Rosemount Analytical 396R, 396RVP Operating Manual
Instruction Manual
IQ-MAN-396R-396RVP
L
Rev. K
March 2017
Rosemount
pH/ORP Sensors
™
396R/396RVP
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Essential Instructions
Read this page before proceeding!
Emerson designs, manufactures and tests its products to meet many national and international stan-
dards. Because these sensors are sophisticated technical products, you MUST properly install, use,
nd maintain them to ensure they continue to operate within their normal specifications. The
a
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
Instruction Manual 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.
DANGER
Hazardous Area InstallationN
This sensor is not Intrinsically Safe. or Explosion Proof. Installations near flammable liquids or in
hazardous area locations must be carefully evaluated by qualified on site safety personnel.
To secure and maintain an intrinsically safe installation, an appropriate transmitter/safety
barrier/sensor combi nation must be used. The installation system must be in accordance with the
governing approval agency (FM, CSA or BASEEFA/CENELEC) hazardous area classification requirements. Consult your transmitter instruc tion manual for details.
Proper installation, operation and servicing of this sensor in a Hazardous Area Instal lation is entirely
the responsibility of the user.
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.
WARNING
Retractable sensors must not be inserted nor retracted when process pressures are in excess of 64 psig
(542kPa) for option 21 or 35 psig (343 kPa) for option 25.
CAUTION
Special Conditions for Safe Use
. All pH/ORP sensors have a plastic enclosure which must only be cleaned with a damp cloth to avoid
1
the danger due to a build up of an electrostatic charge.
2. All pH/ORP sensor models are intended to be in contact with the process fluid and may not meet the
500V r.m.s. a.c. test to earth.
This must be taken into consideration at installation.
About This Document
This manual contains instructions for installation and operation of the Rosemount 396R and
396RVP pH/ORP Sensors.
The following list provides concerning all revisions of this document.
Rev. Level Date Notes
A 01/01 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 07/02 Revised multiple drawings.
C 08/02 Added drawing #40105549, rev. D.
D 04/03 Revised drawing #40396R21/22 on page 18.
E 08/03 Added Silcore information.
F 09/04 Updated ordering info and added/revised wiring drawings.
G 01/05 Delete obsolete options.
H 01/07 Miscellaneous revisions.
I 11/10 Removed mention of patents and updated dnv logo.
J 02/11 Added ATEX directive and updated caution boxes per ANSI
standard.
K 03/17 Updated the Ordering Information, Specifications, Product
Certifications, and Emerson logo and Address.
Instruction Manual Table of Contents
LIQ-MAN-396R-396RVP March 2017
Contents
Section 1: Description and Specifications
1.1 Features and Applications....................................................................................1
1.2 Specifications ......................................................................................................2
1.3 Product Certifications ..........................................................................................4
1.4 Ordering Information...........................................................................................5
Section 2: Installation
2.1 First Time Installation ..........................................................................................7
2.2 Unpacking and Inspection ...................................................................................8
2.3 Mechanical Installation ........................................................................................8
Section 3: Wiring Rosemount 396R
3.1 Wiring for Rosemount 396R...............................................................................17
Section 4: Wiring Rosemount 396RVP
4.1 Wiring for Rosemount 396RVP...........................................................................27
Section 5: Startup and Calibration
5.1 Sartup ...............................................................................................................43
5.2 pH Calibration ...................................................................................................43
5.3 ORP Calibration .................................................................................................44
Section 6: Maintenance
6.1 Maintenance......................................................................................................45
6.2 Sensor Removal .................................................................................................45
6.3 pH Electrode Cleaning .......................................................................................46
6.4 Cleaning Platinum Electrode..............................................................................46
6.5 Automatic Temperature Compensator...............................................................47
6.6 Sensor Tube Replacement When Used With A Sensor Head Junction Box............48
Section 7: Diagnostics and Troubleshooting
7.1 Diagnostics and Troubleshooting with Model 54/81/3081 pH/ORP....................51
Section 8: Accessories
8.1 Accessories........................................................................................................53
EC Declaration of Conformity.............................................................................55
Intrisicallly Safe Sensor Installation Drawing - FM ................................57
Table of Contents i
Table of Contents Instruction Manual
March 2017 LIQ-MAN-396R-396RVP
ii Table of Contents
Instruction Manual Description and Specifications
LIQ-MAN-396R-396RVP March 2017
Section 1: Description and Specifications
1.1 Features and Applications
Rosemount 396R and 396RVP Sensors are specifically designed for improved life in harsh, dirty
applications where a separate sample stream is difficult to provide and greater insertion depths are
required. These sensors are designed for use with a 1-1/4 in. or 1-1/2 in. ball valve for hot tap
installation. Sensors are constructed of molded polypropylene housed in a titanium tube with EPDM
seals to provide maximum chemical resistance. The sensors feature a shrouded tip for protection
from breakage while allowing process to flow by the glass electrode for accurate and reliable pH
and ORP measurements.
Figure 1-1: Cross Section Diagram of the TUpH Reference Technology
All TUpH sensors are designed with a large area reference junction, helical reference pathway, and an
AccuGlass pH glass bulb. This sensor technology ensures superior performance while only requiring
minimal maintenance.
Description and Specifications 1
Description and Specifications Instruction Manual
March 2017 LIQ-MAN-396R-396RVP
1.2 Specifications
able 1-1: Percent linearity over pH
T
pH Range Hemi Bulb Flat Bulb
0-2 pH 94% 93%
2-12 pH 99% 98%
12-13 pH 97% 95%
13-14 pH 92% --
Table 1-2: Rosemount 396R sensor specifications
Measured Range
pH range 0 to 14 pH
ORP range -1500 mV to 1500 mV
Maximum Pressure at Retraction or Insertion
Code 21: 64 psig (542 kPa abs)
Code 25: 35 psig (343 kPa abs)
Minimum Conductivity
100 µS/cm
Maximum Process Pressure and Temperature
Hemi bulb: 150 psig (1136 kPa abs) at 212 °F (100 °C)
Flat bulb: 100 psig (790 kPa abs) at 212 °F (100 °C)
Wetted Materials
Polypropylene, EPDM, titanium, glass, (platinum: ORP only)
Weight/Shipping Weight
Sensor Code 21: 2.0 lb/3.0 lb (.9 kg/1.40 kg)
Code 25: 3.0 lb/4.0 lb (1.40 kg/1.80 kg)
Ball Valve PN 23240-00; 5 lb/7 lb (2.25 kg /3.20 kg)
PN 23634-00 8 lb/10 lb (3.65 kg/4.55 kg)
J-Box: 3 lb/4 lb (1.40 kg/1.80 kg)
Process Connections
None, must use 1 inch process connector or ball valve kit (1-1/2 or 1-1/4 in.) (sold separately)
Cable Length
Integral 15 ft or 9.5 in. 9 conductor cable except option 60 (9.5 in. coaxial cable with BNC)
2 Description and Specifications
Instruction Manual Description and Specifications
LIQ-MAN-396R-396RVP March 2017
Table 1-3: Rosemount 396RVP sensor specifications
Measured Range
pH range 0 to 14 pH
RP range
O
Maximum Pressure at Retraction or Insertion
Code 21: 64 psig (542 kPa abs)
Code 25: 35 psig (343 kPa abs)
Minimum Conductivity
75 µS/cm, nominal
Pressure Range
Hemi bulb 100-1136 kPa abs (0-150 psig)
Flat bulb 100-790 kPa abs (0-100 psig)
Wetted Materials
Polypropylene, EPDM, titanium, glass, (platinum: ORP only)
Weight/Shipping Weight
Sensor Code 21: 2.0 lb/3.0 lb (.9 kg/1.40 kg)
Ball Valve PN 23240-00; 5 lb/7 lb (2.25 kg /3.20 kg)
Process Connections
None, must use 1 inch process connector or ball valve kit (1-1/2 in. or 1-1/4 in.)
Cable Length
Use cable 24281-XX (where XX = -01 through -08 and designates various cable lengths). See accessories.
1500 mV to 1500 mV
-
Code 25: 3.0 lb/4.0 lb (1.40 kg/1.80 kg)
Description and Specifications 3
Description and Specifications Instruction Manual
March 2017 LIQ-MAN-396R-396RVP
1.3 Product Certifications
Please see online certificates for further details.
ECEx
I
Sensors without preamp (pH and ORP) – Ex ia IIC T4 Ga (-20°C ≤ Ta ≤ +60°C)
Sensors with SMART preamp (pH only) – Ex ia IIC T4 Ga (-20°C ≤ Ta ≤ +60°C)
Per standards IEC60079-0 : 2011, IEC 60079-11 : 2011
ATEX
Sensors without preamp (pH and ORP) – II 1 G Ex ia IIC T4 Ga (-20˚C ≤ Ta ≤ +60˚C)
Sensors with SMART preamp (pH only) – II 1 G Ex ia IIC T4 Ga (-20˚C ≤ Ta ≤ +60˚C)
Per standards EN 60079-0: 2012+A11:2013, EN 60079-11:2012
FM
See online FM Certificate of Compliance for applicable sensor options:
Intrinsically Safe for use in Class I, II, and III, Division 1, Groups A, B, C, D, E, F, and G; Temperature
Class T6 Ta = -20 °C to +60 °C
Intrinsically Safe for use in Class I, Zone 0, AEx ia IIC T6 Ta = -20 °C to +60 °C
Nonincendive for use in Class I, Division 2, Groups A, B, C, and D; Temperature Class T6 Ta = -20 °C
to +60 °C
Suitable for use in Class II and III, Division 2, Groups E, F, and G; Temperature Class T6 Ta = -20 °C
to +60 °C Hazardous (Classified) Locations
IS/I,II,III/1/ABCDEFG/T6 Ta = 60°C - 1400332; Entity; I/0/AEx ia IIC/T6 Ta = 60 °C - 1400332; Entity;
NI/I/2/ABCD/T6 Ta = 60 °C; S/II,III/2/EFG/T6 Ta = 60 °C
Per standards 3600:1998, 3610:2010, 3611:2004, 3810:2005
CSA
See online CSA Certificate of Compliance for applicable sensor options:
Sensors with preamp – Intrinsically Safe:
Class I, Division 1, Groups ABCD; Class II, Division 1, Groups EFG; Class III; Class I, Division 2, Groups
ABCD; Ambient temperature rating -20 °C to +60 °C; Ex ia IIC; T6
Sensors without preamp – Intrinsically Safe and Non-Incendive:
Class I, Division 1, Groups ABCD; Class II, Division 1, Groups EFG; Class III; Class I, Division 2, Groups
ABCD; Ex ia IIC; T6; Ambient temperature rating -20 °C to +60 °C: (Simple Apparatus)
Per standards C22.2 No. 0-10, C22.2 No. 0.4-M2004, C22.2 No. 94-M1991, C22.2 No. 142 – M1987,
C22.2 No 157 – M1992, CAN/CSA E60079-0:07, CAN/CSA E60079- 11:02, UL50 11th Ed, UL508
17th Ed, UL913 7th Ed, UL 60079-0: 2005, UL 60079-11: 2002
4 Description and Specifications
Instruction Manual Description and Specifications
LIQ-MAN-396R-396RVP March 2017
1.4 Ordering Information
Table 1-4: Rosemount 396R ordering information
odel
M
96R
3
Measuring Electrode Type
10 pH - GPHT Glass
12 ORP
13 pH - GPLR Flat Glass
Sensor Length
21 21 Inch Titanium Tube
25 36 Inch Titanium Tube
Transmitter/TC Compatibility
50 3K TC
54 Pt-100
Optional Cable Options
_ No Selection
60 9.5 Inch Cable with BNC
61 9.5 Inch Cable without BNC
Typical Model Number: 396R-10-21-54
ensor type
S
H/ORP Sensor
p
(1)
(2)
(3)
(4)
(5)
1. For use with legacy transmitter model 1181.
2. For use with Rosemount model 1056, 1057, 1066, 5081, and 56 transmitters.
3. The sensor will come with a standard 15 ft. integral cable.
4. Used for connection to 1181, 1054 series, and 2081 sensor head junction boxes.
5. Used for connection to sensor head junction box PN 23709-00.
Table 1-5: Rosemount 396RVP ordering information
Model Sensor type
396RVP pH/ORP Sensor
Measuring Electrode Type
10 pH - GPHT Glass
12 ORP
13 pH - GPLR Flat Glass
Sensor Length
21 21 Inch Titanium Tube
25 36 Inch Titanium Tube
Transmitter/TC Compatibility
50 3K TC
54 Pt-100
55 Pt-100 for SMART Preamplifier
(1)
(2)
(3)
Preamplifier Options
_ No Selection
70 SMART Preamplifier
Typical Model Number: 396RVP-10-21-55-70
(4)
1. For use with legacy transmitter model 1181.
2. For use with Rosemount model 1056, 1057, 1066, 5081, and 56 transmitters.
3. Must be selected with option 70. Also suitable for use with Rosemount model 1056, 1057, 1066, 5081, and 56 transmitters.
4. Must be selected with option 55.
Description and Specifications 5
Description and Specifications Instruction Manual
March 2017 LIQ-MAN-396R-396RVP
6 Description and Specifications
Instruction Manual Installation
LIQ-MAN-396R-396RVP March 2017
Section 2: Installation
2.1 First Time Installation
For first time Rosemount 396R installations, using the following guide is recommended:
1. Retractable Mounting
A. Choose one (required for all first time installations):
PN 23166-00, 1 in. x 1 in. NPT process connector, 316 SST
PN 23166-01, 1 in. x 1 in. NPT process connector, Titanium
B. Choose one:
PN 23240-00, 1-1/2 in. ball valve assembly, 316 SST
PN 23765-00, 1-1/4 in. ball valve assembly, 316 SST
2. Junction Boxes (Optional; Choose either Sensor Head or Remote)
A. Sensor Head Junction Boxes (used with options -60 or -61 sensor) - Choose one:
PN 23709-00; includes preamplifier
B. Remote Junction Boxes (used with standard 15 ft. cable length sensor) - Choose one:
PN 23555-00; includes preamplifier
3. Extension Cables - Choose one:
PN 23646-01, 11 conductor, shielded, prepped
PN 9200273, 11 conductor, shielded, unprepped
For first time Rosemount 396RVP installations, using the following guide is recommended:
1. Variopol Cable (required for all first time installations)
Choose one: PN 24281-00 -- 15 ft. VP8 Cable
PN 24281-01 -- 25 ft. VP8 Cable
2. Retractable Mounting
1A. Choose one (required for all first time installations, except as noted):
PN 23166-00 1 in. x 1 in. NPT process connector, 316 SST
PN 23166-01 1 in. x 1 in. NPT process connector, Titanium
Choose one (optional process connector o-rings):
PN 9550220, Kalrez ® O-ring, 2-214
PN 9550099, Viton ® O-ring, 2-214
1b. Choose one:
PN 23240-00 1-1/2 in. ball valve assembly, 316 SST
PN 23765-00 1-1/4 in. ball valve assembly, 316 SST (process connector not needed)
3. Remote Junction Boxes (Optional)
PN 23555-00 includes preamplifier
4. Extension cables
Choose one: PN 23646-01, 11 conductor, shielded, prepped
PN 9200273, 11 conductor, shielded, unprepped
Installation 7
Installation Instruction Manual
March 2017 LIQ-MAN-396R-396RVP
2.2 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.
Note: If the sensor is to be stored, the protective boot should be filled with either KCl electrolyte
solution or pH 4.0 buffer solution and replaced on sensor tip until ready to use.
Note: Save the original packing cartons and materials as most carriers require proof of damage due
to mishandling, etc. Also, if it is necessary to return the instrument to the factory, you must pack the
instrument in the same manner as it was received. Refer to Section 8.0 for instructions.
WARNING
Glass electrode must be wetted at all times (in storage and in line) to maximize sensor life.
2.3 Mechanical Installation
The Rosemount 396R Sensor may be installed through a weldalet or in a pipe tee or “Y”, as shown
in Figure 2-1, when used with a ball valve. Insert the end of the sensor to a depth sufficient to ensure
that the glass bulb is continuously wetted by the process fluid. The Rosemount 396R can also be
inserted directly into the process without the use of a ball valve for appli cations not requiring
continuous operation during sensor maintenance.
CAUTION
Allow sufficient room for safe retraction and insertion of the sensor. Personnel should have room for
stable footing while performing removal or insertion of the sensor.
The sensor must be mounted within 10-90 degrees of the horizontal with the tip pointed
downward, thus keeping air bubbles off of the pH sensitive glass bulb. Bubbles settled on the glass
bulb disrupt the electrical continuity between the pH sensitive glass and the silver/ silver chloride
measuring element.
If the retraction version is to be installed without a ball valve follow the installation procedure for
insertion service (Section 2.3.2). Perform the following steps for sensor installation through a ball
valve:
2.3.1 Installation Through Ball Valve
1. Carefully remove the liquid filled rubber boot which protects the glass electrode and keeps
the liquid junction wet during shipping and storage. Discard the liquid and boot. Make sure
the lubricated O-ring is in place in the groove inside the male connector on the sensor body.
CAUTION
Buffer solution, in the protective boot, may cause skin or eye irritation.
2. With the male connector on the sensor’s body, insert the sensor into the ball valve until it
gently touches the closed valve. The molded electrode guard will protect the glass bulb
from breakage.
8 Installation
Instruction Manual Installation
LIQ-MAN-396R-396RVP March 2017
3. Thread the male connector body tightly into the ball valve assembly. DO NOT tighten the
hex nut on the male connector body; doing so would not allow the sensor to be inserted
through the ball valve.
4. Pull back hard on the sensor assembly, as if trying to remove the sensor, to be certain that
the sensor cannot come free of the ball valve assembly. The built-in retraction stop will butt
against the shoulder of the male connector if properly installed.
CAUTION
The sensor must be captured by the valve assembly and the male connector so that it cannot be blown
free by process pressure if mishandled during insertion or retraction.
5. After confirming that the sensor assembly is properly secured by the valve assembly, the
valve may be opened and the sensor positioned into the process at the desired depth and
orientation.
6. While holding the sensor in position, tighten the hex nut of the male connector to firmly
secure the sensor in place. When the hex nut is tightened, the Teflon ferrule inside the
compression fitting clamps the sensor tube.
CAUTION
Over tightening the hex nut may damage the ferrule.
NOTICE
A stainless steel ferrule is available if the Teflon ferrule does not inadequately grip. When using the
metallic ferrule, care must be taken to avoid over tightening and damaging the sensor tube. If the male
connector leaks during insertion or retraction, replace the O-ring in the male connector.
2.3.2 Installation Without Ball Valve
The Rosemount 396R Sensor may be installed through a weldalet or pipe tee or “Y” when used with
a process connector (PN 23166-00 or 23166-01). The sensor should be installed within 80° of
vertical, with the electrode facing down.
Figure 2-1: Exploded View of Ball Valve Kit PN 23240-00 used with process connector
PN 23166-00 (or PN 23166-01)
Installation 9
Installation Instruction Manual
March 2017 LIQ-MAN-396R-396RVP
Figure 2-1: Typical Mounting Configurations for Rosemount 396R
Figure 2-2: Typical Mounting Configurations for Rosemount 396RVP
10 Calibration and Maintenance
Instruction Manual Installation
LIQ-MAN-396R-396RVP March 2017
Figure 2-3: Dimensional Drawing — Rosemount 396R with Optional Ball Valve PN 23765-00
Note: Add five (5) inches to dimension A if mounting a sensor head junction box onto the sensor.
Calibration and Maintenance 11
Installation Instruction Manual
March 2017 LIQ-MAN-396R-396RVP
igure 2-4: Dimensional Drawing — Rosemount 396R with Optional Ball Valve PN 23240-00
F
Note: Add five (5) inches to dimension A if mounting a sensor head junction box onto the sensor.
12 Installation
Instruction Manual Installation
LIQ-MAN-396R-396RVP March 2017
Figure 2-5: Dimensional Warning Label for Rosemount 396R Hemi Bulb Sensors and Sensor
Note: Pressure rating for flat glass sensors is 100-790 kPa (0-100 psig).
Installation 13
Installation Instruction Manual
March 2017 LIQ-MAN-396R-396RVP
Figure 2-6: Dimensional Drawing — Rosemount 396RVP with Optional 1-1/2 inch Ball Valve
PN 23240-00
14 Installation
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