Model 228
Instruction Manual
PN 5100228
January 2001
Submersion/Insertion
Sensor and Valve
Insertion Assemblies
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures, and tests
its products to meet many national and international standards. Because these instruments 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 Analytical
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
instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and
servicing the product. If this Instruction Manual is not
the correct manual, telephone 1-800-654-7768 and the
requested manual will be provided. Save this
Instruction Manual for future reference.
• If you do not understand any of the instructions, contact
your Rosemount representative for clarification.
• Follow all warnings, cautions, and instructions marked
on and supplied with the product.
DANGER
HAZARDOUS AREA INSTALLATION
Installations near flammable liquids or in hazardous area locations must be carefully evaluated by qualified on site safety personnel.
This sensor is not Intrinsically Safe or
Explosion Proof.
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 analyzer/transmitter instruction
manual for details.
Proper installation, operation and servicing
of this sensor in a Hazardous Area Installation is entirely the responsibility of the user.
• 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
Rosemount. Unauthorized parts and procedures can
affect the product’s performance and place the safe
operation of your process at risk. Look alike substitutions may result in fire, electrical hazards, or improper
operation.
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.
• 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.
SS-SE
Feb. 1992
Rosemount Analytical Inc.
Uniloc Division
2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: (949) 863-1181
http://www.RAuniloc.com
MODEL 228
TABLE OF CONTENTS
MODEL 228
SUBMERSION/INSERTION SENSOR
AND VALVE INSERTION ASSEMBLIES
TABLE OF CONTENTS
Section Title
Page
1.0
MODEL 228 SENSOR ..............................................................................................
1
1.1
General ....................................................................................................................
1
1.2
Specifications ..........................................................................................................
1
1.3
Ordering Information................................................................................................
2
1.4
Replacement Parts and Accessories ......................................................................
2
1.5
Sensor Installation....................................................................................................
3
1.6
Sensor Wiring...........................................................................................................
4
1.7
Extension Cable and Junction Box ..........................................................................
5
1.8
Sensor Calibration ...................................................................................................
13
1.9
Sensor Maintenance ................................................................................................
13
1.10
Troubleshooting .......................................................................................................
13
2.0
VALVE INSERTION/RETRACTION ASSEMBLIES ....................................................
16
2.1
Description...............................................................................................................
16
2.2
Warning....................................................................................................................
16
2.3
Installation Requirements.........................................................................................
16
2.4
Installation of PN 23311-01 Manual Insertion Assembly .........................................
17
2.5
Installation of PN 23311-00 Mechanical Insertion Assembly...................................
18
2.6
Insertion/Retraction Sensor Wiring ..........................................................................
19
2.7
Calibration, Manual Sensor Cleaning, and O-Ring Replacement ...........................
19
2.8
In-Line Sensor Cleaning ..........................................................................................
20
2.9
Replacement Parts ..................................................................................................
20
3.0
RETURN OF MATERIAL ...........................................................................................
24
i
MODEL 228
TABLE OF CONTENTS
TABLE OF CONTENTS, CONT.
LIST OF FIGURES
Figure No. Title
Page
1-1
Sensor Dimensions ..................................................................................................
1
1-2
Insertion Mounting Adapters ...................................................................................
3
1-3
Submersion and Foxboro Adapters.........................................................................
4
1-4
Model 228 Wiring Direct to Transmitters ..................................................................
4
1-5
Model 228 Wiring Through Junction Box PN 23550-00...........................................
5
1-6
Model 228-55 Wiring Through Junction Box PN 23293-00......................................
6
1-7
Junction Box Termination Unprepped Cable Extension ..........................................
7
1-8
Extension Cable PN 9200205 Instrument End (Model 1181T) ................................
8
1-9
Extension Cable PN 9200245 Instrument End (1054 & 2054 Series) ......................
9
1-10
Extension Cable Preparation: For Model 54C and 2081T Using 228-55 Sensor.....
10
1-11
Extension Cable Preparation: For Model 54C and 2081T Using 228-56 Sensor.....
11
1-12
Wiring Model 228-54 to Model 1055-21-31 .............................................................
12
1-13
Wiring Model 228-56 to Model 1055-21-31 .............................................................
12
2-1
Manual Insertion Assembly......................................................................................
17
2-2
Mechanical Insertion Assembly...............................................................................
18
2-3
Insertion/Retraction Sensor Wiring ..........................................................................
19
2-4
Manual Valve Insertion Assembly Replacement Parts ............................................
21
2-5
Mechanical Valve Insertion Assembly Replacement Parts......................................
22
LIST OF TABLES
Table No. Title
Page
1-1
Prepped Extension Cable ........................................................................................
2
1-2
Sensor Resistance Check........................................................................................
14
1-3
Resistance vs. Temperature.....................................................................................
15
2-1
Sensor Retraction Pressures....................................................................................
16
2-2
Maximum Cable Lengths .........................................................................................
16
2-3
Mechanical Insertion Assembly...............................................................................
23
2-4
Manual Insertion Assembly......................................................................................
23
ii
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
SECTION 1.0
MODEL 228 SENSOR
1.1 GENERAL. The Model 228 is available in three
materials (Polypropylene, PEEK, and Tefzel) for optimal corrosion and temperature resistance.
Polypropylene is suitable for most applications up to
110°C. Polyetheretherketone (PEEK) provides excellent corrosion resistance and is available in standard
temperature (120°C) and high temperature (200°C)
versions. The Tefzel version is ideal for use in highly
concentrated oxidizing acids (H2SO4, HNO3) and
Hydrofluoric acid (HF). Note: PEEK, Polypropylene,
and EPDM are not suitable for these acids.
The Model 228 features rigid construction that will
stand up to high vibration applications such as oil
well drilling mud shaker trays. A single piece 304 SS
tube supports the toroid coils and reinforces the
threaded mounting shaft. This subassembly is then
molded in chemically resistant plastic. There are no
seams or welds that can crack and cause leakage
and subsequent failure.
1.2 SPECIFICATIONS.
Maximum Range with 54C,1054AT, 1054BT/2054T,
3081T/81T, and 2081T: 0-2000 mS/cm
Maximum Range with 1181T: 0-1000 mS/cm
Maximum Temperature:
Polypropylene: 110°C (230°F)
PEEK: 120°C (248°F)
PEEK: 200°C (392°F)
Tefzel: 120°C (248°F)
Maximum Pressure: Polypropylene and PEEK: 295
psig (2035 kPa). Tefzel: 200 psig (1345 kPa)
Materials of Construction: Polyetheretherketone
Polypropylene, Tefzel
Option -20: EPDM
Integral Cable Length: 20 ft (6.1 m)
Required Process Connections: 3/4 in. MNPT and
5/8 in. -11 UNC thread
Weight/Shipping Weight: 0.9 kg/1.4 kg (2 Ib/3 Ib)
DWG. NO.
40022818
REV.
B
FIGURE 1-1. Sensor Dimensions
1
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
1.3 ORDERING INFORMATION: Model 228 Insertion/Submersion Toroidal Sensor is molded of chemically resistant
polypropylene or glass-filled PEEK (polyetheretherketone). Includes an integral RTD for automatic temperature compensation
and 20 ft (6.1 m) of cable. Refer to product data sheet 71-228 for information on the valve insertion assemblies.
MODEL
228
INSERTION/SUBMERSION TOROIDAL SENSOR
CODE
01
02
03
04
MATERIALS OF CONSTRUCTION (Required Selection)
Polypropylene, to 110°C (230°F)
PEEK, standard temperature to 120°C (248°F)
PEEK, high temperature to 200°C (392°F)
Tefzel, standard temperature to 120°C (248°F) (not available with codes 50-62 or 54-62)
CODE PROCESS CONNECTION TYPE (Required Selection)
20
5/8 in.-11 UNC thread (*EPDM gasket standard), requires mounting adapter
21
3/4 in. MNPT threads (not available with Codes 01 or 62)
CODE CABLE (Required Selection)
50-61 For connection to Model 1181T (20 ft cable)
54-61 For connection to Models 1054A/1054/1054B series (20 ft cable)
56-61 For connection to Models 54C, 81T, 2081T, and 3081T (20 ft cable)
50-62 For connection via valve insertion assembly mounted junction box to Model 1181T (requires
extension cable, see Table 1-1 below) (10 in. cable)
54-62 For connection via valve insertion assembly mounted junction box to Models 1054B series,
54C, 81T, 2081T, 3081T (requires extension cable, see Table 1-1 below) (10 in. cable)
228
02
20
54-61
EXAMPLE
Note: Cables can be extended with the use of remote junction box PN 23550-00 (see Table 1 for interconnect cable).
* EPDM gasket is standard (Code 20); however, it is not suitable for use in HF or other high-concentration acids such as H2SO4 and HNO3.
Kal-rez (PN 33075-03) is recommended for these processes. A Viton gasket, PN 33075-00, is also available on request.
** Code 56 provides greater RFI/EMI protection.
1.4 REPLACEMENT PARTS AND ACCESSORIES
PART NUMBER
2001990
23242-02
23242-03
23277-01
23311-00
23311-01
23550-00
33075-00
33075-01
33104-01
9200245
9340067
23277-0199SQ7182
33081-0099SQ7091A
33081-0199SQ7091B
1
DESCRIPTION
Mounting adapter, 2 in. insertion, CPVC, Model 228-21 only
Mounting adapter, 1-1/2 in. insertion, Model 228-21 only
Mounting adapter, 1-1/2 in. insertion, Model 228-20 only
Mounting adapter, Foxboro® 1, PEEK, Model 228-20 only (UNC 5/8-11)
Valve insertion assembly, mechanical, Model 228-20-62 only
Valve insertion assembly, manual, Model 228-20-62 only
Junction Box, Remote (54C/2081C)
Gasket, Viton (optional) Model 228-20
Gasket, EPDM (standard) Model 228-20
Mounting adapter, submersion, PEEK, Model 228-20 only
Cable, extension, unprepped (Model 228-56)
Ball valve, full port, 1 1/2" FNPT (rated to 120°C) for use with valve insertion assemblies
Mounting Adapter, Foxboro, UNC 5/8-11, Tefzel (code -20)
Tefzel adapter for PN 23242-02
Tefzel adapter for PN 23242-03
Foxboro is a registered trademark of the Siebe Company.
TABLE 1-1. Prepped Extension Cable
PN
23294-02
23294-03
23294-04
23294-05
23294-06
2
INSTRUMENT
1054/1054A/1054B series
1181T
54C, 81T, 2081T, 3081T
54C, 81T, 2081T
3081T
MODEL 228 W/OPTION
54-61, 54-62
50-61, 50-62
54-62
56-61
56-61
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
1.5 SENSOR INSTALLATION: Figure 1-1 shows that
both sensors (Code 20 & 21) are the same size, but
their thread position and types are different. In order to
facilitate insertion mounting flexibility, several adapters
are available. These are illustrated with dimensions
and thread combinations in Figure 1-2 and Figure 1-3.
Molded Sensor Model 228-21
WARNING
The process seal “O” ring between the peek
adapter and the stainless steel union fitting
neck “O” ring groove must be properly
installed prior to sensor use (see Figure 1-2).
Molded Sensor Model 228-20
2-135 VITON “O” RING
(must be in place prior to use)
DWG. NO.
40022807
REV.
DWG. NO.
H
Molded Sensor Model 228-21
40022803
REV.
M
INSERTION MOUNTING ADAPTER
(FOR FLOW THROUGH INSTALLATIONS)
PN 23242-02 (FOR USE WITH CODE 21)
PN 23242-03 (FOR USE WITH CODE 20)
WETTED PARTS ARE 316SS, PEEK AND EPDM
DWG. NO.
40022808
REV.
J
DWG. NO.
40022818
REV.
B
FIGURE 1-2. Insertion Mounting Adapters
3
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
Refer to Section 2.0 for valve retraction insertion
assemblies.
Please consult the factory for short sensor extension
information.
DWG. NO.
40022818
REV.
B
FIGURE 1-3. Submersion and Foxboro Adapters
1.6 SENSOR WIRING. Sensor cable should not be run
in conduit nor open trays with any A.C. power wiring,
nor routed close to high current demanding electrical
equipment.
If conduit is used, the connections should be sealed
or plugged using sealing compound to avoid accu-
mulation of moisture in the Transmitter/Analyzer housing.
Cable terminations for the various Model 228 sensors
and their compatible instruments are shown in Figure
1-4 below.
DWG. NO.
40022801
FIGURE 1-4. Model 228 Wiring Direct to Transmitters
4
REV.
K
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
1.7 EXTENSION CABLE AND JUNCTION BOX USE.
Junction boxes are recommended when the sensor and Transmitter/Analyzer are not mounted within the sensors
cable length. See Figure 1-5 and Figure 1-6 for junction box wiring.
DWG. NO.
40022819
REV.
G
FIGURE 1-5. Model 228 Wiring Through Junction Box PN 23550-00
5
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
DWG. NO.
40022806
FIGURE 1-6. Model 228-55 Wiring Through Junction Box PN 23293-00
If the unprepped extension cable (PN 9100245) is
selected, refer to Figures 1-7 through 1-11 on the following pages for detailed instructions on cable end
preparation for each sensor to Transmitter/Analyzer
configuration.
6
NOTE
For extension cable applications below
250 µS/cm, please consult factory.
REV.
R
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
DWG. NO.
40022511
REV.
B
FIGURE 1-7. Junction Box Termination Unprepped Cable Extension
7
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
DWG. NO.
40118142
FIGURE 1-8. Extension Cable PN 9200205 Instrument End (Model 1181T)
8
REV.
B
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
Leave spade lugs off for use with Models 54C and 2081T.
DWG. NO.
40205413
REV.
B
FIGURE 1-9. Extension Cable PN 9200245 Instrument End (Model 1054 & 2054 Series)
9
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
DWG. NO.
40022513
FIGURE 1-10. Extension Cable Preparation for Model 54C and 2081T using 228-55 Sensor
10
REV.
B
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
DWG. NO.
40022512
REV.
D
FIGURE 1-11. Extension Cable Preparation for Model 2081T & 54C Instruments using 228-56 Sensor
11
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
DWG. NO.
40105538
REV.
B
FIGURE 1-12. Wiring Model 228-54 to Model 1055-21-31 Analyzer
DWG. NO.
40105535
FIGURE 1-13. Wiring Model 228-56 to Model 1055-21-31 Analyzer
12
REV.
B
MODEL 228
1.8 SENSOR CALIBRATION. After sensor and transmitter/analyzer wiring is completed, calibration and
slope adjustment should be performed prior to field
installation. The appropriate analyzer/transmitter manual should be consulted for this procedure.
The sensor can be calibrated using a known standard
conductivity solution at 25°C, but the calibration
arrangement should approximate the mounting
arrangement. If the sensor is to be used in a submersion application the calibration should be performed
in a very large glass beaker or large plastic container,
with all sides of the sensor at least one in. away from
the walls of the beaker. If the sensor is to be inserted
in a tee for flow through applications using the insertion adapter, it should be calibrated in line using a
grab sample.
When submersing the sensor in the calibration solution, it is extremely important to make sure that there is
no possibility that air could be trapped in the hole of
the sensor. This can be done by submersing the sensor at an angle and dislodging the air bubble.
The calibration procedure should approximate the
mounting configuration because the current path of
the sensor (and thus the cell constant) is affected by
the immediate environment of the sensor. During calibration, if the sensor is placed within approximately
one in. of an insulating material like glass or plastic,
the current path area of the sensor is reduced, thus
increasing the sensor cell constant and reducing the
conductivity reading. If the sensor is placed within
approximately one in. of a conductive material like
metal, the current path of the sensor is “shorted out” in
that direction, and the conductivity reading is
increased because it is partly based on the conductance of the metal.
If a very accurate reading is required, such as in the
case of a very low conductivity system, a special calibration should be performed by spanning (with Model
1181T) or standardizing (with Models 1054AT, 1054BT,
2054T) the loop at or very near the temperature and
conductivity of the process being measured. This
should be done in addition to the procedure
described above, so that the mounting configuration
is approximated as closely as possible. By following
these three calibration steps the tolerance (or error)
introduced by the sensor should be reduced to less
than ±10 µS/cm.
SECTION 1.0
MODEL 228 SENSOR
CAUTION
To avoid an offset error during a decade
box loop calibration (228-20/1181T) with
the sensor in air, the sensor’s metal
process insertion connector and the
1181T must be grounded to the same
potential.
1.9 SENSOR MAINTENANCE
CAUTION
For personal safety. Make sure sensors
have been cleaned of process fluid before
handling.
The only maintenance required during the normal
operational life of the sensor is to ensure that there are
no deposits blocking the opening of the sensor.
1.10 TROUBLESHOOTING. Please refer to Sensor
Resistance Check Table 1-1 and Temperature vs.
Resistance Table 1-2.
CABLE WARNING
The Model 228 warranty may become void if the
cable is cut. The purpose of this warning, which is
noted on a label of the Model 228 cable, is to advise
that incorrect cable termination will result in signal
noise and an unstable zero. This special low-noise
cable requires attention to detail to terminate correctly.
If there is no alternative to cutting the cable, it is recommended that the sensor be returned to Rosemount
Analytical, Irvine, where the cable termination will be performed for a nominal charge. In lieu of this, the cable can
be cut and prepped by the user with the aid of a special
cable termination guide available upon request. However,
Rosemount Analytical is not responsible for incorrectly terminated cable which results in a loss of sensor performance.
13
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
TABLE 1-2. Sensor Resistance Check
For Use with Models 54 C/1054A%/1054AT/1054AA/1054B%/1054BT/2054T/2081T
Analyzers/Transmitters
WIRE
RESISTANCE
(1) WHITE (DRIVE)
1 TO 2 OHMS
(2) BLACK (DRIVE RETURN)
(3) GREEN (INPUT)
1 TO 2 OHMS
(4) BLACK (INPUT COMMON)
(5) GREEN (RTD IN)
110 OHMS**
(6) SHIELD (RTD COMMON)
LESS THAN 2 OHMS
(7) WHITE (SENSE GROUND)
For Use with Model 1181T Transmitter
WIRE
RESISTANCE
(1) GREEN (SENSE)
1 TO 2 OHMS
(2) GREEN (TC SHIELD)
3,000 OHMS**
(3) WHITE (TC)
(3) BLACK (TC)
1 TO 2 OHMS
(4) WHITE (PROBE DRIVE)
** Resistance listed are for TC values at 25°C (77°F) (see TABLE 1-3 for other temperature values).
14
MODEL 228
SECTION 1.0
MODEL 228 SENSOR
TABLE 1-3. Resistance vs. Temperature
for Temperature Compensation (Resistance Temperature Detector)
RTD Type (Transmitter)
Temperature (°C/°F)
Resistance (Ohms)
18/64.4
2910
19/66.2
2920
20/68.0
2930
21/69.8
2950
22/71.6
2960
23/73.4
2970
24/75.2
2990
25/77.0
3000
26/78.8
3010
27/80.6
3030
29/84.2
3050
30/86.0
3060
18/64.4
106.9
19/66.2
107.3
20/68.0
107.7
21/69.8
108.1
22/71.6
108.4
100 ohm RTD
23/73.4
108.9
(54C/1045A/1054T/1054%/1054AT/
24/75.2
109.2
1054BT/1054B%/2054T and 2081T)
25/77.0
109.6
26/78.8
110.0
27/80.6
110.4
3K (1181T)
C = Celsius/F = Fahrenheit
15
MODEL 228
SECTION 2.0
VALVE INSERTION ASSEMBLIES
SECTION 2.0
VALVE INSERTION/RETRACTION ASSEMBLIES
2.1 DESCRIPTION. This entire section should be read
thoroughly before proceeding with installation of either
retraction assembly.
There are two types of insertion/retraction assemblies
designed to be used with the Code 20, (gasket version) Model 228 sensor. Manual, for insertion/ retraction capabilities under low pressure operating conditions (process pressures up to 35 psig), and
Mechanical for higher process pressures (above 35
psig to 295 psig) which utilizes the lead screw and
clamp design. See Table 2-1 below.
TABLE 2-1. Sensor Retraction Pressures
Maximum
Operating
Version
PN
Conditions
392°F
Mechanical
(200°C)
insertion assy. 23311-00 295 psig
(2036kPa)
Maximum
Insertion or
Retraction
Conditions
392°F
(200°C)
295 psig
(2036 kPa)
392°F
Manual
(200°C)
insertion assy. 23311-01 295 psig
(2036kPa)
266°F
(130°C)
35 psig
(241 kPa)
All wetted parts are 316 SS, Teflon, and Ethylene
Propylene. O-rings other than Ethylene Propylene are
available on request.
Two 1/8 in. flush ports are provided on the retraction
chamber so that the sensor can be retracted and
washed without removing it from the insertion assembly. These flush ports may also be used to drain the
chamber when the sensor needs to be changed or
manually cleaned.
IMPORTANT NOTE
These assemblies do not include ball valves.
However, a 1-1/2 in. full port ball valve, rated to
120°C (248 °F) is available as PN 9340067.
The Model 228, options 20 and 62, must be specified
for use with the insertion/retraction assemblies as follows:
228 - (01) - 20 - (50) - 62
(02)
(54)
(03)
16
Special shielded extension cables are required
between the retraction mechanism junction box and
the Analyzer/Transmitters. See Table 2-2. below
TABLE 2-2. Maximum Cable Lengths
228 Option
54
50
Cable PN
23294-02
23294-03
Maximum Cable Length
200 ft
100 ft
2.2 WARNING.The following important warnings apply
to the two retraction/insertion versions.
Lack of adherence to these procedures can cause
severe impact or bodily injury.
A. (PN 23311-00) Mechanical Insertion.
–WARNING–
DO NOT LOOSEN CAP SCREWS
OR COLLAR WHEN PRESSURIZED
B. (PN 23311-01) Manual Insertion.
–WARNING–
SEVERE IMPACT INJURY CAN OCCUR
IF THE COLLET NUT IS LOOSENED
UNDER PRESSURE
2.3 INSTALLATION REQUIREMENTS.
2.3.1 Process Connection: 1-1/2 in. opening required.
NOTE
It is very important that the process connection is a 1-1/2 in. opening. Larger openings may keep the sensor from inserting far
enough into the process.
2.3.2 Process Line Size: When the retractable Model
228 Sensor is used with the Model 1054 Alkali
Analyzer, a minimum 3 in. (76 mm) diameter process
pipe is required.
A minimum process pipe diameter of three inches is
recommended for all other applications.
MODEL 228
SECTION 2.0
VALVE INSERTION ASSEMBLIES
Installation in a 2 in. (51 mm) diameter process pipe
will require final calibration in-line with a known reference conductivity solution or grab sample.
2.3.3 Valve Sizing: A 1-1/2 in. NPT full port ball valve
is required.
2.3.4 There must be 2 ft (0.6 m) of clearance to permit sensor removal or retraction.
2.3.5 Use flexible wiring conduit to permit convenient
sensor removal or retraction.
2.3.6 Two 1/8 in. NPT ports are provided for supply
and drain of water or other solutions to wash the sensor. It is recommended that 1/8 in. ball valves be used
to insure draining contents of retraction chamber.
2.3.7 Additional mechanical support should be provided if excessive vibration is anticipated.
2.4 INSTALLATION OF PN 23311-01 MANUAL
INSERTION ASSEMBLY (FIGURE 2-1).
1.
Loosen the collet nut and retract the sensor tube
into the retraction chamber.
2.
Loosen the union nut and separate the retraction
chamber from the assembly.
3.
Install the retraction chamber on the 1-1/2 in. NPT
full port ball valve mounted on the process line or
vessel.
NOTE
If the assembly is to be mounted horizontally, the 1/8 in. flush ports should
be positioned down so they can be
used for a drain using 1/8 in. NPT ball
valves.
4.
Mount the Model 228 sensor into the sensor tube.
The sensor cable should easily thread through the
tube into the junction box. Hand tighten the Model
228 an additional half turn once the gasket is
seated.
5.
Terminate the sensor wiring to the junction box.
See Figure 2-3 for wiring details.
6.
Insert the sensor and tube assembly into the
retraction chamber.
7.
Tighten the union nut.
8.
Open the ball valve, check for leaks, and manually insert the sensor into the process.
9.
Position the sensor at least 1/2 in. (13 mm) away
from any wall of the vessel or pipe.
10. Tighten the collet nut.
TOROIDAL SENSOR,
MODEL 228-20-62
(ORDERED SEPARATELY
AND SHIPPED LOOSE)
DWG. NO.
REV.
40022812
K
Note: See Table 2-1 for safe retraction pressures.
FIGURE 2-1. Manual Insertion Assembly
-WARNINGSEVERE IMPACT INJURY CAN OCCUR IF THE
COLLET NUT IS LOOSENED UNDER PRESSURE
17
MODEL 228
SECTION 2.0
VALVE INSERTION ASSEMBLIES
2.5 INSTALLATION OF PN 23311-00 MECHANICAL
INSERTION ASSEMBLY (FIGURE 2-2).
1.
Mount the Model 228 sensor into the sensor tube. The
sensor cable should easily thread through the tube
into the junction box. Hand tighten the Model 228 an
additional half turn once the gasket is seated.
2.
Terminate the sensor wiring to the junction box.
See Figure 2-3 for wiring details.
3.
Utilizing a 1/2 in. (13 mm) socket wrench, retract
the sensor into the retraction chamber.
4.
Install the assembly on the 1-1/2 in. NPT full port
ball valve mounted on the process line or vessel.
NOTE
If the assembly is to be mounted horizontally, the 1/8 in. flush ports should be positioned down so they can be used for a
drain using 1/8 in. NPT ball valves.
5.
Tighten the union nut.
6.
Open the ball valve, check for leaks, and manually insert the sensor into the process.
7.
Utilizing a 1/2 in. (13 mm) socket wrench, insert
the sensor into the process line or vessel.
8.
Position the sensor at least 1/2 in. (13 mm) away
from any wall of the vessel or pipe. Set the travel
stop collar “A” next to the nut housing.
Notes:
3. Extension cable is ordered separately, specify
length.
2. Requires customer supplied 1-1/2 in. FPT full port
ball valve.
1. Maximum insertion/retraction and operating conditions: 295 psig (2036 KPa) and 392°F (200°C).
DWG. NO.
40022811
REV.
M
FIGURE 2-2. Mechanical Insertion Assembly
18
MODEL 228
SECTION 2.0
VALVE INSERTION ASSEMBLIES
2.6 INSERTION/RETRACTION SENSOR WIRING.
When the insertion/retraction assembly is ordered with
a 228 sensor, the unit will be shipped with the sensor
mounted to the insertion/retraction assembly and
wired to the Terminal block in the attached junction
box.
When replacement of the sensor is required, wiring of
the sensor to the terminal block in the attached junction box is illustrated in Figure 2-3.
2.7 CALIBRATION, MANUAL SENSOR CLEANING,
AND 0-RING REPLACEMENT.
2.7.1 PN 23311-01 Manual Insertion Assembly (Refer
to Figure 2-1).
WARNING
Severe impact injury can occur if the
collet nut is loosened under pressure.
1.
Make certain that the system pressure is less than
35 psig (241 kPa) before retracting the sensor.
Push in on the sensor using the top of the junction
box. Slowly loosen the collet nut.
2.
When the collet nut is loose enough, slowly ease
the sensor back so that it clears the ball valve.
Close the valve to the process line.
See Figure 2-3 for extension cable connections to the
terminal block in the junction box attached to the
Insertion/Retraction assembly.
Figure 2-4 Illustrates the proper connections from the
extension cables to the instruments used with the 228
sensor.
DWG. NO.
40022811
REV.
M
FIGURE 2-3. Insertion/Retraction Sensor Wiring
19
MODEL 228
3.
SECTION 2.0
VALVE INSERTION ASSEMBLIES
tion assembly. Replace the retraction stop collar
about 1/2 in. in front of the clamp. Tighten the
clamp screws, retraction stop collar and 3 in. hex
union nut. Verify that the 1/8 in. flush ports are
closed.
Drain the retraction chamber contents using the
1/8 in. flush ports.
WARNING
Retraction chamber contents may be
under pressure.
4.
Loosen the 3 in. hex union nut. Remove the sensor and tube assembly and manually clean or
calibrate the sensor. For calibration see Section
1.8. Replace the 3 in. hex nut O-ring (unless
this is the initial calibration). Replace the sensor
and tube assembly back into the retraction
assembly. Tighten the 3 in. hex union nut. Verify
that the 1/8 in. flush ports are closed. Tighten the
3 in. hex union nut.
NOTE
With the ball valve fully closed and the
retraction chamber 1/8 in. flush ports
open, some residual process fluid may
leak from the 3 in. hex union nut female
ACME threads. This leakage is normal and
to be expected
5.
Before opening the process valve, make sure that
the process pressure is not greater than 35 psig
(241 kPa). Open the valve to the process, check for
leaks, and insert sensor into the process. Tighten
the collet nut.
2.7.2. PN 23311-00 Mechanical Insertion Assembly
(See Figure 2-2).
WARNING
Do not loosen cap screws or collar
when pressurized.
1.
2.
3.
Make certain that the system pressure is less than
295 psig (2036 kPa) before retracting the sensor.
Retract the sensor with a 1/2 in. (13 mm) socket
wrench using the wrench flat. When the sensor clears
the ball valve to the process line, close the valve.
Drain the retraction chamber contents using the
1/8 in. flush ports.
WARNING
Retraction chamber contents may
be under pressure.
4.
20
Loosen the 3 in. hex union nut, and remove the
retraction stop collar and orange clamp top.
Remove the sensor and tube assembly and manually clean or calibrate the sensor. For calibration
see Section 1.8. Replace the 3 in. hex nut O-ring
(unless this is the initial calibration). Replace the
sensor and tube assembly back into the retrac-
NOTE
With the ball valve fully closed and the
retraction chamber 1/8 in. flush ports
open, some residual process fluid may
leak from the 3 in. hex union nut female
ACME threads. This leakage is normal and
to be expected.
5.
Before opening the process valve, make sure that
the process pressure is not greater than 295 psig
(2036 kPa). Open the valve to the process, check
for leaks, and insert sensor into the process.
2.8. IN-LINE SENSOR CLEANING. The Model 228 can
be cleaned without removing it from the retraction
mechanism. This can be accomplished by using a 1/8
in. flush port according to 1) or 2):
1. Retract the sensor, close the valve, and wash the
sensor with pressurized hot water.
2.
Retract the sensor and wash the sensor as
described above, except flush the high pressure
wash fluid directly into the process for a brief time
if this is process compatible.
2.9 SEAL REPLACEMENT PROCEDURE FOR MANUAL AND MECHANICAL INSERTION ASSEMBLIES.
Reference Figure 2-4 and Figure 2-5, and Table 2-3
and Table 2-4.
Disassembly:
1. Retract the sensor into the retraction chamber
and fully close the ball valve.
WARNING
Retraction Chamber Contents
May Be Under Pressure.
2.
Drain the retraction chamber contents using the
1/8 in. flush ports.
3.
(Mechanical) Mark the location of the nut housing
cap and retraction collar on the 316 SST. tube.
Remove both socket head cup screws from the
nut housing and loosen the retraction stop collar.
4.
Remove the 3 in. Hex Union nut.
5.
Withdraw the sensor from the retraction chamber.
6.
Open the junction box and disconnect the sensor
wires from the terminal block.
MODEL 228
SECTION 2.0
VALVE INSERTION ASSEMBLIES
DWG. NO.
40022810
REV.
E
FIGURE 2-4. Manual Valve Insertion Assembly Replacement Parts
21
MODEL 228
SECTION 2.0
VALVE INSERTION ASSEMBLIES
DWG. NO.
40022809
FIGURE 2-5. Mechanical Valve Insertion Assembly Replacement Parts
22
REV.
E
MODEL 228
7.
Remove the compression fitting just below the
junction box and remove the junction box from the
316 SST tube.
8.
(Manual) Pull down the nut guard and remove the
collet nut from the bushing housing.
9.
Slide all hardware including the bushing housing
off the 316 SST tube.
10. Remove the retaining ring from the bottom of the
bushing housing.
11. Remove the Teflon guard.
12. From the top of the bushing housing press out the
Teflon bushing. This will also push out the Teflon
cup seal.
Assembly:
1.
Replace all damaged parts with replacement
parts from Table 2-3 and 2-4. Replace the 316
SST tube if the surface is damaged. A rough or
uneven surface will not allow the Teflon cup seal
to properly seal off the process.
2.
Rebuild the bushing housing ensuring the Teflon
cup seal is facing outward such that the seal’s
spring is visible (facing the process).
3.
Carefully slide the bushing housing onto the 316
SST tube so as not to damage the Teflon bushing
or the Teflon cup seal.
4.
(Manual) Slide the 3 in. Hex Union nut, collet nut
with nut guard, junction box compression nut and
plastic ferrules onto the 316 SST tube.
5.
(Mechanical) Slide the 3 in. Hex Union nut, retraction stop collar, junction box compression nut and
plastic ferrules onto the 316 SST tube.
6.
Connect the junction box to the 316 SST tube and
wire the sensor leads to the appropriate terminals
(Figure 2-3).
7.
(Mechanical) Lock the retraction stop collar into
position (see Figure 2-2 or previously marked
position for proper location).
8.
Place the Union nut O-ring on the bottom of the
bushing housing. Insert the sensor assembly into
the retraction chamber and tighten the 3 in. Hex
Union nut.
9.
(Mechanical) Install the nut housing cap (see
Figure 2-2 or previously marked position for proper location).
SECTION 2.0
VALVE INSERTION ASSEMBLIES
TABLE 2-3. Mechanical Insertion Assembly
PART #
33121-01
33168-00
33181-00
33182-00
9090111
9550179
9555004
9560279
9722512
DESCRIPTION
316 stainless steel tube
Cap
Teflon bushing
Teflon guard
Collar (PN 23311-00 only)
Union nut O-ring 2-135EP (Ethylene Propylene)
Teflon cup seal
Retaining ring
Socket head cap screw
TABLE 2-4. Manual Insertion Assembly
PART #
33121-01
33131-00
33180-00
33182-00
9550179
9555004
9560279
DESCRIPTION
316 stainless steel tube
PEEK Collet
Teflon bushing
Teflon guard
Union nut O-ring 2-135EP (Ethylene Propylene)
Teflon cup seal
Retaining ring
23
Model 228
SECTION 3.0
RETURN OF MATERIAL
SECTION 3.0
RETURN OF MATERIAL
3.1 GENERAL. To expedite the repair and return of
instruments, proper communication between the customer and the factory is important. A return material
authorization (RMA) number is required. Call (949)
863-1181. The “Return of Materials Request” form is
provided for you to copy and use in case the situation
arises. The accuracy and completeness of this form
will affect the processing time of your materials.
5.
Rosemount Analytical Inc.
2400 Barranca Parkway
Irvine, CA 92606
Attn: Factory Repair
Mark the package: Returned for Repair
RMA# _____________
3.2 WARRANTY REPAIR. The following is the procedure for returning instruments still under warranty.
1.
Contact the factory for authorization.
2.
Complete a copy of the “Return of Materials
Request” form as completely and accurately as
possible.
3.
To verify warranty, supply the factory sales order
number or the original purchase order number. In
the case of individual parts or sub-assemblies,
the serial number on the mother unit must be supplied.
4.
Carefully package the materials and enclose your
“Letter of Transmittal” and the completed copy of
the “Return of Materials Request” form. If possible, pack the materials in the same manner as it
was received.
IMPORTANT
Please see second section of “Return of
Materials Request Form”. Compliance to
the OSHA requirements is mandatory for
the safety of all personnel. MSDS forms
and a certification that the instruments
have been disinfected or detoxified are
required.
24
Send the package prepaid to:
Model No. __________
3.3 NON WARRANTY REPAIR.
1.
Contact the factory for authorization.
2.
Fill out a copy of the “Return of Materials Request”
form as completely and accurately as possible.
3.
Include a purchase order number and make sure
to include the name and telephone number of the
right individual to be contacted should additional
information be needed.
4.
Do Steps 4 and 5 of Section 3.2.
NOTE
Consult the factory for additional information regarding service or repair.
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A Worldwide Network of Sales and Service
The Rosemount customer sales and service organization comprises a network of fully equipped support centers strategically located throughout the world. From many of these locations, the Rosemount Group provides support, distribution of finished products, repair facilities, and training for our customers.
U.S. Field Service
Field Watch Response Center
1-800-654-7768
International
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RETURN OF MATERIALS REQUEST
C
U
S
T
O
M
E
R
N
O
T
I
C
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T
O
FROM:
RETURN
_____________________________
_____________________________
_____________________________
S
E
N
D
E
R
•IMPORTANT!
This form must be completed to ensure expedient factory service.
BILL TO:
_____________________________
_____________________________
_____________________________
_____________________________
_____________________________
_____________________________
CUSTOMER/USER MUST SUBMIT MATERIAL SAFETY SHEET (MSDS) OR COMPLETE STREAM COMPOSITION, AND/OR
LETTER CERTIFYING THE MATERIALS HAVE BEEN DISINFECTED AND/OR DETOXIFIED WHEN RETURNING ANY PRODUCT,
SAMPLE OR MATERIAL THAT HAVE BEEN EXPOSED TO OR USED IN AN ENVIRONMENT OR PROCESS THAT CONTAINS A
HAZARDOUS MATERIAL ANY OF THE ABOVE THAT IS SUBMITTED TO ROSEMOUNT ANALYTICAL WITHOUT THE MSDS
WILL BE RETURNED TO SENDER C.O.D. FOR THE SAFETY AND HEALTH OF OUR EMPLOYEES. WE THANK YOU IN
ADVANCE FOR COMPLIANCE TO THIS SUBJECT.
SENSOR OR CIRCUIT BOARD ONLY:
(Please reference where from in MODEL / SER. NO. Column)
1. PART NO. _____________________________1. MODEL ____________________________________1.
SER. NO. __________________
2. PART NO. _____________________________2. MODEL ____________________________________2.
SER. NO. __________________
3. PART NO. _____________________________3. MODEL ____________________________________3.
SER. NO. __________________
4. PART NO. _____________________________4. MODEL ____________________________________4.
SER. NO. __________________
R
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A
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O
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F
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N
PLEASE CHECK ONE:
■ REPAIR AND CALIBRATE
■ DEMO EQUIPMENT NO. ______________________________
■ EVALUATION
■ OTHER (EXPLAIN) ___________________________________
■ REPLACEMENT REQUIRED? ■ YES ■ NO
_______________________________________________________
DESCRIPTION OF MALFUNCTION:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
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WARRANTY REPAIR REQUESTED:
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RETURN AUTHORIZED BY: __________________________________________
WARRANTY DEFECT ______________________________________________________________________________________________
_________________________________________________________________________________________________________________
24-6047
Rosemount Analytical Inc.
Uniloc Division
2400 Barranca Parkway
Irvine, CA 92606 USA
Tel: 1-800-854-8257
Fax: (949)-474-7250
WARRANTY
Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by
Seller. Consumables, pH electrodes, membranes, liquid junctions, electrolyte, O-rings, etc. are warranted to be free from
defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and / or material shall
be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, parts(s), or consumables are
returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty
in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and consumables for the remaining portion of the period of the twelve (12) month warranty in the case of goods and part(s) and the remaining portion of the ninety (90) day
warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, parts(s) or consumables are capable of being renewed,
repaired or replaced.
The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage, directly or indirectly, arising
from the use of the equipment or goods, from breach of any warranty or from any other cause. All other warranties,
expressed or implied are hereby excluded.
IN CONSIDERATION OF THE STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS
AND IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
RETURN OF MATERIAL
Material returned for repair, whether in or out of warranty, should be shipped prepaid to:
Rosemount Analytical Inc.
Uniloc Division
2400 Barranca Parkway
Irvine, CA 92606
The shipping container should be marked:
Return for Repair
Model _______________________________
The returned material should be accompanied by a letter of transmittal which should include the following information
(make a copy of the "Return of Materials Request" found on the last page of the Manual and provide the following thereon):
1. Location type of service, and length of time of service of the device.
2. Description of the faulty operation of the device and the circumstances of the failure.
3. Name and telephone number of the person to contact if there are questions about the returned material.
4. Statement as to whether warranty or non-warranty service is requested.
5. Complete shipping instructions for return of the material.
Adherence to these procedures will expedite handling of the returned material and will prevent unnecessary additional
charges for inspection and testing to determine the problem with the device.
If the material is returned for out-of-warranty repairs, a purchase order for repairs should be enclosed.
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© Rosemount Analytical Inc. 1998