Endress+Hauser CCS140 User manual

Products Solutions Services
Operating Instructions
CCS140/141
Sensors for measuring free available chlorine
BA00058C/07/EN/14.18
71423117
2018-10-23

CCS140/141 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 the personnel ........ 6
2.2 Designated use ...................... 6
2.3 Workplace safety .................... 6
2.4 Operational safety ................... 6
2.5 Product safety ....................... 7
3 Product description ............. 7
3.1 Product design ....................... 7
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 ................ 15
5.3 Post-installation check ............... 17
6 Electrical connection .......... 17
6.1 Connecting the sensor ............... 18
6.2 Ensuring the degree of protection ..... 20
6.3 Post-connection check ............... 20
7 Commissioning ................ 21
7.1 Function check ..................... 21
7.2 Sensor polarization .................. 21
7.3 Sensor calibration ................... 21
8 Diagnostics and
troubleshooting ............... 23
9 Maintenance .................. 25
9.1 Maintenance schedule ............... 25
9.2 Maintenance tasks .................. 25
10 Repair .......................... 32
10.1 Spare parts ........................ 32
10.2 Return ............................ 32
10.3 Disposal ........................... 32
11 Accessories .................... 33
11.1 Device-specific accessories ............ 33
12 Technical data ................. 34
12.1 Input .............................. 34
12.2 Performance characteristics .......... 36
12.3 Environment ....................... 36
12.4 Process ............................ 36
12.5 Mechanical construction ............. 37
Index ................................. 38

About this document CCS140/141
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

CCS140/141 About this document
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1.2.1 Symbols on the device
Symbol Meaning
Reference to device documentation

Basic safety instructions CCS140/141
6 Endress+Hauser
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.
‣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, process water and bathing 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. Too low
concentrations in the water could jeopardize the effectiveness of the disinfection. Too high
concentrations can lead to signs of corrosion and have an adverse effect on the taste and
smell, while also generating unnecessary costs.
The sensor was specifically developed for this application and is designed for continuous
measurement of free chlorine in water. In conjunction with measuring and control equipment,
it allows optimal control of disinfection.
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
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.

CCS140/141 Product description
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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.
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
European standards have been observed.
3 Product description
3.1 Product design
The sensor consists of the following functional units:
• Measuring chamber
– To protect the anode or cathode from the medium
– With a large volume of electrolyte for a long service life in combination with the large
anode and the small cathode
• Sensor shaft with
– Large anode
– Cathode embedded in plastic
– Optional temperature sensor
• Membrane cap with
– Robust PTFE membrane
– Special support grid between cathode and membrane for a defined and consistent
electrolyte film and thus a relatively constant indication even at varying pressures and
flows

Product description CCS140/141
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1
4
5
6
7
8
2
3
A0037109
1 Fixed cable
2 Sensor shaft
3 O-ring
4 Large anode, silver/silver chloride
5 Gold cathode
6 Measuring chamber
7 Membrane cap with dirt-repellent membrane
8 Screw cap for securing the membrane cap
3.1.1 Measuring principle
Free available chlorine levels are determined using hypochlorous acid (HOCl) in accordance
with the amperometric measuring principle.
The hypochlorous acid (HOCl) contained in the medium diffuses through the
sensor membrane and is reduced to chloride ions (Cl-) at the gold cathode. At the silver anode,
silver is oxidized to silver chloride. Electron donation at the gold cathode and electron
acceptance at the silver anode causes a current to flow which is proportional to the
concentration of free chlorine in the medium at constant conditions.
The concentration of hypochlorous acid (HOCl) depends on the pH value. An additional pH
measurement should be used to compensate for this dependency.
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
Molecular chlorine (Cl2) is present at pH values < 4. Consequently, hypochlorous acid (HOCl)
and hypochlorite (OCl– remain within the range of pH 4 to 11 as components of free chlorine.

CCS140/141 Product description
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As hypochlorous acid splits up (dissociates) with an increasing pH value to form hypochlorite
ions (OCl–) and hydrogen ions (H+), the amounts of the individual components of free
effective chlorine change with the pH value. For example, if the proportion of hypochlorous
acid is 97 % at pH 6, it drops to approx. 3 % at pH 9.
For amperometric measurement using the chlorine sensor, only the amount of hypochlorous
acid (HOCl) is selectively measured. This works as a powerful disinfectant in an aqueous
solution. Hypochlorite (OCl–), however, is an extremely weak disinfectant. Therefore, when
used as a disinfectant at higher pH values, the effectiveness of chlorine is limited. Since
hypochlorite ions cannot pass through the sensor membrane, the sensor does not record this
part.
pH compensation of chlorine sensor signal
To calibrate and verify the chlorine measuring system, a colorimetric reference measurement
must be carried out using the DPD method. Free chlorine reacts with diethyl-p-
phenylendiamine to form a red dye. The intensity of the red color increases proportionally to
the chlorine content. For the DPD test, the sample is buffered to a specified pH value.
Therefore, the pH value of the sample is not taken into account in the DPD measurement. Due
to the buffer function in the DPD method, all components of free effective chlorine (HOCl and
OCl-) are detected and thus the total free chlorine is measured.
The chlorine sensor only measures the hypochlorous acid. If you select pH compensation in
the transmitter, the sum of hypochlorous acid and hypochlorite is calculated from the
measured signal and the pH value. This value corresponds to the DPD measurement.
When free chlorine is measured with pH compensation switched on, always perform
calibration in pH-compensated mode.
When you use pH compensation, the measured chlorine value displayed and output by the
device corresponds to the DPD value even if the pH value fluctuates. If no pH compensation is
used, the chlorine value of the DPD measurement corresponds only to the chlorine value of

Product description CCS140/141
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the sensor at the same pH value with respect to the calibration. Without pH compensation,
the chlorine measuring system must be recalibrated when the pH value changes.
%
100
80
60
40
20
0
45 6 7 8 9 10 11
100
%
80
60
40
20
0
A
pH
OCl-
HOCl
C
B
A0002017
 1 Principle of pH compensation
A Measured value with pH compensation
B Measured value without pH compensation
C pH compensation
Accuracy of pH compensation
The accuracy of the pH-compensated measured chlorine value is derived from the sum of
several individual deviations (free chlorine, pH, temperature, DPD measurement etc.).
High levels of hypochlorous acid (HOCl) during chlorine calibration have a positive effect on
accuracy, whereas low levels of hypochlorous acid have a negative effect. The inaccuracy of
the pH-compensated measured chlorine value increases the greater the pH difference
between measuring mode and chlorine calibration or the more inaccurate the underlying
individual measured values are.
Calibration taking into account the pH value
For the DPD test, the sample is buffered to a specified pH value. In contrast to this,
amperometric measurement determines only the HOCl component.
During operation, pH compensation is effective up to a pH value of 9. However, there is
virtually no hypochlorous acid (HOCl) left at this pH value, and the measured current is very
low. At this point, pH compensation has the effect of increasing the measured HOCl value to

CCS140/141 Product description
Endress+Hauser 11
the actual value of the free chlorine. Calibration of the entire measuring system is practicable
only if the medium has a pH value of 8 (CCS140) or pH value of 8.2 (CCS141).
Sensor pH value HOCl content Uncompensated value Compensated value
CCS141 8.2 15 % 12 nA 80 nA
CCS140 8.0 20 % 4 nA 20 nA
Above these pH values, the total error of the measuring system is unacceptably high.
Flow
The minimum flow velocity of the membrane-covered measuring cell is 15 cm/s (0.5 ft/s).
When using the CCA250 flow assembly, this corresponds to a flow rate of 30 l/h (7.9 gal/h)
(upper edge of float at level of red bar mark).
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.
The installation of an INS proximity switch in the assembly enables reliable detection of this
invalid operating status, thus triggering an alarm or causing the dosing process to be switched
off if necessary.
Below the minimum flow rate, the sensor current is more sensitive to flow fluctuations. For
abrasive media, it is recommended not to exceed the minimum flow. If suspended solids are
present, which may form deposits, the maximum flow rate is recommended.
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.
Using the sensor in combination with the Liquisys CCM223/253 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.

Incoming acceptance and product identification CCS140/141
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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
• Order code
• 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/ccs140
www.endress.com/ccs141
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.

CCS140/141 Incoming acceptance and product identification
Endress+Hauser 13
4. Search.
 The product structure is displayed in a popup window.
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:
• Chlorine sensor with protection cap (ready for use)
• Bottle with electrolyte (50 ml (1.69 fl.oz))
• Replacement cartridge with pretensioned membrane
• 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.

Installation CCS140/141
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5 Installation
5.1 Installation conditions
5.1.1 Installation position
5.1.2 Dimensions
Ø12 (0.47)
74 (2.91)
88 (3.46)
160 (6.30)
6.5 (0.26)
148 (5.83)
Ø 25 (0.98)
Ø 36 (1.42)
Ø 29 (1.14)
AB
A0037111
 2 Dimensions in mm (in)
A Version with TOP68 plug-in head
B Version with fixed cable connection

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5.2 Mounting the sensor
5.2.1 Measuring system
A complete measuring system comprises:
• Chlorine sensor
• Liquisys CCM223/253 transmitter
• Measuring cable CPK9
• Flowfit CCA250 flow assembly
• Optional: extension cable CYK71
CAL REL
REL 1
REL 1
ALARM
REL 2
REL 2
E
mg/l
25.0 ¡C
0.42
1
2
3
4
6
78
9
10
5
A0037473
 3 Example of a measuring system
1 Flowfit CCA250 flow assembly
2 Inlet to Flowfit CCA250 flow assembly
3 Proximity switch (optional)
4 pH sensor CPS31
5 PML pin
6 Chlorine sensor CCS140
7 Procedure
8 Sampling tap
9 Measuring cable CPK9
10 Liquisys CCM223/253 transmitter

Installation CCS140/141
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‣Ground the medium at the sensor by means of the PML pin to ensure a high reading
stability.
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.

A0037529
 4 Releasing top part of protection cap by turning
2. Carefully remove protection cap from sensor.

A0037504
 5 Carefully remove protection cap

CCS140/141 Electrical connection
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5.2.3 Installing sensor in assembly CCA250
The Flowfit CCA250 flow assembly is designed for installing the sensor. It allows a pH and
ORP sensor to be installed, in addition to the chlorine or chlorine dioxide sensor. A needle
valve controls the flow rate in the range of 30 to 120 l/h (7.9 to 31.7 gal/h).
Please note the following during installation:
‣The flow rate must be at least 30 l/h (7.9 gal/h). If the flow drops below this value or stops
completely, this can be detected by an inductive proximity switch and used to trigger an
alarm with locking of the dosage pumps.
‣If the medium is returned to an overflow basin, pipe or similar, the resulting
counterpressure on the sensor must not exceed 1 bar (14.5 psi) and must remain constant.
‣Negative pressure at the sensor e. g. caused by feedback of the medium to the suction side
of a pump, must be avoided.
‣To avoid buildup, heavily contaminated water should also be filtered.
Additional installation instructions can be found in the Operating Instructions for the
assembly.
5.2.4 Installing sensor in other flow assemblies
When using other flow assemblies, please ensure the following:
‣A flow velocity of at least 15 cm/s (0.49 ft/s) must be guaranteed at all times at the
membrane.
‣The flow direction is upwards. Transported air bubbles must be removed so that they do
not collect in front of the membrane.
‣The flow must be directed to the membrane.
5.3 Post-installation check
1. Check the membrane to ensure it is sealed and undamaged.
 Replace if necessary.
2. Is the sensor installed in an assembly and not suspended from the cable?
 The sensor may be installed only in an assembly or directly via the process
connection.
6 Electrical connection
LCAUTION
Device is live
Incorrect connection may result in injury!
‣The electrical connection may be performed only by an electrical technician.
‣The electrical technician must have read and understood these Operating Instructions and
must follow the instructions contained therein.
‣Prior to commencing connection work, ensure that no voltage is present on any cable.

Electrical connection CCS140/141
18 Endress+Hauser
6.1 Connecting the sensor
‣Install the grounding bar (order number 51501086) in accordance with the accompanying
instructions in order to guarantee a high reading stability.
NOTICE
Measured errors due to faulty connection
‣When connecting the sensor cable, make sure that the black semi-conductor layer is
removed as far as the inner shield.
The sensors have a fixed cable with a maximum length of 3 m (9.8 ft).
‣Connect the sensors to the transmitter according to the following diagram:
Sensor: assignment Sensor: core Transmitter: terminal
Outer shield S
Anode [A] red 91
Cathode [K] transparent 90
NTC temperature
sensor
Green 11
NTC temperature
sensor
Brown 12
GN
1234
5
6
7
8
BN
A0036973
 6 Structure of the sensor cable
1 Outer shield
2 Inner shield, anode
3 Semi-conductor layer
4 Inner insulation
5 Inner conductor, measured signal
6 Temperature sensor connection
7 2nd insulation
8 Outer insulation

CCS140/141 Electrical connection
Endress+Hauser 19
1
2
3
4
5
6
BK
WH
GN
YE
BN
1
6
54
3
2
A0037112
 7 Sensor with TOP68 plug-in head and CPK9 measuring cable with internal PAL (CPK9-N*A1B)
1 Signal (cathode) (black coax)
2 Reference (anode) (screened coax)
3 Not used (white)
4 Temperature sensor (green)
5 Temperature sensor (yellow)
6 Not used (brown)
6.1.1 Connecting the cable extension
To extend the sensor connection, use the VBC junction box.
Extend the connections as follows:
• Chlorine sensor with measuring cable CYK71
• pH and ORP sensors measuring cable CYK71
• Inductive proximity switch with measuring cable MK
A
52 (2.05)
80 (3.15)
113 (4.45)
125 (4.92)
5 x Pg 7
2 x Pg 7 2 x Pg 11
A0037107
 8 VBC junction box with grounding option, specifications in mm (in)

Electrical connection CCS140/141
20 Endress+Hauser
1
2
3
7.2 (0.28)
±0.1
A0037106
 9 Structure of measuring cable CYK71, specifications in mm (in)
1 Coax, e.g. pH, ORP
2 Shielding
3 4 control lines YE/GN/WH/BN
6.2 Ensuring the degree of protection
Only the mechanical and electrical connections which are described in these instructions and
which are necessary for the required, designated use, may be carried out on the device
delivered.
‣Exercise care when carrying out the work.
Otherwise, the individual types of protection (Ingress Protection (IP), electrical safety, EMC
interference immunity) agreed for this product can no longer be guaranteed due, for example
to covers being left off or cable (ends) that are loose or insufficiently secured.
6.3 Post-connection check
Device condition and specifications Notes
Are the sensor, assembly, junction box, or cables free from damage on
the outside?
Visual inspection
Electrical connection Notes
Are the mounted cables strain-relieved and not twisted?
Is a sufficient length of the cable cores stripped, and are the cores
positioned in the terminal correctly?
Check the fit (by pulling gently)
Are all the screw terminals properly tightened? Tighten
Are all the cable entries installed, tightened and sealed? For lateral cable entries, make sure the
cables loop downwards to allow water to drip
off
Are all cable entries installed downwards or mounted laterally?