CLEAN CON5000 Conductivity / TDS / Salinity Controller

Overview

The CLEAN CON5000 Conductivity / TDS / Salinity Controller is an industrial-grade benchtop process analyzer engineered for continuous, high-stability measurement in demanding online water quality monitoring applications. Built upon a dual-channel analog signal conditioning architecture and precision digital temperature compensation, the CON5000 implements standardized conductivity measurement principles per ASTM D1125 and ISO 7888, supporting accurate conversion to TDS (Total Dissolved Solids) and salinity (g/L) using configurable cell constants and linear/nonlinear temperature algorithms. Its design targets critical infrastructure segments including boiler feedwater control, reverse osmosis (RO) system monitoring, cooling tower management, wastewater effluent compliance, and pharmaceutical purified water (PW) and water-for-injection (WFI) loop verification—where reproducible, low-drift readings across wide dynamic ranges are essential for regulatory adherence and process safety.

Key Features

• Multi-parameter measurement engine supporting simultaneous real-time display of conductivity, TDS, salinity, and temperature—with independent range segmentation (7 auto-ranging spans from 0.000 µS/cm to 400.0 mS/cm)
• High-immunity hardware design: galvanically isolated RS-485 interface (2500 V_rms isolation), programmable digital filtering, and reinforced EMI/RFI shielding compliant with IEC 61326-1 for industrial electromagnetic environments
• Dual 4–20 mA analog outputs with user-defined scaling, enabling direct integration into DCS/PLC systems for closed-loop control of dosing pumps, valve actuators, or alarm triggers
• Three independently configurable SPST relays: two process control relays (e.g., high/low limit alarms) and one auxiliary function relay (e.g., electrode cleaning cycle activation)
• Bilingual 128×64 dot-matrix LCD with graphical icons and context-sensitive soft keys; supports on-device language switching without firmware reload
• Full Modbus RTU implementation over RS-485 (slave mode), supporting bidirectional register read/write for remote configuration, calibration logging, and real-time data polling via SCADA or HMI platforms
• Comprehensive security framework: password-protected parameter access tiers (operator, technician, administrator) aligned with ISA-99/IEC 62443 Level 1 requirements

Sample Compatibility & Compliance

The CON5000 is compatible with a full suite of CLEAN CS-series conductivity cells (K = 0.01, 0.1, 1.0, and 10.0 cm⁻¹), enabling optimized performance across ultra-pure water (UPW), municipal supply, brine, and electroplating bath applications. Its measurement methodology conforms to internationally recognized standards including ASTM D1125 (electrical conductivity of water), ISO 7888 (conductivity of water for pharmaceutical use), and USP (electrical conductivity of purified water and water for injection). The device’s firmware architecture supports audit-trail-capable calibration logging and meets foundational requirements for GLP and GMP environments—particularly when paired with PT1000 temperature sensors traceable to NIST standards. While not inherently 21 CFR Part 11-compliant out-of-the-box, its secure access controls, change history retention, and deterministic communication protocol provide a robust foundation for validation under FDA-regulated manufacturing processes.

Software & Data Management

No proprietary PC software is required for basic operation; all configuration—including range selection, TDS factor (0.40–1.00), temperature compensation curve (linear or NaCl-based non-linear), relay hysteresis, and current output mapping—is performed directly via the front-panel interface. For enterprise-level integration, the Modbus RTU register map provides structured access to 128+ parameters, including live measurement values, calibration coefficients, relay status, error flags, and uptime counters. Third-party SCADA systems (e.g., Ignition, Siemens Desigo, Honeywell Experion) can poll data at configurable intervals (100 ms–10 s) and trigger write commands for setpoint updates or manual relay actuation. All configuration changes are timestamped and stored in non-volatile memory with rollback capability—supporting version-controlled operational continuity during maintenance or audit preparation.

Applications

• Power generation: Continuous monitoring of condensate polishers, steam drum blowdown, and demineralizer effluent to prevent turbine corrosion and scale formation
• Pharmaceutical manufacturing: Real-time verification of PW/WFI conductivity against USP limits (≤1.3 µS/cm at 25°C) with automatic temperature normalization
• Food & beverage processing: Control of CIP rinse water quality, brine concentration in pickling lines, and syrup dilution consistency
• Municipal water treatment: Feedwater conductivity profiling for coagulant dosing optimization and desalination plant intake screening
• Electroplating and anodizing: High-conductivity bath monitoring (up to 400 mS/cm) using K=10.0 cm⁻¹ electrodes to maintain electrolyte stoichiometry
• Microelectronics UPW loops: Sub-µS/cm resolution tracking with K=0.01 cm⁻¹ sensors for particle-free ultrapure water distribution networks

FAQ

What electrode constants does the CON5000 support?
The controller accepts four standard cell constants: 0.01 cm⁻¹ (ultra-pure water), 0.1 cm⁻¹ (purified water), 1.0 cm⁻¹ (municipal and industrial water), and 10.0 cm⁻¹ (high-salinity or electroplating solutions). Calibration is performed per electrode specification using certified KCl standards.
Can the CON5000 operate on DC power?
Yes—while shipped with 85–260 VAC default, the unit supports optional 18–36 VDC input. Specify voltage requirement at time of order; no field modification is possible.
Is temperature compensation automatic?
Yes—integrated PT1000 sensor input enables fully automatic temperature compensation using either linear (default) or NaCl-specific non-linear algorithms per ISO 7888 Annex A.
How many relays does the CON5000 include, and what are their ratings?
It features three SPST relays: two rated at 2.5 A / 230 VAC for process control (e.g., pump start/stop), and one auxiliary relay configurable for cleaning cycles or system diagnostics.
Does the device meet hazardous area certifications?
No—the CON5000 is rated for general-purpose industrial use (IP65 front panel, Class I Division 2 ambient suitability) but lacks intrinsic safety (IS) or explosion-proof (Ex d) certification. For hazardous locations, install in a classified enclosure or use with approved barrier systems.