Rosemount 54E User manual

Model 54e pH/ORP
pH/ORP HART®
Analyzer/Controller
Instruction Manual
510054EpH
February 2001
FREE
EXTENDED
WARRANTY!
(See offer at back of manual)

SS-MA54
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 tech-
nical products, you must properly install, use, and main-
tain 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 [phone] and the
requested manual will be provided. Save this
Instruction Manual for future reference.
• If you do not understand any of the instructions, contact
your Rosemount representative for clarification.
• Follow all warnings, cautions, and instructions marked
on and supplied with the product.
• Inform and educate your personnel in the proper instal-
lation, operation, and maintenance of the product.
• Install your equipment as specified in the Installation
Instructions of the appropriate Instruction Manual and
per applicable local and national codes. Connect all
products to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel
to install, operate, update, program, and maintain the
product.
• When replacement parts are required, ensure that qual-
ified people use replacement parts specified by
Rosemount. Unauthorized parts and procedures can
affect the product’s performance and place the safe
operation of your process at risk. Look alike substitu-
tions 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 elec-
trical shock and personal injury.
Rosemount Analytical Inc.
Uniloc Division
2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: [phone]
1-800-854-8257
www.RAuniloc.com
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 volt-
age before accessing the electronics.
Relay contacts made to separate power
sources must be disconnected before servicing.
Electrical installation must be in accordance
with the National Electrical Code (ANSI/NFPA-
70) and/or any other applicable national or local
codes.
Unused cable conduit entries must be securely
sealed by non-flammable closures to provide
enclosure integrity in compliance with personal
safety and environmental protection 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 ground-
ed 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
certification to EN50081-2.

MODEL 54e pH/ORP TABLE OF CONTENTS
MODEL 54E PH/ORP
MICROPROCESSOR ANALYZER
TABLE OF CONTENTS
Section Title Page
1.0 DESCRIPTION AND SPECIFICATIONS ................................................................ 1
1.1 General Description ................................................................................................ 1
1.2 Description of Controls............................................................................................ 1
1.3 Specifications.......................................................................................................... 2
1.4 Ordering Information............................................................................................... 4
2.0 INSTALLATION....................................................................................................... 5
2.1 Locating the Controller............................................................................................ 5
2.2 Unpacking and Inspection...................................................................................... 5
2.3 Mechanical Installation............................................................................................ 5
3.0 WIRING ................................................................................................................... 7
3.1 General.................................................................................................................... 7
3.2 Power Input Wiring.................................................................................................. 7
3.3 Analog Output Wiring.............................................................................................. 7
3.4 Alarm Relay Output Wiring...................................................................................... 7
3.5 pH Sensor Wiring .................................................................................................... 9
3.6 Final Electrical Check.............................................................................................. 12
4.0 CALIBRATION ........................................................................................................ 13
4.1 Temperature Calibration.......................................................................................... 14
4.2 Automatic Two-Point Calibration ............................................................................. 15
4.3 Manual Two-Point Calibration.................................................................................. 17
4.4 Single-Point pH Calibration..................................................................................... 18
4.5 Compensation Options............................................................................................ 19
4.6 pH Slope Adjustment .............................................................................................. 19
4.7 Hold Mode............................................................................................................... 20
5.0 SOFTWARE CONFIGURATION ............................................................................. 21
5.1 Changing Alarm Setpoints ...................................................................................... 25
5.2 Changing Output Setpoints (PID only).................................................................... 26
5.3 Changing Output Setpoints (Normal)...................................................................... 27
5.4 Testing Outputs and Alarms.................................................................................... 28
5.5 Choosing Display Options....................................................................................... 30
5.6 Changing Output Parameters ................................................................................. 32
5.7 Changing Alarm Parameters................................................................................... 35
5.8 On-Line Diagnostics Setup ..................................................................................... 41
5.9 Auto Calibration Setup ............................................................................................ 42
i

Section Title Page
6.0 THEORY OF OPERATION...................................................................................... 44
6.1 The pH Sensor Assembly........................................................................................ 44
6.2 Continuous Sensor Diagnostics.............................................................................. 44
6.3 Interval Timer........................................................................................................... 45
6.4 Alarm Relays ........................................................................................................... 46
6.5 Time Proportional Control (TPC) Mode................................................................... 46
6.6 Normal Mode........................................................................................................... 47
6.7 Analog Outputs ....................................................................................................... 47
6.8 Controller Mode Priority........................................................................................... 48
6.9 PID Control .............................................................................................................. 49
7.0 SPECIAL PROCEDURES AND FEATURES.......................................................... 53
7.1 Password Protection................................................................................................ 53
7.2 Configuring Security................................................................................................ 54
7.3 Solution Temperature Compensation...................................................................... 55
8.0 TROUBLESHOOTING ............................................................................................ 57
8.1 Displaying Diagnostic Variables.............................................................................. 60
8.2 Troubleshooting Guidelines..................................................................................... 62
8.3 Replacement Parts.................................................................................................. 68
9.0 RETURN OF MATERIALS...................................................................................... 69
Appendix Title Page
A ORP CONFIGURATION.......................................................................................... 70
ii
MODEL 54e pH/ORP TABLE OF CONTENTS
TABLE OF CONTENTS (CONTINUED)

iii
MODEL 54e pH/ORP TABLE OF CONTENTS
TABLE OF CONTENTS (CONTINUED)
LIST OF FIGURES
Figure No. Title Page
1-1 Main Display Screen............................................................................. 1
2-1 Wall Mounting....................................................................................... 5
2-2 Pipe Mounting ...................................................................................... 6
2-3 Panel Mounting..................................................................................... 6
3-1 Power Input and Relay Output Wiring for Model 54e pH/ORP............. 8
3-2 Sensor Wiring Photo............................................................................. 9
3-3 Sensor Wiring Diagram ........................................................................ 10
3-4 Cable Dressing..................................................................................... 11
3-5 Wiring for Sensors that have Solution Grounds.................................... 11
3-6 Wiring for Sensors without Solution Grounds Directly to Analyzer....... 12
3-7 Wiring for Sensors without Solution Grounds to a Junction Box.......... 12
5-1 Outline of Menu Levels......................................................................... 24
5-2 Interval Timer Examples....................................................................... 40
6-1 Time Proportional Control..................................................................... 46
6-2 The Process Reaction Curve................................................................ 51
8-1 Theoretical pH vs. Millivolt Values at 25°C (77°F)................................ 61
8-2 Junction Box Preamplifier Check ......................................................... 64
8-3 Controller Preamplifier Check............................................................... 64
A-1 Outline of Menu Levels for ORP........................................................... 73
LIST OF TABLES
Table No. Title Page
5-1 pH Settings List.................................................................................... 21
5-2 Standard Buffers................................................................................... 43
6-1 Controller Mode Priority Chart.............................................................. 48
8-1 Diagnostic Messages........................................................................... 58
8-2 Quick Troubleshooting Guide............................................................... 59
8-3 Troubleshooting Guide......................................................................... 65
A-1 ORP Settings List.................................................................................. 71

1
MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
1.1 GENERAL DESCRIPTION
The Model 54e pH/ORP analyzer/controller monitors
and controls pH in chemical processes used in many
industries. This manual's sections and appendices
cover the system's configuration, calibration, and
maintenance, and provides a troubleshooting guide.
All adjustments to the current outputs, alarm relays,
and calibration of the pH and temperature inputs can
be made using the controller's membrane keypad.
1.2 DESCRIPTION OF CONTROLS
Figure 1-1 shows a diagram of the main display
screen. Similar diagrams are used throughout this
manual. The primary variable is continuously 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 sev-
eral different items, as desired. In this case, it is dis-
playing setpoints for alarms 1 and 2.
The F1-F4 keys 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 Jand down >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 cur-
sor 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 activated and when the time limit has been
reached on a feed limit timer. For more information
on these subjects, see Section 5.7.
FIGURE 1-1. Main Display Screen
7.00pH
26.2°C. 12.0 mA
AL1: 0.0 AL2: 14.0

MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
1.3 SPECIFICATIONS
PHYSICAL SPECIFICATIONS - GENERAL
Enclosure: Epoxy-painted aluminum, NEMA 4X (IP65),144 X 144 X 132 mm, DIN size (5.7 X 5.7 X 5.2 in.)
Front Panel: Membrane keyboard with tactile feedback and user selectable security. Light gray, blue and white
overlay. Light gray enclosure, dark gray bezel
Display: Back-lit dot matrix LCD (7.0 x 3.5 cm), blue on gray-green.The display contrast is compensated for
ambient temperature.
Process Variable Character Height: 16mm (0.6 in.)
Electrical Classification:
Class I, Division 2, Groups A, B, C, & D.
T5 Ta=50°C. Dust ignition proof: Class II, Division 1, Groups E, F, & G; Class III.
CSA-LR34186:
Max. relay contact rating: 28 Vdc; 110 Vac;
230 Vac; 6 amps resistive
FM: Max. relay contact rating: 28 Vdc resistive
150 mA - Groups A & B;
400 mA - Group C;
540 mA - Group D
Power:
Code -01: 100 - 127 VAC, 50/60 Hz ± 6%, 6.0 W
200 - 253 VAC, 50/60 Hz ± 6%, 6.0 W
Code -02: 20 - 30 VDC, 6.0 W
Current Outputs:
Output 1: pH, ORP, temperature, glass impedance, or reference impedance.
Output 2: pH, ORP, temperature, glass impedance, or reference impedance.
Each output is galvanically isolated, 0-20 mA
or 4-20 mA into 600 ohms maximum load at 115/230 Vac or
24 Vdc (Code -02) or 550 ohms maximum load at 100/200 Vac. Output 1 includes digital signal 4-20 mA
superimposed HART (Code -09 only).
RFI/EMI: EN-50081-2
EN-50082-2
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: 1.1 kg/1.6 kg (2.5 lb/3.5 lb)
2

MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
The Model 54e when configured as a pH analyzer,
requires a dual (glass and reference) impedance 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 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
pH units
Span: Any pH from 1 to 14
Accuracy: ± 0.01 pH
Repeatability: ± 0.01 pH
Stability: ± 0.01 pH/month, non-cumulative
Temperature Coefficient: Input: ± 0.003 pH/°C
Output: ± 0.006 pH/°C
Temperature Compensation: Pt 100 or Pt 1000 RTD,
Automatic or Manual
–15 to 120°C (5 to 248°F)
RECOMMENDED SENSORS:
Model 320HP High Purity pH
Model 328A Steam Sterilizable pH
Model 370 EuroSenz™ pH
Model 371 Disposable pH
Model 381+ Insertion/Submersion/FlowThrough pH
Model 389 Disposable pH
Model 396 Disposable pH
Model 396VP Disposable pH with VP 6.0 connector
Model 396P Disposable pH
Model 396R Retractable pH
Model 396RVP Retractable pH withVP 6.0 connector
Model 397 Quik Disconnect pH
Model 399 Disposable pH
The Model 54e when configured as an ORP analyz-
er, measures over a range of -1400 mV to +1400 mV
in either the American convention (Oxidation
Reduction Potential), or the European convention
(Reduction Oxidation-Redox). Although temperature
compensation is not used for ORP measurements, the
process temperature is measured and displayed.
Temperature measurement is made by an RTD locat-
ed 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 371 Disposable pH
Model 381+ Insertion/Submersion/FlowThrough ORP
Model 389 Disposable ORP
Model 396P Disposable ORP
Model 396R Retractable ORP
The Model 54e when ordered for ISE capability,
is suitable for use with a number of ion-selective elec-
trodes.Consult the factory for available measurements
and ranges.
3

MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
4
1.4 ORDERING INFORMATION
The Model 54e pH/ORP Microprocessor Analyzer is housed in a rugged, NEMA 4X (IP65) epoxy- painted cast
aluminum enclosure. Standard features include a back-lit dot-matrix liquid crystal display, sensor diagnostics,
dual isolated outputs, and four relays.The analyzer can measure pH or ORP as configured by the user. For ISE
capability, please consult the factory.
CODE OPTIONS
01 115/230 VAC, 50/60 Hz Power
02 24 VDC Power
MODEL
54e pH/ORP MICROPROCESSOR ANALYZER
CODE OPTIONS
09 HART Communications Protocol
20 Controller Outputs - PID and TPC
ACCESSORIES
PART NO. DESCRIPTION
2002577 Wall and two inch pipe mounting kit
23545-00 Panel mounting kit
23554-00 Cable glands, kit (Qty 5 of PG 13.5)
9240048-00 Stainless steel tag (specify marking)
54e pH/ORP -01 -20 EXAMPLE

5
MODEL 54e pH/ORP SECTION 2.0
INSTALLATION
SECTION 2.0
INSTALLATION
This section is for installation of the controller.
WARNING
All electrical installation must conform to the
National Electrical Code, all state and local
codes, and all plant codes and standards for
electrical equipment. All electrical installations
must be supervised by a qualified and respon-
sible plant electrician.
2.1 LOCATINGTHE CONTROLLER
Position the Model 54e pH/ORP controller to minimize
the effects of temperature extremes and to avoid
vibration and shock. Locate the controller away from
your chemical process to protect it from moisture and
fumes.
Select an installation site that is more than 2 ft from
high voltage conduit, has easy access for operating
personnel, and is not exposed to direct sunlight.
2.2 UNPACKING AND INSPECTION
Inspect the exterior of the shipping container for any
damage. Open the container and inspect the controller
and related hardware for missing or damaged parts.
If there is evidence of damage, notify the carrier 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 can
also fabricate your own bracket or panel mount the
controller using the bracket as an example.
2.3.2 Wall or Surface Mounting:
1. Mount the bracket to the controller using the sup-
plied four screws as shown in Figure 2-2.
2. Mount controller mounting bracket to wall using
any appropriate fastener such as screws, bolts,
etc (see Figure 2-1 below).
2.3.3 Pipe Mounting:
1. Attach the mounting bracket to the rear of the con-
troller and tighten the four screws as shown in
Figure 2-2.
2. Place supplied U bolts around the mounting pipe
and through the pipe mounting bracket and
mounting bracket. Tighten the U bolt nuts until the
controller is securely mounted to the pipe.
FIGURE 2-1.Wall Mounting

6
FIGURE 2-2. Pipe Mounting
MODEL 54e pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-3. Panel Mounting
2.3.4 Panel Mounting:
The controller is designed to fit into a 5.7 x 5.7 inch (DIN standard 144x144 mm) panel cutout (Figure 2-3).
Installation requires both front and rear access.
1. Install the controller as shown in Figure 2-3. Insert the instrument enclosure through the front of the panel
cutout and align the panel mounting brackets as shown.
2. Insert two mounting bracket screws through each of the two mounting brackets and into the tapped holes in
the rear of the controller enclosure and tighten each screw.
3. Insert four panel mounting screws through each hole in the mounting brackets.Tighten each screw until the
mounting bracket holds controller firmly in place.To avoid damaging the controller mounting brackets, do not
use excessive force.

MODEL 54e pH/ORP SECTION 3.0
WIRING
SECTION 3.0
WIRING
3.1 GENERAL
WARNING
All electrical installation must conform to the
National Electrical Code, all state and local
codes, and all plant codes and standards for
electrical equipment. All electrical installations
must be supervised by a qualified and respon-
sible plant electrician.
NOTE
Wire only the analog and alarm outputs
required for your application. Be sure to read
the warning at the beginning of Section 2.0.
The Model 54e pH/ORP has five access holes in the bot-
tom of the instrument housing which accept ½-in. strain
relief connectors or conduit fittings. Be sure to seal any
unused access holes.As you face the front of the unit, the
rear openings are for input power, and alarm relay sig-
nals.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 termi-
nals 1 and 2. Connect earth ground to the nearby
ground lug.A good earth ground is essential for proper
operation of the controller. Be sure to provide a means
of disconnecting the main power to the controller.
CAUTION
Do not apply power to the controller until all
electrical connections are made.
WARNING
Electrical connections to this equipment
must be made in accordance with the cur-
rent National and Local Electrical Codes in
effect for the installation location.
3.3 ANALOG OUTPUT WIRING
The analog output wiring consists of two 4-20 mA 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. All 3 of these alarms may be
activated on pH/ORP or temperature. They can also be
used to control other pumps or valves provided they are
programmed to do so.Refer to Section 5.0 to set up these
functions.
All three alarm contacts on the Model 54e pH/ORP are
rated for a maximum of 3 A (1.5A, 230 VAC, inductive
load). If your associated pump or valve exceeds this,
use a separate contact or relay rated for the external
device.
To use a contact output to control a pump, valve, or
light, the contact must be wired into a circuit together
with a source of power for the device to be controlled.
The power can be jumpered from the main power into
the controller and the circuit can be wired as shown on
the wiring diagrams, Figure 3-1.
PREAMPLIFIER SELECTION
The pH sensor signal requires a preamplifier at some
point in the measuring circuit. The preamp can be 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.
7

8
MODEL 54e pH/ORP SECTION 3.0
WIRING
FIGURE 3-1. Power Input and Relay Output Wiring for Model 54e pH/ORP
DWG. NO. REV.
454EPH02 C

9
MODEL 54e pH/ORP SECTION 3.0
WIRING
pH SENSOR COMPATIBILITY
The following sensors contain solution grounds:
Models 381+, 385+, 396P, 396R
The use of these sensors will allow both glass and ref-
erence diagnostics.
Figure 3-3 shows how these sensors should be wired.
Note that wiring connections depend on whether the
sensor (or junction box) has a preamp or not. If the
sensor (or j-box) has a preamp, then the preamp 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-
ently (see Figure 3-6).Diagnostics will only be possible
on the glass electrode side of the sensor.
When extending cable, the junction box with preamp
(P/N 23555-00) must be used.See Figure 3-7 for wiring
details.
3.5 pH SENSOR WIRING
Be sure that the pH sensor has been properly installed
and mounted.Wire the sensor to the junction box (if so
equipped) and/or Model 54e pH/ORP according to
Figures 3-5 through 3-7, or use the wiring diagram
drawing included inside the controller. Use a 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 terminals 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 54e pH/ORP SECTION 3.0
WIRING
10
FIGURE 3-3. Sensor Wiring Diagram
DWG. NO. REV.
454EPH01 B

MODEL 54e pH/ORP SECTION 3.0
WIRING
To prepare the cable for sensor wiring:
1. Use only the cable specified. Figure 3-4 shows
the 10 conductor cable with 3 shields
(9200273).
2. Strip back the PVC jacket 4 in. or far enough
to access the eleven screw terminals in the
junction box, or the eleven terminals in the
controller. Separate the two coaxial cables and
prepare each as follows:
2a. Strip back the insulating black sheath
about 1½ in.
2b. Separate the braid from the inner black
conductive sheath.
2c. Solder an insulated wire to the braid.
2d. Strip the black conductive sheath 1 in. to
expose the colored (orange or gray) cable
inside.
2e. Insulate the exposed black sheath and braid area to prevent shorts.
3. Strip ¼ in. of insulation on each conductor for terminal mounting. Insulate the exposed foil shields with heat
shrink sleeves or electrical tape. Be sure that heat shrink overlaps the exposed metal end where the foil
shield has been cut. Shields must not be shorted together.The sensor will not work if foil shields or drain
wires are not electrically isolated from each other.
FIGURE 3-4. Cable Dressing
FIGURE 3-5.Wiring for Sensors that have Solution Grounds (Models 381+, 385+, 396P, 396R)
INSIDE FRONT PANEL VIEW
11

MODEL 54e pH/ORP SECTION 3.0
WIRING
3.6 FINAL ELECTRICAL CHECK
When all wiring is completed, apply power to the con-
troller. Observe the controller for any questionable
behavior and remove power if you see a problem. With
the pH sensor in the process, the display will show a pH
value (though it may not be accurate).
CAUTION
To prevent unwanted chemical feed into the
process and to prevent injury to operating
personnel, disconnect the chemical feed
pump and other external devices until the
controller is checked out, programmed, and
calibrated.
FIGURE 3-7.Wiring for Sensors Without Solution Grounds to a Junction Box (Models 389-02-54, 396-54, 399-09)
NOTES:
1. Interconnecting wire maximum length is 500 ft. Use PN 9200273 (no substitutes). Shields must be insulated from each other at all
cable ends. Connect to junction box as shown.
2. If distance to controller is short, the junction box is not required. Connect sensor leads directly to controller.
FIGURE 3-6.Wiring for Sensors Without Solution Grounds Directly to Analyzer (Models 389-02-54, 396-
54, 397-54, 399-09). For wiring to a junction box, see Figure 3-7.
12

13
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
SECTION 4.0
CALIBRATION
The following procedures are described in this section:
• Temperature Calibration (Section 4.1)
• Auto Buffer (Two-Point) Calibration (Section 4.2)
• Manual Two-Point Calibration (Section 4.3)
• Single-Point pH Calibration (Section 4.4)
• Temperature Compensation Options (Section 4.5)
• pH Slope Adjustment (Section 4.6)
• Hold Mode (Section 4.7)
INTRODUCTION
Calibration is the process of adjusting or standardizing
the controller to a lab test (such as free acid titration) or
a calibrated laboratory instrument, or standardizing to
some known reference (such as a commercial pH
buffer).Calibration ensures that the controller shows an
accurate, and therefore, repeatable reading of pH or
temperature.
Since pH measurements are affected by temperature,
the Model 54e pH/ORP reads the temperature at the
sensor and compensates for the changing temperature
by referencing all pH measurements to 25°C (77 °F).
This compensates for temperature-related changes in
the response of the glass pH electrode which would
affect the pH measurement. The pH temperature 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:
• installing this unit for the first time
• changing or replacing electrodes or sensor ele-
ments
• troubleshooting
IMPORTANT
Before attempting to calibrate, inspect the
pH sensor assembly. It must be clean,
undamaged and free from cracks or other
signs of leakage or wear.
WARNINGS
Before performing any of these procedures, be sure to disable or disconnect the chemical feed pumps or
other external devices (see placing controller in hold, Section 4.7)
Perform the calibration procedures in this section only in the order they are given.
Do not attempt to calibrate the controller if the fault LED is lit or the display is showing fault messages.

14
4.1 TEMPERATURE CALIBRATION
MODEL 54e pH/ORP SECTION 4.0
CALIBRATION
This procedure is used to ensure an accurate temperature measurement
by the temperature sensor. It enables the controller to display process
temperature accurately as well as to compensate for the effect of 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.
2. From the main display, press any key and then press Enter (F4) to
access the Calibrate menu.
NOTE
The hold mode screen (top left) will appear if the hold mode was
enabled in Section 5.6.Activate hold mode by pressing Edit (F4),
using the arrow key to change Off to On, and then pressing
Save(F4).The hold mode holds the outputs and relays in a fixed
state to avoid process upsets to a control system. The message
"Hold Mode Activated" will always be displayed when the con-
troller is in hold.To leave the hold mode in it's current state, press
Cont(F3).
Press the êarrow 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)
3. 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 ON, be certain to install the sensor back
in the process and change the setting to OFF to resume normal
operation before leaving the controller. The screen on the top left
will appear again before the main display is shown. Follow the
same routine as in the Note for step 2 to turn the Hold Mode Off
and then press Exit (F1).
7.00pH
Hold Mode: Off
Exit Cont Edit
25.1 °C
Adjust temp: +025.1 °C
Esc Save
Standardize pH
Adjust temperature
Temp compensation
Exit Enter
25.1 °C
Adjust temp: 25.1 °C
Exit Edit