Page 1
Instruction Manual
IQ-MAN-400
L
Rev. L
May 2017
Rosemount
™
400 and 400VP
Contacting Conductivity Sensors
Page 2
asgkas
h
Page 3
Essential Instructions
Read this page before proceeding!
merson designs, manufactures and tests its products to meet many national and international stan-
E
dards. Because these sensors are sophisticated technical products, you MUST properly install, use,
and maintain them to ensure they continue to operate within their normal specifications. The
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
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, the certified safety barrier, transmitter, and
sensor combination must be used. The installation system must comply with the governing approval
agency (FM, CSA or BASEEFA/CENELEC) hazardous area classification requirements. Consult your
transmitter instruction manual for more details.
Proper installation, operation and servicing of this sensor in a Hazardous Area Installation 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
Before removing the sensor, be absolutely certain that the process pressure is reduced to 0 psig and
the process temperature is lowered to a safe level!
Page 4
About This Document
This manual contains instructions for installation and operation of the Rosemount 400 Contacting
Conductivity Sensors. The following list provides concerning all revisions of this document.
Rev. Level Date Notes
J 10/2016 Updated information with new Emerson Style Guidelines, Added
Ordering Information, Added Accessories Information. Added
dimensional drawings.
K 11/2016 Updated Ordering Information and Specification.
L 05/2017 Updated the Emerson Address and Logo.
Page 5
Instruction Manual Table of Contents
LIQ-MAN-400 May 2017
Contents
Section 1: Specifications
1.1 Specifications ......................................................................................................1
1.2 Ordering Information...........................................................................................2
Section 2: Installing the sensor............................................................................3
2.1 Wiring the sensor.................................................................................................5
2.2 Wiring the sensor to the transmitter....................................................................5
Section 3: Calibration and Maintenance
3.1 Calibrating the sensor .........................................................................................9
3.2 Cleaning the sensor ...........................................................................................12
Section 4: Troubleshooting
4.1 Troubleshooting ................................................................................................13
Section 5: Accessories
5.1 Accessories........................................................................................................15
Table of Contents i
Page 6
Table of Contents Instruction Manual
May 2017 LIQ-MAN-400
ii Table of Contents
Page 7
Instruction Manual Specifications
LIQ-MAN-400 May 2017
Section 1: Specifications
1.1 Specifications
Table 1-1 Rosemount 400/400VP contacting conductivity sensor specifications
Wetted materials
Electrodes Titanium
Insulator Glass Filled PEEK
Body 316 Stainless Steel
O-ring EPDM
Temperature range
Standard 32 to 221 °F (0 to 105 °C)
With Optional Integral Junction Box 32 to 392 °F (0 to 200 °C)
Maximum pressure
250 psig (1825 kPa abs)
Vacuum
At 1.6 in. Hg air leakage is less than 0.005 SCFM (0.00014 m3/min)
Cell constants
0.01, 0.1, and 1.0/cm
Process connection
¾ in. MNPT
Cable
10 ft (3.1 m) standard; 50 ft (15.2m) optional; interconnecting VP6 cables sold separately (see Accessories)
Table 1-2 Flow cell (24092-02) specifications
Wetted materials
Body and Nut Polycarbonate and polyester
¼ in. Fittings 316 Stainless Steel
O-ring Silicone
Process connection
Compression fitting for ¼ in. OD tubing
Temperature range
32 to 158 °F (0 to 70 °C)
Maximum pressure
90 psig (722 kPa abs)
Flow cell sold separately; see Accessories.
Specifications 1
Page 8
Specifications Instruction Manual
May 2017 LIQ-MAN-400
1.2 Ordering Information
Table 1-3 Rosemount 400 Contacting Conductivity Sensor ordering information
Model Sensor type
400 Contacting Conductivity Sensor
Cell constant
11 0.01/cm
12 0.1/cm
13 1.0/cm
Temperature compensation
_ Pt-1000
54 Pt-100
55 10K Ohm TC
Option 1
_ No selection
36 Extended insertion length
Option 2
_ No selection
50 Integral 50 ft (15 m) cable
60 Integral junction box
Typical Model Number: 400-11-_-36-50
(1)
(2)
1. For use with Rosemount transmitter models 56, 1056, 1057, 1066, 5081, and legacy transmitter models 1055, 54C, 54eC, 4081C, 6081-C,
2. 5.5 inches from the bottom of threads to tip of sensor.
and XMT-C.
Table 1-4 Rosemount 400VP Contacting Conductivity Sensor with Variopol cable connection ordering
information
Model Sensor type
400VP Contacting Conductivity Sensor
Cell constant
11 0.01/cm
12 0.1/cm
13 1.0/cm
Temperature compensation
_ Pt-1000
54 Pt-100
55 10K Ohm TC
56 100K Ohm TC
(1)
Option 1
_ No selection
36 Extended insertion length
Typical Model Number: 400VP-11-_-36
(2)
1. For use with Rosemount transmitter models 56, 1056, 1057, 1066, 5081, and legacy transmitter models 1055, 54C, 54eC, 4081C, 6081-C,
2. 5.5 inches from the bottom of threads to tip of sensor.
2 Specifications
and XMT-C.
Page 9
Instruction Manual Installation
°
°
Sensor
Weldalet
P
rocess Piping
Inlet
1” Pipe Tee With 3/4”
Bushing Shown
Outlet
Sensor
1” Pipe Tee With 3/4”
Bushing Shown
Inlet
Outlet
Sensor
Flow
Flow
3/4” Inch MNPT
(Typical)
Outlet
Inlet
LIQ-MAN-400 May 2017
Section 2: Installing the sensor
Keep ¼ in. (6 mm) clearance between electrodes and piping. The electrodes must be completely
submerged in the process liquid, i.e., to the level of the threaded connection. See Figures 2-1 to
Figure 2-6 for recommended orientation and installation. Rosemount 400/40VP Contacting
Conductivity Sensors with 0.1 and 1.0/cm cell constants can be installed in ¾-inch pipe tees.
Rosemount 400/400VP Contacting Conductivity Sensors can be installed in 1-inch tees with a
¾-inch bushing. If the sensor is installed in a pipe tee or flow cell with the sample draining to open
atmosphere, bubbles may accumulate on the electrodes. Trapped bubbles will cause errors. As
bubbles accumulate, the conductivity reading normally drifts down. In the plastic flow cell, bubbles
are readily visible. To control bubble formation, apply a small amount of back pressure to the flow
cell or pipe tee.
Figure 2-1 Sensor orientation
Figure 2-3 Insertion in a pipe Tee
Figure 2-5 Insertion in a pipe Tee
Figure 2-2 Direct insertion in a pipe
Figure 2-4 Insertion in a pipe Tee
Figure 2-6 Insertion in a flow cell (24091-02)
Installation 3
Page 10
Installation Instruction Manual
Sensor c onfiguration
A B C D
Inches mm Inches mm Inches mm Inches mm
0.01/cm 1.59 40.39 1.98 50.3 4.43 112.5 6.3 160.0
0.1/cm 0.67 17.0 1.10 27.9 3.47 90.4 5.43 137.9
1.0/cm 0.67 17.0 1.10 27.9 3.58 90.9 5.45 138.4
0.01/cm (with
extended insertion
length)
1.59 40.4 5.48 139.2 7.91 200.9 9.78 248.4
0.1/cm (with extended
insertion length)
0.67 17.0 5.48 139.2 7.91 200.9 9.78 248.4
1.0/cm (with extended
insertion length)
0.67 17.0 5.48 139.2 7.91 200.9 9.78 248.4
3/4 IN-14 NPT
3 x Ø .25
Equally Spaced
C
B
A
D
15.8
.62
Millimeter
Inch
Sensor c onfiguration
A B C
Inches mm Inches mm Inches mm
0.01/cm 1.59 40.39 1.98 50.34 7.41 188.2
0.1/cm 0.687 17.45 1.11 28.15 6.49 164.9
1.0/cm 0.667 16.94 1.13 28.70 6.51 165.4
0.01/cm (with
extended insertion
length)
1.59 40.39 5.49 139.4 10.90 276.9
0.1/cm (with extended
insertion length)
0.687 17.45 5.49 139.4 10.90 276.9
1.0/cm (with extended
insertion length)
0.667 16.94 5.49 139.4 10.90 276.9
3/4 IN-14 NPT
3/4 IN-14 NPT
3 x Ø .25
Equally Spaced
C
B
A
15.96
.63
127
5
104.78
4.13
Millimeter
Inch
Sensor c onfiguration
A B C
Inches mm Inches mm Inches mm
0.01/cm 1.59 40.39 1.98 50.34 4.52 114.8
0.1/cm 0.687 17.45 1.11 28.15 3.65 92.71
1.0/cm 0.667 16.94 1.13 28.70 3.67 93.22
0.01/cm (with
extended insertion
length)
1.59 40.39 5.49 139.4 8.00 203.2
0.1/cm (with extended
insertion length)
0.687 17.45 5.49 139.4 8.00 203.2
1.0/cm (with extended
insertion length)
0.667 16.94 5.49 139.4 8.00 203.2
C
B
A
3/4 IN-14 NPT
3 x Ø .25
Equally Spaced
15.96
.63
Millimeter
Inch
May 2017 LIQ-MAN-400
igure 2-7 Rosemount 400 with integral cable connection dimensional drawing
F
Figure 2-8 Rosemount 400 with integral junction box dimensional drawing
Figure 2-9 Rosemount 400VP with Variopol cable connection dimensional drawing
4 Installation
Page 11
Instruction Manual Installation
RTD in
RTD sense
RTD return
LIQ-MAN-400 May 2017
2.1 Wiring the sensor
For other wiring diagrams not shown below, please refer to the Liquid Transmitter Wiring Diagrams.
able 2-1 Wire color and connections in sensor
T
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
White with red stripe
White
Clear Shield for all RTD lead wires
2.2 Wiring the sensor to the transmitter
Figure 2-10 Wiring for Rosemount 56, 1056 and 1057 transmitters
Installation 5
Page 12
Installation Instruction Manual
RCV B
RCV A
RSHLD
DRVB
RTN
SENSE
RTD IN
SHLD
CLEAR
WHITE/RED
RED
DRVA
DSHLD
WHITE
CLEAR
GRAY
ORANGE
CLEAR
TB1TB2
May 2017 LIQ-MAN-400
Figure 2-11 Wiring for Rosemount 1066 transmitter
Figure 2-12 Wiring for Rosemount 5081 transmitter
6 Installation
Page 13
Instruction Manual Installation
LIQ-MAN-400 May 2017
2.2.1 Wiring through junction box
osemount 400 Contacting Conductivity Sensors can have an optional integral junction
R
box mounted on the end of the sensor. See
If wiring connections are made through a remote junction box (PN 23550-00), wire point-to-point.
Use cable 23747-00 (factory-terminated) or 9200275 (raw cable).
Figure 2-13 Sensor-mounted junction box wiring
Figure 2-13 for wiring instructions.
Notes:
1. The gray sensor wire is connected to the junction box, which makes electrical contact with the
OUTER electrode.
2. Terminals in junction box are not numbered. Refer to transmitter wiring diagram for connections
at transmitter.
Installation 7
Page 14
Installation Instruction Manual
May 2017 LIQ-MAN-400
Figure 2-14 Pin out diagram for Rosemount 400VP Contacting Conductivity Sensor
ith Variopol cable connection
w
8 Installation
Page 15
Instruction Manual Calibration and Maintenance
LIQ-MAN-400 May 2017
Section 3: Calibration and maintenance
3.1 Calibrating the sensor
Rosemount 400/400VP Contacting Conductivity Sensors are calibrated at the factory and do not
need calibration when first placed in service. Simply enter the cell constant printed on the label into
the transmitter. After a period of service, the sensor may require calibration. For more
information on calibration, refer to Application Data Sheet.
3.1.1 Calibrating using a standard solution
If using a standard solution, choose one having conductivity in the recommended operating range
for the sensor cell constant.
1. Immerse the rinsed sensor in the standard solution and adjust the transmitter reading to
match the conductivity of the standard.
2. 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.
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.
Calibration and Maintenance 9
Page 16
Calibration and Maintenance Instruction Manual
May 2017 LIQ-MAN-400
3.1.2 Calibrating using a reference meter and sensor
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 3-1 for the calibration setup.
Figure 3-1 In process calibration setup
NOTICE
The above figure 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
orientatation provides an escape path for bubbles.
3. The 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.
Following precautions are necessary for 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 2%. If
the sensor is calibrated at 0.500 µS/cm, the change will be only 0.500/0.502 or 0.4%.
Calibration at higher conductivity produces a better result because it minimizes the effect
of the offset.
10 Calibration and Maintenance
Page 17
Instruction Manual Calibration and Maintenance
LIQ-MAN-400 May 2017
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 transmitter feature automatic temperature compensation
in which the transmitter applies one of several temperature correction algorithms to
convert the measured conductivity to the value at a reference temperature, typically 25 °C.
Although temperature correction algorithms are useful for routine measurements, they
should not be used during calibration.
There are two following 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, all sources of avoidable error, e.g., temperature compensation
should be eliminated.
4. Keep tubing runs between the sensors short and adjust the sample flow as high as possible.
Short tubing runs and high flow ensure 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, pumping sample at room
temperature from a reservoir through the sensors might be necessary. 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).
3.1.3 Calibrating using a grab sample
1. 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.
2. 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.
3. Take the sample from a point as close to the process sensor as possible.
4. Keep temperature compensation turned on. There is likely to be a lag time between
sampling and analysis, so temperature is likely to change.
5. Be sure the reference and process instruments are using the same temperature correction
algorithm.
Calibration and Maintenance 11
Page 18
Calibration and Maintenance Instruction Manual
May 2017 LIQ-MAN-400
. Grab sample calibration should be used only when the conductivity is fairly high.
6
. The temperature compensation algorithm will most likely be linear slope.
a
. Confirm that both instruments are using the same temperature coefficient in the linear
b
slope calculation.
c. If the reference meter does not have automatic temperature correction, calculate
the conductivity at 25 °C using the equation:
Where: C25 = the conductivity at 25 °C
Ct = the conductivity at t °C
α = the temperature co-efficient 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, trapped bubbles are absent. If they do not agree, bubbles are
present . Continue the process until two subsequent readings agree.
- While making the measurement, do not allow the sensor to touch the sides and,
particularly, the bottom of the beaker. Keep at least 1/4 inch (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 transmitter models 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 the user enters the result of the grab
sample test. Older transmitters do not remember the process conductivity value.
Therefore, the user 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 819 µS/cm, the user should enter (815/810) × 819 or 824 µS/cm.
3.2 Cleaning the sensor
1. Use a warm detergent solution and a soft brush or pipe cleaner to remove oil and scale.
2. To remove oily films, use Isopropyl alcohol (rubbing alcohol).
3. Do not use strong mineral acids to clean conductivity sensors.
12 Calibration and Maintenance
Page 19
Instruction Manual Troubleshooting
LIQ-MAN-400 May 2017
Section 4: Troubleshooting
4.1 Troubleshooting
Problem Probable Cause Solution
Wiring is wrong. Verify wiring.
Temperature element is open or shorted. Check temperature element for open or short circuits.
Figure 4-1
See
Off-Scale Reading
Noisy reading
Sensor is not in process stream. Be sure sensor is completely submerged in process
stream.
Variopol cable is not properly seated. Loosen connector and reseat.
Sensor has failed. Perform isolation checks. See Figure 4-2
Sensor is improperly installed in process
stream.
Variopol cable is not properly seated. Loosen connector and reseat.
Bubbles trapped in sensor. Be sure sensor is properly oriented in pipe or flow cell.
Be sure sensor is completely submerged in process
stream.
See Figure 2-1. Apply back pressure to flow cell.
Reading seem wrong
(lower or higer than
expected)
Sluggish response
Wrong temperature correction algorithm. Check that temperature correction is appropriate for
the sample. See transmitter manual for more
information.
Wrong cell constant. 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 for more information.
Electrodes are fouled. Clean electrodes.
Sensor is installed in dead area in piping. Move sensor to a location more representative of the
process liquid.
Troubleshooting 13
Page 20
Troubleshooting Instruction Manual
May 2017 LIQ-MAN-400
4.1.1 Checking the temperature element
Disconnect leads and measure resistance shown. The measured resistance should be close to the
value in the table.
igure 4-1 Checking the temperature element
F
4.1.2 Checking the continuity and leakage
Disconnect electrode leads and measure resistance and continuity as shown. Sensor must be dry
when checking resistance between electrode leads.
Figure 4-2 Checking the continuity and leakage
Temperature
(°C)
0 100.0 1000
10 103.9 1039
20 107.8 1078
30 111.7 1117
40 115.5 1155
50 119.4 1194
Resistance in ohms
Pt 100 Pt 1000
14 Troubleshooting
Page 21
Instruction Manual Accessories
LIQ-MAN-400 May 2017
Section 5: Accessories
5.1 Accessories
Table 5-1 Rosemount 400/400VP Contacting Conductivity Sensor accessories information
Part Number Description
23550-00 Remote junction box without preamplifier
3747-00
2
9200275 Extension cable, unprepped (must specify length)
24091-02 Low Flow Cell for Rosemount 400/400VP Sensors
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)
23747-06 2.5 ft (0.8 m) Interconnecting VP6 Cable
23747-04 6.4 ft (1.2 m) Interconnecting VP6 Cable
23747-02 10 ft (3.0 m) Interconnecting VP6 Cable
23747-07 15 ft (4.6 m) Interconnecting VP6 Cable
23747-08 20 ft (6.1 m) Interconnecting VP6 Cable
23747-09 25 ft (7.6 m) Interconnecting VP6 Cable
23747-10 30 ft (9.1 m) Interconnecting VP6 Cable
23747-03 50 ft (15.2 m) Interconnecting VP6 Cable
23747-11 100 ft (30.5 m) Interconnecting VP6 Cable
nterconnect cable, prepped (must specify length)
I
Accessories 15
Page 22
LIQ-MAN-400
Rev. L
May 2017
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