Rosemount OCX 4400 O2 / Combustibles Transmitter-Rev 1.0 Manuals & Guides

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Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

OXYGEN/COMBUSTIBLES TRANSMITTER

http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical repre-

sentative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and mainte-

nance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate In-

struction Manual and per applicable local and national codes. Connect all products to the

proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program,

and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts

specified by Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except

when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without notice.

Emerson Process Management

Rosemount Analytical Inc. Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com

http://www.processanalytic.com

HIGHLIGHTS OF CHANGES

Effective October, 2000 Rev. 1.0.

Page Summary

Throughout Added information on the Blowback option.

Page 1-7 Corrected Figure 1-4.

Page 1-8 Updated specifications.

Page 1-11 Updated Accessories section of Product Matrix.

Page 2-7 Updated Figure 2-5 to include ground stud.

Page 2-8 Updated Figure 2-6 to include shield connections and additional wire

colors.

Page 2-11 Corrected Figure 2-8 piping arrangement.

Page 3-1 Added Initial Power Up instructions for voltage selection.

Page 5-4 through 5-6

Page 5-10 Added Line Voltage Selection procedure.

Page 7-1 Added ground stud to removal/replacement instructions.

Page 7-2 Updated Figure 7-1 to include ground stud.

Page 7-4 Updated Figure 7-3 to include shield connections and additional wire

Page 7-6 Updated Figure 7-4 to include new heater configuration and blowback

Page 7-11 Updated Figure 7-6 to include new instrument air solenoid and vent

Section 8 Updated troubleshooting information and fault indications.

Section 9 Updated replacement parts table and added new replacement parts.

11-3 through 11-5 Updated Figure 11-3, menu trees for Local Operator Interface.

Appendix C Added Appendix C.

Updated Figure 5-3, menu trees for HART communicators.

colors.

option.

tube.

OCX 4400

PREFACE........................................................................................................................ P-1

Definitions ........................................................................................................................P-1

Safety Instructions .......................................................................................................... P-2

1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1

1-1 Component Checklist Of Typical System (Package Contents) ................................. 1-1

1-2 System Overview............................................................................................................ 1-1

1-3 OCX 4400 Specifications............................................................................................... 1-8

2-0 INSTALLATION .............................................................................................................. 2-1

2-1 Mechanical Installation ................................................................................................... 2-1

2-2 Electrical Installation....................................................................................................... 2-6

2-3 Pneumatic Installation .................................................................................................... 2-9

2-4 Startup ............................................................................................................................. 2-9

3-0 STARTUP AND OPERATION ...................................................................................... 3-1

3-1 General ............................................................................................................................ 3-1

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

4-0 CALIBRATION ................................................................................................................ 4-1

4-1 General ............................................................................................................................ 4-1

4-2 Calibration Methods........................................................................................................ 4-1

5-0 HART/AMS...................................................................................................................... 5-1

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

5-2 HART Communicator Signal Line Connections .......................................................... 5-1

5-3 HART Communicator PC Connectiions ....................................................................... 5-2

5-4 Off-Line And On-Line Operations ................................................................................. 5-3

5-5 Menu Tree For HART Communicator/ OCX 4400 Applications ................................ 5-3

5-6 HART Communicator Manual O

5-7 HART Communicator Manual COMB CAL Method.................................................... 5-8

5-8 HART Communicator Manual O

5-9 Automatic Calibration Setup Via HART .................................................................... 5-10

5-10 Line Voltage Selection Using HART Communicator ................................................ 5-10

6-0 OPERATION ...................................................................................................................6-1

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

6-2 Operation ......................................................................................................................... 6-1

7-0 MAINTENANCE AND SERVICE .................................................................................... 7-1

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

7-2 OCX 4400 Removal/Replacement ................................................................................ 7-1

7-3 Sensor Housing Component Replacement .................................................................. 7-5

7-4 Electronics Housing Component Replacement.......................................................... 7-10

CAL Method .......................................................... 5-7

And CO CAL Method .......................................... 5-9

8-0 TROUBLESHOOTING .................................................................................................... 8-1

8-1 General ............................................................................................................................ 8-1

8-2 Alarm Output................................................................................................................... 8-1

8-3 Fault Indications.............................................................................................................. 8-1

Rosemount Analytical Inc. A Division of Emerson Process Management i

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

9-0 RETURN OF MATERIAL .............................................................................................. 9-1

10-0 REPLACEMENT PARTS ............................................................................................. 10-1

11-0 APPENDICES ............................................................................................................... 11-1

Appendix A. Local Operator Interface (LOI) ............................................................. 11-1

Appendix B. SPA With HART Alarm ........................................................................ 11-7

Appendix C. Blowback................................................................................................. 11-8

Appendix D. IS Barrier .............................................................................................. 11-10

12-0 INDEX............................................................................................................................ 12-1

OCX 4400

ii Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Figure 1-1. Typical System Package ....................................................................................... 1-2

Figure 1-2. System Operation Diagram ................................................................................... 1-5

Figure 1-3. OCX 440 HART Connections and AMS Application.............................................. 1-6

Figure 1-4. Typical System Installation .................................................................................... 1-7

Figure 2-1. OCX 4400 Installation (with Integral Electronics) .................................................. 2-2

Figure 2-2. OCX 4400 Adapter Plate Dimensions ................................................................... 2-3

Figure 2-3. Adapter Plate Installation ....................................................................................... 2-4

Figure 2-4. Installation with Drip Loop and Insulation Removal............................................... 2-5

Figure 2-5. Line Voltage and 4-20 mA Connections ................................................................ 2-7

Figure 2-6. Electrical Connections Between Split-Electronics and Sensor Housing ............... 2-8

Figure 2-7. Air Set, Plant Air Connection ............................................................................... 2-10

Figure 2-8. OCX 4400 Gas Connections ............................................................................... 2-11

Figure 3-1. OCX 4400 Defaults ................................................................................................ 3-0

Figure 5-1. Signal Line Connections, > 250 Ohms Lead Resistance ...................................... 5-1

Figure 5-2. Signal Line Connections, < 250 Ohms Lead Resistance ...................................... 5-2

Figure 5-3. Menu Tree for HART/AMS on the OCX 4400 (Sheet 1 of 3)................................. 5-4

Figure 7-1. Electronics Housing Terminal Blocks .................................................................... 7-2

Figure 7-2. Sensor Housing Terminal Blocks .......................................................................... 7-3

Figure 7-3. Split-Electronics Housing Cable Connections ....................................................... 7-4

Figure 7-4. Sensor Housing, Exploded View ........................................................................... 7-6

Figure 7-5. O

Figure 7-6. Electronics Housing Exploded View .................................................................... 7-11

Figure 7-7. Electronics Box, Exploded View .......................................................................... 7-13

Figure 11-1. LOI Assembly Mounting....................................................................................... 11-1

Figure 11-2. Local Operator Interface (LOI) Assembly ............................................................ 11-2

Figure 11-3. Menu Tree for Local Operator Interface on the OCX 4400 (Sheet 1 of 3) .......... 11-3

Figure 11-4. SPA With HART Alarm ........................................................................................ 11-7

Figure 11-5. Blowback Connections ........................................................................................ 11-9

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

LIST OF ILLUSTRATIONS

Assembly, Exploded View ................................................................................ 7-8

LIST OF TABLES

Table 1-1. OCX 4400 Specifications ....................................................................................... 1-8

Table 1-2. Product Matrix......................................................................................................1-10

Table 1-3. Accessories.......................................................................................................... 1-11

Table 10-1. Replacement Parts .............................................................................................. 10-1

Rosemount Analytical Inc. A Division of Emerson Process Management iii

OCX 4400

The purpose of this manual is to provide a comprehensive understanding of the OCX 4400 Oxygen/Combustibles Transmitter components, functions, installation, and maintenance.

This manual is designed to provide information about the OCX 4400. We recommend that you thoroughly familiarize yourself with the Introduction and Installation sections before installing your transmitter.

The introduction presents the basic principles of the transmitter along with its performance characteristics and components. The remaining sections contain detailed procedures and information necessary to install and service the transmitter.

Before contacting Rosemount concerning any questions, first consult this manual. It describes most situations encountered in your equipment’s operation and details necessary action.

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

PREFACE

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.

NOTE

Highlights an essential operating procedure, condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

Rosemount Analytical Inc. A Division of Emerson Process Management P-1

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

FOR THE WIRING AND INSTALLATION

The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. NonEU states should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external, where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

OCX 4400

IMPORTANT

SAFETY INSTRUCTIONS

OF THIS APPARATUS

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then only by trained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

P-2 Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1-1 COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS)

A typical Rosemount OCX 4400 Oxygen/ Combustibles Transmitter package should contain the items shown in Figure 1-1. Record the part number, serial number, and order number for each component of your system in the table located on the front page of this manual.

Use the product matrix in Table 1-2 at the end of this section to verify your order number. The first part of the matrix defines the model. The last part defines the various options and features of the OCX 4400. Check the model number against the transmitter features and options, making sure options specified by this number are on or included with the unit. Use this complete model number for any correspondence with Rosemount.

1-2 SYSTEM OVERVIEW

a. Scope

This Instruction Bulletin supplies details needed to install, startup, operate, and maintain the Rosemount OCX 4400 Oxygen/ Combustibles Transmitter. Signal conditioning electronics outputs separate 4-20 mA signals representing oxygen (O combustibles (COMB) values. This information, plus additional details, can be accessed with the HART Model 275 handheld communicator or Asset Management Solutions (AMS) software. An optional local operator interface (LOI) is available to provide local communication with the electronics.

b. System Description

The Rosemount OCX 4400 Oxygen/ Combustibles Transmitter is designed to measure oxygen and combustible concentrations in flue gas temperatures up to

) and

2600°F (1427°C). The transmitter is close coupled to the process and requires minimal sample conditioning requirements.

The equipment measures oxygen percentage by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output of the cell is given by the following Nernst equation:

EMF = KT log10 (P1/P2) + C

Where:

1. P2 is the partial pressure of the oxygen in the measured gas on one side of the cell.

2. P1 is the partial pressure of the oxygen in the reference air on the opposite side of the cell.

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

NOTE

For best results, use clean, dry instrument air (20.95% oxygen) as the reference air.

When the cell is at operating temperature and there are unequal oxygen concentrations across the cell, oxygen ions will travel from the high oxygen partial pressure side to the low oxygen partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade. The output is proportional to the inverse logarithm of the oxygen concentration. Therefore, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the OCX 4400 to provide exceptional sensitivity at low oxygen concentrations.

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

MAN4275A00

English

October1994

HART

Communicator

1. Instruction Bulletin

2. HART



Communicator Package (Optional)

3. Adapter Plate with Mounting Hardware and Gasket

4. OCX 4400 (Shown with Integral Electronics)

5. Reference Air and Calibration Set

6. Blowback Hardware (Optional)

FISHER-ROSEMOUNT

34070023

Figure 1-1. Typical System Package

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

The OCX 4400 measures net oxygen concentration in the presence of all the products of combustion, including water vapor. Therefore, it may be considered an analysis on a “wet” basis. In comparison with older methods, such as the portable apparatus, which provides an analysis on a “dry” gas basis, the “wet” analysis will, in general, indicate a lower percentage of oxygen. The difference will be proportional to the water content of the sampled gas stream.

The OCX 4400 combustibles sensor is a catalytic sensor consisting of two Resistant Temperature Detectors (RTD). One RTD is the reference element covered with an inert coating. The other RTD element is active, coated with a catalyst. As the sample gases flow by the sensor, the combustible gases oxidize on the surface of the active element. The oxidation that occurs produces heat and a temperature rise in the active element. The temperature difference produces a resistance relationship between the two elements that is directly proportional to the concentration of combustibles in the sample gases.

The catalyst is specifically designed to detect carbon monoxide (CO), but the sensor responds to other combustible gases. The sensor is calibrated using carbon monoxide (CO), thus the output should be expressed in terms of CO. However, since the sensor detects other combustible gases, the output cannot just be labeled CO. The response of the sensor to other combustible gases gives an output that is equivalent to the sensor detecting CO. The term COMB is used in this manual to describe the sensor output. This term indicates that the sensor is calibrated in terms of CO, and that the sensor output is equivalent to CO but not specific to CO.

c. System Configuration

Transmitters are available in four length options, giving the user the flexibility to use a penetration appropriate to the size of the stack or duct. The length options are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), or 9 ft (2.7 m). Probes are available in three material options, 316L stainless steel, inconel 600, and ceramic to accommodate higher temperatures.

The electronics are contained in a separate housing from the sensors and may be integrally mounted next to the sensor housing on the probe, or split mounted up to 150 feet away from the probe.

The electronics control both sensor temperatures and provide individual 4-20 mA isolated outputs that are proportional to the measured oxygen and combustibles concentrations. The power supply can accept voltages of 100 to 240 VAC and 50 to 60 Hz. The electronics accepts millivolt signals generated by the sensors and produces the outputs to be used by remotely connected devices. The outputs are isolated 4-20 mA linearized currents. See 3-1b for specific instructions upon initial power up.

d. System Features

1. The O tivity increase as the oxygen concentration decreases.

2. HART communication is standard. To use the HART capability, you must have either:

(a) A HART Model 275

cell output voltage and sensi-

Communicator.

Dilution air is provided to the COMB sensor to ensure there is adequate oxygen to fully oxidize any combustible gases regardless of the concentration of oxygen in the process.

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

(b) Asset Management Solutions

(AMS) software for the PC.

3. Oxygen cell and heater/thermocouple assembly are field replaceable.

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

4. Electronics are configurable for line voltages from 100 to 240 VAC. See Section 3-1b.

5. An operator can calibrate and diagnostically troubleshoot the OCX 4400 in one of two ways:

(a) HART Interface. Each of the OCX

4400’s 4-20 mA output lines transmit an analog signal proportional to oxygen or combustible levels detected. The HART output is superimposed on the oxygen 420 mA output line only. This information can be accessed through the following:

1 Rosemount Model 275 Hand-

held Communicator - The handheld communicator requires Device Description (DD) software specific to the OCX 4400. The DD software will be supplied with many Model 275 units, but can also be programmed into existing units at most FisherRosemount service offices. Refer to Section 5, HART/AMS, for additional information.

2 Personal Computer (PC) -

The use of a personal computer requires AMS software available from FisherRosemount.

3 Selected Distributed Control

Systems - The use of distributed control systems requires input/output (I/O) hardware and AMS software which permit HART communications.

(b) Optional Local Operator Interface

(LOI). The optional LOI is mounted to the end of the electronics module and allows local communications with the electronics. Refer to Appendix A, Local Operator Interface (LOI), for more information.

6. Optional Blowback System. The blowback system periodically blows instrument air back through the inlet filter and out the inlet tube. This clears out particulate and keeps the inlet filter from clogging.

e. System Operation

Figure 1-2 shows the relationship between the components of the OCX 4400. The sensors and the electronics are contained in separate housings. The sensor housing and probe mounts to a duct or process wall so that the probe protrudes into the flue gas stream. An air powered eductor continuously pulls samples of the process flue gas through the probe to a chamber in front of the sensor housing where the sample passes the O

sensor and continues on to

the COMB sensor. Dilution air is provided to the COMB sensor and reference air to the O

sensor. After the gas sample flows past

the O

sensor and through the COMB sen-

sor, it is drawn through the eductor where it mixes with the eductor air and exits through exhaust back into the system. The electronics housing contains the CPU which converts the sensor inputs into 4-20 mA analog output signals. The CPU also initiates and performs calibrations. Three test gasses and instrument air are controlled by solenoids. Test gas flow to the sensors is regulated by a rotometer between the electronics and sensor housings. Instrument air is separated into eductor air, reference air, and dilution air. The instrument air solenoid does not allow air flow until the heaters are up to temperature. This minimizes the amount of sampled process flue gas being pulled into cold sensors causing condensation.

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SAMPLE

GAS

PROBE

EXHAUST

SENSOR

HOUSING

COMBUSTIBLES

SENSOR

EDUCTOR

ROTOMETER

5 SCFH

ELECTRONICS

PRESSURE

SENSOR

TEST GAS

SOLENOIDS

INSTRUMENT AIR

SOLENOID

EDUCTOR AIR

HOUSING

CPU

POWER SUPPLY

LOW O2

TEST GAS

HIGH O2

TEST GAS

HIGH CO

TEST GAS

INSTRUMENT

AIR

REFERENCE AIR

DILUTION AIR

ROTOMETER

50 cc/Min.

(0.106 SCFH)

Figure 1-2. System Operation Diagram

34070001

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

f. Handling the OCX 4400

It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to prevent possible equipment damage.

The OCX 4400 is designed for industrial application. Treat each component of the system with care to avoid physical damage. The probe may contain components made from ceramics, which are susceptible to shock when mishandled.

g. System Considerations

Prior to installing your Rosemount OCX 4400 Oxygen/Combustibles Transmitter, make sure you have all the components necessary to make the system installation. Ensure all the components are properly integrated to make the system functional.

After verifying that you have all the components, select mounting locations and determine how each component will be placed in terms of available line voltage, ambient temperatures, environmental considerations, convenience, and serviceability. Figure 1-3 shows a typical system wiring. A typical system installation is illustrated in Figure 1-4.

A source of instrument air is required at the OCX 4400 for reference gas, dilution air, and eductor air. Since the OCX 4400 is equipped with an in-place calibration feature, provision should be made for connecting test gas tanks to the OCX 4400 when it is to be calibrated.

NOTE

The electronics module is designed to meet NEMA 4X (IP66) and the electronic components are rated to temperatures up to 185°F (85°C).

Retain packaging in which the unit arrived from the factory in case any components are to be shipped to another site. This packaging has been designed to protect the product.

INSTRUMENT

AIR

OCX 4400 O2/COMBUSTIBLES TRANSMITTER

WITH INTEGRAL ELECTRONICS

4-20 MA OUTPUT (TWISTED PAIRS)

3 CALIBRATION GAS LINES BY CUSTOMER [300 FT (90M) MAX]

Figure 1-3. OCX 440 HART Connections and AMS Application

TERMINATION IN

CONTROL ROOM

HART MODEL 275

HANDHELD INTERFACE

CUSTOMER’S LAPTOP

WITH ASSET MANAGEMENT

ASSET MANAGEMENT SOLUTIONS

SOLUTIONS

34070002

1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

INTEGRAL ELECTRONICS

TEST

GAS

ROTOMETER

GASES

STACK

DILUTION AIR

ROTOMETER

ADAPTER

PLATE

DUCT

Instruction Manual

4-20 mA OUTPUTS (2)

LINE VOLTAGE

INSTRUMENT AIR

SUPPLY (REF. GAS)

PRESSURE

REGULATOR

SPAN COMBUSTIBLES TEST GAS LOW O2 TEST GAS

HIGH O2 TEST GAS

IB-106-440 Rev. 1.0

October 2000

ELECTRONICS

CABLE

(UP TO 150FT)

SPLIT-MOUNTED ELECTRONICS

GASES

DUCT

STACK

TEST

GAS

ROTOMETER

DILUTION AIR

ROTOMETER

4-20 mA OUTPUTS (2)

LINE VOLTAGE

INSTRUMENT AIR

SUPPLY (REF. GAS)

PRESSURE

REGULATOR

SPAN COMBUSTIBLES TEST GAS LOW O2 TEST GAS

HIGH O2 TEST GAS

34070003

Figure 1-4. Typical System Installation

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

1-3 OCX 4400 SPECIFICATIONS

transmitter before choosing the mounting loca-

tion. Table 1-2 contains the product matrix. Use Table 1-1 contains information about the OCX 4400 Oxygen/Combustibles Transmitter operating characteristics. Use the table to make sure that available conditions are suitable for the

the product matrix for ordering information and

specific model number information. Table 1-3

contains information on accessories available

with the OCX 4400.

Table 1-1. OCX 4400 Specifications

Net O

Range .................................................. 0-1% to 0-40% O

, Fully field selectable

Combustibles ................................................. 0-1000 ppm to 0-5%, Fully field selectable

Accuracy:

Oxygen..................................................... +0.75% of reading or 0.05% O

, whichever is greater

Combustibles .......................................... +2% F.S.

System Response to Test Gas:

Oxygen..................................................... 10 sec T90

Combustibles .......................................... 25 sec T90

Temperature Limits:

Process .................................................... 32° to 2600°F (0° to 1427°C)

Sensors.................................................... -40° to 392°F (-40° to 200°C)

Electronics............................................... -40° to 185°F (-40° to 85°C)

Nominal and Approximate Shipping Weights:

18 in. (457 mm) package ........................ 54 lbs (24.5 kg)

3 ft (0.91 m) package .............................. 55 lbs (24.5 kg)

6 ft (1.83 m) package .............................. 57 lbs (26 kg)

9 ft (2.74 m) package .............................. 59 lbs (26.8 kg)

Mounting and Mounting Position:

Sensors.................................................... Flange

Electronics............................................... Wall/Pipe

Materials:

Probes...................................................... 316L stainless steel

Inconel 600 Ceramic

Enclosures............................................... Low-copper aluminum

Calibration ...................................................... Semi-automatic or automatic

Calibration Gas Mixtures Recommended.... 0.4% O

8% O

, Balance N2

1000 ppm CO, Balance N2 (Ref. test gas kit #1A99119G04)

Calibration Gas Flow ..................................... 5 scfh (2.5 l/m)

Reference Air.................................................. 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O

regulated to 35 psi (238 kPa)

Eductor Air...................................................... 5 scfh (2.5 l/m), clean, dry, instrument-quality air

(20.95% O

), regulated to 35 psi (238 kPa)

Dilution Air...................................................... 0.1 scfh (0.5 l/m), clean, dry, instrument-quality air

(20.95% O

Blowback Air (Optional) ................................ Clean, dry, instrument-quality air (20.95% O

), regulated to 35 psi (238 kPa)

), regulated to

55 psi (374 kPa)

Operating temperature of electronics inside of electronics housing, as measured by a HART Communicator, or Fisher-

Rosemount Asset Management Solutions Software, or local operator interface.

1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

IB-106-440 Rev. 1.0

OCX 4400

Table 1-1. OCX 4400 Specifications (Continued)

Sensors Housing ........................................... NEMA 4X, IP66 with fitting and pipe on reference exhaust

port to clean, dry atmosphere Two 3/4-14 NPT conduit ports

Electronics Housing ...................................... NEMA 4X, IP66 with fitting and pipe on reference exhaust

port to clean, dry atmosphere Two 3/4-14 NPT conduit ports

Electrical Noise .............................................. Meets EN 50082-2 Electromagnetic Compatibility Generic

Immunity Std., Part II Includes ENG 1000 4-R for Electrostatic Discharge 4 Kv contact, 8 Kv in air Optionally ENG 1000 4-R “Namur-Increased” 8 Kv contact, 16 Kv in air Includes IEC 801-4 fast transients-2 Kv on power supply and control lines

Line Voltage.................................................... Universal 100 to 240 VAC, 50 to 60 Hz, Software selectable,

3/4-14 NPT conduit port

Isolated Output:

Oxygen..................................................... 4-20 mAdc, 950 ohm max, with HART capability for O

COMB

Combustibles .......................................... 4-20 mAdc, 950 ohm max

Logic Signals.................................................. SPA HART Alarm Module (optional)

Low Oxygen Alarm

High Combustibles Alarm Calibration Status Unit Failure Alarm Output Relay (dry contact, 30 mA and 30 VDC capacity)

Power Consumption Limits:

Heaters..................................................... 650 W nominal max

Electronics............................................... 50 W nominal max

Certification .................................................... CE

FM(Pending) CSA(Pending) CENELEC(Pending)

October 2000

and

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

Table 1-2. Product Matrix

OCX44A O2 / Combustibles Transmitter

O2 / Combustibles Transmitter IB-106-440

Code Probe Length and Material

00 No Probe or Exhaust Tube 11 18 in. (457 mm) 316 SST up to 1300°F (704°C) 21 18 in. (457 mm) Inconel 600 up to 1832°F (1000°C) 31 18 in. (457 mm) Ceramic up to 2600°F (1426°C) 12 3 ft (0.91 m) 316 SST up to 1300°F (704°C) 22 3 ft (0.91 m) Inconel 600) up to 1832°F (1000°C) 32 3 ft (0.91 m) Ceramic up to 2600°F (1426°C) 13 6 ft (1.83 m) 316 SST up to 1300°F (704°C) 23 6 ft (1.83 m) Inconel 600 up to 1832°F (1000°C) 14 9 ft (2.7 m) 316 SST up to 1300°F (704°C)

Code Probe Mounting Assembly

10 (ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes 20 (DIN) 185mm dia. flange, 145mm BC with 4 x 18mm dia. holes 30 (JI S ) 155mm dia. flange, 130mm BC with 4 x 15mm dia. holes

OCX 4400

Code Mounting Hardware - Stack Side

0 No Adapter Plate ("0" must also be chosen under "Mounting Adapter - Probe Side" below) 1 New Installation - Square weld plate with studs 2 Model 218/240 Mounting Plate (with Model 218/240 Shield Removed) 3 Existing Model 218/240 Support Shield 4 Mounting to Other Mounting 5 Model 132 Adapter Plate 6 Mounting to Ametek WDG-IVC 7 Mounting to Servomex Xendos 2700 8 Mounting to Elsag Bailey SMA-90

Code Mounting Hardware - Probe Side

0 No Adapter Plate 1 Probe Only (ANSI) 4 Probe Only (DIN) 7 Probe Only (JIS)

OCX44A 11 10 1 1 (Cont’d) Example

(1)

1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Table 1-2. Product Matrix (Continued)

Cont'd Code Electronic Housing - NEMA 4X, IP66 HART Communications

01 Basic Unit 02 Local Operator Interface 03 Calibration Solenoids 04 IS Barrier 05 Local Operator Interface and Calibration Solenoids 06 Local Operator Interface and IS Barrier 07 Calibration Solenoids and IS Barrier 08 Local Operator Interface and Calibration Solenoids and IS Barrier

Code Electronic Mounting

01 Integral to Sensor Housing Electronics 02 Split Electronics and no cable 03 Split Electronics and 20 ft (6m) cable 04 Split Electronics and 40 ft (12m) cable 05 Split Electronics and 60 ft (18m) cable 06 Split Electronics and 80 ft (24m) cable 07 Split Electronics and 100 ft (30m) cable 08 Split Electronics and 150 ft (45m) cable

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

Code Accessories

00 None 01 Cal. Gas Rotometers, Flow Rotometers, and Ref. Gas Set 11 Blowback Option and Cal. Gas Rotometers, Flow Rotometers, and Ref. Gas Set

Cont’d 08 01 11 Example

NOTES:

(1)

Where possible, specify SPS number; otherwise, provide details of the existing mounting plate as follows: Plate with studs Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate. Plate without studs Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.

(2)

If the Local Operator Interface (LOI) is not implemented, remote access and functionality avai l abl e via HART Communicati ons (M o del 275

Handheld Communicator) with Oxygen/Combustibles Device Desc ri ption (DD) requi red.

Table 1-3. Accessories

PART

NUMBER DESCRIPTION

1A99119H01 Oxygen bottles 0.4% balance N2

1A99119H02 Oxygen Bottles 8.0% balance N2

1A99119H06 CO Bottle 1000 PPM and air balance N2

1A99120H02 Regulator for Oxygen (may need 2)

1A99120H03 Regulator for COMB

1A99119G06 3 wide wall mount bracket for gas bottles

1A99119G05 Calibration gas regulators kit

1A99119G04 Calibration gas bottles kit

1A99292H01 Moore Industries SPA for Low O2 Alarm, High

COMB Alarm, Calibration Status, and Unit Fail

275D9EI5D0000 275 HART Communicator with 12 Meg buffer

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-11

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

1-12 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Before installing this equipment, read the “Safety instructions for the wiring and installation of this apparatus” at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury or death.

2-1 MECHANICAL INSTALLATION

a. Selecting Location.

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 2

INSTALLATION

3. Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance access to the unit. Allow adequate clearance for the removal of the OCX 4400.

Do not allow the temperature of the electronics housing to exceed 185°F (85°C) or damage to the electronics may result.

1. The location of the OCX 4400 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The probe must be positioned so the gas it measures is representative of the process. Best results are normally obtained if the transmitter is positioned near the center of the duct (40-60% insertion). Longer ducts may require several transmitters since the oxygen and combustibles can vary due to stratification. A point too near the wall of the duct, or the inside radius of a bend, may not provide a representative sample because of the very low flow conditions. The sensing point should be selected so the process gas temperature falls within the range of probe material used. Figure 2-1 through Figure 2-3 provide mechanical installation references. The ambient temperature inside the electronics housing must not exceed 185°F (85°C).

2. Check the flue or stack for holes and air leakage. The presence of this condition will substantially affect the accuracy of the oxygen and combustibles readings. Therefore, either make the necessary repairs or install the transmitter upstream of any leakage.

b. Installation

1. Ensure all components are available to install the OCX 4400.

2. The OCX 4400 may be installed intact as it is received.

3. Weld or bolt adapter plate (Figure 2-3) onto the duct.

4. In vertical installations for systems with integral electronics, ensure the system cable drops vertically from the OCX 4400 and the conduit is routed below the level of the electronics housing. This drip loop minimizes the possibility that moisture will damage the electronics (Figure 2-4).

NOTE

If process temperatures will exceed 392°F (200°C), use anti-seize compound on stud threads to ease future removal of the OCX 4400.

5. Insert probe through the opening in the mounting flange and bolt the unit to the flange.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

NOTE:

ALL DIMENS IONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.

INSULATE IF EXPOSED TO AMBIENT WEATHER CONDITIONS

0.062 THK GASKET 3535B18H02

ANSI

3535B46H01

JIS

3535B45H01

DIN

DIM “A”DIM “B”

OCX 4400

TABLE 2. INSTALLATION/REMOVAL PROBE

18 IN.

3 FT

6 FT

9 FT

DIM "A"

(406)

(864)

(1778)

106

(2692)

DIM "B"

32.38

(822)

50.38

(1280)

86.38

(2184)

122.38

(3108)

Figure 2-1. OCX 4400 Installation (with Integral Electronics)

BOTT OM VIEW

FLANGE DIA

HOLE DIA

(4) HOLES

EQ SP ON BC

TABLE 1. MOUNTING FLANGE

ANSI

4512C17H01

6.00

(153)

0.75

(20)

4.75

(121)

DIN

4512C19H01

7.28

(185)

0.71

(18)

5.71

(145)

JIS

4512C18H01

6.10

(155)

0.59

(15)

5.12

(130)

29790008

2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

DIMENSIONS

IN.

(mm)

ADAPTER PLATE* DIMENSIONS FOR OCX 4400

ANSI

(P/N 4512C34G01)

DIN

(P/N 4512C36G01)

(P/N 4512C35G01)

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

JIS

"A"

"B"

THREAD

"C"

DIA

*PART NUMBERS FOR ADAPTER PLATES INCLUDE

ATTACHING HARDWARE.

NOTE:DIMENSIONS ARE

IN INCHES WITH MILLIMETERS IN PARENTHESES.

2.500 DIA (63.5)

ADAPTER PLATE FOR OCX 4400 INSTALLATION. SEE FIGURE 2-1.

6.00

(153)

0.625-11

4.75

(121)

7.5

(191)

(M-16 x 2)

5.708 (145)

6.50

(165)

(M-12 x 1.75)

5.118 (130)

4 STUDS, LOCKWASHERS AND NUTS EQUALLY SPACED ON C DIA B.C.

29790013

Figure 2-2. OCX 4400 Adapter Plate Dimensions

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

INSTALLATION FOR METAL

WALL STACK OR DUCT

CONSTRUCTION

OCX 4400

INSTALLATION FOR MASONRY

WALL STACK CONSTRUCTION

MTG HOLES

SHOWN ROTATED

45 OUT OF

TRUE POSITION

WELD OR BOLT ADAPTER

PLATE TO METAL WALL

OF STACK OR DUCT.

JOINT MUST BE AIRTIGHT.

0.50 [13]

3.75 [95]

MIN DIA HOLE IN WALL

STACK OR DUCT

METAL WALL

0.50 [13]

BOLT ADAPTER

PLATE TO OUTSIDE

WALL SURFACE

FIELD WELD

PIPE TO

ADAPTER PLATE

MTG HOLES

SHOWN ROTATED

45 OUT OF

TRUE POSITION

JOINT MUST

BE AIRTIGHT

OUTSIDE WALL

SURFACE

NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPT

ADAPTER PLATE NOT FURNISHED BY ROSEMOUNT.

BOLT ADAPTER

PLATE TO OUTSIDE

WALL SURFACE

4.50 [114] O.D. REF

PIPE 4.00 SCHED 40

PIPE SLEEVE (NOT

BY ROSEMOUNT)

LENGTH BY CUSTOMER

MASONRY

STACK WALL

FIELD WELD PIPE

TO ADAPTER PLATE

3.50 [89] O.D. REF

PIPE 3.00 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH

BY CUSTOMER

MASONRY

STACK WALL

29790014

WELD OR BOLT ADAPTER

PLATE TO METAL WALL

OF STACK OR DUCT.

JOINT MUST BE AIRTIGHT.

2.50 [63.5]

MIN DIA HOLE IN WALL

STACK OR DUCT

METAL WALL

NOTE: DIMENSIONS IN INCHES WITH

MILLIMETERS IN PARENTHESES.

JOINT MUST

BE AIRTIGHT

OUTSIDE WALL

SURFACE

Figure 2-3. Adapter Plate Installation

2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

4-20 mA

SIGNALS

DRIP

LOOP

INSULATION

OCX 4400

ELECTRONICS

REPLACE

INSULATION

AFTER

INSTALLING

OCX 4400

ADAPTER

PLATE

STACK OR DUCT

METAL WALL

29790015

Figure 2-4. Installation with Drip Loop and Insulation Removal

LINE

VOLT AGE

DRIP

LOOP

Uninsulated stacks or ducts may cause ambient temperatures around the electronics to exceed 185°F (85°C), which may cause overheating damage to the electronics.

6. If insulation is being removed to access the duct work for OCX 4400 mounting,

make sure the insulation is replaced afterward (Figure 2-4).

c. Split-Electronics Installation

If OCX 4400 is configured for split electronics mounting, choose a location not to exceed the length of the electronics cable ordered. Split-mounted electronics modules may be pole or wall mounted.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

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 2-5.

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 itself 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 connection 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 Section 3-1b for further instructions.

b. Connect 4-20 mA Signals

Connect the 4-20 mA current loop to the 420 mA signal output terminals in the electronics housing.

1. Oxygen (O

) 4-20 mA Signal. One 4-

20 mA signal represents the O Superimposed on the O

4-20 mA sig-

nal is the HART information that is accessible through a Model 275 Handheld Communicator or AMS software. The O

4-20 mA signal is at the

AOUT 1+ and AOUT 1- terminals.

2. Combustibles (COMB) 4-20 mA Signal. The other 4-20 mA signal represents the COMB value. HART information is not available on the COMB signal. The COMB 4-20 mA signal is at the AOUT 2+ and AOUT 2- terminals.

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 contacts with 30 mA and 30 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 ordered with the package (Figure 2-6). Steel braided cable is available in lengths up to 150 ft. (45 m).

1. Thermocouple Connections. Connect the sensor/thermocouple terminal block in the electronics housing to the corresponding sensor/thermocouple terminal block in the sensor housing. The twisted wire pairs are numbered on the inner plastic wrapper. Keep the twisted pairs together and match the numbers and wire colors shown in Figure 2-6. Connect the twisted pair wire shields to the shield terminals.

value.

2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SOLENOID POWER

TERMINAL B L OCK

(FA CTORY WIRED)

GND

LO O2

HI COMB

HI O2

ALARM OUTPUT

RELA Y TERMINAL

GND

INST AIR

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)

PRESSURE

SENSOR

HI COMB

SOLENOID

4-20 mA

SIGNAL

OUTPUT

PORT

HI O2

SOLENOID

LO O2

SOLENOID

INST AIR

SOLENOID

AOUT 2-

AOUT 2+

AOUT 1-

AOUT 1+

COMB 4-20 mA SIGNAL

O2 4-20 mA SIGNAL

AC POWER IN P U T

TERMINAL B L OCK

F1 POWER

SUPPLY FUSE

Figure 2-5. Line Voltage and 4-20 mA Connections

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 heaters in the sensor housing. Match

F2 HEATER

AC POWER

INPUT PORT

FUSE

GROUND STUD

TWO NUTS

34070021

the wire colors to the corresponding heater power terminal blocks in the sensor and electronics housings as shown in Figure 2-6.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

SPLIT-ELECTRONICS HOUSING

HEATER POWER

TERMINAL B L OCK

ORANGE

GRA Y

BLACK

PURPLE

SL HEATER

ELECTRONICS CABLE

(UP TO 150 FT)

NOTE: KEEP TWISTED

PAIRS TOGETHER

O2 CELL HEATER

BROWN

COMB CELL HEATER

(COVER REMO VED)

RED

SENSOR/THERMOCOUPLE

TERMINAL B L OCK

(1)

YELLOW

O2 T/C +

RED

O2 T/C -

SHIELD

GND

(2)

YELLOW

SL T/C +

RED

SL T/C -

(3)

BLUE

O2 MV +

SHIELD

WHITE

GND

O2 MV -

PRESSURE

SENSOR

ELECTRONICS

CABLE PORT

GROUND STUD

(5)

(4)

YELLOW

WHITE

GREEN

COMB ACTIVE +

WHITE

COMB REF -

COMB REF +

COMB ACTIVE -

CABLE

(6)

SHIELD

GND

WHITE

RED

RTD DRIVE

RTD RETURN

PRESSURE

SENSOR

FACTORY

WIRED

WHITE

RED

GREEN

+ 10 PR SRC

PR SENSOR -

PR SENSOR +

BLACK

PR SRC RTN

(5)

(6)

WHITE

RED

YELLOW

WHITE

RTD DRIVE

COMB REF -

COMB REF +

SENSOR/THERMOCOUPLE

TERMINAL B L OCK

RTD RETURN

ELECTRONICS

CABLE PORT

PROBE

O2 CELL HEATER

SL HEATER

PURPLE

ORANGE

HEATER POWER

TERMINAL B L OCK

COMB CELL HEATER

GRA Y

BLACK

BROWN

RED

(1)

YELLOW

O2 T/C +

RED

O2 T/C -

(2)

YELLOW

SL T/C +

RED

SL T/C -

(3)

BLUE

O2 MV +

WHITE

O2 MV -

(4)

WHITE

GREEN

BLUE

COMB ACTIVE -

COMB ACTIVE +

RED

SENSOR HOUSING

(COVER REMO VED)

34070010

Figure 2-6. Electrical Connections Between Split-Electronics and Sensor Housing

2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

2-3 PNEUMATIC INSTALLATION

a. Connections to Electronics Housing

1. Reference Air Set. After the OCX 4400 is mechanically installed, connect the reference air set (regulator and pressure gage) to the instrument air inlet on the electronics housing. The reference air set should be installed in accordance with Figure 2-7.

Do not use 100% nitrogen as an O2 low gas. It is suggested that O2 low gas be between 0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

2. Calibration Gas. Two O2 calibration gas concentrations and one COMB calibration gas are used with the OCX 4400: O 8%, and COMB high gas - 1000 ppm or 4%. Connect O GAS LO O housing. Connect O CAL GAS HI O ics housing. Connect COMB high gas to the CAL GAS HI COMB input on the

low gas - 0.4%, O2 high gas -

low gas to the CAL

input on the electronics

input on the electron-

high gas to the

electronics housing. Refer to Figure 2-8.

3. Instrument Air Regulator. Connect a regulator to the instrument air inlet on the electronics housing as shown in Figure 2-8. Set the regulator to 35 psig. Instrument air is separated into three air lines after exiting the instrument air regulator. Connect a rotometer to the dilution air line as shown in Figure 2-8. Set the dilution air rotometer to 0.1 scfh.

4. Calibration Gas Rotometer. Connect a rotometer to the calibration gas outlet on the electronics housing as shown in Figure 2-8. Set the rotometer to 5 scfh.

b. Connections to Sensor Housing

1. Calibration Gas. Connect the outlet of the calibration gas rotometer to the CAL GAS input on the sensor housing (Figure 2-8).

2. Instrument Air. Connect the three instrument air lines to their proper connections on the sensor housing (Figure 2-8). Connect dilution air rotometer output to DILUTION AIR input on the sensor housing. Connect the instrument air regulator output to REF AIR input and EDUCTOR AIR input on the sensor housing.

NOTE

Upon completing installation, make sure that the OCX 4400 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold OCX 4400 exposed to the process gases.

During outages, and if possible, leave all OCX 4400 units running to prevent condensation and premature aging from thermal cycling.

2-4 STARTUP

Refer to Section 3, STARTUP AND OPERATION, for startup information.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

DRAIN VALVE

ELECTRONICS

HOUSING

OUTLET

0.250 OR 6mm O.D. TUBING (SUPPLIED BY CUSTOMER)

INSTRUMENT

AIR INLET

3.12 (79.25) MAX

2.250 (57.15)

0.25-18 NPT FEMALE INLET CONNECTION

2.0

(50.80)

1.50

(38.10)

1 2" PRESSURE GAGE 0-60 PSIG 275431-003

2 COMBINATION FILTER-REG. 0-60 PSIG

NOTE: DIMENSIONS ARE IN INCHES WITH

2 MOUNTING HOLES

3.19 (81.03) LG

THROUGH BODY FOR

0.312 (7.92) DIA BOLTS

INSTRUMENT AIR SUPPLY 10-225 PSIG MAX PRESSURE SET TO 35 PSIG

MILLIMETERS IN PARENTHESES.

8.50

(215.90)

MAX

SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OCX 4400 ELECTRONICS HOUSING.

34070004

Figure 2-7. Air Set, Plant Air Connection

2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

ELECTRONICS

HOUSING

CAL GAS HI COMB

INPUT

CAL GAS

ROTOMETER

5 SCFH

SENSOR

HOUSING

CAL GAS

HI O2

INPUT

CALIBRA TION

GAS OUTLET

INSTR UMENT

AIR IN

INSTRUMENT

AIR OUT

CAL GAS

LO O2

INPUT

CAL GAS

INPUT

SET REGULATOR TO 35 PSIG

0 - 60 PSIG

DILUTION AIR

ROTOMETER

0.1 SCFH

EDUCTOR

AIR INPUT

REF AIR

INPUT

DILUTION AIR

INPUT

34070006

Figure 2-8. OCX 4400 Gas Connections

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

SW3

112

C O M

21.1 mA

3.5 mA 2

SECTION 3

DEFAULT POSITION -

3,4 – NOT USED

COMB 21.1 mA/3.5 mA:

INTERNAL:

COMB 4-20 mA IS

INTERNALLY

POWERED

(DEFA U LT)

21.1 mA

O2 21.1 mA/3.5 mA: O2 4-20 mA SIGNAL

RAIL LIMITS: HIGH - 21.1 mA LOW - 3.5 mA

COMB 4-20 mA SIGNAL RAIL LIMITS: HIGH - 21.1 mA LOW - 3.5 mA

SW2

EXTERNAL:

COMB 4-20 mA

REQUIRES

AN EXTERNAL

POWER SUPPLY

FUSE F2

INTERNAL:

O2 4-20 mA IS

INTERNALLY

POWERED

(DEFA U LT)

SW1

Figure 3-1. OCX 4400 Defaults

EXTERNAL: O2 4-20 mA

REQUIRES

AN EXTERNAL

POWER SUPPLY

34070007

3-0 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

STARTUP AND OPERATION

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

3-1 GENERAL

a. Verify Installation

Ensure the OCX 4400 is installed correctly. Verify mechanical installation and all electrical and pneumatic connections (Section 2, INSTALLATION).

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 3

4. Apply power to the OCX 4400 Oxygen/Combustibles Transmitter.

5. If using the HART handheld communicator, connect the communicator to the transmitter.

6. If using the HART communicator, select: Device Setup > Detailed Setup > Line Voltage.

If using the LOI, select: Setup > Parameters > Line Voltage.

7. Set the line voltage to the appropriate value: 100, 110, or 220.

Setting the power input voltage to the wrong value can damage the heaters in the sensor housing or prevent the transmitter from operating properly. Always ensure that the power input voltage is set properly after installing the transmitter.

b. Initial Power Up

The OCX 4400 Oxygen/Combustibles Transmitter has a 12 minute delay before the heaters begin operation. Upon initial power up of the OCX 4400, and any time supply voltage to the unit changes, the power input voltage must be verified in the software to ensure proper operation of the heaters. The input voltage is set as follows:

1. Remove the housing cover from the electronics housing.

2. Remove fuse F2 from the electronics box. See Figure 3-1 for the location of fuse F2.

3. Replace the electronics housing cover.

8. If using the HART communicator, press F4 for Enter and then F2 for send.

If using the LOI, press the right arrow to enter the value.

9. Remove power from the OCX 4400 electronics.

10. Remove the electronics housing cover and install fuse F2.

11. Install the electronics housing cover and restore power to the OCX 4400 electronics.

c. Verify OCX 4400 Configuration

There are three switches on the microprocessor board which are user configurable for the OCX 4400 (Figure 3-1). SW1 determines if the O or externally powered. SW2 determines if the COMB 4-20 mA signal is internally or externally powered. SW3 sets the rail limits for the O switches are accessible through holes in the electronics box.

4-20 mA signal is internally

and COMB 4-20 mA signals. All

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-1

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

Remove power from the OCX 4400 before changing defaults. If defaults are changed under power, damage to the electronics may occur.

1. SW1. The two settings are internally or externally powering the O signal. The factory setting is for the O 4-20 mA signal to be internally powered.

2. SW2. The two settings are internally or externally powering the COMB 4-20 mA signal. The factory setting is for the COMB 4-20 mA signal to be internally powered.

3. SW3. The factory sets this switch as follows:

(a) Position 1 determines the O

4-20 mA signal rail limit. The settings are high, 21.1 mA, or low, 3.5 mA. The factory setting is at high,

21.1 mA.

4-20 mA

OCX 4400

Section 5, HART/AMS or Appendix A, Local Operator Interface (LOI) for additional information.

1. HART/AMS. If using HART/AMS, from the DETAILED SETUP menu, select O

CALIBRATION.

(a) From O

High TG. Enter the percentage of O

(b) From O

Low TG. Enter the percentage of O

menu, select COMB CALIBRATION.

(d) From COMB CALIBRATION, se-

lect High TG. Enter the percentage of CO used for high COMB test gas.

2. LOI. If using the LOI, from the SETUP menu select CALIBRATION.

CALIBRATION, select

used for the high O2 test gas.

CALIBRATION, select

used for the low O2 test gas.

(b) Position 2 determines the COMB

4-20 mA signal rail limit. The settings are high, 21.1 mA, or low,

3.5 mA. The factory setting is at high, 21.1 mA.

(d) Position 4 is not used.

d. Set Test Gas Values

Using HART/AMS or optional LOI, set the test gas values used for calibration. Refer to

(a) From CALIBRATION, select O

High Gas. Enter the percentage of O

used for the high O2 test gas.

(b) Select the down arrow and the

next selection will be O Enter the percentage of O for the low O

test gas.

Low Gas.

used

the next selection will be Comb High Gas. Enter the percentage of O

used for the combustibles span

gas.

3-2 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 4

CALIBRATION

4-1 GENERAL

During a calibration, two calibration gases with known O gas with a known COMB concentration are applied to the OCX 4400. Slope and constant values are calculated to determine if the OCX 4400 is correctly measuring net concentrations of O and combustibles in the industrial process.

Before calibrating the OCX 4400, verify that the calibration gas parameters are correct by setting the test gas values used when calibrating the unit (Section 3, STARTUP AND OPERATION).

4-2 CALIBRATION METHODS

There are three types of calibration methods available to the OCX 4400; automatic, operatorinitiated automatic, and manual. Calibration commands and menus can be accessed by HART/AMS or by the optional LOI.

a. Automatic Calibration

concentrations and one calibration

If the OCX 4400 is equipped with calibration solenoids, the unit can be programmed to automatically calibrate without any operator action. Refer to Section 5, HART/AMS for information on automatic calibration setup via HART/AMS. Refer to Appendix A for information on automatic calibration setup via LOI.

HART/AMS menu tree. Refer to Figure 5-3 for the complete HART/AMS menu tree.

2. Select DIAG/SERVICE from DEVICE SETUP menu.

(a) Select CALIBRATE from the

DIAG/SERVICE menu.

(b) Select PERFORM CAL from CALI-

BRATE menu.

menu.

(d) Select the type of calibration de-

sired: O method, or O method from CAL menu.

3. LOI. To initiate a calibration using the LOI, perform the following steps on the LOI menu tree. Refer to Figure 11-3 for complete LOI menu tree.

(a) From the CALIBRATE SENSORS

menu, select PERFORM CALIBRATION.

(b) At the prompt, select the right ar-

row to initiate automatic calibration.

Cal method, COMB Cal

and COMB Cal

b. Operator Initiated-Automatic Calibration

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

1. HART/AMS. To initiate an automatic calibration by using HART/AMS, perform the following steps on the

Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-1

c. Manual Calibration

If a unit is not equipped with calibration solenoids, a calibration must be performed by an operator following prompts from the unit. Refer to Section 5, HART/AMS for information on manual calibration with HART/AMS. Refer to APPENDIX A for information on manual calibration with LOI.

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

4-2 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 5

HART/AMS

5-1 OVERVIEW

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

To interface with the OCX 4400, the HART Communicator requires a termination point along the O

4-20 mA current loop and a mini-

mum load resistance of 250 ohms between the communicator and the power supply. The HART Communicator accomplishes its task using a frequency shift keying (FSK) technique. With the use of FSK, high-frequency digital communication signals are superimposed on the 4-20 mA oxygen output signal. The communicator does not disturb the 4-20 mA signal since no net energy is added to the loop. HART information is not available on the COMB 4-20 mA output signal.

4-20 mA TERMINAL BLOCK

IN ELECTRONICS HOUSING

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

5-2 HART COMMUNICATOR SIGNAL LINE

CONNECTIONS

The HART Communicator can connect to the OCX 4400 oxygen analog output signal line at any wiring termination in the O

4-20 mA current

loop. There are two methods of connecting the HART Communicator to the signal line. For applications in which the signal line has a load resistance of 250 ohms or more, refer to method

1. For applications in which the signal line load resistance is less than 250 ohms, refer to method 2.

a. Method 1, For Load Resistance > 250

Ohms. Refer to Figure 5-1 and the following steps to connect the HART Communicator to a signal line 250 ohms or more of load resistance.

≥

RL 250Ω

A OUT 1 A OUT 1 +

LOOP CONNECTORS

SERIALPORT & BATTERY

CHARGERMUST

NOTBE USED IN

HAZARDOUSAREAS

LOOPCONNECTORS

HART COMMUNICATOR

REAR PANEL

O2 4-20 mA SIGNAL LINE

USEINTERFACE 002750013 ONLY

SERIAL PORT

HART

COMMUNICA TOR

ANALOG OUTPUT DEVICE

LEAD SET

29790018

Figure 5-1. Signal Line Connections, > 250 Ohms Lead Resistance

Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-1

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

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

Using the supplied lead set, connect the HART Communicator in parallel to the OCX

4400. Use any wiring termination points in the oxygen analog output 4-20 mA signal line.

b. Method 2, For Load Resistance

< 250 Ohms

Refer to Figure 5-2 and the following steps to connect the HART Communicator to a signal line with less than 250 ohms load resistance.

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

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

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

5-3 HART COMMUNICATOR PC

CONNECTIONS

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

IN ELECTRONICS HOUSING

A OUT 1 A OUT 1 +

NOTE:

THE SIGNAL LOOP MUST BE BROKEN TO INSERT TH E O PTIONAL 250 OH M

4-20 mA TERMINAL BLOCK

LOOP CONNECTORS

SERIALPORT & BATTERY

CHARGERMUST

NOTBE USED IN

HAZARDOUSAREAS

HART COMMUNICATOR

REAR PANEL

LOOPCONNECTORS

O2 4-20 mA SIGNAL LINE

USEINTERFACE 002750013 ONLY

SERIAL PORT

LOAD RESISTOR.

RL < 250Ω

ANALOG OUTPUT DEVICE

HART

COMMUNICA TOR

Figure 5-2. Signal Line Connections, < 250 Ohms Lead Resistance

250 OHM

LOAD

RESISTOR

(NOTE 1 )

29790017

5-2 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

5-4 OFF-LINE AND ON-LINE OPERATIONS

The HART Communicator can be operated both off-line and on-line.

a. Off-line operations are those in which the

communicator is not connected to the OCX

4400. Off-line operations can include interfacing the HART Communicator with a PC (refer to applicable HART documentation regarding HART/PC applications.

b. In the on-line mode, the communicator is

connected to the oxygen 4-20 mA analog output signal line. The communicator is connected in parallel to the OCX 4400 or in parallel to the 250 ohm load resistor.

c. The opening menu displayed on the LCD is

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

5-5 MENU TREE FOR HART COMMUNICATOR/

OCX 4400 APPLICATIONS

This section consists of a menu tree for the HART Communicator. This menu is specific to OCX 4400 applications.

Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-3

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

PROCESS VARIABLES

DEVICE SETUP O2 O2 AO COMB COMB AO

DIAG/SERVICE

VIEW FLD DEV VARS

VIEW FLD DEV mV

STATUS

O2 O2 temp Electronics temp COMB COMB temp SL temp Pressure

O2 mV O2 temp mV Elec temp V COMB Act mV COMB Ref mV Pressure V SL temp mV

Status Group 1

Status Group 2

Status Group 3

Status Group 4

OCX 4400

O2 Thermocouple Error O2 Cell Temperature Low O2 Cell Temperature High O2 Cell Temperature Very High O2 Heater Open O2 Cell Open O2 Cell Bad O2 Slope Error

O2 Constant Error O2 Calibration Failed Landusky Error High Electronics Temperature EEPROM Corrupt

Sample Line Thermocouple Error Sample Line Temperature Low Sample Line Temperature High Sample Line Temperature Very High Sample Pressure Low Absolute

Combustibles Cell Error Combustibles Cell Chamber Temperature Low Combustibles Cell Chamber Temperature High Combustibles Cell Chamber Temperature

Very High Combustibles Slope Error CO Constant Error CO Cal Failed

O2 AO Saturated COMB AO Saturated

O2 AO Fixed COMB AO Fixed

Cal methods O2 Optrak TG? COMB Optrak TG? CalState

CalState TimeRemain Present O2 Present COMB

O2 Cal slope O2 Cal Const O2 Cell Imp COMB Slope COMB Const

Reset O2 constants Reset COMB constants

(CONTINUED ON

SHEET 2)

LOOP TEST

CALIBRATE

D/A TRIM

AO Saturated

AO Fixed

Max Electronics Temp

O2 Loop test method COMB Loop test

method

PERFORM CAL

CAL STATUS

LAST CAL CONSTANTS

RESET CAL CONSTANTS

O2 D/A trim method COMB D/A trim method

Figure 5-3. Menu Tree for HART/AMS on the OCX 4400 (Sheet 1 of 3)

O2 Cal method COMB Cal method O2 and COMB Cal

method

34070014

5-4 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

(CONTINUED FROM

SHEET 1)

BASIC SETUP

DETAILED SETUP

Ta g

SELECT RANGE

DEVICE INFORMATION

S/W VERSION INFO

SENSORS

O2 URV COMB URV

Dev id Descriptor Message Date Final asmbly num O2 Snsr s/n COMB Snsr s/n

Ver Chk sum Bld num Bld date

COMB

O2 O2 Temp Electronics temp O2 mV O2 Temp mV Elec temp V

COMB COMB TEMP COMB ACT MV COMB REF MV SL TEMP SL temp mV Pressure Pressure V

(CONTINUED ON

SHEET 3)

SIGNAL CONDITION

OUTPUT CONDITION

LINE VOLTAGE

(CONTINUED ON

SHEET 3)

O2 % range COMB % range

ANALOG OUTPUT

HART OUTPUT

100 115 220

O2 Analog Output

COMB Analog Output

Poll addr Num req preams

O2 AO

O2 Alrm typ

O2 Range

COMB AO

COMB Alrm typ

COMB Range

Figure 5-3. Menu Tree for HART/AMS on the OCX 4400 (Sheet 2 of 3)

3.5 mA

21.1 mA

4-20 20-4

3.5 mA

21.1 mA

4-20 20-4

34070015

Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-5

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

(CONTINUED FROM

SHEET 2)

DETAILED SETUP

(CONTINUED FROM

SHEET 2)

O2 SETUP

O2 CALIBRATION

COMB SETUP

COMB CALIBRATION

ALARM RELAY

BLOWBACK

SLOPE

O2 CONST O2 T90

High TG Low TG OPtrak TG? TG Time Purge Time Sol. Present Cal Intrvl h Next Cal Time h

COMB SLOPE

COMB CONST COMB T90

High TG OPtrak TG? TG Time Purge Time Sol. Present Cal Intrvl h Next Cal Time h

EVENT 1 EVENT 2 EVENT 3 Alarm State

Enabled Interval Duration Purge Time State Do Blowback

OP Locks

OP Tracks

OP Locks

OP Tracks

None In Cal O2 Temp O2 Heater O2 Cell Bad Cal Failed Hi Elect Temp Unit Fail SL Temp SL Pressure Comb Temp All

REVIEW

DEVICE INFORMATION

CAL INFO

DEVICE CONFIG

OUTPUT CONFIG

Manufacturer Model Dev id Ta g Descriptor Message Date Final asmbly num O2 Snsr s/n COMB Snsr s/n Fld dev rev Hardware rev Software rev Universal rev

O2 Cal Info

COMB Cal Info

O2 Device Config

COMB Device Config

O2 URV COMB URV Poll addr

Num req preams

OPtrak TG? TG Time Purge Time Low TG High TG Slope O2 const O2 cell Imp

OPtrak TG? TG Time Purge Time High TG COMB slope COMB const

SLOPE

O2 CONST O2 T90

COMB SLOPE

COMB CONST COMB T90

34070016

Figure 5-3. Menu Tree for HART/AMS on the OCX 4400 (Sheet 3 of 3)

5-6 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

5-6 HART COMMUNICATOR MANUAL O2 CAL

METHOD

To perform a manual O

calibration using the

HART Communicator, use the following procedure. If necessary, use the menu tree in Figure 5-3 (sheet 1 of 3) for reference.

NOTE

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

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

a. From the PERFORM CAL screen, select

menu item 1, CAL, then menu item 1, O

Cal method to access the O2 calibration method.

Failure to remove the OCX 4400 from automatic control loops prior to performing this procedure may result in a dangerous operating condition.

Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O

, as the calibration status updates.

f. When CALSTATE displays APPLY HIGH O

GAS, return to the O2 CAL procedure. When the “Loop should be removed from automatic control” warning appears, press OK.

g. At the APPLY HIGH O

GAS status prompt,

select menu item 2, NEXT CAL STEP. When the status displays HIGH O

GAS

FLOW, select menu item 4, EXIT, to leave the O

CAL procedure.

h. From the PERFORM CAL screen, view

menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O

, as the

calibration status updates.

i. When CALSTATE displays STOP GAS, re-

turn to the O

CAL procedure.

b. In the first O

CAL method screen, a “Loop

should be removed from automatic control” warning appears. Remove the OCX 4400 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

c. The next several screens indicate the cali-

bration status. At each of the following status prompts, select menu item 2, NEXT CAL STEP:

COMPLETE APPLY LOW O LOW O

GAS FLOW

GAS

d. At this point, select menu item 4, EXIT, to

leave the O

CAL procedure.

e. From the PERFORM CAL screen, view

menu item 4, CALSTATE, to monitor the calibration status as it updates.

j. When the “Loop should be returned to

automatic control” message appears, return the OCX 4400 to the automatic control loops previously removed and press OK.

k. At the STOP GAS status prompt, select

menu item 2, NEXT CAL STEP. When the status displays PURGING, select menu item 4, EXIT, to leave the O

CAL procedure.

l. From the PERFORM CAL screen, view

, as the

calibration status updates.

m. When CALSTATE displays COMPLETE,

the calibration is finished.

Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-7

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

5-7 HART COMMUNICATOR MANUAL COMB

CAL METHOD

To perform a manual combustibles calibration using the HART Communicator, use the following procedure. If necessary, use the menu tree in Figure 5-3 (sheet 1 of 3) for reference.

NOTE

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

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

a. From the PERFORM CAL screen, select

menu item 1, CAL, then select menu item 2, COMB Cal method to access the combustibles calibration method.

Failure to remove the OCX 4400 from automatic control loops prior to performing this procedure may result in a dangerous operating condition.

calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 4, PRESENT COMB, as the calibration status updates.

f. When CALSTATE displays APPLY COM-

BUSTIBLES GAS, return to the O procedure. When the “Loop should be removed from automatic control” warning appears, press OK.

g. At the APPLY COMBUSTIBLES GAS status

prompt, select menu item 2, NEXT CAL STEP. When the status displays COMBUSTIBLES GAS FLOW, select menu item 4, EXIT, to leave the COMB CAL procedure.

h. From the PERFORM CAL screen, view

i. When CALSTATE displays STOP GAS, re-

turn to the COMB CAL procedure.

CAL

b. In the first COMB CAL method screen, a

“Loop should be removed from automatic control” warning appears. Remove the OCX 4400 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

c. The next several screens indicate the cali-

bration status. At each of the following status prompts, select menu item 2, NEXT CAL STEP:

COMPLETE APPLY HIGH O HIGH O2 GAS FLOW

d. At this point, select menu item 4, EXIT, to

leave the COMB CAL procedure.

e. From the PERFORM CAL screen, view

menu item 4, CALSTATE, to monitor the

5-8 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

GAS

j. When the “Loop should be returned to

automatic control” message appears, return the OCX 4400 to the automatic control loops previously removed and press OK.

k. At the STOP GAS status prompt, select

menu item 2, NEXT CAL STEP. When the status displays PURGING, select menu item 4, EXIT, to leave the COMB CAL procedure.

l. From the PERFORM CAL screen, view

m. When CALSTATE displays COMPLETE,

the calibration is finished.

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

5-8 HART COMMUNICATOR MANUAL O2 AND

CO CAL METHOD

To perform a manual O

and COMB calibration

using the HART Communicator, use the following procedure. If necessary, use the menu tree in Figure 5-3 (sheet 1 of 3) for reference.

NOTE

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

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

a. From the PERFORM CAL screen, select

menu item 1, CAL, then menu item 3, O and COMB Cal method to access the O

and COMB calibration method.

Failure to remove the OCX 4400 from automatic control loops prior to performing this procedure may result in a dangerous operating condition.

CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O

, as the

calibration status updates.

f. When CALSTATE displays APPLY HIGH O

GAS, return to the O2 and COMB CAL procedure. When the “Loop should be removed from automatic control” warning appears, press OK.

g. At the APPLY HIGH O

GAS status prompt,

select menu item 2, NEXT CAL STEP. When the status displays HIGH O

GAS

FLOW, select menu item 4, EXIT, to leave the O

and COMB CAL procedure.

h. From the PERFORM CAL screen, view

, as the

calibration status updates.

i. When CALSTATE displays APPLY COM-

BUSTIBLES GAS, return to the O

and

COMB CAL procedure. When the “Loop should be removed from automatic control” warning appears, press OK.

b. In the first O

CAL method screen, a “Loop

should be removed from automatic control” warning appears. Remove the OCX 4400 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

c. The next several screens indicate the cali-

bration status. At each of the following status prompts, select menu item 2, NEXT CAL STEP:

COMPLETE APPLY LOW O LOW O

GAS FLOW

GAS

d. At this point, select menu item 4, EXIT, to

leave the O

CAL procedure.

e. From the PERFORM CAL screen, view

menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1,

j. At the APPLY COMBUSTIBLES GAS status

prompt, select menu item 2, NEXT CAL STEP. When the status displays COMBUSTIBLES GAS FLOW, select menu item 4, EXIT, to leave the O

and COMB CAL

procedure.

k. From the PERFORM CAL screen, view

l. When CALSTATE displays STOP GAS, re-

turn to the O

and COMB CAL procedure.

m. When the “Loop should be returned to

automatic control” message appears, return the OCX 4400 to the automatic control loops previously removed and press OK.

Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-9

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

n. At the STOP GAS status prompt, select

menu item 2, NEXT CAL STEP. When the status displays PURGING, select menu item 4, EXIT, to leave the O procedure.

o. From the PERFORM CAL screen, view

p. When CALSTATE displays COMPLETE,

the calibration is finished.

5-9 AUTOMATIC CALIBRATION SETUP

VIA HART

NOTE

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

Use the following procedure to specify a time interval (in hours) at which the OCX 4400 will automatically calibrate the OCX 4400.

and COMB CAL

, and menu item

OCX 4400

When setting automatic calibration times, the CAL INTRVL and the NEXT CAL TIME should be set so that O and combustibles are NOT calibrated simultaneously.

NOTE

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

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

a. From the DEVICE SETUP screen, select

DETAILED SETUP.

b. From the DETAILED SETUP screen, select

CALIBRATION. From the O2 CALIBRA-

TION screen, select menu item 7, CAL INTRVL.

c. At the prompt, input a time interval (in

hours) at which an automatic O will occur and press ENTER.

d. From the DETAILED SETUP screen, select

COMB CALIBRATION.

calibration

To disable the automatic calibration feature for oxygen or combustibles, enter a 0 for the CAL INTRVL for both O

and COMB.

e. From the COMB CALIBRATION screen,

select menu item 7, CAL INTRVL.

f. At the prompt, input a time interval (in

hours) at which an automatic COMB cali-

If desired, the NEXT CAL TIME can be changed

bration will occur and press ENTER. to synchronize a calibration at a specific day or time.

5-10 LINE VOLTAGE SELECTION USING HART

COMMUNICATOR

Use the procedure in Section 3-1b to select or change the line voltage configuration using the HART Communicator.

5-10 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 6

OPERATION

6-1 OVERVIEW

Once the OCX 4400 is installed, set up, and calibrated properly, the unit is ready for operation.

6-2 OPERATION

Before the OCX 4400 can begin normal operation, all heaters must be up to temperature be-

fore the unit begins to take measurements of the sample gas. During normal operation, the unit will perform continuous measurements of the sample gas. The unit is performing properly if there are no alarms present. If the unit is equipped with an LOI, the normal operating display will show a value for Oxygen and Combustible concentrations measured. If an LOI is not used, values for Oxygen and Combustibles are available through HART.

Rosemount Analytical Inc. A Division of Emerson Process Management Operation 6-1

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

6-2 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 7

MAINTENANCE AND SERVICE

7-1 OVERVIEW

This section contains the procedures to maintain and service the OCX 4400.

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

It is recommended that the OCX 4400 be removed from the stack for all service activities. The unit should be allowed to cool and be taken to a clean work area. Failure to comply may cause severe burns.

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

(e) Disconnect and remove the two

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

(f) Disconnect and remove the O

COMB 4-20 mA signal leads from the 4-20 mA signal output terminal block.

(g) If used, disconnect and remove the

external relay leads from the alarm output relay terminal.

(h) Remove insulation to access the

mounting bolts. Unbolt the OCX 4400 from the stack and take it to a clean work area.

(i) Allow the unit to cool to a comfort-

able working temperature.

2. Replace.

(a) Bolt the OCX 4400 to the stack

and install insulation. Remove cover on electronics housing.

and

7-2 OCX 4400 REMOVAL/REPLACEMENT

a. OCX 4400 with Integrally Mounted

Electronics

1. Remove.

(a) Turn off power to the system.

(b) Shut off the calibration gases at

the cylinders and the instrument air.

instrument air lines from the electronics housing.

(d) Remove the cover from the elec-

tronics housing to expose the electronics housing terminal blocks, Figure 7-1.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-1

(b) If used, connect external relay

leads to the alarm output relay terminal, Figure 7-1.

mA signal leads to the 4-20 mA signal output terminal block.

(d) 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 connection with two nuts. Attach a separate line from the ground stud to the G terminal on the power input terminal block.

and COMB 4-20

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

(e) Replace cover on electronics

housing.

(f) Connect the calibration gasses and

instrument air lines to the electronics housing.

4-20 mA

SIGNAL OUTPUT

TERMINAL B L OCK

AC POWER INPUT

TERMINAL B L OCK

(g) Turn on the calibration gasses at

the cylinders and turn on instrument air.

(h) Restore power to the system.

ELECTRONICS HOUSING

(COVER REMOVED)

ALARM OUTPUT

RELA Y TERMINAL

AOUT 2+

COMB

4-20 mA

SIGNAL

AOUT 2-

AOUT 1-

AOUT 1+

O2 4-20 mA SIGNAL

Figure 7-1. Electronics Housing Terminal Blocks

COMMON

29790029

7-2 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

O2 CELL HEATER

SL HEATER

SENSOR HOUSING

(COVER REMO VED)

EMI

BOOT

HEATER POWER

TERMINAL B L OCK

COMB CELL HEATER

ELECTRONICS CABLE

(TO ELECTRONICS HOUSING)

SENSOR/THERMOCOUPLE

TERMINAL B L OCK

(1)

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

(5)

(2)

YELLOW

RED

(3)

BLUE

WHITE

(4)

WHITE

GREEN

(6)

WHITE

RED

YELLOW

RED

GRA Y

BLACK

PURPLE

ORANGE

BROWN

Figure 7-2. Sensor Housing Terminal Blocks

b. OCX 4400 with Split Mounted

Electronics

1. Remove Sensor Housing.

(a) Turn power off to the system.

(b) Shut off the calibration gases at the

cylinders and the instrument air.

ence air, eductor air, and dilution

air lines from the sensor housing.

(d) Remove the cover from the sensor

housing to expose the sensor

housing terminal blocks, Figure

7-2.

(e) Disconnect the electronics cable

from sensor/thermocouple terminal

block and the heater power termi-

nal block.

(f) Remove insulation to access the

mounting bolts. Unbolt the sensor

ELECTRONICS

CABLE PORT

O2 T/C +

PROBE

O2 T/C -

SL T/C +

SL T/C -

BLUE

RED

O2 MV -

O2 MV +

COMB ACTIVE -

COMB ACTIVE +

WHITE

RTD DRIVE

COMB REF -

COMB REF +

34070011

housing from the stack and take it to a clean work area.

(g) Allow the sensor housing to cool

to a comfortable working temperature.

2. Replace Sensor Housing

(a) Bolt the sensor housing to the

stack and install insulation.

(b) With the cover removed, connect

the electronics cable to sensor/ thermocouple terminal block and the heater power terminal block, Figure 7-2. Install sensor housing cover.

ence air, eductor air, and dilution air lines to the sensor housing.

(d) Turn on the calibration gases at the

cylinders and instrument air.

(e) Restore power to the system.

RTD RETURN

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-3

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

HEATER POWER

TERMINAL B L OCK

ORANGE

GRA Y

BROWN

COMB CELL HEATER

RED

BLACK

PURPLE

O2 CELL HEATER

SL HEATER

ELECTRONICS CABLE

(UP TO 150 FT)

NOTE: KEEP TWISTED

PAIRS TOGETHER

SPLIT-ELECTRONICS HOUSING

(COVER REMO VED)

ELECTRONICS

CABLE PORT

SENSOR/THERMOCOUPLE

TERMINAL B L OCK

(2)

(1)

O2 T/C +

(3)

RED

O2 T/C -

GND

YELLOW

SL T/C +

RED

SL T/C -

BLUE

O2 MV +

WHITE

GND

O2 MV -

YELLOW

(4)

WHITE

GREEN

COMB ACTIVE -

COMB ACTIVE +

(5)

YELLOW

COMB REF +

Figure 7-3. Split-Electronics Housing Cable Connections

(6)

RED

WHITE

GND

RTD DRIVE

COMB REF -

PRESSURE

SENSOR

FACTORY

WIRED

WHITE

RTD RETURN

PR SENSOR -

PR SENSOR +

34070025

+ 10 PR SRC

PR SRC RTN

3. Remove Split-Electronics Housing.

(a) Turn power off to the system.

(b) Shut off the calibration gases at the

cylinders and the instrument air.

put terminal block. Remove the ground lead from the ground stud.

(f) Disconnect and remove the O

COMB 4-20 mA signal leads from

and

the 4-20 mA signal output terminal

block. gas input lines and instrument air line from the split-electronics housing. Disconnect the calibration gas outlet and instrument air outlet

(g) If used, disconnect and remove the

external relay leads from the alarm

output relay terminal. lines from the split-electronics

housing.

(d) Remove the cover from the elec-

tronics housing to expose the electronics housing terminal

(h) Disconnect the electronics cable

from sensor/thermocouple terminal

block and the heater power termi-

nal block, Figure 7-3.

blocks, Figure 7-1.

(i) Remove the split-electronics

(e) Disconnect and remove the two

power leads from the AC power in-

7-4 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

housing from mounting and move

to a suitable work area.

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

4. Replace Split-Electronics Housing.

(a) Mount split-electronics housing on

wall or pole within distance of electronics cable used. Remove cover.

(b) Connect electronics cable to the

sensor/thermocouple and heater power terminal blocks, Figure 7-3.

(d) Connect the O

and COMB 4-20

mA signal leads to the 4-20 mA signal output terminal block.

(e) If used, connect external relay

leads to the alarm output relay terminal.

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

cell

replacement kit (Table 10-1).

The O

cell replacement kit contains an O

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

Do not remove items from the packaging until they are ready to be used. Special tools needed for this procedure are part of an available O

Cell Disassembly Kit (Table

10-1).

Use heat-resistant gloves and clothing when removing the OCX 4400. Do not attempt to work on any sensor housing components until they have cooled to room temperature. Components can be as hot as 2600°F (1427°C). This can cause severe burns.

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

(f) Replace cover on electronics

housing.

(g) Connect the three calibration gas

input lines and the instrument air input line to the split-electronics housing. Connect the calibration gas outlet line and instrument air outlet line to the split-electronics housing.

(h) Turn on the calibration gasses at

the cylinders and instrument air.

(i) Restore power to the system.

7-3 SENSOR HOUSING COMPONENT

REPLACEMENT

Each of the following procedures details how to remove and replace a specific component located in the sensor housing of the OCX 4400.

a. O

Cell Replacement

This paragraph covers oxygen sensing cell replacement. Do not attempt to replace the cell until all other possibilities for poor per-

Do not remove the O2 cell unless certain it needs to be replaced. Removal may damage the cell and platinum pad. Only remove the O2 cell if it is to be replaced.

1. Follow the instructions in paragraph 7-2a.1 to remove the OCX 4400 from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 6-2b1 to remove the sensor housing.

2. Remove sensor housing cover (1, Figure 7-4).

3. Remove reference air tube (2) from sensor housing (23).

4. Disconnect and tag all O

assembly (3)

wire leads from the sensor housing terminal blocks.

5. Remove the O

assembly (3) from sen-

sor housing (23).

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-5

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

1. Cover

2. Reference Air Tube Assembly

3. O

4. Gasket

5. Internal Ring

6. Eductor Air Tube

7. Dilution Air Tube

8. Screw

9. Washer

10. Bracket

11. COMB Extractive Tube

12. Heater

13. Screw

14. Plate

15. COMB Sensor

16. Gasket

17. Preheater

18. Heater

19. Connector

20. Eductor

21. COMB Sensor Holder

22. Thermocouple

23. Sensor Housing

24. Probe Tube

25. Exhaust Tube

26. Filter

27. Adapter

28. Check Valve (with

blowback option only)

29. Plug (without blowback option)

30. Screw

34070022

8 9

Figure 7-4. Sensor Housing, Exploded View

7-6 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

6. Remove four allen cap screws (14, Figure 7-5) from O move O

cell and gasket (12). The cell

cell (13) and re-

flange has a notch that may be used to gently pry the flange away from heater tube (11). Note that the pad on the end of contact/thermocouple assembly (4) will sometimes fuse to O

cell is fused to the contact pad,

the O

push the O

cell back into the heater

cell (13). If

tube (against spring pressure) and quickly twist the O

cell. The cell and

contact pad should separate. If the contact pad stays fused to the cell, a new contact/thermocouple assembly must be installed.

7. Remove and discard gasket (12). Clean the mating surface of heater tube (11). Remove burrs and raised surfaces with a block of wood and crocus cloth.

8. Rub a small amount of anti-seize compound on both sides of new gasket (12).

9. Assemble O

cell (13), gasket (12), and

heater tube (11). Make sure the calibration gas passage holes line up with each other in all components. Apply a small amount of anti-seize compound to the screw threads and use screws (14) to secure assembly. Torque to 35 in-lbs (4 N·m).

10. Apply anti-seize compound to threads of O

assembly (3, Figure 7-4) and

sensor housing (23). Replace graphoil gasket (4) with new gasket in kit. Reinstall O

11. Reconnect the wire leads from O

assembly in sensor housing.

assembly (3) to the sensor housing terminal blocks. Refer to Figure 7-2 if necessary.

12. Replace reference air tube (2) in sensor housing (23). Ensure that the open end of reference air tube extends into O

assembly (3).

13. Follow the instructions in paragraph 7-2a.2 to install the OCX 4400 into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.2.

14. Turn on power and after the OCX 4400 stabilizes, calibrate the unit. If new components have been installed, repeat calibration after 24 hours of operation.

b. O

Heater Strut Assembly and

Contact/Thermocouple Assembly Replacement

This paragraph covers O

heater strut and

contact/thermocouple replacement. If heater strut or contact/thermocouple replacement is needed, order the replacement parts from Table 10-1.

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

1. Follow the instructions in paragraph 7-2a.1 to remove the OCX 4400 from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.1 to remove the sensor housing.

2. Remove sensor housing cover (1, Figure 7-4).

3. Remove reference air tube (2) from sensor housing (23).

4. Disconnect and tag O

assembly (3)

wire leads from the sensor housing terminal blocks.

5. Remove four screws (1, Figure 7-5) and washers (2) securing O

heater

strut assembly (3) to heater tube (11). The spring tension should release and the heater strut assembly moves up.

6. Carefully slide heater strut assembly (3) out of heater tube (11).

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-7

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

1. Screw

2. Washer Heater Strut Assembly

3. O

4. Contact/Thermocouple

Assembly

5. Strut Bracket

6. Spring

7. Spring Clip

8. Screw

9. Washer

10. Heater Assembly

11. Heater Tube

12. Gasket Cell

13. O

14. Cap Screw

15. Cell Kit (includes 12,

13, and 14)

34070009

Figure 7-5. O2 Assembly, Exploded View

7-8 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

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

7. If replacing contact/thermocouple assembly (4), use a pencil to mark location of spring clip (7) before removing. Squeeze tabs on spring clip to remove. Retain spring clip and spring (6); replace if damaged.

8. While carefully handling new contact and thermocouple assembly (4), lay old assembly next to new one. Transfer pencil marks to new assembly.

9. Carefully guide new contact and thermocouple assembly (4) through strut bracket (5), spring (6), and spring clip (7) until spring clip reaches pencil mark.

10. Carefully slide new O

heater strut as-

sembly (3) into heater tube (11). Press down on the back plate of strut bracket (5) to ensure spring (6) tension is present to hold contact pad against O (13). Secure with four screws (1) and washers (2).

11. Reconnect the O

assembly wire leads

to the sensor housing terminal blocks. Refer to Figure 7-2 if necessary.

cell

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

2. Remove sensor housing cover (1, Figure 7-4).

3. Disconnect and tag the four wire leads from COMB sensor (15) to the sensor/thermocouple terminal block.

4. Remove two screws (13) securing plate (14) to holder (21). Remove the plate.

5. Remove old COMB sensor (15) and gasket (16). Replace with new COMB sensor and gasket from replacement kit.

12. Replace reference air tube (2, Figure 7-4) in sensor housing (23). Ensure the open end of the reference air tube extends into O

assembly (3).

13. Replace sensor housing cover (1).

14. Follow the instructions in paragraph 7-2a.2 to install the OCX 4400 into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.2.

c. COMB Sensor Replacement

This paragraph covers combustible sensor replacement. Do not attempt to replace the sensor until all other possibilities for poor performance have been considered. If sensor replacement is needed, order the combustibles sensor replacement kit from Table 10-1.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-9

Use care when handling the new combustibles sensor. The RTDs are fragile.

6. Secure new COMB sensor (15) with plate (14) to holder (21) with two screws (13).

7. Reconnect the four wire leads from COMB sensor (15) to the sensor/thermocouple terminal block. Refer to Figure 7-2 if necessary.

8. Replace sensor housing cover (1, Figure 7-4).

9. Follow the instructions in paragraph 7-2a.2 to install the OCX 4400 into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.2.

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

10. Turn on power and monitor COMB sensor output. After the OCX 4400 stabilizes, calibrate the unit. If new components have been installed, repeat calibration after 24 hours of operation.

7-4 ELECTRONICS HOUSING COMPONENT

REPLACEMENT

OCX 4400

When installing a solenoid, do not overtighten. Damage to the solenoid may occur.

4. Install the new solenoid base. Be careful not to overtighten. Install the new washer and coil assembly and secure with the top nut.

Each of the following procedures details how to remove and replace a specific component located in the electronics housing of the OCX

4400.

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

a. Solenoid Replacement

The OCX 4400 has three optional calibration gas solenoids (HI COMB, HI O

) and a standard, 3-way instrument air

solenoid. Use the following procedure to replace one of four solenoids (11, Figure 7-6) in the electronics housing. The replacement procedure for all solenoids is similar.

1. Follow the instructions in paragraph 7-2a to remove the OCX 4400 from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.3 to remove the electronics housing.

, LO

5. Connect the leads to the proper terminations on the solenoid power terminal block. Refer to Figure 2-5 if necessary.

6. Follow the instructions in paragraph 7-2a.2 to install the OCX 4400 into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.4 to install electronics housing.

b. Pressure Sensor Replacement

Use the following procedure to replace pressure sensor (10, Figure 7-6).

2. Tag and remove pressure sensor (10) leads from sensor/thermocouple terminal block.

3. Place a 3/4 in. deep socket over pressure sensor (10) and remove from electronics housing base (12).

2. Tag and disconnect wire leads from solenoid (11, Figure 7-6) to be replaced at the solenoid power terminal block.

3. Remove top nut of solenoid (11) securing the coil assembly and washer to the solenoid base. Remove the coil assembly, including the leads, and washer. Place a 13/16 in. deep socket over the solenoid base and remove from electronics housing base (12).

7-10 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

When installing the pressure sensor, do not overtighten. Damage to the pressure sensor may occur.

4. Install new pressure sensor (10) into electronics housing base (12).

5. Connect leads to the proper terminations on the sensor/thermocouple terminal block. Refer to Figure 2-6 if necessary.

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

6. Follow the instructions in paragraph 7-2a.2 to install the OCX 4400 into the stack or duct. If installing a split-

1. Cover

2. Screw

3. Local Operator Interface

4. Washers

5. Spacer

6. Connector

7. Electronics Box

8. Screw

9. Washer

10. Pressure Sensor

11. Solenoid

12. Electronics Housing Base

13. Screw

14. Nameplate

15. Fitting

16. Instrument Air Solenoid

17. Vent Tube

mounted unit, follow the instructions in paragraph 7-2b.4 to install electronics housing.

4 5

34070005

Figure 7-6. Electronics Housing Exploded View

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-11

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

c. Interface Board Replacement

Use the following procedure to replace interface board (22, Figure 7-7).

1. Follow the instructions in paragraph 7-2a.1 to remove the OCX 4400 from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.3 to remove the electronics housing.

2. If equipped, remove local operator interface (3, Figure 7-6) by removing three screws, double washers (4), spacers (5) and connector (6) securing local operator interface to electronics box assembly (7).

3. Remove four screws (24, Figure 7-7) and lock washers (23) securing interface board (22) to the electronics assembly. Install new interface board to electronics box assembly (7, Figure 7-6) with four screws and lock washers.

4. If equipped, install local operator interface (3, Figure 7-6) to electronics box assembly (7) with three screws (2), double washers (4), spacers (5), and connector (6).

5. Follow the instructions in paragraph 7-2a.2 to install the OCX 4400 into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.4 to install electronics housing.

d. Power Supply Board, Microprocessor

Board and Analog Board Replacement

Use the following procedure to replace power supply board (14, Figure 7-7), microprocessor board (11), or analog board (6). Replace boards as needed.

2. Follow the instructions in paragraph 7-4c to remove interface board (22, Figure 7-7).

3. Disconnect and tag wire leads from solenoids and the pressure sensor to the solenoid power and sensor/ thermocouple terminal blocks.

4. If replacing components on an integral electronics mounted unit, disconnect and tag wire leads from the sensor housing at the sensor/thermocouple, heater power, and solenoid power terminal blocks.

5. Remove four screws (8, Figure 7-6) and washers (9) securing electronics box (7) to electronics housing base (12). Remove the electronics box.

6. Remove four screws (1 and 20, Figure 7-7) and washers (2 and 19) securing top (3) and bottom (21) of electronics box together. Power supply board (14), microprocessor board (11), and analog board (6) stack can now be removed.

7. Remove four screws (25 and 32), lock washers (26 and 31) and standoffs (27) securing power supply board (14) and micro-processor board (11).

8. Remove two screws (4), washers (5), and standoffs (10) securing analog board (6) and microprocessor board (11) to power supply board (14). Note board orientation for proper reassembly. Separate analog board and microprocessor board from power supply board. Note orientation of connector (28).

9. Remove two screws (29), washers (30), nuts (35), washers (34), and standoffs (33) securing analog board (6) to microprocessor board (11). Note board orientation for proper reassembly. Separate analog board (6) from microprocessor board (11). Note orientation of connectors (7, 8 and 9).

7-12 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

1. Screw

2. Washer

3. Electronics Box, Top

4. Screw

5. Washer

6. Analog Board

7. Connector

8. Connector

9. Connector

10. Standoff

11. Microprocessor Board

12. Covers

13. Standoff

14. Power Supply Board

15. Fuse - Heater, F2

16. Fuse Holder

17. Washer

18. Standoff

19. Washer

20. Screw

21. Electronics Box, Bottom

22. Interface Board

23. Washer

24. Screw

25. Screw

26. Washer

27. Standoff

28. Connector

29. Screw

30. Washer

31. Washer

32. Screw

33. Standoff

34. Washer

35. Nut

36. Fuse - Power Supply, F1

34070012

Figure 7-7. Electronics Box, Exploded View

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-13

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

10. Assemble analog board (6) to microprocessor board (11) in proper orientation with connectors (7, 8 and 9), two screws (29), washers (30), standoffs (33), washers (34), nuts (35), two screws (4), washers (5), and standoffs (10).

11. Assemble analog board (6) microprocessor board (11) stack to power supply board (14) with four screws (25 and

32), lock washers (26 and 31) and standoffs (27). Install two standoffs (18) and washers (17) through bottom of power supply board (14) into standoffs (13).

12. Place assembled electronics board stack into electronics box bottom (21). Assemble bottom and top (3) of electronics box with four screws (1 and 20) and washers (2 and 19).

13. Assemble interface board (22) to the assembled electronics box with four screws (24) and washers (23).

17. Follow the instructions in paragraph 7-2a.2 to install the OCX 4400 into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.4 to install electronics housing.

e. Fuse Replacement

The OCX 4400 has two fuses (15 and 36, Figure 7-7) on power supply board (14). The power supply fuse, F1 is to the left of the AC power terminal block. The heater fuse, F2 is to the right of the AC power terminal block. Both fuses are accessible through holes in the electronics box. Refer to Table 10-1 for replacement fuse specifications. Perform the following procedure to check or replace fuses.

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

14. If equipped, install local operator interface (3, Figure 6-6) to electronics box assembly (7) with three screws (2), double washers (4), spacers (5), and connector (6).

15. If replacing components on an integral electronics mounted unit, connect wire leads from the sensor housing to sensor/thermocouple, heater power, and solenoid power terminal blocks.

16. Connect wire leads from the solenoids and the pressure sensor to the solenoid power and sensor/thermocouple terminal blocks.

1. Turn off power to the system.

2. Remove electronics housing cover (1, Figure 7-6).

3. Remove fuseholder (16, Figure 7-7) by pushing in the top and turning 1/4 turn counterclockwise. Remove fuse (15).

4. After checking or replacing fuse (15), install fuseholder (16) by pushing in the top and turning 1/4 turn clockwise.

5. Repeat for fuse (36).

7-14 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 8

TROUBLESHOOTING

d. Electrostatic Discharge

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

8-1 GENERAL

The troubleshooting section describes how to identify and isolate faults that may develop in the OCX 4400. When troubleshooting the OCX 4400, reference the following information.

a. Grounding

It is essential that adequate grounding precautions are taken when installing the system. Thoroughly check both the probe and electronics to ensure the grounding quality has not degraded during fault finding. The system provides facilities for 100% effective grounding and the total elimination of ground loops.

b. Electrical Noise

The OCX 4400 has been designed to operate in the type of environment normally found in a boiler room or control room. Noise suppression circuits are employed on all field terminations and main inputs. When fault finding, evaluate the electrical noise being generated in the immediate circuitry of a faulty system. Also, ensure all cable shields are connected to earth.

c. Loose Integrated Circuits

Electrostatic discharge can damage the ICs used in the electronics. Before removing or handling the processor board or the ICs, ensure you are at ground potential.

e. Line Voltage Configuration

See Section 3-1b for specific instructions.

8-2 ALARM OUTPUT

a. The OCX 4400 is equipped with a set of

alarm relay contacts on the microprocessor board in the electronics housing. This set of dry contacts can be connected to any customer supplied relay device, 30 VDC, 30 mA maximum. Any fault condition in the OCX 4400 will trip the alarm relay.

b. The optional SPA with HART programmable

alarm indicates LOW O

, HIGH COMB,

Calibration Status, and Unit Failure. For more information refer to Appendix B, SPA with HART Alarm.

8-3 FAULT INDICATIONS

Faults in the OCX 4400 are indicated by messages displayed on the HART communicator or LOI. The following faults are as they appear on the HART communicator. Messages on the LOI may appear slightly different.

a. O

Thermocouple Error

thermocouple voltage is not within speci-

fied operating parameters.

The OCX 4400 uses a microprocessor and

b. O

Cell Temperature Low

supporting integrated circuits (IC). If the

electronics are handled roughly during in-

cell temperature is less than 726°C.

stallation or located where subjected to severe vibration, the ICs could work loose.

c. O

Cell Temperature High

Before troubleshooting the system, ensure

all ICs are fully seated.

Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 8-1

cell temperature is greater than 746°C.

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

d. O2 Cell Temperature Very High

cell temperature is greater than 820°C.

The OCX 4400 requires a power reset.

Heater Open

e. O

The O

f. O

The O

cell heater is not operating properly.

Cell Open

cell voltage is not within specified

parameters.

g. O

Cell Bad

Unit is not in warm up or power up mode and O

cell impedance value is greater than

500 ohms.

Slope Error

h. O

The newly calculated O

slope is greater

than 57.5 or less than 34.5 mV/Dec.

Constant Error

i. O

The newly calculated O

constant is greater

than 20 mV or less than –20 mV.

o. Sample Line Temperature High

The unit is not in warm up mode and the sample line temperature is greater than 383°F (195°C).

p. Sample Line Temperature Very High

Sample line temperature is greater than 220°C. The OCX 4400 requires a power reset.

q. Sample Pressure Low Absolute

The sample pressure is low.

r. Comb Cell Error

The temperature of the reference side or the active side of the comb cell is below -40°F (-40°C) (84.27 mV) or above 752°F (400°C) (247.04 mV).

s. Comb Cell Chamber Temperature Low

The unit is not in warm up mode and the combustible cell chamber is less than 554°F (290°C).

t. Comb Cell Chamber Temperature High

Calibration Failed

j. O

Slope Error or an O2 Constant Error

An O

occurred during the last calibration.

k. High Electronics Temperature

The electronics temperature is above 85°C.

l. EEPROM Corrupt

The EEPROM has been corrupted by some means.

m. Sample Line Thermocouple Error

Sample line thermocouple voltage is not within specified parameters.

n. Sample Line Temperature Low

Unit is not in warm up mode and the sample line temperature is less than 311°F (155°C).

The unit is not in warm up mode and the combustible cell chamber temperature is greater than 590°F (310°C).

u. Comb Cell Chamber Temperature

Very High

Combustible cell chamber temperature is greater than 400°C. The OCX 4400 requires a power reset.

v. Comb Slope Error

The newly calculated combustible slope is greater than 3000 or less than 0 ppm/mV.

w. Comb Constant Error

The newly calculated combustible constant is not within acceptable parameters.

x. Comb Calibration Failed

The Comb Slope Error has occurred during the last calibration.

8-2 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 9

RETURN OF MATERIAL

9-1 If factory repair of defective equipment is re-

quired, proceed as follows:

a. Secure a return authorization number from

a Rosemount Analytical Sales Office or representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted.

In no event will Rosemount be responsible for equipment returned without proper authorization and identification.

b. Carefully pack defective unit in a sturdy box

with sufficient shock absorbing material to insure that no additional damage will occur during shipping.

c. In a cover letter, describe completely:

1. The symptoms from which it was determined that the equipment is faulty.

2. The environment in which the equipment has been operating (housing, weather, vibration, dust, etc.).

5. Complete shipping instructions for return of equipment.

6. Reference the return authorization number.

d. Enclose a cover letter and purchase order

and ship the defective equipment according to instructions provided in Rosemount Return Authorization, prepaid, to:

Rosemount Analytical Inc. RMR Department 1201 N. Main Street Orrville, Ohio 44667

If warranty service is requested, the defective unit will be carefully inspected and tested at the factory. If failure was due to conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount's option, and an operating unit will be returned to the customer in accordance with shipping instructions furnished in the cover letter.

3. Site from which equipment was removed.

4. Whether warranty or nonwarranty service is requested.

Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 9-1

For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

9-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

IB-106-440 Rev. 1.0

OCX 4400

SECTION 10

REPLACEMENT PARTS

Table 10-1. Replacement Parts

FIGURE and

INDEX No. PART NUMBER DESCRIPTION

6-4, 24 5R10183H02 Pipe, 18 in. (457mm) 316 Stainless steel 6-4, 24 5R10183H06 Pipe, 18 in. (457mm) Inconel 600 6-4, 24 5R10227G01 Pipe, 18 in. (457mm) Ceramic 6-4, 24 5R10183H03 Pipe, 3 ft. (0.91m) 316 Stainless steel 6-4, 24 5R10183H07 Pipe, 3 ft. (0.91m) Inconel 600 6-4, 24 5R10227G02 Pipe, 3 ft. (0.91m) Ceramic 6-4, 24 5R10183H04 Pipe, 6 ft. (1.83m) 316 Stainless steel 6-4, 24 5R10183H08 Pipe, 6 ft. (1.83m) Inconel 600 6-4, 24 5R10183H05 Pipe, 9 ft. (2.7m) 316 Stainless steel 6-4, 25 5R10183H01 Pipe, Exhaust 6-4, 1 5R10219G01 Housing Cover, Blind 6-4, 4 and 6-5, 15 4851B45G01 O2 Cell Replacement Kit, all sizes

4851B45G02 O2 Cell Disassembly Kit

6-4, 26 5R10246H02 Filter, 20 micron

October 2000

6-5, 3 5R10211G01 Heater Strut Assy. 6-5, 4 4851B44G01 Contact and Thermocouple Assy.

4851B46G01 Combustibles Sensor Replacement Kit 6-6, 1 5R10199G01 Housing Cover, Window 6-6, 11 1A97905H01 Solenoid Valve 6-6, 16 1A97905H02 Instrument Air Solenoid 6-6, 10 4851B47G01 Pressure Sensor 6-4, 12 1A99371H01 Combustibles Chamber Heater 6-4, 18 1A99371H03 Flange Heater 6-4, 22 1A98151H03 Sample Line Thermocouple Assy.

6-7, 6 3D39816G01 Analog Board 6-7, 14 3D39786G01 Power Supply Board 6-7, 11 3D39788G01 Processor Board

6-7, 22 5R10235G01 Local Operator Interface Board 6-6, 3 4851B49G02 Local Operator Interface

6-7, 15 1A97913H18 Heater Fuse, Slo-Blo 6.3 amp 250 VAC, F2 6-7, 36 1A97913H04 Power Supply Fuse, Slo-Blo 1.0 amp 250 VAC, F1 2-1 3535B18H02 ANSI Gasket 1-1, 3 3535B30G02 Adapter Plate 218 w/shield to ANSI OCX 1-1, 3 3535B30G08 FLG Adapter Assy. 132 to ANSI OCX 1-1, 3 3535B31G01 OCX/132 Adapter Plate (DIN)

771B635H02 Flowmeter, 0.2-2 SCFH

771B635H08 Flowmeter, 0.05-0.5 SCFH 2-7 275431-006 Gage, 2 in., 0 -15

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 10-1

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

Table 10-1. Replacement Parts (Continued)

FIGURE and

INDEX No. PART NUMBER DESCRIPTION

1-1, 5 263C152G01 Reference Gas Set

1A99119H01 Oxygen Bottles 0.4% Balance N2

1A99119H02 Oxygen Bottles 8.0% Balance N2

1A99119H06 CO Bottle 1000 ppm, Balance N2

1A99120H02 Regulator for Oxygen

1A99120H03 Regulator for Combustibles

1A99119G06 Wall Mount Bracket for Gas Bottles 1-1, 5 1A99119G05 Test Gas Regulator Kit 1-1, 5 1A99119G04 Test Gas Bottles Kit 1-1, 6 1A99518G01 Blowback Kit 1-1, 2 275D9EI5D0000 275 HART Communicator with 12 meg buffer

1-4 4851B41G01 Cable, 20 ft. (6m) NEMA 1-4 4851B41G02 Cable, 40 ft. (12m) NEMA 1-4 4851B41G03 Cable, 60 ft. (18m) NEMA 1-4 4851B41G04 Cable, 80 ft. (24m) NEMA 1-4 4851B41G05 Cable, 100 ft. (30m) NEMA 1-4 4851B41G06 Cable, 150 ft. (45m) NEMA

OCX 4400

11-4 1A99292H01 Moore Industries SPA for HART Alarm

10-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

APPENDIX A. LOCAL OPERATOR INTERFACE (LOI)

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SECTION 11

APPENDICES

11-1 FORWARD

This appendix describes the installation and operation of the Local Operator Interface (LOI) for the OCX 4400.

CONNECTOR

11-2 INSTALLATION

The LOI mounts to the LOI connector on the LOI board located at the end of the electronics box in the electronics housing of an OCX 4400 Oxygen/Combustibles Transmitter Figure 11-1. There are four matching connectors on the back of the LOI assembly that allow the LOI to be oriented as desired by the user.

ELECTRONIC HOUSING

(COVER REMO VED)

LOI

ASSEMBLY

ELECTRONICS

BOX

LOI

BOARD

29790024

Figure 11-1. LOI Assembly Mounting

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 11-1

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

11-3 OPERATION

The LOI assembly, Figure 11-2, allows local communication with the electronics. The LOI uses infrared sensors near the selection arrows to move the cursor between menus and menu items. The LCD display window shows the operating display, which consists of the O COMB ppm, current menu, or item selected. When a blinking cursor is displayed, the UP or DOWN arrows can be used to increase or decrease the value for that item.

SELECTION

ARROWS

% and

LCD DISPLA Y WINDOW

11-4 LOI MENU TREE

This section consists of a menu tree for the LOI on the OCX 4400, Figure 11-3. This menu is specific to the OCX 4400.

a. First Column Sub-Menus

From the operating display, O COMB ppm, the right arrow is the only option to move into the first column sub-menus of the LOI menu tree. The first column contains three sub-menus: SENSOR DATA, Figure 11-3 sheet 1 of 3, CALIBRATE SENSORS, Figure 11-3 sheet 2 of 3, and SETUP, Figure 11-3 sheet 3 of 3. From the operating display, SENSOR DATA is displayed when the right arrow is selected. Use the down arrow to move to the other first column sub-menus.

b. Second Column Sub-Menus

From the first column sub-menus, selecting the right arrow moves the display into the second column sub-menus. The up and down arrows allow the display to move to the second column sub-menus of the first column sub-menu selected. The left arrow moves the display back to the first column sub-menu selected.

% and

c. Third, and Fourth Column Sub-Menus

SELECTION

ARROWS

Figure 11-2. Local Operator Interface (LOI)

Assembly

From the second column sub-menus, selecting the right arrow moves the display into the third column sub-menus. The third column sub-menu may be another menu or a list of parameters. The up and down arrows allow the display to move to the different parameters or menus. The third or fourth column may be a parameter list. When a parameter list is displayed, the cursor will blink. The up and down arrows allow the value for the parameter displayed to be changed.

11-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

34070017

O2 X.XX% COMB XXX ppm

SENSOR DATA

(CONTINUED ON

SHEET 2)

TEMP/ PRESSURES

VOLTAGES

OUTPUT VALUES

O2 Sensor _____ C

Comb Sensor _____ C

Sample Block Temp _____ C

Sample Block Press _____

Elect Temp _____ C

Max Elect Temp _____

O2 Sensor ___mV

O2 Sensor T/C ___mV

Comb Delta ___

Comb Reference ___mV

Elect Temp ___mV

Sample Block T/C ___mV

Sample Line Pressure ___V

O2 Analog _____%

Comb Analog _____%

O2 Analog ____mA

Comb Analog ____mA

Figure 11-3. Menu Tree for Local Operator Interface on the OCX 4400 (Sheet 1 of 3)

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 11-3

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

(CONTINUED FROM

SHEET 1)

CALIBRATE

(CONTINUED ON

SHEET 3)

Figure 11-3. Menu Tree for Local Operator Interface (LOI) on the OCX 4400 (Sheet 2 of 3)

DO CALIBRATION

VIEW CONSTANTS

CALIBRATION STATUS

If Auto Cal in Setup, YES Press --> To Start

Automatic Calibration

Start Auto Cal O2 High O2 Gas Time Left: 0:00 _____% O2 O2 Cell mV _____mV Low Gas Time Left: 0:00 _____% O2 O2 Cell mV _____mV Calibration Complete

Purging 0:00

O2 Calibration Pass/Fail

Start Auto Cal Comb Low Gas Time Left: 0:00 _____Comb Comb Cell Output _____ High Gas Time Left: 0:00 _____Comb Comb Cell Output _____ Calibration Complete

Purging 0:00

Comb Calibration

If Auto CAL in Setup, NO

--> To Start O2

Press

Manual Calibration

Switch on High Test Gas

--> When ready

Press High Gas _____% O2

-->

Press When ready Turn Off High Test Gas and

On Low Test Gas

-->

Press When ready Low Gas ______% O2

--> When O2

Press

reading is stable

Turn Off Low Test Gas

-->

Press When ready O2 Calibration Pass/Fail

--> When Probe has

Press

returned to process

--> To Start Comb

Press

Manual Calibration

Switch On Low Test Gas

-->

Press When Ready Low Gas _____ Comb

--> When Comb

Press

reading is stable

Turn Off Low Test Gas and

on High Test Gas

-->

Press When ready High Gas _____Comb

--> When Comb

Press

reading is stable

Turn Off High Test Gas

-->

Press When ready Comb Calibration Pass/Fail

--> When Probe has

Press

returned to process

LATEST CALIBRATION

PREVIOUS CALIBRATION

Calibrate Step Calibrate Time O2 Next Calib O2 Slope O2 Constant Comb Next Calib Comb Slope Comb Constant

Pass/Fail

OCX 4400

O2 Slope _______

O2 Constant _______

O2 Cell Imped _______

Comb Slope _______

Comb Constant _______

Pre O2 Slope _______

Pre O2 Constant _______

Pre Comb Slope _______

Pre Comb Constant _______

34070018

11-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

(CONTINUED FROM

SHEET 2)

SETUP

CALIBRATION

PARAMETERS

BLOWBACK

O2 High Gas _____% O2

O2 Low Gas _____% O2

Comb Test Gas _____% O2

Got Solenoids Yes/No

O2 Output Tracks Yes/No

Comb

Out Tracks Yes/No

O2 Cal Interval XDXH

Comb Cal Interval XDXH

Next Cal XH

Comb Next Cal XH

Gas Time 0:00

Purge Time 0:00

Line Voltage _____

O2 Slope _____ mV/D

O2 Constant _____ mV

Comb Slope _____

Comb Constant _____

Blow Bk Present Yes/No

Blow Bk Intvl 99999 min

Blow Bk Durat 99999 sec

Blow Bk Purge 999 sec

Do Blow Back Yes/No

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

ALARM RELAY

ANALOG OUTPUTS

SOFTWARE

Figure 11-3. Menu Tree for Local Operator Interface (LOI) on the OCX 4400 (Sheet 3 of 3)

11-5 AUTOMATIC CALIBRATION SETUP

Use the following procedure to setup the OCX 4400 with the LOI for automatic calibration. If necessary, use the menu tree in Figure 11-3 for reference. The unit must be equipped with calibration solenoids to use automatic calibration.

Trigger 1 Event Trigger 2 Event Trigger 3 Event

O2 Type 20-4 mA

Comb Type 20-4 mA

O2 Range 0-VAR (40% Max.)

Comb Range 50,000 ppm

Do O2 Out Trim Do COMB Out Trim

Version Checksum Build Number Build Date Test Code

4-20 mA

HART

a. From the operating display select SETUP

first column sub-menu.

b. From the SETUP first column sub-menu,

select CALIBRATION second column submenu.

Off All Comb Temp Sample Pr Sen Sample Ln Temp Unit Fail Hi Elect Temp Calib Fail O2 Cell Bad O2 Htr Open O2 Cell Temp In Calibrtn Off

34070019

NOTE

c. From the CALIBRATION second column

sub-menu, select the third column parame-

Automatic calibration is only available

ter list by selecting the right arrow.

on units equipped with calibration solenoids.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 11-5

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

d. Scroll down to the fifth item Auto Cal. If the

unit is equipped with calibration solenoids and timed automatic calibration is desired, select Yes.

e. Use the down arrow to select the next item

Output Tracks. Select Yes or No to de-

termine if updates to the O

lock value will

take place.

f. Use the down arrow to select the next item

CO Output Tracks. Select Yes or No to determine if updates to the COMB lock value will take place.

g. Use the down arrow to select the next item

Cal Interval. Enter the amount of time in days and hours that is desired between automatic calibrations.

h. Use the down arrow to select the next item

Next Cal. Enter the amount of time in hours until the next automatic calibration. Select the left arrow three times to move back to the operating display.

11-6 MANUAL CALIBRATION WITH LOI

Use the following procedure to perform a manual calibration with the LOI. If necessary, refer to the menu tree in Figure 11-3 if needed. Once the manual calibration procedure is initiated by the LOI, a series of prompts will appear giving instructions to the operator.

a. From the operating display select CALI-

BRATE SENSORS first column sub-menu.

b. From the CALIBRATE SENSORS first col-

umn sub-menu select the PERFORM CALIBRA-TION second column sub-menu.

e. “Switch on High Test Gas”. Turn on the high

test gas.

f. Press the right arrow when the high O

test

gas reading is stable.

g. Turn off the high O

low O

test gas. Press the right arrow when

test gas and turn on the

ready.

h. Press the right arrow when the low O

test

gas reading is stable.

i. Turn off the low O

test gas. Press the right

arrow when ready.

j. The LOI will display “O

Calibration

Pass/Fail”.

k. Press the right arrow when the probe has

returned to the process.

l. Press the right arrow to start manual com-

bustibles calibration.

m. Turn on the high O

test gas. High O2 test

gas is used for the low COMB test gas. Press the right arrow when ready.

n. Press the right arrow when the low com-

bustibles reading is stable.

o. Turn off low COMB test gas and turn on

high COMB test gas. Press the right arrow when ready.

p. Press the right arrow when the high COMB

reading is stable.

q. Turn off the high COMB test gas. Press the

right arrow when ready.

c. From the PERFORM CALIBRATION sec-

ond column sub-menu select the third column parameter list by selecting the right

r. “Comb Calibration Pass/Fail” will appear.

Press the right arrow when the probe has returned to the process.

arrow.

d. Scroll down to the “If Auto CAL in Setup,

NO” parameter and select the right arrow to start manual O

11-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

calibration.

OCX 4400

APPENDIX B. SPA WITH HART ALARM

11-7 FORWARD

This appendix describes the Moore Industries SPA with HART Alarm option available for the OCX 4400.

11-8 DESCRIPTION

The Moore Industries SPA with HART, Figure 11-4, is a 4-wire (line or mains powered), siteprogrammable, digital process alarm. It connects to a standard HART field device, and provides up to four, fully configurable, contactclosure outputs based on readings of the HART digital data. The four outputs from the OCX 4400 which are recognized by the SPA are Low O

, High COMB, Calibration Status, and Unit

Failure.

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

11-9 INSTALLATION

Refer to the Users’ Reference Manual for the SPA with HART provided with the SPA for detailed installation, setup, and operation information.

Figure 11-4. SPA With HART Alarm

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 11-7

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

APPENDIX C. BLOWBACK

11-10 FORWARD

This appendix describes the operation of the blow-back option for the OCX 4400 Oxygen/Combustibles Transmitter.

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

11-11 INSTALLATION

Installing an OCX 4400 Oxygen/Combustibles Transmitter with the blowback option is identical to installation without the blowback option with the exception of the pneumatic piping. The blowback option requires the addition of a blowback solenoid, regulator and gage, and check valve.

Refer to Figure 11-5 for the piping arrangement for the OCX 4400 Oxygen/Combustibles Transmitter with the blowback option.

11-12 SETUP

There are three settings that need to be specified to set up the blowback option. These are the blowback interval, duration, and purge time. These settings are available through HART from the Device Setup > Detailed Setup > Blowback menu. Using the LOI, these settings are accessible from the Setup > Blowback menu.

Interval – Length of time between blow-

backs.

Duration – Length of time blowback air is

activated.

Purge Time – Length of time after blowback is

complete before oxygen/ combustibles readings are considered valid.

11-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400

BLOWBACK

INPUT

Instruction Manual

IB-106-440 Rev. 1.0

October 2000

SENSOR

HOUSING

CAL GAS

INPUT

CAL GAS

ROTOMETER

ELECTRONICS

CAL GAS

HI COMB

INPUT

CHECK

VALVE

5 SCFH

HOUSING

CAL GAS

HI O2 INPUT

EDUCTOR

AIR INPUT

CALIBRA TION GAS OUTLET

INSTR UMENT

INSTRUMENT

CAL GAS

LO O2

INPUT

AIR IN

AIR OUT

REF AIR

INPUT

DILUTION AIR

INPUT

BLOWBACK

SOLENOID

NORMALLY

OPEN

DILUTION AIR

ROTOMETER

0.1 SCFH

SET REGU L ATOR TO 35 PSIG

NORMALLY

CLOSED

SET REGULATOR TO 55 PSIG

0 - 60 PSIG

34070020

Figure 11-5. Blowback Connections

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 11-9

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

APPENDIX D. IS BARRIER

11-13 FORWARD

The IS BARRIER feature is currently under development.

OCX 4400

11-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

SECTION 12

INDEX

This index is an alphabetized listing of parts, terms, and procedures having to do with the Hazardous Area Oxygen/Combustibles Transmitter. Every item listed in this index refers to a location in the manual by one or more page numbers.

Accessories, 1-9, 1-11 Alarm Output, 2-6, 8-1 AMS, 1-1, 1-3 Analog Outputs, 1-4

Calibration Gas, 2-9 Calibration Methods, 4-1 COMB Sensor Replacement, 7-9 Contact/Thermocouple, 7-7

Defaults, 3-0 Dilution Air, 1-6

Eductor, 1-6 Eductor Air, 1-6 Electronics Housing, 1-3, 7-11

Faults, 8-1 Fuses, 7-14

Line Voltage, 1-4, 2-6 Local Operator Interface (LOI), 1-4

Maintenance, 7-1

Nernst Equation, 1-1

O2 Cell Replacement, 7-5 Operation, 6-1

Package Contents, 1-1 Pressure Sensor Replacement, 7-10 Probe Lengths, 1-3 Probe Materials, 1-3 Product Matrix, 1-1, 1-10, 1-11

Reference Air, 1-6 Reference Air Set, 2-10 Removal/Replacement, 7-1 Replacement Parts, 10-1

HART, 1-3 HART Communicator, 1-1, 1-4, 5-1 HART Menu Tree, 5-3 Heater Strut, 7-7

Installation

Electrical, 2-6 Mechanical, 2-1 Pneumatic, 2-9

Instrument Air, 1-6, 2-9

Rosemount Analytical Inc. A Division of Emerson Process Management Index 12-1

Sensor Housing, 1-3, 7-6 Sensors, 1-3, 1-6 Solenoid Replacement, 7-10 Solenoids, 1-6 SPA with HART Alarm, 8-1 Specifications, 1-8 Switch Configuration, 3-1 System Features, 1-3

Test Gas Values, 3-2

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

12-2 Index Rosemount Analytical Inc. A Division of Emerson Process Management

ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure of Rosemount to comply with the warranty provisions, whether claims by the purchaser are based in contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deterioration due to environment. Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the warranty period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be subject to the same warranty as is extended to Rosemount by the original manufacturer.

At the time of installation it is important that the required services are supplied to the system and that the electronic controller is set up at least to the point where it is controlling the sensor heater. This will ensure, that should there be a delay between installation and full commissioning that the sensor being supplied with ac power and reference air will not be subjected to component deterioration.

3582/8-01

Instruction Manual

IB-106-440 Rev. 1.0 October 2000

OCX 4400

Part no. _______________ Serial no. _______________ Order no. _______________

Emerson Process Management

Rosemount Analytical Inc. Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd.

1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947

http://www.processanalytic.com

Fisher-Rosemount GmbH & Co.

Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd.

Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount

Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

Rosemount OCX 4400 O2 / Combustibles Transmitter-Rev 1.0 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

HIGHLIGHTS OF CHANGES

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

PREFACE

SAFETY INSTRUCTIONS

1-2 SYSTEM OVERVIEW

1-3 OCX 4400 SPECIFICATIONS

2-2 ELECTRICAL INSTALLATION

2-3 PNEUMATIC INSTALLATION

4-2 CALIBRATION METHODS

5-4 OFF-LINE AND ON-LINE OPERATIONS

OPERATION

7-2 OCX 4400 REMOVAL/REPLACEMENT

8-2 ALARM OUTPUT

8-3 FAULT INDICATIONS

APPENDIX A. LOCAL OPERATOR INTERFACE (LOI)

APPENDIX B. SPA WITH HART ALARM

APPENDIX C. BLOWBACK

APPENDIX D. IS BARRIER