Endress+Hauser Oxymax COS22D User manual

BA00447C/07/EN/02.12
71153853
Operating Instructions
Oxymax COS22D
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
Oxymax COS22D
Table of contents
1 Safety instructions . . . . . . . . . . 4
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning and operation . 5
1.3 Operational safety . . . . . . . . . . . . . . . . . . . 5
2 Identification . . . . . . . . . . . . . . 6
2.1 Order code . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . 6
2.3 Certificates and approvals . . . . . . . . . . . . . . 6
3 Installation . . . . . . . . . . . . . . . . 9
3.1 Incoming acceptance, transport, storage . . . 9
3.2 Installation conditions . . . . . . . . . . . . . . . . 9
3.3 Installation instructions . . . . . . . . . . . . . . 10
3.4 Installation examples . . . . . . . . . . . . . . . . 11
3.5 Post-installation check . . . . . . . . . . . . . . . 14
4 Wiring . . . . . . . . . . . . . . . . . . 15
4.1 Sensor design for hazardous area applications
15
4.2 Connection to the transmitter . . . . . . . . . 17
4.3 Post-connection check . . . . . . . . . . . . . . . 17
5 Function . . . . . . . . . . . . . . . . . 18
5.1 Measuring principle . . . . . . . . . . . . . . . . . 18
5.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Commissioning. . . . . . . . . . . . 23
6.1 Function check . . . . . . . . . . . . . . . . . . . . 23
6.2 Polarization . . . . . . . . . . . . . . . . . . . . . . . 23
6.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 24
7 Maintenance. . . . . . . . . . . . . . 25
7.1 Maintenance tasks . . . . . . . . . . . . . . . . . . 25
7.2 Maintenance intervals . . . . . . . . . . . . . . . 25
7.3 Cleaning the sensor . . . . . . . . . . . . . . . . . 26
7.4 Wear parts and consumables . . . . . . . . . . 26
8 Accessories. . . . . . . . . . . . . . . 30
8.1 Connection accessories . . . . . . . . . . . . . . 30
8.2 Installation accessories . . . . . . . . . . . . . . . 30
9 Trouble-shooting. . . . . . . . . . . 31
9.1 Trouble-shooting instructions . . . . . . . . . . 31
9.2 Spare parts and consumable material . . . . . 32
9.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 Technical data . . . . . . . . . . . . . 33
10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.2 Performance characteristics . . . . . . . . . . . . 33
10.3 Environment . . . . . . . . . . . . . . . . . . . . . . 35
10.4 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.5 Mechanical construction . . . . . . . . . . . . . . 37
Index. . . . . . . . . . . . . . . . . . . . 38

Safety instructions Oxymax COS22D
4Endress+Hauser
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:
• 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
• COS22D-*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.
The COS22D sensor has to be connected with the CYK10 measuring cable for non-contact, digital data
transmission to the digital input of the Liquiline transmitter.
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.

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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.
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.

Identification Oxymax COS22D
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.)
• Disassembly tool for membrane body
• Brief Operating Instructions
• Operating Instructions on USB card
If you have any questions, please contact your supplier or your local sales center.
2.3 Certificates and approvals
2.3.1 Ex approval
Version COS22D-BA
ATEX II 1G / IECEx Ex ia IIC T3/T4/T6 Ga
Notified body
DEKRA EXAM GmbH
Bochum (Germany)

Oxymax COS22D Identification
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a0014925
Fig. 1: EC declaration of conformity

Identification Oxymax COS22D
8Endress+Hauser
2.3.2 FDA conformity
The manufacturer declares the FDA compliance of the materials used.
Ask your local sales center for the certificates.
Note for Ex versions:
For use of these sensors in FDA applications, an additional FDA compliant sealing (e.g. CPA442) is
required in front of the process sealing to separate the process from the Ex zone.
Product FDA certificate for
22D-****22 Membrane, O-rings, process sealing
COS22Z-*2*2 Membrane, O-rings, process sealing
22D-****23 Membrane, O-rings
COS22Z-*2*3 Membrane, O-rings

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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
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.
a0005584-en
Fig. 2: Permitted angle of installation
10° 10° Not permissible!
Not permissible!
Permissible angle of installation

Installation Oxymax COS22D
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3.3 Installation instructions
3.3.1 Measuring system
A complete measuring system comprises:
• A digital oxygen sensor Oxymax COS22D
• A transmitter, e.g. Liquiline CM42
• An measuring cable CYK10
• Optional: an assembly, e.g. fixed installation assembly CPA442, flow assembly CPA240 or retractable
assembly CPA475
a0001398
Fig. 3: Example of a measuring system with COS22D-*1
1 Liquiline M CM42
2 Measuring cable CYK10
3 Digital oxygen sensor Oxymax COS22D-*1
4 Fixed installation assembly CPA442
1
2
3
4

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3.3.2 Installing a measuring point
WARNING
!
Voltage
In case of faults not-grounded, metalic assemblies may be energized
►When using metallic assemblies and installation equipment, comply with national grounding
regulations.
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.
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.

Installation Oxymax COS22D
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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. 4: CPA240 flow assembly with protective hood
a0005721
Fig. 5: Bypass installation
1 Main line
2Mediumremoval
3, 6 Manually actuated or solenoid valves
4 Sampling
5 Flow assembly with installed sensor
7 Medium return

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Flow assembly for water treatment applications
The compact stainless steel assembly (see "Accessories") offers space for a 12-mm sensor with a length
of 120 mm. The assembly has a low sampling volume and, with the 6-mm connections, it is best suited
for residual oxygen measurement in water treatments and boiler feedwater. The flow comes from
below.
a0014081
Fig. 6: Flow assembly
1 Built-in sensor
2Drain
3 Wall mount (clamp D29)
4Inflow
12
3
4

Installation Oxymax COS22D
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3.4.3 Retractable assembly (CPA475 or CPA450)
The assembly is designed for installation on tanks and pipes. Suitable nozzles must be available for this.
Install the assembly at places with constant flow. The minimum pipe diameter is DN 80.
a0005722-en
Fig. 7: Suitable and unsuitable installation positions with a retractable assembly
1 Ascending pipe, best position
2 Horizontal pipe, sensor top down, impermissible due to air cushion or foam bubble forming
3 Horizontal pipe, installation with permissible installation angle (acc. to sensor version)
5 Down pipe, impermissible
NOTICE
Incorrect measurements
Sensor not in the medium all the way, buildup, overhead installation
►Do not install the assembly at places where air cushions or foam bubbles can be formed.
►Avoid deposits on the sensor membrane and/or remove them regularly.
►Do not install the sensor overhead.
3.5 Post-installation check
►Sensor and cable undamaged?
►Compliance with permissible sensor installation position?
►Is the sensor installed in an assembly and is not suspended from the cable?
►Avoid moisture by rain by putting the protective cap on the assembly?
5
3
41
2
3
4
2
Detail A,
(top view)
Detail A, rotated
(side view)
90°

Oxymax COS22D Wiring
Endress+Hauser 15
4Wiring
WARNING
!
Device is energized
Improper connection can cause injury or death.
►The electrical connection must only be carried out by a certified electrician.
►Technical personnel must have read and understood the instructions in this manual and must
adhere to them.
►Prior to beginning any wiring work, make sure voltage is not applied to any of the cables.
4.1 Sensor design for hazardous area applications
4.1.1 Quick wiring guide
The inductive sensor-cable-plug-in system Memosens, consisting of
• oxygen sensor Oxymax COS22D-BA**** and
• measuring cable CYK10-G**1
is suitable for the use in explosion-hazardous areas acc. to the type-examination certificate
BVS 04 ATEX E 121 X . The corresponding EU declaration of conformity is part of this document.
• The certified oxygen sensor Oxymax H COS21D-*12*1COS22D-BA**** in combination with the
measuring cable CYK10-G**1 may only be connected to certified, intrinsically-safe, digital sensor
circuits of the transmitter Liquiline M CM42-*G*********. The electrical connection must be
carried out in compliance with the wiring diagram.
• Oxygen sensors for use in Ex areas have a special, conductive O-ring. The metallic sensor shaft is
electrically connected to the conductive mounting location (e.g. a metallic assembly) by means of the
O-ring.
• You must take appropriate measures to connect the assembly or the mounting location to the
operational ground in accordance with Ex guidelines.
• The sensors must not be used under electrostatical critical process conditions. Strong vapour or dust
streams acting directly on the plug-in system are to be avoided.
• Ex versions of digital sensors with Memosens technology are marked with an orange-red ring on the
plug-in head.
• The maximum permissable cable length is 100 m (330 ft).

Wiring Oxymax COS22D
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a0010056
Fig. 8: Connection in hazardous locations

Oxymax COS22D Wiring
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4.1.2 Temperature classes
If the ambient temperatures indicated are observed, no temperatures which are impermissible for the
temperature class in question will occur at the sensor.
4.2 Connection to the transmitter
The sensor is electrically connected to the transmitter by means of the special measuring cable CYK10.
4.3 Post-connection check
Temperature class
T3 T4 T6
Ambient temperature Ta–5 ... +135 ˚C –5 ... +120 ˚C –5 ... +70 ˚C
Reference temperature Tref +25 ˚C
a0003350
Fig. 9: Special measuring cable CYK10
Instrument status and specifications Remarks
Are the sensor, assembly, junction box or cable damaged? Visual inspection
Electrical connection Remarks
Are the installed cables strain-relieved and not twisted ?
Long enough length of cable core stripped and correct in terminal? Check seating (pull slightly)
Are all the screws terminals properly tightened ? Tighten
Are all the cable entries installed, tightened and sealed ? For cable entries lateral: cable loops downwards
for water to be able to drip off.
Are all the cable entries installed downwards or lateral ?

Function Oxymax COS22D
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5 Function
5.1 Measuring principle
5.1.1 Amperometric principle
The oxygen molecules diffused through the membrane are reduced to hydroxide ions (OH-) at the
cathode. Silver is oxidized to silver ions (Ag+) at the anode (this forms a silver halogenide layer).
A current flows due to the electron donation at the cathode and the electron acceptance at the anode.
Under constant conditions, this flow is proportional to the oxygen content of the medium.
This current is converted in the transmitter and indicated on the display as an oxygen concentration in
mg/l, μg/l, ppm, ppb or Vol%, as a saturation index in % SAT or as an oxygen partial pressure in hPa.
5.1.2 Sensor design
a0011869
Fig. 10: Exploded view
1
2
3
4
Plug-in head
Pressure ring
Sensor shaft
O-ring 8.5 x 1.5 mm
5
6
7
Membrane body
Shaft cover
Glass body with cathode and anode
8
9
Process sealing 10.77 x 2.62 mm
Process connection Pg 13.5

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5.1.3 Memosens technology
The sensor is connected to the cable connection (CYK10) without contact. The power and data are
transferred inductively
Once connected to the transmitter, the data saved in the sensor are read digitally. You can call up these
data using the corresponding DIAG menu.
Data that digital sensors save include the following:
• Manufacturer data
– Serial number
– Order code
– Date of manufacture
• Calibration data
– Calibration date
– Calibration values
– Number of calibrations
– Serial number of the transmitter used to perform the last calibration
• Operational data
– Date of commissioning
– Hours of operation under extreme conditions
– Number of sterilizations
– Data for sensor monitoring.
5.1.4 Polarization
When the sensor is connected to the transmitter, a fixed external voltage is applied between the cathode
and anode. The resulting polarization current is indicated on the display of the transmitter. The current
starts high but then drops over time. The sensor can only be calibrated when the display is stable.
Reference value for practically complete polarization of a sensor that was in storage for an extended
period beforehand:
• COS22D-*1: 2 hours
• COS22D-*3: 12 hours
After this time, measurements close to the determination limit make sense.
The polarization time needed is shorter for sensors which were in operation shortly beforehand.
5.1.5 Membrane body
The oxygen dissolved in the medium is conveyed to the membrane by the incoming flow. The
membrane is only permeable for dissolved gases. Other substances dissolved in the liquid phase e.g.
ionic substances, will not penetrate through the membrane. Therefore, medium conductivity has no
impact on the measuring signal.
The sensor is supplied with a standard membrane body which can be used for all common applications.
The membrane is pretensioned at the factory and can be installed directly.
Electrolytes are version-specific and cannot be mixed in a single application!

Function Oxymax COS22D
20 Endress+Hauser
5.2 Calibration
Calibration is a means of adapting the transmitter to the characteristic values of the sensor.
Normally, sensor calibration is seldom necessary. It is necessary after:
• First commissioning
• Replacing a membrane or electrolyte
• Long breaks in operation without power supply
Within the framework of system monitoring and supervision, for example, the calibration can also be
cyclically monitored (at typical time intervals, depending on operating experience) or renewed.
5.2.1 Types of calibration
You can carry out single-point or two-point calibration for the sensor.
In most applications, single-point calibration suffices in the presence of oxygen (=calibration of
measured value at air).
The additional calibration of the zero point (two-point calibration) improves the precision of the
measurement results in the trace range. Calibrate the zero point with nitrogen (minimum 99.995%) or
with water free from oxygen, for example. In doing so, make sure the measured value has settled
correctly (20 to 30 minutes) to avoid incorrect measurements in the trace range at a later stage.
The available types of calibration depend on the transmitter used. Refer to your transmitter's
Operating Instructions to find out which types of calibration are supported.
The following section only describes the calibration in air (saturated with water vapor) as the easiest
method of calibration and therefore the recommended method.
However, this type of calibration is only possible if the air temperature is ≥–5 ˚C (23 ˚F).
5.2.2 Calibration in air
1. Remove the sensor from the medium.
2. Clean the outside of the sensor with a damp cloth.
3. Then wait while the sensor adjusts to the temperature of the ambient air. This takes about
20 minutes. Check that the sensor is not in direct sunlight during this time.
4. If the measured value display on the transmitter is stable, carry out the calibration in accordance
with the Operating Instructions of the transmitter.
5. Place the sensor in the medium again.
Make sure you comply with the instructions for calibration in the Operating Instructions of the
transmitter.