Emerson Rosemount Analytical HART 5081-A-HT Instruction Manual Download

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Model 5081-A-HT

HART

Two-Wire Chlorine, Dissolved Oxygen, and Ozone

Transmitter

Instruction Manual

LIQ_MAN_5081A-HT/rev.M
January 2015

Summary of Contents for Rosemount Analytical HART 5081-A-HT

Page 1: ...Model 5081 A HT HART Two Wire Chlorine Dissolved Oxygen and Ozone Transmitter Instruction Manual LIQ_MAN_5081A HT rev M January 2015 ...

Page 2: ...ct When replacement parts are required ensure that qualified people use replacement parts specified by Rosemount Unauthorized parts and procedures can affect the product s performance and place the safe operation of your process at risk Look alike substitutions may result in fire electrical hazards or improper operation Ensure that all equipment doors are closed and protective covers are in place ...

Page 3: ... Inspection 7 2 2 Orienting the Display Board 7 2 3 Installation 7 2 4 Power Supply Current Loop 10 3 0 WIRING 11 3 1 Wiring Model 499A Oxygen Chlorine and Ozone Sensors 11 3 2 Wiring Model 499ACL 01 Free Chlorine Sensors and pH Sensors 12 3 3 Wiring Model Hx438 and Gx448 Sensors 14 4 0 INTRINSICALLy SAFE AND ExPLOSION PROOF INSTALLATIONS 15 5 0 DISPLAy AND OPERATION 23 5 1 Display Screens 23 5 2 ...

Page 4: ...In Process Calibration 54 10 0 CALIBRATION FREE CHLORINE 55 10 1 Introduction 55 10 2 Procedure Zeroing the Sensor 56 10 3 Procedure Full Scale Calibration 57 10 4 Dual Slope Calibration 58 11 0 CALIBRATION TOTAL CHLORINE 60 11 1 Introduction 60 11 2 Procedure Zeroing the Sensor 61 11 3 Procedure Full Scale Calibration 62 11 4 Dual Slope Calibration 63 12 0 CALIBRATION OzONE 65 12 1 Introduction 6...

Page 5: ...ms 82 16 5 Free Chlorine Measurement and Calibration Problems 84 16 6 Total Chlorine Measurement and Calibration Problems 86 16 7 Ozone Measurement and Calibration Problems 87 16 8 pH Measurement and Calibration Problems 89 16 9 Simulating Input Currents Dissolved Oxygen 91 16 10 Simulating Input Currents Chlorine and Ozone 91 16 11 Simulating Inputs pH 92 16 12 Simulating Temperature 93 16 13 Mea...

Page 6: ... Free Chlorine sensor with optimum EMI RFI cable or Variopol cable and 399 09 62 pH sensor without internal preamplifier 13 3 9 Hx438 and Gx448 sensors 14 4 1 FMRC Explosion Proof Installation 15 4 2 FM Intrinsically Safe Installation Label 16 4 3 FM Intrinsically Safe Installation 17 4 4 CSA Intrinsically Safe Installation Label 19 4 5 CSA Intrinsically Safe Installation 20 4 6 ATEX Intrinsically...

Page 7: ... can be used If the pH is greater than 7 0 and fluctuates more than about 0 2 units continuous measurement of pH and automatic pH correction is necessary Corrections are valid to pH 9 5 The transmitter fully compensates oxygen ozone free chlorine and total chlorine readings for changes in membrane permeability caused by temperature changes For pH measurements pH is available with free chlorine onl...

Page 8: ... C 2 C above 50 C Digital Communications HART PV SV TV and 4V assignable to measurement oxygen ozone or chlorine temperature pH and sensor current RFI EMI EN 61326 Power Load Requirements Supply voltage at the transmitter terminals should be at least 12 Vdc Power supply voltage should cover the volt age drop on the cable plus the external load resistor required for HART communications 250 W minimu...

Page 9: ... Measurement Range 0 14 pH Resolution 0 01 pH Sensor Diagnostics Glass impedance for broken or aging electrode and reference offset Reference impedance for fouled reference junction is not available Repeatability 0 01 pH at 25 C RECOMMENDED SENSOR pH Use Model 399 09 62 399 14 or 399VP 09 See pH sensor product data sheet for complete order ing information 1 5 SPECIFICATIONS TOTAL CHLORINE Measurem...

Page 10: ...esired value 4 Pressing HOLD puts the transmitter in hold and sends the output current to a pre programmed value Pressing RESET causes the transmitter to abandon the present operation and return to the main display 5 See page 26 for Hazardous Locations information 1 9 HART COMMUNICATION Figure 1 3 The 275 375 or 475 HART Communicator is a hand held device that provides a common link to all HART SM...

Page 11: ...5 MODEL 5081 A SECTION 1 0 DESCRIPTION AND SPECIFICATIONS FIGURE 1 4 MODEL 5081 A MOUNTING AND DIMENSIONAL DRAWINGS MILLIMETER INCH ...

Page 12: ...kit 9241178 Stainless steel tag specify marking CODE AGENCy APPROvALS 60 No approval 67 FM approved intrinsically safe and non incendive when used with approved sensor and safety barrier 68 CSA approved intrinsically safe and non incendive when used with approved sensor and safety barrier 69 CENELEC approved intrinsically safe when used with approved sensor and safety barrier 5081 A HT 20 67 ExAMP...

Page 13: ...transmitter in an area where temperature extremes vibrations and electromagnetic and radio frequency interference are minimized or absent 2 To prevent unintentional exposure of the transmitter circuitry to the plant environment keep the cover lock in place over the circuit end cap See Figure 2 1 To remove the circuit end cap loosen the lock nut until the tab disengages from the cap Then unscrew th...

Page 14: ...MODEL 5081 A SECTION 2 0 INSTALLATION 8 2 3 2 Mounting on a flat surface FIGURE 2 1 Mounting the Model 5081 A on a flat surface INCH MILLIMETER ...

Page 15: ...MODEL 5081 A SECTION 2 0 INSTALLATION FIGURE 2 2 Using the pipe mounting kit PN 2002577 to attach the Model 5081 A to a pipe MILLIMETER INCH 2 3 3 Pipe Mounting DWG NO REV 40508104 G DWG NO REV 40508103 C ...

Page 16: ...mum current is about 24 mA For digital communications the load must be at least 250 ohms To supply the 12 0 Vdc lift off voltage at the transmitter the power supply voltage must be at least 17 5 Vdc FIGURE 2 3 Load Power Supply Requirements FIGURE 2 4 Power Supply Current Loop Wiring 2 4 2 Power Supply Current Loop Wiring Refer to Figure 2 4 Run the power signal wiring through the opening nearest ...

Page 17: ... and ozone sensors 3 2 Wiring Model 499ACL 01 free chlorine and pH sensors NOTE The Model 5081 A transmitter leaves the factory configured for use with the Model 499ADO sen sor ppm dissolved oxygen If a 499ADO sensor is not being used turn to Section 7 5 3 and configure the transmitter for the desired measurement ppb oxygen oxygen measured using a steam sterilizable sensor free chlorine total chlo...

Page 18: ...more than 0 2 pH unit a continuous correction for pH must be applied to the chlorine reading Therefore a pH sensor must be wired to the transmitter This section gives wiring diagrams for the pH sensors typically used When using the 499ACL 01 free chlorine sensor with a pH sensor use the RTD in the pH sensor for measuring temperature DO NOT use the RTD in the chlorine sensor The pH sensor RTD is ne...

Page 19: ...g in the transmitter must be changed See Section 7 8 3 FIGURE 3 8 Free chlorine sensor with optimum EMI RFI cable or variopol cable and 399 09 62 pH sensor without internal preamplifier FIGURE 3 5 Free chlorine sensor with standard cable and 399 09 62 pH sensor without internal preamplifier FIGURE 3 6 Free chlorine sensor with optimum EMI RFI cable or variopol cable and 399vP 09 pH sensor without ...

Page 20: ...14 MODEL 5081 A SECTION 3 0 SENSOR WIRING FIGURE 3 9 Hx438 and Gx448 Sensors 3 3 WIRING Hx438 AND Gx448 SENSORS ...

Page 21: ...MODEL 5081 A SECTION 4 0 INTRINSICALLy SAFE ExPLOSION PROOF INSTALLATIONS SECTION 4 0 INTRINSICALLy SAFE ExPLOSION PROOF INSTALLATIONS FIGURE 4 1 FMRC Explosion Proof Installation 15 ...

Page 22: ...FIGURE 4 2 FM Intrinsically Safe Installation Label 16 ...

Page 23: ...s OR Vdc 16 NON INCENDIVE FIELD WIRING METHODS MAY BE USED FOR CONNECTING SENSORS TO THE INSTRUMENT ATTACHED SENSORS MUST BE FM APPROVED WITH INPUT VALUES OF Vmax AND Imax Voc Vt AND Isc It LISTED IN TABLE II AND THE Ci AND Li OF THE SENSOR AND INTERCONNECTED WIRING MUST BE Ca AND La LISTED IN TABLE 1 OR BE CLASSIFIED AS SIMPLE APPARATUS SIMPLE APPARATUS ARE DEVICES WHICH ARE INCAPABLE OF GENERATI...

Page 24: ...R MODEL 5081 A HT XMTR MODEL 5081 A HT XMTR INFRARED REMOTE CONTROL UNIT RMT PN 23572 00 FOR USE IN CLASS I AREA ONLY SAFETY BARRIER SEE NOTES 1 9 LOAD SAFETY BARRIER SEE NOTES 1 9 LOAD SAFETY BARRIER SEE NOTES 1 9 LOAD SAFETY BARRIER SEE NOTES 1 9 LOAD UNSPECIFIED POWER SUPPLY 30 VDC MAX 24V TYP UNSPECIFIED POWER SUPPLY 30 VDC MAX 24V TYP UNSPECIFIED POWER SUPPLY 30 VDC MAX 24V TYP UNSPECIFIED PO...

Page 25: ...FIGURE 4 4 CSA Intrinsically Safe Installation Label 19 ...

Page 26: ...FIGURE 4 5 CSA Intrinsically Safe Installation 1 of 2 20 ...

Page 27: ...FIGURE 4 5 CSA Intrinsically Safe Installation 2 of 2 21 ...

Page 28: ...URFACE FINISH 125 ANGLES 1 2 XX 03 XXX 010 THIS FILE CREATED USING SOLID EDGE SIZE B DWG NO 9241473 00 REV G 03 06 02 J FLOCK J FLOCK 08 20 02 08 20 02 LABEL I S BAS ATEX 5081 A HT F 8226 08 09 2002 B H C O C E E E S 5 4 2 0 1 D Q L 9241473 00 1 4 Baseefa G No modifications permitted without the approval of the Authorized Person Related Drawing Baseefa Certified Product 3 21 11 JP DOC 1 MATERIAL A...

Page 29: ... Infrared Remote Controller IRC Key Functions 5 3 Menu Tree 5 4 Diagnostic Messages 5 5 Security 5 6 Using Hold FIGURE 5 2 Program Display Screen The program display screen allows access to calibration and programming menus FIGURE 5 1 Process Display Screen If the transmitter is configured to measure free chlorine a second screen showing pH can be displayed by pressing the é or ê key on the remote...

Page 30: ...transmit ter to factory default settings CAL Press CAL to access the calibra tion menu PROG Press PROG to access the pro gram menu DIAG Press DIAG to read diagnostic messages HOLD Press HOLD to access the prompts used for turning on or off the hold function ARROW KEyS Use é and ê keys to increase or decrease a number or to scroll through items in a list Use the ç or è keys to move the cursor acros...

Page 31: ...ng PROG or CAL on the remote controller causes the Id screen to appear 2 Use the arrow keys to enter the security code Press ENTER 3 If the security code is correct the first submenu appears If the code is incorrect the process display reappears 4 To retrieve a forgotton code number enter 555 at the Id prompt The present security code will appear PROGRAM Id EXIT ENTER 000 5 6 USING HOLD During cal...

Page 32: ...ss Unit nnHG sat p pman 760 Unit ppm sensor ADO 0 Cal span Cal Salnty 00 0 SlOpe snGl Man 7 00 Pamp trans diaGnostIC roffst 060 diaG OFF ImptC On GFH 1500 GFL 0100 pH Cal baUtO On bUFFEr Std StAbiLiSE tIME 010 dELtA 0 02 sensor 0 sensor Cal ph Cal temp adj CALIBRATE Cal setup PH temp 025 0 PROGRAM DIAGNOSE MAIN DISPLAy OUTPUT CAL Cur 4 000 Cur 20 00 DEFAULT HART FACTORY NO DPN 0 00 OUTPUT 4 MA 00 ...

Page 33: ...ort is available worldwide on the internet at rosemount com 6 2 Connecting the HART Communicator Figure 6 1 shows how the 275 375 475 HART Communicator connects to the output lines from the Model 5081 A Transmitter MODEL 5081 A SECTION 6 0 OPERATION WITH 275 375 475 SECTION 6 0 OPERATION WITH 275 375 475 6 1 Note on 275 375 475 HART Communicator 6 2 Connecting the HART Communicator 6 3 Operation F...

Page 34: ...ammed settings to the transmitter Off line operation permits settings common to several transmitters to be easily stored in all of them 6 3 2 Use of Infrared Remote Controller In multi drop operation polling addresses can be more conveniently set and debugging more conveniently per formed using the infrared remote controller 6 3 3 Menu Tree Figure 6 2 shows the menu tree for the Model 5081 A trans...

Page 35: ... Temp Sv view Tv Tv is Snsr Cur Tv view 4v 4v is Temp Res 4v view Status Diag Service Test device Loop test view Status Master Reset Fault History Hold Mode Calibration zero Main Sensor Air Calibration In process Cal Dual Range Cal Adjust Temperature pH 2 Pt Cal pH Auto Cal Standardize pH D A trim MODEL 5081 A SECTION 6 0 OPERATION WITH 275 375 475 FIGURE 6 2 Menu Tree HART ...

Page 36: ...URv Pv Pv rnge Device information Distributor Model Dev id Tag Date Write protect Snsr text Descriptor Message Revision s Universal rev Fld dev rev Software rev Hardware rev Detailed setup Sensors Oxygen Oxygen Unit ppm ppb sat Oxygen Sensor ADO TRDO SSDO1 SSDO2 Salinity Bar Press Unit inHg mmHg bar kPa atm Man Bar Press Sensor SST Sensor SSS Sensor zero Limit Dual Range Cal Disable Enable FIGURE ...

Page 37: ... GFL Imped Comp Off On Temperature Temp Comp Auto Manual Man Temp Temp unit ºC ºF Temp Snsr Signal condition LRv URv AO Damp rnge xfer fnctn AO lo end point AO hi end pt Output condition Analog output AO AO Alrm typ Fixed Fault Loop test D A trim HART output Pv is Oxygen Sv is Temp Tv is Snsr Cur 4v is pH Poll addr Burst option Pv range current Process vars crnt Burst mode Off On Num req preams Nu...

Page 38: ...ault Conf Review Sensors Outputs Device information Pv Pv AO Pv LRv Pv URv Notes Can be Oxygen Free Cl Ozone Ttl Cl or Chlrmn Can be Temp pH GI Can be Snsr Cur Temp pH GI Can be Snsr Cur Temp pH GI Temp Res Not Used Units for Ozone can be ppm or ppb For any of the chlorines unit is always ppm valid when Pv Free Cl valid when Pv Oxygen valid when Pv Oxygen and unit sat valid when Pv Free Cl Ttl Cl ...

Page 39: ...diagnostic limits 5 enable and disable automatic temperature correction 6 program the type measurement oxygen ozone or chlorine 7 setup stabilization criteria for calibration 8 enable automatic pH correction for chlorine measurements 9 choose units for barometric pressure oxygen only 10 choose limits for diagnostic fault messages 7 2 DEFAULT SETTINGS Table 7 1 lists the default settings for the 50...

Page 40: ...0 05 ppm 60 Hz 00 05 off 0000000 on 7 00 transmitter ITEM A Outputs 1 4 mA setting if oxygen ppm if oxygen ppb if oxygen saturation if chlorine or ozone 2 20 mA setting if oxygen ppm if oxygen ppb if oxygen saturation if chlorine or ozone 3 Hold 4 Fault 5 Dampen 6 Test current B Temperature compensation 1 Automatic 2 Manual C Display 1 Type of measurement 2 Units oxygen only 3 Units ozone only 4 S...

Page 41: ...ault occurs the output remains at the programmed hold value To alert the user that a fault exists the word FAULT appears in the main display and the display flashes A fault or diagnostic message also appears f If the transmitter is simulating an output current when the fault occurs the transmitter continues to generate the sim ulated current To alert the user that a fault exists the word FAULT app...

Page 42: ...splays the FAULt prompt Use the arrow keys to change the setting to the output desired when the transmitter detects a fault The range is 3 80 to 22 00 mA Entering 00 00 causes the transmitter to hold the output at the value it was when the fault occurred Press ENTER to save 6 The screen displays the dPn prompt Use the arrow keys to change the setting The range is 0 to 255 Press ENTER to save 7 The...

Page 43: ...e tem perature measured by the sensor for all calculations in which temperature is used 2 MANUAL TEMPERATURE COMPENSATION OXYGEN CHLORINE AND OZONE In manual temperature compensation the transmitter uses the temperature entered by the user for membrane permeability and pH corrections and for air calibration calculations It does not use the actual process temperature Do NOT use manual temperature c...

Page 44: ...e arrow keys to change the temperature to the desired value To enter a negative number press è or ç until no digit is flashing Then press é or ê to display the negative sign The temperature entered in this step will be used in all measurements oxygen chlorine ozone or pH no matter what the process temperature is Press ENTER to save 5 Press RESET to return to the process display PROGRAM tAUtO EXIT ...

Page 45: ...pm and ppb level free chlorine total chlorine or ozone 2 FREE CHLORINE Free chlorine is the product of adding sodium hypochlorite bleach calcium hypochlorite bleaching powder or chlorine gas to fresh water Free chlorine is the sum of hypochlorous acid HOCl and hypochlorite ion OCl 3 TOTAL CHLORINE Total chlorine is the sum of free and combined chlorine Combined chlorine generally refers to chlorin...

Page 46: ... based on the sensor being used 7 If you chose O3 in step 3 the screen at left appears Press é or ê to toggle between ppm and ppb Press ENTER to save 8 Press RESET to return to the main display Sensor Units 499ADO ppm or 499ATrDO ppb Gx448 ppm or Hx438 ppm or PROGRAM Unit EXIT ENTER PPb ...

Page 47: ...ENTER to return to factory default settings PROGRAM tYPE EXIT ENTER 02 PROGRAM dISPLAY EXIT NEXT ENTER MODEL 5081 A SECTION 7 0 PROGRAMMING 7 6 FACTORy DEFAULT 7 6 1 Purpose This section describes how to erase ALL user defined configuration settings and return the transmitter to factory default settings 7 6 2 Procedure 7 7 HART For more information see Section 6 3 2 41 ...

Page 48: ...varies from sensor to sensor The transmitter can be programmed not to accept a zero current until the value has fallen below a reasonable limit 3 SALINITY DISSOLVED OXYGEN ONLY The solubility of oxygen in water depends on the concentration of dissolved salts in the water Increasing the concentration decreases the solubility If the salt concentration is greater than about 1000 ppm the accuracy of t...

Page 49: ...e SALnty salinity prompt appears Use the arrow keys to enter the salinity of the water Press ENTER Go to step 10 10 The display returns to the SPAn CAL screen Press NEXT 11 The 0 CAL screen appears Press ENTER 12 Enter the desired zero limit The units are the same as the units programmed in Sec tion 7 5 Default limits are given in the table 13 Press RESET to return to the main display PROGRAM delt...

Page 50: ...s ENTER 3 Use é or ê to toggle the line frequency between 50 and 60 Hz Press ENTER to save 4 Press RESET to return to the main display 7 9 LINE FREQUENCy 7 9 1 Purpose This section describes how to maximize noise rejection by entering the frequency of the mains power into the transmitter PROGRAM line fre9 EXIT NEXT ENTER PROGRAM line EXIT ENTER 60 ...

Page 51: ...n the transmitter reading and the desired value exceeds the programmed limit the transmitter will not accept the new reading To estimate the millivolt difference multiply the pH difference by 60 3 pH SENSOR DIAGNOSTICS The transmitter continuously monitors the pH sensor for faults A fault means that the sensor has failed or is possibly nearing failure The only pH sensor diagnostic available in the...

Page 52: ...nable Press ENTER to save 7 The IMPtC glass impedance temperature correction prompt appears Press é or ê to toggle between OFF disable or On enable Because glass impedance is a strong function of temperature correcting glass impedance for temperature effects is strongly recommended Press ENTER to save 8 The GFH glass fault high prompt appears Use the arrow keys to change the set ting to the desire...

Page 53: ... buFFEr prompt appears Press é or ê to scroll through the list of available buffers See Section 13 1 for a list of the buffer values Press ENTER to save 14 The StAbiLiSE stabilize prompt appears To change stabilization criteria press ENTER To leave stabilization criteria at the default values press EXIT 15 Set the stabilization time between 0 and 99 seconds The default value is 10 seconds Press EN...

Page 54: ...asurements 7 11 2 Definitions 1 BAROMETRIC PRESSURE Because the current generated by an amperometric oxygen sensor is directly propor tional to the partial pressure of oxygen the sensor is generally calibrated by exposing it to water saturated air See Section 9 1 for more information To calculate the equivalent concentration of oxygen in water in ppm the transmitter must know the temperature and b...

Page 55: ...res the temperature From the tem perature the transmitter calculates the vapor pressure of water and using the barometric pressure calculates the partial pressure of atmospheric oxygen Once the transmitter knows the partial pressure it calculates the equilib rium solubility of oxygen in water using a temperature dependent factor called the Bunsen coefficient Overall a 1 C error in the temperature ...

Page 56: ...asured using the standard thermometer Press ENTER to save 5 The tEMP AdJ sub menu appears Press RESET to return to the main display 8 2 PROCEDURE 1 Place the sensor and a calibrated reference thermometer in a container of water at ambient temperature Be sure the temperature element in the sensor is completely submerged by keeping the sensor tip at least three inches below the water level Stir cont...

Page 57: ...otential of oxygen in the two phases air and water is the same Oxygen sensors generate a current directly proportional to the rate at which oxygen molecules diffuse through a membrane stretched over the end of the sensor The diffusion rate depends on the difference in chemical poten tial between oxygen in the sensor and oxygen in the sample An electrochemical reaction which destroys any oxy gen mo...

Page 58: ...the current is already below the limit tiME dELAy will not appear To bypass the time delay press ENTER 6 O donE shows that the zero step is complete Press EXIT 7 Press RESET to return to the main display CALIBRATE time delay EXIT ENTER CALIBRATE 0 done EXIT 9 2 PROCEDURE zEROING THE SENSOR 1 Place the sensor in a fresh solution of 5 sodium sulfite Na2SO3 in water Be sure air bubbles are not trappe...

Page 59: ... transmitter calculates the sensitivity nA ppm of the sensor To check the sensitivity go to the main display Press DIAG Press NEXT until the SenSitvty sensitivity prompt appears Press ENTER to display the sensitivity in nA ppm Typical values at 25 C are given in the table CALIBRATE A ir Cal EXIT NEXT ENTER CALIBRATE nnHG EXIT NEXT CALIBRATE time delay EXIT ENTER CALIBRATE Press EXIT ENTER 760 0 9 ...

Page 60: ... Press ENTER to save 9 Press RESET to return to the main display CALIBRATE time delay EXIT NEXT CALIBRATE Grab spl EXIT ENTER 9 4 PROCEDURE IN PROCESS CALIBRATION 1 The transmitter and sensor can be calibrated against a standard instrument For oxygen sensors installed in aeration basins in waste treatment plants calibration against a second instrument is often preferred For an accurate calibration...

Page 61: ...ine solutions are unstable Run the test immediately after taking the sample Try to calibrate the sen sor when the chlorine concentration is at the upper end of the normal operating range Free chlorine measurements made with the 499ACL 01 sensor also require a pH correction Free chlorine is the sum of hypochlorous acid HOCl and hyprochlorite ion OCl The relative amount of each depends on the pH As ...

Page 62: ... The screen shows the value in units ppm below which the reading must be before the zero current will be accepted The screen shows 0 02 Therefore the reading must be below 0 02 ppm before the zero will be accepted For a typical 499ACL 01 sensor 0 02 ppm corre sponds to about 7 nA To change the zero limit value see Section 7 8 3 Press ENTER NOTE The number shown in the main display may change Durin...

Page 63: ... soon as the stability criteria are met or ENTER is pressed to bypass the time delay the transmitter stores the sensor current Therefore if the chlorine level in the process liquid drifts while the sample is being tested there is no need to compensate for the change when entering test results in step 7 6 The GrAb SPL grab sample prompt appears Take a sample of the process liquid and immediately de...

Page 64: ...is within the range recom mended for the chlorine sensor Refer to the sensor instruction sheet 4 Press CAL on the remote controller Press NEXT 5 The SEnSor CAL prompt appears Press ENTER 6 The CAL Pt 1 prompt appears Adjust the chlorine concentration until it is near the upper end of the linear range of the sensor Press ENTER 7 The tiME dELAy message appears and remains until the sensor read ing m...

Page 65: ...il the sensor read ing meets the stability criteria set in Section 7 8 To bypass the time delay press ENTER 12 The GrAb SPL grab sample prompt appears Take a sample of the process liquid and immediately determine the concentration of free chlorine in the sample Press ENTER 13 The Pt2 prompt appears Use the arrow keys to change the flashing dis play to the concentration of chlorine determined in th...

Page 66: ...t by subtracting it from the meas ured current before converting the result to a total chlorine value New sensors require zeroing before being placed in service and sensors should be zeroed whenever the electrolyte solution is replaced The best zero stan dard is sample without reagent added The purpose of the full scale standard is to establish the slope of the calibration curve Because stable tot...

Page 67: ... BEEN IN ZERO SOLUTION FOR AT LEAST TWO HOURS 4 Press CAL on the remote controller 5 The SEnSor O prompt appears Press ENTER 6 The screen shows the value in units ppm below which the reading must be before the zero current will be accepted The screen shows 0 02 Therefore the reading must be below 0 02 ppm before the zero will be accepted For a typical 499ACL 02 sensor 0 02 ppm corre sponds to abou...

Page 68: ...ty criteria are met or ENTER is pressed to bypass the time delay the transmitter stores the sensor current Therefore if the chlorine level in the process liquid drifts while the sample is being tested there is no need to compensate for the change when entering test results in step 7 6 The GrAb SPL grab sample prompt appears Take a sample of the process liquid and immediately determine the concentr...

Page 69: ... between 80 and 100 mL min and the pressure is between 3 and 5 psig 4 Press CAL on the remote controller Press NEXT 5 The SEnSor CAL prompt appears Press ENTER 6 The CAL Pt 1 prompt appears Adjust the chlorine concentration until it is near the upper end of the linear range of the sensor Press ENTER 7 The tiME dELAy message appears and remains until the sensor read ing meets the stability criteria...

Page 70: ...il the sensor read ing meets the stability criteria set in Section 7 8 To bypass the time delay press ENTER 12 The GrAb SPL grab sample prompt appears Take a sample of the process liquid and immediately determine the concentration of total chlorine in the sample Press ENTER 13 The Pt2 prompt appears Use the arrow keys to change the flashing dis play to the concentration of chlorine determined in t...

Page 71: ...laced Either of the fol lowing makes a good zero standard Deionized water Tap water known to contain no ozone Expose tap water to ozone free air for several hours The purpose of the full scale standard is to establish the slope of the calibration curve Because stable ozone stan dards do not exist the sensor must be calibrated against a test run on a grab sample of the process liquid Several manufa...

Page 72: ...screen shows the value in units ppm below which the reading must be before the zero current will be accepted The screen shows 0 02 Therefore the reading must be below 0 02 ppm before the zero will be accepted For a typical ozone sensor 0 02 ppm corresponds to about 7 nA To change the zero limit value see Section 7 8 3 Press ENTER NOTE The number shown in the main display may change During the zero...

Page 73: ...ensor current Therefore if the chlorine level in the process liquid drifts while the sample is being tested there is no need to compensate for the change when entering test results in step 7 6 The GrAb SPL grab sample prompt appears Take a sample of the process liquid and immediately determine the concentration of ozone in the sample Press ENTER 7 Use the arrow keys to change the flashing display ...

Page 74: ...7 Temperature pH data stored in the controller are valid between at least 0 and 60 C pH at 25 C Standard s nominal pH 1 68 NIST DIN 19266 JSI 8802 BSI see note 1 3 56 NIST BSI 3 78 NIST 4 01 NIST DIN 19266 JSI 8802 BSI 6 86 NIST DIN 19266 JSI 8802 BSI 7 00 see note 2 7 41 NIST 9 18 NIST DIN 19266 JSI 8802 BSI 10 01 NIST JSI 8802 BSI 12 45 NIST DIN 19266 FIGURE 13 1 Calibration Slope and Offset Not...

Page 75: ... 7 10 9 Once the reading is stable the display changes to look like the figure at left The flashing number is the nominal pH that is the pH of the buffer at 25 C If the flashing number does not match the nominal pH press é or ê until the correct pH appears Press ENTER to save 10 The CAL bF2 prompt appears Remove the sensor from the first buffer Rinse the sensor and place it in the second buffer Be...

Page 76: ... bulb and reference junction are completely submerged Swirl the sensor The main display will show the pH of the buffer based on the previous calibration Press ENTER 8 Wait until the pH reading in the main display is constant Use the arrow keys to change the flashing display to the value of the buffer at the measurement temperature Press ENTER 9 The CAL bF2 prompt appears Rinse the sensor and the t...

Page 77: ...nce readings are stable measure the pH of the liquid using a refer ence instrument Normally it is acceptable to test a grab sample Because the pH of the process liquid may change if the temperature changes measure the pH immediately after taking the grab sample For poorly buffered samples it is best to determine the pH of a continuously flowing sample from a point as close as pos sible to the proc...

Page 78: ...slope at 25 C slope at t C Changing the slope overrides the slope determined from the previous buffer calibration 2 Press CAL on the remote controller 3 Press NEXT until PH CAL appears Press ENTER 4 Press NEXT until PH SLOPE appears Press ENTER 5 The SLOPE prompt appears Use the arrow keys to change the flash ing display to the desired slope Press ENTER to save 6 Press RESET to return to the main ...

Page 79: ...e value programmed in Section 7 3 14 2 PROCEDURE 1 Wire an accurate milliammeter as shown in Figure 14 1 2 Press CAL on the remote controller 3 Press NEXT until the OUtPUt CAL submenu appears Press ENTER 4 Use the arrow keys to change the display to match the reading from the milliammeter Press ENTER 5 Use the arrow keys to change the display to match the reading from the milliammeter Press ENTER ...

Page 80: ...divided by concentration O CurrEnt Press ENTER to display the zero current measured during calibration note units bAr PreSS Press ENTER to display the barometric pressure used by the transmitter during air calibration 5081 A Ht This is the model number Press ENTER to display the software revision SFtr level Press NEXT to show the hardware revision HArdr level FAULtS Press ENTER to scroll through e...

Page 81: ...ENTER to display the zero current measured during calibration note units PH Press ENTER to view pH diagnostics Press NEXT to skip pH diagnostics InPut Current pH sensor input voltage in millivolts SLOPE Sensor slope in millivolts per unit pH Slope is calculated during buffer calibration See Figure 13 1 OFFSt Sensor voltage in millivolts in pH 7 buffer GIMP Glass impedance in MW 5081 A Ht This is t...

Page 82: ... measurements should be regarded as erroneous When a WARNING condition exists 1 The main display remains stable it does not flash 2 A warning message appears alternately with the temperature and output readings in the second line of the display See Section 15 4 for an explanation of the warning messages and suggested ways of correcting the problem When a FAULT exists 1 The main display flashes 2 T...

Page 83: ...I pH sensor slope exceeds 62 mV pH 16 2 9 SLOPE LO pH sensor slope is less than 40 mV pH 16 2 9 0 OFFSEt Zero offset during standardization exceeds programmed limit 16 2 10 GLASS FAIL Measured glass impedance is less than programmed limit 16 2 11 FACt FAIL Unit has not been factory calibrated 16 2 12 CPU FAIL Internal CPU tests have failed 16 2 13 ROM FAIL Internal memory has failed 16 2 13 AdC An...

Page 84: ...and electrolyte solution and clean the cathode if necessary See the sensor instruction sheet for details 4 Replace the sensor 16 2 4 CAL Error At the end of the calibration step the transmitter calculates the sensitivity in nA ppm If the sensitivity is outside the range normally expected the transmitter displays the CAL Error message and the transmitter does not update the calibration For assistan...

Page 85: ...d 3 Check the pH sensor for cleanliness If the sensor looks fouled or dirty clean it Refer to the sensor instruction manu al for cleaning procedures 4 Replace the sensor 16 2 9 SLOPE HI or SLOPE LO Once the two point manual or automatic pH calibration is complete the transmitter automatically calculates the sensor slope at 25 C If the slope is greater than 62 mV pH the transmitter displays the SLO...

Page 86: ...To read the glass impedance go to the main display and press DIAG Scroll to the PH prompt and press ENTER Press NEXT until GIMP glass imped ance is showing The default lower limit is 10 MW The default upper limit is 1000 MW Low glass impedance means the glass membrane is broken or cracked High glass impedance means the membrane is aging and nearing the end of its useful life High impedance can als...

Page 87: ... 0 2 Replace the pH sensor with a sensor known to be working 3 If replacing the pH sensor does not cause the message to disappear call the factory for assistance 16 2 17 RitE Err Program settings in the 5081 A can be protected against accidental changes by setting a three digit security code Settings can further be protected by removing a jumper JP 1 from the CPU board If JP 1 has been removed pro...

Page 88: ...connections are tight 2 Readings are often erratic when a new or rebuilt sensor is first placed in service Readings usually stabilize after an hour 3 Is the space between the membrane and cathode filled with electrolyte solution and is the flow path between the elec trolyte reservoir and the membrane clear Often the flow of electrolyte can be started by simply holding the sensor with the membrane ...

Page 89: ... sensor in air and in sodium sulfite solu tion 16 4 5 Process readings are erratic 1 Readings are often erratic when a new sensor or a rebuilt sensor is first placed in service The current usually stabilizes after a few hours 2 Is the sample flow within the recommended range High sample flow may cause erratic readings Refer to the sensor instruc tion manual for recommended flow rates 3 Gas bubbles...

Page 90: ... and the measured concentration is 2 05 ppm The error is now 3 3 The absolute difference between the readings remains the same 0 06 ppm 2 Sensor response depends on flow If the flow is too low readings will be low and flow sensitive Verify that the flow past the sensor equals or exceeds the minimum value See the sensor instruction manual for recommended flows If the sensor is in an aeration basin ...

Page 91: ...ases as pH increases Above pH 7 a 0 1 unit increase in pH lowers the current about 5 2 Sensor current depends on the rate of sample flow past the sensor tip If the flow is too low chlorine readings will be low Refer to the sensor instruction sheet for recommended sample flows 3 Low current can be caused by lack of electrolyte flow to the cathode and membrane See step 4 in Section 16 5 2 4 Is the m...

Page 92: ...he calibration of the pH sensor 3 Is the membrane clean Clean the membrane and replace it if necessary Check that the holes at the base of the cath ode stem are open Use a straightened paper clip to clear blockages Replace the electrolyte solution 4 Replace the sensor 16 5 7 Chlorine readings spike following sudden changes in pH Changes in pH alter the relative amounts of hypochlorous acid HOCl an...

Page 93: ...ood ring remains with the membrane assembly Use the end of a straightened paper clip to clear the holes at the base of the cathode stem Replace the membrane Verify that the sensor is filled with electrolyte solution Refer to the sensor instruction manual for details 16 7 3 Sensor current during calibration is substantially less than 350 nA ppm at 25 C 1 Sensor current is a strong function of tempe...

Page 94: ...New or rebuilt sensors may require several hours to stabilize 16 7 6 Sensor does not respond to changes in ozone level 1 Is the grab sample test accurate Is the grab sample representative of the sample flowing to the sensor 2 Is the membrane clean Clean the membrane and replace it if necessary Check that the holes at the base of the cath ode stem are open Use a straightened paper clip to clear blo...

Page 95: ...eading agree with a reference instrument see Section 13 4 16 8 6 Process pH reading changes when flow changes The 399 pH sensor recommended for use with the 5081A transmitter has some degree of flow sensitivity i e changing the sample flow causes the pH reading to change Flow sensitivity varies from sensor to sensor Flow sensitivity can be a source of error if the pH and chlorine sensor flow cells...

Page 96: ...the simplified wiring 4 Check for extra ground connections or induced noise a If the sensor cable is run inside conduit there may be a short between the cable and the conduit Re run the cable outside the conduit If symptoms disappear there is a short between the cable and the conduit Likely a shield is exposed and touching the conduit Repair the cable and reinstall it in the conduit b To avoid ind...

Page 97: ... has the correct sign A Disconnect the anode and cathode leads from terminals 13 14 and connect a decade box and battery as shown in Figure 16 2 It is not necessary to disconnect the RTD leads B Set the decade box to the resistance shown in the table C Note the sensor current It should be close to the value in the table The actual value depends on the voltage of the battery To view the sensor curr...

Page 98: ...H The pH should be approximately 7 00 Because calibration data stored in the analyzer may be offsetting the input voltage the displayed pH may not be exactly 7 00 5 If a standard millivolt source is available disconnect the jumper wire between the pH IN and REF IN terminals and connect the voltage source as shown in Figure 16 3 6 Calibrate the transmitter using the procedure in Section 13 3 Use 0 ...

Page 99: ...etween the values in the table to within 0 1 C For example start with a simulated resistance of 103 9 W which corresponds to 10 0 C Assume the offset from the sensor calibration was 0 3 W Because of the offset the ana lyzer calculates temperature using 103 6 W The result is 9 2 C Now change the resistance to 107 8 W which corre sponds to 20 0 C The analyzer uses 107 5 W to calculate the temperatur...

Page 100: ...ed millivolts A good way to check for poisoning is to compare the voltage of the reference electrode with a silver silver chloride electrode known to be good The reference electrode from a new sensor is best See Figure 16 6 If the reference electrode is good the voltage difference should be no more than about 20 mV A poisoned reference electrode usually requires replacement FIGURE 16 6 Checking fo...

Page 101: ...Figure 17 1 and Table 17 1 for parts and part numbers FIGURE 17 1 Exploded view of Model 5081 A Transmitter Three screws part 13 in the drawing hold the three circuit boards in place Removing the screws allows the dis play board part 2 and the CPU board part 3 to be easily removed A ribbon cable connects the boards The cable plugs into the CPU board and is permanently attached to the display board...

Page 102: ...7 33360 00 Enclosure center housing 4 lb 1 5 kg 8 33362 00 Enclosure cover rear 3 lb 1 0 kg 9 6560135 Desiccant in bag one each 1 lb 0 5 kg 10 9550187 O ring 2 252 one front and rear covers each require an O ring 1 lb 0 5 kg 12 note Screw 8 32 x 0 5 inch for attaching terminal block to center housing 13 note Screw 8 32 x 1 75 inch for attaching circuit board stack to center housing 14 33342 00 Cov...

Page 103: ...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 Uniloc Division 2400 Barranca Parkway Irvine CA 92606 Attn Factory Repair RMA No ____________ Mark the package Returned for Repair Model No ____ 18 3 NON WARRANTy REPAIR The...

Page 104: ...kPa 0 0 1 013 760 29 91 101 3 250 820 0 983 737 29 03 98 3 500 1640 0 955 716 28 20 95 5 750 2460 0 927 695 27 37 92 7 1000 3280 0 899 674 26 55 89 9 1250 4100 0 873 655 25 77 87 3 1500 4920 0 846 635 24 98 84 6 1750 5740 0 821 616 24 24 82 1 2000 6560 0 795 596 23 47 79 5 2250 7380 0 771 579 22 78 77 1 2500 8200 0 747 560 22 06 74 7 2750 9020 0 724 543 21 38 72 4 3000 9840 0 701 526 20 70 70 1 32...

Page 105: ...is easy to maintain For calibration simply expose the sensor to ambient air and press the air calibration button The analyzer measures the baro metric pressure using an on board pressure sensor and calculates the equilibrium solubility of atmospher ic oxygen at the prevailing temperature and pressure Replacing the membrane requires no special tools or fixtures To replenish the electrolyte solution...

Page 106: ...Time 90 in 20 seconds for a step change using an equilibrated sensor at 25 C Sample Pressure 0 to 50 PSIG Sample Temperature 32 to 110 F Humidity up to 95 non condensing Wetted materials Ryton 1 Teflon 2 1 Ryton is a registered trademark of Chevron Phillips Chemical Company LP 2 Teflon is a registered trademark of E I du Pont de Nemours Co FIGURE 1 Rechargeable Sensor with Fast Response Flow Assem...

Page 107: ...ensor noisy motion sensitive 1 Membrane loose 1 Replace membrane 2 Low electrolyte level 2 Fill properly 3 Cathode contaminated 3 Replace sensor Upscale reading with known Gold cathode loose Replace sensor oxygen free sample CALIBRATION Air calibration is recommended Using a certified span gas is an option but since the concentration of oxygen in ambient air is close to 21 at sea level this is the...

Page 108: ...FIGURE 4 Wiring to Model 5081 102 MODEL 4000 WIRING ...

Page 109: ...blade carefully trim away excess membrane around the edges Take care that the razor blade does not cut into the edges of the membrane assembly 8 Set the sensor body on a flat surface with the cathode facing upward Verify that the o ring is properly posi tioned around the cathode Pour the electrolyte over the cathode central post assembly so it runs down into the sensor electrolyte well Fill the we...

Page 110: ...104 ...

Page 111: ...eed 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 orig...

Page 112: ...ks are the property of their respective owners The contents of this publication are presented for information purposes only and while effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are a...

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