technical note barben retroﬁ t guide...

Technical NoteBarben Retrofi t Guide (Internal) Tips and tricks for replacing the competition

■ ABB Page 2

■ Rosemount (Emerson) Page 5

■ Mettler Toledo Page 9

■ Yokogawa 2

■ Endress & Hauser Page 15

■ Foxboro (Invensys) Page 18

■ Honeywell Page 21

■ Sensorex Page 24

■ Broadley James Page 25

■ Van London Page 26

It’s no secret that Barben Analytical has built its business on replacing pH/ORP sensors from other vendors. The highly successful Performance Series sensors with Axial Ion Path® reference technology provides longer life and higher accuracy in industrial applications when compared to traditional pH sensors sold by many Barben compet-itors. Many endusers choose Barben products to mate with this existing analyzers to improve their process.

The purpose of this guide is to aide in the cross reference of these competitive products. This document is meant for internal use only by Barben representatives and distribu-tion.

Cross Reference BasicsWhen replacing pH sensors, the millivolt response of ALL glass electrode pH sensors is based on the same Nernst Equation. From a theoretical standpoint this means that a Barben sensor can replace any other glass electrode sensor on the market. Our design is really optimized for the following applications:

Good Applications• Extreme pH (closer to 0 or 14pH than neutral)• High pressure• High temperature• High particulates or coating

Less Desirable Applications• Sanitary installations• Ultrapure water• Laboratory measurements

If a simple double junction pH sensor works fi ne in the application than the real advantages a Barben sensor will not always be understood by the customer. When selling our products seek out the problem measurements!

The basic information needed to cross reference a sensor is as follows:

“Must Have” InformationProcess Connection (How does the sensor mount?)Temperature Compensation (PT100, PT1000, 3K Balco)Cable Length (To reach the analyzer)Wiring Termination (BNC or standard wire leads)

“Good to Have” InformationComplete Model Number (aide in exact cross reference)Failure Mode of existing sensor (If known)Process Information (Ave. pH, Temp, Pressure)

When in doubt, the pH sensor application questionnaire found at the end of this document can be used to help with cross referencing another vendor’s product.

Technical NoteBarben Retrofi t Guide (Internal)

2

General NotesBoth ABB and Barben Analytical products have their roots in the TBI Company (or TBI-Bailey as it was later known). The original inventor of the ABB/TBI design, Ted Barben, later patented the Axial Ion Path® currently used in all Barben Performance Series Sensors. Due to this history, there are many similarities in part numbers and product designs.

Most ABB part numbers use the “TB” or “AP” designation. The “TBX” designation adds a solution ground; however the physical design is the same as the TB sensors . The AP sensors are simple gel fi lled double junction versions of the product. For brevity sake we will use the TB designa-tion throughout this document.

TB551 / TBX551 / AP301The ABB TB551 is a twist-lock style sensor. The locking mechanism of the TB551 are two small “ears” on the sen-sor body. These ears fi t into specifi c 1 inch NPT holders which mount into the process piping. The body material is limited to molded Ryton with a fi xed insertion length. This design limits the TB551 to 100 PSIG (Barben 551 sensors can withstand up to 300 PSIG). The sensor tip is only available as fl ush with hemispherical glass thus great care must be taken not to break the exposed glass electrode.

Direct replacement of the TB551 sensor requires using a Barben 551 sensor. A Barben Nut Lock Holder should be specifi ed to directly replace the ABB twist lock holder. In special cases, if the ABB sensor holder Part # 4TB9515-0120 is already installed then the Barben 551 sensor will mount in it. It is the only ABB holder where this works. Refer to Figure 2 for reference.

ABB TB, AP and TBX Series pH/ORP Sensors

Barben 551 Sensor Recommended Insertion Length1” NPT TEE

OptionsBarben Tee

Part NumberBarben Nut-Lock Holder

Insertion LengthABB Holder (4TB9515-0120)

Insertion LengthCPVC 100# B4951-0045 3.0” 3.5”316 SS 150# B4951-0036 2.625” 2.625” (Flush tip only)Kynar 200# B4951-0046 3.0” 3.5”

NUTLOCK FITTING

1" MNPT THREAD

551SENSOR

FITTING NUT

INSERTION LENGTH SEE TABLE

1” PIPE TEE

1.825” (46.4mm)

Sensor Holder Options from Barben and ABB

ABB Ryton ThreadedReceptacle (4TB9515-0120)

Barben High Pressure 316 SS Nut-Lock Receptacle (B4954-0022)

Barben CPVC Nut-Lock Receptacle (B4953-0001)

Figure 1

Figure 2

Barben 551 with Nut-Lock Holder

TB556 / TBX556 / AP303The ABB TB556 uses a 3/4 inch NPT process connection to install the sensor. This type of mounting is very popular; however it does have some drawbacks. Since the sensor must be threaded into the process, care must be taken not to twist or damage the sensor cable. Over tightening the sensor can also damage the internal glass electrode. These rules also apply to the Barben 546 sensor which can be used to directly replace the ABB products.

The TB556 products are limited to Kynar body construction with fi xed installation depths. Barben 546 sensors allow for different body material such as PEEK and CPVC for better process compatibility. Additional tip lengths are also available to ensure that the sensor has proper insertion depth into the process.

Barben 546 Material and Tip Options

PEEK 0.5”Flush

CPVC 1.5”Notched

Kynar 3.0”Notched

Figure 3

ABB Model Number TempSensor

BodyMaterial Mounting Style BAT

Model Barben Application Notes

TB551 / TBX551 / AP301 Ryton Twist Lock Receptacle 551 Check insertion depth notes below, may require Nut Lock AdapterTB556 / TBX556 / AP303 3/4" NPT Threaded 546 Direct matchTB557 / TBX557 / AP305 Ball Valve Hot Tap 547 Direct match, 547 will fit directly into ABB retractable sheath

TB561 / TBX561 Nut Lock Receptacle 551 Direct match, Consult factory if using TB18 Safe-T-Clean ValveTB564 / TBX564 High Pres. Ball Valve Hot Tap 554 Consult factory on special direct match Barben 554 SensorTB567 / TBX567 Ryton High Pressure 1" NPT Threaded 547 Requires use of Barben high pressure sensor housing

3k BalcoPT100 Kynar


3

ABB TB, AP and TBX Series pH/ORP SensorsTB557 / TBX557 / AP305Hot Tap sensors are perhaps the easiest products to interchange between the two brands. The ABB TB557 products are dimensionally the same as Barben 547 cartridge style sensors. In hot tap retractable installations the sheath, backpiece, and all related compression fi ttings and valves are fully compatible with Barben 547 sensors. Also note that Barben offers a full line of hot tap hardware as well as different sensor material options such as PEEK and CPVC to help match the process conditions. Sensor replacement is detailed in the illustrations below.

3/4" NPTTHREAD

O-RINGS:LUBRICATE BEFORE

INSTALLING IN SHEATH

METALLIC SHEATH

547 SENSOR EXTENSION

SENSOR CABLE FED THROUGH EXTENSION AFTER

INSTALLATION IN SHEATH

BLOWOUTSAFETY STOP

COMPLETE 547 HOT TAP ASSEMBLY

12

3 4

Both ABB and Barben Hot Tap Assemblies consist of at least 4 parts:

1. Compression fi tting (Wrench or Hand Tight)2. Metallic Sheath (316SS, Titanium, or Hastelloy C)3. 547 Cartridge Sensor (Kynar, PEEK, or CPVC)4. Kynar Extension

Hot Tap Retractable Sensor Replacement Figure 4

TB561 / TBX561ABB TB561 products are primarily installed in ABB Flow-cells (Part # 4TB9515-0223 and -0190). A Barben 551 sensor with 100mm insertion depth will fi t into these fl ow-cell applications with no modifi cation.

The other common application for ABB TB561 sensors is to be used in conjunction with the TB18 Safe-T-Clean Valve. These valves are manufactured by Satron for a number of different pH vendors. When Barben 551 sen-sors are replacing ABB sensors we recommend consulting the factory. The holder used to insert the sensor through the ball valve typically needs to be changed out.

TB18 Safe-T-Clean (Satron) Valve Examples Figure 5

Instead of linear insertion, these valves allow the pH sensor to be rotated into the process. These valves are mostly found in diffi cult slurry applications such as those found in pulp & paper and mining.

In process

Retracted for cleaning,

calibration, or replacement

TB564 / TBX564Barben offers several products to replace the ABB TB564 high pressure hot tap sensor. Since these types of instal-lations require specialized hardware, Barben can offer a di-rect sensor replacement for the ABB product. The Barben 554 High Pressure pH sensor will mount directly into the ABB hot tap assembly. This product is not shown in our datasheet thus please contact Barben Technical Support for more information.

For new installations, the Barben 546 sensor can be specifi ed for installation pressure up to 300 PSIG. Either 316 Stainless or Titanium Grade 2 hardware is available to complete the installation. The advantage of this design is that the 546 pH sensor is frequently used for other installa-tions. A dedicated sensor for high pressure is not needed. This reduces inventory and replacement hassles. Consult the Barben Accessories Datasheet for more information on hardware options.

ProcessPipeline

ProcessPipeline

BARBEN 546 SENSOR0.5” TIP REQUIRED

Barben 546 with High Pressure Hot Tap HardwareInserted (top) & Retracted (bottom)

TB567/ TBX567The TB567 is ABB’s in-line high pressure sensor. This de-sign uses a dedicated pH sensor with a 1 inch NPT metal housing to withstand pressure up to 1000 PSIG.

The Barben equivalent product uses the 547 cartridge style sensor in a 1 inch high pressure housing. This product can be certifi ed up to 2500 PSIG. Material op-tions include 316 SS, Titanium Grade 2, and Hastelloy C. Insertion depths from 1 to 4.5 inches can be offered to accommodate many different mounting scenarios. The Barben 547 sensor and housing mounts directly in place of the ABB product. Individual sensor and housings are dedicated for each manufacturer.

Figure 6


INSTALLING IN HOUSING

547 SENSOR HIGH PRESSURE HOUSING

3/4" NPTTHREAD1" NPT THREAD

(PROCESS CONNECTION)

COMPLETE 547 HIGH PRESSURE ASSEMBLY

Barben 546 with High Pressure In-line Hardware Figure 7


4

Wiring to ABB TB82 / TB84 (Top) and AX4 Analyzers (Bottom)

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BARBEN ANALYZER TECHNOLOGYpH / ORP SENSOR

546/547/567/551/554

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5

Rosemount pH/ORP Sensors

Rosemount Model TempSensor

BodyMaterial

Mounting Style BATModel

Barben Application Notes

385 / 385+ Tefzel Ball Valve Hot Tap 547 Barben 547 with 16" titanium sheath

389 Tefzel 1" NPT Threaded 551 389 uses 1" NPT process connection. Barben 551 Sensor with Nut Lock Adapter for inline applications

396P / 396PVP TUpH Polypro 1" NPT Threaded 551 396P uses 1" NPT process connection. Barben 551 Sensor with Nut Lock Adapter for inline applications

396 / 396VP TUpH Polypro 1" NPT with compression fitting 547 Barben 547 with 8" 316 stainless sheath 398VP TUpH Tefzel 1" NPT with compression fitting 547 Barben 547 with 8" titanium sheath

396R / 396RVP TUpH Polypro Ball Valve Hot Tap 547 Barben 547 with either 20" or 36" titanium sheath 398RVP TUpH Tefzel Ball Valve Hot Tap 547 Barben 547 with either 20" or 36" titanium sheath

3900 Ryton 3/4" or 1" NPT Threaded 551546

3900 has both 3/4" and 1" threads on sensor body. Use 546 for 3/4" mount. Use 551 with Nut Lock Adapter if 1" mount.

3300HT PERpH-X Ryton 1" NPT with compression fitting 547 Barben 547 with 8" titanium sheath 3400HT PERpH-X Ryton Ball Valve Hot Tap 547 Barben 547 with 24" or 36" titanium sheath

3500P PERpH-X Ryton 1" NPT Threaded 551 Rosemount 3500 uses 1" NPT process connection. Barben 551 Sensor with Nut Lock Adapter for inline applications

372 PT100 Ultem 3/4" NPT Threaded 546 Use 546 with 2" insertion depth. This sensor for HF Acid applications thus consider "FR" glass or Antimony electrode

3k BalcoPT100

PT100

General NotesThe Emerson analytical business got its start as Universal Interloc and later became known as the Uniloc division of Rosemount. Ted Barben, inventor of the current Barben Axial Ion Path® technology was one of the founders of the original Universal Interloc business. Most Rosemount sen-sors use conventional double or triple junction reference designs with either polymer gel or liquid KCl electrolyte. The quick reference guide above lists the most common Rosemount sensors however there are a few specialty products not covered in this guide. Consult Barben techni-cal support for products not listed here.

385 / 385+The 385 is Rosemount’s original hot tap retractable pH sensor. The sensor construction includes a 16 inch tita-nium body and Tefzel tip. When the 385 sensor needs replacement the entire assembly must be replaced and a costly new 16 inch sensor is purchased. The Barben retrofi t solution uses the 547 cartridge style sensor with a reusable 16 inch sheath kit. The Barben sheath kit is available in 316 SS, Titanium Grade 2, and Hastelloy C for compatibility with nearly any chemical process. Longer sheath kits are also available for diffi cult mounting appli-cations. Compression fi ttings and valves are interchange-able between both products.

389The Rosemount 389 is the in-line / submersible version of the 385 sensor. The problematic tip design for both prod-ucts can be seen in Figure 8. The entire 389 sensor body is molded Tefzel with 1 inch NPT threads for mounting. When the 389 sensor is mounted in-line (typically through a 1.5 inch or larger pipe tee) the Barben 551 sensor is best

Rosemount 385 / 385+The images to the right show the tip of the Rose-mount 385 sensor. The Tefzel body is molded into the titanium sheath. The entire assembly must be disposed of when the sensor has died.

There are no tip options for this product thus processes such as slurries tend to get packed up in the crevices around the glass. The Reference junction is quite tiny and susceptible to plugging.

The maximum temperature of the probe is 212°F (100°C) which is quite low for this style of sensor.

Reference Junction

replacement product. The Nut-Lock adapter will provide a 1” NPT process connection. The 551 sensor with 4.5 inch length and notched tip most closely matches the Rose-mount sensor insertion length. If the 389 sensor is mount-ed in a submersible installation then a 3/4 to 1 inch bush-ing will be needed for retrofi t. Reference Figure 9 below.

Figure 8

O-RING

3/4" NPT INSERTION LENGTH4.5”

1" NPT

BARBEN551 SENSOR

BARBEN551 SENSOR

ROSEMOUNT389 SENSOR

1" NPT NUT-LOCKADAPTER FOR MOUNTING

2.6”

2.75”

Rosemount 389 Comparison

Figure 9

ROSEMOUNT 396 / 398 / 3300 SENSOR

ROSEMOUNT 396R / 398R / 3400 HOT TAP SENSOR

21 & 36” LENGTH OPTIONS

3/4" NPT


INSTALLING IN SHEATH

METALLIC SHEATH

BARBEN 547 SENSOREXTENSION

SENSOR CABLE FED THROUGH EXTENSION AFTER

INSTALLATION IN SHEATH

BLOWOUTSAFETY STOP

1 2

34

VARIOPINOPTION

O-RING


1" NPT

BARBEN551 SENSOR

BARBEN551 SENSOR

ROSEMOUNT 396P /3500 SENSOR


2.22”

2.25”

VARIOPINOPTION

1" NPT

ROSEMOUNT3900 SENSOR

2.33”

0.92”

O-RING


BARBEN551 SENSOR

BARBEN551 SENSOR


2.25”

BARBEN546 SENSOR

1.0”

1" NPT

3/4" NPT

3/4" NPT


6

Rosemount pH/ORP Sensors3900The Rosemount 3900 sensor is another the in-line / sub-mersible sensor. This product is an update of the older 389 product and includes such features as an external solution ground, external temperature compensation, and smart sensor abilities. Even with these improvements, the 3900 sensor uses a double junction reference thus cannot provide the long life and stability of the Barben products.

These sensors use either 3/4 or 1 inch NPT mounting for in-line applications. If the3/4 inch mounting is used the Barben 546 sensor with 1 inch insertion is recommended. In 1 inch NPT installations use the Barben 551 sensor mounted with the convenient Nut-Lock adapter and 4 inch insertion depth. Submersible installations will require a bushing to adapt the rear of the Barben sensor.

Rosemount 3900 Comparison Figure 10

Barben 546 Sensoruse 3/4” NPT Mounting and 1” Insertion Length

Barben 551 SensorUse 1” NPT Nut Lock Adapterand 4” Insertion Length

Titanium Sheath Kits for 396 / 398 / 396R / 398R / 3300 / 3400 ReplacementO-RingOptions

8” Sheath Kits (3300 Replacement)

20” Sheath Kits(3400 Replacement)

36” Sheath Kits(3400 Replacement)

VITON B5104-0058V B5104-0120V B5104-0136VEPDM B5104-0058E B5104-0120E B5104-0136E

KALREZ B5104-0058K B5104-0120K B5104-0136K

Successful replacement of Retractable Rosemount sensors involves specifying a 547 cartridge sensor (“3” in drawing above) and a sheath kit. The sheath kit includes items “2” and “4” in the drawing above. Barben provides different o-ring options for our sheath kits for full material compatibility. The compression fi tting (“1” in the drawing above) can either be reused or a new compression fi tting from Barben can be specifi ed.

Rosemount TUpH & PERpH-X Comparison Figure 11

Barben 551 SensorUse 1” NPT Nut Lock Adapterand 4” Insertion Length

396 / 398 / 396R / 398R TUpH The TUpH product line is Rosemount’s solution for diffi -cult process pH measurements. The reference half cell design uses a helical path to lengthen the distance from the process liquid to the AgCl reference element. Their design idea is that poisoning will take longer to occur if the distance between the contaminant and the reference element is extended. Rosemount has also incorporated a triple junction seal within the reference pathway to further block the ingress of the poisoning liquids.

The TUpH design should be more successful than their 385 and 389 products in harsh industrial applications;

however, the overall internal design is quite complex thus adding cost and potential manufacturing variances. When a customer adds on a pre-amplifi er, smart sensor capa-bilities, or a Variopin connector the cost further increases. Interestingly, the new PERpH-X products seem to have been added to replace the TUpH products since the prod-uct lineup is nearly identical.

3300 / 3400 / 3500 PERpH-X PERpH-X is Rosemount’s new family of smart pH/ORP sensors. These products include a pre-amplifi er with additional circuitry to digitally communicate calibration and diagnostics information with newer Rosemount analyzers.

The other big modifi cation with this product line is the abili-ty to rebuild the sensor in the fi eld. Rebuild kits include the


7

reference junction and electrolyte-fi lled syringes. Specifi c kits are available depending on the process (ie - high temp kits, poison resistant kits, oil resistant kits). The addition of electronics at the sensor and the ability to rebuild the prod-uct still do not hide the fact that the PERpH-x design still uses a multi-junction reference half-cell. Loss of accuracy, frequent costly rebuilds, and ongoing maintenance costs cannot be ignored.

The three products in the PERpH-x line include two vari-ably insertion sensors: 3300 and 3400. The 3300 is an 8 inch titanium body sensor with a wrench tight compression fi tting. The 3400 sensor is a longer (20 or 36 inch) titanium body sensor designed to fi t through an isolation ball valve. Both products cross reference to the Barben 547 cartridge style sensor seen below.

The fi nal PERpH-x product is the model 3500. This sen-sor uses a molded Ryton body with 1 inch NPT process connection. The physical design is similar to the 389 and 3900 sensors thus the Barben 551 should be specifi ed.

12

3 - RTD

RTN

4 - RTD

SE

N5 - R

TD IN

6 - DR

AIN

7 - RE

F

8 - SO

L GN

D

9 - DR

AIN

10 - mV

IN

11 - -5VD

C

12 - +5VD

C13 - A

NO

DE

14 - CA

THO

DE

15 - -24VD

C

16 - +24VD

C

"IMPO

RTAN

T WAR

NIN

G"

THE W

IRIN

G SH

OW

S A SENSO

R W

ITH A "SO

L GR

ND

"W

HIC

H IS AVAILABLE IN

MO

DELS W

ITH ( G

T, UT & LT)

e.g. ( B-V-546-X-LT-X-X-X-X-X-X )

FOR

SENSO

RS W

ITHO

UT SO

LUTIO

N G

RO

UN

D ( FT, ST & D

T )YO

U M

UST IN

STALL A JUM

PER

AND

SENSO

R D

IAGN

OSTIC

S MU

ST BE TUR

NED

OFF.

FOR

SENSO

RS W

/O TC

, DISR

EGAR

D TC

WIR

ES. PRO

GR

AMAN

ALYZER FO

R M

ANU

AL TEMPER

ATUR

E CO

MPEN

SATION

.

FOR

OR

P SENSO

RS C

OAX C

OR

E WILL BE LABELED

"OR

P IN" AN

D W

IRIN

G IS TH

E SAME.

"REF" - W

HITE

JUM

PE

R

ANALYZERCONFIGURATION

ANDSETTINGS

• WIR

ING

Des cription

Terminal

"TC R

ET" - Green 3

"TC SN

SE" - Black 4 "TC

IN" - R

ed 5 "R

EF" - White 7

"SOL G

RN

D" - C

lear (Drain) 8

"pH SH

LD" - C

oax Grey 9

"pH IN

" - Coax C

ore Wire 10

• Analyzer accepts PT100 & PT1000 RTD

's

• Select automatic tem

perature compensation m

ode (tAUTO

On)

•Select Integral Pre-Am

p XMTR

(PAMP=trAnS).

If sensor cable > 30-ft Pre-Am

p Required. C

onsult XMTR

Manual.

3

3 12

7 "REF"

8 "SOL G

RN

D"

"TC RET" - Green

"TC SNSE" - Black

"TC IN" - Red

"REF" - White

"SOL G

RND" - Clear

"pH IN

" Coax C

ore

1

BAR

BEN

ANALYZER

TECH

NO

LOG

Y (BAT) pH

/OR

P SENSO

R W

IRED

TO R

OSEM

OU

NT 5081-P

BAT SEN

SOR

CO

NFIG

UR

ATION

"E" TERM

INATIO

N

2P0263

02/22/20131 O

F 21 : 1

5081-P TO

BA

T pH/O

RP

SEN

SO

RS

W. C

OW

AN

A

BA

T pH/O

RP

SEN

SOR

"E" TE

RM

INA

TION

RO

SE

MO

UN

T 5081-P TR

AN

SMITTE

R

- 02/22/13 INITIAL WC JL

NA

UN

LES

SO

THE

RW

ISE

SP

EC

IFIED

ALL ± .015"FR

ACTIO

NAL

.000 ± .005".00 ± .010".0 ± .015"

FOR

AP

VD

BY

DR

AW

N B

YDRAW

ING NO

DATESCALE

SIZESHEET APVDDW

NDESCRIPTIO

NDATE

REVREVISIO

NS

ANGLES ± 1/4°

TOLER

ANC

ES

DIM

ENSIO

NS

IN IN

CH

ES

ECO5200 C

onvair Drive C

arson City, N

V 89706 PH(775)883-2500 FAX (775)297-4740

J. LANG


546/547/567/551/554

2

SENSO

R C

ABLE OR

B39 EXTENSIO

N C

ABLE

3

Rosemount pH/ORP Sensors

Wiring to Rosemount 5081P Transmitters

Rosemount RB SensorsIt should be noted that with all the various sensor designs Rosemount has developed their organizaton still turned to Barben Analytical to market an OEM product for harsh industrial applications. This product is a Barben design sold as the “RB” Series. If these products are encountered in the fi eld please contact Barben sales for support.


8

Wiring to Rosemount 1056 (top) and 1066 (bottom) Analyzers

2P02

66

05/0

7/20

131

OF

2

1056

TO

BA

T pH

SE

NS

OR

S

W. C

OW

AN

A

BA

T pH

/OR

P S

ENSO

R "E

" TE

RM

INA

TIO

NR

OS

EM

OU

NT

1056

-

0

5/07

/13

I

NITI

AL

W

C

JL

1637

UN

LES

SO

THE

RW

ISE

SP

EC

IFIE

D

ALL

± .0

15"

FRAC

TIO

NAL

.000

± .0

05"

.00

± .01

0".0

± .0

15"

FOR

AP

VD

BY

DR

AW

N B

YDR

AWIN

G N

O

DATE

SCAL

ESI

ZESH

EETAP

VDDW

NDE

SCRI

PTIO

NDA

TERE

VRE

VISI

ONS

ANGL

ES ±

1/4°

TOLE

RAN

CES

DIM

ENSI

ON

SIN

INC

HES

ECO

5200

Con

vair

Driv

e C

arso

n C

ity, N

V 89

706

PH(7

75)8

83-2

500

FAX

(775

)297

-474

0

"TC

RET

" - G

reen

"TC

SN

SE" -

Bla

ck"T

C IN

" - R

ed

"REF

" - W

hite

"SO

L G

RN

D" -

Cle

ar

"pH

SH

LD" -

Gre

y

"pH

IN" C

oax

Cor

e

J. L

ANG

BARB

EN A

NALY

ZER

TECH

NOLO

GY (B

AT) p

H/OR

P SE

NSOR

- W

IRED

TO

ROSE

MOU

NT 1

056

BAT

SENS

OR C

ONFI

GURA

TION

: "E"

TER

MIN

ATIO

N

"IMPO

RTA

NT

WAR

NIN

G"

TH

E W

IRIN

G S

HO

WS

A SE

NSO

R W

ITH

A "S

OL

GR

ND

"W

HIC

H IS

AVA

ILAB

LE IN

MO

DEL

S W

ITH

( G

T, U

T &

LT)

e.g.

( B-

V-54

6-X-

LT-X

-X-X

-X-X

-X )

FOR

SEN

SOR

S W

ITH

OU

T SO

LUTI

ON

GR

OU

ND

( FT

, ST

& D

T )

Y OU

MU

ST IN

STAL

L A

JUM

PER

AND

SEN

SOR

DIA

GN

OST

ICS

MU

ST B

E TU

RN

ED O

FF.

F

OR

SEN

SOR

S W

/O T

C, D

ISR

EGAR

D T

C W

IRES

. PR

OG

RAM

ANAL

YZER

FO

R M

ANU

AL T

EMPE

RAT

UR

E C

OM

PEN

SATI

ON

.

F

OR

OR

P SE

NSO

RS

CO

AX C

OR

E W

ILL

BE L

ABEL

ED "

OR

P IN

" AN

D W

IRIN

G IS

TH

E SA

ME.

ANAL

YZER

CONF

IGUR

ATIO

NAN

DSE

TTIN

GS•

WIR

ING

Des

crip

tion

Term

inal

"T

C R

ET" -

Gre

en

1

"T

C S

NSE

" - B

lack

2

"TC

IN" -

Red

3

"S

OL

GR

ND

" - C

lear

(Dra

in)

4

"pH

SH

LD" -

Coa

x G

rey

7

"p

H IN

" - C

oax

Cor

e W

ire

8

"R

EF" -

Whi

te

1

0

• An

alyz

er a

ccep

ts P

T100

& P

T100

0 R

TD's

• Se

lect

aut

omat

ic te

mpe

ratu

re c

ompe

nsat

ion

mod

e.

• Se

lect

Inte

gral

Pre

-Am

p XM

TR.

If

sen

sor c

able

> 3

0-ft

Pre-

Amp

Req

uire

d. C

onsu

lt XM

TR M

anua

l.


546/547/567/551/554

SEN

SOR

CAB

LE O

RB3

9 EX

TEN

SIO

N C

ABLE

2

3

3

3

11 2

1

1 2 3 4 5 6 7 8 9 10

BAC

K VI

EW 1

056

PCB

4

GN

D

"REF

" WH

ITE

10

R

EF

JUM

PER

2P02

71

08/2

6/20

131

OF

21

: 11066

TO

BA

T pH

SE

NS

OR

S

W. C

OW

AN

A

BA

T pH

/OR

P S

ENSO

R "E

" TE

RM

INA

TIO

NR

OS

EM

OU

NT

1066

-

0

8/26

/13

I

NITI

AL

W

C

JL

1727

UN

LES

SO

THE

RW

ISE

SP

EC

IFIE

D

ALL

± .0

15"

FRAC

TIO

NAL

.000

± .0

05"

.00

± .01

0".0

± .0

15"

FOR

AP

VD

BY

DR

AW

N B

YDR

AWIN

G N

O

DATE

SCAL

ESI

ZESH

EETAP

VDDW

NDE

SCRI

PTIO

NDA

TERE

VRE

VISI

ONS

ANGL

ES ±

1/4°

TOLE

RAN

CES

DIM

ENSI

ON

SIN

INC

HES

ECO

5200

Con

vair

Driv

e C

arso

n C

ity, N

V 89

706

PH(7

75)8

83-2

500

FAX

(775

)297

-474

0

"TC

RET

" - G

reen

"TC

SN

SE" -

Bla

ck"T

C IN

" - R

ed

"REF

" - W

hite

"SO

L G

RN

D" -

Cle

ar

"pH

SH

LD" -

Gre

y

"pH

IN" C

oax

Cor

e

J. L

ANG

BARB

EN A

NALY

ZER

TECH

NOLO

GY (B

AT) p

H/OR

P SE

NSOR

- W

IRED

TO

ROSE

MOU

NT 1

066

BAT

SENS

OR C

ONFI

GURA

TION

: "E"

TER

MIN

ATIO

N

ANAL

YZER

CONF

IGUR

ATIO

NAN

DSE

TTIN

GS•

WIR

ING

Des

crip

tion

Term

inal

- La

bel

"T

C R

ET" -

Gre

en

"TC

SN

SE" -

Bla

ck

"TC

IN" -

Red

"R

EF" -

Whi

te

"SO

L G

RN

D" -

Cle

ar (D

rain

)

"pH

SH

LD" -

Coa

x G

rey

"p

H IN

" - C

oax

Cor

e W

ire

• An

alyz

er a

ccep

ts P

T100

& P

T100

0 R

TD's

• Se

lect

aut

omat

ic te

mpe

ratu

re c

ompe

nsat

ion

mod

e.

• Se

lect

Inte

gral

Pre

-Am

p XM

TR.

• If

sens

or c

able

> 3

0-ft

Pre-

Amp

Req

uire

d. C

onsu

lt XM

TR M

anua

l.


546/547/567/551/554

SEN

SOR

CAB

LE O

RB3

9 EX

TEN

SIO

N C

ABLE

2

3

3

"IMPO

RTA

NT

WAR

NIN

G"

TH

E W

IRIN

G S

HO

WS

A SE

NSO

R W

ITH

A "S

OL

GR

ND

"W

HIC

H IS

AVA

ILAB

LE IN

MO

DEL

S W

ITH

( G

T, U

T &

LT)

e.g.

( B-

V-54

6-X-

LT-X

-X-X

-X-X

-X )

FOR

SEN

SOR

S W

ITH

OU

T SO

LUTI

ON

GR

OU

ND

( FT

, ST

& D

T )

Y OU

MU

ST IN

STAL

L A

JUM

PER

AND

SEN

SOR

DIA

GN

OST

ICS

MU

ST B

E TU

RN

ED O

FF.

FO

R S

ENSO

RS

W/O

TC

, DIS

REG

ARD

TC

WIR

ES. P

RO

GR

AMAN

ALYZ

ER F

OR

MAN

UAL

TEM

PER

ATU

RE

CO

MPE

NSA

TIO

N.

FO

R O

RP

SEN

SOR

S C

OAX

CO

RE

WIL

L BE

LAB

ELED

"O

RP

IN" A

ND

WIR

ING

IS T

HE

SAM

E.

"REF

" - W

HIT

E

R

EF

SH

LD

SO

L G

ND

JUM

PER

311 2

TB3

- RTN

TB3

- SN

STB

3 - R

TD IN

TB2

- REF

TB2

- GN

D S

OL

TB1

- SH

LDTB

1 - p

H


9

Mettler Toledo pH/ORP Sensors

General NotesSwiss-based Mettler Toledo got its start in instrumentation by manufacturing laboratory weighing scales. Their analyt-ical product line was developed through the acquisition of Ingold in 1986 (pH/ORP, Dissolved O2, turbidity) and later Thornton in 2001 (conductivity products). Ingold focused on the food and pharmaceutical industries. This history is readily apparent in their current product offering.

The vast majority of Mettler’s sensor offering is based on the 12mm pH sensor standard (DIN 19263) used for com-bination laboratory electrodes. 12mm pH sensors cannot be mounted directly into piping. They require specialized holders to install into the process. Due to this fact, the sensor part number AND sensor holder part number are needed to cross reference the product. The InPro product shown in Figure 12 is the exception to this rule as they are sold with a molded body.

Mettler ToledoModel Number

TempSensor

BodyMaterial



InPro 4501 (Sensor) Kynar 1" NPT Threaded 551 1" NPT process connection. Barben 551 Sensor with Nut Lock Adapter for inline applications.

InPro 4550 (Sensor) Ryton 1" NPT Threaded 551 1" NPT process connection. Barben 551 Sensor with Nut Lock Adapter for inline applications.

InFit 761 (Holder)InFit 764 (Holder)

3/4" or 1" NPT ThreadedIngold DN25 Socket Mount

551546

InFit holders have multiple mounting options. If threaded connection then use the following 546 for 3/4" mount. 551 with Nut Lock Adapter if 1" mount. If mounting into a DN25 bushing then the 551 sensor will mate with the connector.

InTrac 776e (Holder)InTrac 777e (Holder)InTrac 797e (Holder)

1, 1-1/4, 1-1/2" NPT RetractableIngold DN25 Socket Mount

ANSI and DN Flanges

551547

InTrac holders have multiple mounting options. 551 with Nut Lock Adapter if 1" mount. If mounting into a DN25 bushing then the 551 sensor will mate with the connector. All retractable mounting options should consider 547 or 567 hot tap products.

PT100PT1000

N/A Various

Figure 12Mettler Toledo pH Sensor ExamplesInPro 4550 (Top) with molded Ryton bodyTypical 12mm pH sensor (bottom) without the sensor holder required for mounting

InPro and InFit ProductsFor threaded in-line mounting Mettler Toledo has two prod-ucts lines: InFit and InPro. The InFit holders can be speci-fi ed with a variety of process connections. The most com-mon industrial holders are based on 3/4 and 1 inch NPT connections that match the Barben 546 and 551 products. The insertion depth of the holder is identifi ed as part of the InFit model number. Matching Barben insertion depths are covered in the chart to the right. The InPro products cross reference directly to the Barben 551 sensors (4.5” Length).

Mettler Toledo InFit Holder 3/4” and 1” NPT Cross ReferenceMettler Toledo Dimensions

12mm Sensor Length

Barben 546 Tip Length +/- Length* Barben 551

Tip Length +/- Length*

40mm 120mm 0.5” -0.33” (-8mm) N (2.625”) +0.29” (+7mm)70mm 120mm 2” -- 3.5” -0.02” (-0.5mm)100mm 150mm 3” -0.19” (-5mm) 4.5” -0.2” (-5mm)150mm 200mm 5” -0.16” (-4mm) 6.5” -0.25” (-6mm)175mm 225mm 7.5” -0.16” (-4mm)200mm 250mm 8.5” -0.14” (-3.5mm)275mm 325mm 11.5” -0.09” (-2mm)375mm 425mm

O-RING

3/4" NPT

BARBEN551 SENSOR

METTLER TOLEDO 12mm pH SENSOR

METTLER TOLEDOINFIT 761 HOLDER

3/4 OR 1" NPTINGOLD DN25 FITTING

BARBEN551 SENSOR


BARBEN546 SENSOR

3/4" NPT

METTLER TOLEDOINSERTION DIMENSIONS

SEE CHART

SEE CHART

HARDWIRE, VARIOPINOR OTHER CONNECTOR

INGOLD DN25FITTING

G 1-1/4” DINCONNECTION

TANKWALL

1" NPT

METTLER TOLEDOINPRO 4501 / 4550

SENSOR

2.85”1" NPT

INGOLD FITTING UNION NUT

Mettler Toledo InFit and InPro Products Figure 13

NOTE - For InPro products use Barben 551 Sensor with Nut Lock Adapter and 4.5” Insertion Length

Also pictured above is the Ingold DN25 fi tting. This design uses a union nut to secure the sensor in the process. It is rarely seen outside the pharmaceutical industry. If this fi tting is encountered, the Barben 551 sensor can be installed. The insertion depth of the sensor should be de-termined based on fi tting depth and tank wall thickness.

* Negative = Shorter then MT Sensor. Positive = Longer then MT SensorHighlighted red lengths may be candidates for other sensors. Consult Barben Technical Support.


10

InTrac ProductsThe InTrac product line is Mettler Toledo’s unique solution for retractable pH sensor applications. Instead of a tradi-tional isolation ball valve, the InTrac assembly retracts the sensor into a sealed chamber. Retraction of the sensor can be done either manually or pneumatically. Mettler Toledo promotes the pneumatic solution whenever pos-sible. The function is similar to a hydraulic cylinder with two taps to pressurize the cylinder and move the sensor back and forth. Many additional features are available for Intrac products. Optional sensor position indicators can be added to detect the physical presence of the sensor and the position (in process or retracted). Position rods keep the sensor from rotating while being inserted or retracted. Fully automated cleaning and calibration systems can be retrofi tted to the InTrac to service the sensor without re-moval from the process. Even without the various options mentioned above the InTrac is an expensive, complex solution to move a sensor in and out of the process while avoiding shutdown.

When one considers Mettler Toledo’s target market; the pharmaceutical industry, then the InTrac makes perfect sense. Pharmaceutical and biotechnology processes are typically batch reactions. A pH measurement is only required for the duration of the reaction. Once the batch process is completed the pH sensor needs to be removed for calibration or replacement while the reactor vessel and associated piping are cleaned for the next batch. This requirement is much different then the steady state, con-tinuous processes found in refi neries, pulp mills, and other industries that Barben Analytical focus on.

Figure 14 shows the InTrac 777e retractable holder with two styles of process connections suitable for industrial applications. For threaded process connections a female NPT union nut is used to mount the InTrac. The design is modular thus an ANSI 150# fl ange can also be mounted in place of the union nut. The insertion depth of the 12mm sensor is limited to 200mm (7-7/8 inches). Applications where an extended nipple or fl ange is required to mount the sensor assembly maybe create issues with the InTrac length restriction.

METTLER TOLEDO pH SENSOR

HARDWIRE, VARIOPINOR OTHER CONNECTOR

PIPE NIPPLE(MAY NOT BE NEEDED)

1-1/4” OR 1-1/2“FULL PORT BALL VALVE

UNION NUT OPTIONSINGOLD DN25

1-1/4” FNPT1-1/2” FNPT

FLANGE OPTIONS1-1/2” 150#

2” 150#3” 150#

METTLER TOLEDOINTRAC RETRACTABLE

SENSOR HOUSING

BARBEN 547 SENSOR ASSEMBLY

BARBEN 567 ALL PLASTIC SENSOR ASSEMBLY

1-1/4” OR 1-1/2“KYNAR BALL VALVE

PEEK, KYNAR, OR TEFLONCOMPRESSION FITTING OPTIONS

(PEEK WITH STOP LOCK COLLAR SHOWN)

BARBEN 546 SENSOR


Mettler Toledo InTrac Products Figure 14

Traditional hot tap sensors such as the Barben 547 should be presented when replacing an InTrac retraction sys-tem. Off-the-shelf valves and hardware make the Barben solution simple and cost effective. InTrac assemblies are limited to 87 PSIG (6 BAR) maximum thus high pressure applications can take advantage of the Barben 546 sensor with high pressure retraction hardware (rated up to 300 PSIG (20 BAR)). If the application is highly corrosive then the Barben 567 All Plastic Hot Tap sensor will provide a more robust solution then similar offerings from Mettler Toledo.

Mettler Toledo pH/ORP Sensors

Mettler Toledo InTrac Retractable HousingInTrac Model

Number Application

776e Used with liquid electrolyte pH sensors that require a pressurized reference junction. Air supply required.

777e Most common industrial housing for use with gel fi lled 12mm sensors (pictured in fi gure 14)

797e The 797e is a stainless steel steam sterilizable housing targeted specifi cally for food, beverage, and pharmaceutical applications.


11

Mettler Toledo 2100 pH Analyzer

2P0267

05/06/20131 O

F 21 : 1

2100e/2(x)H TO

BA

T pH S

EN

SO

RS

W. C

OW

AN

A


1640U

NLE

SS

OTH

ER

WIS

ES

PE

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J. LANG

BARBEN ANALYZER TECHNOLOGY (BAT) pH/ORP SENSOR - WIRED TO M

ETTLER-TOLEDO 2100e/2(X)HBAT SENSOR CONFIGURATION: "E" TERM

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12

Yokogawa pH/ORP Sensors

YokogawaModel Number

TempSensor

BodyMaterial



FU20 / FU20F Ryton 3/4" or 1" NPT Threaded 546551

FU20 has molded 3/4" NPT threads. If using these threads select 546 sensor. The FU20 is also compatible with a 1" NPT Adapter. Barben replacement would be 551 with Nut Lock Adapter.

FU24 Ryton 1" NPT Threaded 551 The FU24 uses a 1" NPT threaded connection. Use Barben 551 with Nut Lock Adapter for most applications.

PH20 Kynar 3/4" or 1" NPT Threaded using Adapters

546551

PH20 probes use either 3/4" or 1" adapters. Consider the 546 or 551 sensor. Consult Barben on how sensor is mounted.

PH87 / PH97 Ryton Ball Valve Hot Tap 547PH87 is the hardware, PH97 is the sensor. Use Barben 547 with 8" or 24" sheath (Yokogawa sheath is titanium but other materials can be used).

PH18 Ceramic 1" NPT ThreadedIngold DN25 Socket Mount 551 Specially designed Pfaudler Sensor. Consult Barben on installation.

Will require application data.No w

SC SM SR SV Series Glass 12mm Sensors with holders 546551

Yokogawa 12mm sensors have multiple mounting options. If threaded connection then use the following 546 for 3/4" NPT; 551 with Nut Lock Adapter if 1" mount. If mounting into a DN25 bushing then the 551 sensor will mate with the connector.

FF20 / FS20 (Holders) N/A Various 3/4" or 1" NPT Threaded 546551

These common flowcells can be adapted for use with Barben 546 and 551 sensors. Consult Technical Support for more information.

PT1000

General NotesYokogawa is Japan’s premiere instrumentation supplier. They are a full line global supplier with manufacturing in the United States since 1980. Yokogawa has been successful in pH/ORP measurement by expanding their product line through various partnerships with other analytical companies (a fact which is not hidden in their literature and website). The FU products listed below are part of Yokogawa’s original design while their retractable hot tap sensors are manufactured by Broadley James and their 12mm sensors are supplied by the Hamilton Com-pany. While this approach creates a somewhat confusing product line, it provides Yokogawa customers with a wide variety of options for pH measurement.

FU20 / FU24 / PH20 SensorsThe FU and PH series sensors are Yokogawa’s molded body pH sensors for in-line mounting. The FU20 is the most widely known Yokogawa sensor. It uses a tradition-al double junction reference design and a molded Ryton body with 3/4” NPT threads for either in-line or submersible mounting. The FU20 body can be fi tted with a 1” NPT adapter similar to Barben’s Nut-Lock Adapters. When this is encountered the 551 sensor is the correct replacement.

The PH20 sensors incorporate a similar internal design to the FU20 but uses a Kynar molded body for additional chemical resistance. The PH20 cannot be mounted direct-ly into the process. It requires a separate, dedicated 3/4” or 1” NPT fi tting which the sensor threads into.

The fi nal sensor of note is the FU24. The FU24 has a wider 1” Ryton body. The physical size allows a special pressurized double junction reference half cell. A bellows

mechanism is used to keep pressure on the KCl electro-lyte thus preventing process chemicals from poisoning or plugging the reference. While the bellows reference design used in the FU24 is an improvement over the double junction references used in the FU20 and PH20, it is still has issues. High process pressures can still overpower the bellows mechanism allowing contamination of the electrolyte. As the KCl electrolyte is depleted over time the pressurizing affect of the bellows mechanism can change. This change in pressure creates create errors in reading which must be corrected by calibration. Because of the calibration and pressure issues Yokogawa has started to target the FU24 sensor at pure water measurements which are typically installed on pressure regulated sample lines.

Yokogawa FU20 Sensor Example Figure 15

FU20 with Hemispherical Glass

Directly above the glass electrode is a platinum solution ground. The solution ground element can be used as an ORP electrode. This allows one sensor to be used for ORP and pH measure-ment. (This is a nice feature if the process requires both mea-surements. If not then it adds additional cost and a single point of failure for both measurements if the reference is contaminated.)


13

O-RING

3/4" NPT INSERTION LENGTHSEE CHART

BARBEN551 SENSOR

BARBEN551 SENSOR


BARBEN546 SENSOR

SEECHART3/4" NPT

2.3”

0.39”

0.89”

2.2”

2.8”

SEE CHART

FU20 WITH FLAT GLASS

FU20 WITH HEMI GLASS

FU20 WITH 1” ADAPTER &HEMI GLASS

FU24 WITH FLAT GLASS

FU24 WITH HEMI GLASS

PH20 WITHOUT ADAPTERS

1" NPT

3/4" NPT

3/4" NPT

1" NPT

1" NPT

1" NPT

G3/4 FOR ADAPTERS

INSERTION LENGTHSEE CHART

3/4" NPT

3/4" NPT

1" NPT

Yokogawa pH/ORP Sensors

Yokogawa FU20 / FU24 / PH20 Products

Yokogawa FU20 / FU24 / PH20 Cross Reference

Yokogawa Sensor Recommended Barben Sensor +/- Length*

FU20 Flat Tip, 3/4” Mtg 546 Kynar, 0.5” FT tip, FG glass +0.11” (+3mm)

FU20 Notch Tip, 3/4” Mtg 546 Kynar, 1” DT tip, R glass +0.11” (+3mm)

FU20 Flat Tip, 1” Adptr 551 Kynar, 3.5” FT tip, FG glass + Nut-Lock -0.13” (-3.2mm)

FU20 Notch Tip, 1” Adptr 551 Kynar, 4” DT tip, R glass + Nut-Lock -0.13” (-3.2mm)

FU24 Flat Tip, 1” Mtg 551 Kynar, 4” FT tip, FG glass + Nut-Lock -0.03” (-1mm)

FU24 Notch Tip, 1” Mtg 551 Kynar, 4.5” DT tip, R glass + Nut-Lock -0.13” (-3.2mm)

PH20 Notch Tip, 3/4” Adptr 546 Kynar, 3” DT tip, R glass +0.26” (+6.6mm)

PH20 Notch Tip, 1” Adptr 551 Kynar, 4.5” DT tip, R glass + Nut-Lock -0.07” (-1.7mm)

Figure 16

* Negative = Shorter then Yokogawa Sensor. Positive = Longer then Yokogawa Sensor

YOKOGAWA 3/4”ADAPTER (K1523DD)

YOKOGAWA FD40SUBMERSIBLE HOLDER

YOKOGAWA FF40FLOWCELL HOLDER

BA

RB

EN

546

S

EN

SO

R

BA

RB

EN

546

S

EN

SO

R

YOKOGAWA FF20 FLOWCELL

BA

RB

EN

SE

NS

OR

YOKOGAWA FS20 IN-LINE ADAPTER

BA

RB

EN

SE

NS

OR

BARBEN ADAPTERSEE CHART

BARBEN ADAPTERSEE CHART

Due to the physical variations in the FU20 / FU24 / PH20 products Yokogawa offers a variety of fi ttings to mate these products to their sensor holders. If the FU20 is already installed the equivalent Barben 546 sensor will fi t directly in place of the Yokogawa sensors. Certain Yokogawa fl owcells and adapters such as the FS20 and FF20 series have additional fi ttings for Yokogawa 12mm sensors. Bar-ben Analytical has developed specifi c replacement adapt-ers to replace into these sensor holders. Figure 17 below provides some examples. If your specifi c holder is not pictured below then contact technical support for additional assistance.

Common Yokogawa Holders Figure 17

Barben 546 & 551 Adapters for Yokogawa FF20 / FS20 Sensor Holders

Material 546 Adapter Part Number* 551 Adapter Part Number*

316 Stainless B5106-0163 B5106-0162

CPVC B5106-1004 B5106-1002

Kynar B5106-1005 B5106-1003* Due to the many variations of FF20 and FS20 sensors holders the insertion depth of the existing Yoko sensor should be verifi ed prior to selecting a replacement Barben sensor.


14

Yokogawa pH/ORP SensorsPH87 / PH97 The PH87 / PH97 are Yokogawa’s equivalent to the Bar-ben 547 products. PH87 refers to the titanium hardware assembly. The Yokogawa sheath and compression fi tting are fully compatible with the Barben products. PH97 refers to the cartridge sensor that fi ts in the PH87 hardware.

The Yokogawa PH97 sensor is dimensionally the same as the Barben 547 sensor thus our product is a easy upgrade. The PH97 uses a junction box and extension cable to con-nect to the transmitter. Sensor cable lengths of 24 and 36 inches with lugged terminations are used to wire the PH97 sensor. The Barben 547 should be specifi ed with match-ing cable length, Kynar body, R glass, DT tip, PT1000 temperature compensation, and ELL wiring terminations. Please note that Yokogawa private labels the PH97 prod-uct from Broadley James. Yokogawa’s product is based on the ST857 DynaProbe.

PH18 / SC / SM / SR / SV The most recent product additions in the Yokogawa pH /OPR product line have been a wide selection of 12mm (DIN 19263) sensors. For those who are not familiar with 12mm sensors a review of the Mettler Toledo products is worthwhile. Yokogawa 12mm sensors come from two main suppliers - Hamilton and Pfaudler.

The PH18 is the Pfaudler private label sensor. This unique product bears some more in-depth discussion. Pfaudler sensors are non-glass pH sensors. Two special enamel panels bonded to sensor body react to changes in H+ and Na+ ion concentration. The differential between the two panels provides a pH reading. There is no electrolyte or reference junction. The main appeal of Pfaudler sensors is that they cannot be poisoned by process chemicals. Pfaudler sensors are also popular in highly specialized ap-plications such as low temperature pH measurement and processes that have severe reactions to the KCl electrolyte used in conventional sensors.

The Pfaudler sensor is not without downsides though. Since the sensor is so specialized it is quite costly (typi-cally $4000 to $5000 USD). The enamel panels can be damage by impact. Dropping a PH18 on a concrete fl oor can be an expensive mistake! The calibration, output, and isopotential point of the Pfaudler are different then conven-tional pH sensors thus a dedicated pH transmitter must be used (Yokogawa transmitters have additional menus for this purpose). Just like any pH sensor the Pfaudler prod-uct is susceptible to coating and build-up which often occur in industrial processes. It should be noted that the PH18 Pfaudler sensor is NOT a 12mm sensor but slightly larger

18mm diameter. This larger size forces dedicated fi ttings and sensor holders to use this product. Due to these lim-itations Yokogawa forces the user to fi ll out an application form before they will quote the PH18. Using this product is quite a commitment and fi nding actual endusers that have installed the PH18 is very rare!

The SC / SM / SR / SV products are traditional pH sensors that are based on the 12mm (DIN 19263) standard. Like all 12mm sensors these products do not mount directly into the process thus require sensor holders and fi ttings for installation. The holders highlighted in Figure 17 all have options for 12mm sensor installations. To retrofi t Barben sensors in place of the 12 mm sensors the parts highlight-ed in Figure 17 and chart below will be required. Insertion depth of the Yokogawa sensor will drive the length of the 546 or 551 sensor used for replacement.

Yokogawa Transmitters and AnalyzersBarben sensors are fully compatible with Yokogawa electronics. Please consult Barben Technical Support for assistance on wiring diagrams.


15

Endress & Hauser pH/ORP Sensors

Endress & HauserModel Number

TempSensor

BodyMaterial



Orbipac CPF81 / CPF82 PT100 Ryton 3/4" NPT Threaded 546 CPF81 and CPF82 have molded 3/4" NPT threads. If using these threads select 546 sensor.

Cleanfit CPA471 / CPA472 / CPA473 / CPA474 (Holders)

Retractable 1" NPT, DN50 Union Nut, ANSI and DN

Flanges

547567

Cleanfit holders have multiple mounting options. 551 with Nut Lock Adapter if 1" NPT mounting. All other retractable mounting options should consider 547 or 567 hot tap products.

Cleanfit CPA450 (Holder) Retractable 1-1/4 to 1-1/2" NPT and ANSI / DN Flanges

547567

This version of the Cleanfit holders is very similar to the Barben 547 design.

Flowfit CPA240 / CPA250 (Holder)

In-line Tee, 1" NPT Threaded

551 This flowcell design would be replaced by the Barben 551 with 1" NPT metal or plastic tee.

N/A Various

General NotesEndress & Hauser is large family-run instrumentation com-pany hailing from Switzerland. The company was founded in 1953; however it was not well known in North America until the 1990’s. E&H has grown its market share in North America through aggressive investment and expansion.

The pH/ORP offering from E&H very closely parallels Mettler Toledo’s sensor offering. The vast majority of the analytical sensor line is based on the 12mm (DIN 19263) sensor standard. E&H uses an array of confusing names and model numbers to identify their pH sensors. Product families such as “Orbisint”, “Ceraliquid”, and “Tophit” are further divided into sub-categories with six digit model numbers. As with other 12mm sensor manufacturers, E&H offers an extensive range of fi ttings and holders to install the sensors into the process. For the purposes of this document we will concentrate the sensor holders to cross reference to the proper Barben products. (NOTE - En-dress & Hauser does sell a plastic body pH product - The “Orbipac” - which is addressed later in this document).

MemoSensE&H has introduced two sensor innovations that should be discussed. Memosens is E&H’s proprietary smart sensor design. Memosens uses inductive signal transmission through a non-contact connector to store calibration data on a circuit board within the sensor. This inductive signal is used to transmit the sensor reading and diagnostics information back to the pH analyzer. Since the calibration data is stored at the sensor this allows the sensor to be calibrated in the instrument shop then taken out to the fi eld for installation into the process. The primary advantage of this approach is the on-going storage and documentation of sensor information for predictive maintenance purposes. Questions such as sensor lifespan and calibration frequen-cy are always stored on the sensor and can be queried in the fi eld or in the safety of the shop.

E&H has worked hard to make Memosens an industry standard. Unfortunately the inductive signal required to

interface with these proprietary sensors forces any endus-er or OEM manufacturer to either replace their convention-al pH analyzers or redesign them to work with the Memo-sens logic (or simply buy E&H’s electronics). Time will tell if large scale adoption occurs. The other specifi c diffi culty with Barben sensors is that our Axial Ion Path® reference design works best with single point process calibrations. This form of calibration is best done in the fi eld, not in the shop. Memosens also doesn’t improve the basic physical design of E&H sensors. Nearly all of the E&H pH sensor products use some form of single or double junction ref-erence technology which has limits in the harsh industrial applications where Barben sensors thrive.

TOP68The lesser-known innovation from Endress & Hauser is the TOP68 connector system. The TOP68 connector is a liquid-tight (IP68) plug used to easily detach the sensor from the cable. The TOP68 connector is sometimes mis-taken for the more-common Variopin (VP8) connector used by many manufacturers. It physically smaller as can be seen by the picture below. The TOP68 connector provides the same functionality as the Variopin connectors with a much lower cost. Barben Axial Ion Path® pH sensors can be specifi ed with the TOP68 connector that will work with E&H cables for easy replacement.

Common pH / ORP Sensor Connector Options Figure 18

Memosens - Endress & Hauser inductive coupler is completely sealed with no exposed metal connections. Works only with Memosens electronics.

TOP68 - Small form factor water tight (IP68) detachable connector. Available from Endress & Hauser and optional on Barben sensors. (pin outs match between the two products).

Variopin (VP8) - Common stainless steel body connec-tor used by Emerson, Foxboro, Yokogawa, and other sensor suppliers. The Variopin meets water tight (IP68) requirements.


16

Endress & Hauser pH/ORP SensorsCleanfi t ProductsCleanfi t is the name that Endress & Hauser uses for their series of retractable housings. As mentioned earlier in this paper the E&H product line is heavily dependent on 12mm pH sensors. These sensors have no process connection thus require specialized housings for installation.

There are many versions of the Cleanfi t housings. Each model varies depending on the materials of construction and optional accessories. Accessories include limit switch-es, integrated ball valves, and even electric actuators. Please note that the E&H offering is very similar to the Mettler Toledo offering discussed earlier in this document. These types of sensor retractors evolved in pharmaceu-tical and biotechnology industries. pH measurement applications in these industries require frequent removal of the sensor from the process because of the batch style production. CIP/SIP cleaning is performed between batch-es thus the sensor is protected within the retractor while the vessel and piping is prepared for the next batch.

The Cleanfi t style retraction housings have limitations in pressure and insertion depth. Since there is often no valve to seal the sensor from the process the sealing is done with o-rings. The fi nal o-ring seals are fi tted just past the tip of the sensor. These o-rings are fully exposed to the process thus abrasion and material compatibility must be accounted for when specifying the retractor.

The CPA450 seen in Figure 19 is the product that most commonly matches up with the Barben offering. The CPA450 uses a traditional ball valve and compression fi tting arrangement. Unfortunately, with the exception of a 1-1/4” or 1-1/2” NPT ball valve, most of the hardware is proprietary and could not be easily retrofi t with the Barben 547 or 567 sensors. For high pressure applications the 546 sensor with high pressure insertion hardware should be evaluated. It’s ability to withstand up to 300 PSIG ex-ceeds the capabilities of the E&H products.

Flowfi t, Ecofi t and Orbipac ProductsThe Flowfi t and Ecofi t products continue E&H’s theme of using confusing names for their various sensor holders. The Flowfi t products are integrated fl owcells for in-line sensor mounting. The Flowfi t products are broken into two categories. The CPA240 Flowfi t holders are E&H’s industrial fl owcells. A stainless union nut is used to install the 12mm pH sensor into the fl owcell. The fl owcells are available in corrosion resistant PVDF or 316L stainless. Optional fl anged and threaded process connections are highlighted in fi gure 20.

PIPE NIPPLE(MAY NOT BE NEEDED)


BARBEN 547 SENSOR ASSEMBLY

BARBEN 567 ALL PLASTIC SENSOR ASSEMBLY

1-1/4” OR 1-1/2“KYNAR BALL VALVE

PEEK, KYNAR, OR TEFLONCOMPRESSION FITTING OPTIONS

(PEEK WITH STOP LOCK COLLAR SHOWN)

BARBEN 546 SENSOR


MEMOSENS OR TOP68 CONNECTOR E&H 12mm pH SENSOR

E&H CLEANFIT RETRACTABLESENSOR HOUSING MODELS CPA471 / CPA472 / CPA474

PROCESS CONNECTIONS- DN50 FLANGE- G1-1/4” UNION NUT- 1” MALE NPT- VARIOUS SANITARY

E&H CLEANFIT RETRACTABLESENSOR HOUSING WITH INTEGRATED BALL VALVE

MODEL CPA473

PROCESS CONNECTIONS- DN50 FLANGE- 2” ANSI 150#- G1-1/4” UNION NUT- 1” MALE NPT- VARIOUS SANITARY

E&H CLEANFIT RETRACTABLE SENSOR HOUSING WITH BALL VALVE MODEL CPA450

E&H CLEANFIT RETRACTABLE SENSOR HOUSING WITH BALL VALVE MODEL CPA450

PROCESS CONNECTIONS- 1-1/4, 1-1/2, 2” ANSI 150#- G1-1/4” UNION NUT- 1-1/4, 1-1/2” NPT- VARIOUS DN FLANGES

O-RINGS

O-RINGS

E&H Cleanfi t Products Figure 19

(NOTE - If the CPA240 is being used, there is a possibility that BARBEN sensors can be retrofi t through the union nut into the fl owcell using a specialized adapter. Consult Barben Technical Support for additional information).

The second Flowfi t fl owcell is the CPA250. This product is lower cost design for the water treatment market. The CPA250 is a molded polypropylene fl owcell with 3/4 or 1” threaded connections


17

Endress & Hauser pH/ORP Sensors

MEMOSENS OR TOP68 CONNECTOR

E&

H 12m

m pH

SE

NS

OR

BA

RB

EN

551 SE

NS

OR

1" NP

T NU

T-LOC

KA

DA

PTE

R FO

R M

OU

NTIN

G


BARBEN 1” TEEFITTING

E&H FLOWFITFLOW CELL MODELS

CPA240 / CPA250

PROCESS CONNECTIONS- 1/2, 1” NPT- 1“ ANSI 150#- DN25 PN 16 FLANGE- WELD ON ENDS

UNION NUT

2.3”

0.91”

0.49”

ORBIPAC CPF81 / 82 LONG SHAFT

ORBIPAC CPF81 / 82 SHORT SHAFT FLAT

3/4" NPT

ORBIPAC CPF81 / 82 SHORT SHAFT HEMI

3/4 OR 1" NPT

1/2” NPT OR M25

ECOFIT CPA64012mm HOLDERS

E&H 12mm pH SENSOR

0.98 OR 2.3” (USER SPECIFIED)

0.98 OR 2.3” (USER SPECIFIED)

O-RING

3/4" NPT INSERTION LENGTH

BARBEN551 SENSOR

BARBEN551 SENSOR


BARBEN546 SENSOR

SEEABOVE3/4" NPT

INSERTION LENGTHSEE ABOVE

USE 551 WHEN REPLACINGECOFIT CPA640 1” NPT HOLDER

USE 546 WHEN REPLACING ORBIPAC ANDECOFIT CPA640 3/4” NPT HOLDER

The Barben solution for these products is to use commonly available piping tees and 551 Nut-Lock quick change sen-sors. This design is signifi cantly less cost and complexity with the improved reliability of the Barben Axial Ion Path® Reference.

Our fi nal product review is the E&H Ecofi t holders and Orbipac sensors. These products are designed to fi t in the 3/4 and 1” threaded applications where Barben sen-sors are typically installed. The Ecofi t holders are simple threaded sensor bodies for 12mm sensors. They are available in a wide range of materials including PVDF, 316 Stainless, polypropylene, and Monel. If these products are encountered then the process connection size and inser-tion depth (see fi gure 21) are all that are needed to specify the proper Barben sensor for replacement.

E&H Ecofi t and Orbipac Products Figure 21

Endress & Hauser Transmitters and AnalyzersBarben sensors are compatible with E&H electronics. Their products use a modular approach with separate in-put board depending on if a Memosens or a traditional pH sensor will be connected. Please consult Barben Techni-cal Support for assistance on wiring diagrams.

551 Insertion Length Table1” NPT TEE Part Number 551 Insertion LengthCPVC 100# B4951-0045 3.0”316 SS 150# B4951-0036 2.625”

Kynar 200# B4951-0046 3.0”

E&H Flowfi t Products Figure 21

The Orbipac sensors are the only non-12mm sensors that are sold by E&H. These products use a Ryton molded body and a traditional double junction reference design. They are marketed to the low cost water treatment market. The Orbipac sensors use a 3/4” NPT process connection thus the Barben 546 sensor would be a direct replace-ment. The sensor insertion length should be confi rmed based on the installation or the dimensions in fi gure 21.


18

Foxboro pH/ORP SensorsFoxboro

Model NumberTemp

SensorBody

Material Mounting Style BATModel Barben Application Notes

PH10 Dolphin 3k Balco

PT100PT1000

Kynar 3/4" or 1" NPT Threaded 546551

Use 546 if mounting by 3/4" NPT threads. If PH10 uses 1" bushing then Barben 551 or 547 with 8" sheath and wrench tight compression fitting.

871A PT100PT1000 Kynar 1" NPT Threaded 551 Foxboro 871A uses 1" NPT process connection. Barben 551 Sensor with

Nut-Lock Adapter for inline applications

871PH PT1000 RytonCPVC

Twist lock into 1" tee or 1-1/4 or 1-1/2" NPT bushing 551 871PH uses a twist lock in-line connection. Use Barben 551 sensor with

Nut-Lock Adapter. Ball Valve insertion may be used too.

General NotesAnyone involved in instrumentation for a few years has probably heard of Foxboro. The Foxboro Company; who’s name comes from the Massachusetts town where they are based, dates back to 1908. In more recent years, Fox-boro has been bought and sold multiple times. UK based Invensys purchased the company in 1999 and the organi-zation’s current owner. Foxboro is best known for its DCS control systems and other instrumentation products. It’s pH / ORP product line is overshadowed by its conductivity products. Foxboro still retains some analytical focus how-ever its older sensors are OEM designs from ASI (Analyti-cal Sensors & Instruments, LTD).

Product NotesWith a limited offering, Foxboro is creative with fi ttings to help adapt its sensors to different installations. All prod-ucts listed above can be used in hot tap ball valve instal-lations. Foxboro offers 1-1/4 and 1-1/2” valve assemblies with special insertion hardware to retrofi t to each sensor. Sensors are mounted on an insertion rod using the NPT threads similar to the Barben 546 high pressure hot tap de-sign. If a Foxboro hot tap installation is encountered then a special adapter is required. Contact Technical Support for more information (Reference P/N B4951-0128).

PH10 Dolphin The Dophin is Foxboro’s latest pH sensor design. Foxboro touts a specialized patent-pending glass formulation and a Nafi on Ion Trap reference. The ion trap concept is used by several sensor manufacturers; however Foxboro seems to be the only vendor using Nafi on. Nafi on is a fl uoropolymer similar to Tefl on. It is used as a semi-permeable mem-brane in industrial applications such as the Chlor-alkali process. Nafi on allows certain ions to pass through while blocking other ions. Foxboro’s goal of using the Nafi on barrier was to prevent process chemicals from penetrating the reference and poisoning the sensor. In actual fi eld usage this design has proven less then successful as the Nafi on barrier cannot account for exposure to all the vari-ous industrial chemicals it might be exposed to. Further-more, the membrane can get plugged over time causing high impedance of the reference and sensor failure.

Figure 22 below shows the tip of the Dolphin sensor. The ceramic reference junction is extremely small thus suscep-tible to coating. Either a fl at glass or hemispherical glass electrode can be specifi ed. Dolphin sensors use 3/4” NPT threaded mounting thus are physically similar to the Barben 546 sensor. A 1” adapter similar can also be or-dered for use with the Dolphin sensor. The adapter can be adjusted between 2.1 to 3.5” insertion depth. The 547 with 8” sheath is likely the best replacement sensor if Foxboro’s adapter is used.

Foxboro Dolphin PH10 Sensor Example

Foxboro Dolphin PH10

The small white “dot” above the glass electrode is the ceramic ref-erence junction. The small size creates concerns about particulates plugging up the junction. The circular hole to the left of the glass is actually the solution ground. Foxboro uses a conductive Kynar plastic for the Dolphin solution ground. The actual solution ground material is recessed several mm’s below the face of the sensor thus creating an air pocket and potential build-up issues may obscure this diagnostic

measurement creating false alarms.

Figure 22

871AIf the Dolphin is one of Foxboro’s newer products, the 871A is one of their older products. The 871A is a simple, no-frills double junction reference pH sensor. Options are few with this sensor. A fl at glass electrode and, strangely enough, two ORP electrode options are the only measure-ment selections. The 871A can be ordered with an integral pre-amplifi er to extend the cable length. a 1” NPT process connection is used to mount the 871A thus a Barben 551 sensor would be a direct replacement.


19

Foxboro pH/ORP Sensors

871PHThe 871PH sensor is the workhorse of the Foxboro sensor line. The sensor design is rebuildable similar to Rose-mount’s PERpH-X products. Both the glass measurement electrode and the reference junction are fi eld replaceable with rebuild kits supplied by Foxboro. The internals of the sensor are held in place with a single keeper screw. This screw also provides the solution ground measurement. If the screw is lost then sensor diagnostics are lost along with the internals of the sensor.

Mounting of the 871PH involves using a twist lock bushing similar to the ABB TB551 sensors. Due to the diameter of the Foxboro sensor the bushing is either 1-1/4” or 1-1/2” NPT thus a replacement sensor such as the Barben 551 will also need a bushing to fi t into the process.

In recent years the 871PH sensor has seen the addition of a Variopin connector. Its double junction reference has been upgraded to include the Nafi on Ion Trap used in the Dolphin sensors. These improvements add to the long list of options which can be ordered with the 871PH. Endus-ers may tout the ability to rebuild these sensor as a key function however the time and frequency of the rebuilds should be considered when compared to the longer lifes-pan of the Barben sensors in harsh applications.

Foxboro Dolphin PH10 and 871A Sensor Cross Reference**

Foxboro Sensor Recommended Barben Sensor +/- Length*

PH10 Flat Tip, 3/4” Mtg 546 Kynar, 1.5” FT tip, FG glass -0.07” (-2mm)

PH10 Notch Tip, 3/4” Mtg 546 Kynar, 2” DT tip, R glass -0.07” (-2mm)

PH10 Flat Tip, 1” Adptr 547 Kynar, 8” Sheath FT tip, FG glass Variable

PH10 Notch Tip, 1” Adptr 547 Kynar, 8” Sheath, DT tip, R glass Variable

871A Flat Tip, 1” Mtg 551 Kynar, 4” FT tip, FG glass + Nut-Lock -0.07” (-2mm)* Negative = Shorter then Foxboro Sensor. Positive = Longer then Foxboro Sensor** No cross reference for the 871PH products as these products use proprietary fi ttings. Typical replacement would be a Barben 551 for in-line mounting and a Barben 547 for ball valve mounting.

O-RING

3/4" NPT INSERTION LENGTHSEE CHART

BARBEN551 SENSOR

BARBEN551 SENSOR


BARBEN546 SENSOR

SEECHART3/4" NPT


BARBEN 547 SENSORWITH 8” SHEATH

DOLPHIN PH10 WITH FLAT GLASS

DOLPHIN PH10 WITH NOTCHED TIPAND 1” NPT ADAPTER

871PH TWIST LOCK SENSOR WITH HEMI GLASS

VARIOUS SPECIALIZED TEES& BUSHINGS TO MOUNTTHE 871PH ARE REQUIRED

871A SENSOR

3/4" NPT

1" NPT

LOCKING PINS

1" NPT

1.57”

1.97”

2.1 OR 3.1”(FLAT)2.5 OR 3.5” (NOTCHED)

TWIST LOCK TEE1" NPT

TWIST LOCK BUSHINGS1-1/4 or 1-1/2” NPT

2.25”

3/4" NPT

Figure 23Foxboro pH/ORP Sensors


20

Foxboro 873PH Analyzer (Wiring with “E” Terminations)


21

Honeywell pH/ORP Sensors

HoneywellModel Number

TempSensor



7777 Durafet / Meredian

8550 PT100

PT1000Ryton 3/4" NPT Threaded 546 Use 546 if mounting by 3/4" NPT threads.

310743XX515006XX-XXX514513XX-XXX51205554-XXX

8550 PT100

PT1000Ryton 3/4" NPT Threaded 546

These are part numbers for Honeywell replacement electrodes supplied with various holders. All use 3/4" NPT mounting. Use 546 for replacement.

7773 (Holder) N/A Various Flowcell with 3/4" NPT Female 551546

These holders can use either 12mm or 3/4" NPT sensors. Use 546 or 551 sensor with tee mounting as a replacement.

7774 (Holder) N/A Various Retractable 1-1/4" NPT 547 These ball valve holders are similar to the 547 products. Valves can be reused but Barben sheaths and compression fittings are needed.

General NotesHoneywell got involved in analytical instrumentation with the acquisition of Leeds & Northrup in 1996. The purchase of L&N brought analytical expertise in low conductivity boiler water measurement. Even today L&N and Honey-well products are often found in power plant applications. In addition to boiler water experience, Honeywell also gained L&N’s patented ISFET non-glass pH measurement through the purchase.

Product NotesSince the L&N acquisition Honeywell has focused most of their development on electronics. Honeywell users will be familiar with Honeywell’s older UDA and newer APT series analyzers. The sensor product line has received less attention over the years. Honeywell uses the trade name “Meredian” to refer to their glass measurement electrode products. The name “Durafet” is used for their family of ISFET products. Honeywell markets sensors under these names as the model 7777 products. Honeywell also has some 12mm sensors that fi t into various fl owcells and retractable sensor designs. These sensor holders can also be sold with the Durafet / Meredian sensors installed in the holder. These sensors have their own part numbers but are essentially the same design as the 7777 product. This creates plenty of confusion for a customer new to the Honeywell product line.

It should be noted that Honeywell does have an OEM agreement with Barben Analytical. Products sold as the HB and HBD series use the Barben Axial Ion Path® technology and cannot be sold to other channels outside of Honeywell. Their nomenclature follows the Barben part numbers very closely.

Durafet Products Leeds & Northrup released the Durafet non-glass pH elec-trode back in 1992. Durafet products use ISFET (Ion-Sen-sitive Field Effect Transistor) technology to measure pH. The transistor is actually a semi-conductive material that reacts to hydrogen ion (H+) concentration. Changes in H+ concentration cause changes in current through the transistor. The traditional reference electrode forms the other half of the cell. Assuming stable reference voltage and resistance the changes in current will provide a mV response in correlation to changes in pH.

ISFET electrodes have gained popularity in applications where glass is not accepted such as food and pharma-ceutical industries. Unfortunately, in the harsh industrial applications targeted by Barben Performance Series pH sensors, the ISFET electrode offers no performance gains. These applications require a robust reference half cell that can withstand poisoning, plugging and elevated pressures and temperatures. The Honeywell reference design uses gel electrolyte with a single ceramic junction. This makes the Durafet no better performing then most other manufac-turer’s sensor products.

ISFET vs. Glass Measurement Electrodes

The ISFET electrode (top) uses a silicon-based transistor to measure pH. The small blue dot is the sensitive area.

The traditional glass electrode (bottom) uses special alkali metal salts mixed in the glass which produce a voltage when exposed to H+ ions.

Figure 24


22

7777 Durafet / MeredianThe 7777 style products have gone through three re-visions. The current third generation products were launched over ten years ago. The Durafet version will be supplied with the ISFET electrode while the Meredian version will use a glass electrode. These sensors use a KCl gel electrolyte and a annular ceramic junction for their reference design. The reference can be rebuilt in the fi eld. A threaded tip guard is supplied to prevent damage to the electrode while in the process. It should be noted that Honeywell offers a unique temperature sensor option, the 8550Ω thermistor. This thermistor was originally used with Leeds & Northrup analyzers. Honeywell seems to be the only company that still offers this type of temperature compensation. Barben can include the 8550Ω thermistor at additional cost if the customer requires it.

As a fi nal note, these sensors can be ordered pre-mounted in hardware. Honeywell uses different part numbers to identify these replacement sensors. Nearly all designs use 3/4” NPT mounting thus the Barben 546 products are the closest matching designs.

Honeywell pH/ORP Sensors

BARBEN546 SENSOR

0.5” OR1.0”3/4" NPT

7777 DURAFET III 3/4" NPT 0.44”

3/4" NPT

3/4" NPT

7777 DURAFET III WITH OPTIONAL TIP GUARD 0.94”

Figure 25Honeywell 7777 Series Sensors


23

Honeywell APT2000PH (top) & APT4000PH (bottom) Analyzers (Wiring with “E” Terminations)

2P0272

07/15/20131 O

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TO B

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DATESCALE

SIZESHEET APVDDW

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ECO5200 C

onvair Drive C

arson City, N

V 89706 PH(775)883-2500 FAX (775)297-4740

TC-Green

TC-Black

"pH SHLD" - Grey

"pH IN" Coax Core

J. LANG

BARBEN ANALYZER TECHNOLOGY (BAT) pH/ORP SENSOR - WIRED TO HONEYW

ELL APT2000PHBAT SENSOR CONFIGURATION: "E" TERM

INATION

"IMPO

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ITE


ANDSETTINGS

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Description

Terminal - Label

"pH SH

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546/547/567/551/554

SENSO

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23

3

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SHIELD

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J. LANG

BARBEN ANALYZER TECHNOLOGY (BAT) pH/ORP SENSOR - WIRED TO HONEYW

ELL APT4000PHBAT SENSOR CONFIGURATION: "E" TERM

INATION

"IMPO

RTAN

T WAR

NIN

G"

THE W

IRIN

G SH

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S A SENS

OR

WITH

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RN

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CEPTS 2-W

IRE TC

's. USER

S CAN

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OW

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K GR

EEN "TC

RET" LEAD

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FOR

OR

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RS C

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E WILL BE LABELED

"OR

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D W

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G IS TH

E SAME. "R

EF" - WH

ITE


ANDSETTINGS

• WIR

ING

Description

Terminal - Label

"pH IN

" - Coax C

ore Wire

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hite "SO

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ND

" - Clear (D

rain) "pH

SHLD

" - Coax Shield (C

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SNSE" - Black

"TC IN

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• Select PT100, PT1000 or 8550 R

TD's



ode.


546/547/567/551/554

2

3

3

3 12

JUM

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R

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aux. el.ref. el.

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RP

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SENSO

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ABLE OR

B39 EXTENSIO

N C

ABLE

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HLD

" Gray


24

Sensorex pH/ORP Sensors

SensorexModel Number

TempSensor



S645CD N/A Union Nut (Sensorex Specific Design)

BAT4BAT4A

Common OEM Design. Barben sensors fit directly into the Sensorex FC60C Flowcell.

S660CD N/A The S660CD fit through the FC66P Adapter into a Sensorex 3/4" Tee fitting.

S661CD Separate The S661CD fit through the FC66P Adapter into a Sensorex 1" Tee fitting. Barben 551 may be an option. Consult Tech Support.

S662CD Separate The S662CD fit through the FC66P Adapter into a Sensorex 2" Tee fitting. Barben 551 may be an option. Consult Tech Support.

CPVC3/4" NPT Adapter 546

General NotesBased in southern California, Sensorex is a major OEM supplier of pH / ORP products. The company claims to ship over 250,000 sensors per year. Sensorex was purchased in 2012 by the Halma Group. It remains to be seen what impact this will have on their business.

Sensorex products are basic combination electrode which are not designed to survive in the same applications where Barben sensors are used. When they turn up at the jobsite they are often found on chemical feed and water treatment skids. Sensorex products are often specifi ed due to their low cost and simple fi tting options. Many of their designs lack basic features such as integral temperature compen-sation.

Product NotesBecause Sensorex is so common we have had customers request Barben replacement sensors that mate with their proprietary fi ttings. The cross reference chart above and Figure 26 show some of our options to replace Sensorex products. Please note that Sensorex products are consid-erably lower cost then Barben products however custom-ers who have dealt with frequent calibration and replace-ment will have an interest in a quality replacement product.

FC60CFLOWCELL

O-RING

SENSOREXS645CD

FEMALEBNC

3/4"NPT

FEMALEBNC

BAT4BAT4A

BAT4 = 6” CABLEBAT4A = 5’ CABLE

O-RING

SENSOREXS660CD, S661CD, S662CD

FEMALEBNC

INSERTIONLENGTH

BARBEN546 SENSOR

SEECHART 3/4" NPT

3/4" NPT

Sensorex S660 In-line Cross Reference

Sensorex Sensor

Sensorex**Insertion Length

Recommended Barben Sensor +/- Length*

S645CD 0.55” (14mm) BAT4 (6” cable) or BAT4A (5’ cable) Exact Fit

S660CD 2.5” (63.5mm) 546 Kynar, 0.5” FT tip, FG glass -0.05” (-1.3mm)

S661CD*** 3.5” (89mm) 546 Kynar, 1.5” FT tip, FG glass -0.05” (-1.3mm)

S662CD*** 4.25” (108mm) 546 Kynar, 2.5” FT tip, FG glass +0.2” (+5mm)* Negative = Shorter then Sensorex Sensor. Positive = Longer then Sensorex Sensor** 3/4” Sensorex fi tting is 1.95” length.*** S661CD and S662CD are often threaded into 1” NPT bushings. Consider a Barben 551 sensor if a 1” bushing is used.

Sensorex S600 Series SensorsFigure 26


25

Broadley-James pH/ORP Sensors

General NotesBroadley-James is another southern California based pH sensor manufacturer. Broadley-James is a privately owned family business. The company dates back to 1967 when several former Beckman Instruments employees went into business to take advantage of the growing pro-cess instrumentation market.

Broadley-James has two divisions. Their BioProcess business targets the pharmaceutical market with replace-ment 12mm pH / ORP sensors. The Broadley-James Process division manufactures traditional plastic body combination electrodes which are dimensionally similar to Barben products. In fact, Broadley-James was one of the fi rst companies to copy the TBI wood reference design. Their “Ion Trap” reference uses angled baffl es between wooden segments to slow the chemical ingress from the process. The design is quite old and expected longevity should be similar to TBI or current ABB products. Broad-ley-James has done no product development for their Process sensors in well over a decade. Instead they have choosen to focus on the BioProcess division where they will compete against E&H and Mettler Toledo. Note that Broadley-James private labels the Yokogawa PH97 hot tap sensors. They also has a close relationship with Emerson Analytical and resell their Rosemount transmitters and analyzers.

Product NotesBroadley-James DynaProbes use the wood reference de-sign and the “ST” prefi x. Their ProcessProbes are a lower

Broadley-JamesModel Number

TempSensor



ST856ST956S400S410S420

KynarRyton 3/4" NPT Threaded 546

The ST856 / ST956 use a 0.75" notched tip with hemi glass. The S400 uses a 0.875" notched tip with hemi glass. The S410 uses a 0.5" flush tip with flat glass.The S420 uses a 2.3" notched tip with hemi glass. A Barben 546 with closest matching tip length (application dependent) and either "R" glass or "FG" glass are best suited.

ST873ST973S405S415

Ryton 1" NPT Threaded 551

The ST873 / ST973 uses 0.7" flush tip with hemi glass.The S405 uses 0.875" notched tip with hemi glass.The S415 uses 0.5" flush tip with flat glass.The S425 uses 2.3" notched tip with hemi glass.A Barben 551 with closest match tip length (application dependent) and either "R" glass or "FG" glass are best suited.

ST851ST951 Ryton Twist Lock 1" NPT Receptacle 551 Use Barben 551 with standard insertion length and "R" glass. May

require a new Nut-Lock Holder.

ST857 Kynar Ball Valve Hot Tap 547

Use Barben 547 with notched tip and "R" Glass. Broadley-James ST857 sensor has female threads and uses a coupler to mate with backpiece. Couple must be removed to re-use sheath and backpiece with Barben 547 sensor.

S477ST977 Ryton Ball Valve Hot Tap 547 Use Barben 547 with notched tip and "R" glass. Broadley-James

sheath and compression fitting can be re-used. ST864 Kynar High Pres. Ball Valve Hot Tap 546 Use Barben 554 sensor with notched tip and "R" glass.

3k Balco301PT100

PT1000

ST857 DynaProbe

Broadley-James Sensors are easily identifi ed by their unique blue colored glass electrode (top). The ST857 hot tap, retractable sensor (pictured below) uses female threads on the rear of the sensor. It mounts to the Kynar backpiece within the sheath using a separate male-to-male cou-pler. When the coupler is installed it is dimen-sionally identical to the ABB TB557 or Barben 547 sensors. All metallic hot tap hardware can

be reused.

Broadley-James ST857 Sensor Example

cost double junction reference design and are identifi ed by their “S” prefi x. Broadley-James process products are dimensionally the same as ABB / TBI products thus very easy to cross-reference. General replacement information is covered in the chart above.

Figure 27


26

Van London pH/ORP SensorsGeneral NotesVan London is a family-run Houston, Texas based manu-facturer of pH sensors. The company started in 1961 as a distributor of analytical instrumentation. In the mid-1970’s it opened a sister business, Phoenix Electrode, to manu-facture glass electrodes. Eventually the two businesses were combined in 2007 with the company name as Van London - Phoenix Electrode Company (VL-PC).

Similar to Barben, VL-PC has made its core business replacing competitor’s pH sensors. VL-PC is primarily a regional manufacturer with its greatest market share in the gulf-coast region of the United States. They are rarely seen outside of North America.

Product NotesVL-PC has an extensive line of pH /ORP sensors to ret-ro-fi t most every type installation type on the market. (For this reason we have choosen NOT to provide drawings or a cross reference chart). Most VL-PC sensors rely on a polymer gel electrolyte. The visicous gel slows the ingress of process chemicals. These chemical will eventually poi-son the Ag/AgCl element within the reference half-cell. In fl uctuating pressures the gel is also hard to leach through the porous reference junction thus adding to its chemical resistance.

While this gel-fi lled reference design is an upgrade to conventional liquid electrolyte sensors it has become very commonplace in the industrial market. The gel has not proven itself to give greater longevity over a solid state reference design such as the Axial Ion Path® from Barben. Interestingly, while VL-PC products are targeted at indus-trial applications the company focuses their marketing on their glass measurement electrode. Glass is rarely the failure point in applications with strong chemicals, high temperatures, and fl uctuating pressures. Typically the porous reference will fail fi rst causing erroneous readings and inability to calibrate. Strangely enough Van London has not realized this.


27

Date ___________Name ________________________________________ PhoneCompany/Location Email

ApplicationBriefly Describe the Application:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________PROCESS DATAMedia (list primary components and concentration) ________________________________________________________________________________________

pH Range of Detection Set-point/Min/MaxSample Temperature C/F Min/MaxSample Pressure Min/MaxDescribe any Abrasive or wt % Solids:Installation Details, Sensor Mounting (please select installation type_____________ )

1. Specify insertion depth “a” measured from mating thread to inside wall of process pipe or required insertion in process.“a” insertion or stand-off length = ___________________

2. What is current process connection size “b” and process pipe size, “c””b”= _____________________”c” =______________________

Sensor Materials of Construction (Choose one of each – Body, O-Ring & Metal Materials acceptable in process)Body Material: Kynar (Standard) PEEK CPVC O-Ring Material: Viton (Standard) EPDM KalrezMetals (Hardware/Holders): 316 SS (Standard) Titanium Hastelloy C-276

Analyzer/SensorCable length (Distance between transmitter and sensor) ___________________________Manufacturer and Model number of existing transmitterBAT to supply transmitter, define electrical area class

Power: 2 Wire Loop (24V DC), 4 Wire AC (110/220) Mounting: Wall, Pipe, Panel Digital: HART, FF, Profi Outputs: 4-20, relays

Email Application Questionnaire to: [email protected] or fax to +1 (775) 297-4740

Application Questionnaire

Cert. No. 43271ISO 9001:2008

© 2015, by AMETEK, Inc. All rights reserved • Competitors_TN_RevA • Aug, 2015USA • BELGIUM • CHINA • SINGAPORE

Toll Free +1(800)993-9309 • Phone +1(775)883-2500 • Fax +1(775)297-4740 [email protected] • www.BarbenAnalytical.com

Contact Us

Barben Analytical is a leading supplier of analytical mea-surement technology targeting the industrial marketplace. It is a wholly owned subsidiary of Ametek.

Ametek has nearly 14,000 colleagues at over 120 man-ufacturing locations around the world. Supporting those operations are more than 80 sales and service locations across the United States and in more than 30 other coun-tries around the world.

Barben Analytical5200 Convair DriveCarson City, NV 89706 USA

Toll Free: Phone: Fax: email: Web:

+1 (800) 993-9309+1 (775) 883-2500+1 (775) [email protected]


Barben Analytical reserves the right to make technical changes or modify the contents of this document without prior notice. We reserve all rights in this document and in the subject matter and illustrations contained within.

Hastelloy® is a registered trademark of Haynes Intl Inc.Kalrez® and Viton are registered trademarks of DuPont Dow Elastomers L.L.C.Kynar® is a registered trademark of Elf Atochem North America Inc.Tefl on® is a registered trademark of E.I. DuPont de Nemours Company Inc.

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