Emerson 140 Stud Sensor User Manual

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
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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
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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
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