Manual: OCX 8800 O2 / Combustibles Transmitter Hazardous Area with Integral Electronics and LOI Local Operator Interface-Rev 1.3 | Rosemount
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Loading...Rosemount Manual: OCX 8800 O2 / Combustibles Transmitter Hazardous Area with Integral Electronics and LOI Local Operator Interface-Rev 1.3 | Rosemount Manuals & Guides
Instruction Manual
IM-106-880CIL, Rev 1.3
April 2017
Rosemount
OCX8800
Oxygen and Combustibles Transmitter
TM
Hazardous Area Transmitter with Integral Electronics and Local Operator Interface
HIGHLIGHTS OF CHANGES
Effective December 2007, Rev 1.1
Page/Section Summary
Throughout Updated manual number suffixes in page headers to indicate OCX configuration.
Changed references to HART Communicator te read Field Communicator in text and
illustrations.
Page 1-9 Added new illustration Figure 1-5 .
Page 1-12 Updated Product Matrices.
Page 1-13 Revised/updated Table 1-2 .
Page 2-2 Deleted obsolete CAUTION statement.
Page 2-10 Revised paragraph 4 listing of gases for calibration.
Page 2-14 Revised Figure 2-11 to indicate minim um pr ess ur e f or actuation of the blowback valve.
Page 2-15 Revised Figure 2-12 to indicate minimum pr es sur e for actuat ion of t he blowback valve.
Page 5-4 Revised 1st paragraph.
Page 5-5 Revised HART menu items in Figure 5-3, Sh eet 1 of 4
Page 5-9 Added new step 4 to both D/A Trim Procedures.
Page 6-3 Replaced steps 6 through 10 with a repeat of step 4 instruction.
Page 6-4 Revised steps 2 and 3.
Page 8-3 Revised "Ref Current Err" fault indication heading.
Page 8-7 Revised probable cause statements of "Cal Warning/Cal Failed" fault indication.
Page 9-5 Revised parts list for Sensor Housing Components.
Appendix A Updated multi-lingual safety pages.
Effective July 2008, Rev 1.2
Page/Section Summary
Page 4-3 Added note regarding cleaning the LOI screen before each use.
Effective April 2017, Rev 1.3
Page/Section Summary
Title page Removed Rosemount Analytic a l logo.
Updated Emerson logo.
Page 1-10 Updated Blowback Air specification.
Page C-1 Updated Return of Materials information.
Back page Updated to include new addresses, social media information, and Rosemount and
Emerson logos.
Instruction Manual
April 2017
OCX 8800
IM-106-880CIL, Rev 1.3
SECTION 1
Description and
Specifications
SECTION 2
Installation
SECTION 3
Configuration and
Startup
Table of Contents
Essential Instructions ........................................................................................ i
Preface ............................................................................................................... ii
Definitions .......................................................................................................... ii
Symbols .............................................................................................................. ii
Component Checklist ................................................................................... 1-1
System Overview .......................................................................................... 1-1
Specifications ..............................................................................................1-10
Mechanical
Installation ...................................................................................................... 2-2
Electrical Installation ..................................................................................... 2-7
Pneumatic Installation ................................................................................2-10
Initial Startup ................................................................................................2-16
Verify Installation ........................................................................................... 3-1
Initial Power Up ............................................................................................. 3-3
Set Test Gas Values .................................................................................... 3-4
OCX 8800 Reset Procedure ....................................................................... 3-4
SECTION 4
Using the LOI
SECTION 5
Using HART
Communications
SECTION 6
Calibration
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
Overview ........................................................................................................ 5-1
Field Communicator Sig na l Conn ec tio ns .................................................. 5-1
Field Communicator PC Connections ........................................................ 5-4
HART Menu Tr
D/A Trim Procedures .................................................................................... 5-9
Overview ........................................................................................................ 6-1
Fully Automatic Calibration .......................................................................... 6-1
Operator - Initiated Autocalibration ............................................................ 6-4
Manual Calibration ........................................................................................ 6-4
ee .......................................................................................... 5-5
Instruction Manual
April 2017
OCX 8800
TOC-2
IM-106-880CIL, Rev 1.3
SECTION 7
Maintenance and Service
SECTION 8
Troubleshooting
Overview ........................................................................................................ 7-1
OCX 8800 Removal
and Installation .............................................................................................. 7-1
OCX with
Integral Electronics ................................................................................. 7-2
Repair Sensor Housing ................................................................................ 7-5
Sensor Housing Disassembly ............................................................... 7-5
Sensor Housing Assembly .................................................................. 7-15
Repair Electronics Housing ...................................................................... 7-25
Electronics Housing Disassembly ..................................................... 7-25
Electronics Housing Assembly ........................................................... 7-28
Replace Tube Fittings ................................................................................7-31
Remove Tube Fittings ..........................................................................7-31
Install Tube Fittings ...............................................................................7-32
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
SECTION 9
Replacement Parts
APPENDIX A
Safety Data
APPENDIX B
SPA with HART Alarm
APPENDIX C
Return of Materials
Sensor Housing ............................................................................................. 9-2
Electronics Housing ...................................................................................... 9-6
O2 Cell and Heater Strut Assembly ........................................................... 9-9
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . . A-24
High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30
Atex Clarification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
llation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Insta
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Instruction Manual
April 2017
OCX 8800
IM-106-880CIL, Rev 1.3
ESSENTIAL INSTRUCTIONS
Rosemount OCX 8800
Oxygen and Combustibles
Transmitter
Emerson Process Management designs, manufactures and tests its products
to meet many national and international standards. Because these
instruments are sophisticated technical products, you MUST properly install,
use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and
integrated into your safety program when installing, using, and maintaining
Emerson’s Rosemount Analytical products. Failure to follow the proper
instructions may cause any one of the following situations to occur: Loss of
life; personal injury; property damage; damage to this instrument; and
warranty invalidation.
•
Read all instructions prior to installing, operating, and servicing the
product.
•
If you do not understand any of the instructions, contact your
Emerson Process Management representative 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 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 to install,
operate, update, program, and maintain the product.
•
When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson Process Management.
Unauthorized parts and procedures can affect the product's
performance, place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire,
electrical hazards, or improper operation.
•
Ensure that all equipment doors are closed and protective covers
are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.
READ THIS PAGE BEFORE PROCEEDING!
The information contained in this document is subject to change without
notice.
If a Model 275/375 Universal HART® Communicator is used with this unit, the software
within the Model 275/375 may require modification. If a software modification is required,
please contact your local Emerson Process Management Service Group or National
Response Center at 1-800-654-7768.
Instruction Manual
April 2017
OCX 8800
ii
IM-106-880CIL, Rev 1.3
PREFACE The purpose of this manual is to provide a comprehensive understanding of
the OCX 8800 components, functions, installation, and maintenance.
We recommend that you thoroughly familiarize yourself with the Introduction
and Installation sections before installing your transmitter.
The introduction presents the basic principles of the transmitter along with its
performance characteristics and components. The remaining sections contain
detailed procedures and information necessary to install and service the
transmitter.
Before contacting Emerson Process Management concerning any questions,
first consult this manual. It describes most situations encountered in your
equipment's operation and details necessary action.
DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES
found throughout this publication.
Highlights an operation or maintenance procedure, practice, condition, stat ement, 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, stat ement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
NOTE
Highlights an essential operating procedure, condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a
manual illustration number. It is not a part number, and is not related to the
illustration in any technical manner.
Instruction Manual
April 2017
OCX 8800
IM-106-880CIL, Rev 1.3
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-10
COMPONENT
CHECKLIST
SYSTEM OVERVIEW Scope
A typical OCX 8800 Oxygen/Combustibles Transmitter package should
contain the items shown in Figure 1-1.
Use the product matrix in Table 1-1 at the end of this section to verify your
order number. The first part of the matrix defines the model. The last part
defines the various options and features of the OCX 8800. Check the model
number against the transmitter features and options, making sure options
specified by this number are on or included with the unit. Use this complete
model number for any correspondence with Emerson Process Management.
A list of accessories for use with the OCX 8800 is provided in Table 1-2.
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 additiona l detai ls, can be ac ces s ed with the HART
Model 275/375 handheld communicator or Rosemount Analytical AMS
software. The local operator interface (LOI) also provides a communications
interface with the electronic s.
) and combustibles (COe) values.
2
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.
Instruction Manual
April 2017
OCX 8800
1-2
3
37390006
Figure 1-1. Typical System Package
4
6
1.
Instruction Manual
2.
Field Communicator Package (optional)
3.
Adapter Plate with Mounting Hardware and Gasket
4.
Reference Air and Calibration Set
5.
Blowback Hardware (optional)
6.
OCX 8800 with Integral Electronics
MAN 4275A00
English
October 1994
HART Communicator
o
FISHER
-ROSEMOUNT
5
IM-106-880CIL, Rev 1.3
1
TM
2
1-3
Instruction Manual
April 2017
OCX 8800
IM-106-880CIL, Rev 1.3
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.
P2 is the partial pressure of the oxygen in the measured gas on one side
of the cell.
2.
P1 is the partial pressure of the oxygen in the reference air on the
opposite side of the cell.
3.
T is the absolute temperature.
4.
C is the cell constant.
5.
K is an arithmetic constant.
NOTE
For best results, use clean, dry instrument air (20.95% oxygen) as the
reference air.
When the cell is at operating temperature and there are unequal oxygen
concentrations across the cell, oxygen ions will travel from the high oxygen
partial pressure side to the low oxygen partial pressure side of the cell. The
resulting logarithmic output voltage is approximately 50 mV per decade. The
output is proportional to the inverse logarithm of the oxygen concentration.
Therefore, the output signal increases as the oxygen concentration of the
sample gas decreases. This characteristic enables the OCX 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.
1-4
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
IM-106-
The catalyst is specifically designed to detect carbon monoxide (CO), but the
sensor responds to other combustible gases. The sensor is calibrated using
CO, thus the output should be expressed in terms of CO. However, since the
sensor detects other combustible gases, the output cannot just be labeled
CO. The response of the sensor to other combustible gases gives an output
that is equivalent to the sensor detecting CO. The term COe is used in this
manual to describe the sensor output. This term indicates that the sensor is
calibrated in terms of CO, and that the sensor output is equivalent to CO but
not specific to CO.
Dilution air is provided to the COe sensor to ensure there is adequate oxygen
to fully oxidize any combustible gases regardless of the concentration of
oxygen in the process.
System Configuration
Transmitters are available in four lengths, giving the user the flexibility to use
a penetration appropriate to the size of the stack or duct. The length options
are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), or 9 ft (2.7 m). Probes are
available in three material options, 316L stainless steel, inconel 600, and
ceramic to accommodate higher temperatures.
The electronics are contained in a separate housing from the sensors. The
electronics and sensor housings are integrally mounted.
The electronics control both sensor temperatures and provide individual 4-20
mA isolated outputs that are proportional to the measured oxygen and
combustibles concentrations. The power supply can accept voltages of 100 to
240 VAC and 50 to 60 Hz. The electronics accepts millivolt signals generated
by the sensors and produces the outputs to be used by remotely connected
devices. The outputs are isolated 4-20 mA linearized currents. Refer to
Section 3, Configuration and Startup for specific instructions upon initial
power up.
System Features
1.
The O2 cell output voltage and sensitivity increase as the oxygen
concentration decreases.
2.
HART communication is standard. To use the HART capability, you
must have either:
a.
Model 275/375 Field 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.
1-5
Instruction Manual
April 2017
OCX 8800
IM-106-880CIL, Rev 1.3
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 Field Communicator - The handheld field
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 throug h t he sample line filter a nd o ut the s ample
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 wher e t he s am ple p as ses the O
the COe sensor. Dil ution ai r is pr ovided t o the C Oe se nsor and r ef erence a ir
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 sam ple f lows past th e O2 sensor and through
2
sensor and continues o n t o
2
1-6
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
Test Gas
Figure 1-2. S ystem Operation Diagram
37390001
IM-106-
Sample
Gas
Probe
Exhaust
SENSOR
HOUSING
COe
Combustibles
Sensor
O
2
Sensor
Eductor
Dilution Air
Flow Meter
7 scfh
Reference Air
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
2
High O
Test Gas
CO
Test Gas
Instrument
Air
2
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 mak e the system installation. Ens ure al l t he c omponents are
properly integrated to make the system functional.
1-7
Instruction Manual
IM-106-880CIL, Rev 1.3
April 2017
OCX 8800
Figure 1-3. OCX 8800 HART
Connections and AMS Application
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 1-5. Figure 1-5 shows the
dimensions for the optional sample tube support.
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 (8 5°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.
1-8
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
Figure 1-4. Typical System
37390063
Installation
IM-106-
Test Gas
Flow Meter
Gases
Stack
Dilution
Air
Flow
Meter
Adapter
Plate
Duct
Pressure
Regulator
OCX 8800 with
INTEGRAL
ELECTRONICS
4-20 mA Outputs
(2 Twisted Pairs)
Line Voltage
Instrument Air
(Reference Gas)
High O
Low O
CO Test Gas
Test Gas
2
Test Gas
2
Supply
1-9
Instruction Manual
IM-106-880CIL, Rev 1.3
April 2017
OCX 8800
Figure 1-5. Sample Tube Support
Instruction Manual
IM-106-
880CIL, Rev 1.3
April 2017
OCX 8800
1-10
SPECIFICATIONS
Hazardous Area OCX
Specifications
0-1% to 0-40% O2, fully field selectable Net O2 Range
Combustibles 0-1000 ppm to 0-5%, fully field selectable
Accuracy
± 0.75% of reading or 0.05% O2 (whichever is greater)Oxygen
Combustibles ± 2% range
System Response to
Test Gas
Oxygen 10 sec T90
25 sec T90Combustibles
Temperature Limits
32° to 2600°F (0° to 1427°C)Process
Sensors Housing -40° to 212°F (-40° to 100°C), ambie nt
Electronics Housing -40° to 149°F (-40° to 65°C), ambient
Local Operator
Interface
Nominal and Approximate
Shipping Weights
probe package
3 ft (0.91 m) probe 55 lbs (20.5 kg)
package
6 ft (1.83 m) probe
package
9 ft (2.74 m) probe
package
Materials
Probes
Enclosures
Calibration
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% O2),
Dilution Air 0.1 scfh (0.5 l/m), clean, dry, instrument-quality air (20.95% O2)
Blowback Air (optional)
-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
-40° to 158°F (-40° to 70°C), ambient
[At temperatures above 158°F (70°C) inside instrume nt housing,
the infrared keypad will cease to function, but the OCX 8800 will
continue to operate properly.]
54 lbs (20 kg)18 in. (457 mm)
57 lbs (21 kg)
59 lbs (22 kg)
FlangeHousings Mounting
316L stainless steel - 1300°F (704°C)
Inconel 600 - 1832°F (1000°C)
Ceramic - 2600°F (1427°C)
Low-copper aluminum
Semi-automatic or automatic
0.4% O2, Balance N2
8% O2, Balance N2
1000 ppm CO, Balance Air
regulated to 45 psi (310 kPa)
regulated to 45 psi (310 kPa)
regulated to 45 psi (310 kPa)
Clean, dry, instrument-quality air
413 kPa) or greater and ambient temperature of ≥ 0 °F (-18 °C)
Table continued on next page
(20.95% O2), regulated to ≥ 60 psi
Instruction Manual
IM-106-880CIL, Rev 1.3
April 2017
OCX 8800
1-11
Specifications
Sensors Housing
Electronics Housing
Electrical Noise
Certifications
NEMA 4, IP66 with fitting and pipe on reference exhaust port to
clean, dry atmosphere, two 3/4-14 NPT conduit ports
NEMA 4, IP66 with fitting and pipe on reference exhaust port to
clean, dry atmosphere, two 3/4-14 NPT conduit ports
EN 61326-1, Class A
Sensor Housing
0344II2G
KEMA 04ATEX2308
EExdIIB+H2T3
CUS
2005.1602514
CLASS1,ZONE1
ExdIIB+H2T3
AExDIIB+H2T3
TYPE4/IP66
APPROVED
CLASS1,ZONE1
AExDIIB+H2T3
TYPE4/IP66
Electronics Housing
0344II2G
KEMA 04ATEX2308
EExdIIB+H2T6IP66
CUS
2005.1602514
CLASS1,ZONE1
ExdIIB+H2T6
AExDIIB+H2T6
TYPE4/IP66
APPROVED
CLASS1,ZONE1
AExDIIB+H2T3
TYPE4/IP66
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
Over Voltage Category
Relative Humidity
2
II
5 to 95% (non-condensing)
Isolated Output
4-20 mAdc, 950 ohm maximum, with HART capabilityOxygen
Combustibles
Alarm
4-20 mAdc, 950 ohm maximum
Alarm output relay - dry contact, form C, 30 mA, 30VDC capacity
Power Consumption 750 W maximum
NOTE
All static performance characteristics are with operating variables constant. Specifications subject to change
without notice.
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
1-12
OCX88C
O2/Combustibles Transmitter - Flameproof
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)
(4)
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)
(4)
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)
(4)
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)
(4)
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
(1)
5 Model 132 Adapter Plate
Code
Mounting Hardware - Probe Side
0 No Adapter Plate
1 Probe Only (ANSI)
2 Probe Only (DIN)
Code
Electronics Housing - Communications
H1
HART Communications
(2)
H2
HART Communications with LOI
H3
HART Communications with Calibration Solenoids
(2)
H4
HART Communications with LOI and Calibration Solenoids
Code
Electronics Mounting
02
Remote Electronics and no cable
Code
Accessories
00
None
01
Flow meters & Ref. Ai r Set
02
In-Situ Filter (Stainless Steel only)
(3)
03
In-Situ Filter (SST), Flow meters & Ref. Air Set
(3)
11
Flow meters, and Ref. Air Set with Blowback
12
In-Situ Filter (SST) with Blowback
(3)
13
In-Situ Filter (SST), Flow meters & Ref. Air Set with Blowback (3)
OCX88C
11
10 1 1
H2
02
02
Example
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.
IM-106-
Table 1-1. Product Matrix - Hazardous Area OCX 8800
NOTES:
(1)
Provide details of the existi ng mo unti ng pl at e as follows:
(2)
If the LOI is not implemented, remote access and functionality available via HART Communications (Model 275/375 Handheld Communicator)
with Oxygen/Combustibles Device Description (DD) required.
(3)
For use with stainless steel sample tube only.
(4)
For high temperature applications that require a filter, please order 1A99762H03 separately.
Instruction Manual
IM-106-880CIL, Rev 1.3
April 2017
OCX 8800
1-13
Table 1-2. Accessories
PART NUMBER DESCRIPTION
1A99119H01
1A99119H02
1A 99119H07
1A99120H02
1A99120H03
1A99119G06
1A99119G05
1A99119G04
1A99292H01
1A99339H03
4851B40G01
1A99762H03
6A00171G01
6A00288G01
6A00288G02
6A00288G02
6A00288G04
6P00162H02
Oxygen test gas bottle; 0.4% O2, balance N
Oxygen test gas bottle; 8.0% O2, balance N
CO test gas bottle; 1000 ppm CO, balance air
Regulator for Oxygen (may need 2)
Regulator for CO test gas
Wall mount bracket for test gas bottles
Test gas regulators kit
Test gas bottles kit
Moore Industries SPA for Low O2 Alarm, High COe Alarm,
Calibration Status, and Unit Fail
Blowback valve, air operated
Wall or Pipe Mounting Kit
Hasteloy In Situ Filter, High Temperature
Power line filter kit
Sample Tube Support, 18 in. (457 mm)
Sample Tube Support, 3 Ft. (0.91 m)
Sample Tube Support, 6 Ft. (1.83 m)
Sample Tube Support, 9 Ft. (2.7 m)
Flange Insulator
2
2
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
1-14
IM-106-
Instruction Manual
April 2017
OCX 8800
IM-106-880CIL, Rev 1.3
Section 2 Installation
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-7
Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-10
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-16
Before installing this equipment, read the "Safety instructions for the wiring and installation
of this apparatus" in Appendix A: Safety Data. Failure to follow the safety instructions could
result in serious injury or death.
To maintain explosion-proof protection of the OCX 8800 in hazardous areas, all cable entry
devices and blanking elements for unused apertures must be certified flameproof, suitable
for the conditions of use and properly installed.
To maintain explosion-proof protection of the OCX88C in hazardous areas, the sensor
housing must not be mounted to any surface or flange that exceeds 200ºC (392ºF).
To maintain explosion-proof protection of the OCX88C in hazardous areas, the sample
entering the sensor housing must not exceed 200ºC (392ºF).
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
2-2
IM-106-
MECHANICAL INSTALLATION
Selecting Location
1.
The location of the OCX 8800 in the stack or flue is most important for
maximum accuracy in the oxygen analyzing process. The probe must
be positioned so the gas it measures is representative of the process.
Best results are normally obtained if the transmitter is positioned near
the center of the duct (40-60% insertion). Longer ducts may require
several transmitters since the oxygen and combustibles can vary due to
stratification. A point too near the wall of the duct or the inside radius of
a bend, may not provide a representative sample because of the very
low flow conditions. The sensing point should be selected so the
process gas temperature falls within the range of probe material used.
Figure 2-1 through Figure 2-3 provide mechanical installation
references. The ambient temperature inside the electronics housing
must not exceed 185°F (85°C).
2.
Check the flue or stack for holes and air leakage. The presence of this
condition will substantially affect the accuracy of the oxygen and
combustibles readings. Therefore, either make the necessary repairs or
install the transmitter up stream of any leakage.
3.
Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance access to the unit. Allow
adequate clearance for the removal of the OCX 8800.
Do not allow the temperature of the electronics housing to exceed 185°F (85°C) or damage
to the electronics may result.
Whenever a positive stack pressure exists at the installation site, be sure to connect all
pneumatic lines prior to installing the OCX 8800 in the stack or ductwork. Failure to connect
the pneumatic lines can allow the flow of contaminants into the OCX 8800 ports.
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.
4.
Ensure the conduits drop vertically from the OCX 8800 and the conduit
is routed below the level of the conduit ports on the housing to form a
drip loop. Drip loops minimize the possibility that moisture will damage
the electronics (Figure 2-3).
5.
Where a positive stack pressure exists at the installation site, connect all
pneumatic lines prior to installing the OCX 8800 in the stack or
ductwork.
Instruction Manual
April 2017
OCX 8800
2-3
IM-106-880CIL, Rev 1.3
NOTE
If process temperatures will exceed 392°F (200°C), use anti-seize compound
on stud threads to ease future removal of the OCX 8800.
6.
Insert sample and exhaust tubes through the opening in the mounting
flange and bolt the unit to the flange.
Uninsulated stacks or ducts may cause ambient temperatures in the electronics housing to
exceed 185°F (85°C) and damage the electronics.
7.
If insulation is removed to access the duct for OCX 8800 mounting,
make sure to replace insulation afterward.
Enclosures
The OCX 8800 enclosures are designed to meet ingress conditions of IP66.
Each enclosure cover is threaded to its base and sealed with an o-ring that
isolates the threads from external contaminants.
Each cover is secured by a clip attached to the base that engages the cover
between the ribs of the cover sidewall. The clip is held in place by an Allen
head cap screw and lockwasher mounted in a recess. Cover removal and
installation requires an Allen wrench to loosen and tighten the screw.
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
4-2
Optional
In Situ Filter
8.3
(211)
Table 2. Installation/Removal
18
(457)
34
(864)
36
(914)
52
(1321)
72
(1829)
88
(2235)
108
(2743)
124
(3150)
37390008
0.06 In. Thick Gasket
ANSI
3535B18H02
DIN
3535B45H01
Table 1. Mounting
Flange
ANSI
5R10244H01
DIN
5R10244H02
Flange
6.00
7.28
Dia.
(152)
(185)
Hole
Dia.
0.75
0.71
(4) Holes
spaced on
(121)
(145)
B.C. dia
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.
IM-106-
equally
Flange Dia.
B.C. Dia.
Hole Dia.
(19)
4.75
(18)
5.71
Allow 9 in.
(229 mm) for
Cover Removal
Dim “B”
Removal Envelope
Dim “A”
Insertion Depth
Probe Dim “A” Dim “B”
18 in.
3 ft
6 ft
9 ft
BOTTOM VIEW
Instruction Manual
IM-106-880CIL, Rev 1.3
April 2017
OCX 8800
2-5
Figure 2-2. Adapter Plate Installat ion
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
6-2
Figure 2-3. Installation
Conduit Drip Loops
Duct Wall
Conduit Drip Loop
Conduit Drip Loop
Duct Wall
37020004
with Drip Loops
IM-106-
Instruction Manual
IM-106-880CIL, Rev 1.3
April 2017
OCX 8800
2-7
ELECTRICAL INSTALLATION
All wiring must conform to local and national codes. For reference, factory
wired solenoid power connections are shown in Figure 2-4.
Disconnect and lock out power before connecting the unit to the power supply. Failure to
lock out power could result in serious injury or death.
Install all protective equipment covers and safety ground leads after installation. Failure to
install covers and ground leads could result in serious injury or death.
To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation
of this equipment, connection to the main electrical power supply must be made through a
circuit breaker (min 10 A) in close proximity and marked for this equipment which will
disconnect all current-carrying conductors during a fault situation. This circuit breaker
should also include a mechanically operated isolating switch. If not, then another external
means of disconnecting the supply from the equipment should be located close by. Circuit
breakers or switches must comply with a recognized standard such as IEC 947.
To maintain explosion-proof protection of the OCX 8800 in hazardous areas, all cable entry
devices and blanking elements for unused apertures must be certified flameproof, suitable
for the conditions of use and properly installed.
To maintain explosion-proof protection of the OCX88C in hazardous areas, the sensor
housing must not be mounted to any surface or flange that exceeds 200ºC (392ºF).
To maintain explosion-proof protection of the OCX88C in hazardous areas, the sample
entering the sensor housing must not exceed 200ºC (392ºF).
Instruction Manual
880CIL, Rev 1.3
April 2017
OCX 8800
8-2
IM-106-
NOTE
To maintain proper earth grounding, ensure a positive connection exists
between the sensor housing, the electronics housing, and earth. The
connecting ground wire must be 14 AWG minimum. Refer to Figure 2-4.
NOTE
Line voltage, signal, and relay wiring must be rated for at least 105ºC (221ºF).
Electrical Connections
Electrical connections, power and communications are made to the electronic
enclosure. The connections are made through two 3/4 NPT ports in the
enclosure using fittings and cables provided by the customer. Cable
installation must meet NEC, IEC and/or other applicable national or local
codes for Class I, Zone 1, IIB +H2 T3/T6 permanently mounted equipment.
Connect Line Voltage
The OCX 8800 operates on 100 to 240 VAC line voltage at 50 to 60 Hz. The
power supply requires no setup. Connect the line (L wire) to the L terminal,
and the neutral (N wire) to the N terminal on the AC power input terminal
block in the electronics housing. Connect the ground (G wire) to the ground
stud in the electronics housing as shown in Figure 2-4.
Connect 4-20 mA Signals
Connect the 4-20 mA current loop to the 4-20 mA signal output terminals in
the electronics housing as shown in Figure 2-4. Use individual shielded
twisted wire pairs. Terminate the shield at the electronics housing.
4-20 mA Signal
O
2
One 4-20 mA signal represents the O
value. Superimposed on the O
2
2
signal is the HART information accessible through a Model 275/375
Handheld Communicator or AMS software. The O
signal is at the AOUT 1
2
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.
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