Endress + Hauser Operating Instructions Oxymax COS61 Dissolved oxygen sensor

Operating Instructions Oxymax COS61 Dissolved oxygen sensor BA00387C/07/EN/13.12 71162645 Documentation information Warnings 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"). Safety message structure Meaning This symbol alerts you to a dangerous situation. ! DANGER Failure to avoid the situation will result in a fatal or serious Cause (/consequences) Consequences if safety message injury. is not heeded ► Corrective action This symbol alerts you to a dangerous situation. ! WARNING Failure to avoid the situation can result in a fatal or serious Cause (/consequences) Consequences if safety message injury. is not heeded ► Corrective action This symbol alerts you to a dangerous situation. ! CAUTION Failure to avoid this situation can result in minor or medium Cause (/consequences) Consequences if safety message injury. is not heeded ► Corrective action This symbol alerts you to situations that can result in damage to NOTICE property and equipment. Cause/situation Consequences if safety message is not heeded ► Action/note Symbols used Èä1 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). Additional information, tips Permitted or recommended Forbidden or not recommended Endress+Hauser Oxymax COS61 Table of contents 1 Basic safety instructions . . . . . . . . . . . . 4 10 Technical data . . . . . . . . . . . . . . . . . . . 28 1.1 1.2 1.3 1.4 1.5 Requirements for personnel . . . . . . . . . . . . . . . . . . . Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . Occupational safety . . . . . . . . . . . . . . . . . . . . . . . . . Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 10.2 10.3 10.4 10.5 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance characteristics . . . . . . . . . . . . . . . . . . Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical construction . . . . . . . . . . . . . . . . . . . . 2 Identification . . . . . . . . . . . . . . . . . . . . 6 2.1 2.2 2.3 Product page and configurator . . . . . . . . . . . . . . . . . 6 Order code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 Installation . . . . . . . . . . . . . . . . . . . . . . 7 3.1 3.2 3.3 3.4 3.5 Incoming acceptance, transport, storage . . . . . . . . . . 7 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . 7 Installation instructions . . . . . . . . . . . . . . . . . . . . . . 8 Installation examples . . . . . . . . . . . . . . . . . . . . . . . 10 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 14 4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 15 4.1 4.2 4.3 Direct connection to the transmitter . . . . . . . . . . . 15 Connection via junction box . . . . . . . . . . . . . . . . . 16 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 16 5 Device description . . . . . . . . . . . . . . . 17 5.1 5.2 5.3 Sensor design . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . 18 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6 Commissioning. . . . . . . . . . . . . . . . . . 21 6.1 6.2 6.3 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Automatic cleaning . . . . . . . . . . . . . . . . . . . . . . . . 21 7 Maintenance. . . . . . . . . . . . . . . . . . . . 22 7.1 7.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Replacing wear and tear materials . . . . . . . . . . . . . 23 8 Accessories. . . . . . . . . . . . . . . . . . . . . 24 8.1 8.2 8.3 Connection accessories . . . . . . . . . . . . . . . . . . . . . 24 Installation accessories . . . . . . . . . . . . . . . . . . . . . . 24 Cleaning and calibration . . . . . . . . . . . . . . . . . . . . 25 9 Trouble-shooting . . . . . . . . . . . . . . . . 26 9.1 9.2 9.3 9.4 9.5 Trouble-shooting instructions . . . . . . . . . . . . . . . . Sensor checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Endress+Hauser 4 4 4 4 5 28 28 28 28 29 Index . . . . . . . . . . . . . . . . . . . . . . . . . . 30 26 26 27 27 27 3 Basic safety instructions Oxymax COS61 1 Basic safety instructions 1.1 Requirements for personnel ► 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. ► Measuring point faults may only be rectified by authorized and specially trained personnel. Repairs not described in the enclosed Operating Instructions may only be carried out directly at the manufacturer's or by the service organization. 1.2 Designated use The oxygen sensor is suitable for continuous measurement of dissolved oxygen in water. Typical applications are: • Measuring, monitoring and regulating the oxygen content in activated sludge basins. • Monitoring the oxygen content in the sewage treatment plant outlet. • Monitoring, measuring and regulating the oxygen content in public waters and fish farming water. • Monitoring of oxygen enrichment in drinking water. 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. 1.3 Occupational safety As the user, you are responsible for complying with the following safety conditions: • Installation instructions • Local standards and regulations Electromagnetic compatibility With regard to electromagnetic compatibility, this device has been tested in accordance with the applicable European standards for industrial applications. The electromagnetic compatibility indicated only applies to a device that has been connected in accordance with the instructions in these Operating Instructions. 1.4 Operational safety ► 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. ► If faults cannot be rectified, the products must be taken out of service and secured against unintentional commissioning. CAUTION The cleaning system is 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 are not switching off the cleaning system because you wish to test the cleaning function, wear protective clothing, goggles and gloves or take other appropriate measures. ! 4 Endress+Hauser Oxymax COS61 Basic safety instructions 1.5 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. Relevant regulations and European standards have been observed. Endress+Hauser 5 Identification Oxymax COS61 2 Identification 2.1 Product page and configurator You can create a complete and valid order code by using the configurator on the internet product page. Product page link: www.products.endress.com/cos61 2.2 Order code 1. You can choose from the following options on the product page located on the right: 2. Click "Configure this product". 3. The configurator opens in a separate window. Use the radio buttons to configure the order code from the nameplate of your device. 4. Afterwards, you can export the order code as a PDF or Excel file. To do so, click the appropriate button at the top of the page. 2.3 Scope of delivery The following items are included in the delivery: • Oxygen sensor with transport protection cap for membrane protection • Operating Instructions (on CD only) • Brief Operating Instructions (paper version) If you have any questions, please contact your supplier or your local sales center. 6 Endress+Hauser Oxymax COS61 Installation 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 Dimensions a0004083-en Fig. 1: Endress+Hauser Fixed cable version a0004084-en Fig. 2: TOP68 version 7 Installation Oxymax COS61 3.2.2 Angle of installation The sensor can be installed up to the horizontal in an assembly, support or a suitable process connection. Other angles and overhead installation are not recommended. Reason: possible sediment formation and resulting falsification of measured value. The optimum installation angle is 45˚ (e.g. with assembly CYA112). a0004087 Fig. 3: A Angle of installation Permissible installation positions: 0 ... 180 ˚, optimum angle 45 ˚ ► Make sure you comply with the instructions for installing sensors. You will find them in the Operating Instructions for the assembly used. 3.2.3 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. 3.3 Installation instructions 3.3.1 Measuring system A complete measuring system comprises: • Oxygen sensor Oxymax COS61 • Transmitter, e.g. Liquisys COM2x3-W • Special measuring cable • Assembly, e.g. COA250 flow assembly, CYA112 immersion assembly or COA451 retractable assembly Optional: • CYH112 assembly holder for immersion operation • VS junction box (for cable extension) • Cleaning system 8 Endress+Hauser Oxymax COS61 Installation a0012885 Fig. 4: 1 2 3 Measuring system (example) Liquisys COM253 transmitter COS61 oxygen sensor Pipework (ascending pipe) 3.3.2 4 5 6 Medium flow direction Retractable assembly Cleanfit COA451 Sensor cable Installing a measuring point For immersed operation, install the individual modules away from the basin on a solid base. Only carry out the final installation at the intended installation location. 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. 4. Install an immersion or an suspension assembly (if used) into the process. NOTICE No assembly used, sensor not correctly installed, grounding regulations not observed Risk of damaging the sensor cable, no protection to electromagnetic interferencies ► Screw the sensor into the assembly so that the cable is not twisted. ► Avoid exerting excessive tensile force on the cable (e.g. from jerky pulling). ► When using metallic assemblies and installation equipment, comply with national grounding regulations. ► Observe the sensor installation instructions of the Operating Instructions of the assembly used. Endress+Hauser 9 Installation Oxymax COS61 3.4 Installation examples 3.4.1 Immersion operation Upright post and chain assembly For large basins, where sufficient installation distance is required from the basin edge (aeration basin, especially), it is advisable to use the upright post and chain assembly. The free swinging of the immersed assembly practically rules out vibrations from the upright post. A good self-cleaning of the fluorescence cap is reached due to the swinging of the assembly. According to this effect, the sensor life time can be extended. a0013510 Fig. 5: 1 2 3 4 5 10 Chain holder, rail mounted Chain Flexdip CYH112 holder Rail Oxymax sensor Flexdip CYA112 wastewater assembly a0013511 Fig. 6: 1 2 3 4 5 6 Chain holder, mounted to a post Weather protection cover #ontroller / transmitter Chain Flexdip CYA112 wastewater assembly Oxymax sensor Flexdip CYH112 holder Endress+Hauser Oxymax COS61 Installation Upright post and fixed immersion assembly The preferable type of installation for strong or turbulent flow (> 0.5 m/s) in the basin or open channels is to secure the device to an upright post and a securely mounted immersion tube. If the flow is very strong, a second transverse pipe can be installed with its own pipe support. a0013513 Fig. 7: 1 2 3 4 5 Endress+Hauser Assembly holder with immersion tube Weather protection cover CYY101 Controller / transmitter Immersion assembly Flexdip CYA112 Oxymax sensor Assembly holder Flexdip CYH112 11 Installation Oxymax COS61 Basin rim mounting with immersion assembly For fixing to the sides of the basin or channel, we recommend the pendulum holder of the immersion tube. Optionally, you can also use the assembly with a float. 1 2 3 4 a0013693 Fig. 8: 1 2 3 4 Basin rim mounting Pendulum holder CYH112 Assembly Flexdip CYA112 Float of assembly CYA112 Oxymax sensor Floating body To aid installation in strongly fluctuating water levels, e.g. in rivers or lakes, there is a floating body COA 110-50 available (→ å 9). mm/inch 1 2 1 500/19.69 800/31.50 220/8.66 2 Ø200/7.87 3 4 5 6 7 3 Cable route with strain relief and rain protection Mounting ring for ropes and chains with locking screw Lugs Ø15, 3 x 120 ˚ for anchoring Saltwater-resistant plastic float Pipe 40x1, stainless steel 1.4571 (AISI 316Ti) Shock absorber and weight Oxygen sensor 4 G1 5 6 7 a0004108-en Fig. 9: 12 Floating body Endress+Hauser Oxymax COS61 Installation 3.4.2 Flow assembly The COA250 flow assembly with automatic self-venting is suitable for use in pipelines or hose connections. The inlet is at the bottom of the assembly, the outlet at the top (connection thread G¾). It can be installed in a pipe by using two 90˚ pipe brackets to allow inflow to the assembly (→ å 11, Pos. 6). 1 8 3 7 6 5 2 4 a0004114 Fig. 11: a0004113-en Fig. 10: 1 2 3 4 5 Flow assembly COA250 Screw-in part for sensor Screw ring Meter body Connection thread G¾ Dummy plug (connection for spray head CUR3) 3.4.3 1 2 3 4, 7 5 6 8 Bypass installation with manually actuated valves or solenoid valves Main line Medium return Oxygen sensor Manually actuated or solenoid valves Flow assembly COA250 90 ˚ pipe bracket Medium removal Retractable assembly 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"). a0004117-en Fig. 12: 1 2 3 4 5 Endress+Hauser Permissible and impermissible sensor installation positions Ascending pipe, best position Horizontal pipe, sensor top down, impermissible due to air cushion or foam bubble forming Horizontal pipe, installation with permissible emitting angles (acc. to sensor version) Overhead installation, impermissible due to missing electrolyte contact of the sensor electrodes Down pipe, impermissible 13 Installation Oxymax COS61 NOTICE Sensor not immersed into the medium, suspended particles settled on the sensor membrane or sensor optics, sensor installed overhead Measuring errors can occur ► Do not install the assembly at places, where air cushions or foam bubbles can be formed or where suspended particles can settle on the sensor membrane or optics (→ å 12). 3.5 ► ► ► ► ► 14 Post-installation check Sensor and cable undamaged? Cap 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? Endress+Hauser Oxymax COS61 Wiring 4 Wiring 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 Direct connection to the transmitter 4.1.1 Field installation Connect the sensor directly to the transmitter by using the special measuring cable with SXP plug. a0004118 Fig. 13: 4.1.2 SXP plug Panel mounting • Remove the SXP connector (transmitter side!) from the cable. • Refer to the following table for the cable assignment and the assigned terminals for Liquisys COM223-WX/WS. • Please note that the cable assignment varies depending on the sensor version (fixed cable or TOP68 connection). Terminal COM223 Endress+Hauser Sensor with fixed cable (OMK) Sensor with TOP68 connection (CYK71) Core Assignment Core Assignment 87 YE +UB YE +UB 0 GY 0V WH 0V 96 PK Com. (digital) GN Communication (digital) 97 BU Com. (digital) BN Communication (digital) 88 BN –UB Koax innen –UB 15 Wiring Oxymax COS61 4.2 Connection via junction box To lengthen the sensor connection beyond the length of the fixed cable, you require a junction box VS. Always connect the sensor cable with the SXP plug to the junction box. The cable extension to the transmitter then depends from the transmitter version, i.e. field device or panel mounted device. 1 82 / 3.23 80 / 3.15 4 YE GY PK BU BN 2 GN 3 2 WH mm / inch 1 2 4.3 0 96 97 88 19 18 a0004130 a0004129-en Fig. 14: 87 Junction box VS to a field device SXP plug to field device SXP plug from sensor Fig. 15: 2 3 4 Junction box VS to a panel mounted device SXP plug from sensor Measuring cable (OMK) to the transmitter Connection department of the transmitter Post-connection check Instrument status and specifications Remarks Are the sensor, assembly, junction box or cable damaged? Visual inspection Electrical connection Remarks Does the supply voltage of the transmitter match the specifications on the nameplate? Are the installed cables strain-relieved and not twisted ? Is the cable type route completely isolated ? Power cable/weak current cable Are the power supply and signal cable correctly connected to the transmitter ? Use the connection diagram of the transmitter. 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 ? 16 Endress+Hauser Oxymax COS61 Device description 5 Device description 5.1 Sensor design 1 5 2 6 3 7 4 8 a0004151 Fig. 16: 1 2 3 4 5 6 7 8 Sensor design Sensor cable Sensor shaft O-ring Protection guard Threaded connection Detector Emitter diode Fluorescence cap The sensor consists of the following function units: • Sensor shaft • Sensor head with optics (emitter and detector) • Fluorescence cap • Protection basket • Alternatively to the protection basket, you can use a spray head COR 3 (optional, see "Accessories") for use in immersed operation with cleaning function. Endress+Hauser 17 Device description Oxymax COS61 5.2 Measuring principle 5.2.1 Oxygen measurement based on the principle of fluorescence quenching • Sensor design: – Oxygen-sensitive molecules (markers) are integrated in an optically active layer (fluorescence layer). – The surface of the fluorescence layer is in contact with the medium. – The sensor optics are directed at the underside of the fluorescence layer. • There is an equilibrium between the oxygen partial pressure in the medium and that in the fluorescence layer: – If the sensor is immersed in the medium, the equilibrium is established very quickly. • Measuring process: – The sensor optics send green light pulses to the fluorescence layer. – The markers "answer" (fluoresce) with red light pulses. – The duration and intensity of the response signals is directly dependent on the oxygen contents and the partial pressure. – If the medium is free from oxygen, the response signals are long and very intense. – Oxygen molecules quench the marker molecules. As a result, the response signals are shorter and less intense. • Measurement result: – The sensor returns a signal that is in proportion to the oxygen concentration in the medium. – The medium temperature and air pressure are already taken into account calculated in the sensor. – In addition to the standard values of concentration, saturation index and partial pressure, the sensor also returns a raw measured value in μs. The value corresponds to the decay time of the fluorescence and is approx. 20 μs in air, and approx. 60 μs in media free from oxygen. 5.2.2 Fluorescence cap The oxygen dissolved in the medium is diffused into the fluorescence cap. Suitable flow is not necessarily mandatory but it does improve the speed at which the measuring system responds and ensures a more representative measured value compared to a measurement in static medium. The cap 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. 5.3 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: • Changing the fluorescence cap 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. Ideally, use the calibration vessel (see Accessories) for calibration. For this purpose, unscrew the basket protector from the sensor and guide the sensor into the calibration vessel as far as it will go (resting on the vessel rim). 18 Endress+Hauser Oxymax COS61 Device description 5.3.1 Types of calibration Types of calibration: • Air (preferably saturated water vapor, e.g. near the water surface) – Measured values between 70 and 130 %SAT result in the calibration of the measured value at air – Measured values smaller than 15 %SAT result in the calibration of the zero point • Air-saturated water – Like air calibration • Reference measured value (entry at transmitter, sensor remains in the medium). – Measured values between 50 and 150 %SAT result in the calibration of the measured value to the reference value while maintaining the zero point – Measured values smaller than 10 %SAT result in the calibration of the measured value to the reference value while maintaining the measured value at air If necessary, calibrate COS61 practically: • In the air (water-vapor saturated) type of calibration in order to calibrate the measured value at air. • In the air-saturated water type of calibration, but while using oxygen-free water, (see "Sensor check" section), to calibrate the zero point. 5.3.2 Calibration intervals You can determine the intervals with the following method: 1. Check the sensor one month after its being put into operation: – Remove the sensor from the medium. – Clean the outside of the sensor with a damp cloth. – Measure the oxygen saturation index at air after 20 minutes. 2. Decide using the results: a. If the measured value is not at 100 ±2 %SAT, you have to calibrate the sensor. b. Otherwise, lengthen the time to the next inspection. 3. Proceed as per Point 1 after two, four and/or eight months. In this way, you can determine the optimum calibration interval for your sensor. 5.3.3 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). Endress+Hauser 1. Determine: – The ambient temperature for the sensor (air temperature for "air" calibration method,water temperature for "air-saturated water" calibration type) – the altitude above sea level – the current air pressure L (=rel. air pressure to sea level) at the time of calibration. (If undeterminable, use 1013 hPa (407 inH2O) for an approximate calculation.) 2. Define: – the saturation value S acc. to the first table – the factor K acc. to the second table 19 Device description Oxymax COS61 ˚ C / ˚F S [mg/ l=ppm] ˚ C / ˚F S [mg/ l=ppm] ˚ C / ˚F S [mg/ l=ppm] ˚ 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] K Altitude [m / ft] K Altitude [m / ft] K Altitude [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 0.810 300 / 980 0.966 850 / 2790 0.905 1350 / 4430 0.854 1850 / 6070 0.805 350 / 1150 0.960 900 / 2950 0.900 1400 / 4600 0.849 1900 / 6230 0.801 400 / 1320 0.954 950 / 3120 0.895 1450 / 4760 0.844 1950 / 6400 0.796 450 / 1480 0.949 1000 / 3300 0.890 1500 / 4920 0.839 2000 / 6560 0.792 500 / 1650 0.943 3. Calculate the factor L: relative air pressure during calibration L= ----------------------------------------------------------------------------- 1013 hPa 4. Calculate the calibration value C: C=S.K.L Example • Air calibration at 18˚C (64 ˚F), altitude 500 m (1650 ft) above sea level, air pressure 1009 hPa (405 inH2O) • S = 9.45 mg/l, K = 0.943, L = 0.996 Calibration value C = 8.88 mg/l. You do not need factor K from the table if your device returns the absolute air pressure Labs (location-dependent air pressure) as the measured value. Thus, the formula for calculation is: C = S . Labs. 20 Endress+Hauser Oxymax COS61 Commissioning 6 Commissioning 6.1 Function check Before first commissioning, check if: • the sensor is correctly installed • the electrical connection is correct. If using an assembly with automatic cleaning, check the correct connection of the cleaning agent (e.g. water or air). ! WARNING Escaping process medium Risk of injury from high pressure, high temperatures or chemical hazards ► Before applying compressed air to an assembly with cleaning facility, make sure the connections are correctly fitted. ► Do not install the assembly in the process if you cannot make the correct connection reliably. 6.2 Calibration The sensor is calibrated at the factory. A new calibration is only needed in special situations. 6.3 Automatic cleaning Compressed air is most suitable for cyclic cleaning. The cleaning unit is either ready supplied or can be retrofitted, and is attached to the sensor head. It operates at a capacity of 20-60 l/min. Optimum results are achieved with 2 bar (29 psi) and 60 l/min. The following settings are recommended for the cleaning unit: Type of soiling Endress+Hauser Cleaning interval Cleaning duration Media containing grease and oils 15 min 20 s Biofilm 60 min 20 s 21 Maintenance Oxymax COS61 7 Maintenance Maintenance work must carried out at regular intervals. To ensure that it is carried out, we recommend you enter the maintenance dates into an operations logbook or in an operations calendar in advance. The maintenance cycle primarily depends on: • the system • the installation conditions and • the medium in which measurement is taking place. The following activities must be carried out: • Cleaning the sensor • If necessary, replacing wear and tear materials: – sealing ring – electrolyte – fluorescence cap • Check the measuring function: – Remove the sensor from the medium. – Clean and dry the membrane. – After about 10 minutes, measure the oxygen saturation index in air (without recalibration). – The measured value should be near to 100% SAT (display of O2 saturation with COM 2x3: press plus key four times). • Recalibration. (if desired or required) 7.1 Cleaning The measurement can be corrupted by sensor fouling or malfunction, e.g.: • Buildup on the fluorescence cap --> cause longer response times and a reduced slope under certain circumstances. To ensure reliable measurement, the sensor must be cleaned at regular intervals. The frequency and intensity of the cleaning operation depend on the measuring medium. 7.1.1 External cleaning Clean the outside of the sensor: • before every calibration • at regular intervals during operation as necessary • before returning it for repairs. Depending on the type of soiling, proceed as follows: Type of soiling Cleaning Salt deposits Immerse the sensor in drinking water or in 1-5% hydrochloric acid for a few minutes. Afterwards, rinse it with copious amounts of water. Dirt particles on the sensor body (not cap!) Clean the sensor body mechanically with water and a suitable brush. Dirt particles on the fluorescence cap Clean with water and a soft sponge. ► After cleaning, rinse the sensor with copious amounts of clean water. 22 Endress+Hauser Oxymax COS61 Maintenance 7.1.2 Cleaning the optics The optics only need to be cleaned if medium has penetrated through a defective fluorescence cap. To clean it, proceed as follows: 1. Unscrew the protection guard and fluorescence cap from the sensor head. 2. Carefully clean the optical surface with a soft cloth until the buildup is fully removed. 3. Clean the optics with drinking or distilled water. 4. Clean the optics and screw on a new fluorescence cap. NOTICE Damages, scratches on the optical surface Faulty measured values ► Ensure that the optical surface is not scratched or damaged in any way. 7.2 Replacing wear and tear materials 7.2.1 Replacing the sealing ring The sealing ring must be replaced if visibly damaged. For replacement, use only original sealing rings. 7.2.2 Replacing the fluorescence cap The typical operating life of a fluorescence cap is more than 2 years. The sensor checks whether the cap is aging and issues a warning via the transmitter if the rate of aging reaches a specific value. The sensor is still able to measure at this stage. However, it is advisable to change the cap as quickly as possible. Removing the old fluorescence cap 1. Remove the sensor from the medium. 2. Unscrew the protection guard. 3. Clean the outside of the sensor. 4. Unscrew the fluorescence cap. 5. Clean and dry the optical surface if necessary. Installing the new fluorescence cap 6. Make sure that there are no dirt particles on the sealing surface. 7. Carefully screw the fluorescence cap onto the sensor head until the stop. 8. Screw the protection guard back on. After replacing the fluorescence cap, the sensor must be recalibrated. Then insert the sensor into the medium and check that no alarm is displayed on the transmitter. Endress+Hauser 23 Accessories Oxymax COS61 8 Accessories In the following sections, you find the accessories available at the time of issue of this documentation. For information on accessories that are not listed here, please contact your local service or sales center. 8.1 Connection accessories VS junction box • With plug-in socket and 7-pole plug • For cable extension from sensor (COS71, COS61, COS31, COS3 with SXP connector) to transmitter, IP 65; • Order no. 50001054 Measuring cable OMK • for use as extension cable between junction box VS and transmitter, not terminated • sold by the metre - order no. 50004124 COK31 special measuring cable • for sensors COS31, COS61 and COS71 with TOP68 plug-in head • Order numbers: – Cable length 1.5 m (4.9 ft): 51506820 – Cable length 7 m (23 ft): 51506821 – Cable length 15 m (49 ft): 51506822 8.2 Installation accessories Immersion assembly COA110 • for sensor immersion in the basin, PVC pipe resp. PUR floating body with SS 1.4571 (AISI 316Ti) immersion tube • Ordering acc. to product structure (see Technical Information TI035C/07/en) Flow assembly COA250 • For sensor installation in pipe lines, PVC • Ordering acc. to product structure (--> Online configurator: www.products.endress.com/ coa250) • Technical Information TI00111C/07/EN Retractable assembly Cleanfit COA451 • Manually driven retractable assembly, stainless steel, with ball valve, for oxygen sensors; • Ordering acc. to product structure (--> Online configurator: www.products.endress.com/ coa451) • Technical Information TI00368C/07/EN Holder system Flexdip CYH112 for water • Modular holder system for sensors and assemblies in open basins, channels and tanks • The holder system CYH112 works for nearly any type of fixing - fixing on the floor, wall or directly on a rail. • Material: stainless steel • Ordering acc. to product structure (--> Online configurator: www.products.endress.com/ cyh112) • Technical Information TI00430C/07/EN Wastewater assembly Flexdip CYA112 • Modular assembly system for sensors in open basins, channels and tanks • Versions in stainless steel or PVC • Ordering per product structure (--> Online configurator: www.products.endress.com/cya112) • Technical Information TI00432C/07/EN 24 Endress+Hauser Oxymax COS61 Accessories Baffle plate OP • extra protection for extreme flow conditions • order no. 50028712 Membrane protection guard COY3-SK • for sensor use in fish ponds • order no. 50081787 8.3 Cleaning and calibration Pressurized air cleaning system for COSXX • Connection: 6/8 mm or 6.35 mm (¼") • Materials: POM/V4A • Order numbers – 6/8 mm: 71110801 – 6.35 mm (¼"): 71110802 Compressor • For cleaning system • 230 V AC order number: 71072583 • 115 V AC order number: 71096199 Chemoclean • Injector CYR10 • Ordering acc. to product structure • Technical Information TI00046C/07/EN Chemoclean COR3 • Spray head for sensor cleaning in immersion operation • Material: PVC • order no.: COR3-0 Calibration vessel • for COS61/61D • order no. 51518599 Endress+Hauser 25 Trouble-shooting Oxymax COS61 9 Trouble-shooting 9.1 Trouble-shooting instructions Problem No display, no sensor reaction Check Remedial action Mains voltage to the transmitter? Connect mains voltage. Sensor connected correctly? Set up correct connection. Coating on the fluorescence cap? Clean the sensor. Medium flow available? Create flow. With a TOP 68 connection: humidity or dirt in Cleaning of the TOP 68 plug-in plug? connection by using cleaning alcohol. Displayed value too high Displayed value too low Strong deviations in displayed value Temperature display clearly too low? Check sensor, if necessary send sensor in for repair. Humidity or dirt in plug? Cleaning by using cleaning alcohol. Sensor calibrated? Recalibrate Medium flow available? Create flow. Displayesd temperature clearly too high? Check sensor, if necessary send sensor in for repair. Coating on the fluorescence cap? Replace Fluorescence cap worn out? Replace Fluorescence cap damaged? Replace fluorescence cap. EMC interference on the measuring system? Remove outer screening of sensor and extension cable at terminal S. Cut measuring and signalling lines from h.v. power lines. Make sure you comply with the instructions for troubleshooting in the Operating Instructions of the transmitter. If necessary, carry out a test of the transmitter. 9.2 Sensor checks Only authorised and trained personnel may test the sensor! You will also require a multimeter (voltage, resistance). Check Measure Setpoint Voltage inspection With the sensor connected, test the operating voltage on the transmitter: COM2x3-WX/WS between terminals 87 and 0: +8 V between terminals 88 and 0: –8 V Slope inspection Place the sensor in the air, and dry with a paper towel. After 10 minutes: approx. 100% SAT (4 times plus-key) Zero point inspection Immerse the sensor in zero solution1. Display near to 0 mg/l (0% Sat) 1 26 How to use the zero solution: 1. Fill a large beaker (1.5 - 2 l) with approx. 1 l of water. 2. Pour a cap-full of the zero solution into the water. 3. Immerse the sensor into the water and wait a sufficient period of time (15 min. for oxygen depletion). The display drops to around 0 mg/l (0 %SAT). Endress+Hauser Oxymax COS61 Trouble-shooting Depending on the conditions (contact surface water/air), the zero solution is stable for up to 12 hours. If there are deviations from the reference values, follow the troubleshooting instructions or contact your sales office. 9.3 Spare parts Position Spare parts kit order no. 1 Sensor acc. to product structure 2 Sealing ring – 2 pieces 51518597 3 Sensor cap (fluorescence cap) 51518598 1 2 without fig. Zero solution – 3 units to produce 3 x 1 litre oxygen free solution 50001041 3 4 a0004166 Fig. 17: 9.4 Spare parts Return The device must be returned if repairs or a factory calibration are required, or if the wrong device has been ordered or delivered. According to legal regulations, Endress+Hauser, as an ISO-certified company, is required to follow certain procedures when handling returned products that are in contact with medium. To ensure swift, safe and professional device returns, please read the return procedures and conditions on the internet site: www.services.endress.com/return-material 9.5 Disposal The device contains electronic components and must therefore be disposed of in accordance with regulations on the disposal of electronic waste. Please observe local regulations. Endress+Hauser 27 Technical data Oxymax COS61 10 Technical data 10.1 Input Measured variable Dissolved oxygen [mg/l, % SAT, hPa] Temperature [˚ C, ˚ F] Measuring range With Liquisys COM 2x3-W: 0 to 20 mg/l (0 to 20 ppm) 0 to 200 % SAT 0 to 400 hPa 10.2 Performance characteristics Response time t90: 60 s Maximum measured error 0.02 mg/l or ±1 % of measured value (< 12 mg/l) ±2 % of measured value (from 12 to 20 mg/l) Repeatability ±0.5 % of measuring range end Lifetime of the sensor cap >2 years (under reference operating conditions, protect against direct sun light) 10.3 Environment Ambient temperature range –20 to +60 ˚C (0 to 140 ˚F) Storage temperature –20 to +70 ˚C (0 to 160 ˚F) at 95% relative humidity, non condensing Ingress protection • Fixed cable versions: IP 68 (test conditions: 10 m (33 ft) water column at 25 ˚C (77 ˚F) in 30 days) • Top 68 plug-in head versions: IP 68 (test conditions: 1 m (3.3 ft) water column at 50 ˚C (122 ˚F) in 7 days) 10.4 Process Process temperature –5 to 60 ˚C (20 to 140 ˚F) Process pressure max. 10 bar (145 psi) max. 10 bar (145 psi) abs. 28 Endress+Hauser Oxymax COS61 Technical data 10.5 Mechanical construction Weight With cable length 7 m (23 ft): 0.7 kg (1.5 lbs.) With cable length 15 m (49 ft): 1.1 kg (2.4 lbs.) With TOP68 plug-in connection: 0.3 kg (0.66 lbs.) Materials Sensor shaft: Cap with fluorescence layer: Fluorescence layer: Process connection G1 Sensor cable shielded 7-core fixed cable or double-shielded coaxial cable with 4 pilot wires (with TOP68 plug connection) Maximum cable length max. 100 m (330 ft, (including cable extension)) Temperature compensation internal Interface RS 485 Endress+Hauser stainless steel 1.4571 (AISI 316Ti) POM Silicone 29 Oxymax COS61 Index A I Accessories Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 For connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Measurement, controlling and cleaning . . . . . . . . . . . . 25 Protection gard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Ambient temperature range . . . . . . . . . . . . . . . . . . . . . . . 28 Angle of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ausschlagswert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Automatic cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Basin rim holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Immersion assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Immersion operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ingress protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 Angle of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Flow operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Immersion operation . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Measuring point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Retractable assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C M Cable length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Calculating the calibration value . . . . . . . . . . . . . . . . . 19 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Chain assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Checking Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Configurator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Maximum measured error . . . . . . . . . . . . . . . . . . . . . . . . 28 Measuring point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mechanical construction . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 D Occupational safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Order code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 B Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 E Electrical connection Direct connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Via junction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . 4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F Field installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Floating body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Flow operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fluorescence cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 23 30 N Nullpunkt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 O P Panel mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Performance characteristics. . . . . . . . . . . . . . . . . . . . . . . . 28 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Process connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Process pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Process temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Product page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Product safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Protection gard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 R Repeatability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Replacing Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Wear and tear materials. . . . . . . . . . . . . . . . . . . . . . . . 23 Requirements for personnel. . . . . . . . . . . . . . . . . . . . . . . . . 4 Response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Retractable assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 13, 24 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Endress+Hauser Oxymax COS61 S Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Sensor Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacing wear and tear materials . . . . . . . . . . . . . . . . 23 Sensor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Sensor cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Storage temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 T Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Mechanical construction . . . . . . . . . . . . . . . . . . . . . . . 29 Performance characteristics . . . . . . . . . . . . . . . . . . . . . 28 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . 29 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Types of calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 U Upright post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Wiring Field installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Panel mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Endress+Hauser 31 BA00387C/07/EN/13.12 FM10