Rosemount Manual: OCX 4400 O2 / Combustibles Transmitter-Rev 2.0 | Rosemount Manuals & Guides

Instruction Manual
IB-106-440 Rev. 2.0 January 2003
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
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 January, 2003 Rev. 2.0
Page Summary
Throughout Changed IB revision number and release date. Pages 1-4, 1-5 Identified test gas solenoids as optional equipment. Pages 1-8, 1-9 Updated specifications and specification notes. Page 2-1 Expanded drip loop usage to vertical and horizontal installations. Page 2-2 Component view correcti o n s t o Fi g u re 2-1. Page 2-4
Page 2-5 Expanded drip loop usage to vertical and horizontal installations. Page 2-6
Page 2-8 Corrected electrical wiring diagram discrepancies in Figure 2-7. Page 2-9 Revised paragraph 2-3 to link installation instructions to applicable equip-
Page 2-10
Page 2-11 Deleted CAUTION paragraph from NOTE. Page 3-0 Revised Figure 3-1 to correctly identify location of SW1 and SW2. Page 3-1 Revised “Initial Power Up” procedure. Page 7-3 Corrected electrical wiring diagram discrepancies in Figure 7-2. Page 7-4 Corrected electrical wiring diagram discrepancies in Figure 7-3. Page 7-6 Revised Figure 7-4 to clarify location of exhaust tube during assembly and
Page 7-8 Revised Figure 7-5 to include parts availability note. Page 7-11 Revised Figure 7-6 to include parts availability note. Pages 7-12 thru 7-14
Page 8-1 Revised paragraph 8-3 to describe new troubleshooting table. Page 8-2 Replaced fault listings with troubleshooting table. Pages 10-1, 10-2 Corrected discrepancies in Table 10-1, Replacement Parts. Page 11-1 Revised Section 11 list of Appendices A, B, C, and D. Pages A-3 thru A-6 Revised/corrected LOI menu tree displays. Pages B-1 thru B-6 Added SPA setup instructions. Pages C-1, C-2 Revised/clarified blowback installation instructions and illustration. Pages D-1, D-2 Added IS Barrier installation/wiring instructions and illustration.
Revised adapter plate view, Figure 2-3, to simplify recommendations. Added new Figure 2-4 to show electronics housing wall/pole mounting kit.
Added reference to Appendix D for OCX with IS Barrier wiring. Revised alarm relay contact description.
ment options. Revised/changed Figure 2-8 to show pneumatic installation requirements for OCX with reference air option (only).
Revised Figure 2-9 to show pneumatic installation requirements for OCX with reference air and cal gas solenoid options.
to include parts availability note.
Deleted replacement procedures for electronics package components. Added electronics package replacement procedure. Revised Figure 7-7 and fuse replacement procedure.
OCX 4400
PREFACE............................................................................................................................1
Definitions ............................................................................................................................1
Safety Instructions ...............................................................................................................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 Initial Startup.................................................................................................................. 2-11
3-0 STARTUP AND OPERATION ...................................................................................... 3-1
3-1 General ............................................................................................................................ 3-1
Instruction Manual
IB-106-440 Rev. 2.0
January 2003

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 Connections ........................................................................... 5-3
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 Isolation .................................................................................................................. 8-1
Rosemount Analytical Inc. A Division of Emerson Process Management i
Instruction Manual
IB-106-440 Rev. 2.0 January 2003
9-0 RETURN OF MATERIAL .............................................................................................. 9-1
10-0 REPLACEMENT PARTS ............................................................................................. 10-1
11-0 APPENDICES ............................................................................................................... 11-1
Appendix A Local Operator Interface (LOI) ................................................................... A-1
Appendix B SPA with HART Alarm ...............................................................................B-1
Appendix C Blowback....................................................................................................C-1
Appendix D IS Barrier ....................................................................................................D-1
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. Wall or Pole Mounting of Electronics Housing....................................................... 2-4
Figure 2-5. Installation with Drip Loops .................................................................................... 2-5
Figure 2-6. Line Voltage and 4-20 mA Connections ................................................................ 2-7
Figure 2-7. Electrical Connections Between Split-Electronics and Sensor Housing ............... 2-8
Figure 2-8. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration) .... 2-9
Figure 2-9. Pneumatic Installation, OCX with Reference Air Set and Solenoids (with
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. Fuses, Exploded View ......................................................................................... 7-12
Instruction Manual
IB-106-440 Rev. 2.0
January 2003
LIST OF ILLUSTRATIONS
Autocalibration) .................................................................................................... 2-10
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 8-1. Troubleshooting ..................................................................................................... 8-2
Table 10-1. Replacement Parts .............................................................................................. 10-1
Rosemount Analytical Inc. A Division of Emerson Process Management iii
Instruction Manual
IB-106-440 Rev. 2.0 January 2003
OCX 4400
iv Rosemount Analytical Inc. A Division of Emerson Process Management
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. 2.0
January 2003

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. 2.0 January 2003
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, hazard-
ous 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 follow-
ing 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. 2.0
January 2003
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 back cover 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 (P
Where:
1. P
is the partial pressure of the oxygen in
2
the measured gas on one side of the cell.
2. P
is the partial pressure of the oxygen in
1
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.
1/P2
) + C
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
IB-106-440 Rev. 2.0 January 2003
5
HART
MAN4275A00
October1994
Communicator
o
FISHER-ROSEMOUNT
OCX 4400
1
English
TM
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)
Figure 1-1. Typical System Package
2
6
37020025
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
1
Instruction Manual
IB-106-440 Rev. 2.0
January 2003
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 3-1c and 3-1d 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. 2.0 January 2003
OCX 4400
4. Electronics are automatically config­ured for line voltages from 100 to 240 VAC.
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 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 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. 2.0
January 2003
SAMPLE
GAS
PROBE
EXHAUST
SENSOR
HOUSING
COMBUSTIBLES
SENSOR
O2
SENSOR
EDUCTOR
ROTOMETER
5 SCFH
ELECTRONICS
PRESSURE
SENSOR
OPTIONAL 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. (0.1 SCFH)
Figure 1-2. System Operation Diagram
37020001
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
Instruction Manual
IB-106-440 Rev. 2.0 January 2003
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 air, 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 (IP55) 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. 2.0
January 2003
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. 2.0 January 2003
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 Housing .................................... 32° to 392°F (0° to 200°C)
Electronics Housing ............................... 32° to 185°F (0° to 85°C)
2
2
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)
1
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
(Ref. test gas bottles kit #1A99119G04) 8% O2, Balance N
1000 ppm CO, Balance N
NOTES:
(1)
Combustibles sensor is calibrated with CO gas. Sensor may be calibrated with H2 gas. Use in methane service is not rec­ommended.
(2)
Operating temperature of electronics inside of electronics housing, as measured by a HART Communicator, or Emerson Process Management Asset Management Solutions (AMS) Software, or local operator interface. Operation below 0°C (32°F) requires that sensor housing be insulated.
, Balance N
2
2
2
2
1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
1
Table 1-1. OCX 4400 Specifications (Continued)
Calibration Gas Flow..................................... 5 scfh (2.5 l/m)
Instruction Manual
IB-106-440 Rev. 2.0
January 2003
Reference Air.................................................. 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O
regulated to 35 psi (241 kPa)
Eductor Air...................................................... 5 scfh (2.5 l/m), clean, dry, instrument-quality air
(20.95% O
), regulated to 35 psi (241 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 (241 kPa)
2
),
2
regulated to 55 psi (374 kPa)
Sensors Housing ........................................... NEMA 4X, IP55 with fitting and pipe on reference exhaust
port to clean, dry atmosphere, two 3/4-14 NPT conduit ports
Electronics Housing ...................................... NEMA 4X, IP55 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
),
2
Isolated Output:
Oxygen..................................................... 4-20 mAdc, 950 ohm max, with HART capability for O
COMB
Combustibles.......................................... 4-20 mAdc, 950 ohm max
Alarm Output Relay ....................................... No. 2, form C, double-pole, double-throw, 2A, 30 Vdc,
(software assignable)
Logic Signals.................................................. SPA HART Alarm Module (optional)
Low Oxygen Alarm
High Combustibles Alarm Calibration Status Unit Failure
Power Consumption Limits:
Heaters..................................................... 650 W nominal max
Electronics............................................... 50 W nominal max
Certification.................................................... CE
FM(Pending) CSA(Pending) CENELEC(Pending)
NOTE:
All static performance characteristics are with operating variables constant. Specifications subject to change without notice.
and
2
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9
Instruction Manual
IB-106-440 Rev. 2.0 January 2003
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 (JIS) 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, IP55 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
3
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
3
3
Instruction Manual
IB-106-440 Rev. 2.0
January 2003
3
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 available via HART Communica­tions (Model 275 Handheld Communicator) with Oxygen/Combustibles Device Description (DD) required.
(3)
If the IS Barrier option is selected, customer must also purchase the Moore Industries SPA (1A99292H01), current repeater backplane and adpater (intrinsic safety barrier kit p/n 1A99698G01) to maintain the 4 – 20 mA combustibles output.
Table 1-3. Accessories
PART NUMBER DESCRIPTION
1A99119H01 Oxygen Bottle 0.4%, balance N
1A99119H02 Oxygen Bottle 8.0%, balance N
1A99119H06 CO Bottle 1000 PPM and air, balance N
2
2
2
1A99120H02 Regulator for Oxygen (may need 2)
1A99120H03 Regulator for COMB
1A99119G06 Wall mount bracket for gas bottles
1A99119G05 Test gas regulators kit
1A99119G04 Test gas bottles kit
1A99292H01
Moore Industries SPA for Low O
Alarm, High
2
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. 2.0 January 2003
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
Instruction Manual
IB-106-440 Rev. 2.0
January 2003
SECTION 2

INSTALLATION

readings. Therefore, either make the necessary repairs or install the trans­mitter upstream 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 4400.
a. Selecting Location
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 2-5 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
Do not allow the temperature of the electronics housing to exceed 185°F (85°C) or damage to the electronics may result.
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. For systems with split electronics, use the pole or wall mounting hardware as shown in Figure 2-4 to mount the elec­tronics housing. Choose a location not to exceed the length of the electronics cable ordered.
5. For integral electronics installations, ensure the system cable drops verti­cally from the OCX 4400 and the con­duit is routed below the level of the housings. Drip loops minimize the pos­sibility that moisture will damage the electronics (Figure 2-5).
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
Instruction Manual
IB-106-440 Rev. 2.0 January 2003
OCX 4400
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.
6. Insert sample and exhaust tubes through the opening in the mounting flange and bolt the unit to the flange.
NOTE:
ALL DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.
INSULATE IF EXPOSED TO AMBIENT WEATHER CONDITIONS
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 4400 mounting, make sure to replace insulation afterward.
0.062 THK GASKET
3535B18H02
ANSI
3535B46H01
JIS
3535B45H01
DIN
TABLE 2. INSTALLATION/REMOVAL
PROBE
18 IN.
3 FT
6 FT
9 FT
DIM "A"
(406)
(864)34(1280)
(1778)
106
(2692)
DIM "B"
16
70
(2184)
122.38
(3108)
32.38
(822)
50.38
86.38
Figure 2-1. OCX 4400 Installation (with Integral Electronics)
TOP VIEW
DIM “A”DIM “B”
FLANGE DIA
HOLE DIA
(4) HOLES EQ SP ON B.C. DIA.
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)
37020002
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. 2.0
January 2003
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. 2.0 January 2003
OCX 4400
INSTALLATION FOR METAL
WALL STACK OR DUCT
NOTE: ONLY ADAPTER PLATE IS FURNISHED BY ROSEMOUNT.
WELD OR BOLT ADAPTER
PLATE TO METAL WALL
OF STACK OR DUCT.
JOINT MUST BE AIRTIGHT.
DIMENSIONS IN INCHES WITH MILLIMETERS IN PARENTHESES.
2.50 [63.5] MIN DIA HOLE IN WALL
STACK OR DUCT
METAL WALL
Figure 2-3. Adapter Plate Installation
INSTALLATION FOR MASONRY
WALL STACK CONSTRUCTION
BOLT ADAPTER
PLATE TO OUTSIDE
WALL SURFACE
JOINT MUST
BE AIRTIGHT
MASONRY
STACK WALL
FIELD WELD
PIPE TO
ADAPTER PLATE
PIPE 3.00
SCHEDULE 40,
SLEEVE LENGTH
OPTIONAL
37020003
NOTE:
* INDICATES ITEMS ARE INCLUDED
IN MOUNTING KIT P/N 4851B40G01.
*POLE
MOUNTING
CLAMP
*WALL OR POLE
MOUNT BRACKET
AND SCREWS
1/4-20 UNC X 2 IN. M-F STANDOFFS
RECOMMENDED FOR REAR PIPING
CLEARANCE WHEN WALL MOUNTING
(4 EACH BY CUSTOMER)
WALL MOUNTING BOLTS OR LAG SCREWS (4 EACH BY CUSTOMER)
Figure 2-4. Wall or Pole Mounting of Electronics Housing
ELECTRONICS
HOUSING
37020021
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
2
Instruction Manual
IB-106-440 Rev. 2.0
January 2003
CONDUIT
DRIP LOOPS
CONDUIT
DRIP LOOP
Figure 2-5. Installation with Drip Loops
DUCT
WALL
CONDUIT
DRIP LOOP
DUCT
WALL
37020004
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
Instruction Manual
IB-106-440 Rev. 2.0 January 2003
OCX 4400

2-2 ELECTRICAL INSTALLATION

All wiring must conform to local and national codes. For reference, factory wired solenoid power connections are shown in Figure 2-6.
Disconnect and lock out power before connecting the unit to the power supply.
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) 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.
NOTE
To maintain CE compliance, ensure a good connection exists between the mounting flange bolts and earth.
a. Connect Line Voltage
The OCX 4400 is software configured for 100 to 240 VAC line voltage at 50 to 60 Hz. The power supply requires no setup. Con­nect the line, or L wire, to the L terminal, and the neutral, or N wire, to the N terminal on the AC power input terminal block in the electronics housing. Connect the ground, or G wire, to the ground stud in the electronics
housing. Secure the connectio n with two nuts. Attach a separate line from the ground stud to the G terminal on the power input terminal block.
NOTE
Make sure line voltage is correctly set. See paragraph 3-1c for instructions.
b. Connect 4-20 mA Signals
Connect the 4-20 mA current loop to the 4-20 mA signal output terminals in the elec­tronics housing. If the isolation barrier
option is provided, refer to Appendix D for alternate wiring instructions.
1. Oxygen (O
) 4-20 mA Signal. One
2
4-20 mA signal represents the O value. Superimposed on the O2 signal is the HART information accessible through a Model 275 Handheld Com­municator or AMS software. The O signal is at the AOUT 1 terminals.
2. Combustibles (COMB) 4-20 mA Signal. Another 4-20 mA signal at the AOUT 2 terminals represents the COMB value. HART information is not available on the COMB signal.
c. Alarm Output Relay
Connect any customer supplied relay input to the alarm output relay terminal. The alarm output relay terminal is a set of dry, no. 2, form C, double-pole, double-throw contacts with 30 mA and 24 VDC capacity.
d. Split-Electronics Connections
to Sensor Housing
If the OCX 4400 is configured with split­electronics, make the following connections between the electronics and sensor hous­ings with the electronics cable ordere d with the package (Figure 2-7). Braided cable is available in lengths up to 150 ft. (45 m).
1. Thermocouple Connections. Connect the electronics housing sensor/therm­ocouple terminals to the corresponding terminals in the sensor housing. The twisted wire pairs are numbered on the inner plastic wrapper. Keep tw isted pairs together and match the numbers and wire colors shown in Figure 2-7.
2
2
2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
2
Instruction Manual
IB-106-440 Rev. 2.0
January 2003
Connect the twisted pair wire shields to the shield terminals.
2. Heater Power Connections. Use the purple, orange, black, gray, brown, and red stranded wires in the electronics cable to connect power to the three
SOLENOID POWER
TERMINAL B L OCK (FA CTORY WIRED)
GND
GND
LO O2
HI COMB
HI O2
ALARM OUTPUT
RELA Y TERMINAL
GND
GND
INST AIR
NC
NO
COMMON
SIGNAL OUTPUT
TERMINAL B L OCK
4-20 mA
ELECTRONICS HOUSING
(COVER REMO VED)
SENSOR INPUT
HEATER THERMOCOUPLE,
AND HEATER POWER
INPUT PORT
(FROM SENSOR HOUSING)
heaters in the sensor housing. Match the wire colors to the corresponding heater power terminal blocks in the sensor and electronics housings as shown in Figure 2-7.
HI O2
PRESSURE
SENSOR
HI COMB
SOLENOID
SOLENOID
SOLENOID
LO O2
INST AIR
SOLENOID
AOUT 2-
AOUT 2+
COMB 4-20 mA SIGNAL
AOUT 1-
AOUT 1+
O2 4-20 mA SIGNAL
AC POWER INPU T TERMINAL B L OCK
F1 POWER
SUPPLY FUSE
L
F2 HEATER
N
G
FUSE
Figure 2-6. Line Voltage and 4-20 mA Connections
4-20 mA SIGNAL
OUTPUT
PORT
AC POWER
INPUT PORT
GROUND STUD
TWO NUTS
34070021
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7
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