Rosemount OCX 8800 O2 / Combustibles Transmitter General Purpose with Remote Electronics and LOI Local Operator Interface-Rev 1.2 Manuals & Guides

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800
Oxygen/Combustibles Transmitter

General Purpose OCX 8800 Oxygen/Combustibles Transmitter
with Remote Electronics and Local Operator Interface

http://www.raihome.com

HIGHLIGHTS OF CHANGES

Effective December 2007, Rev 1.1

Page/Section Summary

Throughout Updated manual number suffixes in page headers to indicate OCX configuration.

Changed references to HART Communicator te read Field Communicator in text and

illustrations.
Page 1-10 Added new illustration Figure 1-6
Page 1-14 Updated Product Matrices.
Page 1-15 Revised/updated Table 1-2 .
Page 2-2 Deleted obsolete CAUTION statement.
Page 2-14 Revised paragraph 4 listing of gases for calibration.
Page 2-18 Revised Figure 2-11 to indicate minimum pressure for actuation of the blowback valve.
Page 2-19 Revised Figure 2-12 to indicate minimum pressure for actuation of the blowback valve.
Page 5-4 Revised 1st paragraph.
Page 5-5 Revised HART menu items in Figure 5-3, Sheet 1 of 4
Page 5-9 Added new step 4 to both D/A Trim Procedures.
Page 6-3 Replaced steps 6 through 10 with a repeat of step 4 instruction.
Page 6-4 Revised steps 2 and 3.
Page 8-3 Revised "Ref Current Err" fault indication heading.
Page 8-7 Revised probable cause statements of "Cal Warning/Cal Failed" fault indication.
Page 9-5 Revised parts list for Sensor Housing Components.
Appendix A Updated multi-lingual safety pages.

Effective July 2008, Rev 1.2

Page/Section Summary

Page 4-3 Added note regarding cleaning the LOI screen before each use.

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Table of Contents

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

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

SECTION 1

escription and

D
Specifications

SECTION 2
Installation

SECTION 3
Configuration and
Startup

SECTION 4
Using the LOI

Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Mechanical

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

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

Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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

OCX 8800 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

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

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

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

LOI Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

LOI Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

SECTION 5

sing HART

U
Communications

SECTION 6
Calibration

http://www..raihome.com

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

Field Communicator Signal Connections. . . . . . . . . . . . . . . . . . . . . . . 5-1

Field Communicator PC Connections . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

HART Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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

Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

SECTION 7
Maintenance and Service

SECTION 8

oubleshooting

Tr

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

OCX 8800 Removal

and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

OCX with

Remote Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Sensor Housing Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Sensor Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Electronics Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Electronics Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Remove Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Install Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Total Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Diagnostic Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Alarm Relay Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

SECTION 9
Replacement Parts

APPENDIX A

afety Data

S

APPENDIX B
SPA with HART Alarm

APPENDIX C
Return of Materials

Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

O2 Cell and Heater Strut Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . . A-24

High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

TOC-2

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

OCX 8800
Oxygen/Combustibles Transmitter

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

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

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

product.

• If you do not understand any of the instructions, contact your
Emerson Process Management representative for clarification.

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

• Inform and educate your personnel in the proper installation,
operation, and maintenance of the product.

• Install your equipment as specified in the Installation Instructions

of the appropriate Instruction Manual and per applicable local and
national codes. Connect all products to the proper electrical and

pressure sources.

• To ensure proper performance, use qualified personnel to install,
operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson Process Management.
Unauthorized parts and procedures can affect the product's
performance, place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire,
electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers
are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.

http://www..raihome.com

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

If a Model 275/375 Universal HART® Communicator is used with this unit, the software
within the Model 275/375 may require modification. If a software modification is required,
please contact your local Emerson Process Management Service Group or National
Response Center at 1-800-654-7768.

Instruction Manual

:EARTH(GROUND)TERMINAL

:PROTECTIVECONDUCTORTERMINAL

:RISKOFELECTRICAL SHOCK

:WARNING:REFERTOINSTRUCTIONBULLETIN

IM-106-880ASL, Rev 1.2

OCX 8800

July 2008

PREFACE The purpose of this manual is to provide a comprehensive understanding of

the OCX 8800 components, functions, installation, and maintenance.
We recommend that you thoroughly familiarize yourself with the Introduction

and Installation sections before installing your transmitter.
The introduction presents the basic principles of the transmitter along with its

performance characteristics and components. The remaining sections contain
detailed procedures and information necessary to install and service the
transmitter.

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

DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES

und throughout this publication.

fo

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.

SYMBOLS

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.

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.

ii

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Section 1 Description and Specifications

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-12

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 Process Management.
A list of accessories for use with the OCX 8800 is provided in Table 1-2.

SYSTEM OVERVIEW Scope

This Instruction Manual supplies details needed to install, startup, operate,
and maintain the OCX 8800. Signal conditioning electronics outputs separate
4-20 mA signals representing oxygen (O2) and combustibles (COe) values.
This information, plus additional details, can be accessed with the HART
Model 275/375 handheld communicator or Rosemount Analytical AMS
software. The local operator interface (LOI) also provides a communications
interface with the 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.

http://www..raihome.com

OCX 8800

4

6

1

37390076

2

o

HART Communicator

FISHER-ROSEMOUNT

TM

MAN4275A00

English

October1994

3

5

A

n

a

l

y

t

i

c

a

l

Figure 1-1. Typical System Package

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

1. Instruction Manual

2. Field Communicator Package (optional)

3. Adapter Plate with Mounting Hardware and Gasket

4. Reference Air and Calibration Set

5. Blowback Hardware (optional)

6. OCX 8800 with Remote Electronics

1-2

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

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

EMF = KT log10 (P

Where:

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

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

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

NOTE

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

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

1/P2

) + C

The OCX 8800 measures net oxygen concentration in the presence of all the
products of combustion, including water vapor. Therefore, it may be
considered an analysis on a "wet" basis. In comparison with older methods,
such as the portable apparatus, which provides an analysis on a "dry" gas
basis, the "wet" analysis will, in general, indicate a lower percentage of
oxygen. The difference will be proportional to the water content of the
sampled gas stream.

The OCX 8800 combustibles sensor is a catalytic sensor consisting of two
Resistance Devices (RTD). One RTD is the reference element covered with
an inert coating. The other RTD element is active, coated with a catalyst. As
the sample gases flow by the sensor, the combustible gases oxidize on the
surface of the active element. The oxidation that occurs produces heat and a
temperature rise in the active element. The temperature difference produces
a resistance relationship between the two elements that is directly
proportional to the concentration of combustibles in the sample gases.

1-3

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

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

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

System Configuration

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

The electronics are contained in a separate housing from the sensors. The
electronics housing may be mounted up to 150 feet away from the sensor
housing.

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

System Features

1. The O
concentration decreases.

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

a. Model 275/375 Field Communicator.
b. AMS software for the PC.

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

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

cell output voltage and sensitivity increase as the oxygen

2

1-4

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

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

a. LOI. The LOI is mounted to the end of the electronics module and

allows local communications with the electronics. Refer to Section 4,
Using the LOI, for more information.

b. Optional HART Interface. Each of the OCX 8800's 4-20 mA output

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

• Model 275/375 Field Communicator - The handheld field
communicator requires Device Description (DD) software specific
to the OCX 8800. The DD software will be supplied with many
Model 275/375 units, but can also be programmed into existing
units at most Emerson Process Management service offices.
Refer to Section 5, Using HART Communications, for additional
information.

• Personal Computer (PC) - The use of a personal computer
requires AMS software available from Emerson Process
Management.

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

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

System Operation

Figure 1-2 shows the relationship between the components of the OCX 8800.
The sensors and the electronics are contained in separate housings. The
sensor housing and probe mounts to a duct or process wall so that the probe
protrudes into the flue gas stream. An air powered eductor continuously pulls
samples of the process flue gas through the probe to a chamber in front of the
sensor housing where the sample passes the O
the COe sensor. Dilution air is provided to the COe sensor and reference air
to the O2 sensor. After the gas sample flows past the O2 sensor and through
the COe sensor, it is drawn through the eductor where it mixes with the
eductor air and exits through exhaust back into the system. The electronics
housing contains the CPU and HART boards which convert the sensor inputs
into 4-20 mA analog output signals. The CPU can also initiate and perform
calibrations. Three test gasses and instrument air can be turned on and off by
solenoids. Test gas flow to the sensors is regulated by a flow meter between
the electronics and sensor housings. Instrument air is separated into eductor
air, reference air, and dilution air. The instrument air solenoid does not allow
air flow until the heaters are up to temperature. This minimizes the amount of
sampled process flue gas being pulled into cold sensors causing
condensation.

sensor and continues on to

2

1-5

OCX 8800

Low O

Test Gas

2

COe

Combustibles

Sensor

O

Sensor

2

Eductor

Probe

Exhaust

CPU

HART
Board

Optional

Test Gas

Solenoids

Instrument Air

Solenoid

High O

Test Gas

2

CO

Test Gas

Instrument

Air

Dilution Air

Reference Air

Eductor Air

Flow Meter

50 cc/min.

(0.1 scfh)

SENSOR

HOUSING

ELECTR

ONICS

HOUSING

Flow Meter

7 scfh

37390001

Sample

Gas

Power

Supply

Figure 1-2. System Operation Diagram

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

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 make the system installation. Ensure all the components are
properly integrated to make the system functional.

1-6

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

After verifying that you have all the components, select mounting locations
and determine how each component will be placed in terms of available line
voltage, ambient temperatures, environmental considerations, convenience,
and serviceability. Figure 1-3 shows a typical system wiring. Simplified
installations for the OCX 8800 are shown in Figure 1-4. Figure 1-6 shows the
dimensions for the optional sample tube support.

A source of instrument air is required at the OCX 8800 for reference air,
dilution air, and eductor air. Since the OCX 8800 is equipped with an in-place
calibration feature, provision should be made for connecting test gas tanks to
the OCX 8800 when it is to be calibrated.

NOTE

The electronics module is designed to meet NEMA 4 (IP66) and the electronic
components are rated to temperatures up to 185°F (8 5°C).

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

Figure 1-3. OCX 8800 HART
Connections and AMS Application

1-7

OCX 8800

OCX 8800 with

REMOTE

ELECTRONICS

4-20 mA Outputs
(2 Twisted Pairs)

Heater

P

ower Cable

[up to 150 ft (46 m)]

Pressure

Regulator

Duct

Stack

Gases

Line Voltage

Signal Cable

[up to 150 ft (46 m)]

37390064

Low O Test Gas

2

High O Test Gas

2

CO Test Gas

Instrument Air

Supply

(Ref

erence Gas)

Test Gas

Flow Meter

Dilution

Air

Flow

Meter

Figure 1-4. Typical System
Installation

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Figure 1-5. OCX 8800 HART

1-8

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

Connections and AMS Application

OCX 8800

1-9

OCX 8800

Figure 1-6. Sample Tube Support

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

1-10

Instruction Manual

OCX 8800 with

REMOTE

ELECTRONICS

4-20 mA Outputs
(2 Twisted Pairs)

Heater

P

ower Cable

[up to 150 ft (46 m)]

Pressure

Regulator

Duct

Stack

Gases

Line Voltage

Signal Cable

[up to 150 ft (46 m)]

37390064

Low O Test Gas

2

High O Test Gas

2

CO Test Gas

Instrument Air

Supply

(Ref

erence Gas)

Test Gas

Flow Meter

Dilution

Air

Flow

Meter

IM-106-880ASL, Rev 1.2
July 2008

Figure 1-7. Typical System
Installation

OCX 8800

1-11

OCX 8800

SPECIFICATIONS General Purpose OCX

Specifications

Net O2 Range 0-1% to 0-40% O2, fully field selectable
Combustibles 0-1000 ppm to 0-5%, fully field selectable
Accuracy

Oxygen ± 0.75% of reading or 0.05% O2 (whichever is greater)
Combustibles ± 2% range

System Response to
Test Gas

Oxygen 10 sec T90
Combustibles 25 sec T90

Temperature Limits

Process 32° to 2600°F (0° to 1427°C)
Sensors Housing -40° to 212°F (-40° to 100°C), ambie nt
Electronics Housing -40° to 149°F (-40° to 65°C), ambient

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

Mounting and Mounting
Positions

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)
Reference Air 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O2),

Eductor Air 5 scfh (2.5 l/m), clean, dry, instrument-quality air 20.95% O2),

Dilution Air 0.1 scfh (0.5 l/m), clean, dry, instrument-quality air (20.95% O2)

Blowback Air (optional) Clean, dry, instrument-quality air (20.95% O2), regulated to 55 psi

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

-40° to 185°F (-40° to 85°C), internal - operating temperature of
electronics inside instrument housing, as measured by a HART
communicator or AMS software

-40° to 158°F (-40° to 70°C), ambient
[At temperatures above 158°F (70°C) inside instrume nt housing,
the infrared keypad will cease to function, but the OCX 8800 will
continue to operate properly.]

54 lbs (20 kg)

55 lbs (20.5 kg)

57 lbs (21 kg)

59 lbs (22 kg)

Inconel 600 - 1832°F (1000°C)
Ceramic - 2600°F (1427°C)

0.4% O2, Balance N2
8% O2, Balance N2
1000 ppm CO, Balance Air

regulated to 35 psi (241 kPa)

regulated to 35 psi (241 kPa)

regulated to 35 psi (241 kPa)

(379 kPa)

Table continued on next page

1-12

Instruction Manual

APPROVED

CUS

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Specifications

Sensors Housing NEMA 4, IP66 with fitting and pipe on reference exhaust port to

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

Electronics Housing NEMA 4, IP66 with fitting and pipe on reference exhaust port to

Electrical Noise EN 61326-1, Class A
Certifications

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 capability

Combustibles 4-20 mAdc, 950 ohm maximum

Alarm Alarm output relay - dry contact, form C, 30mA, 30VDC capacity
Power Consumption 750 W maximum
Mounting and Mounting

Positions

Sensor Housing Flange

Electronics Housing Wall/Pipe

NOTE

ll static performance characteristics are with operating variables constant. Specifications subject to change

A
without notice.

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

jumpers required, 3/4-14 NPT conduit port

1-13

Instruction Manual

IM-106-880ASL, Rev 1.2

OCX 8800

Table 1-1. Product Matrix - General Purpose OCX 8800

OCX88A O2/Combustibles Transmitter

Code Probe Length and Material

00 No Probe or Exhaust Tube
11 18 in. (457 mm) 316 SST up to 1300°F (704°C) (3)
21 18 in. (457 mm) Inconel 600 up to 1832°F (1000°C)
31 18 in. (457 mm) Ceramic up to 2600°F (1427°C)
12 3 ft (0.91 m) 316 SST up to 1300°F (704°C)
22 3 ft (0.91 m) Inconel 600 up to 1832°F (1000°C) (3)
32 3 ft (0.91 m) Ceramic up to 2600°F (1427°C)
13 6 ft (1.83 m) 316 SST up to 1300°F (704°C)
23 6 ft (1.83 m) Inconel 600 up to 1832°F (1000°C) (3)
14 9 ft (2.7 m) 316 SST up to 1300°F (704°C)
24 9 ft (2.7 m) Inconel 600 up to 1832°F (1000°C) (3)

Code Probe Mounting Assembly

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

Code Mounting Hardware - Stack Side

0 No Adapter Plate (“0” must be chosen under “Mounting Adapter - Probe Side” below)
1 New Installation - Square weld plate with studs
2 Model 218/240 Mounting Plate (with Model 218/240 Shield Removed)
3 Existing Model 218/240 Support Shield
4 Special Mounting
5 Model 132 Adapter Plate

Code Mounting Hardware - Probe Side

0 No Adapter Plate
1 Probe Only (ANSI)
2 Probe Only (DIN)

OCX88A 11 10 1 1 H3 06 02 Example

NOTES:

(1)

Provide details of the existing mounting plate as follows:

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

(2)

For use with stainless steel sample tube only.

(3)

For high temperature applications that require a filter, please order 1A99762H03 separately.

(1)

Code Electronics Housing - Communications

H1 HART Communications
H2 HART Communications with Local Operator Interface
H3 HART Communications with Calibration Solenoids
H4 HART Communications with Local Operator Interface and Calibration Solenoids

Code Electronics Mounting

01 Integral to Sensor Housing
02 Remote Electronics and no cable
03 Remote Electronics and 20 ft (6 m) cable
04 Remote Electronics and 40 ft (12 m) cable
05 Remote Electronics and 60 ft (18 m) cable
06 Remote Electronics and 80 ft (24 m) cable
07 Remote Electronics and 100 ft (30 m) cable
08 Remote Electronics and 150 ft (46 m) cable

Code Accessories

00 None
01 Flow meters & Ref. Air Set
02 In-Situ Filter (Stainless Steel only) (2)
03 In-Situ Filter (SST), Flow meters & Ref. Air Set (2)
11 Flow meters, and Ref. Air Set with Blowback
12 In-Situ Filter (SST) with Blowback (2)
13 In-Situ Filter (SST), Flow meters & Ref. Air Set with Blowback (2)

July 2008

1-14

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

Table 1-2. Accessories

PART NUMBER DESCRIPTION

1A99119H01 Oxygen test gas bottle; 0.4% O2, balance N
1A99119H02 Oxygen test gas bottle; 8.0% O2, balance N

1A 99119H07 CO test gas bottle; 1000 ppm CO, balance air

1A99120H02 Regulator for Oxygen (may need 2)
1A99120H03 Regulator for CO test gas
1A99119G06 Wall mount bracket for test gas bottles
1A99119G05 Test gas regulators kit
1A99119G04 Test gas bottles kit

1A99292H01

1A99339H03 Blowback valve, air operated
4851B40G01 Wall or Pipe Mounting Kit
1A99762H03 Hasteloy In Situ Filter, High Temperature

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)
6P00162H02 Flange Insulator

Moore Industries SPA for Low O2 Alarm, High COe Alarm,
Calibration Status, and Unit Fail

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

OCX 8800

2

2

1-15

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

1-16

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

Section 2 Installation

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

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

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-14

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-20

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.

OCX 8800

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

http://www..raihome.com

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

MECHANICAL INSTALLATION

Selecting Location

1. The location of the OCX 8800 in the stack or flue is most important for
maximum accuracy in the oxygen analyzing process. The probe must
be positioned so the gas it measures is representative of the process.
Best results are normally obtained if the transmitter is positioned near
the center of the duct (40-60% insertion). Longer ducts may require
several transmitters since the oxygen and combustibles can vary due to
stratification. A point too near the wall of the duct or the inside radius of
a bend, may not provide a representative sample because of the very
low flow conditions. The sensing point should be selected so the
process gas temperature falls within the range of probe material used.
Figure 2-1 through Figure 2-4 provide mechanical installation
references. The ambient temperature inside the electronics housing
must not exceed 185°F (85°C).

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

3. Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance access to the unit. Allow
adequate clearance for the removal of the OCX 8800.

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

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

Installation

1. Ensure all components are available to install the OCX 8800.

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

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

4. Use the pipe or wall mounting hardware as shown in Figure 2-3 to
mount the electronics housing. Choose a location not to exceed the
length of the electronics cable ordered.

5. Ensure the conduits drop vertically from the OCX 8800 and the conduit
is routed below the level of the conduit ports on the housing to form a
drip loop. Drip loops minimize the possibility that moisture will damage
the electronics (Figure 2-4).

6. Where a positive stack pressure exists at the installation site, connect all
pneumatic lines prior to installing the OCX 8800 in the stack or
ductwork.

2-2

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

NOTE

If process temperatures will exceed 392°F (200°C), use anti-seize compound
on stud threads to ease future removal of the OCX 8800.

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

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

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

Enclosures

The OCX 8800 enclosures are designed to meet ingress conditions of IP66.
Each enclosure cover is threaded to its base and sealed with an o-ring that
isolates the threads from external contaminants.

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

2-3

OCX 8800

B.C. Dia.

Removal Envelope

Dim “B”

37390009

Insertion Depth

Dim “A”

Flange Dia.

Hole Dia.

8.3

(211)

Allow 9 in.

(229 mm) for

Cover Removal

See Table 1

Optional

In Situ FIilter

Heater Power Cable

Signal Cable

Heater Power Cable

Signal Cable

ELECTRONICS HOUSING

SENSOR HOUSING

See Table 2

All dimensions are in inches with millimeters in parentheses.

NOTE

Insulate if exposed to adverse weather or extreme temperature
changes, install a protective housing and/or insulation
around the unit.

Flange
Dia.

DIN

ANSI

5R10244H025R10244H01

6.00

(152)

Table 1. Mounting Flange

Hole
Dia.

(4) Holes
equally
spaced on
B

.C

. dia

7.28

(185)

0.75
(19)

0.71
(18)

4.75

(121)

5.71

(145)

Dim "B”

3 ft

9 ft

6 ft

Probe

18 in.

Dim "A”

(2235)

88

(3150)

124

(2743)

108

72

(1829)

(914)

36

(1321)

52

(864)

34

(457)

18

Table 2. Installation/Removal

3535B18H02
3535B45H01

DIN

ANSI

0.06 In. Thick Gasket

Figure 2-1. Installation, OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

2-4

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

Figure 2-2. Adapter Plate Installation

OCX 8800

2-5

OCX 8800

37020021

*Pipe

Mounting

Clamp

Electronics

Housing

*Wall or Pipe

Mounting Bracket

and Screws

1/4-20 UNC x 2 in. M-F Standoffs.

Recommended for rear piping

clearance when wall mounting.

(4 each by customer)

Wall Mounting Bolts

or Lag Screws

(4 each by customer)

* Indicates items are included

in mounting kit P/N 4851B40G01.

Note:

Figure 2-3. Wall or Pipe Mounting
of Electronics Housing

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

2-6

Instruction Manual

37020004

Conduit Drip Loops

Duct Wall

Conduit Drip Loop Conduit Drip Loop

Duct Wall

IM-106-880ASL, Rev 1.2
July 2008

Figure 2-4. Installation
with Drip Loops

OCX 8800

2-7

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

ELECTRICAL INSTALLATION

All wiring must conform to local and national codes. For reference, factory
wired solenoid power connections are shown in Figure 2-5.

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

2-8

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

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 2-5.

NOTE

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

Electrical Connections

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

Connect Line Voltage

The OCX 8800 operates on 100 to 240 VAC line voltage at 50 to 60 Hz. The
power supply requires no setup. Connect the line (L wire) to the L terminal,
and the neutral (N wire) to the N terminal on the AC power input terminal
block in the electronics housing. Connect the ground (G wire) to the ground
stud in the electronics housing as shown in Figure 2-5.

Connect 4-20 mA Signals

Connect the 4-20 mA current loop to the 4-20 mA signal output terminals in
the electronics housing as shown in Figure 2-5. Use individual shielded
twisted wire pairs. Terminate the shield at the electronics housing.

4-20 mA Signal

O

2

One 4-20 mA signal represents the O2 value. Superimposed on the O2
signal is the HART information accessible through a Model 275/375
Handheld Communicator or AMS software. The O2 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. HART information is not available on the COe signal.

Alarm Output Relay

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

2-9

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Remote Electronics Connections to Sensor Housing

Make the following connections between the electronics and sensor housings
with the electronics cable ordered with the package (Figure 2-6). Braided
cable is available in lengths up to 150 ft. (46 m).

NOTE

Interconnect wiring shown is for Rosemount Analytical supplied cables. For
customer furnished interconnect wiring or cables, refer to Figure 2-7.

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 2-6.

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 2-6.

2-10

Instruction Manual

37390013

TOP VIEW

(1/2 SIZE)

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

NC

COM

NO

Alarm Output Relay

Terminal Block

#1

AOUT2+
AOUT2­AOUT1-

AOUT1+

O Signal

2

COeSignal

{

{

Ground

Stud

4-20 mA Signal Output

Terminal Block

Power Port

3/4 NPT

Signal Port

3/4 NPT

External Tooth

Lockwasher

#1

G

G

Terminal

Block

N

G

L1

EMI Filter

Customer

Wiring

IM-106-880ASL, Rev 1.2
July 2008

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

OCX 8800

2-11

OCX 8800

37390014

RED
BLK

WHT

GRN
BLK

BLK

BLU
BLK

YEL

BRN

RED

BLK

BLK

ORG

BLK

WHT

T/C CO+
T/C CO-

T/C SB+
T/C SB­T/C O2+
T/C O2-

O2 CELL+
O2 CELL-

EXC

+

+

-

+

-

EXC-

-

+

-

2

1

1

2

2

1

BLU

ORG

YEL

RED

SHIELD

To

ground

screw

GRN

BLK

WHT

BLK

YEL

RED

BLU

WHT

BLK

BLK

GRN

BLK

BLK

BLK

ORG

WHT

RED

BLK

BRN

To ground screw

GRN

ELECTRONICS HOUSING

SENSOR HOUSING

Heater Power Cable

Signal Cable

O Sensor and
Thermocouple

Connector (J5)

2

COe Sensor

and

Cold Junction

Connector (J4)

EXC+
CO A

CT+

CO ACT-

CO REF+
CO REF­CJC+
CJC­EXC-

O2

HTR

O2

HTR

CO

HTR

SB

CO

REF

CO

ACT

CJC

T/C SB

T/C CO

T/C O2

+

-

+

-

+

-

+

#1

#1 #1

#1

#1

To ground

screw

SHLD

WHT

ORG

BLU

BLK

YEL

RED

Heater Power

Connector (J3)

#1

2HTR SB

1HTR O

2

1HTR SB

2HTR CO
1HTR CO
2HTR O

2

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

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

2-12

Instruction Manual

A

#2

#1

3/4 NPT Hub Size,

Liquid-tight

Strain Relief

Connector

Heat Shrink

Tubing

2” Long

1/2” Size

7.0” Long Teflon Tubing,

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

8 twisted pairs 24 AWG,
stranded, insulated,
tinned copper
conductors, 200 C, 300
volts, with overall braid
of 34 AWG tinned
copper, 90% coverage
and 24 AWG tinned
copper, uninsulated
drain wire.

o

7.25

±0.10

Strip Wire

Ends 3/16”

Typical

7.25 ±0.10

9.25 ±0.10
Overall Cable Length

By Customer

150’ Maximum

3.875
±0.10

4.625
±0.10

5.375
±0.10

6.125
±0.10

6.875 ±0.10

8.625 ±0.10

10.375 ±0.10

12.5 ±0.10

Ferrule,
Uninsulated

2.0 ±0.25
Typical

DETAIL

A

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

(typical on both ends of wiring)

SIGNAL WIRING OR CABLE

ELECTRONICS END

PROBE END

0.5

Typ.

3/4 NPT Hub Size,

Liquid-tight

Strain Relief

Connectors

Heat Shrink Tubing

2” Long, 1/2” Size

4.25” Long Teflon Tubing,

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

8 Conductors, 16 AWG, Stranded,
200 C, 600 volts.
Braided shield - tinned copper, 90%
coverage with 18 AWG 24 tinned copper,
uninsulated, drain wire.

O

4.0 ±0.10

Stud Size

#10

4.5 ±0.10

5.5 ±0.10

Ferrule, Uninsulated

2.0 ±0.25 Typical

Heat Shrink Tubing

2” Long, 1/2” Size

HEATER WIRING OR CABLE

ELECTRONICS END

PROBE END

Green,

16 AWG

0.5
Typ.

Stud Size #6

Green, 16 AWG

Strip Wire

Ends 3/16”

Typical

Heat Shrink

Tubing

2” Long

1/2” Size

See Note

See Note

NOTE: For RFI/CE compliance, the connector

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

Stud Size

#10

37390061

IM-106-880ASL, Rev 1.2
July 2008

Figure 2-7. Customer-Furnished
Interconnect Wiring or Cables

OCX 8800

2-13

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

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.

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

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

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

.

Do not use 100% nitrogen as an O2 low gas. It is suggested that O2 low gas be between

0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40

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

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

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

low gas - 0.4% , Balance N

O

2

O2 high gas - 8%, Balance N

2

2

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.

2-14

Instruction Manual

37390011

Electronics

Housing

Eductor

Air In

Sensor

Housing

Dilution Air In

Reference Air In

CAL Gas In

CAL Gas

Flow Meter

7 scfh, 20-30 psig

Recommended

Dilution Air

Flow Meter

0.1 scfh

Instrument

Air Supply

Pressure Reguator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

(

(

2-Stage

Regulators

CO

HI O

2

LO O

2

Instrument

Air Out

IM-106-880ASL, Rev 1.2
July 2008

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

OCX 8800

2-15

OCX 8800

Electronics

Housing

Dilution

Air In

Reference

Air In

CAL Gas In

CAL Gas

Flow Meter

7 scfh, 20-30 psig

Recommended

Dilution Air

Flow Meter

0.1 scfh

Instrument

Air Supply

Pressure Regulator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

2-Stage

Regulators

CO

HI O

2

LO O

2

CAL Gas Out

Eductor

Air In

Sensor

Housing

Instrument Air Out

(

(

37390012

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

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Reference Air Set and Solenoids Option

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

1. Install the reference air set according to the instructions in Reference Air

2. Refer to Figure 2-9. Connect the O

3. Connect the O

Set Option, steps 1 through 3.

low gas source to the CAL GAS LO

2

O2 inlet fitting on the electronics housing. Install a shutoff valve and
pressure regulator with gage in the O2 low supply line, as shown.

high gas source to the CAL GAS HI O2 inlet fitting.

2

Install a shutoff valve and pressure regulator with gage in the O2 high
supply line.

2-16

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

4. 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.

5. 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, Solenoids, and Blowback Option

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

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

Figure 2-10 shows the piping arrangement for the OCX 8800 with the
blowback and autocalibration options. Figure 2-11 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.

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

2. Connect a clean, dry, instrument-quality supply of air (20.95% O
35/45 psig and 55 psig pressure regulators. The inlet to the 35/45 psig
regulator accepts a 1/8" NPT fitting. The inlet to the 55 psig regulator
accepts a 1/4" NPT fitting.

3. See the upper leg of the instrument air supply. Connect the output of the
35/45 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.

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

5. 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.

6. 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.

7. 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.

) to the

2

2-17

OCX 8800

Figure 2-10. Piping Arrangement,
Blowback with Autocalibration

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

2-18

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

Figure 2-11. Piping Arrangement,
Blowback without Autocalibration

OCX 8800

2-19

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

8. 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.

9. There are three settings that need to be specified to set up the blowback
option. These are the blowback interval, duration, and purge time.

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

Duration - Length of time blowback air is activated.
(5 seconds recommended.)

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

These settings are available through HART from the DEVICE SETUP >
DETAILED SETUP > OUTPUT CONDITIONS > BLOWBACK menu.
Using the LOI, these settings are accessible from the SYSTEM >

INPUT/OUTPUT > BLOWBACK menu.

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

nd Startup, for OCX 8800 startup information.

a

Upon completing 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.

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.

2-20

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Section 3 Configuration and Startup

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

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

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

OCX 8800 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . page 3-4

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.

http://www..raihome.com

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Verify Configuration

There are three switches on the microprocessor board which are user
configurable for the OCX 8800 (Figure 3-1). SW1 determines if the O2 4-20
mA signal is internally or externally powered. SW2 determines if the COe 4-20
mA signal is internally or externally powered. SW3 sets the rail limits for the

and COe 4-20 mA signals and configures the sample line heater control

O

2

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.

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 O2 4-20 mA signal to be internally
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 O

4-20 mA signal rail limit. The settings are

2

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.

3-2

Instruction Manual

1 234

Internal:

O 4-20 mA
is Internally

Powered

2

External:
O 4-20 mA

Requires an External
Power Supply
(Default)

2

O 21.1 mA/3.5 mA:2O 4-20 mA Signal

Rail Limits:
High - 21.1 mA
Lo

w - 3.5 mA

2

COe 4-20 mA Signal
Rail Limits:
High- 21.1 mA
Low - 3.5 mA

COe 21.1 mA/3.5 mA:

1

1223344

SW3

3.5 mA

Switch

Default Postions

Shown

COe

SW1

SW2

37390026

O

2

21.1 mA

Closed

External:
COe 4-20 mA
Requires an External
Power Supply
(Default)

Internal:

COe 4-20 mA

is Internally

Powered

Open

Closed

Open

Open

Closed

Open

Closed

IM-106-880ASL, Rev 1.2
July 2008

Figure 3-1. OCX 8800 Defaults

OCX 8800

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

peration and for the OCX 8800 to reach normal operating temperature on

o
power up. Normal operating temperature for the O2 cell is 736°C. Normal
operating temperature for the combustibles cell is 300°C. The normal sample
line temperature is 170°C. During this time the edu ctor 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.

3-3

Instruction Manual

IM-106-880ASL, Rev 1.2

OCX 8800

July 2008

SET TEST GAS VALUES Use HART/AMS or the optional LOI to set test gas values for calibration.

Refer to Section 4, Using the LOI or Section 5, Using HART Communications
for more information.

Setting Test Gas Values with HART

1. Use the 275/375 Field Communicator or AMS software to access the
HART menu.

2. From the DETAILED SETUP menu, select O2 CALIB PARAMS.

3. From O2 CALIB PARAMS, select O2 High Gas. Enter the percent O
used for the high O2 test gas.

4. From O2 CALIB PARAMS, select Low TG. Enter the percent O2 used
for the low O2 test gas.

5. From the DETAILED SETUP menu, select COe CALIB PARAMS.

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

Setting Test Gas Values with the LOI

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

2. From the SYSTEM menu, select Calib Setup.

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

4. Select the down arrow and the next selection will be O2 Low Gas %.
Enter the percent O2 used for the low O2 test gas.

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

2

OCX 8800 RESET

ROCEDURE

P

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

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

2. Select the SYSTEM submenu.

3. From the SYSTEM submenu, select the Status submenu.

4. 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 HART

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

3-4

Instruction Manual

Electronics Housing

(Cover Removed)

LOI Connector

LOI Board

LOI Module

Electronics Stack

37390027

A

n

a

l

y

t

i

c

a

l

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

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

D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-8

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

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Instruction Manual

E

37390042

Display

Window

Selection

Arrows

Selection

Arrow

Selection

Arrow

(Enter key)

Touch

Confirmation

LED

Analytical

LK
AL

Lockout

Notation

Status

Code

IM-106-880ASL, Rev 1.2

OCX 8800

July 2008

LOI CONTROLS

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 Hazardous Area OCX 8800 also utilizes HART
communications, permitting access to all instrument functionality anywhere
the 4-20 mA signal terminates via a HART model 275/375 handheld
communicator.

Figure 4-2. LOI Assembly

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

ntering parameter values (numbers), this key moves the cursor to the left.

e
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.

4-2

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.

Instruction Manual

37390057

E

Analytical

3

4

1

2

IM-106-880ASL, Rev 1.2
July 2008

Figure 4-3. ‘Z’ Pattern Entry

OCX 8800

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. Touch 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

isplay. There are nine status codes to indicate the existing status of the

d
device during operation. The status code descriptions are shown in Table 4-1.

Table 4-1. LOI Status Codes

CODE DESCRIPTION

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.

PO

SF

ST

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

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 stabilizing (after warm up). Sensors
are warming up to operating temperature.

4-3

Instruction Manual

O2 Temp _____dgC

O2 Temp-MAX _____dgC

COe Temp _____dgC

COe Temp-MAX _____dgC

SB Temp _____dgC

SB Temp-MAX _____dgC

Board Temp _____dgC

Board Temp-MAX _____dgC

CJC Temp _____dgC

CJC Temp-MAX _____dgC

Temperatures

SENSOR DATA

Raw Values

O2 Output % _____%

O2 Current ____mA

COe Output % _____%

COe Current ____mA

Analog Outputs

O2 X.XX%
Comb XXX ppm

%

%

37390007

(CONTINUED ON

SHEET 2)

O2 Sensor _____ mV

O2 Sensor R ____ ohm

O2 T/C _____ mV

COe Delta V _____ mV

RTD Current _____ mA

Board Temp IC

CJC Temp Signal _____ mV

____ ohm
_____ mV
____ ohm
_____ mV

COe Delta R
COe Reference V
COe Reference R

COe T/C

SB T/C _____ mV

_____ mV

IM-106-880ASL, Rev 1.2

OCX 8800

July 2008

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

From the operating display (O2% and COe ppm), the left-pointing Enter key is
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

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

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.

4-4

Instruction Manual

NOTE: “Hit E when ready” is displayed during

semi-automatic calibration only (when
Calib Setup value Use Solenoids = n).

(CONTINUED FROM

SHEET 1)

CALIBRATION

(CONTINUED ON

SHEET 3)

Cal
Control

Cal
Constants

Cal
Status

Cal
Verify

Abort Cal

Start Cal
O2

Start Cal
COe

Start Cal
Both

Current
Calib

Prev
Calib

Falied
Calib

Calib Result
Calib Step
Calib Time
Next O2 Cal
Next COe Cal

Flow High Gas
Flow Low Gas
Flow COe Gas
Purge
Status

Apply Lo O2 Gas

Flow O2 Lo _____s

______% _____mV

Read O2 Lo _____s

______% _____mV

Apply Hi O2 Gas

Flow O2 Hi _____s

______% _____mV

Read O2 Hi _____s

______% _____mV

Purge _____s

Hit E when ready

Hit E when ready

Hit E when ready

Apply Lo COe Gas

Flow COe Lo _____s

______% _____mV

Read COe Lo _____s

______% _____mV

Hit E when ready

Apply Hi COe Gas

Flow COe Hi _____s

______% _____mV

Read COe Hi _____s

______% _____mV

Purge _____s

Hit E when ready

Hit E when ready

Apply Lo O2 Gas

Flow O2 Lo _____s

______% _____mV

Read O2 Lo _____s

______% _____mV

Apply Hi O2 Gas

Flow O2 Hi _____s

______% _____mV

Read O2 Hi _____s

______% _____mV

Hit E when ready

Hit E when ready

Purge _____s
Flow COe Hi _____s

______% _____mV

Read COe Hi _____s

______% _____mV

Purge _____s

Hit E when ready

Hit E when ready

O2 Slope _____mV/D
O2 Constant _____mV
O2 Sensor R _____ohm
COe Slope _____ppm/mV
COe Constant _____mV

Pre O2 Slope _____mV/D
Pre O2 Const _____mV
Pre O2 Sensor R _____ohm
Pre COe Slope _____ppm/mV
Pre COe Const _____mV

Bad O2 Slope _____mV/D
Bad O2 Const _____mV
Bad COe Slope _____ppm/mV
Bad COe Const _____mV

37390015

IM-106-880ASL, Rev 1.2
July 2008

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

OCX 8800

4-5

OCX 8800

SYSTEM

O2 High Gas %
O2 Low Gas %
O2 Reset Vals Yes/No
O2 Out Tracks Yes/No
O2 Cal Interval Hrs
O2 Next Cal Hrs
COe Test Gas %
COe Reset Vals Yes/No
COe Out Tracks Yes/No
COe Cal Interval Hrs
COe Next Cal Hrs
COe Slope Warn %
Use Solenoids Yes/No
Gas Time Seconds
Purge Time Seconds

Trigger 1 Event
Trigger 2 Event
Trigger 3 Event

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

Calib Setup

Blowback

Alarm Relay

Analog

37390017

O2 Type 20-4 mA

COe Type 20-4 mA

COe Range HI ___ppm

Trim COe Out (procedure)

O2 Range Hi ___%

O2 Range Lo

___%

O2 AlarM Level ___mA

Trim O2 Out (procedure)

COe Range Lo ___ppm
COe Alarm Lvl ___mA

(CONTINUED ON

SHEET 4)

Input/Output

Blow Bk Enable __Yes/No
Blow Bk Intrvl ___Minutes
Blow Bk Period ___Seconds
Blow Bk Purge ___Seconds
Blow Bk Status

(CONTINUED FROM

SHEET 2)

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

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

4-6

Instruction Manual

SYSTEM

O2 Slope ___ mV/D
O2 Constant ___ mV
O2 T90 Time ___ seconds

COe Constant ___ ohm

COe T90 Time ___ seconds

COe Slope ___ ppm/ohm

Version
Checksum
Build Number
Build Date

Parameters

Software

37390056

(CONTINUED FROM

SHEET 3)

Restart Count
SW Err File
SW Err Line
SW Err Number

Revert Time ___ minutes

O2 T90 Time ___ seconds

Luminance ___ %

PCDC Enable ___ Y/N

Lockout Time ___ seconds

PCNC Enable ___ Y/N

Alarms
CPLD Registers
Line Frequency
Line Voltage

Status

PCD Counter

Sensor Housing
Serial Number

PCN Counter
Reset Device

IM-106-880ASL, Rev 1.2
July 2008

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

OCX 8800

4-7

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

D/A TRIM PROCEDURES O

D/A trim procedure using the LOI

2

Use the following procedure to perform the O2 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.

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

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

2. From the SYSTEM menu, use the down-pointing key to select
Input/Output. Use the right-pointing key to select the Analog
parameters list.

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

trim procedure.

2

NOTE

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

4. Remove the electronics housing cover.

5. Refer to Figure 2-5. Connect a digital multimeter to read the milliamp
output from the O

D/A converter circuit. Connect the positive lead to

2

the AOUT1+ terminal and connect the negative lead to the AOUT1­terminal. Then, touch the Enter key at the LOI.

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

design-equivalent signal for a 4.00 mA output. Read the O2 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.

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

design-equivalent signal for a 20.00 mA output. Read the O2 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.

8. 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.

9. 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.

4-8

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

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.

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

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

2. From the SYSTEM menu, use the down-pointing key to select
Input/Output. Use the right-pointing key to select the Analog
parameters list.

3. 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.

4. Remove the electronics housing cover.

5. Refer to Figure 2-5. 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 negative lead to the AOUT2­terminal. Then, touch the Enter key at the LOI.

6. 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.

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

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

8. 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.

9. 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.

millamp

4-9

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

4-10

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Section 5 Using HART Communications

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

Field Communicator Signal Connections . . . . . . . . . . . . page 5-1

Field Communicator PC Connections . . . . . . . . . . . . . . . page 5-4

HART Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-5

D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-9

OVERVIEW The Field Communicator is a handheld communications interface device. It

provides a common communications link to all microprocessor-based
instruments that are HART compatible.

To interface with the OCX 8800, the Field Communicator requires a
termination point along the O2 4-20 mA current loop and a minimum load
resistance of 250 ohms between the communicator and the power supply.
The Field Communicator accomplishes its task using a Frequency Shift
Keying (FSK) technique. With the use of FSK, high-frequency digital
communication signals are superimposed on the 4-20 mA oxygen output
signal. The communicator does not disturb the 4-20 mA signal since no net
energy is added to the loop. HART information is not available on the COe
output signal.

FIELD COMMUNICATOR

IGNAL CONNECTIONS

S

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

The Field Communicator can connect to the OCX 8800 oxygen analog output
signal line at any wiring termination in the O2 4-20 mA current loop. There are
two methods of connecting the Field Communicator to the signal line. For
applications in which the signal line has a load resistance of 250 ohms or
more, refer to method 1. For applications in which the signal line load
resistance is less than 250 ohms, refer to method 2.

http://www..raihome.com

OCX 8800

Figure 5-1. Signal Line Connections,

≥ 250 Ohms Load Resistance

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Method 1, for Load Resistance ≥ 250 Ohms

efer to Figure 5-1 and the following steps to connect the Field

R
Communicator to a signal line 250 ohms or more of load resistance.

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

Using the supplied lead set, connect the Field Communicator in parallel to the
OCX 8800. Use any wiring termination points in the oxygen analog output
4-20 mA signal line.

5-2

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

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

OCX 8800

Method 2, for Load Resistance < 250 Ohms

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

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

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

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

5-3

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Field Communicator PC Connections

There is an option to interface the Field Communicator with a personal
computer. Load the 375 Easy Upgrade Programming Utility software into the
PC. Then link the Field Communicator to the PC through the IRDA Interface.
Refer to the proper Field Communicator documentation in regard to the PC
interface option.

Off-line 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 documentation regarding
HART/PC applications.)

In the on-line mode, the communicator is connected to the oxygen 4-20 mA
analog output signal line. The Field Communicator is connected in parallel to
the OCX 8800 or in parallel to the 250 ohm load resistor.

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.

5-4

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

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

specific to OCX 8800 applications.

Figure 5-3. HART Menu Tree
(Sheet 1 of 4)

5-5

OCX 8800

DIAG/SERVICE

BCSR0 BCSR3
BCSR1 BCSR4
BCSR2 BCSR5

STATUS

CPLD REGS

D/A TRIM

CAL METHODS
O2OutTracks
COeOutTracks
Cal Step
Cal Time
O2
COe

PERFORM
CAL

CALIBRATE

Cal Step
Cal Time

CAL
STATUS

FAILED CAL
VALUES

Reset O2 CalConsts
Reset COe CalConsts

RESET CAL
CONST

O2 Calibration
COe Calibration
O2 and COe Calib

(CONTINUED FROM

SHEET 1 )

(CONTINUED ON

SHEET 3)

Snsr Housing

Model Number

O2 AO Saturated
COe AO Saturated

O2 AO Fixed
COe AO Fixed

AO fixed

AO saturated

Status group 4

Status group 3

Status group 2

Operate Mode

Status group 6

Status group 5

HW STATUS

Status group 1

LOOP TEST

O2 Loop Test
COe Loop Test

O2 D/A Trim
COe D/A Trim

O2 Slope
O2 Const
O2 Snsr R
COe Slope
COe Const

CAL VALUES

Bad O2 Slope
Bad O2 Const
Bad COe Slope
Bad COe Const

PREV CAL
VALUES

Prev O2 Slope

O2 Const
O2 Snsr R
COe Slope
COe Const

Prev
Prev
Prev
Prev

VERIFY CALIB

Verify Calibration
Status
TimeRemain
O2
COe

BlBk State
Blowback

BLOWBACK

MAX TEMP

O2TempMax
COeTempMax
SBTempMax
BrdTempMax
CJCTempMax

O2 Prop
O2 Int
O2 DutyCyc
O2 SetPt
O2 Temp

HEATER PID

O2 PID

COE PID

SB PID

COe Prop

Int
DutyCyc
SetPt

Temp

COe
COe
COe
COe

SB Prop
SB Int
SB DutyCyc
SB SetPt
SB Temp

37390039

Line Freq
Line Volt
PCN Counter
PCD Counter

Status group 4
RTD Current Err
COe Temp Low
COe Temp Hi
COe Temp Very Hi
COe T/C Open
COe T/C Shorted
COe T/C Reversed
SB T/C Reversed

Status group 3
Cal Failed
Cal Warning
SB T/C Open
SB T/C Shorted
SB Temp Low
SB Temp Hi
SB Temp Very Hi
ADC Ref Error

Status group 2
O2 Temp Low
O2 Temp Hi
O2 Snsr Open
O2 Snsr R Hi
EEPRM Chksm Fail
O2 Htr Ramp Rate
COe Htr Ramp Rate
SB Htr Ramp Rate

Status group 6
O2 Slope Error
O2 Constant Error
O2 Cal Failed
COe Slope Error
COe Constant Error
COe Cal Failed

Status group 5
COe Htr Failure
SB Htr Failure
Line Voltage Low
Line Voltage Hi
Htr Relay Failed
Output Board Failure

Status group 1
O2 T/C Open
O2 T/C Shorted
O2 T/C Reversed
ADC Failure
Line Freq Error
O2 Htr Failure
O2 Temp Very Hi
Board Temp Hi

(procedures)

Figure 5-3. HART Menu Tree (Sheet 2 of 4)

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

5-6

Instruction Manual

BASIC SETUP

DEVICE

INFORMATION

DETAILED
SETUP

(CONTINUED FROM

SHEET 2)

37390040

(CONTINUED ON

SHEET 4)

Tag
Poll addr
Dev id
Num req preams
Fld dev rev

OUTPUT
CONDITION

Trig 1 Event
Trig 2 Event
Trig 3 Event
Alarm State

O2 AO Type
O2 URV
O2 LRV
O2 Alarm Level

COe CALIB
PARAMS

BlBk Enabled
BlBk Intrvl
BlBk Period
BlBk PurgeTm
BlBk State

ANALOG
OUTPUT

ALARM
RELAY

DEVICE
PARAMS

LOI
PARAMS

O2 CALIB
PARAMS

BLOWBACK

COe AO Type
COe URV
COe LRV
COe Alarm Level

O2 ANALOG
OUTPUT

COe ANALOG
OUTPUT

O2OutTracks
O2 High Gas
O2 Low Gas
Gas Time
Purge Time
Solenoids
O2 CalIntv
O2NxtCalTm

COeOutTracks
COe Test Gas
Gas Time
Purge Time
Solenoids
COe CalIntv
COeNxtCalTm
COe Slope Warn

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

User Intface
Luminance
Lockout Time
Revert Time

Date
Descriptor
Message
Final asmbly num
O2 Sensor s/n
COe Sensor s/n

HART
INFORMATION

S/W VERSION
INFO

Version
Chksum
Bld Num
Bld Date
Restart Cntr

IM-106-880ASL, Rev 1.2
July 2008

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

OCX 8800

5-7

OCX 8800

O2 Slope
O2 Const
O2 T90

COe Slope
COe Const
COe T90

O2 CALIB

O2 DEVICE
CONFIG

REVIEW

DEVICE
INFORMATION

HART
INFORMATION

CAL INFO

OUTPUTS
CONFIG

Manufacturer
Model
Date
Descriptor
Message
Final asmbly num
O2 Sensor s/n
COe Sensor s/n
Hardware rev
Software rev

(CONTINUED FROM

SHEET 3)

37390041

Tag
Poll addr
Dev id
Num req preams
Fld dev rev
Universal rev

DEVICE
CONFIG

COE CALIB

O2OutTracks
O2 High Gas
O2 Low Gas
Gas

Time
Purge Time
Solenoids
O2 CalIntv
O2NxtCalTm

COeOutTracks
COe Test Gas
Gas Time
Purge Time
Solenoids
COe CalIntv
COeNxtCalTm
COe Slope Warn

COE DEVICE
CONFIG

DEVICE CONFIG

Trig 1 Event
Trig 2 Event
Trig 3 Event
BlBk Enabled
BlBk Intrvl
BlBk Period
BlBk PurgeTm
PCNC Enable
PCDC Enable
Luminance
Lockout Time
Revert Time

O2 URV
O2 LRV
COe URV
COe LRV
O2 AO Type
COe AO Type
O2 Alarm Level
COe Alarm Level

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

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

5-8

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

D/A TRIM PROCEDURES O

D/A trim procedure using HART

2

Use the following procedure to perform the O2 D/A trim procedure using the
Field Communicator. Refer to the HART menu tree, Figure 5-3.

NOTE

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

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

1. From the DIAG/SERVICE menu, select D/A TRIM. The Field
Communicator displays O2 D/A Trim.

2. Press the right arrow key to start the procedure. (If you wish to exit D/A
Trim with no changes, select ABORT.)

3. 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.

4. The Field Communicator displays Connect reference meter to O2
output.

5. Remove the electronics housing cover.

6. Refer to Figure 2-5. Connect a digital multimeter to read the milliamp
output from the O2 D/A converter circuit. Connect the positive lead to
the AOUT1+ terminal and connect the negative lead to the AOUT1­terminal. Then, press OK at the Field Communicator.

7. The Field Communicator displays Setting Fld dev output to 4 mA.
Press OK. Read the O
the reading at the Field Communicator and press ENTER. (Select
ABORT to exit without changes).

8. The Field Communicator displays Setting Fld dev output to 20 mA.
Press OK. Read the O2 millamp output at the digital multimeter. Enter
the reading at the Field Communicator and press ENTER. (Select
ABORT to exit without changes).

9. 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.

millamp output at the digital multimeter. Enter

2

5-9

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

COe D/A trim procedure using HART

Use the following procedure to perform the COe D/A trim procedure using the
Field Communicator. Refer to the HART menu tree, Figure 5-3.

NOTE

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

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

1. From the DIAG/SERVICE menu, select D/A TRIM. The Field
Communicator displays O2 D/A Trim. Press the up or down arrow to
select COe D/A Trim.

2. Press the right arrow key to start the procedure. (If you wish to exit D/A
Trim with no changes, select ABORT.)

3. 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.

4. The Field Communicator displays Connect reference meter to
Combustibles output.

5. Remove the electronics housing cover.

6. Refer to Figure 2-5. 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 negative lead to the AOUT2­terminal. Then, press OK at the HART communicator.

7. The Field Communicator displays Setting Fld dev output to 4 mA.
Press OK. Read the COe
the reading at the Field Communicator and press ENTER. (Select
ABORT to exit without changes).

8. 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).

9. 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.

millamp output at the digital multimeter. Enter

5-10

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

Section 6 Calibration

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

Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . page 6-1

Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . page 6-4

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-4

OCX 8800

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 O2 and combustibles in the
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.

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

FULLY AUTOMATIC CALIBRATION

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 HART/AMS to set up the OCX
8800 for fully automatic calibration.

Autocalibration Setup using the 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.

concentrations and

2

http://www..raihome.com

1. From the operating display use the right-pointing key to select SYSTEM

first column submenu.

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

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

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

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

5. Use the up-pointing key to select the item O2 Out Tracks. Select Yes or
No to determine if updates to the O2 lock value will take place.

6. Use the down-pointing key to select the item COe Out Tracks. Select
Yes or No to define if updates to the COe lock value will take place.

7. 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.

8. 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 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.

1. From the DEVICE SETUP screen, select DETAILED SETUP.

2. From the DETAILED SETUP screen, select O2 CALIB PARAMS or
COE CALIB PARAMS.

3. 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.

6-2

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

4. Select O2 CalIntrvl (O2 calibration interval) and enter the desired time
in hours between automatic O2 calibrations. Select COE Callintrvl and
enter the desired time between automatic COe calibrations. To disable
automatic calibration for O2 and COe, enter 0 for both CalIntrvl
parameters.

5. If desired, the O2NxtCalTm and the COeNxtCalTm (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 O2
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 the right arrow key or use the number keypad to select
the menu item number.

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

6. Select O2 CalIntrvl (O2 calibration interval) and enter the desired time
in hours between automatic O2 calibrations. Select COE Callintrvl and
enter the desired time between automatic COe calibrations. To disable
automatic calibration for O2 and COe, enter 0 for both CalIntrvl
parameters.

6-3

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

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 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.

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

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

3. At the prompt, use the right-pointing arrow to initiate automatic
calibration.

Autocalibration using HART

To initiate an automatic calibration using HART/AMS, perform the following
steps on the HART menu tree. Refer to Section 5, Using HART
Communications, for the HART menu tree.

1. Select DIAG/SERVICE from DEVICE SETUP menu.

2. Select CALIBRATION from the DIAG/SERVICE menu.

3. Select PERFORM CAL from the CALIBRATION menu.

4. Select CAL METHODS from the PERFORM CAL menu.

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

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

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

erformed by an operator following prompts from the unit. Refer to the

p
following paragraphs for manual calibration.

Manual Calibration using the 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.

1. Use the right-pointing key to select the CALIBRATION first column
submenu.

2. From the CALIBRATION submenu use the right-pointing key to select
the Cal Control second column submenu.

3. From the Cal Control submenu use the right-pointing key to select the
third column Start Cal O2 option.

4. 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.)

5. Use the right-pointing key to start the calibration. Turn on the low O2 test
gas, when prompted by the Flow Low Gas message.

6. Press the right-pointing key when the low O
calibration data changes as the calibration proceeds.

test gas is applied. The

2

6-4

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

7. Press the right-pointing key when the low O2 reading is stable. Turn off
the low O2 test gas and turn on the high O2 test gas as prompted by the
Flow High Gas message.

8. Press the right-pointing key when the high O2 test gas is applied. The
calibration data changes as the calibration proceeds.

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

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.

reading is stable. Turn off

2

Manual O2 Calibration using HART

To perform a manual O2 calibration using the Field Communicator or AMS,
use the following procedure. If necessary, refer to Section 5, Using HART
Communications, 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 the right arrow key or use the number keypad to select
the menu item number.

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

1. From the DIAG/SERVICE menu, select CALIBRATION. From the
CALIBRATION menu, select PERFORM CAL.

2. From the PERFORM CAL menu, select CAL METHODS. Select O2
CALIBRATION to start O2 calibration.

3. In the first O2 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.

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

OCX: TAG NAME
STATUS: Idle
TIME REMAIN: 0s
O2: 0.4 %, 85.95mV
OK/NEXT to Select
ABORT/CANCEL to Exit

6-5

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

5. From the SELECT ACTION screen, select START/NEXT CALSTEP 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

1. START/NEXT CALSTEP

2. ABORT CAL

3. EXIT CAL

6. 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.

7. Select Start/Next Cal Step to start applying the O2 Low Gas. The time
to apply the test gas is specified by the Gas Time.

8. 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/Next Cal Step, 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.

9. When ready, Calibration Status will stop at the AppO2Hi. Switch off the
O2 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.

10. Select Start/Next Cal Step to start applying the O2 High Gas. The time
to apply the test gas is specified by the Gas Time.

11. 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/Next Cal Step, 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.

12. When ready, Calibration Status will stop at STOP GAS. Switch off the
High Gas. Press OK when ready. Select Start/Next Cal Step to start

O

2

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

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

if the calibration is successful or CAL RECOMMENDED if the
calibration has failed. A Calibration Failed alarm will be set if the
calibration has failed.

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

method.

2

6-6

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Manual COe Calibration using HART

To perform a manual COe calibration using the Field Communicator or AMS,
use the following procedure. If necessary, refer to Section 5, Using HART
Communications, 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 the right arrow key or use the number keypad to select
the menu item number.

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

1. From the DIAG/SERVICE menu, select CALIBRATION. From the
CALIBRATION menu, select PERFORM CAL.

2. From the PERFORM CAL menu, select CAL METHODS. Select COe
CALIBRATION to start COe calibration.

3. In the first COe 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.

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

OCX: TAG NAME
STATUS: Idle
TIME REMAIN: 0s
COe: 0.20 ppm, 0.00 mV
OK/NEXT to Select
ABORT/CANCEL to Exit

5. From the SELECT ACTION screen, select START/NEXT CALSTEP 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

1. START/NEXT CALSTEP

2. ABORT CAL

3. EXIT CAL

6. The unit samples reference air as the COe
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/Next Cal Step, 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.

7. 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.

8. Select Start/Next Cal Step to start applying the COe High Gas. The
time to apply the test gas is specified by the Gas Time.

Low Gas. The Calibration

6-7

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

9. The Calibration Status should be automatically changed 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/Next Cal Step, 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.

10. When ready, Calibration Status will stop at STOP GAS. Switch off the
COe High Gas. Press OK when ready. Select Start/Next Cal Step to
start purging gas. The time to purge gas is specified by the Purge Time.

11. When the Purge step is complete, the Calibration Status will be at IDLE
if the calibration is successful or CAL RECOMMENDED if the
calibration has failed. A Calibration Failed alarm will be set if the
calibration has failed.

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

method.

Manual O

To perform a manual O2 and COe calibration using the Field Communicator or
AMS, use the following procedure. If necessary, refer to Section 5, Using
HART Communications, 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 the right arrow key or use the number keypad to select
the menu item number.

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

1. From the DIAG/SERVICE menu, select CALIBRATION. From the

2. From the PERFORM CAL menu, select CAL METHODS. Select 02 &

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

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

and COe Calibration using HART

2

CALIBRATION menu, select PERFORM CAL.

COe CALIBRATION to start O2 and COe calibration.

automatic control warning appears. Remove the OCX 8800 from any

automatic control loops to avoid a potentially dangerous operating
condition and press OK.

continue.

OCX: TAG NAME
STATUS: Idle
TIME REMAIN: 0s
O2: 0.4 %, 85.95mV
COe: 0.20 ppm, 0.00 mV
OK/NEXT to Select
ABORT/CANCEL to Exit

6-8

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

5. From the SELECT ACTION screen, select START/NEXT CALSTEP 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

1. START/NEXT CALSTEP

2. ABORT CAL

3. EXIT CAL

6. 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. Press OK when ready.

7. Select Start/Next Cal Step to start applying the O2 Low Gas. The time
to apply the test gas is specified by the Gas Time.

8. 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/Next Cal Step, 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.

9. When ready, Calibration Status will stop at AppO2Hi. Switch off the O2
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.

10. Select Start/Next Cal Step to apply the O2 High Gas. The time to apply
the test gas is specified by the Gas Time.

11. 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/Next Cal Step, 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.

12. 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.

13. Select Start/Next Cal Step to start applying the COe Gas. The time to
apply the test gas is specified by the Gas Time.

14. 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/Next Cal Step, 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.

15. When ready, Calibration Status will stop at STOP GAS. Switch off the
COe gas. Press OK when ready. Select Start/Next Cal Step to start
purging gas. The time to purge gas is specified by Purge Time.

2

2

6-9

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

6-10

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Section 7 Maintenance and Service

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

OCX 8800 Removal and Installation . . . . . . . . . . . . . . . . . page 7-1

Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-8

Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . page 7-28

Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-34

OVERVIEW This section contains the procedures to maintain and service the OCX 8800.

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

OCX 8800 REMOVAL

ND INSTALLATION

A

It is recommended that the OCX 8800 be removed from the stack for all service activities.
The unit should be allowed to cool and be taken to a clean work area. Failure to comply may
cause severe burns.

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

Use the following procedures to remove or install the OCX 8800.

http://www..raihome.com

OCX 8800

Heater

Power Cable

Low O Test Gas

2

High O Test Gas

2

CO Test Gas

Instrument Air

(Reference Gas)

Test Gas

Reference Air

Dilution Air

Eductor Air

Instrument Air

Duct

Stack

AC Power

Input

Signal Cable

37390044

Sensor

Housing

Electronics
Housing

4-20 mA

Outputs

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

OCX with Remote Electronics

Figure 7-1. OCX with
Remote Electronics

Remove Sensor Housing

1. Turn off power to the system.

2. Shut off the test gasses at the cylinders and close the instrument air
valve.

3. Disconnect the calibration gas, reference air, eductor air, and dilution air
lines from the sensor housing, Figure 7-1.

7-2

Instruction Manual

BLU

ORG

YEL

RED

BLK

WHT

BLK

YEL

RED

BLU

WHT

BLK

BLK

GRN

BLK

BLK

BLK

ORG

WHT

RED

BLK

BRN

To

Ground

Screw

GRN

SENSOR HOUSING

Signal Cable

Heater Power Cable

T/C O2

T/C CO

T/C SB

EXC

CJC

CO REF

CO ACT

+

-

+

-

+

-

+

-

+

-

+

-

+

EXC

-

O2

HTR SB

2

2

1

-

+

HTR 02

2

1

HTR CO

1

NOTE: Wire colors shown are for cables

supplied by Emerson Process
Management.

IM-106-880ASL, Rev 1.2
July 2008

Figure 7-2. Sensor
Housing Terminals

OCX 8800

4. Remove the cover from the sensor housing to expose the sensor
housing terminal blocks, Figure 7-2.

5. Disconnect the signal cable from the O2 and T/C terminal blocks, and
from the CO and CJC terminal blocks.

6. Disconnect the heater power cable from the HTR terminal blocks.

7. If moving the sensor housing to another work site, disconnect and
remove the power and signal cables from the sensor housing.

8. Remove insulation to access the mounting bolts. Unbolt the sensor
housing from the stack and take it to a clean work area.

9. Allow the sensor housing to cool to a comfortable working temperature.

7-3

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Install Sensor Housing

1. Connect the test gas, reference air, eductor air, and dilution air lines to
the sensor housing.

2. Remove the sensor housing cover.

3. If removed, install the power and signal cables and the customer power
and signal conduits and wiring at the sensor housing.

4. Connect the signal cable to O
and CJC terminal blocks, Figure 7-2. Connect the heater power cable to
the HTR terminal blocks.

5. Refer to Figure 7-1 and make sure all test gas lines and electrical
connectors are complete.

6. Install the sensor housing cover.

7. Restore power to the system. Allow OCX to reach normal operating
temperature before installing in a hot process stack.

8. Insert and bolt the sensor housing in the stack and install insulation.

9. Turn on the test gases at the cylinders and open the instrument air
supply valve.

and T/C terminal blocks and to the CO

2

Remove Remote Electronics Housing

1. Turn off power to the system.

2. Shut off the test gases at the cylinders and close the instrument air
supply valve, Figure 7-1.

3. Disconnect the test gas and instrument air lines from the remote
electronics housing.

4. Remove the cover from the electronics housing to expose the
electronics housing terminal blocks, Figure 7-3.

5. Disconnect and remove the power leads from the AC power input
terminal block. Remove the ground lead from the ground stud.

6. Disconnect and remove the O
signal output terminal block.

7. If used, disconnect and remove the external relay leads from the alarm
output relay terminal block.

8. Disconnect the signal cable leads from O2 cell and thermocouple
connector (J4), and from COe and CJC connector (J5), Figure 7-4.

9. Disconnect the heater cable leads from the heater power connector
(J3).

10. If moving the electronics housing to another work site, disconnect and
remove the power and signal cables and customer wiring conduits from
the housing.

11. Remove the remote electronics housing from its mounting and move it
to a suitable work area.

and COe signal leads from the 4-20 mA

2

7-4

Instruction Manual

37390013

TOP VIEW

(1/2 SIZE)

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

NC

COM

NO

Alarm Output Relay

Terminal Block

#1

AOUT2+
AOUT2­AOUT1-

AOUT1+

O Signal

2

COeSignal

{

{

Ground

Stud

4-20 mA Signal Output

Terminal Block

Power Port

3/4 NPT

Signal Port

3/4 NPT

External Tooth

Lockwasher

#1

G

G

Terminal

Block

N

G

L1

EMI Filter

Customer

Wiring

IM-106-880ASL, Rev 1.2
July 2008

Figure 7-3. Electronics Housing
Terminal Blocks

OCX 8800

7-5

OCX 8800

37390016

RED
BLK

WHT

GRN

BLK

BLK

BLU
BLK

YEL

BRN

RED

BLK

BLK

ORG

BLK

WHT

T/C CO+
T/C CO-

T/C SB+
T/C SB­T/C O2+
T/C O2-

O2 CELL+
O2 CELL-

SHIELD

To

Ground

Screw

GRN

ELECTRONICS HOUSING

O2 Cell

& Thermocouple

Connector (J5)

COe Sensor

& CJC

Connector (J4)

EXC+
CO ACT+
CO ACT-

CO REF+
CO REF­CJC+
CJC­EXC-

Heater
Power Cable

Signal Cable

NOTE: Wire colors shown are for cables supplied

by Emerson Process Management.

1

#1

#1 #1

#1

#1

To Ground

Screw

SHLD

Heater Power

Connector (J3)

#1

2HTR SB

1HTR O

2

1HTR SB

2HTR CO
1HTR CO
2HTR O

2

WHT

ORG

BLU

BLK

YEL

RED

Figure 7-4. Remote Electronics
Housing Cable Connections

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

7-6

Instruction Manual

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Install Remote Electronics Housing

1. Mount remote electronics housing on wall or pipe within distance of
signal and heater cables in use.

2. Remove the electronics housing cover.

3. If removed, install the power and signal cables and the customer power
and signal conduits and wiring at the electronics housing.

4. Connect the signal cable leads to the O
connector (J4), and to the COe and CJC connector (J5), Figure 7-4.

5. Connect the heater cable leads to the heater power connector (J3).

6. Connect the line (L1 wire) to the L1 terminal, and the neutral (N wire) to
the N terminal on the AC power input terminal block, Figure 7-4.

7. Connect the ground lead to the ground stud. Secure the connection with
two nuts. Attach a separate ground lead (G wire) from the ground stud
to the G terminal on the power input terminal block.

8. If used, connect external relay leads to the alarm output relay terminal.

9. Connect the test gas and instrument air lines to the remote electronics
housing. Connect the calibration gas line and instrument air line to the
remote electronics housing.

10. Refer to Figure 7-1 and Figure 7-4. Make sure all test gas lines and
electrical connections are complete.

11. Install the cover on the electronics housing.

12. Turn on the test gasses at the cylinders and open the instrument air
valve.

13. Restore power to the system.

cell and thermocouple

2

7-7

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

REPAIR SENSOR HOUSING

Sensor Housing Disassembly

Use the following procedures to remove damaged components from the OCX
8800 sensor housing and to install new replacement parts. Disassemble the
unit only as needed to replace damaged components. Use the assembly
procedures that apply to install replacement parts and reassemble the unit.

Remove Cover and Terminals Insulator

1. Loosen screw (1, Figure 7-5) and slide locking clip (2) away from cover.
Retighten screw (1).

2. With two hands or strap wrench, turn cover (3) counterclockwise to
loosen. Unthread and remove cover.

3. Inspect cover o-ring (4) for wear or damage. Replace cover o-ring if
damaged.

4. Unsnap terminal marking plates (5) and remove terminal insulator (6).

7-8

Instruction Manual

5

6

12

11

10

9

1

2

4

3

7

8

13

37390067

1. Screw

2. Locking Clip

3. Cover

4. O-ring

5. Marking Plate

6. Terminal Insulator

7. Reference Air Tube

8. Sensor Housing

9. Heater Strut Assembly

10. Gasket

11. Screw

12. Heater Clamp

13. Heater Rod

IM-106-880ASL, Rev 1.2
July 2008

Figure 7-5. Removal of O2 Cell
and Heater Strut Assembly

OCX 8800

7-9

OCX 8800

+ +

+

+

O2

Thermocouple Wires

ORG

RED

T/C O2

T/C CO

T/C SB

EXC

CJC

O

Cell Wires

2

O Heater Wires

2

Return Wire

O Cell and Heater Strut

Assembly

2

CO REF

CO ACT

Sensor Housing Terminals

+

-

HTR 02

HTR SB

2

GRN

2

1

+

-

+

-

+

-

+

-

+

-

+

YEL

-

+

+

37390068

HTR 02

2

1

Sample Block

Heater Rods

HTR CO

1

EXC

-

Sample

Block

Thermo-

couple

Figure 7-6. O2 Cell,
Thermocouple, and
Heater Connections

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

7-10

Remove O

Remove Sample Block Heater Rods

1. Remove reference air tube (7, Figure 7-5) from sensor housing (8).

2. See Figure 7-6. Disconnect and tag O2 heater wires, O2 cell and return
wires, and thermocouple wires at the sensor housing terminals.

3. Remove the O2 cell and heater strut assembly (9, Figure 7-5) from
sensor housing (8). Remove and discard gasket (10).

1. Disconnect sample block heater rod wires from terminal block. Refer to
Figure 7-6.

Cell and Heater Strut Assembly

2

Instruction Manual

O2

RED

T/C O2

T/C CO

T/C SB

EXC

CJC

COe Sensor Wires

COe Heater Wires

COe Sensor

Assembly

CO REF

CO ACT

Sensor Housing Terminals

+

-

HTR 02

HTR SB

2

2

1

+

-

+

-

+

-

+

-

+

-

+

YEL

-

+

37390018

HTR 02

2

1

HTR CO

1

WHT

BLU

RED

RED

WHT

COe Thermocouple Wires

-

EXC

RED

BLU

CJC Sensor

NOTE: All wires
at these terminals
are in the CJC
current loop.

IM-106-880ASL, Rev 1.2
July 2008

Figure 7-7. COe Sensor,
Thermocouple, and Heater
Connections

OCX 8800

2. Loosen screws (11, Figure 7-5) and rotate heater clamps (12) to release
heater rods (13). One heater clamp secures each heater rod.

3. Slide sample block heater rods (13) out of housing (8).

Remove COe Sensor Assembly

1. Disconnect COe heater, thermocouple, and sensor wires from terminal
blocks. Refer to Figure 7-7.

2. Remove insulator (1, Figure 7-8).

7-11

OCX 8800

1

5

6

7

8

9

10

11

12

13

14

1. Insulator

2. Dilution Air Tube

3. COe Extractive Tube

4. Eductor Air Tube

5. COe Sensor Assembly

6. Eductor

7. Sensor Housing

8. COe Thermocouple

9. Heater Insulator

10. COe Band Heater

11. Sensor Holder

12. Eductor Elbow

13. Terminal Block Mounting

14. Eductor Holder

15. Tube Fitting

16. CJC Sensor

16

2

3

4

15

Figure 7-8. Removal of
COe Sensor Assembly

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

NOTE

For easier access, you may remove two screws from base of terminal block
mounting (13) and move terminal block assembly out of the way.

3. Remove tubes (2, 3, and 4) from COe sensor assembly (5), eductor
fittings (12 and 15), and sensor housing (7).

4. Unfasten bayonet connector of COe thermocouple (8) and remove
thermocouple.

5. Loosen clamp screw of COe band heater (9) until heater rotates freely
on sensor holder (11).

7-12

Instruction Manual

37390035

Sensor

Holder

Flat

Matchmark

Straightedge

Matchmark

IM-106-880ASL, Rev 1.2
July 2008

Figure 7-9. Alignment of
COe Sensor Assembly

OCX 8800

6. See Figure 7-9. Using straightedge on the sensor holder flat, as shown,
matchmark upper flange of sensor housing to show correct alignment of
sensor holder.

7. With one wrench holding eductor elbow (12, Figure 7-8), and one
wrench on flats of sensor holder (11), unthread and remove COe sensor
assembly (5). Do not allow eductor elbow to turn.

8. Slide band heater (10) and heater insulator (9) from sensor holder (11).

7-13

OCX 8800

37390036

EductorFlat

Matchmark

Straightedge

Figure 7-10. Eductor Alignment
Matchmarks

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Remove Eductor

The O2 cell and heater strut assembly (9, Figure 7-5) and the COe sensor
assembly (5, Figure 7-8) must be removed before you start this procedure.

1. Use straightedge to matchmark alignment of eductor flat and elbow, as
shown in Figure 7-10.

7-14

2. Unscrew terminal block mounting (13, Figure 7-8). Move terminal block
mounting away from eductor (6).

3. Unscrew eductor holder (14) with eductor (6) and fittings (12 and 15)
from sensor housing (7).

4. Clamp flats of eductor (6) in jaws of bench vise.

Use heat resistant gloves when removing mating parts from the eductor. The mating parts
are bonded with a thread sealing compound. The compound softens at 450°F (232°C). The
heated parts can cause severe burns.

5. Use a propane torch to heat the eductor (6) to 450°F (232°C), minimum.
Apply the heat near the screw threads.

6. While heating the eductor (6), use wrench to apply removal torque to
elbow (12), eductor holder (14), or tube fitting (15) until the thread
sealant softens. Remove mating parts (12, 14, and 15).

7. Use MEK or methylene chloride solvent to clean thread sealant residue
from the pipe threads of the mating parts. Refer to applicable MSDS
sheet for solvent handling precautions.

Instruction Manual

37390048

1

2

3

4

1. Sensor Housing

2. Sample Tube

3. Exhaust Tube

4. In Situ Filter

IM-106-880ASL, Rev 1.2
July 2008

OCX 8800

Figure 7-11. Removal of Sample
and Exhaust Tubes

Remove Sample and Exhaust Tubes

Use heat resistant gloves when removing the probe tube or exhaust tube. The tubes are
bonded with a thread sealing compound. The compound softens at 450°F (232°C). The
heated parts can cause severe burns.

1. Secure the sensor housing (1, Figure 7-11) in soft (plastic, wood, or
brass) vice jaws.

2. Use a propane torch to heat the sample tube (2) or exhaust tube (3) to
450°F (232°C), minimum. Apply the heat near the thr eaded end of the
tube.

3. While heating the tube, use a pipe wrench to apply removal torque to
part being removed. Apply torque until the pipe thread sealant softens.
Remove and discard the used sample tube (2), exhaust tube (3), or
in-situ filter (4).

4. Use MEK or methylene chloride solvent to clean thread sealant residue
from the internal pipe threads in the housing. Refer to applicable MSDS
sheet for solvent handling precautions.

7-15

OCX 8800

37390032

10

11

12

4

6

7

8

9

3

5

2

1

1. Screw

2. O Cell

3. Heater Tube

4. Contact/
Thermocouple
Assembly

5. Gasket

6. Screw

7. Lockwasher

8. Return Wire

9. Heater Strut
Assembly

10. Spring Clip

11. Spring

12. Strut Bracket

2

Test Gas
Passage

Holes

Figure 7-12. O2 Cell, Heater,
and Thermocouple, Exploded
View

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Do not remove the O2 cell unless you are certain it needs to be replaced. Removal may
damage the cell and platinum pad. Remove the O2 cell for cell replacement only.

Disassemble O

Cell and Heater Strut Assembly

2

Do not attempt to replace the O2 cell until all other possibilities for poor
performance have been considered. If cell replacement is needed, order the
O2 cell replacement kit (Refer to Section 9, Replacement Parts).

The O2 cell replacement kit contains an O2 cell and flange assembly, gaskets,
socket head cap screws, and anti-seize compound. The items are carefully
packaged to preserve precise surface finishes.

Do not remove items from the package until they are ready to be used.

1. Remove the four allen cap screws (1, Figure 7-12) from the O2 cell (2).
Remove the O2 cell. The cell flange has a notch that may be used to
gently pry the flange away from heater tube (3).

NOTE

The pad on the end of contact/thermocouple assembly (4) will sometimes
fuse to the O2 cell (2).

2. If the O2 cell is fused to the contact pad, push the O2 cell back into the
heater tube (against spring pressure) and quickly twist the O2 cell. The
cell and contact pad should separate. If the contact pad stays fused to
the cell, a new contact/thermocouple assembly (4) must be installed.

3. Remove and discard gasket (5). Clean the mating surface of heater
tube (3). Remove burrs and raised surfaces with a block of wood and
crocus cloth.

7-16

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

4. Remove screws (6), lockwashers (7), return wire (8), and heater strut
assembly (9).

5. If replacing contact and thermocouple assembly (4), use a pencil to
mark location of spring clip (10) before removing. Squeeze tabs on
spring clip to remove. Retain spring clip and spring (11); replace if
damaged.

6. While carefully handling new contact and thermocouple assembly (4)
lay old assembly next to new one. Transfer match marks to new
assembly.

7. Carefully guide new contact and thermocouple assembly (4) through
strut bracket (12), spring (11), and spring clip (10) until spring clip
reaches pencil mark.

Instruction Manual

37390030

8

9

4

5

6

1

2

3

7

1. Screw

2. Lockwasher

3. COe Sensor

4. Sensor Holder

5. Gasket

6. Thermocouple Adapter

7. Pre-Heater

8. Plug

9. Stainless Steel Balls

IM-106-880ASL, Rev 1.2
July 2008

Figure 7-13. COe Sensor,
Exploded View

OCX 8800

Disassemble COe Sensor Assembly

1. Carefully remove screws (1, Figure 7-13), lockwashers (2), and COe
sensor (3) from sensor holder (4). Remove and discard gasket (5).

2. If damaged, use the following procedure to remove thermocouple
adaptor (6) from sensor holder (4):

a. Use a propane torch to heat the thermocouple adaptor to 450°F

(232°C), minimum.

b. While heating, use a flat-head screwdriver to apply removal torque.

Apply torque until the pipe thread sealant softens. Remove and
discard the thermocouple adaptor.

c. Use MEK or methylene chloride solvent to clean thread sealant

residue from the internal pipe threads in the sensor holder. Refer to
applicable MSDS sheet for solvent handling precautions.

7-17

OCX 8800

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Always remove the stainless steel balls (approximately 200) from sensor holder before
removing or installing pre-heater. Turning pre-heater in the sensor holder with the stainless
steel balls in place will cause permanent damage to the pre-heater.

3. If pre-heater (7) is to be removed, clamp flats of sensor holder (4) in vise
jaws with plug (8) pointing up. Remove plug. Unclamp sensor holder
and pour stainless steel balls (9) into a container.

NOTE

Pre-heater should only be removed when pre-heater or sensor holder is
damaged. If removal is not required, leave the pre-heater installed in the
sensor holder.

4. Unthread and remove pre-heater (7).

5. Use a cleaning solvent to thoroughly clean stainless steel balls (9) and
pre-heater chamber in sensor housing (4). Refer to applicable MSDS
sheet for solvent handling precautions.

Sensor Housing Assembly

Assemble COe Sensor Assembly

Always remove the stainless steel balls (approximately 200) from sensor holder before
removing or installing pre-heater. Turning pre-heater in the sensor holder with the stainless
steel balls in place will cause permanent damage to the pre-heater.

1. If pre-heater (7, Figure 7-13) was removed, apply pipe thread sealant
(Loctite #567) to the external pipe threads of pre-heater (7) and plug (8).
Do not apply sealant to the first turn of the pipe threads.

2. Clamp flats of sensor holder (4) in vise jaws with pre-heater port
pointing up.

3. Install and tighten pre-heater (7). Align pre-heater to flat of sensor
holder (4) as shown in Figure 7-14.

4. Invert sensor holder (4, Figure 7-13) in vise and pour stainless steel
balls (9) into plug port. Press down on stainless steel balls and tap
sensor holder with plastic hammer to compact balls in pre-heater
chamber.

5. Install and tighten plug (8).

7-18

Use care when installing the combustibles (COe) sensor. The RTD elements are fragile and
correct alignment in sensor holder is required for proper OCX operation.

6. Lubricate and install COe sensor gasket (5). Apply anti-seize compound
to threads of screws (1).

Instruction Manual

37390034

Pre-Heater

Flat

COe

SENSORASSEMBLY

T

OP VIEW

Sensor

Holder

Flat

COeSensor

Flat

Sensor
Holder

Flat

Sensor

Holder

2to2-1/4in.

(51to57mm)

THERMOCOUPLE

IM-106-880ASL, Rev 1.2
July 2008

Figure 7-14. COe Sensor and
Pre-Heater Alignment

OCX 8800

7. Install COe sensor (3), lockwashers (2), and screws (1). Rotate flat of
COe sensor (3) to center of sensor holder (4).

8. Align COe sensor flat parallel to sensor holder flat, as shown in
Figure 7-14. Tighten screws (1, Figure 7-13).

9. If replacing thermocouple adaptor (6), apply anti-seize to the pipe
threads. Install and tighten thermocouple adaptor.

Assemble O

Sensor and Heater Strut Assembly

2

1. See Figure 7-12. Assemble O2 cell (2), gasket (5), and heater tube (3).
Make sure the test gas passage holes line up with each other in all
components.

2. Apply a small amount of anti-seize compound to the screw threads and
use screws (1) to secure assembly. Torque to 35 in-lbs (4 N·m).

3. Carefully slide O2 heater strut assembly (9) into heater tube (3).

4. Press down on the back plate of strut bracket (12) to ensure spring (11)
tension is present to hold contact pad against O2 cell (2).

5. Secure strut bracket (12) and return wire (8) with four screws (6) and
lockwashers (7). Make sure return wire (8) is tightly fastened. This is the
ground side connection for the O2 cell.

Install Sample and Exhaust Tubes

1. See Figure 7-11. Apply pipe thread sealant (Loctite #567) to the
replacement sample tube (2) or exhaust tube (3) pipe threads. Do not
apply sealant to the first turn of the pipe threads.

2. Thread the sample tube (2) or exhaust tube (3) into the housing (1). Use
a pipe wrench to tighten the tube.

3. If used, install and tighten in-situ filter (4).

7-19

OCX 8800

37390047

1

5

6

7

8

9

10

11

12

13

14

1. Insulator

2. Dilution Air Tube

3. COe Extractive Tube

4. Eductor Air Tube

5. COe Sensor Assembly

6. Eductor

7. Sensor Housing

8. COe Thermocouple

9. Heater Insulator

10. COe Band Heater

11. Sensor Holder

12. Eductor Elbow

13. Terminal Block Mounting

14. Eductor Holder

15. Tube Fitting

16. CJC Sensor

16

2

3

4

15

Figure 7-15. Installation of
Eductor and COe Sensor

Instruction Manual

IM-106-880ASL, Rev 1.2

July 2008

Install Eductor

If installed, the O2 cell and heater strut assembly (9, Figure 7-5) must be
removed from sensor housing (8), before you install the eductor.

1. Apply pipe thread sealant (Loctite #567) to the external pipe threads of
eductor (6, Figure 7-15). Do not apply sealant to the first turn of the pipe
threads.

7-20

Instruction Manual

37390036

EductorFlat

Matchmark

Straightedge

IM-106-880ASL, Rev 1.2
July 2008

Figure 7-16. COe Sensor
Parts Alignment

OCX 8800

2. Install and tighten eductor (6) in eductor holder (14).

3. Install and tighten elbow (12) on eductor (6). Male port of elbow must
point up and be in line with long axis of eductor.

4. Apply anti-seize compound to the external pipe threads of eductor
holder (14).

5. Install and tighten eductor holder (14) in sensor housing (7). Align
eductor with matchmarks, as shown in Figure 7-16.

7-21

Instruction Manual

37390058

0.37 in.
(9,4 mm)

COe Sensor

Band Heater

Insulator

IM-106-880ASL, Rev 1.2

OCX 8800

Install COe Sensor Assembly

Figure 7-17. Band Heater Height 1. Apply pipe thread sealant (Loctite #567) to the exposed pipe threads

of eductor elbow (12, Figure 7-15). Do not apply sealant to the first turn
of the pipe threads.

2. Screw sensor holder (11) onto eductor elbow (12).

3. With wrenches on eductor elbow (12) and on flats of sensor holder (11),
tighten sensor holder. Do not allow eductor elbow to turn.

4. Tighten sensor holder (11) to align outside flat with matchmark on
sensor housing flange, as shown in Figure 7-18.

The heater insulator prevents current leakage between the band heater and the sensor
holder. Failure to properly install the insulator may cause the device to trip a ground fault
interrupt circuit.

5. Wrap heater insulator (9) around sensor holder (11). Make sure the
insulator joint lines up with the band gap of the COe band heater (10).

6. Slide COe band heater (10, Figure 7-15) up onto sensor holder (11). Do
not tighten the band heater at this time. Heater must rotate freely around
sensor holder.

7. Check for proper height of COe heater thermocouple (Figure 7-14).
Thread bayonet connector up or down to adjust height.

8. Install and fasten thermocouple (8, Figure 7-15).

9. Position band heater as shown in Figure 7-17 and Figure 7-18 and
tighten band heater clamp screw. The heater insulator (9) end joint must
line up with the band gap of the COe band heater (10).

July 2008

7-22