Endress+Hauser CCS120D User manual

Products Solutions Services

Operating Instructions

CCS120D

Digital sensor with Memosens technology for

determining total chlorine

BA01950C/07/EN/02.19

71461435

2019-12-31

CCS120D Table of contents

Endress+Hauser 3

Table of contents

1 About this document ........... 4

1.1 Warnings ........................... 4

1.2 Symbols used ........................ 4

2 Basic safety instructions ....... 6

2.1 Requirements for personnel ........... 6

2.2 Designated use ...................... 6

2.3 Workplace safety .................... 7

2.4 Operational safety ................... 7

2.5 Product safety ....................... 7

3 Product description ............. 8

3.1 Product design ....................... 8

4 Incoming acceptance and

product identification ......... 12

4.1 Incoming acceptance ................ 12

4.2 Product identification ................ 12

5 Installation .................... 14

5.1 Installation conditions ............... 14

5.2 Mounting the sensor ................ 16

5.3 Post-installation check ............... 22

6 Electrical connection .......... 22

6.1 Connecting the sensor ............... 23

6.2 Ensuring the degree of protection ..... 23

6.3 Post-connection check ............... 23

7 Commissioning ................ 24

7.1 Function check ..................... 24

7.2 Filling the membrane cap with

electrolyte ......................... 24

7.3 Sensor polarization .................. 24

7.4 Sensor calibration ................... 24

8 Diagnostics and

troubleshooting ............... 26

9 Maintenance .................. 28

9.1 Maintenance schedule ............... 28

9.2 Maintenance tasks .................. 28

10 Repair .......................... 33

10.1 Spare parts ........................ 33

10.2 Return ............................ 33

10.3 Disposal ........................... 33

11 Accessories .................... 34

11.1 Device-specific accessories ............ 34

12 Technical data ................. 35

12.1 Input .............................. 35

12.2 Performance characteristics .......... 36

12.3 Environment ....................... 37

12.4 Process ............................ 37

12.5 Mechanical construction ............. 37

13 Installation and operation in

hazardous environment Class

I Div. 2 .......................... 38

Index ................................. 40

About this document CCS120D

4 Endress+Hauser

1 About this document

1.1 Warnings

Structure of information Meaning

LDANGER

Causes (/consequences)

If necessary, Consequences of non-

compliance (if applicable)

‣Corrective action

This symbol alerts you to a dangerous situation.

Failure to avoid the dangerous situation will result in a fatal or serious injury.

LWARNING

Causes (/consequences)

If necessary, Consequences of non-

compliance (if applicable)

‣Corrective action

This symbol alerts you to a dangerous situation.

Failure to avoid the dangerous situation can result in a fatal or serious injury.

LCAUTION

Causes (/consequences)

If necessary, Consequences of non-

compliance (if applicable)

‣Corrective action

This symbol alerts you to a dangerous situation.

Failure to avoid this situation can result in minor or more serious injuries.

NOTICE

Cause/situation

If necessary, Consequences of non-

compliance (if applicable)

‣Action/note

This symbol alerts you to situations which may result in damage to property.

1.2 Symbols used

Symbol Meaning

Additional information, tips

Permitted or recommended

Not permitted or not recommended

Reference to device documentation

Reference to page

Reference to graphic

 Result of a step

CCS120D About this document

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1.2.1 Symbols on the device

Symbol Meaning

Reference to device documentation

Minimum immersion depth

Basic safety instructions CCS120D

6 Endress+Hauser

2 Basic safety instructions

2.1 Requirements for personnel

Installation, commissioning, operation and maintenance of the measuring system may be

carried out only by specially trained technical personnel.

‣The technical personnel must be authorized by the plant operator to carry out the specified

activities.

‣The electrical connection may be performed only by an electrical technician.

‣The technical personnel must have read and understood these Operating Instructions and

must follow the instructions contained therein.

‣Measuring point faults may be repaired only by authorized and specially trained personnel.

Repairs not described in the Operating Instructions provided must be carried out only

directly at the manufacturer's site or by the service organization.

2.2 Designated use

Drinking water and industrial water must be disinfected through the addition of appropriate

disinfectants such as chlorine gas or inorganic chlorine compounds. The dosing quantity must

be adapted to continuously fluctuating operating conditions. If the concentrations in the water

are too low, this could jeopardize the effectiveness of the disinfection. On the other hand,

concentrations which are too high can lead to signs of corrosion and have an adverse effect on

taste, as well as generating unnecessary costs.

The sensor was specifically developed for this application and is designed for continuous

measurement of total chlorine in water. In conjunction with measuring and control

equipment, it allows optimal control of disinfection.

In this context, the following compounds are referred to collectively as total chlorine:

• Free available chlorine: hypochlorous acid (HOCl), hypochlorite ions (OCl-)

• Combined chlorine (chloramines)

• Organic combined chlorine, e. g. cyanuric acid derivatives

Chloride (Cl-) is not recorded.

The sensor is not suitable for checking the absence of chlorine.

The sensor is particularly suitable for:

• Monitoring of total chlorine content in wastewater, industrial water, process water, cooling

water and pool water

• Measurement, monitoring and control of total chlorine content in fresh water and seawater

during the treatment of process water, swimming pool water and whirlpool bathwater

A typical application is the disinfection of wastewater, industrial, process and cooling water

with disinfectants containing chlorine, particularly at higher pH values up to 9.5. In swimming

pools, the CCS120D sensor is used in combination with the CCS51D sensor for free available

chlorine to monitor the amount of combined chlorine (chloramines).

Use of the device for any purpose other than that described, poses a threat to the safety of

people and of the entire measuring system and is therefore not permitted.

CCS120D Basic safety instructions

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The manufacturer is not liable for damage caused by improper or non-designated use.

2.2.1 Hazardous environment in accordance with cCSAus NI Cl. I, Div. 2 1)

‣Pay attention to the control drawing and the specified application conditions in the

appendix of these Operating Instructions, and follow the instructions.

2.3 Workplace safety

As the user, you are responsible for complying with the following safety conditions:

• Installation guidelines

• Local standards and regulations

Electromagnetic compatibility

• The product has been tested for electromagnetic compatibility in accordance with the

applicable international standards for industrial applications.

• The electromagnetic compatibility indicated applies only to a product that has been

connected in accordance with these Operating Instructions.

2.4 Operational safety

Before commissioning the entire measuring point:

1. Verify that all connections are correct.

2. Ensure that electrical cables and hose connections are undamaged.

3. Do not operate damaged products, and protect them against unintentional operation.

4. Label damaged products as defective.

During operation:

‣If faults cannot be rectified:

products must be taken out of service and protected against unintentional operation.

2.4.1 Special instructions

‣Do not operate the sensors under process conditions where it is expected that osmotic

conditions will cause electrolyte components to pass through the membrane and into the

process.

Use of the sensor for its intended purpose in liquids with a conductivity of at least 10 nS/cm

can be classified as safe in terms of the application.

2.5 Product safety

The product is designed to meet state-of-the-art safety requirements, has been tested, and

left the factory in a condition in which it is safe to operate. The relevant regulations and

international standards have been observed.

1) Only if connected to CM44x(R)-CD*

Product description CCS120D

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3 Product description

3.1 Product design

The sensor consists of the following functional units:

• Membrane cap (measuring chamber with membrane)

• Separates the inner amperometric system from the medium

• With robust PET membrane and pressure relief valve

• Guarantees a defined and consistent electrolyte film between working electrode and

membrane

• Sensor shaft with

• Large counter electrode

• Working electrode embedded in plastic

• Embedded temperature sensor

A0037693

 1 Sensor structure

1 Memosens plug-in head

2 NPT ¾" thread

3 O-ring

4 Sensor shaft

5 Pressure relief valve (elastic)

6 Membrane cap

7 Sensor membrane

3.1.1 Measuring principle

Total chlorine levels are determined in accordance with the amperometric measuring

principle.

CCS120D Product description

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In this context, the following compounds are referred to collectively as total chlorine:

• Free available chlorine: hypochlorous acid (HOCl), hypochlorite ions (OCl-)

• Combined chlorine (chloramines)

• Organic combined chlorine, e.g. cyanuric acid derivatives

Chloride (Cl-) is not recorded.

The sensor is a membrane-covered, two-electrode sensor. A platinum working electrode is

used as the working electrode. A counter electrode coated in silver halide is used as the

counter and reference electrode.

The membrane cap, which is filled with electrolyte, constitutes the measuring chamber. The

measuring electrodes are immersed in the measuring chamber. The measuring chamber is

separated from the medium by means of a microporous membrane. The chlorine compounds

contained in the medium diffuse through the sensor membrane.

The constant polarization voltage present between the two electrodes causes the

electrochemical reaction of the chlorine compounds at the working electrode. Electron

donation at the working electrode and electron acceptance at the counter-electrode cause a

current to flow. In the operational range of the sensor, this current flow is proportional to the

chlorine concentration under constant conditions and is only slightly pH-dependent in the

case of this sensor type. The transmitter uses the current signal to calculate the measured

variable for concentration in mg/l (ppm).

3.1.2 Effects on the measured signal

pH value

pH dependency

The sensor is specified for the pH range of pH 5.5 to 9.5. The measuring signal is practically

independent within this range. However, if the pH increases from pH 7 to pH 8 the measuring

signal for free chlorine is reduced by 10 %.

Flow

The flow to the membrane-covered measuring cell should be at least 15 cm/s and maximum

50 cm/s. The optimum flow velocity is in the 20 to 30 cm/s range.

When using the CCA250 flow assembly, the minimum flow velocity corresponds to a volume

flow of 30 l/h (7.9 gal/h) (upper edge of float at the height of the red bar mark).

Product description CCS120D

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98,5

99,0

100,0

99,5

98,0

97,5

97,0

96,5

96,0

relative slope / maximum slope in %

CCA250 ﬂow gal/hr

ﬂow velocity at the membrane "/s

0 0.5 1 1.5 2 3

0 5 10 25 40

2.5

15 20 30 35

A0039131-EN

 2 Correlation between slope of electrode and flow velocity at the membrane/volume flow in

assembly

At higher flow rates, the measured signal is virtually flow-independent. However, if the flow

rate falls below the specified value, the measured signal depends on the flow.

Temperature

Changes in the temperature of the medium affect the measured value:

• Increases in temperature result in a higher measured value (approx. 4 % per K)

• Decreases in temperature result in a lower measured value.

Use of the sensor in combination with the Liquiline enables automatic temperature

compensation (ATC). Recalibration in the case of temperature changes is not necessary.

1. If automatic temperature compensation is disabled at the transmitter, the temperature

must be maintained at a constant level following calibration.

2. Otherwise, recalibrate the sensor.

In the event of normal and slow changes in temperature (0.3 K / minute), the internal

temperature sensor is sufficient. In the event of very rapid temperature fluctuations with high

amplitude (2 K / minute), an external temperature sensor is necessary to ensure maximum

accuracy.

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