Rosemount OCX 8800 Instruction Manual
Instruction Manual
IM-106-880, Rev 2.1
April 2017
Rosemount
OCX 8800
Oxygen and Combustibles Transmitter
General Purpose Probe with Integral Electronics
TM
HIGHLIGHTS OF CHANGES
Page/Section Summary
Effective September 2009, Rev 2.0
Throughout IM Included coverage of all General Purpose OCX 8800 configurations/options into this single
Instruction Manual.
Added FOUNDATION Fieldbus communications option.
Added coverage of optional COe Purge/Zero function equipment illustrations with related
installation and operating procedures.
Added coverage of three optional in-situ filters.
Added coverage of optional wall-mount or rack-mount blowback panel.
Added coverage of PlantWeb Alert data for OCX 8800 units with FOUNDATION Fieldbus
communications.
Added Appendix B coverage of optional Moore Industries Site Pprogrammable Alarm for
OCX 8800 units with HART communications.
Effective April 2017, Rev 2.1
Page/Section Summary
Title page Removed Rosemount Analytical logo.
Updated Emerson logo.
Page 1-13 Updated Blowback Air specification.
Page 1-11 Updated specifications for Sensor Housings and Electronics Housings.
Page C-1 Updated Return of Materials information.
Back page Updated to include new addresses, social media information, and Rosemount and Emerson
logos.
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
SECTION i
Introduction
SECTION 1
Description and
Specifications
SECTION 2
Installation
SECTION 3
Configuration and
Startup
Table of Contents
Essential Instructions ................................................................................ i
Preface .................................................................................................... iii
Definitions ............................................................................................... iii
Symbols .................................................................................................. iv
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Component Checklist ............................................................................ 1-1
System Overview .................................................................................. 1-3
Specifications ...................................................................................... 1-12
Mechanical Installation .......................................................................... 2-1
Electrical Installation ............................................................................. 2-8
Pneumatic Installation ......................................................................... 2-13
Initial Startup ....................................................................................... 2-24
Verify Installation ................................................................................... 3-1
Initial Power Up ..................................................................................... 3-5
Set Test Gas Values ............................................................................. 3-5
Calibration Solenoids ............................................................................ 3-6
Blowback Feature ................................................................................. 3-7
Calibration Verify Feature ..................................................................... 3-9
Calibration Tolerance Feature ............................................................ 3-11
COe Purge / Zero Feature .................................................................. 3-12
OCX 8800 Reset Procedure ............................................................... 3-14
SECTION 4
Using the LOI
SECTION 5
Calibration
Overview ............................................................................................... 4-1
Display Orientation ................................................................................ 4-1
LOI Controls .......................................................................................... 4-2
Overview .......................................................................................... 4-2
LOI Key Functions ........................................................................... 4-2
LOI Status Codes ............................................................................ 4-3
LOI Menu Tree ...................................................................................... 4-4
Overview ............................................................................................... 5-1
Fully Automatic Calibration ................................................................... 5-1
Operator - Initiated Autocalibration ....................................................... 5-3
Manual Calibration ................................................................................ 5-4
D/A Trim Procedures - LOI ................................................................. 5-12
D/A Trim Procedures - HART ............................................................. 5-14
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IM-106-880, Rev 2.1
April 2017
OCX 8800
TOC-2
SECTION 6
Field Communicator
SECTION 7
Foundation Fieldbus
Overview ............................................................................................... 6-1
Field Communicator Connections ......................................................... 6-1
Off-Line and On-Line Operations .......................................................... 6-4
Hart Menu Tree ..................................................................................... 6-5
Fieldbus Menu Tree .............................................................................. 6-9
Foundation Fieldbus Technology .......................................................... 7-1
Overview .......................................................................................... 7-1
Introduction ...................................................................................... 7-2
Instrument-Specific Function Blocks................................................ 7-4
Network Communication .................................................................. 7-4
OCX Function Blocks ............................................................................ 7-6
Resource Block ..................................................................................... 7-6
PlantWeb Alerts ............................................................................... 7-6
Mapping of PWA .............................................................................. 7-7
PWA Simulate ................................................................................ 7-10
Fieldbus/PWA Simulate ................................................................. 7-10
Configure Simulation with the Model 375 Field Communicator . . 7-11
Support Resource Block Errors ..................................................... 7-13
Transducer Block ................................................................................ 7-13
Transducer Block Parameters ....................................................... 7-13
Transducer Block Enumerations.................................................... 7-17
Transducer Block Channel Assignments for AI Blocks ................. 7-22
Transducer Block Channel Status ................................................. 7-22
Transducer Block Simulate ............................................................ 7-23
Support Transducer Block Errors .................................................. 7-23
Analog Input (AI) Function Block ........................................................ 7-23
Introduction .................................................................................... 7-23
Simulation ...................................................................................... 7-26
Filtering .......................................................................................... 7-27
Signal Conversion .......................................................................... 7-27
Block Errors ................................................................................... 7-28
Modes ............................................................................................ 7-29
Alarm Detection ............................................................................. 7-29
Status Handling ............................................................................. 7-29
Advanced Features ........................................................................ 7-30
Application Information .................................................................. 7-30
Application Examples .................................................................... 7-31
Troubleshooting ............................................................................. 7-35
Proportional/Integral/Derivative (PID) Function Block ........................ 7-36
Setpoint Selection and Limiting ..................................................... 7-40
Filtering .......................................................................................... 7-41
Feedforward Calculation ................................................................ 7-41
Tracking ......................................................................................... 7-41
Output Selection and Limiting ........................................................7-41
Bumpless Transfer and Setpoint Tracking .................................... 7-41
PID Equation Structures ................................................................ 7-42
Reverse and Direct Action ............................................................. 7-42
Reset Limiting ................................................................................ 7-42
Block Errors ................................................................................... 7-42
Modes ............................................................................................ 7-43
Alarm Detection ............................................................................. 7-44
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
Status Handling ............................................................................. 7-44
Application Information .................................................................. 7-45
Application Examples .................................................................... 7-46
Troubleshooting ............................................................................. 7-51
Arithmetic (ARTHM) Function Block ................................................... 7-52
Block Errors ................................................................................... 7-54
Modes ............................................................................................ 7-55
Alarm Detection ............................................................................. 7-55
Block Execution ............................................................................. 7-55
Status Handling ............................................................................. 7-56
Application Information .................................................................. 7-56
Advanced Topics ........................................................................... 7-57
Troubleshooting ............................................................................. 7-59
Input Selector (ISEL) Function Block .................................................. 7-59
Block Errors ................................................................................... 7-61
Modes ............................................................................................ 7-61
Alarm Detection ............................................................................. 7-62
Block Execution ............................................................................. 7-62
Status Handling ............................................................................. 7-62
Application Information .................................................................. 7-63
Troubleshooting ............................................................................. 7-64
Operation with Emerson DeltaV.......................................................... 7-65
About AMS and DeltaV Software ................................................... 7-65
SECTION 8
Troubleshooting
SECTION 9
Maintenance and Service
SECTION 10
Replacement Parts
Overview ............................................................................................... 8-1
Grounding ........................................................................................ 8-1
Electrical Noise ................................................................................ 8-1
Electrostatic Discharge .................................................................... 8-1
Total Power Loss ............................................................................. 8-2
Diagnostic Alarms ................................................................................. 8-2
Fault Isolation ........................................................................................ 8-3
Alarm Relay Events............................................................................. 8-11
Overview ............................................................................................... 9-1
OCX 8800 Removal and Installation ..................................................... 9-1
OCX with Integral Electronics .......................................................... 9-2
OCX with Remote Electronics ......................................................... 9-5
Repair Sensor Housing ....................................................................... 9-10
Sensor Housing Disassembly ........................................................ 9-10
Sensor Housing Assembly ............................................................. 9-20
Repair Electronics Housing ................................................................. 9-29
Electronics Housing Disassembly .................................................. 9-29
Electronics Housing Assembly ...................................................... 9-31
Replace Tube Fittings ......................................................................... 9-35
Remove Tube Fittings .................................................................... 9-35
Install Tube Fittings ........................................................................ 9-36
Sensor Housing................................................................................... 10-2
Electronics Housing ............................................................................ 10-6
O2 Cell and Heater Strut Assembly ....................................................10-9
TOC-3
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
TOC-4
APPENDIX A
Safety Data
APPENDIX B
SPA with HART Alarm
APPENDIX C
Return of Materials
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . . A-24
High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
If a Model 375 Field Communicator is used with this unit, the software within the Model 375
may require modification. If a software modification is required, please contact your local
Emerson Service Group or National Response Center at
1-800-654-7768.
ESSENTIAL
INSTRUCTIONS
Oxygen/Combustibles Transmitter
READ THIS PAGE BEFORE PROCEEDING!
Emerson designs, manufactures and tests its products to meet many national
and international standards. Because these instruments are sophisticated
technical products, you MUST properly install, use, and maintain them to
ensure they continue to operate within their normal specifications. The
following instructions MUST be adhered to and integrated into your safety
program when installing, using, and maintaining Emerson’s Rosemount
products. Failure to follow the proper instructions may cause any one of the
following situations to occur: Loss of life; personal injury; property damage;
damage to this instrument; and warranty invalidation.
•
Read all instructions prior to installing, operating, and servicing the
product.
•
If you do not understand any of the instructions, contact your
Emerson representative for clarification.
•
Follow all warnings, cautions, and instructions marked on and
supplied with the product.
•
Inform and educate your personnel in the proper installation,
operation, and maintenance of the product.
•
Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes. Connect all products to the proper electrical and
pressure sources.
•
To ensure proper performance, use qualified personnel to install,
operate, update, program, and maintain the product.
•
When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson. 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.
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
ii
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
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.
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.
Section i Introduction
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iii
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iv
PREFACE The purpose of this manual is to provide a comprehensive understanding of
the OCX 8800 components, functions, installation, and maintenance.
We recommend that you thoroughly familiarize yourself with the Introduction
and Installation sections before installing your transmitter.
The introduction presents the basic principles of the transmitter along with its
performance characteristics and components. The remaining sections contain
detailed procedures and information necessary to install and service the
transmitter.
Before contacting Emerson concerning any questions, first consult this
manual. It describes most situations encountered in your equipment's
operation and details necessary action.
DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES
found throughout this publication.
NOTE
Highlights an essential operating procedure, condition, or statement.
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
iv
SYMBOLS
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.
NOTE
Read this manual before working with the product. For personal and system
safety, and for optimum product performance, make sure you thoroughly
understand the contents before installing, using, or maintaining this product.
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-12
Product Matrix - OCX 8800 . . . . . . . . . . . . . . . . . . . . . . . . . page 1-14
COMPONENT
CHECKLIST
A typical OCX 8800 Oxygen/Combustibles Transmitter package should
contain the items shown in Figure 1-1.
Use the product matrix in Table 1-1 at the end of this section to verify your
order number. The first part of the matrix defines the model. The last part
defines the various options and features of the OCX 8800. Check the model
number against the transmitter features and options, making sure options
specified by this number are on or included with the unit. Use this complete
model number for any correspondence with Emerson. A list of accessories for
use with the OCX 8800 is provided in Table 1-2.
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
1-2
Figure 1-1. Typical System Package
1.
Instruction Manual
2.
Field Communicator Package (optional)
3.
Adapter Plate with Mounting Hardware and Gasket
4.
Reference Air and Calibration Set (optional)
5.
Blowback Hardware (optional)
6.
OCX 8800 with Remote Electronics
7.
OCX 8800 with Integral Electronics
1-3
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
SYSTEM OVERVIEW Scope
This Instruction Manual supplies details needed to install, startup, operate,
and maintain the OCX 8800. Signal conditioning electronics outputs a digital
signal representing oxygen (O2) and combustibles (COe) values. This
information, plus additional details, can be accessed with the 375 Field
communicator or Emerson AMS software. The optional
local operator interface (LOI) also provides a communications interface with
the electronics.
System Description
The OCX 8800 is designed to measure oxygen and combustible
concentrations in flue gas temperatures up to 2600°F (1427°C). Electrical
connections, power and communications are made through two 3/4 NPT ports
in the flameproof electronics enclosure using fittings and cables provided by
the customer. Cable installation must meet NEC, IEC and/or other applicable
national or local codes for Class I, Zone 1, Group IIB +H2 T3/T6 permanently
mounted equipment. The transmitter is close coupled to the process and
requires minimal sample conditioning requirements.
The equipment measures oxygen percentage by reading the voltage
developed across a heated electrochemical cell, which consists of a small
yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous
metal electrodes. When operated at the proper temperature, the millivolt
output of the cell is given by the following Nernst equation:
EMF = KT log10 (P1/P2) + C
Where:
1.
P2 is the partial pressure of the oxygen in the measured gas on one side
of the cell.
2.
P1 is the partial pressure of the oxygen in the reference air on the
opposite side of the cell.
3.
T is the absolute temperature.
4.
C is the cell constant.
5.
K is an arithmetic constant.
NOTE
For best results, use clean, dry instrument air (20.95% oxygen) as the
reference air.
When the cell is at operating temperature and there are unequal oxygen
concentrations across the cell, oxygen ions will travel from the high oxygen
partial pressure side to the low oxygen partial pressure side of the cell. The
resulting logarithmic output voltage is approximately 50 mV per decade. The
output is proportional to the inverse logarithm of the oxygen concentration.
Therefore, the output signal increases as the oxygen concentration of the
sample gas decreases. This characteristic enables the OCX 8800 to provide
exceptional sensitivity at low oxygen concentrations.
1-4
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
The OCX 8800 measures net oxygen concentration in the presence of all the
products of combustion, including water vapor. Therefore, it may be
considered an analysis on a "wet" basis. In comparison with older methods,
such as the portable apparatus, which provides an analysis on a "dry" gas
basis, the "wet" analysis will, in general, indicate a lower percentage of
oxygen. The difference will be proportional to the water content of the
sampled gas stream.
The OCX 8800 combustibles sensor is a catalytic sensor consisting of two
Resistance Devices (RTD). One RTD is the reference element covered with
an inert coating. The other RTD element is active, coated with a catalyst. As
the sample gases flow by the sensor, the combustible gases oxidize on the
surface of the active element. The oxidation that occurs produces heat and a
temperature rise in the active element. The temperature difference produces
a resistance relationship between the two elements that is directly
proportional to the concentration of combustibles in the sample gases.
The catalyst is specifically designed to detect carbon monoxide (CO), but the
sensor responds to other combustible gases. The sensor is calibrated using
CO, thus the output should be expressed in terms of CO. However, since the
sensor detects other combustible gases, the output cannot just be labeled
CO. The response of the sensor to other combustible gases gives an output
that is equivalent to the sensor detecting CO.
The term COe is used in this manual to describe the sensor output. This term
indicates that the sensor is calibrated in terms of CO, and that the sensor
output is equivalent to CO but not specific to CO.
Dilution air is provided to the COe sensor to ensure there is adequate oxygen
to fully oxidize any combustible gases regardless of the concentration of
oxygen in the process.
System Configuration
Transmitters are available in four lengths, giving the user the flexibility to use
a penetration appropriate to the size of the stack or duct. The length options
are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), or 9 ft (2.7 m). Probes are
available in three material options, 316L stainless steel, Inconel 600, and
ceramic to accommodate higher temperatures.
The electronics are contained in a separate housing from the sensors. When
the transmitter is configured with the integral electronics option the electronics
and sensor housings are mounted as a unit at the stack mounting flange.
When the transmitter is configured with the remote electronics option the
electronics are contained in a separate housing from the sensors. The
electronics housing may be mounted up to 150 feet from the sensor housing.
The electronics control both sensor temperatures and provide output signals
in one of two ways:
1.
Individual 4-20 ma isolated outputs that are proportional to the
measured oxygen and combustibles concentrations. The oxygen output
also contains HART communication.
2.
Single FOUNDATION fieldbus output.
1-5
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
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. Refer to
Section 3, Configuration and Startup for specific instructions upon initial
power up.
System Features
1.
The O2 cell output voltage and sensitivity increase as the oxygen
concentration decreases.
2.
HART or FOUNDATION fieldbus communication is standard. To use this
capability, you must have either:
a.
Model 375 Field Communicator.
b.
AMS software for the PC.
3.
Oxygen cell and heater/thermocouple assembly are field replaceable.
4.
Electronics are automatically configured for line voltages from 100 to
240 VAC.
5.
An operator can calibrate and diagnostically troubleshoot the OCX 8800
in one of two ways:
a.
LOI. The LOI is mounted to the end of the electronics module and
allows local communications with the electronics. Refer to Section 4,
Using the LOI, for more information.
b.
HART or FOUNDATION fieldbus interface. The OCX 8800's output
line transmits a digital signal with the detected oxygen or
combustible levels encoded in a digital format. This information can
be accessed through the following:
•
Model 375 Field Communicator - The handheld field
communicator requires Device Description (DD) software specific
to the OCX 8800. The DD software will be supplied with many
Model 375 units, but can also be programmed into existing units
at most Emerson service offices. Refer to Section 6, Field
Communicator, for additional information.
•
Personal Computer (PC) - The use of a personal computer
requires AMS software available from Emerson.
•
Selected Distributed Control Systems - The use of distributed
control systems requires input/output (I/O) hardware and AMS
software which permit HART or FOUNDATION fieldbus
communications.
6.
When the transmitter is configured without the LOI an operator must
calibrate and diagnostically troubleshoot the OCX 8800 using the HART
or FOUNDATION fieldbus Interface.
7.
Optional Blowback System. The blowback system periodically blows
instrument air back through the sample line filter and out the sample
tube. This clears out particulate and keeps the sample line filter from
clogging.
1-6
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
System Operation
Figure 1-2 shows the relationship between the components of the OCX 8800.
The sensors and the electronics are contained in separate housings. The
sensor housing and probe mounts to a duct or process wall so that the probe
protrudes into the flue gas stream. An air powered eductor continuously pulls
samples of the process flue gas through the probe to a chamber in front of the
sensor housing where the sample passes the O2 sensor and continues on to
the COe sensor. Dilution air is provided to the COe sensor and reference air
to the O2 sensor. After the gas sample flows past the O2 sensor and through
the COe sensor, it is drawn through the eductor where it mixes with the
eductor air and exits through exhaust back into the system. The electronics
housing contains the CPU and communication boards which convert the
sensor inputs into digital output signals. The CPU can also initiate and
perform calibrations. Three test gasses and instrument air can be turned on
and off by solenoids. Test gas flow to the sensors is regulated by a flow meter
between the electronics and sensor housings. Instrument air is separated into
eductor air, reference air, and dilution air. The instrument air solenoid does not
allow air flow until the heaters are up to temperature. This minimizes the
amount of sampled process flue gas being pulled into cold sensors causing
condensation.
Figure 1-2. System Operation Diagram
SENSOR
HOUSING
ELECTRONICS
HOUSING
Sample
Gas
Exhaust
Probe
COe
Combustibles
Sensor
O
2
Sensor
Eductor
Eductor Air
Solenoids
Instrument Air
Flow Meter
7 scfh
Reference Air
CPU
COMM
Board
Power
Supply
Optional
Test Gas
Solenoid
Dilution Air
Low O
Test Gas
High O
Test Gas
CO
Test Gas
Instrument
Air
Flow Meter
50 cc/min.
(0.1 scfh)
2
2
39690001
1-7
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
It is important that printed circuit boards and integrated circuits are handled only when
adequate antistatic precautions have been taken to prevent possible equipment damage.
The OCX 8800 is designed for industrial application. Treat each component of the system
with care to avoid physical damage. The probe may contain components made from
ceramics, which are susceptible to shock when mishandled.
Handling the OCX 8800
System Considerations
Prior to installing your OCX 8800, make sure you have all the components
necessary to make the system installation. Ensure all the components are
properly integrated to make the system functional.
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 for a system with
integral electronics. Figure 1-4 shows a typical system wiring for a system
with remote electronics. Simplified installations for the OCX 8800 are shown
in Figure 1-5 and Figure 1-6. Figure 1-7 shows the dimensions for the
optional sample tube support. Figure 1-8 shows the dimensions for the
optional in-situ filters. Figure 1-9 shows the optional panel mounted blowback.
A source of instrument air is required at the OCX 8800 for reference air,
dilution air, and eductor air. Since the OCX 8800 is equipped with an in-place
calibration feature, provision should be made for connecting test gas tanks to
the OCX 8800 when it is to be calibrated.
NOTE
The electronics module is designed to meet Type 4X and IP66 (when
reference air vents are routed to a dry area) 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.
1-8
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
Figure 1-3. Communication Connections and AMS Application - OCX 8800 with Integral Electronics
38850004
38850003
Model 375
Field
Communicator
Customer’s
Laptop with AMS
AMS
Instrument
Air
OCX 8800 with
Integral Electronics
3 calibration
gas lines by
customer
[300 ft (91 m) max.)
Signal Output
(Twisted Pairs)
Termination in
Control Room
Figure 1-4. Communication Connections and AMS Application - OCX 8800 with Remote Electronics
OCX 8800
Sensor Housing
Instrument
Air
OCX 8800
Electronics Housing
3 calibration
gas lines by
customer
[300 ft (91 m) max.)
(Twisted Pairs)
Signal Output
Termination in
Control Room
Model 375
Communicator
Customer’s
Laptop with AMS
AMS
Field
1-9
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
Figure 1-5. Typical System Installation - Integral Electronics
Gases
Stack
Test Gas
Flow Meter
Dilution
Air
Flow
Meter
Adapter
Plate
Duct
Figure 1-6. Ty pical System Installation - Remote Electronics
Gases
OCX 8800 with
ELECTRONICS
Pressure
Regulator
High O Test Gas
2
Low O Test Gas
2
CO Test Gas
Duct
INTEGRAL
Signal Outputs
(Twisted Pairs)
Line Voltage
Instrument Air
Supply
(Reference Gas)
37390063
OCX 8800 with
REMOTE
ELECTRONICS
Heater
Power Cable
[up to 150 ft (46 m)]
Signal Cable
[up to 150 ft (46 m)]
Stack
Dilution
Air
Flow
Meter
Test Gas
Flow Meter
Pressure
Regulator
High O Test Gas
Low O Test Gas
CO Test Gas
Signal Outputs
(Twisted Pairs)
Line Voltage
Instrument Air
Supply
(Reference Gas)
2
2
37390064
1-10
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
Figure 1-7. Optional Sample Tube Support
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
1-11
Figure 1-8. Optional InSitu Filters
1/4-18 NPT
1.3
(33)
1/4-18 NPT
7.3
(186)
InSitu Stainless Steel or Hastolloy Filter
2.0
(50)
4.0
(102)
1.8
(46)
InSitu High Surface Area Stainless Steel Filter
Figure 1-9. Optional Panel Mounted Blowback and Calibration/Reference Air Set (19” Rack or Wall Mount)
2.2
(55.9)
5.00
(127)
6.97
(177)
CALIBRATION/BLOWBACK
PANEL
OCX 8800
PROCESS ANALYTICAL DIVISION
1-440-914-1261
www.raihome.com
19.00 (482.6)
DILUTION GAS CAL GAS
16.5 (419.1)
Wall Mount
SET TO 55 PSIG BLOWBACK AIR
OCX88A: 35 PSIG
OCX88C: 45 PSIG
PRESSURE
REFERENCE AIR
PRESSURE
39930006
Wall Mount Hole Pattern
6.0 (152.4)
Wall Mount
39930007
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
1-12
SPECIFICATIONS
Specifications
Net O2 Range 0-1% to 0-40% O2, fully field selectable
Combustibles 0-1000 ppm to 0-5%, fully field selectable
Accuracy
Oxygen ± 0.75% of reading or 0.05% O2 (whichever is greater)
Combustibles ± 2% range
System Response to
Test Gas
Oxygen 10 sec T90
Combustibles 25 sec T90
Temperature Limits
Process 32° to 2600°F (0° to 1427°C)
Sensors Housing -40° to 212°F (-40° to 100°C), ambient
Electronics Housing -40° to 149°F (-40° to 65°C), ambient
-40° to 185°F (-40° to 85°C), internal - operating temperature of
electronics inside instrument housing, as read by HART or
FOUNDATION fieldbus
Local Operator
Interface
Nominal and Approximate
Shipping Weights
18 in. (457 mm)
probe package
3 ft (0.91 m) probe
package
6 ft (1.83 m) probe
package
9 ft (2.74 m) probe
package
Housings Mounting Integral Electronics
Mounting and Mounting
Positions - Remote
Electronics
Sensors Housing Flange
Electronics Housing Wall/Pipe
Materials
Probes 316L stainless steel - 1300°F (704°C)
Enclosures Low-copper aluminum
Calibration Semi-automatic or automatic
Calibration Gas Mixtures
Recommended
(Ref. test gas bottles
kit #1A99119G04)
Calibration Gas Flow 7 scfh (3.3 l/m), regulated to 20 to 30 psi (138 to 207 kPa)
Reference Air 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O2),
Eductor Air 5 scfh (2.5 l/m), clean, dry, instrument-quality air 20.95% O2),
Dilution Air 0.1 scfh (0.05 l/m), clean, dry, instrument-quality air (20.95% O2)
Table continued on next page
-40° to 158°F (-40° to 70°C), ambient
[At temperatures above 158°F (70°C) inside instrument housing,
the infrared keypad will cease to function, but the OCX 8800 will
continue to operate properly.]
54 lbs (20 kg)
55 lbs (20.5 kg)
57 lbs (21 kg)
59 lbs (22 kg)
Flange
Inconel 600 - 1832°F (1000°C)
Ceramic - 2600°F (1427°C)
0.4
8% O2, Balance N2
1000 ppm CO, Balance Air
regulated to 35 psi (241 kPa)
regulated to 35 psi (241 kPa)
regulated to 35 psi (241 kPa)
% O2, Balance N
2
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
1-13
Blowback Air (optional) Clean, dry, instrument-quality air (20.95% O2), regulated to ≥ 60 psi
(413 kPa) or greater and ambient temperature of ≥ 0 °F (-18 °C)
Specifications
Sensors Housing Type 4X, IP66 with fitting and pipe on reference exhaust port to
clean, dry atmosphere, two 3/4-14 NPT conduit ports (when
reference air vents are routed to a dry area).
Electronics Housing Type 4X, IP66 with fitting and pipe on reference exhaust port to
clean, dry atmosphere, two 3/4-14 NPT conduit ports (when
Certifications
Electrical Noise EN 61326-1, Class A
Line Voltage Universal 100 to 240 VAC ±10%, 50 to 60 Hz, no switches or
Pollution Degree 2
Over Voltage Category II
Relative Humidity 5 to 95% (non-condensing)
Isolated Output
Oxygen 4-20 mAdc, 950 ohm maximum, with HART or FOUNDATION
Combustibles 4-20 mAdc, 950 ohm maximum (Not present with FOUNDATION
Alarm Alarm output relay - dry contact, form C, 30mA, 30VDC capacity
Power Consumption 750 W maximum
NOTE
All static performance characteristics are with operating variables constant. Specifications subject to change
without notice.
reference air vents are routed to a dry area).
jumpers required, 3/4-14 NPT conduit port
fieldbus capability only
fieldbus)
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
1-14
OCX88A
O2/Combustibles Transmitter
Code
Probe Length and Material
00
No Probe or Exhaust Tube
11
18 in. (457 mm) 316 SST
up to 1300°F (704°C)
12
3 ft (0.91 m) 316 SST
up to 1300°F (704°C)
13
6 ft (1.83 m) 316 SST
up to 1300°F (704°C)
14
9 ft (2.7 m) 316 SST
up to 1300°F (704°C)
21
18 in. (457 mm) Inconel 600
up to 1832°F (1000°C)
22
3 ft (0.91 m) Inconel 600
up to 1832°F (1000°C)
23
6 ft (1.83 m) Inconel 600
up to 1832°F (1000°C)
24
9 ft (2.7 m) Inconel 600
up to 1832°F (1000°C)
31
18 in. (457 mm) Ceramic
up to 2600°F (1427°C)
32
3 ft (0.91 m) Ceramic
up to 2600°F (1427°C)
Code
Probe Mounting Assembly
10
(ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes - Standard O2 Cell
11
(ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes - High Sulfur O2 Cell
20
(DIN) 185 mm dia. flange, 145 mm BC with 4 x 18 mm dia. holes - Standard O2 Cell
21
(DIN) 185 mm dia. flange, 145 mm BC with 4 x 18 mm dia. holes - High Sulfur O2 Cell
Code
Mounting Hardware - Stack Side
0 No Adapter Plate (“0” must be chosen under “Mounting Adapter - Probe Side” below)
1 New Installation - Square weld plate with studs
2 Model 218/240 Mounting Plate (with Model 218/240 Shield Removed)
3 Existing Model 218/240 Support Shield
4 Competitor’s Mount
(1)
5 Model 132 Adapter Plate
Code
Mounting Hardware - Probe Side
0 No Adapter Plate
1 Probe Only (ANSI)
4 Probe Only (DIN)
Code
Electronics Housing - NEMA 4X, IP66 HART Communications
H1
HART Communications - Basic Unit
H2
HART Communications - Local Operator Interface
H3
HART Communications - Calibration Solenoids
H4
HART Communications - Local Operator Interface and Calibration Solenoids
F1
Fieldbus Communications - Basic Unit
F2
Fieldbus Communications - Local Operator Interface
F3
Fieldbus Communications - Calibration Solenoids
F4
Fieldbus Communications - Local Operator Interface and Calibration Solenoids
Code
Electronics Mounting
01
Integral to Sensor Housing Electronics
02
Split Architecture with no cable
03
Split Architecture with 6M (20 Ft.) cable
04
Split Architecture with 12M (40 Ft.) cable
05
Split Architecture with 18M (60 Ft.) cable
06
Split Architecture with 24M (80 Ft.) cable
07
Split Architecture with 30M (100 Ft.) cable
08
Split Architecture with 45M (150 Ft.) cable
OCX88A
11
10 1 1
H3
06
Example
Table 1-1. Product Matrix - OCX 8800
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
1-15
Cont’d
.
Code
In-Situ Filter
0 None 1
Stainless Steel
2 High Surface Area Stainless Steel
3 Hastelloy
Code
Accessories
0 None 2
Cal. Gas/Flow Rotometers & Ref. Gas Set
3 Cal. Gas/Flow Rotometers & Ref. Gas Set w/ Blowback
4
Cal. Gas/Flow Rotometers & Ref. Gas Set w/ Blowback - Panel
Mounted
OCX88A
11
10 1 1
H3
06 0 0
Example
Plate with studs
Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate.
Plate without studs
Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.
NOTES:
(1)
Provide details of the existing mounting plate as follows:
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
1-16
PART NUMBER DESCRIPTION
Table 1-2. Accessories
1A99119H01 Oxygen test gas bottle; 0.4% O2, balance N
1A99119H02 Oxygen test gas bottle; 8.0% O2, balance N
1A 99119H07 CO test gas bottle; 1000 ppm CO, balance air
1A99120H02 Regulator for Oxygen (may need 2)
1A99120H03 Regulator for CO test gas
1A99119G06 Wall mount bracket for test gas bottles
1A99119G05 Test gas regulators kit
1A99119G04 Test gas bottles kit
1A99292H01
4851B40G02 Wall or Pipe Mounting Kit
1A99784H02
6A00171G01 Power line filter kit
6A00288G01 Sample Tube Support, 18 in. (457 mm)
6A00288G02 Sample Tube Support, 3 Ft. (0.91 m)
6A00288G02 Sample Tube Support, 6 Ft. (1.83 m)
6A00288G04 Sample Tube Support, 9 Ft. (2.7 m)
6P00162H01 Flange Insulator
Moore Industries SPA for Low O2 Alarm, High COe Alarm,
Calibration Status, and Unit Fail
375 Field Communicator with 12 Megabyte buffer,
model no. 375HR1EKLU
2
2
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
Before installing this equipment, read the "Safety instructions for the wiring and installation
of this apparatus" in Appendix A: Safety Data. Failure to follow the safety instructions could
result in serious injury or death.
The OCX88A can be installed in general purpose areas only. Do not install the OCX88A in
hazardous areas.
Section 2 Installation
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-8
Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-13
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-24
MECHANICAL
INSTALLATION
Selecting Location
1.
The location of the OCX 8800 in the stack or flue is most important for
maximum accuracy in the oxygen analyzing process. The probe must
be positioned so the gas it measures is representative of the process.
Best results are normally obtained if the transmitter is positioned near
the center of the duct (40-60% insertion). Longer ducts may require
several transmitters since the oxygen and combustibles can vary due to
stratification. A point too near the wall of the duct or the inside radius of
a bend, may not provide a representative sample because of the very
low flow conditions. The sensing point should be selected so the
process gas temperature falls within the range of probe material used.
Figure 2-1 through Figure 2-5 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 readings. Therefore, either make the necessary repairs or
install the transmitter up stream of any leakage.
3.
Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance access to the unit. Allow
adequate clearance for the removal of the OCX 8800.
Instruction Manual
IM-106-880, Rev 2.1
April 2017
OCX 8800
2-2
Do not allow the temperature of the electronics housing to exceed 185°F (85°C) or damage
to the electronics may result.
Whenever a positive stack pressure exists at the installation site, be sure to connect all
pneumatic lines prior to installing the OCX 8800 in the stack or ductwork. Failure to connect
the pneumatic lines can allow the flow of contaminants into the OCX 8800 ports.
Uninsulated stacks or ducts may cause ambient temperatures in the electronics housing to
exceed 185°F (85°C) and damage the electronics.
Installation
1.
Ensure all components are available to install the OCX 8800.
2.
The OCX 8800 may be installed intact as it is received.
3.
Weld or bolt adapter plate (Figure 2-3) onto the duct.
4.
Use the pipe or wall mounting hardware as shown in Figure 2-4 to
mount a remote electronics housing. Choose a location not to exceed
the length of the electronics cable ordered.
5.
Ensure the conduits drop vertically from the OCX 8800 and the conduit
is routed below the level of the conduit ports on the housing to form a
drip loop. Drip loops minimize the possibility that moisture will damage
the electronics (Figure 2-5).
6.
Where a positive stack pressure exists at the installation site, connect all
pneumatic lines prior to installing the OCX 8800 in the stack or
ductwork.
NOTE
If process temperatures will exceed 392°F (200°C), use anti-seize compound
on stud threads to ease future removal of the OCX 8800.
7.
Insert sample and exhaust tubes through the opening in the mounting
flange and bolt the unit to the flange.
8.
If insulation is removed to access the duct for OCX 8800 mounting,
make sure to replace insulation afterward.
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