Product Introduction
The ABB AW600068 is a 2-electrode conductivity sensor designed for integration with the ABB 2600T series of transmitters. It serves as the primary measurement element for monitoring the ionic concentration of process liquids, a critical parameter for quality control and process stability in industries like chemical manufacturing and water treatment.This sensor’s value is most apparent in its straightforward integration and reliable performance. The 1.0 cm⁻¹ cell constant is a standard choice for a wide range of applications, from moderately pure water to more concentrated solutions. Its 3/4″ NPT process connection simplifies installation into existing piping or vessels. In my experience, this combination of a common cell constant and a robust mechanical design makes it a versatile and dependable choice for many plants.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Product Model | AW600068 |
| Manufacturer | ABB |
| Product Type | 2-Electrode Conductivity Sensor |
| Cell Constant | 1.0 cm⁻¹ |
| Compatible Transmitters | ABB 2600T Series |
| Process Connection | 3/4″ NPT |
| Wetted Materials | 316 Stainless Steel Electrodes, PEEK Body |
| Maximum Process Temperature | 140 °C (284 °F) |
| Maximum Process Pressure | 10 bar (145 psi) at 20°C |
| Cable Length | 6 meters (standard) |
| Housing Protection | IP68 |
Application Scenarios & Pain Points
A plant engineer in a food and beverage facility was troubleshooting inconsistent product taste. The root cause was traced back to the CIP (Clean-in-Place) system. The rinse cycle wasn’t removing all the cleaning agent, which was then contaminating the next batch. The old conductivity sensor was sluggish and couldn’t accurately detect the transition from cleaning solution back to pure water. Replacing it with a responsive sensor like the ABB AW600068 provided the sharp, reliable measurement needed to optimize the rinse cycle, ensuring product quality and saving significant water and chemical costs.This is the kind of problem this sensor is built to solve. It provides the accurate, real-time data needed to control critical process steps.
- Chemical Processing: Used to monitor reactant concentrations and ensure batch consistency. An inaccurate reading here can lead to off-spec product and costly rework.
- Water Treatment: Essential for desalination plants and boiler feedwater systems to measure water purity. A failure can lead to scaling or corrosion in expensive downstream equipment.
- Power Generation: Monitors conductivity in steam and condensate cycles. High conductivity indicates ionic contamination, which can cause severe corrosion in turbines and boilers.
- Pharmaceuticals: Critical for Water-for-Injection (WFI) systems where water purity is strictly regulated. The sensor provides the data needed to ensure compliance with quality standards.
- Food & Beverage: As in the CIP example above, it’s used to verify rinse water purity between production runs, preventing cross-contamination and ensuring product safety.
Quality Control Process
We understand that a faulty sensor can disrupt an entire process loop. To prevent this, every ABB AW600068 undergoes a rigorous inspection and testing protocol before it leaves our facility.
- Inbound Inspection: We verify the source and authenticity of every unit, checking serial numbers against ABB records. A visual inspection follows, looking for any signs of physical damage, corrosion on the electrodes, or issues with the cable and connector.
- Live Functional Test: The sensor is connected to a calibrated ABB 2600T transmitter in our test bench. We immerse it in standard calibration solutions (e.g., 1413 µS/cm and 12.88 mS/cm) to verify its measurement accuracy across its range. The response time and stability of the reading are logged.
- Electrical Parameters: We perform an insulation resistance test on the sensor cable and connections to ensure there are no leaks that could affect the signal integrity.
- Physical & Mechanical Check: The 3/4″ NPT threads are checked with a gauge to ensure a proper seal can be made during installation. The PEEK body is inspected for cracks or stress marks.
- Final QC & Packaging: After passing all tests, the sensor is cleaned, its calibration data is documented, and it’s sealed in an anti-static bag for shipping.
Installation Pitfalls Guide
Even a perfect sensor can give bad data if it’s not installed correctly. Here are the most common mistakes we see in the field.
- ❗ Incorrect Sensor Orientation: Installing the sensor pointing upwards can trap air bubbles on the electrode surface. This will cause erratic and inaccurate readings. Always install the sensor so it points downwards or horizontally to allow bubbles to escape.
- ❗ Ignoring Polarization Effects: The 2-electrode design of the AW600068 is great for many applications, but at very high conductivities, polarization can cause measurement errors. If you’re measuring strong acids or bases, verify this sensor type is appropriate for your range.
- ❗ Improper Cable Management: Running the sensor cable alongside high-voltage power lines can induce electrical noise, corrupting the low-level signal from the sensor. Keep instrument cables separate from power cables to ensure a clean signal.
- ❗ Neglecting Regular Cleaning: Process buildup on the electrodes will insulate them and cause a slow, drifting response. Establish a regular cleaning schedule based on your process fluid to maintain accuracy.
- ❗ Forgetting to Calibrate: Don’t assume the sensor is accurate out of the box for your specific application. Always perform a 1 or 2-point calibration with solutions that bracket your normal operating range after installation.
