Endress+Hauser Oxymax COS22D Technical specifications

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Brief Operating Instructions
Oxymax COS22D,
Oxymax COS22
Sensor for measuring dissolved oxygen
0
These instructions are Brief Operating Instructions; they are
not a substitute for the Operating Instructions pertaining to
the device.
Detailed information on the device can be found in the
Operating Instructions and in the other documentation
available at:
• www.endress.com/device-viewer
• Smart phone/tablet: Endress+Hauser Operations App
KA00446C/07/EN/07.19
71436872
2019-03-31

Oxymax COS22D, Oxymax COS22
2 Endress+Hauser
TAG No.: XXX000
Ser. No.: X000X000000
Order code 00X00-XXXX0XX0XXX
www.endress.com/deviceviewer Endress+Hauser Operations App
Serial number
A0023555

Oxymax COS22D, Oxymax COS22
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Table of contents Oxymax COS22D, Oxymax COS22
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Table of contents
1 About this document .............................................................. 5
1.1 Warnings ............................................................................ 5
1.2 Symbols ............................................................................. 5
2 Basic safety instructions .......................................................... 6
2.1 Requirements for the personnel ............................................................ 6
2.2 Designated use ........................................................................ 6
2.3 Workplace safety ...................................................................... 7
2.4 Operational safety ......................................................................7
2.5 Product safety ......................................................................... 7
3 Certificates and approvals ....................................................... 10
3.1 Declaration of Conformity ............................................................... 10
3.2 Ex approvals ......................................................................... 10
3.3 Certification body ..................................................................... 10
3.4 Material certificates ................................................................... 11
3.5 EHEDG ............................................................................. 11
4 Installation ...................................................................... 12
4.1 Installation conditions .................................................................. 12
4.2 Mounting the sensor ................................................................... 13
4.3 Post-installation check ................................................................. 13
5 Electrical connection ............................................................ 14
5.1 Quick wiring guide (COS22D-BA/NA only) ...................................................14
5.2 Connecting the sensor (COS22D) .......................................................... 15
5.3 Connecting the sensor (COS22) ........................................................... 15
5.4 Ensuring the degree of protection ......................................................... 16
5.5 Post-connection check ..................................................................16
6 Commissioning .................................................................. 17
6.1 Function check ....................................................................... 17
6.2 Sensor polarization .................................................................... 17
6.3 Sensor calibration ..................................................................... 19

Oxymax COS22D, Oxymax COS22 About this document
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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
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

Basic safety instructions Oxymax COS22D, Oxymax COS22
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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.
• Faults at the measuring point may only be rectified 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
The sensor is designed for the continuous measurement of dissolved oxygen in water.
The specific suitability depends on the sensor version:
• COS22-**1***** (standard, measuring range 0.01 to 60 mg/l)
COS22D-**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 CO2 partial pressure
COS22D-**3/4***** (trace measurement, measuring range 0.001 to 10 mg/l, preferred
operational range 0.001 to 2 mg/l), also suitable for high CO2 partial 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.
‣Only use the COS22-**1/3***** or COS22D-**1/3***** sensor in media free of
hydrogen.
‣Use the COS22D-**4***** sensor in media containing hydrogen.
For non-contact digital data transmission, the COS22D sensor must be connected to the
digital input of the Liquiline transmitter using the CYK10 measuring cable.
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.

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2.3 Workplace safety
As the user, you are responsible for complying with the following safety conditions:
• Installation guidelines
• Local standards and regulations
• Regulations for explosion protection
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.
NOTICE
Non-designated use
Incorrect measurements, malfunctions and even measuring point failure could result
‣Only use the product in accordance with the product specifications.
‣Pay particular attention to the technical data on the nameplate.
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.
2.5.1 State of the art
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.

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2.5.2 Electrical equipment in hazardous areas
For all approvals
• To avoid incendive sparking, you must install the titanium hazardous area versions
COS22D-BA***D*3, COS22D-GC***D*3, COS22D-8A***D*3, COS22D-TA***D*3 and
COS22D-NA***D*3 in such a way that they are protected against impact and friction.
• When transporting, installing and performing maintenance in the hazardous area, you
must also avoid sparks resulting from impact and friction on the sensor shaft or membrane
body.
• The use of these versions in liquid media with solid particles must be avoided.
ATEX II 1G / IECEx Ex ia IIC T3/T4/T6 Ga
The Memosens inductive sensor cable connection system, consisting of:
• oxygen sensor Oxymax COS22D-BA*****3 and
• measuring cable CYK10-G***
is suitable for use in hazardous areas according to type examination certificate BVS 04 ATEX E
121 X. The corresponding EU Declaration of Conformity is part of this document.
• The certified Oxymax COS22D-BA*****3 oxygen sensor, in conjunction with the CYK10-
G*** measuring cable, may be connected only to certified, intrinsically safe, digital sensor
circuits of the Liquiline M CM42-OE/F/I********* transmitter. The electrical connection
must be made according to the wiring diagram.
• Oxygen sensors for use in the Ex area have a special conductive O-ring. The electrical
connection of the metallic sensor shaft to the conductive mounting location (such as a
metallic assembly) takes place via the O-ring.
• You must connect the assembly or the installation location to ground according to the Ex
guidelines.
• The sensors must not be operated under electrostatically critical process conditions. Avoid
strong steam or dust currents that act directly on the connection system.
• Hazardous area versions of digital sensors with Memosens technology are indicated by a
red-orange ring in the plug-in head.
• The maximum permitted cable length between the sensor and transmitter is 100 m (330
ft).
NEPSI Ex ia IIC T3/T4/T6 Ga
The Memosens inductive sensor cable connection system, consisting of:
• oxygen sensor Oxymax COS22D-NA*****3 and
• measuring cable CYK10-G***
is approved for use in explosive atmospheres in accordance with the National supervision and
inspection center for Explosion protection and Safety of Instrumentation (NEPSI) in China.
The certified oxygen sensor Oxymax COS22D-NA*****3 may only be connected to the
following certified, intrinsically safe, digital sensor circuits in conjunction with the measuring

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cable CYK10-G***, or a Memosens cable with an identical structure both in terms of
hardware and function:
• Liquiline CM42-OJ*********
• Alternatively to an approved, intrinsically safe Memosens sensor output that supplies the
following values at the very maximum:
Parameter set 1 Parameter set 2
U0 = 5.1 V
I0 = 130 mA
P0 = 166 mW (linear output characteristic)
Ci = 15 µF
Li = 95 µH
U0 = 5.04 V
I0 = 80 mA
P0 = 112 mW (trapezoidal output characteristic)
Ci = 14.1 µF
Li = 237.2 µH
• The electrical connection must be made according to the wiring diagram.
• Oxygen sensors for use in the Ex area have a special conductive O-ring. The electrical
connection of the metallic sensor shaft to the conductive mounting location (such as a
metallic assembly) takes place via the O-ring.
• You must connect the assembly or the installation location to ground according to the Ex
guidelines.
• If the CYK10-G*** cable is installed with its terminal head in Ex zone 0, the cable must be
protected against electrostatic charge.
• The user may not change the configuration. Only in this way will the explosion protection of
the unit remain intact. Every change puts safety at risk.
• The sensors must not be operated under electrostatically critical process conditions. Avoid
strong steam or dust currents that act directly on the connection system. The metal sensor
shaft must be installed at the mounting location in such a way that it is electrostatically
conductive (< 1 MΩ).
• To mount, use and maintain the product, you must follow the information in the Operating
Instructions and the following standards:
• GB50257 -1996 "Code for construction and acceptance of electric device for explosion
atmospheres and fire hazard electrical equipment installation engineering"
• GB3836.13-1997 "Electrical apparatus for explosive gas atmospheres Part 13: Repair and
overhaul for apparatus used in explosive gas atmospheres"
• GB3836.15-2000 "Electrical apparatus for explosive gas atmospheres- Part 15: Electrical
installations in hazardous area (other than mines)"
• GB3836.16-2006 "Electrical apparatus for explosive gas atmospheres- Part 16: Inspection
and maintenance of electrical installation (other than mines)"
• Hazardous area versions of digital sensors with Memosens technology are indicated by a
red-orange ring in the plug-in head.
• The maximum permitted cable length between the sensor and transmitter is 100 m (330
ft).
FM/CSA IS/NI Cl.1 Div.1 GP: A-D
Observe the documentation and the control drawings of the transmitter.

Certificates and approvals Oxymax COS22D, Oxymax COS22
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Temperature classes ATEX, IECEx, FM/CSA and NEPSI
Temperature class
T3 T4 T6
Ambient temperature Ta–5 to +135 °C –5 to +120 °C –5 to +70 °C
Reference temperature Tref +25 °C
TIIS Ex ib IIC T4
The certified oxygen sensor Oxymax COS22D-TA*****3 may only be connected to the
certified, intrinsically safe, digital sensor circuit of the transmitter Liquiline M CM42-
OT********* in conjunction with the measuring cable CYK10-U**1.
Temperature classes TIIS
T4
Ambient temperature Ta–5 to +60 °C
Reference temperature T ref +25 °C
3 Certificates and approvals
3.1 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.
3.2 Ex approvals
Version COS22D-BA
ATEX II 1G / IECEx Ex ia IIC T3/T4/T6 Ga
Version COS22D-8A
FM/CSA IS/NI Cl.1 Div.1 GP: A-D
Version COS22D-NA
NEPSI Ex ia IIC T3/T4/T6 Ga
Version COS22D-TA
TIIS Ex ib IIC T4
3.3 Certification body
DEKRA EXAM GmbH
Bochum

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3.4 Material certificates
3.4.1 Manufacturer declaration of FDA compatibility
The manufacturer declares the use of FDA-listed materials.
Product FDA certificate for
COS22-****22
COS22D-****22
Membrane, O-rings, process seal
COS22Z-*2*2 Membrane, O-rings, process seal
COS22-****23
COS22D-****23
Membrane, O-rings
COS22Z-*2*3 Membrane, O-rings
Hazardous area versions
For operation in FDA processes, another FDA-approved seal must be installed before the
process seal (for example CPA442). Doing so will sufficiently separate the process from
the Ex connection.
3.4.2 Material test certificate
A test certificate 3.1 in accordance with EN 10204 is supplied depending on the version (→
Product Configurator on the product page).
3.5 EHEDG
Compliance with EHEDG's criteria for hygienic design
• TÜV Rheinland, Apeldorn, Netherlands
• Certificate type: Type EL Class I

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4 Installation
4.1 Installation conditions
4.1.1 Orientation
135°
10° 170°
45°
A0030545
 1 Permitted orientations
The sensor must be installed at an angle of inclination of 10 to 170 ° in an assembly, holder or
appropriate process connection. Recommended angle: 45° to prevent the attachment of air
bubbles.
Inclination angles other than those mentioned are not permitted. In order to avoid buildup
and condensation on the spot, do not install the sensor upside down.
Follow the instructions for installing sensors in the Operating Instructions for the
assembly used.
4.1.2 Mounting location
1. Choose a mounting location that is easy to access.
2. Ensure that upright posts and assemblies are fully secured and vibration-free.
3. Choose a mounting location with an oxygen concentration that is typical for the
application.

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4.2 Mounting the sensor
Must be installed in a suitable assembly (depending on the application).
LWARNING
Electrical voltage
In the event of a fault, non-grounded metallic assemblies may be live and as such are not safe
to touch!
‣When using metallic assemblies and installation equipment, national grounding provisions
must be observed.
For 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 are using an assembly with a
cleaning function).
3. Install and connect the oxygen sensor.
NOTICE
Installation error
Cable breakage, loss of sensor due to cable separation, unscrewing of membrane cap!
‣Do not install the sensor freely suspended from the cable.
‣Screw the sensor into the assembly, ensuring that the cable is not twisted.
‣Hold on to the sensor body during installation or removal. Turn only at the hexagonal nut
of the armored coupling. Otherwise you might unscrew the membrane cap. This will then
remain in the assembly or process.
‣Avoid exerting excessive tensile force on the cable (e.g. through jerky pulling movements).
‣Choose a mounting location that is easy to access for later calibrations.
‣Follow the instructions for installing sensors in the Operating Instructions for the assembly
used.
4.3 Post-installation check
1. Are the sensor and cable undamaged?
2. Is the orientation correct?
3. Is the sensor installed in an assembly and is not suspended from the cable?
4. Avoid the penetration of moisture by fitting the protection cap on the immersion
assembly.

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5 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.
5.1 Quick wiring guide (COS22D-BA/NA only)
COS22D
CYK10
Ex ia
II 2G
II 1G II 3G
Zone 1
Zone 0 Zone 2
Ex ib
A0024123
 2

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5.2 Connecting the sensor (COS22D)
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
 3 Measuring cable CYK10
5.3 Connecting the sensor (COS22)
A multi-core COK21 measuring cable is used for the electrical connection of the sensor to the
transmitter.
PK
GN / YE
BN
YE
BU
S
12
90
91
11
Assignment Terminal
External shield
Cathode
Anode
NTC temp. sensor
Active internal shield
(NTC temp. sensor)
A0005583-EN
 4 Measuring cable COK21
The polarization voltage must be set at the transmitter as follows:
Standard measuring range: -650 mV
Trace measuring range: -550 mV
The voltage is applied between the working electrode (cathode) and the reference electrode
(anode).

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5.4 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.
5.5 Post-connection check
Device condition and specifications Notes
Are the sensor, assembly, junction box, or cables free from damage on
the outside?
Visual inspection
Electrical connection Notes
Are the mounted cables strain-relieved and not twisted?
Is a sufficient length of the cable cores stripped, and are the cores
positioned in the terminal correctly?
Check the fit (by pulling gently)
Are all the screw terminals properly tightened? Tighten
Are all cable entries mounted, tightened and leak-tight? For lateral cable entries, make sure the
cables loop downwards to allow water to drip
off
Are all cable entries installed downwards or mounted laterally?

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6 Commissioning
6.1 Function check
Prior to initial commissioning, ensure that:
• The sensor is correctly installed
• The electrical connection is correct
• There is sufficient electrolyte in the membrane cap
The transmitter is not displaying a warning about electrolyte depletion
Please note the information on the safety data sheet to ensure safe use of the electrolyte.
If using an assembly with automatic cleaning function:
‣Check that the cleaning medium (water or air, for example) is connected correctly.
LWARNING
Escaping process medium
Risk of injury from high pressure, high temperatures or chemical hazards!
‣Before applying pressure to an assembly with cleaning system, ensure that the system has
been connected correctly.
‣If you cannot reliably establish the correct connection, do not install the assembly in the
process.
Following commissioning, the sensor must be serviced at regular intervals, as only then
can reliable measurement be guaranteed. Further information on this can be found in
the Operating Instructions for the sensor.
• Operating Instructions Oxymax COS22D, BA00447C
• Operating Instructions Oxymax COS22, BA00446C
• Operating Instructions for the transmitter used, such as BA01245C if using the
Liquiline CM44x or CM44xR.
6.2 Sensor polarization
NOTICE
Incorrect measurements due to ambient influences!
‣Always avoid strong direct sunlight on the sensor.
‣Comply with the instructions for commissioning in the Operating Instructions of the
transmitter used.
The sensor has been tested at the factory for proper functioning and is shipped in a condition
in which it is ready to operate.
To prepare for calibration:
1. Remove the sensor protection cap.

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2. Expose the sensor, which is dry on the outside, to the air atmosphere.
 The air should be saturated with water vapor. Therefore, install the sensor as close
as possible to a water surface. However, the sensor membrane must remain dry
during calibration. Therefore, avoid direct contact with the water surface.
3. Connect the sensor to the transmitter.
4. Switch on the transmitter.
 When the sensor is connected to the transmitter, the polarization takes place
automatically after the transmitter powers up.
5. Wait for polarization time to elapse.

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6.3 Sensor calibration
Calibrate the sensor (e.g. air calibration) immediately after the polarization time elapses.
The calibration intervals depend greatly on:
• The application
• The installation position of the sensor
The following method helps you determine the necessary calibration intervals:
1. Inspect the sensor one month after commissioning. To do so, remove the sensor from
the medium and dry it off.
2. After 10 minutes, measure the oxygen saturation index in air.
 Decide using the results:
a) Measured value not 100 ±2 %SAT? → Calibrate the sensor.
b) Measured value = 100 ±2 %SAT? → Double the length of time to the next
inspection.
3. Proceed as indicated in Step 1 after two, four and eight months.
 This allows you to determine the optimum calibration interval for your sensor.
In any case, calibrate the sensor at least once a year.

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