Data sheet DS/TB4CS–EN Rev. G TB4CS Conductivity sensor 4-Electrode Low maintenance sensor with the widest operation range available (0 to 2000 mS/cm) 4-electrode measurement —Increases accuracy, stability, flexibility, and security Resilient — Sensors capable of withstanding the toughest chemical processes at extreme temperatures and pressures Corrosion resistant stainless steel electrodes — For all conductivity ranges without polarization Smaller measurement electrodes — High current densities are permissible due to feedback circuitry and polarization compensation Wide rangeability with excellent linearity — Compensates for polarization effects Overcome and compensate for fouling effects — Reduces frequency of cleaning Extent of fouling notification and fouled sensor relay — Makes it possible for conductivity instrument to notify of dirty sensor condition Rugged construction and materials Installation flexibility — Inline, Twist-lock, Immersion, Tri-Clamp, Flow-cell, TB18 Safe-TClean Valve & Retractable Hot-Tap Interchangeable measurement tips Suitable for all measurements — From low to high solution concentrations
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Data sheet DS/TB4CS–EN Rev. G
TB4CSConductivity sensor4-Electrode
Low maintenance sensor with the widest operation range available (0 to 2000 mS/cm)
4-electrode measurement— Increases accuracy, stability, flexibility, and security
Resilient— Sensors capable of withstanding the toughest chemical
processes at extreme temperatures and pressures
Corrosion resistant stainless steel electrodes— For all conductivity ranges without polarization
Smaller measurement electrodes— High current densities are permissible due to feedback
circuitry and polarization compensation
Wide rangeability with excellent linearity— Compensates for polarization effects
Overcome and compensate for fouling effects— Reduces frequency of cleaning
Extent of fouling notification and fouled sensor relay— Makes it possible for conductivity instrument to notify of
Suitable for all measurements— From low to high solution concentrations
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TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Endura 4-Electrode Conductivity Sensorsfor Process Monitoring
ABB is the industry leader in advancements resulting inthe increased accuracy, dependability, and environ-mental limits of on-stream conductivity sensors. Theconductivity sensor line permits resolutions of 0.001microsiemens per centimeter, full-scale ranges of onesiemen per centimeter, pressure ratings to 2,068kilopascals (300 psig), and temperature ratings of200-degrees Celsius (392-degrees Fahrenheit). GroupA sensors have a measurement range spanning fivedecades of conductivity or TDS concentration.
The ABB 4-electrode conductivity system is a patentedconcept unique in the process industry. It providesultimate sampling flexibility, sensor reliability,rangeability, and helpful operating and maintenanceinformation. Smart circuitry detects and compenstatesfor the buildup of deposits, and scale and corrosionproducts on the sensor. It also provides an alarm beforethe interference becomes so serious as to affect theconductivity signal. The dirty sensor alarm output is acontact closure, a digital signal, or any other easilyobserved format.
Anti-Fouling 4-Electrode Circuit
Figure 1 shows the 4-electrode conductivity systemwhich consists of two current electrodes and twopotential electrodes, a high impedance amplifier provid-ing feedback to an amplitude-controlled ocillator, aconductivity sensing circuit with associated load resistorand display, and a dirty sensor alarm circuit.
Feedback from the high impedance amplifier causes theoscillator to vary its amplitude output to maintain aconstant excitation field, created by the current elec-trodes in the solution, as sensed by the potential elec-trodes. The current required to create the excitationfield passes through the load resistor and is sensed as avoltage drop by the conductivity sensing circuit. Theamount of excitation current required to maintain aconstant excitation field in a solution is directly propor-tional to conductivity. If fouling of the electrodes occurs,the AC potential at the electrodes increases to drive theexcitation through the deposits to maintain the constantexcitation field. The increase in potential at the currentelectrodes compensates for the increase in interfaceresistance at them. The high impedance amplifierdraws no current; therefore, the voltage drop acrossdeposits on the potential electrodes is negligible andcontributes no signficant error.
The dirty sensor alarm circuit measures the oscillatoramplitude. The amplitude stays below a predefinedthreshold during normal operation. If the amplitudeexceeds that threshold, the conductivity measuringinstrument notifies, via an alarm, readout, or othermethod, that the sensor needs cleaning.
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TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
DIMENSIONS
MILLIMETERSINCHES
INTEGRALTEMPERATURECOMPENSATORLOCATION (TYPICAL)
17.40.69
17.40.69
25.41.00
MALE CONDUIT CONNECTION1/2 OR 3/4 NPT
INLINE EXTERNALTB4900
SUBMERSIBLE EXTERNALTB4901
TINNEDLEADS
3/4 OR 1 NPT
SHIELDED2-WIRE CABLE
8.90.35
8.90.35
Figure 1. 4-Electrode Conductivity System
T04254B
25.41.00
50.82.00
25.41.00
124.34.89
1/4 NPT
1/4 NPT
TURN FITTING AROUND FORSUBMERSIBLE APPLICATIONS
PTFE WETTED PARTS 4TB6006-0009
690 KPA (100 PSI),100°C (212°F)
690 KPA (100 PSI),125°C (257°F)
316 STAINLESS STEEL WETTED PARTS4TB6006-0008
10.20.40
6.40.25
WAND TYPE EXTERNAL
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TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Sensor Groups and Ranges
There are two groups of 4-electrode conductivitysensors. The rangeability of any sensor is defined bythe physical structure of the electrodes and the elec-tronic circuitry of the associated instrument. Thephysical structure of the electrodes determines thesensor cell constant; however, the concept of sensorcell constants is more applicable to two-electrodesensors. Unlike 4-electrode sensors, as manufacturedby ABB, the rangeability of two-electrode sensors isrestricted by current density and polarization. 4-electrode sensors are not limited by these factors. Theresult is a virtual dimensionless sensor constant withwide rangeability.
The actual measurement range is determined by thesensor group and the instrument range or range factorin use. All ABB conductivity instruments are multirangetypes. This provides numerous application options forany sensor and instrument combination.
ABB 4-electrode conductivity sensors are arranged intwo groups, loosely adhering to the sensor cell constantstructure in the following manner:
• Group A: General purpose for zero to 100 to zeroto 2,000,000 μS/cm.
• Group B: Low to medium range for zero to 10.00 tozero to 2,000 μS/cm.
Table 1 provides a list of sensor and ranges.
Temperature Compensation
ABB conductivity sensors are available with temperaturecompensators either integral to or separate from them.The type of temperature compensator must be supportedby the instrument. AX4 series microprocessor-basedinstruments accept 3kΩ, Pt 100 and Pt 1000 tempera-ture compensation. Type TB82EC and TB84EC micro-processor-based instruments have the option of using a3kΩ or Pt 100 RTD.
Figure 2 shows the temperature compensators. Theeffect of temperature on conductivity is significant;therefore, for measurements to be accurate, conductiv-ity must be compensated to a reference temperature(typically 25°C).
Flow Cells
The flow cell (Fig. 3) is available for both conductivity andpH sensors. It is designed for use with the EnduraTB264 Two-Electrode Conductivity Sensors, EnduraTB464 4-Electrode Conductivity Sensors, and EnduraTB(X)561 pH/ORP Sensors. Multiple inlet and outletports provide flexibility with installation, calibration, andmounting configurations. The sensor can be insertedand removed from the flow cell quickly and easilywithout disconnecting the sensor from the instrument orjunction box.
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TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Table 2. Ratings and Mounting Arrangements for Conductivity Sensors
Endura TB451 & TB452 sensors (Fig. 4) have anintegral Tri-Clamp® fitting for use in sanitary services.ABB offers two styles of these sensors. The first is aflush face style that meets the process right at the Tri-Clamp fitting. The second has an extended facedesigned to meet the process at the end of a Tri-Clampfitting such as a tee. The extended face type is O-ringsealed to prevent the process solution from gettingbehind the electrode face where cleaning chemicalswill not reach. This style of sensor can be sized to fiteither 1.0-inch or 1.5-inch tubing. The flush style canbe used with either size.
Special FeaturesIntegral Tri-Clamp flange. Security from crevice
formation in process.
Figure 5. Endura TB451 & TB452 Sensor Dimensions
Figure 4. Endura TB451 & TB452 Sensors
T04256ATB452 FLUSH TB451 EXTENDED
T04107A
DIMENSIONS
MILLIMETERSINCHES
3/4 NPT
NO. 216 VITON O-RING
1-1/2 IN. SANITARY TUBE(SUPPLIED BY OTHERS)
FLANGE GASKET(SUPPLIED BYOTHERS)
1-1/2 IN. KYNARFLANGE MOUNTSENSOR
DIA GROOVE
DIA GROOVE
DIA GROOVE
WALL
SANITARY FLANGE GASKET(SUPPLIED BY OTHERS)
VESSEL
DIA
DIA
DIA
DIA
TB451EXTENDED
TB452EXTENDED
TB4521-IN. TUBE STYLE
TB451FLUSH FACE
INSTALLATION
TB451EXTENDED
INSTALLATION
34.31.35
34.31.35
69.82.75
139.75.50
21.60.85
4.570.18
4.570.18
2.280.09
10.80.42
10.80.42
28.91.14
28.91.14
19.00.75
50.51.98
46.21.82
46.21.82
43.01.69
52.42.06
69.82.75
53.32.10
53.32.10
50.21.97
104.14.10
104.14.10
100.93.97
3/4 NPT DIADIA
DIATB451FLUSH
50.41.98
34.31.35
26.71.05
44.51.75
104.14.10
8
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
9
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
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TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Endura TB454 Twist-Lock Conductivity Sensor
Endura TB454 sensors (Fig. 6) combine versatility,easy access, and low cost into one compact package.The sensor is suitable for either inline or immersioninstallations. It fits into a 1-inch NPT receptacle and isinserted with a push and 180-degree twist to lock forinline installations. There is also a Ryton® (PPS) holderwith screw cap available. The wide rangeability of thissensor makes it a perfect match for almost all lessaggressive conductivity measurements.
Endura TB454 Sensor Specifications
ApplicationsCooling towers, water and waste monitoring,packaged water systems.
Endura TB457 and TB458 sensors (Figure 8) have 316stainless steel bodies and integral Tri-clamp fittings foruse in applications requiring steam sterilization. Theelectrode tips and electrodes are sealed with an FDAapproved silicon potting material. ABB offers two stylesof these sensors, a flush face that meets the process atthe Tri-clamp fitting. The second has an extended facedesigned to place the electrodes into the process pastthe fitting. The extended face version is narrow enoughto allow rinsing chemicals or steam to surround thewetted surfaces to ensure effective cleaning. TheEndura TB457 and TB458 sensor specifications areshown to the right and the ordering guide on the nextpage. Dimensions are shown in Figure 9.
Endura TB457 & TB458 Sensor Specifications
ApplicationsFood, beverage, dairy & pharmaceutical serviceswhere process lines must be kept sanitary and /orchemical or steam cleaning takes place.
Max. Pressure/Temperature861 kPag (125 psig) at 175°C (347°F) max.
Ruggedly constructed of 316 stainless steel, thesesensors withstand the most demanding processes andmeasurement requirements. Endura TB46 insertion/submersion sensors (Fig. 10) are easily installed intoprocess lines and vessels by the 3/4-NPT insertionthreads or immersed directly into fluids by the back-threads. Endura TB46 hot tap sensors (Fig. 10) aredirectly inserted and removed from lines and vesselswithout disturbing the process via either a 11/2 inchnormal or 11/4 inch full port ball valve. This series is themost versatile offered by ABB. Full spectrumconductivity measurement is achieved by the widerangeability of the sensor and the uniqueinterchangeable tip design. The specifications arelisted in Table 9 and the ordering guide in Table 10.Dimensions are shown in Figures 11 & 12.
Endura TB46 Sensor Specifications
Applications (typical)
Inline/immersion:Boiler measurements, sewer monitoring,cooling towers, condensate, deionizers andother water treatment applications, heatexchangers, concentration monitoring, andall other general conductivity measurements.
Retractable Hot tap:Boiler condensate measurements, pulpstock lines, sealed vessel monitoring, and allother general conductivity measurementsrequiring sensor/insertion/removal withoutprocess disturbance.
Max. Pressure/Temperature:
Inline/immersion:1,550 kPag (225 psig) at
200°C (392°F)1100 psig at 100°F (special request label)
Retractable Hot tap:689 kPag (100psig) at 200°C (392°F) max.
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
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TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Endura TB461 continued:
19
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
20
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Endura TB465 continued:
21
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Endura TB464 sensors (Fig. 13) are available with abushing nut and union or can be retro-fitted into stan-dard DN25 bushings with 0.983-inch to 0.995-inchinternal diameters. They are also available for installationinto 4TB9515-0190 and 4TB9515-0223 flow cells or theEndura TB18 Safe-T-Clean sensor valve. It quickly andeasily installs into the flow cell without twisting the sensorcable.
Table 12. Endura TB464 Sensor Specifications
Applicationcooling towers, packaged water systems,exchange columns, heat exchangers, all other low tomedium range conductivity measurements.
Max. Pressure/Temperature1,378 kPag (200 psig) at 200°C (392°F) max.
MaterialsBody and electrodes: 316 stainless steelInsulator: PEEKO-rings: Ethylene propylene
Special FeaturesEasy installation into either flow cell, any available25-mm port, or the Endura TB18 Safe-T-Clean sensorvalve. Flexible insertion depth.
Endura TB464 Flow-cell or Safe-T-Clean Conductivity Sensor
Figure 13. Endura TB464 Sensor
Figure 14. Endura TB464 Sensor Dimensions
Figure 14a. Endura TB464 Flow Cell Kits
T04109A
TB464ASENSORGROUP A
TB464BSENSORGROUP B
TB464CSENSORGROUP C
DIMENSIONS
MILLIMETERSINCHES
3/4 NPT 2-020 EPRO-RING
WHEN:
I = ; I = ; I = ; I =, L = , L = , L = , L =
24.00.95
70.02.76
100.03.94
150.05.91
200.07.87
125.04.92
154.96.10
205.08.07
255.010.04
31.81.25
25.00.98DIA DIA
L
I
1/2-NPT x 1/4-IN.SWAGE LOCKFITTING (3 TYP)
T03874C
DIMENSIONS
MILLIMETERSINCHES
TB264/TB464SENSOR(NOT INCLUDED)
NOTES: 1. DASHED LINES REPRESENT DIMENSIONS OF FLOW CELL KIT WITH SWAGE LOCK FITTINGS.
2. FLOW CELL KIT WITHOUT SWAGE LOCK FITTINGS: 4TB9515-0223. FLOW CELL KIT WITH SWAGE LOCK FITTINGS: 4TB9515-0190.
38.11.50
71.92.83
134.95.31
166.46.55
198.17.80
239.39.42
271.010.67
22
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
23
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Endura TB468 Sensor Specifications
Applications (typical)Concentration monitoring of process streams that wouldcorrode 316 stainless steel electrodes. Condensateand heat exchanger monitoring with potential for acidintrusion.
Max. Pressure/TemperatureTB4680: Max. 689 kPag (100 psig) at
MaterialsBody: Kynar (PVDF)Hot tap sheath, pressure ring, electrodes:
Hastelloy CHot tap compression fitting:
PTFE
Special FeaturesCorrosion resistance.
Hastelloy Electrodes
Endura TB468 sensors are available in either inlineinsertion (TB4680) (Fig. 15) or hot tap styles (TB4683).The insertion style is also submersible. A Kynar (PVDF)body and Hastelloy® C electrodes allow use in aggres-sive applications where 316 stainless steel is not ad-vised. The specifications are listed in Table 14 and theordering guide in Table 15. Endura TB4680 insertionstyle sensor dimensions are shown in Figure 16 andEndura TB4683 hot tap style sensor dimensions areshown in Figure 17.
Endura TB468 Insertion or Hot Tap Conductivity Sensorwith Hastelloy Electrodes for Corrosive Service (Group A)
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
PTFE
PTFE
25
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
Figure 17. Endura TB4683 Hot Tap Style Dimensions
T04106A
DIMENSIONS
MILLIMETERSINCHES
1/2 NPT
KYNARTIP
1-IN. KYNARBALL VALVE
1-IN. TO 3/4-IN.REDUCINGBUSHING
PTFECOMPRESSIONFITTING
SS SAFETYRESTRAINING
1-IN. KYNARNIPPLE
508.020.00
19.10.75STOCKO.D.
26
TB4Conductivity sensor – 4-Electrode DS/TB4CS–EN Rev. G
1 1/2” -
316 S.S.
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Endura TB47 sensors (Fig. 18) can be directlyinserted into or removed from lines and vesselswithout disturbing the process. Designed for servicein systems exceeding pressure ranges of standardhot tap sensors, these high pressure hot tap sensorsalso insure worker safety. Closing a ball valve isolatesan extraction housing, separating the operator fromthe sensor and process. The housing can be pres-surized or depressurized and purged by installingflush and/or drain lines to the 1/4-NPT purge con-nections. Ruggedly constructed of 316 stainlesssteel, these sensors withstand the most demandingprocesses and measurement requirements. Thespecifications are listed in Table 16 and the orderingguide in Table 17. Dimensions are shown inFigure 19.
Endura TB47 Sensor Specifications
ApplicationsBoiler condensate measurements, pulp stocklines, sealed vessel monitoring, pulp liquor, toxicchemical monitoring, heat exchangers,concentration monitoring, and other conductivitymeasurements requiring special worker safetyconsiderations.
Max. Pressure/Temperature2,068 kPag (300 psig) at max. temp. of200°C (392°F)
MaterialsSensor and valve bodies, electrodes, extractionhousing, insertion/body assembly, compressionfitting:
NoteWe reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.
We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole or in parts – is forbidden without prior written consent of ABB.