Emerson 228 Stud Sensor User Manual
Contents
1. F 200 C 295 psig 2135 kPa abs 220 psig 1618 kPa abs 23242 03 PEEK Viton 316 SS 392 F 200 C 295 psig 2135 kPa abs 220 psig 1618 kPa abs 100 F 38 C 100 psig 791 kPa abs Maximum pressure for applications requiring CRN registration ROSEMOUNT ey _ Anltical EMERSON Process Management MODEL 228 EABLE LATNET TER FRET 75134 wiTON O fiuc aii ep Rh amp B ItuHNcC 23B X WE 135 VITON CF RING o MUT HEX LNA 2 WP Sasu UNIOM FITTING nt LR a er FITTING FIGURE 2 Adapter 23242 03 use with 228 20 5 8 11 UNC threads FIGURE 1 Adapter PN 23242 02 use with 228 21 3 4 in MNPT INSTALLATION INSTALLATION 2 132 WITON FIGURE 3 Adapter PN 2001990 use with 228 21 3 4 in MNP T Keep at least 1 in 2 5 cm between the sensor and pipe walls If the clearance is too small calibrate the sensor in place Ensure that the sensor is completely submerged in liquid Mounting the sensor in a vertical pipe run with the flow from bottom to top is best If the sensor must be mounted in a horizontal pipe run orient the sensor in the 3 o clock or 9 o clock position WIRING Keep sensor wiring away from ac conductors and high current demanding equipment Do not cut cable Cutting the cable may void the warranty green receive black receive common 2282. Slowly loosen the collet nut A WARNING X Severe impact injury can occur if the collet nut is loosened under pressure 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 LL COLLET NUT 3 Drain the retraction chamber contents using the 1 8 in flush ports ee NUT GUARD 4 Loosen the 3 in hex union nut Remove the sensor WWE BUS and tube assembly Pi SPRING 5 Replace the 3 in hex nut O ring Place the sensor P UNION NUT and tube assembly back in the retraction assembly a 2 53158 Tighten the 3 in hex union nut Verify that the 1 8 Lo Kol flush ports are closed i CHAMBER NOTE 1 a MNP T With the ball valve closed and the retraction Ug 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 1 V2 MNPT to be expected 557 6 Before opening the ball valve make sure that the TUBE process pressure is less than 35 psig 342 kPa abs Open the ball valve and check for leaks Insert the sensor into the process Tighten the collet nut MANUAL VALVE INSERTION ASSY TOROIDAL SENSOR MODEL 228 20 82 Retraction chamber contents may be under pressure FIGURE 14 Manual Retraction Assembly MODEL 228 USE OF INSERTION RETRACTION ASSEMBLIES MECHANICAL RET
3. Retraction chamber contents may be under pressure 3 Mechanical Mark the location of the nut housing cap and retraction collar on the sensor 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 10 11 12 wires from the terminal block Remove the compression fitting just below the junction box and remove the junction box from the sensor tube Manual Pull down the nut guard and remove the collet nut from the bushing housing Slide all hardware including the bushing housing off the sensor tube Remove the retaining ring from the bottom of the bushing housing Remove the Teflon guard From the top of the bushing housing press out the Teflon bushing This will also push out the Teflon cup seal 13 14 15 16 17 18 19 20 21 Replace all damaged parts with replacement parts from Figure 16 or 17 Replace the sensor tube if the surface is damaged rough or uneven surface will prevent the Teflon cup from sealing Rebuild the bushing housing The open end of the cup seal spring visible faces the process Carefully slide the bushing housing onto the sen sor tube Do not damage the Teflon bushing or the Teflon cup seal Manual Slide the 3 in Hex Union nut collet nut with
4. nut guard junction box compression nut and plastic ferrules onto the sensor tube Mechanical Slide the 3 in Hex Union nut retrac tion stop collar junction box compression nut and plastic ferrules onto the sensor tube Connect the junction box to the sensor tube and wire the sensor leads to the appropriate terminals Mechanical Lock the retraction stop collar into position see Figure 15 or previously marked posi tion for proper location 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 Mechanical Install the nut housing cap see Figure 15 or previously marked position for proper location MODEL 228 JUNCTION BOX TRAVEL STOP COLI NUT E LL AR PN 3090111 B nr LEAD SCREW TRA COL PN VEL STOP LAR 8030111 if ff USE OF INSERTION RETRACTION ASSEMBLIES NYLON FERRULE SOCKET HEAD CAP SCREW PN 9722512 PN 33168 00 B _ RETRACTION STOP COLLAR 9080111 316 SST TUBE PN 33121 01 indir en mi TEFLON BUSHING TEFLON BUSHING PN 33181 00 TEFLON CUP SEAL PN 35535300 TEFLON GUARD PN 33182 00 III I HNW UNION NUT O RING EP PN 9550179 RETAINING RING PN 9560279 FIGURE 16 Mechanical Retraction Assembly Replacement Parts 11 12 MODEL 228 USE OF INSERTION RETRACTI
5. 54 white drive black drive common green RTD in white RTD sense clear RTD common 228 56 clear shield high temperature 228 56 sensors only FIGURE 4 Wire Functions green receive black receive common clear shield white drive black drive common clear shield green RTD in white RTD sense black RTD common clear shield MODEL 228 WIRING 2 RID SNS 3 EDIN 4 RID SHLD 5 REC COM amp Ret 7 REC SHLD amp QUT SHLD DRIVE SHUG id CLEAN PRESENT i iE PRESE I1 DRIVE CON IN HIGH TEMPERATURI AE SENSOR OP TKN 03i ONLY CONNECT TO OUT SHLD TERMINAL FIGURE 5 Wiring 228 54 and 228 56 sensors to Model 1056 and 56 analyzers COMMON RTD COMMON RTD SENSE RTD IN RECEIVE COMMON RECEIVE DRIVE COMMON DRIVE COMMON COMMON PRESENT IN HIGH TEMPERATURE RTD COMMON OPTION 03 RTD SENSE BNET RTD IN RECEIVE SHEILD RECEIVE COMMON RECEIVE DRIVE SHIELD DRIVE COMMON DRIVE COMMON FIGURE 6 Wiring 228 54 and 228 56 sensors to Model 54eC analyzer MODEL 228 WIRING PRESENT IN HIGH IEMPERATURE SENSOR OPTION 03 ONL Y 228 56 CLEAR BLACK WHITE GREEN BLACK GREEN 228 56 CLEAR CLEAR PRESENT IN HIGH TEMPERATURE SENSOR OPTION O3 ONL Y FIGURE 8 Wiring 228 54 and 228 56 sensors to Model Xmt T pipe wall mount transmitter MODEL 228 WIRING CLEAR CLEAR SHIELD IS NOT CONNECTED IT IS PRESE
6. Instruction Sheet PN 51A 228 rev P December 2010 Model 228 Submersion Insertion Toroidal Sensor For additional information please visit our website at www emersonprocess com raihome liquid CAUTION ACAUTION gt SENSOR PROCESS APPLICATION COMPATIBILITY Before removing the sensor be absolutely certain that the process pressure is reduced to 0 psig and The wetted sensor materials may not be compatible the process temperature is lowered to a safe level with process composition and operating conditions Application compatibility is entirely the responsi bility of the user SPECIFICATIONS SENSORS CRN pressure 295 psig 2135 kPa abs 220 psig 1618 kPa abs 295 psig 2135 kPa abs 220 psig 1618 kPa abs Tefzel glass filled 248 F 120 C 200 psig 1480 kPa abs 248 F 120 C 200 psig 1480 kPa abs 150 psig 1135 kPa abs Maximum pressure for applications requiring CRN registration SPECIFICATIONS RETRACTION ASSEMBLIES Operating Conditions Retraction Insertion Conditions Wetted Materials Temperature Pressure Temperature Pressure 23311 00 392 F 295 psig 392 F 295 psig mechanical 316 SS Teflon EPDM 200 C 2135 kPa abs 200 C 2135 kPa abs 23311 01 392 F 295 psig 266 F 35 psig c oss lO EPDM 200 C 2135 kPa abs 130 C 343 kPa abs SPECIFICATIONS ADAPTERS PN Wetted Materials Temperature __ pressure 23242 02 PEEK Viton 316 SS 392
7. MODEL 228 USE OF INSERTION RETRACTION ASSEMBLIES INSERTION RETRACTION ASSEMBLIES INSTALLATION REQUIREMENTS 1 Process connection 1 1 2 inch Larger openings 4 Retraction clearance 2 ft 0 6 m may keep the sensor from inserting far enough 5 ie Provide mechanical support if excess vibration is into the process liquid expected Line size 3 2 in line requires in place calibra 6 Flush water provide 1 8 in valves in inlet and tion outlet flush ports Position flush ports so that Valve 1 1 2 NPT full port ball valve PN retraction chamber can be drained 9340065 MANUAL RETRACTION ASSEMBLY PN 23311 01 INSTALLATION 1 Loosen the collet nut and retract the sensor tube into the retraction chamber See Figure 14 2 Loosen the union nut and separate the retraction chamber from the assembly 3 4 Install the retraction chamber on the 1 1 2 in NPT full port ball valve mounted on the process line or vessel Thread the sensor cable through the tube into the junction box Screw the sensor into the tube Hand tighten the sensor an additional half turn once the gasket is seated Connect the sensor and interconnecting cable leads to the terminal strip in the junction box See figure 13 Connect the other end of the cable to the analyzer See the wiring diagrams in Figures 5 through 10 For cable PN 23294 00 follow the wiring for the 228 54 sensor For cable PN 23294 04 and 23294 05 follow the wi
8. NT IN HIGH TEMPERATURE OPTION 03 ONLY FIGURE 9 Wiring 228 54 and 228 56 sensors to Model 1066 transmitter DRV RCV SHLD DRV RCV COM COM RCV SHLD um DRV RTD Pe AD RTD 73 ve cou 3 iA RTD SHLD RESERVED 228 54 DRV RCV SHLD DRV RCV COM COM RCV SHLD GV 9 197 DRV RTD IN O AD RTD SENSE y A RTD COM 74 SHLD 2 RESERVED 1 PRESENT IN HIGH TEMPERATURE SENSOR OPTION 03 ONL Y 228 56 FIGURE 10 Wiring 228 54 and 228 56 sensors to Model 5081 T transmitter MODEL 228 WIRING WIRING THROUGH A REMOTE JUNCTION BOX CLEAR WHITE Z GREEN BLACK GREEN INTERCONNECT CABLE PN 23294 00 PRESENT IN HIGH TEMPERATURE PRESENT IN SENSOR OPTION 23294 05 ONLY 03 ONLY CLEAR A CLEAR _ BLACK 27 WHITE GREEN INTERCONNE CT CABLE PN 23294 05 AND PN 23294 04 JUNCTION BOX FIGURE11 Wiring sensors through a remote junction box Wire sensors point to point For wiring at the analyzer end refer to the appropriate analyzer wiring diagram For interconnecting cable 23294 00 use the 2265 54 wiring diagram For interconnecting cable 23294 04 and 23294 05 use the 226 56 wiring diagram Ese 3 54 NCH FHPT T EM r V e lt l ANAL YZER JUNCTION BOX aN MOUNTING HOLES PATTERN TRANSMITTER Gum a e EE a L pRILL FOR 10 32 SCREW _ m HOH FHFT 10 SEAS 08 FIGURE 12 Remote Junction Box PN 23550 00
9. ON ASSEMBLIES JUNCTION CDA 360 BRASS COLLET PN 33131 00 NYLON FERRULE 316 55T TUBE F COLLET NUT PM 33121 01 NUT GUARD TEFLON BUSHING PN 35180 00 TEFLON CUP SEAL PN 9555004 x TEFLON GUARD PN 33182 0 3 INCH HEX UNION NUT UNION NUT O RING EP PN 9550179 dac NSS PN 33127 00 RETAINING RING PN 9560279 FIGURE 17 Manual Retraction Assembly Replacement Parts MODEL 228 CALIBRATION CALIBRATION The nominal cell constant of the Model 228 sensor is 2 7 cm The error in the cell constant is about 10 so con ductivity readings made using the nominal cell constant will have an error of at least 10 Wall effects discussed below will likely make the error greater For higher accuracy the sensor must be calibrated Wall effects arise from the interaction between the current induced in the sample by the sensor and nearby pipe or vessel walls As Figure 18 shows the measured conductivity can either increase or decrease depending on the wall material Because wall effects do not disappear until the Model 228 sensor is at least 1 inch 25 mm away from the nearest wall wall effects are present in most installations Correcting for them is an important part of cal ibration Conductivity sensors are calibrated against a solution of known conductivity a standard or against a previously calibrated referee sensor and analyzer If wall effects are present calibrating a toroidal sensor with a s
10. RACTION ASSEMBLY PN 23311 00 INSTALLATION 1 Thread the sensor cable through the tube into the junction box Screw the sensor into the tube Hand tighten the sensor an additional half turn once the gas ket is seated See Figure 15 Terminate the sensor wiring in the junction box See Figure 13 for wiring details Using a 1 2 in 13 mm socket wrench retract the sensor into the retraction chamber Install the assembly on the 1 1 2 in NPT full port ball valve mounted in the process line or vessel Tighten the union nut Open the ball valve and check for leaks Using a 1 2 in 13 mm socket wrench insert the sensor into the process line or vessel 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 WARNING Do not loosen cap screws or collar when pressurized RETRACTION 1 Make certain that the system pressure is less than 295 psig 2135 kPa abs before retracting the sensor Retract the sensor using a 1 2 in 13 mm socket wrench When the sensor clears the ball valve close the valve Retraction chamber contents may be under pressure Drain the retraction chamber contents using the 1 8 in flush ports Loosen the 3 in hex union nut and remove the retraction stop collar and orange clamp top Remove the sensor and tube assembly Replace the 3 in hex nut O ring Place the sen sor and tube a
11. or shorted Check the RTD for open or short circuits See Figure 19 Sensor is not in process stream Confirm that the sensor is fully submerged in the process stream See installation section Sensor is damaged Perform isolation checks See Figure 19 Noisy reading Sensor is improperly installed in the Confirm that the sensor is fully submerged process stream in the process stream See installation section Sensor cable is run near high voltage Move cable away from high voltage conductors conductors Sensor cable is moving Keep sensor cable stationary Reading seems wrong lower Bubbles are trapped in the sensor Install the sensor in a vertical pipe run with the or higher than expected particularly in the toroid opening flow against the toroid opening Increase flow if possible Sensor is not completely submerged in the Confirm that the sensor is fully submerged process stream in the process stream See installation section Cell constant is wrong Wall effects are Calibrate the sensor in place in the process present piping See calibration section Wrong temperature correction algorithm Check that the temperature correction is is being used appropriate for the sample See analyzer manual for more information Temperature reading is inaccurate Disconnect the RTD leads Figure 19 and measure the resistance between the in and common leads Resistance should be close to the value in Table 1 Slow temperature re
12. ring for the 228 56 sensor with the following exception Refer to the wire function diagram for the 228 56 option in figure 4 and identify the RTD wire bundle Connect the RTD wires to the analyzer as follows Green RTD in Black no connection Clear RTD common or RTD return White RTD sense Wrap the bare end of the black wire to prevent accidental connections Insert the sensor and tube assembly into the retraction chamber Tighten the union nut Open the ball valve check for leaks and manually insert the sensor into the process 10 11 Position the sensor at least 1 2 in 13 mm away from any wall of the vessel or pipe Tighten the collet nut PREWIRED aay CUSTOMER I BOX CONNECTION WHITE BLACK aL ACI i 23294 00 For cables 23294 04 and CLEAR LEAR 23294 05 see note GREEN BLACK CLEAR WHITE LJ Se N N GREEN FGRE 52 RECEIVER CLEAR FR DRIVER FIGURE 13 Sensor Mounted Junction Box Wiring Note Interconnecting cables PN 23924 04 and 23294 05 have four RTD TC leads clear black white and green Do not connect the black RTD TC lead Cable PN 23294 05 has a clear outer shield See Figure 11 Do not connect the outer shield MODEL 228 USE OF INSERTION RETRACTION ASSEMBLIES RETRACTION MILLIMETER 1 Make certain that the system pressure is less than lt INCH gt 35 psig 342 kPa abs Push in on the sensor using the top of the junction box
13. sponse to sudden Use an RTD in a metal thermowell for changes in temperature temperature compensation Sluggish response Sensor is installed in a dead area in the Move sensor to a location more representative piping of the process liquid Slow temperature response to sudden Use an RTD in a metal thermowell for changes in temperature temperature compensation 14 green 1 2 0 black white 1 20 black green in 1109 clear common white sense 1 212 Resistance between shield and any other wire gt 40 green black clear J white 120 black clear green in 110 0 black common white sense 1 2 eclear shield 120 receive Resistance between shield and any other wire gt 40M0 FIGURE 19 Resistance check Disconnect leads from analyzer before measuring resistances TABLE 1 Temperature Resistance 15 The right people 4 the right answers right now ROSEMOUNT ANALYTICAL CUSTOMER SUPPORT CENTER 1 800 854 8257 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 ON LINE ORDERING NOW AVAILABLE ON OUR WEB SITE http www raihome com Credit Cards for U S Purchases Only EMERSON Process Management
14. ssembly back in the retraction 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 NOTE With the ball valve fully closed and the retraction chamber 1 8 in flush ports open some residual 1 MILLIMETER INCH LEAD SURE W m J BOx WITH IIT TRAVEL SCREW CAP eth j RETAACTION STOP COLL AR MECHANICAL VALVE INSERTION assy MODEL 228 20 62 ORDERED SEPARATELY AND SHIPPED LOOSE t EXTENSION CABLE 5 ORDERED SEPARATELY SPECIFY LENGTH 2 REQUIRES CUSTOMER SUPPLIED T a IN FPT FULL POAT BALL VALVE 1 MAX IMU HSERT IONYRETRACT OPERATING CONDITIONS 295 PSIG 2036 KPpol AMD S392 F 200 UM AND FIGURE 15 Mechanical Retraction Assembly process fluid may leak from the 3 in hex union nut female ACME threads This leakage is normal and to be expected Before opening the ball valve make sure that the process pressure is less than 295 psig 2135 kPa abs Open the valve check for leaks and insert sensor into the process 10 MODEL 228 USE OF INSERTION RETRACTION ASSEMBLIES REPLACING SEALS IN MANUAL AND MECHANICAL RETRACTION ASSEMBLIES 1 2 Retract the sensor into the retraction chamber and fully close the ball valve Drain the retraction chamber contents using the 1 8 in flush ports WARNING 7 4
15. tandard solution is possible only if the vessel holding the standard has exactly the same dimensions as the process pip ing If the Model 228 sensor is installed in a tee duplicating the process environment in the laboratory or shop might be possible Otherwise calibration against a standard solution is probably impractical The alternative is to calibrate the sensor in place against a referee sensor and analyzer ideally while both sensors are simultaneously measuring the same process liquid If this is not practical calibrate the process sensor against the results of a measurement made on a grab sample For more information about calibrating toroidal conductivity sensors refer to application sheet ADS 43 025 available on the Rosemount Analytical website etal pipe ere true conductivity plastic pipe inch 25 mm distance to wall k o c e O D FIGURE 18 Measured conductivity as a function of clearance between sensor and walls 13 MODEL 228 MAINTENANCE MAINTENANCE A WARNNG 8 CAUTION sure sensor has been cleaned of process liquid Retraction chamber contents may be under pressure before handling Generally the only maintenance required is to keep the opening of the sensor clear of deposits Cleaning frequency is best determined by experience TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Off scale reading Verify and correct wiring RTD is open
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