Endress+Hauser COS22D Operating Manual

BA00447C/07/EN/05.19 71436871 2019-03-31

Products Solutions Services

Operating Instructions

Oxymax COS22D

Sensor for the measurement of dissolved oxygen with Memosens technology

Oxymax COS22D Table of contents

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

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

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

2 Basic safety instructions ............ 5

2.1 Requirements for the personnel ............ 5

2.2 Designated use ........................ 5

2.3 Workplace safety ....................... 5

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

2.5 Product safety ......................... 6

3 Device description, function ......... 9

3.1 Amperometric measuring principle .......... 9

3.2 Sensor design ......................... 9

3.3 Membrane body ....................... 9

3.4 Memosens technology .................. 10

3.5 Polarization .......................... 10

4 Incoming acceptance and product

identification ..................... 11

4.1 Incoming acceptance ................... 11

4.2 Product identification ................... 11

4.3 Scope of delivery ...................... 12

4.4 Certificates and approvals ............... 12

10 Maintenance ...................... 29

10.1 Maintenance schedule .................. 29

10.2 Maintenance tasks ..................... 29

10.3 Cleaning of sensor ..................... 29

10.4 Wear parts and consumables ............. 30

10.5 Checking the measurement function ....... 33

11 Accessories ....................... 34

11.1 Assemblies (selection) .................. 34

11.2 Measuring cable ...................... 34

11.3 Zero-point gel ........................ 35

11.4 Maintenance kit ...................... 35

12 Repair ............................ 36

12.1 Spare parts and consumables ............. 36

12.2 Return .............................. 36

12.3 Disposal ............................ 36

13 Technical data .................... 37

13.1 Input ............................... 37

13.2 Performance characteristics .............. 37

13.3 Environment ......................... 39

13.4 Process ............................. 39

13.5 Mechanical construction ................ 40

5 Installation ....................... 14

5.1 Installation conditions .................. 14

5.2 Mounting the sensor ................... 14

5.3 Installation examples ................... 16

5.4 Post-installation check .................. 20

6 Electrical connection .............. 21

6.1 Quick wiring guide (COS22D-BA/NA only) ... 21

6.2 Connecting the sensor .................. 22

6.3 Ensuring the degree of protection .......... 22

6.4 Post-connection check .................. 22

7 Calibration and adjustment ........ 23

7.1 Types of calibration .................... 23

7.2 Calibration in air ...................... 23

7.3 Calculation example for the calibration

value ............................... 23

7.4 Zero point calibration ................... 25

8 Commissioning .................... 26

8.1 Function check ....................... 26

8.2 Sensor polarization .................... 26

8.3 Sensor calibration ..................... 27

14 EU Declaration of Conformity ...... 42

Index .................................. 43

9 Troubleshooting .................. 28

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About this document Oxymax COS22D

1 About this document

1.1 Warnings

Structure of information Meaning

DANGER

Causes (/consequences)

If necessary, Consequences of non-compliance (if applicable)

Corrective action

‣

WARNING

Causes (/consequences)

If necessary, Consequences of non-compliance (if applicable)

Corrective action

‣

CAUTION

Causes (/consequences)

If necessary, Consequences of non-compliance (if applicable)

Corrective action

‣

NOTICE

Cause/situation

If necessary, Consequences of non-compliance (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

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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Oxymax COS22D Basic safety instructions

2 Basic safety instructions

2.1 Requirements for the personnel

• Installation, commissioning, operation and maintenance of the measuring system may be carried out only by specially trained technical personnel.

• The technical personnel must be authorized by the plant operator to carry out the specified activities.

• The electrical connection may be performed only by an electrical technician.

• The technical personnel must have read and understood these Operating Instructions and must follow the instructions contained therein.

• Faults at the measuring point may only be rectified 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

The sensor is designed for the continuous measurement of dissolved oxygen in water. The specific suitability depends on the sensor version:

• COS22D-**1***** (standard, measuring range 0.01 to 60 mg/l)

• Measuring, monitoring and regulating the oxygen content in fermenters

• Monitoring the oxygen content in biotechnology facilities

• COS22D-**3/4***** (trace measurement, measuring range 0.001 to 10 mg/l, preferred operational range 0.001 to 2 mg/l), also suitable for high CO2 partial pressure

• Monitoring inertization equipment in the food industry

• Monitoring the residual oxygen content in carbonated fluids of the beverage industry

• Trace measurement in industrial applications such as inertizations

• Monitoring the residual oxygen content in boiler feedwater

• Monitoring, measuring and regulating the oxygen content in chemical processes

NOTICE

Molecular hydrogen

Hydrogen causes sensitivity in other substances and leads to false low readings or, at the worst, total failure of the sensor.

Only use the COS22D-**1/3***** sensor in media free of hydrogen.

‣

Use the COS22D-**4***** sensor in media containing hydrogen.

‣

For non-contact digital data transmission, the COS22D sensor must be connected to the digital input of the Liquiline transmitter using the CYK10 measuring cable.

Use of the device for any purpose other than that described, poses a threat to the safety of people and of the entire measuring system and is therefore not permitted.

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

2.3 Workplace safety

As the user, you are responsible for complying with the following safety conditions:

• Installation guidelines

• Local standards and regulations

• Regulations for explosion protection

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Basic safety instructions Oxymax COS22D

Electromagnetic compatibility

• The product has been tested for electromagnetic compatibility in accordance with the applicable European standards for industrial applications.

• The electromagnetic compatibility indicated applies only to a product that has been connected in accordance with these Operating Instructions.

2.4 Operational safety

Before commissioning the entire measuring point:

1. Verify that all connections are correct.

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.

2.5 Product safety

2.5.1 State of the art

The product is designed to meet state-of-the-art safety requirements, has been tested, and left the factory in a condition in which it is safe to operate. The relevant regulations and European standards have been observed.

2.5.2 Electrical equipment in hazardous areas

For all approvals

• To avoid incendive sparking, you must install the titanium hazardous area versions COS22D-BA***D*3, COS22D-GC***D*3, COS22D-8A***D*3, COS22D-TA***D*3 and COS22D-NA***D*3 in such a way that they are protected against impact and friction.

• When transporting, installing and performing maintenance in the hazardous area, you must also avoid sparks resulting from impact and friction on the sensor shaft or membrane body.

• The use of these versions in liquid media with solid particles must be avoided.

ATEX II 1G / IECEx Ex ia IIC T3/T4/T6 Ga

The Memosens inductive sensor cable connection system, consisting of:

• oxygen sensor Oxymax COS22D-BA*****3 and

• measuring cable CYK10-G***

is suitable for use in hazardous areas according to type examination certificate BVS 04 ATEX E 121 X. The corresponding EU Declaration of Conformity is part of this document.

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Oxymax COS22D Basic safety instructions

• The certified Oxymax COS22D-BA*****3 oxygen sensor, in conjunction with the CYK10-G*** measuring cable, may be connected only to certified, intrinsically safe, digital sensor circuits of the Liquiline M CM42-OE/F/I********* transmitter. The electrical connection must be made according to the wiring diagram.

• Oxygen sensors for use in the Ex area have a special conductive O-ring. The electrical connection of the metallic sensor shaft to the conductive mounting location (such as a metallic assembly) takes place via the O-ring.

• You must connect the assembly or the installation location to ground according to the Ex guidelines.

• The sensors must not be operated under electrostatically critical process conditions. Avoid strong steam or dust currents that act directly on the connection system.

• Hazardous area versions of digital sensors with Memosens technology are indicated by a red-orange ring in the plug-in head.

• The maximum permitted cable length between the sensor and transmitter is 100 m (330 ft).

NEPSI Ex ia IIC T3/T4/T6 Ga

The Memosens inductive sensor cable connection system, consisting of:

• oxygen sensor Oxymax COS22D-NA*****3 and

• measuring cable CYK10-G***

is approved for use in explosive atmospheres in accordance with the National supervision and inspection center for Explosion protection and Safety of Instrumentation (NEPSI) in China.

The certified oxygen sensor Oxymax COS22D-NA*****3 may only be connected to the following certified, intrinsically safe, digital sensor circuits in conjunction with the measuring cable CYK10-G***, or a Memosens cable with an identical structure both in terms of hardware and function:

• Liquiline CM42-OJ*********

• Alternatively to an approved, intrinsically safe Memosens sensor output that supplies the following values at the very maximum:

Parameter set 1 Parameter set 2

U0 = 5.1 V I0 = 130 mA P0 = 166 mW (linear output characteristic) Ci = 15 µF Li = 95 µH

U0 = 5.04 V I0 = 80 mA P0 = 112 mW (trapezoidal output characteristic) Ci = 14.1 µF Li = 237.2 µH

• The electrical connection must be made according to the wiring diagram.

• You must connect the assembly or the installation location to ground according to the Ex guidelines.

• If the CYK10-G*** cable is installed with its terminal head in Ex zone 0, the cable must be protected against electrostatic charge.

• The user may not change the configuration. Only in this way will the explosion protection of the unit remain intact. Every change puts safety at risk.

• The sensors must not be operated under electrostatically critical process conditions. Avoid strong steam or dust currents that act directly on the connection system. The metal sensor shaft must be installed at the mounting location in such a way that it is electrostatically conductive (< 1 MΩ).

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Basic safety instructions Oxymax COS22D

• To mount, use and maintain the product, you must follow the information in the Operating Instructions and the following standards:

• GB50257 -1996 "Code for construction and acceptance of electric device for explosion

atmospheres and fire hazard electrical equipment installation engineering"

• GB3836.13-1997 "Electrical apparatus for explosive gas atmospheres Part 13: Repair

and overhaul for apparatus used in explosive gas atmospheres"

• GB3836.15-2000 "Electrical apparatus for explosive gas atmospheres- Part 15:

Electrical installations in hazardous area (other than mines)"

• GB3836.16-2006 "Electrical apparatus for explosive gas atmospheres- Part 16:

Inspection and maintenance of electrical installation (other than mines)"

• Hazardous area versions of digital sensors with Memosens technology are indicated by a red-orange ring in the plug-in head.

• The maximum permitted cable length between the sensor and transmitter is 100 m (330 ft).

FM/CSA IS/NI Cl.1 Div.1 GP: A-D

Observe the documentation and the control drawings of the transmitter.

Temperature classes ATEX, IECEx, FM/CSA and NEPSI

Temperature class

T3 T4 T6

Ambient temperature T

Reference temperature T

ref

–5 to +135 °C –5 to +120 °C –5 to +70 °C

+25 °C

TIIS Ex ib IIC T4

The certified oxygen sensor Oxymax COS22D-TA*****3 may only be connected to the certified, intrinsically safe, digital sensor circuit of the transmitter Liquiline M CM42OT********* in conjunction with the measuring cable CYK10-U**1.

Temperature classes TIIS

Ambient temperature T

Reference temperature T

ref

–5 to +60 °C

+25 °C

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Oxymax COS22D Device description, function

1 2

3 Device description, function

3.1 Amperometric measuring principle

The oxygen molecules that diffuse through the membrane are reduced at the cathode to hydroxide ions (OH-). At the anode, silver is oxidized to silver ions (Ag+) (this forms a silver halide layer). A current flows due to the electron donation at the cathode and the electron acceptance at the anode. Under constant conditions, this flow is proportional to the oxygen content of the medium. This current is converted in the transmitter and indicated on the display as an oxygen concentration in mg/l, µg/l, ppm, ppb or Vol%, as a saturation index in % SAT or as an oxygen partial pressure in hPa.

3.2 Sensor design

A0011869

 1 COS22D 1

2 3

Plug-in head Thrust collar Sensor shaft

O-ring 8.5 x 1.5 mm

Membrane body

Shaft sleeve

Glass part with anode and cathode

Process seal 10.77 x 2.62 mm

Process connection Pg 13.5

3.3 Membrane body

The oxygen dissolved in the medium is transported to the membrane by the necessary flow. The membrane is permeable for dissolved gases only. Other substances dissolved in the liquid phase, e.g. ionic substances, will not penetrate through the membrane. Therefore, medium conductivity has no impact on the measuring signal.

The sensor is shipped with a standard membrane body, which can be used for all common applications. The membrane is pretensioned at the factory and can be installed immediately.

Electrolytes are version-specific and cannot be mixed in a single application!

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Device description, function Oxymax COS22D

3.4 Memosens technology

Sensors with Memosens protocol have an integrated electronics unit that stores calibration data and other information. Once the sensor has been connected, the sensor data are transferred automatically to the transmitter and used to calculate the measured value.

Call up the sensor data via the corresponding DIAG menu.

‣

Digital sensors can store measuring system data in the sensor. These include the following:

• Manufacturer data

• Serial number

• Order code

• Date of manufacture

• Calibration data

• Calibration date

• Calibration values

• Number of calibrations

• Serial number of the transmitter used to perform the last calibration

• Operating data

• Temperature application range

• Date of initial commissioning

• Hours of operation under extreme conditions

• Number of sterilizations

3.5 Polarization

When the sensor is connected to the transmitter, a fixed voltage is applied between the cathode and anode. The polarization current this creates can be identified on the transmitter with a reading that is initially high, but decreases with time. The sensor cannot be calibrated until the reading is stable.

Reference value for nearly complete polarization of a sensor that was previously stored for a long time:

• COS22D-*1: 2 hours

• COS22D-*3/4: 12 hours

After this time, even measurements close to the determination limit are useful. The necessary polarization time is reduced for sensors that were in use shortly beforehand.

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Oxymax COS22D 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

• Order code

• Extended order code

• Serial number

• Safety information and warnings

Compare the information on the nameplate with the order.

‣

4.2.2 Product identification

Product page

www.endress.com/cos22d

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 Oxymax COS22D

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.

Manufacturer address

Endress+Hauser Conducta GmbH+Co. KG Dieselstraße 24 D-70839 Gerlingen

4.3 Scope of delivery

The scope of delivery comprises:

• Oxygen sensor with watering cap (filled with tap water) for protecting the membrane

• Electrolyte, 1 bottle, 10 ml (0.34 fl.oz.)

• Tool to push out the membrane body

• Brief Operating Instructions

4.4 Certificates and approvals

4.4.1 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.

4.4.2 Ex approvals

Version COS22D-BA

ATEX II 1G / IECEx Ex ia IIC T3/T4/T6 Ga

4.4.3 Certification body

DEKRA EXAM GmbH

Bochum

4.4.4 Material certificates

Manufacturer declaration of FDA compatibility

The manufacturer declares the use of FDA-listed materials.

Product FDA certificate for

COS22D-****22 Membrane, O-rings, process seal

COS22Z-*2*2 Membrane, O-rings, process seal

COS22D-****23 Membrane, O-rings

COS22Z-*2*3 Membrane, O-rings

Hazardous area versions

For operation in FDA processes, another FDA-approved seal must be installed before the process seal (for example CPA442). Doing so will sufficiently separate the process from the Ex connection.

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Oxymax COS22D Incoming acceptance and product identification

Material test certificate

A test certificate 3.1 in accordance with EN 10204 is supplied depending on the version (→ Product Configurator on the product page).

4.4.5 EHEDG

Compliance with EHEDG's criteria for hygienic design

• TÜV Rheinland, Apeldorn, Netherlands

• Certificate type: Type EL Class I

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Installation Oxymax COS22D

135°

10° 170°

45°

5 Installation

5.1 Installation conditions

5.1.1 Orientation

A0030545

 2 Permitted orientations

The sensor must be installed at an angle of inclination of 10 to 170 ° in an assembly, holder or appropriate process connection. Recommended angle: 45° to prevent the attachment of air bubbles.

Inclination angles other than those mentioned are not permitted. In order to avoid buildup and condensation on the spot, do not install the sensor upside down.

Follow the instructions for installing sensors in the Operating Instructions for the assembly used.

5.1.2 Mounting location

1. Choose a mounting location that is easy to access.

2. Ensure that upright posts and assemblies are fully secured and vibration-free.

3. Choose a mounting location with an oxygen concentration that is typical for the application.

5.2 Mounting the sensor

5.2.1 Measuring system

A complete measuring system comprises:

• an Oxymax COS22D oxygen sensor

• Measuring cable CYK10

• A transmitter, e.g. Liquiline CM42

• Optional: an assembly, e.g. permanent installation assembly CPA442, flow assembly CPA240 or retractable assembly CPA875

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Oxymax COS22D Installation

A0022853

 3 Example of a measuring system with COS22D-*1

1 Liquiline CM42 2 Measuring cable CYK10 3 Oxymax COS22D-*1 digital oxygen sensor 4 Permanent installation assembly CPA442

5.2.2 Installing at a measuring point

Must be installed in a suitable assembly (depending on the application).

WARNING

Electrical voltage

In the event of a fault, non-grounded metallic assemblies may be live and as such are not safe to touch!

When using metallic assemblies and installation equipment, national grounding

‣

provisions must be observed.

For complete installation of a measuring point, proceed as follows:

1. Install a retractable or a flow assembly (if used) into the process.

2. Connect the water supply to the rinse connections (if you are using an assembly with a cleaning function).

3. Install and connect the oxygen sensor.

NOTICE

Installation error

Cable breakage, loss of sensor due to cable separation, unscrewing of membrane cap!

Do not install the sensor freely suspended from the cable.

‣

Screw the sensor into the assembly, ensuring that the cable is not twisted.

‣

Hold on to the sensor body during installation or removal. Turn only at the hexagonal

‣

nut of the armored coupling. Otherwise you might unscrew the membrane cap. This will then remain in the assembly or process. Avoid exerting excessive tensile force on the cable (e.g. through jerky pulling

‣

movements). Choose a mounting location that is easy to access for later calibrations.

‣

Follow the instructions for installing sensors in the Operating Instructions for the

‣

assembly used.

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