Endress+Hauser Oxymax COS22D User manual

BA447C/07/EN/01.11
71098073
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-references in the document
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 stands for a cross-reference to a specific page (e.g. Page 1).
È å 2 This symbol stands for a cross-reference to a specific graphic (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 . . . . . . . . . . . . . . 5
2.1 Interpreting an order code . . . . . . . . . . . . . 5
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . 5
2.3 Certificates and approvals . . . . . . . . . . . . . . 6
3 Installation . . . . . . . . . . . . . . . . 8
3.1 Incoming acceptance, transport, storage . . . 8
3.2 Installation conditions . . . . . . . . . . . . . . . . 8
3.3 Installation instructions . . . . . . . . . . . . . . . 9
3.4 Installation examples . . . . . . . . . . . . . . . . 11
3.5 Post-installation check . . . . . . . . . . . . . . . 13
4 Wiring . . . . . . . . . . . . . . . . . . 14
4.1 Sensor design for hazardous area
applications . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Connection at the transmitter . . . . . . . . . . 16
4.3 Post-connection check . . . . . . . . . . . . . . . 16
5 Function . . . . . . . . . . . . . . . . . 17
5.1 Measuring principle . . . . . . . . . . . . . . . . . 17
5.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Commissioning. . . . . . . . . . . . 22
6.1 Function check . . . . . . . . . . . . . . . . . . . . 22
6.2 Polarization . . . . . . . . . . . . . . . . . . . . . . . 22
6.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 23
7 Maintenance. . . . . . . . . . . . . . 24
7.1 Maintenance tasks . . . . . . . . . . . . . . . . . . 24
7.2 Maintenance intervals . . . . . . . . . . . . . . . 24
7.3 Cleaning the sensor . . . . . . . . . . . . . . . . . 25
7.4 Wear parts and consumables . . . . . . . . . . 25
8 Accessories. . . . . . . . . . . . . . . 29
8.1 Connection accessories . . . . . . . . . . . . . . 29
8.2 Installation accessories . . . . . . . . . . . . . . . 29
9 Troubleshooting . . . . . . . . . . . 30
9.1 Troubleshooting instructions . . . . . . . . . . . 30
9.2 Spare parts and consumables . . . . . . . . . . . 31
9.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10 Technical data. . . . . . . . . . . . . 32
10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.2 Performance characteristics . . . . . . . . . . . . 32
10.3 Environment . . . . . . . . . . . . . . . . . . . . . . 34
10.4 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.5 Mechanical construction . . . . . . . . . . . . . . 35
Index. . . . . . . . . . . . . . . . . . . . 37

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:
• 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, therefore, 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, electrical connection, commissioning, operation and maintenance of the measuring
system must only be carried out by trained technical personnel.
The technical personnel must be authorized to perform such tasks by the owner-operator.
• The electrical connection must only be performed by an electrical technician.
• 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 for correctness. 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 cannot be rectified, the products must be taken out of service and secured against
unintentional commissioning.

Identification
Endress+Hauser 5
• 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 standards and regulations.
1.4 Return
If the device requires repair, please send 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 Contamination" (copy the second last page of these
Operating Instructions) with the packaging and the transportation documents. No repair without
completed "Declaration of contamination"!
2 Identification
2.1 Interpreting an order code
To discover the version of your device, enter the order code from the nameplate into 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 watering cap (filled with tap water) for protecting the membrane
• 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 sales center responsible.

Identification
6Endress+Hauser
2.3 Certificates and approvals
2.3.1 Approval for use in hazardous areas
Version COS22D-BA
ATEX 1G Ex ia IIC T3/T4/T6 Ga
Designated authority
EXAM BBG Prüf- und Zertifizier GmbH
Bochum
a0014925

Identification
Endress+Hauser 7
2.3.2 FDA compatibility
The manufacturer declares the use of FDA-listed materials.
Ask your local sales center for the certificates.
Note for hazardous area versions:
For operation in FDA processes, another FDA-approved seal must be installed before the process seal
(e.g. CPA442). Doing so will sufficiently separate the process from the Ex connection.
Product FDA certificate for
COS22D-****22 Membrane, O-rings, process seal
COS22Z-*2*2 Membrane, O-rings, process seal
COS22D-****23 Membrane, O-rings
COS22Z-*2*3 Membrane, O-rings

Installation
8Endress+Hauser
3 Installation
3.1 Incoming acceptance, transport, storage
►Make sure the packaging is undamaged!
►Inform the supplier about 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 delivery contents. Keep the damaged products until the
matter has been settled.
►Check that the scope of delivery is complete and agrees with your order and the 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 sales center responsible.
3.2 Installation conditions
3.2.1 Orientation
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-de
Fig. 1: Permitted installation angle
10° 10° Not permissible!
Not permissible!
Permissible angle of installation

Installation
Endress+Hauser 9
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 for the individual
application.
3.3 Installation instructions
3.3.1 Measuring system
A complete measuring system comprises:
• An Oxymax COS22D oxygen sensor
• A transmitter, e.g. Liquiline CM42
• A corresponding measuring cable, e.g. CYK10
• Optional: an assembly, e.g. permanent installation assembly CPA442, flow assembly CPA240, or
retractable assembly CPA475
a0001398
Fig. 2: Example of a measuring system with COS22D
1 Liquiline CM42
2 Measuring cable CYK10
3 Digital oxygen sensor Oxymax COS22D
4 Permanent installation assembly CPA442
1
2
3
4

Installation
10 Endress+Hauser
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 error
Cable break, loss of the sensor due to cable separation, 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.
►When installing or uninstalling the sensor body, hold it tightly. Turn it by the threaded end only.
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. from jerky pulling).
►Select an installation location that is easy to access for later calibrations.

Installation
Endress+Hauser 11
3.4 Installation examples
3.4.1 Permanent installation (CPA442)
The permanent installation assembly CPA442 enables easy adaptation of a sensor to nearly any process
connections from Ingold nozzles to Varivent or Tri-Clamp connections.
This kind of installation is very well suited for tanks and larger pipes. You will achieve a defined
immersion depth of the sensor into the medium in the simplest way.
3.4.2 Flow assembly
CPA240
The flow assembly CPA240 offers up to three installation spaces for sensors with a shaft diameter of 12
mm (0.47"), a shaft length of 120 mm (4.7"), and a Pg 13.5 process connection.
It very well suited for use in pipelines or hose connections.
To prevent measured error with trace measurements, pay particular attention to complete ventilation
of the assembly.
a0005720
Fig. 3: Flow assembly CPA240 with protective cover
a0005721
Fig. 4: Bypass installation
1 Main line
2Mediumremoval
3, 6 Manually actuated or solenoid valves
4 Sampling
5 Flow assembly with installed sensor
7Mediumreturn

Installation
12 Endress+Hauser
Flow assembly for water treatments
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. 5: Flow assembly
1 Built-in sensor
2Drain
3 Wall mount (clamp D29)
4Inflow
12
3
4

Installation
Endress+Hauser 13
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 (3").
a0005722-de
Fig. 6: Permissible and impermissible sensor installation positions with 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, lateral 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 the penetration of moisture by fitting the protective cap to the immersion assembly.
5
3
41
2
3
4
2
Detail A,
(top view)
Detail A, rotated
(side view)
90°

Wiring
14 Endress+Hauser
4 Wiring
WARNING
!
Device is energized
Improper connection can cause injury or death.
►The electrical connection must only be carried out by an certified technician.
►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 Memosens inductive sensor cable connection system, consisting of:
• Oxygen sensor Oxymax COS22D-BA***** and
• Measuring cable CYK10-G**1
is suitable for use in potentially explosive atmospheres according to EC type examination certificate BVS
04 ATEX E 121 X. The corresponding EC declaration of conformity is part of this document.
• The certified oxygen sensor Oxymax COS22D-BA***** may be used in conjunction with the
measuring cable CYK10-G**1 on certified, intrinsically safe, digital sensor circuits of the transmitter
Liquiline M CM42-*G********* only. 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 at the conductive mounting location (e.g. a metallic assembly) takes place
via the O-ring.
• You have to connect the assembly or the installation 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 marked by a red-orange
ring on the plug-in head.
• The maximum permitted cable length between the sensor and transmitter is 100 m (330 ft).

Wiring
Endress+Hauser 15
a0010056
Fig. 7:

Wiring
16 Endress+Hauser
4.1.2 Temperature classes
If the specified ambient temperatures are complied with, temperatures that are unacceptably high for
the respective temperature class will not occur on the sensor.
4.2 Connection at the transmitter
The electrical connection of the sensor to the transmitter takes place via special measuring cable CYK10.
4.3 Post-connection check
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
a0003350
Fig. 8: Special measuring cable CYK10
Instrument status and specifications Remarks
Are the outside of the sensor, assembly, junction box, cable
undamaged?
Visual inspection
Electrical connection Remarks
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? 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
Endress+Hauser 17
5 Function
5.1 Measuring principle
5.1.1 Amperometric measuring principle
The oxygen molecules that diffuse through the membrane are reduced at the cathode into hydroxide
ions (OH-). At the anode, silver is oxidized into silver ions (Ag+) (this forms a silver halide 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. 9: Exploded view
1
2
3
4
Plug-in head
Thrust collar
Sensor shaft
O-ring 8.5 x 1.5 mm
5
6
7
Membrane body
Shaft sleeve
Glass portion with anode and
cathode
8
9
Process seal 10.77 x 2.62 mm
Process connection Pg 13.5

Function
18 Endress+Hauser
5.1.3 Memosens technology
After connecting to the transmitter, the data stored in the sensor are read digitally. You can view these
data via the DIAG menu.
Data saved by digital sensors include:
• 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
• Operating data
– Date of initial commissioning
– Hours of operation under extreme conditions
– Number of sterilizations
– Sensor monitoring data
5.1.4 Polarization
When the sensor is connected to the transmitter, a fixed voltage is applied between the cathode and
anode. The polarization current this creates can be identified on the transmitter with a display that is
initially high, but decreases with time. The sensor cannot be calibrated until the display is calibrated.
Reference value for nearly complete polarization of a sensor that was previously stored for a long time:
• COS22D-*1: 2 hours
• COS22D-*3: 12 hours
After this time, even measurements close to the determination limit are useful.
The necessary polarization time is reduced for sensors that were in use a short time before.
5.1.5 Membrane body
The oxygen dissolved in the medium is transported to the membrane by the necessary flow. The
membrane is permeable for dissolved gases only. 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 shipped with a standard membrane body, which can be used for all common applications.
The membrane is pretensioned at the factory and can be installed immediately.
Electrolytes are version-specific and cannot be mixed in a single application!

Function
Endress+Hauser 19
5.2 Calibration
Calibration of the sensor is required after:
• Initial commissioning
• Changing the membrane or electrolyte
• Long pauses 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 a slope or zero point calibration for the sensor.
In most applications, single-point calibration in the presence of oxygen is sufficient (=calibration of the
sensor slope). When switching from process to calibration conditions, you have to allow a longer settling
time for the sensor.
The additional calibration of the zero point improves the accuracy of the measurement results at trace
concentrations. You can calibrate the zero point using nitrogen (min. 99.995%) or oxygen-free water.
Make sure that the sensor is polarized and the measured value is settled at the zero point (at least 20-30
minutes) to prevent later incorrect measurements at trace concentrations.
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 describes calibration of the slope in air (saturated with water vapor) as the easiest and
recommended calibration method.
However, this type of calibration is possible only if the air temperature is ≥0 ˚C (32 ˚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. Allow a temperature compensation time of approx. 20 minutes for the sensor to acclimate to the
Operating Instructions. Make sure that the sensor is not exposed to any direct ambient influences
(direct sunlight, drafts) during this time.
4. When the measured value display on the transmitter is stable, carry out the calibration according
to the operating instructions for the transmitter. Pay particular attention to the software settings
for the stability criteria for calibration.
5. Then insert the sensor into the medium.
Make sure you comply with the instructions for calibration in the Operating Instructions of the
transmitter.

Function
20 Endress+Hauser
5.2.3 Calculation example for the calibration value
As a check, you can calculate the expected calibration value (transmitter display) as shown in the
following example (salinity is 0).
1. Determine:
– the sensor temperature (air temperature for the calibration type "air", water temperature for the
calibration type "air-saturated water")
– the altitude above sea level
– the current air pressure (= rel. air pressure to sea level) at the time of calibration. (If
undeterminable, use 1013 hPa (407 inH2O)).
2. Define:
– the saturation value Sacc. to the first table
– the factor Kacc. to the second table
T
[˚C(˚F)]
S
[mg/l=ppm]
T
[˚C(˚F)]
S
[mg/l=ppm]
T
[˚C(˚F)]
S
[mg/l=ppm]
T
[˚C(˚F)]
S
[mg/l=ppm]
0 (32) 14.64 11 (52) 10.99 21 (70) 8.90 31 (88) 7.42
1 (34) 14.23 12 (54) 10.75 22 (72) 8.73 32 (90) 7.30
2 (36) 13.83 13 (55) 10.51 23 (73) 8.57 33 (91) 7.18
3 (37) 13.45 14 (57) 10.28 24 (75) 8.41 34 (93) 7.06
4 (39) 13.09 15 (59) 10.06 25 (77) 8.25 35 (95) 6.94
5 (41) 12.75 16 (61) 9.85 26 (79) 8.11 36 (97) 6.83
6 (43) 12.42 17 (63) 9.64 27 (81) 7.96 37 (99) 6.72
7 (45) 12.11 18 (64) 9.45 28 (82) 7.82 38 (100) 6.61
8 (46) 11.81 19 (66) 9.26 29 (84) 7.69 39 (102) 6.51
9 (48) 11.53 20 (68) 9.08 30 (86) 7.55 40 (104) 6.41
10 (50) 11.25
Altitude
[m (ft)]
KAltitude
[m / ft]
KAltitude
[m / ft]
KAltitude
[m / ft]
K
0 1.000 550 (1800) 0.938 1050 (3450) 0.885 1550 (5090) 0.834
50 (160) 0.994 600 (1980) 0.932 1100 (3610) 0.879 1600 (5250) 0.830
100 (330) 0.988 650 (2130) 0.927 1150 (3770) 0.874 1650 (5410) 0.825
150 (490) 0.982 700 (2300) 0.922 1200 (3940) 0.869 1700 (5580) 0.820
200 (660) 0.977 750 (2460) 0.916 1250 (4100) 0.864 1750 (5740) 0.815
250 (820) 0.971 800 (2620) 0.911 1300 (4270) 0.859 1800 (5910) 0.810