Rosemount OCX 8800 O2 / Combustibles Transmitter Hazardous Area with Integral Electronics-Rev 1.3 Manuals & Guides

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Rosemount™ OCX 8800 Oxygen and Combustibles Transmitter

Hazardous Location Probe with Integral Electronics

Reference Manual

00809-0100-4881, Rev AA

July 2018

Signal words and symbols

Pay attention to the following signal words, safety alert symbols, and statements.

WARNING!

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION!

Indicates a hazardous situation which, if not avoided, could result in equipment damage.

NOTICE

Used to address messages or practices not related to personal injury or equipment damage.

Symbols

Earth (ground) terminal

Protective conduit terminal

Risk of electrical shock

Warning: Refer to instruction manual

Essential Instructions

Read this page before proceeding!

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

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

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

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

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

• Install your equipment as specified in the installation instructions of the appropriate instruction manual and per applicable

local and national codes. Connect all products to the proper electrical and pressure sources.

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

• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.

Unauthorized parts and procedures can affect the product's performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed

by qualified people, to prevent electrical shock and personal injury.

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

NOTICE

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

Preface

The purpose of this manual is to provide a comprehensive understanding of the OCX8800 components, functions, installation, and maintenance.

Emerson recommends that you thoroughly familiarize yourself with Chapter 1 and Chapter 2 before installing your transmitter.

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

Chapter 1 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.

Product operation personnel

• Read and understand all instructions and operating procedures for this product.

• Install this product as specified in Chapter 2 of this manual per applicable local and national codes.

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

• Follow all instructions during the installation, operation,and maintenance of this product.

• To prevent personal injury, ensure that all components are in place prior to and during operation of this product.

• Connect all products to the proper electrical and pressure sources when and where applicable.

• Ensure that all connections to pressure and electrical sources are secure prior to and during equipment operation.

• If you do not understand an instruction or do not feel comfortable following the instructions, contact your Rosemount

representative for clarification or assistance.

• If this instruction manual is not the correct manual for you Rosemount product, call Rosemount at 800 854 8257, and

Rosemount will provide you with the requested manual. You may also download the manual from

www.Emerson.com/RosemountGasAnalysis.

• Save this instruction manual for future reference.

Notice

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All sales are governed by Rosemount's terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time.

Rosemount does not assume responsibility for the selection, use, or maintenance of any product. Responsibility for proper selection, use, and mainteance of any Rosemount product remains solely with the purchaser and end-user.

To the best of Rosemount's knowledge, the information herein is complete and accurate. Rosemount makes no warranties, expressed or implied, including implied warranties of merchantability and fitness for a particular purpose, with respect to this manual and, in no event, shall Rosemount be liable for any incidental, punitive, special, or consequential damages including, but not limited to, loss of production, loss of profits, loss of revenue or use, and costs incurred, including without limitation for capital, fuel and power, and claims of third parties.

Product names used herein are for manufacturer or supplier identification only and may be trademarks/registered trademarks of these companies.

Rosemount and the Rosemount logo are registered trademarks of Rosemount. The Emerson logo is a trademark and service mark of Emerson Electric Co.

Warranty

1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein, Rosemount warrants that the licensed firmware embodied in the Goods will execute the programming instructions provided by Rosemount and that the Goods manufacturerd by Rosemount will be free from defects in materials or workmanship under normal use and care and Services will be performed by trained personnel using proper equipment and instrumentation for the particular Service provided. The foregoing warranties will apply until the expiration of the applicable warranty period. Goods are warranted for twelve (12) months from the date of initial installation or eighteen (18) months from the date of shipment by Rosemount, whichever period expires first. Consumables and Services are warranted for a period of 90 days from the date of shipment or completion of the Services. Products purchased by Rosemount from a third party for resale to Buyer ("Resale Products") shall

carry only the warranty extended by the original manufacturer. Buyer agrees that Rosemount has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of Resale Products. If Buyer discovers any warranty defects and notifies Rosemount thereof in writing during the applicable warranty period, Rosemount shall, at its option, correct any errors that are found by Rosemount in the firmware or Services or repair or replace F.O.B. point of manufacture that portion of the Goods or firmware found by Rosemount to defective, or refund the purchase price of the defective portion of the Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normal wear and usage, unsuitable power sources, or environmental conditions, accident, misuse, improper installation, modifications, repair, use of unauthorized replacement parts, storage or handling, or any other cause not the fault of Rosemount are not covered by this limited warranty and shall be at Buyer's expense. Rosemount shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by Rosemount. All costs of dismantling, reinstallation and freight, and the time and expenses of Rosemount's personnel and representatives for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Rosemount. Goods repaired and parts replaced by Rosemount during the warranty period shall be in warranty for the remainder of the original warranty period or ninety (90) days, whichever is longer. This limited warranty is the only warranty made by Rosemount and can be amended only in a writing signed by Rosemount. THE WARRANTIES AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE. THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. Buyer acknowledges and agrees that corrosion or erosion of materials is not covered by this warranty.

2. LIMITATION OF REMEDY AND LIABILITY: ROSEMOUNT SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE REMEDIES OF BUYER SET FORTH IN THIS AGREEMENT ARE EXCLUSIVE. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT OR OTHERWISE), SHALL ROSEMOUNT'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXCEED THE PRICE TO BUYER OF THE SPECIFIED GOODS MANUFACTURED OR SERVICES PROVIDED BY ROSEMOUNT GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL ROSEMOUNT'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES. THE TERM "CONSEQUENTIAL DAMAGES" SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED PROFITS, REVENUE, OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF BUYER'S CUSTOMERS.

Contents

Chapter 1 Description and specifications ..........................................................................................1

1.1 Component checklist ..................................................................................................................... 1

1.2 System overview ............................................................................................................................ 3

1.2.1 Scope .............................................................................................................................. 3

1.2.2 System description ..........................................................................................................3

1.2.3 System configurations .....................................................................................................4

1.2.4 System features ...............................................................................................................5

1.2.5 System operation ............................................................................................................ 5

1.2.6 Handling the OCX 8800 ...................................................................................................6

1.2.7 System considerations .....................................................................................................6

1.3 Specifications ...............................................................................................................................11

1.3.1 Net O2 range ..................................................................................................................11

1.3.2 Combustibles ................................................................................................................ 11

1.3.3 Accuracy ........................................................................................................................11

1.3.4 System response to test gas .......................................................................................... 11

1.3.5 Temperature limits ........................................................................................................11

1.3.6 Nominal and approximate shipping weights ..................................................................12

1.3.7 Mounting .......................................................................................................................12

1.3.8 Materials ........................................................................................................................12

1.3.9 Calibration .....................................................................................................................13

1.3.10 Calibration gas mixtures recommended (ref. test gas bottles kit #1A9919G04) .............13

1.3.11 Calibration gas flow ....................................................................................................... 13

1.3.12 Reference air ................................................................................................................. 13

1.3.13 Eductor air ..................................................................................................................... 13

1.3.14 Dilution air .....................................................................................................................13

1.3.15 Blowback air (optional) ..................................................................................................13

1.3.16 Certifications ................................................................................................................. 14

1.3.17 Electrical noise ...............................................................................................................14

1.3.18 Line voltage ................................................................................................................... 14

1.3.19 Pollution degree ............................................................................................................ 14

1.3.20 Over voltage category ................................................................................................... 14

1.3.21 Relative humidity ...........................................................................................................15

1.3.22 Isolated output ..............................................................................................................15

1.3.23 Alarm .............................................................................................................................15

1.3.24 Power consumption ...................................................................................................... 15

1.4 Product matrix - OCX 8800 ...........................................................................................................15

Chapter 2 Install .............................................................................................................................19

2.1 Product safety .............................................................................................................................. 19

2.2 Mechanical installation .................................................................................................................20

2.2.1 Selecting a location ....................................................................................................... 20

2.2.2 Installation .....................................................................................................................21

2.3 Electrical installation .................................................................................................................... 26

2.3.1 Electrical connections ....................................................................................................29

2.3.2 Connect line voltage ......................................................................................................29

2.3.3 Connect output signals ..................................................................................................29

2.3.4 O2 4-20 mA signal ..........................................................................................................29

Reference Manual i

Contents

2.3.5 COe 4-20 mA signal ....................................................................................................... 29

2.3.6 Foundation Fieldbus signal ............................................................................................ 29

2.3.7 Alarm output relay .........................................................................................................29

2.3.8 Remote electronics connections to sensor housing ....................................................... 30

2.3.9 Signal connections .........................................................................................................32

2.3.10 Heater power connections .............................................................................................32

2.4 Pneumatic installation ..................................................................................................................32

2.4.1 Reference air set option (only) .......................................................................................32

2.4.2 Reference air set and solenoids option without COe zero function .................................34

2.4.3 Reference air set and solenoids option with COe zero function ......................................36

2.4.4 Reference air set, solenoids, and blowback option with COe zero function .................... 38

2.5 Initial startup ................................................................................................................................42

Chapter 3 Configuration and startup .............................................................................................. 43

3.1 Verify installation ......................................................................................................................... 43

3.1.1 Verify configuration - HART electronics ......................................................................... 43

3.1.2 Verify configuration - Fieldbus electronics ..................................................................... 45

3.2 Initial power up ............................................................................................................................ 46

3.3 Set test gas values ........................................................................................................................ 46

3.3.1 Setting test gas values with the Field Communicator .....................................................46

3.3.2 Setting test gas values with Fieldbus communicator ......................................................46

3.3.3 Setting test gas values with the LOI ................................................................................47

3.4 Calibration solenoids ....................................................................................................................47

3.4.1 Configuring the calibration solenoids with the Field Communicator - HART ...................47

3.4.2 Configuring the calibration solenoids with the Field Communicator - Fieldbus .............. 48

3.4.3 Configuring the calibration solenoids with the LOI .........................................................48

3.5 Blowback feature ......................................................................................................................... 48

3.5.1 Configuring blowback with the Field Communicator - HART ..........................................48

3.5.2 Configuring blowback with the Field Communicator - Fieldbus ......................................49

3.5.3 Configuring blowback with the LOI ................................................................................49

3.6 Calibration verify feature ..............................................................................................................50

3.6.1 Performing a calibration verify with the Field Communicator - HART ............................. 50

3.6.2 Performing a calibration verify with the Field Communicator - Fieldbus .........................51

3.6.3 Performing a calibration verify with the LOI ................................................................... 51

3.7 Calibration tolerance feature ........................................................................................................52

3.7.1 Configuring the calibration tolerance feature with the Field Communicator -HART ....... 52

3.7.2 Configuring the calibration tolerance feature with the Field Communicator -

Fieldbus .........................................................................................................................52

3.7.3 Configuring the calibration tolerance feature with the LOI .............................................53

3.8 COe purge / zero feature .............................................................................................................. 53

3.8.1 Configuring the COe zero feature with the Field Communicator - HART ........................ 54

3.8.2 Configuring the COe zero feature with the Field Communicator - Fieldbus ....................54

3.8.3 Configuring the COe zero feature with the LOI ...............................................................55

3.9 Reset procedure ...........................................................................................................................55

3.9.1 Reset with the LOI ..........................................................................................................56

3.9.2 Reset with Field Communicator .....................................................................................56

Chapter 4 Using the LOI ..................................................................................................................57

4.1 Display orientation .......................................................................................................................57

4.2 LOI controls ..................................................................................................................................58

4.2.1 Overview ....................................................................................................................... 58

4.2.2 LOI key functions ........................................................................................................... 59

ii OCX 8800

Contents

4.2.3 Lockout ......................................................................................................................... 60

4.2.4 LOI status codes .............................................................................................................62

4.3 LOI menu tree .............................................................................................................................. 62

4.3.1 First column submenus ..................................................................................................66

4.3.2 Second column submenus .............................................................................................66

4.3.3 Third and fourth column submenus ...............................................................................67

Chapter 5 Calibration ..................................................................................................................... 69

5.1 Overview ......................................................................................................................................69

5.2 Fully automatic calibration ........................................................................................................... 69

5.2.1 Autocalibration setup using HART ................................................................................. 69

5.3 Operator-initiated autocalibration ............................................................................................... 70

5.3.1 Autocalibration using HART ...........................................................................................70

5.4 Manual calibration ........................................................................................................................70

5.4.1 Manual calibration using the optional LOI ......................................................................71

5.4.2 Manual O2 calibration using the Field Communicator - HART .........................................72

5.4.3 Manual COe calibration using the Field Communicator - HART ...................................... 73

5.4.4 Manual O2 and COe calibration using the Field Communicator - Fieldbus ...................... 75

5.5 D/A trim procedures - LOI .............................................................................................................77

5.5.1 O2 D/A trim procedure using the LOI ............................................................................. 77

5.5.2 COe D/A trim procedure using the LOI ...........................................................................78

5.6 D/A trim procedures - HART ......................................................................................................... 79

5.6.1 O2 D/A trim procedure using HART ................................................................................79

5.6.2 COe D/A trim procedure using HART ............................................................................. 81

Chapter 6 Field Communicator .......................................................................................................83

6.1 Overview ......................................................................................................................................83

6.2 Field Communicator connections .................................................................................................83

6.2.1 Connecting to a HART loop ............................................................................................83

6.2.2 Connecting to a Fieldbus segment .................................................................................84

6.3 HART menu tree ...........................................................................................................................86

6.4 Fieldbus menu tree .......................................................................................................................90

Chapter 7 Foundation Fieldbus .......................................................................................................95

7.1 Foundation Fieldbus technology .................................................................................................. 95

7.1.1 Overview ....................................................................................................................... 95

7.1.2 Introduction .................................................................................................................. 95

7.1.3 Function blocks ............................................................................................................. 96

7.1.4 Device descriptions ....................................................................................................... 97

7.1.5 Instrument-specific function blocks ...............................................................................97

7.2 Network communication ............................................................................................................. 98

7.2.1 Link active scheduler (LAS) .............................................................................................99

7.2.2 Device addressing ..........................................................................................................99

7.3 OCX function blocks ...................................................................................................................100

7.3.1 Implemented function blocks ......................................................................................100

7.4 Resource block ...........................................................................................................................100

7.4.1 PlantWeb Alerts ...........................................................................................................100

7.4.2 Mapping of PWA ..........................................................................................................101

7.4.3 PWA SIMULATE ............................................................................................................110

7.4.4 Fieldbus/PWA simulate ................................................................................................111

7.4.5 Configure simulation from AMS ...................................................................................111

7.5 Configure simulation with the Model 375 Field Communicator ..................................................112

7.5.1 Support resource block errors ......................................................................................113

Reference Manual iii

Contents

7.6 Transducer block ........................................................................................................................113

7.6.1 Transducer block parameters ...................................................................................... 114

7.7 Transducer block enumerations ................................................................................................. 122

7.7.1 Calibration states .........................................................................................................122

7.7.2 Calibration step command .......................................................................................... 123

7.7.3 Transducer block channel assignments for AI blocks ....................................................128

7.7.4 Transducer block channel status ..................................................................................128

7.7.5 Transducer block simulate ...........................................................................................129

7.7.6 Support transducer block errors .................................................................................. 129

7.8 Analog input (AI) function block .................................................................................................130

7.8.1 Introduction ................................................................................................................ 130

7.8.2 Simulation ...................................................................................................................135

7.8.3 Filtering .......................................................................................................................138

7.8.4 Signal conversion .........................................................................................................138

7.8.5 Direct signal conversion ...............................................................................................138

7.8.6 Indirect signal conversion ............................................................................................ 139

7.8.7 Indirect square root ..................................................................................................... 139

7.8.8 Block errors ................................................................................................................. 139

7.8.9 Modes ......................................................................................................................... 140

7.8.10 Alarm detection ...........................................................................................................140

7.8.11 Status handling ............................................................................................................141

7.8.12 Advanced features .......................................................................................................142

7.8.13 Application information ...............................................................................................142

7.8.14 Application examples .................................................................................................. 143

7.8.15 Pressure transmitter used to measure level in an open tank .........................................143

7.8.16 Differential pressure transmitter to measure flow ........................................................147

7.8.17 Troubleshooting ..........................................................................................................147

7.9 Proportional/integral/derivative (PID) function block ................................................................. 149

7.9.1 Setpoint selection and limiting .................................................................................... 158

7.9.2 PID equation structures ............................................................................................... 160

7.9.3 Reverse and direct action .............................................................................................161

7.9.4 Reset limiting .............................................................................................................. 161

7.9.5 Block errors ................................................................................................................. 161

7.9.6 Modes ......................................................................................................................... 162

7.9.7 Alarm detection ...........................................................................................................162

7.9.8 Status handling ............................................................................................................163

7.9.9 Application information ...............................................................................................164

7.9.10 Application examples .................................................................................................. 165

7.9.11 Cascade control with master and slave loops ............................................................... 167

7.9.12 Cascade control with override ..................................................................................... 169

7.9.13 Troubleshooting ..........................................................................................................170

7.10 Airthmetic (ARTHM) function block ............................................................................................172

7.10.1 Block errors ................................................................................................................. 175

7.10.2 Modes ......................................................................................................................... 176

7.10.3 Alarm detection ...........................................................................................................176

7.10.4 Block execution ........................................................................................................... 177

7.10.5 Compensation input calculations ................................................................................ 177

7.10.6 Application information ...............................................................................................178

7.11 Advanced topics .........................................................................................................................179

7.11.1 Arithmetic types ..........................................................................................................179

7.11.2 Troubleshooting ..........................................................................................................180

iv OCX 8800

Contents

7.12 Input selector (ISEL) function block ............................................................................................ 181

7.12.1 Block errors ................................................................................................................. 185

7.12.2 Modes ......................................................................................................................... 185

7.12.3 Alarm detection ...........................................................................................................186

7.12.4 Block execution ........................................................................................................... 186

7.12.5 Status handling ............................................................................................................187

7.12.6 Application information ...............................................................................................187

7.12.7 Troubleshooting ..........................................................................................................189

7.13 Operation with Emerson DeltaV ................................................................................................. 189

7.13.1 About AMS and DeltaV software ..................................................................................189

Chapter 8 Troubleshooting .......................................................................................................... 193

8.1 Overview ....................................................................................................................................193

8.1.1 Grounding ................................................................................................................... 193

8.1.2 Electrical noise .............................................................................................................193

8.1.3 Electrostatic discharge ................................................................................................ 193

8.1.4 Total power loss ...........................................................................................................194

8.2 Diagnostic alarms .......................................................................................................................196

8.3 Fault isolation .............................................................................................................................196

8.4 Alarm relay events ......................................................................................................................205

Chapter 9 Maintenance and service .............................................................................................. 209

9.1 Overview ....................................................................................................................................209

9.2 Removal and installation ............................................................................................................ 209

9.2.1 OCX with integral electronics ...................................................................................... 209

9.2.2 OCX with remote electronics ....................................................................................... 213

9.2.3 Repair sensor housing ..................................................................................................216

9.2.4 Sensor housing assembly .............................................................................................233

9.3 Repair electronics housing ......................................................................................................... 248

9.3.1 Electronics housing disassembly .................................................................................. 248

9.3.2 Electronics housing assembly ...................................................................................... 252

Chapter 10 Replacement parts ....................................................................................................... 255

10.1 Sensor housing ...........................................................................................................................255

10.2 Electronics housing .................................................................................................................... 259

10.3 O2 cell and heater strut assembly ............................................................................................... 262

Appendices and reference

Appendix A Safety data ................................................................................................................... 265

A.1 Safety Instructions ..................................................................................................................... 265

A.2 Safety data sheet for ceramic fiber products .............................................................................. 266

A.2.1 Identification ............................................................................................................... 266

A.2.2 Physical data ................................................................................................................266

A.2.3 Hazardous ingredients .................................................................................................267

A.2.4 Fire and explosion data ................................................................................................ 267

A.2.5 Health hazard data ...................................................................................................... 267

A.2.6 Reactivity data .............................................................................................................269

A.2.7 Spill or leak procedures ................................................................................................269

A.2.8 Special precautions ......................................................................................................269

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Contents

A.3 High pressure gas cylinders ........................................................................................................ 271

A.3.1 General precautions for handling and storing high pressure gas cylinders ....................271

A.4 ATEX clarification ....................................................................................................................... 272

A.4.1 ATEX compliant gas analysis performed within a flameproof enclosure ....................... 272

Appendix B SPA with HART Alarm ................................................................................................... 275

B.1 Overview ....................................................................................................................................275

B.2 Description ................................................................................................................................ 275

B.3 Installation ................................................................................................................................. 277

B.4 Setup ......................................................................................................................................... 277

B.4.1 Jumper and switch settings ..........................................................................................278

B.4.2 Configuration/calibration ............................................................................................ 279

Appendix C Returning material ....................................................................................................... 285

Appendix D ......................................................................................................................................287

vi OCX 8800

Description and specifications

1 Description and specifications

1.1 Component checklist

A typical OCX 8800 Oxygen/Combustibles Transmitter package contains the items shown in Figure 1-1.

Reference Manual 1

Description and specifications

Typical system packageFigure 1-1:

A. Hazardous Area OCX 8800 with integral electronics B. Field communicator package (optional) C. Quick Start Guide D. Blowback hardware (optional) E. Adapter plate with mounting hardware and gasket F. Reference air and calibration set (optional) G. Hazardous Area OCX 8800 with remote electronics

Use the product matrix in Table 1-1 at the end of this section to verify your order number. The first part of the matrix defines the model. The last part defines the various options and features of the OCX 8800. Check the model number against the transmitter features and options, making sure options specified by this number are on or included with the unit. Use this complete model number for any correspondence with Emerson. A list of accessories for use with the OCX 8800 is provided in Table 1-2.

2 OCX 8800

1.2 System overview

1.2.1 Scope

This Instruction Manual supplies details needed to install, start up, operate, and maintain the OCX 8800. Signal conditioning electronics output a digital signal representing oxygen (O2) and combustibles (COe) values. This information, plus additional details, can be accessed with the 375 Field communicator or Emerson AMS software..

1.2.2 System description

The OCX 8800 is designed to measure oxygen and combustible concentrations in flue gas temperatures up to 1427 °C (2600 °F). Electrical connections, power, and communications are made through two 3/4 NPT ports in the flameproof electronics enclosure using fittings and cables provided by you. 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 minimum sample conditioning requirements.

Description and specifications

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 operating at the proper temperature, the following Nernst equation gives the millivolt output of the cell.

EMF = KT log10 (P1/P2) + C

where:

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

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

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

Note

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

When the cell is at operating temperature and there are unequal oxygen concentrations across the cell, oxygen ions 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 lograrithm of the oxygen concentration. Therefore, the output signal increases as the oxygen concentration of the sample decreases. This characteristic enables the transmitter to provide exceptional sensitivity at low oxygen concentrations.

Reference Manual 3

Description and specifications

The transmitter 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 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 temperature difference produces a resistance relationship between the two elements that is directly proportional to the concentration of combustibles in the sample gases.

The catalyst is specifically designed to detect carbon monoxide (CO), but the sensor responds to other combustible gases. The sensor is calibrated using CO; thus the output should be expressed in terms of CO. However, as 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.

1.2.3

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

System configurations

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

The electronics are contained in a separate housing from the sensors. When the transmitter is configured with the integral electronics option, the electronics and sensor housings are mounted as a unit at the stack mounting flange. When the transmitter is configured with the remote electronics option, the electronics are contained in a separate housing from the sensors. The electronics housing may be mounted up to 150 feet from the sensor housing.

The electronics control both sensor temperatures and provide output signals in one of two ways:

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

2. Single Foundation Feldbus output.

The power supply can accept voltages of 100 to 240 Vac and 50 to 60 Hz. The electronics accepts millivolt signals generated by the snesors and produces the outputs to be used by remotely connected devices. Refer to Chapter 3 for specific instructions upon intial power up.

4 OCX 8800

1.2.4 System features

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

2. HART or Foundation Fieldbus communication is standard. To use this capability, you must have either:

a. Model 375 Field Communicator

b. Asset Management Solutions (AMS) software for the PC

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

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

5. You can calibrate and diagnostically troubleshoot the transmitter 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 Chapter 4 for more information.

b. HART or Foundation Fieldbus interface: The transmitter's output line transmits a

digital signal with the detected oxygen or combustible levels encoded in a digital format. This information can be accessed through the following:

• Model 375 Field Communicator - The handheld field communicator requires

Device Description (DD) software specific to the OCX 8800. The DD software is supplied with many Model 375 units, but can also be programmed into existing units at most Emerson service offices. Refer to Chapter 6Section for additional information.

• Personal computer (PC) - The use of a personal computer requires AMS

software available from Emerson.

• Selected distributed control systems - The use of distributed control systems

requires input/output (I/O) hardware and AMS software which permit HART communications.

6. When the transmitter is configured without the LOI, you must calibrate and diagnostically troubleshoot the transmitter using the HART of Foundation Fieldbus interface.

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

Description and specifications

1.2.5

Reference Manual 5

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 mount to a duct or process wall so that the probe protrudes into the flue gas stream. An air powered eductor continuously pulls samples of the process flue gas through the probe to a chamber in front of the sensor housing where the sample passes the O2 sensor and continues on the COe sensor. Dilution air is provided to the COe sensor and reference air to the O2 sensor. After the gas sample flows past the O2 sensor and through the COe sensor, it is drawn through the eductor where it mixes with the eductor air and exits through exhaust back into the system. The electronics housing contains the CPU and communication boards which convert the sensor inputs into digital output signals. The

Description and specifications

CPU can also initiate and perform calibrations. Three test gases 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 the cold sensors causing condensation.

System operation diagramFigure 1-2:

1.2.6 Handling the OCX 8800

CAUTION!

EQUIPMENT DAMAGE

Only handle printed circuit boards and integrated circuits when adequate anti-static 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.

1.2.7

System considerations

Prior to installing your OCX 8800, make sure you have all the components necessary to make the system installation. Ensure that all components are properly integrated to make the system functional.

After verifying that you have all the components, select mounting locations and determine how each component will be placed in terms of available line voltage, ambient temperatures, environmental considerations, convenience and serviceability. Figure 1-4 shows a typical system wiring for a system with integral electronics. Figure 1-5 shows

6 OCX 8800

Description and specifications

simplified installations for the OCX 8800.Figure 1-5 shows the dimensions for the optional sample tube support. Figure 1-6 shows the dimensions for the optional in-situ filters.

Figure 1-7 shows the optional panel mounted blowback.

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

Note

The electronics module is designed to meet Type 4X and IP66, and the electronic components are rated to temperatures up to 85 °C (185 °F ).

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:

Communications Connections and AMS application - Hazardous Area OCX 8800 with Integral Electronics

Reference Manual 7

Description and specifications

Typical System Installation - Integral ElectronicsFigure 1-4:

A. Adapter plate B. Signal outputs (twisted pairs) C. Line voltage D. Instrument air supply (reference gas) E. High O2 test gas F. Low O2 test gas G. CO test gas

8 OCX 8800

Description and specifications

Optional Sample Tube SupportFigure 1-5:

C. 0.75 (19) dia. on 7.5 (190) dia. B.C. 8 places

D. 0.75 (19) dia. on 4.75 (121) dia. B.C. 4 places

Reference Manual 9

Description and specifications

Probe length L

18 in. 24.5 (621)

3 ft 42.5 (1078)

6 ft 78.5 (1993)

9 ft 114.5 (2907)

Optional In-Situ FiltersFigure 1-6:

Figure 1-7:

Optional Panel Mounted Blowback and Calibration/Reference Air Set (19 in. Rack or Wall Mount)

10 OCX 8800

1.3 Specifications

1. Requires XPS transmitter, P/N 6A00358G03

Note

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

1.3.1 Net O2 range

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

1.3.2 Combustibles

0-1,000 ppm to 0-5%, fully field selectable

1.3.3 Accuracy

Description and specifications

1.3.4

1.3.5

Oxygen

±0.75% of reading or 0.5% O2 (whichever is greater)

Combustibles

±2% range

System response to test gas

Oxygen

10 sec T90

Combustibles

25 sec T90

Temperature limits

Process

0 to 1427 °C (32 to 2600 °F)

Reference Manual 11

Description and specifications

Sensors housing

-40 to 100 °C (-40 to 212 °F)

Electronics housing

-40 to 65 °C (-40 to 149 °F), ambient

-40 to 85 °C (-40 to 185 °F), internal operating temperature of electronics inside housing,

as read by HART® or FOUNDATION Fieldbus™.

1.3.6 Nominal and approximate shipping weights

18 in. (457 mm) probe package

54 lb (20 kg)

3 ft (0.91 m) probe package

1.3.7

1.3.8

55 lb (20.5 kg)

6 ft (1.83 m) probe package

57 lb (21 kg)

9 ft (2.74 m) probe package

59 lb (22 kg)

Mounting

Flange

Materials

Probes

316 stainless steel: 705 °C (1300 °F)

Inconel 600: 1000 °C (1832 °F)

Ceramic: 1427 °C (2600 °F)

Enclosures

Low copper aluminum

12 OCX 8800

Description and specifications

1.3.9 Calibration

Semi-automatic or automatic

1.3.10 Calibration gas mixtures recommended (ref. test gas bottles kit #1A9919G04)

0.4% O2, balance N

8% O2, balance N

1000 ppm CO, balance air

1.3.11 Calibration gas flow

7 scfh (3.3 L/m), regulated to 20 to 30 psi (138 to 207 kPa)

1.3.12 Reference air

2 scfh (1 L/m), clean, dry, instrument-quality air (20.95% O2), regulated to 45 psi (310 kPa)

1.3.13 Eductor air

5 scfh (2.5 L/m), clean, dry, instrument-quality air (20.95% O2), regulated to 45 psi (310 kPa)

1.3.14

Dilution air

0.1 scfh (0.05 L/m), clean, dry, instrument-quality air (20.95% O2), regulated to 45 psi (310 kPa)

1.3.15

Reference Manual 13

Blowback air (optional)

Clean, dry, instrument-quality air (20.95% O2), regulated to ≥ 60 psi (413 kPa) or greater and ambient temperature of ≥ -18 °C (0 °F)

Description and specifications

1.3.16 Certifications

Complies with the following standards:

• 22.2 No. 94-M91; 22.2 No. 60529:05; ANSI/ISA S82.02.01; ANSI/ISA 12.00.01:2002;

ANSI/ISA 12.22.01:2002;UL No. 50 (Ed 10); CAN/CSA C22.2 No. 61010-1-12; CAN/CSA C22.2 No. 60079-0:15; CAN/CSA C22.2 No. 60079-1:16; ISA 60079-0 (12.00.01) – 2013; ISA 60079-0 (12.00.01) – 2013; ISA 60079-1 (12.22.01) – 2009 (R2013) ISA 61010-1-12

• ATEX: En 60079-0 : 2011 + A11 : 2013, EN 60079-1 : 2014, IEC 60079-0 : 2017

1.3.17

1.3.18

1.3.19

Special conditions of use:

- Flame proof joints are not intended to be repaired.

- Avoid installations that could cause electrostatic build-up on the painted

surfaces, and only clean the painted surfaces with a damp cloth.

• IECEx: IEC 60079-0: 2004, Edition 4; IEC 60079-1: 2014, Edition 7.0

• FM: Class 3600:1998; Class 3810:2005; ANSI/ISA 12.00.01:2005; ANSI/ISA

12.22.01:2002; ANSI/ NEMA 250:1991; ANSI/ISA 60529:2004

Electrical noise

Meets EN 61326, Class A

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

1.3.20

14 OCX 8800

Over voltage category

1.3.21 Relative humidity

5 to 95% (non-condensing)

1.3.22 Isolated output

Oxygen

4-10 mAdc, 950 ohm maximum with HART or FOUNDATION Fieldbus capability only

Combustibles

4-20 mAdc, 950 ohm maximum (not present with FOUNDATION Fieldbus)

1.3.23 Alarm

Alarm output relay - dry contact, form C, 30 mA, 30 Vdc capability

Description and specifications

1.3.24 Power consumption

750 W maximum

1.4

Product matrix - OCX 8800

Product matrix - OCX 8800Table 1-1:

OCX88C O2 Combustibles Transmitter - Flameproof

Code Probe length and material

00 No probe or exhaust tube

11 18 in. (457 mm) 316 stainless steel tube up to 704 °C

12 3 ft (0.91 m) 316 stainless steel tube up to 704 °C (1300 °F)

13 6 ft (1.83 m) 316 stainless steel tube up to 704 °C (1300 °F)

14 9 ft (2.7 m) 316 stainless steel tube up to 704 °C (1300 °F)

21 18 in. (457 mm) Inconel 600 up to 1000 °C (1832 ° F)

22 3 ft (0.91 m) Inconel 600 up to 1000 °C (1832 ° F)

23 6 ft (1.83 m) Inconel 600 up to 1000 °C (1832 ° F)

24 9 ft (2.7 m) Inconel 600 up to 1000 °C (1832 ° F)

31 18 in. (457 mm) ceramic up to 1427 °C (2600 °F )

32 3 ft (0.91 m) ceramic up to 1427 °C (2600 °F )

(1300 °F )

Reference Manual 15

Description and specifications

Code Probe mounting assembly

10 (ANSI 2 in. 150 lb) 6 in. diameter flange. 4.75 in. BC with 4 x

20 (DIN) 185 mm diameter flange, 145 mm BC with 4 x 18 mm

21 (DIN) 185 mm diameter flange, 145 mm BC with 4 x 18 mm

Code Mounting hardware - stack side

0 No adapter plate (0 must be chosen under Mounting adapter -

1 New installation - square weld plate with studs

2 Model 218/240 mounting plate (with model 218/240 shield

3 Existing model 218/240 support shield

4 Competitor's mount

5 Model 132 adapter plate

Product matrix - OCX 8800 (continued)Table 1-1:

0.75 in. diameter holes - standard O2 cell

diameter holes - standard O2 cell

diameter holes -high sulfur O2 cell

probe side below)

removed)

Code Mounting hardware - probe side

0 No adapter plate

1 Probe only (ANSI)

4 Probe only (DIN)

Electronics housing - NEMA 4X, IP66 HART communica-

Code

H1 HART communications - basic unit

H2 HART communications - local operator interface

H3 HART communications - calibration solenoids

H4 HART communications - local operator interface and calibra-

F1 Fieldbus communications - basic unit

F2 Fieldbus communications - local operator interface

F3 Fieldbus communications - calibration solenoids

F4 Fieldbus communications - local operator interface and cali-

Code Electronics mounting

01 Integral to sensor housing electronics

02 Split architecture with no cable

tions

tion solenoids

bration solenoids

Code In-situ filter

0 None

2 High surface area stainless steel

16 OCX 8800

Description and specifications

Product matrix - OCX 8800 (continued)Table 1-1:

3 Hastelloy

Code Accessories

0 None

2 Cal. gas/flow rotometers & ref. gas set

3 Cal. gas/flow rotometers & ref. gas set w/blowback

4 Cal. gas/flow rotometers & ref. gas set w/blowback - panel

mounted

02 In-situ filter (stainless steel only)

Example OCX88C111011H30600

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 Bold circle diameter, number, and arrangement of

holes, thread, depth of stud mounting plate with accessories.

AccessoriesTable 1-2:

Part number Description

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

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

1A99119H07 CO test gas bottle; 1,000 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

1A9929H01 Moore industries SPA for low O2 alarm, high COe alarm, calibration status, and

unit fail

4851B40G01 Wall or pipe mounting kit

1A9978H02 375 field communicator with 12 megabyte buffer, model no. 375HR1EKLU

6A00171G01 Power line filter kit

6A00288G01 Sample tube support, 18 in. (457 mm)

6A00288G02 Sample tube support, 3 ft (0.91 mm)

6A00288G03 Sample tube support, 6 ft (1.83 m)

6A00288G04 Sample tube support, 9 ft (2.7 m)

Reference Manual 17

Description and specifications

Part number Description

6P00162H01 Flange insulator

Accessories (continued)Table 1-2:

18 OCX 8800

2 Install

WARNING!

Before installing this equipment, read Section A.1. Failure to follow safety instructions could result in serious injury or death.

WARNING!

ELECTRICAL HAZARD 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.

WARNING!

HAZARDOUS AREAS The Xi Advanced Electronics can be installed in general purpose areas only. Do not install the Xi in hazardous areas or in the vicinity of flammable liquids.

Install

2.1

WARNING!

ELECTRICAL HAZARD If external loop power is used, the power supply must be a safety extra low voltage (SELV) type.

NOTICE

All unused ports on the probe housing and Xi enclosure should be plugged with a suitable filling.

Product safety

WARNING!

Before installing this equipment, read Appendix A. Failure to follow the safety instructions could result in serious injury or death.

CAUTION!

HAZARDOUS AREAS

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

Reference Manual 19

Install

CAUTION!

FLAMEPROOF DEVICES

To maintain explosion-proof protection of the OCX88C 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.

CAUTION!

HIGH TEMPERATURE SURFACES

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 195 °C (383 °F).

CAUTION!

HIGH TEMPERATURE SAMPLE

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sample entering the sensor housing must not exceed 195 °C (383 °F).

2.2 Mechanical installation

2.2.1 Selecting a location

The location of the OCX 8800 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The probe must be positioned so the gas it measures is representative of the process. Best results are normally obtained if the transmitter is positioned near the center of the duct (40 - 60% insertion). Longer ducts may require several transmitters, as 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. Select the sensing point so that the process gas temperature falls within the range of the probe material used.

Figure 2-1 through #unique_73/fig_ght_spm_gz provide mechanical installation references.

The ambient temperature inside the electronics housing must not exceed 85 °C (185 °F) .

Procedure

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

2. 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.

20 OCX 8800

CAUTION!

EQUIPMENT DAMAGE

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

CAUTION!

EQUIPMENT DAMAGE

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.

2.2.2 Installation

Follow the procedure below to install the OCX 8800 in a flue or stack. The OCX 8800 may be installed intact as it is received.

Install

Prerequisites

Ensure all components are available to install the OCX 8800.

Procedure

1. Weld or bolt the adapter plate (Figure 2-1) onto the duct.

Reference Manual 21

Install

Adapter Plate InstallationFigure 2-1:

E. Masonry stack wall

F. Field weld pipe to adapter plate

G. Pipe 3 inch schedule 40. Sleeve length optional.

H. Bolt adapter plate to outside wall surface. Joint must be air-tight.

I. Metal stack or duct wall

J. Weld or bold adapter plate to metal wall. Joint must be air-tight.

Note

Dimensions are in inches with millimeters in parentheses. Only adapter plate is furnished by Emerson.

Adapter Plate Kit Mounting DimensionsTable 2-1:

Type part number

ANSI (P/N 4512C34G01)

DIN (P/N 4512C36G01)

(1) Part numbers for adapter plates include attaching hardware.

(1)

Plate size A Sutd size B Bolt circle dia. C

6.00 (152) 5/8 - 11 UNC - 2A 4.75 (121)

7.50 (191) M - 16 x 2.0 - 6g 5.71 (145)

2. 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 possiblity that moisture will damage the electronics (Figure 2-2).

22 OCX 8800

Install

Drip loopsFigure 2-2:

A. Duct wall

3. 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.

Reference Manual 23

Install

Note

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

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

CAUTION!

EQUIPMENT DAMAGE

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

5. If insulation is removed to access the ducts for the OCX8800 mounting, make sure to replace the insulation afterwards.

24 OCX 8800

Install

Installation, OCX 8800 with Integral ElectronicsFigure 2-3:

A. Insertion depth B. Removal envelope C.

ANSI 3535B18H02

DIN 3535B45H01

Flange dia. 6.00 (152) 7.28 (185)

Hold dia. 0.75 (19) 0.71 (18)

4 holes equally spaced on B.C. dia.

E. B.C. dia. F. Flange dia.

*4.0 (101.6) with high surface stainless steel filter

*7.3 (186.4) with stainless steel or Hastelloy filter

Note

All dimensions are in inches with millimeters in parentheses.

0.06 in. Thick GasketTable 2-2:

Mounting FlangeTable 2-3:

ANSI DIN

4.75 (121) 5.71 (145)

Reference Manual 25

Install

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

2.3 Electrical installation

All wiring must conform to local and national codes.

For reference, factory wired solenoid power connections are shown in Figure 2-4.

26 OCX 8800

Install

Line Voltage, Earth, and 4 - 20 mA ConnectionsFigure 2-4:

A. Terminal block B. External tooth lockwasher C. Customer wiring D. Ground stud

WARNING!

ELECTRIC SHOCK Disconnect and lock out power before connecting the power supply. Failure to lock out power could result in serious injury or death.

Reference Manual 27

Install

WARNING!

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

WARNING!

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

WARNING!

EXPLOSION 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.

WARNING!

EXPLOSION 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 195 °C (383 °F).

WARNING!

EXPLOSION To maintain explosion-proof protection of the OCX88C in hazardous areas, the sample entering the sensor housing must not exceed 195 °C (383 °F).

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 105 °C (221 °F).

28 OCX 8800

2.3.1 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 you. 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.

2.3.2 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 termal block in the electronics housing. Connect the ground (G wire) to the ground stud in the electronics housing shown in Figure 2-4.

2.3.3 Connect output signals

Install

2.3.4

2.3.5

2.3.6

The OCX 8800 may be provided with either two 4-20 mA signals with HART on the O signal or a single Foundation Fieldbus signal.

Connect the 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.

O2 4-20 mA signal

One 4-20 mA signal represents the O2 value.

Superimposed on the O2 signal is the HART information accessible through a Model 375 handheld communicator or AMS device manager softward. The O2 signal is at the AOUT 1 terminals.

COe 4-20 mA signal

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

Foundation Fieldbus signal

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

2.3.7

Reference Manual 29

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.

Install

2.3.8 Remote electronics connections to sensor housing

Make the following connections between the remote electronics and sensor housings with the electronics cable ordered with the package (Figure 2-5). Braided cable is available in lengths up to 150 ft (46 m).

Electrical connections between remote electronics and sensor housingFigure 2-5:

Note

Interconnect wiring shown is for Rosemount supplied cables. For customer furnished interconnect wiring or cables, refer to Figure 2-6.

30 OCX 8800

Install

Customer-furnished interconnect wiring or cablesFigure 2-6:

A. Heat shrink tubing, 2 ft long, 1/2 in. size B. 3/4 NPT hub size, liquid-tight strain relief connector C. Heat shrink tubing, 2 ft long, 1/2 in. size D. Ferrule, uninsulated E. 8 twisted pairs 24 AWG, stranded, insulated, tinned copper conductors, 200 °C (392 °F), 300 volts,

with overall braid of 34 AWG tinned copper, 90% coverage and 24 AWG tinned copper, uninsulated drain wire

F. See Note. G. See Note. H. 7.0 ft long Teflon tubing, 0.042 in. ID (Cut off drain wire at probe end of shield.) I. Stud size #10 J. Strip wire ends 3/16 in. typical

Reference Manual 31

Install

K. Heat shrink tubing 2 ft long, 1/2 in. size L. 3/4 NPT hub size, liquid-tight strain relief connectors M. Heat shrink tubing 2 ft long, 1/2 in. size N. Ferrule, uninsulated O. Stud size #6 P. Green, 16 AWG Q. 8 conductors, 16 AWG, stranded, 200 °C (392 °F), 600 volts braided shield - tinned copper, 90%

coverage with 18 AWG tinned copper, uninsulated, drain wire

R. 4.25 ft long Teflon tubing 0.042 in. ID (Cut off drain wire at probe end of shield). S. Stud size #10 T. Strip wire ends 3/16 in. typical

Note

For RFI/CE compliance, the connector must provide 360 degrees of electrical contact to the cable shield.

2.3.9 Signal connections

Connect the electronics housing terminals to the corresponding terminals in the sensor housing.

The twisted wire pairs are numbered on the inner plastic wrapper. Keep twisted pairs together and match the numbers and wire colors shown in Figure 2-5.

2.3.10

2.4

Heater power connections

Use the blue, white, orange, black, red, and yellow stranded wires in the heater power cable to connect power to the three heaters in the sensor housing.

Match the wire colors to the corresponding heater power terminal blocks in the sensor and electronics housings as shown in Figure 2-5.

Pneumatic installation

2.4.1 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 2-7. Connect the reference air set (regulator/filter and pressure gauge) to the instrument air inlet on the electronics housing and to the inlet side of the dilution air flow meter.

32 OCX 8800

Install

Figure 2-7:

Pneumatic Installation, OCX with Reference Air Set (without Autocalibration)

A. Flowmeter B. Combination filter - reg. C. 2 in. pressure gauge D. Flowmeter

Mounting FlangeTable 2-4:

A Flowmeter 1-10 scfh 771B635H01

B Combination filter-

reg.

C 2 in. pressure gauge 0-60 psig 275431-03

D Flowmeter 0.05 - 0.5 scfh 771b635H08

0-60 psig 1A994422H01

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

Reference Manual 33

Install

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

CAUTION!

FAULTY READINGS

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

0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

4. Use one CO gas and two O2 gases to calibrate the OCX 8800.

• CO - 1000 ppm or up to 4%, balance air

• O2 low gas - 0.4%, balance N

• O2 high gas - 8%, balance N

5. 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.

2.4.2 Reference air set and solenoids option without COe zero function

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.

34 OCX 8800

Install

Figure 2-8:

Pneumatic installation, OCX with Reference Air Set, Solenoids, and Autocalibration without COe Zero Function

A. Flowmeter B. Flowmeter C. Combination filter - reg. D. 2 in. pressure gauge

Replacement PartsTable 2-5:

A Flowmeter 1-10 scfh 771B635H01

B Flowmeter 0.05 - 0.5 scfh 771B635H08

C Combination filter-reg. 0-60 psig 1A99422H01

Reference Manual 35

Install

Replacement Parts (continued)Table 2-5:

D 2 in. pressure gauge 0-60 psig 275431-03

Procedure

1. Install the reference air set according to the instructions in Section 2.4.1, steps 1

through 3.

2. Refer to Figure 2-8. Connect the O2 low gas source to the CAL GAS LO O2 inlet fitting

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

3. Connect the O2 high gas source to the CAL GAS Hi O2 inlet fitting. Install a shutoff

valve and pressure regulator with gauge in the O2 high supply line.

4. Connect the CO high gas to the CAL GAS HI COe inlet fitting. Install a shutoff valve

and pressure regulator with gauge 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.

2.4.3 Reference air set and solenoids option with COe zero function

Figure 2-9 shows the piping arrangement for the OCX 8800 with autocalibration when the

COe zero function is used. The arrangement is similar to Figure 2-7 except instrument air is used as the Hi O2 test gas. Refer to Section for details of this function.

36 OCX 8800

Install

Figure 2-9:

Pneumatic installation, OCX with reference air set, solenoids, and autocalibration with COe zero function

A. Flowmeter B. Flowmeter C. Combination filter - reg D. 2 in. pressure gauge

Replacement PartsTable 2-6:

A Flowmeter 0.05 - 0.5 scfh 7718635H08

Reference Manual 37

Install

Replacement Parts (continued)Table 2-6:

B Flowmeter 1-10 scfh 7718635H01

C Combination filter - reg 0-60 psig 1A99422H01

D 2 in. pressure gauge 0-60 psig 275431-03

Note

If instrument is to be used as the high O2 calibration gas, the low O2 and COe calibration gases must also be set to the same pressure (e.g., 45 psig)

2.4.4 Reference air set, solenoids, and blowback option with COe zero function

Figure 2-11 shows the piping arrangement for the Hazardous Area OCX 8800 with the

blowback and autocalibration options when the COe zero function isused. The arrangement is similar to Figure 2-10 except instrument air is used as the Hi O2 test gas. Refer to Chapter 3 for details of the function.

38 OCX 8800

Install

Figure 2-10:

Pneumatic installation, OCX with reference air set, solenoids, blowback, and autocalibration without COe zero function

A. Flowmeter B. Check valve C. Flowmeter D. Combination filter-reg E. Combination filter-reg F. 2 in. pressure gauge G. Blowback valve, air operated H. Pneumatic actuator

Replacement PartsTable 2-7:

A Flowmeter 1-10 scfh 771B635H01

B Check valve 5 psig 7309A62H01

C Flowmeter 0.05 - 0.5 scfh 771B635H08

D Combination filter-reg 0-60 psig 1A99422H01

Reference Manual 39

Install

Replacement Parts (continued)Table 2-7:

E Combination filter-reg 0-60 psig 4505C21G11

F 2 in. pressure gauge 0-60 psig 275431-03

H Pneumatic actuator 7309A62H01

CAUTION!

EQUIPMENT MALFUNCTION

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

Note

During blowback operation, states of both solenoid valves change.

Note

Wall mount the air-operated blowback valve on a suitable mounting panel.

Note

Actuating air pressure at blowback valve inlet port must be at least 51 psig to fully actuate the valve.

40 OCX 8800

Install

Figure 2-11:

Pneumatic Installation, OCX with Reference Air Set, Solenoid, Blowback, and Autocalibration with CO3 Zero Function

A. Flowmeter B. Check valve C. Flowmeter D. Pneumatic actuator E. 2 in. pressure gauge F. Combination filter-reg G. Combination filter-reg

Replacement PartsTable 2-8:

A Flowmeter 1-10 scfh 771B635H01

B Check valve 5 psig 7309A62H01

C Flowmeter 0.05-0.5 scfh 771B635H08

D Pneumatic actuator 1A99339H03

E 2 in. pressure gauge 0-60 psig 275431-03

Reference Manual 41

Install

Replacement Parts (continued)Table 2-8:

F Combination filter/reg 0-60 psig 4505C21G11

G Combination filter/reg 0-60 psig 1A99422H01

Note

During blowback option, states of both solenoid valves change.

Note

Wall mount the air-operated blowback valve on a suitable mounting plate.

Note

Actuating air pressure at blowback valve inlet port must be at least 51 psig to fully actuate the valve.

Note

If instrument is to be used as the high O2 calibration gas, the low O2 and COe calibration must also be set to the same pressure (i.e., 55 psig).

2.5 Initial startup

Observe the following Caution and Note. Refer to information.

CAUTION!

EQUIPMENT DAMAGE

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.

Chapter 3 for OCX 8800 startup

42 OCX 8800

3 Configuration and startup

3.1 Verify installation

Ensure that the transmitter is installed correctly. Verify mechanical installation and all electrical and pneumatic connections.

Refer to Chapter 2.

CAUTION!

EQUIPMENT DAMAGE

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

Note

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

Configuration and startup

3.1.1 Verify configuration - HART electronics

There are three switches on the microprocessor board which are user configurable for the Rosemount OCX 8800 with HART electronics (Figure 3-1). SW1 determines if the O2 4-20 mA signal is internally or externally powered. SW2 determines if the COe 4-20 mA signal is internally or externally powered. SW3 sets the rail limits for the O2 and COe 4-20 mA signals and configures the sample line heater control circuit. All switches are accessible through holes in the electronics box.

CAUTION!

EQUIPMENT DAMAGE

Remove power from the transmitter 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 installation.

Reference Manual 43

Configuration and startup

Rosemount OCX 8800 Defaults - HART ElectronicsFigure 3-1:

Switch default positions shown.

O2 21.1 mA/3.5 mA: O2 4-20 mA signal

Rail limits:

Open High - 21.1 mA

Closed Low - 3.5 mA

COe 21.1 mA/3.5 mA: COe 4-20 mA signal

Rail limits:

Open High - 21.1 mA

Closed Low - 3.5 mA

SW1: The two settings are internally or externally powering the O2 4-20 mA signal. The

factory setting is for the O2 4-20 mA signal to be internally powered.

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

SW3: The factory sets this switch as follows:

44 OCX 8800

• Position 1 determines the O2 4-20 mA signal rail limit. The settings are high,

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

• Position 2 determines the COe 4-20 mA signal rail limit. The settings are high,

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

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

heaters.

3.1.2 Verify configuration - Fieldbus electronics

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

CAUTION!

EQUIPMENT DAMAGE

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

Configuration and startup

OCX 8800 defaults - Fieldbus electronicsFigure 3-2:

Switch default positions shown.

Reference Manual 45

Configuration and startup

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

SW3: The factory sets this switch as follows:

• Position 1 not used.

• Position 2 not used.

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

3.2 Initial power up

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

Normal operating temperature for the O2 cell is 736 °C (1357 °F) . Normal operating temperature for the combustibles cell is 300 °C (573 °F). The normal sample line temperature is 170 °C (443 °F). During this time, the eductor air solenoid remains closed so no sample is pulled through the analyzer. When the transmitter reaches operating temperatures, the solenoid energizes, eductor air begins to flow, and the unit begins normal operation.

3.3 Set test gas values

Use Field Communicator or the optional LOI to set test gas values for calibration. Refer to

Section or Section 3.3.2 for more information.

3.3.1

Setting test gas values with the Field Communicator

Complete the following steps to set test gas values with the Field Communicator.

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

2. From the DETAILED SETUP menu, select CAL SETUP.

3. From the CAL SETUP menu, select O2 CAL PARAMS or COe CAL PARAMS.

4. From the DETAILED SETUP menu, select O2 CAL PARAMS.

5. From O2 CAL PARAMS, select O2 HIGH GAS. Enter the percent O2 used for the high

O2 test gas.

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

test gas.

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

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

for COe test gas.

3.3.2

46 OCX 8800

Setting test gas values with Fieldbus communicator

Complete the following steps to set test gas values with Fieldbus communicator.

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

2. From the TRANSDUCER menu, select O2 CAL.

3. From O2 CAL, select O2 CAL SETUP.

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

gas.

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

gas.

6. From the TRANSDUCER menu, select COe CAL SETUP.

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

the COe test gas.

3.3.3 Setting test gas values with the LOI

Complete the following steps to set 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.

Configuration and startup

3.4

3.4.1

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

test gas.

4. Press Down to go to the next selection, O2 Low Gas %. Enter the percent O2 used for

the low O2 test gas.

5. Press Down several times to display COe Test Gas. Enter the CO concentration (ppm)

used for COe test gas.

Calibration solenoids

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

A transmitter shipped from the factory with calibration solenoids must be configured before autocalibration can be implemented. The same process must be performed any time a replacement card stack is installed.

Configuring the calibration solenoids with the Field Communicator - HART

Complete the following steps to configure the calibration solenoids with the Field Communicator for the HART communication protocol.

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

2. From the DETAILED SETUP menu, select CAL SETUP.

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

Reference Manual 47

Configuration and startup

4. From the O2 CAL PARAMS/COe CAL PARAMS menu, select Solenoids. Select Yes to

enable the solenoids.

3.4.2 Configuring the calibration solenoids with the Field Communicator - Fieldbus

Complete the following steps to configure the calibration solenoids with the Field Communicator using the Foundation Fieldbus communication protocol.

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

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

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

4. From the O2 CAL PARAM/COe CAL SETUP menu, select Solenoids. Select Present to

enable the solenoids.

3.4.3 Configuring the calibration solenoids with the LOI

Complete the following steps to configure the calibration solenoids with the LOI.

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

2. From the SYSTEM menu, select Calib Setup.

3.5

3.5.1

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

Blowback feature

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

The blowback feature requires the optional blowback hardware to be properly installed external to the transmitter. See Section for details.

A transmitter shipped from the factory must be configured before blowback can be implemented. The same process must be performed any time a replacement card stack is installed.

Configuring blowback with the Field Communicator HART

Complete the following steps to configure blowback with the Field Communicator using the HART communication protocol.

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

2. From the DETAILED SETUP menu, select INPUT/OUTPUT.

48 OCX 8800

Configuration and startup

3. From the INPUT/OUTPUT menu, select BLOWBACK.

4. From the BLOWBACK menu, select BlBk Enabled. Select Yes to enable blowback. Also

set the following parameters:

• BlBk Intrvl: Length of time between blowback events (60 minutes

recommended).

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

• BlBk Purge Time: Length of time after blowback is complete before oxygen/

combustibles readings are considered valid (set as required by application).

5. Manually initiate blowback from DIAG/SERVICE. Select BLOWBACK.

3.5.2 Configuring blowback with the Field Communicator Fieldbus

Complete the following steps to configure blowback with the Field Communicator using the Foundation Fieldbus communication protocol.

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

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

3.5.3

3. From the Alarm Relay/Blowback menu, select Blowback.

4. From the Blowback menu, select Blowback Enabled. Also set the following parameters:

• Blowback Interval: Length of time between blowback events (60 minutes

recommended).

• Blowback Period: Length of time blowback is activated (5 seconds

recommended).

• Blowback Purge Time: Length of time after blowback is complete before oxygen/

combustibles readings are considered valid (set as required by the application).

• Initiate Blowback: Intiates a blowback event manually.

Configuring blowback with the LOI

Complete the following steps to configure blowback with the LOI.

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

2. From the SYSTEM menu, select Blow Back.

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

• Blow Bk Intrvl: Length of time between blowback events. Range is 0 to 32,000

minutes. Default is 60 minutes. 60 minutes is recommended.

• Blow Bk Period: Length of time blowback is activated. Range is 1 to 5 seconds.

Default is 2 seconds. 5 seconds is recommended.

• Blow Bk Purge: Length of time after blowback is complete before oxygen/

combustibles readings are considered valid. Range is 0 to 500 seconds. Default is 88 seconds. Set as required by application.

Reference Manual 49

Configuration and startup

• Force Blow Bk: Initiates a blow back event manually.

3.6 Calibration verify feature

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

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

WARNING!

During the calibration verify function, the analog output signals track the oxygen and combustibles readings. To avoid a potentially dangerous operating condition, remove the transmitter from the automatic combustion control loop before performing the calibration verify procedure.

3.6.1 Performing a calibration verify with the Field Communicator - HART

Complete the following steps to perform a calibration verify with the Field Communicator using the HART communication protocol.

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

2. From the DEVICE SETUP menu, select DIAG/SERVICE.

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

4. From the CALIBRATION menu, select CAL VERIFY. Select Verify Calibration. From this

menu, select the functions as follows:

• Flow High O2 Gas: Flows the high O2 test gas for the time specified in the

calibration setup.

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

calibration setup.

• Flow High COe Gas: Flows the COe test gas for the time specified in the

calibration setup.

• Purge Gas: Initiates a delay for the specified purge time before oxygen/

combustibles readings are considered valid.

Note

A purge automatically follows a gas flow.

50 OCX 8800

3.6.2 Performing a calibration verify with the Field Communicator - Fieldbus

Complete the following steps to perform a calibration verify with the Field Communicator using the Foundation Fieldbus communication protocol.

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

2. From the TRANSDUCER block menu, select METHODS.

3. Set the Mode to OOS (out of service) before starting the calibration verify process.

4. From the METHODS menu, select OCX Cal Verify. From this menu, select the functions

as follows:

• Flow High O2 Gas: Flows the high O2 test gas for the time specified in the

calibration setup.

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

calibration setup.

• Flow High COe Gas: Flows the COe test gas for the time specified in the

calibration setup.

• Purge gas: Intiates a delay for the specified purge time before oxygen/

combustibles readings are considered valid.

Configuration and startup

3.6.3

Note

A purge automatically follows a gas flow.

Performing a calibration verify with the LOI

Complete the following steps to perform a calibration verify with the LOI.

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

2. From the CALIBRATION menu, select Cal Verify.

3. From the Cal Verify menu, select the functions as follows:

• Flow High Gas: Flows the high O2 test gas for the time specified in the calibration

setup.

• Flow Low Gas: Flows the low O2 test gas for the time specified in the calibration

setup.

• Flow COe Gas: Flows the COe gas for the time specified in the calibration setup.

• Purge: Intitiates a delay for the specified purge time before oxygen/combustibles

readings are considered valid.

Note

A purge automatically follows a gas flow.

Reference Manual 51

Configuration and startup

3.7 Calibration tolerance feature

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

A transmitter shipped from the factory must be configured before the calibration tolerance feature can be implemented. The same process must be performed any time a replacement card stack is installed.

3.7.1 Configuring the calibration tolerance feature with the Field Communicator -HART

Complete the following steps to configure the calibration tolerance with the Field Communicator using the HART communication protocol.

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

2. From the DETAILED SETUP menu, select CAL SETUP.

3.7.2

3. From the CAL SETUP menu, select O2 CAL PARAMS.

4. To enable the calibration tolerance feature for the oxygen calibration, from the O2

CAL PARAMS menu, select O2 Tol Check. Select On to enable the calibration tolerance feature.

5. Go back to the CAL SETUP menu and select COe CAL PARAMS.

6. To enable the calibration tolerance for the combustibles calibration, from the COe

CAL PARAMS menu, select COe Tol Check. Select On to enable the calibration tolerance feature.

Configuring the calibration tolerance feature with the Field Communicator - Fieldbus

Complete the following steps to configure the calibration tolerance feature with the Field Communicator using the Foundation Fieldbus communication protocol.

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

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

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

4. From the O2 CAL SETUP/COE CAL SETUP menu, select O2 Tolerance Check/COe Tolerance

Check. Select Yes to enable the calibration tolerance feature.

52 OCX 8800

Configuration and startup

3.7.3 Configuring the calibration tolerance feature with the LOI

Complete the following steps to configure the calibration tolerance feature with the LOI.

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

2. From the SYSTEM menu, select Calib Setup.

3. From the Calib Setup menu, select the following:

• O2 Tol Check: Select Yes to enable the calibration tolerance feature for the

oxygen calibration.

• Comb Tol Check: Select Yes to enable the calibration tolerance feature for the

combustibles calibration.

3.8 COe purge / zero feature

This feature provides a way to periodically flood the COe sensor with air to perform two functions:

1. Provide additional oxygen to burn off any combustible residue from the COe sensor

2. Allow for optional adjustment of the COe calibration constant.

If the transmitter is configured to update the COe calibration constant, only the constant is updated. The COe calibration slope is not affected. To update both the constant and slope, a full calibration must take place.

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

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

When the COe zero feature is used, special pneumatic connections are required. See

Section for details.

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

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

Reference Manual 53

Configuration and startup

WARNING!

During the COe zero function, the analog output signals may track the oxygen and combutibles readings if configured to do so. To avoid a potentially dangerous operating condition, the transmitter must be removed from the automatic combustion control loop before performing the COe zero function.

WARNING!

At the completion of the COe zero function, the COe analog output signal changes if the zero update parameter is set to Yes.

3.8.1 Configuring the COe zero feature with the Field Communicator - HART

Complete the following steps to configure the COe feature with the Field Communicator using the HART communication protocol.

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

2. From the DETAILED SETUP menu, select INPUT/OUTPUT.

3.8.2

3. From the INPUT/OUTPUT menu, select COe ZERO.

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

• Zero Enabled: Select Yes or No to enable or disable this feature.

• Zero Intrvl: Length of time between COe zero events. Range is 60 to 480

minutes. Default is 60 minutes.

• Zero Flow: Length of time the COe zero gas flows. Range is 120 to 600 seconds.

Default is 120 seconds.

• Zero Purge: Length of time after COe zero is complete before oxygen/

combustibles readings are considered valid. Range is 60 to 180 seconds. Default is 60 seconds. Total duration of this function is flow time plus purge time.

• Zero Tracks: Determines if the analog output signals track or hold during the

function. Valid choices ar None, Both, COe, and O2.

• Zero Update: Determines if the COe calibration constant is updated at the end of

the function. Valid choices are Yes and No. A Yes choice causes the COe calibration constant to update.

Configuring the COe zero feature with the Field Communicator - Fieldbus

Complete the following steps to configure the COe zero feature with the Field Communicator using the Foundation Fieldbus communication protocol.

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

2. From the TRANSDUCER block menu, select COe ZERO.

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

54 OCX 8800

Configuration and startup

• COe Zero Enable: Select Yes or No to enable or disable this feature.

• COe Zero Interval: Length of time between COe zero events. Range is 60 to 480

minutes. Default is 60 minutes.

• COe Zero Duration: Length of time the COe zero gas flows. Range is 120 to 600

seconds. Default is 120 seconds.

• COe Zero Purge Time: Length of time after COe zero is complete before oxygen/

combustibles readings are considered valid. Range is 60 to 180 seconds. Default is 60 seconds. Total duration of this function is flow time plus purge time.

• COe Zero Output Track: Determines if the analog output signals track or hold

during the function. Valid choices ar None, Both, COe, and O2.

• COe Zero Update: Determines if the COe calibration constant is updated at the

end of the function. Valid choices are Yes and No. A Yes choice causes the COe calibration constant to update.

3.8.3 Configuring the COe zero feature with the LOI

Complete the following steps to configure the COe zero feature with the LOI.

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

2. From the SYSTEM menu, select INPUT/OUTPUT.

3.9

3. From the INPUT/OUTPUT menu, select COe Zero. Select the functions as follows:

• COe Zero Enable: Select Yes or No to enable or disable this feature.

• COe Zero Intrvl: Length of time between COe zero events. Range is 60 to 480

minutes. Default is 60 minutes.

• COe Zero Flow: Length of time the COe zero gas flows. Range is 120 to 600

seconds. Default is 120 seconds.

• COe Zero Purge: Length of time after COe zero is complete before oxygen/

combustibles readings are considered valid. Range is 60 to 180 seconds. Default is 60 seconds. Total duration of this function is flow time plus purge time.

• COe Zero Tracks: Determines if the analog output signals track or hold during

the function. Valid choices ar None, Both, COe, and O2.

• COe Zero Update: Determines if the COe calibration constant is updated at the

end of the function. Valid choices are Yes and No. A Yes choice causes the COe calibration constant to update.

Reset procedure

Whenever you correct an equipment alarm or fault condition, the transmitter either reverts to normal operation or continues to indicate an alarm status.

If the equipment does not revert to normal operation when a fault condition is cleared, or if instructed to do so in Chapter 8, use the following procedure to reset the transmitter.

Reference Manual 55

Configuration and startup

3.9.1 Reset with the LOI

Complete the following steps to reset the transmitter with the LOI.

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

2. Select the SYSTEM submenu.

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

4. From the Status submenu, select Reset Device.

The transmitter resets, and the LOI reverts to the normal operation display.

3.9.2 Reset with Field Communicator

Remove the transmitter from the process loop and recycle power.

56 OCX 8800

4 Using the LOI

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

4.1 Display orientation

The LOI module mounts to a connector on the LOI board.

The board is installed on the end of the electronics stack in the electronics housing,

Figure 4-1. There are four mating connectors on the back of the LOI module that allow the

LOI to be oriented as desired.

LOI components mountingFigure 4-1:

Using the LOI

A. Electronics housing (cover removed) B. Electronics stack C. LOI connector D. LOI board E. LOI module

Reference Manual 57

Using the LOI

4.2 LOI controls

4.2.1 Overview

The LOI, shown in Figure 4-2, uses 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.

The transmitter also uses HART or Foundation Fieldbus communications, permitting access to all instrument functionality anywhere the digital O2 signal terminates via a Model 375 Field Communicator.

58 OCX 8800

Using the LOI

LOI assemblyFigure 4-2:

A. Touch confirmation LED B. Selection arrow C. Lockout notation D. Status code E. Selection arrows F. Display window G. Selection arrow (Enter key)

4.2.2

Reference Manual 59

LOI key functions

The gray (top left) key moves 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 leftmost position. When Enter is touched, the new parameter value, if accepted, appears 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 moves the cursor to the right when entering the digits of a new parameter value.

Using the LOI

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.

4.2.3 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 disappears. Touch Enter

once more to enter into the menu structure. Whenever a key is touched, additional time to lockout is provided, so that the lockout feature does not become a nuisance. This additional revert time is one hour (default) and is also user-configurable.

Note

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

60 OCX 8800

Using the LOI

Z pattern entryFigure 4-3:

Reference Manual 61

Using the LOI

4.2.4 LOI status codes

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.

LOI status codesTable 4-1:

Code Description

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

BL Blowback - A blowback cycle is active.

CA Calibration - A calibration cycle is active.

CV Calibration Verify - A calibration verify task is in progress.

NM Normal - The device is in a normal operating mode.

PO Power On - A system level initialization sequence is active. This continues for

several seconds.

SF 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.

ST Stabilize - The device heater control is stabilizing (after warm up). Sensors are

warming up to operating temperaturs.

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

4.3 LOI menu tree

This section consists of a menu tree for the LOI on the OCX 8800, specific to the OCX 8800.

Figure 4-4. This menu is

62 OCX 8800

Using the LOI

LOI menu treeFigure 4-4:

Reference Manual 63

Using the LOI

64 OCX 8800

Using the LOI

Reference Manual 65

Using the LOI

4.3.1 First column submenus

From the operating display (O2 % and COe ppm), the left-pointing Enter key is the only option to move into the first column submenus of the LOI menu tree.

The first column contains three submenus: SENSOR DATA, CALIBRATION, and SYSTEM. From the operating display, SENSOR DATA is displayed when the right-pointing key is selected. Use Up or Down to move to the other first column submenus.

4.3.2

66 OCX 8800

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.

4.3.3 Third and fourth column submenus

From the second column submenus, selecting the right 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 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 blinks. The up and down keys select the value for the parameter displayed.

Using the LOI

Reference Manual 67

Using the LOI

68 OCX 8800

5 Calibration

5.1 Overview

During calibration, two calibration gases with known O2 concentrations and one calibration gas with a known COe concentration are applied to the transmitter. Slope and constant values are calculated to determine if the transmitter is correctly measuring net concentration of O2 and combustibles in the industrial process.

Before calibrating the transmitter, verify that the calibration gas parameters are correct by setting the test gas values used when calibrating the unit. Refer to Chapter 3.

There are three calibration methods available to the transmitter: automatic, operatorinitiated, and manual. Calibration commands and menus can be accessed by 375 Field Communicator or by the optional LOI.

Calibration

5.2 Fully automatic calibration

IF the transmitter is equipped with calibration solenoids, the unit can be programmed to automatically calibrate without any operator action.

Refer to the following sections for using the LOI or 375 Field Communicator to set up the transmitter for automatic calibration

5.2.1

Autocalibration setup using HART

Use the following procedure to specify a time interval (in hours) at which the transmitter will automatically calibrate.

Note

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

Procedure

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 you want timed automatic calibrations, select Solenoids; then select Yes. Select No to disable the calibration solenoids.

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

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Calibration

If you want, the O2NxtCalTm and the COENxtCalTm (next calibration time) parameters can be changed to synchronize a calibration at a specific day or time.

CAUTION!

When setting automatic calibration times, set CallIntrvl and NxtCalTm so that O2 and COe are not calibrated simultaneously.

Note

To select a menu item, either use the Up and Down keys to scroll to the menu item and press the Right key or use the number keypad to select the menu item number. To return to a preceding menu, press the Left key.

5.3 Operator-initiated autocalibration

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

5.3.1 Autocalibration using HART

To initiate an autocalibration using HART/AMS, perform the following steps on the HART menu tree. Refer to Section 6.3 for the HART menu tree.

Procedure

1. Select DIAG/SERVICE from the 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.

5.4

Manual calibration

If the unit is not equipped with calibration solenoids, a an operator must calibrate following prompts from the unit. Refer to the following sections for manual calibration.

70 OCX 8800

5.4.1 Manual calibration using the optional LOI

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

Procedure

1. Use the Right key to select the CALIBRATION first column submenu.

2. From the CALIBRATION submenu, use the Right key to select the Cal Control second column submenu.

3. From the Cal Control submenu, use the Right key to select the third column Start Cal O2 option.

4. Remain at the Start Cal O2 option or use the Down key to select Start Cal COe or Start Cal Both.

The following sequence applies when Start Cal Both is selected.

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

Calibration

6. Press the Right key when the low O2 test gas is applied.

The calibration data changes as the calibration proceeds.

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

8. Press the Right key when the high O2 test gas is applied.

The calibration data changes as the calibration proceeds.

9. Press the Right key when the high O2 reading is stable. Turn off the high O2 test gas. Press the Right key to start the high O2 gas purge.

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

10. Press the Right key to start combustibles calibration. Turn on the CO test gas when prompted.

11. Press the Right key when the CO test gas is applied.

The calibration data changes as the calibration proceeds.

12. Press the Right key when the CO reading is stable.

13. Turn off the CO test gas and press the Right key to start the CO gas purge.

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

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Calibration

5.4.2 Manual O2 calibration using the Field Communicator HART

To perform a manual O2 calibration using the HART Communicator or AMS, use the following procedure. If necessary, refer to Section 6.3 for the HART menu tree.

Note

To select a menu item, either use the Up and Down keys to scroll to the menu item and press the Right key or use the number keypad to select the menu item number.

Procedure

1. Select DIAG/SERVICE from the DEVICE SETUP menu.

2. Select CALIBRATION from the DIAG/SERVICE menu.

3. Select CAL CONTROL from the CALIBRATION menu.

4. Select CAL METHODS from the CAL CONTROL menu.

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

In the first O2 Calibration screen, a Loop should be removed from automatic control warning appears.

6. Remove the transmitter from any automatic control loops to avoid a potentially

dangerous operating condition and press OK.

7. The 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

•

8. From the SELECT ACTION screen, select START/NEXT CALSTEP to continue

calibration, select ABORT CAL to abort calibration, or select EXIT CAL to exit calibration. Select one item from the list and press ENTER.

OCX: TAG NAME

•

SELECT ACTION

•

START/NEXT CALSTEP

ABORT CAL

EXIT CAL

9. When the Calibration Status is at the AppO2Low step, switch on O2 low gas. Verify

that the O2 concentration measured matches the O2 LOW GAS parameter in Setup. Press OK when ready.

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Calibration

10. Select Start/Next Cal Step to start applying the O2 low gas.

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

The Calibration Status is automatically changed to FlowO2Low and then ReadO2Low for a period of time. During this period, if you try to go the next calibration step by pressing OK and selecting Start/Next Cal Step, you are prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time.

11. When ready, Calibration Status stops at AppO2Hi. Switch off the O2 Low Gas and

switch on the O2 High Gas. Verify that the O2 concentration measured matches the O2 HIGH GAS parameter in the Setup window. Press OK when ready.

12. Select Start/Next Cal Step to start applying the O2 high gas.

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

The Calibration Status is automatically changed to FlowO2Hi and then ReadO2Hi for a period of time. During this period, if you try to go the next calibration step by

pressing OK and selecting Start/Next Cal Step, you are prompted with with Operator step command is not accepted at this time.The Next Cal Step command is not accepted at this time.

5.4.3

13. When ready, Calibration Status stops at STOP GAS. Switch off the O2 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.

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

14. When calibration is complete, select Exit Cal to exit the calibration method.

Manual COe calibration using the Field Communicator HART

To perform a manual COe calibration using the 375 Field Communicator, use the following procedure. If necessary, refer to Section 6.3 for the HART menu tree.

Note

To select a menu item, either use the Up and Down keys to scroll to the menu item and press Right or use the number keypad to select the menu item number.

Procedure

1. Select DIAG/SERVICE from the DEVICE SETUP menu.

2. Select CALIBRATION from the DIAG/SERVICE menu.

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Calibration

3. Select CAL CONTROL from the CALIBRATION menu.

4. Select CAL METHODS from the CAL CONTROLPERFORM CAL menu.

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

In the first Calibration screen, a Loop should be removed from automatic control warning appears.

6. Remove the transmitter from any automatic control loops to avoid a potentially

dangerous operating condition and press OK.

The main Calibration screen should look like the following.

OCX: TAG NAME

•

Step: Idle

•

TIME REMAIN: 0s

•

COe: 00.20 ppm, 0.00 mV

•

COe DELTA R: 0.00 ohm

•

OK/NEXT to Select

•

ABORT/CANCEL to Exit

•

7. Press OK to continue.

8. From the SELECT ACTION screen, select START/STEP CAL to continue calibration,

ABORT CAL to abort calibration, or EXIT CAL to exit calibration. Select one item from the list and press ENTER.

OCX: TAG NAME

•

SELECT ACTION

•

START/STEP CAL

ABORT CAL

EXIT CAL

The unit samples O2 high gas as the COe low gas. The Calibration Status automatically changes to ReadCOLow for a period of time. During this period, if you

try to go to the next calibration step by pressing OK and selecting START CAL/STEP

CAL, you are 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 stops at AppCOEHi. Switch on the COe high gas.

Verify that the COe concentration measured matches the COe HIGH GAS parameter in the Setup window. Press OK when ready.

10. Select START CAL/STEP CAL to start applying the COe high gas.

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

74 OCX 8800

The Calibration Status is automatically changed to FlowCOeHi and then ReadCOeHi for a period of time. During this period, if you try to go the next calibration step by pressing OK and selecting START CAL/STEP CAL, you are prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time.

11. When ready, Calibration Status stops at STOP GAS. Switch off the COe high gas.

Press OK when ready. Select START CAL/STEP CAL to start purging gas.

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

12. When calibration is complete, select Exit Cal to exit the calibration method.

5.4.4 Manual O2 and COe calibration using the Field Communicator - Fieldbus

Calibration

To perform a manual O2/COe calibration, using the 375 Field Communicator, use the following procedure. If necessary, refer to Section for the Fieldbus menu tree.

Note

To select a menu item, either use Up and Down to scroll to the menu item and pressRight or use the number keypad to select the menu item number. To return to a preceding menu, press the left arrow key.

Procedure

1. To calibrate from Fieldbus, the first step is to set the Transducer Block to Out of

Service mode (OOS). To set the OOS mode, select Transducer, then select Process followed by Out of Service in the Target Mode.

2. From the Transducer screen, select Methods.

3. Select OCX Calibration from the Methods menu.

4. From the OCX Calibration screen, select Calibrate O2 Sensor for O2 calibration, Calibrate

Combustibles Sensor for COe calibration, or Calibrate Both Sensors if you want to calibrate both sensors.

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

control warning appears. Remove the device from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

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

screen, select Update Display to refresh the calibration status, Next Calibration Step to continue calibration, Abort Calibration to abort calibration, or Exit to exit calibration. Select one item from the list and press OK.

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Calibration

The Select Action screen is static, and data is not automatically refreshed.

Calibration Step = Idle

•

Step Time Remaining = 0 seconds

•

O2 Value = 0.40%

•

Combustibles Value = 1000 ppm

•

Update Display

Next Calibration Step

Abort Calibration/Exit

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

The Calibration screen should automatically refresh; however, it may take a while for the data to refresh.

Calibration Step = Apply O2 Low Gas

•

Step Time Remaining = 0 seconds

•

O2 Value = 0.40%

•

Combustibles Value = 1000 ppm

•

Press Next to make a selection.

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

Gas step, switch on O2 low gas/COe low gas. Verify that the O2 concentration measured matches the O2 Low Gas parameter in the setup. The unit samples

reference air as the COe Low Gas. Press OK when ready.

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

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

The calibration step changes to Flow O2 Low Gas/Flow Comb Low Gas and then Read O2 Low Gas/Read Comb Low Gas for a period of time.

10. When ready, the calibration step stops at Apply O2 High Gas/Apply Comb

High Gas. Switch off the O2 low gas/sample reference air and switch on the O

high gas/comb test gas. Verify that the O2/COe concentration measured matches the O2 High Gas/COe Test Gas parameter in the setup. Press OK when ready.

11. Select Next Calibration Step to start applying the test gas.

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

The calibration step changes to Flow O2 High Gas/Flow Comb High Gas and then Read O2 High Gas/Read Comb High Gas for a period of time.

12. Skip over to Step 15, Stop Gas, if executing Calibrate O2 Sensor or Calibrate

Combustibles Sensor.

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Calibration

13. The calibration step changes to Read Comb Low Gas for a period of time. When

ready, the Calibration step stops at Apply Comb High Gas. Switch off the O high gas and switch on the COe test gas. Verify the COe concentration measured

matches the COe test gas parameter in the setup.

14. Select Next Calibration Step to start applying the test gas.

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

The calibration step changes to Flow Comb High Gas and then Read Comb High Gas for a period of time.

15. When ready, the Calibration step stops at Stop Gas. Switch off the O2 high

gas/COe test gas. Press OK when ready. Select Next Calibration Step to start purging gas.

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

When the Purge step is complete, the Calibration step is at Idle. The Calibration Failed alarm is set if the calibration has failed.

16. When calibration is complete, select Exit to exit the calibration method.

5.5 D/A trim procedures - LOI

5.5.1 O2 D/A trim procedure using the LOI

Use the following procedure to perform the O2 D/A trim procedure at the LOI. Refer to the LOI menu tree in Figure 4-4.

WARNING!

To avoid a potentially dangerous operating condition, remove the transmitter from the automatic combustion control loop before you start the D/A trim procedure.

Procedure

1. From the operating display, use Left to select the first column submenu. Use Down

to select SYSTEM.

2. From the SYSTEM menu, use Down to select Input/Output. Use Right to select

theAnalog parameters list.

3. Scroll down to the item, Trim O2 Out. Touch Right to start the O2 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.

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Calibration

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

the O2 D/A converter circuit. Connect the positive lead to the AOUT1+ terminal and connect the negative lead to the AOUT1- terminal. Then touch Enter on the LOI.

The LOI displays 4 mA...Meter. The trim program inputs the design equivalent signal for a 4.00 mA output.

6. Read the O2 milliamp output at the digital multimeter. Use Right to select each digit

and use Up and Down to change the value. When the correct value is displayed, use Enter to input the value.

The LOI displays a 20 mA...Meter. The trim program inputs the designequivalent signal for a 20.00 mA output.

7. Read the O2 milliamp output at the digital multimeter. Use Right to select each digit

and use Up and Down to change the value. When the correct value is displayed, use Enter to input the value.

The LOI displays a Meter at 4 mA prompt.

8. Use Right to select yes or no. Use Up and Down to change the selection. Then use

Enter to input the response. If no, the process repeats from step 7.

5.5.2

The LOI displays a Meter at 20 mA prompt.

9. Use Right to select yes or no. Use Up and Down to change the selection. Then use

Enter to input the response. If no, the process repeats from step 8.

When the responses in steps 8 and 9 are yes, the trim procedure is complete.

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

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.

WARNING!

To avoid a potentially dangerous operating condition, remove the transmitter from the automatic combustion control loop before you start the D/A trim procedure.

Procedure

1. From the operating display, use the Left to select the first column submenu. Use

Down to select SYSTEM.

2. From the SYSTEM menu, use Down to select Input/Output. Use Right to select the

Analog parameters list.

3. Scroll down to the item, Trim COe Out. Touch Right to start the COe trim procedure.

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Calibration

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 2-2. 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 AOUT2- terminal. Then touch Enter on the LOI.

The LOI displays 4 mA...Meter. The trim program inputs the design equivalent signal for a 4.00 mA output.

6. Read the COe milliamp output at the digital multimeter. Use Right to select each

digit and use Up and Down to change the value. When the correct value is displayed, use Enter to input the value.

The LOI displays 20 mA...Meter. The trim program inputs the design-equivalent signal for a 20.00 mA output.

7. Read the O2 milliamp output at the digital multimeter. Use Right to select each digit

and use Up and Down to change the value. When the correct value is displayed, use Enter to input the value.

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

8. Use Right to select yes or no. Use Up or Down to change the selection. Then use Enter

key to input the response. If no, the process repeats from step 7.

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

9. Use Right to select yes or no. Use Up or Down to change the selection. Then use Enter

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

When the responses in steps 8 and 9 are yes, the trim procedure is complete.

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

5.6

D/A trim procedures - HART

5.6.1 O2 D/A trim procedure using HART

Use the following procedure to perform the O2 D/A trim procedure using the Field Communicator. If necessary, refer to Section 6.3 for the HART menu tree.

Note

To select a menu item, either use Up and Down to scroll to the menu item and press Right or use the number keypad to select the menu item number. To return to a preceding menu, press Left.

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Calibration

Procedure

1. Prom the DIAG/SERVICE menu, select D/A TRIM. Select O2 D/A TRIM.

2. Press Right to start the procedure.

If you wish to exit D/A Trim with no changes, select ABORT.

The Field Communicator displays WARNING: Loop should be removed from automatic control.

3. Remove the transmitter from any automatic control loops to avoid a potentially

dangerous operating condition and press OK.

The Field Communicator displays Connect reference meter to O2 output.

4. Remove the electronics housing cover.

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

the O2 D/A converter circuit. Connect the positive lead to the AOUT1+ terminal and connect the negative lead to the AOUT1- terminal. Then press OK on the Field Communicator.

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

6. Press OK. Read the O2 milliamp output at the digital multimeter. Enter the reading

in the Field Communicator and press ENTER.

Select ABORT to exit without changes.

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

7. Press OK. Read the O2 milliamp output at the digital multimeter. Enter the reading

at the Field Communicator and press ENTER.

Select ABORT to exit without changes.

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

8. Press OK.

The Field Communicator displays Fld dev output 4.00 mA equal to

reference meter?

9. Using Up or Down, select 1 Yes or 2 No. Press ENTER.

If No, the process repeats from step 5.

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

10. Press OK.

The Field Communicator displays Fld output 20.00 mA equal to

reference meter?

80 OCX 8800

11. Using Up or Down, select 1 Yes or 2 No. Press ENTER.

If No, the process repeats from step 5.

The Field Communicator displays NOTE: Loop may be returned to automatic control.

5.6.2 COe D/A trim procedure using HART

Use the following procedure to perform the COe D/A trim procedure using the Field Communicator. If necessary, refer to Figure 6-3 for the HART menu tree.

Note

To select a menu item, either use Up and Down to scroll to the menu item and press Right or use the number keypad to select the menu item number. To return to a preceding menu, press Left.

Procedure

1. Prom the DIAG/SERVICE menu, select D/A TRIM. Press Up or Down to select COe D/A

TRIM.

Calibration

2. PressRight to start the procedure.

If you wish to exit D/A Trim with no changes, select ABORT.

The Field Communicator displays WARNING: Loop should be removed from automatic control.

3. Remove the transmitter from any automatic control loops to avoid a potentially

dangerous operating condition and press OK.

The Field Communicator displays Connect reference meter to Combustibles output.

4. Remove the electronics housing cover.

5. Refer to Figure 2-2. 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 AOUT2- terminal. Then press OK on the HART Communicator.

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

6. Press OK. Read the COe milliamp output at the digital multimeter. Enter the reading

in the Field Communicator and press ENTER.

Select ABORT to exit without changes.

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

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Calibration

7. Press OK. Read the COe milliamp output at the digital multimeter. Enter the reading

at the Field Communicator and press ENTER.

Select ABORT to exit without changes.

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

8. Press OK.

The Field Communicator displays Fld dev output 4.00 mA equal to

reference meter?

9. Using Up or Down, select 1 Yes or 2 No. Press ENTER.

If No, the process repeats from step 5.

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

10. Press OK.

The Field Communicator displays Fld output 20.00 mA equal to

reference meter?

11. Using Up or Down, select 1 Yes or 2 No. Press ENTER.

If No, the process repeats from step 5.

The Field Communicator displays NOTE: Loop may be returned to automatic control.

82 OCX 8800

6 Field Communicator

6.1 Overview

The 375 Field Communicator is a communication interface device. It supports HART and Fieldbus devices, letting you configure and troubleshoot in the field.

The 375 Field Communicator includes an LCD with touch-screen display and keypad. Use the touch-screen or keypad to enter data into the 375 Field Communicator.

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

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

Field Communicator

Refer to the 375 Field Communicator User Manual for details.

6.2

Field Communicator connections

6.2.1 Connecting to a HART loop

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

WARNING!

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

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Field Communicator

375 Communicator connections - HARTFigure 6-1:

6.2.2

A. Loop connectors B. Field Communicator Model 375 C. Lead set

Connecting to a Fieldbus segment

Connect the 375 Field Communicator with the supplied lead set in parallel with the device to a Fieldbus segment, Figure 6-2. The 375 Field Commuicator Fieldbus connections are polarity sensitive; an error message displays if the device is connected incorrectly.

84 OCX 8800

Field Communicator

WARNING!

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

375 Communicator connections - FieldbusFigure 6-2:

A. Terminal connectors B. Terminal block C. Terminals D. Field communicator Model 375 E. Lead set

Note

Devices shown are not to scale.

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Field Communicator

6.3 HART menu tree

This section provides a menu tree for the Field Communicator. This menu is specific to OCX 8800 applications.

86 OCX 8800

Field Communicator

HART menu treeFigure 6-3:

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Field Communicator

88 OCX 8800

Field Communicator

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Field Communicator

6.4 Fieldbus menu tree

This section consists of a menu for the Field Communicator using the Fieldbus protocol. This menu is specific to the Hazardous Area OCX 8800 applications. Refer to the Fieldbus parameter descriptions for the applicable range, units, and description for the Fieldbus menu parameters.

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Rosemount OCX 8800 O2 / Combustibles Transmitter Hazardous Area with Integral Electronics-Rev 1.3 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual