Emerson Models 140, 141, and 142 Conductivity Sensors Instruction Sheet

Instruction Sheet Models 140, 141, and 142 PN 51A-140/rev.E December 2010 Conductivity Sensors For additional information, please visit our website at www.emersonprocess.com/raihome/liquid/. CAUTION 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. BEFORE REMOVING THE SENSOR, be absolutely certain the process pressure is reduced to 0 psig and the process temperature is at a safe level! SENSOR SPECIFICATIONS SPECIFICATIONS MODEL 140 Wetted Materials 316SS, PEEK, Viton1 316SS, PEEK, Viton1 Temperature (standard) 302ºF (150ºC) max see graph see graph Temperature (high temp) 392ºF (200ºC) max see graph see graph 100 psig (791 kPa abs) see graph see graph Maximum Pressure MODEL 141 MODEL 142 316SS, Viton1 PEEK (high temp options), Kel-F2 (stand temp options) INSTALLATION HARDWARE FOR 140 SENSOR SPECIFICATION Wetted Materials Ball valve kit (PN 23724-00) Fitting kit (PN 23730-00) 316SS 316SS, PEEK Viton1 is a registered trademark of DuPont Performance Elastomers. Kel-F2 is a registered trademark of 3M MODEL 140,141, and 142 sensors INSTALLATION INSTALLATION Keep 1/4 inch (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 Figure 1 for recommended orientation. ° 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. As bubbles accumulate, the conductivity reading drops. To control bubble formation, apply a small amount of back pressure to the drain. ° FIGURE 1. Sensor Orientation INSTALLATION – 140 SENSOR WITH BALL VALVE KIT (PN 23724-00)* 1. 2. 3. 4. 5. 6. 7. 8. Install the sensor in either a 1-inch NPT weldalet or in a 1-inch pipe tee. Remove the plastic shipping cap from the sensor. Screw the 1-inch hex nipple into the weldalet or pipe tee. See Figure 2. Use pipe tape on the threads. Position the sensor for easy access to the ball valve handle, sensor compression fitting nut, and junction box. Make sure the ball valve is in the fully open position. Finger tighten the sensor compression fitting nut. Do not over tighten because the next step is to press the sensor into the process pipe. Insert the sensor tube until the sensor tip is no closer than 1 inch (25 mm) from the far wall of the process pipe. See Figure 2. Tighten the sensor compression fitting nut to hold the sensor tip in position. See Figure 2 for instructions. *If the ball valve assembly is already in place and the process line is pressurized, refer to Inserting the 140 Sensor Section on page 6. SENSOR COMPRESSION FITTING PROCESS PIPING SENSOR BALL VALVE A DWG. NO. REV. 40014008 E 1-in. NPT HEX NIPPLE WELDALET WRENCH “A” Hold body with wrench B and turn WRENCH A 1 1/4 turns beyond finger tight. CAUTION Process O-Ring must be in place and is critical. Replace if worn or dirty. PUT WRENCH “A” HERE AND TURN PUT WRENCH “B” HERE Tighten finger tight before inserting sensor BALL VALVE SIDE VIEW TOP VIEW WRENCH “B” FIGURE 2. Installing model 140 sensor with ball valve kit (PN 23724-00). 2 MODEL 140,141, and 142 sensors INSTALLATION INSTALLATION – 141 SENSOR 1. Install the sensor in a 3/4-inch NPT weldalet or in a 1-inch pipe tee. 2. Remove the plastic shipping cap from the sensor. 3. Screw the sensor into the fitting. Use pipe tape on the threads. See Figure 3. DWG. NO. 40014204 REV. B FIGURE 3. Installing model 141 sensor INSTALLATION – 142 SENSOR 1. 2. 3. 4. 5. Install the sensor in a 3/4-inch NPT weldalet or in a 1-inch pipe tee. See Figure 4. Remove the plastic shipping cap from the sensor. Screw the sensor into the fitting. Use pipe tape on the threads. DO NOT tighten the sensor compression fitting until the sensor is correctly positioned. If necessary, loosen the sensor compression fitting and position the sensor so that the tip of the sensor is at least 1-inch (25 mm) from the far wall of the pipe. Tighten the compression fitting using the procedure shown in Figure 2. DWG. NO. 40014204 REV. B FIGURE 4. Installing model 142 sensor 3 MODEL 140,141, and 142 sensors WIRING WIRING All 140 series sensors have a junction box mounted on the back of the sensor. Wiring connections in the junction box are shown in Figure 5. 9 8 7 6 5 4 3 2 1 GRAY GRAY MODEL 140 SERIES CABLE Figure 5. Sensor junction box wiring. Terminals in the junction box are not numbered. 141 and 142 sensors have one gray wire (shown). The 140 sensor has two gray wires attached to the terminal. WIRE COLOR AND CONNECTIONS IN SENSOR COLOR FUNCTION Gray Connects to outer electrode Clear Coaxial shield for gray wire Orange Connects to inner electrode Clear Red Coaxial shield for orange wire RTD in White with red stripe RTD White RTD return Shield for all RTD lead wires Clear RTD sense WIRING DIAGRAMS FIGURE 6. Model 54eC Wiring 4 FIGURE 7. Model 1056 and 56 Wiring MODEL 140,141, and 142 sensors WIRING FIGURE 9. Model Xmt-C-11 Wiring (Pipe or Wall) FIGURE 8. Model Xmt-C-10 Wiring (Panel) TB2 RTN TB1 WHITE RCV B RCV A SENSE WHITE/RED RTD IN RED CLEAR RSHLD CLEAR GRAY DRVB SHLD ORANGE DRVA CLEAR DSHLD FIGURE 10. Model 1066 Wiring FIGURE 11. Model 5081C Wiring FIGURE 12. Model 6081-C Wiring 5 MODEL 140,141, and 142 sensors WIRING RETRACTING AND INSERTING THE MODEL 140 SENSOR CAUTION Model 140 sensors are retractable. BEFORE RETRACTING THE SENSOR, be absolutely certain the process pressure is less than 100 psig (791 kPa abs) and the process temperature is at a safe level! RETRACTING THE SENSOR 1. 2. 3. Push in on the sensor junction box and slowly loosen the sensor compression fitting nut by reversing the sensor tightening procedure illustrated in Figure 2. When the sensor compression nut is completely unscrewed, slowly ease the sensor out until the flared tip of the electrode rests firmly within the body of the compression fitting body. Close the ball valve completely. CAUTION Before removing the sensor be sure the ball valve is completely closed. 4. Unscrew the compression fitting body from the reducing bushing and remove the sensor from the ball valve assembly. INSERTING THE SENSOR CAUTION Make sure process O-ring is clean, lubricated, and in place before installing sensor. Replace if worn. 1. DO NOT open the ball valve. WARNING The system pressure must be less than 100 psig (791 kPa). 2. Thread the sensor compression fitting body into the reducing bushing in the rear of the ball valve and tighten. NOTE: Do not push past this point. Damage to the sensor could result. WARNING If the sensor comes free of the valve, refer to Figures 2 and 13 and verify that the valve and associated fittings are as shown. Do not proceed until the sensor is correctly restrained. 6 MODEL 140,141, and 142 sensors 3. WIRING Slowly open the valve. WARNING Stand clear of the sensor. 4. Insert the sensor up to the desired insertion depth and turn the sensor compression fitting nut until it is finger tight. 5. Position the entire sensor for easy access to the ball valve handle, sensor compression fitting nut and J-box terminal block. 6. Tighten sensor compression fitting nut. CAUTION For initial installation of the sensor, tighten the compression fitting nut 1-1/4 turns after finger tight. If it is a reinstallation, turn no more than 1/4 to 1/2 additional turns! REMOVING AND REINSTALLING THE MODEL 142 SENSOR REMOVING THE SENSOR 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! 1. 2. Reduce process temperature and pressure to a safe level. If necessary drain the process line. Loosen the sensor compression fitting and slowly slide the sensor from the pipe fitting or weldalet. REINSTALLING THE SENSOR 1. Slide the sensor into the process fitting and position the sensor the way it was originally installed. CAUTION Be sure the sensor is in the original position. The sensor tube takes a permanent set and could become weakened if the new set is adjacent to the original set. 2. Tighten the sensor compression fitting 1/4 to 1/2 turn after it is finger tight. 7 MODEL 140,141, and 142 sensors CALIBRATION CALIBRATION Model 140 sensors are not calibrated at the factory. The cell constant on the label is a nominal value only. The true cell constant can differ from the nominal value by as much as ±5%. For improved accuracy, calibrate the sensor using either a solution of known conductivity or a referee meter and sensor. If using a standard solution, choose one having conductivity in the recommended operating range for the sensor cell constant. Refer to the analyzer manual or product data sheet and use the range recommended for Model 400 series sensors. For the 0.2/cm cell constant Model 140 sensor, use the range for the 0.1/cm Model 400 sensor and multiply the upper and lower limits by two. Do not use standard solutions having conductivity less than about 100 uS/cm for calibration. They are susceptible to contamination by atmospheric carbon dioxide, which can alter the conductivity by a variable amount as great as 1.2 uS/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 contacting conductivity sensors, refer to application sheet ADS 43-024, available on the Rosemount Analytical website. 8 MODEL 140,141, and 142 sensors MAINTENANCE MAINTENANCE CLEANING THE SENSOR Use a warm detergent solution and a soft brush or pipe cleaner to remove oil and scale. Isopropyl alcohol can also be used to remove oily films. Avoid using strong mineral acids to clean conductivity sensors. CHECKING MODEL 140 RETRACTION RESTRAINT The integrity of the Model 140 will become compromised is the flared tip of the electrode is allowed to blow out against the compression fitting body. In the even a blowout occurs, replace the sensor. REPLACING MODEL 140 SENSOR SEAL. If the process seal is leaking owing to a pitted or uneven sensor tube, a replacement sensor is required. If the sensor tube surface is smooth and clean yet the process seal is leaking, the process O-ring is damaged and requires replacement according to the following procedure (see Figure 2). Replacement parts can be obtained from the Process Fitting Rebuild Kit (PN 23731-00). 1. The junction box with attached compression fitting body, nut and compression fitting must be recovered from the sensor for reuse. Unscrew the junction box cover and set aside. Mark and disconnect the electrical connections from the terminal block. Remove the junction box compression fitting nut from the compression fitting body and separate the junction box from the sensor tube. 2. Remove the nylon ferrule and snap ring (discard both). Remove and save the junction box compression fitting nut. 3. Slide off the sensor compression fitting nut and set aside for reuse. Slide off the remaining PEEK ferrule and split ring (discard both). 4. Remove the sensor compression fitting body and replace the Viton O-ring. Lubricate the O-ring with the barium based lubricant provided. 5. Wrap the threads of the sensor compression fitting body with pipe tape and slide the body on to the sensor tube. 6. Slide on a new PEEK ferrule, beveled side facing the electrode tip, and a new PEEK split ring, flared end towards electrode tip. Slide on the sensor compression fitting nut and thread it onto the compression fitting body. Finger tighten. 7. Reinstall the J-box on the sensor tube. Finger tighten the J-box compression fitting nut. Use a wrench to turn the nut a 1/4 to 1/2 additional turn. 9 MODEL 140,141, and 142 sensors ACCESSORIES REPLACEMENT PARTS PN Description 23724-00 Ball valve kit for Model 140 sensor 23730-00 Process compression fitting kit (3/4-inch NPT) for Model 140 sensor 23731-00 Process fitting rebuild kit for Model 140 sensor (includes ferrule, split ring, O-ring, lubricant) 9310120 Junction box compression fitting for Model 140 sensor 9550200 O-ring, 2-116, Viton for Model 140 sensor 3001882 Process compression fitting (3/4-inch NPT) for Model 142 sensor Junction Box Junction Box Cover Nylon Ferrule (inside) Sensor Tube Junction Box Compression Fitting (PN 9310120) Sensor Compression Fitting Nut (1-in. NPT Hex Nipple) Peek Split Ring (inside) Peek Ferrule (inside) Included in Kit (PN 23730-00) Compression Fitting Body Viton O-ring (inside) (PN 9550200) Ball Valve Kit (PN 23724-00) (Reducing Bushing) DWG. NO. Flared Mechanical Stop FIGURE 13. Model 140 with Ball Valve Kit (PN 23724-00) 10 40014013 REV. D MODEL 140,141, and 142 sensors TROUBLESHOOTING TROUBLESHOOTING PROBLEM PROBABLE CAUSE Off-scale reading Noisy reading Reading seems wrong (lower or higher than expected) Sluggish response SOLUTION Wiring is wrong. Verify wiring. Temperature element is open or shorted. Check temperature element for open or short circuits. See Figure 14. Sensor is not in the process stream. Be sure the sensor is completely submerged in the process stream. Sensor has failed. Perform isolation checks. See Figure 15. Sensor is improperly installed in the process stream. Be sure sensor is completely submerged in process stream. Be sure the sensor is properly oriented in the pipe or flow cell. See Figure 1. Apply back pressure to the flow cell. Bubbles trapped in the sensor. Wrong temperature correction algorithm. Check that the temperature correction is appropriate for the sample. See analyzer manual for more information. Wrong cell constant. Verify that the correct cell constant has been entered in the analyzer and that the cell constant is appropriate for the conductivity of the sample. See analyzer manual. Electrodes are fouled. Clean electrodes. Sensor is installed in a dead area in the piping. Move the sensor to a location more representative of the process liquid. orange red RTD R red terminal strip in sensor junction box temperature qC 0 10 20 30 40 50 Pt 100 100.0 103.9 107.8 111.7 115.5 119.4 gray resistance in : 10K NTC 100K NTC 29.49K 351K 18.79k 208K 12.26K 127K 8194 79.4K 5592 51.0K 3893 33.6K FIGURE 14. Checking Temperature Element Disconnect cable leads and measure resistances shown. The measured resistance should be close to the value in the table. FIGURE 15. Checking Continuity and Leakage Disconnect cable leads and measure resistance and continuity as shown. Sensor must be dry when checking resistance between electrode leads. 11 The right people, the right answers, right now. ON-LINE ORDERING NOW AVAILABLE ON OUR WEB SITE http://www.raihome.com Specifications subject to change without notice. 8 Credit Cards for U.S. Purchases Only. Emerson Process Management 2400 Barranca Parkway Irvine, CA 92606 USA Tel: (949) 757-8500 Fax: (949) 474-7250 http://www.raihome.com © Rosemount Analytical Inc. 2010