EA01460C/07/EN/01.22-00
71596678
2022-12-30

ProductsSolutions

Installation Instructions
Kit COV81
For the maintenance of COS81D/E sensors

Services

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Table of contents
1

Overview of the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3Authorized installation personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Additional documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Replacement of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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1

Overview of the sensor

The exploded drawing shows the structure of the sensor COS81D/E.
1238

7645A0027181

1Structure of the COS81D/E sensor

12345678

Memosens plug-in head
Thrust collar
Sensor shaftSensor cap O-ringSensor cap
Optical waveguide with temperature sensor
Process seal
Process connection Pg 13.5

2

Intended use• The components of the kits are to be used exclusively as maintenance parts for COS81D/E .
Any other use is not permitted!
• Use only original parts from Endress+Hauser.
• In the W@M Device Viewer, check if the spare part is suitable for the existing device.

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3

Authorized installation personnel• Installation, commissioning, operation and maintenance of the measuring system may becarried out only by specially trained technical personnel.
• The technical personnel must be authorized by the plant operator to carry out the specifiedactivities.
• The electrical connection may be performed only by an electrical technician.
• The technical personnel must have read and understood these Installation Instructions andmust follow the instructions they contain.
• Faults at the measuring point may only be rectified by authorized and specially trained
personnel.
Repairs not described in the Operating Instructions provided must only be carried out
directly at the manufacturer's site or by the service organization.

4Safety instructions

LCAUTION
Risk to health due to the removal of sensors from the process!

‣ When removing the sensor from the process, pay attention to the process pressure, processtemperature and the aggressiveness or toxicity of the medium.

LCAUTION
Risk to health due to contact with the process medium!
‣ Pay attention to the warning notices in the safety data sheets.
‣ Wear protective gloves, protective goggles and protective clothing, particularly whenworking with reagents, chemicals or process solutions.
‣ In case of contact with eyes or skin, rinse the affected area with plenty of water and thenseek medical advice. Show the relevant safety data sheet to the physician.
Impact on the process
Before decommissioning an active device, the potential impact on the overall process
must be taken into account! This applies in particular to the use of the switchingcontacts, analog signal outputs or the communication interface of the associatedmeasuring device to control process variables. Coordinate service tasks with the operator!
Electrical safety
The COS81D/E sensor works exclusively with protective extra-low voltage. Therefore it
does not pose an electrical hazard.

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5Scope of delivery

The COV81 service kit has a product structure. In terms of the quantity and version, thecontents of a kit therefore depend on the version ordered (see the product structure below).
A kit always contains:• Sensor cap• Process seal and sensor cap O-ring• Removal and O-ring mounting tool
• Cleaning cloth• Manufacturer certificate• Kit instructions
If required, the following parts must be added to the order code:
Certificates
COV81

Number of optical caps
A1 piece
Type of optical cap
Cc-shaped

Uu-shaped
Material of sensor cap
A

Stainless steel

B

TitaniumC

Alloy C22
Material of O-ring
1

EPDM

3FFKM
Material of process seal
1

FKM

3

FKM Ex+ options ← complete order code

Options
JAInspection certificate 3.1, EN10204 (material certificate, wetted parts)

KB

Surface finish measurement, Ra<0.38 µm, wetted metal parts, inspection certificate

JECoC AMSE BPE, Declaration

JG

Compliance with requirements derived from cGMP, Declaration

J1

EU Food Contact Materials (EC) 1935/2004, Declaration

J2

US Food Contact Materials FDA CFR 21, Declaration

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J3

CN Food Contact Materials GB 4806, Declaration

LW

Pharma Certificate of Compliance

4352
1A0051095

212345

6

Maintenance kit COV81Sensor cap O-rings
Process seal
Cleaning cloth
Sensor cap
Removal and O-ring mounting tool

Additional documentation

Detailed information on the device can be found in the Operating Instructions for the sensor
and in the other documentation available via:• www.endress.com/device-viewer• Smartphone / tablet: Endress+Hauser Operations App

7Replacement of spare parts
Sections 7.1 and 7.2 below describe the fundamental procedures for replacing individual
spare parts. The individual steps are described in detail in the Performing fullmaintenance section →  8.
Only original Endress+Hauser spare parts are permitted. Please ensure that theconfiguration of the maintenance kit is correct (e.g. choice of O-rings) to maintain thehygienic design of the sensor.

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7.1

Replacing the process seal or sensor cap O-ring

The process seal and/or the sensor cap O-ring must be replaced in the event of mechanicaldamage.
1.

Remove the sensor cap.

2.

Clean the sensor shaft and optical waveguide.

3.

Inspect the process seal and/or sensor cap O-ring for damage and replace if necessary.

4.

Mount a new process seal or new sensor cap O-ring.

5.

Screw on the sensor cap.

7.2

Replacing the sensor cap

The sensor cap is replaced without replacing the process seal and the sensor cap O-ring if thelatter are not damaged or their replacement is not desired (however, it is advisable to replace
the process seal and the sensor cap O-ring each time the sensor cap is replaced).
1.

Remove the sensor cap.

2.

Clean the sensor shaft and optical waveguide.

3.

Perform a visual inspection of the new sensor cap.

4.

Screw on the sensor cap.

5.

Reset the counter.

6.

Perform a calibration.

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7.3
Performing full maintenance‣ Observe the warnings in Section 4.
The following section describes the sensor maintenance procedure on a step-by-step basis.
Depending on the necessary maintenance, not all steps are required. See Sections 7.1 - 7.2.
Removing the sensor cap
1.

Remove the sensor from the process and clean it. A cleaning agent appropriate for thetype of contamination should be used for this purpose.

1.

A0051612

2.

Unscrew the sensor cap.

2.

3.

A0051360

3.

Remove the sensor cap.

Cleaning the sensor shaft and optical waveguide‣ Clean and dry the sensor shaft and optical waveguide.
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A0051094

Dab the optical waveguide with the enclosed cleaning cloth. Do not wipe it!
Inspecting the process seal or sensor cap O-ring‣ Check the process seal or sensor cap O-ring for damage. If in doubt, always replace it!
To remove, do not use any sharp or pointed objects so that you do not damage thesensor.
Mounting the process seal or sensor cap O-ring1.

To mount the process seal and the O-ring on the sensor cap, fit the removal and O-ring
mounting tool on the sensor.

2.

Slide the process seal and the O-ring in succession over the removal and O-ring
mounting tool and onto the sensor until they have reached their end position.
Recommendation:
In SIP and CIP applications (sterilization in place, cleaning in place), the sensor cap Oring should also be replaced each time the sensor cap is replaced.

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1.

2.

A0051361

Visual inspection of new sensor cap‣ Hold the sensor cap up against the light. Only the green homogeneous fluorescence layer
should be visible inside the sensor cap.

Screwing on the sensor cap
1.

Fit the sensor cap on the sensor head.

2.

Screw the sensor cap onto the sensor shaft to the end stop so that a gap is no longer
visible between the sensor cap and the sensor shaft.

1.

2.

A0051362

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Resetting the counters
1.

Enter the sensor maintenance with sensor cap changes in the transmitter.
When the event is entered, the counters for the sensor cap are reset simultaneously inthe transmitter. In addition, the calibration quality index is adapted to the new sensor
cap after calibration in air and zero point calibration. Otherwise a maintenance message
is generated.
Warnings can also be configured for the counters to assist with sensor maintenance.
The menu paths indicated refer to the Liquiline CM44x:
Menu/Calibration/Oxygen (opt.)/Change sensor cap

2.

Then press the Save key to confirm the process.

Performing a calibration
1.

Perform a calibration.

2.

Put the measuring system back into operation.
The calibration (point in oxygen and/or zero point calibration is possible) must be
performed after every sensor maintenance!
Follow the Operating Instructions for the measuring device used.

8Disposal

8.1Sensors

If required by the Directive 2012/19/EU on waste electrical and electronic equipment(WEEE), the product is marked with the depicted symbol in order to minimize the disposalof WEEE as unsorted municipal waste. Do not dispose of products bearing this marking as
unsorted municipal waste. Instead, return them to the manufacturer for disposal under theapplicable conditions.

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