Honeywell 4909 CPVC User manual

4909 CPVC Conductivity Cell
Insertion/Removal Assembly
Operations Manual
70-82-25-19
Rev. 1
7/99

ii 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99
Copyright, Notices, and Trademarks
Printed in U.S.A. – © Copyright 1999 by Honeywell Inc.
Revision 1– 7/99
While this information is presented in good faith and believed to be
accurate, Honeywell disclaims the implied warranties of
merchantability and fitness for a particular purpose and makes no
express warranties except as may be stated in its written agreement
with and for its customer.
In no event is Honeywell liable to anyone for any indirect, special or
consequential damages. The information and specifications in this
document are subject to change without notice.
Honeywell
Industrial Automation and Control
Automation College
2820 West Kelton Lane
Phoenix, AZ 85023
[phone]

7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual iii
About This Document
Abstract
The purpose of this document is to support the installation operation and maintenance of the 4909 CPVC
Conductivity Cell Removal/Insertion Assembly.
Revision Notes
The following list provides notes concerning all revisions of this document.
Rev. ID Date Notes
0 11/96 This revision is the initial release of the Honeywell version of the L&N manual
p/n 277731 Rev. E1. There were no major changes to the L&N version when
it was Honeywellized.
1 6/99 Edits were made to standardize terminology and to add the new Model
Selection Guide.
References
Honeywell Documents
The following list identifies all Honeywell documents that may be sources of reference for the material
discussed in this publication.
Document Title ID #
9782 Series Conductivity/Resistivity Analyzer/Controller Operator’s Manual 70-82-25-74
7079-17 Two-Wire Transmitter for Conductivity/Resistivity Operation and
Maintenance Manual 70-82-25-51
Non-Honeywell Documents
The following list identifies select non-Honeywell documents that may be sources of reference for the
material discussed in this publication.
Title Author Publisher ID/ISDN #
Contacts
The following list identifies important contacts within Honeywell.

iv 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99
Organization Telephone Address
Honeywell TAC 1-800-243-9883 Voice 1100 Virginia Drive
Fort Washington, PA 19034

7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual v
Contents
1. INTRODUCTION....................................................................................................1
1.1 Overview.........................................................................................................................................1
1.2 4908 Conductivity Cell...................................................................................................................1
1.3 31074357 Removal Device............................................................................................................2
2. SPECIFICATIONS AND MODEL SELECTION GUIDE.........................................7
2.1 Specifications..................................................................................................................................7
Cell Constants....................................................................................................................................7
Electrode Material.............................................................................................................................7
Wetted Parts.......................................................................................................................................7
Pressure and Temperature (See Fig. 1-1) ..........................................................................................7
Maximum Pressure............................................................................................................................7
Mounting ...........................................................................................................................................7
Purge Port..........................................................................................................................................7
Insertion Depth..................................................................................................................................7
Electrical Connections.......................................................................................................................7
Integral Automatic Temperature Compensation ...............................................................................8
Leadwire............................................................................................................................................8
Weight ...............................................................................................................................................8
2.2 Model Selection Guide ...................................................................................................................8
...........................................................................................................................................................8
3. INSTALLATION...................................................................................................11
3.1 Requirements ................................................................................................................................11
3.2 Location and Position ...................................................................................................................11
Considerations.................................................................................................................................11
3.3 Prepare Assembly .........................................................................................................................12
Initial Prep .......................................................................................................................................12
Mounting into the Process...............................................................................................................12
3.4 Insertion ........................................................................................................................................13
3.5 Removal........................................................................................................................................14
3.6 Electrical Connections..................................................................................................................14

vi 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99
4. MAINTENANCE AND REPLACEMENT PARTS .................................................17
4.1 To Clean The Cell.........................................................................................................................17
4.2 Replacing Removal Device Parts..................................................................................................17
Ball Valve........................................................................................................................................17
Nipples.............................................................................................................................................17
Bushing And Washer.......................................................................................................................17
4.3 Replacement Parts.........................................................................................................................18
5. PLATINIZATION AND PLATINUM BLACK.........................................................19

7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual vii
Tables
Table 4-1 Replacement Parts __________________________________________________________ 18
Table 4-2 Voltage and Time Limits for Platinizing Cells ____________________________________ 18
Figures
Figure 1-1 Temperature/Pressure* Range__________________________________________________ 2
Figure 1-2 4909 CPVC Conductivity Cell Insertion/Removal Assembly with Conductivity Cell Installed3
Figure 1-3 4909 CPVC Conductivity Cell Insertion/Removal Assembly with Universal Head_________ 3
Figure 1-4 4908 Conductivity Cell _______________________________________________________ 4
Figure 1-5 31074357 Removal Device ____________________________________________________ 4
Figure 1-6 Universal Head _____________________________________________________________ 5
Figure 3-1 Outline and dimension drawing for 4909-X-X-X-X-03-X-X Conductivity Cell, Insertion Type
with CPVC Removal Device _______________________________________________________ 15
Figure 3-2 Outline and Dimension drawing for 4909-X-X-X-X1-03-X-X Conductivity Cell, Insertion
Type with CPVC Removal Device and Universal Head __________________________________ 16
Figure 5-1 Installation Diagram-Cat. 4909 Cells with Junction Box Head Connected to 7082
Conductivity/Resistivity Analyzer___________________________________________________ 20
Figure 5-2 Installation Diagram-Cat. 4909 Cells with Junction Box Head Connected to 9782
Conductivity/Resistivity Analyzer___________________________________________________ 21
Figure 5-3 Installation Diagram-Cat. 4909 Cells with 7 or 20 Foot Leads Connected to 7082
Conductivity/Resistivity Analyzer___________________________________________________ 22
Figure 5-4 Installation Diagram-Cat. 4909 Cells with 7 or 20 Foot Leads Connected to 9782
Conductivity/Resistivity Analyzer___________________________________________________ 23

Introduction
7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 1
1. Introduction
1.1 Overview
The 4909 Conductivity Cell Insertion/Removal Assembly is designed for use in a pipeline or closed vessel
where it is desirable to remove the cell for inspection and maintenance without shutting down the system
and releasing the pressure. The assembly comprises a 4908 Conductivity Cell and a 31074357 Removal
Device which are shown assembled in Figs. 1-2 and 1-3. It is to be used in applications for which
maximum pressure does not exceed 125 psig, and can be reduced to 50 psig during insertion and removal of
the cell. Maximum operating temperature is determined by the temperature compensator range. Do not use
in solutions above 80°C.
The depth of insertion is given in Figs. 3-1 and 3-2.
The conductivity cell is made of polyethersuflone (PES), which is resistant to most corrosive inorganic
chemicals over a wide range of temperatures (common exceptions are chlorinated hydrocarbons and
ketones). Sample solutions come into contact with the PES and the platinum or nickel electrode surface of
the cell. (Any cell constant can be supplied with either electrode material). The only materials of the 4909
Assembly with which the sample solution may come into contact are in the removal device which is
comprised of CPVC plastic, Teflon, EPDM and Viton materials. The automatic temperature compensator
may be built into the cell as shown in Section 2.2, Model Selection Guide.
CAUTION
Specific parameters of your process may prohibit the use of nickel electrodes. For example, always use a
platinum cell (Table II = 44) if the cell will measure or be exposed to regeneration acids or bases.
1.2 4908 Conductivity Cell
The molded conductivity cell and its one-inch diameter by 3-inch long adapter comprise a one piece cell
unit and are made of polyethersulfone (PES). This adapter serves as a stop during the removal operation.
The cell can be supplied with a two, three or four conductor, Tefzel-sheathed cable, Fig. 1-2. Either of two
different lengths of cable can be furnished as specified in the Model Selection Guide (MSG) number, see
Section 2.2, Model Selection Guide. Or the insertion/removal assembly can be supplied with a Universal
Head, Fig. 1-3.
The cells having constants of 5, 10, 20, 25 or 50 cm-1 are intended for making measurements in highly
conductive solutions. They differ in construction from those having constants of 0.01, 0.1, or 1. On the 5
to 50 constant cells, the electrodes are short tubes located midway inside the two parallel tubular channels
that run lengthwise through the cell, and are open to the sample at both ends of the cell. The channels are
larger on the 25 constant cell and they are elliptical on the 5 and 10 constant cell. The 0.01, 0.1, and 1.0
constant cells have a removable cell guard which is screwed onto the cell body to protect the electrode
surfaces. Cells with a guard tube must be used with the guard in place or the cell constant may differ from
that specified. Electrodes are three discs on the 1 constant cell, parallel plates on the 0.1 constant cell, and
a pair of concentric wires wound on the cell body on the 0.01 constant cell.

4909 CPVC Conductivity Cell Insertion/Removal Assembly Operations Manual
24909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99
1.3 31074357 Removal Device
This device consists of a ball valve which is connected to the closed system by a 1-1/2 inch CPVC schedule
80 mounting nipple and to a housing by a 6 inch long schedule 80 CPVC nipple into which the support tube
for the cell mounting is inserted. The compression handle provides a seal around the cell support tube.
Depending on the Key Number selected in Section 2.2, MSG, the 31074357 Removal Device may or may
not include the 4908 Cell preinstalled in the device.
If Key Number 04908 is selected, the 4908 Cell (Fig. 1-4) is shipped apart from the removal device.
If Key Number 04909 is selected, the 4908 Cell is preinstalled into the removal device, Fig. 1-3. Details of
each type of installation are given in Section 3.3.
130
120
110
100
90
80
70
60
50
40
30
20
10
0-10 -5 0 10 20 30 40 50 60 70 80
PSIG
DEGREES CELSIUS
a
/
n23349
Figure 1-1 Temperature/Pressure* Range
* 50 psig max. during insertion or removal of 4908 cell.

Introduction
7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 3
1/4" NPT Plug
Cable
1-1/2" NPT Nipple
Conductivity Cell Purge Port Compression Handle
Support Grip
Cable Grip
Housing
6" Nipple
Valve
Adapter (Contains Automatic Temperature Compensator when Specified)
a
/
n23350
Figure 1-2 4909 CPVC Conductivity Cell Insertion/Removal Assembly
with Conductivity Cell Installed
Universal Head Assembly
a/n 23351
Figure 1-3 4909 CPVC Conductivity Cell Insertion/Removal Assembly with Universal Head

4909 CPVC Conductivity Cell Insertion/Removal Assembly Operations Manual
44909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99
Cable
Conductivity
Cell
Adapter *
* Automatic Temperature Compensator,
when specified by catalog number, is
mounted inside adapter.
a
/
n23352
Figure 1-4 4908 Conductivity Cell
Tighten securely to pipe
Do not nick
outside of
support tube
Note: Apply a thin film of Silicone grease
to all surfaces of bushing and to
diameter of support tube as shown.
These parts should be
hand-tightened only
Apply teflon tape to
both ends of support
tube. Tighten all pipe
thread fittings two turns
beyond hand tight.
Modify per sketch*
Apply grease
(See Note above)
Slice through one
side as shown
a
/
n23353
*
Compression
Bushing
Figure 1-5 31074357 Removal Device

Introduction
7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 5
AD
CB
Terminal
Board
Assembly
#6-32
Binding Head
Screw &
Washer
View of Base
with Cap Removed
Nipple (3/4" NPT) Base
Set Screw
Gasket Cap
#6-32 Screw
Chain
#6-32 Screw
Wire
CONDUCTIVITYCELL
a
/
n23354
Figure 1-6 Universal Head

4909 CPVC Conductivity Cell Insertion/Removal Assembly Operations Manual
64909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99

Specifications and Model Selection Guide
7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7
2. Specifications and Model Selection Guide
2.1 Specifications
Cell Constants
0.01, 0.1,1.0, 5, 10, 20, 25 and 50 cm-1.
Electrode Material
Nickel or Platinum, as specified.
Wetted Parts
Cell Body: Polyethersulfone (PES).
Electrodes: See above.
Mounting Materials: Chlorinated Polyvinyl Chloride (CPVC).
Internal Sealing Materials: Viton, Teflon & EPDM
Pressure and Temperature (See Fig. 1-1)
125 psig (862 kPa) max. @ 23°F (-5°C)
90 psig (621 kPa) max. @ 122°F (50°C)
50 psig (345 kPa) max. @ 176°F (80°C)
Maximum Pressure
During Insertion or Removal: 50 psig.
Mounting
1-1/2” NPT male pipe. Overall length of removal device: approximately 20 or 22 inches (allow additional
clearance for cell withdrawal). See Figs. 3-1 and 3-2.
Purge Port
1/4” NPT female opening.
Insertion Depth
Varies between 4.5” and 6.8” nominal, depending upon cell constant. Greater insertion depths are optional.
See Figs. 3-1 and 3-2.
Electrical Connections
Three leads with integral automatic temp. compensator. Two leads without integral automatic temp.
compensator. Four leads with integral automatic temp. compensator)Table III = 333).

4909 CPVC Conductivity Cell Insertion/Removal Assembly Operations Manual
84909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99
Integral Automatic Temperature Compensation
Refer to Section 2.2 – Model Selection Guide
Leadwire
Tefzel covered, 18-gage cable (7 feet, 20 feet, or Universal Head, as specified).
Weight
Approximately 3.5 lb (1.6 Kg) (including cell).
2.2 Model Selection Guide
KEY NUMBER Selection Availability
Description
04909 Complete Conductivity Cell Assembly (Note 2)
(Note 3)
04909
04908 Replacement Cell Only (Note 1)
(Note 3)
04908
TABLE
I
0.01 001
0.1 X01
Cell Constant 1 XX1
5 XX5 gg
10 X10
20 X20 gg
25 X25
50 X50
TABLE II Electrode Material Nickel 33
Platinum 44
TABLE III
Automatic Temperature Compensator (ATC)
No Temperature Compensator 000
Available for 9782 and 7082 Only 333 ff
009
013
014
071
Available for 7079C Transmitter or already withdrawn analytical 072
073
instrumentation.
(
Re
f
er to Tables 1 and 6 under
S
teps to
S
electing 074
088
Appropriate
C
onductivity Instrumentation &
C
ells
f
or available 090
091
Temp. Compensator/Conductivity range.) 093
113
114
160
164
168

Specifications and Model Selection Guide
7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 9
049
TABLE IV Selection 09 08
Leadwire Length ’7 ft. Leadwire X7
20 ft. Leadwire 20
Junction Head (Aluminum) X1
TABLE V
Valve/Cell Material Material
4909 Stainless Steel (SS) Valve Includes SS Valve assembly and 02 c
Assembly Standard insertion cell
4908 PES Replacement Cell for Standard insertion cell only 02 c
4909 SS Valve Assembly
4909 CPVC Valve Assembly Includes CPVC assembly and 03 d
standard CPVC Support tube
(15 3/8") and cell
4908 PES Replacement Cell for Cell only 03 d
CPVC Valve Assembly
TABLE VI
Special Mounting Options - select one option per unit
None 000
SS support tube for 4909 SS Valve 930 e
assemblies only. Use Table V
Option = 02
4908 replacement cells for 4909 SS 930 e
Valve Assembly containin
g
SS Support
tube. Use Table V Option = 02
Special insertion lengths for new/ Uses special insertion cell to 910 hh
replacement cells for 4909 SS increase standard insertion
Valve Assemblies. Only available cell depth by 4.4"
for Table V Option = 02 Uses special insertion cell to 920
increase standard insertion
cell depth by 8.8" (Note 4)
Uses special insertion cell to 925
increase standard insertion
cell depth by 13.2" (Note 4)
Uses special insertion cell to 940 hh
decrease standard insertion
cell depth by 4.4"
Extended Length CPVC Support tube. Supplies special CPVC 950 j
Only available for Table V Option = 03 support tube (21 3/8") to
increase cell insertion depth
by 6.0" in a new CPVC Valve
Assembly. Note: Allow
additional 6.0" for cell removal

4909 CPVC Conductivity Cell Insertion/Removal Assembly Operations Manual
10 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99
049
TABLE VII - OPTIONS
Tagging None 0_
Linen L_
Stainless Steel S_
Certificate of Calibration No _ 0
Yes _ 1
Notes:
1. Replacement cells only, caution look at Restrictions for insertion depth dimensions based on valve
assembly type.
2. When converting from 4806 to 4909, order 4908 directly.
3. Replacement 4908 cells for existing 4908’s and 4909’s manufactured before 8/85 must specify Table V = 02.
4. This option is application sensitive. You must contact Analytical Instruments Marketing for approval.
RESTRICTIONS
Restriction Letter Available Only With Not Available With
Table Selection Table Selection
cV Standard insertion cell for SS valve assemblies consists of a conductivity
cell of variable length based on the cell constant and a 13.2" PES tube
molded to the cell. The conductivity cell insertion depth is listed below:
001, X01, XX1 = 7.5"
XX5 = 6.5"
X10 = 7.7"
X20 = 8.0"
X25, X50 = 8.8"
dV Standard conductivity cell insertion depth dimensions according to cell
constants for CPVC assemblies is listed below:
001, X01, XX1 = 5.5"
XX5 = 4.5"
X10 = 5.7"
X20 = 6.0"
X25, X50 = 6.8"
eV 02 I X25, X50
fIII For 9782 and 7082 Analyzers only
gI Not for 9782 and 7082 Analyzers
hV02
j
V03

Installation
7/99 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 11
3. Installation
3.1 Requirements
To insure that a representative sample is being measured at all times, the solution must move through and
completely purge out the cell channels or guard tube. If the measurement is made in a rapidly moving
liquid, the existing circulation of the solution can be utilized by mounting the assembly as described in the
next section so that the flow of the solution forces liquid through the cell. However, when measurements
are to be made in quiescent solutions, means must be provided for forcing the solution through the
conductivity cell so no air bubbles accumulate or care taken to place the cell in a position to measure the
true value of the solution.
Do not use the cells in solutions which will attack the fittings used or the wetted cell materials. The PES
and platinum or nickel of the electrode are the cell materials with which the solution will come into contact.
The wetted materials of the removal device with which the process may come into contact with are CPVC,
Teflon, EPDM and Viton.
Do not use the cell in a solution having temperatures greater than 80°C. The maximum limit set by the
temperature compensator range must be observed.
For cells having a constant of 0.01, 0.1 or 1, make certain that the guard is in place and is not loose on the
cell body. The guard tube must be hand-tightened only. There is a 1/16 inch space between the guard tube
and the cell body.
Do not install the 4909 Assembly where pressures and/or temperatures may occur outside the operating
range given in Fig. 1-1. Both pressure and temperature must be within the shaded area of the curve.
Avoid installations where the 4909 Assembly will be exposed to pressure shock caused by water hammer.
3.2 Location and Position
Refer to Fig. 3-1 or Fig. 3-2 for mounting dimensions.
Considerations
The cross-channel in the high constant cells or the guard tube holes in the low constant cells must be
covered by the solution during measurements.
Vertical insertion (from above) or horizontal insertion can be used. Make certain the tank or pipeline is full
under all process conditions. If a pipeline is not always full, use a vertical mounting and insert the cell far
enough into the vertical pipe that the cross-channel is below the horizontal exit pipe which may empty out.
Make certain an air bubble in the pipe does not prevent the cell from filling properly. (If the cell becomes
dry after use, it may require cleaning in accordance with Section 4.1 before again being placed in service.)
For best results, whether vertical or horizontal mounting is used, position the cell so that the sample will
flow through the channels or guard tube towards the mounting end of the cell, exiting through the cross-
channel or guard-tube holes. In applications where vertical mounting is required, avoid a position with the
cell channels pointed up, as this will permit solution to flow down into the open end of the cell and may
result in clogging by solids settling in the cell channels.
Allow for insertion depth from the outside wall of the mounting surface as indicated by the dimensions in
Fig. 3-1 or 3-2.

4909 CPVC Conductivity Cell Insertion/Removal Assembly Operations Manual
12 4909 CPVC Conductivity Cell Insertion/Removal Assembly– Operations Manual 7/99
Allow at least 1/2 inch clearance beyond the end of the cell and 1/8 to 3/16 inch radius clearance
surrounding the cell to permit circulation of the solution.
Avoid locations where excessive temperature changes may occur.
Allow clearance behind the support grip to permit removal of the cell per dimensions in Fig. 3-1 or 3-2.
Locate the insertion/removal assembly on the pressure side of pumps; not the vacuum side.
Avoid locations where the operator must take an awkward position to perform the cell insertion or removal
operation.
The 4909 Insertion/Removal Assembly is designed to support only its own weight. Do not install in
locations where it would be used as a foot rest or where it would be used as a hand grip. Do not hang or
support any other piping or objects from the assembly.
The removal device should not be mounted onto pipelines or vessels displaying excessive vibration unless a
support is provided on the 6” long valve nipple.
3.3 Prepare Assembly
If X7 or 20 are selected in Table IV of the Model Selection Guide, then the 4908 Conductivity Cell (Fig. 1-
4) must be joined with the support tube of the 31074357 Removal Device as discussed in Section 1.3.
Refer to Fig. 1-5.
Initial Prep
1. Loosen compression handle by turning it counterclockwise until it is free from housing.
2. Withdraw the support tube, bushing, washer and handle assembly keeping the bushing and washer in
place on the support tube. When greater insertion depth of the conductivity cell into the process
solution is desired, p/n 074344 Support Tube will give an additional 6 inches immersion beyond the
standard depth. See Figs. 3-1 and 3-2. If 074344 Support Tube is to be used, it must be secured to the
support grip.
3. Slide the bushing and washer off of the standard support tube.
4. Turn the compression handle counterclockwise to remove it from the support grip.
5. Using a strap wrench, loosen and remove the standard support tube.
6. Install 074344 Support Tube by wrapping one end with Teflon tape overlapping by 50% on each wrap.
Wrap the tape in a clockwise direction as viewed from the threaded end of the support tube.
7. Thread this end into the support grip by hand and tighten an additional two turns by using a strap
wrench. Do not use stillson or chain type wrenches as they may damage or score the support tube and
prevent a good seal with the bushing.
8. Replace the compression handle, washer and bushing removed earlier. Note the proper orientation of
the bushing with the tapered surface facing away from the compression handle.
Mounting into the Process
The valve nipples and housing can now be mounted into the process pipeline or tank wall.
1. Remove the protective cap and apply Teflon tape to mounting nipple. Wrap the tape on the threads in a
clockwise direction as viewed from the threaded end. Overlap the tape by 50% on each wrap. Cover
the threaded area twice in this manner.
2. Install the mounting nipple and valve assembly hand tight.