ENDURANCE Conductivity Sensors

Transcription

1 Model 400 Series Instruction Manual P/N May 1999 ENDURANCE Conductivity Sensors Model 400 Model 401 Model 402 Model 403 Model 404 Screw-in/Insertion Sensors Screw-in/Insertion Sensors Retractable Sensors Sanitary Flanged Sensors Flow-Through Sensors

2 ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Rosemount Analytical 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. The following instructions must be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical 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 this Instruction Manual is not the correct manual, telephone and the requested manual will be provided. Save this Instruction Manual for future reference. If you do not understand any of the instructions, contact your Rosemount representative for clarification. Follow all warnings, cautions, and instructions marked on and supplied with the product. DANGER HAZARDOUS AREA INSTALLATION This sensor is not Intrinsically Safe. or Explosion Proof. Installations near flammable liquids or in hazardous area locations must be carefully evaluated by qualified on site safety personnel. To secure and maintain an intrinsically safe installation, an appropriate transmitter/ safety barrier/sensor combination must be used. The installation system must be in accordance with the governing approval agency (FM, CSA or BASEEFA/CENELEC) hazardous area classification requirements. Consult your analyzer/transmitter instruction manual for details. Proper installation, operation and servicing of this sensor in a Hazardous Area Installation is entirely the responsibility of the user. Inform and educate your personnel in the proper installation, operation, and maintenance of the product. Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual 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 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. 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. Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury. Rosemount Analytical Inc. Uniloc Division 2400 Barranca Parkway Irvine, CA USA Tel: (949) SS-SE Nov Rosemount Analytical Inc. 1998

3 MODEL 400 Series TABLE OF CONTENTS MODEL 400 Series ENDURANCE CONDUCTIVITY SENSORS TABLE OF CONTENTS Section Title Page 1.0 DESCRIPTION AND SPECIFICATIONS Benefits Sensor Selection Guide Ordering Information Weights and Shipping Weights INSTALLATION Unpacking and Inspection Sensor Dimensions Installation WIRING DIAGRAMS AND CABLE PREPARATION General Information Connecting the Sensor Directly to the Analyzer or Transmitter Connecting the Sensor to the Analyzer or Transmitter Through a Remote... Junction Box Preparing Unprepped Cable For Use CALIBRATION General Cell Constant and Calibration Constant True Cell Constant Experimental Determination of Cell Constant MAINTENANCE AND TROUBLESHOOTING Inspection Cleaning Troubleshooting RETURN OF MATERIAL LIST OF TABLES Number Title Page 1-1 Weights and Shipping Weights for Endurance Sensors Weights and Shipping Weights for Accessories Dimensional Drawings Installation Instructions Cable: Colors and Functions of Wires for all Endurance Sensors except Wiring Diagrams for Model 400, , 402, 403, and 404 Sensors K and 100K Thermistor Resistance Values Pt 100 and Pt 1000 RTD Resistance Values Troubleshooting Guide i

4 MODEL 400 Series TABLE OF CONTENTS TABLE OF CONTENTS CONT D LIST OF FIGURES Number Title Page 2-1 Dimensions of Endurance Model 400 Sensor Dimensions of Endurance Model 401 Sensor Dimensions of Endurance Model 402 Sensor with Integral Cable Dimensions of Endurance Model 402 Sensor with Junction Box (option -60) Dimensions of Endurance Model 403 Sensor Dimensions of Endurance Model Flow Cell (PVC) Dimensions of Endurance Model Flow Cell (Stainless Steel) Sensor Orientation Large Pipe or Tank Installation Standard Tee Installation /4 Inch Tee Installation Model 402 Sensor and Retraction Assembly Kit PN / Model 402 Sensor Installation Model 402 Sensor in Retracted Position Model 402 Retractable Sensor Installed In a Large Pipe or Tank Model 402 Retractable Sensor Installed In a Standard Tee Sanitary Sensor Installation -- Side View Sanitary Sensor Installation -- End View PVC Flow Cells Stainless Steel Flow Cells Prepped Cable for All Endurance Models except Model Wiring Diagram for Model 1181C Wiring Diagram for Model 2081C Wiring Diagram for Model 81C Wiring Diagram for Model 3081C Wiring Diagram for Model 1054C Wiring Diagram for Model 1054A and 2054C Wiring Diagram for Model 1054B C Wiring Diagram for Model 1054B LC Wiring Diagram for Model 1054B DC and 1054B R Wiring Diagram for Model 54C Cable Preparation and Wiring Diagram for Solu Comp Wiring Diagram for Model (Four Electrode) Sensor Wiring Diagram for the Solu Meter Wiring a Model 400, , , or Sensor with Sensor-Mounted... Junction Box (option -60) to the Connecting Cables Wiring a Model Sensor with Sensor-Mounted Junction Box to the... Connecting Cable Wiring the Sensor to the Analyzer Through a Remote Junction Box Model 400 Series Cable Preparation (PN ) ii

5 MODEL 400 Series SECTION 1.0 DESCRIPTION AND SPECIFICATIONS SECTION 1.0. DESCRIPTION AND SPECIFICATIONS 1.1 BENEFITS 1.2 SENSOR SELECTION GUIDE 1.3 ORDERING INFORMATION 1.4 WEIGHTS AND SHIPPING WEIGHTS CALIBRATION NOT REQUIRED. Predetermined calibration factor ensures maximum accuracy 1. RUGGED TITANIUM ELECTRODES available with cell constants of 0.01/cm, 0.1/cm, 1.0/cm, 10.0/cm, and a 4-electrode (.85/cm) provide excellent corrosion resistance for consistent, reliable conductivity measurements. VERSATILE MOUNTING CONFIGURATIONS for screw-in, retractable, sanitary flange, or flow-through process connections. COMPATIBILITY with most Rosemount Analytical conductivity analyzers and transmitters. 1.1 BENEFITS Fast, Easy Start-up. Rosemount Analytical products are designed for fast, easy, and trouble free start-up. Endurance sensors are provided with an accurate predetermined factory calibration constant, removing the need for troublesome calibrations with unstable conductivity standards. Simply zero the sensor in the air and enter the Cal constant into the instrument. This feature is available only when used with Rosemount Analytical Models 81C, 3081C, 1054B DC, 1054B LC, and 1054B R. Low Operating Cost. Durability of materials and high resistance to corrosion mean Endurance conductivity sensors have long life, require less maintenance, and have low total operating cost. Model 400, 402, and 404 sensors have chemical-resistant titanium electrodes and PEEK (polyetheretherketone) insulators, and Model /12/13 sanitary sensors have titanium electrodes with Kel-F 2 insulators. Model 401 and sensors for high conductivity solutions use graphite electrodes with epoxy insulation. Accurate Conductivity Measurement. Sensors are calibrated at the factory to ensure accuracy. Rugged design and corrosion-resistant materials keep electrode spacing and surface area constant, so cell constants remain stable for long periods. For temperature compensation, a Pt 1000 RTD is standard. A Pt 100 RTD and a thermistor option are also available. The Endurance design allows the sensor to closely track the process temperature. The result is accurate temperature compensated conductivity measurements. Versatile Mounting Configurations: Screw-In Or Insertion. Model 400 sensors with 0.01/cm, 0.1/cm, and 1.0/cm cell constants have 316 stainless steel 3/4-inch MNPT process connections. The Model 401 graphite electrode sensors have Kynar 3 fittings. The Model has a 3/4-inch MNPT connection, and the Model has a 1-inch MNPT connection. Retractable or Ball Valve. The Model 402 retractable sensor fits through a standard 1-1/4-inch NPT full port ball valve. The retraction assembly fits any like-size valve. Sanitary Flange. The Model 403 sensor has an integral 1-1/2-inch or 2-inch sanitary flange compatible with Tri-Clover 4 sanitary process connections. Flow-Through. These low flow, fast response sensors have 3/8-inch compression fittings for tubing, 3/8-inch barbed fittings for soft plastic tubing, or 1/4-inch FNPT connections. Endurance conductivity sensors are designed with your plant, your process, and your convenience in mind. 1 This feature is available when used with Rosemount Analytical Models 81C, 3081C, 1054B DC, 1054B LC, and 1054B R. 2 Kel-F is a registered trademark of 3M. 3 Kynar is a registered trademark of Elf Atochem North America, Inc. 4 Tri-Clover is a registered trademark of Jensen, Inc. 1

6 MODEL 400 Series SECTION 1.0 DESCRIPTION AND SPECIFICATIONS 1.2 SENSOR SELECTION GUIDE Model 400 Conductivity Sensors Model 400 insertion/ screw-in sensors are available in cell constants of 0.01/cm, 0.1/cm, and 1.0/cm. The sensors are ideal for monitoring the concentration of dissolved solids in cooling water and, with proper reduction of temperature and pressure, measuring dissolved solids in boiler and boiler feedwater. Model 400 sensors can also be used to monitor the performance of reverse osmosis and ion exchange demineralizers. Model 401Conductivity Sensors The Model 401 insertion/ screw-in sensors have graphite electrodes and are intended for measuring solutions having high conductivity ( ,000 µs/cm). A 10/cm two-electrode sensor (Model ) and a 0.85/cm four-electrode sensor (Model ) are available. The four-electrode sensor can be used only with the four-electrode Solu Comp analyzer. Model 402 Retractable Conductivity Sensors The Model 402 retractable sensor and retraction assembly are ideal for use under pressure, eliminating the need for process shut down to install and remove the sensor for maintenance and replacement. The Model 402 features a long stainless steel sensor tube to accommodate insertion depths from 2.34 inches to 5.34 inches. An optional junction box at the end of the tube makes replacing the sensor easy and gives the operator more control while inserting or retracting the sensor under pressure. The maximum retraction pressure is 64 psig (542 kpa). Two stainless steel retraction assembly kits are available. Use PN with Models /12/13, and use PN with Model The retraction kits differ only in the length of the packing adapter. The kits consist of a 1-1/4 in. full port ball valve, a 1-1/4 in. MNPT process connection, a packing adapter with graphite packing rings, and a clamp to position the sensor at the desired insertion depth. Model 403 Sanitary Flange Conductivity Sensors The Model 403 sanitary sensors are designed for use primarily in the pharmaceutical and the food and beverage industries. The sensors are compatible with Tri-Clover sanitary process connections, and two sanitary flange sizes are available (1-1/2 inch and 2 inch). In addition, the Model /12/13 sensors are suitable for steam sterilization up to 275 F (135 C). Model 404 Flow-Through Conductivity Sensors The Model 404 low flow sensors have small holdup volumes to ensure fast response to rapidly changing process conductivity. Low flow sensors are available in 303 stainless steel and PVC. In both sensors the outer electrode is incorporated into the body of the flow cell. Therefore, the sensor and flow cell must be calibrated as a unit. The stainless steel models can be disassembled for cleaning. The PVC models cannot be taken apart. 2

7 MODEL 400 Series SECTION 1.0 DESCRIPTION AND SPECIFICATIONS SENSOR SPECIFICATIONS SPECIFICATIONS MODEL 400 MODEL 401 MODEL 402 MODEL 403 MODEL 404 Cell Constants 0.01/cm, 0.1/cm, 1.0/cm 10.0/cm, 0.01/cm, 0.1/cm, 0.01/cm, 0.1/cm, 0.01/cm, 0.1/cm 0.85/cm (4 electrode type) 1.0/cm, 10.0/cm 1.0/cm, 10.0/cm Type of Installation Insertion (screw-in) Insertion (screw-in) Retractable (hot tap) Sanitary Flanges Flow-Through (low flow) Temperature Range C ( F) C ( F) C ( F) -11,-12,-13: C -16: 0-60 C ( F) *-60: C ( F), sterilizable up -17: C ( F) ( F) to 135 C (275 F) -14: C ( F) Maximum 250 psig (1825 kpa) 200 psig (1481 kpa) 200 psig (1481 kpa) 250 psig (1825 kpa) -16: 100 psig (791 kpa) Pressure maximum retraction at 77 F (25 C) pressure: 64 psig (542 kpa) 20 psig (239 kpa) at 140 F (60 C) -17: 100 psig (791 kpa) Wetted Materials Titanium, 316 SST, Graphite, Kynar, -11,-12,-13: Titanium, -11,-12,-13: Titanium, -16: Titanium, PEEK, PVC, PEEK,EPDM Epoxy, EPDM 316 SST, PEEK, 316 SST, Kel-F (Neoflon), EPDM, polyethylene, EPDM, Graphite, Neoprene EPDM (all FDA compliant) -17: Titanium, 303 SST, -14: Graphite, 316 SST, -14: Graphite, 316 SST, PEEK, EPDM Epoxy, EPDM, Neoprene Epoxy, EPDM Integral Cable 10 ft (3.1 m) standard 10 ft (3.1 m) standard 10 ft (3.1 m) standard 10 ft (3.1 m) standard 10 ft (3.1 m) standard *optional 50 ft (15.2 m) *optional 50 ft (15.2 m) *Extensions available *optional 50 ft (15.2 m) *optional 50 ft (15.2 m) w/junction box option -60,-61 Process 3/4 inch MNPT -14 3/4 inch MNPT 1-1/4 inch NPT /2 inch Sanitary Flange 3/8 inch barbed for Connections inch MNPT full port ball valve inch Sanitary Flange plastic tubing or 1/4 in. pipe connection Sensor & Instrument Selection Guidelines CELL CONSTANT B LC.02 to 20 µs/cm 1054B R.02 to 20 µs/cm 0.2 to 200 µs/cm 2.0 to 2000 µs/cm 200 to 20,000 µs/cm 1054B DC.02 to 20 µs/cm 0.2 to 200 µs/cm 2.0 to 2000 µs/cm 20 to 20,000 µs/cm 1054B C 1.0 to 200 µs/cm 2.0 to 2000 µs/cm 20 to 20,000 µs/cm 200 to 200,000 µs/cm 54C 1.0 to 200 µs/cm 2.0 to 2000 µs/cm 20 to 20,000 µs/cm 200 to 100,000 µs/cm 1181C 1.0 to 200 µs/cm 2.0 to 2000 µs/cm 20 to 20,000 µs/cm 200 to 200,000 µs/cm 2081C 1.0 to 200 µs/cm 2.0 to 2000 µs/cm 20 to 20,000 µs/cm 200 to 200,000 µs/cm 3081C/81C.02 to 200 µs/cm 2.0 to 2000 µs/cm 200 to 20,000 µs/cm NOTE: Ranges are stated in absolute conductivity at 25 C. 3

8 MODEL 400 Series SECTION 1.0 DESCRIPTION AND SPECIFICATIONS 1.3 ORDERING INFORMATION AND ACCESSORIES Model 400 Screw-in Conductivity Sensors have titanium electrodes and a 316 stainless steel 3/4-inch MNPT process connection. Maximum temperature for the standard sensor is 221 F (105 C). For temperatures up to 392 F (200 C) a sensor-mounted junction box (option 60) must be used. A Pt 1000 RTD and an integral 10-ft (3.1 m) cable are standard. A 50-ft (15.2 m) cable is available as an option. Consult the factory for cable lengths greater than 50 ft (15.2 m). The base 400 sensor is compatible with the Solu Comp, 1054B LC, 1054B R, 1054B DC, 54C, 81C, and 3081C instruments and can be made compatible with other instruments by using code -54, -55, or -56 options. MODEL 400 SCREW-IN CONDUCTIVITY SENSOR CODE Cell Constant (required selection) /cm /cm /cm CODE Temperature Compensation (optional selection) 54 For 1054C, 1054AC, 1054BC, 2054C, and 2081C (Pt100 RTD) 55 For 1181C -08 or -10 (10K ohm TC) 56 For 1181C -09 (100K ohm TC) CODE Additional Options (optional selection) 36 Extended insertion length (5.5 in. from bottom of threads to tip of sensor) 50 Integral 50 ft (15.2 m) cable length (not available with option 60) 60 Junction Box for high temperature and special general purpose applications* EXAMPLE * NOTE: The junction box option requires cable to be purchased as a separate item. Use part number (unprepped) or (prepped) and specify cable length. Consult factory when ordering cable lengths greater than 50 ft (15.2 m). Model 401 Screw-in High Cell Constant Conductivity Sensors have graphite electrodes and Kynar process connections. The sensors are intended for the determination of conductivity in the range 500 to 200,000 µs/cm. Maximum temperature is 212 F (100 C). A Pt1000 RTD and an integral 10-ft cable are standard. For option 15 (only), a 50-ft cable is available. For longer cable lengths, consult the factory. The base sensor is compatible with the Solu Comp, 1054B R, 1054B DC, 54C, 81C, and 3081C instruments and can be made compatible with other instruments by using -54 and -55 options. The is only available for use with the Solu Comp SCL-200 or SCL-220. MODEL 401 SCREW-IN CONDUCTIVITY SENSOR WITH GRAPHITE ELECTRODES CODE Cell Constant (required selection) /cm, 3/4-in. MNPT process connection /cm four electrode-solu Comp SCL-200 or SCL-220 (not available with code 54 and 55), 1-in. MNPT process connection CODE Temperature Compensation (optional selection) [not available with option 15] 54 For 1054C, 1054AC, 1054BC, 2054C, and 2081C (Pt100 RTD) 55 For 1181C -08 or -10 (10K TC) CODE Additional Options (optional selection) [not available with option 14] 36 Extended insertion length (6.0 in. from bottom of threads to tip of sensor) 50 Integral 50 ft (15.2 m) cable length EXAMPLE 4

9 MODEL 400 Series SECTION 1.0 DESCRIPTION AND SPECIFICATIONS Model 402 Retractable Conductivity Sensors feature titanium or graphite electrodes, a 316 stainless steel sensor tube, and 10 ft of integral cable or an optional 4-in. cable for use with a junction box (option -61). The maximum temperature rating for the Model 402 is 212 F (100 C), and the maximum pressure is 200 psig (1480 kpa). Pt 1000 RTD is the standard thermocompensation used. Optional TCs are also available for compatibility with other instruments. The base 402 sensor is compatible with the Solu Comp, 1054B LC, 1054B R, 1054B DC, 54C, 81C, and 3081C instruments. MODEL 402 RETRACTABLE CONDUCTIVITY SENSORS CODE Cell Constant (required selection) /cm /cm /cm /cm CODE Temperature Compensation (optional selection) 54 For 1054C, 1054AC, 1054BC, 2054C, and 2081C (Pt 100 RTD) 55 For 1181C -08 or -10 (10K ohm TC) CODE Additional Options (optional selection) 31 Retraction, 1-1/4 in. full port, 316 SST valve kit (for options -11, -12, -13 only) 32 Retraction, 1-1/4 in. full port, 316 SST valve kit (for option -14 only) 60 Sensor Head Junction Box 61 Sensor cable prepped for junction box EXAMPLE Interconnect cable must be ordered separately when ordering the sensor with a junction box. Use PN (unprepped) or PN (prepped). For maximum cable length, consult the factory. Model 403 Sanitary Flange Sensors are supplied with 1-1/2 inch or 2 inch stainless steel sanitary process connections. Models /12/13 have a maximum temperature rating of 221 F (105 C) and are suitable for sterilization up to 275 F (135 C). The Model has a maximum temperature rating of 212 F (100 C). Maximum pressure rating for all models is 250 psig (1825 kpa). The standard Model 403 sensor has a Pt 1000 RTD and a 10 ft (3.1 m) integral cable. An optional 50 ft (15.2 m) cable is also available. For cable lengths greater than 50 ft (15.2 m), consult the factory. The base Model 403 sensor features a Pt 1000 RTD for compatibility with the Solu Comp, 1054B LC, 1054B R, 1054B DC, 54C, 81C, and 3081C instruments. Optional temperature compensation is also available for compatibility with other instruments. MODEL 403 SANITARY CONDUCTIVITY SENSORS CODE Cell Constant (required selection) /cm /cm /cm /cm CODE Sanitary Fitting (required selection) /2 in. Stainless Steel Sanitary Fitting 21 2 in. Stainless Steel Sanitary Fitting (not available with codes 13 and 14) CODE Temperature Compensation (optional selection) 54 For 1054C, 1054A C, 1054B C, 2081C, and 2054C (Pt 100 RTD) CODE Additional Options (optional selection) 36 Extended insertion length (6.0 in. from inside face of flange to end of sensor) [available with option -11 only] 50 Integral 50 ft cable length EXAMPLE 5

10 MODEL 400 Series SECTION 1.0 DESCRIPTION AND SPECIFICATIONS Model 404 Flow-Through Conductivity Sensors are designed to closely track rapidly changing process conductivity. The sensors have titanium electrodes and either stainless steel or PVC flow cells. The outer electrode is incorporated into the flow cell. The stainless steel flow cell is rated for 100 psig (791 kpa) at 212 F (100 C). The PVC flow cell with the barbed fittings removed is rated for 20 psig (239 kpa) at 140 F (60 C) and 100 psig (791 kpa) at 77 F (25 C). Standard cable length is 10 ft (3.1 m). Optional cable length is 50 ft (15.2 m). For extended cable lengths, consult the factory. The base Model 404 sensor features a Pt 1000 RTD for compatibility with the Solu Comp, 1054B LC, 1054B R, 1054B DC, 54C, 81C, and 3081C instruments. Optional temperature compensation is also available for use with other instruments. MODEL 404 FLOW CELL CONDUCTIVITY SENSORS CODE Cell constant (required selection) /cm /cm CODE Flow Cell Type (required selection) 16 PVC 17 Stainless Steel CODE Temperature Compensation (optional selection) 54 For 1054C, 1054A C, 1054B C, 2081C, and 2054C (Pt 100 RTD) CODE Additional Options (optional selection) 50 Integral 50 ft cable length EXAMPLE ACCESSORIES PART NUMBER DESCRIPTION Connecting cable (unprepped), specify length Connecting cable (prepped), specify length Extension cable for four-electrode sensor (401-15) Cable extension junction box Conductivity standard 2,000 µs/cm, 16 oz (0.47 liter) SS-6 Conductivity standard 200 µs/cm, 1 qt (0.95 liter) SS-6A Conductivity standard 200 µs/cm, 1 gal (3.78 liter) Retraction assembly kit with 1-1/4 in. NPT ball valve for use with Models /12/ Retraction assembly kit with 1-1/4 in. NPT ball valve for use with Model Packing adapter subassembly with 4.55-in. adapter for Models /12/13 (excludes ball valve and close nipple, see figure on page 10) Packing adapter subassembly with 5.66-in. adapter for Models (excludes ball valve and close nipple, see Figure 2-3) /4 in. NPT full port ball valve, 316 stainless steel Packing rings (replacement item for kit PN /01 and PN /01) 6

11 MODEL 400 Series SECTION 1.0 DESCRIPTION AND SPECIFICATIONS 1.4 WEIGHTS AND SHIPPING WEIGHTS TABLE 1-1. Weights and Shipping Weights for Endurance Sensors [Fractional weights are rounded up to whole pound values] MODEL WITH 10 ft. CABLE WITH 50 ft. CABLE WITH JUNCTION BOX Weight Shipping Weight Weight Shipping Weight Weight Shipping Weight lb (0.5 kg) 2 lb (0.9 kg) 4 lb (1.8 kg) 5 lb (2.3 kg) 3 lb (1.4 kg) 4 lb (1.8 kg) lb (0.5 kg) 2 lb (0.9 kg) lb (0.5 kg) 2 lb (0.9 kg) 4 lb (1.8 kg) 5 lb (2.3 kg) lb (1.4 kg) 4 lb (1.8 kg) 5 lb (2.3 kg) 6 lb (2.7 kg) 4 lb (1.8 kg) 5 lb (2.3 kg) lb (0.9 kg) 3 lb (1.4 kg) 4 lb (1.8 kg) 5 lb (2.3 kg) (PVC) 2 lb (0.9 kg) 3 lb (1.4 kg) 4 lb (1.8 kg) 5 lb (2.3 kg) (SS) 4 lb (1.8 kg) 5 lb (2.3 kg) 6 lb (2.7 kg) 7 lb (3.2 kg) NOTE: Connecting cable (P/N or ) weighs 0.6 lb / 10 ft (0.3 kg / 3.1 m). Extended insertion length (option -36) does not change weight or shipping weight. TABLE 1-2. Weights and Shipping Weights for Accessories [Fractional weights are rounded up to whole pound values] Part Number Description Weight Shipping Weight Retraction assembly kit for /12/13 8 lb (3.6 kg) 9 lb (4.1 kg) Retraction assembly kit for lb (3.6 kg) 9 lb (4.1 kg) Packing adapter subassembly for /12/13 4 lb (1.8 kg) 5 lb (2.3 kg) Packing adapter subassembly for lb (1.8 kg) 5 lb (2.3 kg) Cable connecting junction box 2 lb (0.9 kg) 3 lb (1.4 kg) /4 inch ball valve 4 lb (1.8 kg) 5 lb (2.3 kg) Packing rings 1 lb (0.5 kg) 1 lb (0.5 kg) Conductivity standard 2,000 us/cm, 16 oz 2 lb (0.9 kg) 3 lb (1.4 kg) SS-6 Conductivity standard 200 us/cm, 1 qt 3 lb (1.4 kg) 4 lb (1.8 kg) SS-6A Conductivity standard 200 us/cm, 1 gal 9 lb (4.1 kg) 10 lb (4.5 kg) 7

12 MODEL 400 Series SECTION 2.0 INSTALLATION SECTION 2.0. INSTALLATION 2.1 UNPACKING AND INSPECTION 2.2 SENSOR DIMENSIONS 2.3 INSTALLATION 2.1. UNPACKING AND INSPECTION Inspect the shipping container for damage. If damage is found, contact the carrier immediately. Inspect the sensor. Make sure all items on the packing list are present and in good condition. Notify the factory if parts are missing. NOTE Save the original packing carton and materials. Most carriers require proof of damage from mishandling. Use the original packing carton when returning the sensor to the factory. Refer to Section 6.0 for instructions SENSOR DIMENSIONS Refer to Table 2-1 to find the dimensional drawing for each model. TABLE 2-1. Dimensional Drawings Model Description Dimensional Drawing 400 Screw-in sensor Figure Screw-in sensor (high conductivity) Figure Retractable sensor (integral cable) Figure Retractable sensor (sensor-mounted junction box) Figure Sanitary flange sensor Figure Low flow sensor (PVC body) Figure Low flow sensor (stainless steel body) Figure 2-7 8

13 MODEL 400 Series SECTION 2.0 INSTALLATION MILLIMETER INCH E FIGURE 2-1. Dimensions of Endurance Model 400 Sensor MILLIMETER INCH B FIGURE 2-2. Dimensions of Endurance Model 401 Sensor 9

14 MODEL 400 Series SECTION 2.0 INSTALLATION MILLIMETER INCH B FIGURE 2-3. Dimensions of Endurance Model 402 Sensor with Integral Cable and Optional Ball Valve MILLIMETER INCH 11/12/ E FIGURE 2-4. Dimensions of Endurance Model 402 Sensor with Junction Box (option -60) and Optional Ball Valve 10

15 MODEL 400 Series SECTION 2.0 INSTALLATION MILLIMETER INCH FIGURE 2-5. Dimensions of Endurance Model 403 Sensor D MILLIMETER INCH MILLIMETER INCH A FIGURE 2-7. Dimensions of Endurance Model Flow Cell (PVC) FIGURE 2-8. Dimensions of Endurance Model Flow Cell (Stainless Steel) A 11

16 MODEL 400 Series SECTION 2.0 INSTALLATION 2.3. INSTALLATION General Guidelines. Most conductivity measurement problems can be traced to an improperly installed sensor. Endurance conductivity sensors are designed and calibrated for use under the following conditions: 1. Electrodes are completely immersed in the electrolyte solution. Vents are covered and no air bubbles are present. 2. Clearance between the electrodes and piping is at least 1/4 in. on all sides. 3. Process temperature and pressure are within sensor specifications. Choose the mounting location with care. 1. Select a location where the sample is representative of the process. 2. Avoid dead ends or pipe stubs or any locations where circulation may be poor. 3. Ensure that the stream velocity at the point of installation is not so great as to distort or damage the sensor. 4. Where the stream velocity is low, mount the sensor so that the flow enters the end of the sensor and leaves through the vents in the side. This gives the greatest exchange of FIGURE 2-8. Sensor Orientation solution and the fastest response to conductivity changes. To prevent interference from trapped air 5. Orient Model 400, 401, 402, and 403 sensors as shown in or sludge, install the sensors in a horizontal orientation. Figure Mount the sensor so that the liquid contacts the sensor to the pipe threads (Models 400 and 401), the guard (Model 402), or the sanitary flange (Model 403). Table 2-2, below, shows where to find installation instructions for each model. TABLE 2-2. Installation Instructions Model Description Section 400 Screw-in sensor Screw-in sensor (high conductivity) Retractable sensor Sanitary flange sensor Flow cell sensor

17 MODEL 400 Series SECTION 2.0 INSTALLATION Model 400 Screw in/insertion Sensor Installation. Coat the stainless steel threads on the Model 400 sensor with a suitable pipe compound or wrap the threads with pipe tape to seal the connection. Mount the conductivity sensor in line by screwing it into a 3/4-inch NPT female pipe fitting using a parallel jaw wrench. Do not overtighten. Support the cable to reduce strain and minimize the danger of the cable becoming snagged and pulled away from the sensor. See Figure 2-9, Figure 2-10, and Figure 2-11 for examples of sensor installation Model 401 Screw in/insertion Sensor Installation. The Model has a 3/4-inch MNPT Kynar process fitting and Model has a 1-inch MNPT Kynar process fitting. Use the procedure described above to install the Model 401 sensors. Do not overtighten. FIGURE 2-9. Large Pipe or Tank Installation The Endurance Sensor can be screwed into a weldalet in either a large pipe or tank A FIGURE Standard Tee Installation For best performance, orient the sensor with the end facing the liquid flow A A FIGURE /4 Inch Tee Installation 0.1/cm and 1.0/cm sensors can be inserted directly into the branch of a 3/4-inch tee. 13

18 MODEL 400 Series SECTION 2.0 INSTALLATION Model 402 Retractable Sensor Installation and Retraction. Retraction assembly kit PN /01 is used with retractable sensors, such as the Model 402 conductivity sensor. When properly installed, the kit allows for removal of a sensor from a pressurized process for inspection, cleaning, or replacement. The kit should be used within the temperature and pressure limits of the sensor. WARNING Pressurized Sensor. Can cause severe impact or spray injury. Provide adequate working area for retraction. Carefully restrain sensor during removal. See safety information. Follow procedures in manual D FIGURE Model 402 Sensor with Retraction Assembly Kit - PN /01 Installation of Model 402 Sensor with Retraction Assembly Kit (PN /01) Retraction assembly kit PN /01 includes items 1-7, shown in Figure 2-12, plus a hex L-key (PN ) and pipe tape (PN ). Model /12/13 sensors require kit PN ; Model sensors require kit PN , due to the longer sensing element. The sensor assembly includes items Wear a face shield and brace yourself in case the pressure forces the sensor tube (9) out of the ball valve (2). 1. Make sure that the system is shut down and that there is no residual process pressure. IMPORTANT! Do not remove or alter the guard (10) on the sensor tube (9). 2. Attach the ball valve (2) to the system with the 1-1/4-inch FNPT port at the front of the valve or with the 1-1/4 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 (64 psig) before proceeding. If the system will not be restarted until after the sensor installation, leave the valve in the open position. 14

19 MODEL 400 Series SECTION 2.0 INSTALLATION 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 2-13 to install the sensor with 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 inside the packing adapter (3). If it is difficult to slide the sensor through the packing rings, loosen the packing bushing (6) with a crescent wrench. 7. Position the clamp (4) on the sensor tube (9) so that the electrodes (11) will be immersed in the process when the sensor is fully inserted through the ball valve. See Figure Use the hex L-key (PN ) to secure the clamp to the sensor tube. 8. Slide the retainer (5) onto the sensor tube (9). 9. Thread the junction box (8) hand tight onto the sensor tube (9). DO NOT OVERTIGHTEN, for it could damage the threads. Use 2-3 wraps of pipe tape on the tube threads if a NEMA 4 seal is required at the junction box. For Models /12/13, check for continuity (<0.5 Ω) between the outer electrode and the junction box. 10. Apply pipe tape to the packing adapter (3) threads and connect it to the back end of 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. The ball valve (2) can now be opened. 13. There may be some process leakage around the packing bushing (6). Tighten the packing bushing to eliminate process leakage. Use the junction box (8) or sensor rear to push the sensor through the valve and into the process until the clamp (4) rests against the packing bushing. 14. Thread the retainer (5) onto the back of the packing adapter (3) to secure the sensor tube (9) in place. If the sensor tube retracts when the system pressure is increased, reduce the pressure to 542 kpa (64 psig) or less, remove the retainer (5), and tighten the screw in the clamp (4). The retractable sensor can be installed into a large pipe, trunk of a pipe tee, or a tank (see Figure 2-15 and Figure 2-16) C FIGURE Model 402 Sensor Installation 15

20 MODEL 400 Series SECTION 2.0 INSTALLATION Retraction of Model 402 Sensor (refer to Figure 2-14) 1. Make sure the system pressure is at or below 542 kpa (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 L-key (PN ). Pull the clamp back and slowly loosen the packing bushing (6) in 1/8-turn increments. The sensor tube may extend due to system pressure. If it does 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 Slide the handle lock up on the valve handle and close the ball valve (2). NOTE 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 C FIGURE Model 402 Sensor in Retracted Position 16

21 MODEL 400 Series SECTION 2.0 INSTALLATION FIGURE Model 402 Retractable Sensor Installed In a Large Pipe or Tank The Endurance Retractable Sensor can be attached using a weldalet in either a large pipe or tank C C FIGURE Model 402 Retractable Sensor Installed In a Standard Tee For best performance, orient the sensor with the open end facing the liquid flow. 17

22 MODEL 400 Series SECTION 2.0 INSTALLATION Model 403 Sanitary Sensor Installation. The sensors fit Tri Clover sanitary process connections. A clamp presses the sensor and process flanges together and a gasket creates a seal. Sensors are available with integral 1-1/2 or 2 inch flanges. See Figure 2-17 and Figure 2-18 for installation details B CLOVER FIGURE Sanitary Sensor Installation - Side View Secure the sanitary sensor with a Tri Clover clamp. CLOVER FIGURE Sanitary Sensor Installation - End View For best results, the branch containing the sensor must be completely flooded with the liquid being measured B 18

23 MODEL 400 Series SECTION 2.0 INSTALLATION Model 404 Low Flow Cell Installation. PVC Flow Cell (-16). The PVC flow cell is provided with 1/4 inch FNPT inlet and outlet fittings and hose barb fittings that accept 3/8-inch ID soft plastic tubing. See Figure 2-19 for dimensions. Stainless Steel Flow Cell (-17). The stainless steel flow cell has 1/4-inch FNPT process connections and 3/8- inch compression fittings. The flow cell is suitable for direct insertion into sample lines. If a connection to soft plastic tubing is desired, the compression fitting can be removed and replaced with a 1/4-inch MNPT hose barb fitting. See Figure 2-20 for dimensions. MILLIMETER INCH MILLIMETER INCH A A FIGURE PVC Flow Cells FIGURE Stainless Steel Flow Cells 19

24 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION SECTION 3.0. WIRING DIAGRAMS AND CABLE PREPARATION 3.1 GENERAL INFORMATION 3.2 CONNECTING THE SENSOR DIRECTLY TO THE ANALYZER OR TRANSMITTER 3.3 CONNECTING THE SENSOR TO THE ANALYZER OR TRANSMITTER THROUGH A REMOTE JUNCTION BOX 3.4 PREPARING UNPREPPED CABLE FOR USE 3.1. GENERAL INFORMATION The cable for Endurance Models 400, , 402, 403, and 404 sensors contains five conductors. Two leads are connected to the electrodes, and each electrode lead is shielded. The remaining three conductors are connected to the temperature sensor and are surrounded by a third shield. The entire cable is enclosed in a metallic braided shield. The cable design provides electronic shielding and reduces errors caused by lead capacitance. The cable for the Model (four-electrode cell) contains eight conductors. Four leads are connected to the electrodes, and four leads are connected to the RTD. Endurance conductivity sensors have either an integral cable or a sensor-mounted junction box. For sensors having integral cable, the cable is ready to connect to the analyzer or transmitter. If a sensor-mounted junction box is being used, the cable is separate and must be connected to the sensor as well as to the analyzer. Both prepped and unprepped cable are available. Prepped cable PN Unprepped cable PN Prepped cable is terminated as shown in Figure 3-1. The use of factory-prepped cable is strongly recommended. To prepare unprepped cable (PN ), see the instructions in Figure FIGURE 3-1. Prepped Cable for all Endurance Sensors Except Model A

25 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION In the wiring diagrams (Figures 3-2 through 3-17), sensor lead wires are identified by color. Table 3-1 lists the color and the function of each wire. The wiring diagrams show the name given to each terminal in the instrument and the color of the sensor wire to attach to it. In many cases, the terminal designation does not match the wire name. TABLE 3-1. Cable: Colors and Functions of Wires for all Endurance Sensors except NAME COLOR FUNCTION Drive Gray Connects to outer electrode Drive Common Clear Shield for gray drive lead Receive Orange Connects to inner electrode Receive Common Clear Shield for orange receive lead RTD In Red RTD in RTD Sense White with red stripe RTD RTD sense RTD Return White RTD return RTD Shield Clear Shield for all RTD lead wires Notes: 1. For 1181C-compatible sensors, the RTD is replaced with a thermistor. The red and white wires are connected to the thermistor. The red and white striped wire is not used. 2. The RTD sense and return leads are common. The three-wire configuration allows the analyzer to compensate for the resistance of the lead wires and for changes in the resistance of the leads with temperature CONNECTING THE SENSOR DIRECTLY TO THE ANALYZER OR TRANSMITTER Select the appropriate wiring diagram from Table 3-2. For sensors with sensor-mounted junction box, see also Figures 3-15 and TABLE 3-2. Wiring Diagrams for Model 400, 401, 402, 403, and 404 sensors Model Wiring Diagram Two-Wire Transmitters 1181C Figure C Figure C Figure C Figure 3-5 Four-Wire Analyzers 1054C Figure A C Figure B C Figure B LC Figure B DC Figure B R Figure C Figure C Figure 3-11 Solu Comp (SCL) - SCL 005 Figure SCL 008 Figure SCL 401 Figure SCL 200/220 (401-15) Figure 3-13 Solu Meter Figure

26 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION FIGURE 3-2. Wiring Diagram for Model 1181C B FIGURE 3-3. Wiring Diagram for Model 2081C B FIGURE 3-4. Wiring Diagram for Model 81C 22

27 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION 1. SEE FIGURE 3-4 FOR TERMINAL DESIGNATIONS. 2. JUMPER SUPPLIED BY CUSTOMER. FIGURE 3-5. Wiring Diagram for Model 3081C C FIGURE 3-6. Wiring Diagram for Model 1054C FIGURE 3-7. Wiring Diagram for Models 1054A C and 2054C A B FIGURE 3-8. Wiring Diagram for Model 1054B C 23

28 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION FIGURE 3-9. Wiring Diagram 1054B LC B The Model 1054B LC analyzer is designed to measure the conductivity of high purity water. Attaching the inner electrode shield to terminal 5 causes a voltage to be applied to the shield. The applied voltage reduces cable capacitance and allows for a more accurate signal transfer. 24 FIGURE Wiring Diagram for Models 1054B DC and 1054B R B

29 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION B FIGURE Wiring Diagram for Model 54C A CABLE MODIFICATION INSTRUCTIONS 1. Use the orange, red, white, and gray wires. For the -005, -008, and -401 analyzers, connect the shield for the inner electrode (orange wire) only when the cable length exceeds 50 ft. 2. Cut away the white/red wire and the unused shields from the sensor cable and from both ends of the extension cable before wiring the sensor to the analyzer. FIGURE Cable Preparation and Wiring Diagram for Solu Comp 25

30 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION FIGURE Wiring Diagram for Model (Four Electrode) Sensor The blue and green RTD wires are common, and the red and orange RTD wires are common. The yellow and white wires connect to one electrode pair. The brown and black cell wires connect to the other electrode pair A A FIGURE Wiring Diagram for the Solu Meter The instrument terminals are identified by color; however, the colors of the sensor leads do not match the colors on the instrument. 26

31 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION FIGURE Wiring a Model sensor with sensor-mounted junction box (option -60) to the connecting cable. For wiring the connecting cable to the analyzer, see Table A A FIGURE Wiring a Model 402 sensor with sensor-mounted junction box to the connecting cable. For wiring the connecting cable to the analyzer, see Table

32 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION 3.3. CONNECTING THE SENSOR TO THE ANALYZER OR TRANSMITTER THROUGH A REMOTE JUNCTION BOX The sensor can be wired to the analyzer through a remote junction box (PN ). Refer to Figure 3-17 for wiring instructions. Both prepped and unprepped connecting cable are available: Prepped cable PN Unprepped cable PN The use of factory-prepped cable is strongly recommended. To prepare unprepped cable for use, follow the instructions in Figure For maximum EMI/RFI protection, the outer braid of the sensor cable should be connected to the outer braided shield of the extension cable. At the instrument, connect the outer braid of the extension cable to earth ground. MILLIMETER INCH A FIGURE Wiring the Sensor to the Analyzer through a Remote Junction Box 28

33 MODEL 400 Series SECTION 3.0 WIRING DIAGRAMS AND CABLE PREPARATION 3.4. PREPARING UNPREPPED CABLE FOR USE Figure 3-18 shows how to prepare unprepped cable (PN ) for use A FIGURE Model 400 Series Cable Preparation (Part Number ) 29

34 MODEL 400 Series SECTION 4.0 CALIBRATION SECTION 4.0 CALIBRATION 4.1 GENERAL 4.2 CELL CONSTANT AND CALIBRATION CONSTANT 4.3 TRUE CELL CONSTANT 4.4 EXPERIMENTAL DETERMINATION OF CELL CONSTANT 4.1. GENERAL Refer to the analyzer or transmitter manual for detailed start-up and calibration information. In general, Endurance conductivity sensors are ready to use. Simply install the sensor, wire it to the analyzer or transmitter, and apply power. Enter the cell constant or the cell constant and calibration constant, and the instrument/sensor loop is ready CELL CONSTANT AND CALIBRATION CONSTANT Endurance conductivity sensors with a Pt 100 or Pt 1000 RTD have a nominal cell constant and a calibration constant printed on a label attached to the sensor cable. The calibration constant, when entered into the analyzer or transmitter, permits a more accurate determination of conductivity. For all models except the , the calibration constant is between 450 and 550. The calibration constant is used with the Solu Comp, 1054A C, 1054B (C, LC, DC, and R), 3081C, and 81C instruments TRUE CELL CONSTANT To calculate the true cell constant from the nominal cell constant and the calibration constant, use the following equation: K = N ( C ) 1000 where K is the true cell constant, N is the nominal cell constant, and C is the calibration constant. For example, if the nominal cell constant is 0.1/cm and the calibration constant is 485, the true cell constant is (0.1)( )/1000 or The true cell constant is used with the 54C analyzer EXPERIMENTAL DETERMINATION OF CELL CONSTANT Endurance conductivity sensors can also be calibrated using a solution of known conductivity or by comparison with an accurate reference instrument. Refer to the analyzer instruction manual for details. In the Model and flow-through sensors, the outer electrode is incorporated into the body of the flow cell. To calibrate these sensors with a standard solution, do the following: 1. Isolate or remove the sensor from the process stream. 2. Rinse the inside of the flow cell thoroughly with water followed by the standard solution. 3. Fill the flow cell with standard and measure the conductivity. The standard solution can also be circulated through the flow cell. 30

35 MODEL 400 Series SECTION 5.0 MAINTENANCE AND TROUBLESHOOTING 5.1. INSPECTION SECTION 5.0 MAINTENANCE AND TROUBLESHOOTING 5.1 INSPECTION 5.2 CLEANING 5.3 TROUBLESHOOTING CAUTION BEFORE REMOVING THE SENSOR, be absolutely certain the process pressure is reduced to 0 psig and the process temperature is at a safe level! Inspect in-service conductivity sensors regularly. Conditions of service and the magnitude of the conductances being measured will determine the frequency of inspection. In general the more conductive the liquid and the higher the level of suspended solids, the more often inspection is required. Any unusual behavior, not attributable to known variations in the process, should be taken as an indication that the sensor requires maintenance. Periodic inspection should answer the following questions: 1. Are there cracks or chips in the sensors or any signs of wear? 2. Are the flow holes free from obstruction? 3. Is there indication that excessive stream velocities have caused erosion or changes in the position of the electrodes? 4. Do the electrodes show signs of corrosion or deterioration? 5. For all models except , is the leakage resistance of the dry electrodes (measured between the orange and gray leads) at least 50 megohms? 6. For all models except , does the resistance of the temperature compensator (red & white leads only) match the temperature vs. resistance values in Table 5-1 and Table For the Model , does the leakage resistance of the dry electrodes (brown and yellow leads) exceed 50 megohms, and does the resistance of the RTD (orange and green leads) match the values in Table 5-2? NOTE The Model (flow-through sensor with PVC body) CANNOT be disassembled for inspection. TABLE K and 100K Thermistor Resistance Values 10K Ω Thermistor 1 100K Ω Thermistor 1 TEMP ( C) RESISTANCE (Ω) TEMP ( C) RESISTANCE (Ω) TEMP ( C) RESISTANCE (Ω) TEMP ( C) RESISTANCE (Ω) K K K K K K K K K K K K K K K K K K K K K K 1 Sensors with thermistors are compatible with the Model 1181C. A 10 K thermistor is used with standard sensors. A 100 K thermistor is used with high temperature sensors (option 60). 31

36 MODEL 400 Series SECTION 5.0 MAINTENANCE AND TROUBLESHOOTING TABLE 5-2. Pt 100 and Pt 1000 RTD Resistance Values Pt 100 RTD 1 Temperature ( C) Resistance (Ω) Pt 100 is used with Models 1054C, 1054A C, 1054B C, 2054C, and 2081C. Pt 1000 RTD Temperature ( C) Resistance (Ω) Pt 1000 is used with Solu-Comp, 1054B R, 1054B DC, 1054B LC, 54C, 3081C, and 81C CLEANING CAUTION BEFORE REMOVING THE SENSOR, be absolutely certain the process pressure is reduced to 0 psig and the process temperature is at a safe level! Sensors With Titanium Electrodes (all models except 401) After prolonged use, most sensors require cleaning. Sensors exposed to process streams containing oil and grease or high levels of suspended solids may need more frequent cleaning. Oil and grease can be removed with organic solvents followed by washing with warm water and detergent. Gently brushing the electrodes with a soft brush or a pipe cleaner will help remove loose scale adhering to the sensor. A warm detergent solution will also help remove solids. After cleaning, thoroughly rinse the sensor with tap water, followed by deionized water. NOTE Mechanical cleaning of conductivity cells may cause damage. Do not use sandpaper, wire brushes, sand blasters, or drills to clean conductivity cells. 32

37 MODEL 400 Series SECTION 5.0 MAINTENANCE AND TROUBLESHOOTING Harder scale is probably best removed with dilute (5%) hydrochloric acid. Prepare 5% hydrochloric acid by diluting one volume of concentrated hydrochloric acid with about seven volumes of water. CAUTION Use care when handling hydrochloric acid. Follow all recommended safety precautions. Dilution of concentrated hydrochloric acid should be done only by persons thoroughly trained in handling concentrated acids. Do not expose the sensor to dilute hydrochloric acid for longer than five minutes at room temperature. DO NOT HEAT THE ACID SOLUTION. BE CAREFUL TO KEEP HYDROCHLORIC ACID AWAY FROM THE STAINLESS STEEL PARTS OF THE SENSOR. Thoroughly rinse the sensor with water before returning it to service. Sensors, particularly after having been cleaned with hydrochloric acid, may require extensive rinsing with water before being returned to service. A combination of rinsing and soaking often works best. For low cell constant cells (0.01/cm and 0.1/cm), rinse the cell with deionized water and then soak it in deionized water for about 30 minutes. Measure the conductivity. Discard the water, replace it with fresh deionized water, and continue soaking. At the end of 30 minutes, measure the conductivity again. Continue discarding and replacing the soaking solution until the conductivity is low and constant. For higher cell constant cells (1/cm and 10/cm), use tap water in place of deionized water. After cleaning a sensor, it is good practice to check the calibration and recalibrate if necessary. Use care when handling solvents and acids to prevent serious injury to personnel Sensors With Graphite Electrodes (Model 401) Use only tap water and a soft bristle brush to clean graphite electrodes. Do not use a wire or metal brush TROUBLESHOOTING Consult the instrument or transmitter manual for explanation of diagnostic errors. Rosemount analyzers and transmitters (except the Model 1181C) have a diagnostic feature that automatically searches for fault conditions that cause errors in the measured conductivity. If more than one fault exists, the display sequences through all the diagnostic messages. Refer to Table 5-3, below, for a description of common measurement problems, probable causes, and suggested corrective actions. Note that Model (flow-through sensor with PVC) body cannot be disassembled for inspection and cleaning. TABLE 5-3. Troubleshooting Guide Problem Probable Cause Solution Off-scale readings Sensor is incorrectly wired to analyzer. Verify wiring. See Section 3.0. Temperature element in Check temperature element as instructed in Section 5.2. sensor is shorted. Replace sensor if necessary. Sensor is not in process stream Electrodes must be completely submerged in the process stream. Refer to Section 2.3 for details. Electrodes are dirty. Clean sensor. Refer to Section 5.2. Sensor is defective Perform isolation checks. See Section 5.1. Replace sensor if necessary. Noisy display Temperature element in Check temperature element as instructed in Section 5.1. sensor is shorted. Replace sensor if necessary. Sluggish response Electrodes are fouled. Inspect sensor and clean electrodes. Refer to Section 5.2 for cleaning procedures. Sensor is improperly installed Refer to Section 2.3 for installation details. in process stream. 33

38 MODEL 400 Series SECTION 6.0 RETURN OF MATERIAL SECTION 6.0 RETURN OF MATERIAL 6.1 GENERAL. To expedite the repair and return of instruments, proper communication between the customer and the factory is important. Before returning a product for repair, call for a Return Materials Authorization (RMA) number. 6.2 WARRANTY REPAIR. The following is the procedure for returning instruments still under warranty: 1. Call Rosemount Analytical for authorization. 2. To verify warranty, supply the factory sales order number or the original purchase order number. In the case of individual parts or sub-assemblies, the serial number on the unit must be supplied. 3. 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 Attn: Factory Repair RMA No. Mark the package: Returned for Repair Model No. 6.3 NON-WARRANTY REPAIR. The following is the procedure for returning for repair instruments that are no longer under warranty: 1. Call Rosemount Analytical for authorization. 2. Supply the purchase order number, and make sure to provide the name and telephone number of the individual to be contacted should additional information be needed. 3. Do Steps 3 and 4 of Section 6.2. NOTE Consult the factory for additional information regarding service or repair. 34

39 WARRANTY Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, ph electrodes, membranes, liquid junctions, electrolyte, O-rings, etc. are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and / or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, parts(s), or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and consumables for the remaining portion of the period of the twelve (12) month warranty in the case of goods and part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, parts(s) or consumables are capable of being renewed, repaired or replaced. The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage, directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty or from any other cause. All other warranties, expressed or implied are hereby excluded. IN CONSIDERATION OF THE STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STAT- ED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RETURN OF MATERIAL Material returned for repair, whether in or out of warranty, should be shipped prepaid to: Rosemount Analytical Inc. Uniloc Division 2400 Barranca Parkway Irvine, CA The shipping container should be marked: Return for Repair Model The returned material should be accompanied by a letter of transmittal which should include the following information (make a copy of the "Return of Materials Request" found on the last page of the Manual and provide the following thereon): 1. Location type of service, and length of time of service of the device. 2. Description of the faulty operation of the device and the circumstances of the failure. 3. Name and telephone number of the person to contact if there are questions about the returned material. 4. Statement as to whether warranty or non-warranty service is requested. 5. Complete shipping instructions for return of the material. Adherence to these procedures will expedite handling of the returned material and will prevent unnecessary additional charges for inspection and testing to determine the problem with the device. If the material is returned for out-of-warranty repairs, a purchase order for repairs should be enclosed.

40 $10.00 U.S. Dollars The right people, the right answers, right now. UNILOC DIVISION CUSTOMER SUPPORT CENTER ON-LINE ORDERING NOW AVAILABLE ON OUR WEB SITE Credit Cards for U.S. Purchases Only. Rosemount Analytical Inc. Uniloc Division 2400 Barranca Parkway Irvine, CA USA Tel: (949) Rosemount Analytical Inc. 1998