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
4 Endress+Hauser
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

CCS120D About this document
Endress+Hauser 5
1.2.1 Symbols on the device
Symbol Meaning
Reference to device documentation
Minimum immersion depth

Basic safety instructions CCS120D
6 Endress+Hauser
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
Endress+Hauser 7
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
8 Endress+Hauser
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.

CCS120D Product description
Endress+Hauser 9
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
10 Endress+Hauser
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.