Endress+Hauser CCS240 User manual

Products Solutions Services
Operating Instructions
CCS240/241
Sensors for measuring chlorine dioxide
BA00114C/07/EN/14.18
71423118
2018-10-23

CCS240/241 Table of contents
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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 ......... 10
4.1 Incoming acceptance ................ 10
4.2 Product identification ................ 10
5 Installation .................... 12
5.1 Installation conditions ............... 12
5.2 Mounting the sensor ................ 13
5.3 Post-installation check ............... 15
6 Electrical connection .......... 15
6.1 Connecting the sensor ............... 16
6.2 Ensuring the degree of protection ..... 18
6.3 Post-connection check ............... 18
7 Commissioning ................ 19
7.1 Function check ..................... 19
7.2 Sensor polarization .................. 19
7.3 Sensor calibration ................... 19
8 Diagnostics and
troubleshooting ............... 21
9 Maintenance .................. 23
9.1 Maintenance schedule ............... 23
9.2 Maintenance tasks .................. 23
10 Repair .......................... 30
10.1 Spare parts ........................ 30
10.2 Return ............................ 30
10.3 Disposal ........................... 30
11 Accessories .................... 31
11.1 Device-specific accessories ............ 31
12 Technical data ................. 32
12.1 Input .............................. 32
12.2 Performance characteristics .......... 33
12.3 Environment ....................... 33
12.4 Process ............................ 33
12.5 Mechanical construction ............. 34
Index ................................. 35

About this document CCS240/241
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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

Basic safety instructions CCS240/241
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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 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 chlorine dioxide 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.

CCS240/241 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 CCS240/241
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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
Chlorine dioxide levels are determined in accordance with the amperometric measuring
principle.
The chlorine dioxide (ClO2) 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 cause a current to flow which is proportional to the concentration of chlorine dioxide in
the medium. This process does not depend on the pH value over a wide range.
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
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.

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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 CCS240/241
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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/ccs240
www.endress.com/ccs241
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.