Emerson Rosemount 499AOZ User manual

Quick Start Guide
00825-0100-3492, Rev AA
May 2019
Rosemount™ 499AOZ
Dissolved Ozone Sensor

Safety information
CAUTION
Sensor/process application compatibility
The wetted sensor materials may not be compatible with process composition and operating
conditions.
Application compatibility is entirely the operator's responsibility.
CAUTION
Equipment damage
Do not exceed pressure and temperature specifications
Pressure: 65 psig (549 kPa abs) max.
Temperature: 32 to 122 °F (0 to 50 °C)
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of
end users’ equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your
system. Restrict physical access by unauthorized personnel to protect end users’ assets. This is true
for all systems used within the facility.
Contents
First steps.....................................................................................................................................3
Install........................................................................................................................................... 6
Wire........................................................................................................................................... 10
Calibrate.................................................................................................................................... 17
Maintenance.............................................................................................................................. 19
Accessories................................................................................................................................ 22
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1 First steps
1.1 Unpack and inspect
Procedure
1. Inspect the shipping container. If it is damaged, contact the shipper
immediately for instructions.
2. If there is no apparent damage, unpack the container. Be sure all
items shown on the packing list are present. If items are missing,
notify Emerson immediately.
1.2 Product description
Figure 1-1: Rosemount™ 499AOZSensor Parts
A. Membrane retainer
B. Membrane assembly
C. O-ring
D. Cathode
E. Electrolyte fill plug (wrap with pipe tape)
F. Pressure equalizing port
G. Sensor cable (integral cable shown)
1.3 Specifications
Table 1-1: Sensor Specifications
Physical characteristics Specifications
Range 0 to 3 ppm (mg/L) as O3
Pressure 0 to 65 psig (101 to 549 kPa abs)
Temperature (operating) 0 to 50 °C (32 to 122 °F)
Process connection 1 in. MNPT
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Table 1-1: Sensor Specifications (continued)
Physical characteristics Specifications
Wetted parts Polysulfone, Viton®, Teflon®, and silicone
Cathode Gold (not normally wetted)
Accuracy Accuracy depends on the accuracy of the chemical test used to
calibrate the sensor.
Linearity ±5% of reading or ±3 ppb (whichever is greater) at 25 °C (77 °F)
Repeatability ±2% of reading at constant temperature
Response time 30< 20 sec to 90% of final reading at 25 °C (77 °F)
Membrane permeability
connection
Defined between 0 and 50 °C (32 and 122 °F)
Electrolyte volume 25 mL (approx.)
Electrolyte life 3 months (approx.); for best results, replace electrolyte monthly.
Cable length (standard
integral cable)
25 ft (7.6 m)
Cable length (maximum) 300 ft (91 m)
Sample flow Flow through: 1 to 5 gpm (3.8 to 19 L/min)
Open channel: 1 ft/sec (0.3 m/sec)
Low flow cell: 2 to 5 gph (7.6 to 19 L/hr)
Weight/shipping
weight(1)
0.5 kg / 1.5 kg (1 lb / 3 lb)
(1) Weights and shipping weights are rounded up to the nearest whole pound or 0.5 kg.
Table 1-2: Other Specifications
Type PN Wetted
materials
Process
connection
Maximum
temperature
Maximum
pressure
2 in. tee 915240-03 PVC and Buna
N; body is
schedule 80
PVC
3/4 in. NFPT 49 °C (120 °F) 60 psig (515
kPa abs)
915240-04 1 in. NFPT
915240-05 1-1/2 in. NFPT
Low flow
cell (1)
24091-00 and
24091-01
Polycarbonat
e/polyester,
316 stainless
steel, and
silicone
Compression
fitting for 1/4
in. O.D.
tubing or 1/4
in. FNPT
70 °C (158 °F) 90 psig (722
kPa abs)
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Table 1-2: Other Specifications (continued)
Type PN Wetted
materials
Process
connection
Maximum
temperature
Maximum
pressure
Valved
rotameter
9390004 for
use with low
flow cell
Flow: 0.5 to 5
gph (1.4 to 19
L/hr)
Acrylic, 316
stainless
steel, and
Viton
1/4 in. NFPT
(316 stainless
steel)
65 °C (150 °F) 100 psig (858
kPa abs)
(1) Temperature and pressure specifications for the low flow cell exceed the temperature and
pressure specifications for the sensor.
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2 Install
Install the sensor in a flowing sample. Keep the sample flow as constant as
possible at a value within the following limits:
Sample flow unit Flow limits
Flow through 1 to 5 gpm (3.8 to 19 L/min)
Open channel 1 ft/sec (0.3 m/sec)
Low flow cell 2 to 5 gph (7.6 to 19 L/hr)
Figure 2-1: Sensor Orientation
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Figure 2-2: Flow Through 1-1/2 in. Tee
A. Union coupler
B. 1 in. NPT (2 places)
C. Sensor body: Rosemount 499A
D. 1 in. NPT flow cell adapter
E. O-ring 2-222
F. 1 1/2 in. sched 80 CPVC tee body
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Figure 2-3: Flow Through 2 in. Tee
A. Union coupler
B. Adapter
C. 1 in. NPT (2 places)
D. Sensor body: Rosemount 499A
E. O-ring 2-222
F. 2 in. sched 80 PVC tee body
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Figure 2-4: Low Flow Cell (PN 24091-00)
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3 Wire
NOTICE
For additional wiring information on this product, including sensor
combinations not shown here, please refer to the Liquid Transmitter Wiring
Diagrams.
Figure 3-1: Rosemount™ 499AOZ-54 Sensor Wiring to Rosemount 1056
and 56 Transmitters
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Figure 3-2: Rosemount 499AOZ-54-60 and Rosemount 499AOZ-54-VP
Sensor Wiring to Rosemount 1056 and 56 Transmitters
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Figure 3-3: Rosemount 499AOZ-54 Sensor Wiring to Rosemount 5081
Transmitter
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Figure 3-4: Rosemount 499AOZ-60 and 499AOZ-VP Sensor Wiring to
Rosemount 5081 Transmitter
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Figure 3-5: Rosemount 499AOZ-54 Sensor Wiring to Rosemount 1066
Transmitter
Note
Connect clear shield wires to sol gnd terminal on TB 2. Use wire nut and
pigtail if necessary.
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Figure 3-6: Rosemount 499AOZ-60 and 499AOZ-54-VP Sensor Wiring to
Rosemount 1066 Transmitter
Note
Connect clear shield wires to solution ground terminal on TB 2. Use wire nut
and pigtail if necessary.
Figure 3-7: Rosemount 499AOZ Sensor Pin-out Diagram
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When making a connection through a junction box (PN 23550-00), wire
point-to-point.
NOTICE
Use a wire nut and pigtail (included) when connecting several wires to the
same terminal.
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4 Calibrate
4.1 Zero point calibration
Even in the absence of ozone, the Rosemount 499AOZ sensor generates a
small signal called the zero current. Failing to correct for the zero current can
introduce a bias, particularly if the ozone concentration is small (<0.4 ppm).
Zero the sensor when it is first placed in service and every time the fill
solution is changed.
To zero the sensor:
Procedure
1. Pour a cup of deionized or bottled water.
2. Place the sensor in the water.
3. Wait until the sensor current has reached a stable low value (at least
two hours).
4. Follow the transmitter prompts for zeroing the sensor.
Note
Refer to the manual for the transmitter you are using (Rosemount
56, 1056, 5081, or 1066).
The zero current should be between -10 and +10 nA.
4.2 Full scale calibration
Because stable dilute ozone standards are not available, the sensor must be
calibrated against the results of a laboratory test run on a grab sample of the
process liquid.
Procedure
1. Place the sensor in the flow cell.
2. Start the sample and reagent flow.
3. Adjust the sample flow to the correct range.
4. Adjust the concentration so that it is near the upper end of the
operating range.
5. Wait for the readings to stabilize.
6. Follow the transmitter prompts to complete the calibration.
Note
Refer to the manual for the transmitter you are using (Rosemount
56, 1056, 5081, or 1066).
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7. After calibration, go to the Diagnostics menu and check the
sensitivity.
The sensitivity should be between 250 and 450 nA/ppm. For more
information, refer to the transmitter manual.
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5 Maintenance
Periodic maintenance and cleaning are required for best performance of the
sensor. Generally, the membrane and fill solution should be replaced every
four to six months. Sensors installed in harsh or dirty environments require
more frequent maintenance. The optimum maintenance frequency is best
determined by experience.
WARNING
PRESSURIZED SPRAY INJURY
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!
5.1 Cleaning the membrane
Keep the membrane and sensor tip clean and free from dirt. Clean the
membrane with water sprayed from a wash bottle. Use a soft tissue to
gently wipe the membrane.
5.2 Replacing the electrolyte solution and membrane
WARNING
HARMFUL SUBSTANCE
Fill solution may cause irritation. May be harmful if swallowed. Read and
follow manual.
Procedure
1. Unscrew the membrane retainer.
2. Remove the membrane assembly and O-ring.
See Figure 1-1.
3. Hold the sensor over a container with the cathode pointing down.
4. Remove the fill plug.
5. Allow the electrolyte solution to drain out.
6. Inspect the cathode.
a) If it is tarnished, clean it by gently rubbing in the direction of
the existing scratches (do not use a circular motion) with
400-600 grit silicon carbide finishing paper.
b) Rinse thoroughly with water.
7. Remove the old pipe tape from the plug.
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8. Wrap the plug with one or two turns of pipe tape..
9. Prepare a new membrane.
a) Hold the membrane assembly with the cup formed by the
membrane and membrane holder pointing up.
b) Fill the cup with electrolyte solution.
c) Leave the membrane assembly filled with electrolyte solution
and set it aside.
10. Hold the sensor at about a 45° angle with the cathode end pointing
up.
11. Add electrolyte solution through the fill hole until the liquid
overflows.
12. Tap the sensor near the threads to release trapped air bubbles.
13. Add more electrolyte solution if necessary.
14. Place the fill plug in the electrolyte port and begin screwing it in.
15. After several threads have engaged, rotate the sensor so that the
cathode is pointing up and continue tightening the fill plug.
Do not overtighten.
16. Place a new O-ring in the groove around the cathode post.
17. Cover the holes at the base of the cathode stem with several drops of
electrolyte solution.
18. Insert a small blunt probe, like a toothpick with the end cut off,
through the pressure equalizing port.
See Figure 1-1.
CAUTION
EQUIPMENT DAMAGE
Do not use a sharp probe. It will puncture the bladder and destroy
the sensor.
19. Gently press the probe against the bladder several times to force
liquid through the holes at the base of the cathode stem. Keep
pressing the bladder until no air bubbles can be seen leaving the
holes. Be sure the holes remain covered with electrolyte solution.
20. Place a drop of electrolyte solution on the cathode; then place the
membrane assembly over the cathode.
21. Screw the membrane retainer in place.
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