Emerson Process Management 53eA manual

Model 54eA Amperometric HAR T ® Analyzer/Controller Instruction Manual 51-54eA/rev .J May 2006[...]

ESSENTIAL INSTRUCTIONS READ THIS P AGE BEFORE PROCEEDING! Rosemount Analytical designs, manufactures, and tests its products to meet many national and international standards. Because these instru- ments are sophisticated technical product s, you must properly install, use, and maintain them to ensure they continue to operate within their normal sp[...]

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MODEL 54eA T ABLE OF CONTENTS MODEL 54eA ANAL YZER/CONTROLLER T ABLE OF CONTENTS Section Title Page 1.0 SPECIFICA TIONS ................................................................................................... 1 1.1 Features and Applications ....................................................................................... 1 1.2 S pe[...]

9.0 CALIBRA TION - FREE CHLORINE (498 ACL-01) ................................................ 60 9.1 Introduction .............................................................................................................. 60 9.2 Zeroing the Sensor ..................................................................................................[...]

iii MODEL 54eA T ABLE OF CONTENTS LIST OF FIGURES Section Title Page 2-1 W all Mounting .......................................................................................................... 5 2-2 Pipe Mounting .......................................................................................................... 6 2-3 Pipe and W all Mountin[...]

1 MODEL 54eA SECTION 1.0 SPECIFICA TIONS SECTION 1.0 SPECIFICA TIONS 1.1 FEA TURES AND APPLICA TIONS The Model 54eA Analyzer/Controller with the appro- priate sensor monitors and controls dissolved oxy- gen (ppm and ppb level), free chlorine, total chlorine, and ozone in a variety of process liquids. The analyzer is compatible with Rosemount Analyt[...]

MODEL 54eA SECTION 1.0 SPECIFICA TIONS 2 1.2 SPECIFICA TIONS - GENERAL Enclosure: Epoxy-painted (light gray) cast aluminum, NEMA4X (IP65). 144 x 144 x 132 mm (5.7 x 5.7 x 5.2 in.), DIN size. Front Panel: Membrane keypad with t actile feedback. Three green LEDs indicate alarm status. Red LED indicates fault condition. Display: Three-line, back-lit, [...]

MODEL 54eA SECTION 1.0 SPECIFICA TIONS SPECIFICA TIONS — OXYGEN Measurement Range: 0-99 ppm (mg/L), 0-200% sat- uration Resolution: 0.01 ppm, 0.1 ppb for 499A T rDO sen- sor T emperature correction for membrane permeabili- ty: automatic between 0 and 50°C (can be dis- abled) Calibration: automatic air calibration or calibration against a standar[...]

MODEL 54eA SECTION 1.0 SPECIFICA TIONS 4 1.3 ORDERING INFORMA TION The Model 54eA Microprocessor Analyzer measures dissolved oxygen, free chlorine, tot al chlorine, ozone, and pH. pH is available for free chlorine only . The analyzer has an on-board pressure sensor for automatic air calibration of oxygen sensors. Amperometric measurements are fully[...]

5 MODEL 54eA SECTION 2.0 INST ALLA TION SECTION 2.0 INST ALLA TION 2.1 UNP ACKING AND INSPECTION Inspect the shipping container . If it is damaged, contact the shipper immediately for instructions. Save the box. If there is no apparent damage, unp ack the container . Be sure all items shown on the packing list are present. If items are missing, not[...]

6 FIGURE 2-2. Pipe Mounting MODEL 54eA SECTION 2.0 INST ALLA TION 2.2.3 Pipe mounting 9.52 .375 SIDE VIEW FRONT VIEW 4 MOUNTING HOLES WHEN INCH AND METRIC DIMS ARE GIVEN MILLIMETER INCH PIPE MOUNTING PN 2002577 W ALL MOUNTING FIGURE 2-3. Pipe and W all Mounting Dimensions DWG . NO. REV . 40005402 E[...]

MODEL 54eA SECTION 2.0 INST ALLA TION FIGURE 2-4. Panel Mounting 2.2.4 Panel mounting WHEN INCH AND METRIC DIMS ARE GIVEN MILLIMETER INCH FIGURE 2-5. Panel Mounting Dimensions 144 5.7 35 1.38 50.8 2 1.52 .06 33 1.3 66 2.6 28.72 1.17 139.7 5.5 139.7 5.5 155.7 6.13 137.9 5.43 68.96 2.715 137.9 5.43 144 5.7 FRONT VIEW BOTTOM VIEW SIDE VIEW P ANEL SUPP[...]

8 MODEL 54eA SECTION 3.0 WIRING SECTION 3.0 WIRING 3.1 GENERAL W ARNING Electrical installation must conform to the National Electrical Code, all st ate and local codes, and all plant codes and standards for electrical equipment. Electrical inst allation and wiring must be done by qualified personnel. The five holes in the bottom of the instrument [...]

9 MODEL 54eA SECTION 3.0 WIRING FIGURE 3-1. Power Input and Relay Output Wiring for Model 54eA DWG . NO. REV . 454EPH02 D[...]

10 MODEL 54eA SECTION 3.0 WIRING FIGURE 3-3. Amperometric sensors with st andard cable. FIGURE 3-4. Amperometric sensors with optimum EMI/RFI cable or V ariopol cable. FIGURE 3-2. Wiring Label 3.3 SENSOR WIRING 3.3.1 General The wiring label, which is shown in Figure 3-2, is a general purpose label. It has wiring infor- mation concerning other sens[...]

11 MODEL 54eA SECTION 3.0 WIRING 3.3.3 Wiring 499ACL-01 (free chlorine) sensors and pH sensors for automatic pH correction. If free chlorine is being measured using the 499ACL-01 sensor and the pH of the liquid varies more than 0.2 pH unit, a continuous correction for pH must be applied to the chlorine reading. Therefore, a pH sensor must also be w[...]

12 MODEL 54eA SECTION 3.0 WIRING FIGURE 3-6. 499ACL-01 sensor with st andard cable and 399-14 pH sensor having internal preamplifier . FIGURE 3-7. 499ACL-01 sensor with st andard cable and 399-09-62 pH without internal preamplifier . Although the blue wire is connect- ed to a terminal labeled solution ground , the blue wire does not connect to a so[...]

MODEL 54eA SECTION 3.0 WIRING FIGURE 3-9. 499ACL-01 sensor with optimum EMI/RFI cable or V ariopol cable and 399-14 pH sensor having internal preamplifier . FIGURE 3-8. 499ACL-01 sensor with optimum EMI/RFI cable or V ariopol cable and 399VP-09 pH sensor without internal preamplifier . 13 Although the blue wire is connect- ed to a terminal labeled [...]

14 MODEL 54eA SECTION 3.0 WIRING FIGURE 3-10. 499CL-01 sensor with optimum EMI/RFI cable or V ariopol cable and 399-09-62 pH sensor without internal preamplifier . DWG . NO. REV . 4054eA04 A 3.3.4 Wiring 438ACL-01 (pH independent free chlorine) sensors FIGURE 3-1 1. 498CL-01 (pH-independent free chlorine) sensor[...]

Insulate and t ape back unused wires. 3.3.5 Wiring Hx438 and Gx448 sensors Hx438 and Gx448 steam-sterilizable dissolved oxygen sensors use a 22k NTC thermistor . The thermistor is wired to terminals 1 and 3 on TB5. FIGURE 3-12. Hx438 and Gx448 sensors. MODEL 54eA SECTION 3.0 WIRING 15 DWG . NO. REV . 4054eA07 A[...]

16 MODEL 54eA SECTION 4.0 DISPLA Y AND OPERA TION SECTION 4.0 DISPLA Y AND OPERA TION 4.1 GENERAL DESCRIPTION The 54eA analyzer/controller is a normally a single input, dual output instrument. It does, however , accept a second input for pH when the main measurement is free chlorine. Figure 4-1 shows how the instrument inputs and output s can be co[...]

17 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION SECTION 5.0 SOFTW ARE CONFIGURA TION The instrument is configured at the factory to measure oxygen. Figure 5-1 is an outline of the menu structure. T able 5-1 lists the default settings and the range of choices available for each setting. T o reduce the chance of error when configuring the controll[...]

18 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION Continued on the following page ITEM CHOICES F ACTOR Y SETTINGS CONFIGURE A. Display options (Section 5.5) 1. Measurement Oxygen, ozone, free chlorine, total chlorine, monochloramine Oxygen 2. Sensor (Oxygen only) Rosemount standard, Rosemount biopharm, or Rosemount standard other steam sterilizabl[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION ITEM CHOICES F ACTOR Y SETTINGS CONFIGURE (continued) C. Alarms (Section 5.7) (continued) 3. Alarm 1 setup (TPC) a. Setpoint if oxygen (ppm) -20 to 20 ppm 1 ppm if oxygen (ppb) -999 to 999 ppb 100 ppb if oxygen (% saturation) 0 to 200% 100% if chlorine, monochloramine, or ozone -9999 to 9999 ppm 1.0 p[...]

20 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION T ABLE 5-1. Program Settings List (continued) ITEM CHOICES F ACTOR Y SETTINGS CONFIGURE (continued) D. pH measurement (Section 5.8) 1. pH sensor Enable or disable Enable 2. pH compensation (free chlorine only) Auto or manual Auto 3. pH value 0.00 - 14.00 7.00 4. pH diagnostic On or off Off a. Glass[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION FIGURE 5-1. Menu T ree for the 54eA Controller Calibrate Program (see page 23) Diagnostic V ariables Main Menu Calibrate main sensor Zero main sensor Adjust temperature Calibrate pH Slope Buffer calibration S tandardize Main measurement Main sensor current Sensitivity (µA/ppm) Zero current pH reading[...]

22 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION Program Calibrate (see page 21) Diagnostic V ariable (see page 21) Main Menu Alarms 1, 2, and 3 setpoints 4 mA or 0 mA 20 mA Present output current Alarm Setpoints Output setpoints T est output 1 or 2 T est alarm 1, 2, 3, or 4 Simulated tests Configure Display Main Sensor Oxygen Free Chlorine T ota[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION FIGURE 5-1. Menu T ree for the 54eA Controller (continued) Display (see page 22) Outputs (see page 22) Alarms (see page 22) Program Calibrate (see page 21) Diagnostic V ariable (see page 21) Main Menu Alarm Setpoints (see p age 22) Output setpoints (see page 22) Simulated tests (see page 22) Configure[...]

24 5.1 CHANGING ALARM SETPOINTS 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Press Enter (F4). 4. Move the cursor to the desired alarm and press Enter (F4). 5. The screen appearing at this point depends on how the alarm was configured. 6. If the alarm is a normal (i.e., not TPC) alarm, a s[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.2 RANGING THE OUTPUTS 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Move the cursor to "Output setpoint s" and press Enter (F4). 4. Move the cursor to the desired output and press Enter (F4). 5. This screen confirms that changes to[...]

26 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.3 CHANGING OUTPUT SETPOINTS (PID ONL Y) 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Move the cursor to "Output setpoint s" and press Enter (F4). 4. Move the cursor to the desired output and press Enter (F4). 5. This screen con[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.4 TESTING OUTPUTS AND ALARMS 2. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 3. Move the cursor to "Simulated test s" and press Enter (F4). 4. Move the cursor to the desired output or alarm. Both output s and all four alarms can be test[...]

28 Output setpoint s Simulated test s Configure Exit Enter MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.5 CHOOSING DISPLA Y OPTIONS 3. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 4. Move the cursor to "Configure" and press Enter (F4). 5. With the cursor on "Display", pr[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.5 CHOOSING DISPLA Y OPTIONS (CONTINUED) 8. Set the remainder of the display parameters. Use the é and ê keys to choose the desired parameter . Then press Edit (F4). Use the é key to move the cursor to the desired selection. Press Save (F4) to store. SECURITY CAUTION The controller uses the timeou[...]

30 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.6 CHANGING OUTPUT P ARAMETERS 3. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 4. Move the cursor to "Configure" and press Enter (F4). 5. Move the cursor to "Outputs" and press Enter (F4). 6. Five menu headers relate to outp[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.6 CHANGING OUTPUT P ARAMETERS (continued) e. The display returns to the “Output: Process” screen. Press Exit (F1). The display returns to the “Output Measurement” screen. Move the cursor to "Control mode" and press Enter (F4). f. Press Edit (F4). Use the é key to toggle between &q[...]

32 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION Proportional: Proportional is the same as proportional band and is the range over which control is being used. It is the opposite of process gain. Smaller values provide tighter control. Integral: Integral is the number of seconds over which devia- tions from the setpoint are integrated to remove c[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.7 CHANGING ALARM P ARAMETERS 3. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 4. Move the cursor to "Configure" and press Enter (F4). 5. Move the cursor to "Alarms" and press Enter (F4). 6. Nine menu headers relate to alarms. A[...]

34 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.7 CHANGING ALARM P ARAMETERS (continued) c. T o change the activation method, press Edit (F4). Use the é key to scroll through the choices: "Process", "T emperature", and “pH” (if pH was enabled). "Process" means the measurement made by the main sensor (oxygen, [...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.7 CHANGING ALARM P ARAMETERS (continued) 9. Alarm setup for TPC alarms: a. Move the cursor to the desired alarm setup and press Enter (F4). b. Use the é and ê keys to move the cursor to the desired param- eter . Press Edit (F4). Use the arrow keys to change the setting to the desired value and pre[...]

36 Feed limit : Disable T imeout: 3600 sec Exit Edit 1.000 ppm 26.2°C 12.0mA Feed limit alarm 1 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.7 CHANGING ALARM P ARAMETERS (continued) Example: The setpoint is 3.00 ppm. The UR V is +5.00 ppm and the LRV is 0.00 ppm. The time period is 30 seconds. When the concentration is 4.00 ppm, the relay wil[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.7 CHANGING ALARM P ARAMETERS (continued) 1 1. Interval timer setup: Alarm 1, 2, or 3 can be used as an interval timer . The selected relay will open and close at time intervals programmed by the user . The interval timer is useful for automatic cleaning of sensors. NOTE The alarm relay used for the [...]

38 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.8 CONFIGURING THE pH MEASUREMENT 1. Press any key to enter the main menu. Move the cursor to "Program" and press Enter (F4). 2. Move the cursor to "Configure" and press Enter (F4). 3. Move the cursor to “pH” and press Enter (F4). 4. The default settings are “pH sensor: E[...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.8 CONFIGURING THE pH MEASUREMENT (continued) key to change "Off" to "On". Press Save (F4). NOTE Choosing "On" means the controller will display pH diagnos- tic warning messages and fault alarms. Choosing "Off" means the messages and fault alarms will not be di[...]

40 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.8 CONFIGURING THE pH MEASUREMENT (continued) T emp coef f : 0.000 Operate iso: 7.00 pH Sensor iso: 7.00 pH Exit Enter St abilize pH and S tabilize time: For the controller to accept cal- ibration data, the pH must remain within a specified range for a specified period of time. The default values [...]

T emp comp : Auto T emp unit s: °C Exit Edit T emp comp: Manual T emp unit s: °C T emperature : 25.0°C Exit Edit MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.9 TEMPERA TURE COMPENSA TION AND TEMPERA TURE UNITS 1. Refer to Section 6.1 for a discussion of the ways in which temperature affect s amperometric and pH meas- urements. pH T emperatu[...]

42 Noise rejection : 60 Hz Exit Edit MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.10 NOISE REDUCTION 1. For maximum noise reduction the frequency of the ac power must be entered into the analyzer . T emperature Noise rejection Main sensor cal Exit Enter 2. Press any key to enter the main menu. Move the cursor to "Program" and press E[...]

S tabilize : 0.050 ppm S tabilize time: 10 sec Exit Edit S tabilize: 0.050 ppm S tabilize time: 10 sec Dual range cal : Disable Exit Edit S tabilize: 0.050 ppm S tabilize time: 10 sec Salinity : 0.0 o /oo Exit Edit MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.1 1 MAIN SENSOR CALIBRA TION P ARAMETERS 1. Main sensor refers to the amperometric se[...]

44 Bar meas : Auto Bar unit s: mm Hg Exit Edit MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.12 BAROMETRIC PRESSURE 1. The barometric pressure menu header appears only if an oxygen sensor (ppm or ppb level) is being used. Barometric pressure is used during air calibration. Noise rejection Barometric pressure Main sensor cal Exit Enter 2. Press [...]

MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.13 SECURITY 1. The controller can be programmed to require a password for access to menus. There are three levels: Level 1: A level 1 user can 1. Zero and calibrate the main (amperometric) sensor 2. Calibrate the barometric pressure sensor 3. Calibrate the pH sensor 4. Enter a temperature slope for [...]

46 MODEL 54eA SECTION 5.0 SOFTW ARE CONFIGURA TION 5.14 CONTROLLER MODE PRIORITY The Model 54eA controller can function in different modes depending on both how it is configured, what process conditions exist, and actions an operator may have made. T o reconcile these possible modes, there is a set priority that determines exactly what will happen [...]

47 MODEL 54eA SECTION 6.0 CALIBRA TION - TEMPERA TURE SECTION 6.0 CALIBRA TION - TEMPERA TURE 6.1 INTRODUCTION All four amperometric sensors (oxygen, ozone, free chlorine, total chlorine, and monochloramine) are membrane- covered sensors. As the sensor operates, the analyte (the substance to be determined) diffuses through the mem- brane and is con[...]

48 6.2 TEMPERA TURE CALIBRA TION MODEL 54eA SECTION 6.0 CALIBRA TION - TEMPERA TURE 2. From the main display , press any key . With the cursor on “Calibrate,” press Enter (F4). NOTE If Hold was enabled in Section 5.6, the hold screen will appear . T o activate hold, refer to Section 5.6, step 1 1. 3. Press the ê key twice to move the cursor to[...]

MODEL 54eA SECTION 7.0 CALIBRA TION - DISSOL VED OXYGEN SECTION 7.0 CALIBRA TION - DISSOL VED OXYGEN 7.1 INTRODUCTION As Figure 7-1 shows, oxygen sensors generate a current directly proportional to the concentration of dissolved oxygen in the sample. Calibrating the sensor requires exposing it to a solution containing no oxygen (zero st an- dard) a[...]

50 1. Place the sensor in a fresh solution of 5% sodium sulfite (Na 2 SO 3 ) in water . Be sure air bubbles are not trapped against the membrane. The current will drop rapidly at first and then gradually reach a st able zero value. T o monitor the sensor current, go to the main display . Press any key to obtain the main menu. Press the ê key once [...]

1. Remove the sensor from the process liquid. Use a soft tissue and a stream of water from a wash bottle to clean the membrane. Blot dry . The membrane must be dry during air calibration. 2. Pour some water in a beaker and suspend the sensor with the membrane about 0.5 inch (1 cm) above the water surface. T o avoid drift caused by temperature chang[...]

52 MODEL 54eA SECTION 7.0 CALIBRA TION - DISSOL VED OXYGEN 9. During calibration, the analyzer stores the measured current and cal- culates the sensitivity . Sensitivity is the sensor current in nA divided by the saturation concentration of oxygen in ppm. The t able gives typical sensitivity for Rosemount Analytical dissolved oxygen sensors. T o vi[...]

The analyzer and sensor can be calibrated against a standard instrument. For oxygen sensors inst alled in aera- tion basins in waste treatment plants, calibration against a second instrument is of ten preferred. For an accurate calibration be sure that… 1. The standard instrument has been zeroed and calibrated against water-saturated air followin[...]

54 1. If the barometric pressure measured by the controller does not agree with the local barometric pressure, cal- ibrate the pressure sensor . A pressure error of 3 mm Hg introduces an error of about 0.5% in the final meas- urement. When calibrating the pressure reading, be sure to use the actual barometric pressure. Weather fore- casters and air[...]

MODEL 54eA SECTION 8.0 CALIBRA TION - FREE CHLORINE (499ACL-01) SECTION 8.0 CALIBRA TION - FREE CHLORINE (499ACL-01) 8.1 INTRODUCTION This section covers the calibration of the 499ACL-01 free chlorine sensor . See section 9.0 for calibration of the 498CL-01 pH-independent free chlorine sensor . As Figure 8-1 shows, a free chlorine sensor generates [...]

56 1. Place the sensor in the zero standard (see Section 8.1). Be sure no air bubbles are trapped against the mem- brane. The sensor current will drop rapidly at first and then gradually reach a st able zero value. T o monitor the sensor current, go to the main display . Press any key to obtain the main menu. Press the ê key once to high- light ?[...]

1. Place the sensor in the process liquid. If automatic pH correction is being used, calibrate the pH sensor (see Section 1 1.0) and place it in the process liquid. If manual pH correction is being used, measure the pH of the process liquid and enter the value. See Section 5.8. Adjust the sample flow until it is within the range recommended for the[...]

58 MODEL 54eA SECTION 8.0 CALIBRA TION - FREE CHLORINE (499ACL-01) Figure 8-2 shows the principle of dual slope cali- bration. Between zero and concentration C1, the sensor response is linear . When the concentration of chlorine becomes greater than C1, the response is non-linear . In spite of the non-linearity , the response can be approximated by[...]

MODEL 54eA SECTION 8.0 CALIBRA TION - FREE CHLORINE (499 ACL-01+3.) 7. Once the reading is stable, the screen at lef t appears. Sample the process liquid. Make a note of the reading before taking the sample. Immediately determine free chlorine. Note the controller reading again. If the present reading (X) differs from the reading when the sample wa[...]

60 MODEL 54eA SECTION 9.0 CALIBRA TION - FREE CHLORINE (498CL-01) SECTION 9.0 CALIBRA TION - FREE CHLORINE (498CL-01) 9.1 INTRODUCTION This section covers the calibration of the 498CL-01 pH-independent free chlorine sensor only . See section 8.0 for calibration of the 499ACL-01 sensor . As Figure 9-1 shows, a free chlorine sensor generates a curren[...]

MODEL 54eA SECTION 9.0 CALIBRA TION - FREE CHLORINE (498CL-01) 61 1. BEFORE ZEROING THE SENSOR, PLACE IT IN THE FLOW CELL AND ALLOW THE SENSOR T O OPER- A TE IN A FLOWING CHLORINA TED SAMPLE FOR A T LEAST TWO HOURS. 2. After two hours, remove the sensor from the flow cell and place it in the zero standard. See Section 9.1 for suggested zero standar[...]

MODEL 54eA SECTION 9.0 CALIBRA TION - FREE CHLORINE (498CL-01) 1. Place the sensor in the process liquid. Be sure the controller has been programmed for manual pH correction and the pH is 7.00. Adjust the sample flow until it is in the range recommended for the sensor . Refer to the sensor instructions sheet. 2. Adjust the chlorine concentration un[...]

MODEL 54eA SECTION 9.0 CALIBRA TION - FREE CHLORINE (498CL-01) 63 Figure 9-2 shows the principle of dual slope cali- bration. Between zero and concentration C1, the sensor response is linear . When the concentration of chlorine becomes greater than C1, the response is non-linear . In spite of the non-linearity , the response can be approximated by [...]

64 MODEL 54eA SECTION 9.0 CALIBRA TION - FREE CHLORINE (498CL-01) 7. Once the reading is stable, the screen at lef t appears. Sample the process liquid. Make a note of the reading before taking the sample. Immediately determine free chlorine. Note the controller reading again. If the present reading (X) differs from the reading when the sample was [...]

MODEL 54eA SECTION 10.0 CALIBRA TION - TOT AL CHLORINE SECTION 10.0 CALIBRA TION - TOT AL CHLORINE See TCL manual for calibration procedure. 65[...]

This p age intentionally lef t blank. 66[...]

MODEL 54eA SECTION 1 1.0 CALIBRA TION - MONOCHLORAMINE SECTION 1 1.0 CALIBRA TION - MONOCHLORAMINE 67 1 1.1 INTRODUCTION As Figure 1 1-1 shows, a monochloramine sensor generates a current directly proportional to the concentration of monochloramine in the sample. Calibrating the sensor requires exposing it to a solution containing no monochlo- rami[...]

68 MODEL 54eA SECTION 1 1.0 CALIBRA TION - MONOCHLORAMINE 1. Place the sensor in the zero standard. Be sure no air bubbles are trapped against the membrane. The sensor current will drop rapidly at first and then gradually reach a stable zero value. T o monitor the sensor current, go to the main display . Press any key to obtain the main menu. Press[...]

MODEL 54eA SECTION 1 1.0 CALIBRA TION - MONOCHLORAMINE 1. Place the sensor in the process liquid. Adjust the sample flow until it is within the range recommended for the sensor . Refer to the sensor instruction sheet. 2. Adjust the monochloramine concentration until it is near the upper end of the control range. W ait until the con- troller reading[...]

70 MODEL 54eA SECTION 12.0 CALIBRA TION - OZONE SECTION 12.0 CALIBRA TION - OZONE 12.1 INTRODUCTION As Figure 12-1 shows, an ozone sensor generates a current directly proportional to the concentration of ozone in the sample. Calibrating the sensor requires exposing it to a solution containing no ozone (zero st andard) and to a solution containing a[...]

1. Place the sensor in the zero standard. Be sure no air bubbles are trapped against the membrane. The sensor current will drop rapidly at first and then gradually reach a stable zero value. T o monitor the sensor current, go to the main display . Press any key to obtain the main menu. Press the ê key once to highlight “Diagnostic vari- ables.?[...]

72 1. Place the sensor in the process liquid. Adjust the sample flow until it is within the range recommended for the sensor . Refer to the sensor instruction sheet. 2. Adjust the ozone concentration until it is near the upper end of the control range. W ait until the controller read- ing is stable before st arting the calibration. 12.3 FULL SCALE [...]

MODEL 54eA SECTION 13.0 CALIBRA TION - pH SECTION 13.0 CALIBRA TION - pH 13.1 INTRODUCTION A new pH sensor must be calibrated before use. Regular recalibration is also necessary . A pH measurement cell (pH sensor and the solution to be measured) can be pictured as a battery with an extreme- ly high internal resistance. The voltage of the battery de[...]

74 4.02 pH Buf1done: 4.00 @25°C Abort Cont 4.02 pH Autocal buf fer 1 Abort Cont Adjust temperature Calibrate pH Output trim Exit Enter Buf fer calibration S tandardize pH pH slope Exit Enter 1. Be sure the pH feature has been enabled. See Section 5.8. 2. Obtain two buffer solutions. Ideally the buf fer pH values should bracket the range of pH valu[...]

MODEL 54eA SECTION 13.0 CALIBRA TION - pH 9. Remove the sensor from buffer 1, rinse it with water , and place it in buffer 2. Swirl the sensor . Press Cont (F3). "W ait" flashes until the reading is stable. 10. The screen at left appears once the reading is stable. Use the é or ê key to change the reading to the nominal pH of the buffer[...]

76 1. Be sure the pH feature has been enabled. See Section 5.8. 2. The controller comes from the factory set for automatic pH calibration. T o do a manual calibration, the factory default setting must be changed. Refer to Section 5.8. 3. Obtain two buffer solutions. Ideally the buf fer pH values should bracket the range of pH values to be meas- ure[...]

MODEL 54eA SECTION 13.0 CALIBRA TION - pH 10. The screen at left appears if the pH reading in step 9 was changed. Press Pt2 (F3). Go to step 1 1. 1 1. Rinse the sensor and thermometer with water and place them in buffer 2. Be sure the glass bulb and junction are completely sub- merged. Swirl the sensor . Press Cont (F3). "Wait" flashes un[...]

78 1. The pH measured by the controller can be changed to match the reading from a second or referee instrument. The process of making the two reading agree is called standardization, or one-point calibration. 2. During standardization, the dif ference between the two pH values is converted to the equivalent voltage. The voltage, called the referen[...]

1. If the electrode slope is known from other measurements, it can be entered directly into the controller . The slope must be entered as the slope at 25°C. T o calculate the slope at 25°C from the slope at temperature t°C, use the equation: slope at 25°C = (slope at t°C) Changing the slope overrides the slope determined from the previous buff[...]

80 MODEL 54eA SECTION 14.0 CALIBRA TION - CURRENT OUTPUTS SECTION 14.0 CALIBRA TION - CURRENT OUTPUTS 14.1 INTRODUCTION Although the controller outputs are calibrated at the factory , they can be trimmed in the field to match the reading from a standard current meter . Both the low output (0 or 4 mA) and the high output (20 mA) can be trimmed. 14.2[...]

81 MODEL 54eA SECTION 15.0 PID AND TPC CONTROL SECTION 15.0 PID AND TPC CONTROL 15.1 PID CONTROL (CODE -20) PID Control The Model 54eA current outputs can be programmed for PID control. PID control is used with a control device that is capable of varying it s output from 0 to 100 percent in response to a changing signal in mil- liamps. Automated co[...]

82 MODEL 54eA SECTION 15.0 CALIBRA TION - CONTROL Proportional (Gain) Plus Integral (Reset) For the automatic elimination of deviation, I (Integral mode), also referred to as Reset, is used. The propor- tional function is modified by the addition of automatic reset. With the reset mode, the controller continues to change its output until the deviat[...]

MODEL 54eA SECTION 15.0 CALIBRA TION - CONTROL 6. When sufficient dat a have been collected, return the output signal to its original value using the sim- ulate test function. Maintain the controller in this manual mode until you are ready to initiate auto- matic PID control, after you have calculated the tuning constant s. Once these steps are com[...]

84 MODEL 54eA SECTION 15.0 CALIBRA TION - CONTROL concentration, temperature) compared to the measurement range, the dif ference between the 20 mA (Hi) and 4 (or 0) mA (Lo) setpoints, which you determined when configuring the analog output. In the example shown in Figure 15-1: The percent change in pH was: x 100% = = 33.3% The change in the output [...]

MODEL 54eA SECTION 15.0 CALIBRA TION - CONTROL 15.2 TIME PROPORTIONAL CONTROL (TPC) MODE (Code -20) In the TPC mode, you must est ablish the following parameters which will determine how the Model 54eA controller responds to your system (see Section 5.7): • Setpoint • T ime period • URV point (or 100% on) • LRV point (or 0% on) • Proporti[...]

86 MODEL 54eA SECTION 16.0 TROUBLESHOOTING SECTION 16.0 TROUBLESHOOTING 16.1 OVERVIEW The 54eA controller continuously monitors itself and the sensor for faults. When the controller detects a fault in the amperometric or pH sensor or in the instrument itself it displays a fault message . If alarm 4 was enabled, the red F AIL LED will also light and[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.2.1 High input current Excessive sensor current implies that the amperometric sensor is miswired or the sensor has failed. V erify that wiring is correct, including connections through a junction box. See Section 3.3. If wiring is correct, try replacing the sensor . 16.2.2 Check sensor zero The sensor curr[...]

88 MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.2.8 Sense line open Most Rosemount Analytical sensors use a Pt100 or a Pt1000 in a three-wire configuration (see Figure 16-4). The in and return leads connect the RTD to the measuring circuit in the analyzer . A third wire, called the sense line, is connected to the return lead. The sense line allows th[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.4.1 Zero current is too high A. Is the sensor properly wired to the analyzer? See Section 3.3. B. Is the membrane completely covered with zero solution and are air bubbles not trapped against the mem- brane? Swirl and tap the sensor to release air bubbles. C. Is the zero solution fresh and properly made? Z[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.4.5 Barometric pressure reading is too high or too low . A. Is the pressure inside the enclosure equal to ambient pressure? The pressure sensor is inside the controller enclo- sure. When cable glands are in place and the front panel is tightly closed, the enclosure is moderately airtight. Therefore, as the[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.5 TROUBLESHOOTING WHEN NO F AUL T MESSAGE IS SHOWING - FREE CHLORINE 16.5.1 Zero current is too high A. Is the sensor properly wired to the controller . See Section 3.3. B. Is the zero solution chlorine-free? T ake a sample of the solution and test it for free chlorine level. The con- centration should be [...]

92 MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.5.3 Sensor can be calibrated, but the current is too low A. Is the temperature low? For both the 499ACL-01 and 498CL-01 sensors, sensor current is a strong function of temperature. The current decreases about 3% for every ºC drop in temperature. B. Is the pH high? The 499ACL-01 sensor current is a stro[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.5.6 Sensor does not respond to changes in chlorine level. A. Is the grab sample test accurate? Is the grab sample representative of the sample flowing to the sensor? B. Is the pH compensation correct? (Applies only to the 499ACL-01 sensor .) If the controller is using manual pH correction, verify that the [...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.7 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING — MONOCHLORAMINE 16.7.1 Zero current is too high A. Is the sensor properly wired to the analyzer? See Section 3.3. B. Is the zero solution monochloramine-free? T ake a sample of the solution and test it for monochloramine level. The concentration should [...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.7.3 Sensor can be calibrated, but the current is too low A. Is the temperature low? The sensor current decreases about 5% for every °C drop in temperature. B. Sensor current depends on the rate of sample flow past the sensor tip. If the flow is too low , monochloramine readings will be low . Refer to the [...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.7.7 Readings are too low . A. W as the sample tested as soon as it was t aken? Monochloramine solutions are moderately unstable. T est the sample immediately after collecting it. Avoid exposing the sample to sunlight. B. When was the sensor fill solution last replaced? The monochloramine sensor loses sensi[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.8 TROUBLESHOOTING WHEN NO F AUL T MESSAGE IS SHOWING - OZONE 16.8.1 Zero current is too high A. Is the sensor properly wired to the controller . See Section 3.3. B. Is the zero solution ozone free? T est the zero solution for ozone level. The concentration should be less than 0.02 ppm. C. Has adequate time[...]

98 MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.8.4 Process readings are erratic A. Readings are often erratic when a new sensor or a rebuilt sensor is first placed in service. The current usual- ly stabilizes af ter a few hours. B. Is the sample flow within the recommended range? High sample flow may cause erratic readings. Refer to the sensor instr[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.9 TROUBLESHOOTING WHEN NO F AUL T MESSAGE IS SHOWING - pH 16.9.1 W arning or error message during two-point calibration. Once the two-point (manual or automatic) calibration is complete, the controller automatically calculates the sen- sor slope (at 25°C). If the slope is less than 45 mV/pH, the controlle[...]

100 MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.9.2 W arning or error message during two-point calibration. During standardization, the millivolt signal from the pH cell is increased or decreased until it agrees with the pH reading from a reference instrument. A unit change in pH requires an offset of about 59 mV . The controller limits the offset t[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.9.6 Calibration was successful, but process pH is grossly wrong and/or noisy . Grossly wrong or noisy readings suggest a ground loop (measurement system connected to earth ground at more than one point), a floating system (no earth ground), or noise being brought into the analyzer by the sensor cable. The [...]

102 MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.10 TROUBLESHOOTING NOT RELA TED TO MEASUREMENT PROBLEMS Problem Action Display segments missing Replace display board Alarm relays are chattering 1. Check alarm setpoints. 2. Increase hysteresis time delay settings (see Section 5.7) Incorrect current output 1. V erify that output load is less than 600 [...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.12 SIMULA TING INPUTS - OTHER AMPEROMETRIC MEASUREMENTS T o check the performance of the controller , use a decade box and a battery to simulate the current from the sen- sor . The battery , which opposes the polarizing voltage, is necessary to ensure that the sensor current has the cor- rect sign. NOTE It[...]

104 MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.13 SIMULA TING INPUTS - pH 16.13.1 General This section describes how to simulate a pH input into the controller . T o simulate a pH measurement, connect a standard millivolt source to the controller . If the controller is working properly , it will accurately measure the input voltage and convert it t[...]

MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.14 SIMULA TING TEMPERA TURE 16.14.1 General. The 54eA controller accepts either a Pt100 RTD (for pH, 499ADO, 499A T rDO, 499ACL-01, 499ACL-02, 499ACL-03, and 499AOZ sensors) or a 22k NTC thermistor (for Hx438 and Gx448 DO sensors and most steam-sterilizable DO sensors from other manufacturers). The Pt100 R[...]

106 MODEL 54eA SECTION 16.0 TROUBLESHOOTING 16.15 MEASURING REFERENCE VOL T AGE Some processes contain subst ances that poison or shift the potential of the reference electrode. Sulfide is a good example. Prolonged exposure to sulfide converts the ref- erence electrode from a silver/silver chloride electrode to a silver/silver sulfide electrode. Th[...]

MODEL 54eA SECTION 17.0 MAINTENANCE SECTION 17.0 MAINTENANCE REPLACEMENT P ARTS P ART NUMBER DESCRIPTION 23540-05 Enclosure, Front with Keyboard 23848-00 Power Supply Circuit Board Shield 23849-00 Half Shield, Power Supply 23969-02 PCB, CPU and power supply , calibrated, 1 15/230 V ac 23969-06 PCB, CPU and power supply , calibrated, 24 Vdc 33281-00[...]

MODEL 54eA SECTION 18.0 RETURN OF MA TERIAL SECTION 18.0 RETURN OF MA TERIAL 18.1 GENERAL. T o expedite the repair and return of instruments, proper communication between the customer and the factory is important. Before returning a product for rep air , call 1-949-757-8500 for a Return Materials Authorization (RMA) number . 18.2 W ARRANTY REP AIR.[...]

W ARRANTY Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defect s in workman- ship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller . Consumables, pH electrodes, membranes, liquid junctions, electrolyte, O-rings, etc. are warranted to be [...]

Credit Cards for U.S. Purchases Only . The right people, the right answers, right now . ON-LINE ORDERING NOW A V AILABLE ON OUR WEB SITE http://www .raihome.com Specifications subject to change without notice. Emerson Process Management Liquid Division 2400 Barranca Parkway Irvine, CA 92606 USA T el: (949) 757-8500 Fax: (949) 474-7250 http://www .r[...]