Endress+Hauser Oxymax COS22 Series User manual

BA446C/07/EN/01.11
71098071
Operating Instructions
Oxymax COS22
Dissolved oxygen sensor

Notes for using this manual
Warning instructions and their meaning
The structure, signal words and safety colors of the signs comply with the specifications of ANSI Z535.6
("Product safety information in product manuals, instructions and other collateral materials").
Cross reference symbols
Safety message structure Meaning
DANGER
!
Cause (/consequences)
Consequences if safety
message is not heeded
►Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the situation will result in a fatal or serious injury.
WARNING
!
Cause (/consequences)
Consequences if safety
message is not heeded
►Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the situation can result in a fatal or serious injury.
CAUTION
!
Cause (/consequences)
Consequences if safety
message is not heeded
►Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid this situation can result in minor or medium injury.
NOTICE
Cause/situation
Consequences if safety
message is not heeded
►Action/note
This symbol alerts you to situations that can result in damage to
property and equipment.
È ä 1 This symbol indicates a cross reference to a defined page (e.g. p. 1).
È å 2 This symbol indicates a cross reference to a defined figure (e.g. fig. 2).

Endress+Hauser
Table of contents
1 Safety instructions . . . . . . . . . . 4
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning and operation . 4
1.3 Operational safety . . . . . . . . . . . . . . . . . . . 5
1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Identification . . . . . . . . . . . . . . 6
2.1 Order code . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . 6
2.3 Certificates and approvals . . . . . . . . . . . . . . 6
3 Installation . . . . . . . . . . . . . . . . 7
3.1 Incoming acceptance, transport, storage . . . 7
3.2 Installation conditions . . . . . . . . . . . . . . . . 7
3.3 Installation instructions . . . . . . . . . . . . . . . 8
3.4 Installation examples . . . . . . . . . . . . . . . . 10
3.5 Post-installation check . . . . . . . . . . . . . . . 12
4 Wiring . . . . . . . . . . . . . . . . . . 13
4.1 Connection to the transmitter . . . . . . . . . 13
4.2 Post-connection check . . . . . . . . . . . . . . . 13
5 Function . . . . . . . . . . . . . . . . . 14
5.1 Measuring principle . . . . . . . . . . . . . . . . . 14
5.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Commissioning. . . . . . . . . . . . 18
6.1 Function check . . . . . . . . . . . . . . . . . . . . 18
6.2 Polarization . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 19
7 Maintenance. . . . . . . . . . . . . . 20
7.1 Maintenance tasks . . . . . . . . . . . . . . . . . . 20
7.2 Maintenance intervals . . . . . . . . . . . . . . . 20
7.3 Cleaning the sensor . . . . . . . . . . . . . . . . . 21
7.4 Wear parts and consumables . . . . . . . . . . 21
8 Accessories. . . . . . . . . . . . . . . 25
8.1 Connection accessories . . . . . . . . . . . . . . 25
8.2 Installation accessories . . . . . . . . . . . . . . . 25
9 Trouble-shooting. . . . . . . . . . . 26
9.1 Trouble-shooting instructions . . . . . . . . . . 26
9.2 Spare parts and consumable material . . . . . 27
9.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10 Technical data . . . . . . . . . . . . . 28
10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.2 Performance characteristics . . . . . . . . . . . . 28
10.3 Environment . . . . . . . . . . . . . . . . . . . . . . 29
10.4 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.5 Mechanical construction . . . . . . . . . . . . . . 31
Index. . . . . . . . . . . . . . . . . . . . 33

Safety instructions
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1 Safety instructions
1.1 Designated use
The oxygen sensor is suitable for continuous measurement of dissolved oxygen in water.
The specific suitability depends on the sensor design:
• COS22-1 (standard, measuring range 0.01 to 60 mg/l)
– Measuring, monitoring and regulating the oxygen content in fermenters
– Monitoring the oxygen content in biotechnology facilities
• COS22-3 (trace measurement, measuring range 0.001 to 10 mg/l, preferred operational range
0.001 to 2 mg/l), also suitable for high CO2partial pressure
– Monitoring inertization equipment in the food industry
– Monitoring the residual oxygen content in carbonated fluids of the beverage industry
– Trace measurement in industrial applications such as inertizations
– Monitoring the residual oxygen content in boiler feedwater
– Monitoring, measuring and regulating the oxygen content in chemical processes
NOTICE
Molecular hydrogen
Hydrogen causes sensitivity in other substances and leads to false low readings or, at the worst, total
failure of the sensor.
►Do not use the sensor in media containing hydrogen.
Any other use than the one described here compromises the safety of persons and the entire measuring
system and is not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.
1.2 Installation, commissioning and operation
Please note the following items:
• Installation, commissioning, operation and maintenance of the measuring system must only be
carried out by trained technical personnel.
Trained personnel must be authorized for the specified activities by the system operator.
• Electrical connection must only be carried out by a certified electrician.
• Technical personnel must have read and understood these Operating Instructions and must adhere
to them.
• Before commissioning the entire measuring point, check all the connections. Ensure that electrical
cables and hose connections are not damaged.
• Do not operate damaged products and secure them against unintentional commissioning. Mark the
damaged product as being defective.
• Measuring point faults may only be rectified by authorized and specially trained personnel.
• If faults can not be rectified, the products must be taken out of service and secured against
unintentional commissioning.
• Repairs not described in these Operating Instructions may only be carried out at the manufacturer’s
or by the service organization.

Safety instructions
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1.3 Operational safety
The sensor has been designed and tested according to the state of the art and left the factory in perfect
functioning order.
Relevant regulations and European standards have been met.
As the user, you are responsible for complying with the following safety conditions:
• Installation instructions
• Local prevailing standards and regulations.
1.4 Return
If the sensor has to be repaired, please return it cleaned to the sales center responsible.
Please use the original packaging, if possible.
Before returning the device, please clarify all formalities - such as obtaining an identification number -
with your sales center.
Please enclose the completed "Declaration of Hazardous Material and De-Contamination" (copy the
second last page of these Operating Instructions) with the packaging and the transportation documents.
No repair without completed declaration!

Identification
6Endress+Hauser
2 Identification
2.1 Order code
To find out the version of your device, enter the order code indicated on the nameplate in the
search screen at the following address: www.products.endress.com/order-ident
2.2 Scope of delivery
The following items are included in the delivery:
• Oxygen sensor with tap water filled cap for membrane protection
• Electrolyte, 1 bottle, 10 ml (0.34 fl.oz.)
• Brief Operating Instructions
• Operating Instructions on CD
If you have any questions, please contact your supplier or your local sales center.
2.3 Certificates and approvals
The manufacturer declares the FDA compliance of the materials used.
Ask your local sales center for the certificates.
Product FDA certificate for
COS22-****22 Membrane, O-rings, process sealing
COS22Z-*2*2 Membrane, O-rings, process sealing
COS22-****23 Membrane, O-rings
COS22Z-*2*3 Membrane, O-rings

Installation
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3 Installation
3.1 Incoming acceptance, transport, storage
• Make sure the packaging is undamaged!
Inform the supplier about any damage to the packaging.
Keep the damaged packaging until the matter has been settled.
• Make sure the contents are undamaged!
Inform the supplier about damage to the contents. Keep the damaged products until the matter has
been settled.
• Check that the order is complete and agrees with your shipping documents.
• The packaging material used to store or to transport the product must provide shock protection and
humidity protection. The original packaging offers the best protection. Also, keep to the approved
ambient conditions (see "Technical data").
• If you have any questions, please contact your supplier or your local sales center.
3.2 Installation conditions
3.2.1 Angle of installation
The sensor must be installed with an inclination angle of at least 10 ˚to the horizontal in an assembly,
support or a corresponding process connection. Other inclination angles are not permitted. Do not
install the sensor overhead.
Observe the instructions for installing sensors in the Operating Instructions for the assembly used.
a0005584-en
Fig. 1: Permitted angle of installation
10° 10° Not permissible!
Not permissible!
Permissible angle of installation

Installation
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3.2.2 Mounting location
• Select the installation location so that there is easy access for later calibration.
• Make sure that upright posts and assemblies are secured safely and vibration-free.
• Select an installation location which produces a typical oxygen concentration.
3.3 Installation instructions
3.3.1 Measuring system
A complete measuring system comprises:
• A digital oxygen sensor Oxymax COS22
• A transmitter, e.g. Liquisys COM223/253F
• An appropriate measuring cable, e.g. COK21
• Optional: an assembly, e.g. fixed installation assembly CPA442, flow assembly CPA240 or retractable
assembly CPA475
a0006653
Fig. 2: Example of a measuring system with COS22
1 Oxygen sensor COS22
2 Retractable assembly CPA475
3 Measuring cable COK21
4 Transmitter Liquisys COM253F
1
2
3
4
CAL REL
REL1
REL1
ALARM
REL2
REL2
E

Installation
Endress+Hauser 9
3.3.2 Installing a measuring point
WARNING
!
Electrical voltage
In the event of a fault, non-grounded metallic assemblies may be under voltage and then are not
touchable.
►When using metallic assemblies and installation equipment, observe the national grounding
provisions.
For a complete installation of a measuring point, proceed as follows:
1. Install a retractable or a flow assembly (if used) into the process.
2. Connect the water supply to the rinse connections (if you use an assembly with cleaning function).
3. Install and connect the oxygen sensor.
NOTICE
Installation errors
Cable breakage, loss of the sensor, unintended unscrewing of the membrane cap
►Do not install the sensor suspended from the cable.
►Screw the sensor into the assembly so that the cable is not twisted.
►Mounting or dismounting the sensor: hold the sensor body, only turn the threaded plug-in head
while screwing the sensor in or out of the assembly. Otherwise you could unscrew the sensor’s
membrane cap. It will remain in the assembly resp. in the process then.
►Avoid exerting excessive tensile force on the cable (e.g. from jerky pulling).
►Select the installation location so that there is easy access for later calibration.

Installation
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3.4 Installation examples
3.4.1 Fixed installation (CPA442)
The CPA442 fixed installation assembly allows a sensor to be easily adapted to almost any process
connections from Ingold nozzles to Varivent or Triclamp connections.
This type of installation is very suitable for tanks and larger pipes. The sensor achieves a defined
immersion depth in the medium in an easy manner.
3.4.2 Flow assembly
CPA240
The CPA240 flow assembly offers up to three installation slots for sensors with a shaft diameter of 12
mm (0.47"), a shaft length of 120 mm (4.72") and a process connection Pg 13.5.
It is very suitable for use in pipes or at hose connections.
During trace measurement in particular, ensure the assembly is completely vented to avoid measuring
errors.
a0005720
Fig. 3: CPA240 flow assembly with protective hood
a0005721
Fig. 4: Bypass installation
1 Main line
2Mediumremoval
3, 6 Manually actuated or solenoid valves
4 Sampling
5 Flow assembly with installed sensor
7 Medium return