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INSTRUCTION MANUAL FOR DIGITAL pH CONTROLLER DPH 503 GLOBAL ELECTRONICS 3-5-331, NARAYANGUDA, HYDERABAD - 500

INSTRUCTION MANUAL

FOR

DIGITAL

pH CONTROLLER

DPH 503

GLOBAL ELECTRONICS

3-5-331, NARAYANGUDA, HYDERABAD - 500 029 . INDIA .

PHONE No. 2322 6687, 2322 1391FAX: 2322 2484

E-mail: info@ge-india.com

Dear Customer,

Dear Customer, Thank you for purchasing Global Digtal pH Controller DPH 503. Please read this manually

Thank you for purchasing Global Digtal pH Controller DPH 503.

Please read this manually carefully to get the best performance from this instrument, especially the section on use and maintenance of sensors.

We take every care at our manufacturing facility to ensure that a quality product reaches our clients. in case you have a problem, please contact our Service and Support department on 040 - 2326 0406 for assistance.

KIndly send us the Warranty card duly filled within fifteen days from the date of purchase.

GLOBAL ELECTRONICS

INTRODUCTION The DPH 503 is a pH Control System specially designed for pH control in

INTRODUCTION

The DPH 503 is a pH Control System specially designed for pH control in batch neutralising systems.

Any pH electrode has an inherent lag in sensing. It takes about 15 seconds for the pH electrode to respond and stabilise. Additionally when a dose of acid or alkali is given to the process liquid, the dose chemical takes a certain amount of time to mix and result in a uniform batch pH value. In such cases, if the response of the dosing system is immediate with respect to the instantaneous pH value of the liquid, it is certain to result in overdosing and consequent overshoot of corrected pH value. For eg. if the pH value LO set point is at 8.85 and the dose is continuously fed until the pH reading crosses 8.85, after mixing, the final pH could well be above 9 or maybe even 10 pH depending on the strength of the dose chemical, the titration curve for this process and the system dynamics. Now it will be necessary to add acid to bring the pH value down and this process of alternate dosing will continue for a few cycles at least. The consequence of this is two fold: (1) The quantity of dose reagents consumed will be high leading to higher costs and (2) The quality of the process is diluted due the excess reagents.

To overcome these problems in high lag pH control systems, we at “Global” have evolved a unique mark/space dosing system with integrators that not only optimizes the dosing process but also shows you how much dose has been consumed in a batch. This reduces the cost of dose reagents and monitors the quality of the product giving the operator a control that was not hither to possible.

SALIENT FEATURES

SALIENT FEATURES DISPLAY : pH, mV, Temperature, Time, Date, High and Low Integrators and Batch time

DISPLAY: pH, mV, Temperature, Time, Date, High and Low Integrators and Batch time

Annunciators for ATC, Alarm, Dose, Timer-on Control-on, High Temperature, Hi and Lo pH.

CONTROL: All the limit values can be entered through the front panel keyboard with user friendly prompting display.

pH: high and Low limit controls with “Mark/Space” dose control. Controller can be switched OFF from external switch.

V.High and V.Low limits control for plant protection.

Programmable pH control inhibit on High Temperature violation.

ALARM: High/Low or V.High/V.Low limit violation Alarm – Resettable through “ACK” key.

TEMPERATURE: High Temperature setpoint with dead band to protect the electrode and suspend pH control if desired.

INTEGRATORS: Two integrators HIGH and LOW that totalize the respective dose durations in seconds.

CALIBRATION: Automatic calibration using 1 point or 2 point calibration using any two buffers in any order with Automatic recognition and temperature correction for 4.01, 7.00 and 10.00 pH buffers from 0° C to 50° C.

OPTION: Calibration by either single or Two point methods from the Transmitter

DOSING: Automatic Acid and Alkali dosing as set by Mark Space timers and control limits.Manual dosing when required.

TIMER: One Batch Timer to record the Batch duration.

ELECTRODE WASH: Facility for periodic automatic cleaning of the pH electrode with a solvent jet through programmable duration of solvent jet (0 to 99 seconds) and a programmable interval between washes (0 to 99 minutes).

SPECIFICATIONS

SPECIFICATIONS Display : pH, mV, Temperature, Time, Batch Time, Dose Integrators, Control Stage & Status

Display

: pH, mV, Temperature, Time, Batch Time, Dose Integrators, Control Stage & Status Annunciators

Input

: Combination or Glass Reference pair, PT100, Solution Ground Potential free contact inputs for BATCH, WASH, Control HALT, Liquid level

pH

mV

Temperature °C

Range :

-5 to 19.99

± 1999

-50 to +200 °C

Resolution :

0.01 pH

1 mV

0.1°C

Accuracy(Display) :

0.1% ± 1 digit

0.1% ± 1 digit

0.3% ± 1 digit

Drift

Input Impedance : > 10 tera Ohm

Input Current

Temp. Compensation : Auto or Manual, -30 to + 150°C (RTD PT100)

: < 0.02 pH / 24 hrs @ 2 5 °C (non cumulative)

:

< 1 pA @ 25 °C

Programming

: Through user friendly keyboard

Control Stages

: User definable 1 or 2, Stage 1 user selectable as Time period or Operator input

Control Limits

: 6 programmable limits, Hi 1, Hi 2, V.Hi, Lo 1, Lo 2, V.Lo independent for

 

2

stages Hi Temperature limit and Hysterisis

Control

: Dual Mark Space Control with relay outputs for Hi, Lo, V.Hi, V.Lo

 

Relays rated for 230V AC, 3A resistive,

 

Programmable High Temperature Control inhibit.

 

Dose Integrators for Acid and Alkali dosing

Output Analog

:

4 to 20mA DC into 600 Ohms, User programmable Span

Calibration

: Local or Remote, with Autobuffer or Grab sample, Automatic recognition of 7.00, 4.00 & 10.00 pH buffers with Buffer Temp. correction, Warnings for AP> ± 50 mV, Slope < 90% or > 105%

Electrode Cleaning : User programmable Electrode Cleaning (Wash) with relay output. Programmable wash duration, Post wash wait duration, Time interval between washes. Programmable to wash on Level switch input to clean electrode immediately.

Operating Temperature : -10 to + 45°C

Power Supply

: 110 / 230V AC, 45 to 55Hz, 10VA

Dimensions

: Wall Mount

: 200 x 250 x 150 mm

Flameproof

: 250 x 250 x 200 mm

DIGITAL INPUTS

DIGITAL INPUTS Digital inputs are provided in the controller for the following functions HALT : This

Digital inputs are provided in the controller for the following functions

HALT: This input can be used for a remote ‘HALT CONTROLLER’ command. When the two terminals marked HALT IN on the back panel are shorted (through a switch) all Control functions of the DPH 503 are suspended and will remain so as long as the terminals are shorted.

WASH: This input is used to initiate an electrode wash cycle. When the WASH IN terminals are shorted momentarily one Wash cycle as per the programmed WASH ON time (sec) is initiated. If these terminals are kept shorted the WASH cycle will be repeated. During the electrode Wash period the display shows “Wash XX”, XX being the number of seconds of wash remaining to be completed for current cycle. After every electrode wash the pH reading is inhibited for 10 seconds to allow the electrode to stabilise and during this the display will show “Wait XX”.

DRY: In systems having the optional electrode dry level sensor the Transmitter signals the controller through this input that the liquid level is below the electrode bulb. When this happens and remains so for 20 second the instrument shows “El DRY” and all control is suspended.

BATCH: This input is used for Batch processes to Start and Stop control of pH .

Single Stage Operation: In single stage operation, if the switch is pressed, the system starts pH control. The CONTROL LED in the front panel lights up, the batch timer and Integrators are reset to zero and the batch number is incremented by one. On pressing this switch again, the control is switched off.

Stage Operation: In two stage systems there are two modes in which the instrument operates in Stage 1.

STAGE 1 TIME based. In this mode the operation of Stage 1 is time based and the duration of Stage 1 is programmable. On pressing this switch the system starts pH control in stage 1 using the data programmed for stage 1. The batch timer is reset to 0 and started. The batch number is incremented by 1. After the programmed duration of Stage 1, the system automatically goes to pH control of Stage 2 using the data programmed for stage 2. During Stage 2 operation, pressing this switch will stop pH control. The batch timer is also stopped. The indication of pH will however continue.

STAGE 1 OPERATOR DECIDED:

In this mode the changover from Stage1 to Stage 2 is decided by the operator.

On pressing this switch the system starts pH control in Stage 1 using the data programmed for stage 1. The batch timer is reset to 0 and started. The batch number is incremented by 1. On pressing this switch during Stage 1 operation the system will automatically go to pH control of Stage 2 using the data programmed for stage 2. During Stage 2 operation, pressing this switch will stop pH control. The batch timer is also stopped. The indication of pH will however continue.

During Stage 1 the display will show

During Stage 2 the display will show

1P XX.XX

2P XX.XX

STATUS 1P 7.85 ATC ALARM DOSE RST TIMER INTHI NO HI TEMP PRT PROG DISP
STATUS
1P 7.85
ATC
ALARM
DOSE
RST
TIMER
INTHI
NO
HI TEMP
PRT
PROG
DISP
CONTROL
CAL
ESC
DOSE
YES
HIGH
INTLO
ACK
LOW
pH CONTROL SYSTEM
DPH 503

SETTING UP the DPH 503 for CONTROL

SETTING UP the DPH 503 for CONTROL The DPH 503 has a 7 digit display which

The DPH 503 has a 7 digit display which displays the pH/mV/Temp and programming data. It also has 8 LED annunciators to inform the operator of the instrument and process status. The operator can program the instrument through a 8 key keyboard. On switching on, the instrument it does a self check and shows the pH as measured by the electrode with temperature compensation on Automatic. Before the instrument can be put on line the electrode calibration and control parameter programming has to be done.

DPH 503 KEYBOARD LAYOUT and FUNCTIONS

THE DPH 503 is a user friendly instrument and requires no special skills to program. Interaction with instrument is done through the 8 key board.

KEY FUNCTIONS

DISP
DISP

(SELECT DISPLAY MODE): This key allows the user to choose either pH, mV, Temperature, Batchtime, Time or date on the display. On switch on,

the instrument will be in pH display mode. The display can be cycled through pH, mV, Temperature, Batchtime, Time or date using this key.

PRT CAL
PRT
CAL

PRT/CAL: (MAKE A HARD COPY OF THE DATA/CALIBRATE SENSORS) In

systems where a printer is connected, pressing this key will cause print out to be generated. Either process data or program data be chosen for a print out. This key is

also used to calibrate electrode or temperature sensor.

PROG ESC
PROG
ESC
INT HI
INT HI

PROG/ESC: (PROGRAM THE SYSTEM/RETURN TO pH DISPLAY MODE When in pH display mode, pressing this key once will cause the system to go

into programming mode asking the operator for a series of data. Pressing this key again will cause the programming operation to be terminated. In any mode other than pH value

on display , pressing this key will return the system to pH display mode. INT HI: 1. INCREMENT THE CURSOR POSITION CHARACTER, 2. START

BATCH TIMER, 3.

DISPLAY HIGH INTEGRATOR VALUE.

This key has three functions. In normal mode of display (pH value), pressing this key will bring the Hi integrator value on to the display. Pressing PROG key will return the display back to normal mode. The second function of this key is to start the batch timer. When the batch time is on display, pressing this key will start the batch timer and “TIMER ON” annunciater on the front panel is lit. In the programming mode the third function of this key comes into operation. Every time this key is pressed the flashing digit is incremented by one or the scrolling of the available options for a particular parameter is done.

INT LO: 1. DECREMENT THE CURSOR POSITION CHARACTER, 2. SWITCH OFF BATCH TIMER, 3. DISPLAY LOW INTEGRATOR VALUE)

This key also has three functions, During normal mode of display, pressing this key will bring the LOW integrator value on to the display. Pressing ESC key will return the display to normal mode. In the programming mode every time this key is pressed the flashing digit on display is decremented by one or scrolling of the available options for a particular parameter is done. When batch time is on display, pressing this key will stop the batch timer.

DOSE
DOSE

DOSE: 1. MANUAL DOSE, 2. CURSOR CONTROL. During normal mode of display this is used to initiate manual dosing. When this key

is pressed display shows dose: enquiring about choice of dose (Hi or LOW). To initiate HI dose press INT HI Key. The display then shows dosehi? Now the operator can initiate manual HI dose by pressing YES key or abort manual dose by pressing ESC key.

YES/ACK: 1. ENTER DATA, 2. ACKNOWLEDGE AND ALARM This key is used to ENTER the

YES/ACK: 1. ENTER DATA, 2. ACKNOWLEDGE AND ALARM This key is used to ENTER the data on display and transfer the same to

system memory or to give a positive response to a display prompt. If the operating the alarm is sounded, pressing this key will cause the audio alarm to be switched off.

RST/NO: 1. RESET INTEGRATOR/BATCH TIMER ON DISPLAY, 2. SET TIME/DATE ON DISPLAY, 3. GIVE A NEGATIVE RESPONSE TO A DISPLAY PROMPT. This key is used to reset the INTEGRATORS AND BATCH TIMER to zero. This key is used to reset the INTEGRATORS AND BATCH TIMER to zero.

When either of the integrators or batch time is on display, pressing this key causes the

system to display

TIME or DATE is on display pressing this key will enable the operator to set TIME or DATE using, INR, DCR, SHIFT and YES keys. This key can also be used to give a negative response to a display prompt.

CURSOR CONTROL KEYS FOR DATA INPUT:

In the Programming mode, when the instrument asks the operator to enter data for Control limits or for dose durations, the 3 cursor control keys are used viz

, Whenever some numerical data input is required, the instrument will show the current data

with 1 digit of the data FLASHING. For eg. if limit LL for Stage 1 is to be changed from 07.10 to 05.45, at the prompt the instrument will show ILL 07.10 with the last 0 flashing.

The keys

decrementing it by one respectively every time the key is pressed.

The

YES ACK
YES
ACK

SURE ?

Pressing YES will reset the respective counters. When

? Pressing YES will reset the respective counters. When will operate ONLY ON THE FLASHING digit,
? Pressing YES will reset the respective counters. When will operate ONLY ON THE FLASHING digit,

will operate ONLY ON THE FLASHING digit, incrementing or

will operate ONLY ON THE FLASHING digit, incrementing or key causes the presently flashing digit to

key causes the presently flashing digit to freeze and the next digit to flash.

Now if ILL is to be changed from 07.10 to 05.45 at the prompt. the required key sequence is as below:

Press

Press

Press

Press

Press

In cases where there is no numerical data to be entered but the operator has to choose from preset options the L key is used to change the option for eg. at the ATC ON prompt if ATC off option is required, pressure L will bring ATC OFF on display.

is required, pressure L will bring ATC OFF on display. 5 times to make the display

5 times to make the display ILL 07.15 twice the 7 will now flash twice to make the display ILL 05.15 once the 1 will now flash 3 times to make the display ILL 05.45 and Press Ent.

PROGRAMMING

PROGRAMMING The DPH503 is provided with two options in the programming mode viz 1. Program Setup

The DPH503 is provided with two options in the programming mode viz 1. Program Setup and 2. Program change and program review. PROGRAM SETUP: In this mode the operator can set the instrument parameters that are normally entered only during installation of the instrument . If a setup is not being done but you want to change the operational parameters press NO at the Setup prompt to go to Program change. PROGRAM CHANGE: In this mode the operator can set various parameters to suit his application. PROGRAM REVIEW : To review the program data entered ,Press PGM key followed by

DISP key. The program data can be seen using the

PROGRAMMING: Press the PROG key . The system displays

the PROGRAMMING : Press the PROG key . The system displays or keys. Press ESC to

or

PROGRAMMING : Press the PROG key . The system displays or keys. Press ESC to end.

keys. Press ESC to end.

SETUP ? Ht Stg 1 Stg 1 for single stage operation or Stg 2 Prt
SETUP ?
Ht
Stg 1
Stg 1
for single stage operation or
Stg 2
Prt Yes
Prt Al .
Prt Cal
rem cal/1 pt
or rem ca/2pt.
Clean

Only the YES and NO keys are accepted in the setup programming. Press YES to initiate setup routine. The display now shows ATC ON or OFF depending on the current setting. Press YES to retain setting or press NO to change setting. Selection is possible only between ATC ON and ATC OFF. When this setting is entered by pressing the YES key,

the system responds with

on query. If it is desired to inhibit control of the process if

temperature goes above the Hi Temp set limit, select Ht ON , else select Ht OFF.

Now the instrument displays

Select

Now the instrument displays

for 2 stage operations.

Select Prt Yes

if a printer is connected, or press NO if printer is not used.

If Prt Yes is selected ,the instrument displays

Press Yes if you need a printout at every limit violation, or press NO if this is not required.

Now the instrument displays

Press YES if you require a printout of Calibration data after every calibration or press NO.

Now the instrument displays

Select rem 1pt if you require Single point Remote calibration , or rem 2pt Remote calibration is required.

if 2 point

Now the instrument displays

Press YES if an electrode wash facility is ordered. Press NO otherwise.

If a WASH facility is ordered and Clean YES is entered, the system queries with Clean Dry. Press YES if an electrode dry level sensor is ordered AND it is desired to wash the electrode automatically upon the liquid level . Now the instrument displays Clean reg. Press YES if automatic electrode washing at regular intervals is required. Press NO otherwise.

This completes the setup and the instrument goes on to the program change routine.

PROGRAM CHANGE: After the setup as described above or on pressing NO to the Setup

PROGRAM CHANGE: After the setup as described above or on pressing NO to the Setup query at the beginning the data programming can be done. Here the system responds with pompts asking for all required data. The data can be changed using the cursor control keys.

If ATC OFF was selected in setup the prompt MTC xxx comes up. Enter the required MTC value.

The display now shows S1 LIM. Press Yes if you want to change the control limits of Stage 1.

The display now shows 1 LL xx.xx. Set LL (Very Low) limit of stage 1 and press YES.

The display now shows 1 L 2 xx.xx Set L2 limit of stage 1 and press YES.

The display now shows 1 L 1 xx.xx Set L1 limit of stage 1 and press YES.

The display now shows 1H1 xx.xx Set H1 limit of stage 1 and press YES.

The display now shows 1 H 2 xx.xx Set H2 limit of stage 1 and press YES.

The display now shows 1 HH xx,xx Set HH (Very High) limit of stage 1 and press YES.

The display now shows 1H T 040.0 Set High Temperature limit of stage 1 and press YES.

The display now shows 1 D T 005.0 Set high temperature dt of stage 1 and press YES. If pH control is suspended due to high temperature violation, the control will be resumed when the temperature reaches Ht-dt.

The display now shows S1 DOSE. Press yes if you want to change the dose control timings of Stage 1. The display now shows 1.M.H.A.XXX. Set stage 1 High B mark time and press Yes. The display now shows 1.S.H.A. XXX. Set stage 1 High B space time and press yes

The programming can be terminated at any time by pressing ESC key.

The display now shows 1.M.LA. XXX. Set stage 1 High A mark time and press Yes The display now shows 1.S.L.A. XXX. Set stage 1 High A space time and press Yes The display now shows 1.M.LB.XXX. Set stage 1 Low A mark time and press Yes The display now shows 1.S.L.B. XXX. Set stage 1 low A space time and press Yes.

The display now shows 1.M.L.B.XXX . Set stage 1 low B mark time and press

The display now shows 1.M.L.B.XXX. Set stage 1 low B mark time and press yes. The display now shows 1.S.L.B.XXX. Set stage 1 low B space time and press yes.

If two stage operation was selected all limits, mark/space timings are repeated for stage 2 viz.2L2, 2L1 etc.,

If 2 stage operation was selected and the stage 1 operation was set to Time based, then the system will now ask Sl xx. Enter the stage 1 duration in minutes.

The display now shows PRT xx (INTERVAL BETWEEN REGULAR PRINTS). Set required interval and press YES.

The display now shows dly xx (WAIT AFTER WASH JET IS STOPPED xx sec).

Set wait time and press YES. This wait is given to ensure proper fixing of process solution after

a wash.

The display now shows Cln rt xx. Enter the duration between automatic electrode washes (in minutes).

The display now shows A L D L Y xx (VIOLATIN DELAY XX sec.). Set violation time delay using curser control keys and press YES. When the pH value changes from HI to LO or vice versa, the system ensures that the new pH value is consistent for this delay period to be taken as a genuine violation.

The display shows r Hi xx.xx. Set the pH value for recorder output high. Setting Time, Date and Batch No .: To set the Time, Date or Batch No. bring the respective parameter on display using the DISP key. Press NO. The display digit will flash. Now enter the correct Time, Date or Batch No. using the cursor control keys and press DISP key.

This completes the programming.

IT IS RECOMMENDED THAT A RECORD OF PROGRAMMED DATA IS KEPT AS A REFERENCE FOR FUTURE CHANGES OR REPROGRAMMING.

OPTIMISING THE CONTROL PROCESS

OPTIMISING THE CONTROL PROCESS With this system of dosing the operator has 5 parameters through which

With this system of dosing the operator has 5 parameters through which the whole pH control system can be optimised.

Strength of dosing reagent

Flow rate of dosing reagent / second (with dosing element on)

Setting of HH limit

Setting of H2 limit

Setting of mark time A (Dose time)

Setting of space time A (Mixing or response time)

Setting of mark time B (Dose time)

Setting of space time B (Mixing or response time)

The strength of the dosing reagent and the flow rate are determined by the process requirement and past experience can be used as a guideline. However this may be later be changed to optimise the process.

The H2 limit is set at such a value that permits convenient dose quantities to be used without

a

risk of one dose quantum bringing the pH value from H2 to less than H1. The “Mark” time A

is

set such that one Mark doses changes the pH of the process from H1 to L1 band. The

Space time A is set to the time that is required for one “Mark” of dose to mix and result in a display of a stable process pH value. Similarly HH limit and Mark Space B time settings are made to provide a good approach control on the pH value. This setting will depend heavily on the titration curve of the process.

A few batches are processed with the above settings and during these trials a detailed record

of time Vs pH is made with a clear note on every dose, the time of dose and duration. Now plot a X-Y graph with time on the X-axis and pH on the Y-axis. A clear picture of the effectiveness of control can be seen in this graph. It will now be possible to decide which parameters need to be changed to improve the control and optimise the process. Case 1: If the graph shows that the pH control is very gradual and slow and the time taken for the pH to change is high then the control can be improved by increasing the “Mark A”time or increasing the concentration of the dose reagent or by increasing the flow rate of the reagent or by setting a lower H2 limit by increasing the “Mark B time Case 2: If the graph shows that the pH change with dose is very rapid (eg. While controlling High pH the end pH value is going Low), then The Mark time needs to be reduced or

Reagent strength needs to be reduced or The reagent flow rate needs to be reduced or The “Spacetime is insufficient and must be increased. Two extreme cases have been taken to show the possibilities and in each application the state will be different and optimisation has to be judiciously done. It is important though to record all experimentation and results in complete detail so that the final settings can be optimised with minimum iterations and there is a record available for help in future trouble shooting.

ELECTRODE CALIBRATION

ELECTRODE CALIBRATION The DPH 503 allows you to calibrate the electrode with any two buffer solutions,

The DPH 503 allows you to calibrate the electrode with any two buffer solutions, in any order or perform a Standardisation only. The instrument recognises three buffers viz. 4.01 @ 25° C 7.00 @ 25 ° C and 10.00 @ 25°. If any of these buffers are used, the instrument automatically corrects the pH of the buffer for that temperature. The instrument also permits blind calibration of the pH electrode from the transmitter using any of the above three buffers. CALIBRATION FROM THE KEYBOARD : To calibrate the pH electrode from the keyboard proceed as follows. SINGLE POINT CALIBRATION

Press ESC

to bring the instrument to the pH display mode.
to bring the instrument to the pH display mode.

Press PRT/CAL key. The dislay shows PRT? Press NO

The display shows pH CAL? Press YES

The display shows B1 ready?

Asking if the electrode is in the buffer.

Dip the pH electrode and temperature sensor in the first buffer (any one of 4.01, 7.00 or 10.00) and Press YES. The flashing of the ? sign will stop and the display will show busy while the system reads the input from the electrode. After a stable reading is taken the display will

show B2 ready?

If only a single point calibration is to be done Press NO to end calibration. The system will compute the Asymmetric potential of the electrode retaining the existing slope value and display AP=XXX followed by an error message if any. If the AP of the electrode is within +50 mV no error message is shown. Press YES to accept the calibration and update memory or ESC to reject the calibration.

If the AP is > + 50 mV the display alternates between AP=xxx and CAL ERR 1. In this case the system will not accept the calibration and a change of electrode is required. POINT CALIBRATION Press ESC to bring the instrument to the pH display mode.

Proceed as in Single point Calibration till the message b2 ready is seen. Dip the electrode in the second buffer (again one of 4.02, 7.00 or 9.18) and press YES.

The system now computes the AP and SLOPE of the electrode and displays AP=xxx and S=x.xxx with appropriate warnings as earlier.

CAL ERR 1 for AP> + 50 mV (Calibration rejected)

CAL ERR 2 for slope <0.900 or > 1.050 (Calibration rejected) If the pH reading in any of these buffers does not confirm to the expected output or a different solution is used to standardise the electrode, the system displays a message CAL ERR 3 and will not proceed with the calibration. The calibration can be aborted at any time by pressing the ESC key.

GRAB SAMPLE CALIBRATION : It is possible that in some long duration batches, there is

GRAB SAMPLE CALIBRATION:

It is possible that in some long duration batches, there is a need to recalibrate the electrode

because of a small shift in electrode standardisation. In such cases where the electrode can not be removed for recalibration with buffers the contents of the reactor itself can be used for

standardisation. To do this enter the pH calibration procedure by pressing YES at pH Cal? Prompt. At the b1 ready prompt press NO.

The instrument will now show b xx.xx

Enter the correct pH value of the reactor contents and press YES. The instrument will perform

a single point calibration at this pH and show.

AP= xxx

All errors applicable to Single point Calibration are applicable here.

REMOTE CALIBRATION FROM THE TRANSMITTER

In this case of remote calibration from the transmitter the system automatically invokes Single point or 2 point calibration as programmed into the system by the user.

Press ESC to bring the instrument to the pH display mode Press RT/CAL key. The
Press ESC
to bring the instrument to the pH display mode
Press RT/CAL
key. The Display shows PRT? Press NO.
The display shows pH CAL? Press NO.
The display shows REM CAL Press YES.
This enables Remote Calibration as per the method entered under Setup.
SINGLE POINT CALIBRATION
Press the switch on the transmitter. An acknowledge beep will be received.
On getting the ready beep at the transmitter, Dip the electrode in buffer (one of 4.01, 7.00 or
10.00 only) and Press the CAL switch on the Transmitter. The system calculates the AP and
if there is no ERROR gives an acceptance tone in the form of 3 second beeps separated by
three second intervals. Press the CAL switch again to acknowledge and the calibration
procedure is complete.
2 POINT CALIBRATION
On getting the ready beep at the transmitter Dip the electrode in buffer (one of 4.01, 7.00 or
10.00 only) and press the CAL switch on the Transmitter. The system reads the input and

gives a ready beep again. Now dip the electrode in the second buffer and press the CAL switch again. The system calculates the AP and Slope and if there is no error, gives an acceptance tone in the form of 3 second beeps separated by three second intervals. Press the CAL switch again to acknowlege and the calibration procedure is complete. In case of an error in calibration, the system does not give the acceptance tone but gives an ERROR tone in the form of 1 second beeps separated by 1 second intervals. Press the CAL Switch again to acknowledge the Error.

In this case the CALIBRATION PERFORMED IS IGNORED AND THE PREVIOUS VALUES ARE RETAINED.

Temperature Sensor Calibration:

Temperature Sensor Calibration : Place the temperature sensor in a solution of known temperature Press ESC

Place the temperature sensor in a solution of known temperature

Press ESC

sensor in a solution of known temperature Press ESC to brig the instrument to the pH

to brig the instrument to the pH display mode.

Press PRT/CAL key. The Display show PRT? Press NO.

The display shows pH Cal? Press NO,

the display shows rem CAL? Press NO

The display shows tem cal. Press YES

The display now shows

Enter the solution temperature and press YES

The display shows dt xxx.xx i.e. (dt being the difference beteen the factory calibration and the actual temperature entered) Press YES

000.0

The temperature sensor is now calibrated.

NOW THE INSTRUMENT IS READY TO CONTROL YOUR PROCESS

POWER LINE FILTER FUSE 250mA RL4 LOWHIGHWASH RL5 EARTH NEUTRAL PHASE PHASE NEUTRAL COM NO
POWER LINE
FILTER
FUSE 250mA
RL4 LOWHIGHWASH
RL5
EARTH
NEUTRAL
PHASE
PHASE
NEUTRAL
COM
NO
250mAFUSE
ALKALI
DOSING
VALVE
COM
NO
250mAFUSE
COM
NO
250mAFUSE
COM
Remove Black insulation
if present
NO
250mAFUSE
BLACK
GREEN
COM
pH electrode with integral
RTD & Solution ground
NO
RED
ZERO
SPAN
WHITE
250mAFUSE
pH
YELLOW
GLASS
BLUE
TEMP.
DRY
ORANGE
CAL
SHLD
REFERENCE
RED
CAL
+V
BROWN
TMP
GROUNDSOLUTION
pH
-V
-V
GREEN
)(RTDATC
+V
GND
AG
)(RTDATC
BATCH
WASH
TEMP
HALT
GND
HI
SPAN
LO
ZERO

INSTALLATION OF DPH 503

INSTALLATION OF DPH 503 The DPH 503 control system comprises a pH electrode housing a pH

The DPH 503 control system comprises a pH electrode housing a pH transmitter and the controller. Installation and commissioning of the system comprises the following:

Conditioning of the pH electrode Assembly of the electrode housing Connecting the electrode, temperature and level sensor to the transmitter Connecting the transmitter to the Controller Connecting the Dosing elements to the controller Connecting the external digital inputs to the controller Programming the controller Electrode calibration

Conditioning the pH Electrode Remove the pH Electrode from the packing box Clean any salt deposits from the electrode by rinsing Distilled Water Uncover the filling hole and add filling solution to the electrode if required. In the case of GE1 filled electrodes this step is not required. Shake the electrode like a clinical thermometer to remove any air bubbles Soak the electrode in pH Electrode Storage Solution for a few hours, preferably overnight. IMP: Never touch the electrode bulb with the hand. Avoid wiping or rubbing of the electrode bulb to reduce polarisation error.

Assemble the Electrode Housing as per the drawing supplied with the housing. Connect the pH Electrode and the Temperature sensor cables to the transmitter as shown in the connection diagram. IT IS IMPORTANT TO ENSURE THAT THE VESSEL GROUND CONNECTIONS IS FIRMLY CONNECTED TO THE PROCESS SOLUTION GROUND.

Connect the Transmitter to the Controller as shown in the connection diagram.

Connect the Dosing elements (Solenoid valves/Pumps) through the control relay terminals. IMP. The control relays are rated for 230 V, 3A resistive load. Should the dosing element have a higher rating an intermediate Contractor or Relay of an appropriate rating should be used.

Now program the controller following the instructions given under the chapter Programming.

Now Calibrate the electrode folloiwng the instructions given under Electrode Calibration. When calibrating for the first time a 2 point calibration should be done.

ELECTRODE MAINTENANCE The pH Electrode is the heart of the system and proper care in

ELECTRODE MAINTENANCE

The pH Electrode is the heart of the system and proper care in maintenance of the electrode will go a long way in ensuring correct readings and longer life.

Inspect the electrode as frequently as is possible for scratches, salt crystal buildup or membrane/junction coating. This inspection should be done at least once a week and more frequently if possible.

Rinse off any salt deposits with distilled water and remove any membrane deposits by rinsing. If rinsing with distilled water does not remove deposits by rinsing. If rinsing with distilled water does not remove deposits from the membrane follow the Cleaning procedure outlined below.

If the reference electrolyte appears to be contaminated with extraneous matter drain the reference electrode chamber, flush with fresh filling solution and refill.

CLEANING PROCEDURE

General - Rinse electrode well and soak in 0.1M HCl or 0.1 M HNO3 for half an hour. Removal of membrane deposits Inorganic – Soak in 0.1M tetrasodium EDTA soln. For 15 minutes. Protein Soak in 1% pepsin in 0.1M HCl for 15 minutes. Grease & Oil – Rinse with mild detergent or Methanol solution.

After any of these cleaning procedures, drain and refill the reference chamber and soak in storage solution for half an hours.

ERROR MESSAGES

Tmp err: In ATC mode, the system periodically reads the temperature of the solution. If at any time the temperature sensor readings are abnormal.i.e. Sensor is Open or Short this error message appears. In such a case, change the system operation to MTC mode through ‘Program’. And Check the temperature sensor, the connections and replace sensor if necessary Calibrate the temperature sensor and resume ATC operation.

Lim err: In the programming operation, if the operator enters illogical limits for control, for eg. H1<L1 or H2 < H1, the system will not accept these limits and will respond with a ‘LIM ERR’ message, and the interactive promoting display will remain at the limit which is illogical.

Cal err 1, Cal err 2 and Cal err 3: See chapter on Electrode calibration for explanation

WARRANTY

WARRANTY GLOBAL ELECTRONICS warrants its products, when properly applied and operated under normal conditions, to be

GLOBAL ELECTRONICS warrants its products, when properly applied and operated under normal conditions, to be free from faulty workmanship or defective materials for a period of ONE YEAR from the date of original shipment. Global products repaired or replaced pursuant to this warranty shall be warranted for the unexpired portion of the warranty applying to the original products. The liability of Global under this warranty shall exist provided that

a.The attached warranty registration card is sent back to Global within a fortnight of purchase; and b.Global is promptly notified upon discovery of such defects by Buyer; and

c. The defective product is returned to ‘Global, transporation paid by Buyer or at Global’s

discretion the said product is inspected and repaired at Buyer’s site; and

d. Global’s examination of such product disclose that there was a defect in Global material or workmanship; and

e. Global name plates and markings have not been altered or removed.

In the event the defect is determined to be within the terms of this warranty, Global agrees to repair/replace the product or the defective portion at no charge to Buyer and to pay for transportation back to Buyer. This warranty does not apply to consumable items like electrodes, conductivity cells, temperature sensors, fuses etc. or parts which have been subject to misuse, neglect, accident or abnormal conditions of operation.

Global reserves the right to make changes in design and specifications without notice and without any obligation of such changes on units purchased. Until superseded or in contractual

form, this warranty is expreslly in lieu of all other liabilities and obligations on the part of Global

Electronics.

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SERIAL NO:

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for GLOBAL ELECTRONICS