Digital sensor with Memosens technology for
determining free chlorine
CCS51DTable of contents
Table of contents
1About this document ........... 4
1.1Warnings ........................... 4
1.2Symbols used ........................ 4
11Accessories .................... 41
11.1 Maintenance kit CCV05 .............. 41
11.2 Device-specific accessories ............ 41
2Basic safety instructions ....... 6
2.1Requirements for personnel ........... 6
2.2Designated use ...................... 6
2.3Workplace safety .................... 6
2.4Operational safety ................... 7
2.5Product safety ....................... 7
3Product description ............. 8
3.1Product design ....................... 8
4Incoming acceptance and
product identification ......... 13
4.1Incoming acceptance ................ 13
4.2Product identification ................ 13
5Installation .................... 15
5.1Installation conditions ............... 15
5.2Mounting the sensor ................ 17
5.3Post-installation check ............... 25
6Electrical connection .......... 25
6.1Connecting the sensor ............... 26
6.2Ensuring the degree of protection ..... 26
6.3Post-connection check ............... 26
7Commissioning ................ 28
7.1Function check ..................... 28
7.2Sensor polarization .................. 28
7.3Sensor calibration ................... 28
12Technical data ................. 42
12.1 Input .............................. 42
12.2 Performance characteristics .......... 43
12.3 Environment ....................... 44
12.4 Process ............................ 44
12.5 Mechanical construction ............. 45
13Installation and operation in
hazardous environment Class
I Div. 2 .......................... 46
Index ................................. 48
8Diagnostics and
troubleshooting ............... 30
9Maintenance .................. 32
9.1Maintenance schedule ............... 32
9.2Maintenance tasks .................. 33
10Repair .......................... 40
10.1 Spare parts ........................ 40
10.2 Return ............................ 40
10.3 Disposal ........................... 40
Endress+Hauser3
About this documentCCS51D
1 About this document
1.1 Warnings
Structure of informationMeaning
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
SymbolMeaning
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
4Endress+Hauser
CCS51DAbout this document
1.2.1 Symbols on the device
SymbolMeaning
Reference to device documentation
Minimum immersion depth
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Basic safety instructionsCCS51D
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, process water and bathing water must be disinfected through the addition of
appropriate disinfectants such as 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.
2.2.1
‣
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
1)Only if connected to CM44x(R)-CD*
6Endress+Hauser
CCS51DBasic safety instructions
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.
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Product descriptionCCS51D
4
1
2
5
6
8
7
9
3
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
• With special support grid between working electrode and membrane for a defined and
consistent electrolyte film and thus a relatively constant indication even at varying
pressures and flows
• Sensor shaft with
• Large counter electrode
• Working electrode embedded in plastic
• Embedded temperature sensor
1Memosens plug-in head
2Sensor shaft
3O-ring
4Large counter electrode, silver/silver
chloride
5Gold working electrode
6Grooves for installation adapter
7Membrane cap with membrane
8Pressure relief valve (elastic)
9Sensor membrane
1Sensor structure
3.1.1 Measuring principle
A0034227
Free chlorine is determined via hypochlorous acid (HOCl) according to the amperometric
measuring principle.
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CCS51DProduct description
The hypochlorous acid (HOCl) contained in the medium diffuses through the
sensor membrane and is reduced to chloride ions (Cl-) at the gold working electrode. At the
silver counter electrode, silver is oxidized to silver chloride. Electron donation at the gold
working electrode and electron acceptance at the silver counter electrode 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 in nA 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 as components of free chlorine within the range of pH 4 to
11. 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.
With 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 diffuse through the sensor membrane, the sensor does not record
this part.
pH value Result
< 4Chlorine is produced if chloride (Cl-) is present in the medium at the same time causing an increase in the
4 to 9pH compensation works perfectly in this range. A pH-compensated concentration value can be specified.
> 9The measured signal is very weak in this range as the level of hypochlorous acid present is very low. The
measured value.
determined concentration value depends mainly on other conditions of the measuring point.
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-pphenylendiamine 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.
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Product descriptionCCS51D
%
100
80
60
40
20
0
4
5678910 11
100
%
80
60
40
20
0
A
pH
OCl
-
HOCl
C
B
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 changes. If no pH compensation is
used, the chlorine value of the DPD measurement corresponds only to the chlorine value of
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.
2Principle of pH compensation
AMeasured value with pH compensation
BMeasured value without pH compensation
CpH compensation
Accuracy of pH compensation
The accuracy of the pH-compensated measured chlorine value is derived from the sum of
A0002017
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
10Endress+Hauser
CCS51DProduct description
80
90
100
relative slope / maximum slope in %
CCA151 flow gal/hr
CCA250 flow gal/hr
flow velocity at the membrane "/s
00.511.523
05102540
0
1
23456
2.5
15
20
3035
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. pH compensation has the effect of increasing the measured HOCl value to the actual
value of the free chlorine. Calibration of the entire measuring system is practicable only if the
medium has a pH value of up to pH 8.
Above these pH values, the total error of the measuring system is unacceptably high.
Flow
The minimum flow velocity at the membrane-covered measuring cell is 15 cm/s (0.5 ft/s).
• When using the Flowfit CCA151 flow assembly, the minimum flow velocity corresponds to
a volume flow of 5 l/h (1.3 gal/h). The pH value for compensation must be provided in
another way.
• 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).
3Correlation between slope of electrode and flow velocity at the membrane/volume flow in
assembly
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A0041365-EN
Product descriptionCCS51D
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.
The installation of an INS proximity switch in the assembly enables reliable detection of this
invalid operating status, thus triggering an alarm or causing the dosing process to be switched
off if necessary.
Below the minimum flow rate, the sensor current is more sensitive to flow fluctuations. For
abrasive media, it is recommended not to exceed the minimum flow. If suspended solids are
present, which may form deposits, the maximum flow rate is recommended.
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.
For detailed information on the use of external temperature sensors, see the Operating
Instructions for the transmitter.
Cross-sensitivities
2)
There are cross-sensitivities for: chlorine dioxide, ozone, free bromine.
There are no cross-sensitivities for: H2O2, peracetic acid.
2)The listed substances have been tested with different concentrations. An additive effect has not been
investigated.
12Endress+Hauser
CCS51DIncoming acceptance and product identification
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/ccs51d
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.
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Incoming acceptance and product identificationCCS51D
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, ⌀25 mm) with protection cap (ready for use)
• Bottle with electrolyte (50 ml (1.69 fl.oz))
• Replacement membrane cap in protection cap
• Operating Instructions
• Manufacturer inspection 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*
14Endress+Hauser
CCS51DInstallation
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
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.
A0034263
6Releasing top part of protection cap by turning
2.Carefully remove protection cap from sensor.
A0034350
7Carefully remove protection cap
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InstallationCCS51D
1
5.2.3 Installing sensor in CCA151 assembly
The disinfection sensor (membrane-covered, ⌀25 mm) is designed for installation in the
Flowfit CCA151 flow assembly if the pH value for compensation is provided in another
way.
Please note the following during installation:
The volume flow must be at least 5 l/h (1.3 gal/h).
‣
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.
Avoid negative pressure at the sensor, e.g. due to medium being returned to the suction
‣
side of a pump.
To avoid buildup, heavily contaminated water should also be filtered.
‣
Preparing the assembly
1.The assembly is supplied to the customer with a union nut screwed onto the assembly:
unscrew union nut from assembly.
A0034262
8Flowfit CCA151 flow assembly
1Union nut
2.The assembly is supplied to the customer with a dummy plug inserted in the assembly:
remove dummy plug from assembly.
20Endress+Hauser
CCS51DInstallation
1
2
3
Equipping sensor with adapter
The required adapter (clamping ring, thrust collar and O-ring) can be ordered as a mounted
sensor accessory or as a separate accessory → 42.
1.First slide the clamping ring, then the thrust collar, and then the O-ring from the
membrane cap towards the sensor head and into the lower groove.
A0034247
9Slide clamping ring (1), thrust collar (2) and O-ring (3) upwards from the membrane
cap to the sensor shaft and into the lower groove.
Installing sensor in assembly
2.Slide sensor with adapter for Flowfit CCA151 into the opening in the assembly.
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InstallationCCS51D
1
2
3
3.Screw union nut onto assembly on block.
A0034261
10Flowfit CCA151 flow assembly
1Disinfection sensor
2Flowfit CCA151 flow assembly
3Union nut for securing a disinfection sensor
5.2.4 Installing sensor in CCA250 assembly
The sensor can be installed in the Flowfit CCA250 flow assembly. In addition to allowing the
installation of a chlorine or chlorine dioxide sensor, this also allows the simultaneous
operation of a pH and an ORP sensor for example. A needle valve controls the volume flow in
the range of 30 to 120 l/h (7.9 to 31.7 gal/h).
Please note the following during installation:
The volume flow must be at least 30 to 120 l/h (7.9 to 31.7 gal/h). If the flow drops below
‣
this value or stops completely, this can be detected by an inductive proximity switch and
used to trigger an alarm with locking of the dosage pumps.
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.
22Endress+Hauser
CCS51DInstallation
Equipping sensor with adapter
The required adapter can be ordered as a mounted sensor accessory or as a separate
accessory.→ 42
1.Slide adapter for Flowfit CCA250 from the sensor head up to the stop on the sensor.
A0034245
11Slide on adapter for Flowfit CCA250.
2.Fix the adapter with the 2 stud screws supplied and an Allen screw (2 mm).
A0041320
3.Screw the sensor into the assembly.
For detailed information on "Installing sensor in Flowfit CCA250 assembly", see
Operating Instructions for assembly
5.2.5 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.
‣
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InstallationCCS51D
The flow direction is upwards. Transported air bubbles must be removed so that they do
‣
not collect in front of the membrane.
The flow must be directed to the membrane.
‣
Pay attention to the additional installation instructions in the Operating Instructions for
the assembly.
5.2.6 Installing sensor in immersion assembly CYA112
Alternatively, the sensor can be installed in an immersion assembly with a G1 threaded
connection.
Ensure sufficient flow towards the sensor when using the immersion assembly → 11.
Equipping sensor with adapter
The required adapter can be ordered as a mounted sensor accessory or as a separate
accessory.→ 42
1.Slide adapter for Flexdip CYA112 from the sensor head up to the stop on the sensor.
A0034246
12Slide on adapter for Flexdip CYA112.
24Endress+Hauser
CCS51DElectrical connection
2.Fix the adapter with the 2 stud screws supplied and an Allen screw (2 mm).
A0041320
3.Screw the sensor into the assembly. The use of a quick release fastener is recommended.
For detailed information on "Installing sensor in Flexdip CYA112 assembly", see
Operating Instructions for assembly
5.3 Post-installation check
1.Is the adapter locked in place and unable to move freely?
2.Is the sensor installed in an assembly and not freely suspended from the cable?
Install the sensor in an assembly or directly via the process connection.
3.Is the membrane cap leak-tight?
Screw tight or replace.
4.Is the membrane intact and lying flat: Is the membrane bulging slightly (not flat)?
5.Is there electrolyte in the membrane cap?
If necessary, refill the membrane cap with electrolyte.
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.
‣
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Electrical connectionCCS51D
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
13Measuring cable CYK10/CYK20
To extend the cable, use measuring cable CYK11. The maximum cable length is 100 m
‣
(328 ft).
A0018861
14Electrical 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 specificationsNotes
Are the sensor, assembly, or cables free from damage on the outside?Visual inspection
Electrical connectionNotes
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
26Endress+Hauser
Check the fit (by pulling gently)
CCS51DElectrical connection
Device condition and specificationsNotes
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?
loop downwards to allow water to drip off
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CommissioningCCS51D
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 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.
To achieve a stable display value, the sensor requires the following polarization periods:
Initial commissioning60 min.
Recommissioning30 min.
7.3 Sensor calibration
Reference measurement according to the DPD method
To calibrate the measuring system, carry out a colorimetric comparison measurement in
accordance with the DPD method. Chlorine reacts with diethyl-p-phenylendiamine (DPD)
producing a red dye, the intensity of the red color being proportional to the chlorine content.
Measure the intensity of the red color using a photometer (e. g. PF-3→ 41) . The
photometer indicates the chlorine content.
28Endress+Hauser
CCS51DCommissioning
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.
However, a zero point adjustment can be performed if desired.
1.To perform a zero point adjustment, operate the sensor for at least 15 min. in chlorinefree water, using the assembly or protection cap as a vessel.
2.Alternatively, perform the zero point adjustment using the zero point gel
COY8→ 41.
Slope calibration
Always perform a slope calibration in the following cases:
• After replacing the membrane cap
• After replacing electrolyte
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.
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Diagnostics and troubleshootingCCS51D
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:
• Measurement in "temperature-compensated" mode (can be configured on transmitter
CM44x) or constant temperature following calibration
• Flow rate of at least 15 cm/s (0.5 ft/s) (when using the Flowfit CCA151 flow assembly)
• No organic chlorination agents are used
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.
ErrorPossible causeRemedy
No display, no sensor current No supply voltage at the transmitter
Connection cable between sensor and
transmitter interrupted
There is no electrolyte in the
membrane cap
No input flow of medium
Display value too highPolarization of the sensor not yet
completed
Membrane defective
Shunt resistance (e.g. moisture
contact) in the sensor shaft
Foreign oxidants interfering with
sensor
Establish mains connection
‣
Establish cable connection
‣
Fill membrane cap
‣
Establish flow, clean filter
‣
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
‣
30Endress+Hauser
CCS51DDiagnostics and troubleshooting
ErrorPossible causeRemedy
Display value too lowMembrane cap not screwed on fully
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
Display fluctuates
considerably
Hole in membrane
Fill membrane cap with fresh electrolyte
‣
→ 34
Screw membrane cap on fully
‣
Clean membrane → 33
‣
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.
‣
Replace membrane cap
‣
Endress+Hauser31
MaintenanceCCS51D
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
IntervalMaintenance work
If deposits are visible on the membrane (biofilm, limescale)Clean sensor membrane
If dirt is visible on the surface of the electrode bodyClean electrode body of
The operating life of the electrolyte depends greatly on the salt content of the medium. We
recommend you change the electrolyte every 6-9 months. The electrolyte should be changed
every 6 months at least in the case of media with a low conductivity. The membrane cap
should be replaced annually.
• Slope depending on application:
• Every 6-9 months (at maximum) under constant conditions in the permitted range of
0 to 55 °C (32 to 131 °F)
• In the case of severe temperature fluctuations, e.g. from 10 °C (50 °F) to 25°C (77 °F)
and back 100 times
• Zero point calibration:
• If operated in concentration range below 0.5 mg/l (ppm)
• If negative measured value is displayed with factory calibration
• If electrolyte counter warning is active
• If cap is replaced
• For determining the zero point
• 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).
If changes are visible on the working electrode or counter electrode (brown coating no
longer present)
→ 34
sensor → 34
Change electrolyte
Replace membrane cap
→ 35
Sensor calibration
Fill membrane cap with
fresh electrolyte
→ 34
Replace membrane cap
→ 35
Regenerate sensor
→ 38
32Endress+Hauser
CCS51DMaintenance
1
2
3
9.2 Maintenance tasks
9.2.1 Cleaning the sensor
CAUTION
L
Diluted hydrochloric acid
Hydrochloric acid causes irritation if it comes into contact with the skin or eyes.
When using diluted hydrochloric acid, wear protective clothing such as gloves and goggles.
‣
Avoid splashes.
‣
NOTICE
Chemicals that reduce surface tension (e.g. surfactants in cleaning agents or organic
solvents such as alcohol that can be mixed with water)
Due to chemicals that reduce surface tension, the sensor membrane loses its water-repellent
characteristics and becomes permeable to water. The sensor membrane loses its protective
effect, resulting in measured errors.
Do not use any chemicals that reduce surface tension.
‣
Removing the sensor from assembly CCA151
1.Remove the cable.
2.Unscrew the union nut from the assembly.
A0034261
1Disinfection sensor CCS51D
2Flowfit CCA151 flow assembly
3Union nut for securing a disinfection sensor CCS51D
3.Pull sensor out through opening in assembly.
Removing the sensor from assembly CCA250
1.Remove the cable.
Endress+Hauser33
MaintenanceCCS51D
2.Unscrew the sensor, along with the adapter, from the assembly.
The adapter does not need to be disassembled.
For detailed information on "Removing sensor from assembly CCA250", see Operating
Instructions for assembly.
Removing the sensor from assembly CYA112
1.Remove the cable.
2.Unscrew the sensor, along with the adapter, from the assembly.
The adapter does not need to be disassembled.
For detailed information on "Removing sensor from assembly CYA112", see Operating
Instructions for assembly.
Cleaning sensor membrane
If the membrane is visibly dirty, e.g. biofilm, proceed as follows:
1.Remove sensor from flow assembly .
2.Remove membrane cap → 35.
3.Clean the membrane cap mechanically only using a gentle water jet. Alternatively, clean
for several minutes in diluted acids or in specified cleaning agents without any further
chemical additives.
4.Then rinse thoroughly with water.
5.Screw membrane cap back onto sensor → 35.
Cleaning electrode body
1.Remove sensor from flow assembly .
2.Remove membrane cap → 35.
3.Wipe gold electrode carefully using a soft sponge.
4.Rinse electrode body with demineralized water, alcohol or acid.
5.Screw membrane cap back onto sensor → 35.
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.
34Endress+Hauser
CCS51DMaintenance
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 2 years. 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.
‣
Filling the membrane cap with electrolyte
1.Remove membrane cap → 36.
2.Approx. 7 ml (0.24 fl.oz) Fill the membrane cap with electrolyte until it is level with the
start of the internal thread.
3.Slowly screw on membrane cap up to the stop . This will cause excess electrolyte to be
displaced at the valve and thread.
4.If necessary, pat the sensor and membrane cap dry using a cloth.
5.Reset operating hours counter for electrolyte on transmitter. For detailed information,
see Operating Instructions for transmitter.
9.2.3 Replacing membrane cap
1.Remove sensor from flow assembly .
2.Remove membrane cap → 36.
3.Pour fresh electrolyte into the new membrane cap until it is level with the start of the
internal thread.
4.Check if the sealing ring is mounted in the membrane cap.
5.Screw new membrane cap onto sensor shaft → 37.
6.Screw on membrane cap until the membrane at the working electrode is slightly
overstretched (1 mm (0.04 in)).
7.Reset operating hours counter for membrane cap on transmitter. For detailed
information, see Operating Instructions for transmitter.
Endress+Hauser35
MaintenanceCCS51D
1
Removing the membrane cap
Carefully rotate membrane cap and remove.
‣
A0034406
15Carefully rotate membrane cap.
A0034408
16Carefully remove membrane cap.
1Electrode body
36Endress+Hauser
CCS51DMaintenance
1
Screwing the membrane cap onto the sensor
Screw membrane cap onto sensor shaft: hold sensor by the shaft. Keep valve clear.
‣
A0034480
17Screw on membrane cap: keep pressure relief valve clear.
1Pressure relief valve
9.2.4 Storing the sensor
If measurement is suspended for a short period of time and it can be guaranteed that the
sensor will be kept moist while in storage:
1.If the assembly is guaranteed not to empty out,
you may leave the sensor in the flow assembly.
2.If there is a possibility that the assembly may empty out,
remove the sensor from assembly .
3.To keep the membrane moist after the sensor has been removed, refill the protection
cap with electrolyte or clean water.
4.Fit protection cap on sensor → 38.
During longterm interruptions to measurement, particularly if dehydration is possible:
1.Remove sensor from assembly.
2.Clean sensor shaft and membrane cap with cold water and leave to dry.
3.Loosely screw on membrane cap up to the stop. This ensures that the membrane
remains slack.
4.Pour electrolyte or clean water into protection cap and attach → 37.
5.For recommissioning, follow the same procedure as for commissioning → 28.
Ensure that no biofouling occurs during longer interruptions to measurement. Remove
continuous organic deposits, such as films of bacteria.
Endress+Hauser37
MaintenanceCCS51D
Fitting the protection cap on the sensor
1.To keep the membrane moist after the sensor has been removed, fill the protection cap
with some electrolyte or clean water.
A0034264
18Carefully 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.
3.Secure protection cap by rotating the top part of the protection cap.
A0034494
19Securing 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 chloride 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.
38Endress+Hauser
CCS51DMaintenance
A change in the color of the silver chloride 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.
‣
Endress+Hauser39
RepairCCS51D
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.
‣
40Endress+Hauser
CCS51DAccessories
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 Maintenance kit CCV05
Order according to product structure
• 2 x membrane caps and 1 x electrolyte 50 ml (1.69 fl.oz)
• 1 x electrolyte50 ml (1.69 fl.oz)
• 2 x sealing set
11.2 Device-specific accessories
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
Photometer PF-3
• Compact hand-held photometer for determining the reference measured value
• Color-coded reagent bottles with clear dosing instructions
• Order No.: 71257946
Endress+Hauser41
Technical dataCCS51D
Kit adapter CCS5xD for CCA151
• Clamping ring
• Thrust collar
• O-ring
• Order No. 71372027
Adapter kit CCS5x(D) for CCA250
• Adapter incl. O-rings
• 2 studs for locking in place
• Order No. 71372025
Adapter kit CCS5x(D) for CYA112
• Adapter incl. O-rings
• 2 studs for locking in place
• Order No. 71372026
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
Free chlorine (HOCl)
Temperature[°C, °F]
12.1.2 Measuring ranges
CCS51D-**11AD
CCS51D-**11BF0 to 20 mg/l (ppm) HOCl
CCS51D-**11CJ0 to 200 mg/l (ppm) HOCl
12.1.3 Signal current
CCS51D-**11AD
CCS51D-**11BF9 to 18 nA per 1 mg/l (ppm) HOCl
CCS51D-**11CJ9 to 18 nA per 1 mg/l (ppm) HOCl
42Endress+Hauser
Hypochlorous acid (HOCl)
[mg/l, μg/l, ppm, ppb]
0 to 5 mg/l (ppm) HOCl
33 to 63 nA per 1 mg/l (ppm) HOCl
CCS51DTechnical data
12.2 Performance characteristics
12.2.1 Reference operating conditions
Temperature20 °C (68 °F)
pH valuepH 5.5 ±0.2
Flow40 to 60 cm/s
HOCl-free base mediumMains water
12.2.2 Response time
T90 < 25 s (after completing polarization)
The T90 time can be longer under certain conditions. If the sensor is operated or stored in a
chlorine-free medium for a longer period, the sensor response starts immediately if chlorine is
present but only reaches the exact concentration value after a delay.
48 nA per 1 mg/l (ppm) HOCl
CCS51D-**11BF14 nA per 1 mg/l (ppm) HOCl
CCS51D-**11CJ14 nA per 1 mg/l (ppm) HOCl
Endress+Hauser43
Technical dataCCS51D
12.2.7 Long-term drift
< 1 % per month (mean value, determined while operating at varying concentrations and
under reference conditions)
12.2.8 Polarization time
Initial commissioning60 min
Recommissioning30 min
12.2.9 Operating time of the electrolyte
at 10 % of measuring range and 20 °C2 years
at 50 % of measuring range and 20 °C1 year
at maximum concentration and 55 °C60 days
12.3 Environment
12.3.1 Ambient temperature range
-20 to 60 °C (-4 to 140 °F)
12.3.2 Storage temperature
Long-term storage up to 2 years (maximum)Storage up to 48 h (maximum)
With electrolyte0 to 35 °C (32 to 95 °F) (non-freezing)35 to 50 °C (95 to 122 °F)
Without electrolyte–20 to 60 °C (–4 to 140 °F)
12.3.3 Degree of protection
IP68 (1.8 m (5.91 ft)) water column over 7 days at 20 °C (68 °F)
12.4 Process
12.4.1 Process temperature
0 to 55 °C (32 to 130 °F), non-freezing
12.4.2 Process pressure
The inlet pressure depends on the specific fitting and installation.
The measurement can take place with a free outlet.
The sensor can be operated at process pressures up to 1 bar (14.5 psi) (2 bar abs. (29 psi
abs.)).
In terms of sensor condition and performance, it is essential that the flow velocity limits
‣
specified in the following table be observed.
44Endress+Hauser
CCS51DTechnical data
Flow
velocity
[cm/s]
Minimum15305The sensor is suspended freely in the medium; pay
Maximum8012020
Flowfit
CCA250
Flowfit
CCA151
Volume flow [l/h]
Flexdip CYA112
attention to the minimum flow velocity of 15 cm/s
during installation.
12.4.3 pH range
Range of effectiveness of free chlorinepH 4 to 9
1)
CalibrationpH 4 to 8
MeasurementpH 4 to 9
1)
Up to pH 4 and in the presence of chloride ions (Cl-), free chlorine is produced and included in the measurement
12.4.4 Flow
At least 5 l/h (1.3 gal/h), in the Flowfit CCA151 flow assembly
At least 30 l/h (7.9 gal/h), in the Flowfit CCA250 flow assembly
12.4.5 Flow
At least 15 cm/s (0.5 ft/s) , e.g. with Flexdip CYA112 immersion assembly
12.5 Mechanical construction
12.5.1 Dimensions
→ 16
12.5.2 Weight
Sensor with membrane cap and electrolyte (without protection cap and without adapter)
Approx. 95 g (3.35 oz)
12.5.3 Materials
Sensor shaft
PVC
MembranePVDF
Membrane capPVDF
Protection cap• Vessel: PC Makrolon (polycarbonate)
• Seal: Kraiburg TPE TM5MED
• Cover: PC Makrolon (polycarbonate)
Sealing ringFKM
Sensor shaft couplingPPS
12.5.4 Cable specification
max. 100 m (330 ft), incl. Cable extension
Endress+Hauser45
Installation and operation in hazardous environment Class I Div. 2CCS51D
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
46Endress+Hauser
CCS51DInstallation and operation in hazardous environment Class I Div. 2
Endress+Hauser47
IndexCCS51D
Index
A
Accessories ..................... 41
Ambient temperature range ........... 44
C
Cable specification ................. 45
Check
Connection .................. 26
Function ....................28
Installation .................. 25
Cleaning .......................33
Connection
Check ..................... 26
Ensuring the degree of protection ..... 26
D
Declaration of Conformity .............14
Degree of protection
Ensuring ....................26
Technical data ................ 44
Designated use ....................6
Device description .................. 8
Diagnostics ..................... 30
Disposal ....................... 40
E
Effect on the measured signal
Flow ...................... 11
pH value .....................9
Temperature ................. 12
Electrical connection ................25
Environment .................... 44
Ex approvals .................... 14
F
Flow .......................11, 45
Flow assembly ................. 22, 23
Function check ................... 28
I
Immersion assembly ................24
Incoming acceptance ............... 13
Installation
Check ..................... 25
Flow assembly ................ 22
Immersion assembly .............24
Installation position ............. 15
Sensor ..................... 17
Installation position ................ 15
L
Long-term drift ...................44
M
Maintenance schedule ...............32
Maintenance tasks .................33
Materials ...................... 45
Maximum measured error ............ 43
Measured signal ................... 9
Measured value resolution ............ 43
Measured variables ................ 42
Measuring principle .................8
Measuring ranges ................. 42
Measuring system ................. 17
Mounting instructions ...............15
N
Nameplate ..................... 13
Nominal slope ................... 43
O
Operating principle ................. 8
Operating time of the electrolyte .........44
P
Performance characteristics ........... 43
pH range .......................45
pH value ........................9
Polarization time ..................44
Post-installation check .............. 28
Process ........................44
Process pressure .................. 44
Process temperature ................44
R
Reference operating conditions ......... 43
Regeneration .................... 38
Repair ........................ 40
Repeatability .................... 43
Response time ................... 43
Return ........................ 40
48Endress+Hauser
CCS51DIndex
S
Safety instructions ..................6
Scope of delivery .................. 14
Sensor
Calibration .................. 28
Cleaning ....................33
Connecting .................. 26
Mounting ................... 17
Polarization ..................28
Regenerating ................. 38
Storage .................... 37
Spare parts ..................... 40
Storage ....................... 37
Storage temperature ................44
Symbols ........................ 4
T
Technical data
Environment ................. 44
Input ......................42
Mechanical construction .......... 45
Performance characteristics ........ 43
Process .....................44
Temperature .................... 12
Troubleshooting .................. 30
U
Use ...........................6
W
Warnings ....................... 4
Weight ........................45
Endress+Hauser49
*71461453*
71461453
www.addresses.endress.com
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