00825-0100-3403, Rev AB
Rosemount 403/403VP
Contacting Conductivity Sensors
Quick Start Guide
January 2020
Quick Start Guide January 2020
Essential instructions
Read this page before proceeding!
Emerson 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. You
must adhere to the following instructions and integrate them into your safety program when
installing, using, and maintaining Emerson's 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 instrument, 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 Install section of this QSG 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. 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 when
maintenance is being performed by qualified people, to prevent electrical shock and personal
injury.
Note
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 operator's responsibility.
WARNING
Before removing the sensor, be absolutely certain the process pressure is reduced to 0 psig and the
process temperature is at a safe level.
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January 2020 Quick Start Guide
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end
users’ equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your
system. Restrict physical access by unauthorized personnel to protect end users’ assets. This is true for
all systems used within the facility.
Contents
Specifications...............................................................................................................................5
Install......................................................................................................................................... 10
Wire........................................................................................................................................... 12
Calibrate and maintain............................................................................................................... 17
Troubleshoot............................................................................................................................. 23
Accessories................................................................................................................................ 27
Quick Start Guide 3
Quick Start Guide January 2020
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January 2020 Quick Start Guide
1 Specifications
1.1 Specifications
Table 1-1: Rosemount 403/403VP Contacting Conductivity Sensor
Specifications
Wetted materials
Electrodes Titanium
Insulator PCTFE (neoflon), compliant to 21CFR
Sensor tube 316 stainless steel
O-ring EPDM, compliant to 21CFR 177.1380
Temperature range
32 to 221 °F (0 to 105 °C). Sensors are steam sterilizable to 275 °F (135 °C).
Maximum pressure
250 psig (1825 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
1½-in. or 2-in. sanitary flange
Cable length
10 ft. (3 m) standard; other lengths are optional.
177.1380 and USP Class VI
and USP Class VI
Table 1-2: Rosemount 403/403VP Weights and Shipping Weights
Rounded up to the nearest 1 lb. or 0,5 kg.
Sensor Weight Shipping weight
Rosemount 403 with
10-ft. (3.1 m) cable
Rosemount 403 with
50-ft. (15.2 m) integral
cable
Rosemount 403VP with
Variopol cable connection
Quick Start Guide 5
2 lb. (1.0 kg) 3 lb. (1.5 kg)
4 lb. (2.0 kg) 5 lb. (2.5 kg)
1 lb. (0.5 kg) 2 lb. (1.0 kg)
Quick Start Guide January 2020
Note
Elastomers and fluorocarbon resisns are compatible with 21CFR177 and
meet the requirements of USP Class VI. Stainless steel contains less than five
delta ferrite. All surfaces have 16 microinch (0.4 micrometer) Ra finish.
1.2 Rosemount 403 Contacting Conductivity Sensor ordering information
Note
The Endurance™ Rosemount 403 sanitary flange conductivity sensors are
supplied with 1½-in. or 2-in. stainless steel sanitary process connections.
Rosemount 403 sensors have a maximum temperature rating of 221 °F
(105 °C) and are suitable for sterilization up to 275 °F (135 °C). The standard
Rosemount 403 sensor has a Pt-1000 resistance temperature device (RTD)
and a 10-ft. (3 m) integral cable.
All wetted surfaces in the Rosemount 403 have 16 micro-inch
(0.4 micrometer) Ra finish, and all elastomers and plastics in the Rosemount
403 are compliant with 21CFR177 and USP Class VI.
CONFIGURE > VIEW PRODUCT >
1.2.1 Model
Code Description
403 Contacting Conductivity Sensor
1.2.2 Cell constant
Code Description
11 0.01/cm
12 0.1/cm
13 1.0/cm
1.2.3 Flange size
Code Description
20 1½-in. stainless steel sanitary fitting
21 2-in. stainless steel sanitary fitting
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January 2020 Quick Start Guide
1.2.4 Temperature compensation
Code Description
_ Pt-1000 (standard) for Rosemount 1056, 1066-C, 56, and 5081-C
54 Pt-100 for Rosemount 1054; series 2081
1.2.5 Electrode extension insertion length
Code Description
_ No selection
36 Extended insertion length (6.0-in. [152.4 mm] from inside face of flange to end)
1.2.6 Cable length
Code Description
_ No selection
50 Integral 50-ft. (15 m) cable
02 Integral 15-ft. (4.6 m) cable
20 Integral 20-ft. (6 m) cable
03 Integral 33-ft. (10 m) cable
06 Integral 100-ft. (30 m) cable
1.2.7 Calibration and conformance certificates - optional level
Code Description
CC Certificate of Calibration (no test data given)
LC Loop Calibration Certificate (sensor and transmitter calibrated together with test
EC Electronic Calibration Certificate (sensor calibrated against factory instrument with
data)
test data)
1.2.8 Material traceability certificates - optional level
Code Description
MC Material Traceability Certificate
Quick Start Guide 7
Quick Start Guide January 2020
1.3 Rosemount 403VP Contacting Conductivity Sensor ordering information
Note
The standard Rosemount 403VP sensor has an integral six pin Variopol (VP6)
connector. A mating VP6 connector cable is required for use with these
sensors.
CONFIGURE > VIEW PRODUCT >
1.3.1 Model
Code Description
403VP Conductivity sensor - sanitary flange Variopol connector
1.3.2 Cell constant
Code Description
11 0.01/cm
12 0.1/cm
13 1.0/cm
1.3.3 Flange size
Code Description
20 1½-in. stainless steel sanitary fitting
21 2-in. stainless steel sanitary fitting
1.3.4 Temperature compensation
Code Description
_ Pt-1000 (standard) for Rosemount 1056, 1066-C, 56, and 5081-C
54 Pt-100 for Rosemount 1054; series 2081
1.3.5 Electrode extension insertion length
Code Description
_ No selection
36 Extended insertion length (6.0-in. [152.4 mm] from inside face of flange to end)
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January 2020 Quick Start Guide
1.3.6 Calibration and conformance certificates - optional level
Code Description
CC Certificate of Calibration (no test data given)
LC Loop Calibration Certificate (sensor and transmitter calibrated together with test
EC Electronic Calibration Certificate (sensor calibrated against factory instrument with
data)
test data)
1.3.7 Material traceability certificates - optional level
Code Description
MC Material Traceability Certificate
Quick Start Guide 9
Quick Start Guide January 2020
2 Install
2.1 Unpack and inspect
Procedure
1. Inspect the outside of the carton for any damage. If you detect
damage, contact the carrier immediately.
2. 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 Install
Depending on the option you selected first, you can install the sensor in
either a 1½-in. (38.1 mm) or 2-in. (50.8 mm) Tri Clamp tee.
The operator must supply the gasket, clamp, and tee.
Procedure
1. Submerge the electrodes completely within the process liquid (i.e.,
up to the flange's inside surface).
If you install the sensor in a side stream with sample draining to open
atmosphere, bubbles may accumulate on the electrodes. Trapped
bubbles will cause errors. Normally, as bubbles accumulate, the
conductivity reading drifts down.
2. To control bubble formation, apply a small amount of back pressure
to the sensor.
Figure 2-1: Sensor Orientation
A. Trapped air
B. Trapped sludge
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January 2020 Quick Start Guide
Figure 2-2: Recommended Installation
A. Flow
B. Recommended
C. Not recommended
Quick Start Guide 11
Quick Start Guide January 2020
3 Wire
3.1 Wire Rosemount 403/403VP
For additional wiring information on this product, including sensor
combinations not shown here, please refer to Emerson.com/
RosemountLiquidAnalysisWiring.
Table 3-1: Wire Color and Connections in Sensor
Color Function
Gray Connects to outer electrode
Clear Coaxial shield for gray wire
Orange Connects to inner electrode
Clear Coaxial shield for orange wire
Red Resistance temperature device (RTD) in
White with red stripe RTD sense
White RTD return
Clear Shield for all RTD lead wires
Figure 3-1: Rosemount 403/403VP Sensor Wiring to Rosemount 56,
1056, and 1057 Transmitters
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Table 3-2: Rosemount 403/403VP Sensor Wiring to Rosemount 56, 1056, and
1057 Transmitters
Letter Color Terminal number Connects to
A White 1 RTD return
B White/red 2 RTD sense
C Red 3 RTD in
D Clear 4 RTD shield
N/A N/A 5 4 count B
N/A N/A 6 4 count A
E Clear 7 Shield, 2 count
F Orange 8 Sensor, 2 count B
G Clear 9 Shield, 2 count
H Gray 10 Sensor, 2 count A
Figure 3-2: Rosemount 403/403VP Sensor Wiring to Rosemount 1066
Transmitter
Table 3-3: Rosemount 403/403VP Sensor Wiring to Rosemount 1066 Transmitter
Letter Wire color Connects to
A White Return
B White/red Sense
Quick Start Guide 13
Quick Start Guide January 2020
Table 3-3: Rosemount 403/403VP Sensor Wiring to Rosemount 1066 Transmitter
(continued)
Letter Wire color Connects to
C Red RTD in
D Clear Shield
E Clear R shield
F Gray Drive B
G Orange Drive A
H Clear Drive shield
Figure 3-3: Rosemount 403/403VP Sensor Wiring to Rosemount 5081
Transmitter
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Table 3-4: Rosemount 403/403VP Sensor Wiring to Rosemount 5081 Transmitter
Terminal number Letter Wire color Connects to
1 N/A N/A Reserved
2 A Clear RTD shield
3 B White RTD common
4 C White/red RTD sense
5 D Red RTD in
6 N/A N/A RTD shield
7 E Clear RTD common
8 F Orange Receive
9 N/A N/A Drive shield
10 G Clear Drive common
11 H Gray Drive
12 N/A N/A N/A
13 N/A N/A N/A
14 N/A N/A N/A
15 NA N/A HART®/FOUNDATION
Fieldbus (-)
16 N/A N/A HART/FOUNDATION
Fieldbus (+)
™
3.2 Wire through a junction box
Procedure
If making wiring connections through a remote junction box (PN 23550-00)
wire point-to-point. Use cable 23747-00 (factory-terminated) or 9200275
(no termination).
Quick Start Guide 15
Quick Start Guide January 2020
Figure 3-4: Pin out Diagram for Rosemount 403VP Sensor (Viewed from
Connector End of Sensor, Looking Down)
Table 3-5: Pin out Diagram
Number Connects to
1 Cathode
2 N/A
3 Resistance temperature device (RTD)
4 Anode
5 RTD return
6 RTD in
sense
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January 2020 Quick Start Guide
4 Calibrate and maintain
4.1 Clean the sensor
Procedure
Use a warm detergent solution and a soft brush or pipe cleaner to remove oil
and scale.
You can also use isopropyl alcohol to remove oily films. Avoid using strong
mineral acids to clean conductivity sensors.
4.2 Calibration
Emerson calibrates PURSense conductivity sensors at the factory; the
sensors do not need to be calibrated when first placed in service. Simply
enter the cell constant printed on the label into the transmitter. After a
period of service, you may need to calibrate the sensor.
You can calibrate the sensor against a solution having a known conductivity
or against a referee meter and sensor. If using a standard solution, choose
one having conductivity in the recommended operating range for the sensor
cell constant. Refer to the transmitter Reference 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 77 °F [25 °C]).
Because 0.01/cm sensors must be calibrated in low conductivity solutions, it
is best to calibrate them against a referee meter and sensor in a closed
system.
4.2.1 Calibrate using a standard solution
If using a standard solution, choose one having conductivity in the
recommended operating range for the sensor cell constant.
Procedure
1. Immerse the rinsed sensor in the standard solution and adjust the
transmitter reading to match the conductivity of the standard.
2. Calibrate the sensor.
For an accurate calibration:
a. Choose a calibration standard near the midpoint of the
recommended conductivity range for the sensor.
b. Do not use calibration standards having conductivity less than
100 µS/cm.
Quick Start Guide 17
Quick Start Guide January 2020
c. Turn off automatic temperature compensation in the
transmitter.
d. Use a standard for which the conductivity as a function of
temperature is known.
e. Use a good quality calibrated thermometer with an error rate
less than ±0.1 °C to measure the temperature of the standard.
f. Follow good laboratory practice. Rinse the beaker and sensor
at least twice with standard. Be sure the rinse solution
reaches between the inner and outer electrodes by tapping
and swirling the sensor while it is immersed in the standard.
g. Be sure air bubbles are not trapped between the electrodes.
Place the sensor in the standard and tap and swirl to release
bubbles. Note the reading and repeat. If readings agree, no
trapped bubbles are present. Repeat until two subsequent
readings agree.
4.2.2 Calibrate using a reference meter and sensor
Take the following precautions for a successful calibration:
1. If the normal conductivity of the process liquid is less than about
1.0 µS/cm, adjust the conductivity so that it is near the upper end of
the operating range.
The difference between the conductivity measured by the process
and reference meter usually has both a fixed (constant error) and
relative (proportional error) component. Because the cell constant
calibration assumes the error is proportional only, calibration at low
conductivity allows the fixed component to have an outsized
influence on the result.
For example, assume the only difference between reference meter
and process sensor is fixed, and the process sensor always reads
0.002 µS/cm high. If the process sensor is calibrated at 0.100 µS/cm,
the new cell constant will be changed by 0.100/0.102 or two percent.
If the sensor is calibrated at 0.500 µS/cm, the change will be only
0.500/0.502 or 0.4 percent.
Calibration at higher conductivity produces a better result, because it
minimizes the effect of the offset.
2. Orient the sensors so that air bubbles always have an easy escape
path and cannot get trapped between the electrodes.
3. Turn off automatic temperature compensation in the transmitter.
Almost all process conductivity transmitters feature automatic
temperature compensation in which the transmitter applies one of
several temperature correction algorithms to convert the measured
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January 2020 Quick Start Guide
conductivity to the value at a reference temperature, typically 77 °F
(25 °C).
Although temperature correction algorithms are useful for routine
measurements, do not use them during calibration for the following
two reasons:
a. No temperature correction is perfect. If the assumptions
behind the algorithm do not perfectly fit the solution being
measured, the temperature-corrected conductivity will be in
error.
b. If the temperature measurement itself is in error, the
corrected conductivity will be in error.
The purpose of calibrating the sensor is to determine the cell
constant. To minimize the error in the cell constant, eliminate all
sources of avoidable error, e.g., temperature compensation.
4. Keep tubing runs between the sensors short and adjust the sample
flow as high as possible. Short tubing runs and high flow ensure that
the temperature of the liquid does not change as it flows from one
sensor to another.
If the process temperature is appreciably different from ambient,
high flow may not be enough to keep the temperature constant. In
this case, you may need to pump sample at room temperature from
a reservoir through the sensors. Because such a system is likely to be
open to atmosphere, saturate the liquid with air to prevent drift
caused by absorption of atmospheric carbon dioxide.
5. To prevent contamination of low conductivity (< 1 µS/cm) process
liquids, use clean tubing to connect the sensors. To prevent drift
caused desorption of ionic contaminants from tube walls, keep the
sample flow greater than 6 ft./sec (1.8 m/sec).
Procedure
1. Connect the process sensors and reference sensor in series and allow
the process liquid to flow through all sensors.
2. Calibrate the process sensor by adjusting the process transmitter
reading to match the conductivity measured by the reference meter.
See Figure 4-1 for the calibration setup.
Quick Start Guide 19
Quick Start Guide January 2020
Figure 4-1: In Process Calibration Setup
A. Sample inlet
B. In process sensors
C. Reference sensor
D. Sample output
Note
Figure 4-1 shows two process sensors connected in series with a
reference sensor. The horizontal sensor orientation ensures good
circulation of the process liquid past the electrodes. The staircase
orientation provides an escape path for bubbles.
This method is ideal for calibrating the sensors used in low
conductivity water (0.01/cm cell constants), because the calibration
system is closed and cannot be contaminated by atmospheric carbon
dioxide.
4.2.3 Calibrate using a grab sample
Use the grab sample method when it is impractical to remove the sensor for
calibration or to connect a reference sensor to the process line.
Procedure
Take a sample of the process liquid, measuring its conductivity using a
reference instrument and adjusting the reading from the process
transmitter to match the measured conductivity.
Take the sample from a point as close to the process sensor as possible.
Keep temperature compensation turned on. There is likely to be a lag time
between sampling and analysis, so temperature is likely to change.
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January 2020 Quick Start Guide
Be sure the reference and process instruments are using the same
temperature correction algorithm.
Only use grab sample calibration when the conductivity is fairly high.
a. The temperature compensation algorithm will most likely be linear
slope.
b. Confirm that both instruments are using the same temperature
coefficient in the linear slope calculation.
c. If the reference meter does not have automatic temperature
correction, calculate the conductivity at 77 °F (25 °C) using the
equation:
where: C25 = the conductivity at 25 °C
Ct = the conductivity at t °C
α = the temperature coefficient expressed as a decimal fraction
d. Confirm the temperature measurements in both the process and
reference instruments are accurate, ideally to within ±0.5 °C.
e. Follow good laboratory practice when measuring the conductivity of
the grab sample.
• Rinse the beaker and sensor at least twice with sample. Be sure
the rinse solution reaches between the inner and outer
electrodes by tapping and swirling the sensor while it is
immersed in the sample.
• Be sure air bubbles are not trapped in the sensor. Place the sensor
in the sample and tap and swirl to release bubbles. Note the
reading. Then, remove the sensor and return it to the sample.
Tap and swirl again and note the reading. If the two readings
agree, there are no trapped bubbles. If they do not agree,
bubbles are present. Continue the process until two subsequent
readings agree.
• While measuring, do not allow the sensor to touch the sides and,
particularly, the bottom of the beaker. Keep at least ¼ in. (6 mm)
clearance.
f. Be sure to compensate for process conductivity changes that might
have occurred while the grab sample was being tested. Rosemount
conductivity transmitters (Rosemount 1056, 1066, and 56) do this
automatically. They save the value of the process conductivity at the
time the sample was taken and use that value to calculate the new
cell constant when you enter the result of the grab sample test. Older
transmitters do not remember the process conductivity value.
Quick Start Guide 21
Quick Start Guide January 2020
Therefore, you must enter a value adjusted by an amount
proportional to the change in the process conductivity. For example,
suppose the process conductivity is 810 µS/cm when the sample is
taken and 815 µS/cm when the test result is entered. If the grab
sample conductivity is 810 µS/cm, enter (815/810) x 819 or 824
µS/cm.
22 Emerson.com/Rosemount
January 2020 Quick Start Guide
5 Troubleshoot
Note
For any repair or warranty inquiries, please contact our Customer Care
group.
5.1 Off-scale reading
Potential cause
Wiring is incorrect.
Recommended action
Verify and correct wiring.
Potential cause
Resistance temperature device (RTD) is open or shorted.
Recommended actions
1. Check RTD for open or short circuits.
2. Disconnect leads and measure resistance shown.
The measured resistance at room temperature should be close to the
value in Table 5-1.
Table 5-1: Temperature Resistance
Temperature (°C) Resistance in ohms
Pt 100 Pt 1000
0 100.0 1000
10 103.9 1039
20 107.8 1078
30 111.7 1117
40 115.5 1155
50 119.4 1194
Quick Start Guide 23
Quick Start Guide January 2020
Figure 5-1: Checking RTD
A. RTD
B. Red
C. Red/white
D. White
Potential cause
Sensor is not in process stream.
Recommended action
Submerge sensor completely in process stream.
Potential cause
Sensor has failed.
Recommended action
1. Perform isolation checks.
See Figure 5-2.
24 Emerson.com/Rosemount
January 2020 Quick Start Guide
Figure 5-2: Checking the Continuity and Leakage
A. Orange
B. Inner
C. Outer
D. Gray
2. Disconnect electrode leads and measure resistance and continuity as
shown.
Sensor must be dry when checkingt resistance between electrode
leads.
5.2
5.3
Quick Start Guide 25
Noisy reading
Potential cause
Sensor is improperly installed in process stream.
Recommended action
Submerge sensor completely in process stream.
Reading seems wrong (lower or higher than expected)
Potential cause
Bubbles trapped in sensor.
Quick Start Guide January 2020
Recommended actions
1. Ensure the sensor is properly oriented in pipe or flow cell.
See Figure 1.
2. Apply back pressure to flow cell.
Potential cause
Wrong temperature correction algorithm is being used.
Recommended action
Check that the temperature correction is appropriate for the sample.
See transmitter manual for more information.
Potential cause
Wrong cell constant.
Recommended action
Verify that the correct cell constant has been entered in the transmitter and
that the cell constant is appropriate for the conductivity of the sample.
See transmitter manual.
5.4 Sluggish response
Potential cause
Electrodes are fouled.
Recommended action
Clean electrodes.
Potential cause
Sensor is installed in dead area in piping.
Recommended action
Move sensor to a location more representative of the process liquid.
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January 2020 Quick Start Guide
6 Accessories
Part number Description
23747-06 Junction box for a remote cable connection
9200275 Connecting cable, unterminated, specify length
23747-00 Connecting cable, terminated, specify length
05010781899 Conductivity standard SS-6, 200 µS/cm, 32 oz. (0.95 L)
05010797875 Conductivity standard, SS-6A, 200 µS/cm, 1 gal. (3.78 L)
05010782468 Conductivity standard, SS-5, 1000 µS/cm, 32 oz. (0.95 L)
05010783002 Conductivity standard SS-5A, 1000 µS/cm, 1 gal. (3.78 L)
05000705464 Conductivity standard, SS-1, 1409 µS/cm, 32 oz. (0.95 L)
05000709672 Conductivity standard, SS-1A 1409 µS/cm, 1 gal. (3.78 L)
05010782147 Conductivity standard SS-7, 5000 µS/cm, 32 oz. (0.95 L)
05010782026 Conductivity standard SS-7A, 5000 µS/cm, 1 gal. (3.78 L)
Quick Start Guide 27
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*00825-0100-3403*
Quick Start Guide
00825-0100-3403, Rev. AB
January 2020
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