Competitive Advantages
of IOTRON™ & ZEUS™
pH & ORP
Industrial Sensor Design & Technology
The ASTI proprietary
and novel highly modular and application specific sensor design provides the
needed versatility and flexibility to create customized solutions to meet the
most demanding measurement applications. Each built-to-order sensor model
chosen and selected options invoked are based upon a thorough review of the
customer supplied application information by senior in-house chemists to ensure
that the best possible pH sensor or ORP sensor which is suitable for the
intended process measurement & installation scheme is supplied at the
lowest possible price by not including any unnecessary features. These custom
built-to-order sensors can interface with most all existing control equipment to
serve as replacement sensors to retrofit existing installations or else are
also available as smart digital sensors for use in new installation complete
with mating intelligent digital transmitters.
Highlighted Benefits:
·
Substantially improved sensor service lifetime leading
to substantially reduced cost of ownership
·
Reduced cleaning and calibration requirements due to
rugged industrial construction and solid-state reference
·
Reduced
damage from mechanical wear with extremely rugged industrial construction and
fault-tolerant design
·
Optimized
sensor components, design and fabrication that is individually selected for
your exact application requirements ensure optimal performance all while while
minimizing cost of ownership
1. Application specific pH and ORP sensing elements are optimized for each application.
2.
Solid State Reference
Junctions employ non-porous cross-linked conductive polymer optimized for each
process
3.
Resilient Plastic
Housings in the most cost effective configuration to meet the thermal and chemical
resistivity necessitated by each application supplied in the necessary
configuration to support the desired installation scheme.
4. Integrated
electronics components include:
·
Temperature Compensation Elements - Pt100, Pt1000, 3K
Balco, …etc
·
Solution Ground (Liquid Earth) Elements - 316SS,
Titanium, Hastelloy C-276, Platinum Mat’l of Construction
·
Analog Conventional & Differential Preamplifiers for
Rosemount, HACH/GLI, Foxboro,... OEM Transmitters
·
Smart Digital Sensor Boards for use with ASTI 3TX-HiQ-pH
Intelligent Digital Transmitter (New Systems)
5. Waterproofing options for fully submersible sensor assemblies WITHOUT using of an immersion tube or standpipe
Electronics are embedded into sensors as required to interface existing
process control equipment for retrofit installations.
2.
Non-Porous Cross-Linked Polymer Reference System
ASTI pH & ORP sensors employ the ONLY truly solid state reference system
in existence. A solid state reference is a non‑porous & non‑permeable system in which only selective ionic communication with the secondary junction (and tertiary junction) is permitted.
This creates a very stable reference potential even during harsh process conditions.
The advantages of a solid state reference system over more conventional porous
gel filled systems are that:
This solid state reference system is embedded in a support matrix of
either High-Density-Poly-Ethylene (HDPE) or Poly-Vinyli-Dene-Fluoride (PVDF,
Trade name KYNAR) to impart robust industrial mechanical properties for heavy
field use.
The combination of the pH and/or ORP sensor element(s) and the reference
system employed defines the ten base model designation as detailed below. Note that not all base model series are available in sensor body materials of construction.
Base Model Description
of Base Model Sensor Series
X0XX Series: General Purpose (Capabilities vary with materials of
construction)
X1XX Series: High Temperature Resistant (-5 to 135 °C)
X2XX Series: Ultra High Temperature Resistant (-30 to 150 °C)
X3XX Series: Slurry & Viscous Material Resistant i.e. abrasive slurries and high
particulate media
X4XX Series: Acid & Fluoride (HF) Resistant
X5XX Series: Pulp & Paper Resistant
X6XX Series: Dissolved Sulfides resistant i.e. hydrogen sulfide gas (H2S)
and hydrogen sulfide (HS-) are present
X7XX Series: Aggressive Dissolved Gas & Volatile Organic Resistant
X8XX Series: ORP Redox Sensing Sensor (Low-Profile Platinum Ball)
X9XX Series: Saturated Sodium (Brine) Resistant
Selected
Additional Features Designated by Alpha Prefix Option Callouts:
Ammonia gas resistant (“A”) Chlorine gas resistant (“C”) Organic Media Resistant (“L”)
Solvent Resistant (“TS”) Triple Junction (“TJ”) ACCU-TEMP Fast-Response TC (“X”)
4 each Protective Tines (“GR”)
2 ea Protective Tines (“GRO”) No Protective Tines (“NG”)
Extreme Dehydration Resistant (“E”) Wide Range pH Glass (“V”) Low-Impedance Style pH glass (“Z”)
Selected
Suffix Callouts for End of Cable Terminations:
Terminations for Analog pH & ORP sensors
WITHOUT preamplifier or smart digital sensor board
·
Male
BNC Connector (“MBNC”) or Tinned Lead Wires (“TL”) à Black Cable
Terminations for Analog pH & ORP sensors
WITH integral analog preamplifiers
·
Tinned Lead Wires (“TL”) or NEMA 6P & IP67 rated quick disconnect snap connector (“Q7M”) à Gray Cable
·
Braid
Reinforced with Tinned Lead Wires (“BL”) à Blue Cable
Terminations for pH & ORP sensors WITH
smart digital sensor board
·
NEMA 6P
& IP67 rated quick disconnect snap connector (“HiQ4M”) is standard à Green Cable
Body Housing
Materials of Construction:
Chlorinated Poly-Vinyl-Chloride (CPVC, XX1X
series)
Poly-Phenyl-Sulfone (PPSU, trade name RADEL,
XX3X series)
Poly-Ether-Ether-Ketone
(PEEK, trade name KETASPIRE, XX4X series)
Poly-Phenylene-Sulfone (PPS, trade name
RYTON, XX5X series)
Installation Configurations:
¾” – ¾” MNPT Inline/Immersion/Submersible 1” MNPT Twist Lock Bayonet Quick Disconnect
¾” – 1” MNPT Inline/Immersion/Submersible 1.5”, 2.0” & 2.5” TRI-CLOVER Sanitary
1” – 1¼” MNPT Inline/Immersion/Submersible 1.5”& 2.0” NPT HOT-TAP Valve Retractable
4. Integrated Electrical Components
Thermocompensators
& Solution Grounds: Temperature Compensation Elements (TC’s) are embedded
into each sensor to be compatible with the particular make of process
instrumentation to which it shall mate.
Some manufacturer’s instrumentation also requires a conventional or differential preamplifier (miniature high impedance CMOS operational amplifier used as a signal conditioner) as well as a temperature compensation element.
Solution grounds (a.k.a. Liquid Earth) elements can be integrated for instruments employing differential preamplifiers or for sensor diagnostics support.
Analog Preamplifiers: can be integrated all
mounting configurations (internal preamplifier) which are compatible with most all
third party instrumentation make and model.
The appropriate temperature compensation & solution ground elements are always embedded into each sensor as may be required. Analog preamplifiers are available in versions to operate up to a maximum operating temperature of 150 °C for inline installations and 115 °C when fully submersed in process. Analog preamplifiers are ideal for use in noisy electrical areas and long cable lengths up to 500 feet.
Smart Digital Sensor
Boards: are available for all pH & ORP sensor models, configurations &
installation types. This style is recommended for all new installation points to take advantage of all of the modern features such as the ability to calibrate at one location and to install the sensor into service at another location while having those calibration values automatically loaded to the transmitter.
Additional benefits include tracking of last five calibrations, sensor model (item), installation & last used in field date, total time in service as well as traceability for purchase order & invoice number. Distances up to 610 meters (2,000 feet) between sensor & transmitter with standard NEMA 6P rated snap connectors without loss of signal quality allows for locating transmitter away from hazardous areas to reduce new system costs.
5. Waterproofing Options for Submersible
Installations
The waterproofing options are available for all pH & ORP sensor and
divided into four “families”: The “A” family is for basic isolation from washdown, moisture or rain. The “B” family is fully submersible without an immersion tube and include a hose to protect the sensor cable for the entire wetted depth. The “C” family has robust sealing cap added for extra isolation compared to the “A” type seal. The “A”, “B” & “C” families all come standard with a double moisture sealing barrier. The “IT” family is a compact seal that still includes tubing for cable isolation. Waterproofings available in polypropylene (PP) or CPVC materials with installed sealing hoses in braid-reinforced vinyl or NORPRENE materials.
ZEUS™ Analog & Smart Digital pH Sensors (Typically In Stock for Fast Shipment)
The ZEUS sensor series are typically in stock to handle urgent critical
installations. The ZEUS sensors include standard the various features needed for use in slurry/viscous media in dissolved ammonia, chlorine and sulfide gases as well as aggressive volatile organic solvents at temperature up to 150 °C and pressures up to 200 psig. The ZEUS sensor is fully submersible even without the use of an immersion tube or standpipe.
Analog configurations are available without an integral preamplifier (Item # 1202) or else with an integral conventional (Item # 1203) or differential (Item # 1204) preamplifier. ZEUS smart digital configuration (Item # 1205) is for use with the 3TX-HiQ-pH Intelligent pH transmitter.
Selected Photos for Visualization
of Design Aspects of IOTRON™ & ZEUS™ Industrial pH & ORP Sensors
Close-Ups of Sensor Tip
Model: PN 6053-100-15-TL General
Purpose Analog Inline & Immersion pH Sensor (Submersible with Immersion
Tube)
1.
General Purpose Hemispherical 8mm MUGG pH
Glass (X0XX)
2.
General Purpose Solid-State Conductive
Polymer Double Junction Reference System in HDPE Junction Support Matrix
(X0XX)
3.
¾”- ¾” MNPT RYTON Sensor Body Housing
shown in the default 4 each Protective Tines Configuration (6X53 Series)
4.
Integral Pt100 Temperature Compensation
(TC) Element, Complete with 15 feet (4.6
meters) cable & Tinned Lead Wires |
Model: PNTJ 6831/6631-HiQ Sulfide
Resistant Smart Digital Inline & Immersion ORP Sensor (Submersible with
Standpipe)
1.
Low-Profile Platinum Ball ORP Sensing Element
(X8XX)
2.
Sulfide Resistant Solid-State Conductive
Polymer Triple Junction (“TJ”) Reference in KYNAR Junction Support Matrix
(X6XX)
3.
¾”- 1” MNPT RADEL Sensor Body shown in
the default 4 each Protective Tines Configuration (6X31 Series)
4.
Integral Pt1000 TC and Smart Digital Sensor
Board, Complete with 20 feet (6 meters) cable & HiQ4M NEMA 6P snap
connector |
Model: PNGRXPtD 8052-1000-10-TL Dual
pH/ORP All-In-One Sensor for Inline Bayonet Style Quick Disconnect Installations
1.
General Purpose Dual pH/ORP All-In-One
Style Sensor (X0XX) with “PtD” Option Invoked (Two each Reference Half-Cells
Style)
2.
General Purpose Solid-State Conductive
Polymer Double Junction Reference System in HDPE Support Matrix (X0XX)
3.
1” MNPT RYTON Twist Lock Quick
Disconnect Sensor Body in the 4 each Protective Tines “GR” Configuration (8X52
series)
4.
Integral ACCU-TEMP Fast-Response Pt1000
TC, Complete with 10 feet (3 meters) cable & Tinned Lead Wires
Terminations |
Model: PNACXTJ 5331-CONV-30-Q7M High
Viscosity & Slurry Resistant pH Sensor for HOT-TAP Valve Retractable
Installs
1.
Low-Profile Thick-Wall Break-Resistant
Parabolic pH Glass for high Viscosity Solutions & up to 50% Abrasive
Slurries (X3XX series)
2.
Slurry (X5XX), Dissolved Ammonia &
Chlorine Gas (“AC”) Resistant Triple Junction (“TJ”) Reference in KYNAR Matrix
3.
Sanitary & HOT-TAP Style Sensor
Body in no tines configuration, Double O-ring Seals for use with High
Pressure Sensor Holder
4.
Integral Pt1000 TC and Analog
Conventional Preamp, Complete with 30 feet (9 meters) cable & Q7M NEMA 6P
snap connector |
General Note: The large surface area solid-state non-porous conductive
polymer reference system can seen in the photos above between the pH/ORP glass
element and sensor body housing (white for HDPE & brown for KYNAR support
matrix). Normal operation is possible even
when a significant percent of the reference is fouled from process media thus
minimizing the required cleaning frequency.
Model: PNK 8741-3000-20-MBNC Aggressive
Dissolved Gas & Volatile Solvent Resistant Twist Lock Quick Disconnect Sensor
1.
Dissolved Gas & Organic Solvent Resistant
pH Glass (X7XX)
2.
Dissolved Gas & Volatile Organic
Solvent Resistant Solid-State Double Junction Reference in KYNAR Junction
Matrix (X7XX)
3.
1” MNPT PEEK Twist Lock Quick
Disconnect Sensor Body in the default No Protective Tines Configuration (8X41
series)
4.
Integral Balco 3K Temperature
Compensation (TC) Element, Complete with 20 feet (6 meters) cable & Male
BNC Connector |
Model: PNXGRO 5131/5931-HiQ Hi-Temp
& Saturated Sodium Resistant Smart Digital Sanitary Sensor (TRI-CLOVER
Installs)
1.
Saturated Brine & Hi-Temp Resistant
pH Glass (X1XX & X9XX)
2.
Saturated Sodium & High Temperature
Resistant Solid-State Double Junction Reference in KYNAR Matrix (X1XX &
X9XX)
3.
Sanitary & HOT-TAP Style Sensor
Body in 2 each protective tines “GRO” configuration, for TRI-CLOVER sanitary
sensor holder
4.
Integral ACCU-TEMP Pt1000 TC &
Smart Digital Sensor Board, With 20 feet (6 meters) cable & HiQ4M NEMA 6P
snap connector |
Model: PN 2012-1000-10-MBNC Low-Cost
Inline pH Sensor for General Purpose Applications Optimized for Longevity
1.
General Purpose pH Glass (X0XX)
2.
General Purpose Solid-State Double
Junction Reference in Compact Form Factor HDPE Junction Support Matrix (2X12
& 6X11 series)
3.
¾”- ¾” MNPT CPVC Sensor Body Housing in
the No Protective Tines Configuration (Optional removal ¾” NPT guard is
available)
4.
Integral Pt1000 Temperature Compensation
(TC) Element, Complete with 10 feet (3 meters) cable & Male BNC Connector Special
Note: The 2X12 & 6X11 hold a gross excess of potassium chloride in the
reservoir for excellent longevity in moderate service conditions. For more aggressive conditions other sensor
models should be employed. |
Model: ZEUS™ Smart Digital pH Sensor (Item # 1205)
for Severe Service Industrial Inline, Immersion & Submersible Process Use
1.
Low-Profile Thick-Wall Break-Resistant
Parabolic pH Glass for high Viscosity Solutions & up to 50% Abrasive
Slurries & High Temp. & Pressure Service Conditions (Max 150 °C @ 200
psig)
2.
Slurry, Ammonia, Chlorine, Sulfide Gas
& Organic Solvent Resistant Triple Junction (“TJ”) Reference in KYNAR Matrix
3.
1”- 1¼” MNPT RADEL Sensor Body with 4
each Extra Thick Wall Protective Tines Configuration (ZEUS pH Sensor Series)
4.
Integral Pt1000 TC and Smart Digital
Sensor Board, Complete with 20 feet (6 meters) cable & HiQ4M NEMA 6P snap
connector
5.
Waterproofing Style “IT” for 1¼” MNPT
sensors fully submersible up to 12 feet without using an immersion tube of
standpipe |
Note for Sanitary, HOT-TAP & Twist Lock Quick Disconnect Bayonet Style
Sensors:
The standard
material of construction for the double (redundant) sealing O-rings for all
sanitary & HOT-TAP series sensors (5X31, 5X41 & 5X51) is Viton® -75. Alternatively these sealing O-rings can be
supplied in the CV75 (“W”), Simriz®
485 (“U”) or Kalrez® 4079 (“K”)
materials *
* Additional charges
apply for these options. Not all options available on all models (inquire to
factory). ® Viton and Kalrez are registered trademarks of DuPont. Simriz is a registered trademark of Freudenberg Sealing
Technologies (SIMRIT).
Standing Side Views of Selected
Sensor Assemblies
|
|
|
|
|
¾”– ¾” MNPT RYTON Inline & Immersion Series
Shown
with the basic grommet only sealing on back of sensor |
1” MNPT RYTON Twist Lock Inline Sensor Series
PEEK
Receptacle Fitting, Waterproofing “IT” on back of sensor |
¾”– 1” MNPT PEEK Inline & Immersion Series
Inline
& Immersion Use Submersible
without use of immersion tube |
1”– 1¼ “ MNPT RADEL ZEUS pH Sensor
Series Inline
& Immersion Use Submersible
without use of immersion tube |
¾”– 1” MNPT RADEL Inline & Immersion
Series For
submersible use seal the rear threads onto a mating immersion tube |
The photos above are not exhaustive of all of the available sensor
configurations & installation styles but rather are merely meant for
visualization purposes of a few models. The IOTRON™
customized
built-to-order sensors ensure that the materials of construction are
compatible with the process media & conditions while minimizing cost by
selecting only the required features. The sensors with RADEL material of construction for the sensor body the position and size of the solid-state non-porous non-permeable conductive polymer reference system can be seen until the point where the sealing layers obstruct the view. The large surface area single construction solid-state reference system occupies more than 65% of the sensor volume ensuring long lasting operation in even the most aggressive process media and sever service conditions.
Close-Up Views of
Waterproofing Sealing Options for Submersible Installations
Standard (Default) Grommet
on Cable Sealing Complete with double
heat-shrink sealing for basic isolation The
standard grommet on cable sealing is suitable for use in installations where
the back of the sensor will not be exposed to any significant amount of
process fluid, moisture, washdown or rain.
For outdoor installation some type of waterproofing should be
installed unless the cable is run in conduit.
If the sensor will be installed as an immersion of submersible style
the rear threads must be carefully sealed onto an immersion tube or standpipe
if not waterproofing option is invoked. No coding is necessary for this grommet
sealing since it is the default style. |
Waterproofing “A” Suitable
For Most Submersible Installations when installed with immersion tube (a.k.a.
guiderod or standpipe) Complete
isolation of back end threaded fitting from liquid process and good
protection of cable from corrosion and chemical attack. The rear threading is
identical to that specified on original sensor specifications prior to
application of Waterproofing "A" Option. Hex heads for wrench flats
enable easy installations into fixtures. Not recommended for very corrosive
installations or submersible without sealing rear threads. WPA is primarily for elongating sensor life
where attack of liquid from back causes failure prior to chemical or physical
attack through front of probe. |
Waterproofing “B” Suitable for
Very Aggressive Agitated Slurry Solutions & Corrosive Liquids with
Complete Cable Isolation Complete
isolation of back end threaded fitting from liquid process and good
protection of cable from corrosion and chemical attack. Rear threads are
identical to that specified on original sensor specifications prior to
application of Waterproofing "B" Option. Hex heads for wrench flats enable easy
installations into fixtures. Recommended
for extremely corrosive installations, especially those that do not utilizes
any kind of immersion tube, standpipe, guide rod or conduit. WPB sealing is the best choice for extremely
slurry/viscous process media that can abraid cables. |
Waterproofing “WPIT” Suitable For
Most Submersible Installs Cost Effective Waterproofing Option with Complete
Isolation Complete
isolation of back end threaded fitting from liquid process and good
protection of cable from corrosion and chemical attack. Optional NEOPRENE type tubing is shown
above for use in high temperature and highly corrosive solutions. Major rear threading is identical to that
specified on original sensor specifications prior to application of Waterproofing
"IT" option. WPIT uses
polypropylene material of construction and WPITC comes with CPVC material of
construction. WPITC sealing is only
available with thin-style vinyl tubing. |
General Note on Waterproofing Materials of Construction & Sealing
Hose Options:
The
standard material of construction for the WPA/WPB/WPC/WPIT waterproofing seals is
polypropylene (PP). Alternatively CPVC
material of construction is available equivalent to the PP series as
WPG/WPH/WPITC (note that CPVC material is not available as an equivalent to the
WPC). For the WPB, WPH, WPIT, WPITC
seals tubing can be installed. Standard
tubing braid reinforced vinyl tubing with NORPRENE available for especially corrosive
applications or process media that is either not compatible with or too high a temperature
for vinyl tubing. Sensors that have a
Q7M or HiQ4M snap connector the tubing seal must be installed by the ASTI
factory at time of manufacture. No metal
components are used in any of the waterproofing sealing options. Upon request a nylon hose clamp can be fitted
to the tubing for the WPB, WPH, WPIT & WPITC assemblies.
End of Cable Termination
Options Available for Analog pH & ORP Sensors
Terminations for Analog pH & ORP sensors
WITHOUT preamplifier or digital sensor board (Black Composite Cable)
“-MBNC”
Male BNC connector for pH/ORP & Reference Signals, Temperature
Compensation Signal on Two Black Leads |
“-TL”
Tinned Lead Wires: Clear is pH or ORP Signal, Red is for Reference, Black
Leads are for TC, Green is Solution Ground a.k.a. Liquid Earth (if present)
& Optional Drain for Outer Shield |
Tinned
Leads For “PtD” Dual pH/ORP All-In-One Type Sensors: Clear
for pH Signal, Brown is Reference for pH Red
is ORP Signal, Green is Reference for ORP, Blacks
Leads are for Temperature Compensation Elements |
Terminations for Analog pH & ORP sensors
with integral preamp (Gray or Blue Braid Reinforced Multiconductor Cable)
“-Q7M”
quick disconnect male snap connector interfaced to Q7F female extension cable
at top (NEMA 6P rated), Close-up of Q7M at bottom with rugged field sealing
cap for longevity in field use |
“-TL”
for Gray Cable or “-BL” for Blue Braid Reinforced Cable Tinned Lead Wires: Color
coding will vary depending upon mating transmitters. See hook-up schematics webpage or contact
ASTI factory for wiring assistance BEFORE INSTALLATION. |
Sample Complete Analog pH
Sensor Assembly Photos for Visualization
Submersible High HF Resistant pH Sensor
with WPH Sealing & Integral Preamplifier with Braid Reinforced Blue Cable
Option Submersible High HF Resistant pH Sensor
with WPH Sealing & Integral Preamplifier with Braid Reinforced Blue Cable
Option TO RIGHT: Special Order Ultra-High
Temperature Submersible Model 6261 PAEK Bodied pH Sensor with Parabolic pH
glass & Polypropylene WPIT waterproofing with NORPRENE sealing hose, High
Temperature rated analog preamplifier with braid reinforced blue cable for RF
rejection |
6X31 Series pH Sensor with Q7M Snap
& Q7F Snap Extension Cable 5731 Solvent Resistant pH Sensor Without
Preamplifier & Tinned Leads
|
Sample Smart Digital pH Sensor Assembly Photos for
Visualization
PNXGRE 5631/5331-HiQ-12m-WPB/20
Submersible Sulfide & Slurry/Viscous Resistant Smart Digital pH Sensor
with Extreme Dehydration Resistant Junction for Intermittent Wet and Dry Use, 12 meters (40 feet) of integral cable
& WPB with 6 meters (20 feet) of reinforced vinyl tubing for installs
down in a sewer through a manhole |
PNHF 6431-HiQ-WPH/10 Fully Submersible Acid/Fluoride
High HF Resistant Smart Digital pH Sensor with WPH waterproofing seal, 6 meters (20 feet) of integral cable
& 3 meters (10 feet) of braid-reinforced vinyl tubing; Typical
applications include acid fluoride etching control & monitoring or
industrial wastewater treatment (WWT) plants |
Smart Digital ZEUS pH Sensor (Item #
1205) with 12 meters (40 feet) female snap to male snap extension cable shown
interfaced; Max rating of 150 °C @ 200 psig, Fully Submersible to 12 feet,
Typically uses include processes with dissolved ammonia, chlorine, sulfides
& abrasive slurries |
HiQ4F Female Snap connector shown to
Left, HiQ4M Male Snap connector shown to
Right HiQ4M Male Snap & HiQ4F Female Snap
connectors shown interfaced, NEMA 6P fully waterproof and corrosion resistant
allow for convenient installation & maintenance in any industrial
facility or site location |