Endress+Hauser Oxymax COS61D User manual

Products Solutions Services
Operating Instructions
Oxymax COS61D
Sensor for measuring dissolved oxygen
With Memosens protocol
BA00460C/07/EN/16.20
71517958
2020-03-04

Table of contents Oxymax COS61D
2 Endress+Hauser
Table of contents
1 About this document ................ 3
1.1 Warnings ............................ 3
1.2 Symbols .............................. 3
2 Basic safety instructions ............ 4
2.1 Requirements for personnel ............... 4
2.2 Designated use ........................ 4
2.3 Workplace safety ....................... 4
2.4 Operational safety ...................... 4
2.5 Product safety ......................... 5
3 Device description, function ......... 6
3.1 Optical measuring principle ............... 6
3.2 Sensor design ......................... 7
3.3 Memosens technology ................... 8
3.4 Fluorescence cap ....................... 8
4 Incoming acceptance and product
identification ....................... 9
4.1 Incoming acceptance .................... 9
4.2 Product identification .................... 9
4.3 Scope of delivery ...................... 10
4.4 Certificates and approvals ............... 10
5 Installation ....................... 12
5.1 Mounting conditions ................... 12
5.2 Mounting the sensor ................... 13
5.3 Installation examples ................... 16
5.4 Post-installation check .................. 19
6 Electrical connection .............. 20
6.1 Connecting the sensor .................. 20
6.2 Ensuring the degree of protection .......... 20
6.3 Post-connection check .................. 20
7 Calibration and adjustment ........ 21
7.1 Types of calibration .................... 21
7.2 Calibration intervals .................... 21
7.3 Calibration in air with 100% rH ........... 21
7.4 Calculation example for the calibration value .22
8 Commissioning .................... 24
8.1 Function check ....................... 24
8.2 Sensor calibration ..................... 24
8.3 Cleaning the sensor automatically ......... 24
9 Troubleshooting .................. 25
9.1 Troubleshooting instructions ............. 25
9.2 Checking the sensor .................... 25
10 Maintenance ...................... 26
10.1 Maintenance schedule .................. 26
10.2 Maintenance tasks ..................... 26
10.3 Cleaning exterior of sensor ............... 26
10.4 Cleaning sensor optics .................. 27
10.5 Wear parts and consumables ............. 27
10.6 Checking the measurement function ....... 28
11 Accessories ....................... 29
11.1 Assemblies (selection) .................. 29
11.2 Assembly holder ...................... 29
11.3 Measuring cable ...................... 29
11.4 Zero-point gel ........................ 30
11.5 Junction box RM COS61D ................ 30
11.6 Protection guard ...................... 30
11.7 Cleaning unit ......................... 30
11.8 Transmitter .......................... 31
12 Repair ............................ 32
12.1 Spare parts and consumables ............. 32
12.2 Return .............................. 32
12.3 Disposal ............................ 32
13 Technical data .................... 33
13.1 Input ............................... 33
13.2 Performance characteristics .............. 33
13.3 Environment ......................... 33
13.4 Process ............................. 34
13.5 Mechanical construction ................ 34
14 Appendices ....................... 37
Index .................................. 39

Oxymax COS61D About this document
Endress+Hauser 3
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
1.2.1 Symbols on the device
Symbol Meaning
Reference to device documentation
Do not dispose of products bearing this marking as unsorted municipal
waste. Instead, return them to the manufacturer for disposal under the
applicable conditions.

Basic safety instructions Oxymax COS61D
4 Endress+Hauser
2 Basic safety instructions
2.1 Requirements for 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 oxygen sensor is suitable for continuous measurement of dissolved oxygen in water.
The main areas of application are:
• Wastewater treatment plants
• Oxygen measurement and regulation in the activated sludge basin for a highly
efficient biological cleaning process
• Monitoring the oxygen content in the wastewater treatment plant outlet
• Water monitoring
Oxygen measurement in rivers, lakes or seas as an indicator of the water quality
• Water treatment
Oxygen measurement for status monitoring, e.g. of drinking water (oxygen enrichment,
corrosion protection etc.)
• Fish farming
Oxygen measurement and regulation for optimum living and growth conditions
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.
2.3 Workplace safety
As the user, you are responsible for complying with the following safety conditions:
• Installation guidelines
• Local standards and regulations
Electromagnetic compatibility
• The product has been tested for electromagnetic compatibility in accordance with the
applicable international 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.

Oxymax COS61D Basic safety instructions
Endress+Hauser 5
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.
LCAUTION
Cleaning not switched off during calibration or maintenance activities
Risk of injury due to medium or cleaning agent!
‣If a cleaning system is connected, switch it off before removing a sensor from the
medium.
‣If you wish to check the cleaning function and have therefore not switched off the
cleaning system, wear protective clothing, goggles and gloves or take other appropriate
measures.
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
international standards have been observed.

Device description, function Oxymax COS61D
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3 Device description, function
3.1 Optical measuring principle
Sensor structure
Oxygen-sensitive molecules (markers) are integrated into the optically active layer
(fluorescence layer).
The fluorescence layer, an optical insulating layer and a cover layer are applied on top of
one another on the carrier. The cover layer is in direct contact with the medium.
The sensor optics are directed at the rear of the carrier and therefore at the fluorescence
layer.
Measurement process (principle of quenching)
If the sensor is immersed in the medium, an equilibrium is very quickly established
between the oxygen partial pressure in both the medium and the fluorescence layer.
1. The sensor optics send green light pulses to the fluorescence layer.
2. The markers "respond" (fluoresce) with red light pulses.
 The duration and intensity of the response signals are directly dependent on the
oxygen contents and oxygen partial pressure.
If the medium is free from oxygen, the response signals are long and very intense.
Any oxygen molecules present mask the marker molecules. As a result, the response
signals are shorter and less intense.
Measurement result
‣The sensor returns a signal that depends on the concentration of oxygen in the
medium.
The air pressure can be either set statically or entered via an additional sensor. The
medium temperature is automatically recorded in the sensor. Both values are taken into
consideration in the calculation of the oxygen concentration.
The sensor provides measured values for temperature and partial pressure as well as a raw
measured value. This value corresponds to the fluorescence decay time and is approx.
20 μs in air and approx. 60 μs in oxygen-free media.
For optimum measurement results
1. During calibration, enter the current air pressure at the transmitter.
2. If the measurement is not performed at Air 100% rh:
Enter the current humidity.
3. In the case of saline media:
Enter the salinity.
4. For measurements in the units %Vol or %SAT:
Also enter the current operating pressure in the measuring mode.
Operating Instructions for Memosens, BA01245C
For all transmitters, analyzers and samplers in the Liquiline CM44x/P/R, Liquiline
System CA80XX and Liquistation CSFxx product families

Oxymax COS61D Device description, function
Endress+Hauser 7
3.2 Sensor design
1
2
3
4
5
6
7
8
A0042833
 1 Sensor structure
1 Sensor cable 5 Threaded connection
2 Sensor shaft 6 Detector
3 O-ring 7 Emitter diode
4 Protection guard 8 Fluorescence cap
The sensor consists of the following function units:
• Sensor shaft
• Sensor head with optics (emitter and detector)
• Fluorescence cap
• Protection guard
As an alternative to the standard protection guard, other protection guard models and a
cleaning unit can be used. The cleaning unit is suitable for immersion operation.
(→  30).

Device description, function Oxymax COS61D
8 Endress+Hauser
3.3 Memosens technology
Sensors with Memosens protocol have an integrated electronics unit that stores calibration
data and other information. Once the sensor has been connected, the sensor data are
transferred automatically to the transmitter and used to calculate the measured value.
‣Call up the sensor data via the corresponding DIAG menu.
Digital sensors can store measuring system data in the sensor. These 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 or adjustment
• Operating data
• Temperature application range
• Date of initial commissioning
• Hours of operation under extreme conditions
3.4 Fluorescence cap
The oxygen dissolved in the medium is diffused to the fluorescence layer of the
fluorescence cap. A suitable flow is not required, as no oxygen is consumed during
measurement. However, flow improves the speed at which the measuring system reacts
and ensures a more representative measured value compared to a measurement in a static
medium.
The cap is permeable for dissolved gases only. Other substances dissolved in the liquid
phase, such as ionic substances, will not penetrate through the membrane. Therefore,
medium conductivity has no impact on the measuring signal.

Oxymax COS61D Incoming acceptance and product identification
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4 Incoming acceptance and product
identification
4.1 Incoming acceptance
1. Verify that the packaging is undamaged.
 Notify the supplier of any damage to the packaging.
Keep the damaged packaging until the issue has been resolved.
2. Verify that the contents are undamaged.
 Notify the supplier of any damage to the delivery contents.
Keep the damaged goods until the issue has been resolved.
3. Check that the delivery is complete and nothing is missing.
 Compare the shipping documents with your order.
4. Pack the product for storage and transportation in such a way that it is protected
against impact and moisture.
 The original packaging offers the best protection.
Make sure to comply with the permitted ambient conditions.
If you have any questions, please contact your supplier or your local Sales Center.
4.2 Product identification
4.2.1 Nameplate
The nameplate provides you with the following information on your device:
• Manufacturer identification
• Order code
• Extended order code
• Serial number
• Safety information and warnings
‣Compare the information on the nameplate with the order.
4.2.2 Product identification
Product page
www.endress.com/cos61d
Interpreting the order code
The order code and serial number of your product can be found in the following locations:
• On the nameplate
• In the delivery papers
Obtaining information on the product
1. Go to www.endress.com.
2. Call up the site search (magnifying glass).
3. Enter a valid serial number.
4. Search.
 The product structure is displayed in a popup window.

Incoming acceptance and product identification Oxymax COS61D
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5. Click on the product image in the popup window.
 A new window (Device Viewer) opens. All of the information relating to your
device is displayed in this window as well as the product documentation.
Manufacturer address
Endress+Hauser Conducta GmbH+Co. KG
Dieselstraße 24
D-70839 Gerlingen
4.3 Scope of delivery
Scope of delivery of sensor
• Oxygen sensor with protection cap or mounted cleaning system (optional)
• Brief Operating Instructions
4.4 Certificates and approvals
A list of all the approvals is provided below. The approvals that are valid for this product
depend on the device version ordered.
4.4.1  mark
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.
4.4.2 EAC (COS61D-GR)
The product has been certified according to guidelines TP TC 004/2011 and TP TC
020/2011 which apply in the European Economic Area (EEA). The EAC conformity mark
is affixed to the product.
4.4.3 CSA GP (COS61D-CA)
Dieses Gerät hat eine CSA GP Zulassung und erfüllt die folgenden Anforderungen:
• Versorgung durch eine Klasse 2 oder begrenzte Energiequelle gemäß CSA 61010-1-12.
• Überspannungskategorie I.
• Umgebungsbedingungen: max. Höhenlage 2 000 m (6 560 ft)
4.4.4 CSAus NI Cl 1, Div 2 (COS61D-CJ)
Explosionsgefährdete Bereiche nach CSAus CL 1, DIV 2 1)
• Das Gerät muss in einem Gehäuse oder (Montage-)Schrank installiert werden, der nur
mit einem Werkzeug oder Schlüssel zugänglich ist.
• Beachten Sie die Control Drawing und die angegebenen Einsatzbedingungen im Anhang
der Betriebsanleitung sowie die dortigen Hinweise.
Ex-Zulassungen
Class 1, Division 2, Groups A, B, C und D T6; IP67/IP68 1)
1) Nur bei Anschluss an CM44x(R)-CD*

Oxymax COS61D Incoming acceptance and product identification
Endress+Hauser 11
Dieses Produkt erfüllt die Anforderungen der folgenden Normen:
• ANSI/UL 61010-1, 3. Ed.
• ANSI/UL 121201-2017
• ANSI/IEC 60529, Edition 2.2. 2013-08 Degrees of protection provided by enclosures (IP
Code)
Installation und Betrieb in explosionsgefährdeten Bereichen CL 1, DIV 2
Dieses nicht-funkende Gerät hat folgende spezifizierte Explosionsschutz-Daten:
• CSAus CL 1, DIV 2
• Groups A, B, C, and D
• Temperaturklasse T6, –20 °C (–4 °F) ≤ Ta ≤ 60 °C (140 °F)
• IP-Schutzart: IP67/IP68
• Control drawing: 211050778

Installation Oxymax COS61D
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5 Installation
5.1 Mounting conditions
5.1.1 Orientation
45°
135°
45°
0° 180°
A0032281
 2 Installation angle
Recommended installation angle
Possible installation angle
Inadmissible installation angle
The sensor must be installed at an angle of inclination in an assembly, holder or
appropriate process connection. Recommended angle: 45° to prevent the attachment of air
bubbles. At angles of inclination of 45 to 135°, air bubbles at the oxygen-sensitive
membrane may increase the measured value.
The sensor can be installed up to the horizontal in an assembly, holder or suitable process
connection. The optimum installation angle is 45°.
Other angles and upside-down installation are not recommended. Reason: Possible
sediment formation and resulting falsification of measured value.
Follow the instructions for installing sensors in the Operating Instructions for the
assembly used.
5.1.2 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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5.2 Mounting the sensor
5.2.1 Measuring system
COS61D
A complete measuring system consists of the following components at least:
• Oxymax COS61D oxygen sensor
with fixed cable (with ferrules or M12 plug depending on the version ordered)
• Liquiline CM44x multi-channel transmitter
• Assembly, e.g. flow assembly COA250, immersion assembly CYA112 or
retractable assembly COA451
Optionally:
• Flexdip CYH112 assembly holder for immersion operation
• Extension cable CYK11 with junction box
• Cleaning system
1 2
3
4
5
6
A0042837
 3 Example of a measuring system with COS61D
1
2
3
Sensor cable
Transmitter Liquiline CM44x
Assembly Flexdip CYH112
4
5
6
Basin rim with railing
Oxymax COS61D oxygen sensor
Flexdip CYA112 assembly

Installation Oxymax COS61D
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5.2.2 Mounting the cleaning unit or optional protection guard
If the cleaning unit was not delivered as a pre-assembled unit or if an optionally ordered
protection guard is used:
1.
A0042840
Unscrew the standard protection guard.
 Retain the standard protection guard for possible reuse at a later stage without
the cleaning unit.
2.
A0042841
Screw on the cleaning unit or optional protection guard and tighten until the stop.
 The cleaning nozzle of the cleaning unit should now be level with the spot.
1
2
1 Cleaning nozzle
2 Spot
3.
Connect the hose for the compressed air supply (to be provided onsite) or compressor
(→  30) to the hose connection of the cleaning unit.

Oxymax COS61D Installation
Endress+Hauser 15
5.2.3 Installing at a measuring point
Must be installed in a suitable assembly.
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 immersion operation, install individual assemblies away from the basin on a
solid base.
• Final assembly must be performed only at the assigned mounting location.
• Choose a mounting location that is easy to access.
• During final installation, it must be ensured that the metal sensor body is connected
to earth, if necessary.
For complete installation of a measuring point, proceed as follows:
1. Install the retractable assembly or 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 fluorescence 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 the sensor body steady during installation or removal. Otherwise the fluorescence
cap or protection guard might be unscrewed. These will then remain in the process or
assembly.
‣During final installation, it must be ensured that the metal sensor body is connected to
earth.
‣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.

Installation Oxymax COS61D
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5.3 Installation examples
5.3.1 Immersion operation
Universal holder and chain assembly
1
5
2
4
3
6
A0042857
 4 Chain holder on railing
1 Chain
2 Holder Flexdip CYH112
3 Rail
4 Basin rim
5 Oxygen sensor
6 Wastewater assembly Flexdip CYA112
1 2
3
6
4
5
7
A0042858
 5 Chain holder on upright post
1 Weather protection cover CYY101
2 Transmitter
3 Chain
4 Wastewater assembly Flexdip CYA112
5 Oxygen sensor
6 Basin rim
7 Holder Flexdip CYH112

Oxymax COS61D Installation
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Universal holder and fixed immersion tube
12
3
4
6
5
A0042859
 6 Assembly holder with immersion tube
1 Protective cover
2 Transmitter
3 Flexdip CYA112 immersion assembly
4 Oxygen sensor
5 Basin rim
6 Assembly holder Flexdip CYH112
Basin rim mounting with immersion tube
12
3
4
5
A0042860
 7 Basin rim mounting
1 Pendulum holder CYH112
2 Assembly Flexdip CYA112
3 Assembly float
4 Oxygen sensor
5 Basin rim

Installation Oxymax COS61D
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Float
The CYA112 float is for use in the case of large fluctuations in water level, for example in
rivers or lakes.
1
2
3
4
5
6
7
G1
800 (31.50)
500 (19.69) 220 (8.66)
Ø200 (7.87)
A0032159
 8 Dimensions in mm (inch)
1 Cable run with strain relief and rain shield
2 Fixing ring for rope and chains with terminal screw
3 Eyelets Ø15, 3 x 120 ° for anchoring
4 Plastic float, resistant to salt water
5 Pipe 40 x 1, stainless steel 1.4571
6 Bumper and ballast
7 Oxygen sensor
5.3.2 Flow assembly COA250
A0013319
 9 COA250
1
23
4
6
7
8
5
A0030570
 10 Bypass installation with manually actuated valves or solenoid
valves
1 Main pipe
2 Medium return
3 Oxygen sensor
4, 7 Manually actuated or solenoid valves
5 Flow assembly COA250-A
6 90 ° pipe elbow
8 Medium removal

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5.3.3 Retractable assembly COA451
5
3
4
1
2
3
Detail A
Detail A, 90 ° r
A0030571
 11 Permissible and impermissible sensor installation positions with retractable assembly COA451
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)
4 Down pipe, impermissible
Possible installation angle
Inadmissible installation angle
NOTICE
Sensor not fully immersed in the medium, buildup on sensor membrane or sensor
optics, buildup due to sensor being installed upside down
Incorrect measurements are possible and these may affect the measuring point.
‣Do not install the assembly at points where air pockets or bubbles form or where
suspended particles may build up at the sensor membrane or sensor optics (item 2).
5.4 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.

Electrical connection Oxymax COS61D
20 Endress+Hauser
6 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.
6.1 Connecting the sensor
Connection data
Sensor cable connected directly to the terminal connector of the basic module of the
transmitter
GN
PK
GY
YE
COM A
COM B
U+
U–
 12 Sensor fixed cable with terminated cable cores
Optional: sensor cable plug connected to the M12 sensor socket of the transmitter
With this type of connection, the transmitter is already wired at the factory.
6.2 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.
6.3 Post-connection check
Device condition and specifications Action
Are the sensor, assembly or cables free from damage
on the outside?
‣Perform a visual inspection.
Electrical connection Action
Are the mounted cables strain-relieved and not
twisted?
‣Perform a visual inspection.
‣Untwist the cables.
Is a sufficient length of the cable cores stripped, and
are the cores positioned in the terminal correctly?
‣Perform a visual inspection.
‣Pull gently to check they are seated correctly.
Are all the screw terminals properly tightened? ‣Tighten the screw terminals.
Are all cable entries mounted, tightened and leak-
tight?
‣Perform a visual inspection.
In the case of lateral cable entries:
‣Point cable loops downward so that water can drip
off.
Are all cable entries installed downwards or mounted
laterally?