Rosemount Manual: OCX 4400 O2 / Combustibles Transmitter-Rev 1.0 | Rosemount Manuals & Guides
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
OCX 4400
OXYGEN/COMBUSTIBLES
TRANSMITTER
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical 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 and integrated into your
safety program when installing, using, and maintaining 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 prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and mainte-
nance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate In-
struction 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 to install, operate, update, program,
and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts
specified by Rosemount. 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.
The information contained in this document is subject to change without notice.
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
HIGHLIGHTS OF CHANGES
Effective October, 2000 Rev. 1.0.
Page Summary
Throughout Added information on the Blowback option.
Page 1-7 Corrected Figure 1-4.
Page 1-8 Updated specifications.
Page 1-11 Updated Accessories section of Product Matrix.
Page 2-7 Updated Figure 2-5 to include ground stud.
Page 2-8 Updated Figure 2-6 to include shield connections and additional wire
colors.
Page 2-11 Corrected Figure 2-8 piping arrangement.
Page 3-1 Added Initial Power Up instructions for voltage selection.
Page 5-4 through
5-6
Page 5-10 Added Line Voltage Selection procedure.
Page 7-1 Added ground stud to removal/replacement instructions.
Page 7-2 Updated Figure 7-1 to include ground stud.
Page 7-4 Updated Figure 7-3 to include shield connections and additional wire
Page 7-6 Updated Figure 7-4 to include new heater configuration and blowback
Page 7-11 Updated Figure 7-6 to include new instrument air solenoid and vent
Section 8 Updated troubleshooting information and fault indications.
Section 9 Updated replacement parts table and added new replacement parts.
11-3 through 11-5 Updated Figure 11-3, menu trees for Local Operator Interface.
Appendix C Added Appendix C.
Updated Figure 5-3, menu trees for HART communicators.
colors.
option.
tube.
OCX 4400
PREFACE........................................................................................................................ P-1
Definitions ........................................................................................................................P-1
Safety Instructions .......................................................................................................... P-2
1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1
1-1 Component Checklist Of Typical System (Package Contents) ................................. 1-1
1-2 System Overview............................................................................................................ 1-1
1-3 OCX 4400 Specifications............................................................................................... 1-8
2-0 INSTALLATION .............................................................................................................. 2-1
2-1 Mechanical Installation ................................................................................................... 2-1
2-2 Electrical Installation....................................................................................................... 2-6
2-3 Pneumatic Installation .................................................................................................... 2-9
2-4 Startup ............................................................................................................................. 2-9
3-0 STARTUP AND OPERATION ...................................................................................... 3-1
3-1 General ............................................................................................................................ 3-1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
TABLE OF CONTENTS
4-0 CALIBRATION ................................................................................................................ 4-1
4-1 General ............................................................................................................................ 4-1
4-2 Calibration Methods........................................................................................................ 4-1
5-0 HART/AMS...................................................................................................................... 5-1
5-1 Overview.......................................................................................................................... 5-1
5-2 HART Communicator Signal Line Connections .......................................................... 5-1
5-3 HART Communicator PC Connectiions ....................................................................... 5-2
5-4 Off-Line And On-Line Operations ................................................................................. 5-3
5-5 Menu Tree For HART Communicator/ OCX 4400 Applications ................................ 5-3
5-6 HART Communicator Manual O
5-7 HART Communicator Manual COMB CAL Method.................................................... 5-8
5-8 HART Communicator Manual O
5-9 Automatic Calibration Setup Via HART .................................................................... 5-10
5-10 Line Voltage Selection Using HART Communicator ................................................ 5-10
6-0 OPERATION ...................................................................................................................6-1
6-1 Overview.......................................................................................................................... 6-1
6-2 Operation ......................................................................................................................... 6-1
7-0 MAINTENANCE AND SERVICE .................................................................................... 7-1
7-1 Overview.......................................................................................................................... 7-1
7-2 OCX 4400 Removal/Replacement ................................................................................ 7-1
7-3 Sensor Housing Component Replacement .................................................................. 7-5
7-4 Electronics Housing Component Replacement.......................................................... 7-10
CAL Method .......................................................... 5-7
2
And CO CAL Method .......................................... 5-9
2
8-0 TROUBLESHOOTING .................................................................................................... 8-1
8-1 General ............................................................................................................................ 8-1
8-2 Alarm Output................................................................................................................... 8-1
8-3 Fault Indications.............................................................................................................. 8-1
Rosemount Analytical Inc. A Division of Emerson Process Management i
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
9-0 RETURN OF MATERIAL .............................................................................................. 9-1
10-0 REPLACEMENT PARTS ............................................................................................. 10-1
11-0 APPENDICES ............................................................................................................... 11-1
Appendix A. Local Operator Interface (LOI) ............................................................. 11-1
Appendix B. SPA With HART Alarm ........................................................................ 11-7
Appendix C. Blowback................................................................................................. 11-8
Appendix D. IS Barrier .............................................................................................. 11-10
12-0 INDEX............................................................................................................................ 12-1
OCX 4400
ii Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
Figure 1-1. Typical System Package ....................................................................................... 1-2
Figure 1-2. System Operation Diagram ................................................................................... 1-5
Figure 1-3. OCX 440 HART Connections and AMS Application.............................................. 1-6
Figure 1-4. Typical System Installation .................................................................................... 1-7
Figure 2-1. OCX 4400 Installation (with Integral Electronics) .................................................. 2-2
Figure 2-2. OCX 4400 Adapter Plate Dimensions ................................................................... 2-3
Figure 2-3. Adapter Plate Installation ....................................................................................... 2-4
Figure 2-4. Installation with Drip Loop and Insulation Removal............................................... 2-5
Figure 2-5. Line Voltage and 4-20 mA Connections ................................................................ 2-7
Figure 2-6. Electrical Connections Between Split-Electronics and Sensor Housing ............... 2-8
Figure 2-7. Air Set, Plant Air Connection ............................................................................... 2-10
Figure 2-8. OCX 4400 Gas Connections ............................................................................... 2-11
Figure 3-1. OCX 4400 Defaults ................................................................................................ 3-0
Figure 5-1. Signal Line Connections, > 250 Ohms Lead Resistance ...................................... 5-1
Figure 5-2. Signal Line Connections, < 250 Ohms Lead Resistance ...................................... 5-2
Figure 5-3. Menu Tree for HART/AMS on the OCX 4400 (Sheet 1 of 3)................................. 5-4
Figure 7-1. Electronics Housing Terminal Blocks .................................................................... 7-2
Figure 7-2. Sensor Housing Terminal Blocks .......................................................................... 7-3
Figure 7-3. Split-Electronics Housing Cable Connections ....................................................... 7-4
Figure 7-4. Sensor Housing, Exploded View ........................................................................... 7-6
Figure 7-5. O
Figure 7-6. Electronics Housing Exploded View .................................................................... 7-11
Figure 7-7. Electronics Box, Exploded View .......................................................................... 7-13
Figure 11-1. LOI Assembly Mounting....................................................................................... 11-1
Figure 11-2. Local Operator Interface (LOI) Assembly ............................................................ 11-2
Figure 11-3. Menu Tree for Local Operator Interface on the OCX 4400 (Sheet 1 of 3) .......... 11-3
Figure 11-4. SPA With HART Alarm ........................................................................................ 11-7
Figure 11-5. Blowback Connections ........................................................................................ 11-9
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
LIST OF ILLUSTRATIONS
Assembly, Exploded View ................................................................................ 7-8
2
LIST OF TABLES
Table 1-1. OCX 4400 Specifications ....................................................................................... 1-8
Table 1-2. Product Matrix......................................................................................................1-10
Table 1-3. Accessories.......................................................................................................... 1-11
Table 10-1. Replacement Parts .............................................................................................. 10-1
Rosemount Analytical Inc. A Division of Emerson Process Management iii
OCX 4400
The purpose of this manual is to provide a comprehensive understanding of the OCX 4400
Oxygen/Combustibles Transmitter components, functions, installation, and maintenance.
This manual is designed to provide information about the OCX 4400. 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 Rosemount concerning any questions, first consult this manual. It describes most situations encountered in your equipment’s operation and details necessary
action.
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
PREFACE
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.
NOTE
Highlights an essential operating procedure,
condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
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 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.
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
FOR THE WIRING AND INSTALLATION
The following safety instructions apply specifically to all EU member states. They should
be strictly adhered to in order to assure compliance with the Low Voltage Directive. NonEU states should also comply with the following unless superseded by local or National
Standards.
1. Adequate earth connections should be made to all earthing points, internal and external,
where provided.
2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.
The integrity of all earth terminals must be maintained at all times.
3. Mains supply cords should comply with the requirements of IEC227 or IEC245.
OCX 4400
IMPORTANT
SAFETY INSTRUCTIONS
OF THIS APPARATUS
4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.
5. All cable glands used should be of such internal dimensions as to provide adequate cable
anchorage.
6. To ensure safe operation of this equipment, connection to the mains supply should only be
made through a circuit breaker which will disconnect all circuits carrying conductors during a
fault situation. The circuit breaker may also include a mechanically operated isolating switch.
If not, then another means of disconnecting the equipment from the supply must be provided
and clearly marked as such. Circuit breakers or switches must comply with a recognized
standard such as IEC947. All wiring must conform with any local standards.
7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be
removed when power is removed from the equipment — and then only by
trained service personnel.
8. Where equipment or covers are marked with the symbol to the right, there is a
danger from hot surfaces beneath. These covers should only be removed by
trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.
9. Where equipment or covers are marked with the symbol to the right, refer to
the Operator Manual for instructions.
10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.
P-2 Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1-1 COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
A typical Rosemount OCX 4400 Oxygen/
Combustibles Transmitter package should contain the items shown in Figure 1-1. Record the
part number, serial number, and order number
for each component of your system in the table
located on the front page of this manual.
Use the product matrix in Table 1-2 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 4400. 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 Rosemount.
1-2 SYSTEM OVERVIEW
a. Scope
This Instruction Bulletin supplies details
needed to install, startup, operate, and
maintain the Rosemount OCX 4400 Oxygen/ Combustibles Transmitter. Signal conditioning electronics outputs separate 4-20
mA signals representing oxygen (O
combustibles (COMB) values. This information, plus additional details, can be accessed with the HART Model 275 handheld
communicator or Asset Management Solutions (AMS) software. An optional local operator interface (LOI) is available to provide
local communication with the electronics.
b. System Description
The Rosemount OCX 4400 Oxygen/
Combustibles Transmitter is designed to
measure oxygen and combustible concentrations in flue gas temperatures up to
) and
2
2600°F (1427°C). The transmitter is close
coupled to the process and requires minimal sample conditioning requirements.
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 (P1/P2) + C
Where:
1. P2 is the partial pressure of the oxygen in
the measured gas on one side of the cell.
2. P1 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 4400 to provide exceptional sensitivity
at low oxygen concentrations.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
OCX 4400
1
5
MAN4275A00
English
October1994
HART
Communicator
o
4
3
1. Instruction Bulletin
2. HART
Communicator Package (Optional)
3. Adapter Plate with Mounting Hardware and Gasket
4. OCX 4400 (Shown with Integral Electronics)
5. Reference Air and Calibration Set
6. Blowback Hardware (Optional)
FISHER-ROSEMOUNT
6
TM
2
34070023
Figure 1-1. Typical System Package
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
The OCX 4400 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 4400 combustibles sensor is a
catalytic sensor consisting of two Resistant
Temperature Detectors (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.
The catalyst is specifically designed to detect carbon monoxide (CO), but the sensor
responds to other combustible gases. The
sensor is calibrated using carbon monoxide
(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 COMB 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.
c. System Configuration
Transmitters are available in four length options, 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 and may be integrally mounted next to the sensor housing
on the probe, or split mounted up to 150
feet away from the probe.
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. See 3-1b for specific instructions upon initial power up.
d. System Features
1. The O
tivity increase as the oxygen concentration decreases.
2. HART communication is standard. To
use the HART capability, you must
have either:
(a) A HART Model 275
cell output voltage and sensi-
2
Communicator.
Dilution air is provided to the COMB sensor
to ensure there is adequate oxygen to fully
oxidize any combustible gases regardless
of the concentration of oxygen in the
process.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
(b) Asset Management Solutions
(AMS) software for the PC.
3. Oxygen cell and heater/thermocouple
assembly are field replaceable.
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
OCX 4400
4. Electronics are configurable for line
voltages from 100 to 240 VAC. See
Section 3-1b.
5. An operator can calibrate and diagnostically troubleshoot the OCX 4400 in
one of two ways:
(a) HART Interface. Each of the OCX
4400’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 420 mA output line only. This information can be accessed through
the following:
1 Rosemount Model 275 Hand-
held Communicator - The
handheld communicator requires Device Description
(DD) software specific to the
OCX 4400. The DD software
will be supplied with many
Model 275 units, but can also
be programmed into existing
units at most FisherRosemount service offices.
Refer to Section 5,
HART/AMS, for additional
information.
2 Personal Computer (PC) -
The use of a personal computer requires AMS software
available from FisherRosemount.
3 Selected Distributed Control
Systems - The use of distributed control systems requires
input/output (I/O) hardware
and AMS software which
permit HART
communications.
(b) Optional Local Operator Interface
(LOI). The optional LOI is mounted
to the end of the electronics module and allows local communications with the electronics. Refer to
Appendix A, Local Operator Interface (LOI), for more information.
6. Optional Blowback System. The blowback system periodically blows instrument air back through the inlet filter
and out the inlet tube. This clears out
particulate and keeps the inlet filter
from clogging.
e. System Operation
Figure 1-2 shows the relationship between
the components of the OCX 4400. 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
sensor and continues on to
2
the COMB sensor. Dilution air is provided to
the COMB sensor and reference air to the
O
sensor. After the gas sample flows past
2
the O
sensor and through the COMB sen-
2
sor, 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 which
converts the sensor inputs into 4-20 mA
analog output signals. The CPU also initiates and performs calibrations. Three test
gasses and instrument air are controlled by
solenoids. Test gas flow to the sensors is
regulated by a rotometer 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.
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
SAMPLE
GAS
PROBE
EXHAUST
SENSOR
HOUSING
COMBUSTIBLES
SENSOR
O2
SENSOR
EDUCTOR
ROTOMETER
5 SCFH
ELECTRONICS
PRESSURE
SENSOR
TEST GAS
SOLENOIDS
INSTRUMENT AIR
SOLENOID
EDUCTOR AIR
HOUSING
CPU
POWER
SUPPLY
LOW O2
TEST GAS
HIGH O2
TEST GAS
HIGH CO
TEST GAS
INSTRUMENT
AIR
REFERENCE AIR
DILUTION AIR
ROTOMETER
50 cc/Min.
(0.106 SCFH)
Figure 1-2. System Operation Diagram
34070001
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
OCX 4400
f. Handling the OCX 4400
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 4400 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.
g. System Considerations
Prior to installing your Rosemount OCX
4400 Oxygen/Combustibles Transmitter,
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.
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. A
typical system installation is illustrated in
Figure 1-4.
A source of instrument air is required at the
OCX 4400 for reference gas, dilution air,
and eductor air. Since the OCX 4400 is
equipped with an in-place calibration feature, provision should be made for connecting test gas tanks to the OCX 4400
when it is to be calibrated.
NOTE
The electronics module is designed to
meet NEMA 4X (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.
INSTRUMENT
AIR
OCX 4400 O2/COMBUSTIBLES TRANSMITTER
WITH INTEGRAL ELECTRONICS
4-20 MA OUTPUT
(TWISTED PAIRS)
3 CALIBRATION GAS LINES
BY CUSTOMER
[300 FT (90M) MAX]
Figure 1-3. OCX 440 HART Connections and AMS Application
TERMINATION IN
CONTROL ROOM
HART MODEL 275
HANDHELD
INTERFACE
CUSTOMER’S LAPTOP
WITH ASSET MANAGEMENT
ASSET MANAGEMENT SOLUTIONS
SOLUTIONS
34070002
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
1
INTEGRAL ELECTRONICS
TEST
GAS
ROTOMETER
GASES
STACK
DILUTION AIR
ROTOMETER
ADAPTER
PLATE
DUCT
Instruction Manual
4-20 mA OUTPUTS (2)
LINE VOLTAGE
INSTRUMENT AIR
SUPPLY (REF. GAS)
PRESSURE
REGULATOR
SPAN COMBUSTIBLES TEST GAS
LOW O2 TEST GAS
HIGH O2 TEST GAS
IB-106-440 Rev. 1.0
October 2000
ELECTRONICS
CABLE
(UP TO 150FT)
SPLIT-MOUNTED ELECTRONICS
GASES
DUCT
STACK
TEST
GAS
ROTOMETER
DILUTION AIR
ROTOMETER
4-20 mA OUTPUTS (2)
LINE VOLTAGE
INSTRUMENT AIR
SUPPLY (REF. GAS)
PRESSURE
REGULATOR
SPAN COMBUSTIBLES TEST GAS
LOW O2 TEST GAS
HIGH O2 TEST GAS
34070003
Figure 1-4. Typical System Installation
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
OCX 4400
1-3 OCX 4400 SPECIFICATIONS
transmitter before choosing the mounting loca-
tion. Table 1-2 contains the product matrix. Use
Table 1-1 contains information about the OCX
4400 Oxygen/Combustibles Transmitter operating characteristics. Use the table to make sure
that available conditions are suitable for the
the product matrix for ordering information and
specific model number information. Table 1-3
contains information on accessories available
with the OCX 4400.
Table 1-1. OCX 4400 Specifications
Net O
Range .................................................. 0-1% to 0-40% O
2
, Fully field selectable
2
Combustibles ................................................. 0-1000 ppm to 0-5%, Fully field selectable
Accuracy:
Oxygen..................................................... +0.75% of reading or 0.05% O
, whichever is greater
2
Combustibles .......................................... +2% F.S.
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.................................................... -40° to 392°F (-40° to 200°C)
Electronics............................................... -40° to 185°F (-40° to 85°C)
1
Nominal and Approximate Shipping Weights:
18 in. (457 mm) package ........................ 54 lbs (24.5 kg)
3 ft (0.91 m) package .............................. 55 lbs (24.5 kg)
6 ft (1.83 m) package .............................. 57 lbs (26 kg)
9 ft (2.74 m) package .............................. 59 lbs (26.8 kg)
Mounting and Mounting Position:
Sensors.................................................... Flange
Electronics............................................... Wall/Pipe
Materials:
Probes...................................................... 316L stainless steel
Inconel 600
Ceramic
Enclosures............................................... Low-copper aluminum
Calibration ...................................................... Semi-automatic or automatic
Calibration Gas Mixtures Recommended.... 0.4% O
8% O
, Balance N2
2
, Balance N2
2
1000 ppm CO, Balance N2
(Ref. test gas kit #1A99119G04)
Calibration Gas Flow ..................................... 5 scfh (2.5 l/m)
Reference Air.................................................. 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O
regulated to 35 psi (238 kPa)
Eductor Air...................................................... 5 scfh (2.5 l/m), clean, dry, instrument-quality air
(20.95% O
), regulated to 35 psi (238 kPa)
2
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% O
), regulated to 35 psi (238 kPa)
2
), regulated to
2
55 psi (374 kPa)
1
Operating temperature of electronics inside of electronics housing, as measured by a HART Communicator, or Fisher-
Rosemount Asset Management Solutions Software, or local operator interface.
),
2
1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
1
IB-106-440 Rev. 1.0
OCX 4400
Table 1-1. OCX 4400 Specifications (Continued)
Sensors Housing ........................................... NEMA 4X, IP66 with fitting and pipe on reference exhaust
port to clean, dry atmosphere
Two 3/4-14 NPT conduit ports
Electronics Housing ...................................... NEMA 4X, IP66 with fitting and pipe on reference exhaust
port to clean, dry atmosphere
Two 3/4-14 NPT conduit ports
Electrical Noise .............................................. Meets EN 50082-2 Electromagnetic Compatibility Generic
Immunity Std., Part II
Includes ENG 1000 4-R for Electrostatic Discharge 4 Kv
contact, 8 Kv in air
Optionally ENG 1000 4-R “Namur-Increased” 8 Kv contact,
16 Kv in air
Includes IEC 801-4 fast transients-2
Kv on power supply and control lines
Line Voltage.................................................... Universal 100 to 240 VAC, 50 to 60 Hz, Software selectable,
3/4-14 NPT conduit port
Isolated Output:
Oxygen..................................................... 4-20 mAdc, 950 ohm max, with HART capability for O
COMB
Combustibles .......................................... 4-20 mAdc, 950 ohm max
Logic Signals.................................................. SPA HART Alarm Module (optional)
Low Oxygen Alarm
High Combustibles Alarm
Calibration Status
Unit Failure
Alarm Output Relay (dry contact, 30 mA and 30 VDC
capacity)
Power Consumption Limits:
Heaters..................................................... 650 W nominal max
Electronics............................................... 50 W nominal max
Certification .................................................... CE
FM(Pending)
CSA(Pending)
CENELEC(Pending)
October 2000
and
2
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Table 1-2. Product Matrix
OCX44A O2 / Combustibles Transmitter
O2 / Combustibles Transmitter IB-106-440
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 1832°F (1000°C)
31 18 in. (457 mm) Ceramic up to 2600°F (1426°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 (1426°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)
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) 185mm dia. flange, 145mm BC with 4 x 18mm dia. holes
30 (JI S ) 155mm dia. flange, 130mm BC with 4 x 15mm dia. holes
OCX 4400
Code Mounting Hardware - Stack Side
0 No Adapter Plate ("0" must also 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 Mounting to Other Mounting
5 Model 132 Adapter Plate
6 Mounting to Ametek WDG-IVC
7 Mounting to Servomex Xendos 2700
8 Mounting to Elsag Bailey SMA-90
Code Mounting Hardware - Probe Side
0 No Adapter Plate
1 Probe Only (ANSI)
4 Probe Only (DIN)
7 Probe Only (JIS)
OCX44A 11 10 1 1 (Cont’d) Example
(1)
1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
1
Table 1-2. Product Matrix (Continued)
Cont'd Code Electronic Housing - NEMA 4X, IP66 HART Communications
01 Basic Unit
02 Local Operator Interface
03 Calibration Solenoids
04 IS Barrier
05 Local Operator Interface and Calibration Solenoids
06 Local Operator Interface and IS Barrier
07 Calibration Solenoids and IS Barrier
08 Local Operator Interface and Calibration Solenoids and IS Barrier
Code Electronic Mounting
01 Integral to Sensor Housing Electronics
02 Split Electronics and no cable
03 Split Electronics and 20 ft (6m) cable
04 Split Electronics and 40 ft (12m) cable
05 Split Electronics and 60 ft (18m) cable
06 Split Electronics and 80 ft (24m) cable
07 Split Electronics and 100 ft (30m) cable
08 Split Electronics and 150 ft (45m) cable
2
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Code Accessories
00 None
01 Cal. Gas Rotometers, Flow Rotometers, and Ref. Gas Set
11 Blowback Option and Cal. Gas Rotometers, Flow Rotometers, and Ref. Gas Set
Cont’d 08 01 11 Example
NOTES:
(1)
Where possible, specify SPS number; otherwise, 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.
(2)
If the Local Operator Interface (LOI) is not implemented, remote access and functionality avai l abl e via HART Communicati ons (M o del 275
Handheld Communicator) with Oxygen/Combustibles Device Desc ri ption (DD) requi red.
Table 1-3. Accessories
PART
NUMBER DESCRIPTION
1A99119H01 Oxygen bottles 0.4% balance N2
1A99119H02 Oxygen Bottles 8.0% balance N2
1A99119H06 CO Bottle 1000 PPM and air balance N2
1A99120H02 Regulator for Oxygen (may need 2)
1A99120H03 Regulator for COMB
1A99119G06 3 wide wall mount bracket for gas bottles
1A99119G05 Calibration gas regulators kit
1A99119G04 Calibration gas bottles kit
1A99292H01 Moore Industries SPA for Low O2 Alarm, High
COMB Alarm, Calibration Status, and Unit Fail
275D9EI5D0000 275 HART Communicator with 12 Meg buffer
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-11
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
OCX 4400
1-12 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
2
Before installing this equipment, read
the “Safety instructions for the wiring
and installation of this apparatus” at
the front of this Instruction Bulletin.
Failure to follow the safety instructions could result in serious injury or
death.
2-1 MECHANICAL INSTALLATION
a. Selecting Location.
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
SECTION 2
INSTALLATION
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 4400.
Do not allow the temperature of the
electronics housing to exceed 185°F
(85°C) or damage to the electronics
may result.
1. The location of the OCX 4400 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 upstream of any leakage.
b. Installation
1. Ensure all components are available to
install the OCX 4400.
2. The OCX 4400 may be installed intact
as it is received.
3. Weld or bolt adapter plate (Figure 2-3)
onto the duct.
4. In vertical installations for systems with
integral electronics, ensure the system
cable drops vertically from the OCX
4400 and the conduit is routed below
the level of the electronics housing.
This drip loop minimizes the possibility
that moisture will damage the electronics (Figure 2-4).
NOTE
If process temperatures will exceed
392°F (200°C), use anti-seize compound on stud threads to ease future
removal of the OCX 4400.
5. Insert probe through the opening in the
mounting flange and bolt the unit to the
flange.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
NOTE:
ALL DIMENS IONS ARE IN
INCHES WITH MILLIMETERS
IN PARENTHESES.
INSULATE IF EXPOSED TO
AMBIENT WEATHER CONDITIONS
0.062 THK GASKET
3535B18H02
ANSI
3535B46H01
JIS
3535B45H01
DIN
DIM “A”DIM “B”
OCX 4400
TABLE 2. INSTALLATION/REMOVAL
PROBE
18 IN.
3 FT
6 FT
9 FT
DIM "A"
16
(406)
34
(864)
70
(1778)
106
(2692)
DIM "B"
32.38
(822)
50.38
(1280)
86.38
(2184)
122.38
(3108)
Figure 2-1. OCX 4400 Installation (with Integral Electronics)
BOTT OM VIEW
FLANGE
DIA
HOLE
DIA
(4) HOLES
EQ SP
ON BC
TABLE 1. MOUNTING FLANGE
ANSI
4512C17H01
6.00
(153)
0.75
(20)
4.75
(121)
DIN
4512C19H01
7.28
(185)
0.71
(18)
5.71
(145)
JIS
4512C18H01
6.10
(155)
0.59
(15)
5.12
(130)
29790008
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
2
DIMENSIONS
IN.
(mm)
ADAPTER PLATE* DIMENSIONS FOR OCX 4400
ANSI
(P/N 4512C34G01)
DIN
(P/N 4512C36G01)
(P/N 4512C35G01)
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
JIS
"A"
"B"
THREAD
"C"
DIA
*PART NUMBERS FOR ADAPTER PLATES INCLUDE
ATTACHING HARDWARE.
NOTE:DIMENSIONS ARE
IN INCHES WITH
MILLIMETERS IN
PARENTHESES.
2.500 DIA
(63.5)
ADAPTER PLATE
FOR OCX 4400
INSTALLATION. SEE
FIGURE 2-1.
6.00
(153)
0.625-11
4.75
(121)
B
7.5
(191)
(M-16 x 2)
5.708
(145)
A
o
45
C
6.50
(165)
(M-12 x 1.75)
5.118
(130)
A
4 STUDS,
LOCKWASHERS AND
NUTS EQUALLY
SPACED ON
C DIA B.C.
29790013
Figure 2-2. OCX 4400 Adapter Plate Dimensions
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
INSTALLATION FOR METAL
WALL STACK OR DUCT
CONSTRUCTION
OCX 4400
INSTALLATION FOR MASONRY
WALL STACK CONSTRUCTION
MTG HOLES
SHOWN ROTATED
o
45 OUT OF
TRUE POSITION
WELD OR BOLT ADAPTER
PLATE TO METAL WALL
OF STACK OR DUCT.
JOINT MUST BE AIRTIGHT.
0.50 [13]
3.75 [95]
MIN DIA HOLE
IN WALL
STACK OR DUCT
METAL WALL
0.50 [13]
BOLT ADAPTER
PLATE TO OUTSIDE
WALL SURFACE
FIELD WELD
PIPE TO
ADAPTER PLATE
MTG HOLES
SHOWN ROTATED
o
45 OUT OF
TRUE POSITION
JOINT MUST
BE AIRTIGHT
OUTSIDE WALL
SURFACE
NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPT
ADAPTER PLATE NOT FURNISHED BY ROSEMOUNT.
BOLT ADAPTER
PLATE TO OUTSIDE
WALL SURFACE
4.50 [114]
O.D. REF
PIPE 4.00 SCHED 40
PIPE SLEEVE (NOT
BY ROSEMOUNT)
LENGTH BY CUSTOMER
MASONRY
STACK WALL
FIELD WELD PIPE
TO ADAPTER PLATE
3.50 [89]
O.D. REF
PIPE 3.00 SCHED 40
PIPE SLEEVE (NOT BY
ROSEMOUNT) LENGTH
BY CUSTOMER
MASONRY
STACK WALL
29790014
WELD OR BOLT ADAPTER
PLATE TO METAL WALL
OF STACK OR DUCT.
JOINT MUST BE AIRTIGHT.
2.50 [63.5]
MIN DIA HOLE
IN WALL
STACK OR DUCT
METAL WALL
NOTE: DIMENSIONS IN INCHES WITH
MILLIMETERS IN PARENTHESES.
JOINT MUST
BE AIRTIGHT
OUTSIDE WALL
SURFACE
Figure 2-3. Adapter Plate Installation
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
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