Rosemount 396R/396RVP pH/ORP Sensors Manuals & Guides

Rosemount™ 396R/396RVP

pH/ORP Sensors

Reference Manual

0809-0100-4496

0

Rev. KB

February 2019

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Essential Instructions

Read this page before proceeding!

merson designs, manufactures and tests its products to meet many national and international stan-

E
dards. Because these sensors 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 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
sensor; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Emerson representative for

clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and maintenance

of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate

Reference 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 Emerson. Unauthorized parts and procedures can affect the product's
performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY.
Third-party substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when

maintenance is being performed by qualified persons, to prevent electrical shock and
personal injury.

The information contained in this document is subject to change without notice.

DANGER

Hazardous Area InstallationN

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
combi nation 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 trans­mitter instruc tion manual for details.

Proper installation, operation and servicing of this sensor in a Hazardous Area Instal lation is entirely the
responsibility of the user.

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.

WARNING

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

CAUTION

Special Conditions for Safe Use

1. All pH/ORP sensors have a plastic enclosure which must only be cleaned with a damp cloth to avoid the

danger due to a build up of an electrostatic charge.

2. All pH/ORP sensor models are intended to be in contact with the process fluid and may not meet the

500V r.m.s. a.c. test to earth.

his must be taken into consideration at installation.

T

Reference Manual Table of Contents

00809-0100-4496 February 2019

Contents

Section 1: Description and Specifications

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

1.2 Specifications ......................................................................................................2

1.3 Product Certifications..........................................................................................4

1.4 Ordering Information...........................................................................................5

Section 2: Installation

2.1 First Time Installation ..........................................................................................7

2.2 Unpacking and Inspection ...................................................................................8

2.3 Mechanical Installation ........................................................................................8

Section 3: Wiring Rosemount 396R

3.1 Wiring for Rosemount 396R...............................................................................17

Section 4: Wiring Rosemount 396RVP

4.1 Wiring for Rosemount 396RVP...........................................................................27

Section 5: Startup and Calibration

5.1 Sartup ...............................................................................................................43

5.2 pH Calibration ...................................................................................................43

5.3 ORP Calibration .................................................................................................44

Section 6: Maintenance

6.1 Maintenance......................................................................................................45

6.2 Sensor Removal .................................................................................................45

6.3 pH Electrode Cleaning .......................................................................................46

6.4 Cleaning Platinum Electrode..............................................................................46

6.5 Automatic Temperature Compensator...............................................................47

6.6 Sensor Tube Replacement When Used With A Sensor Head Junction Box............48

Section 7: Diagnostics and Troubleshooting

7.1 Diagnostics and Troubleshooting with Model 54/81/3081 pH/ORP....................51

Section 8: Accessories

8.1 Accessories........................................................................................................53

EC Declaration of Conformity ...............................................................................55

Intrisicallly Safe Sensor Installation Drawing - FM ......................................57

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ii Table of Contents

Reference Manual Description and Specifications

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Section 1: Description and Specifications

1.1 Features and Applications

Rosemount 396R and 396RVP Sensors are specifically designed for improved life in harsh, dirty

applications where a separate sample stream is difficult to provide and greater insertion depths

are required. These sensors are designed for use with a 1-1/4 in. or 1-1/2 in. ball valve for hot tap

installation. Sensors are constructed of molded polypropylene housed in a titanium tube with EPDM

seals to provide maximum chemical resistance. The sensors feature a shrouded tip for protection

from breakage while allowing process to flow by the glass electrode for accurate and reliable pH

and ORP measurements.

Figure 1-1: Cross Section Diagram of the TUpH Reference Technology

All TUpH sensors are designed with a large area reference junction, helical reference pathway, and an
AccuGlass pH glass bulb. This sensor technology ensures superior performance while only requiring
minimal maintenance.

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1.2 Specifications

able 1-1: Percent linearity over pH

T

pH Range Hemi Bulb Flat Bulb

0-2 pH 94% 93%

-12 pH

2

12-13 pH 97% 95%

13-14 pH 92% --

Table 1-2: Rosemount 396R sensor specifications

Measured Range

pH range 0 to 14 pH

ORP range -1500 mV to 1500 mV

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

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)

Wetted Materials

Polypropylene, EPDM, titanium, glass, (platinum: ORP only)

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)

Process Connections

None, must use 1 inch process connector or ball valve kit (1-1/2 or 1-1/4 in.) (sold separately)

Cable Length

Integral 15 ft or 9.5 in. 9 conductor cable except option 60 (9.5 in. coaxial cable with BNC)

9%

9

8%

9

2 Description and Specifications

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able 1-3: Rosemount 396RVP sensor specifications

T

Measured Range

pH range 0 to 14 pH

ORP range -1500 mV to 1500 mV

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

Pressure Range

Hemi bulb 100-1136 kPa abs (0-150 psig)

Flat bulb 100-790 kPa abs (0-100 psig)

Wetted Materials

Polypropylene, EPDM, titanium, glass, (platinum: ORP only)

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)

Process Connections

None, must use 1 inch process connector or ball valve kit (1-1/2 in. or 1-1/4 in.)

Cable Length

Use cable 24281-XX (where XX = -01 through -08 and designates various cable lengths). See accessories.

Description and Specifications 3

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1.3 Product Certifications

Please see online certificates for further details.

IECEx

Sensors without preamp (pH and ORP) – Ex ia IIC T4 Ga (-20°C ≤ Ta ≤ +60°C)

Sensors with SMART preamp (pH only) – Ex ia IIC T4 Ga (-20°C ≤ Ta ≤ +60°C)

Per standards IEC60079-0 : 2011, IEC 60079-11 : 2011

ATEX

Sensors without preamp (pH and ORP) – II 1 G Ex ia IIC T4 Ga (-20˚C ≤ Ta ≤ +60˚C)

Sensors with SMART preamp (pH only) – II 1 G Ex ia IIC T4 Ga (-20˚C ≤ Ta ≤ +60˚C)

Per standards EN 60079-0: 2012+A11:2013, EN 60079-11:2012

FM

See online FM Certificate of Compliance for applicable sensor options:

Intrinsically Safe for use in Class I, II, and III, Division 1, Groups A, B, C, D, E, F, and G; Temperature

Class T6 Ta = -20 °C to +60 °C

Intrinsically Safe for use in Class I, Zone 0, AEx ia IIC T6 Ta = -20 °C to +60 °C

Nonincendive for use in Class I, Division 2, Groups A, B, C, and D; Temperature Class T6 Ta = -20 °C

to +60 °C

Suitable for use in Class II and III, Division 2, Groups E, F, and G; Temperature Class T6 Ta = -20 °C

to +60 °C Hazardous (Classified) Locations

IS/I,II,III/1/ABCDEFG/T6 Ta = 60°C - 1400332; Entity; I/0/AEx ia IIC/T6 Ta = 60 °C - 1400332; Entity;

NI/I/2/ABCD/T6 Ta = 60 °C; S/II,III/2/EFG/T6 Ta = 60 °C

Per standards 3600:1998, 3610:2010, 3611:2004, 3810:2005

CSA

See online CSA Certificate of Compliance for applicable sensor options:

Sensors with preamp – Intrinsically Safe:

Class I, Division 1, Groups ABCD; Class II, Division 1, Groups EFG; Class III; Class I, Division 2, Groups

ABCD; Ambient temperature rating -20 °C to +60 °C; Ex ia IIC; T6

Sensors without preamp – Intrinsically Safe and Non-Incendive:

Class I, Division 1, Groups ABCD; Class II, Division 1, Groups EFG; Class III; Class I, Division 2, Groups

ABCD; Ex ia IIC; T6; Ambient temperature rating -20 °C to +60 °C: (Simple Apparatus)

Per standards C22.2 No. 0-10, C22.2 No. 0.4-M2004, C22.2 No. 94-M1991, C22.2 No. 142 –

M1987, C22.2 No 157 – M1992, CAN/CSA E60079-0:07, CAN/CSA E60079- 11:02, UL50 11th Ed, UL508

17th Ed, UL913 7th Ed, UL 60079-0: 2005, UL 60079-11: 2002

4 Description and Specifications

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1.4 Ordering Information

Table 1-4: Rosemount 396R ordering information

Model Sensor type

396R pH/ORP Sensor

Measuring Electrode Type

10 pH - GPHT Glass

2

1
13 pH - GPLR Flat Glass

Sensor Length

21 21 Inch Titanium Tube
25 36 Inch Titanium Tube

Transmitter/TC Compatibility

50 3K TC
54 Pt-100

Optional Cable Options

_ No Selection
60 9.5 Inch Cable with BNC
61 9.5 Inch Cable without BNC

Typical Model Number: 396R-10-21-54

RP

O

(1)

(2)

3)

(

(4)

(5)

1. For use with legacy transmitter model 1181.

2. For use with Rosemount model 1056, 1057, 1066, 5081, and 56 transmitters.

3. The sensor will come with a standard 15 ft. integral cable.

4. Used for connection to 1181, 1054 series, and 2081 sensor head junction boxes.

5. Used for connection to sensor head junction box PN 23709-00.

Table 1-5: Rosemount 396RVP ordering information

Model Sensor type

396RVP pH/ORP Sensor

Measuring Electrode Type

10 pH - GPHT Glass
12 ORP
13 pH - GPLR Flat Glass

Sensor Length

21 21 Inch Titanium Tube
25 36 Inch Titanium Tube

Transmitter/TC Compatibility

50 3K TC
54 Pt-100
55 Pt-100 for SMART Preamplifier

(1)

(2)

(3)

Preamplifier Options

_ No Selection
70 SMART Preamplifier

Typical Model Number: 396RVP-10-21-55-70

(4)

1. For use with legacy transmitter model 1181.

2. For use with Rosemount model 1056, 1057, 1066, 5081, and 56 transmitters.

3. Must be selected with option 70. Also suitable for use with Rosemount model 1056, 1057, 1066, 5081, and 56 transmitters.

4. Must be selected with option 55.

Description and Specifications 5

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6 Description and Specifications

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Section 2: Installation

2.1 First Time Installation

For first time Rosemount 396R installations, using the following guide is recommended:

1. Retractable Mounting

A. Choose one (required for all first time installations):

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

B. 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

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

A. Sensor Head Junction Boxes (used with options -60 or -61 sensor) - Choose one:

PN 23709-00; includes preamplifier

B. Remote Junction Boxes (used with standard 15 ft. cable length sensor) - Choose one:

PN 23555-00; includes preamplifier

3. Extension Cables - Choose one:

PN 23646-01, 11 conductor, shielded, prepped

PN 9200273, 11 conductor, shielded, unprepped

For first time Rosemount 396RVP installations, using the following guide is recommended:

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

Choose one: PN 24281-00 -- 15 ft. VP8 Cable

PN 24281-01 -- 25 ft. VP8 Cable

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)

PN 23555-00 includes preamplifier

4. Extension cables

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

PN 9200273, 11 conductor, shielded, unprepped

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2.2 Unpacking and Inspection

Inspect the outside 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

resent and in good condition. Notify the factory if any part is missing.

p

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 8.0 for instructions.

WARNING

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

2.3 Mechanical Installation

The Rosemount 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 Rosemount 396R can also be
inserted directly into the process without the use of a ball valve for appli cations 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 2.3.2). Perform the following steps for sensor installation through a ball
valve:

2.3.1 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.

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.

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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 retraction 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.

CAUTION

Over tightening the hex nut may damage the ferrule.

NOTICE

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 O-ring in the male connector.

2.3.2 Installation Without Ball Valve

The Rosemount 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.

Figure 2-1: Exploded View of Ball Valve Kit PN 23240-00 used with process connector PN
23166-00 (or PN 23166-01)

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Figure 2-1: Typical Mounting Configurations for Rosemount 396R

Figure 2-2: Typical Mounting Configurations for Rosemount 396RVP

10 Calibration and Maintenance

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igure 2-3: Dimensional Drawing — Rosemount 396R with Optional Ball Valve PN 23765-00

F

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

Calibration and Maintenance 11

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Figure 2-4: Dimensional Drawing — Rosemount 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.

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Figure 2-5: Dimensional Warning Label for Rosemount 396R Hemi Bulb Sensors and Sensor

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

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Figure 2-6: Dimensional Drawing — Rosemount 396RVP with Optional 1-1/2 inch Ball Valve PN
23240-00

14 Installation

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Figure 2-6: Dimensional Drawing — Rosemount 396RVP with Optional 1-1/4 inch Ball Valve PN

3765-00

2

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16 Installation

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Section 3: Wiring Rosemount 396R

3.1 Wiring for Rosemount 396R

Make electrical connections as shown on Figures 3-1 through 3-15 using the following guidelines.

For wiring Rosemount 396RVP, see Section 4.

1. Pay 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 transmitter 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.

NOTICE

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 9200274)

Wiring Rosemount 396R 17

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Figure 3-2: Wiring Rosemount 396R-54 to Models 54e, 81, 3081, 4081, and 5081 pH/ORP

Figure 3-3: Wiring Rosemount 396R-54 with Remote J-Box and Preamp (PN 23555-00)

18 Wiring Rosemount 396R

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Figure 3-4: Wiring Rosemount 396R-50 for use with Remote Junction Box (PN 23309-03)

Figure 3-5: Wiring Rosemount 396R-54 for use with Remote Junction Box (PN 23309-04)

Wiring Rosemount 396R 19

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Figure 3-6: Wiring Rosemount 396R-50/54 to Model 1181 pH/ORP

Figure 3-7: Wiring Rosemount 396R-54 to Models 1054A/B pH/ORP, 2054 pH, and 2081 pH/ORP

20 Wiring Rosemount 396R

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Figure 3-8: Wiring Rosemount 396R-54 to Model SCL-(P/Q)

Figure 3-9: Wiring Rosemount 396R-54-61 to Model Xmt-P-XX-10

Wiring Rosemount 396R 21

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Figure 3-10: Wiring Rosemount 396R-50/54-60 for use with Sensor Head J-Boxes to Models
1181, 1054 Series, 2054, 2081

Figure 3-11: Wiring Rosemount 396R-54-61 for use with Sensor Head J-Box to Models 54e, 81,
3081, 4081, and 5081

22 Wiring Rosemount 396R

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Figure 3-12: Wiring Rosemount 396R-50 for use with J-Box (PN 23707-00) to Models 1181,

050, 1060, 1030, and 1023 pH Transmitters

1

Wiring Rosemount 396R 23

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Figure 3-13: Wiring Rosemount 396R-54 for use with J-Box (PN 23708-01) to Models 1054
Series, 2054, and 2081 pH Transmitters

24 Wiring Rosemount 396R

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igure 3-14: Wiring Rosemount 396R-50/54-60 for use with Sensor Head J-Boxes to Models

F
1181, 1054 Series, 2054, 2081

Figure 3-15: Wiring Rosemount 396R-54-61 to Model 1055-10-22-32

Wiring Rosemount 396R 25

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26 Wiring Rosemount 396R

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Section 3: Wiring Rosemount 396RVP

3.1 Wiring for Rosemount 396RVP

Make electrical connections as shown on Figures 4-1 through 4-20 using the following guidelines.
For wiring Rosemount 396R, see Section 3.

1. Pay 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 Rosemount 396RVP uses a mating VP cable. See attached wiring sheet for wire
functions of the cables and wiring diagrams to various transmitters.

3. The maximum distance from the sensor to the transmitter 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.

NOTICE

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.

Wiring Rosemount 396RVP 27

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Figure 4-1: Model 81 Wiring

Figure 4-2: Model 1181 Wiring

28 Wiring Rosemount 396RVP

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Figure 4-3: Model 81 Wiring through Remote Junction Box

Wiring Rosemount 396RVP 29

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igure 4-4: Model 1181, 1050/1060, & 1003/1023 Wiring through Remote Junction Box

F

30 Wiring Rosemount 396RVP

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igure 4-5: Model 2081 Wiring

F

Figure 4-6: Model 3081, 4081, and 5081 Wiring

Wiring Rosemount 396RVP 31

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igure 4-7: Model 2081 Wiring through Remote Junction Box

F

32 Wiring Rosemount 396RVP

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igure 4-8: Model 3081, 4081, and 5081 Wiring through Remote Junction Box

F

Wiring Rosemount 396RVP 33

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Figure 4-9: Model 1054 Wiring

Figure 4-10: Model 1054A/B & 2054 Wiring

34 Wiring Rosemount 396RVP

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Figure 4-11: Model 1054 Wiring through a Remote Junction Box

Wiring Rosemount 396RVP 35

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igure 4-12: Model 1054A/B & 2054 Wiring through a Remote Junction Box

F

36 Wiring Rosemount 396RVP

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Figure 4-13: Model 54/54e Wiring

Figure 4-14: Model 54 Wiring through Remote Junction Box

Wiring Rosemount 396RVP 37

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igure 4-15: Model 2700 Wiring

F

38 Wiring Rosemount 396RVP

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igure 4-16: Model SCL-(P/Q) Wiring

F

Figure 4-17: Model Xmt-P-XX-10 Wiring

Wiring Rosemount 396RVP 39

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igure 4-18: Model 1055pH/pH Wiring

F

Figure 4-19: Model 1055pH/pH Wiring through Remote Junction Boxes

40 Wiring Rosemount 396RVP

Reference Manual Wiring Rosemount 396RVP

00809-0100-4496 February 2019

igure 4-20: Model 1055-10-22-32 Wiring

F

Wiring Rosemount 396RVP 41

Wiring Rosemount 396RVP Reference Manual

February 2019 00809-0100-4496

42 Wiring Rosemount 396RVP

Reference Manual Wiring Rosemount 396RVP

00809-0100-4496 February 2019

Section 5: Startup and Calibration

5.1 Startup

To obtain best accuracy, the sensor must be calibrated as a loop with the transmitter. Please refer to
the respective transmitter Reference Manual for proper calibration procedures.

5.2 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 transmitter Reference 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 7.0 (pH buffers other than pH 4.0 and
pH 7.0 can be used as long as the pH values are at least two pH units apart).

NOTICE

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 transmitter.

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

Startup and Calibration 43

Startup and Calibration Reference Manual

February 2019 00809-0100-4496

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.

tandardization will not change the sensor’s slope but will simply adjust the transmitters reading

S

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 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 transmitter value to the standardized value.

5.3 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

1. Make a temporary electrical connection between the sensor and the instrument.

2. Obtain a ORP standard solution (PN R508-8oz) or one can 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.

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

44 Startup and Calibration

Reference Manual Maintenance

00809-0100-4496 February 2019

Section 6: Maintenance

6.1 Maintenance

Rosemount 396R and 396RVP sensors are disposable type sensors and require minimum
maintenance. These sensors should be removed from the process periodically and checked in buffer
solutions. If the sensor will not calibrate, refer to your transmitter Reference 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. Rosemount 396R-21 (21 in. 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. Rosemount 396R-25 (36 in. 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.

Maintenance 45

Maintenance Reference Manual

February 2019 00809-0100-4496

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.

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). 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.

46 Maintenance

Reference Manual Maintenance

00809-0100-4496 February 2019

6.5 Automatic Temperature Compensator

The temperature 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. Resist-

ance varies with temperature for a 3K and Pt-100 element and can be determined according to

Table 6-2 or the following formula:

RT=R0[l+R1(T-20)]

Where RT= Resistance

T = Temperature in °C

Refer to Table 4-1 for R

and R1values

0

Table 6-1: R0and R1Values for Temperature Compensation Elements

Temperature Element R

3K 2934 0.0045

PT-100 107.7 0.00385

0

Table 6-2: Temperature vs Resistance of Automatic Temperature Compensator Elements

Temperature °C Resistance (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

R

1

Maintenance 47

Maintenance Reference Manual

February 2019 00809-0100-4496

6.6 Sensor Tube Replacement When Used With A
Sensor Head Junction Box

Replace ment 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.

NOTICE

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

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.

48 Maintenance

Reference Manual Maintenance

00809-0100-4496 February 2019

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.

NOTICE

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.

Maintenance 49

Maintenance Reference Manual

February 2019 00809-0100-4496

igure 6-1: Example of Sensor Tube Replacement

F

Figure 6-2: Male Connector Tightening Diagram

50 Maintenance

Reference Manual Diagnostics and Troubleshooting

00809-0100-4496 February 2019

Section 7: Diagnostics and Troubleshooting

7.1 Diagnostics and Troubleshooting with Model
54/81/3081 pH/ORP

The Model 54 and 54e transmitters 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 transmitter to a lesser degree. Refer to the respective manual for a complete description
of the transmitter’s fault conditions.

Table 7-1 lists the 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.

Table 7-1: Troubleshooting with Diagnostics

Diagnostics and Troubleshooting 51

Diagnostics and Troubleshooting Reference Manual

February 2019 00809-0100-4496

Table 7-2: Troubleshooting without Diagnostics

Trouble Probable Cause Remedy

Meter reads off scale. (Display
reads overrange.)

Display reads between 3 and 6
pH regardless of actual pH of
solution or sample.

Meter or display indication
swings or jumps widely in
AUTO T.C. Mode.

Span between buffers
extremely short in AUTO T.C.
Mode.

Sluggish or slow meter
indication for real changes in
pH level.

Defective preamplifier. Replace preamplifier (for code 02 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 stream is low. Make sure sensor is in process with sufficient

sample stream (refer to Section 2.0 for

nstallation details).

i

Open glass electrode. Replace sensor.

Reference element open - no contact. Replace sensor.

Electrode cracked. Replace sensor.

T.C. element shorted. Check T.C. element as instructed in Section 6.5

and replace sensor if defective.

T.C. element open. Check T.C. element as instructed in Section 6.5

and replace sensor if defective.

Electrode coated. Clean sensor as instructed in Sections 6.3 or

6.4. Replace sensor if cracked.

Electrode at end of life. Replace sensor.

Transmitter cannot be
standardized.

Transmitter short spans
between two different buffer
values.

Electrode coated or cracked. Clean sensor as instructed in Sections 6.3 or

6.4. Replace sensor if cracked.

Electrode at end of life, due to old glass or high
temperature exposure.

Coated glass. Clean sensor as instructed in Sections 6.3 or

Replace sensor.

6.4. Replace sensor if cracked.

Note: For any repair or warranty inquiries please contact our Customer Care group.

52 Diagnostics and Troubleshooting

Reference Manual Accessories

00809-0100-4496 February 2019

Section 8: Accessories

8.1 Accessories

Table 8-1: Accessories for Rosemount 396R

Part Number Description

23550-00 Remote Junction box with extension board

9210012 Buffer solution, 4.01 pH, 16 oz

9210013 Buffer solution, 6.86 pH, 16 oz

9210014 Buffer solution, 9.18 pH, 16 oz

23557-00 Preamplifier for junction box for Models 1055, 54e, 81, 3081, 4081, 5081, Xmt

Table 8-2: Accessories for Rosemount 396RVP

Part Number Description

23557-00 Preamplifier for junction box for Models 54e, 81, 3081, 4081, 5081, Xmt, 1055

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

R508-80Z ORP solution, 460 mv ± 10 at 20°C

Accessories 53

Diagnostics and Troubleshooting Reference Manual

February 2019 00809-0100-4496

54 Accessories

Reference Manual EC Declaration of Conformity

00809-0100-4496 February 2019

EC Declaration of Conformity

ote: Please see websitefor most recent Declaration.

N

EC Declaration of Conformity 55

EC Declaration of Conformity Reference Manual

February 2019 00809-0100-4496

56 EC Declaration of Conformity

Reference Manual EC Declaration of Conformity

00809-0100-4496 February 2019

EC Declaration of Conformity 57

China RoHS Table Reference Manual

February 2019 00809-0100-4496

58 China RoHS Table

ANY FM APPROVED

ASSOCIATED APPARATUS

HAVING ENTITY PARAMETERS

NO

N-

H

AZARDOUS

(UNCLASSIFIED)

AREA

CLASS I, II, III, DIVISION 1, GROUPS A-G

T6 Ta = 60C

SENSOR

ENTITY PARAM ETERS

Ui = 13.1U, Ii = 358mA

Pi = 698 m W

Ci = 0.967 F, Li = 0.1m H

1. NO REVISION TO THIS DRAW ING IS PERMITTED W ITHO UT

FM APPROVAL.

2. U

m ax

> U

t

; I

m ax

> I

t

; (C

i

OF ALL LOOPS + C CABLE) < C

a

;

(L

i

OF ALL LOOPS + L CABLE) < L

a

, P

m ax

OR P

i

> P

0.

3. SINGLE M ULTI-CHANNEL

IS BARRIER OR APPARATUS M UST BEFM APPROVED,

4. SINGLE M ULTI-CHANNEL

IS BARRIER OR APPARATUS M ANUFACTURE’S

CONTROL DRAW INGS M UST BE FOLLOW ED W HEN INSTALLING THE SYSTEM.

IS BARRIER OR EQUIPM ENT M AY BE INSTALLED W ITHIN THE HAZARDOUS

(CLASSIFIED) LOCATION FOR W HICH IT IS APPROVED

.

5. INSTALLATION M UST BE IN ACCORDANCE W ITH ARTICL

E 500 OF THE NEC

(ANSI/NFPA 70) AND ANSI/ISA RP 12.6.

W ARNING: SUBSTITUTION OF COMPONENTS M AY IM PA

IR INTRINSIC SAFETY.

6. pH & AM PEROM ETRIC SENSORS W ITHOUT PREAMPS ARE SIM PLE APPARATUS.

ZON E

ZONE 0

7. CONTROL EQUIPM ENT CO NNECTED TO THE ASSOCIATED APPARATUS M UST

NO T USE OR GENERATE M ORE THAN 250V.

RESISTANCE BETW EEN INTRINSICALLY SAFE GROUND AND EARTH GROUND

M UST BE LESS THAN O R EQUAL TO 1 OHM.

ANY

FM APPROVED TRANSM ITTER FOR

DIVISION 1 W ITH INTRINSICALLY SAFE

OUTPUT PARAM ETERS. THIS

FM

APPROVED DEVICE M UST BE INSTALLED

PER ITS INSTALLATION DRAW IN G.

FM

APPROVED EQUIPM ENT (M AY BE

M ULTIPLE DEVICES, NUM BER IS LIM ITED

BY REQUIREMENTS TO M EET ALL OTHER

IS REQUIREMENTS FOR THE NETWORK)

W ITH EQUIVALENT HAZARDOUS AREA

APPROVALS.

H

AZARDOUS

(CLASSI

F

IED)

AREA

INTRISICALLY SAFE

9. pH/ORP SENSOR M O DELS THAT M AY CONTAIN THE PREAMPLIFIER:

3900/VP

3500/VP

3300HT/VP

3400HT/VP

396/VP

396R/VP

396P/VP

398R/VP

399/VP

389/VP

385/385+

10. W ARNING: TO PREVENT IGNITION O F FLAMMABLE OR COMBUSTIBLE

ATM OSPHERES, DISCONNECT POW ER BEFORE SERVIC

ING.

11. THE ENTITY CONCEPT ALLOW S INTECONNECTION OF INTRINSICALLY SAFE

APPARATUS W ITH ASSOCIATED APPARATUS W HEN THE FOLLOW ING IS TRUE:

U

i

> U

o;

I

i

> I

o;

P

i

> P

o;

C

o

> C

i

+ C CABLE; L

o

> L

i

+ L CABLE.

12. COPY REVISIONS TO 1400332 TO pH/ORP SHIPPING M ANUALS.

13 Ci INCLUDES THE CAPACITANCE OF 500 FEET OF SENSOR CABLE.

13

DW G NO.

1400332

8.

Reference Manual FM Installation

00809-0100-4496 February 2019

Intrisicallly Safe Sensor Installation Drawing - FM

FM Installation 59

00809-0100-4496

Rev. KB

February 2019

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©2019

The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a mark of

he Emerson family of companies. All other marks are the property of their respective

f t

o

ne

o
owners.

ents of this publication are presented for information purposes only, and while effort has

e cont

Th

made to ensure their accuracy, they are not to be construed as warranties or guarantees,

been

or implied, regarding the products or services described herein or their use or applicability.

ess

expr

are governed by our terms and conditions, which are available on request. We reserve the

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modify or improve the designs or specifications of our products at any time without notice.

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