Emerson 8800 User Manual

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800 Oxygen/Combustibles Transmitter

General Purpose OCX 8800 Oxygen/Combustibles Analyzer with Integral Electronics

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HIGHLIGHTS OF CHANGES

Effective January, 2007 Rev 1.0

Page Summary

Page 2-19 Revised Figure 2-11. Page 3-2 Revised the text for SW1 and SW2 to read internally powered. Page 3-3 Revised Figure 3-1. Updated the paragraph Initial Power Up. Page A-2 thru A-23 Added note 11 to the safety data section. Added additional pages/languages. Page C-1 Updated the return of materials address. Back cover Updated the address blocks.

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

Table of Contents

Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

SECTION 1 Description and Specifications

SECTION 2 Installation

SECTION 3 Configuration and Startup

SECTION 4 Using HART Communications

SECTION 5 Calibration

Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Mechanical

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

OCX 8800 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

HART Communicator Signal Connections. . . . . . . . . . . . . . . . . . . . . . 4-1

HART Communicator PC Connections . . . . . . . . . . . . . . . . . . . . . . . . 4-4

HART Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

SECTION 6 Maintenance and Service

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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

OCX 8800 Removal

and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

OCX with

Integral Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Sensor Housing Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Sensor Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Electronics Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6-25

OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Electronics Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Remove Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Install Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

SECTION 7 Troubleshooting

SECTION 8 Replacement Parts

APPENDIX A Safety Data

APPENDIX B SPA with HART Alarm

APPENDIX C Return of Materials

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Total Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Diagnostic Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Alarm Relay Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

O2 Cell and Heater Strut Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . . A-24

High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-30

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

TOC-2

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

OCX 8800 Oxygen/Combustibles Transmitter

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Emerson Process Management designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to integrated into your safety program when installing, using, and maintaining Emerson’s Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions

product.

• If you do not understand any of the instructions, contact your Emerson Process Management representative for clarification.

• Follow all warnings, cautions, and instructions supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.

• Install your equipment as specified in the Installation Instructions

of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and

pressure sources.

• To ensure proper performance, use qualified personnel operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process Management. Unauthorized parts and procedures can affect the product's performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

prior to installing, operating, and servicing the

marked on and

to install,

and

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The information contained in this document is subject to change without notice.

If a Model 275/375 Universal HART® Communicator is used with this unit, the software within the Model 275/375 may require modification. If a software modification is required, please contact your local Emerson Process Management Service Group or National Response Center at 1-800-654-7768.

Instruction Manual

IM-106-880, Rev 1.0

OCX 8800

January 2007

PREFACE The purpose of this manual is to provide a comprehensive understanding of

the OCX 8800 components, functions, installation, and maintenance. We recommend that you thoroughly familiarize yourself with the Introduction

and Installation sections before installing your transmitter. The introduction presents the basic principles of the transmitter along with its

performance characteristics and components. The remaining sections contain detailed procedures and information necessary to install and service the transmitter.

Before contacting Emerson Process Management concerning any questions, first consult this manual. It describes most situations encountered in your equipment's operation and details necessary action.

DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES

found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.

SYMBOLS

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure, condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETI

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

Section 1 Description and Specifications

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-9

COMPONENT CHECKLIST

A typical OCX 8800 Oxygen/Combustibles Transmitter package should contain the items shown in Figure 1-1.

Use the product matrix in Table 1-1 at the end of this section to verify your order number. The first part of the matrix defines the model. The last part defines the various options and features of the OCX 8800. Check the model number against the transmitter features and options, making sure options specified by this number are on or included with the unit. Use this complete model number for any correspondence with Emerson Process Management. A list of accessories for use with the OCX 8800 is provided in Table 1-2.

SYSTEM OVERVIEW Scope

This Instruction Manual supplies details needed to install, startup, operate, and maintain the OCX 8800. Signal conditioning electronics outputs separate 4-20 mA signals representing oxygen (O This information, plus additional details, can be accessed with the HART Model 275/375 handheld communicator or Rosemount Analytical AMS software.

System Description

The OCX 8800 is designed to measure oxygen and combustible concentrations in flue gas temperatures up to 2600°F (1427°C). Electrical connections, power and communications are made through two 3/4 NPT ports in the flameproof electronics enclosure using fittings and cables provided by the customer. Cable installation must meet NEC, IEC and/or other applicable national or local codes for Class I, Zone 1, Group IIB +H2 T3/T6 permanently mounted equipment. The transmitter is close coupled to the process and requires minimal sample conditioning requirements.

) and combustibles (COe) values.

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OCX 8800

Figure 1-1. Typical System Package

MAN4275A00

English

October 1994

HART Communicator

Instruction Manual

IM-106-880, Rev 1.0

January 2007

FISHER-ROSEMOUNT

37390006

1. Instruction Manual

2. HART

Communicator Package (optional)

3. Adapter Plate with Mounting Hardware and Gasket

4. Reference Air and Calibration Set

5. Blowback Hardware (optional)

6. OCX 8800 with Integral Electronics

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Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

The equipment measures oxygen percentage by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output of the cell is given by the following Nernst equation:

EMF = KT log10 (P

Where:

1. P

is the partial pressure of the oxygen in the measured gas on one side

of the cell.

2. P

is the partial pressure of the oxygen in the reference air on the

opposite side of the cell.

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

NOTE

For best results, use clean, dry instrument air (20.95% oxygen) as the reference air.

When the cell is at operating temperature and there are unequal oxygen concentrations across the cell, oxygen ions will travel from the high oxygen partial pressure side to the low oxygen partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade. The output is proportional to the inverse logarithm of the oxygen concentration. Therefore, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the OCX 8800 to provide exceptional sensitivity at low oxygen concentrations.

1/P2

) + C

The OCX 8800 measures net oxygen concentration in the presence of all the products of combustion, including water vapor. Therefore, it may be considered an analysis on a "wet" basis. In comparison with older methods, such as the portable apparatus, which provides an analysis on a "dry" gas basis, the "wet" analysis will, in general, indicate a lower percentage of oxygen. The difference will be proportional to the water content of the sampled gas stream.

The OCX 8800 combustibles sensor is a catalytic sensor consisting of two Resistance Devices (RTD). One RTD is the reference element covered with an inert coating. The other RTD element is active, coated with a catalyst. As the sample gases flow by the sensor, the combustible gases oxidize on the surface of the active element. The oxidation that occurs produces heat and a temperature rise in the active element. The temperature difference produces a resistance relationship between the two elements that is directly proportional to the concentration of combustibles in the sample gases.

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OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

The catalyst is specifically designed to detect carbon monoxide (CO), but the sensor responds to other combustible gases. The sensor is calibrated using CO, thus the output should be expressed in terms of CO. However, since the sensor detects other combustible gases, the output cannot just be labeled CO. The response of the sensor to other combustible gases gives an output that is equivalent to the sensor detecting CO. The term COe is used in this manual to describe the sensor output. This term indicates that the sensor is calibrated in terms of CO, and that the sensor output is equivalent to CO but not specific to CO.

Dilution air is provided to the COe sensor to ensure there is adequate oxygen to fully oxidize any combustible gases regardless of the concentration of oxygen in the process.

System Configuration

Transmitters are available in four lengths, giving the user the flexibility to use a penetration appropriate to the size of the stack or duct. The length options are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), or 9 ft (2.7 m). Probes are available in three material options, 316L stainless steel, inconel 600, and ceramic to accommodate higher temperatures.

The electronics are contained in a separate housing from the sensors. The electronics and sensor housings are integrally mounted.

The electronics control both sensor temperatures and provide individual 4-20 mA isolated outputs that are proportional to the measured oxygen and combustibles concentrations. The power supply can accept voltages of 100 to 240 VAC and 50 to 60 Hz. The electronics accepts millivolt signals generated by the sensors and produces the outputs to be used by remotely connected devices. The outputs are isolated 4-20 mA linearized currents. Refer to Section 3, Configuration and Startup for specific instructions upon initial power up.

System Features

1. The O concentration decreases.

2. HART communication is standard. To use the HART capability, you must have either:

a. HART Model 275/375 Communicator. b. AMS software for the PC.

3. Oxygen cell and heater/thermocouple assembly are field replaceable.

4. Electronics are automatically configured for line voltages from 100 to 240 VAC.

cell output voltage and sensitivity increase as the oxygen

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IM-106-880, Rev 1.0 January 2007

OCX 8800

5. An operator can calibrate and diagnostically troubleshoot the OCX 8800 using the HART Interface. Each of the OCX 8800's 4-20 mA output lines transmit an analog signal proportional to oxygen or combustible levels detected. The HART output is superimposed on the oxygen 4-20 mA output line only. This information can be accessed through the following:

• Model 275/375 Handheld Communicator - The handheld communicator requires Device Description (DD) software specific to the OCX 8800. The DD software will be supplied with many Model 275/375 units, but can also be programmed into existing units at most Emerson Process Management service offices. Refer to Section 4, Using HART Communications, for additional information.

• Personal Computer (PC) - The use of a personal computer requires AMS software available from Emerson Process Management.

• Selected Distributed Control Systems - The use of distributed control systems requires input/output (I/O) hardware and AMS software which permit HART communications.

6. Optional Blowback System. The blowback system periodically blows instrument air back through the sample line filter and out the sample tube. This clears out particulate and keeps the sample line filter from clogging.

System Operation

Figure 1-2 shows the relationship between the components of the OCX 8800. The sensors and the electronics are contained in separate housings. The sensor housing and probe mounts to a duct or process wall so that the probe protrudes into the flue gas stream. An air powered eductor continuously pulls samples of the process flue gas through the probe to a chamber in front of the sensor housing where the sample passes the O the COe sensor. Dilution air is provided to the COe sensor and reference air to the O the COe sensor, it is drawn through the eductor where it mixes with the eductor air and exits through exhaust back into the system. The electronics housing contains the CPU and HART boards which convert the sensor inputs into 4-20 mA analog output signals. The CPU can also initiate and perform calibrations. Three test gasses and instrument air can be turned on and off by solenoids. Test gas flow to the sensors is regulated by a flow meter between the electronics and sensor housings. Instrument air is separated into eductor air, reference air, and dilution air. The instrument air solenoid does not allow air flow until the heaters are up to temperature. This minimizes the amount of sampled process flue gas being pulled into cold sensors causing condensation.

sensor. After the gas sample flows past the O2 sensor and through

sensor and continues on to

1-5

OCX 8800

(

)

Figure 1-2. System Operation Diagram

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Sample

Gas

Probe

Exhaust

SENSOR

HOUSING

COe

Combustibles

Sensor

Eductor

Flow Meter

Reference Air

Dilution Air

7 scfh

ELECTRONICS

Instrument Air

Eductor Air

Flow Meter

50 cc/min.

0.1 scfh

HOUSING

CPU

HART Board

Power

Supply

Optional

Test Gas

Solenoids

Solenoid

Low O

Test Gas

High O

Test Gas

Instrument

Air

37390001

Handling the OCX 8800

It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to prevent possible equipment damage.

The OCX 8800 is designed for industrial application. Treat each component of the system with care to avoid physical damage. The probe may contain components made from ceramics, which are susceptible to shock when mishandled.

System Considerations

Prior to installing your OCX 8800, make sure you have all the components necessary to make the system installation. Ensure all the components are properly integrated to make the system functional.

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OCX 8800

After verifying that you have all the components, select mounting locations and determine how each component will be placed in terms of available line voltage, ambient temperatures, environmental considerations, convenience, and serviceability. Figure 1-3 shows a typical system wiring. Simplified installations for the OCX 8800 are shown in Figure 1-4.

A source of instrument air is required at the OCX 8800 for reference air, dilution air, and eductor air. Since the OCX 8800 is equipped with an in-place calibration feature, provision should be made for connecting test gas tanks to the OCX 8800 when it is to be calibrated.

NOTE

The electronics module is designed to meet NEMA 4 (IP66) and the electronic components are rated to temperatures up to 185°F (85°C).

Retain packaging in which the unit arrived from the factory in case any components are to be shipped to another site. This packaging has been designed to protect the product.

Figure 1-3. OCX 8800 HART Connections and AMS Application

OCX 8800 with

Integral Electronics

3 calibration gas lines by

Instrument

Air

customer [300 ft (91 m) max.)

4-20 mA Output

(Twisted Pairs)

Termination in Control Room

HART

Model 275/375

Handheld

Communicator

Customer’s Laptop

with AMS

AMS

37390002

1-7

OCX 8800

Figure 1-4. Typical System Installation

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Test Gas

Flow Meter

Gases

Stack

Dilution

Air

Flow

Meter

Adapter

Plate

Duct

Pressure

Regulator

High O Test Gas Low O Test Gas

CO Test Gas

OCX 8800 with

INTEGRAL

ELECTRONICS

4-20 mA Outputs

(2 Twisted Pairs)

Line Voltage

Instrument Air

Supply

(Reference Gas)

37390063

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Instruction Manual

IM-106-880, Rev 1.0 January 2007

SPECIFICATIONS General Purpose OCX

Specifications

Net O

Range 0-1% to 0-40% O2, fully field selectable

Combustibles 0-1000 ppm to 0-5%, fully field selectable Accuracy

Oxygen ± 0.75% of reading or 0.05% O2 (whichever is greater) Combustibles ± 2% range

System Response to Test Gas

Oxygen 10 sec T90 Combustibles 25 sec T90

Temperature Limits

Process 32° to 2600°F (0° to 1427°C) Sensors Housing -40° to 212°F (-40° to 100°C), ambient Electronics Housing -40° to 149°F (-40° to 65°C), ambient

Nominal and Approximate Shipping Weights

18 in. (457 mm) probe package

3 ft (0.91 m) probe package

6 ft (1.83 m) probe package

9 ft (2.74 m) probe

package Housings Mounting Flange Materials

Probes 316L stainless steel - 1300°F (704°C)

Enclosures Low-copper aluminum Calibration Semi-automatic or automatic Calibration Gas Mixtures

Recommended

(Ref. test gas bottles

kit #1A99119G04) Calibration Gas Flow 7 scfh (3.3 l/m) Reference Air 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O

Eductor Air 5 scfh (2.5 l/m), clean, dry, instrument-quality air 20.95% O2),

Dilution Air 0.1 scfh (0.5 l/m), clean, dry, instrument-quality air (20.95% O

Blowback Air (optional) Clean, dry, instrument-quality air (20.95% O2), regulated to 55 psi

OCX 8800

-40° to 185°F (-40° to 85°C), internal - operating temperature of electronics inside instrument housing, as measured by a HART communicator or AMS software

54 lbs (20 kg)

55 lbs (20.5 kg)

57 lbs (21 kg)

59 lbs (22 kg)

Inconel 600 - 1832°F (1000°C) Ceramic - 2600°F (1427°C)

0.4% O 8% O 1000 ppm CO, Balance Air

regulated to 35 psi (241 kPa)

(379 kPa)

, Balance N2

Table continued on next page

)

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OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Specifications

Sensors Housing NEMA 4, IP66 with fitting and pipe on reference exhaust port to

clean, dry atmosphere, two 3/4-14 NPT conduit ports

Electronics Housing NEMA 4, IP66 with fitting and pipe on reference exhaust port to

clean, dry atmosphere, two 3/4-14 NPT conduit ports Electrical Noise EN 61326-1, Class A Certifications

CUS

Line Voltage Universal 100 to 240 VAC ±10%, 50 to 60 Hz, no switches or

jumpers required, 3/4-14 NPT conduit port Pollution Degree 2 Over Voltage Category II Relative Humidity 5 to 95% (non-condensing) Isolated Output

Oxygen 4-20 mAdc, 950 ohm maximum, with HART capability Combustibles 4-20 mAdc, 950 ohm maximum

Alarm Alarm output relay - dry contact, form C, 30mA, 30VDC capacity Power Consumption 750 W maximum Mounting and Mounting

Positions

Sensor Housing Flange

Electronics Housing Integral to sensor housing

NOTE All static performance characteristics are with operati ng variables const ant. Specific ations subject to cha nge without notice.

APPROVED

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Instruction Manual

IM-106-880, Rev 1.0 January 2007

Table 1-1. Product Matrix - General Purpose OCX 8800

OCX88A O2/Combustibles Transmitter

Code Probe Length and Material

00 No Probe or Exhaust Tube 11 18 in. (457 mm) 316 SST up to 1300°F (704°C) 21 18 in. (457 mm) Inconel 600 up to 2600°F (1427°C) 31 18 in. (457 mm) Ceramic up to 2600°F (1427°C) 12 3 ft (0.91 m) 316 SST up to 1300°F (704°C) 22 3 ft (0.91 m) Inconel 600 up to 1832°F (1000°C) 32 3 ft (0.91 m) Ceramic up to 2600°F (1427°C) 13 6 ft (1.83 m) 316 SST up to 1300°F (704°C) 23 6 ft (1.83 m) Inconel 600 up to 1832°F (1000°C) 14 9 ft (2.7 m) 316 SST up to 1300°F (704°C) 24 9 ft (2.7 m) Inconel 600 up to 1832°F (1000°C)

Code Probe Mounting Assembly

10 (ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes 20 (DIN) 185 mm dia. flange, 145 mm BC with 4 x 18 mm dia. holes

Code Mounting Hardware - Stack Side

0 No Adapter Plate (“0” must be chosen under “Mounting Adapter - Probe Side” below) 1 New Installation - Square weld plate with studs 2 Model 218/240 Mounting Plate (with Model 218/240 Shield Removed) 3 Existing Model 218/240 Support Shield 4 Special Mounting 5 Model 132 Adapter Plate

Code Mounting Hardware - Probe Side

0 No Adapter Plate 1 Probe Only (ANSI) 2 Probe Only (DIN)

OCX88A 11 10 1 1 H3 06 02 Example

NOTE: (1) Provide details of the existing mounting plate as follows:

Plate with studs Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate. Plate without studs Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.

(1)

Code Electronics Housing - Communications

H1 HART Communications H2 HART Communications with Local Operator Interface H3 HART Communications with Calibration Solenoids H4 HART Communications with Local Operator Interface and Calibration Solenoids

Code Electronics Mounting

01 Integral to Sensor Housing 02 Remote Electronics and no cable 03 Remote Electronics and 20 ft (6 m) cable 04 Remote Electronics and 40 ft (12 m) cable 05 Remote Electronics and 60 ft (18 m) cable 06 Remote Electronics and 80 ft (24 m) cable 07 Remote Electronics and 100 ft (30 m) cable 08 Remote Electronics and 150 ft (46 m) cable

Code Accessories

00 None 01 Flow meters & Ref. 02 In-Situ Filter (Stainless Steel only) 03 In-Situ Filter (SST), Flow meters & Ref. Air Set 11 Flow meters, and Ref. Air Set with Blowback 12 In-Situ Filter (SST) with Blowback 13 In-Situ Filter (SST), Flow meters & Ref. Air Set with Blowback

Air Set

OCX 8800

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OCX 8800

Table 1-2. Accessories

Instruction Manual

PART NUMBER DESCRIPTION

1A99119H01 Oxygen test gas bottle; 0.4% O 1A99119H02 Oxygen test gas bottle; 8.0% O2, balance N 1A 99119H07 CO test gas bottle; 1000 ppm CO, balance air 1A99120H02 Regulator for Oxygen (may need 2) 1A99120H03 Regulator for CO test gas 1A99119G06 Wall mount bracket for test gas bottles 1A99119G05 Test gas regulators kit 1A99119G04 Test gas bottles kit

1A99292H01

1A99339H03 Blowback valve, air operated

1A99784H02

6A00171G01 Power line filter kit

Moore Industries SPA for Low O Calibration Status, and Unit Fail

375 HART Communicator with 12 Megabyte buffer, model no. 375HR1EKLU

, balance N

Alarm, High COe Alarm,

IM-106-880, Rev 1.0

January 2007

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IM-106-880, Rev 1.0 January 2007

Section 2 Installation

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-7

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-10

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-16

Before installing this equipment, read the "Safety instructions for the wiring and installation of this apparatus" in Appendix A: Safety Data. Failure to follow the safety instructions could result in serious injury or death.

OCX 8800

The OCX88A can be installed in general purpose areas only. Do not install the OCX88A in hazardous areas.

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OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

MECHANICAL INSTALLATION

Selecting Location

1. The location of the OCX 8800 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The probe must be positioned so the gas it measures is representative of the process. Best results are normally obtained if the transmitter is positioned near the center of the duct (40-60% insertion). Longer ducts may require several transmitters since the oxygen and combustibles can vary due to stratification. A point too near the wall of the duct or the inside radius of a bend, may not provide a representative sample because of the very low flow conditions. The sensing point should be selected so the process gas temperature falls within the range of probe material used. Figure 2-1 through Figure 2-3 provide mechanical installation references. The ambient temperature inside the electronics housing must not exceed 185°F (85°C).

2. Check the flue or stack for holes and air leakage. The presence of this condition will substantially affect the accuracy of the oxygen and combustibles readings. Therefore, either make the necessary repairs or install the transmitter up stream of any leakage.

3. Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance access to the unit. Allow adequate clearance for the removal of the OCX 8800.

Do not allow the temperature of the electronics housing to exceed 185°F (85°C) or damage to the electronics may result.

Whenever a positive stack pressure exists at the installation site, be sure to connect all pneumatic lines prior to installing the OCX 8800 in the stack or ductwork. Failure to connect the pneumatic lines can allow the flow of contaminants into the OCX 8800 ports.

Before installing the OCX 8800 into a hot stack or ductwork, make sure that the OCX 8800 is turned on and at normal operating temperature. Exposing a cold OCX transmitter to hot process gases can cause permanent damage to the equipment.

Installation

1. Ensure all components are available to install the OCX 8800.

2. The OCX 8800 may be installed intact as it is received.

3. Weld or bolt adapter plate (Figure 2-2) onto the duct.

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OCX 8800

4. Ensure the conduits drop vertically from the OCX 8800 and the conduit is routed below the level of the conduit ports on the housing to form a drip loop. Drip loops minimize the possibility that moisture will damage the electronics (Figure 2-3).

5. Where a positive stack pressure exists at the installation site, connect all pneumatic lines prior to installing the OCX 8800 in the stack or ductwork.

NOTE

If process temperatures will exceed 392°F (200°C), use anti-seize compound on stud threads to ease future removal of the OCX 8800.

6. Insert sample and exhaust tubes through the opening in the mounting flange and bolt the unit to the flange.

Uninsulated stacks or ducts may cause ambient temperatures in the electronics housing to exceed 185°F (85°C) and damage the electronics.

7. If insulation is removed to access the duct for OCX 8800 mounting, make sure to replace insulation afterward.

Enclosures

The OCX 8800 enclosures are designed to meet ingress conditions of IP66. Each enclosure cover is threaded to its base and sealed with an o-ring that isolates the threads from external contaminants.

Each cover is secured by a clip attached to the base that engages the cover between the ribs of the cover sidewall. The clip is held in place by an Allen head cap screw and lockwasher mounted in a recess. Cover removal and installation requires an Allen wrench to loosen and tighten the screw.

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OCX 8800

Figure 2-1. Installation, OCX 8800

NOTE All dimensions are in inches with millimeters in parentheses.

Insulate if exposed to adverse weather or extreme temperature changes, install a protective housing and/or insulation around the unit.

Instruction Manual

IM-106-880, Rev 1.0

January 2007

0.06 In. Thick Gasket

ANSI DIN

3535B18H02 3535B45H01

Flange Dia.

B.C. Dia.

Hole Dia.

Table 1. Mounting Flange

ANSI

Flange Dia.

Hole Dia.

(4) Holes equally spaced on B.C. dia

6.00

(152)

0.75 (19)

4.75

(121)

Dim “B”

Removal Envelope

Allow 9 in.

(229 mm) for

Cover Removal

DIN

5R10244H025R10244H01

7.28

(185)

0.71 (18)

5.71

(145)

BOTTOM VIEW

Dim “A”

Insertion Depth

Table 2. Installation/Removal

Probe

18 in.

3 ft

6 ft

9 ft

Dim “A”

(457)

(914)

(1829)

108

(2743)

Optional

In Situ Filter

8.3

(211)

Dim “B”

(864)

(1321)

(2235)

124

(3150)

37390008

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IM-106-880, Rev 1.0 January 2007

Figure 2-2. Adapter Plate Installation

OCX 8800

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OCX 8800

Figure 2-3. Installation with Drip Loops

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Conduit Drip Loops

Conduit Drip Loop Conduit Drip Loop

Duct Wall

37020004

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OCX 8800

ELECTRICAL INSTALLATION

All wiring must conform to local and national codes. For reference, factory wired solenoid power connections are shown in Figure 2-4.

Disconnect and lock out power before connecting the unit to the power supply. Failure to lock out power could result in serious injury or death.

Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death.

To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, connection to the main electrical power supply must be made through a circuit breaker (min 10 A) in close proximity and marked for this equipment which will disconnect all current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 947.

The OCX88A can be installed in general purpose areas only. Do not install the OCX88A in hazardous areas.

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OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

NOTE

To maintain proper earth grounding, ensure a positive connection exists between the sensor housing, the electronics housing, and earth. The connecting ground wire must be 14 AWG minimum. Refer to Figure 2-4.

NOTE

Line voltage, signal, and relay wiring must be rated for at least 105ºC (221ºF).

Electrical Connections

Electrical connections, power and communications are made to the electronic enclosure. The connections are made through two 3/4 NPT ports in the enclosure using fittings and cables provided by the customer. Cable installation must meet NEC, IEC and/or other applicable national or local codes for Class I, Zone 1, IIB +H2 T3/T6 permanently mounted equipment.

Connect Line Voltage

The OCX 8800 operates on 100 to 240 VAC line voltage at 50 to 60 Hz. The power supply requires no setup. Connect the line (L wire) to the L terminal, and the neutral (N wire) to the N terminal on the AC power input terminal block in the electronics housing. Connect the ground (G wire) to the ground stud in the electronics housing as shown in Figure 2-4.

Connect 4-20 mA Signals

Connect the 4-20 mA current loop to the 4-20 mA signal output terminals in the electronics housing as shown in Figure 2-4. Use individual shielded twisted wire pairs. Terminate the shield at the electronics housing.

4-20 mA Signal

One 4-20 mA signal represents the O signal is the HART information accessible through a Model 275/375 Handheld Communicator or AMS software. The O terminals.

COe 4-20 mA Signal

Another 4-20 mA signal at the AOUT 2 terminals represents the COe value. HART information is not available on the COe signal.

Alarm Output Relay

Connect any customer-supplied relay input to the alarm output relay terminal. Use shielded wire and terminate the shield at the electronics housing. The alarm output relay terminal is a set of dry, no. 2, form C, contacts with 30 mA, 30 VDC capacity.

value. Superimposed on the O2

signal is at the AOUT 1

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IM-106-880, Rev 1.0 January 2007

Figure 2-4. Line Voltage, Earth, and 4-20 mA Connections

OCX 8800

COM

Alarm Output Relay

Terminal Block

COe Signal

O Signal

4-20 mA Signal Output

Terminal Block

AOUT2+

{

AOUT2 -

AOUT1 -

{

AOUT1+

EMI Filter

TOP VIEW

(1/2 SIZE)

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

Customer

Wiring

Signal Port

3/4 NPT

Terminal

Block

Ground

Stud

Power Port

3/4 NPT

External Tooth

Lockwasher

37390013

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OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

PNEUMATIC INSTALLATION

Pneumatic system connections depend on whether reference air set, calibration solenoids, and/or blowback equipment options are equipped on your transmitter. Refer to the following paragraphs and select the option that applies to your transmitter configuration.

Reference Air Set Option (only)

When no options or only the reference air set option is equipped, use the following procedure to install the pneumatic system components.

1. Refer to Figure 2-5. Connect the reference air set (regulator/filter and pressure gage) to the instrument air inlet on the electronics housing and to the inlet side of the dilution air flow meter.

2. Connect the dilution air flow meter output to the dilution air inlet fitting on the sensor housing.

3. Install an air line between the instrument air outlet fitting on the electronics housing and the tee fitting on the sensor housing.

Do not use 100% nitrogen as an O2 low gas. It is suggested that O2 low gas be between

0.4% and 2.0% O parts per million. Failure to use proper gases will result in erroneous readings.

. Do not use gases with hydrocarbon concentrations of more than 40

4. One CO gas and two O2 gases are used to calibrate the OCX 8800:

CO - 1000 ppm or 4%

low gas - 0.4%

high gas - 8%

Connect the output of the test gas sources to the inlet port of the CAL GAS flow meter. Install an air line between the flow meter outlet port and the CAL GAS inlet fitting on the sensor housing.

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