Rosemount OCX 8800 O2 / Combustibles Transmitter Hazardous Area with Integral Electronics and LOI Local Operator Interface-Orig. Issue Manuals & Guides

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Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800 Oxygen/Combustibles Transmitter

Hazardous Area OCX 8800 Oxygen/Combustibles Transmitter with Integral Electronics and Local Operator Interface

http://www.raihome.com

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

Table of Contents

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

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

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

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

SECTION 1 Description and Specifications

SECTION 2 Installation

SECTION 3 Configuration and Startup

SECTION 4 Using the LOI

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

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

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

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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 Using HART Communications

SECTION 6 Calibration

http://www.raihome.com

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

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

HART 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-106-880 Original Issue

February 2005

SECTION 7 Maintenance and Service

SECTION 8 Troubleshooting

SECTION 9 Replacement Parts

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

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

OCX with Integral Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Sensor Housing Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Sensor Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Electronics Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Electronics Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Remove Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Install Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

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

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

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

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

APPENDIX A Safety Data

APPENDIX B SPA with HART Alarm

APPENDIX C Return of Materials

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

Ceramic Fiber Products Material Safety Data Sheet . . . . . . . . . . . . . A-15

High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21

Atex Clarification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22

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

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

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

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

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

TOC-2

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

OCX 8800 Oxygen/Combustibles Transmitter

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and

maintain them

specifications. The following instructions MUST be adhered to into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions

product.

• If you do not understand any of the instructions, contact your

Rosemount Analytical representative

• Follow all warnings, cautions, and instructions

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 operate, update, program, and maintain the product.

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

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

to ensure they continue to operate within their normal

and integrated

prior to installing, operating, and servicing the

for clarification.

marked on and

to install,

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 Rosemount Analytical Service Group or National Response Center at 1-800-654-7768.

OCX 8800

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

Instruction Manual

IM-106-880 Original Issue

February 2005

PREFACE

DEFINITIONS

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

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

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

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.

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

Section 1 Description and Specifications

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

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

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-9

COMPONENT CHECKLIST

SYSTEM OVERVIEW

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

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 (O This information, plus additional details, can be accessed with the HART Model 275/375 handheld communicator or Emerson Process Management 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.

) and combustibles (COe) values.

http://www.processanalytic.com

OCX 8800

Figure 1-1. Typical System Package

MAN4275A00

English

October 1994

HART Communicator

Instruction Manual

IM-106-880 Original Issue

February 2005

FISHER-ROSEMOUNT

37390006

1. Instruction Manual

2. HART

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 Integral Electronics

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Instruction Manual

IM-106-880 Original Issue February 2005

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. P

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

of the cell.

2. P

is the partial pressure of the oxygen in the reference air on the

opposite side of the cell.

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

NOTE

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

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

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OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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 and sensor housings are integrally mounted.

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. HART Model 275/375 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

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Instruction Manual

IM-106-880 Original Issue February 2005

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 Handheld Communicator - The handheld 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 O 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. After the gas sample flows past the O2 sensor and through

sensor and continues on to

1-5

OCX 8800

(

)

Figure 1-2. System Operation Diagram

Instruction Manual

IM-106-880 Original Issue

February 2005

Sample

Gas

Probe

Exhaust

SENSOR

HOUSING

COe

Combustibles

Sensor

Eductor

Flow Meter

Reference Air

Dilution Air

7 scfh

ELECTRONICS

Instrument Air

Eductor Air

Flow Meter

50 cc/min.

0.1 scfh

HOUSING

CPU

HART Board

Power

Supply

Optional

Test Gas

Solenoids

Solenoid

Low O

Test Gas

High O

Test Gas

Instrument

Air

37390001

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.

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Instruction Manual

IM-106-880 Original Issue February 2005

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.

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 (85°C).

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

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

OCX 8800 with

Integral Electronics

3 calibration gas lines by

Instrument

Air

customer [300 ft (91 m) max.)

4-20 mA Output

(Twisted Pairs)

Termination in Control Room

HART

Model 275/375

Handheld

Communicator

Customer’s Laptop

with AMS

AMS

37390002

1-7

OCX 8800

Figure 1-4. Typical System Installation

Instruction Manual

IM-106-880 Original Issue

February 2005

Test Gas

Flow Meter

Gases

Stack

Dilution

Air

Flow

Meter

Adapter

Plate

Duct

Pressure

Regulator

High O Test Gas Low O Test Gas COTest Gas

OCX 8800 with

INTEGRAL

ELECTRONICS

4-20 mA Outputs

(2 Twisted Pairs)

Line Voltage

Instrument Air

Supply

(Reference Gas)

37390063

1-8

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

SPECIFICATIONS

Hazardous Area OCX

Specifications

Range 0-1% to 0-40% O2, fully field selectable

Net O

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 Tes t G a s

Oxygen 10 sec T90 Combustibles 25 sec T90

Temperature Limits

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

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

Local Operator Interface

Nominal and Approximate Shipping Weights

18 in. (457 mm) probe package

3 ft (0.91 m) probe package

6 ft (1.83 m) probe package

9 ft (2.74 m) probe

package Housings Mounting Flange 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% O

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% O

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

54 lbs (20 kg)

55 lbs (20.5 kg)

57 lbs (21 kg)

59 lbs (22 kg)

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

0.4% O2, Balance N2 8% O

, Balance N2

1000 ppm CO, Balance Air

regulated to 45 psi (310 kPa)

(379 kPa)

Table continued on next page

), regulated to 55 psi

1-9

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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

clean, dry atmosphere, two 3/4-14 NPT conduit ports Electrical Noise EN 61326-1, Class A Certifications Sensor Housing

0344 II 2 G

KEMA 04 ATEX 2308

EEx d IIB+H2 T3

CUS

2005.1602514

CLASS 1, ZONE 1

Ex d IIB+H2 T3

AEx D IIB+H2 T3

TYPE 4 / IP66

APPROVED

CLASS 1, ZONE 1 AEx D IIB+H2 T3

TYPE 4 / IP66

Electronics Housing

0344 II 2 G

KEMA 04 ATEX 2308

EEx d IIB+H2 T6 IP66

CUS

2005.1602514

CLASS 1, ZONE 1

Ex d IIB+H2 T6

AEx D IIB+H2 T6

TYPE 4 / IP66

APPROVED

CLASS 1, ZONE 1 AEx D IIB+H2 T3

TYPE 4 / IP66

Line Voltage Universal 100 to 240 VAC ±10%, 50 to 60 Hz, no switches or

jumpers required, 3/4-14 NPT conduit port 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, 30 mA, 30VDC capacity

Power Consumption 750 W maximum

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

1-10

Instruction Manual

IM-106-880 Original Issue February 2005

Table 1-1. Product Matrix - Hazardous Area OCX 8800

OCX88C O2/Combustibles Transmitter - Flameproof

Code Probe Length and Material

00 No Probe or Exhaust Tube 11 18 in. (457 mm) 316 SST up to 1300°F (704°C) 21 18 in. (457 mm) Inconel 600 up to 2600°F (1427°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) 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) 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)

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)

Code Electronics Housing - Communications

OCX88C 11 10 1 1 H2 02 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)

If the LOI is not implemented, remote access and functionality available via HART Communications (Model 275/375 Handheld Communicator) with Oxygen/Combustibles Device Description (DD) required.

(1)

H1 HART Communications H2 HART Communications with LOI H3 HART Communications with Calibration Solenoids H4 HART Communications with LOI and Calibration Solenoids

Code Electronics Mounting

02 Remote Electronics and no cable

Code Accessories

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

(2)

OCX 8800

1-11

OCX 8800

Table 1-2. Accessories

Instruction Manual

IM-106-880 Original Issue

PART NUMBER DESCRIPTION

1A99119H01 Oxygen test gas bottle; 0.4% O

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

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

1A99120H02 Regulator for Oxygen (may need 2)

1A99120H03 Regulator for CO test gas

1A99119G06 Wall mount bracket for test gas bottles

1A99119G05 Test gas regulators kit

1A99119G04 Test gas bottles kit

1A99292H01

1A99339H03 Blowback valve, air operated

4851B40G01 Wall or Pipe Mounting Kit

1A99784H02

6A00171G01 Power line filter kit

Moore Industries SPA for Low O Calibration Status, and Unit Fail

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

, balance N

Alarm, High COe Alarm,

February 2005

1-12

Instruction Manual

IM-106-880 Original Issue February 2005

Section 2 Installation

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

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-7

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-10

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-16

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

To maintain explosion-proof protection of the OCX 8800 in hazardous areas, all cable entry devices and blanking elements for unused apertures must be certified flameproof, suitable for the conditions of use and properly installed.

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sensor housing must not be mounted to any surface or flange that exceeds 200ºC (392ºF).

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sample entering the sensor housing must not exceed 200ºC (392ºF).

http://www.processanalytic.com

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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 2-3 provide mechanical installation references. The ambient temperature inside the electronics housing must not exceed 185°F (85°C).

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

Before installing the OCX 8800 into a hot stack or ductwork, make sure that the OCX 8800 is turned on and at normal operating temperature. Exposing a cold OCX transmitter to hot process gases can cause permanent damage to the equipment.

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.

2-2

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

4. 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 2-3).

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

NOTE

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

6. 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.

7. 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

Figure 2-1. Installation, OCX 8800

NOTE All dimensions are in inches with millimeters in parentheses.

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

Instruction Manual

IM-106-880 Original Issue

February 2005

0.06 In. Thick Gasket

ANSI DIN

3535B18H02 3535B45H01

Flange Dia.

B.C. Dia.

Hole Dia.

Table 1. Mounting Flange

ANSI

Flange Dia.

Hole Dia.

(4) Holes equally spaced on B.C.dia

6.00

(152)

0.75 (19)

4.75

(121)

Dim “B”

Removal Envelope

Allow 9 in.

(229 mm) for

Cover Removal

DIN

5R10244H025R10244H01

7.28

(185)

0.71 (18)

5.71

(145)

BOTTOM VIEW

Dim “A”

Insertion Depth

Table 2. Installation/Removal

Probe

18 in. 3 ft 6 ft 9 ft

Dim “A”

(457)

(914)

(1829)

108

(2743)

Optional

In Situ Filter

8.3

(211)

Dim “B”

(864)

(1321)

(2235)

124

(3150)

37390008

2-4

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 2-2. Adapter Plate Installation

NOTE: Dimensions are in inches with millimeters in parentheses.

Only adapter plate is furnished by Rosemount Analytical.

Adapter Plate Kit - Mounting Dimensions

*Type

Part Number

ANSI

(P/N 4512C34G01)

DIN

(P/N 4512C36G01)

*Part numbers for adapter plates include attaching hardware.

Plate Size "A"

6.00

(152)

7.50

(191)

Stud Size "B"

5/8 -11 UNC - 2A

(M-16 x 2.0 - 6g)

Bolt Circle

Dia.“C"

4.75

(121)

5.71

(145)

OCX 8800

Section

Weld or bolt adapter

plate to metal wall.

Joint must be air-tight.

D-D

2.50 (63.5) Dia. min.

METAL WALL

STACK OR DUCT

CONSTRUCTION

Metal Stack

or DuctWall

2.50

(63.5)

Dia.

Section

Bolt adapter plate to outside wall surface.

Joint must be air-tight.

D-D

Masonary StackWall

Field weld pipe

to adapter plate

Pipe 3 inch

schedule 40.

Sleeve length

optional.

MASONRY WALL

STACK

CONSTRUCTION

37390010

2-5

OCX 8800

Figure 2-3. Installation with Drip Loops

Instruction Manual

IM-106-880 Original Issue

February 2005

Conduit Drip Loops

Conduit Drip Loop Conduit Drip Loop

DuctWall

37020004

2-6

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

ELECTRICAL INSTALLATION

All wiring must conform to local and national codes. For reference, factory wired solenoid power connections are shown in Figure 2-4.

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.

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sensor housing must not be mounted to any surface or flange that exceeds 200ºC (392ºF).

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sample entering the sensor housing must not exceed 200ºC (392ºF).

2-7

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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 2-4.

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 2-4.

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 2-4. Use individual shielded twisted wire pairs. Terminate the shield at the electronics housing.

4-20 mA Signal

One 4-20 mA signal represents the O signal is the HART information accessible through a Model 275/375 Handheld Communicator or AMS software. The O 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.

value. Superimposed on the O2

signal is at the AOUT 1

2-8

Instruction Manual

IM-106-880 Original Issue February 2005

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

OCX 8800

COM

Alarm Output Relay

Terminal Block

COe Signal

O Signal

4-20 mA Signal Output

Terminal Block

AOUT2+

{

AOUT2 -

AOUT1 -

{

AOUT1+

EMI Filter

TOP VIEW

(1/2 SIZE)

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

Customer

Wiring

Signal Port

3/4 NPT

Terminal

Block

Ground

Stud

Power Port

3/4 NPT

ExternalTooth

Lockwasher

37390013

2-9

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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 2-5. 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% O parts per million. Failure to use proper gases will result in erroneous readings.

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

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

CO - 1000 ppm or 4%

low gas - 0.4%

high gas - 8%

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.

2-10

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 2-5. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration)

Eductor

Air In

Sensor

Housing

Reference Air In

Dilution Air In

CAL Gas In

OCX 8800

CAL Gas

Flow Meter

7 scfh, 20-30 psig

(

Recommended

(

Electronics

Housing

Dilution Air Flow Meter

0.1 scfh

Instrument

Air Out

2-Stage

Regulators

HI O

LO O

Instrument

Air Supply

Pressure Reguator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

37390011

2-11

OCX 8800

Figure 2-6. Pneumatic Installation, OCX with Reference Air Set and Solenoids (with Autocalibration)

CAL Gas

Flow Meter

7 scfh, 20-30 psig

(

Recommended

Electronics

Housing

(

Eductor

Air In

Instruction Manual

IM-106-880 Original Issue

February 2005

Sensor

Housing

CAL Gas In

Reference

Air In

Dilution

Air In

Dilution Air

Flow Meter

0.1 scfh

CAL Gas Out

Instrument Air Out

LO O

HI O

Pressure Regulator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

2-Stage

Regulators

Instrument

Air Supply

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 Set Option, steps 1 through 3.

2. Refer to Figure 2-6. Connect the O O

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

pressure regulator with gage in the O

3. Connect the O

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

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

low gas source to the CAL GAS LO

low supply line, as shown.

high

supply line.

37390012

2-12

Instruction Manual

IM-106-880 Original Issue February 2005

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 2-7 shows the piping arrangement for the OCX 8800 with the blowback and autocalibration options. Figure 2-8 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

2-13

OCX 8800

Figure 2-7. Piping Arrangement, Blowback with Autocalibration

Cal Gas

Flow Meter

7 scfh, 20-30 psig

(

Recommended

Eductor Air In

(

CheckValve

Sensor Housing

CAL Gas In

Reference Air In

Instruction Manual

IM-106-880 Original Issue

February 2005

CAUTION

Pressure regulator with 1/8” inlet port is factory set for 35 or 45 psig.Regulator with 1/4” inlet port is factory set for 55 psig.If regulators are not installed in correct locations, the OCX 8800 will not work.

CAL Gas Out

2-Stage

Regulators

Electronics

Housing

HI O

LO O

*Normally

Dilution Air In

Instrument Air

Open Solenoid Valve

Dilution Air Flow Meter

0.1 scfh

*Normally

Closed Solenoid Valve

BlowbackValve,

Air Operated

*NOTE: During blowback operation, states of

both solenoid valves change.

NOTE: Wall mount the air-operated blowback

valve on a suitable mounting plate.

Pressure Regulator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

Pressure

Regulator/Filter

55 psig

Instrument Air Supply

37390004

2-14

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 2-8. Piping Arrangement, Blowback without Autocalibration

Eductor Air In

CheckValve

Reference Air In

Dilution Air In

Sensor Housing

CAL Gas In

OCX 8800

CAUTION

Cal Gas Flow Meter

(

7 scfh, 20-30 psig

Recommended

(

2-Stage

Regulators

Electronics

Housing

Instrument Air

*Normally

Open Solenoid Valve

Dilution Air Flow Meter

0.1 scfh

*Normally

Closed Solenoid Valve

BlowbackValve,

Air Operated

*NOTE: During blowback operation, states of

both solenoid valves change.

NOTE: Wall mount the air-operated blowback

valve on a suitable mounting plate.

Pressure Regulator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

Pressure

Regulator/Filter

55 psig

LO O

HI O

Instrument Air Supply

37390005

2-15

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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 and Startup, for OCX 8800 startup information.

Upon completing installation, make sure that the OCX 8800 is turned on and operating prior to firing up the 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.

2-16

Instruction Manual

IM-106-880 Original Issue February 2005

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. Vertify 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.processanalytic.com

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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 O 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 O

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

circuit. All switches are accessible through holes in the electronics box.

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

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

4-20

SW1 The two settings are internally or externally powering the O mA signal. The factory setting is for the O

4-20 mA signal to be externally

4-20

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 externally powered.

SW3 The factory sets this switch as follows:

• Position 1 determines the O

4-20 mA signal rail limit. The settings are

high, 21.1 mA, or low, 3.5 mA. The factory setting is 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

IM-106-880 Original Issue February 2005

Figure 3-1. OCX 8800 Defaults

Switch

Default Postions

Shown

21.1 mA

3.5 mA

COe

1223344

OCX 8800

Open

Closed

Open

Closed

SW3

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

Open

Closed

1234

COe 21.1 mA/3.5 mA:

Open

Closed

Rail Limits: High - 21.1 mA Low - 3.5 mA

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

Internal:

COe 4-20 mA

is Internally

Powered

SW2

INITIAL POWER UP

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

Internal:

O 4-20 mA

is Internally

Powered

SW1

External: O 4-20 mA

Requires an External Power Supply (Default)

Allow adequate time (approximately 60 minutes) for the heaters to begin operation and for the OCX 8800 to reach normal operating temperature on power up. Normal operating temperature for the O

cell is 736°C. Normal

operating temperature for the combustibles cell is 300°C. The normal sample line temperature is 170°C.

37390026

3-3

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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 HART 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 O

4. From O2 CALIB PARAMS, select Low TG. Enter the percent O for the low O

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 O for the high O

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

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

test gas.

used for the low O2 test gas.

used

OCX 8800 RESET PROCEDURE

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

OCX Reset with the LOI

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

IM-106-880 Original Issue February 2005

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

OCX 8800

OVERVIEW

DISPLAY ORIENTATION

Figure 4-1. LOI Components Mounting

This section describes the installation and operation of the LOI module in the OCX 8800.

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.

Electronics Housing

(Cover Removed)

Electronics Stack

http://www.processanalytic.com

LOI Connector

LOI Board

LOI Module

37390027

OCX 8800

LOI CONTROLS

Instruction Manual

IM-106-880 Original Issue

February 2005

Overview

Figure 4-2. LOI Assembly

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.

Touch

Confirmation

LED

Selection

Arrow

Lockout

Notation

Selection

Arrow

(Enter key)

LK AL

Analytical

Display Window

Status

Code

LOI Key Functions

4-2

Selection

Arrows

37390042

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

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

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

Instruction Manual

IM-106-880 Original Issue February 2005

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.

LOI Status Codes

Table 4-1. LOI Status Codes

Analytical

37390057

The LOI display shows a status code in the lower right hand corner of the display. There are nine status codes to indicate the existing status of the device during operation. The status code descriptions are shown in Table 4-1.

CODE DESCRIPTION

Alarm - The device is in a recoverable alarm state. Bloback - A blowback cycle is active. Calibration - A calibration cycle is active. Calibration Verify - A calibration verify task is in progress. Normal - The device is in a normal operating mode. 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. Warm Up - The device heaters are ramping up to operating temperature.

4-3

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

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 (O

% 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

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.

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

O2 X.XX%

Comb XXX ppm

SENSOR DATA

(CONTINUED ON

SHEET 2)

Temperatures

RawValues

Analog Outputs

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

O2 Sensor _____ mV

O2 Sensor R ____ ohm

O2 T/C _____ mV COe Delta V _____ mV COe Delta R

COe ReferenceV COe Reference R

COe T/C

RTD Current _____ mA

Board Temp IC

CJC Temp Signal _____ mV

O2 Output % _____%

O2 Current ____mA

COe Output % _____%

COe Current ____mA

____ ohm

_____ mV

____ ohm

_____ mV

SB T/C _____ mV

_____ mV

37390007

4-4

Instruction Manual

IM-106-880 Original Issue February 2005

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

OCX 8800

(CONTINUED FROM

SHEET 1)

CALIBRATION

(CONTINUED ON

SHEET 3)

Cal Control

Abort Cal

Start Cal O2

Start Cal COe

Start Cal Both

Apply Lo O2 Gas

Hit E when ready

Flow O2 Lo _____s

______% _____mV

Read O2 Lo _____s

______% _____mV

Apply Hi O2 Gas

Hit E when ready

Flow O2 Hi _____s

______% _____mV

Read O2 Hi _____s

______% _____mV

Hit E when ready

Purge _____s

Apply Lo COe Gas

Hit E when ready

Flow COe Lo _____s

______% _____mV

Read COe Lo _____s

______% _____mV

Apply Hi COe Gas

Hit E when ready

Flow COe Hi _____s

______% _____mV

Read COe Hi _____s

______% _____mV

Hit E when ready

Purge _____s

Apply Lo O2 Gas

Hit E when ready

Flow O2 Lo _____s

______% _____mV

Read O2 Lo _____s

______% _____mV

Apply Hi O2 Gas

Hit E when ready

Flow O2 Hi _____s

______% _____mV

Read O2 Hi _____s

______% _____mV

Hit E when ready

Purge _____s Flow COe Hi _____s

______% _____mV

Read COe Hi _____s

______% _____mV

Hit E when ready

Purge _____s

Cal Constants

Cal Status

Cal Verify

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

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

NOTE: “Hit E when ready” is displayed during

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

37390015

4-5

OCX 8800

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

(CONTINUED FROM

SHEET 2)

SYSTEM

Calib Setup

Instruction Manual

IM-106-880 Original Issue

February 2005

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

Input/Output

(CONTINUED ON

SHEET 4)

Analog

Alarm Relay

Blowback

O2 Type 20-4 mA

O2 Range Hi ___%

O2 Range Lo

O2 AlarM Level ___mA

Trim O2 Out (procedure)

COe Type 20-4 mA COe Range HI ___ppm COe Range Lo ___ppm COe Alarm Lvl ___mA

Trim COe Out (procedure)

Trigger 1 Event Trigger 2 Event Trigger 3 Event

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

___%

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

37390017

4-6

Instruction Manual

IM-106-880 Original Issue February 2005

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

(CONTINUED FROM

SHEET 3)

SYSTEM

Parameters

Software

Status

O2 Slope ___ mV/D

O2 Constant ___ mV

O2 T90Time ___ seconds

COe Slope ___ ppm/ohm

COe Constant ___ ohm

COe T90Time ___ seconds

LockoutTime ___ seconds

Revert Time ___ minutes

O2 T90Time ___ seconds

Luminance ___ % PCDC Enable ___Y/N PCNC Enable ___Y/N

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

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

OCX 8800

37390056

4-7

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

D/A TRIM PROCEDURES

O2 D/A trim procedure using the LOI

Use the following procedure to perform the O

D/A trim procedure at the LOI.

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

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

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.

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 2-4. Connect a digital multimeter to read the milliamp output from the O

D/A converter circuit. Connect the positive lead to

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 O

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 O

millamp

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

10. When the reponses 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-106-880 Original Issue February 2005

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 2-4. 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 reponse. 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 reponse. If no, the process repeats from step 8.

10. When the reponses 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

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

4-10

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

Section 5 Using HART Communications

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

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

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

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

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

OVERVIEW

HART COMMUNICATOR SIGNAL CONNECTIONS

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

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

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

The HART communicator can connect to the OCX 8800 oxygen analog output signal line at any wiring termination in the O two methods of connecting the HART communicator to the signal line. For applications in which the signal line has a load resistance of 250 ohms or more, refer to method 1. For applications in which the signal line load resistance is less than 250 ohms, refer to method 2.

4-20 mA current loop and a minimum load

4-20 mA current loop. There are

http://www.processanalytic.com

OCX 8800

Figure 5-1. Signal Line Connections,

≥

250 Ohms Load Resistance

4-20 mA Terminal Block in

Electronics Housing

Instruction Manual

IM-106-880 Original Issue

February 2005

A OUT 1 + A OUT 1 -

Loop

Connectors

HART Communicator

Rear Panel

Method 1, for Load Resistance

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

O 4-20 mA Signal Line

HART

Communicator

Model 275/375

≥

RL 250Ω

Analog Output Device

Lead Set

250 Ohms

≥

37390023

5-2

Do not make connections to the HART 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 HART communicator in parallel to the OCX 8800. Use any wiring termination points in the oxygen analog output 4-20 mA signal line.

Instruction Manual

IM-106-880 Original Issue February 2005

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 HART communicator to a signal line with less than 250 ohms load resistance.

Do not make connections to the HART 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 HART communicator).

4-20 mA Terminal Block in

Electronics Housing

A OUT 1 + A OUT 1 -

Loop

Connectors

HART Communicator

Rear Panel

O 4-20 mA Signal Line

HART

Communicator

Model 275/375

The signal loop must be broken to insert

NOTE:

the optional 250 ohm load resistor.

RL <250Ω

Analog Output Device

250 OHM

Load Resistor

(See Note)

37390021

5-3

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

HART COMMUNICATOR PC CONNECTIONS

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

Off-line and On-line Operations

The HART 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 HART communicator with a PC. (Refer to applicable HART 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 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 HART communicator manual for detailed menu information.

5-4

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

HART MENU TREE

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

DEVICE SETUP O2 O2 AO COe COe AO

PROCESS VARIABLES

This section consists of a menu tree for the HART communicator. This menu is specific to OCX 8800 applications.

O2 COe

VIEW DEV VARS

VIEW DEV RAW VAL

VIEW OUTPUT VARS

VIEW O2 RAWVAL

VIEW COE RAWVAL

VIEW DEV RAWVAL

PV-AOUT

O2 Temp COe Temp SB Temp Brd Temp CJC Temp

O2 Snsr O2 T/C O2 Snsr R O2 Snsr RS

COe DeltV COe RefV COe DeltaR Coe RefR COe T/C RTD Curr

SB T/C Brd Temp IC CJC Temp S

PV is

O2 O2 AO O2 AO %

SV is

COe COe AO COe AO %

TV is

O2 Temp

4V is

COe Temp

(CONTINUED ON

SHEET 2)

VIEW DEV LIMITS

COE

BOARDTEMP

SB TEMP

O2 O2 USL O2 LSL

O2 TEMP

O2 Temp O2 T/C USL O2 T/C LSL

COE

COe COe USL COe LSL

COE TEMP

COe Temp COe T/C USL COe T/C LSL

Brd Temp Brd TC USL Brd TC LSL

SB Temp SB TC USL SB TC LSL

37390038

5-5

OCX 8800

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

(CONTINUED FROM

SHEET 1 )

STATUS

DIAG/SERVICE

HW STATUS

LOOP TEST

D/A TRIM

CALIBRATE

VERIFY CALIB

Operate Mode Status group 1

Status group 2

Status group 3

Status group 4 Status group 5 Status group 6

AO saturated AO fixed

Model Number Snsr Housing CPLD REGS Line Freq Line Volt PCN Counter PCD Counter

O2 D/A Trim COe D/A Trim

PERFORM CAL

CAL STATUS

CAL VALUES

PREV CAL VALUES

FAILED CAL VALUES

RESET CAL CONST

Verify Calibration Status TimeRemain O2 COe

O2 AO Saturated COe AO Saturated

O2 AO Fixed COe AO Fixed

BCSR0 BCSR3 BCSR1 BCSR4 BCSR2 BCSR5

O2 Loop Test COe Loop Test

(procedures)

CAL METHODS O2OutTracks COeOutTracks Cal Step Cal Time O2 COe

Cal Step Cal Time

O2 Slope O2 Const O2 Snsr R COe Slope COe Const

Prev O2 Slope

O2 Const

O2 Snsr R

COe Slope

COe Const

Prev Bad O2 Slope

Bad O2 Const Bad COe Slope Bad COe Const

Reset O2 CalConsts Reset COe CalConsts

Instruction Manual

IM-106-880 Original Issue

February 2005

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

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

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

O2 Calibration COe Calibration O2 and COe Calib

5-6

(CONTINUED ON

SHEET 3)

BLOWBACK

MAX TEMP

HEATER PID

BlBk State Blowback

O2TempMax COeTempMax SBTempMax BrdTempMax CJCTempMax

O2 PID

COE PID

SB PID

O2 Prop O2 Int O2 DutyCyc O2 SetPt O2 Temp

COe Prop

Int

COe

DutyCyc

COe

SetPt

COe

Temp

COe SB Prop

SB Int SB DutyCyc SB SetPt SB Temp

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

(CONTINUED FROM

SHEET 2)

BASIC SETUP

DETAILED SETUP

(CONTINUED ON

SHEET 4)

DEVICE

INFORMATION

HART INFORMATION

S/W VERSION INFO

OUTPUT CONDITION

O2 CALIB PARAMS

COe CALIB PARAMS

DEVICE PARAMS

LOI PARAMS

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

Tag Poll addr Dev id Num req preams Fld dev rev

Version Chksum Bld Num Bld Date Restart Cntr

ANALOG OUTPUT

ALARM RELAY

BLOWBACK

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 LockoutTime Revert Time

O2 ANALOG OUTPUT

COe ANALOG OUTPUT

OCX 8800

O2 AOType O2 URV O2 LRV O2 Alarm Level

COe AOType COe URV COe LRV COe Alarm Level

Trig 1 Event Trig 2 Event Trig 3 Event Alarm State

BlBk Enabled BlBk Intrvl BlBk Period BlBk PurgeTm BlBk State

37390040

5-7

OCX 8800

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

(CONTINUED FROM

SHEET 3)

Instruction Manual

IM-106-880 Original Issue

February 2005

REVIEW

DEVICE INFORMATION

HART INFORMATION

CAL INFO

DEVICE CONFIG

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

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

O2 CALIB

COE CALIB

O2 DEVICE CONFIG

COE DEVICE CONFIG

DEVICE CONFIG

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

Trig 1 Event Trig 2 Event Trig 3 Event BlBk Enabled BlBk Intrvl BlBk Period BlBk PurgeTm

PCNC Enable PCDC Enable Luminance LockoutTime Revert Time

5-8

OUTPUTS CONFIG

O2 URV O2 LRV COe URV COe LRV O2 AOType COe AOType O2 Alarm Level COe Alarm Level

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OCX 8800

D/A TRIM PROCEDURES

O2 D/A trim procedure using HART/AMS

Use the following procedure to perform the O HART communicator or AMS. 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 HART 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 HART 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. Remove the electronics housing cover.

5. Refer to Figure 2-4. Connect a digital multimeter to read the milliamp output from the O AOUT1+ terminal and connect the negative lead to the AOUT1terminal. Then, press OK at the HART communicator.

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

7. The HART communicator displays Setting Fld dev output to 20 mA. Press OK. Read the O the reading at the HART communicator and press ENTER. (Select ABORT to exit without changes).

8. The HART communicator displays Setting Fld dev output to 4 mA. Press OK.

9. The HART 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.

10. The HART communicator displays Setting Fld dev output to 20 mA. Press OK.

11. The HART 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.

12. The HART communicator displays NOTE: Loop may be returned to automatic control.

D/A coverter circuit. Connect the positive lead to the

millamp output at the digital multimeter. Enter

D/A trim procedure using the

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COe D/A trim procedure using HART/AMS

Use the following procedure to perform the COe D/A trim procedure using the HART communicator or AMS. 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 HART 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.)

4. Remove the electronics housing cover.

5. Refer to Figure 2-4. Connect a digital multimeter to read the milliamp output from the COe D/A coverter circuit. Connect the positive lead to the AOUT2+ terminal and connect the negative lead to the AOUT2terminal. Then, press OK at the HART communicator.

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

7. The HART communicator displays Setting Fld dev output to 20 mA. Press OK. Read the COe the reading at the HART communicator and press ENTER. (Select ABORT to exit without changes).

8. The HART communicator displays Setting Fld dev output to 4 mA. Press OK.

9. The HART 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.

10. The HART communicator displays Setting Fld dev output to 20 mA. Press OK.

11. The HART 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.

12. The HART communicator displays NOTE: Loop may be returned to automatic control.

millamp output at the digital multimeter. Enter

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Instruction Manual

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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

FULLY AUTOMATIC CALIBRATION

During a calibration, two calibration gases with known O2 concentrations and one calibration gas with a known COe concentration are applied to the OCX

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

Before calibrating the OCX 8800, verify that the calibration gas parameters are correct by setting the test gas values used when calibrating the unit. Refer to Section 3, Configuration and Startup.

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.

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.

and combustibles in the

http://www.processanalytic.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.

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Instruction Manual

IM-106-880 Original Issue

February 2005

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 O

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.

lock value will take place.

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. Selct No to disable the calibration solenoids.

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OCX 8800

4. Select O2 CalIntrvl (O2 calibration interval) and enter the desired time in hours between automatic O enter the desired time between automatic COe calibrations. To disable automatic calibration for O 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.

calibrations. Select COE Callintrvl and

and COe, enter 0 for both CalIntrvl

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

6. From the O2 CALIB PARAMS screen, select CalIntrvl.

7. At the prompt, input a time interval (in hours) at which an automatic O calibration will occur and press ENTER.

8. From the DETAILED SETUP screen, select COE CALIB PARAMS.

9. From the COE CALIB PARAMS menu, select CalIntrvl.

10. At the prompt, input a time interval (in hours) at which an automatic COe

calibration will occur and press ENTER.

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February 2005

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 CALIBRATE from the DIAG/SERVICE menu.

3. Select PERFORM CAL from the CALIBRATE 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 performed by an operator following prompts from the unit. Refer to the 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 O 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

test

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OCX 8800

7. Press the right-pointing key when the low O2 reading is stable. Turn off the low O Flow High Gas message.

8. Press the right-pointing key when the high O calibration data changes as the calibration proceeds.

9. Press the right-pointing key when the high O the high O purge.

10. When the purge period expires, the LOI display reverts to the normal operation display. If the calibration failed, the display will indicate an alarm condition.

11. Press the right-pointing key to start combustibles calibration. Turn on the CO test gas when prompted.

12. Press the right-pointing key when the CO test gas is applied. The calibration data changes as the calibration proceeds.

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.

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

test gas is applied. The

reading is stable. Turn off

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

Manual O

To perform a manual O

Calibration using HART

calibration using the HART 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 O

3. In the first O

Calibration screen, a Loop should be removed from

calibration.

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

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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 O

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 O

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 O

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 O

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

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.

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OCX 8800

Manual COe Calibration using HART

To perform a manual COe calibration using the HART 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

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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 O 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

and COe calibration using the HART communicator

CALIBRATION menu, select PERFORM CAL.

COe CALIBRATION to start O

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

and COe calibration.

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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 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 O

concentration measured matches the O2 LOW

GAS parameter in Setup. Press OK when ready.

7. Select Start/Next Cal Step to start applying the O

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 O Low Gas and switch on the O

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 O

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

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.

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Section 7 Maintenance and Service

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

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

Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-5

Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . page 7-25

Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-31

OCX 8800

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.

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.

Observe housing classification guidelines prior to removing cover. Failure to observe classification guidelines may result in serious injury or death.

OCX 8800 REMOVAL AND INSTALLATION

http://www.raihome.com

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

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

OCX with Integral Electronics

Figure 7-1. OCX with Integral Electronics

Remove OCX 8800

1. Turn off power to the system.

2. Shut off the test gases at the cylinders and shut off the instrument air.

3. Disconnect the test gas and instrument air lines from the electronics housing, Figure 7-1.

Adapter

Plate

Stack

Sensor

Housing

Electronics

Housing

Duct

O and COe

4-20 mA Outputs

(2 Twisted Pairs)

AC Power Input

Instrument Air

(Reference Gas)

High O Test Gas

Low O Test Gas

COTest Gas

Explosion hazard! Before removing cover from sensor or electronics housing, allow at least 45 minutes to pass after power is disconnected. Failure to allow adequate time for all internal electrical charges to dissipate can result in serious injury or death.

37390043

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

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

6. Disconnect and remove the O

and COe signal leads from the 4-20 mA

signal output terminal block.

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

8. Disconnect and remove customer power and signal wire conduits and wiring from the electronics housing.

9. Remove insulation to access the sensor housing mounting bolts. Unbolt the OCX 8800 from the stack and take it to a clean work area.

10. Allow the unit to cool to a comfortable working temperature.

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IM-106-880 Original Issue February 2005

Figure 7-2. Electronics Housing Terminal Blocks

OCX 8800

COM

Alarm Output Relay

Terminal Block

COe Signal

O Signal

4-20 mA Signal Output

Terminal Block

AOUT2+

{

AOUT2 -

AOUT1 -

{

AOUT1+

EMI Filter

TOP VIEW

(1/2 SIZE)

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

Customer

Wiring

Signal Port

3/4 NPT

Terminal

Block

Ground

Stud

Power Port

3/4 NPT

ExternalTooth

Lockwasher

37390013

7-3

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

Install OCX 8800

Observe the following cautions when installing the OCX 8800 in a hot process stack. If the process is shut down and cooled, the transmitter can be installed in the stack prior to connecting the pneumatics and wiring.

1. Connect the test gas lines and the instrument air lines to the electronics housing.

2. Remove the electronics housing cover.

3. Install customer power and signal conduits and wiring at the electronics housing.

4. If used, connect external relay leads to the alarm output relay terminal block, Figure 7-2.

5. Connect the O

and COe signal leads to the 4-20 mA signal output

terminal block.

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.

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. Install the cover on the electronics housing.

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

10. Bolt the OCX 8800 to the stack and install insulation. Refer to Figure 7-1 and make sure all test gas lines and electrical connections are complete.

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

7-4

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

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 7-3) 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).

7-5

OCX 8800

390066

Figure 7-3. Removal of O2 Cell and Heater Strut Assembly

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

14. Insulator

15. Thermal Switch

Instruction Manual

IM-106-880 Original Issue

February 2005

7-6

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 7-4. O2 Cell, Thermocouple, and Heater Connections

Sensor HousingTerminals

ORG

GRN

O CellWires

O HeaterWires

ThermocoupleWires

RED

YEL

T/C O2

T/C CO

T/C SB

EXC

CJC

OCX 8800

+ +

O Cell and Heater Strut

Assembly

Sample

Block

Thermo-

couple

ReturnWire

Sample Block

Heater Rods

HTR 02

HTR CO

HTR 02

HTR SB

Remove O

Cell and Heater Strut Assembly

CO REF

CO ACT

EXC

Thermal

Switch

1. Remove reference air tube (7, Figure 7-3) from sensor housing (8).

2. See Figure 7-4. Disconnect and tag O

heater wires, O2 cell and return

wires, and thermocouple wires at the sensor housing terminals.

3. Remove the O

cell and heater strut assembly (9, Figure 7-3) from

sensor housing (8). Remove and discard gasket (10).

Remove Sample Block Heater Rods

1. Disconnect sample block heater rod wires from terminal block. Refer to Figure 7-4.

37390069

7-7

OCX 8800

Figure 7-5. COe Sensor, Thermocouple, and Heater Connections

Instruction Manual

IM-106-880 Original Issue

February 2005

2. Loosen screws (11, Figure 7-3) 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).

4. To replace thermal switch (15), remove insulator (14). Disconnect heater wires. Unscrew and remove thermal switch.

Remove COe Sensor Assembly

1. Disconnect COe heater, thermocouple, and sensor wires from terminal blocks. Refer to Figure 7-5.

2. Remove insulator (1, Figure 7-6).

RED

YEL

T/C O2

T/C CO

Sensor HousingTerminals

HTR 02

HTR CO

HTR SB

CJC Sensor

T/C SB

EXC

BLU

RED

BLU

WHT

RED

COe HeaterWires

COe SensorWires

COeThermocouple Wires

CJC

CO REF

CO ACT

EXC

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

COe Sensor

Assembly

37390018

7-8

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 7-6. Removal of COe Sensor Assembly

OCX 8800

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 rotaters freely on sensor holder (11).

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

7-9

OCX 8800

Figure 7-7. Alignment of COe Sensor Assembly

Instruction Manual

IM-106-880 Original Issue

February 2005

6. See Figure 7-7. 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 7-6), 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).

Matchmark

Straightedge

Sensor

Holder

Flat

Matchmark

37390035

7-10

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

Remove Eductor

Figure 7-8. Eductor Alignment Matchmarks

The O

cell and heater strut assembly (9, Figure 7-3) and the COe sensor

assembly (5, Figure 7-6) must be removed before you start this procedure.

1. Use straightedge to matchmark alignment of eductor flat and elbow, as shown in Figure 7-8.

Eductor Flat

Straightedge

Matchmark

37390036

2. Unscrew terminal block mounting (13, Figure 7-6). 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.

7-11

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

Figure 7-9. 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 7-9) 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 threaded 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.

1. Sensor Housing

2. Sample Tube

3. Exhaust Tube

4. In Situ Filter

37390048

7-12

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 7-10. O2 Cell, Heater, and Thermocouple, Exploded View

OCX 8800

1. Screw

2. O Cell

3. Heater Tube

4. Contact/

5. Gasket

6. Screw

7. Lockwasher

8. Return Wire

9. Heater Strut

10. Spring Clip

11. Spring

12. Strut Bracket

Test Gas Passage

Holes

Thermocouple Assembly

Assembly

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 O

Disassemble O

Do not attempt to replace the O

Cell and Heater Strut Assembly

cell until all other possibilities for poor

cell for cell replacement only.

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

cell replacement kit (Refer to Section 9, Replacement Parts).

The O

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 7-10) from the O Remove the O

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 O

cell is fused to the contact pad, push the O2 cell back into the

heater tube (against spring pressure) and quickly twist the O 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.

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

37390032

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.

cell (2).

cell. The

7-13

OCX 8800

Figure 7-11. COe Sensor, Exploded View

Instruction Manual

IM-106-880 Original Issue

February 2005

Disassemble COe Sensor Assembly

1. Carefully remove screws (1, Figure 7-11), 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.

1. Screw

2. Lockwasher

3. COe Sensor

4. Sensor Holder

5. Gasket

6. Thermocouple Adapter

7. Pre-Heater

8. Plug

9. Stainless Steel Balls

7-14

37390030

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

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

1. If pre-heater (7, Figure 7-11) 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 7-12.

4. Invert sensor holder (4, Figure 7-11) 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).

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).

7-15

OCX 8800

Figure 7-12. COe Sensor and Pre-Heater Alignment

THERMOCOUPLE

SENSOR ASSEMBLY

TOP VIEW

Sensor

Holder

Instruction Manual

IM-106-880 Original Issue

February 2005

COe

COe Sensor

Flat

Sensor

Holder

Flat

2 to 2-1/4 in.

(51 to 57 mm)

Pre-Heater

Flat

Sensor Holder

Flat

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 7-12. Tighten screws (1, Figure 7-11).

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

Assemble O

1. See Figure 7-10. Assemble O

Sensor and Heater Strut Assembly

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 O

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 O

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 O

cell.

Install Sample and Exhaust Tubes

37390034

7-16

1. See Figure 7-9. 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).

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

Install Eductor

Figure 7-13. Installation of Eductor and COe Sensor

If installed, the O

cell and heater strut assembly (9, Figure 7-3) 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 7-13). Do not apply sealant to the first turn of the pipe threads.

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

37390047

7-17

OCX 8800

Figure 7-14. COe Sensor Parts Alignment

Instruction Manual

IM-106-880 Original Issue

February 2005

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 7-14.

Eductor Flat

Straightedge

Matchmark

37390036

7-18

Instruction Manual

IM-106-880 Original Issue February 2005

Install COe Sensor Assembly

Figure 7-15. Band Heater Height 1. Apply pipe thread sealant (Loctite #567) to the exposed pipe threads

of eductor elbow (12, Figure 7-13). 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),

0.37 in. (9,4 mm)

COe Sensor

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 7-16.

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).

Band Heater

Insulator

37390058

6. Slide COe band heater (10, Figure 7-13) 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 7-12). Thread bayonet connector up or down to adjust height.

8. Install and fasten thermocouple (8, Figure 7-13).

9. Position band heater as shown in Figure 7-15 and Figure 7-16 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).

OCX 8800

7-19

OCX 8800

Figure 7-16. COe Sensor Holder Alignment

Instruction Manual

IM-106-880 Original Issue

February 2005

Matchmark

Straightedge

Sensor

Holder

Flat

Matchmark

37390035

7-20

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 7-17. COe Sensor, Thermocouple, and Heater Connections

OCX 8800

10. Reconnect the COe sensor, thermocouple, and heater wires at the sensor housing terminal blocks. Refer to Figure 7-17.

11. Install and fasten the COe insulator (1, Figure 7-13) around COe sensor assembly (5). All wiring must remain outside of the insulator.

12. If terminal block mounting (13, Figure 7-13) was moved, reinstall with two base mounting screws.

Sensor HousingTerminals

HTR 02

HTR CO

HTR 02

HTR SB

CJC Sensor

RED

YEL

BLU

RED

BLU

WHT

RED

T/C O2

T/C CO

T/C SB

EXC

CJC

CO REF

CO ACT

EXC

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

COe Sensor

Assembly

COe HeaterWires

COe SensorWires

COeThermocouple Wires

37390018

7-21

OCX 8800

390066

Figure 7-18. Installation of O2 Cell and Heater Strut Assembly

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

14. Insulator

15. Thermal Switch

Instruction Manual

IM-106-880 Original Issue

February 2005

7-22

Install Sample Block Heater Rods

1. Before installing sample block heater rods (13, Figure 7-18), evenly coat the heater rods with Watlube heater release agent.

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

Figure 7-19. O2 Cell, Thermocouple, and Heater Connections

Sensor HousingTerminals

HTR 02

HTR CO

HTR 02

HTR SB

ellWires

O HeaterWires

ThermocoupleWires

ORG

GRN

RED

YEL

T/C O2

T/C CO

T/C SB

EXC

CJC

CO REF

CO ACT

EXC

O Cell and Heater Strut

Sample

Block

Thermo-

couple

+ +

Assembly

ReturnWire

Sample Block

Heater Rods

Thermal

Switch

2. If thermal switch (15) was removed, install thermal switch on mating heater clamp (12), connect wires of heater rods (13), and install insulator (14).

3. Install the heater rods (13), heater clamps (12), and screws (11).

4. Reconnect the heater rod leads at the sensor housing terminal blocks, (Figure 7-19).

7-23

37390069

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

Install O2 Cell and Heater Strut Assembly

1. Rub a small amount of anti-seize compound on both sides of new gasket (10, Figure 7-18).

2. Apply anti-seize compound to threads of O assembly (9) and sensor housing (8).

cell and heater strut

Stripped threads on the O2 cell and heater strut assembly can allow gas leakage. Gas leakage can affect the O and heater strut assembly .

3. Install O

cell and heater strut assembly (9) in sensor housing (8). Snug

measurements and calibration. Avoid over-tightening the O2 cell

up, but do not over-tighten the assembly.

4. Reconnect the lead wires from O

cell, heater, and thermocouple to the

sensor housing terminal blocks. Refer to Figure 7-19.

5. Install reference air tube (7, Figure 7-18) in sensor housing (8). Make sure that the open end of reference air tube extends into heater tube of O

cell and heater strut assembly (9).

Install Terminals Insulator and Cover

1. Install insulator (6, Figure 7-18) over uppermost terminal blocks. Position one side of insulator against terminal blocks and snap terminal marking plate (5) to mating stand-off.

2. Position opposite side of insulator (6) and secure with related marking plate (5).

3. If removed, install cover gasket (4). Screw cover (3) onto sensor housing (8). Tighten cover firmly.

4. To comply with explosion-proof requirements, the cover gasket (4) must be compressed. For hazardous area applications, verify that the cover gasket is compressed.

5. Align locking clip (2) with gap between cover ribs.

6. Loosen screw (1) and slide locking clip (2) fully into gap between cover ribs. Retighten screw (1).

7-24

Sensor Housing Leak Test

1. Install 1/4 NPT cap on dilution air inlet fitting. Install a 1/4 NPT cap on sample tube (2, Figure 7-9) or plug 1/4 NPT sample inlet port. Capped or plugged ports must be air tight.

2. If not in place, install exhaust tube (3, Figure 7-9) in exhaust port according to the instructions provided.

3. Connect a calibrated manometer to the CAL GAS inlet port.

4. Connect and apply clean instrument air at 35 psig (241 kPa gage) to the instrument air inlet fitting.

5. Observe the manometer reading. The reading should be from 10 to 13 inches, Water Column. Locate and correct leaks if the reading is less than 10 inches WC.

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

REPAIR ELECTRONICS HOUSING

Electronics Housing Disassembly

Use the following procedures to remove damaged components from the OCX 8800 electronics 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

1. See Figure 7-20. Loosen screw (1) and slide locking clip (2) away from cover (3). Retighten screw (1).

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

3. Inspect cover gasket (4) for wear or damage. Replace cover gasket if damaged.

Remove Flash PROM

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

1. Locate Flash PROM access port in electronics stack (5, Figure 7-20).

2. Use suitable IC removal tool to remove Flash PROM (6).

Remove LOI Module and Board

1. Remove three screws (7, Figure 7-20).

2. Carefully lift LOI module (8) from LOI board (9). Note the location of LOI connector (10).

3. Remove two screws (11) and lockwashers (12). Remove LOI board (9).

7-25

OCX 8800

Figure 7-20. Removal/Installation of Electronics Housing Components

Instruction Manual

IM-106-880 Original Issue

February 2005

1. Screw

2. Locking Clip

3. Cover

4. O-ring

5. Electronics Stack

6. Flash PROM

7. Screw

8. LOI Module

9. LOI Board

10. LOI Connector

11. Screw

12. Lockwasher

13. Screw

14. Lockwasher

15. Solenoid Valve (3 way)

16. Solenoid Valve

37390037

7-26

Remove Electronics Stack

1. Unplug power cable, signal cable, and solenoid lead connectors from terminals of electronics stack (5, Figure 7-20).

2. Remove two screws (13) and lockwashers (14).

3. Remove electronics stack (5).

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 7-21. Removal/ Installation of EMI Filter

OCX 8800

Remove Solenoid Valves

1. Disconnect solenoid leads from mating terminal connector.

2. Remove top nut of solenoid valve (15 or 16, Figure 7-20).

3. Remove the solenoid coil assembly and washer.

4. Unthread and remove solenoid valve base.

Remove EMI Filter and Terminal Block

1. Disconnect EMI filter wiring (Figure 7-21) at terminal block (3).

2. Disconnect EMI filter wiring at AC power input terminal block on electronic stack.

3. Unbolt and remove EMI filter (1) from electronic stack.

4. Remove ground wire (2) from terminal block (3).

5. Unbolt and remove terminal block (3) from electronic stack.

Brown

Blue Green

Blue

Brown

Green

37390081

7-27

OCX 8800

Instruction Manual

IM-106-880 Original Issue

February 2005

Electronics Housing Assembly

Install EMI Filter and Terminal Block

1. Install replacement EMI filter (1, Figure 7-21) and/or terminal block (3) on electronic stack.

2. Refer to wiring details in Figure 7-21. Connect EMI filter wiring and ground wire (2) at terminal block (3).

3. Connect EMI filter wiring at AC power input terminal block on electronic stack.

Install Solenoid Valves

1. Disassemble replacement solenoid valve (15 or 16, Figure 7-20).

2. Install new solenoid valve base. Be careful not to overtighten.

3. Install new washer and solenoid coil assembly and secure with nut.

4. Connect the solenoid leads to the proper terminations on the solenoid power terminal block (Figure 7-24).

Install Electronics Stack

1. Install electronics stack (5, Figure 7-20) and secure with lockwashers (14) and screws (13).

2. See Figure 7-23 and Figure 7-24. Reconnect power cable, signal cable, and solenoid lead connectors to electronics stack terminals.

Install LOI Module and Board

Figure 7-22. Flash PROM Alignment

Corner

Bevel

Flash PROM

Access

Port

1. Install LOI board (9, Figure 7-20) and secure with two screws (11) and lockwashers (12).

2. Note the location of the LOI connector (10). Plug LOI module (8) and connector into one of the four mating receptacles provided.

3. Install three screws (7) to secure the LOI module.

Install Flash PROM

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

1. Locate Flash PROM access port in electronics stack (5, Figure 7-20).

2. See Figure 7-22. Align Flash PROM (6, Figure 7-20) with mating receptacle in access port of electronics stack as shown. Flash PROM corner bevel must be in upper left corner of receptacle.

3. Install Flash PROM (6).

7-28

37390060

Instruction Manual

IM-106-880 Original Issue February 2005

Figure 7-23. Electronics Housing Cable Connections

OCX 8800

RED

BLK ORG WHT

BLU

Heater Power

Connector (J3)

RED BLK

WHT BLK

GRN BLK

BLU BLK

&Thermocouple

Connector (J5)

O2 Cell

T/C CO+ T/C CO-

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

O2 CELL+ O2 CELL-

YEL

2HTR CO 1HTR CO 2HTR O 1HTR O 2HTR SB 1HTR SB

SHLD

2 2

#1 #1

YEL

BRN

BLK

RED WHT ORG

BLK

To Ground

Screw

GRN

SHIELD

Ground

Screw

COe Sensor

Connector (J4)

EXC+ CO ACT+ CO ACT-

CO REF+ CO REFCJC+ CJCEXC-

& CJC

ELECTRONICS HOUSING

Signal Cable

Heater Power Cable

NOTE: Wire colors shown are for cables

supplied by Rosemount Analytical.

37390016

7-29

OCX 8800

Figure 7-24. Solenoid Power Terminals

Instruction Manual

IM-106-880 Original Issue

February 2005

SOL 1

TOPVIEW

SOL 3

SOL 4

SOL 2

SOL 4

SOL 3

SOL 2

SOL 1

COTest Gas

High O Test Gas

Low O Test Gas

Instrument Air

7-30

37390033

Install Cover

1. If removed, install cover gasket (4, Figure 7-20). Screw cover (3) onto electronics housing. Tighten cover firmly. Align locking clip (2) with gap between cover ribs.

2. To comply with explosion-proof requirements, cover gasket (4) must be compressed. For hazardous area applications, verify that the cover gasket is compressed.

3. Loosen screw (1) and slide locking clip (2) fully into gap between cover ribs. Retighten screw (1).

Instruction Manual

IM-106-880 Original Issue February 2005

OCX 8800

REPLACE TUBE FITTINGS

Remove Tube Fittings

The OCX transmitter housings have special tube fittings that, if clogged or damaged, must be replaced with the same type of fitting. The special tube fittings have alpha or numeric codes etched on the fitting. Unetched tube fittings are standard 1/4 inch, stainless steel fittings.

‘F’ Type Fitting

The ‘F’ type fitting is a flame arrestor fitting used in all OCX 8800 hazardous area housings. The flame arrestor fitting prohibits spark or flame conduction from the housing. It requires a thread sealing compound (Loctite 567) and at least five threads engagement.

‘13’ Type Fitting

This fitting is an eductor drive air fitting for the OCX 8800 hazardous area housing. This is a 1/8 inch tube fitting with a built-in 0.013 inch restrictor orifice. It seats in a threaded base port inside the housing.

‘R’ Type Fitting

The ‘R’ type fitting is a reference air line fitting for the general purpose and hazardous area sensor housings. This is a 1/4 inch tube fitting with a built-in 0.007 inch restrictor orifice.

The OCX construction includes pipe thread sealant to seal fittings in all ports that pass through to an outer wall of the instrument housing base. Use the following instructions to loosen and remove tube fittings that are secured with pipe thread sealant.

Use heat resistant gloves when removing a damaged tube fitting. The pipe threads are bonded with a pipe thread sealant. The thread sealant softens at 450°F (232°C). The heated parts can cause severe burns.

1. Secure sensor housing (1, Figure 7-25) or electronics housing (2) in soft (plastic, wood, or brass) vice jaws.

2. To soften the pipe thread sealant, use a propane torch to heat the tube fitting (3, 4, 5, or 6) to 450°F (232°C), minimum.

3. While heating the tube fitting, use a wrench to apply removal torque until the pipe thread sealant softens. Remove and discard the used fitting.

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.

7-31

OCX 8800

Figure 7-25. Removal of Tube Fittings

1. Sensor Housing

2. Electronics Housing

3. Tube Fitting

. Tube Fitting (Type R) . Tube Fitting (Type 13)

6. Tube Fitting (Type F)

Instruction Manual

IM-106-880 Original Issue

February 2005

Install Tube Fittings

1. Verify that the replacement tube fitting is identical to the item removed. Special fittings are etched with code markings.

2. Apply pipe thread sealant (Loctite #567) to the mating threads of the tube fitting. Do not apply sealant to the first turn of the external pipe threads.

3. Install and tighten the tube fitting in the mating port of sensor or electronics housing.

37390071

7-32

Rosemount OCX 8800 O2 / Combustibles Transmitter Hazardous Area with Integral Electronics and LOI Local Operator Interface-Orig. Issue Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

PREFACE

DEFINITIONS

SYMBOLS

Section 1 Description and Specifications

COMPONENT CHECKLIST

SYSTEM OVERVIEW

SPECIFICATIONS

Section 2 Installation

MECHANICAL INSTALLATION

ELECTRICAL INSTALLATION

PNEUMATIC INSTALLATION

INITIAL STARTUP

Section 3 Configuration and Startup

VERIFY INSTALLATION

INITIAL POWER UP

SET TEST GAS VALUES

OCX 8800 RESET PROCEDURE

Section 4 Using the LOI

OVERVIEW

DISPLAY ORIENTATION

LOI CONTROLS

Overview

LOI Key Functions

LOI Status Codes

LOI MENU TREE

D/A TRIM PROCEDURES

Section 5 Using HART Communications

OVERVIEW

HART COMMUNICATOR SIGNAL CONNECTIONS

HART COMMUNICATOR PC CONNECTIONS

HART MENU TREE

D/A TRIM PROCEDURES

Section 6 Calibration

OVERVIEW

FULLY AUTOMATIC CALIBRATION

OPERATOR - INITIATED AUTOCALIBRATION

MANUAL CALIBRATION

Section 7 Maintenance and Service

OVERVIEW

OCX 8800 REMOVAL AND INSTALLATION

OCX with Integral Electronics

REPAIR SENSOR HOUSING

Sensor Housing Disassembly

Sensor Housing Assembly

REPAIR ELECTRONICS HOUSING

Electronics Housing Disassembly

Electronics Housing Assembly

REPLACE TUBE FITTINGS

Remove Tube Fittings

Install Tube Fittings