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
Endress+Hauser 3
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

Chloromax CCS142D Document information
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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*

Chloromax CCS142D Basic safety instructions
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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
10 Endress+Hauser
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

Chloromax CCS142D Product description
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sensor's measuring signal that corresponds to hypochlorous acid (HOCl) and by taking into
account the pH value in the range of pH 4 to 9. For this calculation, the curve is stored in the
transmitter.
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 that is displayed and applied to
the device output corresponds to the DPD measured value even if the pH values fluctuate. If
you do not use pH compensation, the measured chlorine value corresponds to the DPD
measurement only if the pH value remains unchanged compared with the calibration.
Without pH compensation, the chlorine measuring system must be recalibrated when the pH
value changes.
Accuracy of pH compensation
The accuracy of the pH-compensated measured chlorine value is derived from the sum of
several individual deviations (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
The reference measurement (DPD method, photometer) determines the total free chlorine by
buffering to pH 6.3. 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 hardly
any 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 the actual value of the
free chlorine. Calibration of the complete measuring system makes sense only if the medium
has a pH value up to 8 or 8.2.
Sensor pH value HOCl content Uncompensated value Compensated value
CCS142D-G 8.2 15 % 12 nA 80 nA
CCS142D-A 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 sensor is 15 cm/s (0.5 ft/s).
When using the CCA250 flow assembly, this corresponds to a flow rate of 30 l/h (8 gal/h)
(upper edge of float at level of red bar mark).
At higher flow rates, the measuring signal is virtually flow-independent. However, if the flow
rate falls below the specified value, the measuring signal depends on the flow.

Product description Chloromax CCS142D
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The installation of an INS proximity switch in the assembly enables reliable detection of this
prohibited operating status, thus triggering an alarm or causing the dosing process to be
switched off if necessary.
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 conjunction with the Liquiline enables automatic temperature
compensation (ATC). In this case, the temperature does not need to remain constant, and a
recalibration in the event of temperature changes is not required.
1. If automatic temperature compensation is disabled at the transmitter, maintain the
temperature following calibration at a constant level.
2. Otherwise, recalibrate the sensor.

Chloromax CCS142D Incoming acceptance and product identification
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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
• Ex labeling on hazardous area versions
‣Compare the information on the nameplate with the order.
4.2.2 Product page
www.endress.com/ccs142d
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. Open the product website.
2. At the top of the page, select the link Services.
 An additional sidebar opens up.

Incoming acceptance and product identification Chloromax CCS142D
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3. Select Online Tools followed by Access device specific information.
 An additional window opens.
4. Enter the order code from the nameplate into the search field. Then select Show
details.
 Details of each feature (selected option) of the order code are displayed.
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
• Bottle of electrolyte (50 ml (1.69 fl.oz))
• Replacement cartridge with pretensioned membrane
• Operating Instructions
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.

Chloromax CCS142D Incoming acceptance and product identification
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Ex approvals 2)
cETLus NI Cl. I, Div. 2
• Conforms to UL STD 61010-1, ANSI/ISA STD 12.12.01, FM STD 3600 and FM STD 3611
• Certified to CSA STD C22.2 NO. 61010-1 and CSA STD C22.2 NO. 213
• ETL control number: 5000765
• Control drawing: 403936
2) Only if connected to CM444R-EA* or CM448R-EA*

Installation Chloromax CCS142D
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5 Installation
5.1 Installation conditions
5.1.1 Installation position
Do not install overhead!
‣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 for the
assembly being used.
15° 15°
B
A
A0026480
A Permitted orientation
B Forbidden orientation

Chloromax CCS142D Installation
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5.1.2 Dimensions
!25
(0.98)
7.5 (0.30)
!31 (1.22)
91.5 (3.60)
148 (5.83)
NPT ¾"
A0007386
 3 Dimensions in mm (in)

Installation Chloromax CCS142D
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5.2 Mounting the sensor
5.2.1 Measuring system
A complete measuring system comprises:
• Chloromax CCS142D chlorine sensor
• Assembly, e. g. Flowfit CCA250
• Measuring cable CYK10
• Transmitter, e. g. Liquiline CM44x or CM44xR
• Optional:
– Extension cable CYK11
– When using assembly CCA250: additional sensor(s), e. g. pH sensor CPS71D
1
3
5
7
2
6
4
A0007341
 4 Example of a measuring system
1 Transmitter Liquiline CM44x
2 Power cable for transmitter
3 Chlorine sensor CCS142D
4 Flowfit CCA250 assembly
5 Inlet to assembly (outlet on rear, not shown in graphic)
6 pH sensor CPS71D
7 Measuring cable CYK10

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5.2.2 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 30 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 fed back into an overflow basin, pipe or similar, the resulting
counterpressure on the sensor may 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.
Additional installation instructions can be found in the Operating Instructions for the
assembly.
5.2.3 Installing sensor in other flow assemblies
When using other flow assemblies, please ensure the following:
‣The flow velocity against the membrane is always at least 15 cm/s (0.49 ft/s).
‣The flow direction is upwards so that transported air bubbles are removed and do not
collect in front of the membrane.
‣The membrane is struck directly by the flow.
5.2.4 Installing sensor in immersion assembly CYA112
Alternatively, the sensor can be installed in an immersion assembly with threaded connection
NPT ¾", e. g. CYA112.
Please note the following during installation:
‣Hold the sensor securely in position and screw the assembly onto the sensor so that it is
handtight. This prevents the cable from twisting and rupturing.
‣To improve the sealing effect, we recommend you wrap a thin PTFE tape around the thread
for assemblies with an NPT ¾" thread.
Additional installation instructions can be found in the Operating Instructions for the
assembly.
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.

Electrical connection Chloromax CCS142D
20 Endress+Hauser
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.
6.1 Connecting the sensor
The electrical connection simulator to the transmitter is established using measuring cable
CYK10.
GN/YE
YE
GN
BN
WH
GND
+
–
Com A
Com B
GY
A0024019
 5 Measuring cable CYK10
‣To extend the cable, use measuring cable CYK11. The maximum cable length is 100 m
(328 ft).
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 outside of the sensor, assembly, cable undamaged? Visual inspection
Electrical connection Notes
Are the installed cables strain-relieved and not twisted?
Is a sufficient length of the cable cores stripped, and is it positioned
in the terminal correctly?
Check the fit (by pulling gently)