller is set to operate two (2)
dosing pumps towards a single desired pH region
as dened by the set points. It will do this in one of
two ways, ‘ON / OFF’ or ‘PROPORTIONAL,’ shown
graphically below:
Figure 8. ON / OFF Control
Figure 9. Proportional
When the unit is plugged in, the computer powers
up and the display illuminates. The display ashes
the pH reading and ‘OFF’. This indicates the pumps
will not operate and the unit is in the ‘OFF’ mode.
When the RUN
EDIT key is pressed the controller starts
and switches into the ‘RUN’ mode.
Example: (Proportional Controller)
This display shows a pH value of 12.0. Pump
A is ashing indicating that the acid pump is in
operation. The pump will stop pumping after 46:35
minutes if set point is not reached.
Pump A
12.0
pH
ATC
46:35
Run Time
min
sec
For two (2) seconds in every eight (8) seconds the
display shows pump speed in pulses / minute. The
pulses / minute displayed relates to the pump that
is in operation.
Pump A
95
ATC
46:28
Run
hr
min Pulse / Min
When the pH value exceeds the programmed pH
alarm point (12.5), the ‘ALARM’ ashes and the
alarm relay is activated.
ALARM
Point 2
Pump A
12.5
pH
ATC
46:28
Run
hr
min

13Instruction Manual
SECTION 4 - OPERATION
NOTE:
Throughout this manual, the term ‘pulse’ is used
to describe the mechanical stroke of the pump,
as strokes per minute (SPM).
4.1.1 Proportional Mode
The unit is shipped preset at the factory for the
‘PROPORTIONAL’ or ‘ON / OFF’ mode. To change
the unit to the opposite mode see ‘Advanced Menu
List,’ Option 2, on page 22.
NOTE:
Controller must be in ‘OFF’ mode to program
changes.
Alarm 2
12.5
Point 3
(Optional)
Point 3
(Optional)
Point 2 Pump A
Point 2 Pump B
Alarm 1
2.0
65
30 20
90
2.5 6.5 7.5 10.5 14
pH
Set Point 1
Pump A
Set Point 1
Pump B
Desired
pH
Region
Pressing
RUN
EDIT switches the mode back and forth
from RUN’ to ‘OFF’. The pH set points and pump
speed (pulses/min) can be changed only in the
‘OFF’ mode.
1. Press ACID
PUMP A
2. Press or to increase / decrease the pH
value of Set Point 1 for turning on ‘Pump A’.
Pump A
7.5
Set Point 1
3. Press ACID
PUMP A again.
4. Press or to increase / decrease pump
speed (pulse/min) for set point 1.
Pump A
20
Set Point 1
Pulse / Min
Figure 10. Pump A Control Prole

14 Instruction Manual
5. Press ACID
PUMP A again.
6. Press or to increase / decrease the pH
for Set Point 2.
Pump A
10.5
pH
Point 2
7. Press ACID
PUMP A again.
8. Press or to increase / decrease pump
speed (pulse/min) for Set Point 2.
Pump A
90
Point 2
Pulse / Min
‘Pump B’ (Base Pump) is programmed in a similar
way.
NOTE:
Set points 1 and 2 must be separated by 0.5 pH
minimum. If ‘Point 3’ is selected in the Advanced
Features Menu, the user will be prompted to
enter a pH value for Set Point 3 and a Pump
Speed at Set Point 3. Set points 1 and 3, 2 and
3 must be separated by 0.1 pH minimum.
4.1.2 ON / OFF Mode
Pump B
ON
Pump A
ON
6.5 7.5
6.0 8.0
Alarm 2
12.5
Alarm 1
2.0
Set Point
Hysteresis
Pumps OFF
NOTE:
Controller must be in ‘OFF’ mode to program
changes.
1. Hysteresis values can be set as low as 0.1 pH
2. Lowest setpoint value for pump B is 1 pH
3. Highest setpoint value for pump B is 12 pH
4. Lowest setpoint value for pump A is 2 pH
5. Highest setpoint value for pump A is 13 pH
For ‘ON / OFF’ controllers with relay outputs (instead
of pulse outputs) each pump is programmed as
follows:
1. Press ACID
PUMP A to display Set Point.
2. Press or to increase / decrease pH Set
Point.
Pump A
7.5
pH
Set Point
Pump A Control Prole
SECTION 4 - OPERATION

15Instruction Manual
3. Press ACID
PUMP A to save programmed Set Point.
4. Press or to program Δ pH (Hysteresis)
period for relay. In this example, ‘Pump A’ will
turn ON at a pH of 8.0 (set point + Δ pH). ‘Pump
A’ will turn OFF when pH drops to 7.5.
Pump A
7.5
pH
Set Point
0.5
ΔpH
‘Pump B’ (Base Pump) is programmed in a similar
way.
In this example, ‘Pump B’ will turn ON at a pH of
3.5 (set point - Δ pH) and will turn OFF when pH
reaches 4.0.
It is highly recommended that the hysteresis (pump
OFF function) be used to prevent relay chatter.
The function of the hysteresis is to prevent pump
relay chattering. It operates by allowing the pump to
be turned ON when the control point plus (or minus)
the hysteresis value has been met, but does not
allow the pump to turn OFF until the control point
has been met. The chosen value will be used for
both upper and lower set points.
The hysteresis, or dead band, designates how
many pH units beyond set point the pump runs
before turning OFF. Any value from 0 to 14.00 is
acceptable. If use of this function is undesirable,
set it to 0.
Example: If the lower set point is pH 4.0 and the
hysteresis has been set at 0.50, a falling pH will
cause the pump to activate at pH 3.50 and it will
run until reaching set point (4.0).
Hysteresis (Dead Band) 0.5 pH
Pump OFF
Pump ON
Lower Set Point
24 6 8 10
Upper Set Point
Without Dead Band
or
Pump Off Delay
Pump ON Pump OFF
Lower Set
Point
3.5 4.5
45
SECTION 4 - OPERATION

16 Instruction Manual
4.2 ALARMS
NOTE:
Controller must be in ‘OFF’ mode to program
change Set Points.
1. Press ALARMS
mA to display Alarm data.
2. Press or to program Alarm Point 1
(low pH). (Pump B)
ALARM
2.0
pH
Point 1
3. Press ALARMS
mA
to save Alarm Point 1 value and to
move to Alarm Point 2.
4. Press or to program Alarm Point 2 (high
pH). (Pump A).
ALARM
12.6
pH
Point 2
5. Press ALARMS
mA to save Alarm Point 2 value and to
move to Alarm Hysteresis.
6. Press or to program Alarm Hysteresis.
This is the point where the alarm turns OFF.
ALARM
0.5
pH
Δ
If the 4-20 mA option board is installed, the
following screens will appear. If these do not appear
and the 4-20 mA PCB is installed, go to Section
4.6, Advanced Menu, and program option “7” to “1”
and option “6” to “1”.
7. Press ALARMS
mA to display current mA output
value.
8. Press ALARMS
mA again to program the 4-20 mA
output.
12.00
mA
9. Press or to select the pH value for Point
1 mA output. Default is 4 mA = 0 pH, 20 mA =14
pH.
0.0
pH
Point 1
10 Press again. Press or to select the mA
value at Point 1.
4.00
mA
Point 1
SECTION 4 - OPERATION