Endress+Hauser CCS51D Operating Manual

BA01906C/07/EN/02.18 71461453 2018-12-03

Products Solutions Services

Operating Instructions

CCS51D

Digital sensor with Memosens technology for determining free chlorine

CCS51D Table of contents

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

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

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

11 Accessories .................... 41

11.1 Maintenance kit CCV05 .............. 41

11.2 Device-specific accessories ............ 41

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

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

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

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

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 ......... 13

4.1 Incoming acceptance ................ 13

4.2 Product identification ................ 13

5 Installation .................... 15

5.1 Installation conditions ............... 15

5.2 Mounting the sensor ................ 17

5.3 Post-installation check ............... 25

6 Electrical connection .......... 25

6.1 Connecting the sensor ............... 26

6.2 Ensuring the degree of protection ..... 26

6.3 Post-connection check ............... 26

7 Commissioning ................ 28

7.1 Function check ..................... 28

7.2 Sensor polarization .................. 28

7.3 Sensor calibration ................... 28

12 Technical data ................. 42

12.1 Input .............................. 42

12.2 Performance characteristics .......... 43

12.3 Environment ....................... 44

12.4 Process ............................ 44

12.5 Mechanical construction ............. 45

13 Installation and operation in

hazardous environment Class

I Div. 2 .......................... 46

Index ................................. 48

8 Diagnostics and

troubleshooting ............... 30

9 Maintenance .................. 32

9.1 Maintenance schedule ............... 32

9.2 Maintenance tasks .................. 33

10 Repair .......................... 40

10.1 Spare parts ........................ 40

10.2 Return ............................ 40

10.3 Disposal ........................... 40

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About this document CCS51D

1 About this document

1.1 Warnings

Structure of information Meaning

DANGER

Causes (/consequences)

If necessary, Consequences of noncompliance (if applicable)

Corrective action

‣

WARNING

Causes (/consequences)

If necessary, Consequences of noncompliance (if applicable)

Corrective action

‣

CAUTION

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

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CCS51D About this document

1.2.1 Symbols on the device

Symbol Meaning

Reference to device documentation

Minimum immersion depth

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Basic safety instructions CCS51D

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.

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*

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CCS51D Basic 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 description CCS51D

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

1 Memosens plug-in head 2 Sensor shaft 3 O-ring 4 Large counter electrode, silver/silver

chloride 5 Gold working electrode 6 Grooves for installation adapter 7 Membrane cap with membrane 8 Pressure relief valve (elastic) 9 Sensor membrane

 1 Sensor 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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CCS51D Product 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

< 4 Chlorine is produced if chloride (Cl-) is present in the medium at the same time causing an increase in the

4 to 9 pH compensation works perfectly in this range. A pH-compensated concentration value can be specified.

> 9 The 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 description CCS51D

100

5 6 7 8 9 10 11

100

OCl

HOCl

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.

 2 Principle of pH compensation

A Measured value with pH compensation B Measured value without pH compensation C pH compensation

Accuracy of pH compensation

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

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

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CCS51D Product description

100

relative slope / maximum slope in %

CCA151 ﬂow gal/hr

CCA250 ﬂow gal/hr

ﬂow velocity at the membrane "/s

0 0.5 1 1.5 2 3

0 5 10 25 40

2 3 4 5 6

2.5

30 35

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).

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

assembly

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A0041365-EN

Product description CCS51D

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

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.

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CCS51D Incoming 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 identification CCS51D

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

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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CCS51D Installation

15°

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

A0034236

5.1.2 Immersion depth

50 mm (1.97 in)

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Installation CCS51D

161 (6.34)

82 (3.23)

102 (4.02)

126 (4.96)

!25

(0.98)

5.1.3 Dimensions

A0034238

 4 Dimensions in mm (in)

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