Endress+Hauser CCS50D User manual

Products Solutions Services
Operating Instructions
CCS50D
Digital sensor with Memosens technology for
determining chlorine dioxide
BA01773C/07/EN/02.19
71431040
2019-02-08

CCS50D 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 ................... 7
2.5 Product safety ....................... 7
3 Product description ............. 8
3.1 Product design ....................... 8
4 Incoming acceptance and
product identification ......... 13
4.1 Incoming acceptance ................ 13
4.2 Product identification ................ 13
5 Installation .................... 15
5.1 Installation conditions ............... 15
5.2 Mounting the sensor ................ 17
5.3 Post-installation check ............... 24
6 Electrical connection .......... 25
6.1 Connecting the sensor ............... 25
6.2 Ensuring the degree of protection ..... 25
6.3 Post-connection check ............... 26
7 Commissioning ................ 27
7.1 Function check ..................... 27
7.2 Sensor polarization .................. 27
7.3 Sensor calibration ................... 27
8 Diagnostics and
troubleshooting ............... 29
9 Maintenance .................. 31
9.1 Maintenance schedule ............... 31
9.2 Maintenance tasks .................. 32
10 Repair .......................... 39
10.1 Spare parts ........................ 39
10.2 Return ............................ 39
10.3 Disposal ........................... 39
11 Accessories .................... 40
11.1 Maintenance kit CCV05 .............. 40
11.2 Device-specific accessories ............ 40
12 Technical data ................. 41
12.1 Input .............................. 41
12.2 Performance characteristics .......... 43
12.3 Environment ....................... 44
12.4 Process ............................ 44
12.5 Mechanical construction ............. 45
13 Installation and operation in
hazardous environment Class
I Div. 2 .......................... 46
Index ................................. 48

About this document CCS50D
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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 CCS50D
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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.
2.2.1 Hazardous environment in accordance with cCSAus NI Cl. I, Div. 2 1)
1. The device must be installed in a housing or cabinet that can be accessed only by means
of a tool or key.
2. 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
1) Only if connected to CM44x(R)-CD*

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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.
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
European standards have been observed.

Product description CCS50D
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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 PVDF membrane and pressure relief valve
– Guarantees a defined and consistent electrolyte film between cathode and membrane
– With special support grid between cathode and membrane for a defined and consistent
electrolyte film and therefore a relatively constant reading at varying pressures and flows
• Sensor shaft with
– Large anode
– Cathode embedded in plastic
– Embedded temperature sensor
3
1
2
4
5
7
6
8
A0034227
 1 Sensor structure
1 Memosens plug-in head
2 Sensor shaft
3 Large anode, silver/silver chloride
4 Gold cathode
5 Grooves for installation adapter
6 Membrane cap with dirt-repellent
membrane
7 Pressure relief valve (elastic)
8 Sensor membrane
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

CCS50D Product description
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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
pH value
pH dependency
pH value Result
< 3.5 Chlorine is produced if chloride (Cl-) is present in the medium at the same time. The strong cross-sensitivity
to chlorine dioxide causes an increase in the measured value.
3.5 to 9 The pH value does not affect measurement of the chlorine dioxide concentration in the medium.
> 9 Chlorine dioxide is unstable and decomposes.
Flow
The minimum flow velocity of the membrane-covered measuring cell is 15 cm/s (0.5 ft/s).
• When using the Flowfit CCA151 flow assembly, this corresponds to a flow rate of
5 l/h (1.3 gal/h).
• 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 the height of the red bar mark).

Product description CCS50D
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80
90
100
relative slope / maximum slope in %
CCA151 flow gal/hr
CCA250 flow gal/hr
flow velocity at the membrane "/s
0 0.5 1 1.5 2 3
0 5 10 25 40
012 3 4 5 6
2.5
15 20 30 35
A0034487-EN
 2 Correlation between slope of electrode and flow velocity at the membrane/flow rate 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.
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.
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.

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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.
For detailed information on the use of external temperature sensors, see the Operating
Instructions for the transmitter.

Product description CCS50D
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Cross-sensitivities 2)
Free chlorine, ozone, free bromine
There were no cross-sensitivities for: H2O2, peracetic acid
2) The listed substances have been tested with different concentrations. An additive effect has not been
investigated.

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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/ccs50d
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, ⌀25 mm) with protection cap (ready for use)
• Bottle with electrolyte (50 ml (1.69 fl.oz)
• Replacement membrane cap in protection cap
• Operating Instructions
• Manufacturer inspection 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*

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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
A0034236
A Permitted orientation
B Incorrect orientation
5.1.2 Immersion depth
50 mm (1.97 in)

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5.1.3 Dimensions
161 (6.34)
82 (3.23)
102 (4.02)
126 (4.96)
!25
(0.98)
A0034238
 3 Dimensions in mm (in)

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5.2 Mounting the sensor
5.2.1 Measuring system
A complete measuring system comprises:
• Disinfection sensor CCS50D (membrane-covered, ⌀25 mm) with corresponding
installation adapter
• Flowfit CCA151 flow assembly
• Measuring cable CYK10, CYK20
• Transmitter , e.g. Liquiline CM44x or CM44xR
• Optional: extension cable CYK11
• Optional: proximity switch
• Optional: CPS31
• Optional: Flowfit CCA250 flow assembly (a pH/ORP sensor can additionally be installed
here)
• Optional: immersion assembly Flexdip CYA112

Installation CCS50D
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1
3
6
8
2
74
5
A0034241
 4 Example of a measuring system
1 Liquiline CM44x transmitter
2 Power cable for transmitter
3 Disinfection sensor CCS50D (membrane-covered, ⌀25 mm)
4 Outlet from Flowfit CCA151 flow assembly
5 Inlet to Flowfit CCA151 flow assembly
6 Flowfit CCA151 flow assembly
7 Union nut for installing a disinfection sensor in the Flowfit CCA151 flow assembly
8 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.

A0034263
 5 Releasing top part of protection cap by turning
2. Carefully remove protection cap from sensor.

A0034350
 6 Carefully remove protection cap

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5.2.3 Installing sensor in CCA151 assembly
The disinfection sensor (membrane-covered, ⌀25 mm) is designed for installation in the
Flowfit CCA151 flow assembly.
Please note the following during installation:
‣The flow rate must be at least 5 l/h (1.3 gal/h).
‣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.
‣Avoid negative pressure at the sensor, e.g. due to medium being returned to the suction
side of a pump.
‣To avoid buildup, heavily contaminated water should also be filtered.
Preparing assembly
1. The assembly is supplied to the customer with a union nut screwed onto the assembly:
unscrew union nut from assembly.

1
A0034262
 7 Flowfit CCA151 flow assembly
1 Union nut
2. The assembly is supplied to the customer with a dummy plug inserted in the assembly:
remove dummy plug from assembly.