Rosemount Analytical 3900 Installation Guide
Installation & Calibration Equipment
Sensor & Instrument Mounting, Accessories, Systems and More
Visualize > Analyze > Optimize
INSTALLATION & CALIBRATION EQUIPMENT
Emerson Process Management offers a variety of
Rosemount Analytical accessories to fit many
requirements. This brochure includes mounting tees, ball
valve kits, and other configurations used for mounting
conductivity, pH, ORP and amperometric (dissolved
oxygen, chlorine, and ozone) sensors and instruments.
Please note that each mounting accessory is only valid for
the stated sensor(s). Also included is information on
instrument mounting, cables, junction boxes and various
chemicals. The accessories in this brochure can be used in
a wide variety of applications commonly found in the
following industries:
TABLE OF CONTENTS
Mounting Recommendations for Sensors includes best practices for in-line and tank mounting............................4-5
> Chemical
> Food and Beverage
> Water and Wastewater Treatment
> Power
> Water Treatment
> Utilities
> Pulp and Paper
> Metals and Mining
> Hydrocarbon Processing
> Textile
> Pharmaceutical
Insertion Sensor Mounting including tees, low flow cells, handrail mounting, floating balls,
jet spray cleaner, mounting adapters, and process connectors.............................................................................6-18
Retraction Assemblies including ball valve kits, retraction assemblies
for higher pressures, and a rotary retraction unit ...............................................................................................19-27
Instrument Mounting with mounting brackets for wall, pipe, or panel mount....................................................28-30
Wiring Accessories includes best practices for cable lengths. Also includes junction boxes,
extension cables, VP connector cables and cable glands....................................................................................31-37
Calibration Accessories with pH buffer solutions and conductivity standard solutions
Also included is a conductivity validation unit, a pH benchtop calibration unit,
a pH simulator, and VP plug simulator for pH and conductivity ..........................................................................38-40
Flow Accessories including rotameters and a constant head flow controller.......................................................41-42
Tags for Sensors and Instruments............................................................................................................................43
Sample Cooler.........................................................................................................................................................43
Special Parts and Assemblies including examples of customer requested panels with sensors,
flow cells, instruments, and sample cooling system mounted for easy installation.............................................44-45
Certificates for Sensors, Instruments and Chemicals including Certificate of Calibration,
Electronic Calibration, Loop Calibration, & Material Certificates. .............................................................................46
Index for quick and easy searching for parts by number or description....................................................................47
2
CHOOSING THE RIGHT MOUNTING SOLUTION
VP CONNECTOR SHOWN; SENSORS ARE
ALSO AVAILABLE WITH INTEGRAL CABLE
PROCESS END (FRONT END)
THREADS, CLOSEST TO
SENSING/MEASURING END
OF THE SENSOR
Figure 1. The 3900 general purpose pH sensor is offered with 1 inch MNPT
threads in two locations: one on the process end and one on the cable end. It also
has a 3/4” MNPT process end thread.
Understanding sensor process
connections:
Rosemount Analytical sensors are offered with a wide
variety of threaded process connections.
The sensor shown above is a 3900 pH sensor. All sensors
use similar terminology for process connection threads.
Note that not all sensors are offered with front and back
end threads. Below are examples of sensors using other
types of sensor-to-process connection threads.
The sensors shown in Figures 2 and 3 are much
different than the sensor shown in Figure 1. Figure 2 is
a 228 Toroidal sensor with 3/4" MNPT threads and is
also available with 5/8" UNC threads. Figure 3 shows a
non-threaded 3300HT pH sensor which is used with a
BACK END PROCESS THREADS, CLOSEST
TO CABLE OR VP CONNECTOR
process connector (sold separately) to allow variable
insertion depths for the sensor and easy sensor
removal without twisting the cable.
Ordering Information
All sensors used with the accessories mentioned in this
catalog must be purchased separately. Also, please note
that additional accessory items must be purchased
along with the stated mounting accessories in order for
the complete mounting to be accomplished. Please
consult your local representative for more information
about sensors or consult the factory at 1-800-854-8257
(in the U.S.) or 1-949-757-8500 (outside of the U.S.).
You can also visit us at RosemountAnalytical.com.
Figure 2. The 228 Toroidal Conductivity Sensor is offered
with back end process threads only.
3
Process connector required for
connection of sensor to process.
Figure 3. The 3300HT sensor is offered without process
threads. A compression fit, process connector is used on
the sensor body and gives the user flexibility for insertion.
Retractable sensors (a longer version of what is shown
above) are also offered without process threads. This is so
the sensor can be mounted through a ball valve.
MOUNTING RECOMMENDATIONS FOR SENSORS
Sensors mounted in
tees and flow cells:
> To prevent leakage, wrap the sensor threads with pipe
tape before inserting into its mounting.
> Do not over tighten the sensor when installing. Hand
tighten the sensor, and then tighten with a wrench.
> The electrodes must be completely submerged in the
process liquid to measure properly
> Air bubbles accumulating on sensors will cause erro-
neous or erratic readings.
> To control air bubble formation, apply a small amount
of back pressure to the flow cell or pipe.
> All sensor cables should be run through a conduit to
protect the back end from moisture intrusion.
Figure 4. pH sensor recommended mounting orientation. pH sensors should be mounted at least 10° from the
horizontal to ensure correct measurement. Sensors can
also be mounted vertically.
Figure 5. Chlorine, dissolved oxygen, and ozone sensor
recommended mounting orientation. Chlorine, dissolved
oxygen, ozone sensors should be mounted vertically or
within 45° of the horizontal position. Also, these sensors
have recommended flow rates that should be observed.
Check instruction manual for more information on recommended flow rates.
Figure 6. Conductivity (contacting) sensors should have at
least 1/4 in. (0.6 cm) clearance between electrodes and
piping (as shown in both illustrations above). The recom-
mended sensor orientation is either horizontal or no more than
30° below horizontal. It is best that the inlet flow is facing the
sensor to ensure full pipe and minimal air bubbles.
4
MOUNTING RECOMMENDATIONS FOR SENSORS
Metal Pipe
Plastic Pipe
True
Conductivity
Distance to Wall
Measured Conductivity
3/4 to 1 Toroidal
Sensor diameter
Conductivity (toroidal) sensors should be kept at a far
enough distance between sensor and pipe wall to ensure
the pipe wall does not interfere with the reading. If
clearance is too small, the sensor should be calibrated
Figure 7. The measured toroidal conductivity value can be
affected when installed close to a pipe wall.
Sensors submerged in tanks,
ponds, or basins
> To prevent leakage, wrap the sensor threads with pipe
tape before inserting into its mounting part.
> Do not over tighten the sensor when installing. Hand
tighten the sensor, and then tighten one or two (1–2)
turns with a wrench.
while in the pipe. The sensor should be completely
submerged in liquid. Mounting the sensor in a vertical
pipe run with the flow from bottom to top is best. If the
sensor must be mounted in a horizontal pipe run, orient
the sensor in the 3 o’clock or 9 o’clock position.
Figure 8. Correct sensor orientation
> The electrodes must be completely submerged in the
process liquid to measure properly.
> All sensor cables should be run through a pipe conduit;
do not use the sensors cable to dangle the sensor into
the tank, pond, or basin.
Do not install sensor by hanging it directly into water.
Incorrect Installation
Figure 9. Correct sensor installation is critical to to proper sensor performance.
Correct Installation
Always install sensor using pipe conduit.
5
INSERTION SENSOR MOUNTING
he mounting parts contained in this section include in-
T
line tees, low flow cells, a handrail mounting assembly, a
floating ball system, a jet spray cleaner, mounting
dapters, and process connectors. The in-line tees are
a
offered in various configurations to assist in easy sensor
insertion and removal without twisting cables. The low
low cells are available for sidestream samples with 1/4"
f
OD tubing. The handrail mounting assembly is available
with all the parts needed to install a sensor into a pond
S
e
nsor
P
r
o
d
uct
N
um
b
MEASUREMENT
e
TYPE
pH and ORP
389, 396, 396P
, T
F396, 3300HT
Conductivity
r basin; the jet-spray cleaner can be used with this
o
assembly for dirty applications. The floating ball system
can be used as an alternative method of installing a
ensor into a pond or basin. Many mounting adapters
s
are offered for tank and pipe insertion, as well as for
submersion applications. The process connectors are
ffered specifically for use with metal body sensors for
o
insertion, submersion, and retractable applications.
r
s*
, 3500, 3900, Hx338, 3800, RB546
140, 400, 228
Dissolved Oxygen
499ADO, 499AT
RDO
Ozone
4
99AOZ
Chlorine
499ACL, 498Cl
* Sensors with integral cable or VP connector can be used.
6
IN-LINE TEES
These versatile in-line tees can be used with Rosemount
Analytical pH, ORP, conductivity, dissolved oxygen,
ozone, and chlorine sensors having 1-inch process
connections. Compatible sensor models are listed in the
table below. Tees can be installed directly in process
piping or in slip streams. PN 23567-00 and PN 91524003, -04, and -05 have union fittings that allow the sensor
In-Line Tees
2002011 23567- 00 915240- 03 915240- 04 915240-05
Size 1.5" 2.0"
Process Connection Ends 1.0" thread 1.5" socket .75" threads 1.0" threads 1.5" threads
Material CPVC, Schedule 80 PVC, Schedule 80
O- ring or Gasket Material – Buna N
Maximum rating 150 psig (1136 kPa) 65 psig (549 kPa) 60 psig (515 kPa) at 120°F (49°C)
@150°F (65°C) @ 122°F (50°C)
Compatible Sensor Models*
pH and ORP 396P, 389, 3500, 3900 396P, 389, 3500,
Conductivity 150 –
Dissolved Oxygen 499ADO 499ADO
Ozone 499AOZ 499AOZ
Chlorine 499ACl 499ACl
*Note: All sensor models noted in this graph are listed with integral cables.
The sensor models with the “VP” connectors can also be used.
In-Line Tee Part Number
to be removed without the need to unscrew it, thus
eliminating the possibility of the cable becoming twisted
and damaged. Tees are offered in PVC and CPVC and can
connect to ¾, 1, and 1 ½ inch process lines.
lways install tees so that the sensor is completely
A
submerged in the process liquid, and allow enough
headroom to remove the sensor.
3900 using adapter PN S10283-LQD
Figure 10. When using sensor Model 3900VP
with Tee PN 915240-03, -04, or -05, order
adapter PN S10283-LQD (top of photo)
Direct mount into tee threads
IN-LINE TEE (PN 2002011)
PRESSURE/TEMPERATURE
SPECIFICATIONS
psig (kPa) °F (°C)
150 (1136) 150 (65)
128 (984) 160 (71)
102 (805) 170 (77)
80 (653) 180 (82)
57 (494) 200 (93)
48 (432) 210 (99)
FIGURE 11. 11⁄2 in. tee with 1 in. threaded process
connection (PN 2002011) shown with TUpH 396P
mounted for angle or straight process flow.
Figure 12. 389 pH sensor in
PN 2002011 Tee
Figure 13. Sensor tip in
process stream flow path.
7
IN-LINE TEES
Tees with union adapters offer quick and easy access and eliminate damage from cable twisting.
Figure 14. 1½ in. tee with 1½ in. socket process connection (PN 23567-00)
shown with a Model 499A amperometric sensor. The tee assembly is offered with
a sensor mounting adapter that allows the user to remove the sensor without twisting
the cable.
Figure 15. 499ACL sensor
in PN 23567-00 Tee
Figure 18. PERpH-X
3500VP pH sensor in PN
915240-03 Tee
Figure 16. Sensor tip in
process stream flow path.
Figure 19. Sensor tip in
process stream flow path
Figure 17. 2 in. tee with ¾, 1, or 1½ in. threaded process connections (PN
915240-03, -04, -05 respectively) shown with a Model 499A amperometric
sensor. The tee assembly is offered with a sensor mounting adapter that allows the
user to remove the sensor without twisting the cable.
8
Figure 20. 3900VP pH sensor
in PN 915240-03 Tee with
adapter PN S10293-LDQ
Figure 21. Sensor tip in
process stream flow path
LOW FLOW CELLS
Emerson offers a variety of low flow cells for sidestream
applications where it is impractical to divert a large
volume of sample, particularly if the sample must be
sent to waste. Choose a transparent plastic or stainless
steel body—both have ¼ inch FPT process connections.
Plastic flow cells PN 24091-00, -01, and -02 are also
supplied with ¼ inch MPT to ¼ inch OD tubing fittings
Low Flow Cells
Process Connection 1/4 inch 316 SST male tube connector
Wetted Materials Body and Nut - Polycarbonate/polyester blend; 316 SST
Maximum Temperature 158°F (70°C) Consult Factory
Maximum Pressure 90 psig (621 kPa) Consult Factory
Sensor Threaded Connection 1 inch 1 inch 3/4 inch 1 inch 3/4 inch
Special features None
Compatible Sensor Models*
pH and ORP Sensors
Conductivity Sensors ––400, 400 VP – 400, 400 VP
Dissolved Oxygen 499ATrDO, 499ADO 499ADO – 499A DO –
Ozone 499AOZ ––––
Chlorine 499ACL 498CL, 499ACL –––
*Note: All sensor models noted in this graph are listed with integral cables. The sensor models with the “VP” designation can also be used.
PN 24091-00 PN 24091-01 PN 24091-02 S10240 (SQ 7716 ) S10290 (SQ 7637)
1/4" Fittings - 316 SST; O-ring - Silicone
Bubble shedding nozzle
396P, 389, 3500, 3900
– RB-546
and have a union connection that allows easy removal of
the sensor.
Valved rotameters are also available (see page 41) to
adjust and measure sample flow in sidestream
nstallations. Accurate control of flow is especially
i
important when measuring dissolved oxygen, chlorine,
and ozone.
None Order as a special request only
396P, 389, 3500, 3900
–
Figure 22. PN 24091-00
with 3900VP pH sensor
Figure 23. Low Flow Cell (PN 24091-00,
24091-01 or 24091-02) dimensions
Figure 24. PN S10290
with 400VP sensor
9
Figure 25. Metal Low Flow Cell
(PN S10240 and S10290) dimensions
HANDRAIL MOUNTING
Use a handrail mounting assembly whenever a pH, ORP,
or dissolved oxygen sensor must be installed in a tank,
aeration basin, pond, or open channel. Two versions are
available. PN 11275-01 consists of a 13-ft (4.0-m) long
PVC pipe with a 45° bend about two feet (0.6 m) from
the lower end where the sensor is connected. The angle
allows bubbles to slide off the sensor. Clamps attach
the pipe to a frame that can be bolted to a handrail.
Handrail Mounting Assemblies
Part Number 11275-01
Process Connection Mounting brackets for Various Sizes of Handrails
Wetted Materials PVC NA NA
Temperature Rating 140°F (60°C) max. NA NA
Compatible Sensors*
pH and ORP Sensors 396P, 389, 3500, 3900
Dissolved Oxygen Sensors 499ADO**
Optional Accessory
* Note: All sensor models noted in this graph are listed with integral cables. The sensor models with the “VP”
connector can also be used.
* If used with the Handrail Mounting Assembly in a tank, the correct measurement can only be made if there is a
*
continuous flow or movement past the membrane of the sensor. These sensors will not operate properly in
standing liquid.
*** 1 1/2 inch pipe not supplied in these systems.
Jet Spray Cleaner (see pg 13)
HRMS-01
***
HMRS-02
***
The pipe insertion depth is adjustable. The HRMS
consists of a 1½ inch pipe clamp held by a clevis and
pin assembly, which can be attached to a railing. The
user supplies the 1 ½ inch pipe. The clamp can be
rotated from side to side and up and down and locked
in place once the pipe is in the desired position. The
sensor attaches to the pipe using either a threaded
adapter (HRMS-02) or a union coupling (HRMS-01).
HINT: Using a sensor with a VP connector and
cable will allow for easier access to the sensor
when cleaning or calibration is necessary.
Figure 26. Photo on left shows sensor being dangled into the pond, an incorrect installation. Photo on
right shows correct sensor mounting – sensor is threaded into a pipe conduit while cable is run through the
pipe of the Handrail Mounting Assembly.
10
Figure 27. HRMS-01 shown with usersupplied 1-1/2" pipe (top) and assembled (bottom).
HANDRAIL MOUNTING ASSEMBLY
Figure 28. Handrail Mounting Assembly (PN 11275-01) shown with Model 499A Dissolved Oxygen Sensor.
11
FLOATING BALL SYSTEM
The floating ball system when used with the HRMS
provides a convenient way of keeping the sensor a fixed
distance below the surface of a pond or basin
independent of the water level. The system
accommodates any sensor having 1-inch back facing
threads. The sensor attaches to the bottom of the float
through a union coupling, and the sensor is held a 45°
angle allows air bubbles to side off the sensor. The float
can be readily inflated using a hand pump.
Floating Ball System
Part No. Description
BB11-01 For Model 499ADO; includes sensor union adapter
BB11-03 For any sensor with a 1 inch rear-facing MNPT
connection; includes union adapter
Wetted Material: Flexible PVC, rigid PVC
Temperature Range: 32°F to 140°F (0°C to 60°C)
Size (Diameter x Length): 11 x 13 inches (28 x 33 cm)
Maximum Inflation Pressure: 2.1 psig (0.15 bar)
Maximum Circumference: 34-1/2 inches (88.0 cm)
Buoyancy: 27lbs (12 kg)
Minimum Sensor Insertion Depth Into Process:
BB11-01 with 499ADO sensor: 13 inches (33 cm)
BB11-03 with standard 1 inch sensor: 17 inches (43 cm)
Pipe Boom Support Arm: 1-1/2 inch Sch 80 PVC pipe
(by others)
Sensor Compatibility: 1 inch MNPT on sensor cable end
12
Figure 29. Assembled
Floating Ball BB11-01 for
the 499ADO dissolved
oxygen sensor
Figure 30. Floating Ball and
Sensor with 1 inch Rear Facing
MNPT Connection
JET SPRAY CLEANER
The jet spray cleaner is intended for use with pH, ORP, or
oxygen sensors. It directs a spray of air, water, or other
cleaning fluid at the end of the sensor flushing away
suspended solids that have accumulated there. The
cleaner can be used only if the sensor is installed in a
tank or basin. It is not suitable for in-pipe installations.
Cleaning frequency and spray duration is controlled by
n interval timer in the analyzer. During cleaning the
a
analyzer can be programmed to hold the last reading,
thus avoiding spurious outputs and relay actions. Hold
can be continued beyond the end of the cleaning
Timer: supplied By
user or uTilize
imer funcTion
T
inside rosemounT
AnAlyTicAl
nsTrumenTs
i
period, allowing the sensor time to stabilize before the
analyzer returns to normal operation.
Cleaning intervals and frequency as well as the best
cleaning agent can be determined only by experience.
Several trials will likely be necessary to determine the
best program.
Jet Spray Cleaner
Part Number 12707-00
Process Connection 2" NPT threads OR use sensor/conduit
Wetted Materials 316 SST, polypropylene, PVC
Maximum Pressure 50 psig (446 Kpa)
Compatible sensors*
pH and ORP 396P, 389, 3900, 3500
Chlorine, dissolved 499ACL, 499ADO, 499AOZ
oxygen, and ozone
*Note: All sensor models noted in this graph are listed with integral
cables. The sensor models with the “VP” designation can also be used.
Figure 31. Example of Jet Spray Cleaner with timer and
solenoid valve for interval timed cleaning
Figure 32. Jet Spray Cleaner shown
with Model 3900 pH sensor using the
front threads to connect to the
cleaner and the back threads to
connect to a watertight pipe conduit
Typical install uses
these threads
13
MOUNTING ADAPTERS – THREADED CONNECTIONS
Use these adapters to install sensors
with back facing threads into
process piping or sample tees. The
sensor screws into a plastic adapter
that is held in the process connector
by a union nut. The rear of the
adapter is threaded for a conduit
connection, if required. The union
connection allows the sensor to be
removed without the danger of
twisting and damaging the cable.
Mounting
Adapters
ADAPTER 23242-02 23242-03 2001990
Materials of 316 SST, 316 SST, CPVC, PEEK,
Construction PEEK, Viton PEEK, Viton Viton
Process Connection 1-1/2" MNPT 1-1/2" MNPT 2" MNPT
Sensor Adapter/ 1" x 3/4" FPT 3/4" x 5/8 - 3/4" x 3/4" FPT
Union Thread Size 11 UNC
Temperature, 392F (200C) 392F (200C) 100F(38C) at
Maximum
Pressure, 295 psig 295 psig 100 psig
Maximum (2135 kPa abs) (2135 kPa abs) (791 kPa abs)
Compatible Sensor Models*
pH and ORP 389, 396P
3500, 3900 --
Conductivity 228-21 228-20 228-21
*Note: Most sensor models noted in this graph are listed with integral cables. The
sensor models with the “VP” designation can also be used.
100 psig (791 kPa abs)
OR
185F (85C) at
45 psig (412 kPa abs)
Figure 33. 3500
PERpH-X pH sensor
with adapter
PN 23242-02
Figure 35. The 228 Toroidal Conductivity
Sensor with Adapter PN 23242-03
Figure 34. 228
Toroidal Conductivity
sensor with adapter
PN 23242-02 (or -03)
A “A” Dimension
Sensor* inches mm
396P 3.5 88.9
389 3.75 95.2
3900 4.5 114.3
3500 5.5 139.7
Figure 36. The 396P pH Sensor with Adapter
PN 23242-02. Can also be used for connection
to a 228-21 toroidal conductivity sensor using
the reversible PEEK adapter.
*The VP connector
versions can also
be used.
Figure 37. Adapter
PN 2001990 with 228-21
Toroidal Conductivity sensor
14
MOUNTING ADAPTERS – SUBMERSION
Use this adapter to connect sensors with 1 inch back
facing threads to standpipes for installation in tanks
and basins.
Figure 38. Example of pipe mounting sensor with mounting
adapter PN 9320057.
Figure 39. 499ADOVP
Dissolved Oxygen Sensor
with adapter PN 9320057
ADAPTER 9320057
Materials of PVC, Sch 80
Construction
Process Connection 1" FNPT
Sensor Adapter/ 1" FNPT
Union Thread Size
Temperature, Ambient
Maximum
Compatible Sensor Models*
pH and ORP 389, 396P,
3500, 3900
Conductivity -
Dissolved Oxygen 499ADO
Ozone 499AOZ
Chlorine 499ACL
*Note: Most sensor models noted in this
graph are listed with integral cables. The
sensor models with the “VP” designation
can also be used.
15
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