Endress+Hauser CCS120D User manual

Products Solutions Services
Operating Instructions
CCS120D
Digital sensor with Memosens technology for
determining total chlorine
BA01950C/07/EN/02.19
71461435
2019-12-31

CCS120D Table of contents
Endress+Hauser 3
Table of contents
1 About this document ........... 4
1.1 Warnings ........................... 4
1.2 Symbols used ........................ 4
2 Basic safety instructions ....... 6
2.1 Requirements for personnel ........... 6
2.2 Designated use ...................... 6
2.3 Workplace safety .................... 7
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 ......... 12
4.1 Incoming acceptance ................ 12
4.2 Product identification ................ 12
5 Installation .................... 14
5.1 Installation conditions ............... 14
5.2 Mounting the sensor ................ 16
5.3 Post-installation check ............... 22
6 Electrical connection .......... 22
6.1 Connecting the sensor ............... 23
6.2 Ensuring the degree of protection ..... 23
6.3 Post-connection check ............... 23
7 Commissioning ................ 24
7.1 Function check ..................... 24
7.2 Filling the membrane cap with
electrolyte ......................... 24
7.3 Sensor polarization .................. 24
7.4 Sensor calibration ................... 24
8 Diagnostics and
troubleshooting ............... 26
9 Maintenance .................. 28
9.1 Maintenance schedule ............... 28
9.2 Maintenance tasks .................. 28
10 Repair .......................... 33
10.1 Spare parts ........................ 33
10.2 Return ............................ 33
10.3 Disposal ........................... 33
11 Accessories .................... 34
11.1 Device-specific accessories ............ 34
12 Technical data ................. 35
12.1 Input .............................. 35
12.2 Performance characteristics .......... 36
12.3 Environment ....................... 37
12.4 Process ............................ 37
12.5 Mechanical construction ............. 37
13 Installation and operation in
hazardous environment Class
I Div. 2 .......................... 38
Index ................................. 40

About this document CCS120D
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1 About this document
1.1 Warnings
Structure of information Meaning
LDANGER
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation will result in a fatal or serious injury.
LWARNING
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation can result in a fatal or serious injury.
LCAUTION
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid this situation can result in minor or more serious injuries.
NOTICE
Cause/situation
If necessary, Consequences of non-
compliance (if applicable)
‣Action/note
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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1.2.1 Symbols on the device
Symbol Meaning
Reference to device documentation
Minimum immersion depth

Basic safety instructions CCS120D
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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 and industrial water must be disinfected through the addition of appropriate
disinfectants such as chlorine gas or inorganic chlorine compounds. The dosing quantity must
be adapted to continuously fluctuating operating conditions. If the concentrations in the water
are too low, this could jeopardize the effectiveness of the disinfection. On the other hand,
concentrations which are too high can lead to signs of corrosion and have an adverse effect on
taste, as well as generating unnecessary costs.
The sensor was specifically developed for this application and is designed for continuous
measurement of total chlorine in water. In conjunction with measuring and control
equipment, it allows optimal control of disinfection.
In this context, the following compounds are referred to collectively as total chlorine:
• Free available chlorine: hypochlorous acid (HOCl), hypochlorite ions (OCl-)
• Combined chlorine (chloramines)
• Organic combined chlorine, e. g. cyanuric acid derivatives
Chloride (Cl-) is not recorded.
The sensor is not suitable for checking the absence of chlorine.
The sensor is particularly suitable for:
• Monitoring of total chlorine content in wastewater, industrial water, process water, cooling
water and pool water
• Measurement, monitoring and control of total chlorine content in fresh water and seawater
during the treatment of process water, swimming pool water and whirlpool bathwater
A typical application is the disinfection of wastewater, industrial, process and cooling water
with disinfectants containing chlorine, particularly at higher pH values up to 9.5. In swimming
pools, the CCS120D sensor is used in combination with the CCS51D sensor for free available
chlorine to monitor the amount of combined chlorine (chloramines).
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.

CCS120D Basic safety instructions
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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 1)
‣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
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.
1) Only if connected to CM44x(R)-CD*

Product description CCS120D
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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
• Guarantees a defined and consistent electrolyte film between working electrode and
membrane
• Sensor shaft with
• Large counter electrode
• Working electrode embedded in plastic
• Embedded temperature sensor
6
1
7
4
2
3
5
A0037693
 1 Sensor structure
1 Memosens plug-in head
2 NPT ¾" thread
3 O-ring
4 Sensor shaft
5 Pressure relief valve (elastic)
6 Membrane cap
7 Sensor membrane
3.1.1 Measuring principle
Total chlorine levels are determined in accordance with the amperometric measuring
principle.

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In this context, the following compounds are referred to collectively as total chlorine:
• Free available chlorine: hypochlorous acid (HOCl), hypochlorite ions (OCl-)
• Combined chlorine (chloramines)
• Organic combined chlorine, e.g. cyanuric acid derivatives
Chloride (Cl-) is not recorded.
The sensor is a membrane-covered, two-electrode sensor. A platinum working electrode is
used as the working electrode. A counter electrode coated in silver halide is used as the
counter and reference electrode.
The membrane cap, which is filled with electrolyte, constitutes the measuring chamber. The
measuring electrodes are immersed in the measuring chamber. The measuring chamber is
separated from the medium by means of a microporous membrane. The chlorine compounds
contained in the medium diffuse through the sensor membrane.
The constant polarization voltage present between the two electrodes causes the
electrochemical reaction of the chlorine compounds at the working electrode. Electron
donation at the working electrode and electron acceptance at the counter-electrode cause a
current to flow. In the operational range of the sensor, this current flow is proportional to the
chlorine concentration under constant conditions and is only slightly pH-dependent in the
case of this sensor type. The transmitter uses the current signal to calculate the measured
variable for concentration in mg/l (ppm).
3.1.2 Effects on the measured signal
pH value
pH dependency
The sensor is specified for the pH range of pH 5.5 to 9.5. The measuring signal is practically
independent within this range. However, if the pH increases from pH 7 to pH 8 the measuring
signal for free chlorine is reduced by 10 %.
Flow
The flow to the membrane-covered measuring cell should be at least 15 cm/s and maximum
50 cm/s. The optimum flow velocity is in the 20 to 30 cm/s range.
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).

Product description CCS120D
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98,5
99,0
100,0
99,5
98,0
97,5
97,0
96,5
96,0
relative slope / maximum slope in %
CCA250 flow gal/hr
flow velocity at the membrane "/s
0 0.5 1 1.5 2 3
0 5 10 25 40
2.5
15 20 30 35
A0039131-EN
 2 Correlation between slope of electrode and flow velocity at the membrane/volume flow in
assembly
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.
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.

CCS120D Product description
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Cross-sensitivities 2)
Oxidants, such as bromine, iodine, ozone, chlorine dioxide, permanganate, peracetic acid and
hydrogen peroxide result in higher readings than expected.
Reducing agents, such as sulfides, sulfites, thiosulfates and hydrazine, result in lower readings
than expected.
2) The listed substances have been tested with different concentrations. An additive effect has not been
investigated.

Incoming acceptance and product identification CCS120D
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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/ccs120d
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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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)
• Bottle with electrolyte (50 ml (1.69 fl.oz)) and nozzle
• Replacement membrane cap
• Operating Instructions
• Manufacturer's 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*

Installation CCS120D
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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.
15° 15°
B
A
A0037695
A Permitted orientation
B Incorrect orientation
5.1.2 Immersion depth
At least 70 mm (2.76 in)

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5.1.3 Dimensions
148 (5.83)
35
(1.38)
!36 (1.42)
!29 (1.14)
NPT ¾
74 (2.9)
!28.8 (1.13)
!25 (0.98)
A0038260
 3 Dimensions in mm (in)

Installation CCS120D
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5.2 Mounting the sensor
5.2.1 Measuring system
A complete measuring system comprises:
• CCS120D disinfection sensor (membrane-covered)
• Flexdip CYA112 immersion assembly
• Measuring cable CYK10, CYK20
• Transmitter, e. g. Liquiline CM44x with firmware version 01.06.08 or higher or CM44xR
with firmware version 01.06.08 or higher
• Optional: extension cable CYK11
• Optional: Flowfit CCA250 flow assembly (a pH/ORP sensor can additionally be installed
here)

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1
2
3
45
6
7
A0038294
 4 Example of a measuring system
1 CYH112 holder, main pipe
2 Transmitter
3 Protective cover
4 CYH112 holder, transverse pipe
5 Hook-and-loop tape
6 CYA112 assembly (gray background)
7 Disinfection sensor CCS120D (membrane-covered, ⌀25 mm)

Installation CCS120D
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3
7
2
4
1
5
6
A0038946
 5 Example of a measuring system
1 Liquiline CM44x transmitter
2 Power cable for transmitter
3 Disinfection sensor CCS120D (membrane-covered, ⌀25 mm)
4 Flowfit CCA250 flow assembly
5 Inlet to Flowfit CCA250 flow assembly
6 Proximity switch (optional)
7 Measuring cable CYK10

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5.2.2 Preparing the sensor
Removing protection cap from sensor
NOTICE
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.

A0037884
 6 Releasing top part of protection cap by turning
2. Carefully remove protection cap from sensor.

A0037885
 7 Carefully remove protection cap

Installation CCS120D
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Filling the membrane cap with electrolyte
Please note the information on the safety data sheet to ensure safe use of the electrolyte.
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 one year. 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.
‣Only use membrane cap once.
‣Store the electrolyte bottle upside down (standing on its head) to ensure that the viscous
electrolyte can be decanted as easily as possible with minimum bubbles. Smaller air bubbles
are not a problem. Larger air bubbles rise to the upper edge of the membrane cap.
Filling the membrane cap with electrolyte
The sensor is dry when delivered from the factory. Before using the sensor, fill the
membrane cap with electrolyte.
1. Open the electrolyte bottle. Screw the nozzle onto the electrolyte bottle.
2. Press out any excess air.
3. Place the electrolyte bottle on the membrane cap.
4. Using a single movement, slowly push the electrolyte into the membrane cap until it
reaches the lower turn of the thread. Withdraw the electrolyte bottle smoothly.
5. Slowly screw on membrane cap up to the stop . This will cause excess electrolyte to be
displaced at the valve and thread.
6. If necessary, pat the sensor and membrane cap dry using a cloth.
7. Thoroughly clean the nozzle with a clean, warm and strong jet of water to ensure that
any electrolyte is removed.
8. Reset operating hours counter for electrolyte on transmitter. For detailed information,
see Operating Instructions for transmitter.