Rosemount 396R, 396RVP Instruction Manual

Model 396R and 396RVP

Retractable pH/ORP
Sensors

Instruction Manual

PN 5100396R

January 2001

WARNING

RETRACTABLE SENSORS

Retractable sensors must not be
inserted nor retracted when process
pressures are in excess of 64 psig
(542kPa), option 21 or 35 psig (343
kPa) option 25.

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.

DANGER

HAZARDOUS AREA INSTALLATION

Installations near flammable liquids or in haz­ardous area locations must be carefully eval­uated by qualified on site safety personnel.
This sensor is not

Intrinsically Safe or

Explosion Proof.
To secure and maintain an intrinsically safe

installation, the certified safety barrier,
transmitter, and sensor combination must
be used. The installation system must com­ply 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.

SS-SE

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 [phone] 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.

• 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.

• Ensure that all equipment doors are closed and protec­tive covers are in place, except while 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: [phone]

© Rosemount Analytical Inc. 2001

MODEL 396R pH/ORP TABLE OF CONTENTS

MODEL 396R AND 396RVP RETRACTABLE

pH/ORP SENSORS

TABLE OF CONTENTS

Section Title Page

1.0 DESCRIPTION AND SPECIFICATIONS............................................................. 1

1.1 Features and Applications................................................................................ 1

1.2 Performance and Physical Specifications ........................................................ 1

1.3 Ordering Information......................................................................................... 2

2.0 INSTALLATION.................................................................................................. 5

2.1 Unpacking and Inspection................................................................................ 5

2.2 Mechanical Installation .................................................................................... 5

3.0 WIRING MODEL 396R...................................................................................... 13

4.0 WIRING MODEL 396RVP.................................................................................. 22

5.0 START UP AND CALIBRATION......................................................................... 29

5.1 Start up.............................................................................................................. 29

5.2 pH Calibration................................................................................................... 29

5.3 ORP Calibration ................................................................................................ 30

6.0 MAINTENANCE................................................................................................. 31

6.1 Maintenance ..................................................................................................... 31

6.2 Sensor Removal................................................................................................ 31

6.3 pH Electrode Cleaning...................................................................................... 31

6.4 Platinum Electrode Cleaning............................................................................. 32

6.5 Automatic Temperature Compensation............................................................. 32

6.6 Sensor Tube Replacement................................................................................ 32

7.0 DIAGNOSTIC AND TROUBLESHOOTING ....................................................... 35

7.1 Diagnostics and Troubleshooting with Model 54/3081 pH/ORP Diagnostics... 35

7.2 Troubleshooting without Diagnostics................................................................ 36

8.0 RETURN OF MATERIAL.................................................................................... 37

LIST OF TABLES

Table No. Title Page

1-1

Commonly Used Accessories for Model 396R................................................. 3

1-2 Other Accessories for Model 396R................................................................... 3

1-3 Commonly Used Accessories for Model 396RVP............................................. 4

1-4 Other Accessories for Model 396RVP............................................................... 4

5-1 ORP of Saturated Quinhydrone Solutions......................................................... 30

6-1 Ro and R1 Values for Temperature Compensation Elements........................... 32

6-2 Temperature vs. Resistance of Auto T.C. Elements .......................................... 32

7-1 Troubleshooting with Diagnostics..................................................................... 35

7-2 Troubleshooting without Diagnostics................................................................ 36

i

MODEL 396R pH/ORP TABLE OF CONTENTS

LIST OF FIGURES

Figure No. Title Page

2-1 Exploded View of Ball Valve Kit PN 23240-00 used with process connector

PN 23166-00 (or PN 23166-01)......................................................................... 6

2-2 Typical Mounting Configurations for Model 396R............................................. 7

2-3 Typical Mounting Configurations for Model 396RVP......................................... 7

2-4 Dimensional Drawing — Model 396R with Optional Ball Valve PN 23765-00 .. 8
2-5 Dimensional Drawing — Model 396R with Optional Ball Valve PN 23240-00 .. 9

2-6 Dimensional Warning Label for Hemi Bulb Sensors and Sensor Diagram....... 10

2-7 Dimensional Drawing — Model 396RVP with Optional 1-1/2 inch Ball Valve ..

PN 23240-00..................................................................................................... 11

2-8 Dimensional Drawing — Model 396RVP with Optional 1-1/4 inch Ball Valve ......

PN 23765-00..................................................................................................... 12

3-1 Cable Preparation Instructions for Model 396R................................................ 13

3-2 Wiring Details Model 396R-54 for use with Model 54/81/3081 pH/ORP........... 14

3-3 Wiring Details Model 396R-54 with Remote Junction Box & Pr eamp (PN 23555-00) 14
3-4 Wiring Details Model 396R-50 for use with Remote Junction Box (PN 23309-03). 15
3-5 Wiring Details Model 396R-54 for use with Remote Junction Box (PN 23309-04). 15

3-6 Wiring Details-Model 396R-54 for use with Model 1181 pH/ORP......................... 16

3-7 Wiring Details-Model 396R-54 for use with Models 1054A/B pH/ORP, 2054 pH, ..

and 2081 pH/ORP.............................................................................................. 16

3-8 Wiring Details-Model 396R-54 for use with Model SCL- (P/Q).............................. 17

3-9 Wiring Details-Model 396R-54 for use with Model 2700 Pr eamp J-Box (PN 23054-03) 17

3-10 Wiring Details-Model 396R-50/54-60 for use with Sensor Head J-Box ............ 18

3-11 Wiring Details-Model 396R-54-61 for use with Sensor Head J-Box ................. 18

3-12 Wiring Details-Model 396R-50 for use with J-Box (PN 23707-00) to................

Models 1181, 1050, 1060, 1030, 1023 pH Transmitters .................................. 19

3-13 Wiring Details-Model 396R-54 for use with J-Box (PN 23708-01) to ...............

Models 1054series, 2054, and 2081 pH Transmitters ...................................... 20

3-14 Wiring Model 396R-( )-54-62-(71) to Model 1055-10-22-32 ............................. 21

3-15 Wiring Model 396R-(02)-( )-54/55-(61) to Model 1055-10-22-32...................... 21

4-1 Wire Functions and Pin Connections for Model 396RVP.................................. 22

4-2 Wiring Model 396RVP to Model 81 ................................................................... 23

4-3 Wiring Model 396RVP to Model 1181 ............................................................... 23

4-4 Wiring Model 396RVP to Model 81 thru a Remote J-Box.................................. 23

4-5 Wiring Model 396R VP to Models 1181/1050/1060/1003/1023 thru Remote J-Box 23

4-6 Wiring Model 396RVP to Model 2081 ............................................................... 24

4-7 Wiring Model 396RVP to Models 3081 and 4081 ............................................. 24

4-8 Wiring Model 396RVP to Model 2081 thru a Remote J-Box.............................. 24

4-9 Wiring Model 396RVP to Models 3081 and 4081 thru a Remote J-Box............ 24

4-10 Wiring Model 396RVP to Model 1054............................................................... 25

4-11 Wiring Model 396RVP to Models 1054A/B and 2054........................................ 25

4-12 Wiring Model 396RVP to Model 1054 thru a Remote J-Box.............................. 25

4-13 Wiring Model 396RVP to Models 1054A/B and 2054 thru a Remote J-Box...... 25

4-14 Wiring Model 396RVP to Model 54................................................................... 26

4-15 Wiring Model 396RVP to Model 54 thru a Remote J-Box.................................. 26

4-16

Wiring Model 396RVP to Model 2700............................................................... 26

4-17 Wiring Model 396RVP to Model SCL-(P/Q)....................................................... 26

4-18 Wiring Model 396RVP to Model 1055pH/pH..................................................... 27

4-19 Wiring Model 396RVP to Model 1055pH/pH thru a Remote J-Box................... 27

4-20

Wiring Model 396RVP to Model 1055-10-22-32................................................ 28

6-1 Sensor Tube Replacement................................................................................ 34

6-2 Male Connector Tightening Diagram................................................................ 34

ii

1.1 FEATURES AND APPLICATIONS
The Model 396R and 396RVP Sensorsare specifical-

ly designed for improv ed life in harsh, dirty applications
where a separate sample stream is difficult to provide
and greater insertion depths are required. Model 396R
is designed for use with a 1-1/4 in.or 1-1/2 in.ball valve
for hot tap installation.The Model 396R is constructed
of molded polypropylene housed in a titanium tube with
EPDM seals to provide maximum chemical resistance.

Model 396R also features a titanium solution ground
for advanced sensor diagnostics when used with the
Model 54, 81, or 3081 pH/ORP Analyzer/Transmitter.
Advanced sensor diagnostics provide preventative
maintenance by notifying the operator for replacement
and cleaning of an aged or fouled sensor for continu­ous optimum performance.

The sensor also features a shrouded tip for protection
from breakage while allowing process to flow by the glass
electrode for accurate and reliable pH measurement.

The Model 396R is available without an integral pre­amplifier only and 15 ft or 9.5 in. of integral high quali­ty 9 conductor cable.The preamplifier must be housed
in a remote location or in a J-Box kit for attachment at
the rear, cable end of the sensor (order separately) or
integral to the Analyzer/Transmitter. The Model 396R
is compatible with all Rosemount Analytical and vari­ous other manufacturers instruments.

Model 396RVP: Rosemount Analytical has recently
released Model 396RVP.This model has identical per­formance and physical specifications to the Model
396R (see Section 1.2) with the following exception:
the Model 396RVP has a Variopol (VP) connector on
the back end of the sensor in place of a cable.

MODEL 396R pH/ORP SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

MODEL 396R

Measured Range:

ORP: -1500 to 1500mV
pH:GPLR A

CCUGLASS

™

Percent Linearity Over pH Range:

Wetted Materials: Polypropylene, EPDM, titanium, glass,

(platinum: ORP only)

Process Connections: 1-1/2 or 1-1/4 in. with ball valve,

1 in. without ball valve

Cable: Integral 15 ft or 9.5 in. 9 conductor cable except

option 60 (9.5 in. coaxial cable with BNC)
Recommended Interconnect (PN 9200273)

Maximum Process Pressure and Temperature:

Hemi bulb: 150 psig (1136 kPa abs) at 212°F (100°C )

Flat bulb: 100 psig (790 kPa abs) at 212°F (100°C )

Maximum Pressure at Retraction or Insertion:

Code 21: 64 psig (542 kPa abs)
Code 25: 35 psig (343 kPa abs)

Minimum Conductivity: 100 µS/cm
Weight/Shipping Weight:

Sensor: Code 21: 2.0 lb/3.0 lb (.9 kg/1.40 kg)

Code 25: 3.0 lb/4.0 lb (1.40 kg/1.80 kg)

Ball Valve: PN 23240-00; 5 lb/7 lb (2.25 kg /3.20 kg)

PN 23634-00 8 lb/10 lb (3.65 kg/4.55 kg)

J-Box: 3 lb/4 lb (1.40 kg/1.80 kg)

MODEL 396RVP

Measured Range:

ORP: -1500 to 1500mV
pH:0 to 14

Available pH glass types:GPLR hemi bulb or flat bulb
Wetted Materials: Polypropylene, EPDM, titanium, glass,

(platinum: ORP only)

Process Connections: none, use 1-inch process connector

or ball valve kit (1-1/2 inch or 1-1/4 inch)

Temperature Range: 0 to 100C (32 to 212F)
Pressure Range (hemi bulb): 100-1136 kPa abs (0-150 psig)
Pressure Range (flat bulb): 100-790 kPa abs (0-100 psig)
Maximum Pressure at Retraction or Insertion:

Code 21: 64 psig (542 kPa abs)
Code 25: 35 psig (343 kPa abs)

Minimum Conductivity: 75 µS/cm, nominal
Preamplifier options: remote
Weight/Shipping Weight:

Sensor: Code 21: 2.0 lb/ 3.0 lb (.9 kg/1.40 kg)

Code 25: 3.0 lb/4.0 lb (1.40 kg/1.80 kg)

Ball Valve: PN 23240-00; 5 lb/7 lb (2.25 kg /3.20 kg)

Hemi Bulb Flat Bulb

1-2 pH 94% 93%

2-12 pH 99% 98%

12-13 pH 97% 95%

1

1.2 PERFORMANCE AND PHYSICAL SPECIFICATIONS

2

MODEL 396R pH/ORP SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

1.3 ORDERING INFORMATION

The Model 396R Sensor is housed in a titanium tube, with a patented polypropylene reference junction and tita-
nium solution ground for use with a ball valve (order separately) for hot tap applications.The sensor is available
with either a hemi or flat glass pH electrode and features a shrouded glass/platinum electrode and PT100 or 3K
temperature compensation. The 396R is available with 9.5 in. or 15 ft of integral cable. The 396R sensor is not
available with a preamp. Junction box kits with preamps must be ordered separately if the analyzer/transmitter
does not have an integral preamp within 15 ft.of the probe. Process connector and ball valve assemblies m ust also
be ordered separately.

MODEL

396R TUpH RETRACTABLE pH SENSOR

CODE MEASURING ELECTRODE TYPE (Required Selection)

10 GPLR hemi glass, General Purpose Low Resistivity (0-14 pH)
12 ORP
13 GPLR flat glass, General Purpose Low Resistivity (0-14 pH)

CODE SENSOR LENGTH

21 21 in. Titanium Tube
25 36 in. Titanium Tube

CODE ANALYZER/TC COMPATIBILITY (Required Selection)

50 For Models 1181 (3K TC)
54 For Models 1054, 1054A/B, 2054, 2081,54, 3081, 81, SCL-(P/Q), Solu Cube (PT 100 RTD)

CODE OPTIONAL OPTIONS

60 9.5 in. Cable with BNC (for use with Model 1181, 1054 series, 2054, 2081 Sensor Head J-Boxes)
61 9.5 in. Cable no BNC (Not Valid w/Option 50) (for use with Model 54, 81, 3081 Sensor Head J-Boxes)

396R - 10 - 21 - 54 EXAMPLE

MODEL
396RVP TUpH RETRACTABLE pH/ORP SENSOR

CODE MEASURING ELECTRODE TYPE (Required Selection)

10 Hemi bulb, General Purpose Low Resistivity (0-14 pH)
12 ORP
13 Flat, GPLR glass

CODE SENSOR LENGTH (Required Selection)

21 21 in. Titanium Tube
25 36 in. Titanium Tube

CODE ANALYZER/TC COMPATIBILITY (Required Selection)

50 For Models 1181 (3K TC)
54 For Models 1054, 1054A, 1054B, 2054, 2081,54, 3081, 4081, 81, SCL-(P/Q), 2700 (Pt 100 RTD)

The Model 396RVP ball valve retractable sensor features a gel-filled electrolyte solution with the large area,
coating resistant TUpH polypropylene reference junction and a standard hemi or optional flat glass bulb. Model
396RVP is housed in a Titanium sensor tube and can be mounted directly into the process using a 1 in. MNPT
threaded process connector and a ball valve assembly kit (both ordered separately). It is offered with the water­tight Variopol sensor-to-cable connector and uses the mating connector cable (ordered separately). Also available
is a choice of temperature element, 3 K Balco or Pt 100 RTD. A remote preamplifier found in the analyzer/trans­mitter or in a junction box (ordered separately) must be used with this sensor for a reliable signal transmission.

396RVP- 10 - 21 - 54 EXAMPLE

TABLE 1-2. OTHER ACCESSORIES FOR MODEL 396R

TABLE 1-1. COMMONLY USED ACCESSORIES FOR MODEL 396R

PART DESCRIPTION
22698-00 Preamplifier plug-in for J-box, for Model 1003,
22698-02 Preamplifier plug-in for J-box, for Models 1181/1050
22698-03 Preamplifier plug-in for J-box, for Models 1054A/B, 2054, 2081
23550-00 Remote Junction box with extension board
9550167 O-ring, 2-214, EPDM for process connector
9210012 Buffer solution, 4.01 pH, 16 oz
9210013 Buffer solution, 6.86 pH, 16 oz
9210014 Buffer solution, 9.18 pH, 16 oz
22743-01 Pt100 preamp for Model 1181
22744-01 3K Preamp for Model 1181
23557-00 Preamplifier for junction box for Models 54/3081

MODEL 396R pH/ORP SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

3

For first time installations, Rosemount Analytical recommends using the following guide

1. Retractable Mounting

AA.. CChhoooossee oonnee ((rreeqquuiirreedd ffoorr aallll ffiirrsstt ttiimmee iinnssttaallllaattiioonnss))::

PN 23166-00, 1 in. x 1 in. NPT process connector, 316 SST
PN 23166-01, 1 in. x 1 in. NPT process connector, Titanium

BB.. CChhoooossee oonnee::

PN 23240-00, 1-1/2 in. ball valve assembly, 316 SST
PN 23765-00, 1-1/4 in. ball valve assembly, 316 SST

2. Junction Boxes (Optional; Choose either Sensor Head or Remote)

AA.. SSeennssoorr HHeeaadd JJuunnccttiioonn BBooxxeess ((uusseedd wwiitthh ooppttiioonnss -6600 oorr -6611 sseennssoorr)) - CChhoooossee oonnee::

PN 23709-00; includes preamplifier for Models 54, 81, 3081
PN 23708-01; includes preamplifier for Models 1054 series, 2054, 2081
PN 23707-00; includes preamplifier for Model 1181

BB.. RReemmoottee JJuunnccttiioonn BBooxxeess ((uusseedd wwiitthh ssttaannddaarrdd 1155 fftt.. ccaabbllee lleennggtthh sseennssoorr)) - CChhoooossee oonnee::

PN 23555-00; includes preamplifier for Models 54, 81, 3081
PN 23309-03; includes preamplifier for Model 1181
PN 23309-04; includes preamplifier for Models 1054 series, 2054, 2081
PN 23054-03; includes preamplifier for Solu Cube Model 2700

3. BNC Adapter - Choose one:

PN 9120516, BNC Adapter for use with remote junction boxes PN’s 23309-03 and 23309-04
Order option -60 (standard with BNC connector) for PN 23707-00 or 23708-01 sensor head junction boxes

4. Extension Cables - Choose one:

PN 23646-01, 11 conductor, shielded, prepped
PN 9200273, 11 conductor, shielded, unprepped

TABLE 1-4. OTHER ACCESSORIES FOR MODEL 396RVP

PART DESCRIPTION
22698-00 Preamplifier plug-in for junction box, for Model 1003,
22698-02 Preamplifier plug-in for junction box, for Models 1181, 1050
22698-03 Preamplifier plug-in for junction box, for Models 1054A/B, 2054, 2081
22743-01 Pt100 preamplifier for Model 1181
22744-01 3K Preamplifier for Model 1181
23557-00 Preamplifier for junction box for Models 54, 3081, 81, 4081
33046-00 Ferrule, 1 in., split 316SS
9310096 Nut, swage, 1 in. 316SST
9210012 Buffer solution, 4.01 pH, 16 oz
9210013 Buffer solution, 6.86 pH, 16 oz
9210014 Buffer solution, 9.18 pH, 16oz
R508-160Z ORP solution, 460 mv ± 10 at 20°C
9550167 EPDM O-ring for Process Connector (PN 23166-00 or 23166-01)
12707-00 Jet Spray Cleaner

1. Variopol Cable (required for all first time installations)

Choose one: PN 23645-06, 15 ft cable with mating VP connector, prepped with BNC on analyzer end

PN 23645-07, 15 ft cable with mating VP connector, prepped without BNC on analyzer end*

2. Retractable Mounting

1A. Choose one (required for all first time installations, except as noted):

PN 23166-00 1 in. x 1 in. NPT process connector, 316 SST
PN 23166-01 1 in. x 1 in. NPT process connector, Titanium

Choose one (optional process connector o-rings):

PN 9550220, Kalrez o-ring, 2-214
PN 9550099, Viton o-ring, 2-214

1B. Choose one:

PN 23240-00 1-1/2 in. ball valve assembly, 316 SST
PN 23765-00 1-1/4 in. ball valve assembly, 316 SST (process connector not needed)

3. Remote Junction Boxes (Optional)

Choose one: PN 23555-00 includes preamplifier for Models 54, 81, 3081, 4081

PN 23309-03 and PN 22698-02 plug-in preamplifier for Model 1181Analyzer
PN 23309-04 and PN 22698-03 plug-in preamplifier for Models 1054 series, 2054, 2081 Analyzers
PN 23054-03 includes preamplifier for Solu Cube Model 2700

4. Extension cables

Choose one: PN 23646-01, 11 conductor, shielded, prepped

PN 9200273, 11 conductor, shielded, unprepped

FOR FIRST TIME 396RVP AND 398RVP INSTALLATIONS, ROSEMOUNT ANALYTICAL RECOMMENDS USING THE FOLLOWING GUIDE:

* Used for connections to Models 1181, 1054, 2081, 54, 81, 3081, 4081, and remote junction box PN 23555-00.

MODEL 396R pH/ORP SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

4

TABLE 1-3. COMMONLY USED ACCESSORIES FOR MODEL 396RVP

5

MODEL 396R pH/ORP SECTION 2.0

INSTALLATION

SECTION 2.0

INSTALLATION

2.1 UNPACKING AND INSPECTION. Inspect the out-

side of the carton for any damage. If damage is
detected, contact the carrier immediately. 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.

NOTE

If the sensor is to be stored, the protective
boot should be filled with either KCl elec­trolyte solution or pH 4.0 buffer solution
and replaced on sensor tip until ready to
use.

NOTE

Save the original packing cartons and
materials as most carriers require proof of
damage due to mishandling, etc. Also, if it
is necessary to return the instrument to the
factory, you must pack the instrument in
the same manner as it was received. Refer
to Section 6.0 for instructions.

WARNING

Glass electrode must be wetted at all
times (in storage and in line) to maximize
sensor life.

2.2 MECHANICAL INSTALLATION. The Model 396R
Sensor may be installed through a weldalet or in a
pipe tee or “Y”, as shown in Figure 2-1, when used
with a ball valve. Insert the end of the sensor to a
depth sufficient to ensure that the glass bulb is con­tinuously wetted by the process fluid. The Model 396R
can also be inserted directly into the process without
the use of a ball valve for applications not requiring
continuous operation during sensor maintenance.

CAUTION

Allow sufficient room for safe retraction
and insertion of the sensor. Personnel
should have room for stable footing while
performing removal or insertion of the sen­sor.

The sensor must be mounted within 10-90 degrees of
the horizontal with the tip pointed downward, thus
keeping air bubbles off of the pH sensitive glass bulb.

Bubbles settled on the glass bulb disrupt the electri­cal continuity between the pH sensitive glass and the
silver/silver chloride measuring element.

If the retraction version is to be installed without a ball
valve follow the installation procedure for insertion
service (Section 2.2.2). Perform the following steps for
sensor installation through a ball valve:

2.2.1 INSTALLATION THROUGH BALL VALVE.

1. Carefully remove the liquid filled rubber boot
which protects the glass electrode and keeps the
liquid junction wet during shipping and storage.
Discard the liquid and boot. Make sure the lubri­cated O-ring is in place in the groove inside the
male connector on the sensor body (Figure 4-1,
item A).

CAUTION

Buffer solution, in the protective boot, may
cause skin or eye irritation.

2. With the male connector on the sensor’s body,
insert the sensor into the ball valve until it gently
touches the closed valve. The molded electrode
guard will protect the glass bulb from breakage.

3. Thread the male connector body tightly into the
ball valve assembly. DO NOT tighten the hex nut
on the male connector body; doing so would not
allow the sensor to be inserted through the ball
valve.

4. Pull back hard on the sensor assembly, as if try­ing to remove the sensor, to be certain that the
sensor cannot come free of the ball valve assem­bly . The built-in r etraction stop will butt against the
shoulder of the male connector if properly
installed.

CAUTION

The sensor must be captured by the valve
assembly and the male connector so that
it cannot be blown free by process pres­sure if mishandled during insertion or
retraction.

5. After confirming that the sensor assembly is prop­erly secured by the valve assembly, the valve may
be opened and the sensor positioned into the
process at the desired depth and orientation.

6. While holding the sensor in position, tighten the hex
nut of the male connector to firmly secure the sen­sor in place. When the hex nut is tightened, the
Teflon ferrule inside the compression fitting clamps
the sensor tube (see Figure 4-2).

NOTE

A stainless steel ferrule is available if the
Teflon ferrule does not inadequately grip.
When using the metallic ferrule, care must be
taken to avoid over tightening and damaging
the sensor tube. If the male connector leaks
during insertion or retraction, replace the O­ring in the male connector.

2.2.2 INSTALLATION WITHOUT A BALL VALVE. The
Model 396R Sensor may be installed through a weldalet
or pipe tee or “Y” when used with a process connector
(PN 23166-00 or 23166-01). The sensor should be
installed within 80° of vertical, with the electrode facing
down.

MODEL 396R pH/ORP SECTION 2.0

INSTALLATION

CAUTION

Over tightening the hex nut may
damage the ferrule.

6

FIGURE 2-1. Exploded View of Ball Valve Kit PN 23240-00

used with process connector PN 23166-00 (or PN 23166-01)

7

MODEL 396R pH/ORP SECTION 2.0

INSTALLATION

JUNCTION BOX IS OPTIONAL

FIGURE 2-2.Typical Mounting Configurations for Model 396R

FIGURE 2-3.Typical Mounting Configurations for Model 396RVP

8

MODEL 396R pH/ORP SECTION 2.0

INSTALLATION

FIGURE 2-4. Dimensional Drawing — Model 396R with Optional Ball Valve PN 23765-00

Note: Add five (5) inches to dimension A if mounting a sensor head junction box onto the sensor.

INCH

MILLIMETER

9

MODEL 396R pH/ORP SECTION 2.0

INSTALLATION

FIGURE 2-5. Dimensional Drawing — Model 396R with Optional Ball Valve PN 23240-00

Note: Add five (5) inches to dimension A if mounting a sensor head junction box onto the sensor.

DWG. NO. REV.

40396R05 A

WHEN INCH AND METRIC DIMS

ARE GIVEN

MILLIMETER

INCH

10

MODEL 396R pH/ORP SECTION 2.0

INSTALLATION

36”

36”

FIGURE 2-6. Dimensional Warning Label for Model 396R Hemi Bulb Sensors and Sensor Diagram

Note: Pressure rating for flat glass sensors is 100-790 kPa (0-100 psig).

Front Side 396R-21
Note: Retraction Pressure

4.920

2.25

Back Side 396R

Front Side 396R-25
Note: Retraction Pressure

A

MM / IN

548.64 / 21.60

916.94 / 36.10

OPTION

21
25

MILLIMETER

INCH

11

MODEL 396R pH/ORP SECTION 2.0

INSTALLATION

FIGURE 2-7. Dimensional Drawing — Model 396RVP with Optional 1-1/2 inch Ball Valve PN 23240-00

WHEN INCH AND METRIC DIMS

ARE GIVEN

MILLIMETER

INCH

12

MODEL 396R pH/ORP SECTION 2.0

INSTALLATION

FIGURE 2-8. Dimensional Drawing — Model 396RVP with Optional 1-1/4 inch Ball Valve PN 23765-00

INCH

MILLIMETER

13

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

SECTION 3.0

WIRING MODEL 396R

WIRING MODEL 396R.

Make electrical connections as shown on Figures 3-1
through 3-15 using the following guidelines. For wiring
Model 396RVP, see Section 4.0.

1. Pa y particular attention to the analyzer or transmit­ter model number when following details on the
wiring diagrams to ensure that the connections are
made to the proper terminals.

2. Use Rosemount custom cable Part Number
9200273 for interconnect.

3. The maximum distance from the sensor to the
analyzer is 15 ft without an integral preamplifier.

4. Signal cable should be run in a dedicated conduit
and should be kept away from AC power lines.

NOTE

For maximum EMI/RFI protection when wiring
from the sensor to the junction box, the outer
braid of the sensor should be connected to the
outer braided shield of the extension cable .The
outer braid of the extension cable to the instru­ment must be terminated at earth ground or by
using an appropriate metal cable gland fitting,
that provides a secure connection to the instru­ment cable.

FIGURE 3-1. Cable Preparation Instructions (PN 900273)

WARNING:IF INNER BLACK
CONDUCTIVE SHEATH IS IN
CONTACT WITH THE EXPOSED
LEADS, OR IS NOT PREPARED
PROPERLY, IT MAY CAUSE AN
ELECTRICAL SHORT.

DWG. NO. REV.

40396R24 A

14

FIGURE 3-2.Wiring Details Model 396R-54 for use with Model 54 pH/ORP and 81/3081 pH/ORP

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

FIGURE 3-3.Wiring Details Model 396R-54 with Remote J-Box and Preamp (PN 23555-00)

DWG. NO. REV.

40396R08 A

WHEN INCH AND METRIC DIMS

ARE GIVEN

MILLIMETER

INCH

DWG. NO. REV.

40396R07 A

MODELS 54, 81, 3081

MODELS 54, 81, 3081

MODELS

54, 81, 3081

15

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

DWG. NO. REV.

40396R011 A

FIGURE 3-4. Wiring Details - Model 396R-50 for use with Remote Junction Box (PN 23309-03)

1

PREP ORANGE WIRE FOR PREAMP
WITH BNC ADAPTER (PN 9120516).

DWG. NO. REV.

40396R012 A

PREP ORANGE WIRE FOR PREAMP
WITH BNC ADAPTER (PN 9120516).

1

DANGER:

Do not connect sensor

cable to power lines.

Serious injury may result.

DANGER:

Do not connect sensor

cable to power lines.

Serious injury may result.

FIGURE 3-5. Wiring Details - Model 396R-54 for use with Remote Junction Box (PN 23309-04)

16

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

DWG. NO. REV.

40396R09 A

FIGURE 3-6. Wiring Details - Model 396R-50/54 for use with Model 1181 pH/ORP

1

PREP ORANGE WIRE FOR PREAMP
WITH BNC ADAPTER (PN 9120516).

DWG. NO. REV.

40396R010 A

FIGURE 3-7. Wiring Details - Model 396R-54

for use with Models 1054A/B pH/ORP, 2054 pH, and 2081 pH/ORP

17

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

DWG. NO. REV.

40396R13 A

DWG. NO. REV.

40396R14 A

FIGURE 3-8. Wiring Details - Model 396R-54 for use with Model SCL-(P/Q)

FIGURE 3-9. Wiring Details - Model 396R-54 for use with Model 2700 Preamp J-Box (PN 23054-03)

18

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

FIGURE 3-11.Wiring Details - Model 396R-54-61 for use with

Sensor Head J-Box for use with Models 54, 81, 3081

FIGURE 3-10.Wiring Details - Model 396R-50/54-60 for use with Sensor Head

J-Boxes for Models 1181, 1054 Series, 2054, 2081

WHEN INCH AND METRIC DIMS

ARE GIVEN

MILLIMETER

INCH

DWG. NO. REV.

40396R21/22 B/C

DWG. NO. REV.

40396R06 C

MILLIMETER

INCH

DANGER:

Do not connect sensor

cable to power lines.

Serious injury may result.

PREP ORANGE WIRE FOR PREAMP
WITH BNC ADAPTER (PN 9120516).

1

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

FIGURE 3-12. Wiring Details-Model 396R-50 for use with J-Box (PN 23707-00)

to Models 1181, 1050, 1060, 1030, and 1023 pH Transmitters

DWG. NO. REV.

40396R21 A

19

FIGURE 3-13. Wiring Details:

Model 396R-54 for use with J-Box (PN 23708-01) to Models 1054 Series, 2054, and 2081 pH Transmitters

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

20

DWG. NO. REV.

40396R22 B

PREPARE ORANGE WIRE FOR
PREAMP, USE BNC ADAPTER
PN 9120516

FIGURE 3-14. Wiring Model 396R-( )-54-62-(71) to Model 1055-10-22-32

FIGURE 3-15. Wiring Model 396R-(02)-( )-54/55-(61) to Model 1055-10-22-32

MODEL 396R pH/ORP SECTION 3.0

WIRING MODEL 396R

21

FIGURE 4-1. Wire Functions and Pin Connections for Model 396RVP

MODEL 396R pH/ORP SECTION 4.0

WIRING MODEL 396RVP

SECTION 4.0

WIRING MODEL 396RVP

WIRING MODEL 396RVP.

Make electrical connections as shown on Figures 4-1
through 4-20 using the following guidelines. For wiring
Model 396R, see Section 3.0.

1. Pa y particular attention to the analyzer or transmit­ter model number when following details on the
wiring diagrams to ensure that the connections are
made to the proper terminals.

2. The Model 396RVP uses a mating VP cable.The
cable part numbers are 23645-06 and 23645-07.
See attached wiring sheet for wire functions of the
cables and wiring diagrams to various analyzers.

3. The maximum distance from the sensor to the
analyzer is 15 ft without an integral preamplifier.

4. Signal cable should be run in a dedicated conduit
and should be kept away from AC power lines.

NOTE

For maximum EMI/RFI protection when wiring
from the sensor to the junction box, the outer
braid of the sensor should be connected to the
outer braided shield of the extension cable .The
outer braid of the extension cable to the instru­ment must be terminated at earth ground or by
using an appropriate metal cable gland fitting,
that provides a secure connection to the instru­ment cable.

Wire Functions for Variopol connector cable

PN 23645-06 (with BNC)
PN 23645-07

22

MODEL 396R pH/ORP SECTION 4.0

WIRING MODEL 396RVP

FIGURE 4-5. Model 1181, 1050/1060, & 1003/1023

Wiring through Remote Junction Box

FIGURE 4-2. Model 81 Wiring

FIGURE 4-4. Model 81 Wiring through Remote

Junction Box

FIGURE 4-3. Model 1181 Wiring

23

MODEL 396R pH/ORP SECTION 4.0

WIRING MODEL 396RVP

FIGURE 4-6. Model 2081 Wiring

FIGURE 4-7. Model 3081 & 4081 Wiring

FIGURE 4-9. Model 3081 & 4081 Wiring through

Remote Junction Box

FIGURE 4-8. Model 2081 Wiring through Remote

Junction Box

24

MODEL 396R pH/ORP SECTION 4.0

WIRING MODEL 396RVP

FIGURE 4-10. Model 1054 Wiring

FIGURE 4-12. Model 1054 Wiring through a Remote

Junction Box

FIGURE 4-11. Model 1054A/B & 2054 Wiring

FIGURE 4-13. Model 1054A/B & 2054 Wiring through

a Remote Junction Box

25

MODEL 396R pH/ORP SECTION 4.0

WIRING MODEL 396RVP

FIGURE 4-14. Model 54 Wiring

FIGURE 4-15. Model 54 Wiring through Remote Junction Box

FIGURE 4-16. Model 2700 Wiring

FIGURE 4-17. Model SCL-(P/Q) Wiring

26

MODEL 396R pH/ORP SECTION 4.0

WIRING MODEL 396RVP

FIGURE 4-18. Model 1055pH/pH Wiring

FIGURE 4-19. Model 1055pH/pH Wiring through Remote Junction Boxes

27

FIGURE 4-20. Model 1055-10-22-32 Wiring

MODEL 396R pH/ORP SECTION 4.0

WIRING MODEL 396RVP

28

29

5.1 START UP. To obtain best accuracy, the sensor

must be calibrated as a loop with the analyzer. Please
refer to the respective analyzer/transmitter instruction
manual for proper calibration procedures.

5.2 396R pH CALIBRATION

1. After a temporary connection is established
between the sensor and the instrument, a buffer
calibration may be performed.

2. Consult appropriate pH/ORP analyzer or
transmitter instruction manual for specific
calibration and standardization procedures or see
below for recommended two point buffer
calibration procedure.

5.2.1 Recommended two point buffer calibration

procedure:

Select two stable buffer solutions, preferably pH 4.0
and 10.0 (pH buffers other than pH 4.0 and pH 10.0
can be used as long as the pH values are at least two
pH units apart).

Note: A pH 7 buffer solution reads a mV value
of approx. zero, and pH buffers read approx.
+/- 59.1 mV for each pH unit above or below
pH 7. Check the pH buffer manufacturer
specifications for millivolt values at various
temperatures since it may affect the actual
value of the buffer solution mV/pH value.

1. Immerse sensor in the first buffer solution. Allow
sensor to adjust to the buffer temperature (to avoid
errors due to temperature differences between the
buffer solution and sensor temperature) and wait
for reading to stabilize. Value of buffer can now be
acknowledged by analyzer/transmitter

2. Once the first buffer has been acknowledged by
the analyzer/transmitter, rinse the buffer solution off
of the sensor with distilled or deionized water.

3. Repeat steps 1 and 2 using the second buffer
solution.

4. Once the analyzer/transmitter has acknowledged
both buffer solutions, a sensor slope (mV/pH) is
established (the slope value can be found within
the analyzer/transmitter).

5. The slope value should read about 59.1 mV/pH for
a new sensor and will decrease over time to
approximately 47 - 49 mV/pH. Once the slope
reads below the 47-49 mV/pH range, a new sensor
should be installed to maintain accurate readings.

5.2.2 Recommended pH Sensor Standardization

For maximum accuracy, the sensor can be standard­ized on-line or with a process grab sample after a
buffer calibration has been performed and the sensor
has been conditioned to the process. Standardization
accounts for the sensor junction potential and other
interferences. Standardization will not change the sen­sor’ s slope but will simply adjust the analyzers r eading
to match that of the known process pH.

1. While obtaining a process solution sample (it is
recommended that the sample is taken close to
the sensor), record the pH value that is shown on
the analyzer/transmitter display.

2. Measure and record the pH of the process solution
sample with a another temperature compensated,
calibrated pH instrument. For best results,
standardization should be performed at the
process temperature.

3. Adjust the analyzer/transmitter value to the
standardized value.

MODEL 396R pH/ORP SECTION 5.0

START UP AND CALIBRATION

SECTION 5.0

START UP AND CALIBRATION

5.3 396R ORP CALIBRATION. An ORP loop is best
calibrated using an ORP standard solution. Most
industrial applications have a number of ORP reac­tions occurring in sequence or simultaneously. There
can be several components that are oxidized or
reduced by the reagents that are used. Theoretically,
the ORP potential is absolute because it is the result of
the oxidation-reduction equilibrium. However, the
actual measured potential is dependent on many fac­tors, including the condition of the surface of the ORP
platinum electrode. Therefore, the sensor should be

allowed 1-2 hours to become “conditioned” to the
stream when first set-up or after being cleaned.

5.3.1 ORP Calibration Procedure
CAUTION

The solution used during the following
check is an acid and should be handled
with care. Follow the directions of the acid
manufacturer. Wear the proper protective
equipment. Do not let the solution come in
contact with skin or clothing. If contact with
skin is made, immediately rinse with clean
water.

1. Make a temporary electrical connection between

the sensor and the instrument.

2. Obtain a standard solution of saturated quinhy-

drone (PN R508-160Z). This can also be made

quite simply by adding a few crystals of quinhy­drone to either pH 4 or pH 7 buffer. Quinhydrone
is only slightly soluble; therefore, only a few crys­tals will be required (refer to Section 6.3. for an
alternate ORP standard solution).

3. Immerse the sensor in the standard solution.
Allow 1-2 minutes for the ORP sensor to stabilize.

4. Adjust the standardize control of the instrument to
the solution value shown in Table 5-1. The resulting
potentials, measured with a clean platinum elec­trode and saturated KCl/AgCl reference electrode,
should be within ±20 millivolts of the value shown in
Table 5-1. Solution temperature must be noted to
insure accurate interpretation of results. The ORP
value of saturated quinhydrone solution is not sta­ble over long periods of time. Therefore, these stan­dards should be made up fresh each time they are
used.

5. Remove the sensor from the buffer, rinse and
install in the process.

TABLE 5-1

ORP of Saturated Quinhydrone Solution

pH 4 pH 7

TEMPERATURE

°C 20 25 30 20 25 30

Millivolt Potential 268 264 260 94 87 80

MODEL 396R pH/ORP SECTION 5.0

START UP AND CALIBRATION

30

31

6.1 Maintenance. The Model 396R Sensor is a dis-

posal type sensor and therefore requires minimum
maintenance. The sensor should be removed from the
process periodically and checked in buffer solutions.
If the sensor will not calibrate, refer to your
analyzer/transmitters instruction manual for proper
test procedures. If the sensor has failed, it should be
discarded and replaced.

6.2 Sensor Removal. Please refer to the appropriate
paragraph for instructions regarding removal of the
sensor for periodic maintenance.

6.2.1 Retractable Version.
WARNING

System pressure may cause the
sensor to blow out with great force
unless care is taken during removal.
Make sure the following steps are
adhered to.

A. Model 396R-21 (21” tube)

1. Be certain system pressure at the sensor is below

64 psig (542 kPa) before proceeding with the
retraction. It is also recommended that the per­sonnel wear a face shield and have a stable foot­ing. Refer to Figure 6-1. Push in on the sensor
end or the top of the J-box and slowly loosen the
hex nut (B) of the process end male connector (A).

B. Model 396R-25 (36” tube)

2. Be certain that pressure at the sensor is below 35

psig (343 KPa) before proceeding with the retrac­tion. It is also recommended that the personnel
wear a face shield and have a stable footing.
Refer to Figure 6-1. Push in on the sensor end or
the top of the J-box and slowly loosen the hex nut
(B) of the process end male connector (A).

CAUTION

Do not remove nut at this time.

3. When the hex nut is loose enough, slowly ease

the sensor back completely until the retraction
stop collar is reached.

CAUTION

Failure to withdraw the sensor completely
may result in damage to the sensor when
the valve is closed.

4. Close the ball valve slowly. If there is resistance,
the valve may be hitting the sensor. Double check
that the sensor has been retracted to the retrac­tion stop collar.

WARNING

Before removing the sensor from the ball valve,
be absolutely certain that the ball valve is fully
closed. Leakage from the male
connector threads may indicate
that the male connector is still
under pressure. Leakage through
a partially open valve could be
hazardous, however with the ball valve closed,
some residual process fluid may leak from the
connector's pipe threads.

5. The Male Connector Body (A) may now be com­pletely unthreaded from the reducing coupling
and the sensor removed for servicing.

CAUTION

If the male connector leaks during inser­tion or retraction, replace the O-ring (PN

9550099) in the male connector A.

6.3 pH Electrode Cleaning. If the electrode is coated

or dirty, it may be cleaned as follows:

1. Remove the sensor from process as instructed in
Section 6.2.

2. Wipe the glass bulb with a soft, clean, lint free
cloth or tissue. If this does not remove the dirt or
coating, proceed to step 3. If the sensor appears
to be clean, go to step 5.

3. Wash the glass bulb in a strong detergent solution
and thoroughly rinse with tap water. If the bulb still
appears to have a coating, proceed to step 4.

CAUTION

The solution used in the following step is
an acid and should be handled with care.
Follow the directions of the acid manufac­turer. Wear the proper protective equip­ment. Do not let the solution come in con­tact with skin or clothing. If contact with the
skin is made, immediately rinse with clean
water.

MODEL 396R pH/ORP SECTION 6.0

MAINTENANCE

SECTION 6.0

MAINTENANCE

32

MODEL 396R pH/ORP SECTION 6.0

MAINTENANCE

4. Following the caution above, wash the glass bulb
in dilute 5% hydrochloric acid solution and then
rinse it thoroughly in tap water. Replace the sen­sor if it cannot be cleaned. If the glass bulb
appears clean, proceed to step 5.

5. Buffer calibrate the sensor (Refer to Section 5.0). If
the sensor appears to respond sluggishly to pH
change, soaking it overnight in a weak acid solution
(5% hydrochloric acid) may improve its response.
Be sure to follow the CAUTION above and to rinse
the sensor’s tip thoroughly with tap water. If the sen­sor will not calibrate, it must be replaced.

6.4 Cleaning Platinum Electrode. The electrode is

never exposed to these undesirable compounds. In the
event poisoning is suspected, the electrode can be
restored to normal operation by simply cleaning the plat­inum electrode with baking soda. Polish it by rubbing it
with a damp paper towel and baking soda until a bright,
shiny appearance is attained.

6.5 Automatic Temperature Compensator. The tem-

perature compensator element is temperature sensi­tive and can be checked with an ohmmeter.
Resistance increases with temperature.

The 3K element will read 3000 ohms ± 1% at 25°C
(77°F) and a Pt-100 will read 110 ohms. Resistance
varies with temperature for a 3K and Pt-100 element
and can be determined according to Table 6-2 or the
following formula:

RT=Ro[l+R1(T-20)]

Where RT = Resistance
T = Temperature in °C

Refer to Table 6-1 for Roand R1values:

TABLE 6-1

Roand R1VALUES FOR TEMPERATURE

COMPENSATION ELEMENTS

6.6 Sensor Tube Replacement When Used With A
Sensor Head Junction Box. Replacement of the

retraction versions sensor tube assembly involves the
removal and installation of two sets of male connectors:
One at the process end of the sensor, and the other at
the junction box end (See Figures 6-1, 6-2). Refer to
Section 6.2 for proper removal of the sensor from
process.

1. Remove sensor from process before proceeding.
The junction box with attached male connector
must be recovered from the old sensor for reuse.
Unscrew the junction box cover and set aside.
Disconnect electrical connections from printed
circuit board inside junction box. Disconnect BNC
connector to preamp. Unscrew hex nut (D) from
male connector body (C). Separate junction box
from used sensor. Set aside.

2. Pry off split ferrule from sensor and set aside for
reuse. Remove hex nut (D) and set aside for
reuse. Check that the internal O-ring is in place in
the male connector body (C) attached to the junc­tion box.

3. Remove hex nut (B) from male connector body (A)
at process end of sensor and set aside. Slide the
Teflon ferrule and the male connector off sensor in
the direction of junction box and set

NOTE

If stainless steel ferrule was used, male
connector body (A) will have to be dis­carded with the sensor tube.

Resistance

Temperature °C (Ohms) ±1%

3K PT-100

0 2670 100.0
10 2802 103.8
20 2934 107.7
25 3000 109.6
30 3066 111.5
40 3198 115.4
50 3330 119.2
60 3462 123.1
70 3594 126.9
80 3726 130.8
90 3858 134.6

100 3990 138.5

Temperature

Compensation Element

R

o

R

1

3K 2934 .0045

PT-100 107.7 .00385

TABLE 6-2

TEMPERATURE vs RESISTANCE OF AUTO

T.C. ELEMENTS

33

4. Discard used O-ring from male connector body
(A). Coat new O-ring with a thin film of the O-ring
lubricant provided. Position it in the machined O­ring groove in place of the discarded O-ring.

CAUTION

Make sure lubricant does not contact any
part of the sensor tip particularly the glass
bulb.

5. Cover the 1" MNPT pipe threads of the male con­nector body (A) with Teflon tape (not provided) to

protect them from galling during reinstallation.

6. Pass the wires from the new sensor through the
process end male connector (A). Make sure that
the beveled edge of the ferrule faces the process
end of the sensor. Snug the hex nut (B) to keep it
in place. Do not tighten down fully on the hex nut
at this time.

7. Pass the wires from the new sensor through the
hex nut (D), the split ferrule (from the old sensor),
male connector body (C), O-ring, and through the
junction box from the “neck” opening and out to
the printed circuit board in the junction box. Butt
the ferrule’s beveled edge and the sensor
tube against the junction male connector (C).
Screw the hex nut (D) by hand until the tube is
“locked” into the male connector body. Make sure
that the male connector body (C) is sufficiently
tightened. The sensor will “click” into place by
pulling the sensor tube away from the junction
box, but will not move from side to side or pull
clear of the male connector. If the sensor tube is
correctly attached to the junction box, wrench
tighten hex nut (D) on male connector body (C)
(see Figure 6-1). Do not put the sensor tube in a
vise or use a pipe wrench to tighten the hardware
as these will damage the sensor. If sensor tube is
not correctly attached to the junction box, loosen
hex nut (D) and repeat.

8. Connect the sensor wires to the terminals on the
printed circuit board in the junction box in the man­ner recommended on the junction box cover,and
reattach the BNC connector to the preamp. Screw
on the cover of the junction box aside. Discard sen­sor tube.

9. Insert the sensor in the process fitting. Stop it
against the closed ball valve. Slide the process­end male connector down the sensor tube to
mate with the process fitting. Tighten the male
connector into the process fitting.

10. Pull back hard on the sensor assembly, as if trying
to remove the sensor, to be certain that the sensor
cannot come free from the valve assembly and
male connector. The built-in retraction stop collar
at the end of the sensor will butt against the
shoulder of the male connector.

11. Open ball valve and position the sensor at the
desired insertion depth and orientation. Using a
crescent or open end wrench, tighten the hex nut
(B) to secure the sensor in place. See Figure 6-2.

NOTE

A stainless steel ferrule is available if the
Teflon ferrule does not adequately grip, be
careful and avoid over tightening. This can
damage the sensor tube.

CAUTION

If the male connector leaks during inser­tion or retraction, replace the O-Ring (PN

9550099) in the male connector body (A).

If the sensor is to be stored, the rubber boot should be
filled with 7pH buffer solution and replaced on sensor
tip until ready to use.

MODEL 396R pH/ORP SECTION 6.0

MAINTENANCE

FIGURE 6-1. Example of Sensor Tube Replacement

FIGURE 6-2. Male Connector Tightening Diagram

MODEL 396R pH/ORP SECTION 6.0

MAINTENANCE

34

35

MODEL 396R pH/ORP SECTION 7.0

DIAGNOSTICS AND TROUBLESHOOTING

SECTION 7.0

DIAGNOSTICS AND TROUBLESHOOTING

7.1 DIAGNOSTICS AND TROUBLESHOOTING WITH MODEL 54/81/3081 pH/ORP. The Model 54 and 54e

Analyzers and Models 81 and 3081 pH Transmitters automatically search for fault conditions that would cause an
error in the measured pH value, as does the Model 1054A/B pH/ORP Analyzer to a lesser degree. Refer to the
respective manual for a complete description of the analyzer’s fault conditions.

Table 7-1 lists the Analyzer/Transmitters diagnostic messages that indicate a possible sensor problem. A more
complete description of the problem and a suggested remedy corresponding to each message is also listed.

DIAGNOSTIC MESSAGE
54 and 54e
81/3081 DESCRIPTION OF PROBLEM REMEDY

“Calibration Warning” 1. Aged glass. 1. Perform buffer calibration.

2. Sensor not immersed. 2. Be sure electrode measuring tip is in

CALIbrAtE process.

“Cracked glass failure” Broken or cracked glass. Replace Sensor.

6LASS FAIL

“High reference imped” 1. Liquid junction coated. 1. Clean sensor; replace if necessary.

2. Reference Cell gel depleted. 2. Replace sensor.

rEF FAIL or rEF WArn 3. Sensor not immersed. 3. Be sure electrode measuring tip is in

process.

“Input voltage high” pH input shorted or sensor. Check wiring. Replace sensor if
“Input voltage low” miswired. necessary.

“Old glass warning” 1. Glass electrode worn out. 1. Replace sensor.

2. Sensor not immersed. 2. Be sure electrode measuring tip is in

6LaSS WArn

process.

“Reference offset err” Reference electrode poisoned. Replace sensor.
(offline only)

Std Err
“Ref voltage high” 1. Reference shorted or sensor Check wiring. Replace sensor if

“Ref voltage low” miswired. necessary.

2. Sensor not immersed.

“Sensor line open” 1.

Open wire between sensor and analyzer.

1. Check sensor wiring.

2. Interconnecting cable greater than 2. Relocate analyzer.

LInE FAIL 1000 ft.

“Sensor miswired” 1.

Open wire between sensor and analyzer.

1. Check wiring.

2. Bad preamplifier. 2. Replace preamplifier.

“Temp error high” 1. Open or shor ted RTD. 1. Replace sensor.
“Temp error low” 2. Temperature out of range. 2. Check process temperature.

tEMP H I
tEMP LO

TABLE 7-1 Troubleshooting with Diagnostics

36

MODEL 396R pH/ORP SECTION 7.0

DIAGNOSTICS AND TROUBLESHOOTING

Problem Probable Cause Remedy

Meter reads off scale. (Display Defective preamplifier. Replace preamplifier (for code 02
reads overrange).

sensors). For code 01, replace sensor.

T.C. element shorted. Check T.C. element as instructed

in Section 6.5 and
replace sensor if defective.

Sensor not in process or sample Make sure sensor is in process with
stream is low. sufficient sample stream (refer to

Section 2.0 for installation details).
Open glass electrode. Replace sensor.
Reference element open - no contact.

Replace sensor.

Display reads between 3 and 6 pH Electrode cracked. Replace sensor.
regardless of actual pH of solution
or sample.

Meter or display indication swings T.C. element shorted. Check T.C. element as instructed
or jumps widely in AUTO T.C. Mode. in Section 6.5 and replace

sensor if defective.

Span between buffers extremely T.C. element open. Check T.C. element as instructed
short in AUTO T.C. Mode. in Section 6.5 and replace sensor

if defective.

Sluggish or slow meter indication Electrode coated. Clean sensor as instructed in
for real changes in pH level. Sections 6.2 or 6.3. Replace

sensor if cracked.
Electrode defective. Replace sensor.

Transmitter cannot be standardized. Electrode coated or cracked. Clean Sensor as instructed in

Sections 6.1 or 6.3 Replace

sensor if cracked.
Defective preamplifier. Replace preamplifier.

Transmitter short spans between Aged glass electrode or high Replace sensor.
two different buffer values. temperature exposure.

Electrode coated . Clean Sensor as instructed in

Sections 6.2 or 6.3. Replace

sensor if cracked.

TABLE 7-2.Troubleshooting without Diagnostics

7.2 TROUBLESHOOTING WITHOUT DIAGNOSTICS. Table 7-2 lists common problems, causes and remedies

typically encountered in process measurement.

37

Model 396R pH/ORP SECTION 8.0

RETURN OF MATERIAL

SECTION 8.0

RETURN OF MATERIAL

8.1 GENERAL.

To expedite the repair and return of instruments, prop­er communication between the customer and the fac­tory is important. The “Return of Materials Request”
form is provided for you (in this manual) to copy and
use in case the situation arises. The accuracy and
completeness of this form will affect the processing
time of your materials. Call 1-949-863-1181 for a
Return Materials Authorization (RMA) number.

8.2 WARRANTY REP AIR.

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 92606

Attn: Factory Repair

RMA No. ____________

Mark the package: Returned for Repair

Model No. ____

8.3 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 8.2.

NOTE

Consult the factory for additional informa­tion regarding service or repair.

FROM: RETURN BILL TO:

_____________________________ _____________________________ _____________________________
_____________________________ _____________________________ _____________________________
_____________________________ _____________________________ _____________________________

CUSTOMER/USER MUST SUBMIT MATERIAL SAFETY SHEET (MSDS) OR COMPLETE STREAM COMPOSITION, AND/OR
LETTER CERTIFYING THE MATERIALS HAVE BEEN DISINFECTED AND/OR DETOXIFIED WHEN RETURNING ANY PRODUCT,
SAMPLE OR MATERIAL THAT HAVE BEEN EXPOSED TO OR USED IN AN ENVIRONMENT OR PROCESS THAT CONTAINS A
HAZARDOUS MATERIAL ANY OF THE ABOVE THAT IS SUBMITTED TO ROSEMOUNT ANALYTICAL WITHOUT THE MSDS
WILL BE RETURNED TO SENDER C.O.D. FOR THE SAFETY AND HEALTH OF OUR EMPLOYEES. WE THANK YOU IN
ADVANCE FOR COMPLIANCE TO THIS SUBJECT.

SENSOR OR CIRCUIT BOARD ONLY:
(Please reference where from in MODEL / SER. NO. Column)

1. PART NO. _____________________________1. MODEL ____________________________________1. SER. NO. __________________

2. PART NO. _____________________________2. MODEL ____________________________________2. SER. NO. __________________

3. PART NO. _____________________________3. MODEL ____________________________________3. SER. NO. __________________

4. PART NO. _____________________________4. MODEL ____________________________________4. SER. NO. __________________

PLEASE CHECK ONE:

■■ REPAIR AND CALIBRATE ■■ DEMO EQUIPMENT NO. ______________________________

■■ EVALUATION ■■ OTHER (EXPLAIN) ___________________________________

■■ REPLACEMENT REQUIRED? ■■ YES ■■ NO _______________________________________________________

DESCRIPTION OF MALFUNCTION:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________

WARRANTY REPAIR REQUESTED:

■■ YES-REFERENCE ORIGINAL ROSEMOUNT ANALYTICAL ORDER NO._______________________________________________

CUSTOMER PURCHASE ORDER NO. ________________________________________________________

■■ NO-PROCEED WITH REPAIRS-INVOICE AGAINST P.O. NO._________________________________________________________

■■ NO-CONTACT WITH ESTIMATE OF REPAIR CHARGES: LETTER ■■ _________________________________________________

PHONE ■■ ________________________________________________

NAME___________________________________________________________ PHONE______________________________________________

ADDRESS_______________________________________________________________________________________________________________

_____________________________________________________________________ ZIP______________________________________________

RETURN AUTHORITY FOR CREDIT ADJUSTMENT [Please check appropriate box(s)]

■■ WRONG PART RECEIVED ■■ REPLACEMENT RECEIVED

■■ DUPLICATE SHIPMENT REFERENCE ROSEMOUNT ANALYTICAL SALES ORDER NO._____________

■■ RETURN FOR CREDIT RETURN AUTHORIZED BY: __________________________________________

WARRANTY DEFECT______________________________________________________________________________________________

_________________________________________________________________________________________________________________

24-6047

RETURN OF MATERIALS REQUEST

•IMPORTANT!

This form must be completed to ensure expedient factory service.

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Rosemount Analytical Inc.
Uniloc Division

2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: [phone]
Fax: [phone]

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 STA T­ED 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.

Rosemount Analytical Inc.
Uniloc Division

2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: [phone]
http://www.RAuniloc.com

© Rosemount Analytical Inc. 2001

Credit Cards for U.S. Purchases Only.

The right people, the right answers, right now.

ON-LINE ORDERING NOW
AVAILABLE ON OUR WEB SITE

http://www.RAuniloc.com

UNILOC DIVISION

CUSTOMER SUPPORT CENTER

1-800-854-8257