Emerson Rosemount Analytical 385+ User manual

Model 385+
Triple Junction pH/ORP Sensor
Instruction Manual
PN 51-385+/rev.I
May 2009

ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures, and tests its products to
meet many national and international standards. Because these instru-
ments 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.
• Inform and educate your personnel in the proper installation, opera-
tion, 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.
• Ensure that all equipment doors are closed and protective covers are
in place, except while maintenance is being performed by qualified
persons, to prevent electrical shock and personal injury.
About This Document
This manual contains instructions for installation and operation of the Model 385+ pH Sensor.The
following list provides notes concerning all revisions of this document.
Rev. Level Date Notes
A 2/01 This is the initial release of the product manual. The manual has been reformatted to
reflect the Emerson documentation style and updated to reflect any changes in the
product offering.
B 5/02 Drawings updated throughout
C 5/03 Drawing 40385+02 updated to rev. C; added drawing 41055119 — both on page 9.
D 9/04 Updated wiring diagrams and Table 5-2
E 10/04 Added 1055 single input wiring diagram.
F 3/05 ORP info revision.
G 5/05 Fixed LED font mis-print on page 16.
H 3/06 Added a note on page 6.
I 5/09 Updated for SMART sensors.
The wetted sensor materials may not be compatible
with process composition and operating conditions.
Application compatibility is entirely the responsi-
bility of the user.
CAUTION
SENSOR/PROCESS
APPLICATION COMPATIBILITY
WARNING
RETRACTABLE SENSORS
Retractable sensors must not be inserted nor retracted
when process pressures are in excess of 64 psig
(442kPa).
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 classifi-
cation 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.
DANGER
HAZARDOUS AREA INSTALLATION

MODEL 385+ pH/ORP TABLE OF CONTENTS
MODEL 385+ TRIPLE JUNCTION pH/ORP SENSOR
TABLE OF CONTENTS
Section Title Page
1.0 DESCRIPTION AND SPECIFICATIONS........................................................... 1
1.1 Features and Applications................................................................................. 1
1.2 Performance Specifications............................................................................... 1
1.3 Physical Specifications...................................................................................... 1
1.4 Ordering Information ......................................................................................... 2
2.0 INSTALLATION ................................................................................................. 3
2.1 Unpacking and Inspection................................................................................. 3
2.2 Mechanical Installation ..................................................................................... 3
2.3 Electrical Installation ........................................................................................ 4
3.0 START UP AND CALIBRATION........................................................................ 16
3.1 Start up.............................................................................................................. 16
3.2 pH Calibration ................................................................................................... 16
3.3 ORP Calibration ................................................................................................ 16
4.0 MAINTENANCE ................................................................................................ 17
4.1 Maintenance...................................................................................................... 17
4.2 Sensor Removal................................................................................................ 17
4.3 pH Electrode Cleaning ...................................................................................... 17
4.4 Platinum Electrode Cleaning............................................................................. 18
4.5 Sensor Tube Replacement................................................................................ 18
5.0 DIAGNOSTIC AND TROUBLESHOOTING ...................................................... 20
5.1 Model 54, 81, 3081, and 4081 pH Diagnostics ................................................. 20
5.2 Troubleshooting................................................................................................. 20
5.3 Model 1056, 1057, SMART Diagnostics ........................................................... 21
6.0 RETURN OF MATERIAL................................................................................... 22
6.1 General ............................................................................................................. 22
6.2 Warranty Repair ................................................................................................ 22
6.3 Non-Warranty Repair ........................................................................................ 22
i

MODEL 385+ pH/ORP TABLE OF CONTENTS
MODEL 385+ PH/ORP SENSOR
LIST OF FIGURES
Figure No. Title Page
2-1 Typical Mounting Details ................................................................................... 4
2-2 Dimensional Drawing: Retraction Version (Code -02)....................................... 5
2-3 Dimensional Drawing: Submersion/Insertion Version (Code -03 and -04)........ 5
2-4 Submersion Accessory (Code -03 and -04) ...................................................... 6
2-5 Submersion Installations, Handrail Mounting Assembly ................................... 6
2-6 6081 VP8 wiring to 385+-02.............................................................................. 6
2-7 6081 VP8 wiring to 385+-03.............................................................................. 7
2-8 6081 VP8 wiring to 385+-04.............................................................................. 7
2-9 5081P-HT VP8 wiring to 385+-02 ..................................................................... 8
2-10 5081P-HT VP8 wiring to 385+-03 ..................................................................... 8
2-11 5081P-HT VP8 wiring to 385+-04 ..................................................................... 9
2-12 1056 VP8 wiring to 385+-02.............................................................................. 9
2-13 1056 VP8 wiring to 385+-03.............................................................................. 10
2-14 1056 VP8 wiring to 385+-04.............................................................................. 10
2-15 Wiring to Model 1055-10-22 (single measurement only) .................................. 11
2-16 Wiring Model 385+-04-( ) Sensor to Model 1055-01-10-22-32 Analyzer .......... 11
2-17 Wiring Details .................................................................................................... 12
2-18 Wiring Model 385+-02 to Model 1055-11-22-32 through a remote j-box........... 12
2-19 Retraction Version Wiring.................................................................................. 13
2-20 Wiring Model 385+-02, -03, and remote J-box w/preamp to Model Xmt-P ....... 13
2-21 Wiring Model 385+-04 to Model Xmt-P ............................................................. 13
2-22 Remote Junction Box Wiring for Extension Cable ............................................ 14
2-23 Remote Junction Box with Preamplifier Wiring ................................................. 15
3-1 SMART Start up Screen .................................................................................... 16
4-1 Sensor Tube Replacement................................................................................ 19
4-2 Male Connector Diagram .................................................................................. 19
ii

iii
MODEL 385+ pH/ORP TABLE OF CONTENTS
LIST OF FIGURES CONT’D
Figure No. Title Page
5-1 SMART Start-up Screen.................................................................................... 21
5-2 Calibration History Menu................................................................................... 21
5-3 Calibration History Screen ............................................................................... 21
5-4 Factory Data, SMART Screen .......................................................................... 21
LIST OF TABLES
Table No. Title Page
1-1 Accessories....................................................................................................... 2
3-1 ORP of Saturated Quinhydrone Solutions (in Millivolts).................................... 16
5-1 Diagnostic Messages ........................................................................................ 20
5-2 Replacement Parts............................................................................................ 21

This page left blank intentionallyiv
MODEL 385+ pH/ORP TABLE OF CONTENTS

1
• SMART enabled
• RETRACTABLE VERSION allows removal and replacement under pressure without
process shutdown.
• LONG-LIFE, TRIPLE JUNCTION REFERENCE ELECTRODE provides longer service life in
applications where poisoning ions are present.
• DISPOSABLE TEFZEL AND TITANIUM DESIGN provides maximum chemical resistance
and economical advantage where minimum troubleshooting and maintenance downtime are
of prime importance.
• PLATINUM ORP Electrode
1.1 FEATURES AND APPLICATIONS
The Triple-junction Model 385+ is now offered with
SMART capabilities. SMART option becomes enabled
when used with the Model 1056, 1057 Analyzer and on
6081P wireless transmitter. The pH-loop capabilities
include auto-recognition of the SMART sensor, auto-
matic upload of calibration data and associated time
stamp, historical recording of pH diagnostics (slope,
offset, reference impedance, glass impedance). This
trending data allows technicians to predict frequency of
maintenance and estimate sensor life for a particular
process condition. Additional SMART features include
factory calibration, resetting SMART sensor calibration
data with user menus without power cycling, and
manufacturing information.
The Model 385+ Sensor measures the pH or ORP
(Oxidation Reduction Potential) of aqueous solutions
in pipelines, open tanks, or ponds. It is suitable for
applications where a low cost, industrial, disposable
sensor is required. The combination electrode features
a peripheral ceramic junction. The triple junction
reference cell provides longer life in processes
containing sugar, ammonia, chlorides, sulfides or other
poisoning ions. The Model 385+ body is constructed
of molded, chemically resistant Tefzel in two standard
body versions.
The retraction version is housed in a titanium tube,
with a plug-in style surface mount preamplifier in a
weatherproof junction box. It is designed for use with a
standard 1-1/2 in. ball valve assembly for process
mounting where a separate sample stream is difficult
or impossible to provide. The entire installation
process is accomplished without line depressurization
and minimal process fluid loss. Upon sensor removal,
from the ball valve, maintenance and replacement is
easy.
The insertion/submersion version has two body configu-
rations: 25 ft (7.6 m) integral cable and preamplifier; 15 ft
(4.5) integral cable for use with remote preamplifier.
1.2 PERFORMANCE SPECIFICATIONS
Measuring Range: pH: 0-14 ±1500mV
ORP: –1500 to 1500 mV
Temperature Compensation: (pH only) 0 to 100°C
(32 to 212°F)
1.3 PHYSICAL SPECIFICATIONS
Wetted Materials: Tefzel, titanium, EPDM, 316 SS
and Teflon1(Code 02), Viton2, glass, ceramic and
(ORP only) platinum.
Maximum Process Pressure and Temperature:
790 KPa abs (100 psig) at 100°C (212°F)
Maximum Pressure at Retraction or Insertion
(ball valve version): 542 KPa abs (64 psig)
Process Connections: 1-1/2 in. with ball valve
1 in. without ball valve
Cable: P/N 9200273 (Unprepped) or P/N 23646-01
(Prepped)
Weight/Shipping Weight:
Submersion/insertion: 1.6 lb/2.8 lb 0.7Kg /1.25 Kg
Retraction: 6 lb/11 lb (2.7 Kg/5.0 Kg)
Ball Valve: 5 lb/10 lb (2.25 Kg/4.5 Kg)
1Teflon is a registered trademark of E.I. du Pont de Nemours and Company.
2Viton is a registered trademark of DuPont Performance Elastomers.
MODEL 385+ pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
Percent Linearity Over pH Range
Option 10 Option 11
0-2 pH 94% 94%
2-12 pH 99% 97%
12-13 pH 97% 98%
13-14 pH 92% 98%

MODEL 385+ pH/ORP SECTION 1.0
DESCRIPTION AND SPECIFICATIONS
TABLE 1-1 ACCESSORIES
ORDERING INFORMATION
The Model 385+ pH/ORP Sensor: Standard features include a Tefzel sensor body with a triple junction gel filled
reference electrode and automatic temperature compensator housed in a titanium tube. The retractable version
comes with a weatherproof junction box, a process connector, and preamplifier. The insertion/submersion version
has two optional body configurations: integral SMART preamplifier (-03) option. The SMART is standard preamp
option. and 25 ft (7.6 m) integral cable, or 15 ft (4.5 m) integral cable for use with remote preamplifier. The 385+ is
designed to be used with the Models 54e,1055, 1056 or 1057 pH/ORP Analyzer, or Models 81, 3081, 4081, 5081,
6081 or Xmt pH/ORP Transmitter.
NOTES:
OPTION-02 recommended interconnecting cable from sensor to transmitter is Rosemount Analytical P/N 23646-01 (prepped) or P/N 9200273
(unprepped). Specify length.
OPTION-03, 04 require a 1 x 1 in. NPT process connector. Recommended PN’s 23166-00 or 23166-01.
Code Combination Electrode (Required Selection)
10 GPLR, General Purpose Low Resistivity (0-13 pH)
11 High (0-14 pH)
12 ORP (Platinum)
Code Body Configuration (Required Selection)
02 Retractable with sensor head junction box, preamplifier, and process connector
03 Insertion/Submersion with Integral SMART Preamplifier (Standard option) and 25 ft (7.6 m) cable
04 Insertion/Submersion for use with Remote Preamplifier and 15 ft (4.5 m) cable
MODEL
385+ pH/ORP SENSOR
385+ -03 -10 EXAMPLE
ACCESSORIES DESCRIPTION
11275-01 Handrail mounting assembly (Code 03, 04 only)
23550-00 Remote J-Box without preamplifier (Code 02, 03 only)
23555-00 Remote J-Box with preamplifier, (Code 04 only)
23166-00 Process connector, 316SS, insertion/submersion 1 in. MNPT (Code 02, 03, 04)
23166-01 Process connector, titanium, insertion/submersion 1 in. MNPT (Code 02, 03, 04)
9510066 Process connector, Nylon, submersion only, 1 in. MNPT (Code 03, 04)
9210012 Buffer solution, 4.01 pH, 16 oz
9210013 Buffer solution, 6.86 pH, 16 oz
9210014 Buffer solution, 9.18 pH, 16 oz
R508-80Z ORP solution, 460 mV ± 10 at 20°C
9550167 EPDM O-ring for Process Connector (PN 23166-00 or 23166-01)
12707-00 Jet Spray Cleaner for submersion service
23566-00 Sensor Tube, pH, Pt 100, Titanium, Low Resistance Glass
23566-01 Sensor Tube, pH, Pt 100, Titanium, High pH
23566-02 Sensor Tube, ORP, Pt 100, Titanium, General Purpose
23240-00 Ball Valve Assembly 316 Stainless Steel
23646-01 Cable, 12 Conductor, Shielded, Prepped
23557-00 Preamplifier, J-box
33046-00 Ferrule, 1 in. 316 SS, Split
9200258 Cable, 12 Conductor, Shielded, Unprepped
9310094 Ferrule, 1 in. 316 SS
9310096 Nut, Swage, 1 in. 316 SS
9310100 Ferrule, 1 in. TEFLON
9550099 O-ring, 2-214, VITON
2

3
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
SECTION 2.0
INSTALLATION
2.1 UNPACKING AND INSPECTION. Inspect the outside
of the carton for any damage. If damage is detected,
contact the carrier immediately. Inspect the instrument
and hardware. Make sure all items in the packing list
are present and in good condition. Notify the factory if
any part is missing.
NOTE
Save the original packing cartons and
materials as most carriers require proof of
damage due to mishandling, etc. Also, if it
is necessary to return the instrument to the
factory, you must pack the instrument in the
same manner as it was received. Refer to
Section 6.0 for instructions.
2.2 MECHANICAL INSTALLATION. The Model 385+
is available in two versions, the retraction version
(Code 02) and the insertion/submersion version (Code
03, & 04). Please refer to the appropriate section below.
2.2.1 Retraction Option. (Code option -02) The Model
385+ Sensor may be installed through a weldalet or in
a pipe tee or “Y”, as shown in Figure 2-1, when used
with a ball valve. Insert the end of the sensor to a depth
sufficient to ensure that the glass bulb is continuously
wetted by the process fluid. The Model 385+ can also
be inserted directly into the process without the use of
a ball valve for applications not requiring continuous
operation during sensor maintenance (Figure 2-2).
ALLOW SUFFICIENT ROOM FOR SAFE RETRAC-
TION AND INSERTION OF THE SENSOR. PERSONNEL
SHOULD HAVE ROOM FOR STABLE FOOTING
WHILE PERFORMING REMOVAL OR INSERTION
OF THE SENSOR.
The sensor must be mounted within 10-90 degrees of
the horizontal with the tip pointed downward, thus
keeping air bubbles out of the pH sensitive glass bulb.
Bubbles settled in the glass bulb disrupt the electrical
continuity between the pH sensitive glass and the
silver/silver chloride measuring element.
If the retraction version is to be installed without a ball
valve follow the installation procedure for insertion
service (Section 2.2.2). Perform the following steps for
sensor installation through a ball valve:
1. Carefully remove the liquid filled rubber boot which
protects the glass electrode and keeps the liquid
junction wet during shipping and storage. Discard
the liquid and boot. Make sure the lubricated O-ring
is in place in the groove inside the male connector
on the sensor body (Figure 4-1, item A).
2. With the male connector on the sensor’s body,
insert the sensor into the ball valve until it gently
touches the closed valve. The molded electrode
guard will protect the glass bulb from breakage.
3. Thread the male connector body tightly into the ball
valve assembly. DO NOT tighten the hex nut on the
male connector body; doing so would not allow the
sensor to be inserted through the ball valve.
4. Pull back hard on the sensor assembly, as if trying to
remove the sensor, to be certain that the sensor
cannot come free of the ball valve assembly. The
built-in retraction stop will butt against the shoulder
of the male connector if properly installed.
5. After confirming that the sensor assembly is prop-
erly secured by the valve assembly, the valve may
be opened and the sensor positioned into the
process at the desired depth and orientation.
6. While holding the sensor in position, tighten the
hex nut of the male connector to firmly secure the
sensor in place. When the hex nut is tightened, the
Teflon ferrule inside the compression fitting clamps
the sensor tube. (See Figure 4-2.)
NOTE
A stainless steel ferrule is available if the
TEFLON ferrule does not inadequately
grip. When using the metallic ferrule, care
must be taken to avoid over tightening and
damaging the sensor tube. If the male con-
nector leaks during insertion or retraction,
replace the O-ring in the male connector.
CAUTION
Buffer solution, in the vinyl boot, may cause skin or eye
irritation
CAUTION
Over tightening the hex nut may damage the ferrule.
CAUTION
The sensor must be captured by the valve assembly
and the male connector so that it cannot be blown free
by process pressure if mishandled during insertion or
retraction.
WARNING
Glass electrode must be wetted at all times (in stor-
age and in line) to maximize sensor life.

4
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-1. Typical Mounting Details-Retraction Version
2.2.2 Submersion/Insertion Option. Code Option -03
& -04). Figure 2-3 and Figure 2-4. The Model 385+
Sensor may be installed through a weldalet or a pipe
tee or “Y” when used with a process connector (P/N
23166-00-01). For submersion service, a process con-
nector (P/N 23166-00-01 or 9510066) may be used
with a water tight 1 in. schedule 80 CPVC or PVDF
standpipe conduit. Refer to Figure 2-5. Tapered
threads in plastic tend to loosen after installation. It is
therefore recommended that TEFLON tape be used on
the threads and that the tightness of the connection be
checked frequently to assure that no loosening has
occurred. The sensor should be installed within 80° of
vertical, with the electrode facing down.
2.3 ELECTRICAL INSTALLATION. Make electrical
connections as shown on Figures 2-6 through 2-14
using the following guidelines:
1. Pay particular attention to the analyzer or transmit-
ter model number when following details on the
wiring diagrams to ensure that the connections are
made to the proper terminals.
2. Use Rosemount custom cable PN 9200273.
3. The maximum distance from the sensor to the ana-
lyzer is 15 ft without an integral preamplifier.
4. Signal cable should be run in a dedicated conduit
and should be kept away from AC power lines.

5
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-2.Dimensional Drawing Retraction Version (Code 02)
WHEN INCH AND METRIC DIMS
ARE GIVEN
MILLIMETER
INCH
FIGURE 2-3. Dimensional Drawing Submersion/Insertion Version (Code -03, -04)
INCH
MILLIMETER

DWG. NO. REV.
400385+07 B
DWG. NO. REV.
400385+05 B
6
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
MILLIMETER
INCH
FIGURE 2-4. Submersion Accessory (Code 03, 04)
FIGURE 2-5. Submersion Installations, Handrail
Mounting Assembly (P/N 11275-01)
NOTE
Remove electrical tape or shrink sleeve from gray
reference wire before connecting wire to terminal.
FIGURE 2-6. 6081 VP8 wiring to 385+-02

7
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-7. 6081 VP8 wiring to 385+-03. SMART sensor
FIGURE 2-8. 6081 VP8 wiring to 385+-04.

8
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-9. 5081P-HT VP8 wiring to 385+-02
FIGURE 2-10. 5081P-HT VP8 wiring to 385+-03. SMART sensor

9
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-11. 5081P-HT VP8 wiring to 385+-04
FIGURE 2-12. 1056 VP8 wiring to 385+-02

10
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-13. 1056 VP8 wiring to 385+-03. SMART sensor
FIGURE 2-14. 1056 VP8 wiring to 385+-04

11
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-16. Wiring Model 385+-04-( ) Sensor to Model 1055-01-10-22-32 Analyzer
DWG. NO. REV.
40105551 B
FIGURE 2-15. Wiring to Model 1055-10-22 (single measurement only)

MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
FIGURE 2-18. Wiring Model 385+-02 Sensor to Model 1055-11-22-32 Analyzer through Remote Junction Box
DWG. NO. REV.
41055119 A
FIGURE 2-17. Wiring Details - Submersion/Insertion (Code 03 & 04)
See Figures 2-12 and 2-13 for wiring to Model Xmt-P
MODELS 54e, 81, 3081, 4081, 5081
WITH PREAMP IN SENSOR
MODELS 54e, 81, 3081, 4081, 5081
WITH PREAMP IN INSTRUMENT
12

13
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
DWG. NO. REV.
40385+02 C
FIGURE 2-19. Wiring Retraction Version (Code-02)
SEE FIGURE 2-10 FOR XMT-P WIRING.
FIGURE 2-20. Wiring 385+-02, -03, and Remote
J-box w/Preamp to Model Xmt-P. FIGURE 2-21. Wiring 385+-04 to Model Xmt-P.

14
DWG. NO. REV.
40396P08 B
MODEL 385+ pH/ORP SECTION 2.0
INSTALLATION
WHEN INCH AND METRIC DIMS
ARE GIVEN
MILLIMETER
INCH
See Figure 2-11 for wiring to Model Xmt-P
FIGURE 2-22. Wiring Details - Remote J-Box for Extension Cable
MODELS
54e, 81,
3081,
4081,
5081
EXTENSION CABLE P.N. 9200273
(UNPREPPED) OR
P.N. 93646-01 (PREPPED)