Rosemount Analytical 403, 403VP Operating Manual

Quick Start Guide

IQ-QSG-403

L

Rev. Q

June 2017

Rosemount

™

403/403VP

Contacting Conductivity Sensors

asgkas

h

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.

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.

CAUTION

Before removing the sensor, be absolutely certain the process pressure is reduced to 0 psig and the
process temperature is at safe level.

About This Document

his manual contains instructions for installation and operation of the Rosemount 403/403VP

T
Contacting Conductivity Sensors.

The following list provides concerning all revisions of this document.

Rev. Level Date Notes

Q 06/17 Reformatted to reflect the latest Emerson documentation style,

Updated the Specifications and Wiring Diagrams.

Quick Start Guide Table of Contents

LIQ-QSG-403 June 2017

Contents

Section 1: Specifications

1.1 Specifications ......................................................................................................1

1.2 Ordering Information...........................................................................................2

Section 2: Installation

2.1 Unpacking and Inspection ...................................................................................5

2.2 Installation...........................................................................................................5

Section 3: Wiring

3.1 Wiring for Rosemount 403/403VP .......................................................................7

3.2 Wiring through a Junction Box .............................................................................9

Section 4: Calibration and Maintenance

4.1 Cleaning the Sensor ...........................................................................................11

4.2 Calibration.........................................................................................................11

Section 5: Troubleshooting

5.1 Troubleshooting ................................................................................................15

Section 6: Accessories

6.1 Accessories........................................................................................................17

Table of Contents i

Table of Contents Quick Start Guide

June 2017 LIQ-QSG-403

ii Table of Contents

Quick Start Guide Specifications

LIQ-QSG-403 June 2017

Section 1: Specifications

1.1 Specifications

Table 1-1: Rosemount 403/403VP Contacting Conductivity Sensor specifications

Cell constants

0.01, 0.1 and 1.0/cm

Wetted materials

titanium; 316 stainless steel; PCTFE (Neoflon), compliant with 21CFR 177.1380; EP, compliant with 21CFR177.2600 and
USP Class VI

Surface finish

All wetted surfaces have 16 micro in. (0.4 micrometer) Ra finish.

Process connection

1-1/2 in. or 2-in. sanitary flange

Temperature

32–221 °F (0–105 °C). Sensors are steam sterilizable to 275 °F (135 °C)

Pressure

250 psig (1825 kPa abs) maximum

Cable length

10 ft (3.1 m) standard; 50 ft (15.2 m) optional

Weight/shipping weight

403 sensor with 10 ft (3.1 m) cable 2 lb (1.0 kg)/3 lb (1.5 kg)

403 sensor with 50 ft (15.2 m) cable 4 lb (2.0 kg)/5 lb (2.5 kg)

403VP sensor 1 lb (0.5 kg)/2 lb (1.0 kg) (rounded up to nearest 1 lb or 0.5 kg)

NOTICE

Elastomers and fluorocarbon resins are compatible with 21CFR177. Elastomers also meet the requirements of USP Class
VI. Stainless steel contains <5 % delta ferrite. All surfaces in have 16 microinch (0.4 micrometer) Ra finish.

Specifications 1

Specifications Quick Start Guide

June 2017 LIQ-QSG-403

1.2 Ordering Information

Table 1-2: Rosemount 403 Contacting Conductivity Sensor ordering information

M

odel

ensor Type

S

403 Contacting Conductivity Sensor

Cell Constant

11 0.01/cm
12 0.1/cm
13 1.0/cm

Flange Size

20 1-1/2 in. Stainless Steel Sanitary Fitting
21 2 in. Stainless Steel Sanitary Fitting

Temperature Compensation

_ No Selection – Pt-1000
54 Pt-100

(2)

(1)

Optional Options

Insertion Length

_ No Selection – Standard Insertion Length
36 Extended Insertion Length

(3)

Cable Length

_ Standard 10 ft. Integral Cable
50 50 ft. Integral Cable

Special

_ No Selection – Supplier Material Traceability Certificate not Included
99Q8 Supplier Material Traceability Certificate Included

Typical Model Number: 403-11-20-_-36-50-99Q8

1. For compatibility with Rosemount 56, 1056, 1057, 1066, and 5081 Transmitters. Also compatible with legacy transmitter models 1055,

2. For compatibility with legacy transmitter models 1054, 2054, and 2081.

3. Extended insertion length is 6 inches from inside face of flange to end of sensor.

2 Specifications

54e, 4081, 6081, and XMT.

Quick Start Guide Specifications

LIQ-QSG-403 June 2017

Table 1-2: Rosemount 403VP Contacting Conductivity Sensor ordering information

Model Sensor Type

403VP Contacting Conductivity Sensor

Cell Constant

11 0.01/cm
12 0.1/cm
13 1.0/cm

Flange Size

20 1-1/2 in. Stainless Steel Sanitary Fitting
21 2 in. Stainless Steel Sanitary Fitting

Temperature Compensation

_ No Selection – Pt-1000
54 Pt-100

(2)

Optional Options

Insertion Length

_ No Selection – Standard Insertion Length
36 Extended Insertion Length

Special

_ No Selection – Supplier Material Traceability Certificate not Included
99Q8 Supplier Material Traceability Certificate Included

Typical Model Number: 403VP-11-20-_-36-99Q8

(1)

(3)

1. For compatibility with Rosemount 56, 1056, 1057, 1066, and 5081 Transmitters. Also compatible with legacy transmitter models 1055,

2. For compatibility with legacy transmitter models 1054, 2054, and 2081.

3. Extended insertion length is 6 inches from inside face of flange to end of sensor.

54e, 4081, 6081, and XMT.

Specifications 3

Specifications Quick Start Guide

June 2017 LIQ-QSG-403

4 Specifications

Quick Start Guide Installation

LIQ-QSG-403 June 2017

Section 2: Installation

2.1 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.

2.2 Installation

Depending on the option selected, the sensor can be installed in either a 1 ½-inch or 2-inch Tri
Clamp tee. The gasket, clamp, and tee must be supplied by the user. The electrodes must be
completely submerged in the process liquid, i.e., up to the inside surface of the flange.

If the sensor is installed in a side stream with the 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. To control bubble formation, apply a small
amount of back pressure to the sensor.

Figure 2-1 Sensor orientation

Figure 2-2 Recommended installation

Installation 5

Installation Quick Start Guide

June 2017 LIQ-QSG-403

6 Installation

Quick Start Guide Wiring

LIQ-QSG-403 June 2017

Section 3: Wiring

3.1 Wiring for Rosemount 403/403VP

For additional wiring information on this product, including sensor combinations not shown here,
please refer to the Liquid Transmitter Wiring Diagrams.

Figure 3-1: Wire color and connections in sensor

Figure 3-2: Rosemount 403/403VP Sensor Wiring to Rosemount 56, 1056, and 1057

Transmitters

Wiring 7

Wiring Quick Start Guide

June 2017 LIQ-QSG-403

Figure 3-3: Rosemount 403/403VP Sensor Wiring to Rosemount 1066 Transmitter

Figure 3-4: Rosemount 403/403VP Sensor Wiring to Rosemount 5081 Transmitter

8 Wiring

Quick Start Guide Wiring

LIQ-QSG-403 June 2017

3.2 Wiring through a Junction Box

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 (no terminations).

Figure 3-5: Pin Out Diagram for Rosemount 403VP Sensor (viewed from connector end of

sensor, looking down)

Wiring 9

Wiring Quick Start Guide

June 2017 LIQ-QSG-403

10 Wiring

Quick Start Guide Calibration and Maintenance

LIQ-QSG-403 June 2017

Section 4: Calibration and Maintenance

4.1 Cleaning the Sensor

se a warm detergent solution and a soft brush or pipe cleaner to remove oil and scale. Isopropyl

U
alcohol (rubbing alcohol) can also be used to remove oily films. Avoid using strong mineral acids to
clean conductivity sensors.

4.2 Calibration

PURSense 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. The sensor can be calibrated against a
solution having known conductivity or against a referee meter and sensor. If using a standard
solution, choose one having conductivity in the recommended operating for the sensor cell
constant. Refer to the transmitter 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 25 °C). Because 0.01/cm sensors must be calibrated in low
conductivity solutions, they are best calibrated against a referee meter and sensor in a closed
system.

For more information about calibrating refer to Application Data Sheet.

4.2.1 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 11

Calibration and Maintenance Quick Start Guide

June 2017 LIQ-QSG-403

4.2.2 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.

12 Calibration and Maintenance

Quick Start Guide Calibration and Maintenance

LIQ-QSG-403 June 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).

4.2.3 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 13

Calibration and Maintenance Quick Start Guide

June 2017 LIQ-QSG-403

6. Grab sample calibration should be used only when the conductivity is fairly high.

a. The temperature compensation algorithm will most likely be linear slope.

. 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 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 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.

14 Calibration and Maintenance

Quick Start Guide Calibration and Maintenance

LIQ-QSG-403 June 2017

Section 5: Troubleshooting

5.1 Troubleshooting

Table 5-1: Troubleshooting

Trouble Probable Cause Remedy

Off-scale reading

Noisy reading

Reading seems wrong
(lower or higher than
expected)

iring is wrong.

W
RTD is open or shorted. Check RTD for open or short circuits.

Sensor is not in process stream. Be sure sensor is completely submerged in

Variopol cable is not properly seated. Loosen connector and reseat.

Sensor has failed. Perform isolation checks. See Figure 5-2.

Sensor is improperly installed in process stream. Be sure sensor is completely submerged

Variopol cable is not properly seated. Loosen connector and reseat.

Bubbles trapped in sensor. Be sure sensor is properly oriented in pipe or

Wrong temperature correction algorithm. Check that temperature correction is appro-

Wrong cell constant. Verify that the correct cell constant has been

erify wiring.

V

See

Figure 5-1.

process stream.

inprocess stream.

flow cell. See
to flow cell.

priate for the sample. See transmitter manual
for more information.

entered in the transmitter and that the cell
constant is appropriate for the conductivity of
the sample. See transmitter manual.

Figure 2-1. Apply back pressure

Sluggish response Electrodes are fouled. Clean electrodes.

Sensor is installed in dead area in piping Move sensor to a location more representative

of the process liquid.

Note: For any repair or warranty inquiries please contact our Customer Care group.

Troubleshooting 15

Troubleshooting Quick Start Guide

June 2017 LIQ-QSG-403

5.1.1 Checking RTD

isconnect leads and measure resistance shown. The measured resistance at room temperature

D
should be close to the value in the table.

Figure 5-1 Checking RTD

5.1.2 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 5-2 Checking the continuity and leakage

Temperature
(°C)

0 1

10 103.9 1039

20 107.8 1078

30 111.7 1117

40 115.5 1155

50 119.4 1194

Resistance in ohms

t 100Pt 1000

P

00.01000

16 Troubleshooting

Quick Start Guide Accessories

LIQ-QSG-403 June 2017

Section 6: Accessories

6.1 Accessories

Table 6-1 Rosemount 403/403VP Sensor accessories information

Part Number Description

23550-00 Interconnecting cable, VP 6, 2.5 ft (0.8 m)

3747-04

2

23747-02 Interconnecting cable, VP 6, 10 ft (3.0 m)

23747-07 Interconnecting cable, VP 6, 15 ft (4.6 m)

23747-08 Interconnecting cable, VP 6, 20 ft (6.1 m)

23747-09 Interconnecting cable, VP 6, 25 ft (7.6 m)

23747-10 Interconnecting cable, VP 6, 30 ft (9.1 m)

23747-03 Interconnecting cable, VP 6, 50 ft (15.2 m)

23747-11 Interconnecting cable, VP 6, 100 ft (30.5 m)

23550-00 Junction Box without Preamplifier

9200275 Interconnect Extension Cable, Unprepped (for use with Junction Box)

23747-00 Interconnect Extension Cable, Prepped (for use with Junction Box)

05010781899 Conductivity standard SS-6, 200 uS/cm, 32 oz (0.95 L)

05010797875 Conductivity standard SS-6A, 200 uS/cm, 1 gal (3.78 L)

05010782468 Conductivity standard SS-5, 1000 uS/cm, 32 oz (0.95 L))

05010783002 Conductivity standard SS-5A, 1000 uS/cm, 1 gal (3.78 L)

05000705464 Conductivity standard SS-1, 1409 uS/cm, 32 oz (0.95 L)

05000709672 Conductivity standard SS-1A, 1409 uS/cm, 1 gal (3.78 L)

05010782147 Conductivity standard SS-7, 5000 uS/cm, 32 oz (0.95 L)

05010782026 Conductivity standard SS-7A, 5000 uS/cm, 1 gal (3.78 L)

nterconnecting cable, VP 6, 4 ft (1.2m)

I

Accessories 17

LIQ-QSG-403

Rev. Q

June 2017

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