ISCO Orbit OCM 223 Operating instructions

Orbit OCM 223 / 253
Transmitter for Free Chlorine/Chlorine Dioxide
Installation and Operation Guide
Isco Part # 69-0043-002
51513336

Foreword
This instruction manual is designed to help you gain a thorough understanding of the
operation of the equipment. Isco recommends that you read this manual completely
before placing the equipment in service.
Although Isco designs reliability into all equipment, there is always the possibility of a
malfunction. This manual may help in diagnosing and repairing the malfunction.
If the problem persists, call or email the Isco Customer Service Department for assis-
tance. Contact information is provided below. Simple difficulties can often be diag-
nosed over the phone. If it is necessary to return the equipment to the factory for
service, please follow the shipping instructions provided by the Customer Service
Department, including the use of the Return Authorization Number specified. Be
sure to include a note describing the malfunction. This will aid in the prompt
repair and return of the equipment.
Isco welcomes suggestions that would improve the information presented in this man-
ual or enhance the operation of the equipment itself.
Isco is continually improving its products and reserves the right to change
product specifications, replacement parts, schematics, and instructions
without notice.
Contact Information
Phone: [phone] (USA, Canada, Mexico)
[phone] (Outside North America)
Repair Service: [phone] (Analytical and Process
Monitoring Instruments)
[phone] (Samplers and Flow Meters)
Fax: [phone]
Email address: [email protected]
Website: www.isco.com
Return equipment to: 4700 Superior Street, Lincoln, NE 68504-1398
Other correspondence: P.O. Box 82531, Lincoln, NE 68501-2531
Revised February 12, 2003

OCM 223 / 253 Table of Contents
3
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 3
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Intended application . . . . . . . . . . . . . . . . . . . . 4
1.3 Installation, start-up, operation . . . . . . . . . . . . 4
1.4 Operational safety . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Return to manufacturer . . . . . . . . . . . . . . . . . . 5
2 Identification . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Equipment name . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Additional functions of ES and EP versions . . . 7
2.3 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Measuring system . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Electrical connection . . . . . . . . . . . . . . . . . . . 14
4.2 Installing the sensor
and connecting the measuring cable . . . . . . 17
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 User interface . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Key functions . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4 Auto / Manual operating modes . . . . . . . . . . 23
5.5 Operating concept . . . . . . . . . . . . . . . . . . . . . 24
5.6 Access codes . . . . . . . . . . . . . . . . . . . . . . . . 26
5.7 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.8 Automatic controller switch-off . . . . . . . . . . . 26
6 Instrument configuration . . . . . . . . . 27
6.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 System configuration . . . . . . . . . . . . . . . . . . . 29
6.3 Current input . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4 Current outputs . . . . . . . . . . . . . . . . . . . . . . . 38
6.5 Monitoring functions . . . . . . . . . . . . . . . . . . . 41
6.6 Relay contact configuration . . . . . . . . . . . . . . 45
6.7 Service 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.8 Service 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.9 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.10 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7 Diagnosis and corrective
maintenance . . . . . . . . . . . . . . . . . . . . . . 65
7.1 Troubleshooting and remedial action
based on common problems . . . . . . . . . . . . . 65
7.2 Troubleshooting based on error messages . . 68
8 Diagnosis and corrective
maintenance . . . . . . . . . . . . . . . . . . . . . . 71
8.1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2 Corrective maintenance of OCM 223 . . . . . . . 74
8.3 Corrective maintenance of OCM 253 . . . . . . . 76
8.4 Ordering spare parts . . . . . . . . . . . . . . . . . . . 79
8.5 “Optoscope” service equipment
with “Scopeware” . . . . . . . . . . . . . . . . . . . . . . 79
8.6 Corrective maintenance of the
complete measuring point . . . . . . . . . . . . . . . 79
8.7 Test and simulation . . . . . . . . . . . . . . . . . . . . . 81
9 Accessories . . . . . . . . . . . . . . . . . . . . . . . 83
9.1 Connection accessories . . . . . . . . . . . . . . . . . 83
9.2 Mounting accessories . . . . . . . . . . . . . . . . . . . 83
9.3 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.4 Calibration accessories . . . . . . . . . . . . . . . . . 84
9.5 Instrument upgrade . . . . . . . . . . . . . . . . . . . . 85
10 Technical data . . . . . . . . . . . . . . . . . . . . 86
11 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
11.1 Operating matrix of EK and ES versions . . . . 90
11.2 Operating matrix of EP version . . . . . . . . . . . . 94
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1 Safety OCM 223 / 253
4
1 Safety
1.1 Safety symbols
#Warning!
This symbol alerts you to hazards which could cause serious injuries as well as damage
to the instrument if ignored.
"Caution!
This symbol alerts you to possible faults which could arise from incorrect operation.
They could cause damage to the instrument if ignored.
!Note!
This symbol indicates important items of information.
1.2 Intended application
OCM 223 / 253 is a field-tested and reliable transmitter which determines the amount of
free chlorine or chlorine dioxide dissolved in water.
It is specially designed for applications in the following industries:
xDrinking water
xWater treatment
xCooling water
xGas scrubbers
xReverse osmosis
xFood processing
xSwimming pool and bathing pool water.
1.3 Installation, start-up, operation
#Warning!
xInstallation, electrical connection, start-up, operation and maintenance of the
measuring instrument must be carried out exclusively by trained specialists
authorised by the system operator.
xThis personnel must have read and understood the instructions in this manual and
must adhere to them.
xBefore connecting the instrument ensure that the power supply complies with the
ratings specified on the nameplate.
xA clearly marked mains disconnecting device must be installed in the vicinity of the
instrument.
xLive components in the interior of the instrument can be touched through the
ventilation slits and the slit openings on the instrument back. Do not insert any tools
or wires into these slits (only OCM 223)!
xBefore switching on the system check all the connections again for correctness.
xDo not operate damaged instruments which could pose a danger, and mark them as
defective.
xMeasuring point faults may only be repaired by authorised and trained personnel.
xIf faults cannot be repaired, the instrument must be taken out of service and secured
against unintentional start-up.
xRepairs may only be carried out by the manufacturer or by your Service Organisation.

OCM 223 / 253 1 Safety
5
1.4 Operational safety
The instrument has been designed according to the state of the art and complies with
the applicable regulations and EN standards (see “Technical Data”). It is built in
accordance with EN 61010-1 and left our factory in perfect condition with regard to
safety aspects.
However, if it is used improperly or other than for its intended purpose, it may pose a
hazard, e.g. due to improper connection.
#Warning!
xIf the device is used for any application other than those described in this manual, it
may lead to unsafe and improper functioning of the measuring system and is therefore
strictly prohibited.
xMake sure you strictly adhere to the safety instructions and warnings in this manual.
Monitoring and safety devices
The instrument is protected against external influences and damage by the following
design measures:
xRugged housing
xHousing protection IP 65 (OCM 253)
xUV resistance.
If system faults or a power failure occur, an alarm is triggered by a fault-signalling
contact.
Fail-safety
This instrument has been tested for electromagnetic compatibility in industrial use
according to applicable European standards. It is protected against electromagnetic
interference by the following design measures:
xGalvanic isolation at input and output
xInterference suppression filter
xHardware and software design meeting EMC requirements.
#Warning!
Protection against interference as specified above is valid only for an instrument
connected according to the instructions in this manual.
1.5 Return to manufacturer
If the instrument has to be repaired by the manufacturer, please return it cleaned to the
sales centre responsible. Please use the original packaging.

2 Identification OCM 223 / 253
6
2 Identification
2.1 Equipment name
2.1.1 Nameplate
Fig. 2.1: Nameplate of OCM 223 (panel-mounted instrument, left) and
OCM 253 (field instrument, right).
“Codes” lists the release code for software upgrades for ChemoClean (left of slash)
or Plus package (right of slash).
2.1.2 Product structure
Version
EK Measurement of free chlorine / chlorine dioxide
ES Measurement of free chlorine / chlorine dioxide with extended features
EP Measurement of free chlorine / chlorine dioxide with extended features,
in addition pH or redox measurement (switchable)
Power supply
0 Power supply 230 V AC
1 Power supply 115 V AC
2 Power supply 230 V AC, CSA Gen. Purp.
3 Power supply 115 V AC, CSA Gen. Purp.
5 Power supply 100 V AC
7 Power supply 24 V AC/DC, CSA Gen. Purp.
8 Power supply 24 V AC/DC
Measurement output
0 1 output signal: Chlorine / chlorine dioxide
1 2 output signals : Chlorine / chlorine dioxide and temperature / chlorine (with
EP version optionally pH / redox / chlorine) or chlorine dioxide / set value
Contacts
05 No additional contacts
10 2 contacts (limit / P(ID) / timer)
15 4 contacts (limit / P(ID) / ChemoClean / three-point step controller for
Cl2/ClO2)
16 4 contacts (limit / P(ID) / timer / three-point step controller for Cl2/ClO2)
20 2 contacts with current input (limit / P(ID) / timer)
25 4 contacts with cleaning, current input (limit / P(ID) / ChemoClean /
three-point step controller for Cl2/ClO2)
26 4 contacts with timer, current input (limit / P(ID) / timer / three-point step
controller for Cl2/ClO2)
OCM 223-
OCM 253-
complete order code
131085-4D
OCM 223
order code
serial no. /
codes
chlorine / chlorine dioxide
OCM 223-EK0110
276945
0.05 … 20 mg/l
0 … 50°C
0/4 … 20 mA
230 VAC 50/60 Hz 7.5 VA
-10 … +55°CIP 54 / IP 30
0/4…20mA
-8732
prot. class ambient temp.
output 1 output 2
mains
meas. range
temperature
3472
131085-4D
OCM 253
order code
serial no. /
codes
chlorine / chlorine dioxide
OCM 253-EK0110
276944
0.05 … 20 mg/l
0…50°C
0/4…20mA
230 VAC 50/60 Hz 7.5 VA
-10 … +55°CIP 65
0/4…20mA
-8732
prot. class ambient temp.
output 1 output 2
mains
meas. range
temperature
3472

OCM 223 / 253 2 Identification
7
2.2 Additional functions of ES and EP versions
ES version
Compared to the basic EK version, this version is extended by the Plus package:
xManual pH compensation for free chlorine, fields B2 and B3
xCurrent output table, fields O33x
xSensor and process monitoring, function group P
xAutomatic start of cleaning function, field F8.
EP version
This version includes the functions of the ES version and in addition:
xOptional pH or redox measurement, field B1
xAutomatic pH compensation for free chlorine
xSensor and process monitoring even for pH or redox, fields P12x
xLimit contact for pH or redox, fields R22x
xpH value control, fields R25x.
2.3 Scope of supply
"Caution!
xMake sure the packaging is undamaged! If any damage is found, contact your postal
service or forwarding agent. Keep any damaged packaging until matters have been
clarified.
xMake sure the contents are undamaged! If any damage is found, contact your postal
service or forwarding agent and inform the suppliers. Keep any damaged goods until
matters have been clarified.
xInspect the delivery for completeness and quantity according to the delivery papers,
and the instrument type and version as shown on the nameplate.
The following items are included in the delivery:
xTransmitter OCM 223 (panel-mounted instrument) or OCM 253 (field instrument)
xOperating instructions BA 214e00
xPanel-mounted instrument:
– 1 set of plug-in screw terminals
– 2 clamping screws for panel mounting
additional for EP version:
– 1 BNC connector (solderless)
xField instrument:
– 1 plug-in screw terminal
– 1 × cable gland Pg 7
– 1 × cable gland Pg 16, tapered
– 2 × cable gland Pg 13.5.
In case of any queries please contact your supplier or your Sales Agency.

3 Installation OCM 223 / 253
8
3 Installation
The following procedure should be followed for a complete measuring system
installation:
1. Installation or attachment of transmitter (see chapter 3.3)
2. Selection and connection of cables and sensor (see chapter 4.2)
3. Start-up (see chapter 6.1).
3.1 Measuring system
A complete measuring system comprises:
xthe OCM 223 or OCM 253 chlorine / chlorine dioxide transmitter
xa OCS 140 / 141 membrane-covered sensor for Cl2or OCS 240 / 241 for ClO2or
a 963 open sensor for Cl2
xa OCA 250 flow assembly (not required for 963 sensor).
Options:
xpH or redox electrode (e.g. OPS 31, OPS 12, OPS 32)
xINS proximity switch for flow monitoring (omitted with 963 sensor)
xOMK extension cable for chlorine measurement
xOYK 71 extension cable for pH/redox measurement if required
xMK extension cable for INS proximity switch
xVBC junction box.
Fig. 3.1: Complete measuring system with OCM 253
CAL REL
REL 1
REL 1
ALARM
REL 2
REL 2
E
mg/l
25.0 °C
0.42
Transmitter
OCM 253
Chlorine or
chlorine dioxide
sensor
Mounting points for pH
or redox electrode
Inductive proximity
switch for flow
monitoring
Flow plummet
Meas. water feed
(sample flow)
Meas. water
drain
Flow assembly
OCA 250
Main stream
Sampling valve for
DPD measurement
Screw and
calibration cap
B214C03E.eps
VBC junction box (only if
connection length > standard length)

OCM 223 / 253 3 Installation
9
3.2 Dimensions
Fig. 3.2: Dimensions of OCM 253
!Note!
There is a hole in the punching for Pg 16 cable entry. Itr serves as a pressure balance
during air freight dispatching. Make sure that there is no moisture penetrating into the
housing before cable installation. After cable installation the housing is completely tight.
Fig. 3.3: Interior view of OCM 253 housing
1 Removable electronics box; 2 Partition plate; 3 Terminal blocks; 4 Fuse
B214C04Y.eps
CAL REL
REL 1
REL 1
ALARM
REL 2
REL 2
E
11
Pg13,5
Pg 7
Pg 16
115 70
154
247
157
70
170
B214C05E.eps
Æ6.5

3 Installation OCM 223 / 253
10
Fig. 3.4: Dimensions of OCM 223
3.3 Mounting
3.3.1 Field instrument
There are several mounting options for the field instrument version of the transmitter:
xMounting on round posts
xMounting on square posts
xWall mounting.
When installing the instrument outdoors, you require weather protection cover OYY 101
for all mounting options.
"Caution!
In case of direct exposition to weather factors, the weather protection cover is
indispensable.
Weather protection cover OYY 101
Weather protection cover for outdoor operation, for mounting on field instrument;
Material: stainless steel 1.4301 (AISI 304).
For post or pipe mounting, the post mounting kit is additionally required.
B214C07Y.eps
90 6
139
96
B214C08Y.eps