Emerson Rosemount 228 User manual

Reference Manual
LIQ-MAN-228, Rev V
April 2018
Rosemount™ 228
Toroidal Conductivity Sensors

Safety Information
WARNING!
HIGH PRESSURE AND TEMPERATURE HAZARD
Before removing the senosr, reduce the process pressure to 0 psig and cool down the process temperature.
Failure to reduce the pressure and temperature may cause serious injury to personnel.
CAUTION!
EQUIPMENT DAMAGE
The wetted sensor materials may not be compatible with process composition and operating conditions. Application compatibility is
entirely your responsibility.

Contents
Chapter 1 Description and specifications ..........................................................................................1
1.1 Description .................................................................................................................................... 1
1.2 Unpacking and inspection .............................................................................................................. 1
1.3 Sensor Specifications ......................................................................................................................1
1.4 Ordering information ..................................................................................................................... 4
Chapter 2 Install ...............................................................................................................................5
2.1 Installing the sensor ....................................................................................................................... 5
2.2 Insertion/Retraction Assembly Installation Requirements .............................................................. 8
2.2.1 Manual Retraction Assembly ............................................................................................9
2.2.2 Mechanical Retraction Assembly (PN 23311-00) ............................................................12
2.2.3 Replacing Seals in Manual and Mechanical Retraction Assemblies ................................. 15
Chapter 3 Wiring ........................................................................................................................... 19
3.1 Wiring the Sensor .........................................................................................................................19
Chapter 4 Calibration ..................................................................................................................... 23
4.1 Sensor calibration .........................................................................................................................23
4.2 Calibrating against a Standard Solution ........................................................................................23
4.3 Calibrating against a Referee - in-Process ..................................................................................... 25
4.4 Calibrating against a Referee - Grab Sample ................................................................................. 26
Chapter 5 Maintaining and Troubleshooting .................................................................................. 29
5.1 Maintaining the sensor .................................................................................................................29
5.2 Troubleshooting .......................................................................................................................... 29
Chapter 6 Accessories .................................................................................................................... 31
Chapter 7 Return of Materials .........................................................................................................33
Contents
Rosemount 228 Sensor i

Contents
ii Reference Manual

1 Description and specifications
1.1 Description
The Rosemount 222 toroidal flow through conductivity sensor measures conductivity in
highly conductive liquids up to 2 S/cm (2,000,000 μS/cm). A noninvasive flow through
design allows for in-line installations without any obstruction to sample and makes these
sensors ideal for use with viscous or fibrous liquids.
1.2 Unpacking and inspection
Complete the following steps when you unpack your instrument.
1. Inspect the shipping container. If there is damage, contact the shipper immediately
for instructions.
2. If there is no apparent damage, and remove the sensor.
3. Ensure that all items shown on the packing list are present. If items are missing,
contact your local Customer Care representative.
4. Save the shipping container and packaging.
They can be reused to return the sensor to the factory in case of damage.
1.3 Sensor Specifications
Sensor specificationsTable 1-1:
Sensor specification Description
Wetted materials Body materials either glass-filled PEEK, glass-filled Tefzel,
or unfilled Tefzel. Option -20 has EPDM gasket
Process connection -20: 5/8 in. 11 UNC, -21: 3/4 in. MNPT
Cable length 20 ft (6.1 m)
Maximum cable length 200 ft (61.0 m)
Weight/shipping weight 2 lb / 3 lb (1.0 kg / 1.5 kg)
Maximum operating temperature and pressureTable 1-2:
Body material option Maximum temperature Maximum pressure
Maximum pressure (for
CRN registration only)
-02 (Glass-filled PEEK
(standard temperature))
248 °F (120 °C) 295 psig (2135 kPa) 220 psig (1618 kPa [abs])
Description and specifications
Rosemount 228 Sensor 1

Maximum operating temperature and pressure (continued)Table 1-2:
Body material option Maximum temperature Maximum pressure
Maximum pressure (for
CRN registration only)
-03 (Glass-filled PEEK (high
temperature))
392 °F (200 °C) 295 psig (2135 kPa) 220 psig (1618 kPa [abs])
-04 (Glass-filled Tefzel) 248 °F (120 °C) 200 psig (1480 kPa) 150 psig (1135 kPa [abs])
-05 (Unfilled Tefzel) 248 °F (120 °C) 200 psig (1480 kPa) 150 psig (1135 kPa [abs])
Insertion adapter specificationsTable 1-3:
Adapter
part num-
ber
Sensor com-
patibility
Process con-
nection
Wetted ma-
terials
Maximum
tempera-
ture
Maximum
pressure
Maximum
pressure
(for CRN
registration
only)
Weight /
shipping
weight
23242-02 For use with
option -21
1-1/2 in.
MNPT
316 stainless
steel, glass-
filled PEEK,
Viton
392 ° F
(200 °C)
295 psig
(2135 kPa)
220 psig
(1618 kPa
[abs])
3 lb / 4 lb
(1.5 kg / 2.0
kg)
23242-03 For use with
option -20
1-1/2 in.
MNPT
316 stainless
steel, glass-
filled PEEK,
Viton
392 °F
(200 °C)
295 psig
(2135 kPa)
220 psig
(1618 kPa
[abs])
3 lb / 4 lb
(1.5 kg / 2.0
kg)
2001990 For use with
option -21
2 in. MNPT CPVC
Viton
100 °F
(38 °C)
100 psig
(791 kPa
[abs])
N/A 1 lb / 2 lb
(0.5 kg / 1.0
kg)
185 °F (85 °
C)
45 psig (412
kPa [abs])
Retraction assembly specficationsTable 1-4:
Specification Description
Sensor compatibility The retraction assemblies are used with 228 - [ ]-20-54-62
only
Wetted materials 315 stainless steel, ethylene polypropylene (EP), unfilled
Teflon, carbon-filled Teflon
Process connection 1 - 1/2 in. MNPT
Maximum operating condition 392 °F (200 °C), 295 psig (2135 kPa [abs])
Description and specifications
2 Reference Manual

Maximum retraction/insertion conditionsTable 1-5:
Description Temperature Pressure
Maximum insertion
travel
Weight / shipping
weight
23311-00, mechani-
cal retraction assem-
bly
392 °F (200 °C) 295 psig (2135 kPa
[abs])
10.5 in. (267 mm) 12 lb / 15 lb (5.5 kg /
7.0 kg)
23311-01, manual re-
traction assembly
266 °F (130 °C) 35 psig (343 kPa
[abs])
12.0 in. (305 mm) 9 lb / 12 lb (4.5 kg /
5.5 kg)
Ball valve specifications (sold separately)Table 1-6:
Specification Description
Part number 9340065
Wetted materials 316 stainless steel, Teflon TFE
Process connection 1-1/2 in. FNPT
Weight / shipping weight 4 lb / 5 lb (2.0 kg / 2.5 kg)
Ball valve pressure and temperature
Description and specifications
Rosemount 228 Sensor 3

1.4 Ordering information
Rosemount 228 Toroidal Conductivity Sensor Ordering InformationTable 1-7:
Model Sensor type
228 Toroidal Conductivity Sensor
Materials of construction
02 Glass-filled PEEK (standard temperature)
03 Glass-filled PEEK (high temperature)
04 Glass-filled Tefzel(1)
05 Unfilled Tefzel(2)
Process connection
20 5/8 in. 11 UNC(3)
21 3/4 in. MNPT(4)
Cable type(5)
54 Unshielded cable(6)
56 EMI/RFI shielded cable(7)
Cable length
61 6.1 m (20 ft)
62 457 mm (18 in.)(8)
(1) Not available with options -50-62 and -54-62.
(2) Not available with option -54-62.
(3) This option requires a mounting adapter. This option comes standard with an EPDM gasket (Viton® and
Kalrez® gaskets are also available).
(4) Not available with option -62.
(5) Cable may be extended using the remote junction box PN 23550-00 (sold separately) and extension cables..
(6) Recommended for use with transmitter models 1054 and 2054. May be used with transmitter models 1055,
1056, 1066, 54C, 54eC, 81T, 2081T, 3081T, 4081T, 5081, and XMT, but not recommended.
(7) Recommended for use with transmitter models 1055, 1056, 1066, 56, 54C, 54eC, 5081, and XMT.
(8) For use with option -54 only. Connects sensor used in valve insertion assembly to junction box. Requires
interconnecting cable to connect junction box to transmitter. Use either cable 23294-00 (unshielded) or
23294-05 (shielded).
Description and specifications
4 Reference Manual

2 Install
2.1 Installing the sensor
Keep at least 1 in. (25 cm) between the sensor and the pipe wall. If 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.
Rosemount 228 dimensional drawingFigure 2-1:
Install
Rosemount 228 Sensor 5

Insertion adapter 23242-02 for use with 3/4 in. MNPT threaded process
connection (-21 option)
Figure 2-2:
Install
6 Reference Manual

Insertion adapter 23242-03 for use with 5/8 in. 11 UNC threaded process
connection (-20 option)
Figure 2-3:
Install
Rosemount 228 Sensor 7

Insertion adapter 2001990 for use with 3/4 in. MNPT threaded process
connection (-21 option)
Figure 2-4:
Procedure
1. Mount the sensor in the pipe.
2. 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.
3. Mount the sensor in a vertical pipe run with flow from top to bottom.
If the sensor must be mounted in a horizontal pipe run, orient the sensor in the
3 o'clock or 9 o'clock position.
4. Ensure that the sensor is completely submerged in liquid.
2.2 Insertion/Retraction Assembly Installation
Requirements
Insertion/Retraction Assembly Installation RequirementsTable 2-1:
Requirement Description
Process connection 1-1/2 in. Larger openings may keep the sensor
from inserting far enough into the process liq-
uid.
Line size 3 in.; 2 in. line requires in-place calibration.
Valve 1-1/2 in. NPT full port valve (PN 9340065)
Retraction clearance 2 ft (0.6 m)
Excess vibration Provide mechanical support if excess vibration is
expected.
Install
8 Reference Manual

Insertion/Retraction Assembly Installation Requirements (continued)Table 2-1:
Requirement Description
Flush water Provide 1/8 in. valves in inlet and outlet flush
ports. Position flush ports so that the retraction
chamber can be drained.
2.2.1 Manual Retraction Assembly
Installing a Manual Retraction Assembly
1. Loosen the collet nut and retract the sensor tube into the retraction chamber.
See Figure 2-5.
Install
Rosemount 228 Sensor 9

Manual retraction assembly dimensional drawingFigure 2-5:
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 valve mounted on the
process line or vessel.
4. 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.
5. Connect the sensor and interconnecting cable leads to the terminal strip in the
junction box.
See Figure 2-6.
Install
10 Reference Manual

Sensor-mounted junction box wiringFigure 2-6:
Note
The wiring diagram shown is for the cable PN 23294-00, which has three RTD (TC) leads. If you are
useing cable PN 23294-05, which has four RTD (TC) leads, connect the green, white, and clear
wires in the RTD bundle as shown in the drawing. Do not disconnect the black wire. When you
reconnect the RTD wires in PN 23294-05 to the transmitter, make the connections as described in
Step 6 (this section) or Step 3 (Installing the Mechanical Retraction Assembly.
6. Connect the other end of the cable to the transmitter. See the wiring diagrams in
Figure 3-2, Figure 3-3, and Figure 3-4. For cable PN 23294-00, follow the wiring for the
228-54 sensor. For cable PN 23294-05, follow the wiring for the 228-56 sensor with
the following exception:
Refer to the wire function diagram for the 228-56 option in Figure 3-1 and identify
the RTD wire bundle. Connect the RTD wires to the transmitter 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.
7. Insert the sensor and tube assembly into the retraction chamber.
8. Tighten the union nut.
9. Open the ball valve, check for leaks, and manually insert the sensor into the process.
10. Position the sensor at least 1/2 in. (13 mm) away from any wall of the vessel or pipe.
11. Tighten the collet nut.
Install
Rosemount 228 Sensor 11

Retracting the Manual Retraction Assembly
Prerequisites
Make certain that the system pressure is less than 35 psig (342 kPa [abs]).
Procedure
1. Push in on the sensor using the top of the junction box. Slowly loosen the collet nut.
WARNING!
HIGH PRESSURE
Reduce pressure to 0 psig. Do not loosen collet nut until pressure is 0 psig.
Failure to reduce pressure may cause a loose collet nut to disengage and cause injury to
personnel.
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.
3. Drain the retraction chamber contents using the 1/8 in. flush ports.
4. Loosen the 3 in. hex union nut. Removt the sensor and tube assembly.
5. Replace the 3 in. hex nut O-ring. Place the sensor and tube assembly back in the
retraction assembly. Tighten the 3 in. hex union nut. Verify that the 1/8 in. flush
ports are closed.
NOTICE
With the ball valve 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.
WARNING!
HIGH PRESSURE
Retraction chamber contents may be under pressure. Before opening the ball valve,
make sure that the process pressure is less than 35 psig (342 kPa [abs]).
Failure to reduce pressure may cause a loose collet nut to disengage and cause injury to
personnel.
6. Open the ball valve and check for leaks. Insert the sensor into the process. Tighten
the collet nut.
2.2.2 Mechanical Retraction Assembly (PN 23311-00)
Installing the Mechanical Retraction Assembly
1. Tighten 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.
Install
12 Reference Manual

See Figure 2-7.
Mechanical retraction assemblyFigure 2-7:
2. Terminate the sensor wiring in the junction box.
See Figure 2-6 for wiring details.
3. Connect the other end of the cable to the transmitter.
Install
Rosemount 228 Sensor 13

See the wiring diagrams in Figure 3-2, Figure 3-3, and Figure 3-4. For cable PN
23294-00, follow the wiring for the 228-54 sensor. For cable PN 23294-05, follow
the wiring for the 228-56 sensor with the following exception:
Refer to the wire function diagram for the 228-56 option in Figure 3-1 and identify
the RTD wire bundle. Connect the RTD wires to the transmitter 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.
4. Using a 1/2 in. (13 mm) socket wrench, retract the sensor into the retraction
chamber.
5. Install the assembly on the 1-1/2 in. NPT full port ball valve mounted in the process
line or vessel.
6. Tighten the union nut.
7. Open the ball valve and check for leaks.
8. Using a 1/2 in. (13 mm) socket wrench, inser the sensor into the process line or
vessel.
9. 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 net to the nut housing.
WARNING!
HIGH PRESSURE
Do not loosen cap screws or collar when pressurized.
Failure to reduce pressure may cause a loose part to disengage and cause injury to
personnel.
Retracting a Mechanical Retraction Assembly
Prerequisites
Make sure that the system pressure is less than 295 psig (2135 kPa [abs]) before retracting
the sensor.
Procedure
1. Retract the sensor using a 1/2 in. (13 mm) socket wrench. When the sensor clears
the ball valve, close the valve.
WARNING!
HIGH PRESSURE
Retraction chamber contents may be under pressure.
Failure to reduce pressure may cause a loose part to disengage and cause injury to
personnel.
Install
14 Reference Manual