Rosemount Analytical 242 Operating Manual
TM
Rosemount
242
Toroidal Flow-Through Conductivity Sensor
Instruction Manual
LIQ-MAN-242
Rev. F
June 2017
Installations near flammable liquids or in hazardous
not
transmitter, and
sensor combination must be used. The installation
system must comply with the governing approval
hazardous area classification requirements.
any
agency
Proper installation, operation and servicing of this
sensor in a Hazardous Ar ea Installation is entirely
ESSENTIAL INSTRUCTIONS
install,
e within their
and
life; perso nal
Read all instructions prior to installing, operating, and servicing the
7768 and the requested manual will be provided.
If you do not understand any of the instructions, contact your
ow all warnings, cautions, and instructions marked on and
ions of
the appropriate Instruction Manual and per applicable local and
the
ensure proper performance, qualified personnel should install,
people
Replacement of
original components with those constructed from alternative
ELEC
agency approvals that were applicable to the original device.
original
process
an affect the
performance, place the safe operation of your process at
are
is being performed by qualified
READ THIS PAGE BEFORE PROCEEDING!
Rosemount designs, manufactures, and tests its products to meet
many national and international standards. Because these instruments are sophisticated technical products, you must properly
use, and maintain them to ensure they continue to operat
normal specifications. The following instructions must be adhered to
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
injury; property damage; damage to this instrument; and warranty
invalidation.
•
product. If this Instruction Manual is not the correct manual, telephone 1-800-654Save this Instruction Manual for future reference.
•
Rosemount representative for clarification.
• Foll
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 Instruct
national codes, for example, ANSI B16.5. Connect all products to
proper electrical and pressure sources.
• To
operate, and maintain the product.
• When repla cement parts are required, ensure that qualified
use replacement parts specified by Rosemount.
materials will void any CSA, FM, and BASEEFA/CENFurthermore, replacement of original components with those con-
structed from alternative materials might change the pressure, temperature, and/or performance specifications from those of the
configuration. Ensure replacement parts are compatible with
requirements. Unauthorized parts and procedures c
product’s
risk, and may result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers
in place, except when maintenance
persons, to prevent electrical shock and personal injury.
DANGER
HAZARDOUS AREA INSTALLATION
area locations mus t be caref ully evaluated by qualified on site safety personnel. This sensor is
Intrinsically Safe or Explosion Proof.
To secure and maintain an intrinsically safe installation, the certified safety barrier,
agency (FM, CSA, BASEEFA/CENELEC, or ATEX)
Consult your anal yzer/trans mitter instruction m anu-
al for details.
Replacement of original components with those con-
structed from alternative materials will void
CSA, FM, and BASEEFA/CENELEC
approvals that were applicable to the original device.
the responsibility of the user.
APPLICATION COMPATIBILITY
The wetted sensor materials may not be compatible
with process com pos iti on a nd oper a tin g co nditions.
Replacement of original components with those constructed from alternative materials might change the
pressure, temperatur e, and/or perform ance spec ifications from thos e of the origin al sensor configur ation. Application compat ibi li t y is entirely the responsibility of the user.
CAUTION
SENSOR/PROCESS
MODEL 242
TABLE OF CONTENTS
Rosemount 242
TOROIDAL CONDUCTIVITY SENSOR
TABLE OF CONTENTS
Section Title Page
1.0 MODEL 242 SENSOR ............................................................................................. 1
1.1 Features and Applications........................................................................................ 1
1.2 Specifications ........................................................................................................... 2
1.3 Ordering Information ................................................................................................ 5
1.4 Installation ................................................................................................................ 7
1.5 Calibration ................................................................................................................ 10
1.6 Maintenance ............................................................................................................ 13
2.0 Troubleshooting ..................................................................................................... 14
3.0 Replacement Parts................................................................................................. 16
3.1 General .................................................................................................................... 16
3.2 Remove the Sensor From the Process .................................................................... 16
3.3 Disassemble the Sensor .......................................................................................... 16
3.4 Re-assemble the Sensor ......................................................................................... 19
3.5 Re-install the Sensor into the Process ..................................................................... 19
4.0 Return of Materials ................................................................................................ 20
LIST OF TABLES
Table No. Title Page
1-1 Nominal Cell Constants for 242 Sensors................................................................. 10
2-1 Resistance vs. Temperature for RTD (Resistance Temperature Detector) ............. 14
2-2 Sensor Resistance Check........................................................................................ 14
3-1 Replacement Parts and Accessories ....................................................................... 17
3-2 Sensor Bolt Removal & Installation Guide............................................................... 18
i
MODEL 242
Rev. Level
Date
Notes
E
03/12
Update addresses pages 22 and 24
TABLE OF CONTENTS
MODEL 242
TOROIDAL CONDUCTIVITY SENSOR
LIST OF FIGURES
Figure No. Title Page
1-1 Pressure-Temperature Specs for 1”, 1.5”, & 2” Sensors: Models 242-02/03/04 .... 3
1-2 Pressure-Temperature Specs for 3” & 4” Sensors: Models 242-06/08 ................... 3
1-3 Pressure-Temperature Specs for 1” & 2” Sensors: Alumina Liner .......................... 4
1-4 Pressure-Temperature Specs for 3” & 4” Sensors: Alumina Liner .......................... 4
1-5 Dimensional Drawing ............................................................................................... 7
1-6 Installation and Torque Guidelines........................................................................... 8
1-7 Sensor to Junction Box Wiring ................................................................................ 9
1-8 Sensor/Junction Box/RTD Assembly ....................................................................... 9
1-9 Extension Cable ...................................................................................................... 10
1-10 Extension Cable to Instrument Model 54eC Wiring................................................ 11
1-11 Extension Cable to Instrument Model 1055 Wiring ................................................. 11
1-12 Extension Cable to Instrument Models 3081T & 4081T Wiring............................... 12
1-13 Extension Cable to Instrument Model 81T Wiring ................................................... 12
1-14 Extension Cable to Instrument Model Xmt Pipe/Wall Mount Enclosure.................. 12
1-15 Extension Cable to Instrument Model Xmt Panel Mount Enclosure........................ 13
2-1 Sensor Circuit for Troubleshooting .......................................................................... 15
3-1 Model 242 Sensor - Exploded View ........................................................................ 18
3-2 Flange Assembly...................................................................................................... 19
About This Document
This manual contains ins tructions for installation and operation of the Model 242 Flow-Through
Toroidal Conductivit y Sensor. The following list provides notes concerning all revisions of this document.
A 11/02 This is the initial release of the product manual. The manual has been
reformatted to reflect the Emerson documentation style and updated to reflect
any changes in the product offering.
B 8/03 Corrected wiring references in text and drawings. Added information regarding
ATEX approvals with Model 5081T.
C 5/04 Added information regarding the alumina liner, and updated wiring diagrams.
D
ii
MODEL 242
SECTION 1.0 242 SENSOR
•
FLOW THROUGH DESIGN is ideal for use with viscous,
abrasive, or fibrous process liquids.
SECTION 1.0
242 SENSOR
• OVER 250 CONFIGURATIONS to meet customers' needs.
• REPLACEABLE LINER in glass-filled PEEK, TEFLON, or
ALUMINA reduces long-term operating costs.
•
DIN and ANSI FLANGES compatible with all piping installations.
•
LINE SIZES of 1 through 4 inches (DN 25, 40, 50, 80 and
100).
• IN-LINE CALIBRATION saves money by reducing labor
and down-time.
• TEMPERATURE SENSOR and JUNCTI ON-BOX included.
1.1 FEATURES AND APPLICATIONS
Rosemount Toroidal Conductivity Sensors are ideal
for use in processes where contacting sen- sors -those with electrodes exposed to the measured
solution -- would corrode or become fouled.
The 242 Flow Through Toroidal conductivity sensor
consists of two toroids surrounding a pipe through
which the process liquid flows. One toroid acts as a
transmitter and the other as a rec eiver. Energi zing the
transmitter toroid induces an electric current in the
process solution which induces an electric current in
the receiver toroid. T he s tr engt h of th e i nduc e d c urr en t
is directly proport ional to the conductivity of the solution.
The 242 sensor is availab le in over two hundred fifty
configurations to meet the needs of m any applications
and installations. Line sizes of 1, 1.5, 2, 3, and 4 inch-
es (25, 40, 50, 80, and 100 mm) are available with
both ANSI and DIN compatible flanges. A variety of
liner materials and O-rings are available to ensure
compatibility with most process liquids.
The 242 sensor is easy to install. It fits in the process
piping between mounting flanges. Spec ial grounding
rings are not needed because the sensor has contact rings built into it. Rec es sed bo lts hold the s ensor
together to ensure all internal parts stay in perfect
alignment. A junction box and a Pt 100 RTD are
included. The RTD slips ea sil y into on e of the sens or
contact rings. T here is no need to insta ll a separate
thermowell, and temperature measurements are
made at the sam e po int as the c o nductivity measurements.
The sensor is not sensit ive to flow rate or direction.
It does not obstruct t he process flow. The sensor is
rugged and constructed from chemically resistant
materials. All these features make the sensor ideal
for applications in mining and metals processing,
pulp and paper processing, and the chemical processing industry.
The 242 Flow Throug h Conductivity Sensor is com patible with instrument instumentsL 54eC, 1055,
3081T, 4081T, 5081-T, and Xmt-T.
1
MODEL 242
MODEL 242 SENSOR
Installation Type
Flow Through
Conductivity Range
Process Connections
150# ANSI, 300# ANSI, PN16 DIN 2501 compatible flanges
Maximum Temperature
Maximum Pressure
Wetted Materials:
Shipping Weight
SECTION 1.0
1.2 SPECIFICATIONS
The Model 242 Flow Through Sensor comprises a toroid
housing constructed from 316 stainless steel and polyethyleneterephthalate, process connection flanges of 316
stainless steel, two metal c ontact rings (available in choice
of three materials), an insulating liner (choice of three
materials), O-rings (choice of three materials), a Pt 100
RTD, and a sensor-mounted junction box. Only the liner,
contact rings, and O-rings are wetted b y the process. The
Pt 100 RTD is designed for insertion into one pre-drilled
contact ring. The NEMA 7D junction box is constructed of
heavy duty epoxy-painted cast aluminum . The conductivity
range is user-selectable with the tappe d toroid windings. Inline calibration can be perform ed with resistors connect- ed
to an integral wire around the toroids that is terminated in
the junction box.
Liners are available in T eflon, glass-filled Polyetherether ketone (PEEK), and alumina. These m aterials provide
excellent chem ical resistance. P EEK is recom mended for high pressure or high tem perature appl ications. Tef lon
is recommended when the process solution contains hydrofluoric acid or other strong oxidizing agents. Alumina is
recommended if the process solution is abrasive, such as in alumina/caustic ratio applications.
Pt 100 RTD
Flange
Contact Ring
Liner
O-ring (not visible)
100 μS/cm to 2 S/cm
Depends on configuration. For plastic-lined sensors, see charts on facing page.
For alumina-lined sensors, see charts on page 4.
Depends on configuration. For plastic-lined sensors, see charts on facing page.
For alumina-lined sensors, see charts on page 4.
Liner
Contact Rings
O-rings
®
Teflon
(PTFE), glass-filled PEEK, or alumina
316 SST, Carpenter 20Cb-3
EPDM, Viton
1” to 2”: 22 lbs. (10kg)
3” to 4”: 86 lbs. (39 kg)
Teflon is a registered trademark of E.I. du Pont de Nemours & Co.
Viton is a registered trademark of Du Pont Dow Elastomers.
Carpenter 20Cb-3 is a registered trademark of Carpenter Technologies.
Hastelloy is a registered trademark of Haynes International.
Chemraz is a registered trademark of Greene, Tweed, & Co.
2
®
SST, or Hastelloy® C-276
®
(FKM), or Chemraz® (FFKM)
MODEL 242
MODEL 242 SENSOR
FIGURE 1-1. Pressure - Temperature Specifications for 1”, 1.5”, and 2” (25, 40, and 50 mm) Sensors:
SECTION 1.0
Models 242-02, 242-03, and 242-04
FIGURE 1-2. Pressure - Temperature Specifications for 3” and 4” (80 and 100 mm) Sensors:
Models 242-06 and 242-08
3
MODEL 242
MODEL 242 SENSOR
FIGURE 1-4. Pressure - Temperature Specifications for 3” and 4” Sensors: Alumina Liner
SECTION 1.0
4
FIGURE 1-3. Pressure - Temperature Specifications for 1” and 2” Sensors: Alumina Liner
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