Thermo Scientific AquaSensors AnalogPlus 1.0 User manual

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 1
Preface
This instruction manual serves to explain the use of the Thermo Scientific AquaSensors
AnalogPlus 1.0 inch Contacting Conductivity sensor and is written to cover as many applications
as possible. Please do not hesitate to contact Thermo Fisher Scientific or an authorized
representative with questions or concerns.
The information presented in this instruction manual is subject to change without notice as
improvements are made, and does not represent any commitment whatsoever on the part of
Thermo Fisher Scientific.
Thermo Fisher Scientific cannot accept any responsibility for damage or malfunction of the sensor
due to improper use.
Contact Information
To contact Thermo Scientific AquaSensors Technical Support:
Within the United States call 1.800.225.1480 or fax [phone].
Outside the United States call 978.232.6000 or fax [phone].
In Europe, the Middle East and Africa, contact your local authorized dealer.
Visit us on the web at www.thermo.com/processwater

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 2
Safety Information
The Thermo Scientific AquaSensors AnalogPlus 1.0 inch Contacting
Conductivity sensor shall be installed and operated only in the manner
specified. Only a skilled, trained or authorized person should carry out
installation, setup and operation of the sensor system.
Before using the sensor, make sure that the sensor cable is
connected as specified. Failure to do so may result in permanent
damage to the sensor or controller.
Protection against electric shock will be achieved only by observance
of the corresponding installation rules.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 3
TABLE OF CONTENTS
1. INTRODUCTION...................................................................................................................................4
1.1. GENERAL INFORMATION.................................................................................................................... 4
1.2. INTENDED USE.................................................................................................................................... 5
2. PRODUCT DESCRIPTION.................................................................................................................. 6
2.1. SENSOR DESCRIPTION........................................................................................................................ 6
2.2. SPECIFICATIONS................................................................................................................................. 7
3. INSTALLATION.................................................................................................................................... 8
3.1. WIRING.............................................................................................................................................. 8
3.2. MOUNTING HARDWARE..................................................................................................................... 9
3.2.1. PIPE TEE MOUNTING.................................................................................................................... 10
3.2.2. UNION MOUNTING....................................................................................................................... 12
3.2.3. IMMERSION MOUNTING ............................................................................................................... 14
3.2.4. SANITARY MOUNTING ................................................................................................................. 16
4. CONDUCTIVITY SENSOR MAINTENANCE................................................................................18
4.1. CLEANING THE CONTACTING CONDUCTIVITY SENSOR HEAD .......................................................... 18
4.2. CONTACTING CONDUCTIVITY SENSOR TROUBLESHOOTING............................................................. 19
5. CONTACTING CONDUCTIVITY SENSOR SPARE PARTS AND ACCESSORIES................21
5.1 REPLACEMENTS ............................................................................................................................... 21
5.2 THERMO SCIENTIFIC AQUASENSORS CONDUCTIVITY STANDARDS.................................................. 21
5.3 MOUNTING HARDWARE REPLACEMENTS......................................................................................... 22
6. LIMITED WARRANTY...................................................................................................................... 23
7. TERMS AND CONDITIONS..............................................................................................................24

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 4
1. INTRODUCTION
1.1. General Information
Thank you for purchasing the Thermo Scientific AquaSensors AnalogPlus Contacting Conductivity Sensor.
This industrial sensor has many enhanced features that offer superior performance in process applications.
The product is designed for continuous use in industrial process applications and complies with safety
regulations currently in force. Improper use could lead to hazards for the user or a third-party, and/or adverse
effects to the plant or other equipment.
Thermo Fisher Scientific does not accept any liability for damage that may arise if information in this
manual is not followed. Therefore, the operating instructions and specifications must be read and
understood by all persons involved in installation and operation of this equipment.
This manual identifies safety instructions and additional information by means of the following symbols:
This symbol draws attention to safety instructions and warnings of potential danger,
which if neglected, could result in injury to persons and/or damage to property.
This symbol identifies additional information and instructions, which if neglected, could
lead to inefficient operation and possible loss of production.
It is recommended that this manual be made accessible to everyone who may need it as a reference.
Please contact Thermo Fisher Scientific or an authorized representative with any questions.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 5
1.2. Intended use
The Thermo Scientific AquaSensors AnalogPlus 1.0 inch Contacting Conductivity sensor is designed to
continuously measure Conductivity/Resistivity and temperature in aqueous solutions in accordance with the
technical product specifications in Section 2.2 of this manual.
Any other use, or use not mentioned here, that is incompatible with the technical specifications is deemed
inappropriate. The operator is solely responsible for any damage arising from such use.
Other prerequisites for appropriate use include:
•Observing the instructions, notes and requirements set out in this instruction manual.
•Observing all local safety regulations.
•Observing all warnings and cautions in the documentation regarding all products used in this
measurement system, including the Conductivity sensor, mounting hardware, analyzer
electronics and cabling.
•Observing the prescribed environmental and operational conditions.
•Observing chemical compatibility with all wetted materials.
1.3. Safety Instructions
The AnalogPlus 1.0 inch Contacting Conductivity sensor should be installed and
operated only by personnel familiar with the sensor and qualified for such work.
A defective sensor should be returned to Thermo Fisher Scientific for repair or
replacement. Contact Thermo Fisher Scientific to obtain a Return Material
Authorization (RMA) number.
No modifications to the AnalogPlus 1.0 inch Contacting Conductivity sensor are
allowed. The manufacturer/supplier accepts no responsibility for damage caused by
unauthorized modifications. The risk is borne entirely by the user.
1.4. Removal from Service / Correct Disposal of the Sensor
Removal from Service
•Disconnect the cable wiring from the controller terminal block.
•Remove the sensor from the mounting hardware.
Correct Disposal of Unit
•When the sensor is taken out of service, observe the local environmental regulations for correct
disposal.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 6
2. PRODUCT DESCRIPTION
2.1. Sensor Description
The Thermo Scientific AquaSensors 1.0 inch Contacting Conductivity sensor is available in different cell
constants to accurately measure your continuous industrial application. The wires in the sensor cable are
color coded to allow for quick and easy installation into the Model C99 controller.
The wires in the sensor cable are color coded to match the
terminal strip connection within the Model C99 Controller.
Figure 2.2: Conductivity sensor hook-up
The sensor body has 1 inch NPT threads for the following
mounting options:
¾Standard 1 inch NPT pipe tee insertion.
¾Thermo Scientific AquaSensors immersion mounting
assembly.
¾Thermo Scientific A
q
uaSensors
p
i
p
e ada
p
ter for union

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 7
2.2. Specifications
Wetted Materials……………………………. Sensor Body – CPVC, PEEK or 316 Stainless Steel
Electrodes - Titanium
O-Ring Seals - Viton®
(Consult factory for customized material construction)
Operating Temperature…………………….. -4°F to 257°F (-20°C to 125°C)
Maximum Pressure…………………………. 300 psi @ 212°F (2,068 Pa @ 100°C)
Maximum Flow Rate………………………... 10 ft/sec (3 m/sec)
Measuring Range…………………………… 0 to 5000 μS/cm
Resolution……………………………………. 4.5 significant digits
Standard Sensor Cable Length……………. 10 ft (3 m)
Cable Wire Colors…………………………... White Wire (-5V)
Black Wire (Ground)
Red Wire (Active Electrode)
Green Wire (Reference Electrode)
Yellow Wire (Temperature/RTD)
Drain/Shield (Earth)
Maximum Transmission Distance…………. 3,000 ft (914 m)
The sensor will arrive with a protective cap. Remove when in process or calibrating.
Replace the cap on the sensor when placed in storage.
Make sure all wetted materials are compatible with process chemicals at operating temperatures
and pressures.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 8
3. INSTALLATION
3.1. Wiring
There are two different methods for electrical connection between the sensor and the conductivity controller:
either direct or through a junction box.
3.1.1. Direct Connection
1. Insert the sensor cable through a watertight cord grip into the Model C99 Controller. Conduit holes are
found on the bottom of the C99 controller for this purpose.
2. Connect the sensor wires to the C99 controller as outlined in the controller manual.
3.1.2. Indirect Connection (Using a Junction Box)
1. Insert the sensor cable and the interconnect cable through a watertight cord grip into the junction box
that has a terminal strip designed to make the proper connections.
2. Connect both the sensor cable wires and the interconnect wires to the terminal strip.
3. Insert the interconnect cable through a watertight cord grip into the Model C99 Controller.
Conduit holes are found on the bottom of the C99 controller for this purpose.
4. Connect the sensor wires to the C99 controller as outlined in the controller manual.
Be sure that the wire colors of the sensor cable match those of the interconnect cable on
either side of the terminal strip.
Route the interconnect cable through metal conduit to minimize electrical noise that may
interfere with the sensor signal.
Figure 3.1: Conductivity Sensor Hook-Up

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 9
3.2. Mounting Hardware
The Thermo Scientific AquaSensors 1.0 inch Contacting Conductivity sensor can be
installed in standard plastic and metal 1-inch full bore tees, union mount tees, immersion
mounts and sanitary mounts.
K 1.0
Save the protective cap and use it
whenever the sensor is removed
from service.
DO NOT USE PIPE SEALANT.
Pipe sealants may not provide
adequate sealing or may react with
different plastic materials. Use thread
tape.
If the sensor does not calibrate, refer
to Section 4 to review maintenance,
refurbishment and troubleshooting
options.
DO NOT OVER TIGHTEN!
Maximum torque: 65 lbs⋅inch (7 N⋅m)
The sensor should be positioned with
the electrodes into the flow. This will
insure that entrained air does not
form a pocket around the sensor
head.
K 0.1
Figure 3.2: 1 Inch Sensor Body

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 10
3.2.1. Pipe Tee Mounting
Normally available pipe tees vary widely in construction dimensions. CPVC pipe tees are most
generally available with schedule 80 walls. Stainless steel tees have thinner walls that change
the final position of the sensor. Common mounting arrangements are shown.
Dimensions: IN (mm) Dimensions: IN (mm)
Figure 3.4: Schedule 40 PVC Tee
Figure 3.5: Schedule 80 PVC Tee