Rosemount OCX 8800 O2 / Combustibles Transmitter General Purpose-Rev 2.1 Manuals & Guides

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Reference Manual

00809-0100-4880, Rev AA

July 2018

Rosemount

OCX 8800

Oxygen and Combustibles Transmit t er

General Purpose Probe with Integral Electronics

Reference Manual

July 2018

OCX 8800

TOC-2

00809-0100-4880, Rev AA

Table of Contents

Essential Instructions ................................................................................ i

SECTION i Introduction

SECTION 1 Description and Specifications

SECTION 2 Installation

SECTION 3 Configuration and Startup

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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Reference Manual

00809-0100-4880, Rev AA

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

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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

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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

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00809-0100-4880, Rev AA

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.

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.

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OCX 8800

00809-0100-4880, Rev AA

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.

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.

NOTE

Highlights an essential operating procedure, condition, or statement.

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SYMBOLS

00809-0100-4880, Rev AA

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.

Reference Manual

July 2018

OCX 8800

00809-0100-4880, Rev AA

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.

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1-2

Figure 1-1. Typical System Package

00809-0100-4880, Rev AA

Instruction Manual Field Communicator Package (optional) Adapter Plate with Mounting Hardware and Gasket Reference Air and Calibration Set (optional) Blowback Hardware (optional) OCX 8800 with Remote Electronics OCX 8800 with Integral Electronics

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1-3

00809-0100-4880, Rev AA

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 ( O 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.

) and combustibles (COe) values. This

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:

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

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

T is the absolute temperature.

C is the cell constant.

K is an arithmetic constant.

NOTE

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

When the cell is at operating temperature and there are unequal oxygen concentrations across the cell, oxygen ions will travel from the high oxygen partial pressure side to the low oxygen partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade. The output is proportional to the inverse logarithm of the oxygen concentration. Therefore, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the OCX 8800 to provide exceptional sensitivity at low oxygen concentrations.

1/P2

) + C

1-4

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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, ind icate a lower percent age 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 c on tai n ed i n a s eparat e h ous i ng f r om 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:

Individual 4-20 ma isolated outputs that are proportional to the measured oxygen and combustibles concentrations. The oxygen output also contains HART communication.

Single FOUNDATION fieldbus output.

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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

The O2 cell output voltage and sensitivity increase as the oxygen concentration decreases.

HART or FOUNDATION fieldbus communication is standard. To use this capability, you must have either:

Model 375 Field Communicator.

AMS software for the PC.

Oxygen cell and heater/thermocouple assembly are field replaceable.

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

An operator can calibrate and diagnostically troubleshoot the OCX 8800 in one of two ways:

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.

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.

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.

Optional Blowback System. The blowback system periodically blows instrument air back through the sample lin e f ilter and o ut the s ample tube. This clears out particulate and keeps the sample line filter from clogging.

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Instrument

COMM

Power

Supply

Probe

Sensor

Sample

Gas

Flow Meter

7 scfh

Exhaust

Eductor Air

Flow Meter

(0.1 scfh)

Reference Air

Dilution Air

39690001

Figure 1-2. System Operation Diagram

00809-0100-4880, Rev AA

System Operation

Figure 1-2 shows the relationship between the components of the OCX 8800. The sensors and the electronics are contained in separate housings. The sensor housing and probe mounts to a duct or process wall so that the probe protrudes into the flue gas stream. An air powered eductor continuously pulls samples of the process flue gas through the probe to a chamber in front of the sensor housing where the sample passes the O

sensor and continues on to

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

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.

SENSOR

HOUSING

ELECTRONICS

HOUSING

COe

Combustibles

Sensor

Eductor

CPU

Board

Optional Test Gas Solenoids

Instrument Air

Solenoid

Low O

Test Gas

High O

Test Gas

Air

50 cc/min.

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Handling the OCX 8800

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

The OCX 8800 is designed for industrial application. Treat each component of the system with care to avoid physical damage. The probe may contain components made from ceramics, which are susceptible to shock when mishandled.

System Considerations

Prior to installing your OCX 8800, make sure you have all the components necessary to mak e the system installation. Ens ure al l t he c omponents are properly integrated to make the system functional.

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.

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38850004

38850003

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Figure 1-3. Communication Connections and AMS Application - OCX 8800 with Integral Electro nics

OCX 8800 with

Integral Electronics

Model 375

Communicator

Signal Output

(Twisted Pairs)

Customer’s Laptop

wi th AMS

Instrument

Air

3 calibration gas lines by customer [300 ft (91 m) max.)

Termination in Control Room

AMS

Figure 1-4. Communication Connections and AMS Application - OCX 8800 with Remote Electronics

OCX 8800

Sensor Housing

Model 375

Field

Communicator

OCX 8800

Electronics Housing

Signal Output

(Twisted Pairs)

Customer’s Laptop

wi th AMS

Air

3 calibration gas lines by customer [300 ft (91 m) max.)

Termination in

Control Room

AMS

Instrument

Field

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1-9

37390063 37390064

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Figure 1-5. Typical System Installation - Integral Electronics

Test Gas

Flow Meter

Gases

Stack

Adapter

Plate

Dilution

Air

Flow

Meter

Figure 1-6. Typical System Installation - Remote Electronics

Gases

Heater

Power Ca ble

[up to 150 ft (46 m)]

Signal Cable

[up to 150 ft (46 m)]

Stack

Dilution

Air

Flow

Meter

Duct

Pressure

Regulator

High O Low O CO Test Gas

Duct

OCX 8800 with

INTEGRAL

ELECTRONICS

Signal Outputs (Twisted Pairs)

Line Voltage

Instrument Air

Supply

(Reference Gas)

Test Gas

OCX 8800 with

REMOTE

ELECTRONICS

Test Gas

Flow Meter

Pressure

Regulator

High O2 Test Gas Low O CO Test Gas

Signal Outputs (Twisted Pairs)

Line Voltage

Instrument Air

Supply

(Reference Gas)

Test Gas

1-10

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Figure 1-7. Optional Sample Tube Support

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1-11

1.8

(46)

4.0 (102)

DILUTION GAS CAL GAS

SET TO 55 P SIG BLOWBACK AIR

PRESSURE

CALIBRATION/BLOWBACK

OCX 8800

OCX88A: 35 PSIG REFERENCE AIR OCX88C: 45 PSIG PRESSURE

PROCES S ANA LYTI CAL DIVIS ION

www.raihome.com

2.2 5.00

(55.9) (127)

6.97

(177)

39930006 39930007

16.5 (419.1)

6.0 (

00809-0100-4880, Rev AA

Figure 1-8. Optional InSitu Filters

1/4-18 NPT

(

1/4-18 NPT

(

7.3

InSitu Stainless Steel or Hastolloy Filter

Figure 1-9. Optional Panel Mounted Blowback and Calibration/Reference Air Set (19” Rack or Wall Mount)

InSitu High Surface Area Stainless Steel Filter

PANEL

1-440-914-1261

Wall Mount Hole Pattern

19.00 (482.6)

Wall Mount

Wall

152.4) Mount

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SPECIFICATIONS

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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% O Combustibles ± 2% range

System Response to Test G as

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% O

Eductor Air 5 scfh (2.5 l/m), clean, dry, instrument-quality air 20.95% O

Dilution Air 0.1 scfh (0.05 l/m), clean, dry, instrument-quality air (20.95% O

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)

% O2, Balance N

(whichever is greater)

)

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July 2018

OCX 8800

1-13

Blowback Air (optional) Clean, dry, instrument-quality air (20.95% O2), regulated to ≥ 60 psi

00809-0100-4880, Rev AA

Specifications

(413 kPa) or greater and ambient temperature of ≥ 0 °F (-18 °C)

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)

Reference Manual

July 2018

OCX 8800

1-14

OCX88A

O2/Combustibles Transmitter

Code

Probe Length and Material

No Probe or Exhaust Tube

18 in. (457 mm) 316 SST

up to 1300°F (704°C)

3 ft (0.91 m ) 316 SST

up to 1300°F (704°C)

6 ft (1.83 m ) 316 SST

up to 1300°F (704°C)

9 ft (2.7 m) 316 SST

up to 1300°F (704°C)

18 in. (457 mm) Inconel 600

up to 1832°F (1000°C)

3 ft (0.91 m) Inconel 600

up to 1832°F (1000°C)

6 ft (1.83 m) Inconel 600

up to 1832°F (1000°C)

9 ft (2.7 m) Inconel 600

up to 1832°F (1000°C)

18 in. (457 mm) Ceramic

up to 2600°F (1427°C)

3 ft (0.91 m) Ceramic

up to 2600°F (1427°C)

Code

Probe Mounting Assembly

(ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes - Standard O2 C ell

(ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes - High Sulfur O2 Cell

(DIN) 185 mm dia. flange, 145 mm BC with 4 x 18 mm dia. holes - Standard O2 Cell

(DIN) 185 mm dia. flange, 145 mm BC with 4 x 18 mm dia. holes - High Sulf ur O2 Cell

Code

Mounting Hardware - Stac k 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 Communi cati ons

HART Communications - Basic Unit

HART Communications - Local Operator Interface

HART Communications - Calibration Solenoids

HART Communications - Local Operator Interface and Calibration Solenoids

Fieldbus Communications - Basic Unit

Fieldbus Communications - Local Operator Interface

Fieldbus Communications - Calibration Sol enoids

Fieldbus Communications - Local Operator Interface and Calibration Soleno ids

Code

Electronics Mounting

Integr al to Sensor H ousing Electronics

Split Architecture with no cable

Split Architecture with 6M (20 Ft.) cable

Split Architecture with 12M (40 Ft.) cable

Split Architecture with 18M (60 Ft.) cable

Split Architecture with 24M (80 Ft.) cable

Split Architecture with 30M (100 Ft.) cable

Split Architecture with 45M (150 Ft.) cable

OCX88A

10 1 1

Example

00809-0100-4880, Rev AA

Table 1-1. Product Matrix - OCX 8800

Reference Manual

July 2018

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

Cal. Gas/Flow Rotometers & Ref. Gas Set w/ Blowback - Panel

OCX88A

10 1 1

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.

00809-0100-4880, Rev AA

NOTES:

(1)

Provide details of the existi ng mo unti ng pl at e as foll o ws:

Mounted

Reference Manual

July 2018

OCX 8800

1-16

Table 1-2. Accessories

00809-0100-4880, Rev AA

PART NUMBER DESCRIPTION

1A99119H01 Oxygen test gas bottle; 0.4% O 1A99119H02 Oxygen test gas bottle; 8.0% O2, balance N 1A 99119H07 CO test gas bottle; 1000 ppm CO, balance air

1A99120H02 Regulator for Oxygen (may need 2)

1A99120H03 Regulator for CO test gas

1A99119G06 Wall mount bracket for test gas bottles

1A99119G05 Test gas regulators kit

1A99119G04 Test gas bottles kit

1A99292H01

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 O Calibration Status, and Unit Fail

375 Field Communicator with 12 Megabyte buffer, model no. 375HR1EKLU

, balance N

Alarm, High COe Alarm,

2 2

Reference Manual

July 2018

OCX 8800

00809-0100-4880, Rev AA

Section 2 Installation

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

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-8

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-13

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-24

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.

MECHANICAL INSTALLATION

Selecting Location

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).

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.

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.

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2-2

00809-0100-4880, Rev AA

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

Whenever a positive stack pressure exists at the installation site, be sure to connect all pneumatic lines prior to installing the OCX 8800 in the stack or ductwork. Failure to connect the pneumatic lines can allow the flow of contaminants into the OCX 8800 ports.

Installation

Ensure all components are available to install the OCX 8800.

The OCX 8800 may be installed intact as it is received.

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

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.

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).

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.

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

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

If insulation is removed to access the duct for OCX 8800 mounting, make sure to replace insulation afterward.

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July 2018

OCX 8800

2-3

00809-0100-4880, Rev AA

Enclosures

The OCX 8800 enclosures are designed to meet ingress conditions of Type 4X and IP66 (when reference air vents are routed to a dry area). Each enclosure cover is threaded to its base and sealed with an o-ring that isolates the threads from external contaminants.

Each cover is secured by a clip attached to the base that engages the cover between the ribs of the cover sidewall. The clip is held in place by an Allen head cap screw and lockwasher mounted in a recess. Cover removal and installation requires an Allen wrench to loosen and tighten the screw.

Figure 2-1. Installation, OCX 8800 with Integral Electronics

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OCX 8800

4-2

Figure 2-2. Installation, OCX 8800 with Remote Electronics

00809-0100-4880, Rev AA

Reference Manual

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OCX 8800

2-5

00809-0100-4880, Rev AA

Figure 2-3. Adapter Plate Installat ion

Reference Manual

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OCX 8800

6-2

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

00809-0100-4880, Rev AA

Reference Manual

July 2018

OCX 8800

2-7

Conduit Drip Loops

Duct Wall

Conduit Drip Loop

Duct Wall

37020004

00809-0100-4880, Rev AA

Figure 2-5. Installation with Drip Loops

Reference Manual

July 2018

OCX 8800

8-2

00809-0100-4880, Rev AA

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. Failure to lock out power could result in serious injury or death.

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

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

The OCX88A can be installed in general purpose areas only. Do not install the OCX88A in hazardous areas.

NOTE

To maintain proper earth grounding, ensure a positive connection exists between the sensor housing, the electronics housing, and earth. The connecting ground wire must be 14 AWG minimum. Refer to Figure 2-6.

NOTE

Line voltage, signal, and relay wiring must be rated for at least 105ºC (221ºF).

Electrical Connections

Electrical connections, power and communications are made to the electronic enclosure. The connections are made through two 3/4 NPT ports in the enclosure using fittings and cables provided by the customer. Cable installation must meet NEC, IEC and/or other applicable national or local codes for Class I, Zone 1, IIB +H2 T3/T6 permanently mounted equipment.

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OCX 8800

2-9

00809-0100-4880, Rev AA

Connect Line Voltage

The OCX 8800 operates on 100 to 240 VAC line voltage at 50 to 60 Hz. The power supply requires no setup. Connect the line (L wire) to the L terminal, and the neutral (N wire) to the N terminal on the AC power input terminal block in the electronics housing. Connect the ground (G wire) to the ground stud in the electronics housing as shown in Figure 2-6.

Connect Output Signals

The OCX 8800 may be provided with either two 4-20 mA signals with HART on the O2 signal or a single FOUNDATION fieldbus signal. Connect the output terminals in the electronics housing as shown in Figure 2-6. Use individual shielded twisted wire pairs. Terminate the shield at the electronics housing.

4-20 mA Signal

One 4-20 mA signal represents the O

value. Superimposed on the O

signal is the HART information accessible through a Model 375 Handheld Communicator or AMS software. The O

signal is at the AOUT 1 terminals.

COe 4-20 mA Signal

Another 4-20 mA signal at the AOUT 2 terminals represents the COe value.

FOUNDATION fieldbus Signal

The FOUNDATION fieldbus signal provides all output information and is accessible through a Model 375 handheld communicator.

Alarm Output Relay

Connect any customer-supplied relay input to the alarm output relay terminal. Use shielded wire and terminate the shield at the electronics housing. The alarm output relay terminal is a set of dry, no. 2, form C, contacts with 30 mA, 30 VDC capacity.

Remote Electronics Connections to Sens or Housing

Make the following connections between the remote electronics and sensor housings with the electronics cable ordered with the package (Figure 2-7). Braided cable is available in lengths up to 150 ft. (46 m).

NOTE

Interconnect wiring shown is for Rosemount supplied cables. For customer furnished interconnect wiring or cables, refer to Figure 2-8.

Signal Connections

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

Heater Power Connections

Use the blue, white, orange black, red, and yellow stranded wires in the heater power cable to connect power to the three heaters in the sensor housing. Match the wire colors to the corresponding heater power terminal blocks in the sensor and electronics housings as shown in Figure 2-7.

Reference Manual

July 2018

OCX 8800

10-

Terminal Block

Not used

{

- +

Fieldbus +

{

HART

COe Signal

{

AOUT2+ AOUT2 -

O Signal/

{

AOUT1 -

OUNDATION

HART AOUT1+

Fieldbus

37390013

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

OUNDATION

COM

Alarm Output Relay

Signal Output

Terminal Block

00809-0100-4880, Rev AA

Signal Port

3/4 NPT

TOP VIEW

(1/2 SIZE)

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

EMI Filter

Customer

Wiring

N L1

Terminal

Block

Ground

Stud

Power Port

3/4 NPT

External Tooth

Lockwasher

Reference Manual

July 2018

OCX 8800

2-11

Signal Cable

Heater Power Cable

BLU

BLK

GRN

BLK + BLK - T/C CO

RED + BLK - T/C SB

WHT + BLK

EXC-

BLK - CJC

ORG + BLK

HTR

WHT

ORG - CO

YEL

REF

RED

BLK

GRN

RED - CO

SHIELD

BRN

WHT

ACT

HTR

BLU

YEL

EXC

GRN

37390014

00809-0100-4880, Rev AA

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

YEL RED BLK ORG

WHT

BLU

Heater Power

Connector (J3)

2HTR CO 1HTR CO 2HTR O

1HTR O 2HTR

1HTR SB

2 To

ground

screw

#1 #1

RED

BLK

WHT BLK GRN BLK

BLU BLK

Sensor and

Thermocouple Connector (J5)

T/C CO+ T/C CO-

T/C SB+ T/C SBT/C O2+ T/C O2-

O2 CELL+ O2 CELL-

SHLD

To ground

screw

YEL

BRN

BLK

RED WHT ORG

BLK

EXC+ CO ACT+ CO ACT-

CO REF+ CO REF-

CJC+ CJCEXC-

COe Sensor

and

Cold Junction

Connector (J4)

ELECTRONICS HOUSING

T/C O2

SENSOR HOUSING

HTR

To ground screw

Reference Manual

July 2018

OCX 8800

2-12

37390061

Figure 2-8. Customer-Furnished Interconnect Wiring or Cables

SIGNAL WIRING OR CABLE

NOTE: For RFI/CE compliance, the connector

must provide 360 degrees of electrical contact to the cable shield.

ELECTRONICS END

7.25

±0.10

Strip Wire

Ends 3/16”

Typical

Heat Shrink

Tubing

2” Long

1/2” Size

0.5

Typ.

3/4 NPT Hub Size,

Liquid-tight Strain Relief Connector

See Note

8 twisted pairs 24 AWG, stranded, insulated, tinned copper conductors, 200 volts, with overall braid of 34 AWG tinned copper, 90% coverage and 24 AWG tinned copper, uninsulated drain wire.

4.0 ±0.10

Strip Wire

Ends 3/16”

Typical

Green,

16 AWG

Stud Size

#10

Stud Size

#10

7.25 ±0.10

9.25 ±0.10

ELECTRONICS END

0.5 Typ.

4.5 ±0.10

See Note

2.0 ±0.25 Typical

7.0” Long Teflon Tubing,

0.042” ID (Cut off drain wire at probe end of shield).

Overall Cable Length

By Customer

150’ Maximum

HEATER WIRING OR CABLE

3/4 NPT Hub Size,

Liquid-tight Strain Relief Connectors

Heat Shrink Tubing

2” Long, 1/2” Size

2.0 ±0.25 Typical

4.25” Long Teflon Tubing,

0.042” ID. (Cut off drain wire at probe end of shield).

00809-0100-4880, Rev AA

PROBE END

12.5 ±0.10

10.375 ±0.10

Heat Shrink

Tubing

2” Long

1/2” Size

C, 300

(typical on both ends of wiring)

Heat Shrink Tubing

2” Long, 1/2” Size

8 Conductors, 16 AWG, Stranded,

200

C, 600 volts. Braided shield - tinned copper, 90% coverage with 18 AWG 24 tinned copper, uninsulated, drain wire.

8.625 ±0.10

6.875 ±0.10

3.875 ±0.10

4.625 ±0.10

DETAIL

5.375 ±0.10

6.125 ±0.10

#1 #2

PROBE END

5.5 ±0.10

Ferrule, Uninsulated

Green, 16 AWG

Ferrule, Uninsulated

Heat Shrink Tubing 1” Long, 3/16” Size

Stud Size #6

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July 2018

OCX 8800

2-13

00809-0100-4880, Rev AA

PNEUMATIC INSTALLATION

Pneumatic system connections depend on whether reference air set, calibration solenoids, and/or blowback equipment options are equipped on your transmitter. Refer to the following paragraphs and select the option that applies to your transmitter configuration.

Reference Air Set Option (only)

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

Refer to Figure 2-9. 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 flow meter.

Connect the dilution air flow meter output to the dilution air inlet fitting on the sensor housing.

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% O parts per million. Failure to use proper gases will result in erroneous readings.

One CO gas and two O2 gases are used to calibrate the OCX 8800:

. Do not use gases with hydrocarbon concentrations of more than 40

CO - 1000 ppm or up to 4%, Balance air

low gas - 0.4% , Balance N

O2 high gas - 8%, Balance N

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

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July 2018

OCX 8800

2-14

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

00809-0100-4880, Rev AA

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OCX 8800

2-15

00809-0100-4880, Rev AA

Figure 2-10. Pneumatic Installation, OCX with Reference Air Set, Solenoids and Autocalibration, without COe Zero Function

Reference Air Set and Solenoids Option without COe Zero Function

When the reference air set and test gas solenoids are includ ed with your OCX 8800, use the following procedure to install the pneumatic system components.

Install the reference air set according to the instructions in Reference Air Set Option, steps 1 through 3.

Refer to Figure 2-10. Connect the O2 low gas source to the CAL GAS LO O pressure regulator with gage in the O

Connect the O2 high gas source to the CAL GAS HI O2 inlet fitting. Install a shutoff valve and pressure regulator with gage in the O

inlet fitting on the electronics housing. Install a shutoff valve and

low supply line, as shown.

high

supply line.

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OCX 8800

2-16

00809-0100-4880, Rev AA

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

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

Reference Air Set and Solenoids Option with COe Zer o F un ction

Figure 2-11 shows the piping arrangement for the OCX 8800 with autocalibration when the COe Zero Function is used. The arrangement is similar to Figure 2-10 except instrument air is used as the Hi O Refer to Section 3 for details of this function.

Figure 2-11. Pneumatic Installation, OCX with Reference Air Set, Solenoids and Autocalibration, with COe Zero Function

test gas.

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OCX 8800

2-17

00809-0100-4880, Rev AA

Reference Air Set, Solenoids, and Blowback Option with COe Zero Function

Figure 2-13 shows the piping arrangement for the OCX 8800 with the blowback and autocalibration options when the COe Zero Function is used. The arrangement is similar to Figure 2-12 except instrument air is used as the

test gas. Refer to Sectio 3 for details of the function.

Hi O

Reference Air Set, Solenoids, and Blowback Option without COe Zero Function

Installing an OCX 8800 with the blowback option requires the addition of air operated blowback valve, regulator and gage, and check valve.

Figure 2-12 shows the piping arrangement for the OCX 8800 with the blowback and autocalibration options. Figure 2-14 shows the piping arrangement for the OCX 8800 with the blowback option, but without autocalibration (without test gas solenoids).

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

Connect the calibration gas sources according to the instructions in the previous paragraph “Reference Air Set and Solenoids Option”, steps 2 through 5.

Connect a clean, dry, instrument-quality supply of air (20.95% O2) to the 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.

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 flow meter.

Connect the dilution air flow meter output to the DILUTION AIR inlet fitting on the sensor housing.

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

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

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.

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.

Reference Manual

July 2018

OCX 8800

2-18

00809-0100-4880, Rev AA

Figure 2-12. Pneumatic Installation, OCX with Reference Air Set, Solenoids, Blowback and Autocalibration, without COe Zero Function

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July 2018

OCX 8800

2-19

00809-0100-4880, Rev AA

Figure 2-13. Pneumatic Installation, OCX with Reference Air Set, Solenoids, Blowback and Autocalibration, with COe Zero Function

Reference Air Set, Solenoids, and Blowback Option with COe Zero Function

Figure 2-13 shows the piping arrangement for the OCX 8800 with the blowback and autocalibration options when COe Zero Function is used. The arrangement is similar to Figure 2-12 except instrument air is used as the Hi

test gas. Refer to Section 3 for details of this function.

Reference Manual

July 2018

OCX 8800

2-20

00809-0100-4880, Rev AA

Figure 2-14. Pneumatic Installation, OCX with Reference Air Set and Blowback without Autocalibration

Reference Manual

July 2018

OCX 8800

2-21

LO O

HI O

39930003

00809-0100-4880, Rev AA

Reference Air Set and Blowback Panels

An optional blowback panel is shown in Figure 1-9. Piping arrangement for blowback panel without autocalibration without COe Zero Function is shown in Figure 2-15. Piping arangement for blowback panel with autocalibration without COe Zero Function is shown in Figure 2-16. Piping arrangement for blowback panel with autocalibration with COe Zero Function is shown in Figure 2-17.

Figure 2-15. Pneumatic Instal lat ion, Blo wbac k Panel witho ut Autoc a l ibrat ion wit hout COe Zero Function

Check Valve

Sensor Housing

Eductor Air In

CAL Gas In

Instrument Air

Reference Air In

Dilution Air In

Instrument

Air Supply

CAL Gas

Out

CAL Gas

Regulators

2-Stage

Dilution

Air Out

Instrument Air to Electronics

Blowback

Air Out

Blowback

Control Air

Instrument

Air Out

Actuating Air

Electronics

Housing

Reference Manual

July 2018

OCX 8800

2-22

LO O

HI O

39930004

00809-0100-4880, Rev AA

Figure 2-16. Pneumatic Installation, Blowback Panel with Autocalibration without COe Zero Function

Check Valve

Eductor Air In

Instrument Air

Reference Air In

Dilution Air In

Instrument

Air Supply

CAL Gas

Out

CAL Gas

Electronics

Housing

Dilution

Air Out

Instrument

Air t o

Electronics

Blowback

Air Out

Blowback

Control Air

Instrument

Air Out

CAL Gas

Out

2-Stage

Regulators

Actuating Air

Sensor Housing

CAL Gas In

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Figure 2-17. Pneumatic Installation, Blowback Panel with Autocalibration with COe Zero Function

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INITIAL STARTUP Observe the following Caution and Note. Refer to Section 3: Configuration

and Startup, for OCX 8800 startup information.

Upon completing installation, make sure that the OCX 8800 is turned on and operating prior to firing up the combusti on process . Damage can res ult from having a cold OCX 8800 exposed to the process gases.

If ducts will be washed down during outages, make sure to power down the OCX 8800 units and remove them from the wash area.

NOTE

During outages, and whenever possible, leave OCX 8800 units running to prevent condensation and premature aging from thermal cycling.

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Section 3 Configuration and Startup

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1

Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-4

Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-4

Calibration Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-5

Blowback Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-6

Calibration Verify Feature . . . . . . . . . . . . . . . . . . . . . . . . . page 3-7

Calibration Tolerance Feature . . . . . . . . . . . . . . . . . . . . . . page 3-9

COe PURGE / ZERO FEATURE . . . . . . . . . . . . . . . . . . . . . page 3-10

OCX 8800 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . page 3-12

OCX 8800

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.

VERIFY INSTALLATION Ensure the OCX 8800 is installed correctly. Verify mechanical installation and

all electrical and pneumatic connections. Refer to Section 2, Installation.

Make sure that the OCX 8800 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold OCX 8800 exposed to the process gases.

NOTE

During outages, and whenever possible, leave all OCX 8800 units running to prevent condensation and premature aging from thermal cycling.

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Verify Configuration - HART Electronics

There are three switches on the microprocessor board which are user configurable for the OCX 8800 with HART electronics (Figure 3-1). SW1 determines if the O determines if the COe 4-20 mA signal is internally or externally powered. SW3 sets the rail limits for the O sample line heater control circuit. All switches are accessible through holes in

the electronics box.

Remove power from the OCX 8800 before changing defaults. If defaults are changed under power, damage to the electronics may occur.

Figure 3-1. OCX 8800 Defaults - HART Electronics

00809-0100-

4-20 mA signal is internally or externally powered. SW2

and COe 4-20 mA signals and configures the

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Verify that the following switch settings are correct for your OCX 8800 installation:

SW1 The two settings are internally or externally powering the O2 4-20 mA signal. The factory setting is for the O powered.

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

SW3 The factory sets this switch as follows:

•

Position 1 determines the O2 4-20 mA signal rail limit. The settings are high, 21.1 mA, or low, 3.5 mA. The factory setting is low, 3.5 mA.

•

Position 2 determines the COe 4-20 mA signal rail limit. The settings are high, 21.1 mA, or low, 3.5 mA. The factory setting is high, 21.1 mA.

•

Positions 3 and 4 must be set as shown for proper software control of the device heaters.

Verify Configuration - Fieldbus Electronics

4-20 mA signal to be internally

There is one switch on the microprocessor board which must be set for the OCX 8800 with fieldbus electronics (Figure 3-2). SW3 configures the sample line heater control circuit. This switch is accessible through holes in the electronics box.

Remove power from the OCX 8800 before changing defaults. If defaults are changed under power, damage to the electronics may occur.

Verify that the following switch settings are correct for your OCX 8800 installation:

SW3 The factory sets this switch as follows:

•

Position 1 not used.

•

Position 2 not used.

•

Positions 3 and 4 must be set as shown for proper software control of the device heaters.

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Figure 3-2. OCX 8800 Defaults Fieldbus Electronics

00809-0100-

INITIAL POWER UP Allow adequate time (approximately 60 minutes) for the heaters to begin

operation and for the OCX 8800 to reach normal operating temperature on power up. Normal operating temperature for the O

operating temperature for the combustibles cell is 300°C. The normal sample line temperature is 170°C. During this time the eductor air solenoid will remain closed so no sample is pulled through the analyzer. When the OCX reaches operating temperature the solenoid will energize, eductor air will begin to flow, and the unit will begin normal operation.

cell is 736°C. Normal

SET TEST GAS VALUES Use Field Communicator or the optional LOI to set test gas values for

calibration. Refer to Section 4, Using the LOI or Section 6, Field Communicator for more information.

Setting Test Gas Values with the Field Communicator

Use the 375 Field Communicator software to access the HART menu.

From the DETAILED S ETUP menu, select CAL SETUP.

From the CAL SETU P menu, select O2 CAL PARAMS or COe CAL PARAMS.

From O2 CAL PARAMS, select O2 HIGH GAS. Enter the percent O used for the high O2 test gas.

From O2 CAL PARAMS, select O2 LOW GAS. Enter the percent O used for the low O2 test gas.

From COe CAL PARAMS, select COe Test Gas. Enter the CO concentration (ppm) used for COe test gas.

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Setting Test Gas Values with Fieldbus Communicator

Use the 375 Field Communicator software to access the Fieldbus menu.

From the TRANSDUCER menu, select O2 CAL.

From O2 CAL menu select O2 CAL SETUP.

From O2 CAL SETUP, select O2 HIGH GAS. Enter the percent O2 used for the high test gas.

From O2 CAL SETUP, select O2 LOW GAS. Enter the percent O2 used for the low test gas

From the TRANSDUCER menu select COe CAL SETUP.

From COe CAL SETUP, select COe Test Gas. Enter the CO concentration (ppm) used for the COe Test Gas.

Setting Test Gas Values with the LOI

Use the "Z" pattern to enter the LOI menu tree.

From the SYSTEM menu, select Calib Setup.

From Calib Setup, select O2 High Gas %. Enter the percent O2 used for the high O

Select the down arrow and the next selection will be O2 Low Gas %. Enter the percent O

Select the down arrow several times to display COe Test Gas. Enter the CO concentration (ppm) used for COe test gas.

test gas.

used for the low O2 test gas.

CALIBRATION SOLENOIDS

The OCX 8800 can be provided with optional calibration solenoids for the purpose of performing autocalibration. The solenoids are controlled by the OCX 8800 software and automatically switch in the proper calibration gas during the calibration cycle.

An OCX 8800 shipped from the factory with calibration solenoids must be configured before autocalibration can be implemented. This same process must be performed any time a replacement card stack is installed.

Configuring the Calibration Solenoids with the Field Communicator - HART

Use the 375 Field Communicator to access the HART menu.

From the DETAILED SET U P menu, select CAL SETUP.

From the CAL SETU P menu, select O2 CAL PARAMS/COe CAL PARAMS.

From the O2 CAL PARAMS/COe CAL PARAMS, select Solenoids. Select Yes to enable the solenoids.

Configuring the Calibration Solenoids with the Field Communicator Fieldbus

Use the 375 Field Communicator to access the Fieldbus menu.

From the TRANSDUCER block menu, select O2 CAL/COE CAL.

From the O2 CAL/COE CAL menu, select O2 CAL SETUP/COE CAL SETUP.

From the O2 CAL SETUP/COE CAL SETUP, select Solenoids. Select

Present to enable the solenoids.

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Configuring the Calibration Solenoids with the LOI

Use the "Z" pattern to enter the LOI menu tree.

From the SYSTEM menu, select Calib Setup.

From the Calib Setup menu, select Use Solenoids. Select Yes to enable the solenoids.

BLOWBACK FEATURE The blowback feature blows instrument air back through the center of the

internal filter and out the sample tube of the probe. This removes built up dirt and particulate from the internal filter, sample line and any optional in-situ filter on the end of the sample tube. The blowback feature is normally used in systems that have heavy particulate in the process stream.

The blowback feature requires the optional blowback hardware to be properly installed external to the OCX 8800. See Section 2, Pneumatic Installation, for details.

An OCX 8800 shipped from the factory must be configured before blowback can be implemented. This same process must be performed any time a replacement card stack is installed.

Configuring Blowback with the Field Co m municator - HART

Use the 375 Field Communicator or AMS software to access the HART menu.

From the DETAILED SETUP menu, select INPUT/OUTPUT.

From the INPUT/OUTPUT menu, select BLOWBACK.

From the BLOWBACK, select BlBk Enabled. Select Yes to enable blowback. Also set the following parameters:

BlBk Intrvl - Length of time between blowback events (60 minutes recommended).

BlBk Period - Length of time blowback is activated (5 seconds recommended).

BlBk Purge Time - Length of time after blowback is complete before oxygem/combustibles readings are considered valid (Set as required by the application).

Manually initiate blowback from DIAG/SERVICE, then BLOW BACK, When select BLOWBACK.Configuring Blowback with the Field Communicator - Fieldbus

Use the 375 Field Communicator or AMS software to access the Fieldbus menu.

From the TRANSDUCER block menu, select Alarm Relay/Blowback.

From the Alarm Relay/Blowback menu, select Blowback.

From the Blowback menu, select Blowback Enab led . Also set the following parameters:

Blowback Interval - Length of time between blowback events (60 minutes recommended).

Blowback Period - Length of time blowback is activated (5 seconds recommended).

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Blowback Purge Time - Length of time after blowback is complete before oxygem/c om bus tible s r ead ings ar e c onsi der ed va lid ( S et as required by the application).

Initiate Blowback - Initiates a blow back event manually.

Configuring Blowback with the LOI

Use the "Z" pattern to enter the LOI menu tree.

From the SYSTEM menu, select Blow Back.

From the Blow Back menu, select Blow Bk Enable. Select Yes to enable blowback. Also set the following parameters:

Blow Bk Intrvl - Length of time between blowback events. Range is 0 to 32,000 minutes. Default is 60 minutes. 60 minutes is recommended.

Blow Bk Period - Length of time blowback in activated. Range is 1 to 5 seconds. Default is 2 seconds. 5 seconds is recommended.

Blow Bk Purge - Length of time after blowback is complete before oxygem/combustibles readings are considered valid. Range is 0 to 500 seconds. Default is 88 seconds. Set as required by the application.

CALIBRATION VERIFY FEATURE

Force Blow Bk - Initiates a blow back event manually.

The calibration verify feature flows one or more calibration gases to verify the analyzer is reading correctly. The calibration verify feature flows each calibration gas on demand to verify calibration, but does not change the slope or constant of the current calibration. This function uses the same gas flow and purge times from the basic calibration setup.

The calibration verify feature is only valid if the OCX 8800 is supplied with calibration solenoids and the solenoids have been activated.

During the Calibration Verify function the analog output signals will track the oxygen and combustibles readings. To avoid a potentially dangerous operating condition, the OCX 8800 must be removed from the automatic combustion control loop before performing the Calibration Verify procedure.

Performing a Calibration Verify with the Fiel d Communicator - HART

Use the 375 Field Communicator or AMS software to access the HART menu.

From the DEVICE SETUP menu, select DIAG/SERVICE.

From the DIAG/SERVICE menu, select CALIBRATION.

From the CALIBRATION, select CAL VERIFY. Select Verify

Calibration. From this menu, select the functions as follows: Flow High O2 Gas - Flows the high O2 test gas for the time specified in

the calibration setup. Flow Low O2 Gas - Flows the low O2 test gas for the time specified in

the calibration setup. Flow High COe Gas - Flows the COe test gas for the time specified in

the calibration setup.

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Purge Gas - Initiates a delay for the specified purge time before oxygen/combustibles readings are considered valid.

NOTE: A Purge will automatically follow a gas flow.

Performing a Calibration Verify with the Fiel d Communicator - Fieldbus

Use the 375 Field Communicator or AMS software to access the Fieldbus menu.

From the TRANSDUCER block menu, select METHODS.

Set the Mode to OOS (Out of Service) before starting the Calibration Verify process.

From the METHODS menu, select OCX Cal Verify. From this menu, select the functions as follows:

Flow High O2 Gas - Flows the high O2 test gas for the time specified in the calibration setup.

Flow Low O2 Gas - Flows the low O2 test gas for the time specified in the calibration setup.

Flow High COe Gas - Flows the COe test gas for the time specified in the calibration setup.

Purge Gas - Initiates a delay for the specified purge time before oxygen/combustibles readings are considered valid.

NOTE: A Purge will automatically follow a gas flow.

Performing a Calibration Verify with the LOI

Use the "Z" pattern to enter the LOI menu tree.

From the CALIBRATION menu, select Cal Verify.

From the Cal Verify menu, select the functions as follows: Flow High Gas - Flows the high O2 test gas for the time specified in the

calibration setup.

Flow Low Gas - Flows the low O2 test gas for the time specified in the

calibration setup.

Flow COe Gas - Flows the COe test gas for the time specified in the

calibration setup.

Purge - Initiates a delay for the specified purge time before

oxygen/combustibles readings are considered valid.

NOTE: A Purge will automatically follow a gas flow.

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CALIBRATION TOLERANCE FEATURE

The calibration tolerance feature provides a mechanism to fail a calibration if the calibration measurement does not fall within a specific tolerance of the test gas value. The tolerance is preset within the OCX 8800 software and is not user adjustable. The tolerance is different between the oxygen and combustibles test gases. For oxygen, the calibration will fail if the measured value differs by more than ±10% of the configured value. For combustibles, the calibration will fail if the measured value differs by more than ±30% of the configured value.

An OCX 8800 shipped from the factory must be configured before the calibration tolerance feature can be implemented. This same process must be performed any time a replacement card stack is installed.

Configuring the Calibration Tolerance Feature with the Field Communicator - HART

Use the 375 Field Communicator or AMS software to access the HART menu.

From the DETAILED S ETUP menu, select CAL SETUP.

From the CAL SETU P menu, select O2 CAL PARAMS.

To enable the calibration tolerance feature for the oxygen calibration, from the O2 CAL PARAMS, select O2 Tol Check. Select On to enable the calibration tolerance feature.

Back out to the CAL SETUP menu, select COe CAL PARAMS.

To enable the calibration tolerance feature for the combustibles calibration, from the COe CAL PARAMS, select COe Tol Check. Select On to enable the calibration tolerance feature.

Configuring the Calibration Tolerance Feature with the Field Communicator - Fieldbus

Use the 375 Field Communicator or AMS software to access the Fieldbus menu.

From the TRANSDUCER block menu, select O2 CAL/COe CAL.

From the O2 CAL/COe CAL menu, select O2 CAL SETUP/COe CAL SETUP.

From the O2 CAL SETUP/COe CAL SETUP menu, select O2 Tolerance Check/COe Tolerance Check. Selec t Yes to enable the calibration tolerance feature.

Configuring the Calibration Tolerance Feature with the LOI

Use the "Z" pattern to enter the LOI menu tree.

From the SYSTEM menu, select Calib Setup.

From the Calib Setup menu, select the following:

O2 Tol Check - Select Yes to enable the calibration tolerance feature for the oxygen calibration.

Comb Tol Check - Select Yes to enable the calibration tolerance feature for the combustibles calibration.

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COe PURGE / ZERO FEATURE

This feature provides a way to periodically flood the COe sensor with air to perform two functions; a) provide additional oxygen to help burn off any combustible residue from the COe sensor, and b) allow for optional adjustment of the COe calibration constant. If the OCX8800 is configured to update the COe calibration constant, only the constant is updated. The COe calibration slope is not affected. To update both the constant and slope a full calibration must take place.

The feature uses the calibration solenoid that is also used for high O2 test gas and COe zero gas. For the feature to work properly, instrument air is used as the high O2 test gas. This also requires the high O2 test gas value to be set at 20.95%.

As an option, a two way valve may be installed to switch the high O2 test gas between the normal calibration gas and instrument air. This allows the OCX 8800 to use a specified calibration gas for calibration, then instrument air for the COe zero feature. Switching between the two gases must be manually coordinated between scheduled calibrations and COe zero events.

When the COe zero feature is used, special pneumatic connections are required. See Section 2, Pneumatic Installation, for details.

The COe zero feature is only valid if the OCX 8800 is supplied with calibration solenoids and the solenoids have been activated.

An OCX 8800 shipped from the factory must be configured before the COe zero feature can be implemented. This same process must be performed any time a replacement card stack is installed.

During the COe Zero Function the analog output signals may track the oxygen and combustibles readings if configured to do so. To avoid a potentially dangerous operating condition, the OCX 8800 must be removed from the automatic combustion control loop before performing the COe Zero Function procedure.

At the completion of the COe Zero Function, the COe analog output signal will change if the Zero Update parameter is set to "Yes".

Configuring the COe Zero Feature with the Field Communicator - HART

Use the 375 Field Communicator or AMS software to access the HART menu.

From the DETAILED SETUP menu, select INPUT/OUTPUT.

From the INPUT/OUTPUT menu, select COE ZERO.

From the COE ZERO menu, select the functions as follows:

Zero Enabled - Select "Yes" or "No" to enable or disable this feature. Zero Intrvl - Length of time between COe zero events. Range is 60 to

480 minutes. Default is 60 minutes.

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Zero Flow - Length of time COe zero gas flows. Range is 120 to 600 seconds. Default is 120 seconds.

Zero Purge - Length of time after COe zero is complete before oxygen/combustibles readings are considered valid. Range is 60 to 180 seconds. Default is 60 seconds. Total duration of this function is flow time plus purge time.

Zero Tracks - Determines if the analog output signals track or hold during the function. Valid choices are None, Both, COe, and O2.

Zero Update - Determines if the COe calibration constant is updated at the end of the function. Valid ch oices ar e Yes and No. A Yes choice w i ll cause the COe calibration constant to update.

Configuring the Calibration Tolerance Feature with the Field Communicator - Fieldbus

Use the 375 Field Communicator or AMS software to access the Fieldbus menu.

From the TRANSDUCER block menu, select COe ZERO.

From the COe ZERO menu, select the functions as follows:

COe Zero Enable - Select "Yes" or "No" to enable or disable this feature.

COe Zero Interval - Length of time between COe zero events. Range is 60 to 480 minutes. Default is 60 minutes.

COe Zero Duration - Length of time COe zero gas flows. Range is 120 to 600 seconds. Default is 120 seconds.

COe Zero Purge Time - Length of time after COe zero is complete before oxygen/combustibles readings are considered valid. Range is 60 to 180 seconds. Default is 60 seconds. Total duration of this function is flow time plus purge time.

COe Zero Output Track - Determines if the analog output signals track or hold during the function. Valid choices are None, Both, COe, and O2.

COe Zero Update - Determines if the COe calibration constant is updated at the end of the function. Valid choices are Yes and No. A Yes choice will cause the COe calibration constant to update.

Configuring the COe Zero Feature with the LOI

Use the "Z" pattern to enter the LOI menu tree.

From the SYSTEM menu, select Input/Output.

From the Input/Output menu, select COe Zero. Select the functions as follows:

COe Zero Enable - Select "Yes" or "No" to enable or disable this feature.

COe Zero Intrvl - Length of time between COe zero events. Range is 60 to 480 minutes. Default is 60 minutes.

COe Zero Flow - Length of time COe zero gas flows. Range is 120 to 600 seconds. Default is 120 seconds.

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COe Zero Purge - Length of time after COe zero is complete before oxygen/combustibles readings are considered valid. Range is 60 to 180 seconds. Default is 60 seconds. Total duration of this function is flow time plus purge time.

COe Zero Tracks - Determines if the analog output signals track or hold during the function. Valid choices are None, Both, COe, and O2.

COe Zero Update - Determines if the COe calibration constant is updated at the end of the function. Valid choices are Yes and No. A Yes choice will cause the COe calibration constant to update.

OCX 8800 RESET PROCEDURE

Whenever you correct an equipment alarm or fault condition, the OCX 8800 will either revert to normal operation or continue to indicate an alarm status condition. If the equipment does not revert to normal operation when a fault condition is cleared, or if instructed to do so in Section 8, Troubleshooting, use the following procedure to reset the OCX 8800.

OCX Reset with the LOI

Use the "Z" pattern to enter the LOI menu tree. (Refer to Section 4, Using the LOI).

Select the SYSTEM submenu.

From the SYSTEM submenu, select the Status submenu.

From the Status submenu, select Reset Device. The OCX 8800 will reset and the LOI will revert to the normal operation display.

OCX Reset with the Field Communicator

Remove the OCX 8800 from the process loop and recycle power.

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Section 4 Using the LOI

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1

Display Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1

LOI Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-2

LOI Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-4

OVERVIEW This section describes the installation and operation of the LOI module in the

OCX 8800.

DISPLAY ORIENTATION The LOI module mounts to a connector on the LOI board. The board is

installed on the end of the electronics stack in the electronics housing, Figure 4-1. There are four mating connectors on the back of the LOI module that allow the LOI to be oriented as desired by the user.

Figure 4-1. LOI Components Mounting

Electronics Housing

(Cover Removed)

Electronics Stack

LOI Connector

LOI Board

LOI Module

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Overview The LOI, shown in Figure 4-2, utilizes a bright blue gas-fluorescent display.

Intensity is adjustable. There is an Infrared LED source and a detector for each key. The detectors can detect a finger placed above the button through the glass window. There is no need to open the instrument in bad weather or in hazardous areas in order to access the electronics.

It should be noted that the OCX 8800 also uses HART or F

OUNDATION

Fieldbus communications, permitting access to all instrument functionality anywhere the digital O

signal terminates via a model 375 Field

communicator.

Figure 4-2. LOI Assembly

Selection

Arrow

(Enter key)

Touch

Confirmation

LED

Selection

Arrow

Lockout

Notation

Display

Window

Analytical

Selection

Arrows

Status

Code

LOI Key Functions The gray (top left) key will move one level higher in the menu structure. When

entering parameter values (numbers), this key moves the cursor to the left. The left-pointing key also doubles as an Enter key, used after the digits of a parameter value are entered, and the cursor is moved to its left-most position. When the Enter key is touched, the new parameter value, if accepted, will appear in the top line of the display.

The blue (bottom left) key acts as a selector when choosing from among several menu items. This right-pointing key also will move the cursor to the right when entering the digits of a new parameter value.

The up and down-pointing keys are used to increment up and down when selecting from a vertical list of menu items. These keys are also used for incrementing values up and down for new data input.

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Figure 4-3. ‘Z’ Pattern Entry

Lockout

The LOI has a lockout feature that prevents nuisance actuation by someone brushing against the glass window, raindrops, dirt, insects, etc. This lockout mode is automatically established when no buttons are pushed for 30 seconds (default). This countdown to lockout is configurable.

In order to unlock the display, input a "Z" pattern (Figure 4-3). First, touch the top left (gray) Enter key. Next, touch the top right key, followed by the bottom left key and the bottom right key. The LK notation in the upper right corner of the display will disappear. T ouc h the Enter key once more to enter into the menu structure. Whenever a key is touched additional time to lockout is provided, so that the lockout feature does not become a nuisance. This additional revert time is one hour (default) and is also user configurable.

NOTE

Always clean dust and soil away from the LOI screen each time the LOI is used. Excessive dust can prevent the LOI from entering lockout. This condition can cause uncommanded operations to occur.

LOI Status Codes The LOI display shows a status code in the lower right hand corner of the

Table 4-1. LOI Status Codes

display. There are nine status codes to indicate the existing status of the device during operation. The status code descriptions are shown in Table 4-1.

AL Alarm - The device is in a recoverable alarm state.

BL Blowback - A blowback cycle is active. CA Calibration - A calibration cycle is active. CV Calibration Verify - A calibration verify task is in progress. NM Normal - The device is in a normal operating mode.

WU Warm Up - The device heaters are ramping up to operating temperature.

CZ COe Zero - The COe Zero cycle is active.

Power On - A system level initialization sequence is active. This will continue for several seconds.

System Fault - The device is in a non-recoverable alarm condition. The unit must be reset or power must be cycled off and on to resume operation.

Stabilize - The device heater control is stabi li zi ng (aft er warm up). Sensors are warming up to operating temperature.

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LOI MENU TREE This section consists of a menu tree for the LOI on the OCX 8800, Figure 4-4.

This menu is specific to the OCX 8800.

First Column Submenus

Figure 4-4. LOI Menu Tree (Sheet 1 of 4)

From the operating display (O the only option to move into the first column submenus of the LOI menu tree.

The first column contains three submenus: SENSOR DATA, Figure 4-4 sheet 1 of 4, CALIBRATION, sheet 2 of 4, and SYSTEM, sheets 3 and 4 of 4. From the operating display, SENSOR DATA is displayed when the right-pointing key is selected. Use the up or down-pointing key to move to the other first column submenus.

Second Column Submenus

From the first column submenus, selecting the right-pointing key moves the display into the second column submenus. The up and down-pointing keys allow the display to move to the second column submenus of the first column submenu selected. The left-pointing key moves the display back to the first column submenu.

Third and Fourth Column Submenus

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

% and COe ppm), the left-pointing Enter key is

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Abort Cal

Start Cal COe

Start Cal Both

Apply Lo O2 Gas

Cal Control

Cal Constants

Cal Status

Cal Verify

Apply Lo COe Gas Apply Lo O2 Gas

Current Calib

Prev Calib

Falied Calib

ppm/mV

Bad COe Const mV

Next COe Cal

NOTE: “Hit E when ready” is displayed during

automatic calibration only (when

Calib Setup value Use Solenoids = n).

CALIBRATION

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Figure 4-4. LOI Menu Tree (Sheet 2 of 4)

(CONTINUED FROM

SHEET 1)

Start Cal

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

Hit E when ready

Flow COe Lo s

% mV

Read COe Lo s

% mV

Apply Hi COe Gas

Hit E when ready

Flow COe Hi s

% mV

Read COe Hi s

% mV

Hit E when ready

Purge s

(CONTINUED ON

SHEET 3)

Hit E when ready

Flow O2 Lo s

% mV

Read O2 Lo s

% mV

Apply Hi O2 Gas

Calib Result Calib Step Calib Time Next O2 Cal

Flow High Gas Flow Low G as Flow COe Gas Purge Status

Hit E when ready

Flow O2 Hi s

% mV

Read O2 Hi s

% mV

O2 Slope mV/D O2 Constant mV O2 Sensor R ohm COe Slope COe Constant mV

Pre O2 Slope mV/D Pre O2 Const mV Pre O2 Sensor R ohm Pre COe Slope Pre COe Const mV

Bad O2 Slope mV/D Bad O2 Const mV Bad COe Slope ppm/mV

semi-

Hit E when ready

Purge s Flow COe Hi s

% mV

Read COe Hi s

% mV

Hit E when ready

Purge s

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Figure 4-4. LOI Menu Tree (Sheet 3 of 4)

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Parameters

Software

Status

Alarms

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Figure 4-4. LOI Menu Tree (Sheet 4 of 4)

(CONTINUED FROM

SHEET 3)

SYSTEM

O2 Slope mV/D

O2 Constant mV

O2 T90 Time seconds

COe Slope ppm/ohm COe Constant ohm COe T90 Time seconds Lockout Time seconds

Revert Time minutes

Luminance %

PCDC Enable Y/N PCNC Enable Y/N

Version Checksum Build Number Build Date Restart Count SW Err File SW Err Line SW Err Number

CPLD Registers Line Frequency Line Voltage PCD Counter PCN Counter Reset Device Sensor Housing Serial Number

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Section 5 Calibration

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

Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . page 5-1

Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . page 5-3

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-4

D/A Trim Procedures - LOI . . . . . . . . . . . . . . . . . . . . . . . . . page 5-12

D/A Trim Procedures - HART . . . . . . . . . . . . . . . . . . . . . . . page 5-14

OVERVIEW During a calibration, two calibration gases with known O

one calibration gas with a known COe concentration are applied to the OCX

8800. Slope and constant values are calculated to determine if the OCX 8800 is correctly measuring net concentrations of O

industrial process. Before calibrating the OCX 8800, verify that the calibration gas parameters

are correct by setting the test gas values used when calibrating the unit. Refer to Section 3, Configuration and Startup.

and combustibles in the

concentrations and

FULLY AUTOMATIC CALIBRATION

There are three calibration methods available to the OCX 8800; automatic, operator-initiated automatic, and manual. Calibration commands and menus can be accessed by 375 Field Communicator or by the optional LOI.

If the OCX 8800 is equipped with calibration solenoids, the unit can be programmed to automatically calibrate without any operator action. Refer to the following paragraphs for using the LOI or 375 Field Communicator to set up the OCX 8800 for fully automatic calibration.

Autocalibration Setup using the optiona l LOI

Use the following procedure to set up the OCX 8800 for automatic calibration. If necessary, use the LOI menu tree in Figure 4-4 for reference. The unit must be equipped with calibration solenoids to use automatic calibration.

NOTE

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

From the operating display use the right-pointing key to select SYSTEM first column submenu.

From the SYSTEM first column submenu, use the right-pointing key to select the Calib Setup second column submenu.

From the Calib Setup second column submenu, use the right-pointing key to select the third column parameter list.

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Scroll down to the last item Use Solenoids. If the unit is equipped with calibration solenoids and timed automatic calibration is desired, select Yes.

Use the up-pointing key to select the item O2 Out Tracks. Select Yes or No to determine if updates to the O

Use the down-pointing key to select the item COe Out Tracks. Select

lock value will take place.

Yes or No to define if updates to the COe lock value will take place.

Use the down-pointing key to select the item O2 Cal Interval. Enter the amount of time in days and hours that is desired between automatic calibrations.

Use the down-pointing key to select the next item O2 Next Cal. Enter the amount of time in hours until the next automatic calibration. Select the left-pointing key three times to move back to the LOI operating display.

Autocalibration Setup using the Field Communicator - 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 8800 will automatically calibrate.

From the DEVICE SETUP screen, select DETAILED SETUP.

From the DETAILED S ETUP screen, select CAL SETUP, then select O2 CAL PARAMS or COE CAL PARAMS.

If the unit is equipped with calibration solenoids and timed automatic calibrations are desired, select Solenoids, then select Yes. Select No to disable the calibration solenoids.

Select O2 Cal Intrvl (O2 calibration interval) and enter the desired time in hours between automatic O

calibrations. Select COE Cal In trvl and

enter the desired time between automatic COe calibrations. To disable automatic calibration for O

and COe, enter 0 for both Cal Intrvl

parameters.

If desired, the O2 Next Cal T i me and the COe Next Cal Time (next calibration time) parameters can be changed to synchronize a calibration at a specific day or time.

When setting automatic calibration times, CalIntrvl and NxtCalTm should be set so that O and COe 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 th e ri ght ar r o w key or use the number keypad to select the menu item number.

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

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Autocalibration Setup using the Field Communicator - Fieldbus

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 8800 will automatically calibrate.

From the Transducer screen select O2 Cal or COe Cal.

From the O2 Cal or COe Cal screen, select O2 Cal Setup or COe Setup.

If the unit is equipped with calibration solenoids and timed automatic calibration are desired, select Solenoids, then select Yes. Select No to disable the calibration solenoids.

Select O2 Cal Interval and/or COe Cal Interval and enter the desired time in hours between automatic calibrations. To disable automatic calibration for O2 and COe, enter 0 for both Cal Interval parameters.

If desired, the O2 Next Cal and CO 2 Next Cal (next calibration time) parameters can be changed to synchronize a calibration at a specific day or time.

OPERATOR - INITIATED AUTOCALIBRATION

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

Autocalibration using the optional LOI

To initiate a calibration using the LOI, perform the following steps on the LOI menu tree. Refer to Section 4, Using the LOI, for the LOI menu tree.

From the CALIBRATION menu, use the right-pointing arrow to select the Cal Control menu.

Select Start Cal-O2, Start Cal COe, or Start Cal Both to start the calibration. Select Cal Verify to access the calibration window.

At the prompt, use the right-pointing arrow to initiat e automatic calibration.

Autocalibration using the Field Communicator - HART

To initiate an automatic calibration using 375 Field Communicator, perform the following steps. Refer to Section 6, F i eld Com municator, for the H ART menu tree.

Select DIAG/SERVICE from DEVICE SET U P menu.

Select CALIBRATION from the DIAG/SERVICE menu.

Select CAL CONTROL from the CALIBRATION menu.

Select CAL METHODS from the CAL CONTROL menu.

From the CAL METHODS menu, select the type of calibration desired:

O2 Calibration, COe Calibration, or O2 and COe Calibration.

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Autocalibration using the Field Communicator - Fieldbus

To initiate an automatic calibration using 375 Field Communicator, perform the following steps. Refer to Section 6, Field Communicator, for the FOUNDATION Fieldbus menu tree.

From Transducer screen select Methods.

Select OCX Calibration from the Methods menu.

From the OCX Calibration menu, select the type of calibration desired:

Calibrate O2 Sensor,

Calibrate Combustibles Sensor, or

Calibrate Both Sensors.

MANUAL CALIBRATION If a unit is not equipped with calibration solenoids, a calibration must be

performed by an operator following prompts from the unit. Refer to the following paragraphs for manual calibration.

Manual Calibration using the optional LOI

Use the following procedure to perform a manual calibration with the LOI. If necessary, refer to the menu tree in Section 4, Using the LOI. Once the manual calibration procedure is initiated at the LOI, a series of prompts will appear giving instructions to the operator.

Use the right-pointing key to select the CALIBRATION first column

submenu.

From the CALIBRATION submenu use the right-pointing key to select

the Cal Control second column submenu.

From the Cal Control submenu use the right-pointing key to select the

third column Start Cal O2 option.

Remain at the Start Cal O2 option or use the down-pointing key to

select the Start Cal COe option or Start Cal Both option. (The following

sequence applies when Start Cal Both is selected.)

Use the right-pointing key to start the calibration. Turn on the low O2 test

gas, when prompted by the Flow Low Gas message.

Press the right-pointing key when the low O2 test gas is applied. The

calibration data changes as the calibration proceeds.

Press the right-pointing k e y when the lo w O2 reading is stable. Turn off

the low O

Flow High Gas message.

Press the right-pointing key when the high O2 test gas is applied. The

calibration data changes as the calibration proceeds.

Press the right-pointing key when the high O2 reading is stable. Turn off

the high O

purge.

10.

When the purge period expires, the LOI display reverts to the normal

operation display. If the calibration failed, the display will indicate an

alarm condition.

11.

Press the right-pointing key to start combustibles calibration. Turn on

the CO test gas when prompted.

12.

Press the right-pointing key when the CO test gas is applied. The

calibration data changes as the calibration proceeds.

test gas and turn on the high O2 test gas as prompted by the

test gas. Press the right-pointing key to start the high O2 gas

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13.

Press the right-pointing key when the CO reading is stable.

14.

Turn off the CO test gas and press the right-pointing key to start the CO

gas purge.

15.

When the purge period expires, the LOI display reverts to the normal

operation display. If the calibration failed, the display will indicate an

alarm condition.

Manual O

To perform a manual O

Calibration using the Field Communicator - HART

calibration using the 375 Field Communicator, use

the following procedure. If necessary, refer to Section 6, Field Communicator, for the HART menu tree.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press th e ri ght ar r o w key or use the number keypad to select the menu item number.

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

Select DIAG/SERVICE from DEVICE SET U P menu.

Select CALIBRATION from the DIAG/SERVICE menu.

Select CAL CONTROL from the CALIBRATION menu.

Select CAL METHODS from the CAL CONTROL menu.

From the CAL METHODS menu, select the type of calibration desired:

O2 Calibration

In the first Calibration screen, a Loop should be removed from

automatic control warning appears. Remove the OCX 8800 from any

automatic control loops to avoid a potentially dangerous operating

condition and press OK.

The Calibration screen should look like the following. Press OK to

continue.

OCX: TAG NAME

STEP: Idle TIME REMAIN: 0s O2: 0.4 % O2 Snsr: 85.95mV OK/NEXT to Select ABORT/CANCEL to Exit

From the SELECT ACTION screen, select START CAL/STEP CAL to

continue calibration, select ABORT CAL to abort calibration or EXIT

CAL to exit calibration. Select one item from the list and press ENTER.

OCX: TAG NAME SELECT ACTION

START CAL/STEP CAL

ABORT CAL

EXIT CAL

When the Calibration Status is at the AppO2Low step, switch on O

Low Gas. Verify the O2 concentration measured matches the O2 LOW

GAS parameter in the Setup. Press OK when ready.

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10.

Select START CAL/STEP CAL to start applying the O2 Low Gas. The

time to apply the test gas is specified by the Gas Time.

11.

The Calibration Status should be automatically changed to FlowO2Low

and then ReadO2Low for a period of time. During this period, if an

attempt is made to go to the next calibration step by pressing OK and

selecting START CAL/STEP CAL, you will be prompted with Operator

step command is not accepted at this time.

12.

When ready, Calibration Status will stop at the AppO2Hi. Switch off the

Low Gas and switch on the O2 High Gas. Verify the O2 concentration

measured matches the O2 HIGH GAS parameter in the Setup. Press

OK when ready.

13.

Select START CAL/STEP CAL to start applying the O2 High Gas. The

time to apply the test gas is specified by the Gas Time.

14.

The Calibration Status should be automatically changed to FlowO2Hi

and then ReadO2Hi for a period of time. During this period, if an attempt

is made to go the next calibration step by pressing OK and selecting

START CAL/STEP CAL, you will be prompted with Operator step

command is not accepted at this time.

15.

When ready, Calibration Status will stop at STOP GAS. Switch off the

High Gas. Press OK when ready. Select START CAL/STEP CAL to

start purging gas. The time to purge gas is specified by the Purge Time.

16.

When the Purge step is complete, the Calibration Status will be at IDLE.

A Calibration Failed alarm will be set if the calibration has failed.

17.

When calibration is complete. Select Exit Cal to exit the calibration

method.

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Manual COe Calibration using the Field Communicator - HART

To perform a manual COe calibration using the 375 Field Communicator, use the following procedure. If necessary, refer to Section 6, Field Communicator, for the HART menu tree.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press th e ri ght ar r o w key or use the number keypad to select the menu item number.

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

Select DIAG/SERVICE from DEVICE SET U P menu.

Select CALIBRATION from the DIAG/SERVICE menu.

Select CAL CONTROL from the CALIBRATION menu.

Select CAL METHODS from the CAL CONTROL menu.

From the CAL METHODS menu, select the type of calibration desired:

COe Calibration, or

In the first Calibration screen, a loop should be removed from

automatic control warning appears. Remove the OCX 8800 from any

automatic control loops to avoid a potantially dangerous operating

condition and press OK.

The main Calibration screen should look like the following. Press OK to

continue.

OCX: TAG NAME

STEP: Idle TIME REMAIN: 0s COe: 0.20 ppm

COe DELTA R: 0.00 ohm

OK/NEXT to Select ABORT/CANCEL to Exit

From the SELECT ACTION screen, select START CAL/STEP CAL to

continue calibration, select ABORT CAL to abort calibration or EXIT

CAL to exit calibration. Select one item from the list and press ENTER.

OCX: TAG NAME

SELECT ACTION

START CAL/STEP CAL

ABORT CAL

EXIT CAL

The unit samples O2 High Gas as the COe Low Gas. The Calinration

Status should automatically change to ReadCOLow for a period of time.

During this period, if an attempt is made to go to the next calibration

step by pressing OK and selecting START CAL/STEP CAL, you will be

prompted with Operator step command is not accepted at this time.

10.

When ready, Calibration Status will stop at the AppCOeHi. Switch on

the COe High Gas. Verify the COe concentration measured matches the

COe HIGH GAS parameter in the Setup. Press OK when ready.

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11.

Select START CAL/STEP CAL to start applying the COe High Gas. The

time to apply the test gas is specified by the Gas Time.

12.

The calibration status should automatically change to FlowCOeHI and

then ReadCOeHigh for a period of time. During this period, if an attempt

is made to go to the next calibration step by pressing OK and selecting

START CAL/STEP CAL, you will be prompted with Operator step

command is not accepted at this time.

13.

When ready, Calibration Status will stop at STOP GAS, switch off the

COe High Gas. Press OK when ready. Select START CAL/STEP CAL

to start purging gas. The time to purge gas is specified by the Purge

time.

14.

When the Purge step is complete, the Calibration Status will be at IDLE.

A Calibration Failed alarm will be set if the calibration has failed.

15.

When calibration is complete. Select Exit Cal to exit the calibration

method.

Manual O

To perform a manual O

and COe Calibration using the Field Communicator - HART

and COe calibration using the Field Communicator or

AMS, use the following procedure. If necessary, refer to Section 6, Field Communicator, for the HART menu tree.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press th e ri ght ar r o w key or use the nu mber keypad to select the menu item number.

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

Select DIAG/SERVICE from DEVICE SET U P menu.

Select CALIBRATION from the DIAG/SERVICE menu.

Select CAL CONTROL from the CALIBRATION menu.

Select CAL METHODS from the CAL CONTROL menu.

From the CAL METHODS menu, select the type of calibration desired: O2 and COe Calibration.

In the first Calibration screen, a Loop should be removed from

automatic control warning appears. Remove the OCX 8800 from any

automatic control loops to avoid a potentially dangerous operating

condition and press OK.

The main Calibration screen should look like the following. Press OK to

continue.

OCX: TAG NAME

STEP: Idle TIME REMAIN: 0s O2: 0.4 %, 85.95mV COe: 0.20 ppm OK/NEXT to Select ABORT/CANCEL to Exit

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From the SELECT ACTION screen, select START CAL/STEP CAL to

continue calibration, select ABORT CAL to abort calibration or EXIT

CAL to exit calibration method. Select one from the list and press

ENTER.

OCX: TAG NAME SELECT ACTION

START CAL/STEP CAL

ABORT CAL

EXIT CAL

When the Calibration Status is at the AppO2Low step, switch on O

Low Gas. Verify the O2 concentration measured matches the O2 LOW

GAS parameter in Setup CAL. Press OK when ready.

10.

Select START CAL/STEP to start applying the O2 Low Gas. The time to

apply the test gas is specified by the Gas Time.

11.

The Calibration Status should automatically change to FIowO2Low and

then ReadO2Low for a period of time. During this period, if an attempt

is made to go to the next calibration step by pressing OK and selecting

START CAL/STEP CAL, you will be prompted with Operator step

command is not accepted at this time.

12.

When ready, Calibration Status will stop at AppO2Hi. Switch off the O

Low Gas and switch on the O2 High Gas. Verify the O2 concentration

measured matches the O2 HIGH GAS parameter in Setup. Press OK

when ready.

13.

Select START CAL/STEP CAL to apply the O2 High Gas. The time to

apply the test gas is specified by the Gas Time.

14.

The Calibration Status should automatically change to FlowO2Hi, then

ReadO2Hi, and then ReadCOeLo for a period of time. During this

period, if an attempt is made to go the next calibration step by pressing

OK and selecting START CAL/STEP CAL, you wil l be prompted with

Operator step command is not accepted at this time.

15.

When ready, Calibration Status will stop at AppCOeHi. Switch off the O

High Gas and switch on the COe Gas. Verify the COe concentration

measured matches the COe TEST GAS parameter in the Setup. Press

OK when ready.

16.

Select START CAL/STEP CAL to start applying the COe Gas. The time

to apply the test gas is specified by the Gas Time.

17.

The Calibration Status should automatically change to FlowCOeHi and

then ReadCOeHi for a period of time. During this period, if an attempt is

made to go the next calibration step by pressing OK and selecting

START CAL/STEP CAL, you will be prompted with Operator step

command is not accepted at this time. The Next Cal Step command

is not accepted at this time.

When ready, Calibration Status will stop at STOP G AS. Switch of f the CO e gas. Press OK when ready. Select START CAL/STEP C AL to start purging gas. The time to purge gas is specified by Purge Time.

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Manual O2/COe Calibration using the Field Communicator - Fieldbus

To perform a manual O use the following procedure. If necessary, refer to Section 6, Field

Communicator, for the Fieldbus menu tree.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press th e ri ght ar r o w key or use the number keypad to select the menu item number.

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

To calibrate from Fieldbus, the first step is to set the Transducer Block to

Out of Service Mode (OOS).

To set the OOS mode, select Transducer then select Process, followed

by select Out of Service in the Target Mode.

From Transducer screen select Methods.

Select OCX Calibration from the Methods menu.

From the OCX Calibration screen, select Calibrate O 2 Sensor for O2

calibration, select Calibrate Combustibles Sensor for COe calibration,

or select Calibrate Both Sensors if calibrate both sensors is desired.

In the calibration screen, a Loop should be removed from automatic

control warning appears. Remove the device from any automatic

control loops to avoid a potentially dangerous operating condition and

press OK.

The Select Action screen should look like the following. From the

Select Action screen, select Update Display to refresh the calibration

status, select Next Calibration Step to continue calibration, select

Abort Calibration to abort calibration or Exit to exit calibration. Select

one item from the list and press OK. The Select Action screen is static

and data will not be automatically refreshed.

/COe calibration using the 375 Field Communicator,

Calibration Step = Idle Step Time Remaining = 0 seconds O2 Value = 0.40 % Combustibles Value = 1000 ppm

Update Display

Next Calibration Step

Abort Calibration

Exit

The Calibration Screen should look like the following, press OK to

continue. The Calibration Screen should be automatically refreshed,

however it may take a while for the data to refresh. Calibration Step = Apply O2 Low Gas

Step Time Remaining = 0 seconds O2 Value = 0.40 % Combustibles Value = 1000 ppm Press Next for Selection

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When the calibration status is at the Apply O2 Low Gas/ Apply Comb

Low Gas step, switch on O2 Low Gas/COe Low Gas. Verify the O2

concentration measured matches the O2 Low Gas parameter in the

setup. The unit samples reference air as the COe Low Gas. Press OK

when ready.

10.

Select Next Calibration Step and press OK to start applying the test

gas. The time to apply the test gas is specified by the Gas Time.

11.

The calibration step will change to Flow O2 Low Gas/ Flow Comb Low

Gas and then Read O2 Low Gas/ Read Comb Low Gas for a period of

time.

12.

When ready, Calibration Step will stop at the Apply O2 High Gas/

Apply Comb High Gas. Switch off the O2 Low Gas/Sample Reference

Air and switch on the O2 High Gas/Comb Test Gas. Verify the O2/COe

concentration measured matches the O2 High Gas/COe Test Gas

parameter in the setup. Press OK when ready.

13.

Select Next Calibration Step to start applying the test gas. The time to

apply the test gas is specified by the Gas Time.

14.

The calibration step will change to Flow O2 High Gas/ Flow Comb

High Gas and then Read O2 High Gas/ Read Comb High Gas for a

period of time.

15.

Skip over to Step 19, Stop Gas, if executing Calibrate O2 Sensor or

Calibrate Combustibles Sensor.

16.

The calibration step will change to Read Comb Low Gas for a period of

time. When ready, Calibration Step will stop at Apply Comb High Gas.

Switch off the O2 High Gas and switch on the COe Test Gas. Verify the

COe concentration measured matches the COe Test Gas parameter in

the setup.

17.

Select Next Calibration Step to start applying the test gas. The time to

apply the test gas is specified by the Gas Time.

18.

The calibration step will change to Flow Comb High Gas and then

Read Comb High Gas for a period of time.

19.

When ready, Calibration step will stop at Stop Gas. Switch off the O2

High Gas/COe Test Gas, Press OK when ready. Select Next Calibration

Step to start purging gas. The time to purge gas is specified by the

Purge Time.

20.

When the Purge step is complete, the Calibration Step will be at Idle.

The Calibration Failed alarm will be set if the calibration has failed.

21.

When calibration is complete. Select Exit to exit the calibration method.

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D/A TRIM PROCEDURES - LOI

O2 D/A trim procedure using the LOI

Use the following procedure to perform the O

D/A trim procedure at the LOI.

Refer to the LOI menu tree in Figure 4-4.

To avoid a potentially dangerous operating condition, the OCX 8800 must be removed from the automatic combustion control loop before you start the D/A trim procedure.

From the operating display use the left-pointing key to select the first

column submenu. Use the down-pointing key to select SYSTEM.

From the SYSTEM menu, use the down-pointing key to select

Input/Output. Use the right-pointing k e y to s e lect the Analog

parameters list.

Scroll down to the item Trim O2 Out. Touch the right-pointing key to

start the O

NOTE

If you wish to exit D/A Trim with no changes, step through the procedure using yes responses, and enter no meter readings.

Remove the electronics housing cover.

Refer to Figure 2-6. Connect a digital multimeter to read the milliamp

output from the O

the AOUT1+ terminal and connect the neg ative lead to the AOUT1-

terminal. Then, touch the Enter key at the LOI.

The LOI displays 4 mA........Meter. The trim program inputs the

design-equivalent signal for a 4.00 mA output. Read the O

output at the digital multimeter. Use the right-pointing key to select each

digit and use the up- and down-pointing keys to change the value. When

the correct value is displayed, use the Enter key to input the value.

The LOI displays 20 mA........Meter. The trim program inputs the

design-equivalent signal for a 20.00 mA output. Read the O

output at the digital multimeter. Use the right-pointing key to select each

digit and use the up- and down-pointing keys to change the value. When

the correct value is displayed, use the Enter key to input the value.

The LOI displays a Meter at 4 mA prompt. Use the right-pointing key to

select the letter yes or no. Use the up- or down-pointing key to change

the letter. Then use the Enter key to input the response. If no, the

process repeats from step 7.

The LOI displays a Meter at 20 mA prompt. Use the right-pointing key

to select the letter yes or no. Use the up- or down-pointing key to

change the letter. Then use the Enter key to input the response. If no,

the process repeats from step 8.

10.

When the ropiness in steps 9 and 10 are yes, the trim procedure is

complete. Exit the LOI menu and return the control loop to automatic

control.

trim procedure.

D/A converter circuit. Connec t the p os iti ve lead to

millamp

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COe D/A trim procedure using the LOI

Use the following procedure to perform the COe D/A trim procedure at the LOI. Refer to the LOI menu tree in Figure 4-4.

To avoid a potentially dangerous operating condition, the OCX 8800 must be removed from the automatic combustion control loop before you start the D/A trim procedure.

From the operating display use the left-pointing key to select the first column submenu. Use the down-pointing key to select SYSTEM.

From the SYSTEM menu, use the down-pointing key to select

Input/Output. Use the right-pointing k e y to s e lect the Analog

parameters list.

Scroll down to the item Trim COe Out. Touch the right-pointing key to

start the COe trim procedure.

NOTE

If you wish to exit D/A Trim with no changes, step through the procedure using yes responses, and enter no meter readings.

Remove the electronics housing cover.

Refer to Figure 2-6. Connect a digital multimeter to read the milliamp

output from the COe D/A converter circuit. Connect the positive lead to

the AOUT2+ terminal and connect the neg ative lead to the AOUT 2-

terminal. Then, touch the Enter key at the LOI.

The LOI displays 4 mA........Meter. The trim program inputs the

design-equivalent signal for a 4.00 mA output. Read the COe millamp

output at the digital multimeter. Use the right-pointing key to select each

digit and use the up- and down-pointing keys to change the value. When

the correct value is displayed, use the Enter key to input the value.

The LOI displays 20 mA........Meter. The trim program inputs the

design-equivalent signal for a 20.00 mA output. Read the COe millamp

output at the digital multimeter. Use the right-pointing key to select each

digit and use the up- and down-pointing keys to change the value. When

the correct value is displayed, use the Enter key to input the value.

The LOI displays a Meter at 4 mA prompt (question). Use the

right-pointing key to select the letter yes or no. Use the up- or

down-pointing key to change the letter. Then use the Enter key to input

the response. If no, the process repeats from step 7.

The LOI displays a Meter at 20 mA prompt (question). Use the

right-pointing key to select the letter yes or no. Use the up- or

down-pointing key to change the letter. Then use the Enter key to input

the response. If no, the process repeats from step 8.

10.

When the ropiness in steps 9 and 10 are yes, the trim procedure is

complete. Exit the LOI menu and return the control loop to automatic

control.

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D/A TRIM PROCEDURES - HART

O2 D/A trim procedure using HART

Use the following procedure to perform the O

D/A trim procedure using the

Field Communicator. If necessary, refer to Section 6, Field Communicator, for the HART menu tree.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press th e ri ght ar r o w key or use the number keypad to select the menu item number.

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

From the DIAG/SERVICE menu, select D/A TRIM. Select O2 D/A Trim.

Press the right arrow key to start the procedure. (If you wish to exit D/A

Trim with no changes, select ABORT.)

The Field Communicator displays WARNING: Loop should be

removed from automatic control. Remove the OCX 8800 from any

automatic control loops to avoid a potentially dangerous operating

condition and press OK.

The Field Communicator displays Connect reference meter to O2

output.

Remove the electronics housing cover.

Refer to Figure 2-6. Connect a digital multimeter to read the milliamp

output from the O

D/A converter circuit. Connec t th e p os iti ve lead to

the AOUT1+ terminal and connect the neg ative lead to the AOUT1-

terminal. Then, press OK at the Field Communicator.

The Field Communicator displays Setting Fld dev output to 4 mA.

Press OK. Read the O

millamp output at the digital multimeter. Enter

the reading at the Field Communicator and press ENTER. (Select

ABORT to exit without changes).

The Field Communicator displays Setting Fld dev output to 20 mA.

Press OK. Read the O

millamp output at the digital multimeter. Enter

the reading at the Field Communicator and press ENTER. (Select

ABORT to exit without changes).

The Field Communicator displays Setting Fld dev output to 4 mA.

Press OK.

10.

The Field Communicator displays Fld dev output 4.00 mA equal to

reference meter? Using the up or down arrow, select 1 Yes or 2 No

and Press ENTER. If No, the process repeats from step 6.

11.

The Field Communicator displays Setting Fld dev output to 20 mA.

Press OK.

12.

The Field Communicator displays Fld dev output 20.00 mA equal to

reference meter? Using the up or down arrow, select 1 Yes or 2 No

and Press ENTER. If No, the process repeats from step 7.

13.

The Field Communicator displays NOTE: Loop may be returned to

automatic control.

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COe D/A trim procedure using HART

Use the following procedure to perform the COe D/A trim procedure using the Field Communicator. If necessary, refer to Section 6, Field Communicator, Field Communicator, for the HART menu tree.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press th e ri ght ar r o w key or use the number keypad to select the menu item number.

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

From the DIAG/SERVICE menu, select D/A TRIM. Press the up or

down arrow to select COe D/A Trim.

Press the right arrow key to start the procedure. (If you wish to exit D/A

Trim with no changes, select ABORT.)

The Field Communicator displays WARNING: Loop should be

removed from automatic control. Remove the OCX 8800 from any

automatic control loops to avoid a potentially dangerous operating

condition and press OK.

The Field Communicator displays Connect reference meter to

Combustibles output.

Remove the electronics housing cover.

Refer to Figure 2-6. Connect a digital multimeter to read the milliamp

output from the COe D/A converter circuit. Connect the positive lead to

the AOUT2+ terminal and connect the neg ative lead to the AOUT 2-

terminal. Then, press OK at the HART communicator.

The Field Communicator displays Setting Fld dev output to 4 mA.

Press OK. Read the COe millamp output at the digital multimeter. Enter

the reading at the Field Communicator and press ENTER. (Select

ABORT to exit without changes).

The Field Communicator displays Setting Fld dev output to 20 mA.

Press OK. Read the COe millamp output at the digital multimeter. Enter

the reading at the Field Communicator and press ENTER. (Select

ABORT to exit without changes).

The Field Communicator displays Setting Fld dev output to 4 mA.

Press OK.

10.

The Field Communicator displays Fld dev output 4.00 mA equal to

reference meter? Using the up or down arrow, select 1 Yes or 2 No

and Press ENTER. If No, the process repeats from step 6.

11.

The Field Communicator displays Setting Fld dev output to 20 mA.

Press OK.

12.

The Field Communicator displays Fld dev output 20.00 mA equal to

reference meter? Using the up or down arrow, select 1 Yes or 2 No

and Press ENTER. If No, the process repeats from step 7.

13.

The Field Communicator displays NOTE: Loop may be returned to

automatic control.

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Section 6 Field Communicator

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

Field Communicator Connections . . . . . . . . . . . . . . . . . . page 6-1

Hart Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-5

Fieldbus Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-9

OVERVIEW The 375 Field Communicator is a communication interface device. It supports

HART and Fieldbus devices letting you configure and troubleshoot in the field. The 375 Field Com m unicator incl udes an LCD wit h to uch-s creen dis pla y and

keypad. Use touch-screen or keypad to enter data into 375 Field Communicator.

Three terminals for the lead set are on the top of the 375 Field Communicator. The lead set and the terminals let you connect the 375 Field Communicator to a device. An access door ensures only one pair of the terminals can be used at any time. Several markings indicate which pair of terminals is for which protocol. The "F" indicates the Fieldbus protoc o l while "H" ind icates the H ART protocol.

FIELD COMMUNICATOR CONNECTIONS

The infrared port (IrDA) lets the 375 Field Communicator interface with the PC. IrDA is a PC interface supported for transfer of device descriptions (DD), software update, configurations and application licenses. IrDA communication can either be built into the PC or provided through a USB to IrDA adaptor. The PC application can either be AMS Suite or 375 Easy Upgrade Programming Utility. The 375 must be in the "Listen for PC" mode when communicating through IrDA.

Refer to the 375 Field Communicator User Manual for details.

Connecting to a HART loop

Connect 375 Field Communicator with the supplied lead set in parallel with the device or load resistor, Figure 6-1. The HART connections are not polarity sensitive. A minimum 250 ohms resistance must be present in the HART loop for the 375 Field Communicator to function properly.

Explosions can result in death or serious injury. Do not make connections to the Fiel d Communicator's serial port, digital signal line, or NiCad recharger jack i n an explosive atmosphere.

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38850006

Figure 6-1. 375 Communicator Connections - HART

4-20 mA Terminal Block in

Electronics Housing

A OUT 1 + A OUT 1 -

4-20 mA Signal Line

Loop

Connectors

Field Communicator

Rear Panel

Connecting to a Fieldbus Segment

Field

Communicator

Model 375

00809-0100-



250ν

Analog Output Device

Lead Set

Connect 375 Field Comm unicator with the s upplied lead s et in parallel with the device to a Fieldb us s egm ent, Figur e 6-2. The 375 Field Com m unicator Fieldbus connections ar e p olari t y sens iti ve, an er ror m es sage dis p lays if the device is connected incorrectly.

Explosions can result in death or serious injury. Do not make connections to the Fiel d Communicator's serial port, digital signal line, or NiCad recharger jack in an explosive atmosphere.

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OUT1+

39710006

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Figure 6-2. 375 Communicator Conections - Fieldbus

OUT1 -

Fieldbus Signal

{

NOTE: Devices shown are not to scale.

Fieldbus Digital Signal Fieldbus Digital Signal

Terminal

Connectors

Field Communicator

Rear Panel

Terminal

Block

Terminals

Field

Communicator

Model 375

OCX 8800 Electronics

Fieldbus Computer

Terminal (PC)

Lead Set

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OFF-LIN E AND ON-LINE OPERATIONS

The Field Communicator can be operated both off-line and on-line. Off-line operations are those in which the communicator is not connected to

the OCX 8800. Off-line operations can include interfacing the Field Communicator with a PC (refer to applicable Field Communicator documentation regarding Model 375/PC applications). In the on-line mode the communicator is connected to a fieldbus terminal block.

NOTE

If the Field Communicator is turned on while connected to the fieldbus terminal block, an undefined status indication appears while the communicator warms up. Wait until the warm-up period ends to continue.

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

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39930012

Sensor Values

Sensor Raw Inputs

Output Variables

Sensor Limits

O2 Raw Inputs

COE Raw Inputs

DEV Raw Inputs

SB T/C CJC Temp Signal

PV-AOUT

O2 AO %

SV is

COe AO %

TV is

4V is

COe

O2 Temp

COe

COe Temp

Process Variables

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HART MENU TREE This section provides a menu tree for the Field Communicator. This menu is

specific to the OCX 8800 applications.

Figure 6-3. HART Menu Tree (Sheet 1 of 4)

O2 COe O2 Temp COe Temp SB Temp Brd Temp CJC Temp

O2 Snsor O2 T/C O2 Snsor Imp

COe Delta V COe Ref V COe Delta R Coe Ref R COe T/C RTD Current

Board Temp IC

PV is O2 O2 AO

DEVICE SETUP O2 O2 AO COe COe AO

(CONTINUED ON

SHEET 2)

COe COe AO

O2 Temp

COe Temp

O2 O2 USL O2 LSL

O2 Temp O2 TC USL O2 TC LSL

COe COe USL COe LSL

COe Temp COe TC USL COe TC LSL

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AO Fixed

Model Number Sensor Housing CPLD Regs

Line Frequency Line Voltage PCN Counter PCD Counter

CJC Temp Max

Diag/Service

Status

Calibration

Blowback

Loop Test

D/A Trim

Hardware

Max Temp

BCSR0

BCSR5

COe

O2 & COe Calibration

39930013

Prev COe Constant

Failed O2 Slope

Failed COe Constant

Reset O2 CalConsts Reset COe CalConsts

COe

Figure 6-4. HART Menu Tree (Sheet 2 of 4)

(CONTINUED FROM

SHEET 1 )

Operate Mode Status Group 1 Status Group 2 Status Group 3 Status Group 4 Status Group 5 Status Group 6 AO Saturated

Cal Control

Cal Methods

State TimeRemain O2

00809-0100-

O2 Calibration COe Calibration

(CONTINUED ON

SHEET 3)

(CONTINUED ON

SHEET 3)

Cal Constants

Cal Verify

BlBk State Blowback

O2 Loop Test COe Loop Test

O2 D/A Trim COe D/A Trim

O2 Temp Max COe Temp Max SB Temp Max Board Temp Max

Current Cal

Previous Cal

Failed Cal

Reset Cal Constant

Verify Calibration State TimeRemain O2

BCSR1 BCSR2 BCSR3 BCSR4

O2 Slope O2 Constant Sensor Imp Cal COe Slope COe Constant

Prev O2 Slope Prev O2 Constant Prev Sensor Imp Prev COe Slope

Failed O2 Constant Failed COe Slope

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Diag/Service

(continued)

Basic Setup

Detailed Setup

39930014

Device

Date

COe Sensor S/N

Tag

Fld Dev Rev

Restart Cntr

Cal Setup

O2 Cal Params

Analog Output

SB Prop

SB Temp

Solenoids

Cal Rec Enable

O2 Analog Output

Alarm Relay State

BlBk State

Zero State

Zero Update

O2 AO Range

COe AO Range

COe Alarm Level

-0100-4880, Rev AA

Figure 6-5. HART Menu Tree (Sheet 3 of 4)

(CONTINUED FROM

(CONTINUED ON

SHEET 2 )

SHEET 4)

(CONTINUED FROM

SHEET 2 )

Heater PID

Information

HART Information

S/W Version Info

Input/Output

O2 PID

COe PID

SB PID

Descriptor Message Final Asmbly Num O2 Sensor S/N

Poll Addr Dev ID Num Req Preams

Version Checksum Build Number Build Date

COe Cal Params

Alarm Relay

Blowback

COe Zero

O2 Prop O2 Int O2 Duty Cycle O2 Set Point O2 Temp

COe Prop COe Int COe Duty Cycle COe Set Point COe Temp

SB Int SB Duty Cycle SB Set Point

Gas Time Purge Time O2 Out Tracks O2 High Gas O2 Low Gas O2 Cal Intrv O2 Next Cal Time O2 Tol Check Cal Rec Enable

Gas Time Purge Time COe Out Tracks COe Test Gas COe Cal Intrv COe Next Cal Time COe Slope Warn COe Tol Check

COe Analog Output

Trig 1 Event Trig 2 Event Trig 3 Event

BlBk Enabled BlBk Intrvl BlBk Period BlBk Purge Time

Zero Enabled Zero Intrvl Zero Flow Zero Purge Zero Tracks

O2 URV O2 LRV O2 Alarm Level

COe URV COe LRV

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Device

Information

HART Information

Cal Setup

Input/Output

Device Params

LOI Params

O2 Cal Setup

COe Cal Setup

Revert Time

Detailed Setup

(continued)

Device Params

LOI Params

Review

Solenoids

Cal Rec Enable

39930015

Figure 6-6. HART Menu Tree (Sheet 4 of 4)

(CONTINUED FROM

SHEET 3 )

O2 Slope O2 Const O2 T90 COe Slope COe Const COe T90 PCNC Enable PCDC Enable

User Intface Luminance Lockout Time Revert Time

Manufacturer Model Date Descriptor Message Final Asmbly Num O2 Sensor S/N COE Sensor S/N Hardware Rev Software Rev

Tag Poll Addr Dev ID Num Req Preams Fld Dev Rev Universal Rev

00809-0100-

Gas Time Purge Time O2 Out Tracks O2 Low Gas O2 High Gas O2 Cal Intrvl O2 Next Cal Time O2 Tol Check

O2 URV O2 LRV COe URV COe LRV O2 AO Range COe AO Range O2 Alarm Level COe Alarm Level Trig 1 Event Trig 2 Event Trig 3 Event BlBk Enabled BlBk Intrvl BlBk Period BlBk Purge Time Zero Enabled Zero Intrvl Zero Flow Zero Purge Zero Tracks Zero Update

O2 Slope O2 Const O2 T90 COe Slope COe Const COe T90 PCNC Enable PCDC Enable

Luminance Lockout Time

Solenoids Gas Time Purge Time COe Out Tracks COe Test Gas COe Cal Intrvl COe Next Cal Time COe Slope Warn COe Tol Check Cal Rec Enable

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PWA Simulate

Advisory Active

PWA Simulate Detailed Status

Recommended Action

Value

Failure Active

Value

Block Mode: Actual

Master Reset

PlantWeb Alerts

Simulate PWA

Simulate Status

PWA Status

PWA SubStatus

Status

Methods

Manufacturer ID

ITK Version

Block Mode: Actual

Sched Remote Casacade

Grant Deny: Deny

Write Priority

RESOURCE

TRANSDUCER AI 1 AI 2 AI 3 AI 4 PID 1 ISEL ARTHM ADVANCED

Cycle Selection

Physical Device Tag

Device Revision

Identification

Process*

Alarms

Hardware

Options

Continued with

Plant Web Alerts

See Sheet 2

Detail

Network

Management

Schedule

39930009

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FIELDBUS MENU TREE This section consists of a menu for the Field Communicator. This menu is

specific for the OCX 8800 Applications. Refer to the Fieldbus Parameter Descriptions for the applicable range, units, and description for the fieldbus menu parameters.

Figure 6-7. Fieldbus Menu Tree (Sheet 1 of 3)

Device Type Device Revision DD Revision Characteristics Tag Description Hardware Revision Software Revision Private Label Dist ri b uto r Final Assembl y Numbe r Output Board

Serial Number

Block Mode: Target Block Mode: Permitted Strategy Alert Key

Sched Remote Out Grant Deny: Grant

Continued from

Options

*Note:

Contains information regarding

specific implementation for the fieldbus. Refer to the fieldbus documentation for further information.

Failure Priority Maintenance Priority Advisory Priority Failure Active Maintenance Active Advisory Active Failure Enable Maintenance Enable Advisory Enable Failure Mask Maintenance Mask Advisory Mask

Confirm Time Limit Notify Max Noti fy Fault State Set Fault State Clear Fault State Alarm Summary Acknowledge Option

Memory Size Free Time Minimum Cycle Time Hard Types Nonvolatile Cycle Time Free Space

Cycle Type Feature Selection Features Download Mode Write Lock Write Lock Definition

Failure Active Maintenance Active

Health Index Failure Alarm Maintenance Alarm Advisory Alarm

Failure Mask Maintenance Active Maintenance Mask Advisory Active Advisory Mask

Block Mode: Target Resource State Fault State Block Error Detailed Status Summary Status Alarm Summary

Self Test DD Version Info Transmitter Options

Subcode Time Start Alarm State Unacknowledge

Value Subcode Time Start Alarm State Unacknowledge

Address Device ID

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Block Mode: Actual

O2 Primary Value

O2 Cal Const

COe Primary Value

Heater Control

39930010

Figure 6-8. Fieldbus Menu Tree (Sheet 2 of 3)

See Sheet 1

RESOURCE TRANSDUCER AI 1 AI 2 AI 3 AI 4 PID ISEL ARTHM ADVANCED

Process

COe

Temperatures

Raw Inputs

Continued

with O2 Cal

Sheet 3

Block Mode: Target Block Mode: Permitted Strategy Alert Key Characteristics Tag Description

O2 Secondary Value O2 Sensor Imp O2 Primary Value Range:

EU at 100%

O2 Primary Value Range:

EU at 0%

O2 Secondary Value Range:

EU at 100%

O2 Secondary Value Range:

EU at 0% O2 Sensor Type O2 T90

COe Secondary Value COe Primary Value Range:

EU at 100%

COe Primary Value Range:

EU at 0%

COe Secondary Value Range:

EU at 100%

COe Secondary Value Range:

EU at 0% COe Sensor Type COe T90 COe Cal Cons

O2 Secondary Value COe Secondary Value SB Tem p Board Temp CJC Temp O2 Temp Max COe Max SB Tem p Max Board Temp Max CJC Temp Max

O2 Sensor O2 Sensor Imp COe Delta Resistance COe Reference Ohms COe RTD Current O2 T/C COe T/c SB T/C Board Temp IC CJC Temp Signal

00809-0100-

O2 Slope O2 Constant O2 Impedance Cal Prev O2 Slope Prev O2 Constant Prev O2 Impedence Failed O2 Slope Failed O2 Constant

COe Slope COe Constant Prev COe Slope Prev COe Constant Failed COe Slope Failed COE Constant

O2 Set Point O2 Duty Cycle COe Set Point COe Duty Cycle SB Set Point SB Duty Cycle

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Figure 6-9. Fieldbus Menu Tree (Sheet 3 of 3

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Section 7 Foundation Fieldbus

Foundation Fieldbus Technology . . . . . . . . . . . . . . . . . . . page 7-1

Resource Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-6

Transducer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-13

Analog Input (AI) Functio n Blo ck . . . . . . . . . . . . . . . . . . . p age 7-23

Proportional/ Integral/Derivative (PID) Function Block . . page 7-35

Arithmetic (ARTHM) Function Block . . . . . . . . . . . . . . . . . page 7-51

Input Selector (ISEL) Function Block . . . . . . . . . . . . . . . . page 7-57

Operation with Emerson DeltaV . page 7-62

FOUNDATION FIELDBUS TECHNOLOGY

Overview FOUNDATION Fieldbus is an all digital, serial, two-way communication system

that interconnects field equipment such as sensors, actuators, and controllers. Fieldbus is a Local Area Network (LAN) for instruments used in both process and manufacturing automation with built-in capacity to distribute the control application across the network. It has the ability to distribute control among intelligent field devices on the plant floor and digitally

communicate that information at high speed that makes F Fieldbus an enabling technology.

EMERSON offers a full range of products from field devices to the DeltaV scalable control system to allow an easy transition to Fieldbus technology.

The Fieldbus retains the features of the 4-20 mA analog system, including standardized physical interface to the wire, bus powered devices on a single wire, and intrinsic safety options, and enables additional capabilities such as:

•

Increased capabilities due to full digital communications.

•

Reduced wiring and wire terminations due to multiple devices on one set of wires.

•

Increased selection of suppliers due to interoperability.

•

Reduced loading on control room equipment with the distribution of some control and input/output functions to field devices.

•

Speed options for process control and manufacturing applications.

OUNDATION

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NOTE:

The following descriptions and definitions are not intended as a training guide

OUNDATION Fieldbus technology but are presented as an overview for

for F those not familiar with Fieldbus and to define device specific attributes for the Fieldbus system engineer. Anyone attempting to implement Fieldbus communications and control with this analyzer must be well versed in Fieldbus technology and protocol and must be competent in programming using available tools such as DeltaV. See “References” below for additional sources for Fieldbus technology and methodology.

Introduction A Fieldbus system is a distributed system composed of field devices and

control and monitoring equipment integrated into the physical environment of a plant or factory. Fieldbus devices work together to provide I/O and control for automated processes and operations. The Fieldbus Foundation provides a framework for describing these systems as a collection of physical devices interconnected by a Fieldbus network. One of the ways that the physical devices are used is to perform their portion of the total system operation by implementing one or more function blocks.

Function Blocks

Function blocks within the Fieldbus device perform the various functions required for process control. Because each system is different, the mix and configuration of functions are different. Therefore, the Fieldbus FOUNDATION has designed a range of function blocks, each addressing a different need.

Function blocks perform process control functions, such as analog input (AI) and analog output (AO) functions as well as proportional-integral-derivative (PID) functions. The standard function blocks provide a common structure for defining function block inputs, outputs, control parameters, events, alarms, and modes, and combining them into a process that can be implemented within a single device or over the Fieldbus network. This simplifies the identification of characteristics that are common to function blocks.

The Fieldbus F

OUNDATION has established the function blocks by defining a

small set of parameters used in all function blocks called universal parameters. The F

OUNDATION has also defined a standard set of function

block classes, such as input, output, control, and calculation blocks. Each of these classes also has a small set of parameters established for it. They have also published definitions for transducer blocks commonly used with standard function blocks. Examples include temperature, pressure, level, and flow transducer blocks.

OUNDATION specifications and definitions allow vendors to add their own

The F parameters by importing and subclassing specified classes. This approach permits extending function block definitions as new requirements are discovered and as technology advances.

Figure 7-1 illustrates the internal structure of a function block. When execution begins, input parameter values from other blocks are snapped-in by the block. The input snap process ensures that these values do not change during the block execution. New values received for these parameters do not affect the snapped values and will not be used by the function block during the current execution.

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Once the inputs are snapped, the algorithm operates on them, generating outputs as itprogresses. Algorithm executions are controlled through the setting of containedparameters. Contained parameters are internal to function blocks and do not appear asnormal input and output parameters. However, they may be accessed and modified remtely, as specified by the fundtion block.

Input events may affect the operation of the algorithm. An execution control function regulates the receipt of input events and the generation of output events during execution of the algorithm. Upon completion of the algorithm, the data internal to the block is saved for use in the next execution, and the output data is snapped, releasing it for use by other function blocks.

Figure 7-1. Function Block Internal Structure

A block is a tagged logical processing unit. The tag is the name of the block. System management services locate a block by its tag. Thus the service personnel need only know the tag of the block to access or change the appropriate block parameters.

Function blocks are also capable of performing short-term data collection and storage for reviewing their behavior.

Device Descriptions

Device Descriptions are s p ec if ied to ol definitions that are assoc iate d with the function blocks. Device descriptions provide for the definition and description of the function blocks and their parameters.

To promote consistency of definition and understanding, descriptive information, such as data type and length, is maintained in the device description. Device Descr ip tions ar e writ ten usin g an open lan gua ge ca ll ed the Device Description Language (DDL). Parameter transfers between function blocks can be easily verified because all parameters are described using the same language. Once written, the device description can be stored on an external medium, such as a CD-ROM or diskette. Users can then read the device description from the external medium. The use of an open language in the device description permits interoperability of function blocks within devices from various vendors. Additionally, human interface devices,

Reference Manual

July 2018

OCX 8800

7-4

Instrument-Specific Function Blocks

00809-0100-4880, Rev AA

such as operator consoles and computers, do not have to be programmed specifically for each type of device on the bus. Instead their displays and interactions with devices are driven from the device descriptions.

Device descriptions may also include a set of processing routines called methods. Methods provide a procedure for accessing and manipulating parameters within a device.

In addition to function blocks, Fieldbus devices contain two other block types to support the function blocks. These are the resource block and the transducer block. The resource block contains the hardware specific characteristics associated with a device. Transducer blocks couple the function blocks to local input/output functions.

Resource Blocks

Resource blocks contain the hardware specific characteristics associated with a device; they have no input or output parameters. The algorithm within a resource block monitors and controls the general operation of the physical device hardware. The execution of this algorithm is dependent on the characteristics of the physical device, as defined by the manufacturer. As a result of this activity, the algorithm may cause the generation of events. There is only one resource block defined for a device. For example, when the mode of a resource block is “out of service,” it impacts all of the other blocks.

Transducer Blocks

Transducer blocks connect function blocks to local input/output functions. They read sensor hardware and write to effector (actuator) hardware. This permits the transducer block to execute as frequently as necessary to obtain good data from sensors and ensure proper writes to the actuator without burdening the function blocks that use the data. The transducer block also isolates the function block from the vendor specific characteristics of the physical I/O.

Alerts

When an alert occurs, execution control sends an event notification and waits a specified period of time for an acknowledgment to be received. This occurs even if the condition that caused the alert no longer exists. If acknowledgment is not received within the prespecified time-out period, the event notification is retransmitted. This assures that alert messages are not lost.

Two types of alerts are defined for the block, events and alarms. Events are used to report a status change when a block leaves a particular state, such as when a parameter crosses a threshold. Alarms not only report a status change when a block leaves a particular state, but also report when it returns back to that state.

Network Communication Figure 7-2 illu s trates a simple Fieldbus network consisting of a single

segment (link).

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