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
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 ......... 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
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

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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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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
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.

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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:
• Disinfection sensor (membrane-covered, ⌀25 mm) 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 CCS240/241
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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
 1 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
5
67
8
9
4
A0037976
 2 Example of a measuring system
1 Flowfit CCA250 flow assembly
2 Inlet to Flowfit CCA250 flow assembly
3 Proximity switch (optional)
4 PML pin
5 Chlorine dioxide sensor l CCS240
6 Procedure
7 Sampling tap
8 Measuring cable CPK9
9 Liquisys CCM223/253 transmitter

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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
 3 Releasing top part of protection cap by turning
2. Carefully remove protection cap from sensor.

A0037504
 4 Carefully remove protection cap

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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.

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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
 5 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

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1
2
3
4
5
6
BK
WH
GN
YE
BN
1
6
54
3
2
A0037112
 6 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
 7 VBC junction box with grounding option, specifications in mm (in)

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1
2
3
7.2 (0.28)
±0.1
A0037106
 8 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, 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?

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7 Commissioning
7.1 Function check
Prior to initial commissioning, ensure that:
• The sensor is correctly installed
• The electrical connection is correct.
• There is sufficient electrolyte in the membrane cap and the transmitter is not displaying a
warning about electrolyte depletion.
Please note the information on the safety data sheet to ensure safe use of the electrolyte.
LWARNING
Escaping process medium
Risk of injury from high pressure, high temperatures or chemical hazards
‣Before applying pressure to an assembly with cleaning system, ensure that the system has
been connected correctly.
‣Do not install the assembly in the process if you cannot reliably establish the correct
connection.
7.2 Sensor polarization
The voltage applied by the transmitter between cathode and anode polarizes the surface of
the working electrode. Therefore, after switching on the transmitter with the sensor
connected, you must wait until the polarization period has elapsed before starting calibration.
To achieve a stable display value, the sensor requires the following polarization periods:
Initial commissioning
CCS240
CCS241
30 minutes
90 minutes
Recommissioning
CCS240
CCS241
10 minutes
45 minutes
7.3 Sensor calibration
Reference measurement according to the DPD method
To calibrate the measuring system, carry out a colorimetric comparison measurement in
accordance with the DPD method for chlorine dioxide. Chlorine dioxide reacts with diethyl-p-
phenylendiamine (DPD) to form a red dye, the intensity of the red color being proportional to
the chlorine dioxide content.
Measure the intensity of the red color using a photometer, e.g. PF-3 (→  31). The
photometer indicates the chlorine dioxide content.
If the photometer used indicates the presence of chlorine, follow the manufacturer's
instructions to convert the chlorine content into the chlorine dioxide content.

Commissioning CCS240/241
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Requirements
The sensor reading is stable (no drifts or unsteady values for at least 5 minutes), and the
medium is stable. This is normally guaranteed once the following preconditions have been
met:
• The polarization period has elapsed.
• The flow is constant and within the correct range.
• The sensor and the medium are at the same temperature.
• The pH value is within the permitted range.
• Optional:
For zero point adjustment: electrolyte has been replaced.
Zero point adjustment
A zero point adjustment is not required due to the zero point stability of the membrane-
covered sensor.
However, a zero point adjustment can be performed if desired.
1. To perform a zero point adjustment, operate the sensor for at least 15 minutes in
chlorine-free water, using the assembly or protection cap as a vessel.
2. Alternatively, perform the zero point adjustment using the zero point gel
COY8→  31.
Slope calibration
Always perform a slope calibration in the following cases:
• After replacing membrane
• After replacing electrolyte
• After the membrane cap has been screwed back on
1. Ensure that the temperature of the medium is constant.
2. Take a representative sample for the DPD measurement. This must be done in close
proximity to the sensor. Use the sampling tap if available.
3. Determine the chlorine dioxide content using the DPD method.
4. Enter the measured value into the transmitter (see Operating Instructions for
transmitter).
5. To ensure greater accuracy, check the calibration several hours or 24 hours later using
the DPD method.