Honeywell 5000TC Series User manual

Series 5000TC
Toroidal (Electrodeless)
Conductivity Sensors
Operation and Maintenance Manual
www.honeywell.nt-rt.ru

Contents
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance iii
About This Document
Abstract
This manual describes the installation and operation of Series 5000TC Toroidal (electrodeless)
Conductivity Sensors.
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Series 5000TC Toroidal (electrodeless) Conductivity Sensors
Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 4/00iv
Symbol Definitions
The following table lists those symbols used in this document to denote certain conditions.
Symbol Definition
This CAUTION symbol on the equipment refers the user to the Product Manual for
additional information. This symbol appears next to required information in the
manual.
WARNING
PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a
potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms,
42.4 Vpeak, or 60 Vdc may be accessible. Failure to comply with these
instructions could result in death or serious injury.
ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for
handling electrostatic sensitive devices
Protective Earth (PE) terminal. Provided for connection of the protective earth (green
or green/yellow) supply system conductor.
Functional earth terminal. Used for non-safety purposes such as noise immunity
improvement. NOTE: This connection shall be bonded to protective earth at the
source of supply in accordance with national local electrical code requirements.
Earth Ground. Functional earth connection. NOTE: This connection shall be bonded
to Protective earth at the source of supply in accordance with national and local
electrical code requirements.
Chassis Ground. Identifies a connection to the chassis or frame of the equipment
shall be bonded to Protective Earth at the source of supply in accordance with
national and local electrical code requirements.

Contents
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance v
Contents
1. INTRODUCTION....................................................................................................1
1.1 Description......................................................................................................................................1
2. SPECIFICATIONS AND MODEL SELECTION GUIDE.........................................3
2.1 Specifications..................................................................................................................................3
2.1.1 Sensors.....................................................................................................................................3
2.1.2 Insertion/Removal Mounting Type*........................................................................................3
2.1.3 Basic Mounting Types.............................................................................................................4
2.2 Model Selection Guide ...................................................................................................................5
3. INSTALLATION OF MOUNTING TYPES..............................................................7
3.1 Overview.........................................................................................................................................7
3.2 Location Requirements...................................................................................................................7
3.3 Basic Mounting Types....................................................................................................................7
3.4 Insertion/Removal Sensors Mounting Types................................................................................12
4. SENSOR/INTERCONNECT CABLE TERMINATION..........................................19
5. TROUBLESHOOTING.........................................................................................23
5.1 Overview.......................................................................................................................................23
5.2 Checking the Sensor .....................................................................................................................23
5.3 Customer Assistance.....................................................................................................................23
6. MAINTENANCE...................................................................................................25
6.1 Recommended Cleaning Procedure..............................................................................................25

Series 5000TC Toroidal (electrodeless) Conductivity Sensors
Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 4/00vi
Tables
Table 3-1 Mounting Procedure ....................................................................................................................7
Table 3-2 Union Mount Procedure...............................................................................................................9
Table 3-3 Sanitary Flange Procedure.........................................................................................................11
Table 3-4 Procedure for Fastening Sensor to Extractor Shaft....................................................................13
Table 3-5 Procedure for Setting Sensor Insertion Depth ...........................................................................14
Table 3-6 Procedure for Installing Hardware into Process Pipe/Vessel....................................................16
Table 3-7 Procedure for Installing Sensor into Hardware Assembly.........................................................16
Table 3-8 Procedure for Inserting Sensor into Pressurized Process ..........................................................17
Table 3-9 Procedure for Extracting Sensor from Pressurized Process ......................................................18
Table 4-1 Termination Procedure for All Applications Except CE...........................................................20
Table 4-2 Termination Procedure for CE-only Applications.....................................................................21
Table 5-1 Sensor Troubleshooting Procedure............................................................................................23
Table 6-1 Cleaning Procedure....................................................................................................................25
Figures
Figure 2-1 HW Sensor and Mounting Hardware Combinations*................................................................4
Figure 3-1 Immersion Mounting Details......................................................................................................8
Figure 3-2 Tee Mounting Details...............................................................................................................10
Figure 3-3 Flange Mounting Details ..........................................................................................................10
Figure 3-4 Sanitary (CIP) Flange Mounting Details..................................................................................12
Figure 3-5 Insertion/Removal Mounting Details for Toroidal Sensors .....................................................13
Figure 3-6 Insertion/Removal Mounting Details for Toroidal Sensors .....................................................15
Figure 4-1 Standard Termination Details (for All Applications Except CE).............................................20
Figure 4-2 CE Termination Details (for CE-only Applications)................................................................21

Introduction
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 1
1. Introduction
1.1 Description
Mounting Styles
The Model 5000TC-series toroidal (electrodeless) conductivity sensor measures the conductivity of solutions from
0.2 to 2000 millisiemens/cm.
These sensors may be provided in one of two basic forms:
Convertible Style -- The convertible style sensor can be directly fastened to the end of a pipe for
immersion mounting or, by using the Honeywell union-mount adapter, it can be mounted into any standard
2-inch NPT fitting (tee, weldolet, pipe saddle, etc.). The convertible style sensor can also be insertion
mounted into a 2-inch ball valve assembly.
Sanitary Style -- This clean-in-place style sensor is constructed of 3A-approved materials. It has an integral
2-inch sanitary-mount flange which mates to Honeywell sanitary tee mounting hardware. The sanitary style
sensor includes a special cap and EPDM compound gasket. The gasket is also available separately for
mounting to a 2-inch sanitary clamp-type ferrule or butt-weld tee.
Mounting Types
The 5000TC sensors are available with a number of different mounting types. These include immersion
mounting (CPVC or PVDF materials, also PVC junction box), union adapter mounting (316 SS, CPVC, or
PVDF materials with optional 2”tee), sanitary mounting (316 SS 2”tee with heavy-duty clamp), or
insertion/removal mounting (316 SS or CPVC materials).
Wetted Materials
To simplify chemical resistance problems, these sensors are constructed so that only one material is wetted
by the process. The sanitary style sensor may be provided in polypropylene, PVDF or PFA Teflon material.
The convertible style sensor is also available in these same materials, and also in PEEK.

Specifications and Model Selection Guide
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 3
2. Specifications and Model Selection Guide
2.1 Specifications
2.1.1 Sensors
Wetted Materials........................Polypropylene, PVDF, or PEEK
Operating Temp. Range ............-10 °C to 125 °C (14 °F to 257 °F)
Maximum Flow Rate ..................10 ft. (3 m) per second
Measuring Range.......................From 0.2 to 2000 millisiemens/cm
Temperature Compensator........Pt 1000 RTD
Sensor Cable.............................5 conductor (plus two isolated shields) cable with XLPE (cross-linked polyethylene)
jacket; rated to 150 °C (302 °F); 20 ft. (6 m) long
Pressure/Temperature Limits:
Sensor Only (no hardware):
Polypropylene .................100 psi at 212 °C (6.9 bar at 100 °C)
PVDF...............................100 psi at 248 °C (6.9 bar at 120 °C)
PEEK...............................200 psi at 302 °F (13.8 bar at 150 °C)
PFA Teflon......................200 psi at 302 °F (13.8 bar at 150 °C)
2.1.2 Insertion/Removal Mounting Type*
Wetted Materials........................Plastic Hardware: Brass, CPVC, Teflon Valve Seats, Viton O-ring Seals
Stainless Steel Hardware: 316 Stainless Steel, Teflon Valve seats, Viton O-ring
seals
Temperature Limits....................Plastic Hardware: 23 °F to 176 °F (-5 °C to 80 °C) unsupported if installed vertically;
23 °F to 203 °F (-5 °C to 95 °C) when supported with a bracket**
Stainless Steel Hardware: 23 °F to 203 °F (-5 °C to 95 °C) supported or
unsupported
Pressure Limits..........................Plastic Hardware: 50 psi @ 90 °C
Stainless Steel Hardware: 100 psi @ 90 °C
Net Hardware Weight ................Plastic Hardware: 7.5 lb. (3.4 kg)
Stainless Steel Hardware: 25 lb. (11.3 kg)
*These sensor/mounting hardware assembly temperature ratings are limited by the hardware material, maximum
pressure, and whether the assembly is supported or unsupported.
**The CPVC insertion/removal assembly must be supported with a bracket or strap if it is not installed vertically.

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Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 4/004
2.1.3 Basic Mounting Types
Figure 2-1 HW Sensor and Mounting Hardware Combinations*
*Ratings for the above Honeywell sensor and mounting hardware combinations are based upon water
service. More severe service may require a correction factor.
▲Sanitary mounting hardware ratings are for 51451248-001 hardware using the 51451257-001 heavy duty
sanitary clamp. Other hardware and clamp combinations may reduce the listed ratings.

Specifications and Model Selection Guide
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 5
2.2 Model Selection Guide
51-52-16-54
Issue 1
Instructions
Make one selection from Table I through IV
A dot ( ) denotes unrestricted availability.
5000TC Series Offers:
Toroidal (Electrodeless) Conductivity Sensor with 1/2" Nominal Diameter Bore
Mounting Types:
Immersion Mount with Pipe and Junction Box
Union Mount with Optional Pipe Tee
Sanitary Tee with Clamp
Insertion/Removal Mounting
Standard CE Approval
Cable Length - 20 Feet
1000 Ohm Platinum RTD
Key Number I II III
_ _ _ _ _ _ - _ _ - _ - _ _ _
KEY NUMBER Selection Availability
Description
Toroidal (Electrodeless) Conductivity Probe 5000TC
TABLE I
Mounting No Mounting Assembly 00
Material CPVC Pipe, PVC Junction Box
51451240-001
11
Type PVDF Pipe, PVC Junction Box
51451241-001
12
316 SS Union Adapter & Standard 2" Tee
51451242-001
21
316 SS Union Adapter Only
51451243-001
22
CPVC Union Adapter & Standard 2" Tee
51451244-001
23
CPVC Union Adapter Only
51451245-001
24
PVDF Union Adapter & Standard 2" Tee
51451246-001
25
PVDF Union Adapter Only
51451247-001
26
316 SS Sanitary 2" Tee & Heavy-Duty Clamp
51451248-001
31
316 SS Insertion/Removal Device
51451249-001
41
CPVC Insertion/Removal Device
51451250-001
42
TABLE II
Sensor No Sensor 0
Material Convertible Polypropylene Sensor
51451251-001
1a
Type Convertible PVDF Sensor
51451252-001
2a
Convertible PEEK Sensor
51451253-001
3a
Convertible PFA Teflon Sensor
51451254-001
4a
Sanitary Polypropylene Sensor
51500150-001
5b
Sanitary PVDF Sensor
51500151-001
6b
Sanitary PFA Teflon Sensor
51500152-001
7b
TABLE III
Future None 000

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ACCESSORIES
51451255-001 6-Conductor Interconnect Cable
51451256-001 6-Conductor Junction Box (comes standard with immersion hardware)
51451257-001 Spare Sanitary Clamp (standard with option 31 from Table I)
51451258-001 Spare Special Cap (standard with option 31 from Table I)
51451259-001 Spare Sanitary Gasket (standard with option 31 from Table I)
RESTRICTIONS
Restriction Available Only With Not Available With
Letter Table Selection Table Selection
aI31
bI31

Installation of Immersion, Sanitary or Union Mounting
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 7
3. Installation of Mounting Types
3.1 Overview
This section describes the installation requirements and procedures for the 5000 TC toroidal probes and
associated mountings.
3.2 Location Requirements
Locate the sensor as close as possible to the measuring instrument in order to minimize electrical
interference and signal loss.
REFERENCE
When indirectly wiring the sensor to the instrument with interconnect cable and a junction box, use only
Honeywell cable part number 51451255-001. If a different cable is used, it must have equivalent
construction: five conductors and two separate isolated shields -- one shielding the signal, and one
shielding the overall cable. These specific cable characteristics protect the measurement signal from
electromagnetic interference. Using a cable with different construction may interfere with the measurement
system’s performance.
3.3 Basic Mounting Types
Regardless of the mounting method, always use Teflon tape on the sensor and mounting hardware threads to
avoid leaks. Do not use pipe sealant.
Immersion (no adapter needed)
The convertible style sensor may be immersion mounted by threading it onto the end of a pipe of an
appropriate length (Figure 3-1).
Table 3-1 Mounting Procedure
Step Action
1Screw a 3/4 x 1/2-inch NPT reducer coupling onto the cable end of the sensor. Use an adjustable or
open-end wrench on the flatted section below the sensor threads to carefully tighten the connection
to prevent leaks.
CAUTION
Do not tighten the sensor connection by holding and turning the “doughnut-shaped”end of the sensor. This
could crack the sensor body.
2Route the sensor cable through a 1/2-inch diameter mounting pipe of an appropriate length. Screw
the pipe onto the reducer coupling.
3Fasten the pipe-mount junction box onto the 1/2-inch NPT threads of the mounting pipe.
4Route the sensor cable into the junction box. If the cable is too long, cut it to just the length needed
which minimizes electromagnetic interference. Then very carefully re-terminate the sensor wires and
shields by following the procedure described in Section 4.

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Step Action
5Route the interconnect cable from the junction box to the instrument. If the cable is too long, cut it to
just the length needed which minimizes electromagnetic interference. Then very carefully terminate
the wires and shields of the interconnect cable by following the procedure described in Section 4.
Recommendation: Run the interconnect cable in 1/2-inch or larger flexible, metal conduit to protect
it from moisture and mechanical damage. The flexible conduit must be long enough to allow the
sensor to be removed from the process for maintenance and calibration.
ATTENTION
Do not route the interconnect cable in any conduit containing ac power wiring (“electrical noise”may interfere
with the sensor signal).
6Refer to the instructions in the instrument manual for connecting the sensor and interconnect cable
wires in the junction box, and for connecting the other end of the interconnect cable to the
instrument.
7Fasten the cover onto the junction box.
8Before mounting the sensor/hardware assembly into the process, calibrate the measurement system
with conductivity reference solution using the procedure in the instrument instruction manual.
This completes the sensor mounting using the special Honeywell immersion mounting.
Figure 3-1 Immersion Mounting Details

Installation of Immersion, Sanitary or Union Mounting
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 9
Union Mount (for Tee, Weldolet, Pipe Saddle, etc.)
The convertible style sensor may be mounted in any standard 2-inch NPT fitting (pipe tee, weldolet, pipe
saddle, etc.) by using a special Honeywell union-mount adapter.
Table 3-2 Union Mount Procedure
Step Action
1Install a standard 2-inch NPT fitting (pipe tee, weldolet, pipe saddle, etc.) into the process line.
Preferably, the fitting should be made of a material to provide a suitable maximum
pressure/temperature rating for the application. Refer to Subsection 2.1 for specifications.
2Fasten the special short nipple of the Honeywell union-mount adapter into the 2-inch NPT fitting.
Carefully tighten the threaded connection to prevent leaks. Figure 3-2 and Figure 3-3 respectively
show pipe tee and flange mounting details.
3Route the sensor cable through the cord grip of the Honeywell union-mount adapter, and tighten the
sensor into the adapter’s flanged piece.
4Wire the sensor directly to the instrument or indirectly using interconnect cable and a junction box. In
either case, make sure that the sensor or interconnect cable is cut to the proper length to minimize
electromagnetic interferences.
A Make sure to very carefully terminate the wires and shields of the respective cable(s) by
following the procedure described in Section 4.
B Refer to the instructions in the instrument manual to electrically connect the sensor to the
instrument.
5Before mounting the sensor into the process line or vessel, calibrate the measurement system with
conductivity reference solution using the procedure in the instrument instruction manual.
6After calibration, mount the sensor into the installed 2-inch NPT fitting:
A Properly seat the gasket into its mating groove on the special short nipple of the Honeywell
union-mount adapter.
B Carefully place the sensor into the short nipple, making sure the gasket is in place and
contacting the adapter’s flanged surface.
C Tighten the union-mount adapter lock-ring onto the special short nipple to secure the
connection.
This completes the sensor mounting using the special Honeywell union-mount adapter.

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Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 4/0010
Figure 3-2 Tee Mounting Details
Figure 3-3 Flange Mounting Details

Installation of Immersion, Sanitary or Union Mounting
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 11
Sanitary Flange
The sanitary style sensor may be clamp-mounted for clean-in-place applications by using a sanitary clamp-
type tee or ferrule and a heavy duty clamp (Figure 3-4).
Table 3-3 Sanitary Flange Procedure
Step Action
1Install a 2-inch sanitary clamp-type tee or ferrule into the process line or vessel.
2Route the sensor cable through the hole in the stainless steel endcap so that the endcap’s taper
faces towards the top surface of the integral sensor flange.
3Wire the sensor directly to the instrument or indirectly using interconnect cable and a junction box. In
either case, make sure that the sensor or interconnect cable is cut to the proper length to minimize
electromagnetic interference.
A Make sure to very carefully terminate the wires and shields of the respective cable(s) by
following the procedure described in Section 4.
B Refer to the instructions in the instrument manual to electrically connect the sensor to the
instrument.
4Before mounting the sensor into the process line or vessel, calibrate the measurement system with
conductivity reference solution using the procedure in the instrument instruction manual.
5After calibration, mount the sensor into the sanitary tee or ferrule:
A Properly seat the sanitary gasket onto the mating surface of the tee or ferrule.
B Carefully place the sensor into the tee or ferrule, making sure the gasket is in place and
contacting the bottom surface of the integral sensor flange.
C Place the stainless steel endcap onto the top surface of the integral sensor flange and secure
the sensor onto the tee or ferrule with the heavy duty clamp. Tighten wing nut on the heavy
duty clamp to 25 inch-lbs. torque. If the sensor is installed in a temperature cycling process, the
wing nut may need to be periodically re-tightened.
CAUTION
Steam sterilization is not recommended for cleaning the Honeywell sanitary style electrodeless conductivity
sensor.
This completes the sensor mounting using a sanitary clamp-type tee or ferrule and a heavy duty clamp.

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Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 4/0012
Figure 3-4 Sanitary (CIP) Flange Mounting Details
3.4 Insertion/Removal Sensors Mounting Types
Location Requirements
Mount the sensor vertically with electrodes pointing downward. If the sensor must be installed on an angle,
it should be at least 15°above horizontal. Other mounting angles may cause erratic measurement readings.
Mounting
When following the instructions in this section, refer to Figure 3-5 or Figure 3-6. The instructions refer to
specific component parts that are identified by letter designations in the respective figures.
ATTENTION
Use Teflon tape on all sensor and mounting hardware threads to avoid leaks. (If using pipe sealant with
Teflon, Locktite No. 59321 or equivalent, it may not provide an adequate seal at higher solution
temperatures.)

Installation of Immersion, Sanitary or Union Mounting
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 13
Fastening Sensor to Extractor Shaft
Table 3-4 Procedure for Fastening Sensor to Extractor Shaft
Step Action
1Remove the extractor shaft from the insertion hardware assembly by unscrewing the retaining cap
(item G) and then the lock ring (item F).
2Disregard the small, plastic cylindrical spacer that is tie-wrapped to the insertion hardware assembly.
3After loosening the cable grip on the end of the extractor shaft, route the sensor cable through the
extractor shaft.
4Screw the extractor shaft into the sensor, and then tighten the cable grip.
Figure 3-5 Insertion/Removal Mounting Details for Toroidal Sensors

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Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 4/0014
Setting Sensor Insertion Depth
The sensor insertion depth is the distance that the sensor electrodes extend beyond the threaded end of the
insertion hardware assembly. The sensor insertion depth, shown in Figure 3-5 or Figure 3-6, is factory set to
the maximum distance of:
•3.0 inches for standard style sensor/hardware
In some cases the application may require the insertion depth distance to be reduced. Carefully determine
the required insertion depth before installing the hardware.
CAUTION
Do not exceed the factory-set maximum insertion depth which may damage the sensor.
If the factory-set insertion depth is sufficient, disregard this procedure, and install the insertion hardware
assembly into the process pipe/vessel (Table 3-6). If the depth needs adjusting:
Table 3-5 Procedure for Setting Sensor Insertion Depth
Step Action
1Loosen the two set screws on the metal inner collar (item E) located at the back end of the extractor
shaft.
2Slide the collar towards the sensor to reduce the insertion depth as needed.
NOTE: Reduce the insertion depth minimally. Optimum sensor performance depends upon the
sensor electrodes being fully inserted into the process.
3Tighten the two set screws to secure the metal inner collar (item E) to the extractor shaft.

Installation of Immersion, Sanitary or Union Mounting
4/00 Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 15
Figure 3-6 Insertion/Removal Mounting Details for Toroidal Sensors

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Series 5000TC Toroidal (electrodeless) Conductivity Sensors - Operation and Maintenance 4/0016
Installing Hardware into Process Pipe/Vessel
Mount the insertion hardware assembly into a portion of the process pipe or vessel where air cannot be
trapped and subsequently contact the toroidal sensors.
Table 3-6 Procedure for Installing Hardware into Process Pipe/Vessel
Step Action
1Install a 2-inch NPT female fitting (tee or flange) into the process pipe or vessel.
2Screw the insertion hardware assembly’s 2-inch NPT nipple (item A) into the mounted fitting.
Securely tighten the connection.
3Connect a water line to the insertion hardware assembly.
4Follow steps a through c to counterbalance pressure
a To help counterbalance the pressure of the process during insertion and extraction, and to
clean the insertion assembly with an internal water flush, connect a 1/4-inch water line to the
1/4-inch tube fitting on the insertion hardware assembly.
b Install a hand-operated shutoff valve upstream of the hardware’s 1/4-inch tube fitting to control
the flow of water.
c Install a check valve in the water line to prevent process solution from surging into the water
line should the process pressure exceed the water pressure.
CAUTION: THE WATER LINE PRESSURE MUST BE GREATER THAN THE PROCESS
PRESSURE, BUT CANNOT EXCEED 100 PSI.
5Turn the insertion hardware ball valve (item B) to the fully closed position.
6Start the process flow.
Installing Sensor into Hardware Assembly
After calibration, install the sensor/extractor shaft assembly into the mounted insertion hardware assembly.
Table 3-7 Procedure for Installing Sensor into Hardware Assembly
Step Action
1With the ball valve (item B) fully closed and the sensor/extractor shaft assembly extracted
approximately halfway, insert the sensor/shaft assembly into the valve housing (item C) until the
surface of the flanged bushing (item D) presses against the O-ring on the housing. Make sure that
the O-ring is properly seated.
2Tighten the lock ring (item F) onto the valve housing.