Endress+Hauser CCS140 User manual

Products Solutions Services

Operating Instructions

CCS140/141

Sensors for measuring free available chlorine

BA00058C/07/EN/14.18

71423117

2018-10-23

CCS140/141 Table of contents

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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 the personnel ........ 6

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

2.3 Workplace safety .................... 6

2.4 Operational safety ................... 6

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

3 Product description ............. 7

3.1 Product design ....................... 7

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 ................ 15

5.3 Post-installation check ............... 17

6 Electrical connection .......... 17

6.1 Connecting the sensor ............... 18

6.2 Ensuring the degree of protection ..... 20

6.3 Post-connection check ............... 20

7 Commissioning ................ 21

7.1 Function check ..................... 21

7.2 Sensor polarization .................. 21

7.3 Sensor calibration ................... 21

8 Diagnostics and

troubleshooting ............... 23

9 Maintenance .................. 25

9.1 Maintenance schedule ............... 25

9.2 Maintenance tasks .................. 25

10 Repair .......................... 32

10.1 Spare parts ........................ 32

10.2 Return ............................ 32

10.3 Disposal ........................... 32

11 Accessories .................... 33

11.1 Device-specific accessories ............ 33

12 Technical data ................. 34

12.1 Input .............................. 34

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

12.3 Environment ....................... 36

12.4 Process ............................ 36

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

Index ................................. 38

About this document CCS140/141

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

CCS140/141 About this document

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1.2.1 Symbols on the device

Symbol Meaning

Reference to device documentation

Basic safety instructions CCS140/141

6 Endress+Hauser

2 Basic safety instructions

2.1 Requirements for the 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, process water and bathing 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. Too low

concentrations in the water could jeopardize the effectiveness of the disinfection. Too high

concentrations can lead to signs of corrosion and have an adverse effect on the taste and

smell, while also generating unnecessary costs.

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

measurement of free chlorine in water. In conjunction with measuring and control equipment,

it allows optimal control of disinfection.

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.

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

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 European 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.

CCS140/141 Product description

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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.

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

European standards have been observed.

3 Product description

3.1 Product design

The sensor consists of the following functional units:

• Measuring chamber

– To protect the anode or cathode from the medium

– With a large volume of electrolyte for a long service life in combination with the large

anode and the small cathode

• Sensor shaft with

– Large anode

– Cathode embedded in plastic

– Optional temperature sensor

• Membrane cap with

– Robust PTFE membrane

– Special support grid between cathode and membrane for a defined and consistent

electrolyte film and thus a relatively constant indication even at varying pressures and

flows

Product description CCS140/141

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A0037109

1 Fixed cable

2 Sensor shaft

3 O-ring

4 Large anode, silver/silver chloride

5 Gold cathode

6 Measuring chamber

7 Membrane cap with dirt-repellent membrane

8 Screw cap for securing the membrane cap

3.1.1 Measuring principle

Free available chlorine levels are determined using hypochlorous acid (HOCl) in accordance

with the amperometric measuring principle.

The hypochlorous acid (HOCl) contained in the medium diffuses through the

sensor membrane and is reduced to chloride ions (Cl-) at the gold cathode. At the silver anode,

silver is oxidized to silver chloride. Electron donation at the gold cathode and electron

acceptance at the silver anode causes a current to flow which is proportional to the

concentration of free chlorine in the medium at constant conditions.

The concentration of hypochlorous acid (HOCl) depends on the pH value. An additional pH

measurement should be used to compensate for this dependency.

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

Molecular chlorine (Cl2) is present at pH values < 4. Consequently, hypochlorous acid (HOCl)

and hypochlorite (OCl– remain within the range of pH 4 to 11 as components of free chlorine.

CCS140/141 Product description

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As hypochlorous acid splits up (dissociates) with an increasing pH value to form hypochlorite

ions (OCl–) and hydrogen ions (H+), the amounts of the individual components of free

effective chlorine change with the pH value. For example, if the proportion of hypochlorous

acid is 97 % at pH 6, it drops to approx. 3 % at pH 9.

For amperometric measurement using the chlorine sensor, only the amount of hypochlorous

acid (HOCl) is selectively measured. This works as a powerful disinfectant in an aqueous

solution. Hypochlorite (OCl–), however, is an extremely weak disinfectant. Therefore, when

used as a disinfectant at higher pH values, the effectiveness of chlorine is limited. Since

hypochlorite ions cannot pass through the sensor membrane, the sensor does not record this

part.

pH compensation of chlorine sensor signal

To calibrate and verify the chlorine measuring system, a colorimetric reference measurement

must be carried out using the DPD method. Free chlorine reacts with diethyl-p-

phenylendiamine to form a red dye. The intensity of the red color increases proportionally to

the chlorine content. For the DPD test, the sample is buffered to a specified pH value.

Therefore, the pH value of the sample is not taken into account in the DPD measurement. Due

to the buffer function in the DPD method, all components of free effective chlorine (HOCl and

OCl-) are detected and thus the total free chlorine is measured.

The chlorine sensor only measures the hypochlorous acid. If you select pH compensation in

the transmitter, the sum of hypochlorous acid and hypochlorite is calculated from the

measured signal and the pH value. This value corresponds to the DPD measurement.

When free chlorine is measured with pH compensation switched on, always perform

calibration in pH-compensated mode.

When you use pH compensation, the measured chlorine value displayed and output by the

device corresponds to the DPD value even if the pH value fluctuates. If no pH compensation is

used, the chlorine value of the DPD measurement corresponds only to the chlorine value of

Product description CCS140/141

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the sensor at the same pH value with respect to the calibration. Without pH compensation,

the chlorine measuring system must be recalibrated when the pH value changes.

100

45 6 7 8 9 10 11

100

OCl-

HOCl

A0002017

 1 Principle of pH compensation

A Measured value with pH compensation

B Measured value without pH compensation

C pH compensation

Accuracy of pH compensation

The accuracy of the pH-compensated measured chlorine value is derived from the sum of

several individual deviations (free chlorine, pH, temperature, DPD measurement etc.).

High levels of hypochlorous acid (HOCl) during chlorine calibration have a positive effect on

accuracy, whereas low levels of hypochlorous acid have a negative effect. The inaccuracy of

the pH-compensated measured chlorine value increases the greater the pH difference

between measuring mode and chlorine calibration or the more inaccurate the underlying

individual measured values are.

Calibration taking into account the pH value

For the DPD test, the sample is buffered to a specified pH value. In contrast to this,

amperometric measurement determines only the HOCl component.

During operation, pH compensation is effective up to a pH value of 9. However, there is

virtually no hypochlorous acid (HOCl) left at this pH value, and the measured current is very

low. At this point, pH compensation has the effect of increasing the measured HOCl value to

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