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

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 11
Detailed Pipe Tee Installation Instructions
1. Wiring:
a. Route the cable either through conduit or on a cable tray.
b. Insert the sensor cable into the Model C99 controller through a watertight cord grip.
Conduit holes are provided for the cord grip on the bottom of the C99 controller.
c. Connect the sensor wires into the C99 sensor terminal block as shown in the C99
manual.
2. Calibrate:
a. Power the C99 controller.
b. Remove the protective cap from the sensor head. Connect and calibrate the
Conductivity sensor as explained in the C99 manual. Subsequent calibrations
should be scheduled based on process demands.
c. If measurement response time is slow or if the sensor will not calibrate, refer to
Section 4 for maintenance, refurbishment and troubleshooting suggestions.
3. Mount:
a. Apply Teflon®tape to the sensor body threads.
b. Insert the sensor into the tee and slowly turn clockwise until secure. Tighten the
sensor with a wrench until snug to prevent leaking. Be sure the pipe remains full
when the sensors are installed.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 12
3.2.2. Union Mounting
Union mount hardware makes it easy to remove and insert the sensor for applications where
calibration and/or cleaning is frequent.
Dimensions: IN (mm)
Figure 3.8: Union Mounting
Union Mount Advantages
9Optimal positioning of sensing
surface.
9Trouble-free installation.
9Quick disconnect.
9No cable twisting during installation
or removal.
9Easy maintenance.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 13
Detailed Union Mount Installation Instructions
1. Wiring:
a. Apply Teflon® tape to the rear sensor body threads and pass the cable through
the adapter. Thread the adapter onto the sensor clockwise until it is secure.
b. Pass the union collar over the cable and onto the adapter with the threads facing
the sensor.
c. Route the cable either through conduit or on a cable tray.
d. Insert the sensor cable into the Model C99 controller through a watertight cord grip.
Conduit holes are provided for the cord grip on the bottom of the C99 controller.
e. Connect the sensor wires into the C99 sensor terminal block as shown in the C99
manual.
2. Calibrate:
a. Power the C99 controller.
b. Remove the protective cap from the sensor head. Connect and calibrate the
Conductivity sensor as explained in the C99 manual. Subsequent calibrations
should be scheduled based on process demands.
c. If measurement response time is slow or if the sensor will not calibrate, refer to
Section 4 for maintenance, refurbishment and troubleshooting suggestions.
3. Mount:
a. Assemble the lower portion of the mounting hardware by threading the pipe nipple
into the threaded flange and the tee. Apply Teflon® tape to the threads.
b. Inspect the O-ring on the union-mounting threaded flange for imperfections or
particles of dirt that may prevent the O-ring seal from seating properly.
c. Carefully insert the sensor into the Thermo Scientific AquaSensors union-
mounting tee. Turning the retaining collar clockwise and hand tighten until snug.
Be sure the pipe remains full when the sensor is installed.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 14
3.2.3. Immersion Mounting
For immersion mounting applications the sensor is connected to a 1 inch to 1.5 inch reducing coupling.
A 1.5 inch extension pipe is added to protect the cable from damage.
Figure 3.9: Immersion mounting assembly

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 15
Detailed Insertion Mount Installation Instructions
1. Wiring:
a. Route the sensor cable through the 1.5 inch extension pipe.
b. Apply Teflon® tape to the sensor threads.
c. Attach the sensor to the 1.0 inch NPT reducing coupling by turning the sensor in a
clockwise direction until secure.
d. Either route the cable directly to the C99 or splice the wires in a junction box and
use an extension cable.
e. Insert the cable into the Model C99 controller through a watertight cord grip.
Conduit holes are provided for the cord grip on the bottom of the C99 controller.
f. Connect the sensor wires into the C99 sensor terminal block as shown in the C99
manual.
2. Calibrate:
a. Power the C99 controller.
b. Remove the protective cap from the sensor head. Connect and calibrate the
Conductivity sensor as explained in the C99 manual. Subsequent calibrations
should be scheduled based on process demands.
c. If measurement response time is slow or if the sensor will not calibrate, refer to
Section 4 for maintenance, refurbishment and troubleshooting suggestions.
3. Mount:
a. Secure the pipe assembly so that the sensor is fully immersed in the process.
Handrail mounting hardware can be ordered from Thermo Fisher Scientific.
Be sure that the wire colors of the sensor cable match those of the
interconnect cable on either side of the terminal strip.
Do not route the interconnect cable conduit where there are AC or DC
power cables which create electrical noise that may interfere with the
sensor signal.
Route the interconnect cable through metal conduit to minimize electrical
noise that may interfere with the sensor signal.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 16
Figure 3.10: Sanitary mounting assembly
3.2.4. Sanitary Mounting
For sanitary mounting applications the sensor is connected to an adapter with a retaining collar and
clamped into a short-branch sanitary tee.
Dimensions: IN (mm)

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 17
Detailed Sanitary Mount Installation Instructions
1. Wiring:
a. Thread the retaining collar over the cable and onto the sensor with the threads facing the front
of the sensor.
b. Route the cable either through conduit or on a cable tray.
c. Insert the sensor cable into the Model C99 controller through a watertight cord grip. Conduit
holes are provided for the cord grip on the bottom of the C99 controller.
d. Connect the sensor wires into the C99 sensor terminal block as shown in the C99 manual.
2. Calibrate:
a. Power the C99 controller.
b. Remove the protective cap from the sensor head.
c. Calibrate the Conductivity sensor as explained in the C99 manual. Subsequent calibrations
should be scheduled based on process demands.
d. If measurement response time is slow or if the sensor will not calibrate, refer to Section 4 for
maintenance, refurbishment and troubleshooting suggestions.
3. Mount:
a. Insert the sensor into the adapter making sure the front o-ring on the sensor is seated.
b. Thread the retaining collar into the adapter and tighten with a wrench until the face of the
sensor head is flush with the adapter and the o-ring forms a seal.
c. Place a sanitary gasket on the branch flange.
d. Insert the sensor with the adapter into the branch of the tee; be sure the pipe remains full while
installing to minimize trapped air.
e. Install and tighten the sanitary clamp to retain the sensor and adapter in the tee.
Route the interconnect cable through metal conduit to minimize electrical noise
that may interfere with the sensor signal.
Do not route the interconnect cable conduit where there are AC or DC power
cables which create electrical noise that may interfere with the sensor signal.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 18
4. CONDUCTIVITY SENSOR MAINTENANCE
4.1. Cleaning the Contacting Conductivity Sensor Head
4.1.1. In order to maintain an accurate measurement value, the sensor will need occasional maintenance.
The maintenance interval will be dictated by the process in which it is installed. The harsher the
process, the more often the sensor will require maintenance. Regular maintenance will yield a longer
sensor life.
4.1.2. The sensor cleaning procedure is as follows:
4.1.2.1. Remove sensor from service and rinse or spray it with warm water to remove heavy deposits.
4.1.2.2. Soak the sensor in a container of hot detergent water for one hour. Do not use detergents that
contain oily skin softeners like aloe or lanolin that can coat the electrodes. Alconox®and Dawn™
dishwashing liquid work well.
4.1.2.3. Use a soft-bristled brush, such as a soft toothbrush, and hot detergent water to scrub the entire
electrode end of the sensor.
4.1.2.4. Rinse the electrode end with clean warm water.
4.1.2.5. If deposits are still present on the electrode repeat steps 2 and 3. In the case of lime or other
mineral deposits a weak solution (about 0.1 M) of hydrochloric acid may be used. In some cases, a
dilute solution (about 10:1) of water and chlorine bleach or a solution of water and EDTA may also
work. Stubborn oil or grease deposits may require cleaning with a solvent such as acetone or
alcohol. Protein deposits may be cleaned with a pepsin-based cleaning solution. Bacterial or mold
growth may be removed with dilute chlorine bleach.
Caution: Ensure that dangerous chemical reactions will not occur between process
deposits and cleaning solutions. Compounds of cyanide and hydrochloric acid will react
and pose health risks. Cyanide is often used in electroplating and in gold refining. If in
doubt about potential chemical reactions, check with a chemist before cleaning.
4.1.3. Before returning the sensor to service, allow it to soak in water at ambient temperature for about an
hour to restabilize the Conductivity electrode.
4.1.4. After cleaning the sensor, calibrate sensor per instructions in the Model C99 controller manual.
4.1.5. Reinstall sensor in process.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 19
4.2. Contacting Conductivity Sensor Troubleshooting
General Inspection
If the sensor is not providing reasonable signals to the analyzer, check the following:
1. Inspect the integrity of the electrodes. If the electrode is broken, replace the sensor.
2. Inspect the sensor cable for damage to the outer jacket. Any cuts or kinks may damage signal
connections.
3. Inspect terminal block connections to be sure wires are not corroded or loose.
4. Make sure all sensor wires are connected to the correct places on the analyzer terminal block. Depending
on the analyzer, some terminal block jumpers may be required and it is common to put those jumpers in the
wrong place.
5. The sensor electrodes should be immersed in a solution of known conductivity solution.
6. Establish that the analyzer electronics are working correctly by verifying operation with another sensor.
If the sensor passes the general inspection, there are four basic tests that can verify the Temperature
Measurement, the Conductivity Short Test, the Conductivity Span Test and the Sensor Power Test. If the
sensor passes these tests it should be ready for service.
Temperature Span
Disconnect the BLACK and YELLOW sensor wires from the analyzer. Use an ohmmeter to measure the
resistance between the BLACK and YELLOW wires. The meter should measure a resistance corresponding
to the sensor temperature as outlined in the following table.
Sensor Temperature 5°C 15°C 25°C 35°C 45°C
Thermistor Resistance 1020 Ω1058 Ω1097 Ω1136 Ω1175 Ω
If the measured resistance is within 20 to 40 ohms of the expected value, the element should be satisfactory.
If not, please consult the factory.
If after cleaning and refurbishment sensors still have slow responses, low measurement
slopes or are seriously abraded or scratched, they must be replaced. Contact your local
distributor or call Thermo Fisher Scientific Customer Service.

Thermo Scientific AquaSensors™AnalogPlus™Contacting Conductivity Sensor User Guide 20
Conductivity Short Test
1. Disconnect the RED and GREEN sensor wires from the analyzer terminal block while leaving the other
wires connected. Connect the (+) lead of an ohmmeter to the RED wire and the (-) lead of the ohmmeter to
the GREEN wire.
2. The ohmmeter should read open.
After testing, the RED and GREEN wires should be reconnected to the analyzer terminal block.
Conductivity Span Test
1. The sensor can be tested by substituting a resistor (or resistance decade box) for the process to determine
if the system is reading correctly.
2. Sensors are available in both 0.1 and 1.0 cell constants. To obtain the equivalent resistance for any
conductivity, divided the conductivity in Siemens by the cell constant. The equivalent resistances for some
cell constants and process conductivities are shown in the table below:
Cell Constant = 0.1
Process Conductivity - 1k μS 100 μS 10 μS 1 μS
Nominal Resistance - 100 Ω1k Ω10k Ω100k Ω
Cell Constant = 1.0
Process Conductivity 10k μS 1k μS 100 μS 10 μS 1 μS
Nominal Resistance 100 Ω1k Ω10k Ω100k Ω1M Ω
3. Connect the leads from the resistor (or properly adjusted decade box) to the electrodes. If the reading is
not correct continue to the power test.
Sensor Power Test
If the sensor does not respond with any reasonable signal in the span test, it may be worthwhile to verify that
power is being supplied to the sensor from the analyzer. To do this, connect a voltmeter from the BLACK lead
to the WHITE lead (It is not necessary to disconnect the wires from the terminal block). The meter should
read –5 VDC +/- 0.3 VDC. If the voltage is low, disconnect the white wire from the terminal block and
measure the voltage on the terminal block. If the voltage comes back into specification there is a defect in the
sensor that is loading down the analyzer. If the voltage remains low then the analyzer may be defective.
If the sensor passes the temperature, short, span and power tests but the analyzer is not displaying the
correct values, the analyzer may be defective.