Emerson Rosemount 3900 User manual

Quick Start Guide
00825-0100-3389, Rev AA
May2023
Rosemount™ pH/ORP Sensors
Models 3900, 3900VP, 396P, 396PVP,
396R, 396RVP, 3300HT, 3300HTVP,
3400HT, 3400HTVP, 3500P, and 3500VP

Contents
Essential instructions...................................................................................................................3
Installation.................................................................................................................................... 5
Wiring.......................................................................................................................................... 18
Calibration and maintenance................................................................................................... 22
Rosemount pH/ORP sensor(s) product certifications............................................................27
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1 Essential instructions
Read this page before proceeding!
Emerson 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. You must adhere to the following instructions
and integrate them into your safety program when installing, using,
and maintaining Emerson's Rosemount products.
WARNING
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.
Follow all warnings, cautions, and instructions marked on and
supplied with the product.
If this Quick Start Guide is not the correct one, call 1-800-854-8257
or 949-757-8500 to request the correct Quick Start Guide. Save
this Quick Start Guide for future reference.
Inform and educate your personnel in the proper installation,
operation, and maintenance of the product.
Use only qualified personnel to install, operate, program, and
maintain the product.
Install equipment as specified in the installation instructions of
the appropriate Quick Start Guide and per applicable local and
national codes. Connect all products to the proper electrical and
pressure sources.
When replacement parts are required, ensure that qualified
people use replacement parts specified by Emerson.
Ensure that all equipment doors are closed and protective covers
are in place, except when maintenance is being performed by
qualified people, to prevent electrical shock and personal injury.
NOTICE
The information contained in this document is subject to change
without notice.
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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.
CAUTION
Special conditions for safe use
All pH/ORP sensors have a plastic enclosure which must be cleaned
with a damp cloth to avoid the danger due to a buildup of
electrostatic discharge.
NOTICE
Sensor/process application compatibility
The wetted sensor material may not be compatible with process
composition and operating conditions.
Application compatibility is entirely the owner's responsibility.
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2 Installation
2.1 Storing the sensor
•Emerson recommends storing pH/ORP sensors in their original
shipping containers until needed.
•Store sensors in a temperature-controlled environment.
•If the sensor must be stored after it has been removed from
its shipping container, store the sensor tip downward with the
protective cap in place and containing KCL solution (PN 9210342).
•For overnight storage, immerse the sensor in tap water or a 4 pH
buffer solution.
•pH glass electrodes slowly deteriorate in storage. There is no
specific expiration date. Follow the calibration procedures in
Calibration and maintenance to determine if the sensor calibrates
properly.
2.2 Prepare sensor
Procedure
1. Remove sensor from shipping container
2. Remove the protective cap covering the electrode bulb.
3. Rinse away salt film with clean water; then shake the electrode
so that the internal solution fills the bulb, removing any air
trapped there.
2.3 Installing sensors
2.3.1 Installation accessories
See the Liquid Analysis Sensor Mounting, Wiring, and Calibration
Product Data Sheet for a full list of accessories available from
Emerson to enable convenient and reliable sensor installation for
your application.
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2.3.2 Sensor orientation
Install all Rosemount pH/ORP sensors within 80 degrees of vertical,
as shown in Figure 2-1. This ensures that the air bubble within the
sensor does not stay at the sensor tip and disrupt the measurement.
Figure 2-1: Sensor orientation
Install the sensor tip down within 80 degrees of vertical.
2.3.3 Install insertion style sensors
Emerson offers two primary mounting styles for pH/ORP sensors:
insertion and retractable.
Insertion style sensors have NPT pipe threads that you can connect
directly into the process or into a mounting adapter.
Figure 2-2: Example of a Rosemount insertion style sensor
A. Forward facing ¾-in. NPT are present on some Rosemount pH/ORP
sensor models.
B. Forward facing 1-in. NPT
C. Wrench flats
D. Rear facing 1-in. NPT
You can connect insertion style sensors to the process using the
forward facing NPT threads or you can use the rear facing NPT
threads for immersion mounting in a pond or basin.
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For immersion mounting, connect the sensor to a pipe using the rear
facing threads to keep the cable connection on the back of the sensor
dry.
Procedure
1. When using the sensor's NPT threads to connect to your
process, wrap the sensor threads with six or seven turns of
PTFE tape to prevent leakage.
2. Hand tighten the sensor and then tighten one or two turns
with a wrench.
Do not over tighten.
2.3.4 Installing retractable style sensors
Emerson offers two primary mounting style designs for pH/ORP
sensors: insertion and retractable.
Retractable style sensors have 1-in. (25 mm) outer diameter metal
bodies that you must connect to the process using an Emerson
provided insertion adapter or a ball valve retraction mounting
assembly.
Figure 2-3: Example of Rosemount retractable style sensor
A. 1-in. (25 mm) outer diameter retractable sensor body
Retractable sensors are available in several different lengths.
Retractable sensors with a length of less than 15 in. (381 mm) require
the use of an insertion adapter (PN 23166-00, PN 23166-01, or PN
9510066).
You can install retractable sensors with lengths greater than 15 in.
(381 mm) with an insertion adapter or with a Rosemount ball valve
assembly (PN 23240-00 or PN 23765-00). Ball valve assemblies allow
the sensor to be isolated from the process, so that you can remove
the sensor for cleaning, service, or replacement while the process
remains on-line.
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Install retractable sensor with an insertion adapter
Figure 2-4: Insertion adapter (PN 23166-00 or PN 23166-01) with
Rosemount retractable sensor
A. 1-in. NPT
B. Ferrule fitting process connector assembly: PN 23166-00 or PN
23166-01
C. Sensor body
Procedure
1. Slide the fitting onto the sensor from the back of the sensor.
Install the threads facing forward for insertion installations.
Install the threads facing backward for connection to a
submersion pipe.
2. Connect the NPT threads on the adapter to the process piping
or submersion pipe.
3. Adjust the position of the fitting on the sensor to achieve the
desired sensor insertion length.
4. While holding the sensor in position, tighten the hex nut of the
male connector to firmly secure the sensor in place.
NOTICE
Over-tightening the hex nut may damage the ferrule.
When you tighten the hex nut, the PTFE ferrule inside the
compression fitting clamps the sensor tube.
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Install retractable sensor with ball valve assembly PN
23240-00
Figure 2-5: PN 23240-00 ball valve assembly and PN 23166-00 or
PN 23166-01 adapter with Rosemount retractable sensor
Dimension in drawing shows millimeters above and inches below.
A. Dimension (see Table 2-1)
B. Dimension (see Table 2-1)
C. Process connector (PN 23166-00 or PN 23166-01). Not included
with ball valve kit.
D. 1.5-in. (38.1 mm) by 1-in. (25.4 mm) reducer (PN 9310104)
E. Ball valve (PN 934065)
F. Ball valve kit (PN 23240-00)
G. 1.5-in. (38.1 mm) close nipple (PN 931012)
Table 2-1: Insertion lengths for retraction assembly PN 23240-00
Sensor tube length A B (maximum)
21 in. (533 mm) 23.1 in. (587 mm) 12.9 in. (328 mm)
36 in. (914 mm) 37.58 in. (955 mm) 27.4 in. (696 mm)
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Figure 2-6: Exploded view ball valve assembly (PN 23240-00) used
with process connector (PN 23166-00 or PN 23166-01)
A. Kit, 1-in. (25.4 mm) ferrule fitting (PN 23166-00)
B. 1.5-in. (38.1 mm) by 1-in. (25.4 mm) reducer (PN 9310104)
C. 1.5-in. (38.1 mm) close nipple, 316 stainless steel (PN 9310103)
D. 1.5-in. (38.1 mm) ball valve, 316 stainless steel (PN 9340065)
E. Sensor
Procedure
1. Securely connect the ball valve assembly (ball valve, nipple,
and reducer) to the process.
2. Make sure the ball valve is closed and the system pressure is
at or below the maximum rated retraction pressure for the
sensor length you are using before proceeding.
WARNING
Before removing the sensor, be absolutely certain that the
process pressure is reduced to 0 psig (0 barg) and the
process temperature is lowered to a safe level.
Do not insert or retract retractable sensors when process
pressure is above the specified retraction pressure limit for
the length of sensor being used.
For 21-in. (533 mm) length sensors the maximum allowed
retraction pressure is 64 psig (5.4 barg).
For 36-in. (914 mm) length sensors the maximum allowed
retraction pressure is 35 psig (3.4 barg).
3. Slide the ferrule fitting (PN 23166-00 or 23166-01) onto the
sensor from the back of the sensor.
4. With the ferrule fitting on the sensor's body, insert the sensor
into the ball valve until it gently touches the closed valve.
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The electrode tip guard will protect the electrode glass from
breakage.
5. Thread the ferrule fitting tightly into the ball valve assembly.
NOTICE
Do not tighten the hex nut on the ferrule fitting. Tightening
the hex nut would not make it possible to insert the sensor
through the ball valve.
6. Pull back hard on the sensor, as if trying to remove it, to be
certain that the sensor cannot come free of the ball valve
assembly.
If the sensor is properly installed, the built-in retraction stop
will butt against the shoulder of the ferrule fitting.
NOTICE
The sensor must be captured by the valve assembly so that it
cannot be blown free by process pressure if mishandled
during insertion or retraction.
7. After confirming that the sensor assembly is properly secured
by the valve assembly, open the ball valve and position the
sensor into the process at the desired depth and orientation.
8. While holding the sensor in position, tighten the hex nut of the
ferrule fitting to firmly secure the sensor in place.
NOTICE
Over-tightening the hex nut may damage the ferrule.
NOTICE
A stainless steel ferrule is available if the PTFE ferrule does not
adequately grip. When using the metallic ferrule, take care to
avoid over-tightening and damaging the sensor tube. If the
ferrule fitting leaks during insertion or retraction, replace the
O-ring in the ferrule fitting.
When the hex nut is tightened, the PTFE ferrule inside the
ferrule fitting clamps the sensor tube.
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Retract sensor with ball valve assembly PN 23240-00
WARNING
System pressure may cause the sensor to blow out with great force.
Take care when removing the sensor.
Make sure that the system pressure at the sensor is below the
maximum allowed retraction pressure for the length of sensor
you are using. For 21-in. (533.4 mm) length sensors, the
maximum allowed retraction pressure is 64 psig (5.4 barg). For
36-in. (914.4 mm) length sensors, the maximum allowed
retraction pressure is 35 psig (3.4 barg).
Wear a face shield.
Make sure your footing is stable.
Procedure
1. Push in on the sensor from the back end and slowly loosen the
hex nut of the ferrule fitting.
NOTICE
Do not remove the nut at this time.
2. When the hex nut is loose enough, slowly ease the sensor back
completely until it reaches the retraction stop collar.
NOTICE
Failure to withdraw the sensor completely may result in
damage to the sensor when the valve is closed.
3. Close the ball valve slowly. If there is resistance, the valve may
be hitting the sensor. Double check that the sensor has been
retracted to the retraction stop collar.
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WARNING
Leakage from the ferrule fitting threads may indicate that the
male connector is still under pressure. Leakage through a
partially open ball valve could be hazardous; however, with the
ball valve fully closed some residual process fluid may leak
from the connector's pipe threads.
Before removing the sensor from the ball valve, make sure
that the ball valve is fully closed.
4. Unthread the ferrule fitting completely from the reducing
coupling and remove the sensor for servicing.
NOTICE
If the ferrule fitting leaks during insertion or retraction,
replace the O-ring (PN 25394-1) in the ferrule fitting.
Install retractable sensor with ball valve assembly PN
23765-00
Contents of ball valve assembly kit (PN 23765-00)
•1¼-in. male NPT nipple
•1¼-in. ball valve
•Packing adapter (includes packing rings and busing)
•Stop ring
•Retainer
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Figure 2-7: Ball valve assembly kit (PN 23765-00) and sensor
Dimensions in drawing are in millimeters with inches below.
A. Ball valve kit, PN 23765-00
B. Knurl retainer
C. Packing adapter
D. Ball valve
E. 1¼-in. male NPT close nipple
F. Housing titanium
G. Retraction stop collar
H. Electrode housing
I. pH electrode
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Figure 2-8: Exploded view of ball valve assembly kit (PN 23765-00)
Ball valve kit (PN 23765-00) includes a 1¼-in. by 1¼-in. nipple, 1¼-in.
ball valve, and all packing adapter pieces shown.
A. Stop ring with three set screws (PN 33579-00)
B. Packing bushing (PN 4357M)
C. Packing rings (PN 9160410). Install metal ring last.
D. Retainer (PN 33577-00)
E. Packing adapter (PN 33578-00)
F. 1¼-in. NPT ball valve (PN 9340078)
G. 1¼-in. male NPT nipple (PN 4342M)
H. Retractable pH sensor
Procedure
1. Securely connect the ball valve to the process.
2. Make sure the ball valve is closed and the system pressure is
at or below the maximum rated retraction pressure for the
sensor length you are using before proceeding.
WARNING
Before removing the sensor, be absolutely certain that the
process pressure is reduced to 0 psig (0 barg) and the
process temperature is lowered to a safe level.
Do not insert or retract retractable sensors when process
pressure is above the specified retraction pressure limit for
the length of sensor being used.
For 21-in. (533 mm) length sensors the maximum allowed
retraction pressure is 64 psig (5.4 barg).
For 36-in. (914 mm) length sensors the maximum allowed
retraction pressure is 35 psig (3.4 barg).
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3. Slide the packing adapter (including packing rings and packing
bushing), stop ring, and retainer onto the sensor from the
back in the order shown in Figure 2-8.
4. Slide the stop ring to the desired position on the sensor and
tighten the stop ring set screw.
The position of the stop ring will set the distance the sensor is
inserted into the process.
5. Insert the sensor into the ball valve until it gently touches the
closed valve.
The electrode tip guard will protect the electrode glass from
breakage.
6. Securely connect the front of the packing adapter to the ball
valve.
7. Pull back hard on the sensor, as if trying to remove it, to be
certain that the sensor cannot break free of the ball valve
assembly.
The built-in retraction stop will butt against the packing
adapter.
NOTICE
The sensor must be captured by the valve assembly and
packing adapter so that it cannot be blown free by process
pressure if it is mishandled during insertion or retraction.
8. After confirming that the sensor assembly is properly secured
by the valve assembly, open the ball valve and push the sensor
into the process until the stop ring rests against packing
bushing.
9. Connect the retainer to the back of the packing adapter (hand
tighten only).
Retract sensor with ball valve assembly PN 23765-00
Prerequisites
Make sure that the system pressure at the valve is below the
maximum retraction pressure for the length of the sensor being used
before proceeding.
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WARNING
Before removing the sensor, be absolutely certain that the
process pressure is reduced to 0 psig (0 barg) and the process
temperature is lowered to a safe level.
Do not insert or retract retractable sensors when process
pressure is above the specified retraction pressure limit for the
length of sensor being used.
For 21-in. (533 mm) length sensors the maximum allowed
retraction pressure is 64 psig (5.4 barg).
For 36-in. (914 mm) length sensors the maximum allowed
retraction pressure is 35 psig (3.4 barg).
Provide adequate working area for retraction.
Procedure
1. Unscrew the retainer from the packing adapter.
If it is difficult to unscrew the retainer, system pressure may
be forcing the clamp stop ring into the retainer. The packing
bushing may not be tight enough to hold the sensor in place.
To prevent a sudden retraction of the sensor as the retainer is
removed, hold onto the back of the sensor to restrain it.
2. If the sensor does not slide back as the retainer is unscrewed,
pull from the back of the sensor to release it.
3. If you cannot retract the sensor, loosen the clamp stop ring
using the hex key. Pull the stop ring back and slowly loosen
the packing bushing in ⅛ turn increments.
System pressure may cause the sensor to retract. If the sensor
still does not retract, pull on the back of the sensor to retract
it.
4. Withdraw the sensor until the sensor guard contacts the stop
inside the packing adapter.
NOTICE
Failure to withdraw the sensor completely may result in
damage to the sensor when the valve is closed.
5. Unscrew the packing adapter from the ball valve to remove
the sensor.
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3 Wiring
The wire connections required between the sensor and transmitter
depend on the transmitter model, the sensor model, the sensor cable
color, and whether the sensor has a preamplifier.
To determine if your sensor has a preamplifier, look up the model
string description in the sensor Product Data Sheet.
For additional wiring information for your product, including wiring
diagrams for sensor and transmitter combinations not shown here
and for sensor wiring using a remote junction box and extension
cable please refer to Emerson.com/RosemountLiquidAnalysisWiring.
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3.1 Wiring diagrams for sensors with preamplifier
Figure 3-1: Rosemount 396P, 396PVP, 396RVP, 3300HTVP, 3400
HTVP, 3500P, 3500VP, 3900, or 3900VP pH/ORP Sensor with
preamplifier to Rosemount 56, 1056, 1057, or 1058 Transmitter
wiring
Figure 3-2: Rosemount 396P, 396PVP, 396RVP, 3300HTVP, 3400
HTVP, 3500P, 3500VP, 3900, or 3900VP pH/ORP Sensor with
preamplifier to Rosemount 1066 Transmitter wiring
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Figure 3-3: Rosemount 396P, 396PVP, 396RVP, 3300HTVP, 3400
HTVP, 3500P, 3500VP, 3900, or 3900VP pH/ORP Sensor with
preamplifier to Rosemount 5081 Transmitter wiring
3.2 Wiring diagrams for sensors without preamplifier
Figure 3-4: Rosemount 396P, 396PVP, 396RVP, 3300HTVP, 3400
HTVP, 3500P, 3500VP, 3900, or 3900VP pH/ORP Sensor without
preamplifier to Rosemount 56, 1056, 1057, or 1058 Transmitter
wiring
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