Models 403 and 403VP Instruction Manual PN 5100403 February 2001 ENDURANCE Conductivity Sensors Model 403 Model 403VP Sanitary Flange Sensors Sanitary Flange Sensors with Variopol Connector
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 1-800-654-7768 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 92606 USA Tel: (949) 863-1181 1-800-854-8257 www.rauniloc.com SS-SE Nov. 1992 Rosemount Analytical Inc. 2000
MODEL 403/403VP SECTION 1 SPECIFICATIONS SECTION 1. SPECIFICATIONS SENSOR SPECIFICATIONS SPECIFICATIONS MODEL 403 MODEL 403-14 MODEL 403VP MODEL 403VP-14 Cell Constants 0.01/cm, 0.1/cm, 1.0/cm 10.0/cm, 0.01/cm, 0.1/cm, 1.0/cm 10.0cm Process Connection sanitary flange (Tri-clover) sanitary flange (Tri-clover) sanitary flange (Tri-clover) sanitary flange (Tri-clover) -20: 1-1/2 in. -20: 1-1/2 in. -20: 1-1/2 in. -20: 1-1/2 in. -21: 2 in. -21: 2 in. Electrode/Insulator titanium/kel-f graphite/epoxy titanium/kel-f graphite/epoxy Other Wetted Materials 316 SS and EPDM 316 SS and EPDM 316 SS and EPDM 316 SS and EPDM Temperature Element stnd: Pt 1000 stnd: Pt 1000 stnd: Pt 1000 stnd: Pt 1000-54: Pt 100-54: Pt 100-54: Pt 100-54: Pt 100 Temperature Range 0-105 C (32-221 F) 0-100 C (32-212 F) 0-105 C (32-221 F) 0-100 C (32-212 F) Sensors tolerate steam Sensor is not suitable for Sensors tolerate steam Sensor is not suitable for sterilization up to 135 C steam sterilization sterilization up to 135 C steam sterilization (275 F) (275 F) Maximum Pressure 250 psig (1825 kpa) 250 psig (1825 kpa) 250 psig (1825 kpa) 250 psig (1825 kpa) Integral Cable Length stnd: 10 ft (3.1 m) stnd: 10 ft (3.1 m) Sensor has VP 6.0 connector. Sensor has VP 6.0 connector. -50: 50 ft (15.2 m) -50: 50 ft (15.2 m) Mating cable is available in Mating cable is available in 10 ft (3.1 m) and 50 ft (15.2 m) 10 ft (3.1 m) and 50 ft (15.2 m) lengths. lengths. NOTE: All wetted materials used in Models 403-11, -12, and -13, and Models 403VP-11, -12, and -13 are FDA-compliant. Materials used in Model 403-14 and 403VP-14 are not FDA-compliant. RECOMMENDED CELL CONSTANT AND INSTRUMENT COMBINATIONS FOR MODEL 403 AND 403VP SENSORS CELL CONSTANT 0.01/cm 0.1/cm 1.0/cm 10.0/cm 1054B 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 200 to 20,000 µs/cm 1054B C Not recommended 10 to 2000 µs/cm 50 to 20,000 µs/cm 500 to 20,000 µs/cm 1055C.02 to 20 µs/cm 0.2 to 200 µs/cm 2.0 to 2000 µs/cm 200 to 20,000 µs/cm 54e C.02 to 20 µs/cm 2.0 to 200 µs/cm 20 to 2000 µs/cm 200 to 20,000 µs/cm 1181C Not recommended 10 to 2000 µs/cm 50 to 20,000 µs/cm 500 to 200,000 µs/cm 2081C Not recommended 10 to 2000 µs/cm 50 to 20,000 µs/cm 500 to 200,000 µs/cm 3081C/81C.02 to 20 µs/cm 2.0 to 200 µs/cm 20 to 2000 µs/cm 4081C.02 to 20 µs/cm 2.0 to 200 µs/cm 20 to 2000 µs/cm 1
MODEL 403/403VP SECTION 1 SPECIFICATIONS ORDERING INFORMATION AND ACCESSORIES Model 403 Sanitary Flange Sensors: The base 403 sensor is compatible with the Solu Comp, Solu Comp II (1055C), 1054B LC, 1054B R, 1054B DC, 54e C, 81C, 3081C, and 4081C instruments and can be made compatible with other instruments by using code -54 option. MODEL 403 SANITARY FLANGE SENSOR CODE Cell Constant (required selection) 11 0.01/cm 12 0.1/cm 13 1.0/cm 14 10.0/cm CODE Sanitary Fitting (required selection) 20 1-1/2 inch Stainless steel sanitary fitting 21 2 inch Stainless steel sanitary fitting (not available with codes -13 and -14) CODE Temperature Compensation (optional selection) For 1054B LC, 1054B R, 1054B DC, 54e C, 81C, 3081C, 4081C, and 1055C (Pt 1000 RTD) 54 For 1054C, 1054A C, 1054B C, 2054C, and 2081C (Pt 100 RTD) CODE Additional Option (optional selection) 36 Extended insertion length (6 in. from inside face of flange to end of sensor, available with option -11 only) 50 Integral 50 ft (15.2 m) cable length 403 12 20 54 EXAMPLE Model 403VP Sanitary Flange Sensors: The base 403VP sensor is compatible with the Solu Comp, Solu Comp II (1055C), 1054B LC, 1054B R, 1054B DC, 54e C, 81C, 3081C, and 4081C instruments and can be made compatible with other instruments by using code -54 option. MODEL 403VP SANITARY FLANGE SENSOR CODE Cell Constant (required selection) 11 0.01/cm 12 0.1/cm 13 1.0/cm 14 10.0/cm CODE Sanitary Fitting (required selection) 20 1-1/2 inch Stainless steel sanitary fitting 21 2 inch Stainless steel sanitary fitting (not available with codes -13 and -14) CODE Temperature Compensation (optional selection) For 1054B LC, 1054B R, 1054B DC, 54e C, 81C, 3081C, 4081C, and 1055C (Pt 1000 RTD) 54 For 1054C, 1054A C, 1054B C, 2054C, and 2081C (Pt 100 RTD) CODE Additional Option (optional selection) 36 Extended insertion length (6 in. from inside face of flange to end of sensor, available with option -11 only) 403VP 12 20 54 EXAMPLE * NOTE: A Variopol (VP) connector cable must be purchased separately. See ACCESSORIES. 2
MODEL 403/403VP SECTION 1 SPECIFICATIONS ACCESSORIES PART NUMBER DESCRIPTION 23747-00 Connecting cable (terminated), for connecting junction box to analyzer. Cable does not mate with 402VP (Variopol) sensors. Specify length. 23747-02 Cable with mating Variopol connector, 10 ft (3 m) 23747-03 Cable with mating Variopol connector, 50 ft (15.2 m) 9200275 Connecting cable (unterminated), for connecting junction box to analyzer. Specify length. 23550-00 Cable extension junction box SS-1 Conductivity Standard, 1409 µs/cm at 25 C, 1 quart (945 ml) SS-1A SS-5 SS-5A SS-6 SS-6A SS-7 SS-7A Conductivity Standard, 1409 µs/cm at 25 C, 1 gallon (3785 ml) Conductivity Standard, 1000 µs/cm at 25 C, 1 quart (945 ml) Conductivity Standard, 1000 µs/cm at 25 C, 1 gallon (3785 ml) Conductivity Standard, 200 µs/cm at 25 C, 1 quart (945 ml) Conductivity Standard, 200 µs/cm at 25 C, 1 gallon (3785 ml) Conductivity Standard, 5000 µs/cm at 25 C, 1 quart (945 ml) Conductivity Standard, 5000 µs/cm at 25 C, 1 gallon (3785 ml) 3
MODEL 403/403VP SECTION 2 INSTALLATION UNPACKING AND INSPECTION SECTION 2. INSTALLATION Inspect the shipping container. If it is damaged, contact the shipper immediately for instructions. Save the box. If there is no apparent damage, unpack the container. Be sure all items on the packing list are present. If items are missing, notify Rosemount Analytical immediately. SENSOR DIMENSIONS INCH MILLIMETER DWG. NO. REV. 400403004 B 4 FIGURE 2-1. Model 403 Sensor Dimensional Drawing
MODEL 403/403VP SECTION 2 INSTALLATION INCH MILLIMETER DWG. NO. 4403VP01 REV. C FIGURE 2-2. Model 403VP Sensor Dimensional Drawing 5
MODEL 403/403VP SECTION 3 WIRING DIAGRAMS AND CABLE PREPARATION SECTION 3. WIRING DIAGRAMS AND CABLE PREPARATION CABLE 1. Model 400 The sensor can be connected to the analyzer through a remote junction box. Both factory-terminated and unterminated connecting cable are available. PN 23747-00 Factory-terminated cable PN 9200275 Unterminated cable. To terminate cable, see instructions in Figure 3-13. 2. Model 400VP The sensor has a Variopol 6-pin connector. Two lengths of cable terminated with a mating connecter are available. PN 23747-02 10 ft (3 m) cable with mating Variopol 6.0 connector PN 23747-03 50 ft (15 m) cable with mating Variopol 6.0 connector For longer cable runs, use a junction box (PN 23550-00) and extension cable. PN 23747-00 Factory-terminated cable PN 9200275 Unterminated cable. To terminate cable, see instructions in Figure 3-13. TABLE 3-1. Colors and Functions of Wires NAME COLOR FUNCTION Drive Gray Connects to outer electrode Drive Common Clear Shield for gray lead; coaxial with gray lead Receive Orange Connects to inner electrode Receive Common Clear Shield for orange lead; coaxial with orange 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 WIRING DIAGRAMS MODEL 400 SENSORS WITH JUNCTION BOX GRAY GRAY NOTE: TERMINALS IN JUNCTION BOX ARE NOT NUMBERED. 6 FIGURE 3-1. Sensor-Mounted Junction Box Wiring FIGURE 3-2. Model 2081C Wiring
MODEL 403/403VP SECTION 3 WIRING DIAGRAMS AND CABLE PREPARATION FIGURE 3-3. Model 81C Wiring FIGURE 3-4. Model 3081C & 4081C Wiring FIGURE 3-5. Model 1054C Wiring FIGURE 3-6. Model 1054BLC Wiring FIGURE 3-7. Model 1054BDC & 1054BR Wiring 7
MODEL 403/403VP SECTION 3 WIRING DIAGRAMS AND CABLE PREPARATION FIGURE 3-8. Model 1054AC & 2054C Wiring CUT OFF WHITE/RED WIRE AND CLEAR SHIELD WIRES FROM SENSOR CABLE OR EXTENSION CABLE. INSULATE AFTER TRIMMING. FOR -005, -008, AND -401 ANALYZERS, CONNECT THE CLEAR WIRE ONLY WHEN THE CABLE LENGTH EXCEEDS 50 FT. FIGURE 3-9. Solu Comp Wiring FIGURE 3-10. Model 1054BC Wiring FIGURE 3-11. Model 1055C Wiring FIGURE 3-12. Model 54C & 54e C Wiring FIGURE 3-13. Model 1055-01-10-20-30 Wiring 8
MODEL 403/403VP SECTION 3 WIRING DIAGRAMS AND CABLE PREPARATION FIGURE 3-15. Model 1055-10-20-30 Wiring through Junction Box 9
MODEL 403/403VP SECTION 3 WIRING DIAGRAMS AND CABLE PREPARATION PREPARING UNTERMINATED CABLE FOR USE DWG. NO. REV. 40040022 A FIGURE 3-15. Model 400 Series Cable Preparation (Part Number 9200275) 10
MODEL 403/403VP SECTION 4 TROUBLESHOOTING SECTION 4. TROUBLESHOOTING INSPECTION Remove sensor from process and inspect electrodes for signs of wear or corrosion. Be sure vent holes are not blocked. 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! TROUBLESHOOTING TABLE 4-1. Troubleshooting Guide Problem Probable Cause Action Off-scale readings Sensor is incorrectly wired to analyzer. Verify wiring. See Section 3. Temperature element in sensor is Check temperature element. See Figures 4-2 and 4-3. shorted or open. Replace the sensor if necessary. Sensor is not in process stream. Electrodes must be completely submerged in the process stream. See Section 2. Electrodes are fouled. Clean sensor. Sensor is defective. Perform isolation checks. See Figures 4-1 and 4-3. Replace the sensor if necessary. Variopol connector is not properly Loosen connector and reseat. seated. Noisy display Temperature element in sensor is Check temperature element. See Figures 4-2 and 4-3. shorted. Replace the sensor if necessary. Sensor is improperly installed in See Section 2. process stream. Variopol connector is not properly Loosen connector and reseat. seated. Sluggish response Electrodes are fouled. Inspect sensor and clean electrodes. Sensor is improperly installed in See Section 2. process stream. Low conductivity Air bubbles or sludge are trapped Be sure sensor is in a horizontal or nearly horizontal readings in sensor position. See Section 2. For additional troubleshooting advice, refer to analyzer instruction manual, or visit our website at www.rauniloc.com to view deluxe manual. Cleaning Sensors Use a warm detergent solution and a soft brush or pipe cleaner to remove oil and scale. Do not use sandpaper, wire brushes, sand blasters, or drills. Avoid using acids to clean conductivity sensors. 11
MODEL 403/403VP SECTION 4 TROUBLESHOOTING FIGURE 4-1. Checking Continuity and Leakage Disconnect electrode leads and measure resistance and continuity as shown. Sensor must be dry when checking resistance between electrode leads. FIGURE 4-2. Checking Temperature Element Disconnect leads and measure resistances shown. The measured resistance at room temperature should be close to the value in the table. FIGURE 4-3. Model 400VP Pin Assignments - Top View 12
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 STATED 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 92606 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.
The right people, the right answers, right now. UNILOC DIVISION CUSTOMER SUPPORT CENTER 1-800-854-8257 ON-LINE ORDERING NOW AVAILABLE ON OUR WEB SITE http://www.rauniloc.com Credit Cards for U.S. Purchases Only. Rosemount Analytical Inc. Uniloc Division 2400 Barranca Parkway Irvine, CA 92606 USA Tel: (949) 863-1181 http://www.rauniloc.com Rosemount Analytical Inc. 2000