51 54eph

Instruction Manual
51-54epH/rev.H
May 2006 Model 54e pH/ORP
pH/ORP HART® Analyzer/Controller

WARNING
ESSENTIAL INSTRUCTIONS ELECTRICAL SHOCK HAZARD
READ THIS PAGE BEFORE PROCEEDING!
Making cable connections to and servicing this
Rosemount Analytical designs, manufactures, and tests its instrument require access to shock hazard level
products to meet many national and international stan- voltages which can cause death or serious injury,
dards. Because these instruments are sophisticated techni- therefore, disconnect all hazardous voltage
cal products, you must properly install, use, and maintain before accessing the electronics.
them to ensure they continue to operate within their normal
specifications. The following instructions must be adhered
Relay contacts made to separate power sources
to and integrated into your safety program when installing,
using, and maintaining Rosemount Analytical products. must be disconnected before servicing.
Failure to follow the proper instructions may cause any one
of the following situations to occur: Loss of life; personal Electrical installation must be in accordance
injury; property damage; damage to this instrument; and with the National Electrical Code (ANSI/NFPA-
warranty invalidation. 70) and/or any other applicable national or local
codes.
• 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
Unused cable conduit entries must be securely
requested manual will be provided. Save this Instruction
sealed by non-flammable closures to provide
Manual for future reference. enclosure integrity in compliance with personal
safety and environmental protection require-
• If you do not understand any of the instructions, contact ments. Use NEMA 4X or IP65 conduit plugs sup-
your Rosemount representative for clarification. plied with the instrument to maintain the ingress
• Follow all warnings, cautions, and instructions marked on
protection rating (IP65).
and supplied with the product.
For safety and proper performance this instru-
• Inform and educate your personnel in the proper installa- ment must be connected to a properly grounded
tion, operation, and maintenance of the product. three-wire power source.
• Install your equipment as specified in the Installation
Instructions of the appropriate Instruction Manual and
Proper relay use and configuration is the
per applicable local and national codes. Connect all
responsibility of the user. No external connec-
products to the proper electrical and pressure sources. tion to the instrument of more than 60VDC or
43V peak allowed with the exception of power
• To ensure proper performance, use qualified personnel to and relay terminals. Any violation will impair the
install, operate, update, program, and maintain the prod- safety protection provided.
uct.
• When replacement parts are required, ensure that quali-
Do not operate this instrument without front
fied people use replacement parts specified by cover secured. Refer installation, operation and
Rosemount. Unauthorized parts and procedures can servicing to qualified personnel.
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 WARNING
being performed by qualified persons, to prevent electri-
cal shock and personal injury. This product is not intended for use
in the residential, commercial or
light industrial environment per
certification to EN50081-2.
Emerson Process Management

Liquid Division
2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: (949) 757-8500
Fax: (949) 474-7250
http://www.raihome.com
© Rosemount Analytical Inc. 2006

MODEL 54e pH/ORP TABLE OF CONTENTS
MODEL 54E PH/ORP

MICROPROCESSOR ANALYZER
TABLE OF CONTENTS
Section Title Page
1.0 DESCRIPTION AND SPECIFICATIONS ................................................................ 1
1.1 General Description................................................................................................. 1
1.2 Description of Controls ............................................................................................ 1
1.3 Specifications........................................................................................................... 2
1.4 Ordering Information................................................................................................ 4
2.0 INSTALLATION....................................................................................................... 5
2.1 Locating the Controller ............................................................................................ 5
2.2 Unpacking and Inspection ....................................................................................... 5
2.3 Mechanical Installation ............................................................................................ 5
3.0 WIRING ................................................................................................................... 7

3.1 General .................................................................................................................... 7
3.2 Power Input Wiring .................................................................................................. 7
3.3 Analog Output Wiring .............................................................................................. 7
3.4 Alarm Relay Output Wiring...................................................................................... 7
3.5 pH Sensor Wiring .................................................................................................... 9
3.6 Final Electrical Check .............................................................................................. 12
4.0 CALIBRATION ........................................................................................................ 14

4.1 Temperature Calibration .......................................................................................... 15
4.2 Automatic Two-Point Calibration ............................................................................. 16
4.3 Manual Two-Point Calibration.................................................................................. 18
4.4 Single-Point pH Calibration ..................................................................................... 19
4.5 Compensation Options ............................................................................................ 20
4.6 pH Slope Adjustment ............................................................................................... 20
4.7 Hold Mode ............................................................................................................... 21
4.8 Trim Outputs ............................................................................................................ 21
5.0 SOFTWARE CONFIGURATION ............................................................................. 22

5.1 Changing Alarm Setpoints ....................................................................................... 26
5.2 Changing Output Setpoints (PID only) .................................................................... 27
5.3 Changing Output Setpoints (Normal) ...................................................................... 28
5.4 Testing Outputs and Alarms .................................................................................... 29
5.5 Choosing Display Options ....................................................................................... 31
5.6 Changing Output Parameters.................................................................................. 33
5.7 Changing Alarm Parameters ................................................................................... 36
5.8 On-Line Diagnostics Setup...................................................................................... 42
5.9 Auto Calibration Setup ............................................................................................ 43
i
TABLE OF CONTENTS (CONTINUED)
Section Title Page

6.0 THEORY OF OPERATION...................................................................................... 45
6.1 The pH Sensor Assembly........................................................................................ 45
6.2 Continuous Sensor Diagnostics .............................................................................. 45
6.3 Interval Timer........................................................................................................... 46
6.4 Alarm Relays ........................................................................................................... 47
6.5 Time Proportional Control (TPC) Mode................................................................... 47
6.6 Normal Mode ........................................................................................................... 48
6.7 Analog Outputs........................................................................................................ 48
6.8 Controller Mode Priority........................................................................................... 49
6.9 PID Control .............................................................................................................. 50
7.0 SPECIAL PROCEDURES AND FEATURES.......................................................... 54

7.1 Password Protection................................................................................................ 54
7.2 Configuring Security ................................................................................................ 55
7.3 Solution Temperature Compensation ...................................................................... 56
8.0 TROUBLESHOOTING ............................................................................................ 58

8.1 Displaying Diagnostic Variables .............................................................................. 61
8.2 Troubleshooting Guidelines ..................................................................................... 63
8.3 Replacement Parts .................................................................................................. 69
9.0 RETURN OF MATERIALS...................................................................................... 70
Appendix Title Page

A ORP CONFIGURATION.......................................................................................... 71
LIST OF TABLES
Table No. Title Page

5-1 pH Settings List .................................................................................... 22
5-2 Standard Buffers ................................................................................... 44
6-1 Controller Mode Priority Chart .............................................................. 49
8-1 Diagnostic Messages ........................................................................... 59
8-2 Quick Troubleshooting Guide ............................................................... 60
8-3 Troubleshooting Guide ......................................................................... 66
A-1 ORP Settings List ................................................................................. 72
ii
TABLE OF CONTENTS (CONTINUED)
LIST OF FIGURES
Figure No. Title Page

1-1 Main Display Screen............................................................................. 1
2-1 Wall Mounting ....................................................................................... 5
2-2 Pipe Mounting....................................................................................... 6
2-3 Panel Mounting..................................................................................... 6
3-1 Power Input and Relay Output Wiring for Model 54e pH/ORP............. 8
3-2 Sensor Wiring Photo............................................................................. 9
3-3 Sensor Wiring Diagram ........................................................................ 10
3-4 Cable Dressing ..................................................................................... 11
3-5 Wiring for Sensors that have Solution Grounds ................................... 11
3-6 Wiring for Sensors without Solution Grounds Directly to Analyzer ....... 12
3-7 Wiring for Sensors without Solution Grounds to a Junction Box .......... 12
3-8 Wiring to Model 399-14 ........................................................................ 13
5-1 Menu Tree ............................................................................................ 25
5-2 Interval Timer Examples ....................................................................... 41
6-1 Time Proportional Control..................................................................... 47
6-2 The Process Reaction Curve................................................................ 52
8-1 Theoretical pH vs. Millivolt Values at 25°C (77°F) ................................ 62
8-2 Junction Box Preamplifier Check.......................................................... 65
8-3 Controller Preamplifier Check............................................................... 65
A-1 Outline of Menu Levels for ORP........................................................... 74
About This Document

This manual contains instructions for installation and operation of the Model 54epH
pH/ORP HART Analyzer/Controller. The following list provides notes concerning all
revisions of this document.
Rev. Level Date Notes

0 5/00 This is the initial release of the product manual. The manual
has been reformatted to reflect the Emerson documentation
style and updated to reflect any changes in the product offering.
0 11/01 Added trip output infor & fixed panel dimension reference.
A 3/02 Updated multiple drawings & added menus.
B 7/02 Fixed setpoint example screen on page 27.
C 4/03 Updated CE info.
D 7/04 Fixed power and weight specs on page 2.
E 3/05 Updated recommended sensors on page 3.
F 4/05 Added note re ordering circuit board stack on page 69.
G 2/06 Updated Figure 1, Menu tree.
H 5/06 Noted 0-20 mA limitation for HART versions on pp. 22, 28, & 34.
iii
MODEL 54e pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
SECTION 1.0
1.1 GENERAL DESCRIPTION The F1-F4 keys are multifunction. The active opera-
tion for that key is displayed as a label just above
The Model 54e pH/ORP analyzer/controller monitors
each function key as needed. For example, F1 is
and controls pH in chemical processes used in many
usually labeled Exit and F4 may be labeled Edit,
industries. This manual's sections and appendices
Save, or Enter. Pressing Enter 4 will access sub-
cover the system's configuration, calibration, and
menus, while pressing Edit allows changing values
maintenance, and provides a troubleshooting guide.
and Save stores the values in memory. Esc 3 can
All adjustments to the current outputs, alarm relays, be used to abort unwanted changes. Exit 1 returns
and calibration of the pH and temperature inputs can to the previous screen. Other labels may appear for
be made using the controller's membrane keypad. more specialized tasks.
The up t and down b keys are used to:
1. Move the cursor (shown in reverse video) up and
down on the menu screens.
2. Scroll through the list of options available for the
7.00 pH 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
26.2°C. 12.0 mA cursor is on the second line, there are more
items to see with the down arrow key.
AL1: 0.0 AL2: 14.0 3. Scroll through values when a highlighted numer-
ical value is to be set or changed.
FIGURE 1-1. Main Display Screen 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
1.2 DESCRIPTION OF CONTROLS relay indicates a fault condition. When a fault
Figure 1-1 shows a diagram of the main display occurs, the red LED (labeled FAIL) lights up, a
screen. Similar diagrams are used throughout this descriptive error message is displayed, and the
manual. The primary variable is continuously dis- action of the outputs and relays will be as described
played in large numerals. The process temperature in Section 5.6 and Section 5.7 under fault value
and primary current output value are always dis- (e.g. 22 mA).
played on the second line of the main display The red LED also indicates when the interval timer
screen. The third line can be configured to read routine is activated and when the time limit has been
several different items, as desired. In this case, it is reached on a feed limit timer. For more information
displaying setpoints for alarms 1 and 2. on these subjects, see Section 5.7.
1
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 500 ohms maximum load at 115/230 Vac or
24 Vdc (Code -02) or 500 ohms maximum load at 100/200 Vac. Output 1 includes digital signal 4-20 mA
superimposed HART (Code -09 only).
RFI/EMI: EN-61326
LVD (Code -01 only): EN-61010-1

Ambient Temperature: 0 to 50°C (32 to 122°F)
NOTE: The analyzer is operable from -20 to 60°C (-4 to 140°F) with some degradation in display performance.
Relative Humidity: 95%, non condensing
Alarms:
Relay 1 - Process, Interval*, or Time Proportional Control (code -20)
Relay 4 - Sensor/analyzer and process fault alarm
Each relay has a dedicated LED on the front panel.
*maximum of one interval timer
Relay Contacts: Relays 1-3: Epoxy sealed form A contacts, SPST, normally open
Relay 4: Epoxy sealed form C, SPDT
Resistive Inductive
28 Vdc 5.0 Amps 3.0 Amps
115 Vac 5.0 Amps 3.0 Amps
230 Vac 5.0 Amps 1.5 Amps
Weight/Shipping Weight: 1.8 kg/2.3 kg (4 lb/5 lb)
2
The Model 54e when configured as a pH analyzer, The Model 54e when configured as an ORP
requires a dual (glass and reference) impedance pre- analyzer, measures over a range of -1400 mV to
amplifier (patent pending). This preamp converts the +1400 mV in either the American convention
high impedance pH glass electrode signal to a low (Oxidation Reduction Potential), or the European con-
impedance signal. The preamplifier may be located in vention (Reduction Oxidation-Redox). Although tem-
one of three areas: 1) in the pH sensor for best per- perature compensation is not used for ORP
formance, 2) in a remote junction box when process
measurements, the process temperature is measured
temperatures exceed 80°C (176°F) in submersion
applications, or 3) in the analyzer when the distance and displayed. Temperature measurement is made by
between the pH sensor and the analyzer is 4.5 meters an RTD located in the sensor assembly.
(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- ANALYZER SPECIFICATIONS @ 25°C
sent any 1 to 14 pH span. Measurement Range: –1400 to +1400 mV
A two-point calibration is made by immersing the sen-
Output Scale Expansion: Zero suppression: up to
sor in two different buffer solutions and entering the
pH values. When two buffers are used, the micro- ±1300 mV
processor automatically calculates the electrode slope Span: Any ORP range from 100 to 2800 mV
which is used for self-diagnostics. The electrode slope Accuracy: ± 1.0 mV
can be read on the display and manually adjusted. A
one-point process standardization is easily accom- Repeatability: ± 1.0 mV
plished by entering the pH value of a grab sample. Stability: ± 1.0 mV/month, non-cumulative
Temperature Coefficient: Input: ± 0.2 mV/°C
Output: ± 0.4 mV/°C
ANALYZER SPECIFICATIONS @ 25°C
Temperature Measurement: –15 to 120°C (5 to 248°F)
Measurement Range: 0 to 14 pH Pt 100 or Pt 1000 RTD
Output Scale Expansion: Zero suppression: up to 13
pH units
Span: Any pH from 1 to 14 RECOMMENDED SENSORS:
Accuracy: ± 0.01 pH Model 330 Flow Through ORP
Repeatability: ± 0.01 pH *Model 371 EuroSenz ORP
Stability: ± 0.01 pH/month, non-cumulative Model 381+ Insertion/Submersion/Flow Through ORP
*Model 389 Disposable ORP
Temperature Coefficient: Input: ± 0.003 pH/°C
Model 396P Disposable ORP
Output: ± 0.006 pH/°C Model 396R Retractable ORP
Temperature Compensation : Pt 100 or Pt 1000 RTD, Model 398 Insertion/Submersion ORP
Automatic or Manual Model 398VP Insertion/Submersion with VP 6.0 connector
–15 to 120°C (5 to 248°F) Model 398R Retractable ORP
Model 398RVP Retractable ORP with VP 6.0 connector
RECOMMENDED SENSORS:
Model 320B Flow Through pH
Model 320HP High Purity pH The Model 54e when ordered for ISE capability,
*Model 328A Steam Sterilizable pH is suitable for use with a number of ion-selective elec-
*Model 370 and 371 EuroSenz pH trodes. Consult the factory for available measure-
Model 381+ Insertion/Submersion/Flow Through pH ments and ranges.
*Model 389 Disposable pH
*Model 396/VP Disposable pH
Model 396P/VP Disposable pH
Model 396R/VP Retractable pH
Model 397 Quik Disconnect pH
Model 398/VP Insertion/Submersion pH
*Model 398R/VP Retractable pH
*Model 399 Disposable pH
*Model Hx338 Steam Sterilizable pH
*Model Hx348 Steam Sterilizable pH 3
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.
MODEL
54e pH/ORP MICROPROCESSOR ANALYZER
CODE OPTIONS
01 115/230 VAC, 50/60 Hz Power
02 24 VDC Power
CODE OPTIONS
09 HART Communications Protocol
20 Controller Outputs - PID and TPC
54e pH/ORP -01 -20 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)
4
INSTALLATION
SECTION 2.0
INSTALLATION
This section is for installation of the controller. 2.3.2 Wall or Surface Mounting:
WARNING 1. Mount the bracket to the controller using the sup-
All electrical installation must conform to the plied four screws as shown in Figure 2-2.
National Electrical Code, all state and local 2. Mount controller mounting bracket to wall using
codes, and all plant codes and standards for any appropriate fastener such as screws, bolts,
electrical equipment. All electrical installations etc (see Figure 2-1 below).
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 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- FIGURE 2-1. Wall Mounting
mediately. If parts are missing, contact Rosemount
Analytical customer support.
2.3.3 Pipe Mounting:

2.3 MECHANICAL INSTALLATION 1. Attach the mounting bracket to the rear of the con-
2.3.1 Mounting the Controller troller and tighten the four screws as shown in
Figure 2-2.
The Model 54e pH/ORP controller may be supplied
with a mounting bracket accessory. If you use the 2. Place supplied U bolts around the mounting pipe
mounting bracket on wall or pipe installations, avoid and through the pipe mounting bracket and
mounting on pipes which vibrate or are close to the mounting bracket. Tighten the U bolt nuts until the
process. The bracket may be modified to mount the controller is securely mounted to the pipe.
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.
5
INSTALLATION
2.3.4 Panel Mounting:

The controller is designed to fit into a 5.43 x 5.43 inch (DIN standard 137.9 x137.9 mm) panel cutout (Figure 2-3).
Installation requires both front and rear access.
1. Install the controller as shown in Figure 2-3. Insert the instrument enclosure through the front of the panel
cutout and align the panel mounting brackets as shown.
2. Insert two mounting bracket screws through each of the two mounting brackets and into the tapped holes in
the rear of the controller enclosure and tighten each screw.
3. Insert four panel mounting screws through each hole in the mounting brackets. Tighten each screw until the
mounting bracket holds controller firmly in place. To avoid damaging the controller mounting brackets, do not
use excessive force.
FIGURE 2-2. Pipe Mounting
FIGURE 2-3. Panel Mounting
6
WIRING
SECTION 3.0
WIRING
3.1 GENERAL 3.3 ANALOG OUTPUT WIRING

WARNING The analog output wiring consists of two 4-20 mA sig-
nals: output one from terminals 4 and 5, output 2 from
All electrical installation must conform to the
1 and 2 on TB2, as shown in Figure 3-1. These signals
National Electrical Code, all state and local can be used for chart recorder, computer monitoring, or
codes, and all plant codes and standards for PID control output. The analog outputs can be pro-
electrical equipment. All electrical installations grammed for 4-20 mA or for 0-20 mA, direct or reverse
must be supervised by a qualified and respon- acting. Current output 1 includes superimposed HART
sible plant electrician. (code -09 only).
NOTE
Wire only the analog and alarm outputs
required for your application. Be sure to read 3.4 ALARM RELAY OUTPUT WIRING
the warning at the beginning of Section 2.0. The controller has 3 "dry" alarm relay contacts which are
The Model 54e pH/ORP has five access holes in the bot- normally open. Alarm 1 is across terminals 4 and 5 on
tom of the instrument housing which accept ½-in. strain TB3. This alarm is typically used to control the pump in a
relief connectors or conduit fittings. Be sure to seal any chemical feed system. Alarm 2 across terminals 6 and 7
unused access holes. As you face the front of the unit, on TB3 is usually used to operate a light or horn as a
the rear openings are for input power, and alarm relay means of alerting the chemical process operator when
signals. The opening on the front left is for sensor wiring pH/ORP is outside the control range. Alarm 3 is across
only (DC). The front right is for analog output wiring. terminals 8 and 9 on TB3. All 3 of these alarms may be
activated on pH/ORP or temperature. They can also be
NOTE used to control other pumps or valves provided they are
For best EMI/RFI protection, the output cable programmed to do so. Refer to Section 5.0 to set up these
should be shielded and enclosed in an earth functions.
grounded, rigid, metal conduit. Connect the All three alarm contacts on the Model 54e pH/ORP are
output cable's outer shield to the earth ground rated for a maximum of 3 A (1.5A, 230 VAC, inductive
connection on TB2 (Figure 3-1) 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
3.2 POWER INPUT WIRING light, the contact must be wired into a circuit together
Figure 3-1 depicts the wiring detail for the Model 54e with a source of power for the device to be controlled.
pH/ORP. Code -01: connect AC power to TB3, termi- The power can be jumpered from the main power into
nals 1 and 2 for 115 VAC (terminals 2 and 3 for 230 the controller and the circuit can be wired as shown on
VAC). Code -02: connect DC power to TB3 terminals 1 the wiring diagrams, Figure 3-1.
and 2. Connect earth ground to the nearby ground lug.
A good earth ground is essential for proper operation of PREAMPLIFIER SELECTION
the controller. Be sure to provide a means of discon-
The pH sensor signal requires a preamplifier at some
necting the main power to the controller.
point in the measuring circuit. The preamp can be in-
CAUTION side the sensor, in the junction box, or in the controller.
Do not apply power to the controller until all To allow for these options, the Model 54e pH/ORP has
electrical connections are made. a jumper selectable preamp mounted on the CPU cir-
cuit board (Figure 3-3). The jumper is placed in the
WARNING "analyzer" position when there is no preamp in the sen-
Electrical connections to this equipment sor (or junction box). Generally, this jumper is in the
must be made in accordance with the cur- "sensor" position.
rent National and Local Electrical Codes in
effect for the installation location.
7
WIRING
DWG. NO. REV.

454EPH02 D
FIGURE 3-1. Power Input and Relay Output Wiring for Model 54e pH/ORP
8
WIRING
pH SENSOR COMPATIBILITY 3.5 pH SENSOR WIRING

The following sensors contain solution grounds: Be sure that the pH sensor has been properly installed
Models 381+, 385+, 396P, 396R and mounted. Wire the sensor to the junction box (if so
The use of these sensors will allow both glass and ref- equipped) and/or Model 54e pH/ORP according to
erence diagnostics. Figures 3-5 through 3-7, or use the wiring diagram
drawing included inside the controller. Use a narrow-
Figure 3-3 shows how these sensors should be wired. bladed screwdriver to facilitate sensor wiring (see
Note that wiring connections depend on whether the Figure 3-2).
sensor (or junction box) has a preamp or not. If the
sensor (or j-box) has a preamp, then the preamp loca- The wiring diagrams show connections between
tion jumper is moved accordingly and wiring connected the Model 54e pH/ORP and the junction box used
as on the left of Figure 3-3. Otherwise, the jumper is where distance from the sensor to the controller
moved to the "analyzer" position and wiring for TB1 is exceeds the integral sensor cable length and inter-
connected as on the right hand side. connecting wire is required. The interconnecting
sensor wire recommended is P/N 9200273. Use of
Junction box (P/N 23550-00) wiring for sensors that
this cable provides EMI/RFI protection and com-
contain a preamp is strictly point to point. All sensor
plete sensor diagnostics (for sensors so
leads are run to the junction box and carried through by
equipped). The maximum interconnecting wire
the extension cable (P/N 9200273). Only use this rec-
length is 500 ft.
ommended extension cable and be careful to connect
all cable leads in the junction box. Sensors without pre- IMPORTANT
amps that require cable extension should be wired up All interconnecting sensor cable ends must be
to the junction box (P/N 23555-00) as per the appropri- properly dressed, as shown in Figure 3-4, to pre-
ate sensor instruction manual. vent the individual sensor and shield wires from
The following sensors do not contain solution grounds shorting. All shields must be kept electrically sep-
but are compatible with the Model 54e pH/ORP: arate all the way back to the terminals on the Model
Models 389-02-54, 396-54, 397-54, 399-09 54e pH/ORP. Check that there is no continuity
Sensors without solution grounds must be wired differ- between the shield wires and any other sensor
ently (see Figure 3-6). Diagnostics will only be possible conductors or shields prior to connecting the sen-
on the glass electrode side of the sensor. sor wiring to the terminals on the Model 54e
pH/ORP. FAILING TO FOLLOW THESE INSTRUC-
When extending cable, the junction box with preamp TIONS WILL RESULT IN CONTROLLER MALFUNC-
(P/N 23555-00) must be used. See Figure 3-7 for TION.
wiring details.
FIGURE 3-2. Sensor Wiring Photo
9
WIRING
DWG. NO. REV.

454EPH01 C
FIGURE 3-3. Sensor Wiring Diagram
10
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
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 FIGURE 3-4. Cable Dressing
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.
INSIDE FRONT PANEL VIEW
FIGURE 3-5. Wiring for Sensors that have Solution Grounds (Models 381+, 385+, 396P, 396R)
11
WIRING
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.
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.
3.6 FINAL ELECTRICAL CHECK CAUTION

When all wiring is completed, apply power to the con- To prevent unwanted chemical feed into the
troller. 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
WIRING
FIGURE 3-8. Wiring to Model 399-14
13
CALIBRATION
SECTION 4.0
CALIBRATION
The following procedures are described in this section: This compensates for temperature-related changes in
• Temperature Calibration (Section 4.1) the response of the glass pH electrode which would
affect the pH measurement. The pH temperature com-
• Auto Buffer (Two-Point) Calibration (Section 4.2) pensation does not account for changes in chemical
• Manual Two-Point Calibration (Section 4.3) activity which affect the actual pH value of the solution
being measured. See Section 7.0 for information on
• Single-Point pH Calibration (Section 4.4) solution temperature compensation.
• Temperature Compensation Options (Section 4.5) To ensure the controller's accuracy, it is important to
• pH Slope Adjustment (Section 4.6) perform all the calibration procedures provided in this
section if you are:
• Hold Mode (Section 4.7)
• installing this unit for the first time
• changing or replacing electrodes or sensor ele-
INTRODUCTION
ments
Calibration is the process of adjusting or standardizing
• troubleshooting
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 IMPORTANT
buffer). Calibration ensures that the controller shows
an accurate, and therefore, repeatable reading of pH or Before attempting to calibrate, inspect the
temperature. pH sensor assembly. It must be clean,
undamaged and free from cracks or other
Since pH measurements are affected by temperature, signs of leakage or wear.
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).
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
CALIBRATION
4.1 TEMPERATURE 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
7.00 pH 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
Hold Mode: Off access the Calibrate menu.
Exit Cont Edit 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,
Standardize pH press Cont(F3).
Adjust temperature Press the arrow key twice to bring up the screen to the left and
then press Enter (F4).
Temp compensation
Exit Enter
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)
25.1 °C 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
Adjust temp: 25.1 °C the value into memory. To abort the change, press Esc (F3).
Afterwards, to continue with buffer calibration, go to Section 4.2 or
Exit Edit 4.3, otherwise press Exit (F1) three times for the main display.
NOTE
25.1 °C 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
Adjust temp: +025.1 °C 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
Esc Save
and then press Exit (F1).
15
CALIBRATION
4.2 AUTOMATIC TWO-POINT CALIBRATION
The two-point calibration is performed when the controller is initially

installed and whenever elements of the sensor assembly or controller are
replaced. The two-point calibration re-establishes the slope of the elec-
trode. This is necessary because the slope (mV/pH change) decreases
as the glass pH electrode ages.
7.00 pH 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
Hold Mode: Off 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-
Exit Cont Edit
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. 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
Buffer calibration the cursor on "Calibrate", press Enter (F4). With the cursor on "Buffer
Standardize pH calibration", press Enter (F4) again.
NOTE
Adjust temperature The hold mode screen (top left) will appear if the hold mode was
Exit Enter 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).
4.02 pH 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.
Autocal buffer 1
The controller is waiting for the pH reading to stabilize within the
Abort Cont 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-
4.02 pH tion.
Press Abort (F1) to cancel the calibration if it appears to be taking too
long.
Buffer 1 -- “Wait”
Abort Cont
16
CALIBRATION
3. A screen like the one on the left will appear after stabilization.
4.02 pH Use the arrow keys to select the correct buffer.

If the correct buffer does not appear, refer to Section 5.9 and select
Buf1 done: 4.01 @25°C a buffer group that includes the desired buffers. As usual, to cancel
the calibration, press Abort (F1).
Abort Cont
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.
4. This screen appears immediately after pressing the Cont key in

10.02 pH step 3.
Place the sensor into the second buffer. Press Cont (F3) to proceed.
Autocal buffer 2 The word "Wait" flashes (as before) until the sensor is stabilized.
Press Abort (F1) to cancel the calibration if the process is taking too
Abort Cont
long. (see step 2).
5. A screen like the one on the left will appear after stabilization. Use the
10.02 pH arrow keys to select the correct buffer, and press Cont (F3). If
the correct buffer does not appear, refer to Section 5.9 and select a
buffer group that includes the desired buffers. As usual, to cancel the
Buf2 done: 10.01 @25°C calibration, press Abort (F1).
Abort Cont This completes the calibration. The controller has now recalculated
the slope and the zero offset of the sensor.
CALIBRATION NOTES
1. A two-point calibration should always be followed by a sin-
gle-point calibration (see Section 4.4).
10.02 pH 2. After a buffer calibration, the electrode slope value can be

checked to see if the electrode is aging.
Auto buffer cal done 3. If the sensor is not at the same temperature as the buffer the cal-
ibration will be in error.
Abort Cont
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
CALIBRATION
4.3 MANUAL TWO-POINT CALIBRATION
This procedure is followed if Autocal is set to "Manual" in Section 5.9.

2-pt calibration Buffer values are entered manually and no stabilization check is used.
Standardize pH 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
Adjust temperature Calibration", press Enter (F4) again.
NOTE
Exit Enter
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
4.01 pH 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-
Calibrate point 1 ature. The display will flash “wait’ while the reading is stabilizing.
When the pH reading is stable, press Cont (F3) to update the read-
Abort Cont 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
4.01 pH 2 (pt. 2) calibration.

NOTE
Press Abort (F1) to cancel buffer calibration and return to the cal-
Pt. 1: 04.00pH 25°C ibration menu.
Pt 2 Edit
5. Remove the sensor from buffer 1 and rinse in water.
10.01 pH 6. Place the pH sensor into a beaker containing the second buffer solu-
tion.
7. Allow the pH and temperature to stabilize (as before) and press Cont
Calibrate point 2 (F3). The display will flash “wait’ while the reading is stabilizing.
8. Enter the correct value for buffer 2 as described in step 3 and press
Abort Cont
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
10.01 pH 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.
2-pt calibration done 4. If the hold mode is ON, be certain to reinstall the sensor in the
Esc Save process and change the setting to OFF to return to normal oper-
ation.
18
CALIBRATION
4.4 SINGLE-POINT pH CALIBRATION
A single-point calibration (standardization) should always be performed

following a two-point calibration. It may have to be performed as often as
once a day to ensure that the sensor is accurately reading pH. As the
glass electrode or the porous reference plug fouls and ages, the pH read-
ing will drift. The single-point calibration re-establishes the exact pH read-
ing. Experience with your process and it's acceptable 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.
the cursor on "Calibrate", press Enter (F4).
Buffer calibration
NOTE
Standardize The Hold Mode screen may appear if the feature was enabled in
Adjust temperature section 5.6. Changing the Hold Mode to ON holds the outputs in
a fixed state, and avoids process upsets during calibration.
Exit Enter 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 pH reading. The

7.01 pH next line displays the pH reading when this screen was first
accessed. Press Edit (F4) to perform the standardize.
Standardize: 7.01 pH Use the arrow keys to change the second line standardize value to
the correct pH and press Save (F4) to complete the procedure. Esc
Exit Enter (F3) will cancel.
The pH reading in the large display will change to the new value and
the zero offset number will be recalculated.
4.01 pH NOTE
Before exiting the calibration mode, remember to change the
hold mode setting to OFF (if it was turned on in step 3).
Standardize: +07.00 pH
Esc Save
19
CALIBRATION
4.5 TEMPERATURE COMPENSATION OPTIONS
Automatic Temperature Compensation is a standard option for pH equip-

Adjust temperature ment and is used in virtually all pH measurement situations. If compen-
sation is not desired, the temperature signal from the sensor can be
Temp compensation ignored by placing the controller in the manual temperature compensa-
pH slope tion mode.
Manual mode allows the input of a fixed value that will be used instead of
Exit Enter
the sensor value. The manual temperature value need only be entered if
the temperature compensation setting is manual. In this case, a value
may be entered between -15 and 120°C (5 and 248°F).
To change these settings, obtain the top screen by pressing Enter (F4)
Temp comp: Auto when Calibrate is highlighted in the main menu and then press the arrow
key. Press Enter (F4) again to obtain the lower screen. Highlight the
Manual temp: 025.0°C 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)
Exit Enter will cancel the change.
NOTE
When the temperature compensation setting is manual, all tem-
perature specific faults are disabled.
4.6 pH SLOPE ADJUSTMENT

The slope of the glass electrode is normally calculated during buffer cali-
Temp compensation bration. It can, however, be entered directly (if known) using this proce-
dure. A new electrode has a slope of about 59 mV/pH but as it ages the
pH slope 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
Output trim slope can also be viewed on the diagnostic variables screen.
Exit Enter 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).
pH slope: 59.16 mV/pH Acceptable slope values are between 45.0 and 60.0 mV/pH.
NOTE
Before exiting the calibration mode, if the Hold Mode is ON, be
certain to change the setting to OFF to resume normal operation.
Exit Enter
20
CALIBRATION
4.7 HOLD MODE
Placing the Controller on Hold for Maintenance. Before performing main-
7.00 pH 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
Hold Mode: Off default states (see Section 5.6). The relays will act as selected in relay
default, see Section 5.7.
Exit Cont Edit 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
7.00 pH press Save (F4).
NOTE
26.2°C 12.0mA When the Hold Mode is activated ("On"), "Hold Mode Activated"
will always appear on the bottom line of the display.
Hold Mode Activated
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 OFF.
4.8 TRIM OUTPUTS
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).
Temp compensation With the cursor on “Output trim,” press Enter (F4) again. Select “Trim out-
pH slope put 1” or “Trim output 2” as appropriate.
Press Edit (F4) to select Cal point 1 (4 mA expected and simulated) or Cal
Output trim point 2 (20 mA expected and simulated). Adjust the Meter value to match
Exit Enter the reading of the calibrated meter connected to the output. Press Enter
(F4) to complete the calibration.
21
SOFTWARE CONFIGURATION
SECTION 5.0
This section contains the following:
• An introduction to using the configuration process
• A List of Settings for the controller
• 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 possible 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°C _______
CONFIGURE LEVEL (Sections 5.5-5.9)
A. Display (Section 5.5)
1. Measurement type pH/ORP/Redox pH _______
2. pH Resolution 0.01 pH/0.1 pH 0.01 pH
3. Temperature Units °C/°F °C _______
4. Output 1 Units mA/% (of full scale) mA _______
5. Output 2 Units mA/% (of full scale) mA _______
6. Language English/Français/Español/Deutsch/Italiano English _______
7. Main display lower left See Section 5.5 Alarm 1 Setpoint _______
8. Main display lower right See Section 5.5 Alarm 2 Setpoint _______
9. 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) Output1 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 _______
* Option-09, HART-enabled version operates at 4-20 mA only on output 1.
22 Continued on the following page

TABLE 5-1. pH Settings List (continued)
ITEM RANGES FACTORY SETTINGS USER SETTINGS

2b. Output 1 Setup (PID)
(a) Setpoint -2 to 16 pH or -15 to 130°C 7 pH _______
(b) Proportional 0-299.9% 100.0% _______
(c) Integral 0-2999 sec 0 sec _______
(d) Derivative 0-299.9% 0.0% _______
(e) LRV (4 mA) -2 to 16 pH or -15 to 130°C 2 pH _______
(f) URV (20 mA) -2 to 16 pH or -15 to 130°C 0 pH _______
3. Output 2 Control
(a) Output 2 Measurement Process/Temp/Glass Imp/Ref Imp Temperature _______
(b) Output 2 Control Mode Normal/PID Normal _______
4a. Output 2 Setup (Normal)
(a) Current Range 4-20 mA/0-20 mA 4-20 mA _______
(e) Fault value 0-22 mA 22 mA _______
4b. Output 2 Setup (PID)
(b) Proportional 0-299.9% 100.0% _______
(d) Derivative 0-299.9% 0.0% _______
(e) LRV (4 mA) -2 to 16 pH or -15 to 130°C 2 pH _______
(f) URV (20 mA) -2 to 16 pH or -15 to 130°C 0 pH _______
5. Hold (Outputs and Relays) Disable/Enable/ 20 min timeout Disable feature _______
C. Alarms (Section 5.7)
1. Alarm 1 Control
(a) Activation Method Process/Temp Process _______
(b) Alarm 1 Control Mode Normal/TPC Normal _______
2a. Alarm 1 Setup (Normal)
(a) Configuration Low alarm/High alarm/Off Low _______
(b) Hysteresis (deadband) 0 - 5.00 pH 0.01 pH _______
(c) Delay Time 0-99 sec 0 sec _______
(d) Relay Fault Open/Closed/None None _______
2b. Alarm 1 Setup (TPC)
(b) Proportional 0-299.9% 100.0% _______
(d) Derivative 0-299.9% 0.0% _______
(e) Time Period 10-2999 sec 30 sec _______
(f) LRV (100% On) -2 to 16 pH or -15 to 130°C 2 pH _______
(g) URV (100% Off) -2 to 16 pH or -15 to 130°C 0 pH _______
(h) Relay Fault None/Open/Closed None _______
3. Alarm 2 Control
(a) Configuration Low alarm/High alarm/Off High _______
(b) Proportional 0-299.9% 100.0% _______
(d) Derivative 0-299.9% 0.0% _______
Continued on the following page 23

TABLE 5-1. pH Settings List (continued)

ITEM RANGES FACTORY SETTINGS USER SETTINGS
5. Alarm 3 Control
(e) Delay Time 0-99 sec 0 sec _______
(b) Proportional 0-299.9% 100.0% _______
(d) Derivative 0-299.9% 0.0% _______
7. Alarm 4 Control
(a) Alarm Fault/Off Fault _______
8. Feed Limit Timer
(a) Feed Limit Disable/alarm 1/alarm 2/alarm 3 Disable _______
(b) Timeout Value 0-10,800 sec 3600 sec _______
9. Interval Timer
(a) Timer (selection) Disable/alarm 1/alarm 2/alarm 3 Disable _______
(b) Timer (activation method) Time activated/Imped. activated Time activated _______
(c) Interval 0-999.9 hr 24.0 hr _______
(d) Repeats 1-60 1 _______
(e) On Time 0-2999 sec 120 sec _______
(f) Off Time 0-2999 sec 1 sec _______
(g) Recovery 0-999 sec 600 sec _______
D. Diagnostics (Section 5.8)
1. Diagnostics (Glass and Reference) On/Off 000 (no security) _______
2. Glass Imp(edance) High Setpoint 0-2000 MOhms (0 disables) 000 (no security) _______
3. Glass Imp(edance) Low Setpoint 0-900 MOhms (0 disables)
4. Ref(erence) Imp(edance) High 0-140 KOhms (0 disables) 000 (no security) _______
5. Zero Offset 0-999 mV (0 disables) 000 (no security) _______
6. Cal(ibration) Warn(ing) 0-500% (0 disables)
7. Imped(ance Temperature) Comp(ensation) On/Off 000 (no security) _______
E. Auto Calibration (Section 5.9)
1. Autocal (Buffer List Selection) Manual/Standard/DIN 19267 000 (no security) _______
2. Stabilize pH (Auto Calibration) .01-.50 pH 000 (no security) _______
3. Stabilization Time (Auto Calibration) 0-30 sec 000 (no security) _______
F. Security (Section 7.1)
1. Lock all 000-999 000 (no security) _______
2. Lock Program (Lock all except Calibrate) 000-999 000 (no security) _______
3. 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) -0.044 to 0.028pH/°C 000 (no security) _______
2. Operate Iso(potential pH) -1.35 to 20.12 pH 000 (no security) _______
3. Sensor Iso(potential) 0-14 pH 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
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
Accessing Calibrate, Program and Configure Menus. Level 2 Program. To access the program level from the
Operating configuration changes are made at the levels main menu, place the cursor over "Program" with the
shown in Figure 5-1. Pressing any key from the main dis- down arrow key. Then press Enter (F4). From the program
play will access the main menu (top left). Refer to level menu, changes can be made to the alarm setpoints
Appendix A for ORP measurements. and the output setpoints.
Level 1 Calibrate. To access calibration selections from Level 3 Configure. To access the configure level from the
the main menu, with the cursor on "Calibrate" press Enter main menu place cursor over "Program" and Enter (F4),
(F4). All buffer calibration, pH standardization and tem- then place cursor over "Configure" and Enter (F4). This
perature adjustments are made at this level (refer to level contains advanced selections, such as alarms, diag-
Section 4.0 for these procedures). nostics, autocal and others.
Blank
Out 2
R1
GI
In
AL2
AL3
FIGURE 5-1. Outline of Menu Levels 25

5.1 CHANGING ALARM SETPOINTS
This section describes how the three alarm setpoints can be changed.
Alarm setpoints Move the cursor down by pressing the arrow key.
Output setpoints
1. From the main menu, move the cursor down to "Program" and press
Simulate tests Enter (F4). On the next display, with the cursor on "Alarm setpoints",
Exit Enter
press Enter (F4).
2. Select the desired alarm by moving the cursor down to highlight it.
Alarm 1 setpoint When the correct alarm is highlighted, press Enter (F4) to get to the
adjustment screen.
Alarm 2 setpoint In this example we have pressed the arrow key down once to access
Alarm 3 setpoint the alarm 2 setpoint.
Exit Enter NOTE

There are 2 different possible screens at the next point, depend-
ing on whether the alarm has been configured as normal or TPC.
3a. (normal alarm). The setpoint now being used for this alarm and the
Alarm High: 14.00pH 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).
Exit Enter 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.
3b. (TPC alarm only). When the alarm has been configured as TPC, the
Setpoint: 07.00 pH 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).
Exit Edit
After the F4 key is pressed, use the arrow keys to change the 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.
26
5.2 CHANGING OUTPUT SETPOINTS (PID ONLY)
This section describes how the two output setpoints can be changed.
Alarm setpoints 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",
Output setpoints then "Not applicable" will be displayed. For reranging outputs, go to
Section 5.3.
Simulate tests
Exit Enter 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).
Output 1 setpoints 2. Highlight the desired Output setpoints and press Enter (F4).
Output 2 setpoints
Exit Enter
3. The setpoint now being used is displayed. Press Edit (F4) and use
Setpoint: 7.00 pH the arrow keys to change the display to the new value.
4mA: 0.00 pH 4 mA is the deviation from setpoint that will result in a 4 mA out. 20
mA is the deviation from setpoint that will result in a 20 mA setpoint.
20mA: 2.00 pH Highlight the desired item and press Edit 4 and the arrow keys to
change the display to the new value.
Exit Enter
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) = 50% of range (12
mA). If the setpoint is changed to 6.5 pH, the output will be 7 - 6.5)/(2
- 0) = 25% of range (8 mA).
4. Press Save (F4) to enter into memory or Esc (F3) to abort the
Setpoint: + 06.90 pH change.
The Control setpoint is typically the condition where the current output is
at a minimum. The P and I control calculations use the setpoint to adjust
the current output to the desired level based on the parameters estab-
Exit Enter
lished in Section 5.6.
27
5.3 CHANGING OUTPUT SETPOINTS (NORMAL ONLY)
This section describes how the 4 (or 0) to 20 mA current outputs can be

Alarm setpoints reranged. Note that the current outputs can be configured to represent
pH, temperature, glass impedance, or reference impedance. See
Output setpoints Section 5.6 for details on configuration.
Simulated test 1. From the main menu, move the cursor down to "Program" and press
Enter (F4). On this display, move the cursor to "Rerange outputs"
Exit Enter and press Enter (F4).
Note: 0-20 mA output range is disabled on output 1 with HART-
enabled version (-09 option).
2. Select the desired output by moving the cursor down to highlight it.
Output 1 When the correct output is highlighted, press Enter (F4) to get to the
Output 2 adjustment screen.
Exit Enter
3. This message asks for confirmation of the requested change.

CAUTION: Current Changes in these settings may degrade process control, so use cau-
Output 1 will be tion when making changes. Press Enter (F4) to continue. Otherwise
press Abort (F1).
affected.
Exit Enter
This screen allows changing the setpoints for output 1. A similar screen
4 mA: 0.00 pH is available for output 2. The live current output now being transmitted
by the controller is shown on the third line.
20 mA: 14.00 pH 4. Press Edit (F4) to make changes in the setpoints. The Edit key
Output 1: 12.00 mA 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-
Exit Enter 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,
4 mA: +00.00 pH will show 0 mA instead of 4 mA on the top line. Outputs that are
based on temperature or impedance values will show matching
20 mA: 14.00 pH units such as °C, MΩ, or kΩ. See Section 5.6 for output config-
uration.
Output 1: 12.00 mA
Esc Save
28
5.4 TESTING OUTPUTS AND ALARMS
This section describes how the current outputs and alarm relays can be
Alarm setpoints manually set for the purposes of checking devices such as valves,
pumps, or recorders.
Output setpoints 1. From the main menu, move the cursor down to "Program" and press
Simulated tests Enter 4. On this display, move the cursor to "Simulated tests" and
press Enter 4.
Exit Enter
Test output 1 2. At this point there are six separate screens for testing each of the
current outputs and each of the alarm relays. Highlight the desired
Test output 2 item by pressing the arrow b t keys as needed.
Test alarm 1
When the desired item is highlighted, press Enter 4 to continue.
Exit Enter Go to step 3a for outputs and 3b for alarms.
NOTE
Test alarm 2 A cautionary message will appear to warn that the out-
put or alarm that was selected will be changed by the fol-
Test alarm 3 lowing action. Be sure to alert plant personnel that
these changes are simulated and do not represent a
Test alarm 4 change in the actual process. Press Enter 4 to contin-
ue or Abort 1 to cancel the simulation.
Exit Enter
Test output 1: 10.00 mA 3a. The output is now being simulated. In the example to the left, out-
put 1 has been set to 10.00 mA. The output will remain at 10.00 mA
until either Exit 1 (or Edit 4 see below) is pressed or the test is
Simulating output1 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-
Exit Edit ation. To configure the timeout option, see Section 5.5.
If the displayed current is not the desired value, press the Edit 4
key and the next screen will allow changing the value. Use the arrow
Test output 1: 10.00 mA keys to change the display as needed, and press Test 4 to use that
value. Press Esc 3 to cancel the change in the value and contin-
ue simulating the previous current.
Esc Test
29
5.4 TESTING OUTPUTS AND ALARMS (continued)
3b. The alarm relay is now being simulated. In the example to the left,
Test alarm 1: Open 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 1 or Edit
4 is pressed or the test is concluded by timeout. The default value
Simulating alarm1 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
Exit Edit menu. To configure the timeout option, see Section 5.5.
If the displayed alarm action is not as desired, press the Edit 4 key
and the next screen will allow changing it. Use the arrow keys to
change the display as needed, and press Test 4 to enter the
Test alarm 1: Open change. Press Esc 3 to cancel the change in the value and con-
tinue simulating the previous action.
NOTE
Exit More Enter
Alarm relays may be simulated in the energized
(Closed) position or the de-energized (Open) position.
30
5.5 CHOOSING DISPLAY OPTIONS
This section describes the options available for the changing of engineering
Display units and variables on the main display.
Outputs 1. From the main menu, move the cursor down to "Program" and press
Enter 4. From the program menu, move the cursor down using the
Alarms arrow key to highlight "Configure" and press Enter 4.
The first configuration menu is displayed. With the cursor on "Display"
Exit Enter
press Enter 4.
2. Menu Item Options

Measure: pH Measure pH/ORP/Redox
Resolution: 0.01 Resolution (pH only) 0.01pH/0.1pH
Temp Units: °C Temperature units °C/°F
Exit Enter 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.
WARNING: This WARNING
change resets analyzer Changing the measurement selection from pH to ORP or

ORP to pH will reset all controller settings to factory values.
to factory settings Press Abort (F1) to cancel the change. Press Cont (F3) to
change the measurement. Refer to Appendix A for more
Abort Cont about ORP measurements.
Output 1: mA 3. Menu Item Options

Output 1 units mA/%
Output 2: mA
Output 2 units mA/%
Language: English Language English/Français/Español/Deutsch/Italiano
Exit Edit
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
Display left: AL1 is mA. To change any of these items, use the arrow key to highlight the
Display right: AL2 desired item and press Edit (F4). Use the arrow keys to make the change
and press Save (F4) to enter the change into memory.
Display contrast: 5 Further menu items are available by pressing the arrow key repeatedly.
Exit Edit 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.
Measure: pH
Resolution: 0.01
Temp Units: °C
Exit Enter
31
5.5 CHOOSING DISPLAY OPTIONS (CONTINUED)
4. This screen allows you to choose the items displayed on the third line
Display left: AL1 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
Display right: AL2 main display. This screen allows you to make the following choices:
Display contrast: 5
Lower Left of Main Display Lower Right of Main Display
Exit Edit
• AL 1 (alarm 1 setpoint - no units shown) • AL 2 (alarm 2 setpoint - no units shown)
• AL 3 (alarm 3 setpoint - no units shown) • AL 3 (alarm 3 setpoint - no units shown)
• In (sensor mV input) • In (sensor mV input)
• GI (glass impedance in Megohms) • RI (reference impedance in Kohms)
• RO (reference offset in mV) • Out 2 (Output 2 value in mA or %)
• Slp (slope of glass in mV/pH - • Blank (nothing displayed in lower right)
no units shown)
• Blank (nothing displayed in lower left)
Display left: AL1

The "Display contrast" selection allows the display to be made lighter
Display right: AL2 or darker. Entry 0 is the lightest and 9 is the darkest. The display
Display contrast: 5 changes as the number is changed.
To change any of these items, use the arrow key to highlight the
Esc Save
desired item and press Edit 4. Use the arrow keys to make the
change and press Save 4 to enter the change into memory. Press
Esc 3 to abort.
5. The timeout feature works on both the display and simulated tests
using the current outputs and alarm relays.
Display contrast: 5 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.
Timeout: On This is useful because the main display screen is usually the most
Timeout Value: 10 min important screen to the operator.
The timeout feature also allows simulating the current output and
Exit Edit 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 4. Use the arrow keys to make the
change and press Save 4 to enter the change into memory. Press
Esc 3 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.
32
5.6 CHANGING OUTPUT PARAMETERS
This section describes the options available for configuration of the out-
Display puts. Each output can be configured to represent pH (or ORP/Redox, see
Appendix A), temperature, glass impedance, or reference impedance. In
Outputs addition, each output can be linear (normal) or nonlinear (PID). Several
options for both modes of outputs can be configured. This section
Alarms describes the features and shows how to make modifications in the set-
Exit Enter tings.
1. Beginning from the main menu, move the cursor down to "Program"
and press Enter 4. From the program menu, move the cursor down
using the arrow key b to highlight "Configure" and press Enter 4.
Use the arrow key again to highlight "Outputs" (as shown on the left)
and press Enter 4.
Output 1 control 2. 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
Output 1 setup turned on here. The hold feature is mostly used to prevent upsets dur-
Output 2 control ing buffer calibration of the pH sensor.
To access each header, highlight the desired item and press the Enter
Exit Enter 4 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.
Output 2 control NOTE

Output 2 setup Always configure the control parameters BEFORE mak-
ing changes in the output setup. Changes in the output
Hold feature setup setup in step 4 will depend on the options that have been
selected in step 3.
Exit Edit
Output Control Parameters

Output Measurement Process/Temperature/Ref
Output Measurement Impedance/Glass Impedance
Control Mode Control Mode Normal/PID
Each output can be configured with the options above. The default
Exit Enter
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.
Output: Process
To make changes in these parameters, highlight the desired menu
header and press Enter 4. 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 4 to
Exit Edit store the value. Repeat for the other output and/or items as needed.
33
5.6 CHANGING OUTPUT PARAMETERS (continued)
Output Setup Parameters 4a. Menu Item Options

(for Normal Outputs) Range 4-20mA/0-20mA
Dampen(ing) 0-299 sec
Hold Last value/fixed value
Range: 4-20 mAl Fixed Hold (if Output 1 hold is "fixed value") 0-22.00 mA
Dampen: 0 sec Fault (fixed value in a fault condition) 0-22.00 mA
Hold: Last Value Note: 0-20 mA output range is disabled on output 1 with HART-
enabled version (-09 option).
Exit Edit
These parameters can be adjusted by highlighting the desired item
and pressing the Edit 4 key. Once Edit has been pressed, change
the item as needed and then press Save 4 to store the value.
"Range" determines whether the 4-20mA or 0-20 mA convention is
Hold: Last Value used for the current output. If the range is changed, be sure to
rerange the outputs as described in Section 5.3.
Fixed Hold: 21.00 mA
"Dampening" is used to time-average the current output, smoothing
Fault: 22.00 mA out the effect of a noisy reading. Higher values provide more smooth-
ing.
Exit Edit
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.
4b. Menu Item Options

Output Setup Parameters
(for PID Outputs only) Setpoint -2 to 16 (pH), ±1400 mV (ORP/Redox)
-15 to 120°C (Temp), 0-140 kΩ(Ref Imp),
0-2000 MΩ(Glass Imp)
Setpoint: 7.00 pH Proportional 0-299.9 %
Proportional: 100.0% Integral 0-2999 sec
Integral: 0 sec Derivative 0-299.9 %
Exit Edit
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 4 key. Once Edit has been
Derivative: 0.0% pressed, change the item as needed and then press Save 4 to
store the value.
Range: 4-20 mA Use caution in changing the values of these parameters.
Hold: Last Value "Setpoint" is usually the desired value at which the process is being
controlled, typically the output will be 4(or 0) mA when the parameter
Exit Edit
is near the setpoint. This setting can also be changed using the pro-
cedure in Section 5.1.
34
5.6 CHANGING OUTPUT PARAMETERS (continued)
"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
Fixed Hold: 21.00mA higher response.
"Derivative" is a form of control that resists all changes in readings.
Fault: 22.00mA 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.
Exit Edit 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 normal outputs. See step 4a for details .
Hold Feature Setup 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
Output 2 control controller starts out with the hold feature turned off (disabled).
Output 2 setup 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).
Hold feature setup Press Enter 4 and the screen below will appear.
Exit Enter
Press the Edit 4 key to enable changes. Options include Disable,

Hold: Disable feature 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.
Exit Edit
7.00 pH When the hold feature has been enabled, this Hold Mode Screen will
appear when the Calibrate routine is entered. Possible actions are Exit
1 which cancels the calibration, Enter 4 which enters the calibrate
Hold mode: Off menu without putting the controller in hold, and Edit 4 which allows
turning Hold Mode On. Note that when hold has been enabled, this
Exit Enter screen requires pushing Cont 3 to enter and leave the calibrate menu.
35
5.7 CHANGING ALARM PARAMETERS
This section describes the options available for configuration of the

Outputs 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
Alarms limit timer and another alarm can be dedicated as an interval timer. Alarm
4 is reserved as a fault alarm.
Security
Alarms that activate on pH (or ORP/Redox) or temperature can be con-
Exit Enter 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.
Use the arrow key again to highlight "Alarms" (as shown on the left)
and press Enter 4.
2. There are 9 menu headers that relate to alarms. Alarms 1, 2, and 3

Alarm 1 control 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
Alarm 1 setup timer is also described here.
Alarm 2 control To access each header, highlight the desired item and press the Enter
4 key. To select another header, use the arrow keys. The bottom
Exit Enter menu header will only be highlighted if the end of the menu has been
reached.
NOTE
Always configure the control parameters BEFORE mak-
Alarm 2 setup ing changes in the alarm setup. Changes in the output
setup in step 4 will depend on the options that have been
Alarm 3 control selected in step 3.
Alarm 3 setup
Exit Enter 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.
Alarm 4 setup TPC: Alarm turns on for a time that depends on what the reading is.
Feed limit timer 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)
Interval timer 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
Exit Enter
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
36 automatic retraction of sensors in processes.
5.7 CHANGING ALARM PARAMETERS (continued)
Alarm Control Parameters 3. Menu Item Options

Activation Method Process/Temperature
Control Mode Normal/TPC
Activation Method
Control Mode 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
Exit Enter step 4a.
To make changes in these parameters, highlight the desired menu
header and press Enter 4. The value now being used is displayed
Activate: Process 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 4 to
store the value. Repeat for the other output and/or items as needed.
Exit Edit
Alarm Setup Parameters

4a. Menu Item Options
(for Normal Alarms only)
Alarm (action) Low/High/Off
Setpoint -1400 to1400 mV, -2.00 to 20.00 pH, 0 to 200°C.
Alarm: Low Hysteresis -2.00 to 20.00 pH, 0 to 10°C.

Delay 0-99 sec
Setpoint: 0.01 pH
Relay default None/Close/Open
Delay: 0 sec
Exit Enter These parameters can be adjusted by highlighting the desired item
and pressing the Edit 4 key. Once Edit has been pressed, change
the item as needed and then press Save 4 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
Hysteresis: 0.01 pH the reading has dropped below the setpoint minus the hysteresis
amount (high alarm example).
Delay: 0 sec "Delay" will delay activation (and deactivation) of the relay for a cer-
Relay Default: None tain number of seconds. Larger delays can reduce relay chatter.
"Relay Default" determines how the relay will act if there is a fault or
Exit Enter hold condition. Each alarm can be forced on (Close), off (Open) or
can remain unchanged (None). The factory configuration is "None".
37
Alarm Setup Parameters 4b. Menu Item Options

(for TPC Alarms) Set point -2 to 20 pH, -1400 to +1400 mV(ORP/Redox)
Proportional 0-299.9 %
Integral 0-2999 sec
Setpoint: +07.00 pH Derivative 0-299.9 %

Time period 10-2999 sec
Proportional: 100.0% URV -2 to 20 pH, -1400 to +1400 mV(ORP/Redox)
Integral: 0 sec LRV -2 to 20 pH, -1400 to +1400 mV(ORP/Redox)
Exit Edit Relay Default None/Close/Open
These parameters are available for alarms that have been config-
ured as TPC alarms in step 3. Parameters can be adjusted using the
Derivative: 0.0% same technique as in step 4a, by highlighting the desired item and
pressing the Edit 4 key. Once Edit has been pressed, change the
Time period: 30 sec item as needed and then press Save 4 to store the value.
URV: 2.00 pH "Setpoint" is usually the desired value at which the process is being
controlled, typically the alarm will not be on very much when the
Exit Enter 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
URV: 2.00 pH process gain. Smaller values provide tighter control.
"Integral" is the number of seconds over which deviations from the
LRV: 0.00 pH setpoint are integrated to remove continuing offsets. Smaller values
Relay default: None provide higher response.
"Derivative" is a form of control that resists all changes in readings.
Exit Enter
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 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
be 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 on 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".
38
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 5. Alarm 4 is dedicated as a fault alarm. The only option for this alarm
is to enable it or to disable it. To disable the alarm, press Edit 4 and
use the arrow key to change "Fault" to "Off" .
Alarm: Fault When a fault condition exists, the relay will energize and the red LED
on the front display will turn on.
Exit Enter

Feed Limit Timer Setup Feed limit (timer) Disable/AL1/AL2/AL3
Timeout 0-10,800 sec
Feed limit: Disable

The controller allows configuring one of the alarms as a Feed Limit
Timeout: 3600 sec 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
Exit Edit left), use the arrow key to select an alarm relay and then press Save
4.
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 2 (Ack) key is
7.00 pH 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.
26.2°C 12.0mA
NOTE
Feed limit alarm 1 Pressing the 2 (Ack) key will acknowledge all condi-
tions that turn the red LED on. If another event occurs
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
Interval Timer Setup 7. Menu Item Options

Timer (enable) Disable/AL1/AL2/AL3
Interval 0-999.9 hr
Timer: Disable Repeats 1-60
Timer: Time activated On time 1-2999 sec
Interval: 24.0 hr Off time 0-2999 sec
Recovery 0-999 sec
Exit Edit
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
Repeats: 1 the timer is to select an alarm relay (1, 2, or 3), which will enable the
On time: 120 sec feature. All parameters can be adjusted by highlighting the desired
item and pressing the Edit 4 key. Once Edit has been pressed,
Off time: 1 sec change the item as needed and then press Save 4 to store the
value.
Exit Edit
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
On time: 120 sec current outputs will be placed in hold (even if hold was
not enabled in Section 5.6) and the other 2 alarms will be
Off time: 1 sec placed in their default states.
Recovery: 600 sec "Interval" determines how often the timer sequence will run. When set to
Exit Edit
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.
40
“On” “On”
Time Time
(sec) (sec)
RELAY RELAY
ACTIVATION ACTIVATION
Interval Recovery Interval Recovery

(hr) (sec) (hr) “Off” (sec)
Time
(sec)
TIME TIME
Sequence A: One repeat per cycle Sequence B: Two repeats per cycle
FIGURE 5-2. Interval Timer Examples
41
5.8 ON-LINE DIAGNOSTICS SETUP
This section describes the options available for configuration of the on-
Alarms line sensor diagnostics. The controller checks the integrity of the glass
electrode (for pH only) and the reference electrode by continuously meas-
Diagnostics uring the impedance of each. The original controller configuration is with
diagnostic messages turned off. To enable this feature, see below.
Auto Calibration
Exit Enter 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 Related Fault Messages

Diagnostics: Off Diagnostics On/Off
Glass imp hi: 1000 MΩ Glass impedance 1-2000 MΩ “Aged glass warning”
high setpoint (0 disables)
Glass imp lo: 20 MΩ Glass impedance 1-900 MΩ “Cracked glass
Exit Edit low setpoint (0 disables) failure”
Reference impedance 1-140 kΩ "High reference
high setpoint (0 disables) imped"
Zero offset 1-999 mV "Zero offset err"
Ref imp hi: 140 kΩ (0 disables)
Calibration recommended 1-500% "Calibration warning"
Zero offset: 60 mV (0 disables)
Cal warn: 0% Imped comp On/Off
Exit Edit
The values now being used by the controller are displayed. To change
press Edit(F4). Use the arrow keys to make the change and press
Save(F4) to enter the change into memory.
Zero offset; 60 mV "Glass Imp hi" warns of a glass electrode that may have exceeded it's
Cal warn: 0% 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
Imped comp: On MΩ, a setting of 400 MΩ may be appropriate.
Exit Edit "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 MΩ.
"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.
42
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 0 (dis-
abled).
"Imped comp" is used to compensate 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

This section describes how the controller may be set up for auto calibra-
tion, which includes automatic buffer recognition and auto stabilization.
Diagnostics Alternatively, the controller may be configured to perform a manual cali-
Auto Calibration bration without the automatic features.
Security and press Enter (F4). From the program menu, move the cursor
Exit Enter 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 recognition
and stabilization.

Autocal: Standard Autocal Standard/ DIN 19267/ Manual
Stabilize pH: 0.01 pH Stabilize pH 0.01-0.50 pH

Stabilize time 0-30 sec
Stabilize time: 10 sec
Exit Edit
The values now being used by the controller are displayed. To change
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
5.9 AUTO CALIBRATION SETUP (continued)
TABLE 5-2. Standard Buffers
Buffer Value @ 25°C 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 KH2 citrate
4.01 NIST, DIN 19266, BSM, JIS 8802 0.05 KH Phthalate X
4.64 BSM 0.1M HOAc
.01M NaOAc
6.86 NIST, DIN 19266, BSM, JIS 8802 0.025M KH2PO4
0.025M KH2HPO4
7.00 0.05M NA2HPO4 X
0.05M KH2PO4
7.41 NIST, JIS 8802 0.0087M KH2PO4
0.0302M KH2HPO4
9.18 NIST, DIN 19266, BSM, JIS 8802 0.01M Na2B4O7
10.01 NIST, BSM, JIS 8802 0.025M NaHCO3 X
0.025M Na2CO3
12.45 NIST, DIN 19266 Ca(OH)2 (sat’d @ 25°C)
44
THEORY OF OPERATION
SECTION 6.0
THEORY OF OPERATION
6.1 THE pH SENSOR ASSEMBLY designed to avoid blocking of the internal liquid junc-
tion. It is essentially a complete electrode within an
The pH measurement is accomplished by means of a electrode outer body, using two liquid junctions.
measuring electrode (usually made of glass) which
develops a potential directly related to the hydrogen ion A non-reactive electrolyte (potassium chloride gel) is
concentration (pH) of the solution in which the elec- the filling solution in the outer body, and only this solu-
trode is immersed. A second electrode, called the ref- tion is in contact with the process. Clogging of the outer
erence electrode, is necessary to complete the electri- junction is minimized, since neither potassium ions nor
cal circuit and to serve as a constant reference poten- chloride ions form insoluble compounds with the
tial against which the potential of the glass electrode majority of materials found in process streams.
can be compared. Together, the two electrodes com- Contamination of the inner junction is not likely with this
prise the pH sensor. configuration.
The Glass Electrode The Temperature Compensation Element

The glass electrode is a thin-walled bulb of glass con- In addition to the glass electrode and reference cell, a
taining a pH-buffered solution and the elements of a third element required in the pH measurement system
half-cell (typically silver/silver chloride). The glass is the temperature compensation element. Its purpose
membrane provides a means of collecting hydrogen is to compensate for "apparent" pH changes due to the
ions so the potential can be measured. The hydrogen pH response of a glass electrode increasing with tem-
ions on the surface of the glass membrane are in equi- perature. At values around 7 pH, the variation with tem-
librium with the hydrogen ions in the solution being perature is zero. Thus, no compensation is required at
measured. As the hydrogen ion concentration in the 7 pH. The error caused by varying temperatures is
solution changes, the concentration of hydrogen ions greater at high/low pH values; in other words, as you
on the electrode changes, creating a change in poten- move away from a neutral pH of 7. This compensation
tial on the glass electrode. is done automatically by the Model 54e pH/ORP unless
specifically disabled.
The Reference Cell
The Preamp
The purpose of the reference cell is to maintain a sta-
ble reference potential regardless of a change in sam- Because of the high resistance of the glass measuring
ple pH. The cell is comprised of the reference elec- electrode, a preamplifier must be used to transform the
trode, reference fill solution and porous reference junc- extremely low level, high impedance signal to a low-
tion. The reference cell also serves to complete the impedance signal. The Model 54e pH/ORP includes a
voltage measuring circuit. Within the reference elec- switchable preamplifier that may be used if the dis-
trode, a silver chloride element is surrounded by a con- tance to the pH sensor is less than 15 feet. When
centrated potassium chloride solution. The internal ele- longer runs of cable are necessary, the preamp can be
ment maintains electrical contact with the pH sensitive located in the pH sensor itself or in a remote junction
glass electrode through the porous liquid junction (a box. Either design allows transmission of the pH signal
multi-capillary hardwood plug) of the internal reference long distances without suffering degradation or inter-
electrode. ference from outside voltage sources.
The external wood reference junction and the gelled

reference fill solution provide protection for the internal 6.2 CONTINUOUS SENSOR DIAGNOSTICS
reference electrode to prevent contamination from
harsh chemical environments. The internal liquid junc- The Model 54e pH/ORP verifies the integrity of the
tion can become blocked if the process contains any glass and reference segments of the pH sensor by con-
material that reacts with the filling solution to form a tinuously measuring the impedance between each
precipitate. The double-junction reference electrode is segment and the solution ground.
45
THEORY OF OPERATION
A new glass electrode has an impedance of approxi- 6.3 INTERVAL TIMER

mately 200 megohms As it ages, this value typically
increases over time because lithium ions (which carry The interval timer may be used for periodic sensor
current) in the glass are slowly depleted by the cleaning or periodic process adjustment (see Section
process. If an electrode cracks, the impedance drops 5.7 for procedure).
sharply, usually to below 5 MΩ. The interval timer settings are:
The following Diagnostic Checks are possible with the 1. Timer - Enables/disables the interval timer.
Model 54e pH/ORP:
2. Interval - the time period between cycles.
Cracked Glass Diagnostic. One way to tell that you
3. Repeats - the number of relay activations per
have a broken or cracked glass electrode is that the
cycle.
controller will read a constant value (usually between
5.0-7.0 pH) in any process or buffer. The other way is 4. On time - the time period of one relay
to note the impedance value. The controller can be activation.
configured to generate a fault when the glass imped- 5. Off time - the time period between two or more
ance drops below a setpoint. When a crack occurs, the relay activations.
controller will indicate that the electrode is broken.
6. Recovery - the time period following the final relay
NOTE activation.
A broken electrode may not be detected above The cycle begins at the Interval time when the Switch
70°C (158°F). is turned on. When the Interval time has expired the
Old Glass Diagnostic. This diagnostic is used for pro- analyzer activates hold mode and the relay is activated
gramming the high impedance limit. For example, if the for the On time period. If the number of Repeats is
set point is 1000 megohms, and the impedance rises greater than one, the relay is deactivated for the Off
above this value, the controller will go into a fault mode. time period and reactivated for the On time period for
The electrode is either worn out, severely coated, or the number of relay activations selected. When the
not immersed in the process fluid.. final relay activation is complete the relay is deactivat-
ed for the Recovery time period. Note that no Off time
Calibration Warning. Under this diagnostic you can
period follows this last relay activation. When the
select the percent increase in impedance before a cal-
Recovery time period expires the Hold mode deacti-
ibration warning fault appears. It is recommended to
vates, and the cycle repeats, beginning with the
keep this feature disabled.
Interval time.
High Reference Impedance. The reference is also
Typically, the interval timer is configured with a long
continuously checked. High values indicate a plugged
Interval, several Repeats of fairly short On times, fairly
liquid junction or a coated sensor. The setpoint can be
short Off times and a Recovery time which allows the
adjusted depending on the sensor used. Always set
process to stabilize. Setting Interval to zero results in
this value above the value for a new clean sensor.
continuous pulsing and setting Off time to zero will
You may also get this fault if: cause a single pulse equal to [On time x Repeats].
1. The sensor becomes excessively coated. High reference impedance can be used to trigger timer
2. The sensor is not immersed in the process activation. In this case, the interval time is used only to
allow the analyzer time to determine whether the refer-
Typical set points: ence impedance has exceeded the reference imped-
1. 1000 Megohms for old glass diagnostics. ance setpoint. If the reference impedance setpoint is
exceeded, the timer cycle will begin. This is an ideal
2. 10 Megohms for cracked glass. way to start a cleaning cycle in a dirty application.
3. 0 Megohms for calibration warning (disabled) Note that the hold mode supersedes the Timer State. If
4. 40 Kohms for high reference impedance. 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-
NOTE mation on Controller Mode Priority, see Table 6-1.
See Section 5.8 for instructions on chang-
ing these setpoints.
46
THEORY OF OPERATION
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 on 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):
• Setpoint FIGURE 6-1. Time Proportional Control
• Time period value approaches the setpoint, the pump will be feed-
• URV point (or 100% on) ing for shorter and shorter intervals, and the chemicals
will be allowed to mix for longer and longer intervals of
• LRV point (or 0% on)
the period. This relationship is illustrated in Figure 6-1.
• Proportional
The exact amount of on time and off time per period is
• Integral determined by the settings for proportional, integral,
• Derivative and derivative bands. The proportional band (P) in %
is a separate adjustment that narrows (or widens) the
The setpoint is the desired value that you want to con- range of the TPC 0-100% action. Smaller values are
trol at. Time period is programmed in seconds and de- used for more control response. For a setpoint of 7 pH,
fines the interval during which the controller compares a URV of 2 pH, and P=100%, a pH reading of 8 would
the pH input from the sensor with the Setpoint. In the result in a relay on (8-7)/((2-0)*(100%)) or 50% of the
TPC mode the controller divides the period up into time. If P was changed to 50%, the same relay would
pump on-time (feed time) and pump off-time (blend be on (8-7)/((2-0)*50%) or 100% of the time.
time).
The integral band is set in seconds and acts to
The URV setting determines how far the pH must devi- increase the controller output as more time is spent
ate from the setpoint to get the pump to be on for the away from the setpoint. A smaller value in seconds will
entire period. The LRV setting determines how close result in faster integration response. Too low a value
the pH must be to the setpoint for the pump to be off for will result in excess oscillation.
the entire period. The LRV setting should always be set
at zero. When the error (the pH minus the setpoint) is The derivative band is set in % and acts to prevent
between the URV and LRV values, the relay will be en- changes in the reading. This setting should generally
ergized for some portion of the time period. As the pH be set to zero for pH and ORP applications.
47
THEORY OF OPERATION
TPC offers precise control by forcing the pump to feed 6.7 ANALOG OUTPUTS
chemical for shorter periods of time as you approach
the desired setpoint. If the process faces a large upset, The Model 54e pH/ORP controller includes a second
TPC mode forces the pump to feed chemical for longer analog output. An analog output produces an electri-
periods of time as the process deviates further from the cal current signal which varies in linear proportion to a
setpoint. This action continues until the pump is feed- value measured by the controller. You can configure
ing all the time, providing a speedy recovery from large the controller to produce a 4-20 mA or 0-20 mA cur-rent
up-sets. output proportional to pH or temperature. See Section
5.6 for programming details.
The controller can be programmed to be direct or re-
verse acting, depending on the pH (or temperature) The analog output must be "scaled" so that 4 (or 0) mA
value selected for URV. For example, if the controller is corresponds to the low end of the scale and 20 mA cor-
direct acting based on pH, such as in caustic chemical responds to the high end. The operator can scale the
addition control, the pH will rise as chemical is added, output as in the following example:
so the URV value will be below the LRV (i.e. below The Model 54e pH/ORP is connected to a strip chart
zero). As the pH rises toward the control point value, recorder with a 0 to 100% scale. The average value of
the pump will be on for gradually less time. Conversely, the bath is 10.0 pH, plus or minus 0.5 pH. The opera-
if the controller is reverse-acting based on pH, such as tor wants to match this value with the 50% mark on the
in acid addition for control, the pH will drop as acid is recorder. To do so, the operator selects 9.5 pH as the
added, and the URV value will be positive. The pH will 4 mA value and 10.5 pH as the 20 mA value by enter-
fall toward the control point value, and the pump will be ing them as in Section 5.3. The chart on the recorder
on for gradually less time. will display 0% when the pH is 9.5 or below and 100%
Complete TPC configuration is explained and typical when the pH equals 10.5 or greater. (this is for a 4-20
settings for these parameters are listed in Section 5.0. mA recorder).
After startup, the operator needs to adjust only the 0% The Model 54e pH/ORP is also capable of PID control
On to maintain the desired chemical concentration. 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
6.6 NORMAL MODE used to modulate a pump or valve, rather than to turn
Normal mode is on-and-off control based on an alarm a device off and on.
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
THEORY OF OPERATION
6.8 CONTROLLER MODE PRIORITY
Your Model 54e pH/ORP can function in different modes Priority is in the following order (from lowest to highest):
depending on both how it is configured, what process normal, fault, timer, hold, feed limit, test. Each output or
conditions exist, and actions an operator may have relay acts as if it is only in the state of highest priority.
made. To reconcile these possible modes, there is a set
NOTE
priority that determines exactly what will happen to the 2
current outputs and the 4 alarm relays in the event of mul- Some of these features may not be in use for your con-
tiple modes occurring at the same time. See Table 6-1 troller.
below.
TABLE 6-1. Controller Mode Priority Chart
Condition Priority Current Current Alarm Alarm Alarm Alarm

Output 1 Output 2 Relay 1 Relay 2 Relay 3 Relay 4
Normal 1 Normal Normal Normal Normal Normal Open
Fault 2 Default Default Default Default Default Closed
Interval Timer 3 Hold Hold Default/ Default/ Default/ Prior
Normal1 Normal1 Normal1
Hold Mode 4 Hold Hold Default Default Default Prior
Feed Limit 5 Normal Normal Open1 Open1 Open1 Closed
Simulate tests 6 Test1 Test1 Test1 Test1 Test1 Test1
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). Unconfigured or unselected items are not affected by that mode.
Condition Definitions:
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.
3. Interval Timer is only while the timer sequence is occurring.
4. Hold Mode is while hold is activated by the operator (i.e. during calibration).
5. Feed Limit occurs when a feed limit timer has reached it's limit and is turned off after being on for too long.
6. 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)
2. Open is a deenergized alarm relay. (alarm off)
3. Default is the setting configured for each item if there is a fault. (Sections 5.5, 5.6)
4. Closed is an energized alarm relay. (alarm on)
5. 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)
6. Prior is the state the alarm had before that mode occurred.
7. Test is the value input by the operator (mA for current, on or off for a relay).
49
THEORY OF OPERATION
6.9 PID CONTROL (CODE -20)
PID Control Measurement and Set Point (Feedback Control)

The Model 54e pH/ORP current outputs can be pro- The Model 54e pH/ORP controller is given two items
grammed for PID control. PID control is used with a of information: measurement and set point. The con-
control device which is capable of varying its output troller reacts to the difference in value of these two
from 0 to 100 percent in response to a changing sig- signals and produces an analog output signal to
nal in milliamps. Automated control valves or vari- eliminate that difference. As long as the difference
able volume pumps are commonly used. These exists, the controller will try to eliminate it with the
types of devices are referred to as modulating con- output signal. When measurement and set point are
trol devices because of their 0 to 100% adjustability. equal, the condition of the controller is static and its
PID control is typically used where greater accuracy output is unchanged. Any deviation of measurement
than is achievable with an on/off device is required, from set point will cause the controller to react by
or where it is desirable to have the pump or valve changing its output signal.
"on" continuously, or where the existing or preferred
pump or valve is of the modulating type.
PID Control Mode Combinations
Any process control system must manually or auto-
matically hold the controlled variable (pH, conductiv- All PID controllers have several control modes which
ity, temperature) in a steady condition at selected set can be used in various combinations: proportional
point values. For manual control, the operator looks plus integral (reset), proportional plus derivative
at the value of the process variable, decides (rate) and a combination of proportional (P), integral
whether or not it is correct, and makes necessary (I) and derivative (D). Each control mode produces a
adjustments. He decides the amount, direction, rate response to the deviation of measurement from set
of change and duration of the adjustment. With auto- point that is the result of a specific characteristic of
matic control, the controller does all of this. The the deviation, and each control mode is separately
operator only adjusts the set point of the controller to adjustable. D, the derivative, or rate mode, is seldom
the selected value of the measured variable. used in water treatment and is beyond the scope of
Automatic process control such as PID is usually this manual.
feedback control; it eliminates the deviation between
measurement and set point based on continuous
updates (feedback) from the process itself.
50
THEORY OF OPERATION
6.9 PID CONTROL (continued)
Proportional Mode (Gain) The reset mode repeats the proportional action as long
The simplest control is proportional. Proportional may as an offset from the set point exists. Reset action is
also be referred to as sensitivity or gain. Although these cumulative. The longer the offset exists, the more the
terms may refer to a different version of proportional, output signal is increased.
the control function is still fundamentally the same - the The controller configured with reset continues to
error from set point is multiplied by this factor to pro- change until there is no offset. If the offset persists, the
duce the output. reset action eventually drives the controller output to its
The Model 54e pH/ORP's proportional mode is 100% limit - a condition known as "reset windup". To
referred to as proportional "band" which is config- prevent reset windup, a controller with reset mode
urable from 0 to 299%. For good control of a specific should never be used to control a measured variable
process, the proportional band must be properly influenced by uncorrectable conditions. Once the con-
adjusted. The proportional band is the percent of the troller is "wound up", the deviation must be eliminated
analog output span (the difference between the 4 (or 0) or redirected before the controller can unwind and
mA and 20 mA settings) through which the measured resume control of the measured variable. The integral
variable must move to change the output from mini- time can be cleared and the "windup" condition quickly
mum to maximum. The larger the proportional band, eliminated by manually overriding the Model 54e
the less the controller reacts to changes in the pH/ORP's analog output using the simulate tests
measured variable. As the proportional band is feature (detailed in Section 5.4).
made smaller, the reaction of the controller
increases. At 0 proportional band, the proportional- Control Loop Adjustment and Tuning
only controller behaves like an on/off controller (an
alarm set at 20 mA). There are several methods for tuning PID loops includ-
ing: Ziegler-Nichols frequency response, open loop
Most processes require that the measured variable be step response, closed loop step response, and trial and
held at the set point. The proportional mode alone will error. Described in this section is a form of the open
not automatically do this. Proportional alone will only loop response method called the process reaction
stabilize the measured variable at some offset to the curve method. The reaction times and control charac-
actual control point. To control at an exact setpoint, teristics of installed equipment and real processes are
proportional plus integral mode is used. difficult to predict. The Process Reaction Curve Method
of tuning works well because it is based on the
Proportional (Gain) Plus Integral (Reset) response of the installed system. This procedure, out-
lined in the following paragraphs, can be used as a
For the automatic elimination of deviation, I (Integral starting point for the P and I settings. Experience has
mode), also referred to as Reset, is used. The propor- shown that PID controllers will do a fair job of control-
tional function is modified by the addition of automatic ling most processes with many combinations of rea-
reset. With the reset mode, the controller continues to sonable control mode settings.
change its output until the deviation between measure-
ment and set point is eliminated.
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.
51
THEORY OF OPERATION
Process Reaction Curve Method This can be done by observing the reading on the
A PID loop can be tuned using the Process Reaction Model 54e pH/ORP and noting values at intervals
Curve Method. This method involves making a step timed with a stop watch. A strip chart recorder can be
change in the chemical feedrate (usually about 50% of used for slower reacting processes. To collect the data,
the pump or valve range) and graphing the response of perform the following steps:
the Model 54e pH/ORP reading versus time. 1. Let the system come to a steady state where the
The process reaction curve graphically shows the reac- measured variable (pH, conductivity or tempera-
tion of the process to step change in the input signal. ture) is relatively stable.
Figure 6-2 shows an example of a tuning process for a 2. Observe the output current on the main display of
pH controller. Similar results can be obtained for the the controller.
conductivity controller. 3. Using the simulate test, manually set the controller
To use this procedure with a Model 54e pH/ORP and a output signal at the value which represented the
control valve or metering pump, follow the steps out- stable process measurement observed in step 1,
lined below. then observe the process reading to ensure steady
The Model 54e pH/ORP should be wired to the control state conditions (a stable process measurement).
valve or metering pump. You will introduce a step 4. Using the simulate test, cause a step change in the
change to the process by using the simulate test func- output signal. This change should be large enough
tion to make the step change in the output signal. to produce a significant change in the measured
The change in the measured variable (conductivity, pH, variable in a reasonable amount of time, but not
or millivolts) will be graphed as shown in Figure 6-2. too large to drive the process out of desired limits.
FIGURE 6-2. The Process Reaction Curve
52
THEORY OF OPERATION
5. The reaction of the system, when graphed, will In the example, the process Delay Time (D) was four
resemble Figure 6-2, showing a change in the seconds and the Response Time period (L) was 12
measured variable over the change in time. After a seconds, so:
period of time (the process delay time), the meas-
ured variable will start to increase (or decrease) L 12 seconds
rapidly. At some further time the process will begin R= =3
D 4 seconds
to change less rapidly as the process begins to sta-
bilize from the imposed step change. It is important The last parameter used in the equations is a plant gain
to collect data for a long enough period of time to (C). The plant gain is defined as a percent change in the
see the process begin to level off to establish a tan- controlled variable divided by the percent change in
gent to the process reaction curve. manipulated variable; in other words, the change in the
6. When sufficient data has been collected, return the measured variable (pH, conductivity, temperature) divid-
output signal to its original value using the simulate ed by the percent change in the analog output signal.
test function. Maintain the controller in this manual The percent change in the controlled variable is
mode until you are ready to initiate automatic PID defined as the change in the measured variable (pH,
control, after you have calculated the tuning con- conductivity, temperature) compared to the measure-
stants. ment range, the difference between the 20 mA (Hi) and
4 (or 0) mA (Lo) setpoints, which you determined when
Once these steps are completed, the resulting process
configuring the analog output.
reaction curve is used to obtain information about the
overall dynamics of the system. It will be used to cal- In the example shown in Figure 6-2:
culate the needed tuning parameters of the Model 54e The percent change in pH was:
pH/ORP controller.
NOTE pH2 - pH1 8.2 - 7.2 pH
x 100% = = 33.3%
The tuning procedure outlined below is pH “Hi” - pH “Lo” 9.0 - 6.0 pH
adapted from "Instrumentation and
Process Measurement and Control", The change in the output signal was:
by Norman A. Anderson, Chilton Co.,
Radnor, Pennsylvania, ©1980. 6 - 4 milliamps
x 100% = 12.5%
Information derived from the process reaction curve 20 - 4
will be used with the following empirical formulas to
predict the optimum settings for proportional and inte- So the Plant Gain is:
gral tuning parameters.
33.3
Four quantities are determined from the process reac- C= = 2.66
tion curve for use in the formulas: time delay (D), time 12.5
period (L), a ratio of these two (R), and plant gain (C).
Once R and C are calculated, the proportional and inte-
A line is drawn on the process reaction curve tangent gral bands can be determined as follows:
to the curve at point of maximum rise (slope) as shown C
in Figure 6-2. The Time Delay (D), or lag time, extends Proportional band (%) = P = 286
R
from "zero time" on the horizontal axis to the point Integral Time (seconds per repeat) = I = 3.33 D x C
where the tangent line intersects the time axis. The
Response Time period (L), extends from the end of So for the example:
delay period to the time at which the tangent line inter- 286 (2.66)
P= = 254%
sects the 100% reaction completion line representing 3
the process stabilization value. The ratio (R) of the
Response Time period to the Time Delay describes the I = 3.33 (4 sec.) 2.66 = 36 seconds
dynamic behavior of the system. To enter these parameters, use the procedure detailed
in Section 5.6.
53
SPECIAL PROCEDURES AND FEATURES
SECTION 7.0
This section covers features of the Model 54e Level 1 - 3 Password Privileges
pH/ORP controller that are used less frequently.
Level 1 access is usually given to an operator who
Use of the features outlined in the appendix is
simply needs to calibrate during the course of normal
optional.
operation. A separate section of the manual contains
Special procedures and features outlined in this operating procedures normally used by this type of per-
appendix include the following: sonnel. Level 1 restricts the operator from changing the
• Password Protection major control mode configuration by preventing access
to the Program Menu.
• Temperature Slope Calculation
The Level 1 user can do the following:
• Temperature Sensor
1. Access Diagnostic Variables (Section 8.1).
• Reference Temperature
2. Zero the controller in air (Section 4.3).
• Controller Mode Priority
3. Enter the Temperature Slope (Section 4.4).
• PID Control
4. Change Temperature Compensation from Auto to
Before using this section, you should become familiar Manual and select a temperature (Section 4.7).
with the basic Theory of Operation of the controller as
outlined in Section 6.0, the keypad functions in Section 5. Calibrating pH and Temperature readings (Section
1.0, and the List of Settings Table and configuration 4.1 and Section 4.6).
procedures outlined in Section 5.0. A Level 2 user can do all of the above and:
As with all the settings in your Model 54e pH/ORP, the 1. Change control setpoints for PID current outputs
first step to configuration is obtaining a good under- (Section 5.1).
standing of how the feature works, before determining
2. Change alarm setpoints for normal and TPC
the values of the settings to achieve the desired con-
alarms (Section 5.2).
trol. This appendix provides more background for
deciding on the appropriate settings. Configuring the 3. Rerange both 4-20 (or 0-20) mA outputs
settings is done using the instructions in this appendix (Section 5.3).
and Section 5.0, Software Configuration. 4. Manually test both outputs and all 4 alarm relays
for operation.
7.1 PASSWORD PROTECTION A Level 3 user has total access to the Configure Menu
and can make any changes that are deemed neces-
Your Model 54e pH/ORP can be programmed so that a
sary.
3-digit password must be entered before any changes
in the configuration are allowed. This protects your These privileges should be given only to an indi-
controller from tampering by unauthorized users. There vidual who fully understands the controller, the
are three levels of password access, Level 1 (calibra- process and the potential effects of modifying the
tion only), Level 2 (lockout of Configure Menu), and setup.
Level 3 (total access). Password privileges for each An individual with no password access privilege can
level are described below. only view the main display, containing conductivity,
If password protection is not desirable, you can config- temperature, current output 1, and the lower line dis-
ure all security codes to be 000. This will leave the con- play items configured in Section 5.5.
troller unlocked so the configuration can be changed
NOTE
without entering a password. The controller is shipped
from the factory with the password set at 000. You must have level 3 access to
change any security code.
54
7.2 CONFIGURING SECURITY
Security clearance is required at the following security "gates". Users

Alarms without the security code will only be able to use the features indicated in
parentheses:
Security I. Lock out all access (read main screen only)
Custom Curve II. Lock out program features (only calibration is allowed)
Exit Enter III. 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 and 2 and the level 2 security code will be accepted at level 1.
Use the arrow key again to highlight "Security" (as shown on the left)
and press Enter 4.
Lock all: 000 1 Lock all 000-999

2 Lock program 000-999
Lock program: 000
3 Lock configuration 000-999
Lock config: 000
Exit Enter 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 4. Use the arrow keys to make the change and
press Save 4 to enter the change into memory.
NOTES ON SECURITY:
a. A code of 000 disables security for that level.
b. The security feature will not activate until the keypad has not
been pressed for a short period of time (the timeout value pro-
grammed in Section 5.5).
c. A hold 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
7.3 SOLUTION TEMPERATURE COMPENSATION
This section is for advanced users only.

Security It explains how to input values for:
Temperature Coeff • the isopotential pH and
Temperature sensor • the temperature coefficient for solution temperature compensation.

Exit Enter 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.
Temp coeff: +.000 Sensor Temperature Compensation. The millivolt output of a pH sen-
sor changes with temperature, which in turn, changes the measured pH
Operate iso: +07.00 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
Sensor iso: 07.00 pH 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-
Exit Edit
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 Temperature 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.
56
7.3 SOLUTION TEMPERATURE COMPENSATION (continued)

Temp coeff: +.000 Temperature coefficient -0.044 to 0.028 pH/°C (0.00 for
most applications)
Operate iso: +07.00 pH
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)
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 4. Use the arrow keys to make the change and
press Save 4 to enter the change into memory.
57
TROUBLESHOOTING
SECTION 8.0
TROUBLESHOOTING
The Model 54e pH/ORP automatically searches for Many control problems are unrelated to the pH meas-
fault conditions that would cause an error in the measurement system. When problems arise, first check
ured pH reading. If such a condition occurs, the current other systems that affect chemical concentration.
outputs and alarm relays will act as configured in Consider what may have changed in the system that
Section 5.6 and Section 5.7, the red "FAIL" LED on the can cause poor control. Some causes for poor control
controller panel will be lit and a diagnostic message will other than controller malfunction are:
be displayed. If more than one fault exists, the display 1. An empty chemical drum.
will sequence through the diagnostic messages. This
will continue until the cause of the fault has been cor- 2. Malfunction of a chemical feed pump, pump motor,
rected or until the Ack 2 key is pressed. or motor starter.
3. Water inlet or drain valves stuck or left open by
operators.
Troubleshooting is easy as 1, 2, 3…
4. Check flow interlocks (if used).
Step 1 Look for a diagnostic fault message on the dis-
play to help pinpoint the problem. Refer to 5. A temperature control malfunction.
Table 8-1 for an explanation of the message 6. Broken or blocked chemical feed lines.
and a list of the possible problems that trig-
gered it. 7. A conductivity probe that has been left out of the
bath.
Step 2 Refer to the Quick Troubleshooting Guide,
Table 8-2, for common pH hardware problems 8. The level of bath is below the probe and the probe
and the recommended actions to resolve them. is dry.
Step 3 Follow the step by step troubleshooting 9. The probe needs to be cleaned.
approach offered in Table 8-3 to diagnose less 10. The condition of the incoming metal has changed,
common or more complex problems. i.e., temperature, cleanliness, speed.
11. The condition of the incoming water has changed,
CAUTION i.e., temperature, cleanliness, flow rate, hardness,
pH.
Do not attempt to troubleshoot unless
you have familiarized yourself with this 12. Unauthorized personnel have tampered with the
manual. Only trained, qualified techni- controller settings.
cians should perform these procedures. 13. Standardizing procedure is not accurate due to a
Do not attempt to troubleshoot, repair, or malfunctioning laboratory instrument or contami-
modify the printed circuit cards or elec- nated chemical standard solutions.
tronic components inside the controller.
WARNING
IMPORTANT
Always recalibrate the controller To prevent chemical feed into the
before returning it to service. 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.
58
TROUBLESHOOTING
TABLE 8-1. Diagnostic Messages
Diagnostic Messages Description of problem

"Cracked glass failure" Broken or cracked glass electrode
"Zero offset error" * 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 error"* 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
(operator activated)
"High input voltage" Open connection from preamplifier 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 tested. see Section 5.4
"Simulating Alarm 1, 2, 3, or 4"
"Feed limit alarm 1, 2, or 3" Indicated alarm has been on for longer 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
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% HCl for 1 hr.
Replace electrode if not rejuvenated by the HCl 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 continuously; won't stabilize 1. Readjust stabilization pH or time for Auto Cal (Section 5.9)
during Auto Buffer Calibration. 2. Clean the sensor and retry Auto Cal in buffers.
3. Try a Manual Buffer Calibration. (see Section 5.9 for configuration)
Calibrates in buffers but not in the process 1. Verify process reading to be correct
2. Possible ground loop. Make sure that the shield wires do NOT
touch grounded metal. (Process noise).
Incorrect temperature reading. 1. Standardize the temperature
Suspected temp. compensation problem. 2. Verify sensor's RTD resistance vs. temperature
"Temp. error high" 3. 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 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
TROUBLESHOOTING
8.1 DISPLAYING DIAGNOSTIC VARIABLES
This section explains how these helpful diagnostics can 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).
2. Glass impedance in MΩ: Used to check integrity of glass electrode.
Broken glass membranes will have low impedance.
3. Reference impedance in kΩ: Used to indicate how coated the ref-
erence electrode has become. Coated or plugged sensors will have
high values of reference impedance.
4. 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.
5. 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 too low for calibration.
6. Software version
Use the following procedure :

Calibrate 1. From the main display, press any key.
Diagnostic Variables 2. With the down arrow key, move the cursor down to "Diagnostic
Variables" and then press Enter (F4).
Program
Exit
Input: 120 mV 3. Diagnostic variables are displayed three at a time. More variables are
viewable until the cursor (showing highlighted text) is brought down
Glass imped: 300 MΩ to the bottom line.
Ref imped: 8 kΩ Use the down arrow key to view the items on the lower screen.
Exit 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-
Zero offset: 0 mV play in the lower left or lower right positions. For details, see
Section 5.5.
pH slope: 59.02 mV/pH
Version: pH1.01
Exit
61
TROUBLESHOOTING
FIGURE 8-1. Theoretical pH vs. Millivolt Values at 25°C (77°F)
62
TROUBLESHOOTING
8.2 TROUBLESHOOTING GUIDELINES
NOTE TEMPERATURE COMPENSATION CIRCUIT

To clear any Fault message, press the Troubleshooting Procedure
2 key.
Use this procedure to diagnose problems in the tem-
If no specific error message is being displayed, the fol- perature compensation circuit or as directed by the
lowing procedure can identify the specific problem. Troubleshooting Guide, Table 8-3. Refer to the appro-
priate wiring diagram in Section 3.
The only sure way to diagnose sensor related condi-
tions is to isolate the pH sensor from the process, im- To check the sensor:
merse the sensor in a pH buffer solution, and observe 1. Check the resistance of the RTD element at the
the controller response. end of the sensor lead. Do not include intercon-
For any given pH value, the millivolt reading at the necting wire. Disconnect the red lead and white
controller should be approximately that shown in lead on the end of the sensor cable.
Figure 8-1, Theoretical pH vs. Millivolt Values. 2. Check the resistance between the red and the white
Therefore, one way to check the controller is to see if leads. If values do not agree within ±1% of those
the incoming millivolt signal corresponds to the proc- shown below, replace the sensor (see Step 4).
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 OHMS AMBIENT TEMPERATURE
"Diagnostic variables", see Section 8.1) will always be 100.00 32°F/0°C
the exact incoming value. Another good check of the 107.79 68°F/20°C
controller is to check the slope obtained after per-form- 109.62 77°F/25°C
ing the two-point calibration with two different buffer
111.67 86°F/30°C
solutions, as described in Section 3.
115.54 104°F/40°C
If the controller reads correctly when the sensor is
119.40 122°F/50°C
removed from the process and isolated in a container
of buffer solution, then the sensor and controller are 3.
most likely functioning correctly. The problem is Disconnect sensor leads from interconnecting wire
caused by something in the process such as: prior to measuring resistance. Values shown are
only accurate when measured at the end of the
• Sensor "seeing" poorly mixed, non-homogeneous cable directly attached to the sensor. Allow enough
solution. time for the temperature compensation RTD
• Sensor located too close to chemical feed lines or embedded in the sensor to stabilize to the sur-
heat sources. rounding temperature. Temperature coefficient =
0.215 ohms per °F.
• Air bubbles entrained in the process or entrapped
around the sensor. 4. If the sensor is bad, you can replace the sensor, or
you can clear the fault by switching to manual tem-
• Voltage on the process due to static electricity
perature compensation as a short-term solution.
buildup, improperly grounded recirculation pump
Refer to Section 3.5 to program for manual tem-
motors, or some other electrical source.
perature compensation. If the temperature com-
• A ground loop caused by improper sensor wiring, pensator RTD in the sensor is bad, the displayed
as outlined in Installation, Section 2. temperature will be incorrect. Using manual tem-
• A source of electrical noise which only takes effect perature compensation will remove all temperature
when the sensor is immersed in the process. related faults.
Most of these problems can be eliminated by either

moving the sensor or providing proper grounding.
63
TROUBLESHOOTING
PREAMPLIFIER TROUBLESHOOTING B. Controller preamp check (Figure 8-3)

PROCEDURE 1. Disconnect all sensor wiring from the controller
Use this procedure when diagnosing the circuit which at TB2.
carries the signal from the sensor. There are 3 sepa- 2. Verify that the preamp location switch is in the
rate procedures, depending on where the preamplifi- analyzer position, and that temperature compen-
er is located. sation is set to manual at 25°C or 77°F (see
A. Preamp in a junction box (Figure 8-2) Section 3.5).
1. Verify that the controller's preamp switch is in the 3. Jumper TB2-3 to TB2-4 and TB2-7 to TB2-8.
sensor/J box position (see Figure 2-5). 4. Jumper TB2-7 to TB2-10 to simulate 7 pH.
2. Remove the cover of the junction box. 5. The controller should now read 7 pH (or 0 mV in
3. Disconnect the BNC adapter or remove leads ORP mode).
from TB1-7 and TB1-10 (whichever is connect- NOTE
ed).
If the controller has been calibrated with a
4. Install a jumper between 7 and 10, 3 and 4, and large zero offset, the pH may not be close
7 and 8 (see Figure 8-2). to 7. In this case, standardize the con-
5. The controller should now read approximately troller at 7. (Section 3.4).
7 pH. 6. If the controller does not read correctly (after
NOTE standardizing, if necessary), replace the con-
troller.
If the controller has been calibrated with a
large zero offset, the pH may not be close 7. If a millivolt source is available, it can be con-
to 7. In this case, standardize the connected to TB2-7 and TB2-10 to simulate pH val-
troller at 7. (Section 3.4). ues. Refer to Figure 8-1 for the relationship
between mV and pH, sample values are +172
6. If the controller does not read correctly (after mV for 4 pH and -172 mV for 10 pH.
standardizing, if necessary), go to step B.
64
TROUBLESHOOTING
FIGURE 8-2. Junction Box Preamplifier Check
FIGURE 8-3. Controller Preamplifier Check
65
TROUBLESHOOTING
TABLE 8-3. Troubleshooting Guide
PROBLEM OR CONDITION PROBABLE CAUSE AND FOR MORE HELP,

CORRECTIVE ACTION REFER TO
Controller completely inoperative No Power - Wiring, Section 3.0 and Figure 3-1
Check power supply at breaker and
inside controller: 115 V across
terminals 1 and 2 on TB3.
Cut-off circuit -
Check power supply board. Figure 3-1
Electronics Failure -
Replace the electronics.
Controller operating, but adding Incorrect or Changed Settings - Software Configuration,

chemical above setpoint, or not Refer to software configuration Section 5.0
adding below setpoint, procedure and verify that control
or not holding setpoint. parameters are correct and entered
properly. Pay special attention
to the TPC settings.
Electronics Failure - Simulated tests
Try power down and power back Section 5.4
up to reboot the program. Test
alarm relays.
Replace electronics if necessary.
Inability to standardize pH Incorrect standardization procedure - Calibration, Section 4.0

"Zero Offset Err" 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 - Section 8.2
Simulate sensor in "Preamp
Troubleshooting".
Replace sensor if preamp ok.
Electrode coated -
Clean electrode as needed.
(381+ Sensor) Reference chamber
is contaminated -
Replace gel-filled solution as instructed
in 381+ manual
Defective preamplifier - Section 8.0
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.
66 Table 8-3 is continued on the following page

TROUBLESHOOTING
TABLE 8-3. Troubleshooting Guide (continued)

Controller "short spans." Coated glass electrode -
Buffer check with 2-point Clean with soft cloth
calibration gives slope less and clean water.
than 47 mV/pH .
"lo slope error" Service 381+ Reference Junction
and Solution.
Old glass electrode -
If used for more than 1 yr, replace
electrode.
Change in pH slope (value Old or coated glass electrode -

shrinking) after 2-point calibration. Clean or replace glass electrode.
Bad RTD value - Temp.Comp. Troubleshooting
See Temp. Comp. Troubleshooting Procedure, Section 8.2
Procedure with expected RTD value
resistances at temperature values.
pH value locks up Glass electrode cracked -

(no change in buffers). Replace glass electrode.
Coated glass electrode -
Clean glass electrode.
Displayed pH value not the same Grab sample incorrect - Calibration, Section 4.0
as grab sample of process. Reevaluate sample technique and
equipment.
Unclear which is correct - Calibration, Section 4.0
Retest with new buffer solution.
Controller out of calibration - Calibration, Section 4.0
Recalibrate per Calibration,
(See Section 3.0)
Display reads off scale. (381+ Sensor) Reference depleted -

Replace reference electrolyte as
instructed in 381+ manual.
Defective preamplifier - Section 8.0
Check preamplifier as instructed in
Preamp Troubleshooting Procedure, and
replace preamplifier, if defective.
Electrode not in process solution - Wiring, Section 3.0
Make sure sensor is in solution.
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
TROUBLESHOOTING
TABLE 8-3. Troubleshooting Guide (continued)

Display reads between 3 and Electrode cracked -
6 pH regardless of actual pH Replace electrode.
solution or sample.
"cracked glass failure"
Sluggish or slow display indica- Electrode coated -

tion for real changes in pH level. Clean electrode as instructed in
sensor manual
Inability to change Password protected - Section 7.0

parameters in the controller. Your controller has password protection.
"Level 1 security: Lock" You must enter the correct password to
"Level 2 security: Lock" make changes in the controller.
"Level 3 security: Lock"
Outputs do not change Controller is in Hold or simulate mode - Software Configuration, Section 5.6
"Hold Mode activated" To remove from Hold, press any key Calibration , Section 4.7
"simulating output 1 or 2" and then press Enter (F4). Press Edit (F4),
"simulating alarm 1,2,3, or 4" 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.
Red LED light is on Unit has gone into fault mode - Section 8.0
Various fault messages Read the message and take action as
shown on lower display. indicated in Table 8-2.
68
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
33293-00 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
RETURN OF MATERIAL
SECTION 9.0
RETURN OF 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. In 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 forms
and a certification that the instruments have
RMA No. ____________ 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. Call 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 3 and 4 of Section 9.2.
NOTE
Consult the factory for additional information regarding service or repair.
70
MODEL 54e pH/ORP APPENDIX A
ORP CONFIGURATION
APPENDIX A
ORP CONFIGURATION
QUICK STARTUP (ORP) CONFIGURING THE CONTROLLER

The Model 54e pH/ORP controller comes pre-pro- Configuration of the ORP settings can be done at any
grammed by the factory as a pH controller. In order time after the controller has been set to ORP mode
to perform a quick startup as an ORP controller, the (step 3 in Quick Startup on the left). Procedures for
controller must first be switched to the pre-configured these operations follow the ORP Standardization
ORP program. Most ORP sensors will look and con- instructions in this appendix.
nect very much like pH sensors, but will have a metal Before attempting any changes refer to the configu-
ring electrode over a glass shaft with a thick end ration setup list shown in Table A-1. This table pres-
instead of a thin pH glass membrane. ents a brief description and the configurable items.
To switch to an ORP controller and perform a quick The factory setting is also given with a space for the
startup: user setting. It is recommended that the list be care-
1. Connect the ORP sensor to the controller. Wire fully reviewed before any changes are made.
to controller per Figure 2-5 or 2-6. On initial configuration, it is recommended that the
2. Apply primary power (Figure 2-4) to the con- settings be entered in the order shown on the work-
troller. sheet. This will reduce the chance of accidentally
omitting a needed setting.
3. Change the controller to ORP operation. Refer to
Section 5.3, or:
A. Press any key to display the main menu.
B. Move cursor until Program is highlighted.
C. Press Enter (F4).
D. Highlight "Configure" and press Enter (F4).
E. Highlight "Display" and press Edit (F4).
F. Use the arrow key to change "Measure" from
pH to ORP and press Save (F4). Warning
screen appears - press Cont (F3).
4. Complete the ORP standardize instructions).
5. 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): +1400mV
Alarm 3 (high alarm): +1400mV
Output 1 (4mA setpoint): -1400mV
Output 1 (20mA setpoint): +1400mV
71
ORP CONFIGURATION
TABLE A-1. ORP Settings List

ITEM CHOICES ORP SETTINGS USER SETTINGS
PROGRAM LEVEL (Sections A.2 - A.3)
A. Alarm Setpoints (Section A.2)
1. Alarm 1 (low action) -1400 to +1400 mV -1400 mV _______
2. Alarm 2 (high action) -1400 to +1400 mV +1400 mV _______
3. Alarm 3 (high action) -1400 to +1400 mV +1400 mV _______
B. Output Setpoints (Section A.3)
1. Output 1: 4 mA -1400 to +1400 mV -1400 mV _______
2. Output 1: 20 mA -1400 to +1400 mV +1400 mV _______
3. Output 2: 4 mA -15 to 130 °C 0.0 °C _______
4. Output 2: 20 mA -15 to 130 °C 100.0 °C _______
CONFIGURE LEVEL (Sections 5.5 - 5.9)
A. Display (Section 5.5)
1. Measurement type pH/ORP ORP _______
2. Convention ORP/Redox ORP _______
3. Temperature Units °C/°F °C _______
4. Output 1 Units mA/% of full scale mA _______
5. Output 2 Units mA/% of full scale mA _______
6. Language English/Français/Español/Deutsch/Italiano English _______
7. Main display lower left See Section 5.5 Alarm 1 Setpoint _______
8. Main display lower right See Section 5.5 Alarm 2 Setpoint _______
9. Display contrast 0-9 (9 darkest) 5 _______
10. Tests 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/Ref Imp Process (ORP) _______
2. Output 1 Setup
(e) Fault Value 0-22 mA 22 mA _______
3. Output 2 Control
(a) Output 2 Measurement Process/Temp /Ref Imp Temperature _______
4. Output 2 Setup
(e) Fault Value 0-22 mA 22 mA _______
5. Hold (Outputs and Relays) Disable/Enable/ 20 min timeout Disable feature _______
1. Alarm 1 Control
(a) Activation Method Process/Temp Process(ORP) _______
Continued on the following page.
72
ORP CONFIGURATION
TABLE A-1. ORP Settings List
ITEM CHOICES ORP SETTINGS USER SETTINGS

2. Alarm 1 Setup
(a) Configuration Low alarm/High alarm/Off Low _______
(b) Hysteresis (deadband) 0-500 mV 0 mV _______
(d) Relay Default Open/Closed/None None _______
3. Alarm 2 Control
4. Alarm 2 Setup
5. Alarm 3 Control
6. Alarm 3 Setup
7. Alarm 4 Control
(a) Alarm Fault/Off Fault _______
8. Feed Limit Timer
(a) Feed Limit Disable/alarm 1/alarm 2/alarm 3 Disable _______
(b) Timeout Value 0-10,800 sec 3600 sec _______
9. Interval Timer
(a) Timer (selection) Disable/alarm 1/alarm 2/alarm 3 Disable _______
(b) Timer (activation method) Time activated/Imped.activated Time activated _______
(c) Interval 0-999.9 hr 24.0 hr _______
(d) Repeats 1-60 1 _______
(e) On Time 0-2999 sec 120 sec _______
(f) Off Time 0-2999 sec 1 sec _______
(g) Recovery 0-999 sec 600 sec _______
D. Diagnostics (Section 5.8)
1. Diagnostics (Glass and Reference) On/Off Off _______
4. Ref(erence) Imp(edance) High 0-140 KOhms (0 disables) 140 KOhms _______
5. Zero Offset 0-999 mV (0 disables) 60 mV _______
E. Security (Section 7)
1. Lock all 000-999 000 (no security) _______
2. Lock Program (Lock all except Calibrate) 000-999 000 (no security) _______
3. Lock Config. (Lock all except Calibrate,
Alarm Setpoints and Rerange Outputs) 000-999 000 (no security) _______
73
ORP CONFIGURATION
Accessing Calibrate, Program and Configure Level 2 Program. To access the program level from
Menus. Operating configuration changes are made at the main menu, place the cursor over "Program" with
the levels shown in Figure A-1. Press any key from the down arrow key. Then press Enter (F4). From the
the main display to access the main menu (top left). program level menu, changes can be made to the
Refer to Section 5 for pH measurements. alarm setpoints and the output setpoints.
Level 1 Calibrate. To access calibration selections Level 3 Configure. To access the configure level
from the main menu, with the cursor on "Calibrate" from the main menu place cursor over "Program" and
press Enter (F4). ORP standardization and tempera- Enter (F4) then place cursor over "Configure" and
ture adjustments are made at this level (refer to Enter (F4). This level contains advanced selections,
Section A.1 and Section 3.1 for these procedures). such as alarms and diagnostics.
Calibrate
Diagnostic variables
Program PRESS TWO ARROWS b
and then ENTER
Exit Enter
Display
Alarm setpoints Outputs
PRESS ENTER Output setpoints Alarms
Simulated tests Exit More Enter
Exit Enter
Standardize PRESS
ARROWS
Adjust temperature PRESS
ARROWS b
Exit Enter b
CALIBRATE MENUSEC- Diagnostics
TION Security
Buffer Calibration 4.2, 4.3
Standardize pH 4.4 Simulated tests Exit More Enter
Adjust Temperature 4.1 Configure
Temp Compensation4.5 CONFIGURE MENUSEC-
pH slope 4.6 TION
Exit Enter
Display 5.5
PRESS
PROGRAM MENU SEC- Outputs 5.6
ENTER
TION Alarms 5.7
Alarm setpoints 5.1 Diagnostics 5.8
Output setpoints (PID)5.2 Security 7.1
Output setpoints 5.3
Simulated tests 5.4
FIGURE A-1. Outline of Menu Levels for ORP
74
ORP CONFIGURATION
A.1 ORP CALIBRATION
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.
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.
Standardize Skip to step 4 if using an ORP standard solution.
Adjust temperature 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.
Exit Enter
4. Move the cursor to “Standardize” and press Enter (F4).
400 mV 5. The number on the large display is the live process ORP reading. The
next line displays the ORP reading when the display was accessed.
Press Edit (F4) to perform the standardize.
Standardize: 400 mV Use the arrow b key to change the reading to the desired value and then
press Save (F4) to complete the procedure. Esc (F3) will cancel.
Exit Enter
NOTE
The + sign can be changed to a - sign after the numerical portion
of the number has been entered by highlighting the + and press-
ing the down arrow key.
400 mV Before exiting the calibration mode, remember to change the hold mode
setting to OFF (if it was turned on in step 3).
Standardize: +0402 mV
Esc Save
75
RETURN OF MATERIALS REQUEST •IMPORTANT!
This form must be completed to ensure expedient factory service.
C FROM: RETURN BILL TO:

U
S _____________________________ _____________________________ _____________________________
T
O _____________________________ _____________________________ _____________________________
M
E
R _____________________________ _____________________________ _____________________________
N CUSTOMER/USER MUST SUBMIT MATERIAL SAFETY SHEET (MSDS) OR COMPLETE STREAM COMPOSITION, AND/OR
O LETTER CERTIFYING THE MATERIALS HAVE BEEN DISINFECTED AND/OR DETOXIFIED WHEN RETURNING ANY PROD-
S
T E
I N UCT, SAMPLE OR MATERIAL THAT HAVE BEEN EXPOSED TO OR USED IN AN ENVIRONMENT OR PROCESS THAT CON-
C D TAINS A HAZARDOUS MATERIAL ANY OF THE ABOVE THAT IS SUBMITTED TO ROSEMOUNT ANALYTICAL WITHOUT
E E
T R THE MSDS WILL BE RETURNED TO SENDER C.O.D. FOR THE SAFETY AND HEALTH OF OUR EMPLOYEES. WE THANK
O YOU IN ADVANCE FOR COMPLIANCE TO THIS SUBJECT.
SENSOR OR CIRCUIT BOARD ONLY:

(Please reference where from in MODEL / SER. NO. Column)
1. PART NO.__________________________1. MODEL_________________________________1. SER. NO. ________________
R
E PLEASE CHECK ONE:
A
S REPAIR AND CALIBRATE DEMO EQUIPMENT NO. __________________________
O
N EVALUATION OTHER (EXPLAIN) _______________________________
F
O
REPLACEMENT REQUIRED? YES NO _________________________________________________
R
DESCRIPTION OF MALFUNCTION:
R
E ______________________________________________________________________________________________________
T
U
R ______________________________________________________________________________________________________
N
______________________________________________________________________________________________________
R
E WARRANTY REPAIR REQUESTED:
P
A
I
YES-REFERENCE ORIGINAL ROSEMOUNT ANALYTICAL ORDER NO. ________________________________________
R
CUSTOMER PURCHASE ORDER NO. _________________________________________________
S
T
A
NO-PROCEED WITH REPAIRS-INVOICE AGAINST P.O. NO. _________________________________________________
T
U NO-CONTACT WITH ESTIMATE OF REPAIR CHARGES: LETTER __________________________________________
S
PHONE ___________________________________________
NAME _____________________________________________________ PHONE ________________________________________
ADDRESS ___________________________________________________________________________________________________
______________________________________________________________ ZIP ________________________________________
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

Liquid Division
Tel: (949) 757-8500
Fax: (949) 474-7250

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 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 Seller.
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:

Liquid Division
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):
1. Location type of service, and length of time of service of the device.

2. Description of the faulty operation of the device and the circumstances of the failure.
3. Name and telephone number of the person to contact if there are questions about the returned material.
4. Statement as to whether warranty or non-warranty service is requested.
5. Complete shipping instructions for return of the 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,
ON-LINE ORDERING NOW AVAILABLE ON OUR WEB SITE
right now.
Specifications subject to change without notice.
Credit Cards for U.S. Purchases Only.

Liquid Division
Tel: (949) 757-8500
Fax: (949) 474-7250

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Instruction Manual

pH/ORP HART® Analyzer/Controller

Emerson Process Management

© Rosemount Analytical Inc. 2006

MODEL 54E PH/ORP

3.0 WIRING ................................................................................................................... 7

4.0 CALIBRATION ........................................................................................................ 14

5.0 SOFTWARE CONFIGURATION ............................................................................. 22

TABLE OF CONTENTS (CONTINUED)

Section Title Page

7.0 SPECIAL PROCEDURES AND FEATURES.......................................................... 54

8.0 TROUBLESHOOTING ............................................................................................ 58

9.0 RETURN OF MATERIALS...................................................................................... 70

Appendix Title Page

Table No. Title Page

TABLE OF CONTENTS (CONTINUED)

Figure No. Title Page

About This Document

Rev. Level Date Notes

7.00 pH field shown in reverse video. When the last

LVD (Code -01 only): EN-61010-1

1.4 ORDERING INFORMATION

PART NO. DESCRIPTION

2.1 LOCATING THE CONTROLLER

2.2 UNPACKING AND INSPECTION

2.3.3 Pipe Mounting:

2.3.4 Panel Mounting:

FIGURE 2-2. Pipe Mounting

FIGURE 2-3. Panel Mounting

3.1 GENERAL 3.3 ANALOG OUTPUT WIRING

DWG. NO. REV.

pH SENSOR COMPATIBILITY 3.5 pH SENSOR WIRING

FIGURE 3-2. Sensor Wiring Photo

DWG. NO. REV.

To prepare the cable for sensor wiring:

INSIDE FRONT PANEL VIEW

3.6 FINAL ELECTRICAL CHECK CAUTION

FIGURE 3-8. Wiring to Model 399-14

4.1 TEMPERATURE CALIBRATION

This procedure is used to ensure an accurate temperature measurement

7.00 pH controller temperature to a calibrated temperature reading device.

4.2 AUTOMATIC TWO-POINT CALIBRATION

The two-point calibration is performed when the controller is initially

7.00 pH Buffer calibration uses measurements of two solutions to calculate the

4.02 pH Use the arrow keys to select the correct buffer.

4. This screen appears immediately after pressing the Cont key in

10.02 pH 2. After a buffer calibration, the electrode slope value can be

4.3 MANUAL TWO-POINT CALIBRATION

This procedure is followed if Autocal is set to "Manual" in Section 5.9.

2 . Place the sensing portion of the pH sensor into a beaker containing

4.01 pH 2 (pt. 2) calibration.

5. Remove the sensor from buffer 1 and rinse in water.

4.4 SINGLE-POINT pH CALIBRATION

A single-point calibration (standardization) should always be performed

5. The pH reading in large numbers is the live process pH reading. The

4.5 TEMPERATURE COMPENSATION OPTIONS

Automatic Temperature Compensation is a standard option for pH equip-

4.6 pH SLOPE ADJUSTMENT

4.7 HOLD MODE