Rosemount Hx438 Sensor Amperometric Steam Sterilizable Dissolved Oxygen Sensors Quick Start Guide
Quick Start Guide
00825-0100-3494, Rev AA
June 2019
Rosemount™ Hx438
Amperometric Steam Sterilizable Dissolved
Oxygen Sensors
Quick Start Guide June 2019
Safety Information
WARNING
High pressure and temperature
Failure to reduce the pressure and temperature may cause serious injury to personnel.
Before removing the sensor, reduce the process pressure to 0 psig and cool down the process
temperature.
Do not exceed temperature and pressure limitations of 266 °F (130 °C) and 43 psig (400 kPa, 4
bar).
WARNING
The electrolyte is highly alkaline.
Protect your hands with gloves and use safety goggles.
Avoid contact of the electrolyte with the skin, eyes, and mucous membranes.
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June 2019 Quick Start Guide
1 Plan
1.1 Unpack and inspect
Procedure
1. Inspect the outside of the carton for any damage.
2. If damage is detected, contact the carrier immediately.
3. Inspect the hardware.
4. Make sure all the items in the packing list are present and in good
condition.
5. Notify the factory if any part is missing.
1.2 Specifications
Table 1-1: Rosemount Hx438 dissolved oxygen sensor specifications
Hx438 Dissolved Oxygen Sensor Material and Units
Operating Temperature Range 32 to 266 °F (0 to 130 °C)
Maximum Pressure 43 psig (400 kPa abs, 4 bar)
Measurement Range 0 to 20 ppm or 0 to 250% saturation,
Wetted Materials Stainless steel and EPDM
Process Connections PG 13.5 thread
Cable Connector Standard 4-pin
Cable Compatibility Standard 4-pin connector cable
Compatible Mounting Accessory Insertion Mounting Assembly
Compatible Transmitters Rosemount Transmitter Models 56,
Temperature Compensation 22K NTC
depending on instrument
1056, 5081, and 1066
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2 Install
2.1 Preparing the sensor
Procedure
1. Remove the plastic cap carefully which covers the sensing end of
sensor.
2. Avoid causing a vacuum by gently and slowly twisting the sensor and
cap until it is removed.
3. Sensor is shipped dry, so electrolyte must be added prior to
installation.
4. Remove membrane cartridge.
5. Add 1.5 ml of electrolyte to the membrane cartridge.
6. Screw membrane cartridge back onto sensor body.
2.2 Connecting the sensor to the trasmitter
Procedure
1. Wire the sensor to the transmitter.
2. Apply power to the transmitter.
3. Make the sensor ready for calibration after two hours.
The polarization time is necessary to get stable signals from the
sensors
4. If the sensor is disconnected from the transmitter for a short time,
allow the sensor to stabilize for at least two times longer than the
time was disconnected.
Time needed for stabilization should not exceed two hours.
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June 2019 Quick Start Guide
2.3 Mount the sensor
Procedure
Use PG 13.5 process thread to mount the sensor.
NOTICE
Do not install the sensor upside down.
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Figure 2-1: Dimensional Drawing for Rosemount Hx438-01
A.
Sensor part number
Hx438-01 4.725 120
B. 4-pin connector
C. Free rotating PC 13.5 screw thread
D. O-ring
2.4
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Wire the sensor to the transmitter
Procedure
Wire the sensor to the transmitter.
See wiring diagrams below.
A dimension
in. mm
June 2019 Quick Start Guide
Figure 2-2: Wiring for Rosemount™ 1056 and 56 Transmitter
A. Yellow
B. Blue
C. Yellow/green
D. Brown
E. Clear
F. Resistance temperature device return
G. Resistance temperature device sense
H. Resistance temperature device in
I. Resistance temperature device shield
J. Anode shield
K. Anode
L. Cathode shield
M. Cathode
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Figure 2-3: Wiring for Rosemount 1066 Transmitter
A. Hinge inside of front panel
B. Anode
C. Cathode
D. TB5/input-anode-brown
E. TB5/input-cathode-clear
F. TB3/resistance temperature device-return-yellow
G. TB3/resistance temperature device/resistance temperature device in-blue
H. TB2/reference and solution ground-solution ground-yellow/green
Follow recommended order.
a. TB4/anode and cathode
1. Anode
2. Cathode
b. TB3/resistance temperature device
1. Return
2. Sense
3. Resistance temperature device in
c. TB2/solution ground
1. No connection
2. No connection
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June 2019 Quick Start Guide
3. Solution ground
Note
TB1, TB4, TB6, and TB& not used for oxygen and ozone sensor wiring.
TB1, TB2, and TB4 may be used for pH sensor wiring if free chlorine
measurement requires live pH input.
Figure 2-4: Wiring for Rosemount 5081 Transmitter
A. Clear
B. Brown
C. Yellow/green
D. Blue
E. Yellow
F. Cathode
G. Anode
H. mV in
I. Drain
J. Solution ground
K. Reference
L. Resistance temperature device in
M. Resistance temperature device sense
N. Resistance temperature device return
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3 Calibrate
3.1 Sterilizing the sensor
Procedure
1. Before autoclaving the sensor, cover the connector end of the sensor
with a tight protective cap (PN 242000).
2. If the connector end gets wet despite the protective cap, dry the
connector with pressurized air or hair dryer.
Drying prevents corrosion and damage to insulation.
Note
No protection is necessary, when doing in-situ sterilization.
3.2 Dismounting the sensor
Procedure
1. Unscrew the free rotating PG 13.5 threaded connector.
2. Pull the sensor out of the process or mounting assembly.
3.3 Calibrate
Prerequisites
Before calibrating the sensor, refer to the transmitter instruction manual for
more details on calibration.
Prerequisites
Make sure that the sensor is operated for at least two hours before zeroing
and calibrating.
Procedure
1. Place the sensor in nitrogen gas or in water containing about 5%
sodium sulfite to make it zero.
If using nitrogen gas, make sure that the membrane is dry.
2. Once the reading is stable, zero the sensor. Refer to transmitter
instruction manual.
3. If sodium sulfite is used to zero the sensor, rinse the sensor with
water and gently dry the membrane.
4. Place the sensor in water-saturated air. Once the reading is stable,
complete the full scale calibration. Refer to transmitter instruction
manual.
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June 2019 Quick Start Guide
5. Calibration can also be done using air-saturated water or airsaturated medium.
Altough the sensor has an extremely low oxygen consumption rate,
the liquid should be gently stirred during calibration.
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4 Maintaining and troubleshooting
4.1 Maintaining the sensor
Procedure
1. Periodically check the sensor response in air and nitrogen.
2. Place the sensor in air. Allow the reading to become stable and note
the value.
Also, note the sensor current, which should be between 40 and 80
nA.
3. Place the sensor in nitrogen. A small plastic bag with a stream of
nitrogen gas discharging into the bottom works well.
4. After one minute, the sensor current should be less than 2% of the
value in air.
4.2 Replacing the electrolyte and the membrane cartridge
Replace the membrane cartridge (membrane kit PN 9160487) as follows:
Procedure
1. Hold the sensor vertically with the membrane pointing down.
Carefully unscrew the membrane cartridge.
2. Carefully clean the tip of the glass body with the polishing cloth
included with membrane kit, or clean with the polishing tool in one
direction only.
CAUTION
Glass Body Damage
Do not polish in circular motion. Failure to correctly polish the glass
body may result in permanent damage to the equipment.
NOTICE
When replacing the membrane cartridge, do not touch the anode
wire.
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June 2019 Quick Start Guide
3. Rinse the sensor under running water and dry it carefully.
4. Check the small O-ring above the glass body. If it is damaged, replace
it.
5. Use the plastic pipette in the membrane kit to add 2 ml of electrolyte
solution to the new membrane cartridge.
6. Carefully screw the cartridge onto the sensor shaft.
If too much electrolyte solution was used, the excess will be pushed
out.
7. Wash off the excess electrolyte with water.
4.3 Replace the cathode
If the sensor stil lhas a sluggish response to saturated air and/or too small
current in air, then the cathode should be replaced.
Procedure
1. Put the sensor in an upright position and carefully unscrew the
membrane cartridge.
Note
The membrane should be changed whenever the cathode is
replaced.
2. Flush the replaceable cathode with deionized water then dry the
metal parts. Do not touch anode and cathode.
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Figure 4-1: Replacing the Cathode
A. Sensor shaft thread
B. Cathode - metal part
C. Sensor shaft
D. Cathode O-ring
3. Hold the cathode on the metal part (B) in front of the thread (A) and
the sensor on the shaft (C) and pull apart. Just pull, do not turn.
4. Check that all contacts are dry and clean.
5. Replace cathode. (Part number 24262-00) Rotate the cathode until
the correct position is found and then push cathode into the shaft.
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6. Check the small O-ring (D) above the cathode. Replace if damaged.
7. Add 1.5 ml of electrolyte into the new membrane cartridge.
NOTICE
The pipette must NOT touch the membrane itself.
8. Screw the membrane cartridge onto the sensor shaft.
Any spillage of electrolyte should be rinsed away with water.
4.4 Troubleshoot
Table 4-1: Troubleshoot
Current in air too high (>80
nA at 25 °C)
Problem Solution Problem Solution Problem
Very thin or
defective
membrane
Defective
glass body or
connector
Poisoned
anode
Cathode
contaminated
by silver
Replace with
new
membrane
cartridge
Return to
Emerson
Return to
Emerson
Clean
cathode with
polishing
paper. If
cleaning does
not restore
the sensor,
then replace
the cathode
Sluggish response Current in air too low (<40
Contaminate
d, fouled, or
dirty
membrane
Loose
membrane
Dried out
electrolyte
film
Cathode
contaminated
by silver
Clean
membrane or
replace with
new
membrane
cartridge
Replace with
new
membrane
cartridge
Loosen
membrane
cartridge and
tighten
Clean
cathode with
polishing
paper. If
cleaning does
not restore
the sensor,
then replace
the cathode
nA at 25 °C)
Contaminate
d, fouled, or
dirty
membrane
Dried out
electrolyte
film
Cathode
contaminated
by silver
Exhausted
electrolyte
Solution
Clean
membrane or
replace with
new
membrane
cartridge
Loosen
membrane
cartridge and
tighten
Clean
cathode with
polishing
paper. If
cleaning does
not restore
the sensor,
then replace
the cathode
Return to
Emerson
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Table 4-1: Troubleshoot (continued)
Current in air too high (>80
nA at 25 °C)
Problem Solution Problem Solution Problem
- - - - Defective
Sluggish response Current in air too low (<40
nA at 25 °C)
glass body or
connector
FDA Approved Membrane replacement kit, which includes electrolyte
solution and polishing paper, is PN 9160487.
Solution
Fill with new
electrolyte
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5 Accessories
Part number Description
Cable accessories
9160493 5 m (16.4 ft). 4-pin connector, bare wire on transmitter
Mounting accessories
9160478 Insertion 70 mm insertion, use 120 mm sensor
9160484 Service kit for insertion mounting assembly
9160483 15° weld-in socket, G 1¼ in. thread, 44 mm
Servicing accessories
9160487 Service kit for sensors, includes three FDA approved
9160489 30 ml bottle electrolyte
242000 Third party labeled connector cap for 4-pin connector for
24262-00 Third party labeled replacement anode/cathode cartridge
end
membranes modules, O-rings, polishing tool, 20 ml
electrolyte
autoclaving (compatible with Rosemount™ Hx438-01)
The 4-pin connector cable is offered in three lengths.
The insertion mounting assembly can be used to mount the Rosemount
Hx438-01 into the process tanks or pipes.
The weld-in socket is used to mount the insertion mounting assembly into
tanks or pipes.
Figure 5-1: Weld-in Socket
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Quick Start Guide 19
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*00825-0100-3494*
Quick Start Guide
00825-0100-3494, Rev. AA
June 2019
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