Quick Start Guide 15. Figure 3-4: Pin out Diagram for Rosemount 403VP Sensor (Viewed from Connector End of Sensor, Looking Down) Table 3-5: Pin out Diagram. Number Connects to 1 Cathode 2 N/A 3 Resistance temperature device (RTD) sense 4 Anode *00825-0100-3403* Quick Start Guide
Quick Start Guide. 00825-0100-3403, Rev AB. January 2020. Rosemount 403/403VP. Contacting Conductivity Sensors ...
Quick Start Guide 00825-0100-3403, Rev AB January 2020 Rosemount 403/403VP Contacting Conductivity Sensors
Rosemount 403/403VP Quick Start Guide 00825-0100-3403, Rev AB January 2020 Contacting Conductivity Sensors Quick Start Guide January 2020 Essential instructions Read this page before proceeding! Emerson designs, manufactures, and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you must properly install, use, and maintain them to ensure they continue to operate within their normal specifications. You must adhere to the following instructions and integrate them into your safety program when installing, using, and maintaining Emerson's Rosemount products. Failure to follow the proper instructions may cause any one of the following situations to occur: loss of life, personal injury, property damage, damage to this instrument, and warranty invalidation. · Read all instructions prior to installing, operating, and servicing the product. · If you do not understand any of the instructions, contact your Emerson representative for clarification. · Follow all warnings, cautions, and instructions marked on and supplied with the product. · Inform and educate your personnel in the proper installation, operation, and maintenance of the product. · Install your equipment as specified in the Install section of this QSG and per applicable local and national codes. Connect all products to the proper electrical and pressure sources. · To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product. · When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson. Unauthorized parts and procedures can affect the product's performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. 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, except when maintenance is being performed by qualified people, to prevent electrical shock and personal injury. Note The information contained in this document is subject to change without notice. CAUTION Sensor/process application compatibility The wetted sensor materials may not be compatible with process composition and operating conditions. Application compatibility is entirely the operator's responsibility. WARNING Before removing the sensor, be absolutely certain the process pressure is reduced to 0 psig and the process temperature is at a safe level. 2 Emerson.com/Rosemount January 2020 Quick Start Guide WARNING Physical access Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users' equipment. This could be intentional or unintentional and needs to be protected against. Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access by unauthorized personnel to protect end users' assets. This is true for all systems used within the facility. Contents Specifications............................................................................................................................... 5 Install......................................................................................................................................... 10 Wire........................................................................................................................................... 12 Calibrate and maintain............................................................................................................... 17 Troubleshoot............................................................................................................................. 23 Accessories................................................................................................................................ 27 Quick Start Guide 3 Quick Start Guide January 2020 4 Emerson.com/Rosemount January 2020 Quick Start Guide 1 1.1 Specifications Specifications Table 1-1: Rosemount 403/403VP Contacting Conductivity Sensor Specifications Wetted materials Electrodes Titanium Insulator PCTFE (neoflon), compliant to 21CFR 177.1380 and USP Class VI Sensor tube 316 stainless steel O-ring EPDM, compliant to 21CFR 177.1380 and USP Class VI Temperature range 32 to 221 °F (0 to 105 °C). Sensors are steam sterilizable to 275 °F (135 °C). Maximum pressure 250 psig (1825 kPa [abs]) Vacuum At 1.6-in. Hg (5.2 kPa), air leakage is less than 0.005 SCFM (0.00014 m3/min.) Cell constants 0.01, 0.1, and 1.0/cm Process connection 1½-in. or 2-in. sanitary flange Cable length 10 ft. (3 m) standard; other lengths are optional. Table 1-2: Rosemount 403/403VP Weights and Shipping Weights Rounded up to the nearest 1 lb. or 0,5 kg. Sensor Weight Shipping weight Rosemount 403 with 10-ft. (3.1 m) cable 2 lb. (1.0 kg) 3 lb. (1.5 kg) Rosemount 403 with 50-ft. (15.2 m) integral cable 4 lb. (2.0 kg) 5 lb. (2.5 kg) Rosemount 403VP with 1 lb. (0.5 kg) Variopol cable connection 2 lb. (1.0 kg) Quick Start Guide 5 Quick Start Guide January 2020 Note Elastomers and fluorocarbon resisns are compatible with 21CFR177 and meet the requirements of USP Class VI. Stainless steel contains less than five delta ferrite. All surfaces have 16 microinch (0.4 micrometer) Ra finish. 1.2 Rosemount 403 Contacting Conductivity Sensor ordering information Note The EnduranceTM Rosemount 403 sanitary flange conductivity sensors are supplied with 1½-in. or 2-in. stainless steel sanitary process connections. Rosemount 403 sensors have a maximum temperature rating of 221 °F (105 °C) and are suitable for sterilization up to 275 °F (135 °C). The standard Rosemount 403 sensor has a Pt-1000 resistance temperature device (RTD) and a 10-ft. (3 m) integral cable. All wetted surfaces in the Rosemount 403 have 16 micro-inch (0.4 micrometer) Ra finish, and all elastomers and plastics in the Rosemount 403 are compliant with 21CFR177 and USP Class VI. 1.2.1 Code 403 CONFIGURE > VIEW PRODUCT > Model Description Contacting Conductivity Sensor 1.2.2 Code 11 12 13 Cell constant Description 0.01/cm 0.1/cm 1.0/cm 1.2.3 Code 20 21 Flange size Description 1½-in. stainless steel sanitary fitting 2-in. stainless steel sanitary fitting 6 Emerson.com/Rosemount January 2020 Quick Start Guide 1.2.4 Code _ 54 Temperature compensation Description Pt-1000 (standard) for Rosemount 1056, 1066-C, 56, and 5081-C Pt-100 for Rosemount 1054; series 2081 1.2.5 Electrode extension insertion length Code _ 36 Description No selection Extended insertion length (6.0-in. [152.4 mm] from inside face of flange to end) 1.2.6 Code _ 50 02 20 03 06 Cable length Description No selection Integral 50-ft. (15 m) cable Integral 15-ft. (4.6 m) cable Integral 20-ft. (6 m) cable Integral 33-ft. (10 m) cable Integral 100-ft. (30 m) cable 1.2.7 Calibration and conformance certificates - optional level Code CC LC EC Description Certificate of Calibration (no test data given) Loop Calibration Certificate (sensor and transmitter calibrated together with test data) Electronic Calibration Certificate (sensor calibrated against factory instrument with test data) 1.2.8 Material traceability certificates - optional level Code MC Description Material Traceability Certificate Quick Start Guide 7 Quick Start Guide January 2020 1.3 Rosemount 403VP Contacting Conductivity Sensor ordering information Note The standard Rosemount 403VP sensor has an integral six pin Variopol (VP6) connector. A mating VP6 connector cable is required for use with these sensors. CONFIGURE > VIEW PRODUCT > 1.3.1 Model Code 403VP Description Conductivity sensor - sanitary flange Variopol connector 1.3.2 Code 11 12 13 Cell constant Description 0.01/cm 0.1/cm 1.0/cm 1.3.3 Code 20 21 Flange size Description 1½-in. stainless steel sanitary fitting 2-in. stainless steel sanitary fitting 1.3.4 Code _ 54 Temperature compensation Description Pt-1000 (standard) for Rosemount 1056, 1066-C, 56, and 5081-C Pt-100 for Rosemount 1054; series 2081 1.3.5 Electrode extension insertion length Code _ 36 Description No selection Extended insertion length (6.0-in. [152.4 mm] from inside face of flange to end) 8 Emerson.com/Rosemount January 2020 Quick Start Guide 1.3.6 Calibration and conformance certificates - optional level Code CC LC EC Description Certificate of Calibration (no test data given) Loop Calibration Certificate (sensor and transmitter calibrated together with test data) Electronic Calibration Certificate (sensor calibrated against factory instrument with test data) 1.3.7 Material traceability certificates - optional level Code MC Description Material Traceability Certificate Quick Start Guide 9 Quick Start Guide January 2020 2 Install 2.1 Unpack and inspect Procedure 1. Inspect the outside of the carton for any damage. If you detect damage, contact the carrier immediately. 2. Inspect the instrument and hardware. Make sure all items in the packing list are present and in good condition. Notify the factory if any part is missing. 2.2 Install Depending on the option you selected first, you can install the sensor in either a 1½-in. (38.1 mm) or 2-in. (50.8 mm) Tri Clamp tee. The operator must supply the gasket, clamp, and tee. Procedure 1. Submerge the electrodes completely within the process liquid (i.e., up to the flange's inside surface). If you install the sensor in a side stream with sample draining to open atmosphere, bubbles may accumulate on the electrodes. Trapped bubbles will cause errors. Normally, as bubbles accumulate, the conductivity reading drifts down. 2. To control bubble formation, apply a small amount of back pressure to the sensor. Figure 2-1: Sensor Orientation A. Trapped air B. Trapped sludge 10 Emerson.com/Rosemount January 2020 Figure 2-2: Recommended Installation Quick Start Guide A. Flow B. Recommended C. Not recommended Quick Start Guide 11 Quick Start Guide January 2020 3 Wire 3.1 Wire Rosemount 403/403VP For additional wiring information on this product, including sensor combinations not shown here, please refer to Emerson.com/ RosemountLiquidAnalysisWiring. Table 3-1: Wire Color and Connections in Sensor Color Gray Clear Orange Clear Red White with red stripe White Clear Function Connects to outer electrode Coaxial shield for gray wire Connects to inner electrode Coaxial shield for orange wire Resistance temperature device (RTD) in RTD sense RTD return Shield for all RTD lead wires Figure 3-1: Rosemount 403/403VP Sensor Wiring to Rosemount 56, 1056, and 1057 Transmitters 12 Emerson.com/Rosemount January 2020 Quick Start Guide Table 3-2: Rosemount 403/403VP Sensor Wiring to Rosemount 56, 1056, and 1057 Transmitters Letter A B C D N/A N/A E F G H Color White White/red Red Clear N/A N/A Clear Orange Clear Gray Terminal number 1 2 3 4 5 6 7 8 9 10 Connects to RTD return RTD sense RTD in RTD shield 4 count B 4 count A Shield, 2 count Sensor, 2 count B Shield, 2 count Sensor, 2 count A Figure 3-2: Rosemount 403/403VP Sensor Wiring to Rosemount 1066 Transmitter Table 3-3: Rosemount 403/403VP Sensor Wiring to Rosemount 1066 Transmitter Letter A B Wire color White White/red Connects to Return Sense Quick Start Guide 13 Quick Start Guide January 2020 Table 3-3: Rosemount 403/403VP Sensor Wiring to Rosemount 1066 Transmitter (continued) Letter C D E F G H Wire color Red Clear Clear Gray Orange Clear Connects to RTD in Shield R shield Drive B Drive A Drive shield Figure 3-3: Rosemount 403/403VP Sensor Wiring to Rosemount 5081 Transmitter 14 Emerson.com/Rosemount January 2020 Quick Start Guide Table 3-4: Rosemount 403/403VP Sensor Wiring to Rosemount 5081 Transmitter Terminal number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Letter N/A A B C D N/A E F N/A G H N/A N/A N/A NA N/A Wire color N/A Clear White White/red Red N/A Clear Orange N/A Clear Gray N/A N/A N/A N/A N/A Connects to Reserved RTD shield RTD common RTD sense RTD in RTD shield RTD common Receive Drive shield Drive common Drive N/A N/A N/A HART®/FOUNDATIONTM Fieldbus (-) HART/FOUNDATION Fieldbus (+) 3.2 Wire through a junction box Procedure If making wiring connections through a remote junction box (PN 23550-00) wire point-to-point. Use cable 23747-00 (factory-terminated) or 9200275 (no termination). Quick Start Guide 15 Quick Start Guide January 2020 Figure 3-4: Pin out Diagram for Rosemount 403VP Sensor (Viewed from Connector End of Sensor, Looking Down) Table 3-5: Pin out Diagram Number 1 2 3 4 5 6 Connects to Cathode N/A Resistance temperature device (RTD) sense Anode RTD return RTD in 16 Emerson.com/Rosemount January 2020 Quick Start Guide 4 Calibrate and maintain 4.1 4.2 4.2.1 Clean the sensor Procedure Use a warm detergent solution and a soft brush or pipe cleaner to remove oil and scale. You can also use isopropyl alcohol to remove oily films. Avoid using strong mineral acids to clean conductivity sensors. Calibration Emerson calibrates PURSense conductivity sensors at the factory; the sensors do not need to be calibrated when first placed in service. Simply enter the cell constant printed on the label into the transmitter. After a period of service, you may need to calibrate the sensor. You can calibrate the sensor against a solution having a known conductivity or against a referee meter and sensor. If using a standard solution, choose one having conductivity in the recommended operating range for the sensor cell constant. Refer to the transmitter Reference Manual or Product Data Sheet for recommended ranges. Do not use standard solutions having conductivity less than about 100 µS/cm. They are susceptible to contamination by atmospheric carbon dioxide, which can alter the conductivity by a variable amount as great as 1.2 µS/cm (at 77 °F [25 °C]). Because 0.01/cm sensors must be calibrated in low conductivity solutions, it is best to calibrate them against a referee meter and sensor in a closed system. Calibrate using a standard solution If using a standard solution, choose one having conductivity in the recommended operating range for the sensor cell constant. Procedure 1. Immerse the rinsed sensor in the standard solution and adjust the transmitter reading to match the conductivity of the standard. 2. Calibrate the sensor. For an accurate calibration: a. Choose a calibration standard near the midpoint of the recommended conductivity range for the sensor. b. Do not use calibration standards having conductivity less than 100 µS/cm. Quick Start Guide 17 Quick Start Guide January 2020 c. Turn off automatic temperature compensation in the transmitter. d. Use a standard for which the conductivity as a function of temperature is known. e. Use a good quality calibrated thermometer with an error rate less than ±0.1 °C to measure the temperature of the standard. f. Follow good laboratory practice. Rinse the beaker and sensor at least twice with standard. Be sure the rinse solution reaches between the inner and outer electrodes by tapping and swirling the sensor while it is immersed in the standard. g. Be sure air bubbles are not trapped between the electrodes. Place the sensor in the standard and tap and swirl to release bubbles. Note the reading and repeat. If readings agree, no trapped bubbles are present. Repeat until two subsequent readings agree. 4.2.2 Calibrate using a reference meter and sensor Take the following precautions for a successful calibration: 1. If the normal conductivity of the process liquid is less than about 1.0 µS/cm, adjust the conductivity so that it is near the upper end of the operating range. The difference between the conductivity measured by the process and reference meter usually has both a fixed (constant error) and relative (proportional error) component. Because the cell constant calibration assumes the error is proportional only, calibration at low conductivity allows the fixed component to have an outsized influence on the result. For example, assume the only difference between reference meter and process sensor is fixed, and the process sensor always reads 0.002 µS/cm high. If the process sensor is calibrated at 0.100 µS/cm, the new cell constant will be changed by 0.100/0.102 or two percent. If the sensor is calibrated at 0.500 µS/cm, the change will be only 0.500/0.502 or 0.4 percent. Calibration at higher conductivity produces a better result, because it minimizes the effect of the offset. 2. Orient the sensors so that air bubbles always have an easy escape path and cannot get trapped between the electrodes. 3. Turn off automatic temperature compensation in the transmitter. Almost all process conductivity transmitters feature automatic temperature compensation in which the transmitter applies one of several temperature correction algorithms to convert the measured 18 Emerson.com/Rosemount January 2020 Quick Start Guide conductivity to the value at a reference temperature, typically 77 °F (25 °C). Although temperature correction algorithms are useful for routine measurements, do not use them during calibration for the following two reasons: a. No temperature correction is perfect. If the assumptions behind the algorithm do not perfectly fit the solution being measured, the temperature-corrected conductivity will be in error. b. If the temperature measurement itself is in error, the corrected conductivity will be in error. The purpose of calibrating the sensor is to determine the cell constant. To minimize the error in the cell constant, eliminate all sources of avoidable error, e.g., temperature compensation. 4. Keep tubing runs between the sensors short and adjust the sample flow as high as possible. Short tubing runs and high flow ensure that the temperature of the liquid does not change as it flows from one sensor to another. If the process temperature is appreciably different from ambient, high flow may not be enough to keep the temperature constant. In this case, you may need to pump sample at room temperature from a reservoir through the sensors. Because such a system is likely to be open to atmosphere, saturate the liquid with air to prevent drift caused by absorption of atmospheric carbon dioxide. 5. To prevent contamination of low conductivity (< 1 µS/cm) process liquids, use clean tubing to connect the sensors. To prevent drift caused desorption of ionic contaminants from tube walls, keep the sample flow greater than 6 ft./sec (1.8 m/sec). Procedure 1. Connect the process sensors and reference sensor in series and allow the process liquid to flow through all sensors. 2. Calibrate the process sensor by adjusting the process transmitter reading to match the conductivity measured by the reference meter. See Figure 4-1 for the calibration setup. Quick Start Guide 19 Quick Start Guide Figure 4-1: In Process Calibration Setup January 2020 A. Sample inlet B. In process sensors C. Reference sensor D. Sample output Note Figure 4-1 shows two process sensors connected in series with a reference sensor. The horizontal sensor orientation ensures good circulation of the process liquid past the electrodes. The staircase orientation provides an escape path for bubbles. This method is ideal for calibrating the sensors used in low conductivity water (0.01/cm cell constants), because the calibration system is closed and cannot be contaminated by atmospheric carbon dioxide. 4.2.3 Calibrate using a grab sample Use the grab sample method when it is impractical to remove the sensor for calibration or to connect a reference sensor to the process line. Procedure Take a sample of the process liquid, measuring its conductivity using a reference instrument and adjusting the reading from the process transmitter to match the measured conductivity. Take the sample from a point as close to the process sensor as possible. Keep temperature compensation turned on. There is likely to be a lag time between sampling and analysis, so temperature is likely to change. 20 Emerson.com/Rosemount January 2020 Quick Start Guide Be sure the reference and process instruments are using the same temperature correction algorithm. Only use grab sample calibration when the conductivity is fairly high. a. The temperature compensation algorithm will most likely be linear slope. b. Confirm that both instruments are using the same temperature coefficient in the linear slope calculation. c. If the reference meter does not have automatic temperature correction, calculate the conductivity at 77 °F (25 °C) using the equation: where: C25 = the conductivity at 25 °C Ct = the conductivity at t °C = the temperature coefficient expressed as a decimal fraction d. Confirm the temperature measurements in both the process and reference instruments are accurate, ideally to within ±0.5 °C. e. Follow good laboratory practice when measuring the conductivity of the grab sample. · Rinse the beaker and sensor at least twice with sample. Be sure the rinse solution reaches between the inner and outer electrodes by tapping and swirling the sensor while it is immersed in the sample. · Be sure air bubbles are not trapped in the sensor. Place the sensor in the sample and tap and swirl to release bubbles. Note the reading. Then, remove the sensor and return it to the sample. Tap and swirl again and note the reading. If the two readings agree, there are no trapped bubbles. If they do not agree, bubbles are present. Continue the process until two subsequent readings agree. · While measuring, do not allow the sensor to touch the sides and, particularly, the bottom of the beaker. Keep at least ¼ in. (6 mm) clearance. f. Be sure to compensate for process conductivity changes that might have occurred while the grab sample was being tested. Rosemount conductivity transmitters (Rosemount 1056, 1066, and 56) do this automatically. They save the value of the process conductivity at the time the sample was taken and use that value to calculate the new cell constant when you enter the result of the grab sample test. Older transmitters do not remember the process conductivity value. Quick Start Guide 21 Quick Start Guide January 2020 Therefore, you must enter a value adjusted by an amount proportional to the change in the process conductivity. For example, suppose the process conductivity is 810 µS/cm when the sample is taken and 815 µS/cm when the test result is entered. If the grab sample conductivity is 810 µS/cm, enter (815/810) x 819 or 824 µS/cm. 22 Emerson.com/Rosemount January 2020 Quick Start Guide 5 Troubleshoot Note For any repair or warranty inquiries, please contact our Customer Care group. 5.1 Off-scale reading Potential cause Wiring is incorrect. Recommended action Verify and correct wiring. Potential cause Resistance temperature device (RTD) is open or shorted. Recommended actions 1. Check RTD for open or short circuits. 2. Disconnect leads and measure resistance shown. The measured resistance at room temperature should be close to the value in Table 5-1. Table 5-1: Temperature Resistance Temperature (°C) 0 10 20 30 40 50 Resistance in ohms Pt 100 100.0 103.9 107.8 111.7 115.5 119.4 Pt 1000 1000 1039 1078 1117 1155 1194 Quick Start Guide 23 Quick Start Guide Figure 5-1: Checking RTD January 2020 A. RTD B. Red C. Red/white D. White Potential cause Sensor is not in process stream. Recommended action Submerge sensor completely in process stream. Potential cause Sensor has failed. Recommended action 1. Perform isolation checks. See Figure 5-2. 24 Emerson.com/Rosemount January 2020 Quick Start Guide Figure 5-2: Checking the Continuity and Leakage A. Orange B. Inner C. Outer D. Gray 2. Disconnect electrode leads and measure resistance and continuity as shown. Sensor must be dry when checkingt resistance between electrode leads. 5.2 Noisy reading Potential cause Sensor is improperly installed in process stream. Recommended action Submerge sensor completely in process stream. 5.3 Reading seems wrong (lower or higher than expected) Potential cause Bubbles trapped in sensor. Quick Start Guide 25 Quick Start Guide January 2020 Recommended actions 1. Ensure the sensor is properly oriented in pipe or flow cell. See Figure 1. 2. Apply back pressure to flow cell. Potential cause Wrong temperature correction algorithm is being used. Recommended action Check that the temperature correction is appropriate for the sample. See transmitter manual for more information. Potential cause Wrong cell constant. Recommended action Verify that the correct cell constant has been entered in the transmitter and that the cell constant is appropriate for the conductivity of the sample. See transmitter manual. 5.4 Sluggish response Potential cause Electrodes are fouled. Recommended action Clean electrodes. Potential cause Sensor is installed in dead area in piping. Recommended action Move sensor to a location more representative of the process liquid. 26 Emerson.com/Rosemount January 2020 Quick Start Guide 6 Accessories Part number 23747-06 9200275 23747-00 05010781899 05010797875 05010782468 05010783002 05000705464 05000709672 05010782147 05010782026 Description Junction box for a remote cable connection Connecting cable, unterminated, specify length Connecting cable, terminated, specify length Conductivity standard SS-6, 200 µS/cm, 32 oz. (0.95 L) Conductivity standard, SS-6A, 200 µS/cm, 1 gal. (3.78 L) Conductivity standard, SS-5, 1000 µS/cm, 32 oz. (0.95 L) Conductivity standard SS-5A, 1000 µS/cm, 1 gal. (3.78 L) Conductivity standard, SS-1, 1409 µS/cm, 32 oz. (0.95 L) Conductivity standard, SS-1A 1409 µS/cm, 1 gal. (3.78 L) Conductivity standard SS-7, 5000 µS/cm, 32 oz. (0.95 L) Conductivity standard SS-7A, 5000 µS/cm, 1 gal. (3.78 L) Quick Start Guide 27 *00825-0100-3403* Quick Start Guide 00825-0100-3403, Rev. AB January 2020 GLOBAL HEADQUARTERS 6021 Innovation Blvd. Shakopee, MN 55379 +1 866 347 3427 +1 952 949 7001 liquid.csc@emerson.com NORTH AMERICA Emerson Automation Solutions 8200 Market Blvd Chanhassen, MN 55317 Toll Free +1 800 999 9307 F +1 952 949 7001 liquid.csc@emerson.com MIDDLE EAST AND AFRICA Emerson Automation Solutions Emerson FZE Jebel Ali Free Zone Dubai, United Arab Emirates, P.O. 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