Emerson Rosemount 499AOZ Quick Start Guide

Rosemount™ 499AOZ

Dissolved Ozone Sensor

Quick Start Guide

00825-0100-3492, Rev AB

November 2019

Quick Start Guide November 2019

Safety information

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.

CAUTION

Equipment damage

Do not exceed pressure and temperature specifications

Pressure: 65 psig (549 kPa abs) max.
Temperature: 32 to 122 °F (0 to 50 °C)

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

First steps.....................................................................................................................................3

Install........................................................................................................................................... 6

Wire........................................................................................................................................... 10

Calibrate.................................................................................................................................... 15

Maintenance.............................................................................................................................. 17

Accessories................................................................................................................................ 20

2 Emerson.com/Rosemount

November 2019 Quick Start Guide

1 First steps

1.1 Unpack and inspect

Procedure

1. Inspect the shipping container. If it is damaged, contact the shipper
immediately for instructions.

2. If there is no apparent damage, unpack the container. Be sure all
items shown on the packing list are present. If items are missing,
notify Emerson immediately.

1.2 Product description

Figure 1-1: Rosemount 499AOZ Sensor Parts

A. Membrane retainer
B. Membrane assembly
C. O-ring

D. Cathode

E. Electrolyte fill plug (wrap with pipe tape)
F. Pressure equalizing port

G. Sensor cable (integral cable shown)

1.3

Table 1-1: Sensor Specifications

Physical characteristics Specifications

Range 0 to 3 ppm (mg/L) as O

Pressure 0 to 65 psig (101 to 549 kPa abs)

Temperature (operating) 32 to 122 °F (0 to 50 °C)

Process connection 1-in. male national pipe thread (MNPT)

Quick Start Guide 3

Specifications

3

Quick Start Guide November 2019

Table 1-1: Sensor Specifications (continued)

Physical characteristics Specifications

Wetted parts Polysulfone, Viton®, Teflon®, and silicone

Cathode Gold (not normally wetted)

Accuracy Accuracy depends on the accuracy of the chemical test used to

Linearity ±5% of reading or ±3 ppb (whichever is greater) at 77 °F (25 °C)

Repeatability ±2% of reading at constant temperature

Response time 30< 20 sec to 90% of final reading at 77 °F (25 °C)

Membrane permeability
connection

Electrolyte volume 0.8 oz. (25 mL), approximately

Electrolyte life 3 months (approximately); for best results, replace electrolyte

Cable length See Ordering information table in the Product Data Sheet for cable

Cable length (maximum) 300 ft. (91 m), up to 100 ft. (30.5 m) is standard.

Sample flow Flow through: 1 to 5 gpm (3.8 to 19 L/min)

calibrate the sensor.

Defined between 32 and 122 °F (0 and 50 °C)

monthly.

length options.

Open channel: 1 ft./sec (0.3 m/sec)
Low flow cell: 2 to 5 gph (7.6 to 19 L/hr)

Weight/shipping

(1)

weight

1 lb./3 lb. (0.5 kg/1.5 kg)

(1) Weights and shipping weights are rounded up to the nearest whole pound or 0.5 kg.

Table 1-2: Other Specifications

Type PN Wetted

materials

2-in. tee 915240-03 PVC and Buna

N; body is
schedule 80
PVC

Polycarbon­ate/

Low flow

(1)

cell

915240-04 1-in. NFPT

915240-05 1½-in. NFPT

24091-00 and
24091-01

polyester,
316 stainless
steel, and
silicone

4 Emerson.com/Rosemount

Process
connection

Maximum
temperature

Maximum
pressure

¾-in. NFPT 120 °F (49 °C) 60 psig (515

kPa abs)

Compression
fitting for

158 °F (70 °C) 90 psig

(722 kPa abs)
¼-in. O.D.
tubing or
¼-in. female
national pipe
thread (FNPT)

November 2019 Quick Start Guide

Table 1-2: Other Specifications (continued)

Type PN Wetted

Valved
rotameter

(1) Temperature and pressure specifications for the low flow cell exceed the temperature and

pressure specifications for the sensor.

9390004 for
use with low
flow cell
Flow: 0.5 to 5
gph (1.4 to 19
L/hr)

materials

Acrylic, 316
stainless
steel, and
Viton

Process
connection

¼-in. NFPT
(316 stainless
steel)

Maximum
temperature

150 °F (65 °C) 100 psig (858

Maximum
pressure

kPa abs)

Quick Start Guide 5

Quick Start Guide November 2019

2 Install

Install the sensor in a flowing sample. Keep the sample flow as constant as
possible at a value within the following limits:

Sample flow unit Flow limits

Flow through 1 to 5 gpm (3.8 to 19 L/min)

Open channel 1 ft/sec (0.3 m/sec)

Low flow cell 2 to 5 gph (7.6 to 19 L/hr)

Figure 2-1: Sensor Orientation

Install sensor within 45 degrees of vertical.

6 Emerson.com/Rosemount

November 2019 Quick Start Guide

Figure 2-2: Flow Through 1½-in. Tee

A. Union coupler
B. 1-in. national pipe thread (NPT), two places
C. Sensor body: Rosemount 499A

D. 1-in. NPT flow cell adapter

E. O-ring 2-222
F. 1½-in. sched 80 CPVC tee body

Quick Start Guide 7

Quick Start Guide November 2019

Figure 2-3: Flow Through 2-in. Tee

A. Union coupler
B. Adapter
C. 1-in. NPT (two places)

D. Sensor body: Rosemount 499A

E. O-ring 2-222
F. 2-in. sched 80 PVC tee body

8 Emerson.com/Rosemount

November 2019 Quick Start Guide

Figure 2-4: Low Flow Cell (PN 24091-00)

A. Inches
B. Millimeters
C. Outlet

D. Inlet

Quick Start Guide 9

Quick Start Guide November 2019

3 Wire

NOTICE

For additional wiring information on this product, including sensor
combinations not shown here, please refer to the Liquid Transmitter Wiring

Diagrams.

Figure 3-1: Rosemount 499AOZ Sensor Wiring to Rosemount 1056 and
56 Transmitters

Table 3-1: Rosemount 499AOZ Sensor Wiring to Rosemount 1056 and 56
Transmitters

Terminal
number

1 A White Resistance temperature

2 B White/red RTD sense

3 C Red RTD in

4 D Clear RTD shield

5 N/A N/A +5 V out

6 N/A N/A -4.5 V out

7 D Clear Anode shield

8 E Gray Anode

9 D Clear Cathode shield

10 Emerson.com/Rosemount

Letter Wire color Description

device (RTD) return

November 2019 Quick Start Guide

Table 3-1: Rosemount 499AOZ Sensor Wiring to Rosemount 1056 and 56
Transmitters (continued)

Terminal
number

10 F Orange Cathode

Letter Wire color Description

Figure 3-2: Rosemount 499AOZ Sensor Wiring to Rosemount 5081
Transmitter

Table 3-2: Rosemount 499AOZ Sensor Wiring to Rosemount 5081 Transmitter

Terminal
number

1 N/A N/A N/A

2 N/A N/A +0.8 V

3 A White RTD return

Quick Start Guide 11

Letter Wire color Description

Quick Start Guide November 2019

Table 3-2: Rosemount 499AOZ Sensor Wiring to Rosemount 5081 Transmitter

(continued)

Terminal
number

4 B White/red RTD sense

5 C Red RTD in

6 N/A N/A Reference guard

7 N/A N/A Reference in

8 D Clear Solution ground

9 N/A N/A pH guard

10 N/A N/A pH in

11 N/A N/A -5 V

12 N/A N/A +5 V

13 E Gray Anode

14 F Orange Cathode

15 N/A N/A HART®/FOUNDATION™ Fieldbus

16 N/A N/A HART/FOUNDATION Fieldbus (+)

Letter Wire color Description

(-)

12 Emerson.com/Rosemount

November 2019 Quick Start Guide

Figure 3-3: Rosemount 499AOZ Sensor Wiring to Rosemount 1066
Transmitter

Note

Connect clear shield wires to solution ground terminal on TB 2. Use wire nut
and pigtail if necessary.

Table 3-3: Rosemount 499AOZ Wiring to Rosemount 1066 Transmitter

Letter Color Terminal description

A Orange Cathode

B Gray Anode

C White Return

D White/red Sense

E Red RTD in

Quick Start Guide 13

Quick Start Guide November 2019

Figure 3-4: Rosemount 499AOZ Sensor Pin-out Diagram

Table 3-4: Pin-out Diagram

Terminal number Description

1 Cathode

2 N/A

3 RTD sense

4 Anode

5 RTD return

6 RTD in

When making a connection through a junction box (PN 23550-00), wire
point-to-point.

NOTICE

Use a wire nut and pigtail (included) when connecting several wires to the
same terminal.

14 Emerson.com/Rosemount

November 2019 Quick Start Guide

4 Calibrate

4.1 Zero point calibration

Even in the absence of ozone, the sensor generates a small signal called the
zero current. Failing to correct for the zero current can introduce a bias,
particularly if the ozone concentration is small (<0.4 ppm). Zero the sensor
when it is first placed in service and every time the fill solution is changed.

To zero the sensor:

Procedure

1. Pour a cup of deionized or bottled water.

2. Place the sensor in the water.

3. Wait until the sensor current has reached a stable low value (at least
two hours).

4. Follow the transmitter prompts for zeroing the sensor.

Note

Refer to the manual for the transmitter you are using (Rosemount
56, 1056, 5081, or 1066).

The zero current should be between -10 and +10 nA.

4.2 Full scale calibration

Because stable dilute ozone standards are not available, the sensor must be
calibrated against the results of a laboratory test run on a grab sample of the
process liquid.

Procedure

1. Place the sensor in the flow cell.

2. Start the sample and reagent flow.

3. Adjust the sample flow to the correct range.

4. Adjust the concentration so that it is near the upper end of the
operating range.

5. Wait for the readings to stabilize.

6. Follow the transmitter prompts to complete the calibration.

Note

Refer to the manual for the transmitter you are using (Rosemount
56, 1056, 5081, or 1066).

7. After calibration, go to the Diagnostics menu and check the
sensitivity.

Quick Start Guide 15

Quick Start Guide November 2019

The sensitivity should be between 250 and 450 nA/ppm. For more
information, refer to the transmitter manual.

16 Emerson.com/Rosemount

November 2019 Quick Start Guide

5 Maintenance

Periodic maintenance and cleaning are required for best performance of the
sensor. Generally, the membrane and fill solution should be replaced every
four to six months. Sensors installed in harsh or dirty environments require
more frequent maintenance. The optimum maintenance frequency is best
determined by experience.

WARNING

Pressurized spray injury

Before removing the sensor, be absolutely certain that the process pressure
is reduced to 0 psig and the process temperature is lowered to a safe level!

5.1 Cleaning the membrane

Keep the membrane and sensor tip clean and free from dirt. Clean the
membrane with water sprayed from a wash bottle. Use a soft tissue to
gently wipe the membrane.

5.2 Replacing the electrolyte solution and membrane

WARNING

Harmful substance

Fill solution may cause irritation. May be harmful if swallowed.

Read and follow the instructions.

Procedure

1. Unscrew the membrane retainer.

2. Remove the membrane assembly and O-ring.
See Figure 1-1.

3. Hold the sensor over a container with the cathode pointing down.

4. Remove the fill plug.

5. Allow the electrolyte solution to drain out.

6. Inspect the cathode.

a) If it is tarnished, clean it by gently rubbing in the direction of

the existing scratches (do not use a circular motion) with
400-600 grit silicon carbide finishing paper.

b) Rinse thoroughly with water.

Quick Start Guide 17

Quick Start Guide November 2019

7. Remove the old pipe tape from the plug.

8. Wrap the plug with one or two turns of pipe tape..

9. Prepare a new membrane.
a) Hold the membrane assembly with the cup formed by the

membrane and membrane holder pointing up.

b) Fill the cup with electrolyte solution.

c) Leave the membrane assembly filled with electrolyte solution

and set it aside.

10. Hold the sensor at about a 45 degree angle with the cathode end
pointing up.

11. Add electrolyte solution through the fill hole until the liquid
overflows.

12. Tap the sensor near the threads to release trapped air bubbles.

13. Add more electrolyte solution if necessary.

14. Place the fill plug in the electrolyte port and begin screwing it in.

15. After several threads have engaged, rotate the sensor so that the
cathode is pointing up and continue tightening the fill plug.

Do not overtighten.

16. Place a new O-ring in the groove around the cathode post.

17. Cover the holes at the base of the cathode stem with several drops of
electrolyte solution.

18. Insert a small blunt probe, like a toothpick with the end cut off,
through the pressure equalizing port.

See Figure 1-1.

CAUTION

Equipment damage

A sharp probe may puncture the bladder and destroy the sensor.

Do not use a sharp probe.

19. Gently press the probe against the bladder several times to force
liquid through the holes at the base of the cathode stem. Keep
pressing the bladder until no air bubbles can be seen leaving the
holes.

Be sure the holes remain covered with electrolyte solution.

20. Place a drop of electrolyte solution on the cathode; then place the
membrane assembly over the cathode.

21. Screw the membrane retainer in place.

18 Emerson.com/Rosemount

November 2019 Quick Start Guide

The sensor may require several hours operating at the polarizing
voltage to equilibrate after the electrolyte solution has been
replenished.

Quick Start Guide 19

Quick Start Guide November 2019

6 Accessories

Part number Description

23747-06 Interconnecting cable, Variopol (VP) 6, 2.5 ft. (0.8 m)

23747-04 Interconnecting cable, VP 6, 4 ft. (1.2 m)

23747-02 Interconnecting cable, VP 6, 10 ft. (3.0 m)

23747-07 Interconnecting cable, VP 6, 15 ft. (4.6 m)

23747-08 Interconnecting cable, VP 6, 20 ft. (6.1 m)

23747-09 Interconnecting cable, VP 6, 25 ft. (7.6 m)

23747-10 Interconnecting cable, VP 6, 30 ft. (9.1 m)

23747-03 Interconnecting cable, VP 6, 50 ft. (15.2 m)

23747-11 Interconnecting cable, VP 6, 100 ft. (30.5 m)

23567-00 1½-in. flow through tee with 1½-in. socket connections

915240-03 2-in. flow through tee with ¾-in. female national pipe

915240-04 2-in. flow through tee with 1-in. FNPT connections

915240-05 2-in. flow through tee with 1½-in. FNPT connections

24091-00 Low flow cell with ¼-in. OD tubing compression fittings

9390004 Rotameter: 0.5 - 5.0 gph

22550-00 Junction box, 12 terminals

9200266 Extension cable for option -54, unterminated (specify

9200275 Extension cable for optimum EMI/RFI cable,

23747-00 Extension cable for optimum EMI/RFI cable, terminated

2001492 Stainless steel tag

23501-11 Dissolved ozone membrane assembly; includes 1

23502-11 Dissolved ozone membrane assembly; includes 3

9210299 #3 Dissolved ozone sensor fill solution, 4 oz (125 ml)

33521-02 Membrane retainer

33523-03 Fill plug

thread (FNPT) connections

length)

unterminated (specify length)

(specify length)

membrane assembly and 1 O-ring

membrane assemblies and 3 O-rings

20 Emerson.com/Rosemount

November 2019 Quick Start Guide

Quick Start Guide 21

Quick Start Guide November 2019

22 Emerson.com/Rosemount

November 2019 Quick Start Guide

Quick Start Guide 23

*00825-0100-3492*

EMERSON AUTOMATION SOLUTIONS

6021 Innovation Blvd.
Shakopee, MN 55379

[phone]
[phone]
[e-mail]

00825-0100-3492, Rev. AB

Quick Start Guide

November 2019

NORTH AMERICA

Emerson Automation Solutions
8200 Market Blvd
Chanhassen, MN 55317

Toll Free [phone]
F [phone]
[e-mail]

MIDDLE EAST AND AFRICA

Emerson Automation Solutions
Emerson FZE
Jebel Ali Free Zone
Dubai, United Arab Emirates, P.O. Box
17033

[phone]
[phone]
[e-mail]

Linkedin.com/company/Emerson-

Automation-Solutions

twitter.com/rosemount_news

Facebook.com/Rosemount

youtube.com/RosemountMeasurement

EUROPE

Emerson Automation Solutions
Neuhofstrasse 19a PO Box 1046
CH-6340 Baar
Switzerland

[phone]
[phone]
[e-mail]

ASIA-PACIFIC

Emerson Automation Solutions
1 Pandan Crescent
Singapore 128461
Republic of Singapore

[phone]
[phone]
[e-mail]

©

2020 Emerson. All rights reserved.

The Emerson logo is a trademark and service
mark of Emerson Electric Co. Rosemount is a
mark of one of the Emerson family of companies.
All other marks are the property of their
respective owners.