Emerson 402 and 402VP ENDURANCE™ Conductivity Sensors Instruction Manual

Instruction Manual 402 and 402VP LIQ_MAN_ABR_402_402VP January 2014 ENDURANCE™ Conductivity Sensors For additional information, please visit our website at www.rosemountanalytical.com CAUTION Sensor/Process Application Compatibility The wetted sensor materials may not be compatible with process composition and operating conditions. Application compatibility is entirely the responsibility of the user. CAUTION The 402 and 402VP sensors are retractable. BEFORE RETRACTING THE SENSOR, be absolutely certain the process pressure is less than 64 psig (542 kPa abs) and the process temperature is at a safe level! Sensor Specifications Specifications 402 402VP Electrode -11, -12, -13 titanium -11, -12, -13 titanium Insulator -11, -12, -13 PEEK (glass filled) -11, -12, -13 PEEK (glass filled) Other Wetted Materials 316 SST, EPDM, graphite, Neoprene 316 SST, EPDM, graphite, Neoprene Temperature Range 32–212 °F (0–100 °C) 32–212 °F (0–100 °C) Maximum Pressure 200 psig (1481 kPa abs) 200 psig (1481 kPa abs) Maximum Retraction Pressure 64 psig (542 kPa abs) 64 psig (542 kPa abs) Sensor Orientation Figure 2. Recommended Installation Figure 1. Sensor Orientation trapped air flow 30°° flow 30° ° recommended trapped sludge not recommended flow Keep ¼ in. (6 mm) clearance between electrodes and piping. The electrolytes must be completely submerged in the process liquid, i.e., to the upper edge of the guard (item 10 in Figure 3). 402 and 402VP January 2014 Instruction Manual LIQ_MAN_ABR_402_402VP Installation and Retraction of Sensor Installation Retraction assembly kit (PN 23765-00) consists of items 1 through 7 shown in Figure 3 as well as a hex key and pipe tape. The sensor assembly includes items 8 through 11. IMPORTANT! Do not remove or alter the guard (10) on the sensor tube (9). Figure 3. 402 Sensor with Retraction Assembly Kit 2 Instruction Manual LIQ_MAN_ABR_402_402VP 402 and 402VP January 2014 1. Make sure the system is shut down and there is no residual pressure. 2. Attach the ball valve (2) to the process piping using the 1–¼-inch FNPT port on the valve or the 1–¼ inch NPT nipple (1). Use pipe tape on male threads. 3. Slide the handle lock up on the ball valve handle and close the ball valve (2). If the process will be restarted before the sensor is installed, make sure the system pressure is at or below 542 kPa abs (64 psig) before proceeding. If the system will not be restarted until after the sensor installation, leave the valve in the open position. 4. If the sensor includes a junction box (8), it must be removed from the sensor to install the retraction assembly kit. Disconnect the sensor wires inside the junction box prior to disassembly. 5. Follow Figure 4 to assemble the sensor and retraction assembly. Keep items 3-7 in the proper sequence. Items 3, 6, and 7 are factory assembled. 6. Position the sensor tube (9) so that the electrodes (11) are completely withdrawn inside the packing adapter (3). If it is difficult to slide the sensor through the packing rings, loosen the packing bushing (6). 7. Position the clamp (4) on the sensor tube (9) so that the electrodes (11) will be completely immersed in the process liquid when the sensor is fully inserted through the ball valve. See Figure 3. Use the hex key to secure the clamp to the sensor tube. 8. Slide the retainer (5) onto the sensor tube (9). 9. Screw the junction box (8) — hand tight — onto the sensor tube (9). DO NOT OVERTIGHTEN. Use 2-3 wraps of pipe tape on the tube threads if a NEMA 4 seal is required at the junction box. 10. Apply pipe tape to the packing adapter (3) threads and screw the packing adapter onto the ball valve. 11. Check to ensure that the packing bushing (6) has been tightened. You should be able to push the sensor tube (9) against the resistance provided by the packing rings (7). 12. Open the ball valve (2). 13. There may be some leakage around the packing bushing (6). Tighten the packing bushing to stop the leak. Use the junction box (8) or sensor rear to push the sensor through the valve until the clamp (4) rests against the packing bushing. 14. To secure the sensor tube (9) in place, tighten — hand tighten only — the retainer (5) against the back of the packing adapter (3). If the sensor tube retracts when the system pressure is increased, reduce the pressure to 542 kPa abs (64 psig) or less, remove the retainer (5), and tighten the screw in the clamp (4). Figure 4. 402 Sensor Installation 3 402 and 402VP January 2014 Instruction Manual LIQ_MAN_ABR_402_402VP Retraction 1. Make sure the system pressure is at or below 542 kPa abs (64 psig) at the valve before proceeding. Provide adequate working area for retraction. 2. Unscrew the retainer (5) from the packing adapter (3). If it is difficult to unscrew the retainer, system pressure may be forcing the clamp (4) into the retainer. The packing bushing (6) may not be tight enough to hold the sensor tube (9) in place. To prevent a sudden retraction of the sensor tube as the retainer is removed, hold onto the junction box (8) or sensor rear to restrain the sensor. 3. If the sensor tube (9) does not slide back as the retainer is unscrewed, pull back on the junction box (8) or sensor tube to retract the sensor. 4. If the sensor tube (9) cannot be retracted, loosen the clamp (4) using the hex key. Pull the clamp back and slowly loosen the packing bushing (6) in 1/8-turn increments. System pressure may cause the tube to retract. If not, pull back on the junction box (8) or sensor tube (9) to withdraw the sensor. 5. Withdraw the sensor tube until the guard (10) contacts the stop inside the packing adapter (3). The electrodes (11) are now inside the packing adapter. See Figure 5. Slide the handle lock up on the valve handle and close the ball valve (2). IMPORTANT! Failure to withdraw the sensor completely may result in damage to the electrodes when the valve is closed. 6. Unscrew the packing adapter (3) from the ball valve (2) to remove the sensor and retraction assembly. Figure 5. 402 Sensor in Retracted Position 4 Instruction Manual 402 and 402VP LIQ_MAN_ABR_402_402VP January 2014 Wiring Note For additional wiring information on this product, including sensor combinations not shown here, please refer to either our online wiring programs or the Manual DVD enclosed with each product. 1056, 1057, 56, 5081, 6081, 54e, and XMT : http://www3.emersonprocess.com/raihome/sp/liquid/wiring/XMT/ 1066 and sensors with SMART preamps: http://www2.emersonprocess.com/en-US/brands/rosemountanalytical/Liquid/Sensors/ Pages/Wiring_Diagram.aspx 1055: http://www3.emersonprocess.com/raihome/sp/liquid/wiring/1055/ Wire Color and Connections in Sensor Color Function Gray Connects to outer electrode Clear Coaxial shield for gray wire Orange Connects to inner electrode Clear Coaxial shield for orange wire Red RTD in RTD White with red stripe RTD sense White RTD return Clear Shield for all RTD lead wires Wiring Diagrams Figure 7. Wiring for 54eC and 54C GRAY MODEL 54C & 54eC ANALYZERS RED ORANGE RED Figure 6. Wiring for Sensor-Mounted Junction Box SENSOR WIRES TB1 GROUND RTD SHIELD TB Note: Terminals in junction box are not numbered. CLEAR WHT/RED CLEAR GRAY RED WHITE ORANGE RTD RETURN RTD SENSE CLEAR CABLE SENSOR CABLE RTD IN N/C RECEIVE COMMON RECEIVE N/C DRIVE COMMON DRIVE CLEAR WHITE WHITE/RED RED CLEAR ORANGE CLEAR GRAY GROUND 5 402 and 402VP Instruction Manual January 2014 Figure 8. Wiring for 56 and 1056 CLEAR CLEAR ORANGE CLEAR GRAY Figure 9. Wiring (Panel) for Xmt-C-10 TB1 1 RTD RTN 2 TB1 WHEN INCH AND METRIC DIMS 3 RTD SENSE RTD IN 4 RTD SHLD 5 4CTB 4CTA SHLD 2CT RECEIVE COM SEN 2CTB RTD SENSE 6 7 8 9 WHITE RED/WHITE RED CLEAR ORANGE CLEAR GRAY B DATE 12-8-10 J. C ORANGE RECEIVE 10 SEN 2CTA DESCRIPTION REVISED CLEAR DRIVE COM SHLD 2CT CLEAR RED RED/WHITE RTD COM WHITE RTD SHIELD CLEAR Figure 11. Wiring for 1066 RTD SHIELD TB2 RTD COM RTN RTN RTD SENSE RTD IN RECEIVE COM TB1 TB1 RCV B RCV B WHITE WHITE SENSE SENSE WHITE/RED WHITE/RED RTD IN RTD IN RED RED SHLD SHLD CLEAR CLEAR RECEIVE RCV RCV A A RSHLD RSHLD CLEAR CLEAR GRAY GRAY DRVB DRVB ORANGE ORANGE DRVA DRVA DSHLD DSHLD CLEAR CLEAR DRIVE COM DRIVE Figure 12. Wiring for 5081-C MODEL 5081 TRANSMITTER Figure 13. Wiring for 6081-C SHIELD 2CT-A 2CT-B DRV RCV DRV SHLD RCV COM COM DRV RCV SHLD RTD SHIELD SHIELD RTD IN RTD IN 4CT-A SENSE RTD SENSE 4CT-B RTD RTN RTD COM RTD SHLD HT/FF (-) RESERVED HT/FF (+) CLEAR WHITE WHITE/RED RED CLEAR ORANGE CLEAR GRAY 6 INCH RTD IN Figure 10. Wiring for Xmt-C-11 (Pipe or Wall) TB1 CLEAR MILLIMETER REVISIONS GRAY LTR DRIVE ARE GIVEN NOTES: UNLESS OTHERWISE SPECIFIED SMART PWR APPROVALS C. HOANG 7-7-10 CHECKED J. COVEY 7-23-10 PROJECT ENGR APVD THIS DWG CREATED IN SOLID EDGE Rosemount Analytical, Inc. DATE DRAWN WHITE RED/WHITE RED CLEAR CLEAR ORANGE GRAY CLEAR WHITE WHITE/RED RED LIQ_MAN_ABR_402_402VP 2400 Barranca Pkwy Irvine, CA 92606 TITLE WIRING MODEL 400 SE SENSORS TO MODEL B SIZE DWG NO 40106607 R Instruction Manual LIQ_MAN_ABR_402_402VP 402 and 402VP January 2014 Wiring through a Junction Box If wiring connections are made through a remote junction box (PN 23550-00), wire point-to-point. Use interconnecting cable 23747-00 (factory-terminated) or 9200275 (no terminations). Pin Out Diagram for 402VP Figure 14. VP pin-out Cleaning the Sensor Use a warm detergent solution and a soft brush or pipe cleaner to remove oil and scale. Isopropyl alcohol (rubbing alcohol) can also be used to remove oily films. Avoid using strong mineral acids to clean conductivity sensors. Calibration ENDURANCE conductivity sensors are calibrated at the factory and do not need calibration when first placed in service. Simply enter the cell constant printed on the label into the analyzer. After a period of service, the sensor may require calibration. The sensor can be calibrated against a solution having known conductivity or against a referee meter and sensor. If using a standard solution, choose one having conductivity in the recommended operating for the sensor cell constant. Refer to the analyzer manual or product data sheet for recommended ranges. Do not use standard solutions having conductivity less than about 100 uS/cm. They are susceptible to contamination by atmospheric carbon dioxide, which can alter the conductivity by a variable amount as great as 1.2 uS/cm (at 25 °C). Because 0.01/cm sensors must be calibrated in low conductivity solutions, they are best calibrated against a referee meter and sensor in a closed system. For more information about calibrating contacting conductivity sensors, refer to application sheet ADS 43-024, available on the Rosemount Analytical website. Troubleshooting Problem Probable Cause Solution Wiring is wrong. Off-scale reading Noisy reading Reading seems wrong (lower or higher than expected Sluggish response Verify wiring. temperature element for open or Temperature element is open or shorted. Check short circuits. See Figure 15 (next page). Be sure sensor is completely submerged in Sensor is not in process stream. process stream. Variopol cable is not properly seated. Loosen connector and reseat. Perform isolation checks. Sensor has failed. See Figure 16 (next page). Sensor is improperly installed in process Be sure sensor is completely submerged in stream. process stream. Variopol cable is not properly seated. Loosen connector and reseat. Be sure sensor is properly oriented in Bubbles trapped in sensor. pipe or flow cell. See Figure 1. Apply back pressure to flow cell. Check that temperature correction is Wrong temperature correction algorithm. appropriate for the sample. See analyzer manual for more information. Verify that the correct cell constant has been entered in the analyzer and that Wrong cell constant. the cell constant is appropriate for the conductivity of the sample. See analyzer manual. Electrodes are fouled. Clean electrodes. Move sensor to a location more Sensor is installed in dead area in piping. representative of the process liquid. 7 402 and 402VP Instruction Manual January 2014 Figure 15. Checking Temperature Element Disconnect leads and measure resistances shown. The measured resistance should be close to the value in the table. LIQ_MAN_ABR_402_402VP Rev. L Figure 16. Checking Continuity and Leakage Disconnect electrode leads and measure resistance and continuity as shown. Sensor must be dry when checking resistance between electrode leads. facebook.com/EmersonRosemountAnalytical AnalyticExpert.com 8 Credit Cards for U.S. Purchases Only. twitter.com/RAIhome youtube.com/user/RosemountAnalytical Emerson Process Management 2400 Barranca Parkway Irvine, CA 92606 USA Tel: (949) 757-8500 Fax: (949) 474-7250 rosemountanalytical.com © Rosemount Analytical Inc. 2013 ©2014 Rosemount Analytical, Inc. All rights reserved. The Emerson logo is a trademark and service mark of Emerson Electric Co. Brand name is a mark of one of the Emerson Process Management family of companies. All other marks 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. 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