Endress+Hauser ISEmax CAS40D User manual

BA491C/07/EN/01.11
71130408
Operating Instructions
ISEmax CAS40D
Ion-selective sensor

Endress+Hauser
Notes on these instructions
Warning information and its meaning
Structure, signal words and color coding of warning information are in compliance with
ANSI Z535.6 specifications ("Product safety information in product manuals, instructions and other
collateral materials").
Cross-references in the document
Other symbols
Structure of information Meaning
DANGER
!
Cause (/Consequences)
Consequences of non-
compliance (if applicable)
►Protection measures
This note alerts you to a dangerous situation.
If you do not avoid this dangerous situation, it will result in
death or serious injury.
WARNING
!
Cause (/Consequences)
Consequences of non-
compliance (if applicable)
►Protection measures
This note alerts you to a dangerous situation.
If you do not avoid the dangerous situation, it may result in
death or serious injury.
CAUTION
!
Cause (/Consequences)
Consequences of non-
compliance (if applicable)
►Protection measures
This note alerts you to a dangerous situation.
If you do not avoid the dangerous situation, it may result in
minor or more serious injuries.
NOTICE
Cause/Situation
Consequences of non-
compliance (if applicable)
►Measure/Note
This note alerts you to situations which may result in damage to
property.
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).
Additional information, tips
Permitted or recommended
Forbidden or not recommended

ISEmax CAS40D
Endress+Hauser 3
Table of contents
1 Safety instructions . . . . . . . . . . . . . . . . 4
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning and operation . . . . . . . . 4
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Identification . . . . . . . . . . . . . . . . . . . . 5
2.1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Interpreting the order code . . . . . . . . . . . . . . . . . . . 5
2.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 5
3 Installation . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Incoming acceptance, transport, storage . . . . . . . . . . 6
3.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Installation example . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 10
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Connecting to the transmitter . . . . . . . . . . . . . . . . 11
4.2 Electrode connection in the sensor: . . . . . . . . . . . . 11
4.3 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 12
5 Calibration . . . . . . . . . . . . . . . . . . . . . 13
5.1 Calibration modes . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Calibration and adjustment of ion-selective electrodes
13
5.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4 Checking the calibration . . . . . . . . . . . . . . . . . . . . 14
6 Maintenance. . . . . . . . . . . . . . . . . . . . 15
6.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Cleaning the membrane . . . . . . . . . . . . . . . . . . . . 15
6.3 Replacing membrane cap and electrolyte . . . . . . . . 15
7 Accessories. . . . . . . . . . . . . . . . . . . . . 18
7.1 Assembly holder . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2 Maintenance kits . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.3 Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.4 Standard solutions . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.5 Compressed air cleaning . . . . . . . . . . . . . . . . . . . . 20
8 Troubleshooting . . . . . . . . . . . . . . . . . 21
8.1 Troubleshooting instructions . . . . . . . . . . . . . . . . . 21
8.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9 Technical data . . . . . . . . . . . . . . . . . . . 24
9.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.2 Performance characteristics . . . . . . . . . . . . . . . . . . 24
9.3 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.4 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.5 Mechanical construction . . . . . . . . . . . . . . . . . . . . 26
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Safety instructions ISEmax CAS40D
4Endress+Hauser
1 Safety instructions
1.1 Designated use
The ion-selective sensor is designed for measuring tasks in the activated sludge basin and in the inlet
to the activated sludge basin of municipal sewage treatment plants.
The following parameters can be monitored and regulated depending on the device version:
•Nitrate
•Ammonium
• Potassium (also to compensate ammonium)
• Chloride (also to compensate nitrate)
•pHvalue
•ORP
Any use other than that described here compromises the safety of persons and the entire measuring
system and is therefore not permitted.
The manufacturer is not liable for damage resulting from improper or non-designated use.
1.2 Installation, commissioning and operation
Note the following points:
• Installation, commissioning, operation and maintenance of the measuring system must only be
carried out by trained technical personnel.
The technical personnel must be authorized by the plant operator to carry out the specified
activities.
• The electrical connection may only be performed by an electrical technician.
• The technical personnel must have read and understood these Operating Instructions and must
follow the instructions they contain.
• Before commissioning the entire measuring point, make sure all the connections are correct.
Ensure that electrical cables and hose connections are not damaged.
• Do not operate damaged products, and safeguard them to ensure that they are not operated
inadvertently. Mark the damaged product as 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.
• Repairs not described in these Operating Instructions may only be carried out directly at the
manufacturer's or by the service organization.
1.3 Operational safety
The sensor 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.
Relevant regulations and European standards have been observed.
As the user, you are responsible for complying with the following safety conditions:
• Installation instructions
• Local prevailing standards and regulations
1.4 Return
Note the following prior to return:
• Contact your Endress+Hauser sales center for information on the different modes of dispatch.
• Enclose a completed "Declaration of contamination" form.
You will find a template for this form at the end of these instructions.

ISEmax CAS40D Identification
Endress+Hauser 5
2 Identification
2.1 Nameplate
You can find the following information on the nameplate.
• Manufacturer details
•Ordercode
• Extended order code
• Serial number
• Operating conditions
• Safety information symbols
Compare the order code on the nameplate with your order.
2.2 Interpreting the order code
To establish your device version, enter the order code from the nameplate into the search field
at the following address: www.products.endress.com/order-ident
2.3 Scope of delivery
The scope of delivery comprises:
• 1 sensor in version as ordered
• 1 socket wrench
• 1 Operating Instructions
If you have any questions, please contact your supplier or your local sales center.
2.4 Certificates and approvals
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 4mark.

Installation ISEmax CAS40D
6Endress+Hauser
3 Installation
3.1 Incoming acceptance, transport, storage
• Make sure the packaging is undamaged!
• Notify the supplier of any damage to the packaging. Keep the damaged packaging until the matter
has been settled.
• Make sure the contents are undamaged!
• Notify the supplier of any damage to the delivery contents. Keep the damaged products until the
matter has been settled.
• Check that the scope of delivery is complete and matches your order and the shipping documents.
• Pack the product for storage and transportation in such a way that it is reliably protected against
impact and moisture. The original packaging offers the best protection. Furthermore, the
permitted ambient conditions must also be observed (see "Technical data").
• If you have any questions, please contact your supplier or your local sales center.
3.2 Installation conditions
3.2.1 Dimensions
3.2.2 Mounting location
• Choose a mounting location that can be easily accessed at a later stage.
• Ensure that upright posts and fittings are fully secured and vibration-free.
a0015207
Fig. 1: CAS40D dimensions

ISEmax CAS40D Installation
Endress+Hauser 7
3.3 Installation instructions
3.3.1 Electrode installation
NOTICE
Electrode protection caps
Drying out of pH electrode or damage to ion-selective membrane
►Remove the protection cap from the pH electrode before immersing the sensor in the medium.
►Retain the protection cap.
►If you remove the sensor from the medium for longer than 20 minutes, replace the protection
cap filled with 1-3 M KCl solution on the pH electrode. This prevents the electrode from drying
out.
►pH electrodes which have dried out due to incorrect storage can be made ready for
measurement again by leaving them in 3 M KCl solution for up to 12 hours.
►The ion-selective electrodes do not have a protection cap. Never put such a cap on the
electrodes.
All electrodes are installed and wired in the factory in accordance with the version ordered.
Installing an additional electrode (optional)
1. Release and remove the protection guard (→å2).
2. Unscrew the coupling nut (→å3).
3. Pull the electrode holder out of the sensor and release the electrode cable on a dummy
electrode (placeholder, must be present for impermeability reasons, →å4).
4. Remove the dummy electrode using a open-end or socket wrench, SW17 (→å5).
5. Screw the new electrode into the free space and hand-tighten using the open-end or socket
wrench, SW17.
6. Attach the electrode connector.
7. Carefully push the electrode holder and the air hose back into the sensor.
8. Screw on the coupling nut and then the protection guard.
NOTICE
Air bubbles
Air bubbles may accumulate in the electrodes following transportation and if they have been stored
in a horizontal position. These air bubbles cause measuring errors.
►Before installing the sensor, eliminate any air bubbles e.g. by shaking gently.
►Then make sure to hold the sensor in an upright position (electrodes facing downwards) at all
times until the sensor is installed at the measuring point.
a0015225
Fig. 2: Release protection
guard.
a0015226
Fig. 3: Remove coupling
nut.
a0015227
Fig. 4: Release cable.
a0015229
Fig. 5: Remove electrode.

Installation ISEmax CAS40D
8Endress+Hauser
3.3.2 Installing at the measuring point
NOTICE
Compressed air
Damage to the relay
►The compressed air supply must not exceed 3.5 bar (50 psi).
►The compressed air must be supplied through an air filter (5 μm). This filter is already installed
in the optional cleaning unit (--> Accessories).
Installing at the measuring point
1. If need be, install additional electrodes in the sensor and connect these to the appropriate cable
connector.
2. Hang the sensor onto the chain of the optional holder.
3. Adjust the chain length and the cross bearer for the holder in such a way that the sensor is
immersed in the medium up to the coupling nut and is approximately 0.5 m (1.64 ft) from the
basin rim.
4. Route the cables in such a way that no mechanical damage or interference influences can arise
from other cables.
Connecting an optional cleaning unit or an external compressed air supply
1. Remove the watertight plug seal from the sensor's compressed air connection.
To do so, press against the black ring and pull out the metal plug seal.
2. Plug the pressure hose (AD 8) belonging to the cleaning unit or compressed air supply into the
compressed air connection.
3. Only optional cleaning unit:
Connect the cleaning unit to the transmitter.

ISEmax CAS40D Installation
Endress+Hauser 9
3.4 Installation example
A complete measuring system comprises:
•SensorCAS40D
– Ion-selective electrode(s) for ammonium, nitrate, potassium or chloride
– pH glass electrode, Orbisint CPS11-1AT2GSA
– Temperature sensor, CTS1
• Transmitter, e.g. Liquiline CM442
Optional
• Assembly holder, e.g. CYH112
• Weather protection cover - absolutely essential if mounting the transmitter outdoors!
• Compressed air generator (if no compressed air available on site)
a0015206
Fig. 6: Example: measuring system on basin rim
1
2
3
Wastewater assembly holder, secure to rail, with
transverse pipe and chain
Transmitter, e.g. Liquiline CM442 (in graphic: wall-
mounted with weather protection cover)
Rail
4
5
6
Sensor CAS40D with ion-selective electrodes
Connection for optional compressed air cleaning
(not in graphic)
Sensor cable

Installation ISEmax CAS40D
10 Endress+Hauser
3.5 Post-installation check
• After mounting, check all the connections to ensure they are secure and leak-tight.
• Check all cables and hoses for damage.
• Check whether the cables are routed such that they are free from electromagnetic interference
influences.