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/13.15
71290810

Chloromax CCS142D Table of contents
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Table of contents
1 Document information ......... 4
1.1 Warnings ........................... 4
1.2 Symbols ............................ 4
2 Basic safety instructions ....... 5
2.1 Requirements for personnel ........... 5
2.2 Designated use ...................... 5
2.3 Workplace safety .................... 5
2.4 Operational safety ................... 6
2.5 Product safety ....................... 6
3 Device description, function ... 6
3.1 Measuring principle .................. 6
3.2 Effects on the measuring signal ........ 7
3.3 Sensor design ....................... 9
4 Incoming acceptance and
product identification ......... 11
4.1 Incoming acceptance ................ 11
4.2 Product identification ................ 11
4.3 Scope of delivery .................... 12
4.4 Certificates and approvals ............ 12
5 Installation .................... 13
5.1 Installation conditions ............... 13
5.2 Installing the sensor ................. 15
5.3 Post-installation check ............... 16
6 Electrical connection .......... 17
6.1 Connecting the sensor ............... 17
6.2 Ensuring the degree of protection ..... 17
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 interval ................ 23
9.2 Clean sensor ....................... 23
9.3 Replacing the membrane ............. 24
9.4 Refilling the electrolyte .............. 24
9.5 Storing the sensor ...................25
9.6 Regenerating the sensor ............. 25
9.7 Reconditioning the sensor ............ 26
10 Accessories .................... 28
10.1 Connection accessories .............. 28
10.2 Installation accessories .............. 28
10.3 Accessories for maintenance and
calibration ......................... 28
11 Repairs ......................... 29
11.1 Return ............................ 29
11.2 Disposal ........................... 29
12 Technical data ................. 29
13 Installation and operation in
hazardous environment Class
I Div. 2 .......................... 32
Index ................................. 34

Document information Chloromax CCS142D
4 Endress+Hauser
1 Document information
1.1 Warnings
Structure of information Meaning
LDANGER
Causes (/consequences)
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)
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)
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
Consequences of non-compliance (if
applicable)
‣Action/note
This symbol alerts you to situations which may result in damage to property.
1.2 Symbols
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 Basic safety instructions
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2 Basic safety instructions
2.1 Requirements for 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
2.2.1 General
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. If the
concentrations in the water are too low, this could jeopardize the effectiveness of the
disinfection process. 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 free chlorine in water. In conjunction with measuring and control equipment,
it allows optimum control of the disinfection process.
2.2.2 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.
2.2.3 Non-designated use
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
1) only if connected to CM444R-EA* or CM448R-EA*

Device description, function Chloromax CCS142D
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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
1. Before commissioning the entire measuring point, verify that all connections are
correct. Ensure that electrical cables and hose connections are undamaged.
2. Do not operate damaged products, and safeguard them to ensure that they are not
operated inadvertently. Label the damaged product as defective.
3. If faults cannot be rectified:
Take the products out of operation and safeguard them to ensure that they are not
operated inadvertently.
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 Device description, function
3.1 Measuring principle
Free chlorine is determined as hypochlorous acid according to the amperometric measuring
principle.
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.

Chloromax CCS142D Device description, function
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3.2 Effects on the measuring signal
3.2.1 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
effective chlorine change with the pH value. For example, if the amount 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
B
C
pH
OCl-
HOCl
A0002017
 1 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.

Device description, function Chloromax CCS142D
8 Endress+Hauser
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
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 up to a
pH value of the medium of 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

Chloromax CCS142D Device description, function
Endress+Hauser 9
Above these pH values, the total error of the measuring system is unacceptably high.
3.2.2 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 value 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. If an INS
proximity switch is installed in the assembly, this unpermitted operating status can be reliably
detected. This triggers an alarm or, if necessary, results in the dosing process being switched
off.
3.2.3 Temperature
Changes in the medium temperature also influence the measuring signal. An increase in
temperature causes the measured value to increase (approx. 4 % per K), while a reduction in
temperature causes the measured value to decrease. Therefore, the temperature should
remain constant after calibration. If the temperature has changed, a recalibration must be
performed.
The Chloromax CCS142D, when used 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.
3.3 Sensor design
The sensor consists of the following function units:
• Measuring chamber
– to protect the anode and cathode from the medium
– with 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

Device description, function Chloromax CCS142D
10 Endress+Hauser
3
4
5
6
7
1
2
A0026479
 2 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

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 your supplier of any damage to the packaging.
Keep the damaged packaging until the matter has been settled.
2. Verify that the contents are undamaged.
 Notify your supplier of any damage to the delivery contents.
Keep the damaged products until the matter has been settled.
3. Check the delivery for completeness.
 Check it against the delivery papers and 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.
The permitted ambient conditions must be observed (see "Technical data").
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
• Ambient and process conditions
• Safety information and warnings
• Ex labeling on hazardous area versions
Compare the data on the nameplate with your order.
4.2.2 Product identification
Product page
www.endress.com/ccs142d
Interpreting the order code
The order code and serial number of your device can be found in the following locations:
• On the nameplate
• In the delivery papers
Obtaining information on the device
1. Go to the product page for your device on the internet.

Incoming acceptance and product identification Chloromax CCS142D
12 Endress+Hauser
2. In the navigation area on the right-hand side, select "Check your device features" under
"Device support".
 An additional window opens.
3. Enter the order code from the nameplate into the search field.
 You will receive information on each feature (selected option) of the order code.
4.3 Scope of delivery
The scope of delivery comprises:
• Chlorine sensor
• Bottle containing electrolyte (50 ml)
• Replacement cartridge with pretensioned membrane
• Operating Instructions
4.4 Certificates and approvals
4.4.1 -mark
Declaration of Conformity
The product meets the requirements of the harmonized European standards. As such, it
complies with the legal specifications of the EC directives. The manufacturer confirms
successful testing of the product by affixing to it the  mark.
4.4.2 Ex approvals 2)
cETLus NI Cl. I, Div. 2
• Conforms with UL STD 61010-1, ANSI/ISA STD 12.12.01, FM STD 3600 and FM STD 3611
• Certified according 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*

Chloromax CCS142D Installation
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5 Installation
5.1 Installation conditions
5.1.1 Orientation
Do not install overhead!
‣Install the sensor with an angle of inclination of at least 15 °to the horizontal in an
assembly, support or suitable process connection.
‣Other angles of inclination are not permitted.
‣Observe the instructions for installing sensors in the Operating Instructions for the
assembly used.
15° 15°
B
A
A0026480
A Permitted orientation
B Forbidden orientation

Installation Chloromax CCS142D
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5.1.2 Dimensions
Ø25 (0.98)
7.5 (0.30)
Ø 31 (1.22)
91.5 (3.60)
148 (5.83)
NPT 3/4"
A0007386
 3 Dimensions in mm (inch)

Chloromax CCS142D Installation
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5.2 Installing 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 CPS31D
1
3
5
7
2
6
4
A0007341
 4 Example of a measuring system
1 Liquiline CM44x transmitter
2 Power cable for transmitter
3 Chlorine sensor CCS142D
4 Flowfit assembly CCA250
5 Inlet to assembly (outlet on rear, not shown in graphic)
6 pH sensor CPS71D
7 Measuring cable CYK10

Installation Chloromax CCS142D
16 Endress+Hauser
5.2.2 Installation in CCA250 flow assembly
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 regulates the flow 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 Installation 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 Installation in CYA112 immersion assembly
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?
 Install the sensor only in an assembly or directly via the process connection.

Chloromax CCS142D Electrical connection
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6 Electrical connection
LWARNING
Device is live
Incorrect connection may result in injury or death.
‣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 of the sensor to the transmitter is performed using the 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) which are loose or insufficiently secured.

Electrical connection Chloromax CCS142D
18 Endress+Hauser
6.3 Post-connection check
Device condition and specifications Notes
Are the outside of the sensor, assembly, junction box, 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)
Are all the screws terminals properly tightened? Tighten
Are all the cable entries installed, tightened and sealed? In the case of lateral cable entries: Cable loops
facing downwards to allow water to drip off.
Are all cable entries facing downwards or mounted laterally?

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Endress+Hauser 19
7 Commissioning
7.1 Function check
Before first commissioning, check if:
• the sensor is correctly installed
• the electrical connection is correct.
If using an assembly with automatic cleaning, check that the cleaning medium (e.g. water or
air) is connected correctly.
LWARNING
Escaping process medium
Risk of injury from high pressure, high temperatures or chemical hazards
‣Before applying compressed air to an assembly with cleaning facility, make sure the
connections are correctly fitted.
‣Do not install the assembly in the process if you cannot make the correct connection
reliably.
7.2 Sensor polarization
The voltage applied between cathode and anode by the transmitter polarizes the surface of
the working electrode. Therefore, after switching on the transmitter with the senor
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:
First commissioning
CCS142D-A:
CCS142D-G:
60 min.
90 min.
Recommissioning
CCS142D-A:
CCS142D-G:
30 min.
45 min.
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. Chlorine reacts with diethyl-p-phenylendiamine (DPD)
producing a red dye, the intensity of the red color being proportional to the chlorine content.
The intensity of the red color is measured by a photometer (e.g. CCM182) and displayed as
chlorine content.

Commissioning Chloromax CCS142D
20 Endress+Hauser
Prerequisites
The sensor reading is stable (no drifts or unsteady values for at least 5 minutes). 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.
Zero point adjustment
A zero point adjustment is not required due to the zero point stability of the membrane-
covered sensor.
However, if you wish to do so, you may perform a zero point adjustment by operating the
sensor in chlorine-free water for at least 15 min..
Slope calibration
1. Ensure that the pH value and temperature of the medium are constant.
2. Take a sample for DPD measurement. This must be done in close proximity to the
sensor. Use the sampling tap if available.
3. Determine the chlorine content using the DPD method.
4. Enter the measured value into the transmitter (see Operating Instructions for
transmitter).
5. Using the DPD method, check the calibration several hours or 24 hours later.
You must carry out a slope calibration every time the electrolyte or membrane is
changed!