4905 Style Conductivity Cells
Installation and Maintenance Manual
70-82-25-18
Revision 6
Honeywell Process Solutions
About This Document
Abstract
This document is intended to support the installation, operation and maintenance of the 4905 Series of
Conductivity Cells.
Revision Notes
The following list provides notes concerning all revisions of this document.
Rev. ID
Date
Notes
0
12/96
This document is the initial Honeywell release of the L&N manual p/n 177667
Rev. M2. There has been no significant changes made to this manual. The
format has been changed to reflect the Honeywell layout.
1
6/99
Edits done to add new Model Selection Guide information and to correct
some errors in the text.
2
4
5
6
6/03
9/05
Removed obsolete info, added DL4000 details.
Edit text and add electrical connection drawings for UDA2182 analyzer
Added Platinizing information to Maintenance/ revised Parts List
Added CRN approval and quick disconnect option
7/06
12/07
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 #
APT2000CC Transmitter User Manual
70-82-25-95
70-82-25-104
70-82-25-119
APT4000CC Analyzer User Manual
UDA2182 Analyzer User Manual
World Wide Web
The following lists Honeywell’s World Wide Web sites that will be of interest to our customers.
Honeywell Organization
WWW Address (URL)
Corporate
Honeywell Process Solutions
Telephone
Contact us by telephone at the numbers listed below.
Organization
Phone Number
United States and Canada
Honeywell
1-800-423-9883 Tech. Support
1-800-525-7439 Service
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4905 Series Conductivity Cells – Installation and Maintenance
iii
Contents
INTRODUCTION................................................................................................... 1
1.1 Overview ........................................................................................................................................ 1
2.1 Specifications for 04905 Series...................................................................................................... 3
2.2 Specifications for 276127 Flow Chamber...................................................................................... 4
3.1 Overview ........................................................................................................................................ 5
3.2 Types of Mounting......................................................................................................................... 5
3.3 The Differences between the Quick Disconnect and Integral Cable Option.................................. 5
3.4 Flow-Type Mounting ..................................................................................................................... 6
3.5 Immersion-Type Mounting for 04905 Series Cells........................................................................ 6
3.6 Insertion-Type Mounting ............................................................................................................... 7
ELECTRICAL CONNECTIONS........................................................................... 10
4.1 Overview ...................................................................................................................................... 10
4.2 Instrument Wiring for 4905 Cells with Integral Cable................................................................. 10
4.2.1 Model 4905 Series with Integral Cable to UDA2182 Analyzer........................................ 10
4.2.2 Model 4905 Series with Integral Cable to APT Series Analyzer/Transmitter................... 12
4.3 Instrument Wiring for 4905 Cells with Quick Disconnect Cable................................................. 13
4.3.1 Wiring Model 4905 with Quick Disconnect Cable to UDA2182...................................... 13
4.3.2 Wiring Model 4905 with Quick Disconnect Cable to APT............................................... 13
MAINTENANCE.................................................................................................. 15
5.1 Introduction .................................................................................................................................. 15
5.2 To Clean the Cell.......................................................................................................................... 15
5.3 To Check Conductivity System.................................................................................................... 15
5.4 Platinizing the Cell Electrodes ..................................................................................................... 16
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4905 Series Conductivity Cells – Installation and Maintenance
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Figures
Figure 4-1 Installation Diagram, 4905 Cells, with Junction Box head connected to UDA2182 Analyzer 10
Figure 4-2 Installation Diagram, 4905 Cells, with 20′ leads directly connected to UDA2182 Analyzer or
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4905 Series Conductivity Cells – Installation and Maintenance
v
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4905 Series Conductivity Cells – Installation and Maintenance
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Introduction
1. Introduction
1.1 Overview
These cells form the sensing network for industrial analyzers and transmitters designed to make continuous
measurements of electrolytic conductivity. The cells are primarily suited to measurements in effluents of
ion-exchangers and distillation columns; but appropriate constants are provided for many other
applications, including measurements in micro-electronic component washing and plating-rinse effluents.
Universal in mounting, any of the cells can be arranged for immersion (for applications where the
temperature does not exceed 85°C), insertion (1” NPT) or flow type sampling. The latter can be achieved
by use of a CPVC flow housing, a 1” pipe tee (schedule 40), or 1-1/4” plastic tee (schedule 80) installed in
a process line or bypass line as pictured in Figure 1-1.
Cell Assembly
Adapter Bushing
Schedule 80
1-1/4" Pipe Tee
Guard Tube
on Cell
a/n 23381
Figure 1-1 4905 Type Conductivity Cell Mounted in a 1-1/4”
Schedule 80 Tee Using an Adapter Bushing
ATTENTION
Please note that specific parameters of your process may prohibit the use of nickel elements. For example,
use a platinum-element cell if the cell will measure or be exposed to regeneration acids or bases.
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4905 Series Conductivity Cells – Installation and Maintenance
1
Introduction
The cell constant is selected according to the range of the measuring instrument used and the solution
measured. In general, a high-constant cell is used for solutions having low electrical resistance (high
conductivity) and a low-constant cell is used for solutions having high electrical resistance (low
conductivity). Automatic Temperature Compensation (ATC) during the measurement is provided by a
built-in temperature sensing network located near the cross-channel or guard-tube holes.
The cells are molded from Polyethersulfone (PES) which is resistant to most corrosive chemicals over a
wide range of temperatures. (A common exception is chlorinated hydrocarbons.) Sample solutions come
into contact only with the above plastic and the platinum or nickel electrode surface. Any cell can be
supplied with either electrode material.
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4905 Series Conductivity Cells – Installation and Maintenance
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Specifications
2. Specifications
2.1 Specifications for 04905 Series
Parameter
Description
Cell Constant
04905 Series: 0.01, 0.1, 1.0, 10 and 50 as
specified
Nickel, Platinum or Monel as specified
1724 kPa @ 140°C (250 psig @ 284°F)
140°C (284°F)
Electrode Material
Maximum Pressure Limit
Maximum Continuous Temperature Limit
For immersion applications:
80°C (176°F)
Materials of Construction
Cable Options
Cell Body: PES (polyethersulfone)
Support Fittings: Ryton
Electrodes: Nickel, Platinum or Monel as specified
Quick Disconnect Receptacle: Stainless Steel
Leadwire: PVC insulated 22 gage cable, 0.245”
OD, 20 and 50 feet lengths available.
Quick Disconnect Option
Mating cables must be purchased from Honeywell
Universal Head (Aluminum)
Approximately 1 lb (0.45 kg)
Weight
If using universal head:
3 lb (1.35 kg)
Manufactured to comply with ASME boiler and
pressure vessel code Section III, Div.1, UG-101
Approvals
CRN #0F11607.5C
1” NPT male, Schedule 40
Inlet: 3/4" MNPT
Insertion
Flow Chamber
Outlet: 3/4" FNPT
5” to 7” (127 to 178 mm) depending on cell
constant
Insertion Depth
Overall Length
Approximately 6 to 8” (152 to 203 mm)
If using universal head:
10 to 12-1/4” (254 to 311 mm)
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4905 Series Conductivity Cells – Installation and Maintenance
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Specifications
2.2 Specifications for 276127 Flow Chamber
Parameter
Description
2 gpm @ 40psig and atmospheric discharge
200 psig @ 25°C
Maximum Flow
Maximum Pressure
Maximum Temperature
Dimensions
140°C (284°F) at atmospheric pressure
1-1/2” (3.8 cm) octagon x 8-3/4” (22.2 cm) long.
Sample Inlet: 3/4" MNPT
Sample Outlet: 3/4" FNPT
Cell Inlet: 1” MNPT
Polyethersulfone (PES)
Materials of Construction
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4905 Series Conductivity Cells – Installation and Maintenance
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Installation
3. Installation
3.1 Overview
The conductivity cell is secured permanently to the 1” N.P.T. bushing which is used for all types of
mountings. Although the physical appearance of the various cells is the same (except for length), the cell
construction differs according to the constant. On the 10 and 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 elliptical on the 10 constant cell. The 1, 0.1,
and 0.01 constant cells have a removable cell guard which is screwed onto the cell body to protect the
electrode surfaces. Electrodes are three disks on the 1 constant cell, parallel plates on the 0.1 constant cell,
and wire wound on the cell body on the 0.01 constant cell. Cells must be used with the guard in place or
the cell constant may differ from that specified.
Most of the auxiliary parts which enable the user to achieve the various types of mounting are readily
obtained from local suppliers. For an immersion mounting (only applicable in applications where the
temperature does not exceed 85°C)with 04905 Series cells, only the appropriate length of 1/2 inch pipe
(e.g., CPVC) and if desired, a 1/2 inch end coupling is needed. For an in-line flow mounting, only a 1”
schedule 40 tee is required. The basic cell can be converted to a flow cell for either bypass or in-line
arrangements by use of the PES flow-cell housing (Honeywell Part 276127) shown in Figure 3-2.
However, the temperature and pressure specifications listed for this flow chamber under Specifications
apply.
3.2 Types of Mounting
There are three types of mounting: Flow, Immersion (for use in applications where temperatures do not
exceed 85°C) and Insertion. Mounting dimensions for each type of cell assembly are given in Figure 3-2,
3.3 The Differences between the Quick Disconnect and Integral
Cable Option
The cable options of quick disconnect and integral cable do not affect the performance of the cell. These
options only relate to how the cell is connected to the instrument.
ATTENTION
•There are different electrical connections for these options. Please refer to Section 4 for instructions.
NOTE: The wire colors for the integral cable and quick disconnect option are not the same. Do not use shielded
cable except where shown in the following figures.
•
•
Integral cable means the cable is potted into the cell. The cable and cell are one entity and cannot be
separated.
The quick disconnect option means the cell is connected to the cell by a receptacle on the top of the
cell. The cell and the cable are separate entities. When the time comes to replace the cell, the cable
does not have to be replaced. The cable can simply be mated with another cell that has the quick
disconnect option. This option cannot be used in immersion applications. The cable must be
purchased from Honeywell.
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4905 Series Conductivity Cells – Installation and Maintenance
5
Installation
3.4 Flow-Type Mounting
The cross-channel or guard-tube hole in the cell must always be covered by the solution and the solution
level must be 1-1/2 inches above these holes. When mounting the cell in a pipe tee such as shown in
Figure 3-1, have the solution enter the tee from below and exit to the side. As shown, the guard-tube hole
is in line with the horizontal pipe run. However, if it is possible that the pipe line will not be full at all
times, locate the hole just below the exit pipe to insure flooding of the cell under all conditions. As shown
in Figure 3-1, always locate the cell on the pressure side, not the vacuum side of the pump. The flow-cell-
housing, an accessory part having 3/4” male inlet and female outlet threads, can be used for an in-line
measurement or in a bypass line as shown in Figure 3-1, depending upon the flow volume or pipe size.
Adapter bushings are available to convert inlet and outlet fittings to 1/4” female threads. See Section 0 .
The cell must be covered by the solution at all times. Therefore, make certain the lowest solution head is
higher than the cell location. See that an air bubble does not prevent the cell from filling properly.
Flow-cell housing can be used “in-line” only if a maximum flow of 2 gallons per minute can be tolerated.
To avoid cracking the 276127 flow-cell housing, use Teflon tape on cell threads and tighten cell only
enough to prevent leakage.
To install, tighten the cell into a 1” schedule 40 pipe tee. If the flow-cell housing is used, assemble the cell
and housing and install it in the process flow line or in a bypass line.
Preferred
Cell Locations
Process
Cooler
15"
(381mm)
Pump
a/n 23383
Figure 3-1 Typical Conductivity Measuring Installation
3.5 Immersion-Type Mounting for 04905 Series Cells
For use in applications where temperature does not exceed 85°C. The cell must be immersed to a level
above the cross-channel or guard tube hole and must be immersed to 1-1/2 inches above this hole if an
integral compensator is used. For most immersion applications, a 1/2” support pipe, preferably CPCV
must be threaded into the cell bushing, using Teflon tape to seal the threads, thus permitting adequate
immersion. Unless this pipe extension is used, do not immerse the top of the bushing. To insured that a
representative sample is measured at all times, the solution must circulate through the channels. In
quiescent solutions, provide sufficient agitation.
To install the cell, determine the length of 1/2” pipe required to give the immersion needed to keep the cell
completely immersed at all times. Up to six feet of pipe can be used for the standard cell having seven feet
of cable. Remove the small bushing at the top of the cell, slide it off the cable, and replace it with the 1/2-
inch pipe. At the top of the pipe slide a pipe coupling and the small bushing back over the leadwire as
shown in Fig. 3-1, or install a junction box to terminate the pipe.
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4905 Series Conductivity Cells – Installation and Maintenance
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Installation
3.6 Insertion-Type Mounting
The cell can be inserted into a 1” N.P.T. threaded opening, but it is imperative that the tank or chamber be
full under all process conditions. Make certain the liquid head is above the cell location. A vertical
insertion (from above) or a horizontal insertion can be used. To install, simply tighten the cell into a 1”
N.P.T. threaded opening (using a Teflon thread compound such as Teflon tape) so that the entire electrode
is immersed in the measured solution. Allow at least 1/2-inch clearance beyond the end of the cell. 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
Flow Out
11/2"
1 1/2"
3/4" NPT
(38mm)
Octagon
(38mm)
Flow Chamber
3/4" NPT
11/2"
(38mm)
Octagon
11/2"
(38mm)
Flow In
83/4"
(222mm)
13 1/4"
(337mm)
1" Fitting
Allow 7 3/4" (197mm) for removal o
fcell
Notes
1.
2.
Mount cell and flow chamber horizontally as shown above with flow exit “up to eliminate possible air gap around cell body.
If cell and flow chamber must be mounted vertically, attach a short length of tubing to flow exit as shown below and form
a trap to ensure filing of flow chamber, especially at low flow.
2" min.
(51mm)
Figure 3-2 Dimension Drawing for 276127 Flow Housing
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4905 Series Conductivity Cells – Installation and Maintenance
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Installation
1.687"
(42.8mm)
“X”
See Table
Celll
Constant
mm
138
X" Approx.
5.4"
001
0.1
5.4"
5.4"
138
138
146
1
10
50
5.8"
6.9
175
1" NPT
1.5"
Cell cable is approx. 0.250”
(6.4 mm) O.D. max with 4
conductors of #18 AWG wire.
0.940"
(24mm)
Dia
Octagon
(38mm)
Figure 3-3 Mounting Dimensions for 04905 Series
Cell
constant
X" Approx.
001
0.1
1
5.4"
5.4"
5.4"
4.5"
5.8"
6.0"
5
10
20
25
50
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4905 Series Conductivity Cells – Installation and Maintenance
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Electrical Connections
4. Electrical Connections
4.1 Overview
The terminal board connections for the various Honeywell measuring instruments are given in the
appropriate Figures in this section.
To avoid the possibility of AC pickup in the cell leads, separate them from all AC line-voltage wiring or
run them in a separate grounded conduit.
ATTENTION
Do not use shielded cable except where shown in the following figures.
4.2 Instrument Wiring for 4905 Cells with Integral Cable
4.2.1 Model 4905 Series with Integral Cable to UDA2182 Analyzer
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4905 Series Conductivity Cells – Installation and Maintenance
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Electrical Connections
50 FT. MAX.
WIRE. 20 FT. OR 50 FT. CABLE LENGTH.
Direct Cell to Analyzer Installation
50 FT. MAXIMUM
4905SERIESCONDUCTIVITYCELL
Cell to Analyzer through Junction Box
NOTES:
1. FOR PURE WATER SAMPLES IN NON-CONDUCTIVE (PLASTIC, GLASS, ETC)
PIPING, GROUND THE BLACK CELL ELECTRODE LEAD NEAR THE CELL.
ALTERNATELY, CONNECT TO THE UDA GROUND SCREW AS SHOWN DOTTED.
DO NOT GROUND 10, 25, OR 50 CONSTANT CELLS
2. FOR CELL LEADS BLACK AND WHITE, USE 16 TO 22 AWG CABLE SHIELDED TWISTED PAIR,
WITH 30pF MAX. CAPACITANCE BETWEEN CONDUCTORS, CONNECT SHIELD TO TERMINAL “10”
3. FOR COMPENSATOR LEADS RED AND GREEN, USE 16 TO 22 AWG, TWO CONDUCTOR CABLE
4. CELL TO ANALYZER CABLES ARE CONSIDERED LOW LEVEL. RUN SEPARATE FROM HIGH LEVEL WIRING.
Figure 4-2 Installation Diagram, 4905 Cells, with 20′ leads directly connected to
UDA2182 Analyzer or connected to Junction Box
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4905 Series Conductivity Cells – Installation and Maintenance
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Electrical Connections
4.3 Instrument Wiring for 4905 Cells with Quick Disconnect Cable
4.3.1 Wiring Model 4905 with Quick Disconnect Cable to UDA2182
Wire
Color
Signal
name
10
9
Yellow
Coax
Cell Low
8
7
6
Cell High
RTH 3rd Wire
RTH Low
5
4
3
2
1
Green
Red
RTH High
Brown
Blue
Wire to chassis
ground screw
Earth Ground
Figure 4-4 Wiring Diagram for 4905 Cells with Quick Disconnect Cable Connected to
UDA2182 Analyzer
4.3.2 Wiring Model 4905 with Quick Disconnect Cable to APT
NOTE: Ignore
blue and brown
wires.
Figure 4-5 Wiring Diagram for 4905 Cells with Quick Disconnect Cable Connected to
APT4000
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4905 Series Conductivity Cells – Installation and Maintenance
13
Maintenance
5. Maintenance
5.1 Introduction
If abnormal readings occur, this may indicate poor response because the cell is not filled with process
solution. Check the cell installation. Note that a grayish dull surface on the cell plastic (normally glassy)
can result from exposure to temperatures above 140°C.
The only maintenance which may be required is occasional cleaning in certain applications.
Cell constants 0.01, 0.1, and 1 cannot be used if solution resistance measures less than 1000 ohms unless
the cell is platinized in accordance with Section 5.
5.2 To Clean the Cell
The cell will require cleaning if sludge, slime, etc., accumulates in the flow channels. Since the materials
of construction are chemically inert, chemical agents may be used and are recommended for cleaning the
cells. The particular cleaning agent used must be selected according to the type of contamination to which
the cell is exposed.
CAUTION
The cell housing is PES (Polyethersulfone). DO NOT clean with acetone, chloroform, toluene, benzene, or any
other chlorinated hydrocarbon.
In general, soap and hot water are effective and adequate. If necessary, a soft bristle brush of about 1/4”
diameter may be used to clean out the tubular channels of the 10 and 50 constant cells. Do not scratch the
electrode surfaces. Be especially careful not to bend the electrode plates of the 0.1 constant cell. Rinse the
cell thoroughly in tap water and then in distilled water if available.
5.3 To Check Conductivity System
To check the conductivity system comprising conductivity cell, leadwire, and measuring instrument, the
user may desire to make a measurement in a reference solution of known conductivity. Control the
temperature only within limits consistent with the desired accuracy. The 25°C temperature value is
suggested. The solutions may be prepared in the presence of air. The solution must fill the cell during
measurement.
For optimum accuracy in acid measurements above 5% concentration, use the “Calibration Trim” function
available in the conductivity instrument. See the appropriate Analyzer/Transmitter manuals for details on
the trim function.
To check the constant of a cell, use a second cell having the same constant and compare the reading of one
against the other.
If the 04905 Series conductivity cell model number contains ‘333’, the normal resistance of the
temperature sensor as measured across the red (B) and green (D) leads is 8550 ohms at 25°C.
To check the electrode insulation, connect an ohmmeter across the black (A) and white (C) leads. With a
dry and clean cell, the resistance should be greater than 50 megohms.
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4905 Series Conductivity Cells – Installation and Maintenance
15
Maintenance
5.4 Platinizing the Cell Electrodes
Only the electrodes having constants 10 and 50 must be replatinized if the velvety-black deposit has been
rubbed off the electrodes in service or in cleaning or if platinized electrodes are recommended and this
black deposit is not present when the new cell is received. Always replatinize if a brush was used in
cleaning the electrodes. The indication of a need for replatinization of the electrodes is loss in sensitivity
(slow response of measuring instrument), erratic behavior of measuring instrument, or difficulty in
balancing. The electrodes of the high constant cells are not visible since they are located near the middle
of the flow channels. Therefore the need for platinization is only indicated by the effect on the measuring
instrument. Do not platinize cells intended for high purity water measurements.
Before platinizing, clean the cell with detergent and brush as described in Section 5.2.
Support the cell in a cylindrical vessel with the end of the cell raised from the bottom. It is not necessary to
remove the cell from the fittings for platinizing. However, the guard tube must be removed from the low
constant cells. Pour in a platinizing solution to a level above the cross-channel.
To platinize the 10 or 50 constant cells, immerse an auxiliary platinum electrode in the solution to a point
about midway between the cross-channel or tube hole and the open end of the cell. (This third electrode
should be chemically pure platinum. Its shape is unimportant. It may be one of the electrodes in another
conductivity cell or a platinum strip, sheet, rod, wire, etc.) Both electrodes of the cell are platinized
simultaneously by connecting the negative terminal of the battery (see Table 5-1) to both leadwires of the
cell. Connect the positive terminal of the battery to the auxiliary platinum electrode. Note the time lapse
and continue the platinizing operation for the time in seconds listed in Table 5-1. Then disconnect the
battery and remove the cell. Rinse the cell thoroughly in tap water and then rinse in distilled water.
During the platinizing operation, move the cell up and down gently to keep the solution stirred.
CAUTION
The preceding procedure produces a barely visible coating of platinum black on the electrode surfaces. Do not
attempt to darken electrodes by additional platinization since this will affect the cell performance adversely.
Pour the platinizing solution back into its container as it may be used a number of times.
If the cell is not to be installed immediately after platinizing, it should be kept submerged in distilled water
until put into use, as platinum black is not stable when dry.
Table 5-1 Voltage and Time Limits for Platinizing Cells
DC
10
50
Volts
6.0
100 sec. 300 sec.
---- 240 sec.
12.0
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4905 Series Conductivity Cells – Installation and Maintenance
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Replacement Parts and Accessories
6. Replacement Parts and Accessories
Description
Part Number
276127
Flow Cell Housing, PES
Junction Box
31316260
Legacy updates cap
50028816-001
Extension Cables for Sensors with Quick Disconnect Option
50024092-001
50024092-002
50024092-003
50024092-004
2m (6.56 ft)
3m (9.84 ft)
6m (19.69 ft)
15m (49.21 ft)
EXTENSION CABLE MUST BE PURCHASED FROM HONEYWELL
Cell Extension Leadwire
For ATC value of 333:
Standard Range of 9782 or 7082, also APT 2000
To 1000 ft:
834059
835024
3-conductor, 18 gage cable (Belden 9493) and
Coax cable (Belden 9259)
Wide Range 9782 and 7082:
To 1000 ft:
31834052
834059
4-conductor, 18 gage cable only
For all instruments with an ATC other than 333:
3 conductor, 18 gage, cable (Belden 9493) only
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4905 Series Conductivity Cells – Installation and Maintenance
17
Honeywell Process Solutions
Honeywell, Inc.
512 Virginia Drive
Fort Washington, Pennsylvania 19034
70-82-25-18 1207 Printed in USA
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