Thermo Scientific AquaSensors AnalogPlus User manual

Thermo Scientific AquaSensors™
AnalogPlus™Differential
pH Sensors
User Guide

Thermo Scientific AquaSensors™AnalogPlus™Differential pH Sensor User Guide 2
Safety Information
The Thermo Scientific AquaSensors AnalogPlus pH sensors 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™Differential pH 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. COMPATIBLE ANALYZERS AND CONTROLLERS.................................................................................. 7
2.3. SPECIFICATIONS ................................................................................................................................. 8
3. INSTALLATION................................................................................................................................ 9
3.1. SENSOR BODY DIMENSIONS............................................................................................................. 11
3.2. IMPORTANT POINTS TO REMEMBER DURING INSTALLATION ........................................................... 12
3.3. WIRING OVERVIEW.......................................................................................................................... 13
3.3.1. Connections for AV88 Controllers ............................................................................... 14
3.3.2. Connections for P99 Controllers.................................................................................. 14
3.4. SENSOR MOUNTING ......................................................................................................................... 15
3.4.1. Pipe Tee Mounting ...................................................................................................... 15
3.4.2. UNION MOUNTING ....................................................................................................................... 17
3.4.3. IMMERSION MOUNTING ............................................................................................................... 19
3.4.4. TRI-CLAMP MOUNTING ................................................................................................................ 21
3.4.5. BALL VALVE MOUNTING............................................................................................................. 22
3.4.6. FLOW CHAMBER MOUNTING ....................................................................................................... 23
3.4.7. WASH HEAD ACCESSORY ............................................................................................................ 23
4. PH SENSOR MAINTENANCE ...................................................................................................... 24
4.1. CLEANING THE PHSENSOR .............................................................................................................. 24
4.2. PHSENSOR REFURBISHMENT -REPLACING THE SALT BRIDGE AND REFERENCE SOLUTION ............ 25
4.3. PHSENSOR TROUBLESHOOTING ...................................................................................................... 26
5. ANALOGPLUS DIFFERENTIAL PH SENSORS AND HARDWARE FOR 1.0-INCH
BODIES ......................................................................................................................................................... 28
6. ANALOGPLUS DIFFERENTIAL PH SENSORS AND MOUNTING HARDWARE FOR 1.5-
INCH BODIES.............................................................................................................................................. 29
7. PH SOLUTIONS AND SALT BRIDGE REPLACEMENTS ...................................................... 30
8. LIMITED WARRANTY.................................................................................................................. 31
9. TERMS AND CONDITIONS.......................................................................................................... 32

Thermo Scientific AquaSensors™AnalogPlus™Differential pH Sensor User Guide 4
1. Introduction
1.1. General Information
Thank you for purchasing a Thermo Scientific AquaSensors AnalogPlus Differential pH 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™Differential pH Sensor User Guide 5
1.2. Intended use
The Thermo Scientific AquaSensors AnalogPlus pH sensor is designed to continuously measure pH 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 pH 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
AnalogPlus pH sensors should be installed and operated only by personnel familiar
with the sensor and qualified for such work.
A defective sensor should be returned for repair or replacement. Contact Thermo
Fisher Scientific to obtain a Return Material Authorization (RMA) number.
No modifications to AnalogPlus pH sensors 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™Differential pH Sensor User Guide 6
2. Product Description
2.1. Sensor Description
Thermo Scientific AquaSensors AnalogPlus pH sensors use a differential measurement technique to
maximize lifetime in continuous industrial applications.
• The ground rod and encapsulated preamplifier construction reduce the effects of ground loops
and allow the pH signals to be transmitted up to 3,000 feet. Titanium is the standard ground rod
material. For special applications. 316 stainless steel and Hastelloy C are also available.
• A replaceable heavy-duty salt bridge makes it simple to refurbish the sensor when necessary.
The salt bridge is offered in PEEK® and CPVC materials and can be configured to protect the
glass electrode or it can be configured with a flat face seal to minimize sensor body exposure to
the process.
• A reference reservoir filled with buffered solution minimizes the effects of dilution and extends
the life of the reference electrode.
• Temperature elements are embedded in all pH sensors and are used to compensate the pH
measurement. There are three different choices of temperature element depending on which
pH analyzer/controller electronics the sensor is to be used with.
• The standard cable lengths are 10, 20 and 30 feet. It is recommended that for longer cable runs
that a junction box be used with an extension cable.
The AnalogPlus pH sensor comes in a variety of 1.0-inch and 1.5-inch diameter body styles. NPT threaded
sensors are used for standard pipe tees and immersion mount applications. Smooth body sensors and
sensors with Teflon wipers are used for insertion applications. Sensors with 2-inch and 2.5-inch Triclamp
flange fittings can be installed in sanitary style mounting applications.
Standard 1.0-inch
Sensor Body
PEEK® Body with NPT
threads for immersion
and insertion
applications.
Standard 1.5-inch
Sensor Body
CPVC Body with NPT
threads for immersion
and insertion
applications.
Insertion Sensor Bodies for 2” Valves
Left: Peek® material with Teflon wiper
Right: CPVC material with smooth body.
Sanitary Style -
2.5” Triclamp
316 Stainless Steel
Flange with CPVC
sensor body.

Thermo Scientific AquaSensors™AnalogPlus™Differential pH Sensor User Guide 7
2.2. Compatible Analyzers and Controllers
All AnalogPlus pH sensors use the differential measurement technique to insure longer life and less signal
interference. Differential pH sensors also make it possible to have long cable runs. Sensor cables have
either 5 or 6 wires, depending on the type of analyzer that the sensor is to be used with. The wires are
designed for terminal block connection and each wire must be individually connected. All analyzers are
rated NEMA 4X for outdoor use as long as proper mounting and conduit practices are used.
AV88 Universal Analyzer
Thermo Fisher Scientific offers the AV88 Universal Analyzer. The analyzer can
be configured to measure with any AnalogPlus sensor. With the pH personality
module installed, AnalogPlus pH sensors with a temperature hookup code of “9”
in the part number can be used (EG: FP21A-9-D10). These sensors have 6
conductor cables while other versions of the sensor have 5 conductors. The
analyzer has a very intuitive menu system that makes it easy to navigate
through measurement, calibration, configuration and diagnostic display options.
Two current outputs, two relays, PID control, and optional digital host
communications are provided. Host communications make it possible to
integrate all sensor functions remotely with any computer system while allowing
local control through the AV88 keypad. Supported host communications
protocols include Modbus RTU, DeviceNet, Modbus TCP, Ethernet/IP,
CANopen and Profibus. The AV88 enclosure is rated for outdoor use and can
be mounted to a wall, a panel or a pipe. Input power options of 24 VDC and
Line Power (90 VAC to 240 VAC) are available with this Analzyer.
P99 pH/ORP Analyzer
Thermo Fisher Scientific offers the P99 pH/ORP Analyzer which
is compatible with all AnalogPlus pH and ORP sensors with a
temperature/hookup code of “8” in the part number (EG: FP21A-
8-D10). It provides a large LCD display, password protected
menu access, 2 current outputs and 3 relays. It is compatible
with GLI/HACH P63/P53/P33/P3 analyzers and transmitters.
The P99 enclosure is rated for outdoor use and can be mounted
to a wall, a panel or a pipe.
Third Party Analyzers
AnalogPlus pH sensors with a temperature/hookup code of “7”
(EG: FP21A-7-D10) are compatible with AquaMetrix differential
pH analyzers. AnalogPlus pH sensors with a
temperature/hookup code of “8” work with our P99 analyzer or
GLI/HACH P63/P53/P33/P3 analyzers and transmitters.
Figure 2.1: AV88 Universal
Analyzer
Figure 2.2: P99 pH/ORP
Analyzer

Thermo Scientific AquaSensors™AnalogPlus™Differential pH Sensor User Guide 8
Thermo Scientific AquaSensors AV88 and P99 analyzers have a number of options to provide the right
features at the right price for an application. Common part numbers are shown in the table below.
Analyzers Description Part Number
AV88 Universal Analyzer 2 outputs, 2 relays, PID. AC power. ¼ DIN.
2 outputs, PID, Modbus. 24VDC. ¼ DIN.
AV88AB0C2
AV88AB4A1
P99 pH/ORP Analyzer 2 outputs, 3 relays. AC power. ½ DIN. P99
2.3. Specifications
All AnalogPlus pH sensors are rated for continuous use in industrial and municipal process applications.
Construction variables of electrode type, ground rod material, sensor body material, temperature element
and cable length are described in Sections 6 and 7 of this manual. Specifications shown here are general
in nature and assume that the proper materials have been chosen for the application.
Measuring Range…………………... 0 to 14 pH
Resolution……… ………………..…. 0.01 pH
Operating Temperature……………...
Maximum Pressure…………………..
Maximum Flow Rate……..…………..
PEEK® Sensor CPVC Sensor
-5°C to 95°C -5°C to 75°C
100 PSIG @ 95°C 85 PSIG @ 75°C
10 ft/second 10 ft/second
Standard Sensor Cable Lengths……. 10 ft, 20 ft and 30 ft
Maximum Transmission Distance….. 3,000 ft (914 m)
The sensor will arrive with a protective cap that keeps the sensor hydrated.
For short-term storage, put several drops of Thermo Scientific AquaSensors storage solution on the
absorbent material in the protective cap and replace the cap on the sensor. This keeps the process
electrode and salt bridge moist.
For extended storage, repeat the above short-term storage procedure every 2 to 4 weeks, depending
on the surrounding environmental conditions.
Make sure all wetted materials are compatible with process chemicals at operating temperatures and
pressures.

Thermo Scientific AquaSensors™AnalogPlus™Differential pH Sensor User Guide 9
3. Installation
Standard AnalogPlus pH sensors have NPT threads on the front and on the back of the sensor body. 1.5-
inch diameter sensors can be threaded into standard 1.5 inch pipe extensions and tees. 1.0-inch diameter
sensors can be threaded into standard 1.0 inch pipe extensions and tees. These standard NPT threads are
used for a majority of immersion and insertion applications.
Five wire cables are routed through conduit or a cable tray to
a Differential pH analyzer or controller. Standard cable
lengths are 10, 20 and 30 feet. Custom cable lengths up to
300 feet are available.
The sensor body has 1.0 inch or 1.5 inch NPT threads for the
following mounting options:
¾ Standard pipe tee insertion.
¾ AquaSensors immersion mounting assembly.
¾ AquaSensors pipe adapter for union mounting.
CPVC and PEEK® Salt bridges are available in three
styles:
¾ Protected electrode for standard applications.
¾ Flat for sanitary applications.
¾ Flat with face seal for flow chambers.
Figure 3.1: 1.5 inch pH Sensor
with Salt Bridge Options

Thermo Scientific AquaSensors™AnalogPlus™Differential pH Sensor User Guide 10
When ball valve and sanitary mounting are needed sensors can be provided with smooth bodies and sanitary
flanges.
PEEK® pH Sensor with removable
Teflon Wiper for 2-Inch ball valves.
Smooth CPVC 1.5 Inch Body for 2
inch Ball Valve insertion.
CPVC pH Sensor with 2.5-inch
Tri-clamp flange.
Figure 3.2: Body Variations for pH Sensors