Rosemount™ 402 and 402VP
Contacting Conductivity Sensors
Quick Start Guide
0825-0100-3402
0
Rev. AA
May 2019
hasgkas
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
Quick Start Guide 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.
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.
CAUTION
The 402 and 402VP sensors are retractable. BEFORE RETRACTING THE SENSOR, be absolutely certain the
process pressure is less than 64 psig (542 kPa abs) and the process temperature is at a safe level!
Quick Start Guide Table of Contents
00825-0100-3402 May 2019
Contents
Section 1: Specifications
1.1 Specifications ......................................................................................................1
Section 2: Installation
2.1 Unpacking and Inspection ...................................................................................3
2.2 Sensor Installation ...............................................................................................3
2.3 Installation and Retraction of Sensor....................................................................4
Section 3: Wiring
3.1 Wiring for Rosemount 402/402VP .......................................................................7
Section 4: Calibration and Maintenance
4.1 Cleaning the Sensor...........................................................................................11
4.2 Calibrating the Sensor........................................................................................11
Section 5: Troubleshooting
5.1 Troubleshooting ................................................................................................13
Section 6: Accessories
6.1 Accessories........................................................................................................15
Table of Contents i
Table of Contents Quick Start Guide
May 2019 00825-0100-3402
ii Table of Contents
Quick Start Guide Specifications
00825-0100-3402 May 2019
Section 1: Specifications
1.1 Specifications
Table 1-1: Rosemount 402/402VP contacting conductivity sensor specifications
Wetted Materials
Electrodes Titanium
Insulator Glass Filled PEEK
Sensor tube 316 Stainless Steel
O-ring EPDM
Washer Neoprene
Temperature range
Standard 32 to 212 °F (0 to 100 °C)
Maximum pressure
200 psig (1481 kPa abs)
Maximum retraction pressure
64 psig (542 kPa abs)
Vacuum
At 1.6 in. Hg (5.2 kPa) air leakage is less than 0.005 SCFM (0.00014 m3/min)
Cell constants
0.01, 0.1, and 1.0/cm
Process connection
Sensor is inserted through 1¼ in. NPT full port ball valve
Cable
10 ft (3.1 m) standard; for longer cable lengths, choose option -60 (integral junction box) and order interconnecting cable
separately; 402VP Interconnecting VP6 cables sold separately. (See
Accessories).
Table 1-2: Weights and shipping weights
Sensor model With 10 ft. (3.1 m) cable With junction box
Rosemount 402 Contacting Conductivity Sensor 3 lb. (1.5 kg) 4 lb. (2.0 kg) 4 lb. (2.0 kg) 5 lb. (2.5 kg)
Rosemount 402VP Contacting Conductivity Sensor 3 lb. (1.5 kg) 4 lb. (2.0 kg)
1. Rounded up to the nearest 1 lb or 0.5 kg
Specifications 1
(1)
Weight Shipping
weight
Weight Shipping
weight
Specifications Quick Start Guide
May 2019 00825-0100-3402
Table 1-3: Retraction Assembly Specifications
Assembly includes
Ball valve, retraction body, and pipe nipple.
Wetted materials
all valve
B
ipple
N
acking rings
P
Packing bushing 303 Stainless Steel
Retraction body 316 Stainless Steel
Process connection
Ball valve 1¼ in. FNPT; Nipple 1¼ in. MNPT
Temperature
32 to 212 °F (0 to 100 °C)
Pressure
200 psig (1481 kPa abs) maximum
Maximum retraction pressure
64 psig (542 kPa abs) maximum
Vacuum
At 1.6 in. Hg (5.2 kPa) air leakage is less than 0.005 SCFM (0.00014 m3/min)
2 to 212 °F (0 to 100 °C)
3
16 Stainless Steel
3
raphite
G
2 Specifications
Quick Start Guide Installation
00825-0100-3402 May 2019
Section 2: Installation
2.1 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
present and in good condition. Notify the factory if any part is missing.
2.2 Sensor Installation
Figure 2-1 Sensor orientation
Figure 2-2 Recommended installation
Keep ¼ in. (6 mm) clearance between electrodes and piping. The electrolytes must be completely
submerged in the process liquid, i.e., to the upper edge of the guard (item 10 in Figure 2-4).
Installation 3
Installation Quick Start Guide
May 2019 00825-0100-3402
2.2 Installation and Retraction of Sensor
Figure 2-3 Label
2.1.1 Installation
Retraction assembly kit (PN 23765-00) consists of items 1 through 7 shown in Figure 2-4 as well as
a hex key and pipe tape. The sensor assembly includes items 8 through 11.
IMPORTANT
Do not remove or alter the guard (10) on the sensor tube (9).
Figure 2-4 Sensor with retraction assembly kit
1. Make sure the system is shut down and there is no residual pressure.
2. Attach the ball valve (2) to the process piping using the 1–¼-in. FNPT port on the valve
or the 1–¼ in. NPT nipple (1). Use pipe tape on male threads.
4 Installation
Quick Start Guide Installation
00825-0100-3402 May 2019
3. Slide the handle lock up on the ball valve handle and close the ball valve (2). If the process
will be restarted before the sensor is installed, make sure the system pressure is at or below
542 kPa abs (64 psig) before proceeding. If the system will not be restarted until after the
ensor installation, leave the valve in the open position.
s
4. If the sensor includes a junction box (8), it must be removed from the sensor to install the
retraction assembly kit. Disconnect the sensor wires inside the junction box prior to
disassembly.
5. Follow
6. Position the sensor tube (9) so that the electrodes (11) are completely withdrawn inside
7. Position the clamp (4) on the sensor tube (9) so that the electrodes (11) will be completely
8. Slide the retainer (5) onto the sensor tube (9).
9. Screw the junction box (8) — hand tight — onto the sensor tube (9). DO NOT OVER
10. Apply pipe tape to the packing adapter (3) threads and screw the packing adapter onto
11. Check to ensure that the packing bushing (6) has been tightened. You should be able to
12. Open the ball valve (2).
13. There may be some leakage around the packing bushing (6). Tighten the packing bushing
Figure 2-5 to assemble the sensor and retraction assembly. Keep items 3-7 in the
proper sequence. Items 3, 6, and 7 are factory assembled.
the packing adapter (3). If it is difficult to slide the sensor through the packing rings, loosen
the packing bushing (6).
immersed in the process liquid when the sensor is fully inserted through the ball valve. See
Figure 2-4. Use the hex key to secure the clamp to the sensor tube.
TIGHTEN. Use 2-3 wraps of pipe tape on the tube threads if a NEMA 4 seal is required at the
junction box.
the ball valve.
push the sensor tube (9) against the resistance provided by the packing rings (7).
to stop the leak. Use the junction box (8) or sensor rear to push the sensor through the
valve until the clamp (4) rests against the packing bushing.
14. To secure the sensor tube (9) in place, tighten — hand tighten only — the retainer (5)
against the back of the packing adapter (3). If the sensor tube retracts when the system
pressure is increased, reduce the pressure to 542 kPa abs (64 psig) or less, remove the
retainer (5), and tighten the screw in the clamp (4).
Figure 2-5 Sensor installation
Installation 5
Installation Quick Start Guide
May 2019 00825-0100-3402
2.1.2 Retraction
1. Make sure the system pressure is at or below 542 kPa abs (64 psig) at the valve before
proceeding. Provide adequate working area for retraction.
2. Unscrew the retainer (5) from the packing adapter (3). If it is difficult to unscrew the
retainer, system pressure may be forcing the clamp (4) into the retainer. The packing
bushing (6) may not be tight enough to hold the sensor tube (9) in place. To prevent a
sudden retraction of the sensor tube as the retainer is removed, hold onto the junction
box (8) or sensor rear to restrain the sensor.
3. If the sensor tube (9) does not slide back as the retainer is unscrewed, pull back on the
junction box (8) or sensor tube to retract the sensor.
4. If the sensor tube (9) cannot be retracted, loosen the clamp (4) using the hex key. Pull the
clamp back and slowly loosen the packing bushing (6) in 1/8-turn increments. System pres
sure may cause the tube to retract. If not, pull back on the junction box (8) or sensor tube
(9) to withdraw the sensor.
5. Withdraw the sensor tube until the guard (10) contacts the stop inside the packing adapter
(3). The electrodes (11) are now inside the packing adapter. See
lock up on the valve handle and close the ball valve (2).
Figure 2-6. Slide the handle
IMPORTANT
Failure to withdraw the sensor completely may result in damage to the electrodes when the valve is closed.
6. Unscrew the packing adapter (3) from the ball valve (2) to remove the sensor and
retraction assembly.
Figure 2-6 Rosemount 402 Contacting Conductivity Sensor in Retracted Position
6 Installation
Quick Start Guide Wiring
00825-0100-3402 May 2019
Section 3: Wiring
3.1 Wiring for Rosemount 402/402VP
For other wiring diagrams not shown below, please refer to the Liquid Transmitter Wiring Diagrams.
Figure 3-1: Wire color and connections in sensor
Figure 3-2: Wiring for integral junction box
Wiring 7
Wiring Quick Start Guide
May 2019 00825-0100-3402
Figure 3-3: Wiring for Rosemount 56 and 1056 transmitters
Figure 3-4: Wiring for Rosemount 56 and 1056 transmitters
8 Wiring
Quick Start Guide Wiring
00825-0100-3402 May 2019
Figure 3-5: Wiring for Rosemount 5081 transmitter
3.1.1 Wiring through a Junction Box
If wiring connections are made through a remote junction box (PN 23550-00), wire point-to-point.
Use interconnecting cable 23747-00 (factory-terminated) or 9200275 (no terminations).
Figure 3-6: Pin out diagram for Rosemount 402VP contacting conductivity sensors with
Variopol cable connection
Wiring 9
Wiring Quick Start Guide
May 2019 00825-0100-3402
10 Wiring
Quick Start Guide Calibration and Maintenance
00825-0100-3402 May 2019
Section 4: Calibration and Maintenance
4.1 Cleaning the sensor
Use a warm detergent solution and a soft brush or pipe cleaner to remove oil and scale. Isopropyl
alcohol (rubbing alcohol) can also be used to remove oily films. Avoid using strong mineral acids
to clean conductivity sensors.
4.1 Calibrating the sensor
Rosemount 402 conductivity sensors are calibrated at the factory and do not need calibration when
first placed in service. Simply enter the cell constant printed on the label into the transmitter. After
a period of service, the sensor may require calibration. The sensor can be calibrated against a
solution having known conductivity or against a referee meter and sensor. If using a standard
solution, choose one having conductivity in the recommended operating for the sensor cell
constant. Refer to the analyzer manual or product data sheet for recommended ranges. Do not
use standard solutions having conductivity less than about 100 µS/cm. They are susceptible to
contamination by atmospheric carbon dioxide, which can alter the conductivity by a variable
amount as great as 1.2 µS/cm (at 25 °C). Because 0.01/cm sensors must be calibrated in low
conductivity solutions, they are best calibrated against a referee meter and sensor in a closed
system. For more information about calibrating refer to Application Data Sheet.
Calibration and Maintenance 11
Calibration and Maintenance Quick Start Guide
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12 Calibration and Maintenance
Quick Start Guide Troubleshooting
00825-0100-3402 May 2019
Section 5: Troubleshooting
5.1 Troubleshooting
Table 5-1: Troubleshooting
Trouble Probable Cause Remedy
Wiring is incorrect. Verify wiring.
Temperature element is open or shorted. Check temperature element for open or short
Off-scale reading
circuits. See
Sensor is not in process stream. Be sure sensor is completely submerged in
process stream.
Variopol cable is not properly seated. Loosen connector and reseat.
Sensor has failed. Perform isolation checks. See Figure 5-2.
Figure 5-1.
Sensor is improperly installed in process
Noisy reading
Reading seems wrong (lower
or higher than expected)
Sluggish response Electrodes are fouled. Clean electrodes.
stream.
Variopol cable is not properly seated. Loosen connector and reseat.
Bubbles trapped in sensor. Be sure sensor is properly oriented in pipe or
Wrong temperature correction algorithm. Check that temperature correction is appro-
Wrong cell constant. Verify that the correct cell constant has been
Sensor is installed in dead area in piping Move sensor to a location more representative
Be sure sensor is completely submerged in
process stream.
flow cell. See
to flow cell.
priate for the sample. See transmitter manual
for more information.
entered in the analyzer and that the cell
constant is appropriate for the conductivity of
the sample. See transmitter manual.
of the process liquid.
Figure 2-1. Apply back pressure
Note: For any repair or warranty inquiries please contact our Customer Care group.
Troubleshooting 13
Troubleshooting Quick Start Guide
May 2019 00825-0100-3402
5.1.1 Checking the temperature element
Disconnect leads and measure resistance shown. The measured resistance should be close to the
value in the table.
Figure 5-1 Checking the temperature element
5.1.2 Checking the continuity and leakage
Disconnect electrode leads and measure resistance and continuity as shown. Sensor must be dry
when checking resistance between electrode leads.
Figure 5-2 Checking the continuity and leakage
Temperature
(°C)
0 100.0 1000
10 103.9 1039
20 107.8 1078
30 111.7 1117
40 115.5 1155
50 119.4 1194
Resistance in ohms
Pt 100 Pt 1000
14 Troubleshooting
Quick Start Guide Accessories
00825-0100-3402 May 2019
Section 6: Accessories
6.1 Accessories
Table 6-1: Accessories for Rosemount 402/402VP Contacting Conductivity Sensor accessories information
Part Number Description
23550-00 Remote junction box without preamplifier
23747-00 Interconnect cable, prepped (must specify length)
9200275 Extension cable, unprepped (must specify length)
23765-00 Retraction assembly kit (includes nipple, ball valve, and retraction body)
23796-00 Retraction Body
9340078 1¼ in. NPT Full Port Ball Valve
05010781899
05010797875
05010782468
05010783002
05000705464
05000709672
05010782147
05010782026
23747-06 2.5 ft (0.8 m) Interconnecting VP6 Cable
23747-04 6.4 ft (1.2 m) Interconnecting VP6 Cable
23747-02 10 ft (3.0 m) Interconnecting VP6 Cable
23747-07 15 ft (4.6 m) Interconnecting VP6 Cable
23747-08 20 ft (6.1 m) Interconnecting VP6 Cable
23747-09 25 ft (7.6 m) Interconnecting VP6 Cable
23747-10 30 ft (9.1 m) Interconnecting VP6 Cable
23747-03 50 ft (15.2 m) Interconnecting VP6 Cable
23747-11 100 ft (30.5 m) Interconnecting VP6 Cable
Conductivity standard SS-6, 200 µS/cm, 32 oz (0.95 L)
Conductivity standard SS-6A, 200 µS/cm, 1 gal (3.78 L)
Conductivity standard SS-5, 100k0 µS/cm, 32 oz (0.95 L)
Conductivity standard SS-5A, 1000 µS/cm, 1 gal (3.78 L)
Conductivity standard SS-1, 1409 µS/cm, 32 oz (0.95 L)
Conductivity standard SS-1A, 1409 µS/cm, 1 gal (3.78 L)
Conductivity standard SS-7, 5000 µS/cm, 32 oz (0.95 L)
Conductivity standard SS-7A, 5000 µS/cm, 1 gal (3.78 L)
Accessories 15
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Rev. AA
May 2019
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