BA01950C/07/EN/02.19
71461435
2019-12-31
Products Solutions Services
Operating Instructions
CCS120D
Digital sensor with Memosens technology for
determining total chlorine
CCS120D Table of contents
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
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
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
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About this document CCS120D
1 About this document
1.1 Warnings
Structure of information Meaning
DANGER
L
Causes (/consequences)
If necessary, Consequences of noncompliance (if applicable)
Corrective action
‣
WARNING
L
Causes (/consequences)
If necessary, Consequences of noncompliance (if applicable)
Corrective action
‣
CAUTION
L
Causes (/consequences)
If necessary, Consequences of noncompliance (if applicable)
Corrective action
‣
NOTICE
Cause/situation
If necessary, Consequences of noncompliance (if applicable)
Action/note
‣
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation will result in a fatal or serious injury.
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation can result in a fatal or serious injury.
This symbol alerts you to a dangerous situation.
Failure to avoid this situation can result in minor or more serious injuries.
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
4 Endress+Hauser
CCS120D About this document
1.2.1 Symbols on the device
Symbol Meaning
Reference to device documentation
Minimum immersion depth
Endress+Hauser 5
Basic safety instructions CCS120D
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.
6 Endress+Hauser
CCS120D Basic safety instructions
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
Pay attention to the control drawing and the specified application conditions in the
appendix of these Operating Instructions, and follow the instructions.
1)
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*
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Product description CCS120D
6
1
7
4
2
3
5
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
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
A0037693
1 Sensor structure
3.1.1 Measuring principle
Total chlorine levels are determined in accordance with the amperometric measuring
principle.
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CCS120D Product description
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).
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Product description CCS120D
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.
10 Endress+Hauser
CCS120D Product description
Cross-sensitivities
2)
Oxidants, such as bromine, iodine, ozone, chlorine dioxide, permanganate, peracetic acid and
hydrogen peroxide result in higher readings than expected.
Reducing agents, such as sulfides, sulfites, thiosulfates and hydrazine, result in lower readings
than expected.
2) The listed substances have been tested with different concentrations. An additive effect has not been
investigated.
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Incoming acceptance and product identification CCS120D
4 Incoming acceptance and product identification
4.1 Incoming acceptance
1. Verify that the packaging is undamaged.
Notify the supplier of any damage to the packaging.
Keep the damaged packaging until the issue has been resolved.
2. Verify that the contents are undamaged.
Notify the supplier of any damage to the delivery contents.
Keep the damaged goods until the issue has been resolved.
3. Check that the delivery is complete and nothing is missing.
Compare the shipping documents with your order.
4. Pack the product for storage and transportation in such a way that it is protected
against impact and moisture.
The original packaging offers the best protection.
Make sure to comply with the permitted ambient conditions.
If you have any questions, please contact your supplier or your local Sales Center.
4.2 Product identification
4.2.1 Nameplate
The nameplate provides you with the following information on your device:
• Manufacturer identification
• Extended order code
• Serial number
• Safety information and warnings
Compare the information on the nameplate with the order.
‣
4.2.2 Product page
www.endress.com/ccs120d
4.2.3 Interpreting the order code
The order code and serial number of your product can be found in the following locations:
• On the nameplate
• In the delivery papers
Obtaining information on the product
1. Go to www.endress.com.
2. Call up the site search (magnifying glass).
3. Enter a valid serial number.
4. Search.
The product structure is displayed in a popup window.
12 Endress+Hauser
CCS120D Incoming acceptance and product identification
5. Click on the product image in the popup window.
A new window (Device Viewer) opens. All of the information relating to your
device is displayed in this window as well as the product documentation.
4.2.4 Manufacturer address
Endress+Hauser Conducta GmbH+Co. KG
Dieselstraße 24
D-70839 Gerlingen
4.2.5 Scope of delivery
The delivery comprises:
• Disinfection sensor (membrane-covered)
• Bottle with electrolyte (50 ml (1.69 fl.oz)) and nozzle
• Replacement membrane cap
• Operating Instructions
• Manufacturer's certificate
4.2.6 Certificates and approvals
mark
Declaration of Conformity
The product meets the requirements of the harmonized European standards. As such, it
complies with the legal specifications of the EU directives. The manufacturer confirms
successful testing of the product by affixing to it the mark.
EAC
The product has been certified according to guidelines TP TC 004/2011 and TP TC 020/2011
which apply in the European Economic Area (EEA). The EAC conformity mark is affixed to the
product.
Ex approvals
3)
cCSAus NI Cl. I, Div. 2
This product complies with the requirements defined in:
• UL 61010-1
• ANSI/ISA 12.12.01
• FM 3600
• FM 3611
• CSA C22.2 NO. 61010-1-12
• CSA C22.2 NO. 213-16
• Control drawing: 401204
3) Only if connected to CM44x(R)-CD*
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Installation CCS120D
15°
15°
B
A
5 Installation
5.1 Installation conditions
5.1.1 Installation position
Do not install upside-down!
Install the sensor in an assembly, support or appropriate process connection at an angle of
‣
at least 15 ˚ to the horizontal.
Other angles of inclination are not permitted.
‣
Follow the instructions for installing the sensor in the Operating Instructions of the
‣
assembly used.
A Permitted orientation
B Incorrect orientation
A0037695
5.1.2 Immersion depth
At least 70 mm (2.76 in)
14 Endress+Hauser
CCS120D Installation
148 (5.83)
35
(1.38)
!36 (1.42)
!29 (1.14)
NPT ¾
74 (2.9)
!28.8 (1.13)
!25 (0.98)
5.1.3 Dimensions
A0038260
3 Dimensions in mm (in)
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Installation CCS120D
5.2 Mounting the sensor
5.2.1 Measuring system
A complete measuring system comprises:
• CCS120D disinfection sensor (membrane-covered)
• Flexdip CYA112 immersion assembly
• Measuring cable CYK10, CYK20
• Transmitter, e. g. Liquiline CM44x with firmware version 01.06.08 or higher or CM44xR
with firmware version 01.06.08 or higher
• Optional: extension cable CYK11
• Optional: Flowfit CCA250 flow assembly (a pH/ORP sensor can additionally be installed
here)
16 Endress+Hauser
CCS120D Installation
1
2
3
4
5
6
7
4 Example of a measuring system
1 CYH112 holder, main pipe
2 Transmitter
3 Protective cover
4 CYH112 holder, transverse pipe
5 Hook-and-loop tape
6 CYA112 assembly (gray background)
7 Disinfection sensor CCS120D (membrane-covered, ⌀25 mm)
A0038294
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Installation CCS120D
3
7
2
4
1
5
6
5 Example of a measuring system
1 Liquiline CM44x transmitter
2 Power cable for transmitter
3 Disinfection sensor CCS120D (membrane-covered, ⌀25 mm)
4 Flowfit CCA250 flow assembly
5 Inlet to Flowfit CCA250 flow assembly
6 Proximity switch (optional)
7 Measuring cable CYK10
18 Endress+Hauser
A0038946
CCS120D Installation
5.2.2 Preparing the sensor
Removing protection cap from sensor
NOTICE
Negative pressure causes damage to the sensor's membrane cap
If the protection cap is attached, carefully remove it from sensor.
‣
1. When supplied to the customer and when in storage, the sensor is fitted with a
protection cap: First release just the top part of the protection cap by turning it.
A0037884
6 Releasing top part of protection cap by turning
2. Carefully remove protection cap from sensor.
A0037885
7 Carefully remove protection cap
Endress+Hauser 19
Installation CCS120D
Filling the membrane cap with electrolyte
Please note the information on the safety data sheet to ensure safe use of the electrolyte.
NOTICE
Damage to membrane and electrodes, air bubbles
Possibility of measured errors to complete failure of the measuring point
Avoid damage to membrane and electrodes.
‣
The electrolyte is chemically neutral and is not hazardous to health. Nonetheless, do not
‣
swallow it and avoid contact with eyes.
Keep the electrolyte bottle closed after use. Do not transfer electrolyte to other vessels.
‣
Do not store electrolyte for longer than one year. The electrolyte must not be yellow in
‣
color. Observe the use-by date on the label.
Avoid air bubbles when pouring electrolyte into membrane cap.
‣
Only use membrane cap once.
‣
Store the electrolyte bottle upside down (standing on its head) to ensure that the viscous
‣
electrolyte can be decanted as easily as possible with minimum bubbles. Smaller air bubbles
are not a problem. Larger air bubbles rise to the upper edge of the membrane cap.
Filling the membrane cap with electrolyte
The sensor is dry when delivered from the factory. Before using the sensor, fill the
membrane cap with electrolyte.
1. Open the electrolyte bottle. Screw the nozzle onto the electrolyte bottle.
2. Press out any excess air.
3. Place the electrolyte bottle on the membrane cap.
4. Using a single movement, slowly push the electrolyte into the membrane cap until it
reaches the lower turn of the thread. Withdraw the electrolyte bottle smoothly.
5. Slowly screw on membrane cap up to the stop . This will cause excess electrolyte to be
displaced at the valve and thread.
6. If necessary, pat the sensor and membrane cap dry using a cloth.
7. Thoroughly clean the nozzle with a clean, warm and strong jet of water to ensure that
any electrolyte is removed.
8. Reset operating hours counter for electrolyte on transmitter. For detailed information,
see Operating Instructions for transmitter.
20 Endress+Hauser
CCS120D Installation
2
3
4
A
5
A0037963
8 Membrane cap with electrolyte bottle
1 Nozzle
2 Ventilation hole
3 Electrolyte bottle
4 Membrane cap
5 Hose seal
A Electrolyte level
5.2.3 Installing sensor in CCA250 assembly
The Flowfit CCA250 flow assembly is designed for installing the sensor. It allows a pH and an
ORP sensor to also be installed, in addition to the total chlorine sensor. A needle valve
controls the flow rate in the range of 30 to 120 l/h (7.9 to 31.7 gal/h).
Please note the following during installation:
The flow rate must be at least 30 l/h (7.9 gal/h). If the flow drops below this value or stops
‣
completely, this can be detected by an inductive proximity switch.
If the medium is fed back into an overflow basin, pipe or similar, the resulting
‣
counterpressure on the sensor may not exceed 1 bar (14.5 psi)(2 bar abs. (29 psi abs.)) and
must remain constant.
Negative pressure at the sensor, e.g. due to medium being returned to the suction side of a
‣
pump, must be avoided.
To avoid buildup, heavily contaminated water should also be filtered.
‣
Additional installation instructions can be found in the Operating Instructions for the
assembly.
5.2.4 Installing sensor in other flow assemblies
When using other flow assemblies, please ensure the following:
A flow velocity of at least 15 cm/s (0.49 ft/s) must always be ensured at the membrane.
‣
The flow direction is upwards. Transported air bubbles must be removed so that they do
‣
not collect in front of the membrane.
Endress+Hauser 21
Electrical connection CCS120D
The flow must be directed to the membrane.
‣
Pay attention to the additional installation instructions in the Operating Instructions for
the assembly.
5.2.5 Installing sensor in immersion assembly CYA112
Alternatively, the sensor can be installed in an immersion assembly with threaded connection
NPT ¾", e. g. CYA112.
Please note the following during installation:
Do not twist the sensor measuring cable. Recommendation: use a quick release fastener.
‣
To improve the sealing effect, we recommend you wrap a thin PTFE tape around the thread
‣
for assemblies with an NPT ¾" thread.
Additional installation instructions can be found in the Operating Instructions for the
assembly.
5.3 Post-installation check
1. Check the membrane to ensure it is sealed and undamaged.
Replace if necessary.
2. Is the sensor installed in an assembly and not suspended from the cable?
The sensor may be installed only in an assembly or directly via the process
connection.
6 Electrical connection
CAUTION
L
Device is live
Incorrect connection may result in injury!
The electrical connection may be performed only by an electrical technician.
‣
The electrical technician must have read and understood these Operating Instructions and
‣
must follow the instructions contained therein.
Prior to commencing connection work, ensure that no voltage is present on any cable.
‣
22 Endress+Hauser
CCS120D Electrical connection
GN/YE
YE
GN
BN
WH
GND
+
–
Com A
Com B
GY
6.1 Connecting the sensor
The electrical connection to the transmitter is established using measuring cable CYK10 or
CYK20.
A0024019
9 Measuring cable CYK10/CYK20
A0018861
10 Electrical connection, M12 plug
6.2 Ensuring the degree of protection
Only the mechanical and electrical connections which are described in these instructions and
which are necessary for the required, designated use, may be carried out on the device
delivered.
Exercise care when carrying out the work.
‣
Otherwise, the individual types of protection (Ingress Protection (IP), electrical safety, EMC
interference immunity) agreed for this product can no longer be guaranteed due, for example
to covers being left off or cable (ends) that are loose or insufficiently secured.
6.3 Post-connection check
Device condition and specifications Notes
Are the sensor, assembly, or cables free from damage on the outside? Visual inspection
Electrical connection Notes
Are the mounted cables strain-relieved and not twisted?
Is a sufficient length of the cable cores stripped, and are the cores
positioned in the terminal correctly?
Are all the screw terminals properly tightened? Tighten
Are all the cable entries installed, tightened and sealed? For lateral cable entries, make sure the cables
Are all cable entries installed downwards or mounted laterally?
Endress+Hauser 23
Check the fit (by pulling gently)
loop downwards to allow water to drip off
Commissioning CCS120D
7 Commissioning
7.1 Function check
Prior to initial commissioning, ensure that:
• The sensor is correctly installed.
• The electrical connection is correct.
• There is sufficient electrolyte in the membrane cap and the transmitter is not displaying a
warning about electrolyte depletion.
Please note the information on the safety data sheet to ensure safe use of the electrolyte.
Always keep the sensor moist after commissioning.
WARNING
L
Escaping process medium
Risk of injury from high pressure, high temperatures or chemical hazards
Before applying pressure to an assembly with cleaning system, ensure that the system has
‣
been connected correctly.
Do not install the assembly in the process if you cannot reliably establish the correct
‣
connection.
7.2 Filling the membrane cap with electrolyte
Fill the membrane cap with electrolyte
The sensor is dry when delivered from the factory.
Fill the membrane cap with electrolyte before commissioning the sensor → 20.
‣
7.3 Sensor polarization
The voltage applied by the transmitter between the working electrode and counter electrode
polarizes the surface of the working electrode. Therefore, after switching on the transmitter
with the sensor connected, you must wait until the polarization period has elapsed before
starting calibration.
Polarization time: → 36
7.4 Sensor calibration
Reference measurement according to the DPD method
To calibrate the measuring system, carry out a colorimetric comparison measurement
according to the DPD-1/DPD-3 method. Chlorine reacts with diethyl-p-phenylendiamine
(DPD) producing a red dye, the intensity of the red color being proportional to the chlorine
content. Alternatively, the DPD 4 method can also be used.
Measure the intensity of the red color using a photometer (e. g. PF-3→ 34) . The
photometer indicates the chlorine content.
24 Endress+Hauser
CCS120D Commissioning
Requirements
The sensor reading is stable (no drifts or unsteady values for at least 5 minutes). This is
normally guaranteed once the following preconditions have been met:
• The polarization period has elapsed.
• The flow is constant and within the correct range.
• The sensor and the medium are at the same temperature.
• The pH value is within the permitted range.
Zero point adjustment
A zero point adjustment is not required due to the zero point stability of the membranecovered sensor.
Slope calibration
Always perform a slope calibration in the following cases:
• After replacing the membrane cap
• After replacing electrolyte
The slope of the sensor is strongly influenced by the application conditions. The interval
for the slope calibration must be adjusted accordingly.
Repeat the slope calibration at regular intervals.
Recommended calibration intervals → 28
1. Ensure that the pH value and temperature of the medium are constant.
2. Take a representative sample for the DPD measurement. This must be done in close
proximity to the sensor. Use the sampling tap if available.
3. Determine the chlorine content using the DPD method.
4. Enter the measured value into the transmitter (see Operating Instructions for
transmitter).
5. To ensure greater accuracy, check the calibration several hours or 24 hours later using
the DPD method.
Endress+Hauser 25
Diagnostics and troubleshooting CCS120D
8 Diagnostics and troubleshooting
When troubleshooting, the entire measuring point must be taken into account. This
comprises:
• Transmitter
• Electrical connections and lines
• Assembly
• Sensor
The possible causes of error in the following table refer primarily to the sensor. Before
commencing troubleshooting, ensure that the following operating conditions have been met:
• The chlorine content is within the measuring range of the sensor (check with the DPD-1/
DPD-3 method)→ 35.
• The pH value is within the pH range of the sensor → 37.
• The temperature is within the temperature range of the sensor → 37.
• The conductivity is within the conductivity range of the sensor → 37.
• Measurement in "temperature-compensated" mode (can be configured on transmitter
CM44x) or constant temperature following calibration
• Medium flow rate of at least 30 l/h (7.9 gal/h)(red bar mark when using the CCA250 flow
assembly)
If the value measured by the sensor differs significantly from that of the DPD method,
first consider all possible malfunctions of the photometric DPD method (see Operating
Instructions for photometer). If necessary, repeat the DPD measurement several times.
Error Possible cause Remedy
No display, no sensor current No supply voltage at the transmitter‣Establish mains connection
Connection cable between sensor
and transmitter interrupted
There is no electrolyte in the
membrane cap
No input flow of medium
Zero point has shifted 1. Check condition of counter electrode.
Display value too high Polarization of the sensor not yet
completed
Membrane defective
Shunt resistance (e.g. moisture
contact) in the sensor shaft
Foreign oxidants interfering with
sensor
DPD chemicals are too old
pH value < pH 5
Establish cable connection
‣
Fill membrane cap with fresh electrolyte
‣
→ 29
Establish flow, clean filter
‣
2. Reset transmitter to factory settings.
Wait for polarization to be completed
‣
Replace membrane cap
‣
Remove membrane cap, rub working
‣
electrode dry.
If the transmitter display does not return to
‣
zero, there is a shunt present: replace sensor.
Examine medium, check chemicals
‣
Replace DPD chemicals.
‣
Stay within permitted pH range (pH
‣
5.5 to 9.5.
26 Endress+Hauser
CCS120D Diagnostics and troubleshooting
Error Possible cause Remedy
Display value too low Membrane cap not screwed on fully‣Fill membrane cap with fresh electrolyte
Membrane soiled
Air bubble in front of membrane
Air bubble between working
electrode and membrane
Input flow of medium too low
Foreign oxidants interfering with
DPD reference measurement
Use of organic disinfectants
Polarization time is too low
pH value
There is no electrolyte in the
membrane cap
Display fluctuates
considerably
Hole in membrane
Fluid pressure variations
→ 29
Screw membrane cap on fully
‣
Clean membrane → 28
‣
Release air bubble
‣
Remove membrane cap, top up electrolyte
‣
Remove air bubble by tapping on the outside
‣
of the membrane cap
Screw on membrane cap
‣
Establish correct flow
‣
Examine medium, check chemicals
‣
Use suitable agent (e.g. as per DIN 19643)
‣
(water may need to be replaced first)
Use suitable reference system
‣
Wait for polarization to be completed
‣
Stay within permitted pH range (pH
‣
5.5 to 9.5.
Fill membrane cap with fresh electrolyte
‣
→ 29
Replace membrane cap
‣
Adjust the process
‣
Endress+Hauser 27
Maintenance CCS120D
9 Maintenance
Please note the information on the safety data sheet to ensure safe use of the electrolyte.
Take all the necessary precautions in time to ensure the operational safety and reliability of
the entire measuring system.
NOTICE
Effects on process and process control!
When carrying out any work on the system, bear in mind any potential impact this could
‣
have on the process control system and the process itself.
For your own safety, only use genuine accessories. With genuine parts, the function,
‣
accuracy and reliability are also ensured after maintenance work.
9.1 Maintenance schedule
Interval Maintenance work
If deposits are visible on the membrane (biofilm, limescale) Clean sensor membrane
If dirt is visible on the surface of the electrode body Clean electrode body of
Recommended calibration intervals:
• Drinking water, industrial water, process water, cooling water: depending on the
special conditions (1 to 4 weeks)
• Swimming pools: weekly
• Whirlpools: daily
• If cap is replaced
• If the slope is too low or too high relative to the nominal slope and the membrane cap
is not visibly damaged or dirty
• If there are grease/oil deposits (dark or transparent spots on the membrane)
• If slope is too high or too low or sensor current is very noisy
• If it is obvious that the sensor current is significantly dependent on the temperature
(temperature compensation not working).
In the event of visible silvery or white changes to the counter electrode (brown/gray or
yellow/green discoloration is not a problem)
→ 29
sensor
Sensor calibration
Fill membrane cap with
fresh electrolyte → 29
Replace membrane cap
→ 29
Regenerate sensor
→ 32
9.2 Maintenance tasks
9.2.1 Cleaning the sensor
Removing the sensor from assembly CCA151
1. Remove the cable.
2. Unscrew the union nut from the assembly.
3. Pull sensor out through opening in assembly.
28 Endress+Hauser
CCS120D Maintenance
Cleaning sensor membrane
If the membrane is visibly soiled, proceed as follows:
1. Remove sensor from flow assembly.
2. Only clean membrane mechanically with a gentle jet of water.
9.2.2 Filling membrane cap with fresh electrolyte
Please note the information on the safety data sheet to ensure safe use of the electrolyte.
NOTICE
Damage to membrane and electrodes, air bubbles
Possibility of measured errors to complete failure of the measuring point
Avoid damage to membrane and electrodes.
‣
The electrolyte is chemically neutral and is not hazardous to health. Nonetheless, do not
‣
swallow it and avoid contact with eyes.
Keep the electrolyte bottle closed after use. Do not transfer electrolyte to other vessels.
‣
Do not store electrolyte for longer than one year. The electrolyte must not be yellow in
‣
color. Observe the use-by date on the label.
Avoid air bubbles when pouring electrolyte into membrane cap.
‣
Only use membrane cap once.
‣
Fill the membrane cap with electrolyte→ 20
9.2.3 Replacing membrane cap
1. Remove sensor from flow assembly.
2. Remove membrane cap → 30.
3. Fill new membrane cap with fresh electrolyte → 20.
4. Check the condition of the sealing ring and check whether the sealing ring is mounted
on the shaft.
5. Screw new membrane cap onto sensor shaft → 30.
6. Reset operating hours counter for membrane cap on transmitter. For detailed
information, see Operating Instructions for transmitter.
Endress+Hauser 29
Maintenance CCS120D
1
Remove membrane cap
Carefully rotate membrane cap and remove.
‣
A0037888
11 Carefully rotate membrane cap.
Screw membrane cap onto sensor
Screw membrane cap onto sensor shaft: hold sensor by the shaft. Keep valve clear.
‣
A0037889
12 Screw on membrane cap: keep pressure relief valve clear.
1 Pressure relief valve
9.2.4 Storing the sensor
If measurement is suspended:
1. Remove sensor from assembly.
2. Unscrew membrane cap and dispose of it.
30 Endress+Hauser
CCS120D Maintenance
3. Rinse electrodes thoroughly with clean, warm water ensuring all residue of electrolyte is
removed.
4. Allow the electrodes to dry.
5. Screw a new membrane cap loosely onto the electrodes to protect them.
6. Fit protection cap on sensor → 31.
7. For recommissioning, follow the same procedure as for commissioning → 24.
Ensure that no biofouling occurs during longer interruptions to measurement. Remove
continuous organic deposits such as films of bacteria from media with a high
concentration of chlorine.
Fitting the protection cap on the sensor
1. To keep the membrane moist after the sensor has been removed, fill the protection cap
with clean water.
A0037886
13 Carefully slide protection cap onto the membrane cap.
2. Top part of protection cap is in the open position.
Carefully slide protection cap onto the membrane cap.
Endress+Hauser 31
Maintenance CCS120D
3. Secure protection cap by rotating the top part of the protection cap.
A0037887
14 Securing protection cap by rotating the top part
9.2.5 Regenerating the sensor
During measurement, the electrolyte in the sensor is gradually exhausted due to chemical
reactions. The gray-brown silver halide layer that is applied to the counter electrode at the
factory continues to grow during sensor operation. However, this has no effect on the reaction
taking place at the working electrode.
A change in the color of the silver halide layer indicates an effect of the reaction that is taking
place. Carry out a visual inspection to ensure that the gray-brown color of the counter
electrode has not changed. If the color of the counter electrode has changed, e.g. if it is
spotted, white or silvery, the sensor must be regenerated.
Send the sensor to the manufacturer for regeneration.
‣
32 Endress+Hauser
CCS120D Repair
10 Repair
10.1 Spare parts
For more detailed information on spare parts kits, please refer to the "Spare Part Finding Tool"
on the Internet:
www.endress.com/spareparts_consumables
10.2 Return
The product must be returned if repairs or a factory calibration are required, or if the wrong
product was ordered or delivered. As an ISO-certified company and also due to legal
regulations, Endress+Hauser is obliged to follow certain procedures when handling any
returned products that have been in contact with medium.
To ensure the swift, safe and professional return of the device:
Refer to the website www.endress.com/support/return-material for information on the
‣
procedure and conditions for returning devices.
10.3 Disposal
The device contains electronic components. The product must be disposed of as electronic
waste.
Observe the local regulations.
‣
Endress+Hauser 33
Accessories CCS120D
11 Accessories
The following are the most important accessories available at the time this documentation
was issued.
For accessories not listed here, please contact your Service or Sales Center.
‣
11.1 Device-specific accessories
Kit CCS120/120D, maintenance kit
• 2 x membrane caps and 1 x electrolyte 50 ml (1.69 fl.oz)
• Order number: 71412917
Kit CCS120/120D, electrolyte
• 1 × electrolyte 50 ml (1.69 fl.oz)
• Order number: 71412916
Kit CCS120/120D, Viton ring set
• 2 × Viton rings
• Order number: 71105209
Memosens data cable CYK10
• For digital sensors with Memosens technology
• Product Configurator on the product page: www.endress.com/cyk10
Technical Information TI00118C
Memosens data cable CYK11
• Extension cable for digital sensors with Memosens protocol
• Product Configurator on the product page: www.endress.com/cyk11
Technical Information TI00118C
Memosens laboratory cable CYK20
• For digital sensors with Memosens technology
• Product Configurator on the product page: www.endress.com/cyk20
Flowfit CCA250
• Flow assembly for disinfection and pH/ORP sensors
• Product Configurator on the product page: www.endress.com/cca250
Technical Information TI00062C
Flexdip CYA112
• Immersion assembly for water and wastewater
• Modular assembly system for sensors in open basins, channels and tanks
• Material: PVC or stainless steel
• Product Configurator on the product page: www.endress.com/cya112
Technical Information TI00432C
34 Endress+Hauser
CCS120D Technical data
Photometer PF-3
• Compact hand-held photometer for determining the reference measured value
• Color-coded reagent bottles with clear dosing instructions
• Order No.: 71257946
COY8
Zero-point gel for oxygen and disinfection sensors
• Oxygen-free and chlorine-free gel for the verification, zero point calibration and adjustment
of oxygen and disinfection measuring points
• Product Configurator on the product page: www.endress.com/coy8
Technical Information TI01244C
12 Technical data
12.1 Input
12.1.1 Measured variables
Total chlorine
[mg/l, μg/l, ppm, ppb]
• Free available chlorine:
• Hypochlorous acid (HOCl)
• Hypochlorite ions (OCl-)
• Combined chlorine (chloramines)
• Organically combined chlorine (e.g. cyanuric acid derivatives)
Temperature
[°C, °F]
12.1.2 Measuring ranges
0.1 to 10 mg/l (ppm)
The sensor is not suitable for checking the absence of chlorine.
12.1.3 Signal current
2.4 to 5.4 nA per 1 mg/l (ppm)
Endress+Hauser 35
Technical data CCS120D
12.2 Performance characteristics
12.2.1 Reference operating conditions
Temperature 30 °C (86 °F)
pH value pH 7.2
12.2.2 Response time
T90 approx. 60 s (with increasing and decreasing concentration)
12.2.3 Measured value resolution of sensor
0.01 mg/l (ppm)
12.2.4 Maximum measured error
±2 % or 200 µg/l (ppb) of value measured (depending on which value is higher)
LOD (limit of detection)
1)
LOQ (limit of quantification)
1)
0.022 mg/l (ppm) 0.072 mg/l (ppm)
1) Based on ISO 15839. The measured error includes all the uncertainties of the sensor and transmitter (electrode
system). It does not contain all the uncertainties caused by the reference material and adjustments that may have
been performed.
12.2.5 Repeatability
0.008 mg/l (ppm)
12.2.6 Nominal slope
4 nA per 1 mg/l (ppm) (under reference operating conditions)
12.2.7 Long-term drift
< ±3 % per month
12.2.8 Polarization time
Initial commissioning
Up to 24 h
After replacing the membrane cap Typically 1 to 6 h
Recommissioning Pour approx. 4 to 24 h
12.2.9 Operating time of the electrolyte
3 to 6 months (depending on water quality)
12.2.10 Operating time of membrane cap
With electrolyte
Typically 3 to 6 months, depending on water quality
Without electrolyte > 2 years (25 °C (77 °F))
36 Endress+Hauser
CCS120D Technical data
12.3 Environment
12.3.1 Ambient temperature range
5 to 45 °C (41 to 113 °F), no temperature fluctuations
12.3.2 Storage temperature
Without electrolyte –20 to 60 °C (–4 to 140 °F)
12.3.3 Degree of protection
IP68
12.4 Process
12.4.1 Process temperature
5 to 45 °C (41 to 113 °F), no temperature fluctuations
12.4.2 Process pressure
max. 1 bar (14.5 psi) absolute, if installed in the Flowfit CCA250 assembly
12.4.3 pH range
pH5.5 to 9.5
pH dependency: increase from pH 7 to pH 8: approx. -10 % for free chlorine
12.4.4 Conductivity range
0.03 to 40 mS/cm
12.4.5 Flow CCA250
• Optimum 40 to 60 l/h (10.6 to 15.8 gal/h)
• Minimum 30 l/h (7.9 gal/h)
• Maximum 100 l/h (26.4 gal/h)
12.4.6 Flow
• Optimum 20 to 30 cm/s
• Minimum 15 cm/s
• Maximum 50 cm/s
12.5 Mechanical construction
12.5.1 Dimensions
→ 15
12.5.2 Weight
75 g (2.65 oz)
Endress+Hauser 37
Installation and operation in hazardous environment Class I Div. 2 CCS120D
12.5.3 Materials
Sensor shaft PVC
Membrane PET
Membrane cap PPE
Clamping ring PTFE
Hose seal Silicone
Electrode body PMMA
12.5.4 Cable specification
max. 100 m (330 ft), incl. Cable extension
13 Installation and operation in hazardous environment
Class I Div. 2
Non-sparking device for use in specified hazardous environment in accordance with:
• cCSAus Class I Div. 2
• Gas group A, B, C, D
• Temperature class T6, -5 °C (23 °F) < Ta < 55 °C (131 °F)
• Control drawing: 401204
38 Endress+Hauser
CCS120D Installation and operation in hazardous environment Class I Div. 2
Endress+Hauser 39
Index CCS120D
Index
A
Accessories ..................... 34
Ambient temperature range ........... 37
C
Cable specification ................. 38
Check
Connection .................. 23
Function ....................24
Installation .................. 22
Cleaning .......................28
Connection
Check ..................... 23
Ensuring the degree of protection ..... 23
D
Declaration of Conformity .............13
Degree of protection
Ensuring ....................23
Technical data ................ 37
Designated use ....................6
Device description .................. 8
Diagnostics ..................... 26
Disposal ....................... 33
E
Effect on the measured signal
Flow ....................... 9
pH value .....................9
Temperature ................. 10
Electrical connection ................22
Environment .................... 37
Ex approvals .................... 13
F
Flow ........................9, 37
Flow assembly ................... 21
Function check ................... 24
I
Immersion assembly ................22
Incoming acceptance ............... 12
Installation
Check ..................... 22
Flow assembly ................ 21
Immersion assembly .............22
Installation position ............. 14
Sensor ..................... 16
Installation position ................ 14
L
Long-term drift ...................36
M
Maintenance schedule ...............28
Maintenance tasks .................28
Materials ...................... 38
Maximum measured error ............ 36
Measured signal ................... 9
Measured value resolution ............ 36
Measured variables ................ 35
Measuring principle .................8
Measuring ranges ................. 35
Measuring system ................. 16
Mounting instructions ...............14
N
Nameplate ..................... 12
Nominal slope ................... 36
O
Operating principle ................. 8
Operating time of the electrolyte .........36
P
Performance characteristics ........... 36
pH range .......................37
pH value ........................9
Polarization time ..................36
Post-installation check .............. 24
Process ........................37
Process pressure .................. 37
Process temperature ................37
R
Reference operating conditions ......... 36
Regeneration .................... 32
Repair ........................ 33
Repeatability .................... 36
Response time ................... 36
Return ........................ 33
40 Endress+Hauser
CCS120D Index
S
Safety instructions ..................6
Scope of delivery .................. 13
Sensor
Calibration .................. 24
Cleaning ....................28
Connecting .................. 23
Mounting ................... 16
Polarization ..................24
Regenerating ................. 32
Storage .................... 30
Spare parts ..................... 33
Storage ....................... 30
Storage temperature ................37
Symbols ........................ 4
T
Technical data
Environment ................. 37
Input ......................35
Mechanical construction .......... 37
Performance characteristics ........ 36
Process .....................37
Temperature .................... 10
Troubleshooting .................. 26
U
Use ...........................6
W
Warnings ....................... 4
Weight ........................37
Endress+Hauser 41
*71461435*
71461435
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