Endress+Hauser COS51D Operating Manual
Operating Instructions
Oxymax COS51D
Digital sensor for dissolved oxygen
With Memosens technology
BA00413C/07/EN/13.12
71153927
Documentation information
DANGER
!
WARNING
!
CAUTION
!
NOTICE
Warnings
The structure, signal words and safety colors of the signs comply with the specifications of
ANSI Z535.6 ("Product safety information in product manuals, instructions and other collateral
materials").
Safety message structure Meaning
This symbol alerts you to a dangerous situation.
Cause (/consequences)
Consequences if safety message
is not heeded
► Corrective action
Cause (/consequences)
Consequences if safety message
is not heeded
► Corrective action
Cause (/consequences)
Consequences if safety message
is not heeded
► Corrective action
Failure to avoid the situation will result in a fatal or serious
injury.
This symbol alerts you to a dangerous situation.
Failure to avoid the 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 medium
injury.
This symbol alerts you to situations that can result in damage to
Cause/situation
Consequences if safety message
is not heeded
► Action/note
property and equipment.
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1 This symbol indicates a cross reference to a defined page (e.g. p. 1).
È ä
2 This symbol indicates a cross reference to a defined figure (e.g. fig. 2).
È å
Additional information, tips
Permitted or recommended
Forbidden or not recommended
Endress+Hauser
Oxymax COS51D
Table of contents
1 Basic safety instructions . . . . . . . . . . . . 4
1.1 Requirements for personnel . . . . . . . . . . . . . . . . . . . 4
1.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Occupational safety . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Special safety instructions COS51D-G*8*0* . . . . . . 5
2 Identification . . . . . . . . . . . . . . . . . . . . 6
2.1 Product page and configurator . . . . . . . . . . . . . . . . . 6
2.2 Order code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 7
3 Installation . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Incoming acceptance, transport, storage . . . . . . . . . . 8
3.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Installation examples . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 15
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 16
9 Trouble-shooting . . . . . . . . . . . . . . . . . 31
9.1 Trouble-shooting instructions . . . . . . . . . . . . . . . . . 31
9.2 Sensor checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.3 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10 Technical data . . . . . . . . . . . . . . . . . . . 34
10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.2 Performance characteristics . . . . . . . . . . . . . . . . . . 34
10.3 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.4 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.5 Mechanical construction . . . . . . . . . . . . . . . . . . . . 35
11 EC Declaration of Conformity . . . . . . . 36
Index . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Quick wiring guide . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Temperature ranges . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Direct connection to the transmitter . . . . . . . . . . . 17
4.4 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 17
5 Device description . . . . . . . . . . . . . . . 18
5.1 Sensor design . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Commissioning. . . . . . . . . . . . . . . . . . 24
6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Polarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4 Automatic cleaning . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Maintenance. . . . . . . . . . . . . . . . . . . . 26
7.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Replacing wear and tear materials . . . . . . . . . . . . . 27
8 Accessories. . . . . . . . . . . . . . . . . . . . . 29
8.1 Connection accessories . . . . . . . . . . . . . . . . . . . . . 29
8.2 Installation accessories . . . . . . . . . . . . . . . . . . . . . . 29
8.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Basic safety instructions Oxymax COS51D
1 Basic safety instructions
1.1 Requirements for personnel
► Installation, commissioning, operation and maintenance of the measuring system must only be
carried out by trained technical personnel.
► The technical personnel must be authorized by the plant operator to carry out the specified
activities.
► The electrical connection may only be performed by an electrical technician.
► The technical personnel must have read and understood these Operating Instructions and must
follow the instructions they contain.
► Measuring point faults may only be rectified by authorized and specially trained personnel.
Repairs not described in the enclosed Operating Instructions may only be carried out directly
at the manufacturer's or by the service organization.
1.2 Designated use
The oxygen sensor is suitable for continuous measurement of dissolved oxygen in water.
Typical applications are:
• Measuring, monitoring and regulating the oxygen content in activated sludge basins.
• Monitoring the oxygen content in the sewage treatment plant outlet.
• Monitoring, measuring and regulating the oxygen content in public waters and fish farming
water.
• Monitoring of oxygen enrichment in drinking water.
Any other use than the one described here compromises the safety of persons and the entire
measuring system and is not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.
1.3 Occupational safety
As the user, you are responsible for complying with the following safety conditions:
• Regulations for explosion protection
• Installation instructions
• Local standards and regulations
Electromagnetic compatibility
With regard to electromagnetic compatibility, this device has been tested in accordance with the
applicable European standards for industrial applications.
The electromagnetic compatibility indicated only applies to a device that has been connected in
accordance with the instructions in these Operating Instructions.
1.4 Operational safety
► Before commissioning the entire measuring point, make sure all the connections are correct.
Ensure that electrical cables and hose connections are not damaged.
► Do not operate damaged products, and safeguard them to ensure that they are not operated
inadvertently. Mark the damaged product as defective.
► If faults cannot be rectified, the products must be taken out of service and secured against
unintentional commissioning.
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Oxymax COS51D Basic safety instructions
CAUTION
!
The cleaning system is not switched off during calibration or maintenance activities
Risk of injury due to medium or cleaning agent
► If a cleaning system is connected, switch it off before removing a sensor from the medium.
► If you are not switching off the cleaning system because you wish to test the cleaning function,
wear protective clothing, goggles and gloves or take other appropriate measures.
1.5 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. Relevant regulations and European standards
have been observed.
1.6 Special safety instructions COS51D-G*8*0*
• The certified oxygen sensor Oxymax COS51D-G*8*0* may only be connected via the measuring
cable CYK10-G**1 to approved intrinsically safe digital sensor circuits of the transmitter Liquiline
M CM42-*G*. The electrical connection instruction must be followed.
• The measuring cable CYK10-G and its coupling must be protected from electrostatic charging, if
installed through zone 0.
• The sensor may not be operated under process conditions where electrostatic charging is likely to
occur. The designated use in media with a conductivity of at least 10 nS/cm can be assumed as
electrostatic uncritical.
• Ex versions of digital sensors with Memosens technology are indicated by an orange-red ring on
the plug-in head.
• The maximum permissible cable length is 100 m (330 ft).
Endress+Hauser 5
Identification Oxymax COS51D
2 Identification
2.1 Product page and configurator
You can create a complete and valid order code by using the configurator on the internet product
page.
Product page link:
www.products.endress.com/cos51d
2.2 Order code
1. You can choose from the following options on the product page located on the right:
2. Click "Configure this product".
3. The configurator opens in a separate window.
Use the radio buttons to configure the order code from the nameplate of your device.
4. Afterwards, you can export the order code as a PDF or Excel file.
To do so, click the appropriate button at the top of the page.
2.3 Scope of delivery
The following items are included in the delivery:
• Oxygen sensor with transport protection cap for membrane protection
• Accessories set with the following contents:
– 2 replacement cartridges (replacement membrane caps)
– 10 plastic ampoules containing electrolyte
– 1 sealing kit with 3 O-rings
– 6 abrasive sheets
• Operating Instructions (on CD only)
• Brief Operating Instructions (paper version)
If you have any questions, please contact your supplier or your local sales center.
6 Endress+Hauser
Oxymax COS51D Identification
2.4 Certificates and approvals
2.4.1 ATEX II 1G/IECEx Ex ia IIC T6 Ga
The inductive sensor-cable-plug-in system Memosens consisting of:
• oxygen sensor Oxymax W COS51D-G*8*0 and
• measuring cable CYK10-G**1
is suitable for the use in explosion-hazardous locations acc. to the type-examination certificate BVS
04 ATEX E 121 X . The corresponding EC declaration of conformity is part of this document.
2.4.2 FM/CSA
Version COS51D-O****
IS Class 1 Division 1 ABCD T4/T6
Class 1 Zone 0 AEx ia IIC T4/T6
2.4.3 Notified body
DEKRA EXAM GmbH
Bochum (Germany)
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Installation Oxymax COS51D
3 Installation
3.1 Incoming acceptance, transport, storage
► Make sure the packaging is undamaged!
► Inform the supplier about any damage to the packaging.
Keep the damaged packaging until the matter has been settled.
► Make sure the contents are undamaged!
► Inform the supplier about damage to the contents. Keep the damaged products until the matter
has been settled.
► Check that the order is complete and agrees with your shipping documents.
► The packaging material used to store or to transport the product must provide shock protection
and humidity protection. The original packaging offers the best protection. Also, keep to the
approved ambient conditions (see "Technical data").
► If you have any questions, please contact your supplier or your local sales center.
3.2 Installation conditions
3.2.1 Dimensions
a0006742
Fig. 1: Dimensions
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Oxymax COS51D Installation
10° 10°
Not permissible!
Not permissible!
Permissible angle of installation
3.2.2 Angle of installation
The sensor must be installed with an angle of inclination of at least 10 ˚ to the horizontal in an
assembly, support or a suitable process connection. Other angles are not permissible. Do not install
the sensor overhead.
► Make sure you comply with the instructions for installing sensors. You will find them in the
Operating Instructions for the assembly used.
a0006741-en
Fig. 2: Permissible angle of installation
3.2.3 Mounting location
• Select the installation location so that there is easy access for later calibration.
• Make sure that upright posts and assemblies are secured safely and vibration-free.
• Select an installation location which produces a typical oxygen concentration.
3.3 Installation instructions
3.3.1 Measuring system
A complete measuring system comprises at least:
• the digital oxygen sensor Oxymax COS51D
• a transmitter, e.g. Liquiline CM42
• a special measuring cable, CYK10
• an assembly, e.g. immersion assembly CYA112 or retractable assembly COA451
Optional (see accessories):
•Holder system CYH112 for immersion operation
• Automatic cleaning system Chemoclean with spray head
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Installation Oxymax COS51D
NOTICE
a0006735
Fig. 3: Measuring system (example)
1 Digital oxygen sensor Oxymax W COS51D
2 Retractable assembly COA451
3 Liquiline M CM42
4 Measuring cable CYK10
3.3.2 Installing a measuring point
For immersed operation, install the individual modules away from the basin on a solid base.
Only carry out the final installation at the intended installation location.
For a 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 use an assembly with cleaning
function).
3. Install and connect the oxygen sensor.
4. Install an immersion or an suspension assembly (if used) into the process.
No assembly used, sensor not correctly installed, grounding regulations not observed
Risk of damaging the sensor cable, no protection to electromagnetic interferencies
► For immersed operation, the sensor must be installed in an immersion assembly (e.g. CYA611).
Do not install the sensor suspended from the cable.
► Screw the sensor into the assembly so that the cable is not twisted.
► Avoid exerting excessive tensile force on the cable (e.g. from jerky pulling).
► When using metallic assemblies and installation equipment, comply with national grounding
regulations.
► Observe the sensor installation instructions of the Operating Instructions of the assembly used.
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Oxymax COS51D Installation
3.4 Installation examples
3.4.1 Immersion operation
Upright post and chain assembly
For large basins, where sufficient installation distance is required from the basin edge (aeration
basin, especially), it is advisable to use the upright post and chain assembly. The free swinging of
the immersed assembly practically rules out vibrations from the upright post.
According to this effect, the sensor life time can be extended.
Fig. 4: Chain holder, rail mounted
1Chain
2 Flexdip CYH112 holder
3Rail
4Oxymax sensor
5 Flexdip CYA112 wastewater assembly
a0013510
Fig. 5: Chain holder, mounted to a post
1 Weather protection cover
2 Liquiline CM44x controller
3Chain
4 Flexdip CYA112 wastewater assembly
5Oxymax sensor
6 Flexdip CYH112 holder
a0013511
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Installation Oxymax COS51D
Upright post and fixed immersion assembly
The preferable type of installation for strong or turbulent flow (> 0.5 m/s) in the basin or open
channels is to secure the device to an upright post and a securely mounted immersion tube. If the
flow is very strong, a second transverse pipe can be installed with its own pipe support.
Fig. 6: Assembly holder with immersion tube
1 Weather protection cover CYY101
2 Controller Liquiline CM44x
3 Immersion assembly Flexdip CYA112
4Oxymax sensor
5 Assembly holder Flexdip CYH112
a0013513
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