Endress+Hauser Chloromax CCS142D User manual

Products Solutions Services
Operating Instructions
Chloromax CCS142D
Digital sensor with Memosens technology for
determining free chlorine
BA00419C/07/EN/15.17
71378188
AUTHORIZED DISTRIBUTOR:
InstrumentsAndControl.com
Houston, Texas USA
[email protected]
281-609-7170

Chloromax CCS142D Table of contents
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Table of contents
1 Document information ......... 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 Occupational 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 .................... 16
5.1 Installation conditions ............... 16
5.2 Mounting the sensor ................ 18
5.3 Post-installation check ............... 19
6 Electrical connection .......... 20
6.1 Connecting the sensor ............... 20
6.2 Ensuring the degree of protection ..... 20
6.3 Post-connection check ............... 20
7 Commissioning ................ 22
7.1 Function check ..................... 22
7.2 Sensor polarization .................. 22
7.3 Calibrating the sensor ............... 22
8 Diagnostics and
troubleshooting ............... 24
9 Maintenance .................. 26
9.1 Maintenance schedule ............... 26
9.2 Maintenance tasks .................. 26
10 Repair .......................... 31
10.1 Spare parts ........................ 31
10.2 Return ............................ 31
10.3 Disposal ........................... 31
11 Accessories .................... 32
11.1 Device-specific accessories ............ 32
12 Technical data ................. 33
13 Installation and operation in
hazardous environment Class
I Div. 2 .......................... 36
Index ................................. 38

Document information Chloromax CCS142D
4 Endress+Hauser
1 Document information
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 Chloromax CCS142D
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 involved must be adapted to continuously fluctuating operating conditions. Too low
concentrations in the water could jeopardize the effectiveness of the disinfection process. Too
high concentrations can lead to signs of corrosion and have an adverse effect on taste, 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 optimum control of the disinfection process.
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 cETLus NI Cl. I, Div. 2 1)
‣Please note the control drawing and the specified application conditions in the appendix of
these Operating Instructions and follow the instructions.
2.3 Occupational 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 CM444R-EA* or CM448R-EA*

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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 electrostatically safe.
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 Chloromax CCS142D
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3 Product description
3.1 Product design
The sensor consists of the following function 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
– Temperature sensor
• Membrane cap with
– Robust PTFE membrane
– Special support grid between cathode and membrane for a specified and constant
electrolyte film and thus a relatively constant indication even at varying pressures and
flows
3
4
5
6
7
1
2
A0026479
 1 Sensor structure
1 Memosens plug-in head
2 O-ring
3 Large anode, silver/silver chloride
4 Gold cathode
5 Measuring chamber
6 Membrane cap with dirt-repellent membrane
7 Screw cap for securing the membrane cap
3.1.1 Measuring principle
Free chlorine is determined as hypochlorous acid according to the amperometric measuring
principle.

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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 in proportion to the concentration of free
chlorine in the medium at constant conditions.
The concentration of hypochlorous acid depends on the pH value. This dependency can be
compensated for by measuring the pH value in the flow assembly.
The transmitter uses the current signal to calculate the measured variable for concentration in
mg/l.
3.1.2 Effects on the measuring 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.
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

Product description Chloromax CCS142D
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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.
%
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
 2 Principle of pH compensation
A Measured value with pH compensation
B Measured value without pH compensation
C pH compensation
For amperometric measurement using the CCS142D chlorine sensor, only the amount of
hypochlorous acid is selectively measured. This works as a powerful disinfectant in a watery
solution. In contrast to this, hypochlorite is an extremely weak disinfectant. Therefore, when
used as a disinfectant at higher pH values, the effectiveness of chlorine is limited. As
hypochlorite ions cannot permeate the sensor membrane, the sensors do not record this
value.
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. With the DPD method, the sample is buffered to a pH value of approx.
6.3. Therefore, the pH value of the sample is not included in the DPD measurement. Due to
the buffer function in the DPD method, all components of free effective chlorine are recorded
and thus the total free chlorine is measured.
If pH compensation is switched on in the transmitter, the sum of hypochlorous acid (HOCl)
and hypochlorite corresponding to the DPD measurement is calculated from the chlorine