Reference Manual

00809-0100-3222, Rev AA
September 2018

Rosemount™ 222
Toroidal Flow Through Conductivity Sensors
2
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.

3
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Reference Manual Contents
00809-0100-3222 September 2018

Contents
Chapter 1 Description and specifications ...................................................................................... 7
1.1 Description ..................................................................................................................................... 7
1.2 Unpacking and inspection ............................................................................................................... 7
1.3 Sensor specifications ....................................................................................................................... 7
1.4 Ordering information ...................................................................................................................... 8

Chapter 2 Install ......................................................................................................................... 11

2.1 Installing the sensor ...................................................................................................................... 11

Chapter 3 Wiring ........................................................................................................................ 15

3.1 Wiring the sensor .......................................................................................................................... 15

Chapter 4 Calibration .................................................................................................................. 19

4.1 Sensor calibration ......................................................................................................................... 19

Chapter 5 Troubleshooting ......................................................................................................... 21

5.1 Troubleshooting ........................................................................................................................... 21

Chapter 6 Accessories ................................................................................................................. 23

Chapter 7 Return of Materials ..................................................................................................... 25

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Contents Reference Manual
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6 Reference Manual
Reference Manual Description and specifications
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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.

Procedure
1. Inspect the shipping container. If there is damage, contact the shipper immediately
for instructions.
2. Save the box.
3. If there is no apparent damage, unpack the container. If there is no apparent
damage, unpack the container and remove the sensor.
4. Ensure that all items shown on the packing list are present. If items are missing, If
items are missing, contact your local Customer Care representative
5. Save the shipping container and packaging.

1.3 Sensor specifications

Table 1-1: Sensor Specifications
Sensor specification Description
Wetted materials Teflon-lined carbon steel pipe, with carbon steel after
flanges; 316 stainless steel outer flange (option -21)
Process connection 1 in. 150 lb or 300 lb raised face threaded ANSI B16.5
flange
2 in. 150 lb or 300 lb raised face threaded ANSI B16.5
flange
Cable length 20 ft. (6.1 m)
Maximum cable length 100 ft. (30 m)
Cell constant (nominal) 1 in. diameter - 6/cm
2 in. diameter - 4/cm

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Table 1-2: Temperature and Pressure

Flange Temperature range Maximum pressure
150 lb 5 to 182 °C (41 to 360 °F) 125 psig (963 kPa [abs])
300 lb 250 psig (1825 kPa [abs])

Table 1-3: Pressure (For CRN Registration Only)

Option Flange Diameter Maximum pressure
-01 150 lb 1 in. 125 psig (963 kPa [abs])
-02 2 in.
-05 300 lb 1 in. 200 psig (1480 kPa [abs])
-06 2 in. 250 psig (1825 kPa [abs])
-01-21 150 lb 1 in. 125 psig (963 kPa [abs])

Table 1-4: Weight/Shipping Weight (Weights are rounded up to the nearest 1 lb or 0.5 kg)
Flange Diameter Weight Shipping weight
150 lb 1 in. 11 lb (5.0 kg) 14 lb (6.5 kg)
300 lb 17 lb (8.0 kg) 20 lb (9.0 kg)
150 lb 2 in. 33 lb (15.0 kg). 37 lb (17.0 kg)
300 lb 35 lb (16.0 kg) 40 lb (18.0 kg)

1.4 Ordering information

Table 1-5: Rosemount™ 222 Flow Through Toroidal Conductivity Sensor Ordering
Information
Model Sensor type
222 Flow Through Toroidal Conductivity Sensor
Sizes (1)
01 1 inch, 150 lb flange
02 2 inch, 150 lb flange
05 1 inch, 300 lb flange
06 2 inch, 300 lb flange
Flange option
20 No selection
21 316 stainless steel outer flange (2)
Cable type
54 Standard integral cable (3)

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Table 1-5: Rosemount™ 222 Flow Through Toroidal Conductivity Sensor Ordering
Information (continued)
Typical Model Number: 222-01-_-54

(1) Grounding rings are required for proper operation if the outer flanges of the Rosemount 222
sensor are substituted by the customer with non-conductive flanges. Order SQ 7430 and consult
the factory for pricing.
(2) Only available with option -01.
(3) Cables can be extended using remote junction box PN 23550-00 and extension cable.

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Reference Manual Install
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2 Install
2.1 Installing the sensor
Prerequisites
First, decide whether the initial calibration will be done in the shop before installing the
sensor or in the process piping after installing the sensor. For information about in-shop
and in-process calibrations, refer to the Sensor calibration section.
Note
Install the sensor in a location where it is completely filled with process liquid. A vertical
pipe run with the flow from bottom to top is best.

Procedure
1. Remove the grounding strap from the outer flanges. See Figure 2-1.
Save the strap and all the hardware for reassembly.
2. Carefully remove the nuts, bolts, insulating bushings, and washers from the flanges.
Keep them safe.
3. Separate the flange sets and remove the flange gaskets. Keep them safe.
4. Install the outer flanges on the process piping as per dimensions noted in Figure 2-2
and Figure 2-3
Use pipe joint compound or pipe tape to ensure the connections do not leak.
5. Install a ½ in. FNPT thermowell in the process piping within 6 ft. (1.8 m) of the
sensor.
For best results place the thermowell as close as possible to the sensor.
6. Put the sensor between the process mating flanges with the flange gaskets inserted
between each set of flanges.
If the process piping is lined with a non-conductive material, a metal orifice plate
(contact ring) must be installed between the flanges. Consult the factory for more
information.
7. Align the bolt holes.
8. Insert an insulating sleeve in each bolt hole. See Figure 2-1.
9. Place a metal washer on each bolt, followed by an insulating washer.
Insert the bolt through the insulating sleeve.
10. Put an insulating washer followed a metal washer on each bolt.
Note
Before tightening the bolts (step 11), be sure the flange gaskets are installed
between the system piping and the sensor and that the insulating sleeves and
washers are in place. For the sensor to operate properly, there must no metal to
metal contact between the sensor and the process piping.

11. Screw a nut onto each bolt and tighten according to torque given in Table below.

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Follow the torquing sequence shown in Figure 2-1.

Flange Torque
1 inch flange bolts 10 ft-lb (7.37 N-m)
2 inch flange bolts 25 ft-lb (18.43 N-m)

Note
Do not overtighten the bolts.

12. Connect the grounding strap between the two outer flanges using the screws and
washers removed in step 1.
If an orifice plate contact ring is being used, connect the shorting strap to the two
contact rings.
13. Install the temperature sensor in the thermowell. Use Teflon tape on the pipe
threads.
The insertion length is adjustable from 1.4 to 4.0 inches (36 to 102 mm). The
temperature sensing zone, which extends 1.3 inches (33 mm) from tip of the
sensor, must be inside the thermowell

Figure 2-1: Rosemount 222 Toroidal Conductivity Sensor/Assembly Installation

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Figure 2-2: Rosemount 222 Dimensional Drawings - Option -01 and -02

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Figure 2-3: Rosemount 222 Dimensional Drawings - Option -05 and -06

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3 Wiring
3.1 Wiring the sensor
Keep sensor wiring away from AC conductors and high current demanding equipment. Do
not cut the cable.

NOTICE
For additional wiring information on this product, please refer to the Liquid Transmitter
Wiring Diagrams.

Figure 3-1: Wire Functions

Figure 3-2: Rosemount 222 Sensor Wiring to Rosemount 1056 and 56 Transmitters

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Wiring Reference Manual
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Figure 3-3: Rosemount 222 Sensor Wiring to Rosemount 1066 Transmitter

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Figure 3-4: Rosemount 222 Sensor Wiring to Rosemount 5081 Transmitter

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Figure 3-5: Wiring Sensor Through a Remote Junction Box

Wire cable point to point. For wiring at the transmitter end, refer to the appropriate
transmitter wiring diagram.

Figure 3-6: Remote Junction Box (PN 23550-00)

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Reference Manual Calibration
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4 Calibration
4.1 Sensor calibration
The nominal cell constant of the 1 in. diameter sensor is 6/cm and the nominal cell
constant of the 2 in. diameter sensor is 4/cm. The error in the cell constant is about ±10%,
so conductivity readings made using the nominal cell constant will have an error of at least
±10%.
For higher accuracy the sensor must be calibrated. The sensor can be calibrated using a
standard solution or a previously calibrated sensor and transmitter. Calibration against a
standard solution requires that the sensor and outer flanges be removed from the process
piping. Generally it is a useful method only when the sensor is first installed. Otherwise,
the sensor should be calibrated in place against a referee sensor and transmitter.
To calibrate against a standard solution, screw a short length of metal pipe into one of the
outer flanges and cap the open end of the pipe. Stand the sensor on the capped end and
fill it with standard to the level of the upper surface of the second outer flange. Be sure the
shorting strap is connected to both flanges.
Adjust the analyzer reading to match the known conductivity of the standard. Do not
place a temperature sensor or any object inside the conductivity sensor during calibration.
Doing so will alter the measured conductivity and introduce an error in the measurement.
Once the sensor has been installed in the process piping, removing it for calibration is
impractical. In this case, calibrate the sensor against a referee sensor and transmitter,
ideally while both sensors are simultaneously measuring the same process liquid. If this is
not practical, calibrate the sensor against the results of a measurement made on a grab
sample.
For more detailed information on calibration methods, please reference application data
sheet ADS-43-025 available on the Emerson Liquid Analysis website

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Calibration Reference Manual
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5 Troubleshooting
5.1 Troubleshooting
Figure 5-1: Disconnect Wires From Transmitter Before Measuring Resistance

Table 5-1: Resistance vs. Temperature for Temperature Compensation (PT-100 RTD)
Temperature Resistance
10 °C (50 °F) 103.9 Ω
20 °C (68 °F) 107.8 Ω
25 °C (77 °F) 109.7 Ω
30 °C (86 °F) 111.7 Ω
40 °C (104 °F) 115.5 Ω
50 °C (122 °F) 119.4 Ω

5.1.1 Checking the toroid operation

Use the following procedure to check the operation of the toroids.

Procedure
1. Disconnect the shorting strap from one of the outer flanges.
The conductivity reading will drop to zero.
2. Pass a short piece of heavy gauge wire through the space between the toroid
assembly and the pipe.
3. Connect the ends of the wire to a resistance decade box.
4. Turn off temperature correction in the transmitter.

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Troubleshooting Reference Manual
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If raw conductivity is available as a temperature compensation selection, choose

raw.
If raw is not available, choose manual temperature correction and set the
temperature to 25 °C (77 °F).
5. Adjust the resistance to the values shown in the table below. See Table 5-2.
The conductivity reading displayed by the transmitter should be close to the values
shown.
Table 5-2: Resistance Values
Resistance 1-inch sensor K = 6/cm 2-inch sensor K = 4/cm
100 Ω 60 mS/cm 40 mS/cm
200 Ω 30 mS/cm 20 mS/cm

The toroids are working properly if increasing the resistance by a factor of two
causes the displayed conductivity to decrease by a factor of two.

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Reference Manual Accessories
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6 Accessories
Part number Description
2001492 Stainless steel tag (must specify marking)
23550-00 Remote junction box without preamplifier
23294-00 Interconnecting extension cable, unshielded, prepped (for use with
remote junction box)
23294-05 Interconnecting extension cable, shielded, prepped (for use with remote
junction box)
9200276 Interconnecting extension cable, shielded, unprepped (for use with
remote junction box)
2002557 Insulation kit, 1 in. 150 lb flange, 2 sets *
2002558 Insulation kit, 1 in. 300 lb flange, 2 sets *
2002559 Insulation kit, 2 in. 150 lb flange, 2 sets *
2002560 Insulation kit, 2 in. 300 lb flange, 2 sets *
8950101 Pt-100 RTD assembly

* Each insulation kit contains two flange gaskets and sufficient insulating sleeves,
insulating washers, and stainless steel washers to replace both flange seals of one sensor.
The kit does not contain flange bolts or nuts.

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7 Return of Materials
For repair and warranty inquiries, please contact Rosemount Customer Care to obtain a
Return Material Authorization (RMA) number. Drain the sensor of fluids before shipping it
back to Rosemount.

Rosemount 222 Sensors 25


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Rev. AA
2018
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