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

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Page 1

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

OXYGEN/COMBUSTIBLES TRANSMITTER

http://www.processanalytic.com

Page 2

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

Page 3

HIGHLIGHTS OF CHANGES

Effective January, 2003 Rev. 2.0

Page Summary

Throughout Changed IB revision number and release date. Pages 1-4, 1-5 Identified test gas solenoids as optional equipment. Pages 1-8, 1-9 Updated specifications and specification notes. Page 2-1 Expanded drip loop usage to vertical and horizontal installations. Page 2-2 Component view correcti o n s t o Fi g u re 2-1. Page 2-4

Page 2-5 Expanded drip loop usage to vertical and horizontal installations. Page 2-6

Page 2-8 Corrected electrical wiring diagram discrepancies in Figure 2-7. Page 2-9 Revised paragraph 2-3 to link installation instructions to applicable equip-

Page 2-10

Page 2-11 Deleted CAUTION paragraph from NOTE. Page 3-0 Revised Figure 3-1 to correctly identify location of SW1 and SW2. Page 3-1 Revised “Initial Power Up” procedure. Page 7-3 Corrected electrical wiring diagram discrepancies in Figure 7-2. Page 7-4 Corrected electrical wiring diagram discrepancies in Figure 7-3. Page 7-6 Revised Figure 7-4 to clarify location of exhaust tube during assembly and

Page 7-8 Revised Figure 7-5 to include parts availability note. Page 7-11 Revised Figure 7-6 to include parts availability note. Pages 7-12 thru 7-14

Page 8-1 Revised paragraph 8-3 to describe new troubleshooting table. Page 8-2 Replaced fault listings with troubleshooting table. Pages 10-1, 10-2 Corrected discrepancies in Table 10-1, Replacement Parts. Page 11-1 Revised Section 11 list of Appendices A, B, C, and D. Pages A-3 thru A-6 Revised/corrected LOI menu tree displays. Pages B-1 thru B-6 Added SPA setup instructions. Pages C-1, C-2 Revised/clarified blowback installation instructions and illustration. Pages D-1, D-2 Added IS Barrier installation/wiring instructions and illustration.

Revised adapter plate view, Figure 2-3, to simplify recommendations. Added new Figure 2-4 to show electronics housing wall/pole mounting kit.

Added reference to Appendix D for OCX with IS Barrier wiring. Revised alarm relay contact description.

ment options. Revised/changed Figure 2-8 to show pneumatic installation requirements for OCX with reference air option (only).

Revised Figure 2-9 to show pneumatic installation requirements for OCX with reference air and cal gas solenoid options.

to include parts availability note.

Deleted replacement procedures for electronics package components. Added electronics package replacement procedure. Revised Figure 7-7 and fuse replacement procedure.

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OCX 4400

PREFACE............................................................................................................................1

Definitions ............................................................................................................................1

Safety Instructions ...............................................................................................................2

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

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

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

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

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

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

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

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

2-4 Initial Startup.................................................................................................................. 2-11

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

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

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

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

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

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

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

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

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

5-3 HART Communicator PC Connections ........................................................................... 5-3

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

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

5-6 HART Communicator Manual O

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

5-8 HART Communicator Manual O

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

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

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

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

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

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

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

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

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

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

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

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 Isolation .................................................................................................................. 8-1

Rosemount Analytical Inc. A Division of Emerson Process Management i

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Instruction Manual

IB-106-440 Rev. 2.0 January 2003

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

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

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

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

Appendix B SPA with HART Alarm ...............................................................................B-1

Appendix C Blowback....................................................................................................C-1

Appendix D IS Barrier ....................................................................................................D-1

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

OCX 4400

ii Rosemount Analytical Inc. A Division of Emerson Process Management

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OCX 4400

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

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

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

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

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

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

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

Figure 2-4. Wall or Pole Mounting of Electronics Housing....................................................... 2-4

Figure 2-5. Installation with Drip Loops .................................................................................... 2-5

Figure 2-6. Line Voltage and 4-20 mA Connections ................................................................ 2-7

Figure 2-7. Electrical Connections Between Split-Electronics and Sensor Housing ............... 2-8

Figure 2-8. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration) .... 2-9

Figure 2-9. Pneumatic Installation, OCX with Reference Air Set and Solenoids (with

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

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

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

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

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

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

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

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

Figure 7-5. O

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

Figure 7-7. Fuses, Exploded View ......................................................................................... 7-12

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

LIST OF ILLUSTRATIONS

Autocalibration) .................................................................................................... 2-10

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

LIST OF TABLES

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

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

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

Table 8-1. Troubleshooting ..................................................................................................... 8-2

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

Rosemount Analytical Inc. A Division of Emerson Process Management iii

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Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

iv Rosemount Analytical Inc. A Division of Emerson Process Management

Page 9

OCX 4400

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

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

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

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

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

PREFACE

DEFINITIONS

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

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

NOTE

Highlights an essential operating procedure, condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

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

NOTE TO USERS

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

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

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Instruction Manual

IB-106-440 Rev. 2.0 January 2003

FOR THE WIRING AND INSTALLATION

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

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

where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.

The integrity of all earth terminals must be maintained at all times.

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

OCX 4400

IMPORTANT

SAFETY INSTRUCTIONS

OF THIS APPARATUS

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

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

anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be

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

7. Where equipment or covers are marked with the symbol to the right, hazard-

ous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then only by trained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is a

danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to

the Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the follow-

ing standards: EN61010-1, IEC417, and ISO3864.

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

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OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1-1 COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS)

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

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

1-2 SYSTEM OVERVIEW

a. Scope

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

b. System Description

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

) and

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

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

EMF = KT log10 (P

Where:

1. P

is the partial pressure of the oxygen in

the measured gas on one side of the cell.

2. P

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.

1/P2

) + C

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

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Instruction Manual

IB-106-440 Rev. 2.0 January 2003

HART

MAN4275A00

October1994

Communicator

FISHER-ROSEMOUNT

OCX 4400

English

1. Instruction Bulletin

2. HART



Communicator Package (Optional)

3. Adapter Plate with Mounting Hardware and Gasket

4. OCX 4400 (Shown with Integral Electronics)

5. Reference Air and Calibration Set

6. Blowback Hardware (Optional)

Figure 1-1. Typical System Package

37020025

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

Page 13

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

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

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

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

c. System Configuration

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

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

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

d. System Features

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

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

(a) A HART Model 275

cell output voltage and sensi-

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.

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Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

4. Electronics are automatically configured for line voltages from 100 to 240 VAC.

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

(a) HART Interface. Each of the OCX

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

1 Rosemount Model 275 Hand-

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

2 Personal Computer (PC) -

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

3 Selected Distributed Control

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

(b) Optional Local Operator Interface

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

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

e. System Operation

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

sensor and continues on to

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 can also initiate and perform calibrations. Three test gasses and instrument air can be turned on and off by solenoids. Test gas flow to the sensors is regulated by a rotometer between the electronics and sensor housings. Instrument air is separated into eductor air, reference air, and dilution air. The instrument air solenoid does not allow air flow until the heaters are up to temperature. This minimizes the amount of sampled process flue gas being pulled into cold sensors causing condensation.

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

Page 15

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

SAMPLE

GAS

PROBE

EXHAUST

SENSOR

HOUSING

COMBUSTIBLES

SENSOR

EDUCTOR

ROTOMETER

5 SCFH

ELECTRONICS

PRESSURE

SENSOR

OPTIONAL TEST GAS

SOLENOIDS

INSTRUMENT AIR

SOLENOID

EDUCTOR AIR

HOUSING

CPU

POWER SUPPLY

LOW O2

TEST GAS

HIGH O2

TEST GAS

HIGH CO

TEST GAS

INSTRUMENT

AIR

REFERENCE AIR

DILUTION AIR

ROTOMETER

50 CC/MIN. (0.1 SCFH)

Figure 1-2. System Operation Diagram

37020001

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

Page 16

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

f. Handling the OCX 4400

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

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

g. System Considerations

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

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

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

NOTE

The electronics module is designed to meet NEMA 4X (IP55) and the electronic components are rated to temperatures up to 185°F (85°C).

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

INSTRUMENT

AIR

OCX 4400 O2/COMBUSTIBLES TRANSMITTER

WITH INTEGRAL ELECTRONICS

4-20 MA OUTPUT (TWISTED PAIRS)

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

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

TERMINATION IN

CONTROL ROOM

HART MODEL 275

HANDHELD INTERFACE

CUSTOMER’S LAPTOP

WITH ASSET MANAGEMENT

ASSET MANAGEMENT SOLUTIONS

SOLUTIONS

34070002

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

Page 17

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. 2.0

January 2003

ELECTRONICS

CABLE

(UP TO 150FT)

SPLIT-MOUNTED ELECTRONICS

GASES

DUCT

STACK

TEST

GAS

ROTOMETER

DILUTION AIR

ROTOMETER

4-20 mA OUTPUTS (2)

LINE VOLTAGE

INSTRUMENT AIR

SUPPLY (REF. GAS)

PRESSURE

REGULATOR

SPAN COMBUSTIBLES TEST GAS LOW O2 TEST GAS

HIGH O2 TEST GAS

34070003

Figure 1-4. Typical System Installation

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

Page 18

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

1-3 OCX 4400 SPECIFICATIONS

transmitter before choosing the mounting loca-

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

the product matrix for ordering information and

specific model number information. Table 1-3

contains information on accessories available

with the OCX 4400.

Table 1-1. OCX 4400 Specifications

Net O

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

, 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 Housing .................................... 32° to 392°F (0° to 200°C)

Electronics Housing ............................... 32° to 185°F (0° 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

(Ref. test gas bottles kit #1A99119G04) 8% O2, Balance N

1000 ppm CO, Balance N

NOTES:

(1)

Combustibles sensor is calibrated with CO gas. Sensor may be calibrated with H2 gas. Use in methane service is not recommended.

(2)

Operating temperature of electronics inside of electronics housing, as measured by a HART Communicator, or Emerson Process Management Asset Management Solutions (AMS) Software, or local operator interface. Operation below 0°C (32°F) requires that sensor housing be insulated.

, Balance N

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

Page 19

OCX 4400

Table 1-1. OCX 4400 Specifications (Continued)

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

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

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

regulated to 35 psi (241 kPa)

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

(20.95% O

), regulated to 35 psi (241 kPa)

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

(20.95% O

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

), regulated to 35 psi (241 kPa)

regulated to 55 psi (374 kPa)

Sensors Housing ........................................... NEMA 4X, IP55 with fitting and pipe on reference exhaust

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

Electronics Housing ...................................... NEMA 4X, IP55 with fitting and pipe on reference exhaust

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

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

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

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

software selectable, 3/4-14 NPT conduit port

Isolated Output:

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

COMB

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

Alarm Output Relay ....................................... No. 2, form C, double-pole, double-throw, 2A, 30 Vdc,

(software assignable)

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

Low Oxygen Alarm

High Combustibles Alarm Calibration Status Unit Failure

Power Consumption Limits:

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

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

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

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

NOTE:

All static performance characteristics are with operating variables constant. Specifications subject to change without notice.

and

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

Page 20

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

Table 1-2. Product Matrix

OCX44A O2 / Combustibles Transmitter

O2 / Combustibles Transmitter IB-106-440

Code Probe Length and Material

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

Code Probe Mounting Assembly

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

OCX 4400

Code Mounting Hardware - Stack Side

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

Code Mounting Hardware - Probe Side

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

OCX44A 11 10 1 1 (Cont’d) Example

(1)

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

Page 21

OCX 4400

Table 1-2. Product Matrix (Continued)

Cont'd Code Electronic Housing - NEMA 4X, IP55 HART Communications

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

Code Electronic Mounting

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. 2.0

January 2003

Code Accessories

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

Cont’d 08 01 11 Example

NOTES:

(1)

Where possible, specify SPS number; otherwise, provide details of the existing mounting plate as follows:

Plate with studs Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate. Plate without studs Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.

(2)

If the Local Operator Interface (LOI) is not implemented, remote access and functionality available via HART Communications (Model 275 Handheld Communicator) with Oxygen/Combustibles Device Description (DD) required.

(3)

If the IS Barrier option is selected, customer must also purchase the Moore Industries SPA (1A99292H01), current repeater backplane and adpater (intrinsic safety barrier kit p/n 1A99698G01) to maintain the 4 – 20 mA combustibles output.

Table 1-3. Accessories

PART NUMBER DESCRIPTION

1A99119H01 Oxygen Bottle 0.4%, balance N

1A99119H02 Oxygen Bottle 8.0%, balance N

1A99119H06 CO Bottle 1000 PPM and air, balance N

1A99120H02 Regulator for Oxygen (may need 2)

1A99120H03 Regulator for COMB

1A99119G06 Wall mount bracket for gas bottles

1A99119G05 Test gas regulators kit

1A99119G04 Test gas bottles kit

1A99292H01

Moore Industries SPA for Low O

Alarm, High

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

Page 22

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

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

Page 23

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

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

SECTION 2

INSTALLATION

readings. Therefore, either make the necessary repairs or install the transmitter upstream of any leakage.

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

a. Selecting Location

1. The location of the OCX 4400 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The probe must be positioned so the gas it measures is representative of the process. Best results are normally obtained if the transmitter is positioned near the center of the duct (40-60% insertion). Longer ducts may require several transmitters since the oxygen and combustibles can vary due to stratification. A point too near the wall of the duct, or the inside radius of a bend, may not provide a representative sample because of the very low flow conditions. The sensing point should be selected so the process gas temperature falls within the range of probe material used. Figure 2-1 through Figure 2-5 provide mechanical installation references. The ambient temperature inside the electronics housing must not exceed 185°F (85°C).

2. Check the flue or stack for holes and air leakage. The presence of this condition will substantially affect the accuracy of the oxygen and combustibles

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

b. Installation

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

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

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

4. For systems with split electronics, use the pole or wall mounting hardware as shown in Figure 2-4 to mount the electronics housing. Choose a location not to exceed the length of the electronics cable ordered.

5. For integral electronics installations, ensure the system cable drops vertically from the OCX 4400 and the conduit is routed below the level of the housings. Drip loops minimize the possibility that moisture will damage the electronics (Figure 2-5).

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

Page 24

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

NOTE

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

6. Insert sample and exhaust tubes through the opening in the mounting flange and bolt the unit to the flange.

NOTE:

ALL DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.

INSULATE IF EXPOSED TO AMBIENT WEATHER CONDITIONS

Uninsulated stacks or ducts may cause ambient temperatures in the electronics housing to exceed 185°F (85°C) and damage the electronics.

7. If insulation is removed to access the duct for OCX 4400 mounting, make sure to replace insulation afterward.

0.062 THK GASKET

3535B18H02

ANSI

3535B46H01

JIS

3535B45H01

DIN

TABLE 2. INSTALLATION/REMOVAL

PROBE

18 IN.

3 FT

6 FT

9 FT

DIM "A"

(406)

(864)34(1280)

(1778)

106

(2692)

DIM "B"

(2184)

122.38

(3108)

32.38

(822)

50.38

86.38

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

TOP VIEW

DIM “A”DIM “B”

FLANGE DIA

HOLE DIA

(4) HOLES EQ SP ON B.C. DIA.

TABLE 1. MOUNTING FLANGE

ANSI

4512C17H01

6.00

(153)

0.75

(20)

4.75

(121)

DIN

4512C19H01

7.28

(185)

0.71

(18)

5.71

(145)

JIS

4512C18H01

6.10

(155)

0.59

(15)

5.12

(130)

37020002

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

Page 25

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. 2.0

January 2003

JIS

"A"

"B"

THREAD

"C"

DIA

*PART NUMBERS FOR ADAPTER PLATES INCLUDE

ATTACHING HARDWARE.

NOTE: DIMENSIONS ARE

IN INCHES WITH MILLIMETERS IN PARENTHESES.

2.500 DIA (63.5)

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

6.00

(153)

0.625-11

4.75

(121)

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

Page 26

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

INSTALLATION FOR METAL

WALL STACK OR DUCT

NOTE: ONLY ADAPTER PLATE IS FURNISHED BY ROSEMOUNT.

WELD OR BOLT ADAPTER

PLATE TO METAL WALL

OF STACK OR DUCT.

JOINT MUST BE AIRTIGHT.

DIMENSIONS IN INCHES WITH MILLIMETERS IN PARENTHESES.

2.50 [63.5] MIN DIA HOLE IN WALL

STACK OR DUCT

METAL WALL

Figure 2-3. Adapter Plate Installation

INSTALLATION FOR MASONRY

WALL STACK CONSTRUCTION

BOLT ADAPTER

PLATE TO OUTSIDE

WALL SURFACE

JOINT MUST

BE AIRTIGHT

MASONRY

STACK WALL

FIELD WELD

PIPE TO

ADAPTER PLATE

PIPE 3.00

SCHEDULE 40,

SLEEVE LENGTH

OPTIONAL

37020003

NOTE:

* INDICATES ITEMS ARE INCLUDED

IN MOUNTING KIT P/N 4851B40G01.

*POLE

MOUNTING

CLAMP

*WALL OR POLE

MOUNT BRACKET

AND SCREWS

1/4-20 UNC X 2 IN. M-F STANDOFFS

RECOMMENDED FOR REAR PIPING

CLEARANCE WHEN WALL MOUNTING

(4 EACH BY CUSTOMER)

WALL MOUNTING BOLTS OR LAG SCREWS (4 EACH BY CUSTOMER)

Figure 2-4. Wall or Pole Mounting of Electronics Housing

ELECTRONICS

HOUSING

37020021

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

Page 27

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

CONDUIT

DRIP LOOPS

CONDUIT

DRIP LOOP

Figure 2-5. Installation with Drip Loops

DUCT

WALL

CONDUIT

DRIP LOOP

DUCT

WALL

37020004

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

Page 28

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

2-2 ELECTRICAL INSTALLATION

All wiring must conform to local and national codes. For reference, factory wired solenoid power connections are shown in Figure 2-6.

Disconnect and lock out power before connecting the unit to the power supply.

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

To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, connection to the main electrical power supply must be made through a circuit breaker (min 10 A) which will disconnect all current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 947.

NOTE

To maintain CE compliance, ensure a good connection exists between the mounting flange bolts and earth.

a. Connect Line Voltage

The OCX 4400 is software configured for 100 to 240 VAC line voltage at 50 to 60 Hz. The power supply requires no setup. Connect the line, or L wire, to the L terminal, and the neutral, or N wire, to the N terminal on the AC power input terminal block in the electronics housing. Connect the ground, or G wire, to the ground stud in the electronics

housing. Secure the connectio n with two nuts. Attach a separate line from the ground stud to the G terminal on the power input terminal block.

NOTE

Make sure line voltage is correctly set. See paragraph 3-1c for instructions.

b. Connect 4-20 mA Signals

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

option is provided, refer to Appendix D for alternate wiring instructions.

1. Oxygen (O

) 4-20 mA Signal. One

4-20 mA signal represents the O value. Superimposed on the O2 signal is the HART information accessible through a Model 275 Handheld Communicator or AMS software. The O signal is at the AOUT 1 terminals.

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

c. Alarm Output Relay

Connect any customer supplied relay input to the alarm output relay terminal. The alarm output relay terminal is a set of dry, no. 2, form C, double-pole, double-throw contacts with 30 mA and 24 VDC capacity.

d. Split-Electronics Connections

to Sensor Housing

If the OCX 4400 is configured with splitelectronics, make the following connections between the electronics and sensor housings with the electronics cable ordere d with the package (Figure 2-7). Braided cable is available in lengths up to 150 ft. (45 m).

1. Thermocouple Connections. Connect the electronics housing sensor/thermocouple terminals to the corresponding terminals in the sensor housing. The twisted wire pairs are numbered on the inner plastic wrapper. Keep tw isted pairs together and match the numbers and wire colors shown in Figure 2-7.

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

Page 29

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

Connect the twisted pair wire shields to the shield terminals.

2. Heater Power Connections. Use the purple, orange, black, gray, brown, and red stranded wires in the electronics cable to connect power to the three

SOLENOID POWER

TERMINAL B L OCK (FA CTORY WIRED)

GND

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)

heaters in the sensor housing. Match the wire colors to the corresponding heater power terminal blocks in the sensor and electronics housings as shown in Figure 2-7.

HI O2

PRESSURE

SENSOR

HI COMB

SOLENOID

LO O2

INST AIR

SOLENOID

AOUT 2-

AOUT 2+

COMB 4-20 mA SIGNAL

AOUT 1-

AOUT 1+

O2 4-20 mA SIGNAL

AC POWER INPU T TERMINAL B L OCK

F1 POWER

SUPPLY FUSE

F2 HEATER

FUSE

Figure 2-6. Line Voltage and 4-20 mA Connections

4-20 mA SIGNAL

OUTPUT

PORT

AC POWER

INPUT PORT

GROUND STUD

TWO NUTS

34070021

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

Page 30

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

SPLIT-ELECTRONICS HOUSING

HEATER POWER

TERMINAL BLOCK

GRAY

BROWN

COMB CELL HEATER

RED

ORANGE

BLACK

PURPLE

SL HEATER

O2 CELL HEATER

ELECTRONICS CABLE

(UP TO 150 FT)

NOTE: KEEP TWISTED

PAIRS TOGETHER

(COVER REMOVED)

SENSOR/THERMOCOUPLE

TERMINAL BLOCK

(1)

YELLOW

O2 T/C +

RED

O2 T/C -

(2)

SHIELD

YELLOW

GND

SL T/C +

RED

SL T/C -

(3)

SHIELD

WHITE

BLUE

GND

O2 MV -

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)

WHITE

SHIELD

RED

GND

COMB DRIVE

COMB RETURN

PRESSURE

SENSOR

FACTORY

WIRED

WHITE

RED

GREEN

+ 10 PR SRC

PR SENSOR -

PR SENSOR +

BLACK

PR SRC RTN

(5)

(6)

WHITE

RED

YELLOW

BLUE

COMB REF -

COMB REF +

COMB DRIVE

COMB RETURN

SENSOR/THERMOCOUPLE

TERMINAL BLOCK

ELECTRONICS

CABLE PORT

PROBE

SL HEATER

O2 CELL HEATER

COMB CELL HEATER

GRAY

BLACK

PURPLE

ORANGE

HEATER POWER

TERMINAL BLOCK

BROWN

RED

(1)

YELLOW

O2 T/C +

RED

O2 T/C -

(2)

YELLOW

SL T/C +

RED

SL T/C -

(4)

(3)

WHITE

BLUE

O2 MV -

O2 MV +

WHITE

GREEN

RED

WHITE

COMB ACTIVE -

COMB ACTIVE +

SENSOR HOUSING

(COVER REMOVED)

37020005

Figure 2-7. Electrical Connections Between Split-Electronics and Sensor Housing

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

Page 31

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

2-3 PNEUMATIC INSTALLATION

Pneumatic system connections depend on which OCX 4400 options are equipped on your transmitter. Refer to paragraphs 2-3a, 2-3b, and 2-3c, and select the paragraph that applies to your OCX transmitter configuration.

a. Reference Air Set Option (only)

When no options or only the reference air set option is equipped, use the following procedure to install the pneum atic system components.

1. Refer to Figure 2-8. Connect the reference air set (regulator/filter and pressure gage) to the instrument air inlet on the electronics housing and to the inlet side of the dilution air rotometer.

2. Connect the dilution air rotometer output to the DILUTION AIR inlet fitting on the sensor housing.

3. Install an air line between the instrument air outlet fitting on the electronics housing and the tee fitting on the sensor housing.

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.

4. One CO gas and two O2 gases are used to calibrate the OCX 4400: CO - 1000 ppm or 4%, O

0.4%, O

high gas - 8%. Connect the

low gas -

output of the test gas sources to the inlet port of the CAL GAS rotometer. Install an air line between the rotometer outlet port and the CAL GAS inlet fitting on the sensor housing.

SENSOR

HOUSING

EDUCTOR

ELECTRONICS

HOUSING

AIR IN

CAL GAS IN

REFERENCE

AIR IN

DILUTION

AIR IN

DILUTION

AIR FLOW

METER

0.1 SCFH

REGULATOR/FILTER

HI CO

INSTRUMENT

AIR SUPPLY

PRESSURE

35 PSIG

CAL GAS

FLOW METER

5 SCFH

20-30 PSIG

(

RECOMMENDED

2-STAGE

REGULATORS

HI O

LO O

(

37020006

Figure 2-8. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration)

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

Page 32

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

SENSOR

HOUSING

CAL GAS IN

CAL GAS

FLOW METER

5 SCFH

20-30 PSIG

(

RECOMMENDED

ELECTRONICS

HOUSING

HI CO

(

HI O

EDUCTOR

AIR IN

2-STAGE

REGULATORS

LO O

REFERENCE

AIR IN

DILUTION AIR IN

DILUTION AIR FLOW METER

0.1 SCFH

INSTRUMENT

AIR SUPPLY

PRESSURE

REGULATOR/FILTER

35 PSIG

37020007

Figure 2-9. Pneumatic Installation, OCX with Reference Air Set and Solenoids

(with Autocalibration)

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

Page 33

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

b. Reference Air Set and Solenoids

When the reference air set and test gas solenoids are included with your OCX, use the following procedure to install the pneumatic system components.

1. Install the reference air set according to the instructions in paragraph 2-3a, steps 1 through 3.

2. Refer to Figure 2-9. Connect the O low gas source to the CAL GAS LO O

inlet fitting on the electronics

housing. Install a shutoff valve and pressure regulator with gage in the O

low supply line, as shown.

3. Connect the O the CAL GAS HI O

high gas source to

inlet fitting. In-

stall a shutoff valve and pressure regulator with gage in the O

supply line.

4. Connect the CO high gas to the CAL GAS HI COMB inlet fitting. Install a shutoff valve and pressure regulator with gage in the CO high supply line.

5. Connect the CAL GAS outlet fitting of the electronics housing to the inlet port of the CAL GAS rotometer. Install an air line between the rotometer outlet port and the CAL GAS inlet fitting on the sensor housing.

high

c. Reference Air, Solenoids, and

Blowback

When the reference air set, calibration gas solenoids, and blowback options are included with your OCX transmitter, use the following procedure to install the pneumatic system components.

1. Connect the calibration gas sources according to the instructions in paragraph 2-3b, steps 2 through 5.

2. Use the instructions in Appendix C to install the reference air set and blowback system components.

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.

NOTE

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

2-4 INITIAL STARTUP

Observe the preceding Caution and Note. Refer to Section 3, STARTUP AND OPERATION, for OCX 4400 startup information.

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

Page 34

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

SWITCH

DEFAULT POSITIONS

SHOWN

SW3

CLOSED

112

OCX 4400

SECTION 3

COMB

21.1 mA

3.5 mA

O221.1 mA/3.5 mA: O24-20 mA SIGNAL

RAIL LIMITS: HIGH - 21.1 mA LOW - 3.5 mA

COMB 21.1 mA/3.5 mA:

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

FUSE F2

INTERNAL:

COMB 4-20 mA IS

INTERNALLY

POWERED (DEFAULT)

SW2

Figure 3-1. OCX 4400 Defaults

INTERNAL:

O 4-20 mA IS

INTERNALLY

POWERED

(DEFAULT)

EXTERNAL:

COMB 4-20 mA

REQUIRES

AN EXTERNAL

POWER SUPPLY

SW1

EXTERNAL: O 4-20 mA

REQUIRES

AN EXTERNAL

POWER SUPPLY

37020008

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

Page 35

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

SECTION 3

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).

NOTE

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

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.

b. 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

4-20 mA signal is internally

for the O configures the sample line heater control circuit. All switches are accessible through holes in the electronics box.

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

and COMB 4-20 mA signals and

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 low,

3.5 mA.

(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.

4-20 mA

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

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OCX 4400

c. Initial Power Up

Allow adequate time for the heaters to begin operation and for the OCX transmitter to reach normal operating temperature on power up. Normal operating temperature for the O

cell is 736°C. Normal operating tem-

perature for the combustibles cell is 300°C. The normal sample line temperature is 130°C.

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.

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

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

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

d. Set Test Gas Values

Using HART/AMS or optional LOI, set the test gas values for calibration. Refer to Section 5, HART/AMS or Appendix A, Local Operator Interface for more information.

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

CALIBRATION.

(a) From O

CALIBRATION, select

High TG. Enter the percentage of O

used for the high O2 test gas.

(b) From O

CALIBRATION, select

Low TG. Enter the percentage of O

used for the low O2 test gas.

menu, select COMB CALIBRATION.

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.

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.

(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.

(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

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January 2003

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 (Refer to 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

(a) Select DIAG/SERVICE from DE-

VICE SETUP menu.

(b) Select CALIBRATE from the

DIAG/SERVICE menu.

BRATE menu.

(d) Select CAL from PERFORM CAL

menu.

(e) Select the type of calibration de-

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

2. LOI. To initiate a calibration using the LOI, perform the following steps on the LOI menu tree. Refer to APPENDIX A for complete LOI menu tree.

(a) From the CALIBRATE menu, use

the right-pointing arrow to select DO CALIBRATION.

Cal method, COMB Cal

and COMB Cal

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.

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 using HART/AMS, perform the following steps on the HART/AMS menu tree. Refer to Figure 5-3 for the complete HART/AMS menu tree.

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

c. Manual Calibration

(b) Select O2, COMBUSTIBLES, or

BOTH sensors for calibration. Use the right-pointing arrow to access the calibration window.

pointing arrow to initiate automatic 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.

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OCX 4400

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

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January 2003

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 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

COMMUNICATOR

ANALOG OUTPUT DEVICE

LEAD SET

29790018

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

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

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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

OCX 4400

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).

IN ELECTRONICS HOUSING

A OUT 1 A OUT 1 +

NOTE:

THE SIGNAL LOOP MUST BE BROKEN TO INSERT THE OPTIONAL 250 OHM

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

COMMUNICATOR

Figure 5-2. Signal Line Connections, ≤ 250 Ohms Load Resistance

250 OHM

LOAD

RESISTOR

(NOTE 1)

29790017

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

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January 2003

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.

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 (online) 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.

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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

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(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

37020023

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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

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January 2003

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.

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 O2, 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 O2 CAL procedure.

e. From the PERFORM CAL screen, view

menu item 4, CALSTATE, to monitor the

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

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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

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.

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

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January 2003

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.

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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

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.

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.

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

and COMB.

If desired, the NEXT CAL TIME can be changed to synchronize a calibration at a specific day or time.

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

calibration

will occur and press ENTER.

d. From the DETAILED SETUP screen, select

COMB CALIBRATION.

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 calibration will occur and press ENTER.

5-10 LINE VOLTAGE SELECTION USING HART

COMMUNICATOR

Use the procedure in paragraph 3-1c 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

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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.

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

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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

Page 52

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

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 BLOCK

ELECTRONICS HOUSING

AC POWER INPUT

TERMINAL BLOCK

(COVER REMOVED)

(g) Turn on the calibration gasses at

the cylinders and turn on instrument air.

(h) Restore power to the system.

GROUND STUD

TWO NUTS

ALARM OUTPUT

RELAY TERMINAL

AOUT 2+

COMB 4-20 mA SIGNAL

AOUT 2-

AOUT 1-

4-20 mA

SIGNAL

AOUT 1+

COMMON

34070013

Figure 7-1. Electronics Housing Terminal Blocks

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

Page 53

OCX 4400

SL HEATER

O2 CELL HEATER

SENSOR HOUSING

(COVER REMOVED)

EMI

BOOT

HEATER POWER

TERMINAL BLOCK

COMB CELL HEATER

ELECTRONICS CABLE

(TO ELECTRONICS HOUSING)

SENSOR/THERMOCOUPLE

TERMINAL BLOCK

(1)

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

(5)

YELLOW

(6)

WHITE

RED

WHITE

(2)

RED

YELLOW

RED

YELLOW

(3)

BLUE

(4)

WHITE

GREEN

WHITE

RED

GRAY

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 terminal 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 -

O2 MV +

RED

O2 MV -

COMB ACTIVE +

WHITE

COMB ACTIVE -

BLUE

COMB REF -

COMB REF +

COMB DRIVE

37020009

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.

COMB RETURN

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

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Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

HEATER POWER

TERMINAL BLOCK

GRAY

BROWN

COMB CELL HEATER

RED

ORANGE

BLACK

PURPLE

SL HEATER

O2 CELL HEATER

ELECTRONICS CABLE

(UP TO 150 FT)

NOTE: KEEP TWISTED

PAIRS TOGETHER

SPLIT-ELECTRONICS HOUSING

(COVER REMOVED)

ELECTRONICS

CABLE PORT

SENSOR/THERMOCOUPLE

TERMINAL BLOCK

(2)

(1)

YELLOW

O2 T/C +

RED

O2 T/C -

GND

YELLOW

SL T/C +

RED

SL T/C -

(3)

WHITE

BLUE

GND

O2 MV -

O2 MV +

(4)

WHITE

GREEN

COMB ACTIVE -

COMB ACTIVE +

(5)

YELLOW

COMB REF +

Figure 7-3. Split-Electronics Housing Cable Connections

(6)

WHITE

RED

WHITE

GND

COMB REF -

COMB DRIVE

COMB RETURN

PRESSURE

SENSOR

FACTORY

WIRED

+ 10 PR SRC

PR SENSOR -

PR SENSOR +

37020010

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.

Page 55

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

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.

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 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 (24).

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 (24).

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

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Instruction Manual

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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. Thermocouple

19. Heater

20. Heater Clamp

21. Connector

22. Eductor

23. COMB Sensor

Holder

24. Sensor Housing

25. Sample Tube

26. Sample Filter

27. Adapter

28. Check Valve

(w/ blowback only)

29. Plug

(w/out blowback)

30. Exhaust Tube

BLOWBACK

FILTER

HOUSING

NOTES: NOT ALL ITEMS IDENTIFIED ARE AVAILABLE FOR SALE.

1. SEE SECTION 10, REPLACEMENT PARTS, FOR A LIST OF AVAILABLE PARTS.

EXHAUST TUBE (30) MUST BE INSTALLED IN FLANGE PORT NEAREST TO THE BLOWBACK FILTER HOUSING.

37020011

Figure 7-4. Sensor Housing, Exploded View

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

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OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

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 (24). 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 (24). 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.

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

3. Remove reference air tube (2) from sensor housing (24).

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

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IB-106-440 Rev. 2.0 January 2003

OCX 4400

NOTE: NOT ALL ITEMS IDENTIFIED

ARE AVAILABLE FOR SALE. SEE SECTION 10, REPLACEMENT PARTS, FOR A LIST OF AVAILABLE PARTS.

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)

Figure 7-5. O2 Assembly, Exploded View

37020012

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

Page 59

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

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 (23). 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 (24). 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 (23) 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.

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Instruction Manual

IB-106-440 Rev. 2.0 January 2003

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 2-6 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 2-7 if necessary.

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Instruction Manual

IB-106-440 Rev. 2.0

January 2003

1. Cover

2. Screw

3. Local Operator Interface

4. Washers

5. Spacer

6. Connector

7. Electronics Package

8. Screw

9. Washer

10. Solenoid

11. Housing Base

12. Fitting

13. Screw

14. Nameplate

15. Instrument Air Solenoid

16. Vent Tube

NOTES: NOT ALL ITEMS IDENTIFIED

ARE AVAILABLE FOR SALE. SEE SECTION 10, REPLACEMENT PARTS, FOR A LIST OF AVAILABLE PARTS.

37020013

Figure 7-6. Electronics Housing Exploded View

c. Electronics Package Replacement

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. Disconnect and tag wire leads from solenoids and the pressure sensor to

Use the following procedure to replace the electronics package (7, Figure 7-6).

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

the solenoid power and sensor/ thermocouple terminal blocks.

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OCX 4400

3. 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.

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

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

6. 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.

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

8. 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. Fuse Replacement

The OCX 4400 has two fuses (1 and 3, Figure 7-7). 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.

1. Turn off power to the system.

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

3. Remove fuseholder (2, Figure 7-7) by pushing in and turning 1/4 turn counterclockwise. Remove fuse (1 or 3).

4. After checking or replacing fuse (1 or

3), install fuseholder (2) by pushing in and turning 1/4 turn clockwise.

ELECTRONICS

HOUSING

1. Fuse – Heater, F2

2. Fuse Holder

3. Fuse – Power Supply, F1

37020014

Figure 7-7. Fuses, Exploded View

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

Page 63

OCX 4400

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

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

SECTION 8

TROUBLESHOOTING

Before troubleshooting the system, ensure all ICs are fully seated.

d. Electrostatic Discharge

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.

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

The OCX 4400 uses a microprocessor and supporting integrated circuits (IC). If the electronics are handled roughly during installation or located where subjected to severe vibration, the ICs could work loose.

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, 2 Amp maximum. Any fault condition in the OCX 4400 will trip the alarm relay.

b. The optional SPA with HART programmable

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

8-3 FAULT ISOLATION

Faults in the OCX 4400 Transmitter are indicated by messages displayed on the HART communicator or LOI. Fault indications that can appear are listed in the PROBLEM column of Table 8-1, Troubleshooting.

If a fault is indicated on the HART communicator or LOI, locate the fault indication in the PPOBLEM column of Table 8-1. For each fault listed, there are related PROBABLE CAUSES and RECOMMENDED CORRECTIVE ACTIONS. The PROBABLE CAUSES are listed in the order of most probable to least probable. Starting with the most probable cause, inspect and test the unit to isolate the actual cause, then use the RECOMMENDED CORRECTIVE ACTION listed to correct the problem.

, HIGH COMB,

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

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Instruction Manual

IB-106-440 Rev. 2.0 January 2003

Table 8-1. Troubleshooting

PROBLEM PROBABLE CAUSE RECOMMENDED CORRECTIVE ACTION

OCX 4400

Thermocouple Error

(thermocouple voltage out of limits)

O2 Cell Temperature Low

(< 726°C)

O2 Cell Temperature High (> 746°C) or Very High (> 820°C)

O2 thermocouple or thermocouple circuit open

O2 thermocouple or thermocouple circuit shorted

thermocouple

wires reversed

Sensor housing ex-

Check O2 thermocouple and circuit wires for breaks or loose connection. Repair break or loose connection or replace failed thermocouple. Cycle OCX power to resume operation.

Check O

thermocouple and thermocouple circuit wires for

short circuit condition. Repair shorted wiring or replace faulty thermocouple. Cycle OCX power to resume operation.

Check O2 thermocouple wiring per Figure 2-7. Correct reversed-wires fault. Cycle OCX power to resume operation.

Install sensor housing insulating jacket. posed to wind or very cold temperatures.

O2 cell heater open Check O2 cell heater circuit for broken wire or loose con-

nection. Repair broken wire or loose connection.

Heater electronics failure

Check heater fuse F2 in electronics housing. If open, locate

and correct cause of overload. If F2 is not open or if cause

of overload cannot be found, replace electronics package.

Transmitter in warmup mode

High noise in OCX power supply

Electronics package

During warm-up, heater temperature rise may surpass

heater control response. Cycle power to resume operation.

Check power supply for line noise or voltage surges. Install

high quality line filter if high noise or voltages are indicated.

Replace electronics package. power supply failure

O2 Heater Open

O2 Cell Circuit Open

Cell Bad

O2 heater or heater circuit wiring open.

Check O2 cell heater circuit for broken wire or loose con-

nection. Repair broken wire or loose connection.

Check resistance of the O

cell heater; heater resistance

should be less than 100 ohms. Replace heater if heater coil

circuit is open.

Transmitter in powerup or warm-up mode

Loose or open O2 cell lead or circuit wire

During power-up and warm-up, low heater temperature give

false O

Check O

indication. Cycle power to resume operation.

cell tip and cell circuit wires for breaks or loose

connection. Repair cell lead wire break or loose connection. connection

O2 cell failure Check O2 cell impedance value at LOI (see Figure A-3,

sheet 2). If cell impedance is zero, replace O

cell.

If cell impedance is less than 500 ohms, check for cell

housing ground fault. Repair ground fault.

If cell impedance is greater than 500 ohms and no ground

Very low O

concen-

fault is indicated, replace O

Cycle power to resume operation.

cell.

tration in process gas

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

Page 65

OCX 4400

Table 8-1. Troubleshooting (Continued)

PROBLEM PROBABLE CAUSE RECOMMENDED CORRECTIVE ACTION

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

O2 Slope Error

slope

> 57.5 or < 34.5 mV/Dec)

O2 Constant Error

(> 20 mV or < –20 mV)

Calibration

Failed

High Electronics Temperature

Calibration gas supply low or gas connection leaking

Check calibration gas supplies and connections. Adjust gas

pressure and flow. Replenish low calibration gas supplies

and tighten or repair loose or leaking connections. When

calibration gas supplies are adequate, recalibrate.

O2 cell degraded Recalibrate the OCX.

cell failure Check O2 cell impedance value at LOI (see Figure A-3,

sheet 2). If cell impedance is zero, replace O

cell.

If cell impedance is less than 500 ohms, check for cell

housing ground fault. Repair ground fault.

If cell impedance is greater than 500 ohms and no ground

Calibration gas supply low or gas connection leaking

fault is indicated, replace O

Check calibration gas supplies and connections. Adjust gas

pressure and flow. Replenish low calibration gas supplies

and tighten or repair loose or leaking connections. When

cell.

calibration gas supplies are adequate, recalibrate.

O2 cell degraded Recalibrate the OCX.

cell failure Check O2 cell impedance value at LOI (see Figure A-3,

sheet 2). If cell impedance is zero, replace O

cell.

If cell impedance is less than 500 ohms, check for cell

housing ground fault. Repair ground fault.

If cell impedance is greater than 500 ohms and no ground

Electronics housing exposed high ambient temperature.

fault is indicated, replace O

Insulate housing from source of high temperature and/or

install cooling fan to remove heat from housing. Cycle OCX

power to resume operation.

cell.

(> 85°C)

EEPROM Corrupt

Unit powered down during calibration

With power on, wait five minutes, cycle power and recali-

brate the OCX. parameter storage

EEPROM failure Replace EEPROM.

Sample Line Thermocouple Error

(voltage out of limits)

Sample line thermocouple wires reversed.

Sample line thermocouple or thermocouple circuit open.

Check thermocouple wiring per Figure 2-7. Correct

reversed-wires fault. Cycle OCX power to resume operation.

Check thermocouple and thermocouple circuit wires for

breaks or loose connection. Repair break or loose connec-

tion or replace failed thermocouple. Cycle OCX power to

resume operation.

Sample line thermocouple or wiring circuit shorted.

Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 8-3

Check thermocouple and thermocouple circuit wires for

short circuit condition. Repair shorted wiring or replace

faulty thermocouple. Cycle OCX power to resume operation.

Page 66

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

Table 8-1. Troubleshooting (Continued)

PROBLEM PROBABLE CAUSE RECOMMENDED CORRECTIVE ACTION

OCX 4400

Sample Line Temperature Low

(< 155°C; unit not in warmup mode)

Sample Line Temperature High (> 195°C) or Very High (> 220°C)

Combustibles Cell Error

(cell temp. < –40°C;

84.27 mV or > 400°C;

247.04 mV ref. side or active side)

Sensor housing exposed to wind or very cold temperatures.

Sample line heater open

Heater electronics failure

Transmitter in warmup mode

High noise in OCX power supply

Electronics package power supply failure

COMB sensor circuit wiring

COMB sensor RTD shorted or open (reference or active)

Electronics package power supply failure

Install sensor housing insulating jacket.

Check sample line heater circuit for broken wire or loose

connection. Repair broken wire or loose connection.

Check heater fuse F2 in electronics housing. If open, locate

and correct cause of overload. If F2 is not open or if cause

of overload cannot be found, replace electronics package.

During warm-up, heater temperature rise may surpass

heater control response. Cycle power to resume operation.

Check power supply for line noise or voltage surges. Install

high quality line filter if high noise or voltages are indicated.

Replace electronics package.

Check COMB sensor circuit for broken wire or loose con-

nection. Repair broken wire or loose connection.

Check RTD resistance (lead to ground) of reference and

active RTDs. If either RTD is open or shorted to ground,

replace COMB sensor.

Replace electronics package.

Combustibles Temperature Low

(< 290°C; unit not in warmup mode)

Combustibles Temperature High (> 310°C) or Very High (> 400°C)

8-4 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Sensor housing exposed to wind or very cold temperatures.

COMB cell heater open

Heater electronics failure

Transmitter in warmup mode

Large rise in COMB concentration.

High noise in OCX power supply

Electronics package power supply failure

Install sensor housing insulating jacket.

Check COMB cell heater circuit for broken wire or loose

connection. Repair broken wire or loose connection.

Check heater fuse F2 in electronics housing. If open, locate

and correct cause of overload. If F2 is not open or if cause

of overload cannot be found, replace electronics package.

During warm-up, heater temperature rise may surpass

heater control response. Cycle power to resume operation.

High temperature rise in cell may surpass heater control re-

sponse. Cycle power to resume operation.

Check power supply for line noise or voltage surges. Install

high quality line filter if high noise or voltages are indicated.

Replace electronics package.

Page 67

OCX 4400

Table 8-1. Troubleshooting (Continued)

PROBLEM PROBABLE CAUSE RECOMMENDED CORRECTIVE ACTION

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

Combustibles Slope Error

(< 0 or > 3000 ppm/mV)

Combustibles Constant Error

Combustibles Calibration Failed

(slope error during last calibration)

Calibration gas supply low or gas connection leaking

Check calibration gas supplies and connections. Adjust gas

pressure and flow. Replenish low calibration gas supplies

and tighten or repair loose or leaking connections. When

calibration gas supplies are adequate, recalibrate.

O2 cell degraded Recalibrate the OCX.

cell failure Check O2 cell impedance value at LOI (see Figure A-3,

sheet 2). If cell impedance is zero, replace O

cell.

If cell impedance is less than 500 ohms, check for cell

housing ground fault. Repair ground fault.

If cell impedance is greater than 500 ohms and no ground

fault is indicated, replace O

cell.

Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 8-5

Page 68

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

8-6 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Page 69

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

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.

Page 70

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

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

Page 71

Instruction Manual

IB-106-440 Rev. 2.0

OCX 4400

SECTION 10

REPLACEMENT PARTS

Table 10-1. Replacement Parts

FIGURE and

INDEX No. PART NUMBER DESCRIPTION

1-1, 2 275D9EI5D0000 275 HART Communicator with 12 meg buffer 1-1, 3 3535B30G02 Adapter Plate 218 w/shield to ANSI OCX 1-1, 3 3535B30G08 FLG Adapter Assembly, 132 to ANSI OCX 1-1, 3 3535B31G01 OCX/132 Adapter Plate (DIN) 1-1, 5 263C152G01 Reference Gas Set, includes:

771B635H01 Flowmeter, 0.2-10 SCFH 771B635H08 Flowmeter, 0.05-0.5 SCFH 1A99422H01 Pressure Regulator/Filter, 0 – 60 psig 275431-003 Pressure Gage, 2 in., 0 – 60 psi

1-1, 6 1A99518G01 Blowback Kit

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

January 2003

2-1 3535B18H02 ANSI Gasket 2-8 1A99119G05 Test Gas Regulator Kit 2-8 1A99119G04 Test Gas Bottles Kit 2-8 1A99119H01 Oxygen Bottle 0.4%, Balance N 2-8 1A99119H02 Oxygen Bottle 8.0%, Balance N 2-8 1A99119H06 CO Bottle 1000 ppm, Balance N 2-8 1A99120H02 Regulator for Oxygen 2-8 1A99120H03 Regulator for Combustibles

1A99119G06 Wall Mount Bracket for Gas Bottles (not shown)

7-4, 1 5R10219G01 Cover, Sensor Housing 7-4, 3 and 7-5, 15 4851B45G01 O2 Cell Replacement Kit 7-4, 12 1A99371H01 Combustibles Chamber Heater 7-4, 13 thru 16 4851B46G01 Combustibles Sensor Replacement Kit 7-4, 18 1A98151H03 Sample Line Thermocouple Assembly 7-4, 19 1A99371H02 Sample Line Heater 7-4, 25 5R10183H02 Tube, Sample, 18 in. (457mm) 316 Stainless steel 7-4, 25 5R10183H06 Tube, Sample, 18 in. (457mm) Inconel 600 7-4, 25 5R10227G01 Tube, Sample, 18 in. (457mm) Ceramic 7-4, 25 5R10183H03 Tube, Sample, 3 ft. (0.91m) 316 Stainless steel 7-4, 25 5R10183H07 Tube, Sample, 3 ft. (0.91m) Inconel 600 7-4, 25 5R10227G02 Tube, Sample, 3 ft. (0.91m) Ceramic 7-4, 25 5R10183H04 Tube, Sample, 6 ft. (1.83m) 316 Stainless steel 7-4, 25 5R10183H08 Tube, Sample, 6 ft. (1.83m) Inconel 600 7-4, 25 5R10183H05 Tube, Sample, 9 ft. (2.7m) 316 Stainless steel 7-4, 26 5R10246H02 Filter, 20 micron 7-4, 30 5R10183H01 Tube, Exhaust

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

Page 72

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

Table 10-1. Replacement Parts (Continued)

FIGURE and

INDEX No. PART NUMBER DESCRIPTION

7-5, 3 5R10211G01 Heater Strut Assembly 7-5, 4 4851B44G01 Contact and Thermocouple Assembly

7-6, 1 5R10199G01 Cover, Electronics Housing 7-6, 3 4851B49G02 Local Operator Interface 7-6, 7 5R10214G01 Electronics Package 7-6, 11 1A97905H01 Solenoid Valve, Cal. Gas 7-6, 16 1A97905H02 Solenoid Valve, Instrument Air

7-7, 1 1A97913H18 Heater Fuse, Slo-Blo, 6.3 amp, 250 VAC, F2 7-7, 3 1A97913H04 Power Supply Fuse, Slo-Blo, 1.0 amp, 250 VAC, F1

B-1 1A99292H01 Moore Industries SPA for HART Alarm C-1 1A99339H03 Blowback Valve, Air Operated D-1 1A99376H01 IS Barrier Module, Model MTL 5046

D-1 1A99698G01 Intrinsic Safety Barrier Kit

OCX 4400

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

Page 73

OCX 4400

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

SECTION 11

APPENDICES

APPENDIX A LOCAL OPERATOR INTERFACE (LOI)

APPENDIX B SPA WITH HART ALARM

APPENDIX C BLOWBACK

APPENDIX D IS BARRIER

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

Page 74

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

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

Page 75

OCX 4400

Instruction Manual

Appendix A Rev 2.0

January 2003

APPENDIX A

LOCAL OPERATOR INTERFACE (LOI)

A-1 FORWARD

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

CONNECTOR

A-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 A-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 REMOVED)

LOI

ASSEMBLY

ELECTRONICS

LOI

BOARD

BOX

29790024

Figure A-1. LOI Assembly Mounting

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

Page 76

Instruction Manual

Appendix A Rev. 2.0 January 2003

OCX 4400

A-3 OPERATION

The LOI assembly, Figure A-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 DISPLAY WINDOW

A-4 LOI MENU TREE

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

a. First Column Sub-Menus

From the operating display, O COMB ppm, the left-pointing 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 A-3 sheet 1 of 3, CALIBRATE, sheet 2 of 3, and SETUP, sheet 3 of 3. From the operating display, SENSOR DATA is displayed when the right arrow is selected. Use the up or downpointing arrow to move to the other first column sub-menus.

b. Second Column Sub-Menus

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

% and

c. Third, and Fourth Column Sub-Menus

SELECTION

ARROWS

Figure A-2. Local Operator Interface (LOI)

Assembly

From the second column sub-menus, selecting the right-pointing 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-pointing 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-pointing arrows select the value for the parameter displayed.

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

Page 77

OCX 4400

O2 X.XX% Comb XXX ppm

Instruction Manual

Appendix A Rev 2.0

January 2003

O2 Sensor _____dgC

Te mp / Pressure

Sensor Data

Voltages

Output Values

Comb Sensor _____dgC

Sample Block Temp _____dgC

Sample Block Press _____psi

Electronics _____

Max Elect Temp _____dgC

O2 Sensor _____mV

O2 Sensor T/C _____mV

Comb Delta _____mV

Comb Reference _____mV

Elect Temp _____V

Smpl Blok T/C _____mV

Smpl Line Pres _____V

O2 Analog _____%

Comb Analog _____%

O2 Analog mA ____mA

Comb Analog mA ____mA

(CONTINUED ON

SHEET 2)

36390006

Figure A-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 A-3

Page 78

Instruction Manual

Appendix A Rev. 2.0 January 2003

OCX 4400

(CONTINUED FROM

SHEET 1)

Calibrate

(CONTINUED ON

SHEET 3)

NOTE:

“Hit E when ready” prompt is displayed during semiautomatic calibration only (when Setup Calibration value “Got Solenoids” = “n”).

Do Calibrate

View Constants

Calib Status

Combustibles

Both

Latest Calib

Prev Calib

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

Apply Lo O2 Gas

Hit E when ready

Flow O2 Lo _____s

_____% _____mV

Read O2 Lo _____s

_____% _____mV

Apply Hi O2 Gas

Hit E when ready

Flow O2 Hi _____s

_____% _____mV

Read O2 Hi _____s

_____% _____mV

Hit E when ready

Purge _____s O2 Calibration Pass/Fail

Apply Lo CO Gas

Hit E when ready

Flow CO Lo _____s

_____% _____mV

Read CO Lo _____s

_____% _____mV

Apply Hi CO Gas

Hit E when ready

Flow CO Hi _____s

_____% _____mV

Read CO Hi _____s

_____% _____mV

Hit E when ready

Purge _____s

Apply Lo O2 Gas

Hit E when ready

Flow O2 Lo _____s

_____% _____mV

Read O2 Lo _____s

_____% _____mV

Apply Hi O2 Gas

Hit E when ready

Flow O2 Hi _____s

_____% _____mV

Read O2 Hi _____s

_____% _____mV

Hit E when ready

Purge _____s

Apply Lo CO Gas

Hit E when ready

Flow CO Lo _____s

_____% _____mV

Read CO Lo _____s

_____% _____mV

Apply Hi CO Gas

Hit E when ready

Flow CO Hi _____s

_____% _____mV

Read CO Hi _____s

_____% _____mV

Hit E when ready

Purge _____s

O2 Slope _____mV/D O2 Constant _____mV O2 Cell Imped _____ Comb Slope _____ppm/mv Comb Constant _____mV

Pre O2 Slope _____mV/D Pre O2 Const _____mV Pre Co Slope _____ ppm/mV Pre Co Const _____mV

36390007

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

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

Page 79

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

Next Cal XH

Comb Cal Interval XDXH

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

Appendix A Rev 2.0

January 2003

ALARM RELAY

ANALOG OUTPUTS

SOFTWARE

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

A-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 A-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 use the right-

b. From the SETUP first column sub-menu,

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

37020024

pointing arrow to select SETUP first column sub-menu.

use the right-pointing arrow to select the CALIBRATION second column sub-menu.

NOTE

c. From the CALIBRATION second column

sub-menu, use the right-pointing arrow to

Automatic calibration is only avail-

select the third column parameter list.

able on units equipped with calibration solenoids.

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

Page 80

Instruction Manual

Appendix A Rev. 2.0 January 2003

OCX 4400

d. Scroll down to the forth item Got Sole-

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

e. Use the down-pointing arrow to select the

next item O

Output Tracks. Select Yes or

No to determine if updates to the O value will take place.

f. Use the down-pointing arrow to select the

next item Comb Out Tracks. Select Yes or No to determine if updates to the COMB lock value will take place.

g. Use the down-pointing arrow to select the

next item O

Cal Interval. Enter the

amount of time in days and hours that is desired between automatic calibrations.

h. Use the down-pointing arrow to select the

next item O

Next Cal. Enter the amount

of time in hours until the next automatic calibration. Select the left-pointing arrow three times to move back to the operating display.

A-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 A-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. Use the right-pointing arrow to select the

CALIBRATE first column sub-menu.

lock

e. Use the right-pointing arrow to start the

calibration. Turn on the low O when prompted by “Apply Lo O

test gas,

Gas”.

f. Press the right-pointing arrow when the

low O

test gas is applied. The calibration

data changes as the calibration proceeds.

g. Press the right-pointing arrow when the

low O

reading is stable. Turn off the low

test gas and turn on the high O2 test

gas as prompted by “Apply Hi O

Gas”.

h. Press the right-pointing arrow when the

high O

test gas is applied. The calibration

data changes as the calibration proceeds.

i. Press the right-pointing arrow when the

high O O to start the high O

reading is stable. Turn off the high

test gas. Press the right-pointing arrow

gas purge.

j. When the Purge period expires, the LOI

displays “O

Calibration Pass or Fail”.

(Calibration Fail exits the program.)

k. Press the right-pointing arrow to start

combustibles calibration. Turn on the low CO test gas, when prompted.

l. Press the right-pointing arrow when the

low CO test gas is applied. The calibration data changes as the calibration proceeds.

m. Press the right-pointing arrow when the

low CO reading is stable. Turn off the low CO test gas and turn on the high CO test gas when prompted.

b. From the CALIBRATE sub-menu use the

right-pointing arrow to select the DO CALIBRATION second column sub-menu.

n. Press the right-pointing arrow when the

high CO test gas is applied. The calibration data changes as the calibration proceeds.

c. From the DO CALIBRATION sub-menu

use the right-pointing arrow to select the third column O

d. Remain at the O

sensor calibrate option.

sensor option or use the

down-pointing arrow to calibrate COMBUSTIBLES or BOTH sensors. (The following sequence applies when BOTH sensors are selected.)

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

o. Turn off the high CO test gas and press

the right-pointing arrow to start the high CO

gas purge.

p. When the Purge period expires, the LOI

displays “CO Calibration Pass or Fail

”. A failure reapplies the last good calibration parameters for O

/combustibles sensing.

Page 81

OCX 4400

B-1 FORWARD

Instruction Manual

Appendix B Rev 2.0

January 2003

APPENDIX B

SPA WITH HART ALARM

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

B-2 DESCRIPTION

The Moore Industries SPA with HART Alarm, Figure B-1, is a 4-wire (line or mains powered), site-programmable, 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 OCX

Unit Failure.

B-3 INSTALLATION

Refer to Figure B-2 for the typical interface connections for the OCX 4400 and the SPA with HART alarm. Refer to the Moore Industries user’s manual provided with the SPA for additional information concerning SPA installation, setup, and operation.

Electrostatic discharge (ESD) protection is required to avoid damage to the SPA electronic circuits.

1. Refer to Figure B-3. Turn the SPA over and slide the access cover out. Before changing any jumper or switch position, take adequate precautions to avoid an electrostatic discharge.

B-4 SETUP

Setup of the SPA for communication with the OCX 4400 includes setting internal jumpers and dip switches and configuring the SPA operating parameters via a menu-driven selection and calibration procedure.

a. Jumper and Switch Settings

37020018

SPA jumper and switch settings are shown in Figure B-3. If the SPA with HART was factoryconfigured by Rosemount Analytical for operation with your OCX 4400, jumper and switch setting adjustments are not required. However, you may use the following procedure to verify that the jumper and switch settings are correct. Adjust or verify jumper and switch settings as follows:

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

Figure B-1. SPA With HART Alarm

Page 82

Instruction Manual

Appendix B Rev 2.0 January 2003

250Ω

950Ω

OCX 4400

HART MODEL 275 HANDHELD

COMMUNICATOR

4-20 mA

O SIGNAL LOOP

F1 F2 F3 F4

789

456

123

ANALOG OUTPUT

OCX 4400

CUSTOMERS

DCS, PLC,

PC with AMS

SOFTWARE

IN IN

4-20 mA

0-24 vdc

EVENT RECORDER,

AUDIBLE ALARM,

OR OTHER

ANALOG DEVICE

Figure B-2. OCX 4400 and SPA Interface Connections

NOTICE

REMOVE THIS PANEL

FOR SERVICE ACCESS.

STATIC SENSITIVE.

USE CAUTION WHEN

CHANGING JUMPERS

ACCESS COVER

37020019

SPA

BOTTOM

VIEW

SOURCE CURRENT

DIP SWITCHES

PASSWORD

FAILSAFE

DIP SWITCHES

JUMPER PINS

SWITCHES SHOWN IN

CORRECT POSITION

PASSWORD

OFF

SWITCHES SHOWN IN

CORRECT POSITION

37020022

Figure B-3. SPA Jumper and Dip Switch Settings

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

Page 83

OCX 4400

Instruction Manual

Appendix B Rev 2.0

January 2003

2. Verify that the PASSWORD jumper is set to the OFF position. If the jumper is in the ON position, reposition the jumper.

3. Check the position of the FAILSAFE dip switches. Position the dip switches as shown in Figure B-3.

4. Check the position of the SOURCE CURRENT dip switches. Position the dip switches as shown in Figure B-3.

5. Reinstall the SPA access cover.

b. Configuration/Calibration.

Prior to operation, the SPA operating parameters must be configured via a menudriven setup procedure. At the end of the configuration procedure, the SPA analog output signal is calibrated to insure valid communications.

1. See Figure B-4. Connect a calibrated ammeter (Fluke Model 87 or

equivalent, accurate to ±0.025%) to the SPA analog output terminals. Observe polarity.

2. Connect a 90 to 260 VAC or 22 to 300 VDC power source to the SPA power terminals. When connecting an AC power source, use the AC and ACC (AC Common) terminals. For a DC source, use the AC and Ground terminals.

3. If desired, you can connect the 4 to 20 mA O

signal wires from the OCX

4400 analog output terminal block to the SPA INput terminals. (The OCX must be operational to transmit the O

signal. Observe polarity.)

NOTE

The O

signal connection is not re-

quired for SPA configuration or calibration. The OCX interface will allow you to observe the O

signal level

when the SPA configuration procedure is completed.

FLUKE MODEL 87

MULTIMETER

OCX 4400

OPTIONAL

250Ω

950Ω

IN IN

OR EQUIVALENT

ACC

GND

AC or DC

POWER INPUT

37020020

Figure B-4. SPA Setup for Calibration

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

Page 84

Instruction Manual

Appendix B Rev 2.0 January 2003

OCX 4400

4. Observe the front panel of the SPA, Figure B-5:

(a) A process value display in the

SPA display window indicates that the SPA is operational. Four pushbuttons are located below the display window.

(b) Pressing a left-hand pushbutton

scrolls up (Ï) or down (Ð) through the SPA command menu, a submenu, or parameter values list.

displays rail limits and alarm re-

lay configurations. There are five sequential displays in the VIEW mode. While in the VIEW mode, the up (Ï), down (Ð), and SELECT pushbuttons are disabled.

NOTE

In the VIEW mode, you can scroll through and display the output zero and full scale settings and the alarm relay trip points and configurations.

(d) Pressing the SELECT pushbut-

ton selects the displayed menu or submenu command or selects a displayed parameter variable.

SPA

DISPLAY

WINDOW

LEFT-HAND

PUSHBUTTONS

RIGHT-HAND

PUSHBUTTONS

37020017

Figure B-5. SPA Front Panel

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

Page 85

OCX 4400

Instruction Manual

Appendix B Rev 2.0

January 2003

5. Figure B-6 shows the SPA menu, submenus, and parameter values that must be selected to configure the SPA for use with the OCX 4400.

6. Use the following instructions and selections shown in Figure B-6 to properly configure the SPA.

(a) Press the SELECT pushbutton.

Observe the display window on the SPA front panel. The display window should read SET HART.

(b) See the SET HART command in

Figure B-6. To the right of the command window is the SET HART submenu and related parameter values that must be selected via the front panel pushbuttons on the SPA.

Figure B-6, Ð means press the down pushbutton. Ï means press the up pushbutton.

(d) Â means press the SELECT

pushbutton one time. Ú means press the Ï or Ð pushbutton until the desired parameter value is shown in the SPA window.

(e) Proceed through the SPA menu,

selecting the menu commands and parameter values indicated in Figure B-6. After completing the sequence in the first column, go to the top of the second column and continue.

(f) To exit the menu, repeatedly

press SELECT to display any main menu command. Then, press Ï or Ð until CONF EXIT is displayed. Select CONF EXIT.

(g) Detailed instructions concerning

the configuration menu and the submenu structure for each main command are provided in the SPA user’s manual.

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

Page 86

Instruction Manual

Appendix B Rev 2.0 January 2003

OCX 4400

SET

HART

SGNL SRCE

FLT

SRCE

CONF

OPTS

SET MSTR Â Ú PRIM

Â Â SET FUCT Â Ú NRML Â NUM VARS Â Ú 02 Â NUM TRYS Â Ú 03 Â EXIT HART Â SGNL SRCE

Â AOUT SRCE Â Ú SV Â AL2 SRCE Â Ú PV

AL3 SRCE Â Ú PV

AL4 SRCE Â Ú PV

Â Â EXIT SRCE Â FLT SRCE

Ð CONF OPTS

Â SET LINR Â Ú LINR OFF Â PV SCLE Â Ú AUTO Â DSPL EGU Â Ú CSTM Â Ú PPM

(select P, select P, select M)

Â DSPL SRCE Â Ú SV Â AL2 SEL Â AL2 FLT Ð SET FAIL Â FAIL LOW Ð EXIT OPTS Â SET EGU

SCLE INPT

SCLE DSPL

SCLE

OUT

TRIM

OUT

CONF ALRM

Â PV DSPL Â SET ZERO Â Ú 0000 PCT Â SET FULL Â Ú 25 PCT Â SV DSPL Â SET ZERO Â Ú 0000 PPM Â SET FULL Â Ú 1000 PPM Â EXIT DSPL Â SCLE OUT

SET ZERO Â Ú 4.000 MA

SET FULL Â Ú 20.00 MA

EXIT Z/FS

Â Â TRIM OUT

Â TRIM ZERO Â Ú 4.000 MA

TRIM FULL Â Ú 20.00 MA

Â Â EXIT TRIM Â CONF ALRM

Refer to SPA manual for settings or

PASS WORD

SET

EGU

SCLE

INPT

SCLE DSPL

Â PV EGU Â Ú PCT Â SV EGU Â Ú CSTM Â Ú PPM

(select P, select P, select M)

EXIT EGU Â SCLE INPT

Â PV SCLE Â PV ZERO Ú 0000 PCT Â PV FULL Ú 25 PCT Â SCLE SV Â SET ZERO Ú 0000 PPM

Â SET FULL Ú 1000 PPM Â EXIT SCLE Â SCLE DSPL

PASS

WORD

CONF

EXIT

Ð CONF EXIT

Â SPA setup complete;

observe process value display.

Figure B-6. SPA Configuration Menu for OCX 4400 Communication

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

Page 87

OCX 4400

Instruction Manual

Appendix C Rev 2.0

January 2003

APPENDIX C

BLOWBACK

C-1 FORWARD

This appendix describes the operation of the blowback 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.

C-2 INSTALLATION

Installing an OCX 4400 Oxygen/Combustibles Transmitter with the blowback option requires the addition of air operated blowback valve, regulator and gage, and check valve.

Figure C-1 shows the piping arrangement for the OCX 4400 Oxygen/Combustibles Transmitter with the blowback and autocalibration options. Figure C-2 shows the piping arrangement for the OCX 4400 Oxygen/Combustibles Transmitter with the blowback option without autocalibration (without test gas solenoids).

1. Connect a clean, dry, instrumentquality supply of air (20.95% O 35 psig and 55 psig pressure regulators. The inlet to the 35 psig regulator accepts a 1/8” NPT fitting. The inlet to the 55 psig regulator accepts a 1/4” NPT fitting.

2. See the upper leg of the instrument air supply. Connect the output of the 35 psi regulator/filter to one port of the normally-closed air-operated solenoid valve, and to the inlet side of the dilution air rotometer.

3. Connect the dilution air rotometer output to the DILUTION AIR inlet fitting on the sensor housing.

) to the

4. Install an instrument air line between the open port of the normally-open airoperated solenoid valve and the tee fitting on the sensor housing.

5. Connect the output of the 55 psi regulator/filter to one port of the normallyopen air-operated solenoid valve, and to the instrument air inlet on the back of the electronics housing.

6. Install an air line between the open port of the normally-closed air-operated solenoid valve and the check valve inlet fitting on the sensor housing.

7. Install an air line between the instrument air outlet fitting on the electronics housing and the control air inlet fitting on the air-operated solenoid valve.

C-3 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-

back events. (60 minutes recommended.)

Duration – Length of time blowback air is

activated. (5 seconds recommended.)

Purge Time – Length of time after blowback is

complete before oxygen/ combustibles readings are considered valid. (Set as required by the application.)

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

Page 88

Instruction Manual

Appendix C Rev 2.0 January 2003

OCX 4400

CAL GAS

FLOW METER

5SCFH

20-30 PSIG

(

RECOMMENDED

CHECK

VALV E

ELECTRONICS

HOUSING

(

EDUCTOR

AIR IN

SENSOR

HOUSING

CAL GAS IN

REFERENCE

AIR IN

INSTRUMENT AIR

BLOWBACK

OPERATED

Pressure regulator with 1/8” inlet port is factory set for 35 psig. Regulator with 1/4” inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the OCX 4400 will not work.

DILUTION AIR IN

VALVE,

AIR

NORMALLY

OPEN

SOLENOID

VALV E

NORMALLY

CLOSED

SOLENOID

VALV E

DILUTION AIR

FLOW METER

0.1 SCFH

AIR PRESSURE

REGULATOR/FILTER

35 PSIG

INSTRUMENT

55 PSIG

AIR SUPPLY

HI CO

2-STAGE

REGULATORS

HI O

LO O

NOTE: DURING OPERATION, STATE OF NORMALLY-OPEN AND NORMALLY-CLOSED SOLENOID VALVES CHANGE.

Figure C-1. Piping Arrangement, Blowback with Autocalibration

AIR PRESSURE

REGULATOR/FILTER

37020015

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

Page 89

OCX 4400

CHECK

VALV E

ELECTRONICS

HOUSING

SENSOR

HOUSING

EDUCTOR

AIR IN

(

RECOMMENDED

CAL GAS IN

REFERENCE

AIR IN

INSTRUMENT AIR

BLOWBACK

OPERATED

CAL GAS

FLOW METER

5 SCFH

20-30 PSIG

DILUTION AIR IN

VALVE,

AIR

(

2-STAGE

REGULATORS

DILUTION AIR FLOW METER

AIR PRESSURE

REGULATOR/FILTER

Instruction Manual

Appendix C Rev 2.0

January 2003

HI CO

0.1 SCFH

HI O

LO O

Pressure regulator with 1/8” inlet port is factory set for35 psig. Regulator with 1/4” inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the OCX 4400 will not work.

Figure C-2. Piping Arrangement, Blowback without Autocalibration

NORMALLY

OPEN

SOLENOID

VALV E

NOTE: DURING OPERATION, STATE OF NORMALLY-OPEN AND NORMALLY-CLOSED SOLENOID VALVES CHANGE.

NORMALLY

CLOSED

SOLENOID

VALV E

35 PSIG

55 PSIG

AIR PRESSURE

REGULATOR/FILTER

INSTRUMENT

AIR SUPPLY

37020026

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

Page 90

Instruction Manual

Appendix C Rev 2.0 January 2003

OCX 4400

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

Page 91

OCX 4400

Instruction Manual

Appendix D Rev 2.0

January 2003

APPENDIX D

IS BARRIER

D-1 DESCRIPTION

A twisted pair of signal wires provide communication from the OCX 4400 Transmitter to the customer’s analog devices (alarms, PC, DCS, etc.). In normal operation, the signal wires carry a low-voltage, 4 to 20 milliamp analog signal.

An OCX equipment fault, however, could generate a higher energy signal at the transmitter output terminals. Where the OCX analog signal is transmitted through hazardous areas, failure to use IS barriers could allow higher energy signals to ignite combustible gases or materials.

The OCX 4400 Transmitter is available with an IS barrier option. The IS barrier limits the energy (voltage and current) that can be produced at the analog output terminals of the transmitter. Whenever the OCX with IS barrier protection is selected, the customer’s devices must also be

IS barrier protected to avoid transmitting a feedback energy surge through the OCX signal wires.

The recommended interface for connecting the OCX 4400 with IS barrier protection to the customer’s analog devices is shown in Figure D-1. The MTL Model 44041A Current Repeater with adapter and BPS 04 Backplane (intrinsic barrier kit) has been selected by Rosemount Analytical to protect against feedback from the customer’s equipment through the O

Notice that an SPA with HART alarm is included in the IS barrier interconnect diagram. The SPA unit is necessary to decode the 4 to 20 mA combustibles (COMB) concentration signal or line fault detection signals superimposed on the O

analog signal. Without the SPA, only the O

analog signal would be available for input to the customer’s analog devices.

signal loop.

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

Page 92

Instruction Manual

Appendix D Rev 2.0 January 2003

OCX 4400

HART MODEL 275 HANDHELD

COMMUNICATOR

F1 F2 F3 F4

789

456

123

345 6

500Ω

NON-HAZARDOUS

AREA

ISOLATING DRIVER

MTL 5046

PWR

HAZARDOUS

AREA

CUSTOMER’S

O SIGNAL LOOP 4 - 20 mA

EQUIPMENT

NON-HAZARDOUS

AREA

789101112

OCX 4400 4 - 20 mA

SIGNAL OUTPUT

TERMINAL BLOCK

SITE-PROGRAMMABLE HART

LOOP MONITOR AND ALARM

24 VDC

AOUT 2

MOORE INDUSTRIES

IN IN

ELECTRONICS

HOUSING

O SIGNAL

AOUT 1

ANALOG OUTPUT

ADAPTER

INTRINSIC SAFETY

BARRIER KIT

P/N 1A99698G01

12345 6

250Ω

950Ω

9 1011121314

CURRENT

REPEATER

MTL 4041A

MTL BACKPLANE

28 VDC PWR IN

O SIGNAL 4 - 20 mA

BPS 04

AC/DC

PWR IN

EVENT

RECORDER,

AUDIBLE ALARM

OR OTHER

ANALOG

DEVICE

DCS or

PC with AMS

SOFTWARE

37020016

Figure D-1. IS Barrier Interface Diagram

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

Page 93

OCX 4400

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.

Instruction Manual

IB-106-440 Rev. 2.0

January 2003

SECTION 12

INDEX

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

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

Dilution Air, 1-6

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

Faults, 8-1 Fuses, 7-12

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

Installation

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

Instrument Air, 1-6

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, 2-11 Removal/Replacement, 7-1 Replacement Parts, 10-1

Sensor Housing, 1-3, 7-6 Sensors, 1-3, 1-6 Solenoid Replacement, 7-10 Solenoids, 1-6, 2-11 SPA with HART Alarm, 8-1 Specifications, 1-8 Switch Configuration, 3-1 System Features, 1-3

Test Gas Values, 3-2

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

Page 94

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

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

Page 95

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.

3702/1-03

Page 96

Instruction Manual

IB-106-440 Rev. 2.0 January 2003

OCX 4400

Pa rt n o. _______________ Se ria l n o. _______________ Ord er 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 2.0 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

HIGHLIGHTS OF CHANGES

TABLE OF CONTENTS

LIST OF TABLES

PREFACE

SAFETY INSTRUCTIONS

DESCRIPTION AND SPECIFICATIONS

1-2 SYSTEM OVERVIEW

1-3 OCX 4400 SPECIFICATIONS

INSTALLATION

2-2 ELECTRICAL INSTALLATION

2-3 PNEUMATIC INSTALLATION

STARTUP AND OPERATION

CALIBRATION

4-2 CALIBRATION METHODS

HART/AMS

5-4 OFF-LINE AND ON-LINE OPERATIONS

OPERATION

MAINTENANCE AND SERVICE

7-2 OCX 4400 REMOVAL/REPLACEMENT

TROUBLESHOOTING

8-2 ALARM OUTPUT

8-3 FAULT ISOLATION

RETURN OF MATERIAL

REPLACEMENT PARTS

APPENDICES

APPENDIX A

LOCAL OPERATOR INTERFACE (LOI)

APPENDIX B

SPA WITH HART ALARM

APPENDIX C

BLOWBACK

APPENDIX D

IS BARRIER

INDEX

ROSEMOUNT WARRANTY