Emerson 8800 User Manual

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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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Instruction Manual

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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IM-106-880, Rev 1.0 January 2007

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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Instruction Manual

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.

2-3

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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Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 2-2. Adapter Plate Installation

OCX 8800

2-5

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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Instruction Manual

IM-106-880, Rev 1.0 January 2007

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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Instruction Manual

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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Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 2-5. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration)

Eductor

Air In

Sensor

Housing

Reference Air In

Dilution Air In

CAL Gas In

OCX 8800

CAL Gas

Flow Meter

7 scfh, 20-30 psig

(

Recommended

(

Electronics

Housing

Dilution Air

Flow Meter

0.1 scfh

Instrument

Air Out

2-Stage

Regulators

HI O

LO O

Instrument

Air Supply

Pressure Reguator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

37390011

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OCX 8800

Figure 2-6. Pneumatic Installation, OCX with Reference Air Set and Solenoids (with Autocalibration)

CAL Gas

Flow Meter

7 scfh, 20-30 psig

(

Recommended

Electronics

Housing

(

Eductor

Air In

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Sensor

Housing

CAL Gas In

Reference

Air In

Dilution

Air In

Dilution Air

Flow Meter

0.1 scfh

CAL Gas Out

Instrument Air Out

LO O

HI O

Pressure Regulator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

2-Stage

Regulators

Instrument

Air Supply

Reference Air Set and Solenoids Option

When the reference air set and test gas solenoids are included with your OCX 8800, use the following procedure to install the pneumatic system components.

1. Install the reference air set according to the instructions in Reference Air Set Option, steps 1 through 3.

2. Refer to Figure 2-6. Connect the O O

inlet fitting on the electronics housing. Install a shutoff valve and

pressure regulator with gage in the O

3. Connect the O

high gas source to the CAL GAS HI O2 inlet fitting.

Install a shutoff valve and pressure regulator with gage in the O

low gas source to the CAL GAS LO

low supply line, as shown.

high

supply line.

37390012

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IM-106-880, Rev 1.0 January 2007

OCX 8800

4. Connect the CO high gas to the CAL GAS HI COe inlet fitting. Install a shutoff valve and pressure regulator with gage in the CO high supply line.

5. Connect the CAL GAS outlet fitting of the electronics housing 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.

Reference Air Set, Solenoids, and Blowback Option

The blowback system blows instrument air back through the blowback filter and out the sample tube of the transmitter. This removes built up dirt and particulate from the filter and sample line. The blowback option is normally used in systems that have a dirty process stream.

Installing an OCX 8800 with the blowback option requires the addition of air operated blowback valve, regulator and gage, and check valve.

Figure 2-7 shows the piping arrangement for the OCX 8800 with the blowback and autocalibration options. Figure 2-8 shows the piping arrangement for the OCX 8800 with the blowback option, but without autocalibration (without test gas solenoids).

When the reference air set, calibration gas solenoids, and blowback options are included with your transmitter, use the following procedure to install the pneumatic system components.

1. Connect the calibration gas sources according to the instructions in the previous paragraph “Reference Air Set and Solenoids Option”, steps 2 through 5.

2. Connect a clean, dry, instrument-quality supply of air (20.95% O 35/45 psig and 55 psig pressure regulators. The inlet to the 35/45 psig regulator accepts a 1/8" NPT fitting. The inlet to the 55 psig regulator accepts a 1/4" NPT fitting.

3. See the upper leg of the instrument air supply. Connect the output of the 35/45 psi regulator/filter to one port of the normally-closed air-operated solenoid valve, and to the inlet side of the dilution air flow meter.

4. Connect the dilution air flow meter output to the DILUTION AIR inlet fitting on the sensor housing.

5. Install an instrument air line between the open port of the normally-open air-operated solenoid valve and the tee fitting on the sensor housing.

6. Connect the output of the 55 psi regulator/filter to one port of the normally-open air-operated solenoid valve, and to the instrument air inlet on the back of the electronics housing.

7. Install an air line between the open port of the normally-closed air-operated solenoid valve and the check valve inlet fitting on the sensor housing.

) to the

2-13

OCX 8800

Figure 2-7. Piping Arrangement, Blowback with Autocalibration

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Cal Gas Flow Meter

7 scfh, 20-30 psig

(

Recommended

Eductor Air In

Electronics

Housing

(

Check

Valve

Dilution Air In

Instrument Air

*Normally

Open Solenoid Valve

Tee - (3 x 1/4 in. Tube Unions)

Check Valve

Sensor Housing

Reference Air In

Vacuum Gage

*Normally

Closed Solenoid Valve

CAUTION

Pressure regulator with 1/8” inlet port is factory set for 35 or 45 psig. Regulator with 1/4” inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the OCX 8800 will not work.

Dilution Air Flow Meter

0.1 scfh

Pressure Regulator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

CAL Gas Out

2-Stage

Regulators

2-14

LO O

HI O

Blowback Valve,

Air Operated

*NOTE: During blowback operation, states of

both solenoid valves change.

NOTE: Wall mount the air-operated blowback

valve on a suitable mounting plate.

Pressure

Regulator/Filter

55 psig

Instrument Air Supply

38850004

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 2-8. Piping Arrangement, Blowback without Autocalibration

Eductor Air In

Check Valve

Reference Air In

Dilution Air In

Sensor Housing

CAL Gas In

OCX 8800

CAUTION

Cal Gas Flow Meter

(

7 scfh, 20-30 psig

Recommended

(

2-Stage

Regulators

Electronics

Housing

Instrument Air

*Normally

Open Solenoid Valve

Dilution Air Flow Meter

0.1 scfh

*Normally

Closed Solenoid Valve

Blowback Valve,

Air Operated

*NOTE: During blowback operation, states of

both solenoid valves change.

NOTE: Wall mount the air-operated blowback

valve on a suitable mounting plate.

Pressure Regulator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

Pressure

Regulator/Filter

55 psig

LO O

HI O

Instrument Air Supply

37390005

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OCX 8800

8. Install an air line between the instrument air outlet fitting on the electronics housing and the control air inlet fitting on the air-operated solenoid valve.

9. There are three settings that need to be specified to set up the blowback option. These are the blowback interval, duration, and purge time.

Interval - Length of time between blowback events. (60 minutes recommended.)

Duration - Length of time blowback air is activated. (5 seconds recommended.)

Purge - Length of time after blowback is complete before oxygen/combustibles readings are considered valid. (Set as required by the application.)

These settings are available through HART from the DEVICE SETUP > DETAILED SETUP > OUTPUT CONDITIONS > BLOWBACK menu.

January 2007

INITIAL STARTUP Observe the following Caution and Note. Refer to Section 3: Configuration

and Startup, for OCX 8800 startup information.

Upon completing installation, make sure that the OCX 8800 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold OCX 8800 exposed to the process gases.

If ducts will be washed down during outages, make sure to power down the OCX 8800 units and remove them from the wash area.

NOTE

During outages, and whenever possible, leave OCX 8800 units running to prevent condensation and premature aging from thermal cycling.

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IM-106-880, Rev 1.0 January 2007

OCX 8800

Section 3 Configuration and Startup

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

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

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

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

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.

VERIFY INSTALLATION Ensure the OCX 8800 is installed correctly. Vertify mechanical installation and

all electrical and pneumatic connections. Refer to Section 2, Installation.

Make sure that the OCX 8800 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold OCX 8800 exposed to the process gases.

NOTE

During outages, and whenever possible, leave all OCX 8800 units running to prevent condensation and premature aging from thermal cycling.

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OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Verify Configuration

There are three switches on the microprocessor board which are user configurable for the OCX 8800 (Figure 3-1). SW1 determines if the O mA signal is internally or externally powered. SW2 determines if the COe 4-20 mA signal is internally or externally powered. SW3 sets the rail limits for the O

and COe 4-20 mA signals and configures the sample line heater control

circuit. All switches are accessible through holes in the electronics box.

Remove power from the OCX 8800 before changing defaults. If defaults are changed under power, damage to the electronics may occur.

Verify that the following switch settings are correct for your OCX 8800 installation:

4-20

SW1 The two settings are internally or externally powering the O mA signal. The factory setting is for the O

4-20 mA signal to be internally

4-20

powered. SW2 The two settings are internally or externally powering the COe 4-20

mA signal. The factory setting is for the COe 4-20 mA signal to be internally powered.

SW3 The factory sets this switch as follows:

• Position 1 determines the O

4-20 mA signal rail limit. The settings are

high, 21.1 mA, or low, 3.5 mA. The factory setting is low, 3.5 mA.

• Position 2 determines the COe 4-20 mA signal rail limit. The settings are high, 21.1 mA, or low, 3.5 mA. The factory setting is high, 21.1 mA.

• Positions 3 and 4 must be set as shown for proper software control of the device heaters.

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IM-106-880, Rev 1.0 January 2007

Figure 3-1. OCX 8800 Defaults

Switch

Default Postions

Shown

21.1 mA

3.5 mA

COe

1223344

OCX 8800

Open

Closed

Open

Closed

SW3

O 21.1 mA/3.5 mA:2O 4-20 mA Signal

Open

Closed

1234

COe 21.1 mA/3.5 mA:

Open

Closed

Rail Limits: High - 21.1 mA Low - 3.5 mA

COe 4-20 mA Signal Rail Limits: High- 21.1 mA Low - 3.5 mA

Internal:

COe 4-20 mA

is Internally

Powered

SW2

External: COe 4-20 mA Requires an External Power Supply (Default)

Internal:

O 4-20 mA

is Internally

Powered

SW1

External: O 4-20 mA

Requires an External Power Supply (Default)

INITIAL POWER UP Allow adequate time (approximately 60 minutes) for the heaters to begin

operation and for the OCX 8800 to reach normal operating temperature on power up. Normal operating temperature for the O operating temperature for the combustibles cell is 300°C. The normal sample line temperature is 170°C. During this time the eductor air solenoid will remain closed so no sample is pulled through the analyzer. When the OCX reaches operating temperature the solenoid will energize, eductor air will begin to flow, and the unit will begin normal operation.

cell is 736°C. Normal

37390026

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IM-106-880, Rev 1.0

OCX 8800

January 2007

SET TEST GAS VALUES Use HART/AMS to set test gas values for calibration. Refer to Section 4,

Using HART Communications for more information.

Setting Test Gas Values with HART

1. Use the HART communicator or AMS software to access the HART menu.

2. From the DETAILED SETUP menu, select O2 CALIB PARAMS.

3. From O2 CALIB PARAMS, select O2 High Gas. Enter the percent O used for the high O

4. From O2 CALIB PARAMS, select Low TG. Enter the percent O for the low O

5. From the DETAILED SETUP menu, select COe CALIB PARAMS.

6. From COe CALIB PARAMS, select COe Test Gas. Enter the CO concentration (ppm) used for COe test gas.

test gas.

used

OCX 8800 RESET PROCEDURE

Whenever you correct an equipment alarm or fault condition, the OCX 8800 will either revert to normal operation or continue to indicate an alarm status condition. If the equipment does not revert to normal operation when a fault condition is cleared, or if instructed to do so in Section 7, Troubleshooting, use the following procedure to reset the OCX 8800.

OCX Reset with HART

Remove the OCX 8800 from the process loop and recycle power.

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OCX 8800

Section 4 Using HART Communications

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

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

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

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

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

OVERVIEW The HART communicator is a handheld communications interface device. It

provides a common communications link to all microprocessor-based instruments that are HART compatible. The handheld communicator contains an 8 x 21 character liquid crystal display (LCD) and 25 keys. A pocket-sized manual, included with the HART communicator, details the specific functions of all the keys.

To interface with the OCX 8800, the HART communicator requires a termination point along the O resistance of 250 ohms between the communicator and the power supply. The HART communicator accomplishes its task using a Frequency Shift Keying (FSK) technique. With the use of FSK, high-frequency digital communication signals are superimposed on the 4-20 mA oxygen output signal. The communicator does not disturb the 4-20 mA signal since no net energy is added to the loop. HART information is not available on the COe output signal.

4-20 mA current loop and a minimum load

HART COMMUNICATOR SIGNAL CONNECTIONS

The HART communicator may be interfaced with a personal computer (PC), providing special software has been installed. To connect the HART communicator to a PC, an interface adapter is required. Refer to the proper HART communicator documentation in regard to the PC interface option.

The HART communicator can connect to the OCX 8800 oxygen analog output signal line at any wiring termination in the O two methods of connecting the HART communicator to the signal line. For applications in which the signal line has a load resistance of 250 ohms or more, refer to method 1. For applications in which the signal line load resistance is less than 250 ohms, refer to method 2.

4-20 mA current loop. There are

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OCX 8800

Figure 4-1. Signal Line Connections,

≥ 250 Ohms Load Resistance

4-20 mA Terminal Block in

Electronics Housing

Instruction Manual

IM-106-880, Rev 1.0

January 2007

A OUT 1 + A OUT 1 -

Loop

Connectors

HART Communicator

Rear Panel

Method 1, for Load Resistance

Refer to Figure 4-1 and the following steps to connect the HART communicator to a signal line 250 ohms or more of load resistance.

O 4-20 mA Signal Line

HART Communicator Model 275/375

≥

RL 250Ω

Analog Output Device

Lead Set

≥ 250 Ohms

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Do not make connections to the HART communicator's serial port, 4-20 mA signal lines, or NiCad recharger jack in an explosive atmosphere. Explosions can result in death or serious injury.

Using the supplied lead set, connect the HART communicator in parallel to the OCX 8800. Use any wiring termination points in the oxygen analog output 4-20 mA signal line.

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 4-2. Signal Line Connections, < 250 Ohms Load Resistance

OCX 8800

Method 2, for Load Resistance < 250 Ohms

Refer to Figure 4-2 and the following steps to connect the HART communicator to a signal line with less than 250 ohms load resistance.

Do not make connections to the HART communicator's serial port, 4-20 mA signal lines, or NiCad recharger jack in an explosive atmosphere. Explosions can result in death or serious injury.

1. At a convenient point, break the oxygen analog output 4-20 mA signal line and install the optional 250 ohm load resistor.

2. Plug the load resistor into the loop connectors (located on the rear panel of the HART communicator).

4-20 mA Terminal Block in

Electronics Housing

A OUT 1 + A OUT 1 -

Loop

Connectors

HART Communicator

Rear Panel

O 4-20 mA Signal Line

HART

Communicator

Model 275/375

The signal loop must be broken to insert

NOTE:

the optional 250 ohm load resistor.

RL <250Ω

Analog Output Device

250 OHM

Load Resistor

(See Note)

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January 2007

HART COMMUNICATOR PC CONNECTIONS

There is an option to interface the HART communicator with a personal computer. Load the designated AMS software into the PC. Then link the HART communicator to the PC using the interface PC adapter that connects to the serial port (on the communicator rear panel). Refer to the proper HART communicator documentation in regard to the PC interface option.

Off-line and On-line Operations

The HART communicator can be operated both off-line and on-line. Off-line operations are those in which the communicator is not connected to

the OCX 8800. Off-line operations can include interfacing the HART communicator with a PC. (Refer to applicable HART documentation regarding HART/PC applications.)

In the on-line mode, the communicator is connected to the oxygen 4-20 mA analog output signal line. The communicator is connected in parallel to the OCX 8800 or in parallel to the 250 ohm load resistor.

The opening menu displayed on the LCD is different for on-line and off-line operations. When powering up a disconnected (off-line) communicator, the LCD will display the Main Menu. When powering up a connected (on-line) communicator, the LCD will display the On-line Menu. Refer to the HART communicator manual for detailed menu information.

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OCX 8800

HART MENU TREE This section consists of a menu tree for the HART communicator. This menu

is specific to OCX 8800 applications.

Figure 4-3. HART Menu Tree (Sheet 1 of 4)

O2 COe O2 Temp COe Temp SB Temp Brd Temp CJC Temp

O2 Snsr O2 T/C O2 Snsr R O2 Snsr RS

COe DeltV COe RefV COe DeltaR Coe RefR COe T/C RTD Curr

SB T/C Brd Temp IC CJC Temp S

PROCESS VARIABLES

VIEW DEV VARS

VIEW DEV RAW VAL

VIEW O2 RAW VAL

VIEW COE RAW VAL

VIEW DEV RAW VAL

DEVICE SETUP O2 O2 AO COe COe AO

(CONTINUED ON

SHEET 2)

VIEW OUTPUT VARS

VIEW DEV LIMITS

PV-AOUT

COE

BOARD TEMP

SB TEMP

PV is

O2 O2 AO O2 AO %

SV is

COe COe AO COe AO %

TV is

O2 Temp

4V is

COe Temp

O2 O2 USL O2 LSL

O2 TEMP

O2 Temp O2 T/C USL O2 T/C LSL

COE

COe COe USL COe LSL

COE TEMP

COe Temp COe T/C USL COe T/C LSL

Brd Temp Brd TC USL Brd TC LSL

SB Temp SB TC USL SB TC LSL

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OCX 8800

Figure 4-3. HART Menu Tree (Sheet 2 of 4)

(CONTINUED FROM

SHEET 1 )

STATUS

DIAG/SERVICE

HW STATUS

LOOP TEST

D/A TRIM

CALIBRATE

VERIFY CALIB

Operate Mode Status group 1

Status group 2

Status group 3

Status group 4 Status group 5 Status group 6

AO saturated

AO fixed

Model Number Snsr Housing CPLD REGS Line Freq Line Volt PCN Counter PCD Counter

O2 D/A Trim COe D/A Trim

PERFORM CAL

CAL STATUS

CAL VALUES

PREV CAL VALUES

FAILED CAL VALUES

RESET CAL CONST

Verify Calibration Status TimeRemain O2 COe

O2 AO Saturated COe AO Saturated

O2 AO Fixed COe AO Fixed

BCSR0 BCSR3 BCSR1 BCSR4 BCSR2 BCSR5

O2 Loop Test COe Loop Test

(procedures)

CAL METHODS O2OutTracks COeOutTracks Cal Step Cal Time O2 COe

Cal Step Cal Time

O2 Slope O2 Const O2 Snsr R COe Slope COe Const

Prev O2 Slope

O2 Const

O2 Snsr R

COe Slope

COe Const

Bad O2 Slope Bad O2 Const Bad COe Slope Bad COe Const

Reset O2 CalConsts Reset COe CalConsts

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Status group 1 O2 T/C Open O2 T/C Shorted O2 T/C Reversed ADC Failure Line Freq Error O2 Htr Failure O2 Temp Very Hi Board Temp Hi

Status group 2 O2 Temp Low O2 Temp Hi O2 Snsr Open O2 Snsr R Hi EEPRM Chksm Fail O2 Htr Ramp Rate COe Htr Ramp Rate SB Htr Ramp Rate

Status group 3 Cal Failed Cal Warning SB T/C Open SB T/C Shorted SB Temp Low SB Temp Hi SB Temp Very Hi ADC Ref Error

Status group 4 RTD Current Err COe Temp Low COe Temp Hi COe Temp Very Hi COe T/C Open COe T/C Shorted COe T/C Reversed SB T/C Reversed

Status group 5 COe Htr Failure SB Htr Failure Line Voltage Low Line Voltage Hi Htr Relay Failed Output Board Failure

Status group 6 O2 Slope Error O2 Constant Error O2 Cal Failed COe Slope Error COe Constant Error COe Cal Failed

O2 Calibration COe Calibration O2 and COe Calib

4-6

(CONTINUED ON

SHEET 3)

BLOWBACK

MAX TEMP

HEATER PID

BlBk State Blowback

O2TempMax COeTempMax SBTempMax BrdTempMax CJCTempMax

O2 PID

COE PID

SB PID

O2 Prop O2 Int O2 DutyCyc O2 SetPt O2 Temp

COe Prop

Int

COe

DutyCyc

COe

SetPt

COe

Temp

COe

SB Prop SB Int SB DutyCyc SB SetPt SB Temp

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Figure 4-3. HART Menu Tree (Sheet 3 of 4)

(CONTINUED FROM

SHEET 2)

BASIC SETUP

DETAILED SETUP

(CONTINUED ON

SHEET 4)

DEVICE

INFORMATION

HART INFORMATION

S/W VERSION INFO

OUTPUT CONDITION

O2 CALIB PARAMS

COe CALIB PARAMS

DEVICE PARAMS

LOI PARAMS

Date Descriptor Message Final asmbly num O2 Sensor s/n COe Sensor s/n

Ta g Poll addr Dev id Num req preams Fld dev rev

Version Chksum Bld Num Bld Date Restart Cntr

ANALOG OUTPUT

ALARM RELAY

BLOWBACK

O2OutTracks O2 High Gas O2 Low Gas Gas Time Purge Time Solenoids O2 CalIntv O2NxtCalTm

COeOutTracks COe Test Gas Gas Time Purge Time Solenoids COe CalIntv COeNxtCalTm COe Slope Warn

O2 Slope O2 Const O2 T90 COe Slope COe Const COe T90 PCNC Enable PCDC Enable

User Intface Luminance Lockout Time Revert Time

O2 ANALOG OUTPUT

COe ANALOG OUTPUT

OCX 8800

O2 AO Type O2 URV O2 LRV O2 Alarm Level

COe AO Type COe URV COe LRV COe Alarm Level

Trig 1 Event Trig 2 Event Trig 3 Event Alarm State

BlBk Enabled BlBk Intrvl BlBk Period BlBk PurgeTm BlBk State

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OCX 8800

Figure 4-3. HART Menu Tree (Sheet 4 of 4)

(CONTINUED FROM

SHEET 3)

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January 2007

REVIEW

DEVICE INFORMATION

HART INFORMATION

CAL INFO

DEVICE CONFIG

Manufacturer Model Date Descriptor Message Final asmbly num O2 Sensor s/n COe Sensor s/n Hardware rev Software rev

Ta g Poll addr Dev id Num req preams Fld dev rev Universal rev

O2 CALIB

COE CALIB

O2 DEVICE CONFIG

COE DEVICE CONFIG

DEVICE CONFIG

O2OutTracks O2 High Gas O2 Low Gas Gas Time Purge Time Solenoids O2 CalIntv O2NxtCalTm

COeOutTracks COe Test Gas Gas Time Purge Time Solenoids COe CalIntv COeNxtCalTm COe Slope Warn

O2 Slope O2 Const O2 T90

COe Slope COe Const COe T90

Trig 1 Event Trig 2 Event Trig 3 Event BlBk Enabled BlBk Intrvl BlBk Period BlBk PurgeTm

PCNC Enable PCDC Enable Luminance Lockout Time Revert Time

4-8

OUTPUTS CONFIG

O2 URV O2 LRV COe URV COe LRV O2 AO Type COe AO Type O2 Alarm Level COe Alarm Level

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OCX 8800

D/A TRIM PROCEDURES O

D/A trim procedure using HART/AMS

Use the following procedure to perform the O HART communicator or AMS. Refer to the HART menu tree, Figure 4-3.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number.

To return to a preceding menu, press the left arrow key.

1. From the DIAG/SERVICE menu, select D/A TRIM. The HART communicator displays O2 D/A Trim.

2. Press the right arrow key to start the procedure. (If you wish to exit D/A Trim with no changes, select ABORT.)

3. The HART communicator displays WARNING: Loop should be removed from automatic control. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

4. Remove the electronics housing cover.

5. Refer to Figure 2-4. Connect a digital multimeter to read the milliamp output from the O AOUT1+ terminal and connect the negative lead to the AOUT1terminal. Then, press OK at the HART communicator.

6. The HART communicator displays Setting Fld dev output to 4 mA. Press OK. Read the O the reading at the HART communicator and press ENTER. (Select ABORT to exit without changes).

7. The HART communicator displays Setting Fld dev output to 20 mA. Press OK. Read the O the reading at the HART communicator and press ENTER. (Select ABORT to exit without changes).

8. The HART communicator displays Setting Fld dev output to 4 mA. Press OK.

9. The HART communicator displays Fld dev output 4.00 mA equal to reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 6.

10. The HART communicator displays Setting Fld dev output to 20 mA. Press OK.

11. The HART communicator displays Fld dev output 20.00 mA equal to reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 7.

12. The HART communicator displays NOTE: Loop may be returned to automatic control.

D/A coverter circuit. Connect the positive lead to the

millamp output at the digital multimeter. Enter

D/A trim procedure using the

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January 2007

COe D/A trim procedure using HART/AMS

Use the following procedure to perform the COe D/A trim procedure using the HART communicator or AMS. Refer to the HART menu tree, Figure 4-3.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number.

To return to a preceding menu, press the left arrow key.

1. From the DIAG/SERVICE menu, select D/A TRIM. The HART communicator displays O2 D/A Trim. Press the up or down arrow to select COe D/A Trim.

2. Press the right arrow key to start the procedure. (If you wish to exit D/A Trim with no changes, select ABORT.)

4. Remove the electronics housing cover.

5. Refer to Figure 2-4. Connect a digital multimeter to read the milliamp output from the COe D/A coverter circuit. Connect the positive lead to the AOUT2+ terminal and connect the negative lead to the AOUT2terminal. Then, press OK at the HART communicator.

6. The HART communicator displays Setting Fld dev output to 4 mA. Press OK. Read the COe the reading at the HART communicator and press ENTER. (Select ABORT to exit without changes).

7. The HART communicator displays Setting Fld dev output to 20 mA. Press OK. Read the COe the reading at the HART communicator and press ENTER. (Select ABORT to exit without changes).

8. The HART communicator displays Setting Fld dev output to 4 mA. Press OK.

9. The HART communicator displays Fld dev output 4.00 mA equal to reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 6.

10. The HART communicator displays Setting Fld dev output to 20 mA. Press OK.

11. The HART communicator displays Fld dev output 20.00 mA equal to reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 7.

12. The HART communicator displays NOTE: Loop may be returned to automatic control.

millamp output at the digital multimeter. Enter

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Section 5 Calibration

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

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

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

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

OCX 8800

OVERVIEW During a calibration, two calibration gases with known O

one calibration gas with a known COe concentration are applied to the OCX

8800. Slope and constant values are calculated to determine if the OCX 8800

FULLY AUTOMATIC CALIBRATION

is correctly measuring net concentrations of O industrial process.

Before calibrating the OCX 8800, verify that the calibration gas parameters are correct by setting the test gas values used when calibrating the unit. Refer to Section 3, Configuration and Startup.

There are three calibration methods available to the OCX 8800; automatic, operator-initiated automatic, and manual. Calibration commands and menus can be accessed by HART/AMS.

If the OCX 8800 is equipped with calibration solenoids, the unit can be programmed to automatically calibrate without any operator action. Refer to the following paragraphs for using HART/AMS to set up the OCX 8800 for fully automatic calibration.

Autocalibration Setup using HART

NOTE

Automatic calibration is only available on units equipped with calibration solenoids.

Use the following procedure to specify a time interval (in hours) at which the OCX 8800 will automatically calibrate.

and combustibles in the

concentrations and

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1. From the DEVICE SETUP screen, select DETAILED SETUP.

2. From the DETAILED SETUP screen, select O2 CALIB PARAMS or COE CALIB PARAMS.

3. If the unit is equipped with calibration solenoids and timed automatic calibrations are desired, select Solenoids, then select Yes. Selct No to disable the calibration solenoids.

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January 2007

4. Select O2 CalIntrvl (O2 calibration interval) and enter the desired time in hours between automatic O enter the desired time between automatic COe calibrations. To disable automatic calibration for O parameters.

5. If desired, the O2NxtCalTm and the COeNxtCalTm (next calibration time) parameters can be changed to synchronize a calibration at a specific day or time.

When setting automatic calibration times, CalIntrvl and NxtCalTm should be set so that O2 and COe are NOT calibrated simultaneously.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number.

calibrations. Select COE Callintrvl and

and COe, enter 0 for both CalIntrvl

To return to a preceding menu, press the left arrow key.

6. From the O2 CALIB PARAMS screen, select CalIntrvl.

7. At the prompt, input a time interval (in hours) at which an automatic O calibration will occur and press ENTER.

8. From the DETAILED SETUP screen, select COE CALIB PARAMS.

9. From the COE CALIB PARAMS menu, select CalIntrvl.

10. At the prompt, input a time interval (in hours) at which an automatic COe

calibration will occur and press ENTER.

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OCX 8800

OPERATOR - INITIATED AUTOCALIBRATION

An operator can initiate an automatic calibration at any time provided that the unit is equipped with calibration solenoids.

Autocalibration using HART

To initiate an automatic calibration using HART/AMS, perform the following steps on the HART menu tree. Refer to Section 4, Using HART Communications, for the HART menu tree.

1. Select DIAG/SERVICE from DEVICE SETUP menu.

2. Select CALIBRATE from the DIAG/SERVICE menu.

3. Select PERFORM CAL from the CALIBRATE menu.

4. Select CAL METHODS from the PERFORM CAL menu.

5. From the CAL METHODS menu, select the type of calibration desired:

O2 Calibration, COe Calibration, or O2 and COe Calibration.

MANUAL CALIBRATION If a unit is not equipped with calibration solenoids, a calibration must be

performed by an operator following prompts from the unit. Refer to the following paragraphs for manual calibration.

Manual O

To perform a manual O use the following procedure. If necessary, refer to Section 4, Using HART Communications, for the HART menu tree.

Calibration using HART

calibration using the HART communicator or AMS,

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number.

To return to a preceding menu, press the left arrow key.

1. From the DIAG/SERVICE menu, select CALIBRATION. From the CALIBRATION menu, select PERFORM CAL.

2. From the PERFORM CAL menu, select CAL METHODS. Select O2 CALIBRATION to start O

3. In the first O automatic control warning appears. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

4. The main Calibration screen should look like the following. Press OK to continue.

OCX: TAG NAME STATUS: Idle TIME REMAIN: 0s O2: 0.4 %, 85.95mV OK/NEXT to Select ABORT/CANCEL to Exit

Calibration screen, a Loop should be removed from

calibration.

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January 2007

5. From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT

CAL to exit calibration. Select one item from the list and press ENTER.

OCX: TAG NAME SELECT ACTION

1. START/NEXT CALSTEP

2. ABORT CAL

3. EXIT CAL

6. When the Calibration Status is at the AppO2Low step, switch on O Low Gas. Verify the O

concentration measured matches the O2 LOW

GAS parameter in the Setup. Press OK when ready.

7. Select Start/Next Cal Step to start applying the O

Low Gas. The time

to apply the test gas is specified by the Gas Time.

8. The Calibration Status should be automatically changed to FlowO2Low and then ReadO2Low for a period of time. During this period, if an attempt is made to go to the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time.

9. When ready, Calibration Status will stop at the AppO2Hi. Switch off the O

Low Gas and switch on the O2 High Gas. Verify the O2 concentration

measured matches the O2 HIGH GAS parameter in the Setup. Press OK when ready.

10. Select Start/Next Cal Step to start applying the O

High Gas. The time

to apply the test gas is specified by the Gas Time.

11. The Calibration Status should be automatically changed to FlowO2Hi and then ReadO2Hi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting

Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command

is not accepted at this time.

12. When ready, Calibration Status will stop at STOP GAS. Switch off the

High Gas. Press OK when ready. Select Start/Next Cal Step to start

purging gas. The time to purge gas is specified by the Purge Time.

13. When the Purge step is complete, the Calibration Status will be at IDLE if the calibration is successful or CAL RECOMMENDED if the calibration has failed. A Calibration Failed alarm will be set if the calibration has failed.

14. When calibration is complete. Select Exit Cal to exit the calibration method.

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OCX 8800

Manual COe Calibration using HART

To perform a manual COe calibration using the HART communicator or AMS, use the following procedure. If necessary, refer to Section 4, Using HART Communications, for the HART menu tree.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number.

To return to a preceding menu, press the left arrow key.

1. From the DIAG/SERVICE menu, select CALIBRATION. From the CALIBRATION menu, select PERFORM CAL.

2. From the PERFORM CAL menu, select CAL METHODS. Select COe CALIBRATION to start COe calibration.

3. In the first COe Calibration screen, a Loop should be removed from automatic control warning appears. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

4. The main Calibration screen should look like the following. Press OK to continue.

OCX: TAG NAME STATUS: Idle TIME REMAIN: 0s COe: 0.20 ppm, 0.00 mV OK/NEXT to Select ABORT/CANCEL to Exit

5. From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT

CAL to exit calibration. Select one item from the list and press ENTER.

OCX: TAG NAME SELECT ACTION

1. START/NEXT CALSTEP

2. ABORT CAL

3. EXIT CAL

6. The unit samples reference air as the COe Status should automatically change to ReadCOLow for a period of time. During this period, if an attempt is made to go to the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time.

7. When ready, Calibration Status will stop at the AppCOeHi. Switch on the COe High Gas. Verify the COe concentration measured matches the COe HIGH GAS parameter in the Setup. Press OK when ready.

8. Select Start/Next Cal Step to start applying the COe High Gas. The time to apply the test gas is specified by the Gas Time.

Low Gas. The Calibration

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9. The Calibration Status should be automatically changed to FlowCOeHi and then ReadCOeHi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time.

10. When ready, Calibration Status will stop at STOP GAS. Switch off the COe High Gas. Press OK when ready. Select Start/Next Cal Step to start purging gas. The time to purge gas is specified by the Purge Time.

11. When the Purge step is complete, the Calibration Status will be at IDLE if the calibration is successful or CAL RECOMMENDED if the calibration has failed. A Calibration Failed alarm will be set if the calibration has failed.

12. When calibration is complete. Select Exit Cal to exit the calibration

method.

Manual O

To perform a manual O or AMS, use the following procedure. If necessary, refer to Section 4, Using HART Communications, for the HART menu tree.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number.

To return to a preceding menu, press the left arrow key.

1. From the DIAG/SERVICE menu, select CALIBRATION. From the

2. From the PERFORM CAL menu, select CAL METHODS. Select 02 &

3. In the first Calibration screen, a Loop should be removed from

4. The main Calibration screen should look like the following. Press OK to

and COe Calibration using HART

and COe calibration using the HART communicator

CALIBRATION menu, select PERFORM CAL.

COe CALIBRATION to start O

automatic control warning appears. Remove the OCX 8800 from any

automatic control loops to avoid a potentially dangerous operating condition and press OK.

continue.

OCX: TAG NAME STATUS: Idle TIME REMAIN: 0s O2: 0.4 %, 85.95mV COe: 0.20 ppm, 0.00 mV OK/NEXT to Select ABORT/CANCEL to Exit

and COe calibration.

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OCX 8800

5. From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT

CAL to exit calibration. Select one from the list and press ENTER.

OCX: TAG NAME SELECT ACTION

1. START/NEXT CALSTEP

2. ABORT CAL

3. EXIT CAL

6. When the Calibration Status is at the AppO2Low step, switch on O Low Gas. Verify the O

concentration measured matches the O2 LOW

GAS parameter in Setup. Press OK when ready.

7. Select Start/Next Cal Step to start applying the O

Low Gas. The time

to apply the test gas is specified by the Gas Time.

8. The Calibration Status should automatically change to FIowO2Low and then ReadO2Low for a period of time. During this period, if an attempt is made to go to the next calibration step by pressing OK and selecting

Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command

is not accepted at this time.

9. When ready, Calibration Status will stop at AppO2Hi. Switch off the O Low Gas and switch on the O

High Gas. Verify the O2 concentration

measured matches the O2 HIGH GAS parameter in Setup. Press OK when ready.

10. Select Start/Next Cal Step to apply the O

High Gas. The time to apply

the test gas is specified by the Gas Time.

11. The Calibration Status should automatically change to FlowO2Hi, then ReadO2Hi, and then ReadCOeLo for a period of time. During this period, if an attempt is made to go the next calibration step by pressing

OK and selecting Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time.

12. When ready, Calibration Status will stop at AppCOeHi. Switch off the O

High Gas and switch on the COe Gas. Verify the COe concentration measured matches the COe TEST GAS parameter in the Setup. Press OK when ready.

13. Select Start/Next Cal Step to start applying the COe Gas. The time to apply the test gas is specified by the Gas Time.

14. The Calibration Status should automatically change to FlowCOeHi and then ReadCOeHi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting

Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command

is not accepted at this time.

15. When ready, Calibration Status will stop at STOP GAS. Switch off the COe gas. Press OK when ready. Select Start/Next Cal Step to start purging gas. The time to purge gas is specified by Purge Time.

5-7

OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

5-10

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

Section 6 Maintenance and Service

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

OCX 8800 Removal and Installation . . . . . . . . . . . . . . . . . page 6-1

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

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

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

OVERVIEW This section contains the procedures to maintain and service the OCX 8800.

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

OCX 8800 REMOVAL AND INSTALLATION

It is recommended that the OCX 8800 be removed from the stack for all service activities. The unit should be allowed to cool and be taken to a clean work area. Failure to comply may cause severe burns.

Disconnect and lock out power before working on any electrical components. There may be voltage up to 264 VAC.

Use the following procedures to remove or install the OCX 8800.

http://www..raihome.com

OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

OCX with Integral Electronics

Figure 6-1. OCX with Integral Electronics

Remove OCX 8800

1. Turn off power to the system.

2. Shut off the test gases at the cylinders and shut off the instrument air.

3. Disconnect the test gas and instrument air lines from the electronics housing, Figure 6-1.

Adapter

Plate

Stack

Sensor

Housing

Electronics

Housing

Duct

O and COe

4-20 mA Outputs

(2 Twisted Pairs)

AC Power Input

Instrument Air

(Reference Gas)

High O Test Gas

Low O Test Gas

CO Test Gas

Explosion hazard! Before removing cover from sensor or electronics housing, allow at least 45 minutes to pass after power is disconnected. Failure to allow adequate time for all internal electrical charges to dissipate can result in serious injury or death.

37390043

4. Remove the cover from the electronics housing to expose the electronics housing terminal blocks, Figure 6-2.

5. Disconnect and remove the power leads from the AC power input terminal block and remove the ground lead from the ground stud.

6. Disconnect and remove the O

and COe signal leads from the 4-20 mA

signal output terminal block.

7. If used, disconnect and remove the external relay leads from the alarm output relay terminal block.

8. Disconnect and remove customer power and signal wire conduits and wiring from the electronics housing.

9. Remove insulation to access the sensor housing mounting bolts. Unbolt the OCX 8800 from the stack and take it to a clean work area.

10. Allow the unit to cool to a comfortable working temperature.

6-2

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 6-2. Electronics Housing Terminal Blocks

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

6-3

OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Install OCX 8800

Observe the following cautions when installing the OCX 8800 in a hot process stack. If the process is shut down and cooled, the transmitter can be installed in the stack prior to connecting the pneumatics and wiring.

1. Connect the test gas lines and the instrument air lines to the electronics housing.

2. Remove the electronics housing cover.

3. Install customer power and signal conduits and wiring at the electronics housing.

4. If used, connect external relay leads to the alarm output relay terminal block, Figure 6-2.

5. Connect the O

and COe signal leads to the 4-20 mA signal output

terminal block.

6. Connect the line (L1 wire) to the L1 terminal, and the neutral (N wire) to the N terminal on the AC power input terminal block.

7. Connect the ground lead to the ground stud. Secure the connection with two nuts. Attach a separate ground lead (G wire) from the ground stud to the G terminal on the power input terminal block.

8. Install the cover on the electronics housing.

9. Restore power to the system. Allow OCX to reach normal operating temperature before installing in a hot process stack.

10. Bolt the OCX 8800 to the stack and install insulation. Refer to Figure 6-1 and make sure all test gas lines and electrical connections are complete.

11. Turn on the test gasses at the cylinders and open the instrument air supply valve.

6-4

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

REPAIR SENSOR HOUSING

Sensor Housing Disassembly

Use the following procedures to remove damaged components from the OCX 8800 sensor housing and to install new replacement parts. Disassemble the unit only as needed to replace damaged components. Use the assembly procedures that apply to install replacement parts and reassemble the unit.

Remove Cover and Terminals Insulator

1. Loosen screw (1, Figure 6-3) and slide locking clip (2) away from cover. Retighten screw (1).

2. With two hands or strap wrench, turn cover (3) counterclockwise to loosen. Unthread and remove cover.

3. Inspect cover o-ring (4) for wear or damage. Replace cover o-ring if damaged.

4. Unsnap terminal marking plates (5) and remove terminal insulator (6).

6-5

OCX 8800

39006

Figure 6-3. Removal of O2 Cell and Heater Strut Assembly

1. Screw

2. Locking Clip

3. Cover

4. O-ring

5. Marking Plate

6. Terminal Insulator

7. Reference Air Tube

8. Sensor Housing

9. Heater Strut Assembly

10. Gasket

11. Screw

12. Heater Clamp

13. Heater Rod

Instruction Manual

IM-106-880, Rev 1.0

January 2007

6-6

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 6-4. O2 Cell, Thermocouple, and Heater Connections

Sensor Housing Terminals

ORG

GRN

O Cell Wires

O Heater Wires

Thermocouple Wires

RED

YEL

T/C O2

T/C CO

T/C SB

EXC

CJC

OCX 8800

+ +

O Cell and Heater Strut

Assembly

Sample

Block

Thermo-

couple

Return Wire

Sample Block

Heater Rods

HTR 02

HTR CO

HTR 02

HTR SB

Remove O

Cell and Heater Strut Assembly

CO REF

CO ACT

EXC

1. Remove reference air tube (7, Figure 6-3) from sensor housing (8).

2. See Figure 6-4. Disconnect and tag O

heater wires, O2 cell and return

wires, and thermocouple wires at the sensor housing terminals.

3. Remove the O

cell and heater strut assembly (9, Figure 6-3) from

sensor housing (8). Remove and discard gasket (10).

Remove Sample Block Heater Rods

1. Disconnect sample block heater rod wires from terminal block. Refer to Figure 6-4.

3739006

6-7

OCX 8800

Figure 6-5. COe Sensor, Thermocouple, and Heater Connections

Instruction Manual

IM-106-880, Rev 1.0

January 2007

2. Loosen screws (11, Figure 6-3) and rotate heater clamps (12) to release heater rods (13). One heater clamp secures each heater rod.

3. Slide sample block heater rods (13) out of housing (8).

Remove COe Sensor Assembly

1. Disconnect COe heater, thermocouple, and sensor wires from terminal blocks. Refer to Figure 6-5.

2. Remove insulator (1, Figure 6-6).

RED

YEL

T/C O2

T/C CO

Sensor Housing Terminals

HTR 02

HTR CO

HTR 02

HTR SB

CJC Sensor

T/C SB

EXC

BLU

RED

BLU

WHT

RED

COe Heater Wires

COe Sensor Wires

COe Thermocouple Wires

CJC

CO REF

CO ACT

EXC

NOTE: All wires at these terminals are in the CJC current loop.

COe Sensor

Assembly

37390018

6-8

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 6-6. Removal of COe Sensor Assembly

OCX 8800

NOTE

For easier access, you may remove two screws from base of terminal block mounting (13) and move terminal block assembly out of the way.

3. Remove tubes (2, 3, and 4) from COe sensor assembly (5), eductor fittings (12 and 15), and sensor housing (7).

4. Unfasten bayonet connector of COe thermocouple (8) and remove thermocouple.

5. Loosen clamp screw of COe band heater (9) until heater rotaters freely on sensor holder (11).

1. Insulator

2. Dilution Air Tube

3. COe Extractive Tube

4. Eductor Air Tube

5. COe Sensor Assembly

6. Eductor

7. Sensor Housing

8. COe Thermocouple

9. Heater Insulator

10. COe Band Heater

11. Sensor Holder

12. Eductor Elbow

13. Terminal Block Mounting

14. Eductor Holder

15. Tube Fitting

16. CJC Sensor

6-9

OCX 8800

Figure 6-7. Alignment of COe Sensor Assembly

Instruction Manual

IM-106-880, Rev 1.0

January 2007

6. See Figure 6-7. Using straightedge on the sensor holder flat, as shown, matchmark upper flange of sensor housing to show correct alignment of sensor holder.

7. With one wrench holding eductor elbow (12, Figure 6-6), and one wrench on flats of sensor holder (11), unthread and remove COe sensor assembly (5). Do not allow eductor elbow to turn.

8. Slide band heater (10) and heater insulator (9) from sensor holder (11).

Matchmark

Straightedge

Sensor

Holder

Flat

Matchmark

37390035

6-10

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

Remove Eductor

Figure 6-8. Eductor Alignment Matchmarks

The O

cell and heater strut assembly (9, Figure 6-3) and the COe sensor

assembly (5, Figure 6-6) must be removed before you start this procedure.

1. Use straightedge to matchmark alignment of eductor flat and elbow, as shown in Figure 6-8.

Eductor Flat

Straightedge

Matchmark

37390036

2. Unscrew terminal block mounting (13, Figure 6-6). Move terminal block mounting away from eductor (6).

3. Unscrew eductor holder (14) with eductor (6) and fittings (12 and 15) from sensor housing (7).

4. Clamp flats of eductor (6) in jaws of bench vise.

Use heat resistant gloves when removing mating parts from the eductor. The mating parts are bonded with a thread sealing compound. The compound softens at 450°F (232°C). The heated parts can cause severe burns.

5. Use a propane torch to heat the eductor (6) to 450°F (232°C), minimum. Apply the heat near the screw threads.

6. While heating the eductor (6), use wrench to apply removal torque to elbow (12), eductor holder (14), or tube fitting (15) until the thread sealant softens. Remove mating parts (12, 14, and 15).

7. Use MEK or methylene chloride solvent to clean thread sealant residue from the pipe threads of the mating parts. Refer to applicable MSDS sheet for solvent handling precautions.

6-11

OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Figure 6-9. Removal of Sample and Exhaust Tubes

Remove Sample and Exhaust Tubes

Use heat resistant gloves when removing the probe tube or exhaust tube. The tubes are bonded with a thread sealing compound. The compound softens at 450°F (232°C). The heated parts can cause severe burns.

1. Secure the sensor housing (1, Figure 6-9) in soft (plastic, wood, or brass) vice jaws.

2. Use a propane torch to heat the sample tube (2) or exhaust tube (3) to 450°F (232°C), minimum. Apply the heat near the threaded end of the tube.

3. While heating the tube, use a pipe wrench to apply removal torque to part being removed. Apply torque until the pipe thread sealant softens. Remove and discard the used sample tube (2), exhaust tube (3), or in-situ filter (4).

4. Use MEK or methylene chloride solvent to clean thread sealant residue from the internal pipe threads in the housing. Refer to applicable MSDS sheet for solvent handling precautions.

1. Sensor Housing

2. Sample Tube

3. Exhaust Tube

4. In Situ Filter

37390048

6-12

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 6-10. O2 Cell, Heater, and Thermocouple, Exploded View

OCX 8800

1. Screw

2. O Cell

3. Heater Tube

4. Contact/

5. Gasket

6. Screw

7. Lockwasher

8. Return Wire

9. Heater Strut

10. Spring Clip

11. Spring

12. Strut Bracket

Test Gas Passage

Holes

Thermocouple Assembly

Assembly

Do not remove the O2 cell unless you are certain it needs to be replaced. Removal may damage the cell and platinum pad. Remove the O

Disassemble O

Do not attempt to replace the O

Cell and Heater Strut Assembly

cell until all other possibilities for poor

cell for cell replacement only.

performance have been considered. If cell replacement is needed, order the O

cell replacement kit (Refer to Section 8, Replacement Parts).

The O

cell replacement kit contains an O2 cell and flange assembly, gaskets,

socket head cap screws, and anti-seize compound. The items are carefully packaged to preserve precise surface finishes.

Do not remove items from the package until they are ready to be used.

1. Remove the four allen cap screws (1, Figure 6-10) from the O Remove the O

cell. The cell flange has a notch that may be used to

gently pry the flange away from heater tube (3).

NOTE

The pad on the end of contact/thermocouple assembly (4) will sometimes fuse to the O2 cell (2).

2. If the O

cell is fused to the contact pad, push the O2 cell back into the

heater tube (against spring pressure) and quickly twist the O cell and contact pad should separate. If the contact pad stays fused to the cell, a new contact/thermocouple assembly (4) must be installed.

3. Remove and discard gasket (5). Clean the mating surface of heater tube (3). Remove burrs and raised surfaces with a block of wood and crocus cloth.

Use care when handling contact and thermocouple assembly. The ceramic rod in this assembly is fragile.

4. Remove screws (6), lockwashers (7), return wire (8), and heater strut assembly (9).

5. If replacing contact and thermocouple assembly (4), use a pencil to mark location of spring clip (10) before removing. Squeeze tabs on spring clip to remove. Retain spring clip and spring (11); replace if damaged.

6. While carefully handling new contact and thermocouple assembly (4) lay old assembly next to new one. Transfer match marks to new

37390032

assembly.

7. Carefully guide new contact and thermocouple assembly (4) through strut bracket (12), spring (11), and spring clip (10) until spring clip reaches pencil mark.

cell (2).

cell. The

6-13

OCX 8800

Figure 6-11. COe Sensor, Exploded View

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Disassemble COe Sensor Assembly

1. Carefully remove screws (1, Figure 6-11), lockwashers (2), and COe sensor (3) from sensor holder (4). Remove and discard gasket (5).

2. If damaged, use the following procedure to remove thermocouple adaptor (6) from sensor holder (4):

a. Use a propane torch to heat the thermocouple adaptor to 450°F

(232°C), minimum.

b. While heating, use a flat-head screwdriver to apply removal torque.

Apply torque until the pipe thread sealant softens. Remove and discard the thermocouple adaptor.

c. Use MEK or methylene chloride solvent to clean thread sealant

residue from the internal pipe threads in the sensor holder. Refer to applicable MSDS sheet for solvent handling precautions.

1. Screw

2. Lockwasher

3. COe Sensor

4. Sensor Holder

5. Gasket

6. Thermocouple Adapter

7. Pre-Heater

8. Plug

9. Stainless Steel Balls

6-14

37390030

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

Always remove the stainless steel balls (approximately 200) from sensor holder before removing or installing pre-heater. Turning pre-heater in the sensor holder with the stainless steel balls in place will cause permanent damage to the pre-heater.

3. If pre-heater (7) is to be removed, clamp flats of sensor holder (4) in vise jaws with plug (8) pointing up. Remove plug. Unclamp sensor holder and pour stainless steel balls (9) into a container.

NOTE

Pre-heater should only be removed when pre-heater or sensor holder is damaged. If removal is not required, leave the pre-heater installed in the sensor holder.

4. Unthread and remove pre-heater (7).

5. Use a cleaning solvent to thoroughly clean stainless steel balls (9) and pre-heater chamber in sensor housing (4). Refer to applicable MSDS sheet for solvent handling precautions.

Sensor Housing Assembly

Assemble COe Sensor Assembly

1. If pre-heater (7, Figure 6-11) was removed, apply pipe thread sealant (Loctite #567) to the external pipe threads of pre-heater (7) and plug (8). Do not apply sealant to the first turn of the pipe threads.

2. Clamp flats of sensor holder (4) in vise jaws with pre-heater port pointing up.

3. Install and tighten pre-heater (7). Align pre-heater to flat of sensor holder (4) as shown in Figure 6-12.

4. Invert sensor holder (4, Figure 6-11) in vise and pour stainless steel balls (9) into plug port. Press down on stainless steel balls and tap sensor holder with plastic hammer to compact balls in pre-heater chamber.

5. Install and tighten plug (8).

Use care when installing the combustibles (COe) sensor. The RTD elements are fragile and correct alignment in sensor holder is required for proper OCX operation.

6. Lubricate and install COe sensor gasket (5). Apply anti-seize compound to threads of screws (1).

6-15

OCX 8800

Figure 6-12. COe Sensor and Pre-Heater Alignment

THERMOCOUPLE

SENSOR ASSEMBLY

TOP VIEW

Sensor

Holder

Instruction Manual

IM-106-880, Rev 1.0

January 2007

COe

COe Sensor

Flat

Sensor

Holder

Flat

2 to 2-1/4 in.

(51 to 57 mm)

Pre-Heater

Flat

Sensor Holder

Flat

7. Install COe sensor (3), lockwashers (2), and screws (1). Rotate flat of COe sensor (3) to center of sensor holder (4).

8. Align COe sensor flat parallel to sensor holder flat, as shown in Figure 6-12. Tighten screws (1, Figure 6-11).

9. If replacing thermocouple adaptor (6), apply anti-seize to the pipe threads. Install and tighten thermocouple adaptor.

Assemble O

1. See Figure 6-10. Assemble O

Sensor and Heater Strut Assembly

cell (2), gasket (5), and heater tube (3).

Make sure the test gas passage holes line up with each other in all components.

2. Apply a small amount of anti-seize compound to the screw threads and use screws (1) to secure assembly. Torque to 35 in-lbs (4 N·m).

3. Carefully slide O

heater strut assembly (9) into heater tube (3).

4. Press down on the back plate of strut bracket (12) to ensure spring (11) tension is present to hold contact pad against O

cell (2).

5. Secure strut bracket (12) and return wire (8) with four screws (6) and lockwashers (7). Make sure return wire (8) is tightly fastened. This is the ground side connection for the O

cell.

Install Sample and Exhaust Tubes

37390034

6-16

1. See Figure 6-9. Apply pipe thread sealant (Loctite #567) to the replacement sample tube (2) or exhaust tube (3) pipe threads. Do not apply sealant to the first turn of the pipe threads.

2. Thread the sample tube (2) or exhaust tube (3) into the housing (1). Use a pipe wrench to tighten the tube.

3. If used, install and tighten in-situ filter (4).

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

Install Eductor

Figure 6-13. Installation of Eductor and COe Sensor

If installed, the O

cell and heater strut assembly (9, Figure 6-3) must be

removed from sensor housing (8), before you install the eductor.

1. Apply pipe thread sealant (Loctite #567) to the external pipe threads of eductor (6, Figure 6-13). Do not apply sealant to the first turn of the pipe threads.

1. Insulator

2. Dilution Air Tube

3. COe Extractive Tube

4. Eductor Air Tube

5. COe Sensor Assembly

6. Eductor

7. Sensor Housing

8. COe Thermocouple

9. Heater Insulator

10. COe Band Heater

11. Sensor Holder

12. Eductor Elbow

13. Terminal Block Mounting

14. Eductor Holder

15. Tube Fitting

16. CJC Sensor

37390047

6-17

OCX 8800

Figure 6-14. COe Sensor Parts Alignment

Instruction Manual

IM-106-880, Rev 1.0

January 2007

2. Install and tighten eductor (6) in eductor holder (14).

3. Install and tighten elbow (12) on eductor (6). Male port of elbow must point up and be in line with long axis of eductor.

4. Apply anti-seize compound to the external pipe threads of eductor holder (14).

5. Install and tighten eductor holder (14) in sensor housing (7). Align eductor with matchmarks, as shown in Figure 6-14.

Eductor Flat

Straightedge

Matchmark

37390036

6-18

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Install COe Sensor Assembly

Figure 6-15. Band Heater Height 1. Apply pipe thread sealant (Loctite #567) to the exposed pipe threads

of eductor elbow (12, Figure 6-13). Do not apply sealant to the first turn of the pipe threads.

2. Screw sensor holder (11) onto eductor elbow (12).

3. With wrenches on eductor elbow (12) and on flats of sensor holder (11),

0.37 in. (9,4 mm)

COe Sensor

tighten sensor holder. Do not allow eductor elbow to turn.

4. Tighten sensor holder (11) to align outside flat with matchmark on sensor housing flange, as shown in Figure 6-16.

The heater insulator prevents current leakage between the band heater and the sensor holder. Failure to properly install the insulator may cause the device to trip a ground fault interrupt circuit.

5. Wrap heater insulator (9) around sensor holder (11). Make sure the insulator joint lines up with the band gap of the COe band heater (10).

Band Heater

Insulator

37390058

6. Slide COe band heater (10, Figure 6-13) up onto sensor holder (11). Do not tighten the band heater at this time. Heater must rotate freely around sensor holder.

7. Check for proper height of COe heater thermocouple (Figure 6-12). Thread bayonet connector up or down to adjust height.

8. Install and fasten thermocouple (8, Figure 6-13).

9. Position band heater as shown in Figure 6-15 and Figure 6-16 and tighten band heater clamp screw. The heater insulator (9) end joint must line up with the band gap of the COe band heater (10).

OCX 8800

6-19

OCX 8800

Figure 6-16. COe Sensor Holder Alignment

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Matchmark

Straightedge

Sensor

Holder

Flat

Matchmark

37390035

6-20

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 6-17. COe Sensor, Thermocouple, and Heater Connections

OCX 8800

10. Reconnect the COe sensor, thermocouple, and heater wires at the sensor housing terminal blocks. Refer to Figure 6-17.

11. Install and fasten the COe insulator (1, Figure 6-13) around COe sensor assembly (5). All wiring must remain outside of the insulator.

12. If terminal block mounting (13, Figure 6-13) was moved, reinstall with two base mounting screws.

Sensor Housing Terminals

HTR 02

HTR CO

HTR 02

HTR SB

CJC Sensor

RED

YEL

BLU

RED

BLU

WHT

RED

WHT

RED

T/C O2

T/C CO

T/C SB

EXC

CJC

CO REF

CO ACT

EXC

NOTE: All wires at these terminals are in the CJC current loop.

COe Sensor

Assembly

COe Heater Wires

COe Sensor Wires

COe Thermocouple Wires

37390018

6-21

OCX 8800

39006

Figure 6-18. Installation of O2 Cell and Heater Strut Assembly

1. Screw

2. Locking Clip

3. Cover

4. O-ring

5. Marking Plate

6. Terminal Insulator

7. Reference Air Tube

8. Sensor Housing

9. Heater Strut Assembly

10. Gasket

11. Screw

12. Heater Clamp

13. Heater Rod

Instruction Manual

IM-106-880, Rev 1.0

January 2007

6-22

Install Sample Block Heater Rods

1. Before installing sample block heater rods (13, Figure 6-18), evenly coat the heater rods with Watlube heater release agent.

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

Figure 6-19. O2 Cell, Thermocouple, and Heater Connections

Sensor Housing Terminals

HTR 02

HTR CO

HTR SB

O Cell Wires

O Heater Wires

Thermocouple Wires

ORG

GRN

RED

YEL

T/C O2

T/C CO

T/C SB

EXC

CJC

CO REF

CO ACT

EXC

O Cell and Heater Strut

Sample

Block

Thermo-

couple

+ +

Assembly

Return Wire

Sample Block

Heater Rods

2. Install the heater rods (13), heater clamps (12), and screws (11).

3. Reconnect the heater rod leads at the sensor housing terminal blocks, (Figure 6-19).

6-23

3739006

OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Install O2 Cell and Heater Strut Assembly

1. Rub a small amount of anti-seize compound on both sides of new gasket (10, Figure 6-18).

2. Apply anti-seize compound to threads of O assembly (9) and sensor housing (8).

cell and heater strut

Stripped threads on the O2 cell and heater strut assembly can allow gas leakage. Gas leakage can affect the O and heater strut assembly .

3. Install O

cell and heater strut assembly (9) in sensor housing (8). Snug

measurements and calibration. Avoid over-tightening the O2 cell

up, but do not over-tighten the assembly.

4. Reconnect the lead wires from O

cell, heater, and thermocouple to the

sensor housing terminal blocks. Refer to Figure 6-19.

5. Install reference air tube (7, Figure 6-18) in sensor housing (8). Make sure that the open end of reference air tube extends into heater tube of O

cell and heater strut assembly (9).

Install Terminals Insulator and Cover

1. Install insulator (6, Figure 6-18) over uppermost terminal blocks. Position one side of insulator against terminal blocks and snap terminal marking plate (5) to mating stand-off.

2. Position opposite side of insulator (6) and secure with related marking plate (5).

3. If removed, install cover gasket (4). Screw cover (3) onto sensor housing (8). Tighten cover firmly.

4. Align locking clip (2) with gap between cover ribs.

5. Loosen screw (1) and slide locking clip (2) fully into gap between cover ribs. Retighten screw (1).

6-24

Sensor Housing Leak Test

1. Install 1/4 NPT cap on dilution air inlet fitting. Install a 1/4 NPT cap on sample tube (2, Figure 6-9) or plug 1/4 NPT sample inlet port. Capped or plugged ports must be air tight.

2. If not in place, install exhaust tube (3, Figure 6-9) in exhaust port according to the instructions provided.

3. Connect a calibrated manometer to the CAL GAS inlet port.

4. Connect and apply clean instrument air at 35 psig (241 kPa gage) to the instrument air inlet fitting.

5. Observe the manometer reading. The reading should be from 10 to 13 inches, Water Column. Locate and correct leaks if the reading is less than 10 inches WC.

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

REPAIR ELECTRONICS HOUSING

Electronics Housing Disassembly

Use the following procedures to remove damaged components from the OCX 8800 electronics housing and to install new replacement parts. Disassemble the unit only as needed to replace damaged components. Use the assembly procedures that apply to install replacement parts and reassemble the unit.

Remove Cover

1. See Figure 6-20. Loosen screw (1) and slide locking clip (2) away from cover (3). Retighten screw (1).

2. With two hands or strap wrench, turn cover (3) counterclockwise to loosen. Unthread and remove cover.

3. Inspect cover gasket (4) for wear or damage. Replace cover gasket if damaged.

Remove Flash PROM

Electrostatic discharge (ESD) protection is required to avoid damage to the electronic circuits.

1. Locate Flash PROM access port in electronics stack (5, Figure 6-20).

2. Use suitable IC removal tool to remove Flash PROM (6).

6-25

OCX 8800

Figure 6-20. Removal/Installation of Electronics Housing Components

Instruction Manual

IM-106-880, Rev 1.0

January 2007

1. Screw

2. Locking Clip

3. Cover

4. O-ring

5. Electronics Stack

6. Flash PROM

7. thru 12. Not used

13. Screw

14. Lockwasher

15. Solenoid Valve (3 way)

16. Solenoid Valve

Remove Electronics Stack

37390037

6-26

1. Unplug power cable, signal cable, and solenoid lead connectors from terminals of electronics stack (5, Figure 6-20).

2. Remove two screws (13) and lockwashers (14).

3. Remove electronics stack (5).

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 6-21. Removal/ Installation of EMI Filter

OCX 8800

Remove Solenoid Valves

1. Disconnect solenoid leads from mating terminal connector.

2. Remove top nut of solenoid valve (15 or 16, Figure 6-20).

3. Remove the solenoid coil assembly and washer.

4. Unthread and remove solenoid valve base.

Remove EMI Filter and Terminal Block

1. Disconnect EMI filter wiring (Figure 6-21) at terminal block (3).

2. Disconnect EMI filter wiring at AC power input terminal block on electronic stack.

3. Unbolt and remove EMI filter (1) from electronic stack.

4. Remove ground wire (2) from terminal block (3).

5. Unbolt and remove terminal block (3) from electronic stack.

Electronics Housing Assembly

Brown

Blue Green

Green

Blue

Brown

Green

Install EMI Filter and Terminal Block

1. Install replacement EMI filter (1, Figure 6-21) and/or terminal block (3) on electronic stack.

2. Refer to wiring details in Figure 6-21. Connect EMI filter wiring and ground wire (2) at terminal block (3).

3. Connect EMI filter wiring at AC power input terminal block on electronic stack.

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OCX 8800

Instruction Manual

IM-106-880, Rev 1.0

January 2007

Install Solenoid Valves

1. Disassemble replacement solenoid valve (15 or 16, Figure 6-20).

2. Install new solenoid valve base. Be careful not to overtighten.

3. Install new washer and solenoid coil assembly and secure with nut.

4. Connect the solenoid leads to the proper terminations on the solenoid power terminal block (Figure 6-24).

Install Electronics Stack

1. Install electronics stack (5, Figure 6-20) and secure with lockwashers (14) and screws (13).

2. See Figure 6-23 and Figure 6-24. Reconnect power cable, signal cable, and solenoid lead connectors to electronics stack terminals.

Figure 6-22. Flash PROM Alignment

Corner

Bevel

Flash PROM

Access

Port

Install Flash PROM

Electrostatic discharge (ESD) protection is required to avoid damage to the electronic circuits.

1. Locate Flash PROM access port in electronics stack (5, Figure 6-20).

2. See Figure 6-22. Align Flash PROM (6, Figure 6-20) with mating receptacle in access port of electronics stack as shown. Flash PROM corner bevel must be in upper left corner of receptacle.

3. Install Flash PROM (6).

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6-28

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Figure 6-23. Electronics Housing Cable Connections

OCX 8800

YEL RED BLK

ORG WHT

BLU

Heater Power

Connector (J3)

RED BLK

WHT BLK

GRN BLK

BLU BLK

& Thermocouple

Connector (J5)

O2 Cell

T/C CO+ T/C CO-

T/C SB+ T/C SBT/C O2+ T/C O2-

O2 CELL+ O2 CELL-

2HTR CO 1HTR CO 2HTR O 1HTR O 2HTR SB 1HTR SB

SHLD

#1 #1

YEL

BRN

BLK

RED WHT ORG

BLK

To Ground

Screw

GRN

SHIELD

Ground

Screw

COe Sensor

Connector (J4)

EXC+ CO ACT+ CO ACT-

CO REF+ CO REFCJC+ CJCEXC-

& CJC

ELECTRONICS HOUSING

Signal Cable

Heater Power Cable

NOTE: Wire colors shown are for cables supplied

by Emerson Process Management.

37390016

6-29

OCX 8800

Figure 6-24. Solenoid Power Terminals

Instruction Manual

IM-106-880, Rev 1.0

January 2007

SOL 1

TOP VIEW

SOL 3

SOL 4

SOL 2

SOL 4

SOL 3

SOL 2

SOL 1

CO Test Gas

High O Test Gas

Low O Test Gas

Instrument Air

6-30

37390033

Install Cover

1. If removed, install cover gasket (4, Figure 6-20). Screw cover (3) onto electronics housing. Tighten cover firmly. Align locking clip (2) with gap between cover ribs.

2. Loosen screw (1) and slide locking clip (2) fully into gap between cover ribs. Retighten screw (1).

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

REPLACE TUBE FITTINGS

The OCX transmitter housings have special tube fittings that, if clogged or damaged, must be replaced with the same type of fitting. The special tube fittings have alpha or numeric codes etched on the fitting. Unetched tube fittings are standard 1/4 inch, stainless steel fittings.

‘E’ Type Fitting

The ‘E’ type fitting is an eductor drive air fitting for the OCX 8800 general purpose sensor housing. It is a 1/8 inch tube fitting with a built-in 0.011 inch restrictor orifice. It seats in a threaded base port inside the housing.

‘R’ Type Fitting

The ‘R’ type fitting is a reference air line fitting for the general purpose and hazardous area sensor housings. This is a 1/4 inch tube fitting with a built-in 0.007 inch restrictor orifice.

Remove Tube Fittings The OCX construction includes pipe thread sealant to seal fittings in all ports

that pass through to an outer wall of the instrument housing base. Use the following instructions to loosen and remove tube fittings that are secured with pipe thread sealant.

Use heat resistant gloves when removing a damaged tube fitting. The pipe threads are bonded with a pipe thread sealant. The thread sealant softens at 450°F (232°C). The heated parts can cause severe burns.

1. Secure sensor housing (1, Figure 6-25) or electronics housing (2) in soft (plastic, wood, or brass) vice jaws.

2. To soften the pipe thread sealant, use a propane torch to heat the tube fitting (3, 4, or 5) to 450°F (232°C), minimum.

3. While heating the tube fitting, use a wrench to apply removal torque until the pipe thread sealant softens. Remove and discard the used fitting.

4. Use MEK or methylene chloride solvent to clean thread sealant residue from the internal pipe threads in the housing. Refer to applicable MSDS sheet for solvent handling precautions.

6-31

OCX 8800

Figure 6-25. Removal of Tube Fittings

1. Sensor Housing

2. Electronics Housing

3. Tube Fitting 4

. Tube Fitting (Type R) . Tube Fitting (Type E)

Instruction Manual

IM-106-880, Rev 1.0

January 2007

37390070

Install Tube Fittings 1. Verify that the replacement tube fitting is identical to the item removed.

Special fittings are etched with code markings.

2. Apply pipe thread sealant (Loctite #567) to the mating threads of the tube fitting. Do not apply sealant to the first turn of the external pipe threads.

3. Install and tighten the tube fitting in the mating port of sensor or electronics housing.

6-32

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

Section 7 Troubleshooting

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

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

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

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

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

OVERVIEW The troubleshooting section describes how to identify and isolate faults that

may develop in the OCX 8800. When troubleshooting the OCX 8800, reference the following information.

Grounding It is essential that adequate grounding precautions are taken when installing

the system. Thoroughly check both the probe and electronics to ensure the grounding quality has not degraded during fault finding. The system provides facilities for 100% effective grounding and total elimination of ground loops.

Electrical Noise The OCX 8800 has been designed to operate in the type of environment

normally found in a boiler room or control room. Noise suppression circuits are employed on all field terminations and main inputs. When fault finding, evaluate the electrical noise being generated in the immediate circuitry of a faulty system. Ensure all cable shields are connected to earth.

Electrostatic Discharge Electrostatic discharge can damage ICs in the electronics. Before removing or

handling the processor board or the ICs, ensure you are at ground potential.

http://www..raihome.com

Instruction Manual

IM-106-880, Rev 1.0

OCX 8800

January 2007

Total Power Loss In the event that the OCX 8800 will not power up at all, check the incoming

power supply to make sure power is being delivered to the OCX 8800. If the incoming power supply is good, then check fuses F1 and F6 in the electronics housing. Refer to Figure 7-1 for fuse locations.

Figure 7-1. Fuse Locations

DIAGNOSTIC ALARMS

Neutral (N)

10 Amp, 250 VAC

Line (L1)

10 Amp, 250 VAC

O2 and COe Heater

4 Amp, 250 VAC

Sample Block Heater

8 Amp, 250 VAC

37390079

Always install a blocking diode on the customers relay coil. Failure to install a blocking diode may create noise spikes and cause faults in the OCX electronics.

7-2

The OCX 8800 is equipped with a set of alarm relay contacts on the microprocessor board in the electronics housing. This set of dry contacts can be connected to any customer supplied relay device, 30 VDC, 30 mA maximum. A blocking diode is required on the customers relay coil.

Any fault condition in the OCX 8800 will trip the alarm relay. The optional SPA with HART programmable alarm indicates LOW O2, HIGH COe, Calibration Status, and Unit Failure. For more information refer to Appendix B - SPA with HART Alarm.

Instruction Manual

IM-106-880, Rev 1.0 January 2007

OCX 8800

FAULT ISOLATION Faults in the OCX 8800 Transmitter are indicated by messages displayed on

the HART communicator. Fault indications that can appear are listed in Table 7-1, Troubleshooting.

If a fault is indicated on the HART communicator, locate the fault indication in Table 7-1. For each fault listed, there are related Probable Causes and Recommended Corrective Actions. The Probable Causes are listed in the order of most probable to least probable. Starting with the most probable cause, inspect and test the unit to isolate the actual cause, then use the Recommended Corrective Action listed to correct the problem.

Table 7-1. Troubleshooting

O2 Sensor R High (Oxygen sensor resistance high, > 5000 Ohms) O2 Sensor Open (Oxygen sensor disconnected)

Probable Cause Recommended Corrective Action

Loose or open O

O2 cell degraded or failed Check O2 cell impedance by reading the O2 Snsr R value via HART (see Figure 4-3,

cell circuit connection Check O2 cell circuit wires for breaks or loose connections. Repair lead wire break or

loose connections.

sheet 2). If cell impedance is zero, replace O impedance is less than 5000 ohms, check for cell housing ground fault. Repair ground fault. If cell impedance is greater than 5000 ohms and no ground fault is indicated, replace O

cell with cell replacement kit.

cell with cell replacement kit. If cell

Ref Current Err (RTD excitation current error)

Probable Cause Recommended Corrective Action

Loose or open lead or circuit wire connection for COe sensor or CJC sensor current loop

COe sensor grounded Check resistance of COe sensor leads to ground per Figure 6-5. Replace COe sensor if

COe sensor failed Check resistance of both COe sensor elements per Figure 6-5. Replace COe sensor if

CJC sensor grounded Check resistance of CJC sensor to ground per Figure 6-5. Replace CJC sensor if

CJC sensor failed Check resistance of CJC sensor per Figure 6-5. Replace CJC sensor if resistance of

Check all COe and CJC sensor current loop wiring per Figure 7-3 and Figure 6-5. Correct wiring faults.

resistance is less than 10M Ohms.

resistance of sensor element is not between 100 and 250 Ohms.

resistance is less than 10M Ohms.

sensor is not between 100 and 150 Ohms.

O2 Temp Hi (Oxygen sensor heater temperature high, > 750ºC)

Probable Cause Recommended Corrective Action

High noise in OCX power supply Check power supply for line noise or voltage fluctuations. Install power line filter kit

(PN 6A00171G01) or high quality line filter for input power.

COe Temp Hi (Combustion sensor heater temperature high, 310ºC)

Probable Cause Recommended Corrective Action

High noise in OCX power supply Check power supply for line noise or voltage fluctuations. Install power line filter kit

(PN 6A00171G01) or high quality line filter for input power.

Table continued on next page

7-3

Instruction Manual

IM-106-880, Rev 1.0

OCX 8800

SB Temp Hi (Sample block heater temperature high, > 190ºC)

Probable Cause Recommended Corrective Action

High noise in OCX power supply Check power supply for line noise or voltage fluctuations. Install power line filter kit

(PN 6A00171G01) or high quality line filter for input power.

O2 Temp Very Hi (Oxygen sensor hea te r over maximum temperature, > 820ºC) O2 Htr Rmp Rate (Oxygen sensor heater over maximum temperature ramp rate)

Probable Cause Recommended Corrective Action

Incorrect O

Incorrect O2 thermocouple wiring Check O2 thermocouple wiring per Figure 7-3 and Figure 6-4. Check the wiring at the

Electronics package failure Replace electronics package.

COe Temp Very Hi (Combustion sensor heater over maximum temperature, > 400ºC) COe Htr Rmp Rate (Combustibles sensor heater over maximum temperature ramp rate)

Probable Cause Recommended Corrective Action

Incorrect COe heater wiring Check COe heater wiring per Figure 7-3 and Figure 6-5. Check the wiring at the heater

Incorrect COe thermocouple wiring Check COe thermocouple wiring per Figure 7-3 and Figure 6-5. Check the wiring at the

Electronics package failure Replace electronics package.

heater wiring Check O2 heater wiring per Figure 7-3 and Figure 6-4. Check the wiring at the heater

and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

thermocouple and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

thermocouple and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

January 2007

SB Temp Very Hi (Sample block heater over maximum temperature, > 260ºC) SB Htr Rmp Rate (Sample block heater over maximum temperature ramp rate)

Probable Cause Recommended Corrective Action

Incorrect sample block heater wiring Check sample block heater wiring per Figure 7-3 and Figure 6-4. Check the wiring at

the heater and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Incorrect sample block thermocouple wiring Check sample block thermocouple wiring per Figure 7-3 and Figure 6-4. Check the

wiring at the thermocouple and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Electronics package failure Replace electronics package.

O2 TC Open (Oxygen sensor heater thermocouple open)

Probable Cause Recommended Corrective Action

thermocouple or thermocouple circuit open Check O2 thermocouple and circuit wires for breaks or loose connections per Figure 7-3

and Figure 6-4. Repair breaks or loose connections or replace failed thermocouple. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

COe TC Open (Combustibles sensor heater thermocouple open)

Probable Cause Recommended Corrective Action

Combustibles sensor thermocouple open Check thermocouple resistance (lead to ground) of reference and active thermocouples

per Figure 7-3 and Figure 6-5. If either thermocouple is open or shorted to ground, replace combustibles sensor.

Table continued on next page

7-4

Instruction Manual

IM-106-880, Rev 1.0 January 2007

SB TC Open (Sample block heater thermocouple open)

Probable Cause Recommended Corrective Action

Sample block thermocouple or thermocouple circuit open

O2 TC Shorted (Oxygen sensor heater thermocoupl e shorted)

Probable Cause Recommended Corrective Action

thermocouple or thermocouple circuit shorted Check O2 thermocouple and circuit wires for short circuit condition per Figure 7-3 and

Slow heatup during cold start Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

COe TC Shorted (Combustibles sensor heater thermocouple shorted)

Probable Cause Recommended Corrective Action

Combustibles sensor thermocouple shorted Check thermocouple resistance (lead to ground) of reference and active thermocouples

Slow heatup during cold start Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Check sample block thermocouple and circuit wires for breaks or loose connections per Figure 7-3 and Figure 6-4. Repair breaks or loose connections or replace failed thermocouple. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Figure 6-4. Repair shorted wiring or replace failed thermocouple. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

If alarm persists, refer to the O2 Htr Failure alarm procedure.

per Figure 7-3 and Figure 6-5. If either thermocouple is open or shorted to ground, replace combustibles sensor.

If alarm persists, refer to the COe Htr Failure alarm procedure.

OCX 8800

SB TC Shorted (Sample block heater thermocouple shorted)

Probable Cause Recommended Corrective Action

Sample block thermocouple or thermocouple circuit shorted

Slow heatup during cold start Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Check sample block thermocouple and circuit wires for short circuit condition per Figure 7-3 and Figure 6-4. Repair shorted wiring or replace failed thermocouple. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

If alarm persists, refer to the SB Htr Failure alarm procedure.

O2 TC Reversed (Oxygen sensor heater thermocouple reversed)

Probable Cause Recommended Corrective Action

thermocouple wires reversed Check O2 thermocouple wiring per Figure 7-3 and Figure 6-4. Check the wiring at the

sensor and inside the electronics housing. Correct reversed-wires fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

COe TC Reversed (Combustibles sensor block heater thermocouple reversed)

Probable Cause Recommended Corrective Action

Combustibles thermocouple wires reversed Check combustibles thermocouple wiring per Figure 7-3 and Figure 6-5. Check the

wiring at the sensor and inside the electronics housing. Correct reversed-wires fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

SB TC Reversed (Sample block heater thermocouple re versed)

Probable Cause Recommended Corrective Action

Sample block thermocouple wires reversed Check sample block thermocouple wiring per Figure 7-3 and Figure 6-4. Check the

wiring at the sensor and inside the electronics housing. Correct reversed-wires fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Table continued on next page

7-5

Instruction Manual

IM-106-880, Rev 1.0

OCX 8800

ADC Failure (Voltage to digital conversion could not complete) ADC Ref Error (Voltage to digital conversion not accurate)

Probable Cause Recommended Corrective Action

Incorrect wiring between electronics and sensor housings

Electronics package failure Replace electronics package.

O2 Htr Failure (Oxygen sensor heater could not reach final temperature)

Probable Cause Recommended Corrective Action

heater circuit wiring open Check O2 cell heater circuit for broken wire or loose connection per Figure 7-3 and

O2 heater open Check resistance of O2 heater per Figure 6-4. Normal O2 heater resistance is 62.5

Heater electronics failure Check heater fuse F3 in electronics housing per Figure 7-1. If open, locate and correct

COe Htr Failure (Combustibles sensor heater could not reach final temperature)

Probable Cause Recommended Corrective Action

COe heater circuit wiring open Check COe heater circuit for broken wire or loose connection per Figure 7-3 and

COe heater open Check resistance of COe heater per Figure 6-5. Normal COe heater resistance is 97.7

Heater electronics failure Check heater fuse F3 in electronics housing per Figure 7-1. If open, locate and correct

Check all wiring between the electronics and sensor housings per Figure 7-3. Correct wiring faults.

Figure 6-4. Repair broken wire or loose connection.

Ohms. Replace O

cause of overload. If F3 is not open, or if cause of overload cannot be found, replace electronics package.

Figure 6-5. Repair broken wire or loose connection.

Ohms. Replace COe heater if heater is open or has a large resistance.

cause of overload. If F3 is not open, or if cause of overload cannot be found, replace electronics package.

heater if heater is open or has a large resistance.

January 2007

SB Htr Failure (Sample block heater could not reach final temperature)

Probable Cause Recommended Corrective Action

Sample block heater circuit wiring open Check sample block heater circuit for broken wire or loose connection per Figure 7-3

and Figure 6-4. Repair broken wire or loose connection.

Sample block heater open Check resistance of sample block heater per Figure 6-4. Normal sample block heater

Heater electronics failure Check heater fuse F4 in electronics housing per Figure 7-1. If open, locate and correct

Sensor housing exposed to high wind and/or extreme cold temperatures

resistance is 36.4 Ohms each (18.2 Ohms with both heaters in parallel). Replace sample block heater if heater is open or has a large resistance.

cause of overload. If F4 is not open, or if cause of overload cannot be found, replace electronics package.

If above probable causes are not causing the SB heater failure, install flange insulator (PN 6P00162H01).

Table continued on next page

7-6

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Cal Warning (Calibration warning) Cal Failed (Calibration failed)

Probable Cause Recommended Corrective Action

Calibration gas supply low or gas connection leaking

O2 cell degraded or failed Check O2 cell impedance by reading the O2 Snsr R value via HART (see Figure 4-3,

Check calibration gas supplies and connections. Adjust gas pressure and flow. Replenish low calibration gas supplies and tighten or repair loose or leaking connections. When calibration gas supplies are adequate, recalibrate.

sheet 2). If cell impedance is zero, replace O ohms, check for cell housing ground fault. Repair ground fault. If cell impedance is greater than 5000 ohms and no ground fault is indicated, replace O

cell. If cell impedance is less than 5000

OCX 8800

cell.

Flow calibration gas to the O output and the calibration gas O plotted values do not fall on the slope line shown in Figure 7-2, replace the O

COe sensor degraded Replace COe sensor or increase warning level (SYSTEM, CALIB SETUP, COe Slope

Warn via HART.)

Low sample gas flow in sensor housing due to flow path plugging

Check the following portions of the flow path for plugging:

• blowback filter

• in-situ filter

• eductor outlet path

Table continued on next page

cell. Read the cell millivolt output. Plot the cell millivolt

concentration on the chart shown in Figure 7-2. If the

cell.

Figure 7-2. Oxygen and Cell Output

(23)

OXYGEN CONCENTRATION (%)

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

-20 0 20 40 60 80 100 120

(73)

ANALYZER OUTPUT (MILLIVOLT)

37390051

7-7

OCX 8800

Board Temp Hi (Electronics temperature maximum exceeded, > 85ºC)

Probable Cause Recommended Corrective Action

Electronics housing exposed to high ambient temperature

EEPRM Chksm Fail (Non-volatile parameter st or age corrupted)

Probable Cause Recommended Corrective Action

Unit powered down during calibration parameter storage

Flash PROM failure Replace electronics package.

O2 Temp Low (Oxygen sensor heater temperature low, < 710ºC)

Probable Cause Recommended Corrective Action

Sensor housing exposed to high wind and/or extreme cold temperatures

High noise or voltage fluctuations in power supply

Insulate housing from source of high temperature and/or install cooling fan to remove heat from housing. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Perform Reset procedure in Section 3, Configuration and Startup. Recalibrate the OCX and check/trim analog outputs.

Install sensor housing flange insulator (PN 6P00162H01).

Check power supply for line noise or voltage fluctuations. Install filter power line kit (PN 6A00171G01) or high quality line filter for input power.

Instruction Manual

IM-106-880, Rev 1.0

January 2007

COe Temp Low (Combustion sensor heater temperature low, < 290ºC)

Probable Cause Recommended Corrective Action

Sensor housing exposed to high wind and/or extreme cold temperatures

High noise or voltage fluctuations in power supply

Install sensor housing flange insulator (PN 6P00162H01).

Check power supply for line noise or voltage fluctuations. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power.

SB Temp Low (Sample block heater temperature low, < 150ºC)

Probable Cause Recommended Corrective Action

Sensor housing exposed to high wind and/or extreme cold temperatures

High noise or voltage fluctuations in power supply

Install sensor housing flange insulator (PN 6P00162H01).

Check power supply for line noise or voltage fluctuations. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power.

Line Freq Error (AC power line frequency out of usable range, < 45 Hz or > 66 Hz)

Probable Cause Recommended Corrective Action

High noise or voltage fluctuations in power supply

AC power line frequency is outside the usable range of the OCX universal power supply

Electronics package failure Check power supply frequency with a calibrated oscilloscope or frequency meter and

Check power supply for line noise or voltage fluctuations. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power.

Correct power supply frequency. AC power line frequency must be between 50 and 60 Hz.

compare with line frequency. Replace electronics package if they do not agree within 1 Hz.

Line Voltage Low (AC power line voltage below minimum, < 85 VAC)

Probable Cause Recommended Corrective Action

High noise or voltage fluctuations in power supply

Electronics package failure Check power supply voltage and compare with line voltage. Replace electronics

Check power supply for line noise or voltage fluctuations. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power.

package if they do not agree within 5%.

7-8

Table continued on next page

Instruction Manual

IM-106-880, Rev 1.0 January 2007

Line Voltage High (AC power line voltag e above maximum, > 278 VAC)

Probable Cause Recommended Corrective Action

High noise or voltage fluctuations in power supply

Electronics package failure Check power supply voltage and compare with line voltage. Replace electronics

Htr Relay Failed (Heater relay failure)

Probable Cause Recommended Corrective Action

High noise or voltage fluctuations in power supply

Electronics package failure Replace electronics package.

Out Brd Failure (Output board failure)

Probable Cause Recommended Corrective Action

Electronics package failure Replace electronics package.

Check power supply for line noise or voltage fluctuations. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power.

package if they do not agree within 5%.

Check power supply for line noise or voltage fluctuations. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power.

OCX 8800

7-9

OCX 8800

Figure 7-3. Electrical Connections Between Electronics and Sensor Housing

Instruction Manual

IM-106-880, Rev 1.0

January 2007

YEL RED BLK

ORG WHT

BLU

Heater Power

Connector (J3)

RED BLK

WHT BLK

GRN BLK

BLU BLK

Heater Power Cable

O Sensor and

Thermocouple

Connector (J5)

T/C CO+ T/C CO-

T/C SB+ T/C SBT/C O2+ T/C O2-

O2 CELL+ O2 CELL-

SHLD

2HTR CO

1HTR CO

2HTR O

1HTR O

2HTR SB

1HTR SB

To ground

screw

#1 #1

YEL

BRN

BLK

RED WHT ORG

BLK

EXC+ CO ACT+ CO ACT-

CO REF+ CO REFCJC+ CJCEXC-

GRN

SHIELD

ground

screw

COe Sensor

and

Cold Junction

Connector (J4)

ELECTRONICS HOUSING

7-10

SENSOR HOUSING

GRN

T/C O2

BLK

Signal Cable

BLU

RED

T/C CO

BLK

WHT

T/C SB

BLK

EXC-

BLK

ORG

CJC

WHT

RED

BLK

HTR

ORG

REF

YEL

HTR

RED

BRN

ACT

WHT

YEL

HTR

BLU

EXC

To ground screw

GRN

37390014

Emerson 8800 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1 Description and Specifications

SECTION 2 Installation

SECTION 3 Configuration and Startup

SECTION 4 Using HART Communications

SECTION 5 Calibration

SECTION 6 Maintenance and Service

SECTION 7 Troubleshooting

SECTION 8 Replacement Parts

APPENDIX A Safety Data

APPENDIX B SPA with HART Alarm

APPENDIX C Return of Materials

OCX 8800

ESSENTIAL INSTRUCTIONS

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

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

SYMBOLS

Section 1 Description and Specifications

COMPONENT CHECKLIST

SYSTEM OVERVIEW Scope

Specifications

Section 2 Installation

MECHANICAL INSTALLATION

ELECTRICAL INSTALLATION

PNEUMATIC INSTALLATION

INITIAL STARTUP Observe the following Caution and Note. Refer to Section 3: Configuration

Section 3 Configuration and Startup

VERIFY INSTALLATION Ensure the OCX 8800 is installed correctly. Vertify mechanical installation and

INITIAL POWER UP Allow adequate time (approximately 60 minutes) for the heaters to begin

SET TEST GAS VALUES Use HART/AMS to set test gas values for calibration. Refer to Section 4,

OCX 8800 RESET PROCEDURE

Section 4 Using HART Communications

OVERVIEW The HART communicator is a handheld communications interface device. It

HART COMMUNICATOR SIGNAL CONNECTIONS

HART COMMUNICATOR PC CONNECTIONS

HART MENU TREE This section consists of a menu tree for the HART communicator. This menu

D/A TRIM PROCEDURES O

Section 5 Calibration

OVERVIEW During a calibration, two calibration gases with known O

FULLY AUTOMATIC CALIBRATION

OPERATOR - INITIATED AUTOCALIBRATION

MANUAL CALIBRATION If a unit is not equipped with calibration solenoids, a calibration must be

Section 6 Maintenance and Service

OVERVIEW This section contains the procedures to maintain and service the OCX 8800.

OCX 8800 REMOVAL AND INSTALLATION

OCX with Integral Electronics

REPAIR SENSOR HOUSING

Sensor Housing Disassembly

Sensor Housing Assembly

REPAIR ELECTRONICS HOUSING

Electronics Housing Disassembly

Electronics Housing Assembly

REPLACE TUBE FITTINGS

Remove Tube Fittings The OCX construction includes pipe thread sealant to seal fittings in all ports

Install Tube Fittings 1. Verify that the replacement tube fitting is identical to the item removed.

Section 7 Troubleshooting

OVERVIEW The troubleshooting section describes how to identify and isolate faults that

Grounding It is essential that adequate grounding precautions are taken when installing

Electrical Noise The OCX 8800 has been designed to operate in the type of environment

Electrostatic Discharge Electrostatic discharge can damage ICs in the electronics. Before removing or

Total Power Loss In the event that the OCX 8800 will not power up at all, check the incoming

DIAGNOSTIC ALARMS

FAULT ISOLATION Faults in the OCX 8800 Transmitter are indicated by messages displayed on