Endress+Hauser CCS120 User manual

BA388C/07/en/07.06
51517372
Operating Instructions
CCS120
Sensor for total chlorine

Brief overview
Here is how to use these Operating Instructions to commission your sensor quickly and safely:
Safety instructions
→Page 4 ff.
→Page 5
General safety instructions
Explanation of the warning symbols
Æ
Installation
→Page 7
→Page 8 ff.
Here you can find installation conditions such as sensor dimensions.
Installation examples can be found here.
Æ
Wiring
→Page 11 ff. Refer to these pages for sensor wiring.
Æ
Operating
→Page 14 ff. This chapter describes how to fill in the electrolyte.
Æ
Commissioning
→Page 16 ff. Here you find how to calibrate the sensor.
Æ
Maintenance
→Page 18
→Page 19 ff.
It is absolutely essential to carry out maintenance tasks on a regular basis.
An overview of the available spare parts and accessories.
Æ
Trouble shooting
→Page 20 ff. If faults occur during operation, use the checklist to locate the cause.
Æ
Index
→Page 25 ff. You can find important terms and keywords on the individual sections
here. Use the keyword index to find the information you need quickly and
efficiently.

Endress+Hauser
CCS120
Table of contents
1 Safety instructions . . . . . . . . . . 4
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning and operation . 4
1.3 Operational safety . . . . . . . . . . . . . . . . . . . 5
1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Notes on safety icons and symbols . . . . . . . 5
2 Identification . . . . . . . . . . . . . . 6
2.1 Product structure . . . . . . . . . . . . . . . . . . . . 6
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . 6
3 Installation . . . . . . . . . . . . . . . . 6
3.1 Incoming acceptance, transport, storage . . . 6
3.2 Installation conditions . . . . . . . . . . . . . . . . 7
3.3 Installation instructions . . . . . . . . . . . . . . . 8
3.4 Post-installation check . . . . . . . . . . . . . . . 10
4 Wiring . . . . . . . . . . . . . . . . . . 11
4.1 Direct connection to the transmitter . . . . . 11
4.2 Connection via junction box . . . . . . . . . . 12
4.3 Post-connection check . . . . . . . . . . . . . . . 12
5 Operation . . . . . . . . . . . . . . . . 13
5.1 Sensor design . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Measuring principle . . . . . . . . . . . . . . . . . 13
5.3 Electrolyte fill in . . . . . . . . . . . . . . . . . . . . 14
6 Commissioning. . . . . . . . . . . . 16
6.1 Function check . . . . . . . . . . . . . . . . . . . . 16
6.2 Polarisation . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Maintenance. . . . . . . . . . . . . . 18
8 Accessories. . . . . . . . . . . . . . . 19
8.1 Connection accessories . . . . . . . . . . . . . . 19
8.2 Installation accessories . . . . . . . . . . . . . . . 19
8.3 Transmitter . . . . . . . . . . . . . . . . . . . . . . . 19
8.4 Maintenance/calibration . . . . . . . . . . . . . 20
9 Troubleshooting . . . . . . . . . . . 20
9.1 Troubleshooting instructions . . . . . . . . . . . 20
9.2 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10 Technical data . . . . . . . . . . . . 23
10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.2 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.3 Performance characteristics . . . . . . . . . . . . 23
10.4 Power supply . . . . . . . . . . . . . . . . . . . . . . 24
10.5 Environment . . . . . . . . . . . . . . . . . . . . . . 24
10.6 Mechanical construction . . . . . . . . . . . . . . 24
Index. . . . . . . . . . . . . . . . . . . . 25

Safety instructions CCS120
4Endress+Hauser
1 Safety instructions
1.1 Designated use
The sensor is used for continuous measurement of total chlorine in water. Within this context
the following compounds are included in the term total chlorine:
• free chlorine (Cl2(dissolved), HOCl, OCL-)
• bound chlorine (chloramines)
• organic-bound chlorine (e.g. cyanuric acid derivates)
Typical applications are:
• Controlling total chlorine content of drinking, industrial, process, cooling water and pool
sector
• Measuring total chlorine content in fresh water and sea water for process, swimming pool and
whirl pool treatment
Any other use than the one described here compromises the safety of persons and the entire
measuring system and is, therefore, not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.
1.2 Installation, commissioning and operation
Please note the following items:
• Installation, commissioning, operation and maintenance of the measuring system must only
be carried out by trained technical personnel.
The technical personnel must be authorized for the specified activities by the system operator.
• Electrical connection must only be carried out by a certified electrician.
• Technical personnel must have read and understood these Operating Instructions and must
adhere to them.
• Before commissioning the entire measuring point, check all the connections for
correctness. Ensure that electrical cables and hose connections are not damaged.
• Do not operate damaged products and secure them against unintentional
commissioning. Mark the damaged product as being defective.
• Measuring point faults may only be rectified by authorized and specially trained
personnel.
• If faults can not be rectified, the products must be taken out of service and secured against
unintentional commissioning.
• Repairs not described in these Operating Instructions may only be carried out at the
manufacturer’s or by the service organisation.

CCS120 Safety instructions
Endress+Hauser 5
1.3 Operational safety
The sensor has been designed and tested according to the state of the art and left the factory in
perfect functioning order.
Relevant regulations and European standards have been met.
As the user, you are responsible for complying with the following safety conditions:
• Installation instructions
• Local prevailing standards and regulations.
1.4 Return
If the sensor has to be repaired, please return it cleaned to the sales centre responsible.
Please use the original packaging, if possible.
Please enclose the completed "Declaration of Hazardous Material and De-Contamination" (copy
the second last page of these Operating Instructions) with the packaging and the transportation
documents.
No repair without completed declaration!
1.5 Notes on safety icons and symbols
#
Warning!
This symbol alerts you to hazards. They can cause serious damage to the instrument or to
persons if ignored.
"
Caution!
This symbol alerts you to possible faults which could arise from incorrect operation. They could
cause damage to the instrument if ignored.
!Note!
This symbol indicates important items of information.

Identification CCS120
6Endress+Hauser
2 Identification
2.1 Product structure
2.2 Scope of delivery
The following items are included in the delivery:
• 1 sensor CCS120
• 1 bottle containing electrolyte (50 ml) and nozzle
• 1 membrane cap for replacement
• 1 operating instructions BA 388C/07/en
3 Installation
3.1 Incoming acceptance, transport, storage
• Make sure the packaging is undamaged!
Inform the supplier about 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 delivery contents. Keep the damaged products until
the matter has been settled.
• Check that the scope of delivery is complete and agrees with your order and the 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 sales center responsible.
Mesuring range
A 0.1 ... 10 mg/l
Head type
S Thread NPT 3/4"; plug TOP 68
Options
0none
CCS120- complete order code

CCS120 Installation
Endress+Hauser 7
3.2 Installation conditions
3.2.1 Dimensions
a0003082
Fig. 1: Dimensions
mm/inch
Ø 29/
1.14
Ø 36/
1.42
Ø 28.8/
1.13
Ø 25/
0.98
27/1.06
183/7.20
74/2.91
NPT 3/4

Installation CCS120
8Endress+Hauser
3.3 Installation instructions
3.3.1 Measuring system
A complete measuring system in the flow mode comprises at least:
• Chlorine sensor
• Transmitter Liquisys M CCM223/253
• Special measuring cable
• Flow assembly
a0001691
Fig. 2: Measuring system in the flow mode (example)
The measuring system described above is available as CCE-system (fully mounted on a board).
CAL REL
REL1
REL1
ALARM
REL2
REL2
E
mg/l
25.0 ¡C
0.42
1
2
3
4
5
67
8
9
1 Flow assembly CCA250 6 Medium outlet
2 Medium inlet 7 Sampling tap
3 Inductive proximity switch for flow monitoring 8 Measuring cable CPK9-N*A1B
4 Mounting place for pH/redox sensor 9 Transmitter
5 Chlorine sensor CCS120

CCS120 Installation
Endress+Hauser 9
A complete measuring system in the immersion mode comprises at least:
• Chlorine sensor
• Transmitter Liquisys M CCM223/253
• Special measuring cable
• Immersion assembly
a0003087
Fig. 3: Measuring system in the immersion mode (example)
3.3.2 Installing the sensor in flow assembly CCA250
The flow assembly CCA250 is designed for on-site installation of the sensor. In addition to the
chlorine sensor, a pH and redox sensor can be installed. A needle valve regulates the flow within
the range of 30 ... 100 l/h (7.92 ... 26.40 US.gal/h). If the value drops below 30 l/h (7.92
US.gal/h) or flow stops completely, this can be detected by an inductive proximity switch and
an alarm signal plus locking of the dosage pumps can be triggered.
Note the instructions and safety guidelines in the operating instructions of the flow assembly.
If the medium is fed back into a surge tank, pipeline or the like, ensure that the thus generated
back pressure on the sensor does not exceed 1 bar (14.5 psi) and remains constant.
Negative pressure at the sensor, e.g. by feedback of medium to the suction side of a pump, must
be avoided.
12
4
53
CAL REL
REL1
REL1
ALARM
REL2
REL2
E
mg/l
25.0 ¡C
0.42
1 Junction box VBM 4 Immersion assembly CYA611-0B
2 Transmitter 5 Chlorine sensor CCS120
3 Measuring cable CYK71

Installation CCS120
10 Endress+Hauser
3.3.3 Installing the sensor in immersion assembly CYA611
The immersion assembly CYA611-0B is designed for on-site installation of the sensor. Cover the
thread NPT 3/4" with a layer of Teflon tape. Screw the sensor into the assembly.
Note the instructions and safety guidelines in the operating instructions of the immersion
assembly.
3.4 Post-installation check
• Check the membrane for leak tightness und replace it if necessary.
• Is the sensor installed in an assembly and is not suspended from the cable?