Rosemount 54E User manual

Model 54e pH/ORP
pH/ORP HART®
Analyzer/Controller
Instruction Manual
510054EpH
February 2001
FREE
EXTENDED
WARRANTY!
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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