ABB AX400 series low conductivity analyzer(AX411/511010)

ABB AX400 series low conductivity analyzer

Product Overview: The Core Positioning of ABB AX400 Series

The AX400 series low conductivity analyzer launched by ABB Measurement&Analysis includes five models: AX410, AX411, AX416, AX450, and AX455. It is a single/dual input analysis device designed for low-level conductivity measurement and belongs to the ABB process analysis instrument system. The design concept emphasizes high reliability, strong flexibility, and full functional integration, which can meet the process monitoring and control needs of multiple industries such as water treatment, power, semiconductor, and pharmaceuticals. This series is an important branch of the AX400 analytical instrument family, which also includes solutions for pH/oxidation-reduction (ORP) and dissolved oxygen measurement. The AX41x and AX45x models are specifically designed for low conductivity measurement and are equipped with ABB dual electrode conductivity cells to achieve ultra-high precision continuous measurement. They also support local display and signal retransmission. The AX45x series is specifically developed for the United States Pharmacopeia<645>(USP<645>) standard, meeting the strict compliance requirements of the pharmaceutical industry.

The AX400 series adopts an IP65 protection level design and supports three installation methods: wall mounted, pipeline mounted, and panel mounted. While balancing measurement performance, it achieves the core goals of reducing installation costs, minimizing maintenance costs, and optimizing energy consumption. Its integrated design can replace multiple single function instruments and provide a cost-effective process analysis solution for industrial sites. Whether it is single parameter low conductivity monitoring, combined measurement of conductivity and pH/ORP, or compliance testing in the pharmaceutical industry, the AX400 series can adapt to scene requirements through flexible configuration and powerful functions, and is a key device for water quality analysis and process control in industrial processes.

Core Product Advantage: Comprehensive Performance and Cost Optimization

The core competitiveness of the ABB AX400 series low conductivity analyzer lies in four dimensions: functional integration, cost controllability, convenient operation, and wide applicability. It achieves a balance between performance and cost throughout the entire lifecycle from design, installation, operation to maintenance. The specific advantages can be divided into the following six aspects:

（1） High cost-effective functional configuration

This series supports flexible input combinations, allowing for the selection of 1 or 2 conductivity inputs, as well as the integration of conductivity and pH/ORP into one analyzer (AX416 model), eliminating the need for separate configuration of multiple instruments and significantly reducing equipment investment; The AX410 model also has a built-in PID controller, which can directly achieve process closed-loop control and reduce the need for external control modules. At the same time, the equipment comes standard with various calculation functions such as conductivity, resistivity, difference, ratio, pass rate, removal rate, and pH calculation, which can achieve multi parameter analysis and output without additional programming, achieving high functionality at the lowest cost.

（2） Significantly reduced installation and space costs

The device adopts an easily accessible wiring terminal design, and the wall mounted/pipeline installation version of the cable connection is simple and convenient. Even if the terminal room is opened, the protection level of the electronic components can remain unchanged, achieving fast and low-cost on-site installation; The size of the panel installation version is only 96mm × 96mm, greatly reducing the space occupied by the panels inside the control cabinet and suitable for compact industrial site layouts.

（3） Scalable monitoring and control capabilities

The AX400 series comes standard with 2 fully isolated current outputs and 3 programmable relay settings. By adding an option board, it can be expanded to 4 current outputs and 5 alarm relays. All outputs can be assigned to measurement parameters, sample temperature, or calculation variables, meeting the multi signal output and alarm requirements of complex scenarios. The option board adopts a plug and play design, and ABB exclusive software can automatically reconfigure the analyzer without user programming, making the expansion process simple and efficient. In addition, the option board also integrates real-time clock and electronic logbook, which can record process events and calibration data, providing data support for process traceability and equipment maintenance.

（4） Humanized design for energy consumption optimization

The device is equipped with a high visibility backlit LCD display, which can be set to automatically turn off after 60 seconds of inactivity, achieving energy savings; The display screen adopts a dual 5-digit 7-segment design, paired with a 16 character dot matrix single line display area, which can simultaneously display measurement parameters, diagnostic information, and calculation data. The dual input model can also display two measurement parameters synchronously, making on-site readings intuitive and convenient.

（5） Minimize annual maintenance costs

The AX400 series comes standard with 85-265V AC wide voltage power supply, no internal switch needs to be set, and supports 24V AC or 12-30V DC power supply. The equipment can automatically identify the power supply type; The 12-30V DC power supply option eliminates expensive annual safety testing, significantly reducing maintenance costs and labor investment. In addition, ABB conductivity sensors are pre calibrated at the factory and do not require additional adjustments after installation. The sensor structure is sturdy and the measurement values are stable for a long time. The single point calibration function is only activated when needed for on-site verification, further reducing maintenance workload.

（6） Ultra wide industry applicability

With flexible measurement configuration, precise performance, and compliant design, the AX400 series can adapt to multiple industries such as water treatment and wastewater treatment, power pure water treatment, semiconductor manufacturing, chemical, pharmaceutical, pulp and paper, etc. Whether it is conventional low conductivity monitoring, high-purity water preparation, reverse osmosis process, boiler water monitoring, or purified water/injection water detection in the pharmaceutical industry, stable and reliable measurements can be achieved.

Core functional feature: Integration of precise measurement and intelligent control

（1） Single/dual input measurement: full coverage of multiple parameters and calculation functions

The single/dual input models of the AX400 series can achieve precise measurement of low conductivity. The measurement units can be flexibly configured as μ S/cm, μ S/m, mS/cm, mS/m, and can also be set as megaohm centimeters (M Ω - cm), total dissolved solids (TDS), and salinity. The measurement range can be programmed from 0-0.5 to 0-10000 μ S/cm (adjusted according to different electrode constants), with a minimum range of 10 times the electrode constant and a maximum range of 10000 times the electrode constant, meeting the measurement needs of different low conductivity scenarios.

In addition to basic measurement, the dual input model can also achieve the calculation, display, and signal transmission of ratio, difference, pass rate, removal rate, and calculated pH. These functions are key analysis tools for desalination, reverse osmosis, ion exchange, and other processes: pass rate is (tank 1/tank 2) × 100, removal rate is (1-tank 1/tank 2) × 100, and ratio is the ratio of the measured values of tank 1 and tank 2, which can intuitively reflect the processing efficiency of the process. For example, in the reverse osmosis process, the removal rate of the process can be quickly calculated by measuring the conductivity of the raw water and the produced water, providing data basis for process adjustment.

（2） Exclusive Function Model: Targeted Solution to Industry Scenario Requirements

The AX400 series models have been specially designed according to their functional positioning, which can accurately match the application needs of different industries. The functional differences and positioning of the core models are as follows:

AX411: specializes in cation conductivity and pH measurement, suitable for low conductivity scenarios such as ammonia boiler water. The device can calculate the pH based on the conductivity value and the preset ammonia concentration, without the need to configure a pH electrode, reducing the maintenance cost and failure probability of the pH electrode; At the same time, the conductivity value after cation exchange is detected through the second input to achieve self-monitoring of pH measurement effectiveness. Alarm contacts such as cation conductivity, invalid pH, and resin depletion can be configured to provide safety guarantees for boiler water quality monitoring.

AX410: The only model with a built-in P/PI/PID three action controller, supporting three control modes: analog, pulse width (time ratio), and pulse frequency. It can be set to positive or negative action and is suitable for low conductivity processes that require closed-loop control. The proportional band, integration time, and differentiation time of the controller can be programmed, with a pulse period of 1.0-300.0 seconds and a pulse frequency of 1-120 times/minute. It can directly drive the actuator and achieve automatic adjustment of process parameters.

AX416: Achieve combined measurement of conductivity and pH/ORP, with one device capable of monitoring two key water quality parameters. Equipped with pH/mV input, solution and temperature sensor interfaces, it can connect glass/enamel pH electrodes, reference electrodes, and ORP sensors. The pH measurement range is -2 to 16, and the ORP is -1200 to+1200mV, with an accuracy of 0.01pH, meeting the needs of scenarios that require both conductivity and pH monitoring (such as chemical wastewater treatment and pure water preparation). In addition, the AX416 is equipped with sensor cleaning function, which can achieve continuous or pulse cleaning through relay contacts. The cleaning frequency, duration, and recovery time can be programmed to reduce sensor contamination and ensure measurement accuracy.

AX450/AX455: Developed specifically for USP<645>standards, suitable for testing purified water (PW) and water for injection (WFI) in the pharmaceutical industry. The United States Pharmacopeia USP<645>replaces offline qualitative detection of impurities in water with online primary detection based on conductivity. AX450/AX455 fully meets the requirements of this standard and is a specialized equipment for water quality compliance testing in the pharmaceutical industry.

（3） Accurate temperature compensation: suitable for complex scenarios such as high-purity water

The AX41x and AX45x models are equipped with a full range of temperature compensation functions, which can achieve true temperature compensation for different media such as high-purity water, ammonia solution, acid solution, etc. The compensation range is -10 to 200 ℃, with a reference temperature of 25 ℃ and a programmable temperature coefficient of 0-5%/℃. At the same time, they have built-in fixed temperature compensation curves, which are suitable for different application scenarios:

Unreimbursed: Applicable to the testing of purified water and injection water as specified in USP<645>;

NaCl curve: suitable for routine monitoring, mixed bed exchangers, final refined effluent, etc;

HCl curve: suitable for cation exchanger effluent, deaerated cation conductivity, semiconductor rinse water, etc;

NH3 curve: suitable for ammonia feed water, boiler feed water, condenser sampling, etc., and is also the basis for calculating pH;

Ultra pure water (UPW): only compensates for the temperature effect of pure water;

Linear: Manually input temperature coefficient, suitable for special media.

The temperature sensor can be configured as Pt100 or Pt1000 to ensure the accuracy of temperature measurement, provide reliable basis for temperature compensation in conductivity measurement, and solve the problem of temperature affecting measurement results in low conductivity media such as high-purity water.

（4） Flexible output configuration: adapted to different on-site transmission requirements

The current output of the AX400 series is designed with full electrical isolation, with 2 channels as standard and 4 channels after expansion. The output range can be configured as 4-20mA, 0-20mA, or 0-10mA, and the analog output can be programmed to any value between 0-22mA to indicate system faults. The output accuracy is ± 0.25% of full range or ± 0.5% reading (whichever is greater), and the maximum load resistance is 750 Ω (at 20mA).

In addition to linear output, current output also supports 2-fold logarithmic, 3-fold logarithmic, and bilinear (configurable breakpoint) modes. Users can also customize the output range between 0.1-100% of the total range. Bilinear and logarithmic outputs can achieve range segmentation, precise conventional monitoring in low ranges, and clear resolution in alarm states in high ranges, maximizing the measurement sensitivity of critical ranges.

The relay output is equipped with 3 channels as standard and 5 channels after expansion. It is a single pole double throw contact with a rated value of 5A/115/230V AC and 5A DC, and an insulation level of 2kV RMS (contact to ground). It can be configured as a normal or fail safe high/low fixed value alarm or diagnostic alarm, with a hysteresis of 0-5% (0.1% step) and a delay of 0-60 seconds (1-second step), which can effectively avoid false alarms caused by on-site interference.

（5） AX450/AX455: Core Design for USP<645>Compliance

As a specialized model for the pharmaceutical industry, AX450/AX455 fully complies with USP<645>standards in terms of hardware, software, certification, and other aspects. The core compliant design and functions are as follows:

High precision measurement performance: The instrument display resolution reaches 0.01 μ S/cm, with an accuracy of ± 1.0% or ± 0.1 μ S/cm (whichever is greater). The traceable verification accuracy of the conductivity cell constant is ± 2% (conventional accuracy ± 1%), and traceable testing certificates are provided with the equipment to meet the measurement requirements of the pharmaceutical industry;

Automatic Level 1 Detection: USP<645>specifies that the first level detection of purified water and injection water requires checking the uncompensated conductivity and temperature limits in increments of 5 ℃. AX45x stores these limits in the instrument and can activate automatic detection through limit alarm contacts. The alarm values can be customized within the safe working range, and compliance monitoring can be achieved without manual intervention;

Traceable recording and verification: Standard configuration includes 2 channels (4 channels after expansion) of current output, which can simultaneously record conductivity and temperature, providing permanent external records for compliance; ABB also provides revalidation services for the 2278 conductivity cell, which can regularly send the electrodes back for cell constant re certification to meet the stringent certification requirements of the pharmaceutical industry;

Adaptive measurement range: Supports low range measurements from 0.01 μ S/cm to 0.1 μ S/cm, while covering configurable ranges from 0-1 μ S/cm to 0-10 μ S/cm, catering to the low conductivity measurement needs of purified water and injection water. Supports both uncompensated and compensated measurement modes, fully matching the detection requirements of USP<645>.

Technical specifications: Detailed explanation of performance parameters in all dimensions

（1） Core specifications for conductivity measurement (AX41x/AX45x)

Range: Programmable from 0-0.5 to 0-10000 μ S/cm (adjusted according to electrode constant), with a minimum range of 10 times electrode constant and a maximum range of 10000 times electrode constant;

Measurement units: μ S/cm, μ S/m, mS/cm, mS/m, M Ω - cm, TDS;

Accuracy: better than ± 0.01% range within the range of 0-100 μ S/cm, and better than ± 1% reading within the range of 10000 μ S/cm;

Working temperature: -10 to 200 ℃ (14 to 392 ° F);

Temperature compensation: -10 to 200 ℃, programmable temperature coefficient 0-5%/℃, built-in NaCl/HCl/NH3/UPW/linear compensation curve;

Temperature sensor: Pt100/Pt1000 (programmable);

Reference temperature: 25 ℃ (77 ° F).

（2） AX411 Calculation Variable Specification

Ratio: 0-19999;

Difference: 0-10000 μ S/cm;

Passing rate/removal rate: 0-100.0%;

Total dissolved solids (TDS): 0-8000ppm;

Calculated pH: 7.0-10.0 pH for ammonia system and 7.0-11.0 pH for sodium hydroxide system (calculated according to Appendix VGB 450L 1988).

（3） AX416 pH/ORP measurement specifications

Input: pH/mV input+solution ground, Pt100/Pt1000/Alco 3k temperature sensor;

Input resistance: glass electrode>1 × 10 ¹³ Ω, reference electrode 1 × 10 ¹³ Ω;

Range: pH -2 to 16, ORP -1200 to+1200mV;

Minimum range: any 2pH span or 100mV;

Resolution: 0.01pH;

Accuracy: 0.01pH;

Temperature compensation: automatic/manual Nernst compensation (-10 to 200 ℃), process solution compensation (coefficient -0.05 to 0.02%/℃);

Calibration mode: 1/2 point automatic calibration (supporting ABB/DIN/Merck/NIST/US Tech buffer), 2 user-defined buffer tables, single point process calibration.

（4） Display and logging function

Display type: Dual 5-digit 7-segment backlit LCD, 16 character dot matrix single line display;

Energy saving function: The backlight can be set to remain on or automatically turn off after 60 seconds of inactivity;

Logbook: Electronic recording of process events and calibration data (requires the installation of an optional board);

Real time clock: Provides timestamps for the logbook and automatic/manual functions (requires the installation of an optional board).

（5） Communication and control functions

Digital communication: Profibus DP (requires the installation of an option board, some configurations of the panel installation version are not supported);

AX410 PID control: supports P/PI/PID mode, analog/pulse width/pulse frequency output, positive/negative action, proportional band 0.1-999.9%, integration time 1-7200 seconds, differentiation time 0.1-999.9 seconds.

（6） Mechanical and Environmental Specifications

Installation and Dimensions

Wall mounted/pipeline installation: IP65 protection, dimensions 192mm × 230mm × 94mm, weight 1kg;

Panel installation: IP65 (front only), size 96mm × 96mm × 162mm, weight 0.6kg;

Cable entry: Standard 5/7 M20 cable glands, North American version 7 1/2-inch Hubble gland knock off holes.

power supply specifications

Voltage: 100-240V AC (50/60Hz, minimum 90V, maximum 264V), 12-30V DC;

Power consumption: 10W;

Insulation: 2kV RMS from mains to ground.

environmental parameters

Working temperature: -20 to 55 ℃ (-4 to 131 ° F);

Storage temperature: -25 to 75 ℃ (-13 to 167 ° F);

Working humidity: ≤ 95% RH (no condensation);

EMC: Compliant with EN61326, EN50081-2, EN50082-2 standards.

Authentication and Security

Safety certification: UL, CE (covering EMC and low voltage directives, compliant with EN61010);

General safety: EN61010-1, input/output overvoltage class II, pollution level 2;

Language configuration: Supports English, French, German, Italian, and Spanish.

（7） AX416 sensor cleaning function

Cleaning mode: continuous/pulse (1-second on/off);

Frequency: 5 minutes to 24 hours (15 minute step within 1 hour, 1 hour step after 1 hour);

Duration: 15 seconds to 10 minutes (15 second step within 1 minute, 1 minute step after 1 minute);

Recovery time: 30 seconds to 5 minutes (30 second step).

Installation and wiring: convenient on-site implementation

The wiring design of the AX400 series fully considers the convenience of on-site operation. The terminal layout for wall/pipe installation and panel installation versions is different, but both use modular terminal block design, divided into three terminal blocks: A, B, and C. The C terminal block is an analog option board terminal, Profibus DP、 The extended current output and relay are both connected through this terminal block.

The sensor wiring block with terminal block B as the core can adapt to the wiring requirements of conductivity and pH/ORP sensors, supporting dual sensor inputs (sensor A/B). The wiring of the temperature compensator can be adapted to a 2-wire Pt100/Pt1000/Alco system through jumper wires, and the solution ground (ground rod) is the standard wiring for pH/ORP measurement, ensuring measurement stability. The equipment is also equipped with independent grounding bolts, which can achieve reliable grounding and reduce the impact of on-site electromagnetic interference on measurements.

All wiring terminals are designed for easy access, and wiring can be completed without disassembling the instrument body. The wall mounted/pipe mounted version maintains IP65 protection for the electronic part even when the terminal compartment is opened, and can be operated with water on site, greatly improving installation and maintenance efficiency.

Ordering Code: Standardized Configuration Selection

The ordering code for the AX400 series adopts the 8-digit/letter combination of AX4XXXX0X, with each position representing different configuration options that can be flexibly selected according to on-site needs. The core coding rules are as follows:

Position 3: First process variable (PV1), where 1 is conductivity (dual electrode, 0-10000 μ S/cm), 5 is USP<645>conductivity, and 6 is pH/ORP;

4th position: Second process variable (PV2), 0 represents no second variable (AX410 PID control specific), 1 represents conductivity, 5 represents USP<645>conductivity, and 6 represents pH/ORP (PV2 encoding must be ≥ PV1);

5th position: Shell type, 1 is wall mounted (with cable gland), 2 is pipeline installation, 6 is North American wall mounted, 7 is North American pipeline, and 5 is panel installation;

6th place: Advanced functions and communication, 0 is the basic version (2 currents+3 relays), 1 is the advanced version (4 currents+5 relays+logbook), 2 is the Profibus DP basic version, and 3 is the Profibus DP advanced version;

7th position: Power supply, 0 is 100-240V AC, 1 is 12-30V DC;

8th place: Manual language, 1 is English, 2 is French, 3 is Italian, 4 is German, and 5 is Spanish.

Please note that when PV2 selects a four electrode conductivity of 0-1999mS/cm, the panel installation version does not support Profibus DP communication. When ordering, the configuration should be selected reasonably according to the installation method and communication requirements.

Industry application: Full scenario process monitoring and control

The ABB AX400 series low conductivity analyzer, with its flexible configuration and powerful functions, has been widely used in key process links in multiple industrial fields. The core application scenarios are as follows:

Power industry: cation conductivity and calculated pH monitoring of boiler feedwater, ammonia boiler water, condenser cooling water, conductivity measurement of high-purity water preparation, AX411's self-monitoring function can ensure the safety of boiler water quality, avoid corrosion and scaling;

Pharmaceutical industry: USP<645>compliance testing for purified water and injection water, AX450/AX455's automatic primary testing function achieves compliance monitoring without manual intervention, meeting GMP requirements;

Semiconductor industry: Low conductivity monitoring of ultrapure water, rinse water, and recycled water, accurate temperature compensation, and low range measurement can ensure the quality of ultrapure water and meet the high requirements of semiconductor manufacturing;

Water treatment and wastewater treatment: Conductivity measurement and pass/removal rate calculation for reverse osmosis, nanofiltration, and ion exchange processes. The PID control of AX410 can achieve automatic adjustment of process parameters and improve water treatment efficiency;

Chemical industry: Combined measurement of electrical conductivity and pH of chemical process water and wastewater (AX416), low electrical conductivity monitoring of corrosive media, and wide temperature working range of equipment that can adapt to the complex environment of chemical sites;

Pulp and paper industry: Electrical conductivity monitoring of process water to achieve real-time control of water quality and ensure the stability of paper making processes.

Core analyzer model

AX410

AX411

AX411/511010

AX416

AX450

AX455