1pH sensor (accessories, not in scope of delivery)
2PML connection
3Vent screw
4Chlorine sensor (accessories, not in scope of delivery)
5Outlet (adapter depending on version)
6Needle valve for flow <120 l/h (32 gal/h)
7Locking cap with calibration vessel
8Inlet (adapter depending on version)
9Inductive limit switch for flow measurement (optional)
10Installation position for a second pH/ORP sensor
The flow assembly has been designed for the installation of the membrane covered chlorine sensors
CCS120, CCS140, CCS141, CCS240, CCS241 and CCS142D. Additionally, there are two more
installation positions for the installation of sensors with Pg 13.5 and installation length 120 mm
(4.72 inch), e.g. pH resp. ORP sensors.
Its mechanical design permits its use in pressurised systems (see "Technical data").
Any other use than the one described here compromises the safety of persons and the entire
measuring system and is not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.
1.2Installation, commissioning and operation
Please note the following items:
• Installation, commissioning, operation and maintenance of the measuring system must only be
carried out by trained technical personnel.
Trained personnel must be authorized for the specified activities by the system operator.
• Electrical connection must only be carried out by a certified electrician.
• Technical personnel must have read and understood these Operating Instructions and must
adhere to them.
• Before commissioning the entire measuring point, check all the connections. Ensure that
electrical cables and hose connections are not damaged.
• Do not operate damaged products and secure them against unintentional commissioning.
Mark the damaged product as being defective.
• Measuring point faults may only be rectified by authorized and specially trained personnel.
• If faults can not be rectified, the products must be taken out of service and secured against
unintentional commissioning.
• Repairs not described in these Operating Instructions may only be carried out at the
manufacturer’s or by the service organization.
1.3Operational safety
The assembly has been designed and tested in accordance with the latest industry standards and left
the factory in perfect functioning order.
Relevant regulations and standards have been met.
As the user, you are responsible for complying with the following safety conditions:
• Installation instructions
• Local prevailing standards and regulations.
1.4Return
If the assembly has to be repaired, please return it cleaned to the appropriate sales center.
Please use the original packaging, if possible.
Please enclose the completed "Declaration of contamination" (copy the second to last page of these
Operating Instructions) with the packaging and the transportation documents.
No repair without completed "Declaration of contamination"!
4
Page 5
#
"
!
Safety instructions
1.5Notes on safety icons and symbols
Warning!
This symbol alerts you to hazards that can cause serious damage to the instrument or to persons if
ignored.
Caution!
This symbol alerts you to possible faults which could arise from incorrect operation. They could
cause damage to the instrument if ignored.
Note!
This symbol indicates important items of information.
5
Page 6
Identification
2Identification
2.1Nameplate
You can read the following information from the nameplate on the assembly:
•Product name
•Order code
• Serial number or week code
• Permissible process pressure and maximum process temperature
You can find possible assembly versions and the resulting order codes in the product structure.
2.2Product structure
Process connection, adapter
A G1/2, none
B G1/2, 2x NV 1/2"
C G1/2, 2x D 6/12
D G1/2, D 6/12 + D 16
M NPT 1/2", none
Q NPT 1/4", none
Proximity switch
0none
1with inductive proximity switch
CCA250-complete order code
2.3Scope of delivery
The scope of delivery comprises:
• Flowfit assembly (ordered version)
• a PML adapter
• Operating Instructions (English)
If you have any questions, please contact your supplier or your local sales center.
6
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Installation
3Installation
3.1Incoming acceptance, transport, storage
• Make sure the packaging is undamaged!
Inform the supplier about any damage to the packaging.
Keep the damaged packaging until the matter has been settled.
• Make sure the contents are undamaged!
Inform the supplier about damage to the contents. Keep the damaged products until the matter
has been settled.
• Check that the order is complete and agrees with your shipping documents.
• The packaging material used to store or to transport the product must provide shock protection
and humidity protection. The original packaging offers the best protection. Also, keep to the
approved ambient conditions (see "Technical data").
• If you have any questions, please contact your supplier or your local sales center.
3.2Installation conditions
3.2.1Dimensions
Fig. 2: Dimensions
adepending on version: G1/2, NPT 1/2" or NPT 1/4"
a0007328
7
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Installation
3.2.2Notes on installation
Parts descriptionused at ...
two shut-off valvesbypass version
one shut-off valveversion with open outlet
aperture in the main conduitbypass version
particle filter (500 μm or finer)if the process water contains large dirt particles
pressure-relief valveif the process water pressure is above the maximum
value (see chapter " technical data")
3.3Installation instructions
3.3.1Measuring system
A complete measuring system comprises:
• Flowfit CCA250
• Chlorine sensor, e.g. CCS142D
• Measuring cable, e.g. CYK10
• Transmitter, e.g. Liquiline M
Optional:
• up to two pH sensors, e.g. Orbisint CPS11D
• Junction box for cable extension, e.g. RM junction box
a0007341
Fig. 3: Measuring system
1Transmitter Liquiline M CM44 with weather protection cover
2Supply line of the transmitter
3Chlorine sensor CCS142D
4Flowfit CCA250
5Assembly inlet (outlet at backside, not to be seen in figure)
6pH-Sensor
7Measuring cable CYK10
8
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Installation
12
3
4
3.3.2Installing the assembly into the process
To get a flow through the bypass, pressure p1 has to be higher than pressure p2. Therefore, you
have to install an aperture in the main conduit (→ å 4, pos. 5).
a0007337
Fig. 4: Installation example with bypass and aperture in the main conduit
1Stop valve (to be provided by customer)
2Dirt trap (filter), d = 500 μm (to be provided by customer). Installation of dirt trap is mandatory!
3Pressure reducer (with p > 4 bar (58 psi))
4Stop valve (to be provided by customer)
5Aperture in the main conduit
!
In case of an open outlet installation, no pressure increasing procedure is needed (→ å 5).
a0007338
Fig. 5: Installation example with open outlet
Legend → å 4
Note!
• The flow assembly must be installed upright.
• Connect the process water with commercial fittings. You can use the normal sealing (e.g. teflon
tape) or an O-ring (e.g. EPDM).
• Installation in the by-pass is preferable to installation in the process pipe as the by-pass pipe can
be blocked off without process interruption (you have to install shut-off valves upstream and
downstream from the flow assembly). This permits maintenance of the sensors without
interrupting the process.
• A stop valve and a dirt trap (e.g.,a strainer) with a mesh size of 500 μm must be located upstream
from the flow assembly. Pressure reducers usually contain a dirt trap, i.e. an additional dirt trap
is not required when a pressure reducer is installed.
9
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Commissioning
"
!
• For the version with an open outlet, you have to install a shut-off valve upstream.
• Install a DN 5-8 sampling cock downstream from the flow assembly to permit reference
measurements according to the DPD method.
Caution!
• The medium pressure must not exceed the maximum permissible pressure of the flow assembly
or of the sensors.
• If the medium pressure exceeds 4 bar (58 psi), you have to install a pressure-relief valve.
3.3.3Sensor installation
1.Installation of proximity switch: Screw in all the way and lock with hex nut.
2.Loosen and remove the clamping screw.
3.Insert the chlorine sensor in the mounting position and firmly tighten with the clamping screw.
4.Remove the two dummy plugs, place the pH/ORP sensors in the openings with the Pg13.5
threads and screw in.
5.Connect the sensors via the corresponding measuring cable to the transmitter.
Note!
Vent the assembly by unscrewing and screwing the vent screw at the time of the first
commissioning.
#
3.4Post-installation check
• After installation, check that all connections are firmly in position and leak-tight.
• Check all hoses for damage.
4Commissioning
Before the first commissioning, make sure of the following items:
• all seals are correctly seated (on the assembly and process connection)
• the sensor is correctly installed and connected
Warning!
Danger of squirting medium.
Before applying the process pressure to the assembly, make sure the connections are correctly fitted.
10
Page 11
5Maintenance
Maintenance
#
!
!
Warning!
Risk of injury!
Before starting maintenance work on the assembly, make sure that the process line is depressurised,
empty and rinsed.
5.1Cleaning the assembly
To ensure a reliable measurement, the assembly and the sensor must be cleaned at regular intervals.
The frequency and intensity of the cleaning operation depend on the process medium.
All parts in contact with the medium, e.g. the sensor and the sensor holder, must be cleaned at
regular intervals. Remove the sensor
• Remove light dirt using suitable cleaning agents (see chapter "Cleaning agents").
• Remove severe fouling with a soft brush and a suitable cleaning agent.
• Remove persistant fouling by soaking in a liquid cleaner and if neccessary by cleaning with a soft
brush.
Note!
A typical cleaning interval for e.g. drinking water is at least half a year.
1)
.
5.2Cleaning the sensor
You have to clean the sensor:
• before every calibration
• regularly during operation
• before being returned for repair
• depending on the local conditions, at least twice a year
Note!
• Clean the sensor outside only. Do not open it!
• Do not use any abrasive cleaning agents. This can lead to irreparable damage of the sensor.
• After cleaning the sensor, rinse the rinse chamber of the assembly with copious amounts of water.
Otherwise, remaining residues of cleaning agent can corrupt measurement.
• If required, re-calibrate after cleaning.
5.3Cleaning agents
The selection of the cleaning agent is dependent on the degree and type of contamination. The most
common contaminations and the suitable cleaning agents are listed in the following table.
Type of contamination Cleaning agent
Greases and oilsSubstances containing tensides (alkaline) or water-soluble organic
Calciferous deposits, metal hydroxide deposits,
lyophobic biological deposits
Sulphide depositsMixture of 3% hydrochloric acid and thiocarbamide (commercially
Protein depositsMixture of 3% hydrochloric acid and pepsin (commercially
Fibres, suspended substancesWater under pressure, poss. with surface-active agents
Light biological depositsWater under pressure
1) in reverse sequence of operations to the installation procedure
solvents (e.g. Ethanol)
approx. 3% hydrochloric acid
available)
available)
11
Page 12
Maintenance
Caution!
"
Do not use organic solvents containing halogen or acetone. These solvents could destroy plastic
components on the assembly or the sensor and it is also partly suspected that they cause cancer (e. g.
Chloroform).
12
Page 13
6Accessories
Accessories
!
Note!
In the following sections, you find the accessories available at the time of issue of this
documentation.
For information on accessories that are not listed here, please contact your local service.
6.1Accessories kits
For G1/2 process connection versions only!
NV 1/2
• 2 PVC nipples for connection to PVC pipework
• for pipes with OD 16 mm (0.63 inch)
• order no. 50003228
SV 1/2
• 2 PVC nipples
• different adaptersfor hose connection
– with Ø 6/12 mm (0.24/0.47 inch) inlet and Ø 16 mm (0.63 inch) outlet
– order no. 50003232
• identical adapters
– for hose connection with Ø 6/12 mm (0.24/0.47 inch) inlet and outlet
– order no. 50003230
6.2Sensors
CCS120
• Membrane covered amperometric sensor for total chlorine
• Measuring range 0.1 to 10 mg/l
• Ordering acc. to product structure, see Technical Information (TI388C/07/en)
CCS140
• Membrane covered amperometric sensor for free chlorine
• Measuring range 0.05 to 20 mg/l
• Ordering acc. to product structure, see Technical Information (TI058C/07/en)
CCS141
• Membrane covered amperometric trace sensor for free chlorine
• Measuring range 0.01 to 5 mg/l
• Ordering acc. to product structure, see Technical Information (TI058C/07/en)
CCS142D
• Membrane covered amperometric sensor for free chlorine
• Memosens technology
• Measuring range 0.01 to 20 mg/l
• Ordering acc. to product structure, see Technical Information (TI419C/07/en)
CCS240
• Membrane covered amperometric sensor for chlorine dioxide
• Measuring range 0.05 to 20 mg/l
• Ordering acc. to product structure, see Technical Information (TI114C/07/en)
CCS241
• Membrane covered amperometric trace sensor for chlorine dioxide
• Measuring range 0.01 to 5 mg/l
• Ordering acc. to product structure, see Technical Information (TI114C/07/en)
Orbisint CPS11/11D
• pH electrode for process applications with dirt-repellent PTFE diaphragm
• Optional Memosens technology (CPS11D)
• Ordering acc. to product structure, see Technical Information (TI028C/07/en)
13
Page 14
Accessories
Ceragel CPS71/CPS71D
• pH electrode with double junction reference system and integrated bridge electrolyte
• Optional with Memosens technology (CPS71D)
• Ordering acc. to product structure, see Technical Information (TI245C/07/en)
Ceragel CPS72/CPS72D
• Redox sensor with double junction reference system and integrated bridge electrolyte
• Optional with Memosens technology (CPS72D)
• Ordering acc. to product structure, see Technical Information (TI374C/07/de)
14
Page 15
7Trouble-shooting
7.1Replacing damaged parts
Trouble-shooting
#
Warning!
Damage to the assembly which affects the pressure safety must only be repaired by authorized
technical personnel.
After every repair and maintenance activity, suitable measures must be taken to test whether the
assembly shows any signs of leaking. The assembly must then correspond to the specifications stated
in the technical data.
Replace all other damaged components immediately. To order accessories and spare parts, please
use the "Accessories" and "Spare parts" chapters or contact your local sales center.
7.2Return
If the assembly has to be repaired, please return it cleaned to the appropriate sales center.
Please use the original packaging, if possible.
Please enclose the completed "Declaration of contamination" (copy the second to last page of these
Operating Instructions) with the packaging and the transportation documents.
No repair without completed "Declaration of contamination"!
7.3Disposal
Please dispose of the device in accordance with the local regulations.
15
Page 16
Technical data
8Technical data
8.1Environment
Ambient temperature
range
Storage temperature0 to 50 °C (32 to 120 °F)
0 to 50 °C (32 to 120 °F)
8.2Process
Process temperature0 to 45 °C (32 to 110 °F), non-freezing
Process pressuremax. medium pressure: 4 bar (58 psi) at 40 °C (104 °F)
Temperature-pressurediagram
Fig. 6: Temperature-Pressure diagram
Flowoptimum 30 l/h (7.9 gal/h)
30 to 120 l/h (7.9 to 31.7 gal/h), adjustable
16
a0007413
Page 17
8.3Mechanical construction
Design, dimensionssee chapter "Installation"
Weight0.5 to 0.8 kg (1.1 to 1.8 lbs), depending on process connection
Because of legal regulations and for the safety of our employees and operating equipment, we need the "Declaration of Hazardous Material
and De-Contamination", with your signature, before your order can be handled. Please make absolutely sure to attach it to the outside of the
packaging.
Aufgrund der gesetzlichen Vorschriften und zum Schutz unserer Mitarbeiter und Betriebseinrichtungen, benötigen wir die unterschriebene
"Erklärung zur Kontamination und Reinigung", bevor Ihr Auftrag bearbeitet werden kann. Bringen Sie diese unbedingt außen an der
Verpackung an.
“We hereby certify that this declaration is filled out truthfully and completely to the best of our knowledge.We further certify that the returned
parts have been carefully cleaned. To the best of our knowledge they are free of any residues in dangerous quantities.”
“Wirbestätigen
w
bestätigen, die vorliegende Erklärung nach unserem besten Wissen wahrheitsgetreu und vollständig ausgefüllt zu haben. Wir
eiter, dass die zurückgesandten Teile sorgfältig gereinigt wurden und nach unserem besten Wissen frei von Rückständen in gefahrbringen-
Used as SIL device in a Safety Instrumented System / Einsatz als SIL Gerät in Schutzeinrichtungen
RA No.
Erklärung zur Kontamination und Reinigung
Declaration of Hazardous Material and De-Contamination
Please reference the Return Authorization Number (RA#), obtained from Endress+Hauser, on all paperwork and mark the RA#
clearly on the outside of the box. If this procedure is not followed, it may result in the refusal of the package at our facility.
Bitte geben Sie die von E+H mitgeteilte Rücklieferungsnummer (RA#) auf allen Lieferpapieren an und vermerken Sie diese
auch außen auf der Verpackung. Nichtbeachtung dieser Anweisung führt zur Ablehnung ihrer Lieferung.
Name, dept./Abt.
(please print /)bitte Druckschrift
Signature / Unterschrift
Page 20
www.endress.com/worldwide
BA062C/07/en/07.09
71099066
FM+SGML 6.0
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