Manual: OCX 8800 O2 / Combustibles Transmitter General Purpose with Remote Electronics and LOI Local Operator Interface-Orig. Issue | Rosemount
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Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
Oxygen/Combustibles Transmitter
General Purpose OCX 8800 Oxygen/Combustibles Transmitter
with Remote Electronics and Local Operator Interface
http://www.raihome.com
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1
Description and
Specifications
SECTION 2
Installation
SECTION 3
Configuration and
Startup
SECTION 4
Using the LOI
Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
OCX 8800 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Display Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
LOI Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
LOI Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
LOI Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
LOI Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
SECTION 5
Using HART
Communications
SECTION 6
Calibration
http://www.raihome.com
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
HART Communicator Signal Connections. . . . . . . . . . . . . . . . . . . . . . 5-1
HART Communicator PC Connections . . . . . . . . . . . . . . . . . . . . . . . . 5-4
HART Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
OCX 8800
Instruction Manual
IM-106-880 Original Issue
February 2005
SECTION 7
Maintenance and Service
SECTION 8
Troubleshooting
SECTION 9
Replacement Parts
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
OCX 8800 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
OCX with Remote Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Sensor Housing Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Sensor Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Electronics Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Electronics Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Remove Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Install Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Total Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Diagnostic Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Alarm Relay Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
O2 Cell and Heater Strut Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
APPENDIX A
Safety Data
APPENDIX B
SPA with HART Alarm
APPENDIX C
Return of Materials
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Ceramic Fiber Products Material Safety Data Sheet . . . . . . . . . . . . . A-15
High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
TOC-2
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
OCX 8800
Oxygen/Combustibles Transmitter
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
specifications. The following instructions MUST be adhered to
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
product.
• If you do not understand any of the instructions, contact your
Rosemount Analytical representative
• Follow all warnings, cautions, and instructions
supplied with the product.
• Inform and educate your personnel in the proper installation,
operation, and maintenance of the product
• Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes. Connect all products to the proper electrical and
pressure sources.
• To ensure proper performance, use qualified personnel
operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use
replacement parts specified by 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.
to ensure they continue to operate within their normal
and integrated
prior to installing, operating, and servicing the
for clarification.
marked on and
.
to install,
.
http://www.raihome.com
The information contained in this document is subject to change without
notice.
If a Model 275/375 Universal HART® Communicator is used with this unit, the software
within the Model 275/375 may require modification. If a software modification is required,
please contact your local Rosemount Analytical Service Group or National Response
Center at 1-800-654-7768.
OCX 8800
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
Instruction Manual
IM-106-880 Original Issue
February 2005
PREFACE
DEFINITIONS
The purpose of this manual is to provide a comprehensive understanding of
the OCX 8800 components, functions, installation, and maintenance.
We recommend that you thoroughly familiarize yourself with the Introduction
and Installation sections before installing your transmitter.
The introduction presents the basic principles of the transmitter along with its
performance characteristics and components. The remaining sections contain
detailed procedures and information necessary to install and service the
transmitter.
Before contacting Rosemount Analytical concerning any questions, first
consult this manual. It describes most situations encountered in your
equipment's operation and details necessary action.
The following definitions apply to WARNINGS, CAUTIONS, and NOTES
found throughout this publication.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
SYMBOLS
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
NOTE
Highlights an essential operating procedure, condition, or statement.
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.
ii
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-9
COMPONENT CHECKLIST
SYSTEM OVERVIEW
A typical OCX 8800 Oxygen/Combustibles Transmitter package should
contain the items shown in Figure 1-1.
Use the product matrix in Table 1-1 at the end of this section to verify your
order number. The first part of the matrix defines the model. The last part
defines the various options and features of the OCX 8800. Check the model
number against the transmitter features and options, making sure options
specified by this number are on or included with the unit. Use this complete
model number for any correspondence with Rosemount Analytical. A list of
accessories for use with the OCX 8800 is provided in Table 1-2.
Scope
This Instruction Manual supplies details needed to install, startup, operate,
and maintain the OCX 8800. Signal conditioning electronics outputs separate
4-20 mA signals representing oxygen (O
This information, plus additional details, can be accessed with the HART
Model 275/375 handheld communicator or Emerson Process Management
AMS software. The local operator interface (LOI) also provides a
communications interface with the electronics.
System Description
The OCX 8800 is designed to measure oxygen and combustible
concentrations in flue gas temperatures up to 2600°F (1427°C). Electrical
connections, power and communications are made through two 3/4 NPT
ports in the flameproof electronics enclosure using fittings and cables
provided by the customer. Cable installation must meet NEC, IEC and/or
other applicable national or local codes for Class I, Zone 1, Group IIB +H2
T3/T6 permanently mounted equipment. The transmitter is close coupled to
the process and requires minimal sample conditioning requirements.
) and combustibles (COe) values.
2
http://www.processanalytic.com
OCX 8800
Figure 1-1. Typical System Package
4
MAN4275A00
English
October 1994
HART Communicator
o
FISHER-ROSEMOUNT
Instruction Manual
IM-106-880 Original Issue
TM
February 2005
1
A
n
a
l
y
t
i
c
a
l
6
3
1. Instruction Manual
®
2. HART
Communicator Package (optional)
3. Adapter Plate with Mounting Hardware and Gasket
4. Reference Air and Calibration Set
5. Blowback Hardware (optional)
6. OCX 8800 with Remote Electronics
2
5
37390076
1-2
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
The equipment measures oxygen percentage by reading the voltage
developed across a heated electrochemical cell, which consists of a small
yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous
metal electrodes. When operated at the proper temperature, the millivolt
output of the cell is given by the following Nernst equation:
EMF = KT log10 (P
Where:
1. P
is the partial pressure of the oxygen in the measured gas on one side
2
of the cell.
2. P
is the partial pressure of the oxygen in the reference air on the
1
opposite side of the cell.
3. T is the absolute temperature.
4. C is the cell constant.
5. K is an arithmetic constant.
NOTE
For best results, use clean, dry instrument air (20.95% oxygen) as the
reference air.
When the cell is at operating temperature and there are unequal oxygen
concentrations across the cell, oxygen ions will travel from the high oxygen
partial pressure side to the low oxygen partial pressure side of the cell. The
resulting logarithmic output voltage is approximately 50 mV per decade. The
output is proportional to the inverse logarithm of the oxygen concentration.
Therefore, the output signal increases as the oxygen concentration of the
sample gas decreases. This characteristic enables the OCX 8800 to provide
exceptional sensitivity at low oxygen concentrations.
1/P2
) + C
The OCX 8800 measures net oxygen concentration in the presence of all the
products of combustion, including water vapor. Therefore, it may be
considered an analysis on a "wet" basis. In comparison with older methods,
such as the portable apparatus, which provides an analysis on a "dry" gas
basis, the "wet" analysis will, in general, indicate a lower percentage of
oxygen. The difference will be proportional to the water content of the
sampled gas stream.
The OCX 8800 combustibles sensor is a catalytic sensor consisting of two
Resistance Devices (RTD). One RTD is the reference element covered with
an inert coating. The other RTD element is active, coated with a catalyst. As
the sample gases flow by the sensor, the combustible gases oxidize on the
surface of the active element. The oxidation that occurs produces heat and a
temperature rise in the active element. The temperature difference produces
a resistance relationship between the two elements that is directly
proportional to the concentration of combustibles in the sample gases.
1-3
OCX 8800
Instruction Manual
IM-106-880 Original Issue
February 2005
The catalyst is specifically designed to detect carbon monoxide (CO), but the
sensor responds to other combustible gases. The sensor is calibrated using
CO, thus the output should be expressed in terms of CO. However, since the
sensor detects other combustible gases, the output cannot just be labeled
CO. The response of the sensor to other combustible gases gives an output
that is equivalent to the sensor detecting CO. The term COe is used in this
manual to describe the sensor output. This term indicates that the sensor is
calibrated in terms of CO, and that the sensor output is equivalent to CO but
not specific to CO.
Dilution air is provided to the COe sensor to ensure there is adequate oxygen
to fully oxidize any combustible gases regardless of the concentration of
oxygen in the process.
System Configuration
Transmitters are available in four lengths, giving the user the flexibility to use
a penetration appropriate to the size of the stack or duct. The length options
are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), or 9 ft (2.7 m). Probes are
available in three material options, 316L stainless steel, inconel 600, and
ceramic to accommodate higher temperatures.
The electronics are contained in a separate housing from the sensors. The
electronics housing may be mounted up to 150 feet away from the sensor
housing.
The electronics control both sensor temperatures and provide individual 4-20
mA isolated outputs that are proportional to the measured oxygen and
combustibles concentrations. The power supply can accept voltages of 100 to
240 VAC and 50 to 60 Hz. The electronics accepts millivolt signals generated
by the sensors and produces the outputs to be used by remotely connected
devices. The outputs are isolated 4-20 mA linearized currents. Refer to
Section 3, Configuration and Startup for specific instructions upon initial
power up.
System Features
1. The O
concentration decreases.
2. HART communication is standard. To use the HART capability, you
must have either:
a. HART Model 275/375 Communicator.
b. AMS software for the PC.
3. Oxygen cell and heater/thermocouple assembly are field replaceable.
4. Electronics are automatically configured for line voltages from 100 to
240 VAC.
cell output voltage and sensitivity increase as the oxygen
2
1-4
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
5. An operator can calibrate and diagnostically troubleshoot the OCX 8800
in one of two ways:
a. LOI. The LOI is mounted to the end of the electronics module and
allows local communications with the electronics. Refer to Section 4,
Using the LOI, for more information.
b. Optional HART Interface. Each of the OCX 8800's 4-20 mA output
lines transmit an analog signal proportional to oxygen or combustible
levels detected. The HART output is superimposed on the oxygen
4-20 mA output line only. This information can be accessed through
the following:
• Model 275/375 Handheld Communicator - The handheld
communicator requires Device Description (DD) software specific
to the OCX 8800. The DD software will be supplied with many
Model 275/375 units, but can also be programmed into existing
units at most Emerson Process Management service offices.
Refer to Section 5, Using HART Communications, for additional
information.
• Personal Computer (PC) - The use of a personal computer
requires AMS software available from Emerson Process
Management.
• Selected Distributed Control Systems - The use of distributed
control systems requires input/output (I/O) hardware and AMS
software which permit HART communications.
6. Optional Blowback System. The blowback system periodically blows
instrument air back through the sample line filter and out the sample
tube. This clears out particulate and keeps the sample line filter from
clogging.
System Operation
Figure 1-2 shows the relationship between the components of the OCX 8800.
The sensors and the electronics are contained in separate housings. The
sensor housing and probe mounts to a duct or process wall so that the probe
protrudes into the flue gas stream. An air powered eductor continuously pulls
samples of the process flue gas through the probe to a chamber in front of the
sensor housing where the sample passes the O
the COe sensor. Dilution air is provided to the COe sensor and reference air
to the O
the COe sensor, it is drawn through the eductor where it mixes with the
eductor air and exits through exhaust back into the system. The electronics
housing contains the CPU and HART boards which convert the sensor inputs
into 4-20 mA analog output signals. The CPU can also initiate and perform
calibrations. Three test gasses and instrument air can be turned on and off by
solenoids. Test gas flow to the sensors is regulated by a flow meter between
the electronics and sensor housings. Instrument air is separated into eductor
air, reference air, and dilution air. The instrument air solenoid does not allow
air flow until the heaters are up to temperature. This minimizes the amount of
sampled process flue gas being pulled into cold sensors causing
condensation.
sensor. After the gas sample flows past the O2 sensor and through
2
sensor and continues on to
2
1-5
OCX 8800
(
)
Figure 1-2. System Operation Diagram
Instruction Manual
IM-106-880 Original Issue
February 2005
Sample
Gas
Probe
Exhaust
SENSOR
HOUSING
COe
Combustibles
Sensor
O
2
Sensor
Eductor
Flow Meter
Reference Air
Dilution Air
7 scfh
ELECTRONICS
Instrument Air
Eductor Air
Flow Meter
50 cc/min.
0.1 scfh
HOUSING
CPU
HART
Board
Power
Supply
Optional
Test Gas
Solenoids
Solenoid
Low O
Test Gas
High O
Test Gas
CO
Test Gas
Instrument
Air
2
2
37390001
Handling the OCX 8800
It is important that printed circuit boards and integrated circuits are handled only when
adequate antistatic precautions have been taken to prevent possible equipment damage.
The OCX 8800 is designed for industrial application. Treat each component of the system
with care to avoid physical damage. The probe may contain components made from
ceramics, which are susceptible to shock when mishandled.
System Considerations
Prior to installing your OCX 8800, make sure you have all the components
necessary to make the system installation. Ensure all the components are
properly integrated to make the system functional.
1-6
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
After verifying that you have all the components, select mounting locations
and determine how each component will be placed in terms of available line
voltage, ambient temperatures, environmental considerations, convenience,
and serviceability. Figure 1-3 shows a typical system wiring. Simplified
installations for the OCX 8800 are shown in Figure 1-4.
A source of instrument air is required at the OCX 8800 for reference air,
dilution air, and eductor air. Since the OCX 8800 is equipped with an in-place
calibration feature, provision should be made for connecting test gas tanks to
the OCX 8800 when it is to be calibrated.
NOTE
The electronics module is designed to meet NEMA 4 (IP66) and the electronic
components are rated to temperatures up to 185°F (85°C).
Retain packaging in which the unit arrived from the factory in case any
components are to be shipped to another site. This packaging has been
designed to protect the product.
Figure 1-3. OCX 8800 HART
Connections and AMS Application
OCX 8800
Sensor Housing
Instrument
Air
4-20 mA Output
OCX 8800
Electronics Housing
3 calibration
gas lines by
customer
[300 ft (91 m) max.)
(Twisted Pairs)
Termination in
Control Room
HART
Model 275/375
Handheld
Communicator
Customer’s Laptop
with AMS
AMS
37390065
1-7
OCX 8800
Figure 1-4. Typical System
Installation
Instruction Manual
IM-106-880 Original Issue
February 2005
Heater
Power Cable
[up to 150 ft (46 m)]
Signal Cable
[up to 150 ft (46 m)]
Gases
Stack
Dilution
Air
Flow
Meter
Duct
OCX 8800 with
REMOTE
ELECTRONICS
Test Gas
Flow Meter
Pressure
Regulator
High O Test Gas
Low O Test Gas
COTest Gas
4-20 mA Outputs
(2 Twisted Pairs)
Line Voltage
Instrument Air
Supply
(Reference Gas)
2
2
37390064
1-8
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
SPECIFICATIONS
General Purpose OCX
Specifications
Range 0-1% to 0-40% O2, fully field selectable
Net O
2
Combustibles 0-1000 ppm to 0-5%, fully field selectable
Accuracy
Oxygen ± 0.75% of reading or 0.05% O2 (whichever is greater)
Combustibles ± 2% range
System Response to
Tes t G a s
Oxygen 10 sec T90
Combustibles 25 sec T90
Temperature Limits
Process 32° to 2600°F (0° to 1427°C)
Sensors Housing -40° to 212°F (-40° to 100°C), ambient
Electronics Housing -40° to 149°F (-40° to 65°C), ambient
-40° to 185°F (-40° to 85°C), internal - operating temperature of
electronics inside instrument housing, as measured by a HART
communicator or AMS software
Local Operator
Interface
Nominal and Approximate
Shipping Weights
18 in. (457 mm)
probe package
3 ft (0.91 m) probe
package
6 ft (1.83 m) probe
package
9 ft (2.74 m) probe
package
Mounting and Mounting
Positions
Sensors Housing Flange
Electronics Housing Wall/Pipe
Materials
Probes 316L stainless steel - 1300°F (704°C)
Enclosures Low-copper aluminum
Calibration Semi-automatic or automatic
Calibration Gas Mixtures
Recommended
(Ref. test gas bottles
kit #1A99119G04)
Calibration Gas Flow 7 scfh (3.3 l/m)
Reference Air 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O2),
Eductor Air 5 scfh (2.5 l/m), clean, dry, instrument-quality air 20.95% O
Dilution Air 0.1 scfh (0.5 l/m), clean, dry, instrument-quality air (20.95% O2)
Blowback Air (optional) Clean, dry, instrument-quality air (20.95% O
-40° to 158°F (-40° to 70°C), ambient
[At temperatures above 158°F (70°C) inside instrument housing,
the infrared keypad will cease to function, but the OCX 8800 will
continue to operate properly.]
54 lbs (20 kg)
55 lbs (20.5 kg)
57 lbs (21 kg)
59 lbs (22 kg)
Inconel 600 - 1832°F (1000°C)
Ceramic - 2600°F (1427°C)
0.4% O2, Balance N2
8% O
, Balance N2
2
1000 ppm CO, Balance Air
regulated to 35 psi (241 kPa)
regulated to 35 psi (241 kPa)
regulated to 35 psi (241 kPa)
(379 kPa)
Table continued on next page
), regulated to 55 psi
2
2
),
1-9
OCX 8800
Instruction Manual
IM-106-880 Original Issue
February 2005
Specifications
Sensors Housing NEMA 4, IP66 with fitting and pipe on reference exhaust port to
clean, dry atmosphere, two 3/4-14 NPT conduit ports
Electronics Housing NEMA 4, IP66 with fitting and pipe on reference exhaust port to
clean, dry atmosphere, two 3/4-14 NPT conduit ports
Electrical Noise EN 61326-1, Class A
Certifications
CUS
Line Voltage Universal 100 to 240 VAC ±10%, 50 to 60 Hz, no switches or
jumpers required, 3/4-14 NPT conduit port
Pollution Degree 2
Over Voltage Category II
Relative Humidity 5 to 95% (non-condensing)
Isolated Output
Oxygen 4-20 mAdc, 950 ohm maximum, with HART capability
Combustibles 4-20 mAdc, 950 ohm maximum
Alarm Alarm output relay - dry contact, form C, 30mA, 30VDC capacity
Power Consumption 750 W maximum
Mounting and Mounting
Positions
Sensor Housing Flange
Electronics Housing Wall/Pipe
NOTE
All static performance characteristics are with operating variables constant. Specifications subject to change
without notice.
APPROVED
1-10
Instruction Manual
IM-106-880 Original Issue
February 2005
Table 1-1. Product Matrix - General Purpose OCX 8800
OCX88A O2/Combustibles Transmitter
Code Probe Length and Material
00 No Probe or Exhaust Tube
11 18 in. (457 mm) 316 SST up to 1300°F (704°C)
21 18 in. (457 mm) Inconel 600 up to 2600°F (1427°C)
31 18 in. (457 mm) Ceramic up to 2600°F (1427°C)
12 3 ft (0.91 m) 316 SST up to 1300°F (704°C)
22 3 ft (0.91 m) Inconel 600 up to 1832°F (1000°C)
32 3 ft (0.91 m) Ceramic up to 2600°F (1427°C)
13 6 ft (1.83 m) 316 SST up to 1300°F (704°C)
23 6 ft (1.83 m) Inconel 600 up to 1832°F (1000°C)
14 9 ft (2.7 m) 316 SST up to 1300°F (704°C)
24 9 ft (2.7 m) Inconel 600 up to 1832°F (1000°C)
Code Probe Mounting Assembly
10 (ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes
20 (DIN) 185 mm dia. flange, 145 mm BC with 4 x 18 mm dia. holes
Code Mounting Hardware - Stack Side
0 No Adapter Plate (“0” must be chosen under “Mounting Adapter - Probe Side” below)
1 New Installation - Square weld plate with studs
2 Model 218/240 Mounting Plate (with Model 218/240 Shield Removed)
3 Existing Model 218/240 Support Shield
4 Special Mounting
5 Model 132 Adapter Plate
Code Mounting Hardware - Probe Side
0 No Adapter Plate
1 Probe Only (ANSI)
2 Probe Only (DIN)
OCX88A 11 10 1 1 H3 06 02 Example
NOTE:
(1) Provide details of the existing mounting plate as follows:
Plate with studs Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate.
Plate without studs Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.
(1)
Code Electronics Housing - Communications
H1 HART Communications
H2 HART Communications with Local Operator Interface
H3 HART Communications with Calibration Solenoids
H4 HART Communications with Local Operator Interface and Calibration Solenoids
Code Electronics Mounting
01 Integral to Sensor Housing
02 Remote Electronics and no cable
03 Remote Electronics and 20 ft (6 m) cable
04 Remote Electronics and 40 ft (12 m) cable
05 Remote Electronics and 60 ft (18 m) cable
06 Remote Electronics and 80 ft (24 m) cable
07 Remote Electronics and 100 ft (30 m) cable
08 Remote Electronics and 150 ft (46 m) cable
Code Accessories
00 None
01 Flow meters & Ref.
02 In-Situ Filter (Stainless Steel only)
03 In-Situ Filter (SST), Flow meters & Ref.
11 Flow meters, and Ref.
12 In-Situ Filter (SST) with Blowback
13 In-Situ Filter (SST), Flow meters & Ref.
Air
Air Set
Set
with Blowback
OCX 8800
Air
Set
Air
Set with Blowback
1-11
OCX 8800
Table 1-2. Accessories
Instruction Manual
IM-106-880 Original Issue
PART NUMBER DESCRIPTION
1A99119H01 Oxygen test gas bottle; 0.4% O
1A99119H02 Oxygen test gas bottle; 8.0% O2, balance N
1A 99119H07 CO test gas bottle; 1000 ppm CO, balance air
1A99120H02 Regulator for Oxygen (may need 2)
1A99120H03 Regulator for CO test gas
1A99119G06 Wall mount bracket for test gas bottles
1A99119G05 Test gas regulators kit
1A99119G04 Test gas bottles kit
1A99292H01
1A99339H03 Blowback valve, air operated
4851B40G01 Wall or Pipe Mounting Kit
1A99784H02
6A00171G01 Power line filter kit
Moore Industries SPA for Low O
Calibration Status, and Unit Fail
375 HART Communicator with 12 Megabyte buffer,
model no. 375HR1EKLU
, balance N
2
Alarm, High COe Alarm,
2
February 2005
2
2
1-12
Instruction Manual
IM-106-880 Original Issue
February 2005
Section 2 Installation
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-8
Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-14
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-20
Before installing this equipment, read the "Safety instructions for the wiring and installation
of this apparatus" in Appendix A: Safety Data. Failure to follow the safety instructions could
result in serious injury or death.
OCX 8800
The OCX88A can be installed in general purpose areas only. Do not install the OCX88A in
hazardous areas.
http://www.processanalytic.com
OCX 8800
Instruction Manual
IM-106-880 Original Issue
February 2005
MECHANICAL INSTALLATION
Selecting Location
1. The location of the OCX 8800 in the stack or flue is most important for
maximum accuracy in the oxygen analyzing process. The probe must
be positioned so the gas it measures is representative of the process.
Best results are normally obtained if the transmitter is positioned near
the center of the duct (40-60% insertion). Longer ducts may require
several transmitters since the oxygen and combustibles can vary due to
stratification. A point too near the wall of the duct or the inside radius of
a bend, may not provide a representative sample because of the very
low flow conditions. The sensing point should be selected so the
process gas temperature falls within the range of probe material used.
Figure 2-1 through Figure 2-4 provide mechanical installation
references. The ambient temperature inside the electronics housing
must not exceed 185°F (85°C).
2. Check the flue or stack for holes and air leakage. The presence of this
condition will substantially affect the accuracy of the oxygen and
combustibles readings. Therefore, either make the necessary repairs or
install the transmitter up stream of any leakage.
3. Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance access to the unit. Allow
adequate clearance for the removal of the OCX 8800.
Do not allow the temperature of the electronics housing to exceed 185°F (85°C) or damage
to the electronics may result.
Whenever a positive stack pressure exists at the installation site, be sure to connect all
pneumatic lines prior to installing the OCX 8800 in the stack or ductwork. Failure to connect
the pneumatic lines can allow the flow of contaminants into the OCX 8800 ports.
Before installing the OCX 8800 into a hot stack or ductwork, make sure that the OCX 8800
is turned on and at normal operating temperature. Exposing a cold OCX transmitter to hot
process gases can cause permanent damage to the equipment.
Installation
1. Ensure all components are available to install the OCX 8800.
2. The OCX 8800 may be installed intact as it is received.
3. Weld or bolt adapter plate (Figure 2-2) onto the duct.
2-2
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
4. Use the pipe or wall mounting hardware as shown in Figure 2-3 to
mount the electronics housing. Choose a location not to exceed the
length of the electronics cable ordered.
5. Ensure the conduits drop vertically from the OCX 8800 and the conduit
is routed below the level of the conduit ports on the housing to form a
drip loop. Drip loops minimize the possibility that moisture will damage
the electronics (Figure 2-4).
6. Where a positive stack pressure exists at the installation site, connect
all pneumatic lines prior to installing the OCX 8800 in the stack or
ductwork.
NOTE
If process temperatures will exceed 392°F (200°C), use anti-seize compound
on stud threads to ease future removal of the OCX 8800.
7. Insert sample and exhaust tubes through the opening in the mounting
flange and bolt the unit to the flange.
Uninsulated stacks or ducts may cause ambient temperatures in the electronics housing to
exceed 185°F (85°C) and damage the electronics.
8. If insulation is removed to access the duct for OCX 8800 mounting,
make sure to replace insulation afterward.
Enclosures
The OCX 8800 enclosures are designed to meet ingress conditions of IP66.
Each enclosure cover is threaded to its base and sealed with an o-ring that
isolates the threads from external contaminants.
Each cover is secured by a clip attached to the base that engages the cover
between the ribs of the cover sidewall. The clip is held in place by an Allen
head cap screw and lockwasher mounted in a recess. Cover removal and
installation requires an Allen wrench to loosen and tighten the screw.
2-3
OCX 8800
Figure 2-1. Installation, OCX 8800
NOTE
All dimensions are in inches with millimeters in parentheses.
Insulate if exposed to adverse weather or extreme temperature
changes, install a protective housing and/or insulation
around the unit.
SeeTable 1
Flange Dia.
B.C. Dia.
Hole Dia.
Table 1. Mounting Flange
ANSI
Flange
Dia.
Hole
Dia.
(4) Holes
equally
spaced on
B.C.dia
6.00
(152)
0.75
(19)
4.75
(121)
Instruction Manual
IM-106-880 Original Issue
February 2005
DIN
5R10244H025R10244H01
7.28
(185)
0.71
(18)
5.71
(145)
Removal Envelope
Dim “B”
SeeTable 2
Insertion Depth
Dim “A”
SENSOR HOUSING
Optional
In Situ FIilter
Table 2. Installation/Removal
Probe
18 in.
3 ft
6 ft
Signal Cable
Heater Power Cable
9 ft
Dim "A”
18
(457)
36
(914)
72
(1829)
108
(2743)
Allow 9 in.
(229 mm) for
Cover Removal
Dim "B”
34
(864)
52
(1321)
88
(2235)
124
(3150)
0.06 In. Thick Gasket
3535B18H02
ANSI
3535B45H01
Signal Cable
DIN
Heater Power Cable
8.3
(211)
2-4
ELECTRONICS HOUSING
37390009
Instruction Manual
IM-106-880 Original Issue
February 2005
Figure 2-2. Adapter Plate Installation
NOTE: Dimensions are in inches with millimeters in parentheses.
Only adapter plate is furnished by Rosemount Analytical.
Adapter Plate Kit - Mounting Dimensions
*Type
Part Number
ANSI
(P/N 4512C34G01)
DIN
(P/N 4512C36G01)
*Part numbers for adapter plates include attaching hardware.
Plate Size "A"
6.00
(152)
7.50
(191)
Stud Size "B"
5/8 -11 UNC - 2A
(M-16 x 2.0 - 6g)
Bolt Circle
Dia.“C"
4.75
(121)
5.71
(145)
OCX 8800
Section
Weld or bolt adapter
plate to metal wall.
Joint must be air-tight.
D-D
2.50 (63.5)
Dia. min.
METAL WALL
STACK OR DUCT
CONSTRUCTION
Metal Stack
or DuctWall
2.50
(63.5)
Dia.
AA
Section
D
C
B
D
Bolt adapter plate to
outside wall surface.
Joint must be air-tight.
D-D
Masonary
StackWall
Field weld pipe
to adapter plate
Pipe 3 inch
schedule 40.
Sleeve length
optional.
MASONRY WALL
STACK
CONSTRUCTION
37390010
2-5
OCX 8800
Figure 2-3. Wall or Pipe Mounting
of Electronics Housing
Note:
* Indicates items are included
in mounting kit P/N 4851B40G01.
*Pipe
Mounting
Clamp
*Wall or Pipe
Mounting Bracket
and Screws
Wall Mounting Bolts
or Lag Screws
(4 each by customer)
Instruction Manual
IM-106-880 Original Issue
February 2005
Electronics
Housing
1/4-20 UNC x 2 in. M-F Standoffs.
Recommended for rear piping
clearance when wall mounting.
(4 each by customer)
37020021
2-6
Instruction Manual
IM-106-880 Original Issue
February 2005
Figure 2-4. Installation
with Drip Loops
OCX 8800
Conduit Drip Loops
Conduit Drip Loop Conduit Drip Loop
DuctWall
DuctWall
37020004
2-7
OCX 8800
Instruction Manual
IM-106-880 Original Issue
February 2005
ELECTRICAL INSTALLATION
All wiring must conform to local and national codes. For reference, factory
wired solenoid power connections are shown in Figure 2-5.
Disconnect and lock out power before connecting the unit to the power supply. Failure to
lock out power could result in serious injury or death.
Install all protective equipment covers and safety ground leads after installation. Failure to
install covers and ground leads could result in serious injury or death.
To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation
of this equipment, connection to the main electrical power supply must be made through a
circuit breaker (min 10 A) in close proximity and marked for this equipment which will
disconnect all current-carrying conductors during a fault situation. This circuit breaker
should also include a mechanically operated isolating switch. If not, then another external
means of disconnecting the supply from the equipment should be located close by. Circuit
breakers or switches must comply with a recognized standard such as IEC 947.
The OCX88A can be installed in general purpose areas only. Do not install the OCX88A in
hazardous areas.
2-8
Instruction Manual
IM-106-880 Original Issue
February 2005
OCX 8800
NOTE
To maintain proper earth grounding, ensure a positive connection exists
between the sensor housing, the electronics housing, and earth. The
connecting ground wire must be 14 AWG minimum. Refer to Figure 2-5.
NOTE
Line voltage, signal, and relay wiring must be rated for at least 105ºC (221ºF).
Electrical Connections
Electrical connections, power and communications are made to the electronic
enclosure. The connections are made through two 3/4 NPT ports in the
enclosure using fittings and cables provided by the customer. Cable
installation must meet NEC, IEC and/or other applicable national or local
codes for Class I, Zone 1, IIB +H2 T3/T6 permanently mounted equipment.
Connect Line Voltage
The OCX 8800 operates on 100 to 240 VAC line voltage at 50 to 60 Hz. The
power supply requires no setup. Connect the line (L wire) to the L terminal,
and the neutral (N wire) to the N terminal on the AC power input terminal
block in the electronics housing. Connect the ground (G wire) to the ground
stud in the electronics housing as shown in Figure 2-5.
Connect 4-20 mA Signals
Connect the 4-20 mA current loop to the 4-20 mA signal output terminals in
the electronics housing as shown in Figure 2-5. Use individual shielded
twisted wire pairs. Terminate the shield at the electronics housing.
O
4-20 mA Signal
2
One 4-20 mA signal represents the O
signal is the HART information accessible through a Model 275/375
Handheld Communicator or AMS software. The O
terminals.
COe 4-20 mA Signal
Another 4-20 mA signal at the AOUT 2 terminals represents the COe
value. HART information is not available on the COe signal.
Alarm Output Relay
Connect any customer-supplied relay input to the alarm output relay terminal.
Use shielded wire and terminate the shield at the electronics housing. The
alarm output relay terminal is a set of dry, no. 2, form C, contacts with 30 mA,
30 VDC capacity.
value. Superimposed on the O2
2
signal is at the AOUT 1
2
2-9
OCX 8800
Instruction Manual
IM-106-880 Original Issue
February 2005
Remote Electronics Connections to Sensor Housing
Make the following connections between the electronics and sensor housings
with the electronics cable ordered with the package (Figure 2-6). Braided
cable is available in lengths up to 150 ft. (46 m).
NOTE
Interconnect wiring shown is for Rosemount Analytical supplied cables. For
customer furnished interconnect wiring or cables, refer to Figure 2-7.
Signal Connections
Connect the electronics housing terminals to the corresponding terminals
in the sensor housing. The twisted wire pairs are numbered on the inner
plastic wrapper. Keep twisted pairs together and match the numbers and
wire colors shown in Figure 2-6.
Heater Power Connections
Use the blue, white, orange black, red, and yellow stranded wires in the
heater power cable to connect power to the three 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 2-6.
2-10
Instruction Manual
IM-106-880 Original Issue
February 2005
Figure 2-5. Line Voltage, Earth,
and 4-20 mA Connections
OCX 8800
#1
NC
COM
NO
Alarm Output Relay
Terminal Block
COe Signal
O Signal
4-20 mA Signal Output
Terminal Block
AOUT2+
{
AOUT2 -
2
AOUT1 -
{
AOUT1+
EMI Filter
TOP VIEW
(1/2 SIZE)
Ground Stud
Earth Ground
Typical for Electronics and
Sensor Housing
#1
Customer
Wiring
Signal Port
3/4 NPT
Terminal
G
L1
N
Block
G
Ground
Stud
Power Port
3/4 NPT
G
ExternalTooth
Lockwasher
37390013
2-11
OCX 8800
Figure 2-6. Electrical Connections Between Remote Electronics and Sensor Housing
Instruction Manual
IM-106-880 Original Issue
February 2005
YEL
RED
BLK
ORG
WHT
BLU
Heater Power
Connector (J3)
RED
BLK
WHT
BLK
GRN
BLK
BLU
BLK
Heater Power Cable
O Sensor and
2
Thermocouple
Connector (J5)
#1
T/C CO+
T/C CO-
T/C SB+
T/C SBT/C O2+
T/C O2-
O2 CELL+
O2 CELL-
SHLD
#1
2HTR CO
1HTR CO
2HTR O
1HTR O
2HTR SB
1HTR SB
To ground
2
2
screw
#1
#1 #1
YEL
BRN
BLK
RED
WHT
ORG
BLK
BLK
#1
EXC+
CO ACT+
CO ACT-
CO REF+
CO REFCJC+
CJCEXC-
GRN
SHIELD
To
ground
screw
COe Sensor
and
Cold Junction
Connector (J4)
ELECTRONICS HOUSING
2-12
SENSOR HOUSING
GRN
+
T/C O2
O2
-
BLK
BLK
-
BLK
Signal Cable
-
+
BLU
RED
+
T/C CO
BLK
-
WHT
+
T/C SB
BLK
EXC-
BLK
-
ORG
CJC
WHT
RED
BLK
2
BLK
HTR
-
O2
1
ORG
CO
+
+
REF
2
YEL
HTR
-
CO
1
RED
CO
BRN
+
ACT
2
WHT
HTR
YEL
+
EXC
SB
1
BLU
To ground screw
GRN
37390014
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