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

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Reference Manual

00809-0400-4881, Rev AA

July 2018

Rosemount

OCX 8800

Oxygen and Combustibles Transmitter

Hazardous Location Transmitter with Remote Electronics

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

TOC-2

Table of Contents

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

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

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

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

SECTION 1 Description and Specifications

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

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

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

SECTION 2 Installation

Mechanical

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

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

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

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

SECTION 3 Configuration and Startup

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

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

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

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

SECTION 4 Using HART Communications

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

Field Communicator Signal Connections .................................................. 4-1

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

HART Menu Tree .......................................................................................... 4-5

D/A Trim Procedures .................................................................................... 4-9

SECTION 5 Calibration

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

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

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

Manual Calibration ........................................................................................ 5-3

SECTION 6 Maintenance and Service

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

OCX 8800 Removal

and Installation .............................................................................................. 6-1

OCX with

Remote Electronics ................................................................................. 6-2

Repair Sensor Housing ................................................................................ 6-8

Sensor Housing Disassembly ............................................................... 6-8

Sensor Housing Assembly .................................................................. 6-18

Repair Electronics Housing ...................................................................... 6-28

Electronics Housing Disassembly ..................................................... 6-28

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OCX 8800

Electronics Housing Assembly ........................................................... 6-30

Replace Tube Fittings ................................................................................6-34

Remove Tube Fittings ..........................................................................6-34

Install Tube Fittings ...............................................................................6-35

SECTION 7 Troubleshooting

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

Grounding ................................................................................................. 7-1

Electrical Noise ........................................................................................ 7-1

Electrostatic Discharge........................................................................... 7-1

Total Power Loss .................................................................................... 7-2

Diagnostic Alarms ......................................................................................... 7-2

Fault Isolation ................................................................................................ 7-3

Alarm Relay Events ................................ ................................ ....................7-11

SECTION 8 Replacement Parts

Sensor Housing ............................................................................................. 8-2

Electronics Housing ...................................................................................... 8-6

O2 Cell and Heater Strut Assembly ........................................................... 8-9

APPENDIX A Safety Data

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

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

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

Atex Clarification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31

APPENDIX B SPA with HART Alarm

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

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

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

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

APPENDIX C Return of Materials

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

Reference Manual

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July 2018

OCX 8800

TOC-2

ESSENTIAL INSTRUCTIONS

Rosemount OCX 8800 Oxygen and Combustibles Transmitter

READ THIS PAGE BEFORE PROCEEDING!

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

•

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

•

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

•

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

•

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

•

Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and

pressure sources.

•

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

•

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

•

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

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

If a Model 275/375 Universal HART® Communicator is used with this unit, the software within the Model 275/375 may require modification. If a software modification is required, please contact your local Emerson Service Group or National Response Center at 1-800654-7768.

Reference Manual

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OCX 8800

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

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

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

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

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

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

found throughout this publication.

NOTE

Highlights an essential operating procedure, condition, or statement.

SYMBOLS

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL : RISK OF ELECTRICAL SHOCK : WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

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

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

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OCX 8800

Section 1 Description and Specifications

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

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

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

COMPONENT CHECKLIST

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

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

SYSTEM OVERVIEW Scope

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

System Description

The OCX 8800 is designed to measure oxygen and combustible concentrations in flue gas temperatures up to 2600°F (1427°C). Electrical connections, power and communications are made through two 3/4 NPT ports in the flameproof electronics enclosure using fittings and cables provided by the customer. Cable installation must meet NEC, IEC and/or other applicable national or local codes for Class I, Zone 1, Group IIB +H2 T3/T6 permanently mounted equipment. The transmitter is close coupled to the process and requires minimal sample conditioning requirements.

Reference Manual

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July 2018

OCX 8800

1-2

MAN 4275A00

English

October 1994

HART Communicator

FISHER

-ROSEMOU NT

Figure 1-1. Typical System Package

Instruction Manual

Field Communicator Package (optional)

Adapter Plate with Mounting Hardware and Gasket

Reference Air and Calibration Set

Blowback Hardware (optional)

OCX 8800 with Remote Electronics

2 3

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OCX 8800

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

EMF = KT log10 (P1/P2) + C

Where:

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

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

T is the absolute temperature.

C is the cell constant.

K is an arithmetic constant.

NOTE

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

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

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

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

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

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

System Configuration

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

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

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

System Features

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

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

Model 275/375 Field Communicator.

AMS software for the PC.

Oxygen cell and heater/thermocouple assembly are field replaceable.

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

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An operator can calibrate and diagnostically troubleshoot the OCX 8800 using the HART Interface. Each of the OCX 8800's 4-20 mA output lines transmit an analog signal proportional to oxygen or combustible levels detected. The HART output is superimposed on the oxygen 4-20 mA output line only. This information can be accessed through the following:

•

Model 275/375 Handheld Communicator - The handheld communicator requires Device Description (DD) software specific to the OCX 8800. The DD software will be supplied with many Model 275/375 units, but can also be programmed into existing units at most Emerson service offices. Refer to Section 4, Using HART Communications, 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.

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

System Operation

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

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July 2018

OCX 8800

Low O

Test Gas

COe

Combustibles

Sensor

CPU

High O

Test Gas

Optional Test Gas Solenoids

Test Gas

Instrument Air

Solenoid

Instrument

Air

Figure 1-2. System Operation Diagram

SENSOR

HOUSING

ELECTRONICS

HOUSING

Sample

Gas

Probe

Sensor

Eductor

HART Board

Power

Supply

Flow Meter

7 scfh

Exhaust

Eductor Air

Reference Air

Dilution Air

Flow Meter

50 cc/min.

(0.1 scfh)

Handling the OCX 8800

System Considerations

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

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

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

37390001

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

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

NOTE

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

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

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

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Figure 1-4. Typical System Installation

Gases

Duct

OCX 8800 with

REMOTE

ELECTRONICS

Heater

Power Cable

[up to 150 ft (46 m)]

Stack

Signal Cable

[up to 150 ft (46 m)]

Test Gas

Flow Meter

Dilution

Air

Flow

4-20 mA Outputs (2 Twisted Pairs)

Line Voltage

Instrument Air

Meter

Pressure

Regulator

Supply

(Reference Gas)

High O2 Test Gas Low O2 Test Gas CO Test Gas

Figure 1-5. OCX 8800 HART

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Connections and AMS Application

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Figure 1-6. Sample Tube Support

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1-11

Figure 1-7. Typical System Installation

Gases

Duct

OCX 8800 with

REMOTE

ELECTRONICS

Heater

Power Cable

[up to 150 ft (46 m)]

Stack

Signal Cable

[up to 150 ft (46 m)]

Test Gas

Flow Meter

Dilution

Air

Flow

4-20 mA Outputs (2 Twisted Pairs)

Line Voltage

Instrument Air

Meter

Pressure

Regulator

Supply

(Reference Gas)

High O2 Test Gas Low O2 Test Gas CO Test Gas

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1-12

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

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

SPECIFICATIONS Hazardous Area OCX

Specifications

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

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

System Response to Test Gas

Oxygen 10 sec T90 Combustibles 25 sec T90

Temperature Limits

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

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

Nominal and Approximate Shipping Weights

18 in. (457 mm) probe package

3 ft (0.91 m) probe package

6 ft (1.83 m) probe package

9 ft (2.74 m) probe package

Mounting and Mounting Positions

54 lbs (20 kg)

55 lbs (20.5 kg)

57 lbs (21 kg)

59 lbs (22 kg)

Sensors Housing Flange

Electronics Housing Wall/Pipe

Materials

Probes 316L stainless steel - 1300°F (704°C)

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

Enclosures Low-copper aluminum Calibration Semi-automatic or automatic Calibration Gas Mixtures

Recommended

(Ref. test gas bottles

kit #1A99119G04)

0.4

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

Calibration Gas Flow 7 scfh (3.3 l/m) Reference Air 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O2),

regulated to 45 psi (310 kPa)

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

regulated to 45 psi (310 kPa)

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

regulated to 45 psi (310 kPa)

Table continued on next page

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Sensors Housing

NEMA 4, IP66 with fitting and pipe on reference exhaust port to clean, dry atmosphere, two 3/4-14 NPT conduit ports

Specifications

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

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

Electrical Noise EN 61326-1, Class A Certifications Sensor Housing

0344 II 2 G

KEMA 04 ATEX 2308

C US

2005.1602514

APPROVED

EEx d IIB+H2 T3

Electronics Housing

0344 II 2 G

KEMA 04 ATEX 2308

EEx d IIB+H2 T6 IP66

CLASS 1, ZONE 1

Ex d IIB+H2 T3

AEx D IIB+H2 T3

TYPE 4 / IP66

C US

2005.1602514

CLASS 1, ZONE 1

Ex d IIB+H2 T6

AEx D IIB+H2 T6

TYPE 4 / IP66

CLASS 1, ZONE 1

AEx D IIB+H2 T3

TYPE 4 / IP66

APPROVED

CLASS 1, ZONE 1

AEx D IIB+H2 T3

TYPE 4 / IP66

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

jumpers required, 3/4-14 NPT conduit port

Pollution Degree 2

Over Voltage Category II

Relative Humidity 5 to 95% (non-condensing)

Isolated Output

Oxygen 4-20 mAdc, 950 ohm maximum, with HART capability Combustibles 4-20 mAdc, 950 ohm maximum Alarm Alarm output relay - dry contact, form C, 30 mA, 30VDC capacity

Power Consumption 750 W maximum

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

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

OCX88C

O2/Combustibles Transmitter - Flameproof

Code

Probe Length and Material

No Probe or Exhaust Tube

18 in. (457 mm) 316 SST

up to 1300°F (704°C)

18 in. (457 mm) Inconel 600

up to 1832°F (1000°C)

(4)

18 in. (457 mm) Ceramic

up to 2600°F (1427°C)

3 ft (0.91 m) 316 SST

up to 1300°F (704°C)

3 ft (0.91 m) Inconel 600

up to 1832°F (1000°C)

(4)

3 ft (0.91 m) Ceramic

up to 2600°F (1427°C)

6 ft (1.83 m) 316 SST

up to 1300°F (704°C)

6 ft (1.83 m) Inconel 600

up to 1832°F (1000°C)

(4)

9 ft (2.7 m) 316 SST

up to 1300°F (704°C)

9 ft (2.7 m) Inconel 600

up to 1832°F (1000°C)

(4)

Code

Probe Mounting Assembly

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

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

Code

Mounting Hardware - Stack Side

0 No Adapter Plate (“0” must be chosen under “Mounting Adapter - Probe Side” below)

1 New Installation - Square weld plate with studs

2 Model 218/240 Mounting Plate (with Model 218/240 Shield Removed)

3 Existing Model 218/240 Support Shield

4 Special Mounting

(1)

5 Model 132 Adapter Plate

Code

Mounting Hardware - Probe Side

0 No Adapter Plate

1 Probe Only (ANSI)

2 Probe Only (DIN)

Code

Electronics Housing - Communications

HART Communications

(2)

HART Communications with LOI

HART Communications with Calibration Solenoids

(2)

HART Communications with LOI and Calibration Solenoids

Code

Electronics Mounting

Remote Electronics and no cable

Code

Accessories

None

Flow meters & Ref. Air Set

In-Situ Filter (Stainless Steel only)

(3)

In-Situ Filter (SST), Flow meters & Ref. Air Set

(3)

Flow meters, and Ref. Air Set with Blowback

In-Situ Filter (SST) with Blowback

(3)

In-Situ Filter (SST), Flow meters & Ref. Air Set with Blowback (3)

OCX88C

10 1 1

Example

NOTES:

(1)

Provide details of the existing mounting plate as follows:

Plate with studs

Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate.

Plate without studs

Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.

(2)

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

(3)

For use with stainless steel sample tube only.

(4)

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

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Table 1-2. Accessories

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

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

1A 99119H07 CO test gas bottle; 1000 ppm CO, balance air 1A99120H02 Regulator for Oxygen (may need 2) 1A99120H03 Regulator for CO test gas 1A99119G06 Wall mount bracket for test gas bottles 1A99119G05 Test gas regulators kit 1A99119G04 Test gas bottles kit

1A99292H01

Moore Industries SPA for Low O2 Alarm, High COe Alarm,

Calibration Status, and Unit Fail 1A99339H03 Blowback valve, air operated 1A99762H03 Hasteloy In Situ Filter, High Temperature

1A99784H02

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 m) 6A00288G02 Sample Tube Support, 6 Ft. (1.83 m) 6A00288G04 Sample Tube Support, 9 Ft. (2.7 m) 6P00162H02 Flange Insulator

PART NUMBER DESCRIPTION

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OCX 8800

Section 2 Installation

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

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

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

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

Before installing this equipment, read the "Safety instructions for the wiring and installation of this apparatus" in Appendix A: Safety Data. Failure to follow the safety instructions could result in serious injury or death.

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

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

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

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July 2018

OCX 8800

2-2

MECHANICAL INSTALLATION

Selecting Location

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

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

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

Installation

Ensure all components are available to install the OCX 8800.

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

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

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

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

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.

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

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

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OCX 8800

2-3

NOTE

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

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

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

Enclosures

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

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

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

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July 2018

OCX 8800

4-2

Figure 2-1. Installation, OCX 8800

NOTE

All dimensions are in inches with millimeters in parentheses. Insulate if exposed to adverse weather or extreme temperature

changes, install a protective housing and/or insulation around the unit.

See Table 1

Flange Dia.

B.C. Dia.

Hole Dia.

Removal Envelope

Dim “B”

Insertion Depth

Dim “A”

See Table 2

SENSOR HOUSING

Optional

In Situ FIilter

Table 2. Installation/Removal

Probe

Dim "A”

Dim "B”

18 in.

(457)

(864)

3 ft

(914)

(1321)

6 ft

(1829)

(2235)

9 ft

108

(2743)

124

(3150)

Allow 9 in.

(229 mm) for

Cover Removal

8.3

(211)

0.06 In. Thick Gasket

ANSI

3535B18H02

DIN

3535B45H01

ELECTRONICS HOUSING

Heater

wer Ca

Signal Ca

ble

Signal Ca

ble

Heater

wer Ca

37390009

Table

1. Mounting

Flange

ANSI

DIN

5R10244H01

5R10244H02

Flange Dia.

6.00

7.28

(152)

(185)

Hole

0.75

0.71

Dia.

(19)

(18)

(4) Holes equally spaced on

4.75

(121)

5.71

(145)

B.C. dia

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OCX 8800

2-5

Figure 2-2. Adapter Plate Installation

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6-2

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

Note: * Indicates items are included

in mounting kit P/N 4851B40G01.

*Pipe

Mounting

Clamp

Electronics

Housing

*Wall or Pipe

Mounting Bracket

and Screws

Wall Mounting Bolts

or Lag Screws

(4 each by customer)

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

Recommended for rear piping

clearance when wall mounting.

(4 each by customer)

37020021

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2-7

Figure 2-4. Installation with Drip Loops

Conduit Drip Loops

Duct Wall

Conduit Drip Loop

Duct Wall

37020004

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July 2018

OCX 8800

8-2

ELECTRICAL INSTALLATION

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

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

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

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

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

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

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OCX 8800

2-9

NOTE

To maintain proper earth grounding, ensure a positive connection exists between the sensor housing, the electronics housing, and earth. The connecting ground wire must be 14 AWG minimum. Refer to Figure 2-5.

NOTE

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

Electrical Connections

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

Connect Line Voltage

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

Connect 4-20 mA Signals

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

O2 4-20 mA Signal

One 4-20 mA signal represents the O2 value. Superimposed on the O

signal is the HART information accessible through a Model 275/375

Handheld Communicator or AMS software. The O2 signal is at the AOUT 1

terminals.

COe 4-20 mA Signal

Another 4-20 mA signal at the AOUT 2 terminals represents the COe value. HART information is not available on the COe signal.

Alarm Output Relay

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

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2-10

Remote Electronics Connections to Sensor Housing

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

NOTE

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

Signal Connections

Connect the electronics housing terminals to the corresponding terminals in the sensor housing. The twisted wire pairs are numbered on the inner plastic wrapper. Keep twisted pairs together and match the numbers and wire colors shown in Figure 2-6.

Heater Power Connections

Use the blue, white, orange black, red, and yellow stranded wires in the heater power cable to connect power to the three heaters in the sensor housing. Match the wire colors to the corresponding heater power terminal blocks in the sensor and electronics housings as shown in Figure 2-6.

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OCX 8800

2-11

{

AOUT1 -

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

COM

Alarm Output Relay

Terminal Block

4-20

mA Signal Output

Terminal Block

COe Signal

AOUT2+

AOUT2 -

Signal

{

AOUT1+

Signal Port

3/4 NPT

TOP VIEW

(1/2 SIZE)

EMI Filter

Customer

N L1

Terminal

Block

Power Port

3/4 NPT

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

Wiring

Ground

Stud

External Tooth

Lockwasher

37390013

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OCX 8800

2-12

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

YEL RED BLK

ORG

2HTR CO 1HTR CO 2HTR O

1HTR O

WHT

2 To

2HTR

BLU

Heater Power

Connector (J3)

1HTR SB

ground

screw

#1 #1

RED BLK

WHT BLK GRN

BLK BLU

BLK

T/C CO+ T/C CO-

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

O2 CELL+ O2 CELL-

YEL

BRN

BLK

RED WHT ORG

EXC+ CO ACT+ CO ACT-

CO REF+ CO REF-

COe Sensor

and

Cold Junction

Connector

(J4)

Sensor and Thermocouple Connector (J5)

BLK BLK

CJC+ CJCEXC-

SHLD

To ground

screw

ELECTRONICS HOUSING

SENSOR HOUSING

To ground screw

Signal Ca

ble

Heater

wer Ca

BLU BLK -

O2 T/C

GRN BLK +

BLK - T/C CO RED +

BLK - T/C

SB WHT + BLK EXC- BLK - CJC ORG + BLK

HTR

ORG

WHT

- CO

YEL

REF

RED BLK GRN RED - CO

SHIELD BRN WHT

ACT

2 HTR BLU YEL

EXC

+ GRN

37390014

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OCX 8800

2-13

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

SIGNAL WIRING OR CABLE

NOTE: For RFI/CE compliance, the connector

must provide 360 degrees of electrical

PROBE END

12.5 ±0.10

contact to the cable shield.

3/4 NPT Hub Size,

10.375 ±0.10

ELECTRONICS END

7.25

±0.10

Heat Shrink

Tubing

2” Long

1/2” Size

Liquid-tight Strain Relief Connector

Heat Shrink

Tubing

2” Long

1/2” Size

8.625 ±0.10

6.875 ±0.10

Strip Wire

Ends 3/16”

Typical

0.5

Typ.

See Note

2.0 ±0.25

Stud Size

#10

7.25 ±0.10

Typical

7.0” Long Teflon Tubing,

0.042” ID (Cut off drain

wire at probe end of shield).

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

3.875 ±0.10

4.625 ±0.10

5.375 ±0.10

6.125 ±0.10

Ferrule, Uninsulated

9.25 ±0.10 Overall Cable Length

By Customer

150’ Maximum

drain wire.

# 1

# 2

DETAIL

Heat Shrink Tubing

1” Long, 3/16” Size

(typical on both ends of wiring)

ELECTRONICS END

4.0 ±0.10

HEATER WIRING OR CABLE

3/4 NPT Hub Size,

Liquid-tight Strain Relief Connectors

PROBE END

5.5 ±0.10

Ferrule, Uninsulated

Heat Shrink Tubing

2” Long, 1/2” Size

Heat Shrink Tubing

2” Long, 1/2” Size

Strip Wire

Ends 3/16”

Typical

0.5 Typ.

Green,

16 AWG

Stud Size

#10

4.5 ±0.10

2.0 ±0.25 Typical

4.25” Long Teflon Tubing,

0.042” ID. (Cut off drain wire

at probe end of shield).

Green, 16 AWG

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

Stud Size #6

37390061

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OCX 8800

2-14

PNEUMATIC INSTALLATION

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

Reference Air Set Option (only)

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

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

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

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

One CO gas and two O2 gases are used 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

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.

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.

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2-15

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

Sensor

Housing

Eductor

Air In

CAL Gas In

Reference Air In

CAL Gas

Flow Meter

7 scfh, 20-30 psig

Recommended

Dilution Air In

Dilution Air

Flow Meter

0.1 scfh

Stage

Regulators

Instrument

Air Out

Instrument

Air Supply

Electronics

Housing

Pressure Reguator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

(

HI O

LO O

37390011

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OCX 8800

2-16

Sensor

Housing

(

CAL Gas

Flow Meter

7 scfh, 20-30 psig

Recommended

CAL Gas In

Reference

Air In

Eductor

Air In

Dilution

Air In

Dilution Air

Flow Meter

0.1 scfh

Electronics

Housing

Ins

Air

Pressure Regulator/Filter 35 psig - General Purpose 45 psig - Hazardous Area

2-Stage

Regulators

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

trument

Supply

Reference Air Set and Solenoids Option

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

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

Refer to Figure 2-9. 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 gage in the O2 low supply line, as shown.

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

Instrument

Air

Out

CAL Gas

Out

LO O

HI O

37390012

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2-17

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

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

Reference Air Set, Solenoids, and Blowback Option

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

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

Figure 2-10 shows the piping arrangement for the OCX 8800 with the blowback and autocalibration options. Figure 2-11 shows the piping arrangement for the OCX 8800 with the blowback option, but without autocalibration (without test gas solenoids).

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

Connect the calibration gas sources according to the instructions in the

previous paragraph “Reference Air Set and Solenoids Option”, steps 2

through 5.

Connect a clean, dry, instrument-quality supply of air (20.95% O2) to the 35/45 psig and 55 psig pressure regulators. The inlet to the 35/45 psig regulator accepts a 1/8" NPT fitting. The inlet to the 55 psig regulator accepts a 1/4" NPT fitting.

See the upper leg of the instrument air supply. Connect the output of the 35/45 psi regulator/filter to one port of the normally-closed air-operated solenoid valve, and to the inlet side of the dilution air flow meter.

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

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

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

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

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Figure 2-10. Piping Arrangement, Blowback with Autocalibration

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2-19

Figure 2-11. Piping Arrangement, Blowback without Autocalibration

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2-20

Install an air line between the instrument air outlet fitting on the electronics housing and the control air inlet fitting on the air-operated solenoid valve.

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

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

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

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

These settings are available through HART from the DEVICE SETUP >

DETAILED SETUP > OUTPUT CONDITIONS > BLOWBACK menu.

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

and Startup, for OCX 8800 startup information.

NOTE

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

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.

Reference Manual

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OCX 8800

Section 3 Configuration and Startup

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

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

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

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

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

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

NOTE

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

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.

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.

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Verify Configuration

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

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

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

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

SW3 The factory sets this switch as follows:

•

Position 1 determines the 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.

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

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OCX 8800

Figure 3-1. OCX 8800 Defaults

Open

Switch

Default Postions

Shown

21.1 mA

3.5 mA 1 2 3

Open

Closed

21.1 mA/3.5 mA: O

4-20 mA Signal

Rail Limits:

Open

Closed

High - 21.1 mA Low - 3.5 mA

Closed

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

Rail Limits:

Open

Closed

High- 21.1 mA Low - 3.5 mA

1 2 3 4

Internal:

COe 4-20 mA

is Internally

Powered

SW2

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

Internal:

4-20 mA

is Internally

Powered

SW1

External: O

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

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

operation and for the OCX 8800 to reach normal operating temperature on power up. Normal operating temperature for the O2 cell is 736°C. Normal

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

3-3

SW3

COe

37390026

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3-4

SET TEST GAS VALUES Use HART/AMS to set test gas values for calibration. Refer to Section 4,

Using HART Communications for more information.

Setting Test Gas Values with HART

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

From the DETAILED SETUP menu, select O2 CALIB PARAMS.

From O2 CALIB PARAMS, select O2 High Gas. Enter the percent O

used for the high O2 test gas.

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

From the DETAILED SETUP menu, select COe CALIB PARAMS.

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

OCX 8800 RESET PROCEDURE

Whenever you correct an equipment alarm or fault condition, the OCX 8800 will either revert to normal operation or continue to indicate an alarm status condition. If the equipment does not revert to normal operation when a fault condition is cleared, or if instructed to do so in Section 7, Troubleshooting, use the following procedure to reset the OCX 8800.

OCX Reset with HART

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

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OCX 8800

Section 4 Using HART Communications

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

Field Communicator Signal Connections . . . . . . . . . . . . page 4-1

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

HART Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-5

D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-9

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

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

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

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

FIELD COMMUNICATOR SIGNAL CONNECTIONS

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

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Figure 4-1. Signal Line Connections,

 250 Ohms Load Resistance

Method 1, for Load Resistance  250 Ohms

Refer to Figure 4-1 and the following steps to connect the Field Communicator to a signal line 250 ohms or more of load resistance.

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

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

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Method 2, for Load Resistance < 250 Ohms

Refer to Figure 4-2 and the following steps to connect the Field Communicator to a signal line with less than 250 ohms load resistance.

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

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

Figure 4-2. Signal Line Connections, < 250 Ohms Load Resistance

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

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Field Communicator PC Connections

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

Off-line and On-line Operations

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

the OCX 8800. Off-line operations can include interfacing the Field Communicator with a PC. (Refer to applicable documentation regarding HART/PC applications.)

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

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

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

specific to OCX 8800 applications.

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

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

(CONTINUED FROM

SHEET 1 )

STATUS

DIAG/SERVICE

HW STATUS

Operate Mode Status group 1

Status group 2 Status group 3 Status group 4 Status group 5

Status group 6 AO saturated

AO fixed

Model Number Snsr Housing CPLD REGS

Line Freq Line Volt PCN Counter PCD Counter

O2 AO Saturated COe AO Saturated

O2 AO Fixed COe AO Fixed

BCSR0 BCSR3 BCSR1 BCSR4 BCSR2 BCSR5

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

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

O2 Loop Test

COe Loop Test

Status group 3 Cal Failed

D/A TRIM

CALIBRATE

VERIFY CALIB

O2 D/A Trim COe D/A Trim

PERFORM CAL

CAL STATUS

CAL VALUES

PREV CAL VALUES

FAILED CAL VALUES

RESET CAL CONST

Verify Calibration Status TimeRemain O2 COe

(procedures)

CAL METHODS O2OutTracks COeOutTracks Cal Step Cal Time O2 COe

Cal Step

Cal Time O2 Slope

O2 Const O2 Snsr R COe Slope COe Const

Prev O2 Slope Prev O2 Const Prev O2 Snsr R Prev COe Slope Prev COe Const

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

Reset O2 CalConsts Reset COe CalConsts

Cal Warning SB T/C Open SB T/C Shorted SB Temp Low SB Temp Hi SB Temp Very Hi ADC Ref Error

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

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

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

O2 Calibration COe Calibration O2 and COe Calib

BLOWBACK

BlBk State Blowback

(CONTINUED ON

SHEET 3)

MAX TEMP

HEATER PID

O2TempMax COeTempMax SBTempMax BrdTempMax CJCTempMax

O2 PID

COE PID

SB PID

O2 Prop O2 Int O2 DutyCyc O2 SetPt O2 Temp

COe Prop COe Int COe DutyCyc COe SetPt COe Temp

SB Prop SB Int SB DutyCyc SB SetPt SB Temp

LOOP TEST

37390039

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

DEVICE

INFORMATION

HART INFORMATION

S/W VERSION INFO

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

Tag Poll addr Dev id Num req preams Fld dev rev

Version Chksum Bld Num Bld Date Restart Cntr

OUTPUT CONDITION

O2 CALIB PARAMS

COe CALIB PARAMS

DEVICE PARAMS

LOI PARAMS

ANALOG OUTPUT

ALARM RELAY

BLOWBACK

O2 ANALOG OUTPUT

COe ANALOG OUTPUT

O2 AO Type O2 URV O2 LRV O2 Alarm Level

COe AO Type COe URV COe LRV COe Alarm Level

Trig 1 Event Trig 2 Event Trig 3 Event Alarm State

BlBk Enabled BlBk Intrvl BlBk Period BlBk PurgeTm BlBk State

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

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

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

User Intface Luminance Lockout Time Revert Time

(CONTINUED FROM

SHEET 2)

BASIC SETUP

DETAILED SETUP

(CONTINUED ON

SHEET 4)

37390040

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

O2 CALIB

COE CALIB

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

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

REVIEW

DEVICE INFORMATION

HART INFORMATION

CAL INFO

DEVICE CONFIG

OUTPUTS CONFIG

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

(CONTINUED FROM

SHEET 3)

Manufacturer

Model

Date

Descriptor

Message

Final asmbly num

O2 Sensor s/n

COe Sensor s/n

Hardware rev

Software rev

O2 DEVICE CONFIG

O2 Slope O2 Const O2 T90

COE DEVICE

COe Slope COe Const COe T90

CONFIG

Trig 1 Event

Trig 2 Event

Trig 3 Event

BlBk Enabled

DEVICE CONFIG

BlBk Intrvl BlBk Period

BlBk PurgeTm

PCNC Enable

PCDC Enable

Luminance

Lockout Time

Revert Time

O2 URV

O2 LRV

COe URV

COe LRV

O2 AO Type

COe AO Type

O2 Alarm Level

COe Alarm Level

37390041

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D/A TRIM PROCEDURES O

D/A trim procedure using HART

Use the following procedure to perform the O2 D/A trim procedure using the Field Communicator. Refer to the HART menu tree, Figure 4-3.

NOTE

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

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

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

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

The Field Communicator displays WARNING: Loop should be removed from automatic control. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

The Field Communicator displays Connect reference meter to O2 output.

Remove the electronics housing cover.

Refer to Figure 2-5. Connect a digital multimeter to read the milliamp output from the O2 D/A converter circuit. Connect the positive lead to

the AOUT1+ terminal and connect the negative lead to the AOUT1terminal. Then, press OK at the Field Communicator.

The Field Communicator displays Setting Fld dev output to 4 mA. Press OK. Read the O2 millamp output at the digital multimeter. Enter the reading at the Field Communicator and press ENTER. (Select ABORT to exit without changes).

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

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

10.

The Field Communicator displays Fld dev output 4.00 mA equal to reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 6.

11.

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

12.

The Field Communicator displays Fld dev output 20.00 mA equal to reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 7.

13.

The Field Communicator displays NOTE: Loop may be returned to

automatic control.

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COe D/A trim procedure using HART

Use the following procedure to perform the COe D/A trim procedure using the Field Communicator. Refer to the HART menu tree, Figure 4-3.

NOTE

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

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

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

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

The Field Communicator displays Connect reference meter to Combustibles output.

Remove the electronics housing cover.

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

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

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

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

10.

The Field Communicator displays Fld dev output 4.00 mA equal to reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 6.

11.

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

12.

The Field Communicator displays Fld dev output 20.00 mA equal to reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 7.

13.

The Field Communicator displays NOTE: Loop may be returned to

automatic control.

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Section 5 Calibration

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

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

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

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-3

OVERVIEW During a calibration, two calibration gases with known O

concentrations and

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

8800. Slope and constant values are calculated to determine if the OCX 8800 is correctly measuring net concentrations of O2 and combustibles in the industrial process.

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

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

FULLY AUTOMATIC CALIBRATION

If the OCX 8800 is equipped with calibration solenoids, the unit can be programmed to automatically calibrate without any operator action. Refer to the following paragraphs for using HART/AMS to set up the OCX 8800 for fully automatic calibration.

Autocalibration Setup using HART

NOTE

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

Use the following procedure to specify a time interval (in hours) at which the OCX 8800 will automatically calibrate.

From the DEVICE SETUP screen, select DETAILED SETUP.

From the DETAILED SETUP screen, select O2 CALIB PARAMS or

COE CALIB PARAMS.

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

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

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

NOTE

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

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

When setting automatic calibration times, CalIntrvl and NxtCalTm should be set so that O

and COe are NOT calibrated simultaneously.

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OPERATOR - INITIATED AUTOCALIBRATION

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

Autocalibration using HART

To initiate an automatic calibration using HART/AMS, perform the following steps on the HART menu tree. Refer to Section 4, Using HART Communications, for the HART menu tree.

Select DIAG/SERVICE from DEVICE SETUP menu.

Select CALIBRATION from the DIAG/SERVICE menu.

Select PERFORM CAL from the CALIBRATION menu.

Select CAL METHODS from the PERFORM CAL menu.

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

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

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

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

Manual O2 Calibration using HART

To perform a manual O2 calibration using the Field Communicator or AMS, use the following procedure. If necessary, refer to Section 4, Using HART

Communications, for the HART menu tree.

NOTE

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

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

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

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

In the first O2 Calibration screen, a Loop should be removed from automatic control warning appears. Remove the OCX 8800 from any

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

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

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

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From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT

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

OCX: TAG NAME

SELECT ACTION

START/NEXT CALSTEP

ABORT CAL

EXIT CAL

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

Low Gas. Verify the O2 concentration measured matches the O2 LOW GAS parameter in the Setup. Press OK when ready.

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

When ready, Calibration Status will stop at the AppO2Hi. Switch off the O2 Low Gas and switch on the O2 High Gas. Verify the O2 concentration

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

OK when ready.

10.

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

11.

The Calibration Status should be automatically changed to FlowO2Hi and then ReadO2Hi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting

Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command

is not accepted at this time.

12.

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

13.

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

14.

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

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Manual COe Calibration using HART

To perform a manual COe calibration using the Field Communicator or AMS, use the following procedure. If necessary, refer to Section 4, Using HART Communications, for the HART menu tree.

NOTE

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

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

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

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

In the first COe Calibration screen, a Loop should be removed from automatic control warning appears. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

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

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

From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT

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

OCX: TAG NAME

SELECT ACTION

START/NEXT CALSTEP

ABORT CAL

EXIT CAL

The unit samples reference air as the COe Low Gas. The Calibration Status should automatically change to ReadCOLow for a period of time. During this period, if an attempt is made to go to the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time.

When ready, Calibration Status will stop at the AppCOeHi. Switch on the COe High Gas. Verify the COe concentration measured matches the COe HIGH GAS parameter in the Setup. Press OK when ready.

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

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The Calibration Status should be automatically changed to FlowCOeHi and then ReadCOeHi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time.

10.

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

11.

12.

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

Manual O2 and COe Calibration using HART

To perform a manual O2 and COe calibration using the Field Communicator or AMS, use the following procedure. If necessary, refer to Section 4, Using

HART Communications, for the HART menu tree.

NOTE

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

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

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

From the PERFORM CAL menu, select CAL METHODS. Select 02 & COe CALIBRATION to start O2 and COe calibration.

In the first Calibration screen, a Loop should be removed from automatic control warning appears. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

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

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

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From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT

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

OCX: TAG NAME

SELECT ACTION

START/NEXT CALSTEP

ABORT CAL

EXIT CAL

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

Low Gas. Verify the O2 concentration measured matches the O2 LOW GAS parameter in Setup. Press OK when ready.

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 should automatically change to FIowO2Low and then ReadO2Low for a period of time. During this period, if an attempt is made to go to the next calibration step by pressing OK and selecting

Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command

is not accepted at this time.

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

Low Gas and switch on the O2 High Gas. Verify the O2 concentration measured matches the O2 HIGH GAS parameter in Setup. Press OK

when ready.

10.

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

11.

The Calibration Status should automatically change to FlowO2Hi, then ReadO2Hi, and then ReadCOeLo for a period of time. During this period, if an attempt is made to go the next calibration step by pressing

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

12.

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

High Gas and switch on the COe Gas. Verify the COe concentration measured matches the COe TEST GAS parameter in the Setup. Press

OK when ready.

13.

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

14.

The Calibration Status should automatically change to FlowCOeHi and then ReadCOeHi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting

Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command

is not accepted at this time.

15.

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

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Section 6 Maintenance and Service

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

OCX 8800 Removal and Installation . . . . . . . . . . . . . . . . . page 6-1

Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-8

Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . page 6-28

Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-34

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

OCX 8800 REMOVAL AND INSTALLATION

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

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

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

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

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

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July 2018

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6-2

OCX with Remote Electronics

Remove Sensor Housing

Turn off power to the system.

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

Disconnect the calibration gas, reference air, eductor air, and dilution air lines from the sensor housing, Figure 6-1.

Figure 6-1. OCX with Remote Electronics

Duct

Stack

Sensor

Housing

Heater

Power Cable

Signal Cable

4-20 mA

Outputs

AC Power

Input

Electronics Housing

Instrument Air

(Reference Gas)

High O2 Test Gas Low O2 Test Gas CO Test Gas

37390044

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July 2018

OCX 8800

6-3

Remove the cover from the sensor housing to expose the sensor housing terminal blocks, Figure 6-2.

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

Disconnect the heater power cable from the HTR terminal blocks.

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

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

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

Figure 6-2. Sensor Housing Terminals

SENSOR HOUSING

NOTE: Wire colors shown are for cables

supplied by Emerson.

Ground

Screw

+ Heater

Power Cable

Signal Cable

BLU BLK

- O2

T/C O2

BLK GRN BLK

T/C CO

RED BLK

T/C

WHT

BLK

EXC

CJC

BLK ORG

BLK

HTR 02

ORG

WHT

- CO REF

YEL

RED

HTR CO

BLK RED

CO ACT

WHT

BRN

HTR SB

YEL

BLU

EXC

GRN

37390028

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-4

Install Sensor Housing

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

Remove the sensor housing cover.

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

Connect the signal cable to O2 and T/C terminal blocks and to the CO and CJC terminal blocks, Figure 6-2. Connect the heater power cable to

the HTR terminal blocks.

Refer to Figure 6-1 and make sure all test gas lines and electrical connectors are complete.

Install the sensor housing cover.

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

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

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

Remove Remote Electronics Housing

Turn off power to the system.

Shut off the test gases at the cylinders and close the instrument air supply valve, Figure 6-1.

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

Remove the cover from the electronics housing to expose the electronics housing terminal blocks, Figure 6-3.

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

Disconnect and remove the O2 and COe signal leads from the 4-20 mA signal output terminal block.

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

Disconnect the signal cable leads from O2 cell and thermocouple connector (J4), and from COe and CJC connector (J5), Figure 6-4.

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

10.

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

11.

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

Reference Manual

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July 2018

OCX 8800

6-5

{

AOUT1 -

Figure 6-3. Electronics Housing Terminal Blocks

COM

Alarm Output Relay

Terminal Block

4-20 mA Signal Output

Terminal Block

COe Signal

AOUT2+

AOUT2 -

Signal

{

AOUT1+

Signal Port

3/4 NPT

TOP VIEW

(1/2 SIZE)

EMI Filter

Customer

N L1

Terminal

Block

Power Port

3/4 NPT

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

Wiring

Ground

Stud

External Tooth

Lockwasher

37390013

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-6

Figure 6-4. Remote Electronics Housing Cable Connections

YEL RED BLK ORG WHT BLU

Heater Power

Connector (J3)

2HTR CO

1HTR CO

2HTR O

1HTR O

2HTR SB

1HTR SB

Ground

Screw

#1 #1

RED BLK

WHT BLK GRN

BLK BLU

BLK

T/C CO+ T/C CO-

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

O2 CELL+ O2 CELL-

YEL BRN BLK

RED WHT ORG

COe Sensor

& CJC

Connector (J4)

EXC+ CO ACT+ CO ACT-

CO REF+ CO REF-

O2 Cell

& Thermocouple

Connector (J5)

SHLD

BLK

To Ground

Screw

CJC+ CJCEXC-

ELECTRONICS HOUSING

Signal Cable

Heater Power Cable

NOTE: Wire colors shown are for cables supplied

by Emerson.

GRN SHIELD

37390016

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-7

Install Remote Electronics Housing

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

Remove the electronics housing cover.

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

Connect the signal cable leads to the O2 cell and thermocouple connector (J4), and to the COe and CJC connector (J5), Figure 6-4.

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

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

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

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

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

10.

Refer to Figure 6-1 and Figure 6-4. Make sure all test gas lines and electrical connections are complete.

11.

Install the cover on the electronics housing.

12.

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

13.

Restore power to the system.

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-8

REPAIR SENSOR HOUSING

Sensor Housing Disassembly

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

Remove Cover and Terminals Insulator

Loosen screw (1, Figure 6-5) and slide locking clip (2) away from cover. Retighten screw (1).

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

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

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

Reference Manual

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July 2018

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6-9

Figure 6-5. Removal of O2 Cell and Heater Strut Assembly

Screw

Locking Clip

Cover

O-ring

Marking Plate

Terminal Insulator

Reference Air Tube

Sensor Housing

Heater Strut Assembly

10.

Gasket

11.

Screw

12.

Heater Clamp

13.

Heater Rod

14.

Insulator

15.

Thermal Switch

15 5

37390066

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July 2018

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6-10

HTR 02

Heater Wires

Thermocouple Wires

- O2

ORG

RED

GRN

YEL

T/C O2

+ +

T/C CO

O2 Cell and Heater Strut

Assembly

T/C SB

EXC

Sample

Block

Thermo-

couple

Sample Block

Heater Rods

CJC

HTR 02

HTR CO

CO REF

Thermal

Switch

HTR SB

CO ACT

EXC

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

Cell Wires

Remove O2 Cell and Heater Strut Assembly

Remove reference air tube (7, Figure 6-5) from sensor housing (8).

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

Remove the O2 cell and heater strut assembly (9, Figure 6-5) from sensor housing (8). Remove and discard gasket (10).

Remove Sample Block Heater Rods

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

Sensor

Housing

erminals

Return

Wire

37390069

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July 2018

OCX 8800

6-11

HTR 02

Loosen screws (11, Figure 6-5) and rotate heater clamps (12) to release heater rods (13). One heater clamp secures each heater rod.

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

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

Remove COe Sensor Assembly

Disconnect COe heater, thermocouple, and sensor wires from terminal blocks. Refer to Figure 6-7.

Remove insulator (1, Figure 6-8).

Figure 6-7. COe Sensor, Thermocouple, and Heater Connections

- O2

T/C O2

RED -

YEL

T/C CO

CJC Sensor

T/C SB

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

EXC

CJC

COe Sensor

Assembly

HTR 02

HTR CO

CO REF

HTR SB

CO ACT

EXC

COe Heater Wires

COe Sensor Wires

COe Thermocouple Wires

Sensor

Housing

erminals

RED WHT

BLU RED BLU RED WHT

37390018

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-12

NOTE

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

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

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

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

Figure 6-8. Removal of COe Sensor Assembly

1. Insulator

Dilution Air Tube

COe Extractive Tube

Eductor Air Tube

COe Sensor Assembly

Eductor

Sensor Housing

COe Thermocouple

Heater Insulator

10.

COe Band Heater

11.

Sensor Holder

12.

Eductor Elbow

13.

Terminal Block Mounting

14.

Eductor Holder

15.

Tube Fitting

16.

CJC Sensor

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July 2018

OCX 8800

6-13

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

With one wrench holding eductor elbow (12, Figure 6-8), and one wrench on flats of sensor holder (11), unthread and remove COe sensor assembly (5). Do not allow eductor elbow to turn.

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

Figure 6-9. Alignment of COe Sensor Assembly

Sensor

Holder

Flat

Matchmark

Straightedge

Matchmark

37390035

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-14

Figure 6-10. Eductor Alignment Matchmarks

Remove Eductor

The O2 cell and heater strut assembly (9, Figure 6-5) and the COe sensor assembly (5, Figure 6-8) must be removed before you start this procedure.

Use straightedge to matchmark alignment of eductor flat and elbow, as shown in Figure 6-10.

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

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

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

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

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

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

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

Eductor Flat

Straightedge

Matchmark

37390036

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00809-0400-4881, Rev AA

July 2018

OCX 8800

6-15

Figure 6-11. Removal of Sample and Exhaust Tubes

Remove Sample and Exhaust Tubes

Secure the sensor housing (1, Figure 6-11) in soft (plastic, wood, or brass) vice jaws.

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

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

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

Sensor Housing

Sample Tube

Exhaust Tube

In Situ Filter

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

37390048

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July 2018

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6-16

Figure 6-12. O2 Cell, Heater, and Thermocouple, Exploded View

Disassemble O2 Cell and Heater Strut Assembly

Do not attempt to replace the O2 cell until all other possibilities for poor performance have been considered. If cell replacement is needed, order the O2 cell replacement kit (Refer to Section 8, Replacement Parts).

The O2 cell replacement kit contains an O2 cell and flange assembly, gaskets,

socket head cap screws, and anti-seize compound. The items are carefully

packaged to preserve precise surface finishes.

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

1. Remove the four allen cap screws (1, Figure 6-12) from the O2 cell (2). Remove the O2 cell. The cell flange has a notch that may be used to

gently pry the flange away from heater tube (3).

1. Screw

2. O2 Cell

3. Heater Tube

4. Contact/ Thermocouple Assembly

5. Gasket

6. Screw

7. Lockwasher

8. Return Wire

9. Heater Strut Assembly

10. Spring Clip

11. Spring

12. Strut Bracket

Test Gas Passage

Holes

NOTE

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

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

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

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

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

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

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

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

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

37390032

Reference Manual

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July 2018

OCX 8800

6-17

3 2

7 6

5 4

Disassemble COe Sensor Assembly

Carefully remove screws (1, Figure 6-13), lockwashers (2), and COe sensor (3) from sensor holder (4). Remove and discard gasket (5).

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

Use a propane torch to heat the thermocouple adaptor to 450°F (232°C), minimum.

While heating, use a flat-head screwdriver to apply removal torque. Apply torque until the pipe thread sealant softens. Remove and discard the thermocouple adaptor.

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

Figure 6-13. COe Sensor, Exploded View

Screw

Lockwasher

COe Sensor

Sensor Holder

Gasket

Thermocouple Adapter

Pre-Heater

Plug

Stainless Steel Balls

37390030

Reference Manual

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July 2018

OCX 8800

6-18

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

NOTE

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

Sensor Housing Assembly

Unthread and remove pre-heater (7).

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

Assemble COe Sensor Assembly

If pre-heater (7, Figure 6-13) was removed, apply pipe thread sealant (Loctite #567) to the external pipe threads of pre-heater (7) and plug (8). Do not apply sealant to the first turn of the pipe threads.

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

Install and tighten pre-heater (7). Align pre-heater to flat of sensor holder (4) as shown in Figure 6-14.

Invert sensor holder (4, Figure 6-13) in vise and pour stainless steel balls (9) into plug port. Press down on stainless steel balls and tap sensor holder with plastic hammer to compact balls in pre-heater chamber.

Install and tighten plug (8).

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

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

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

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-19

Figure 6-14. COe Sensor and Pre-Heater Alignment

THERMOCOUPLE

COe

SENSOR ASSEMBLY

TOP VIEW

Sensor

Holder

COe Sensor

Flat

2 to 2-1/4 in.

(51 to 57 mm)

Sensor

Holder

Flat

Pre-Heater

Flat

Sensor

Holder

Flat

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

Align COe sensor flat parallel to sensor holder flat, as shown in Figure 6-14. Tighten screws (1, Figure 6-13).

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

Assemble O2 Sensor and Heater Strut Assembly

See Figure 6-12. Assemble O2 cell (2), gasket (5), and heater tube (3). Make sure the test gas passage holes line up with each other in all components.

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

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

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

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

Install Sample and Exhaust Tubes

See Figure 6-11. Apply pipe thread sealant (Loctite #567) to the replacement sample tube (2) or exhaust tube (3) pipe threads. Do not apply sealant to the first turn of the pipe threads.

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

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

37390034

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-20

Install Eductor

If installed, the O2 cell and heater strut assembly (9, Figure 6-5) must be removed from sensor housing (8), before you install the eductor.

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

Figure 6-15. Installation of Eductor and COe Sensor

1. Insulator

Dilution Air Tube

COe Extractive Tube

Eductor Air Tube

COe Sensor Assembly

Eductor

Sensor Housing

COe Thermocouple

Heater Insulator

10.

COe Band Heater

11.

Sensor Holder

12.

Eductor Elbow

13.

Terminal Block Mounting

14.

Eductor Holder

15.

Tube Fitting

16.

CJC Sensor

37390047

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6-21

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

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

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

Install and tighten eductor holder (14) in sensor housing (7). Align eductor with matchmarks, as shown in Figure 6-16.

Figure 6-16. COe Sensor Parts Alignment

Eductor Flat

Straightedge

Matchmark

37390036

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July 2018

OCX 8800

6-22

Install COe Sensor Assembly

Figure 6-17. Band Heater Height 1. Apply pipe thread sealant (Loctite #567) to the exposed pipe threads

of eductor elbow (12, Figure 6-15). Do not apply sealant to the first turn

0.37 in. (9,4 mm)

COe Sensor

of the pipe threads.

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

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

Tighten sensor holder (11) to align outside flat with matchmark on sensor housing flange, as shown in Figure 6-18.

Band Heater

Insulator

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

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

Check for proper height of COe heater thermocouple (Figure 6-14). Thread bayonet connector up or down to adjust height.

Install and fasten thermocouple (8, Figure 6-15).

Position band heater as shown in Figure 6-17 and Figure 6-18 and tighten band heater clamp screw. The heater insulator (9) end joint must line up with the band gap of the COe band heater (10).

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

37390058

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July 2018

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6-23

Figure 6-18. COe Sensor Holder Alignment

Sensor

Holder

Flat

Matchmark

Straightedge

Matchmark

37390035

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July 2018

OCX 8800

6-24

HTR 02

10.

Reconnect the COe sensor, thermocouple, and heater wires at the sensor housing terminal blocks. Refer to Figure 6-19.

11.

Install and fasten the COe insulator (1, Figure 6-15) around COe sensor assembly (5). All wiring must remain outside of the insulator.

12.

If terminal block mounting (13, Figure 6-15) was moved, reinstall with two base mounting screws.

Figure 6-19. COe Sensor, Thermocouple, and Heater Connections

T/C O2

RED -

YEL

T/C CO

CJC Sensor

T/C SB

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

EXC

CJC

COe Sensor

Assembly

HTR 02

HTR CO

CO REF

HTR SB

CO ACT

EXC

COe Heater Wires

COe Sensor Wires

COe Thermocouple Wires

Sensor

Housing

erminals

RED WHT

BLU RED BLU RED WHT

37390018

Reference Manual

00809-0400-4881, Rev AA

July 2018

OCX 8800

6-25

Figure 6-20. Installation of O2 Cell and Heater Strut Assembly

Screw

Locking Clip

Cover

O-ring

Marking Plate

Terminal Insulator

Reference Air Tube

Sensor Housing

Heater Strut Assembly

10.

Gasket

11.

Screw

12.

Heater Clamp

13.

Heater Rod

14.

Insulator

15.

Thermal Switch

15 5

Install Sample Block Heater Rods

Before installing sample block heater rods (13, Figure 6-20), evenly coat the heater rods with Watlube heater release agent.

37390066

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6-26

HTR 02

Heater Wires

Thermocouple Wires

- O2

ORG

RED

GRN

YEL

T/C O2

+ +

T/C CO

O2 Cell and Heater Strut

Assembly

T/C SB

EXC

Sample

Block

Thermo-

couple

Sample Block

Heater Rods

CJC

HTR 02

HTR CO

CO REF

Thermal

Switch

HTR SB

CO ACT

EXC

Figure 6-21. O2 Cell, Thermocouple, and Heater Connections

Cell Wires

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

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

Reconnect the heater rod leads at the sensor housing terminal blocks, (Figure 6-21).

Sensor

Housing

erminals

Return

Wire

37390069

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July 2018

OCX 8800

6-27

Install O2 Cell and Heater Strut Assembly

Rub a small amount of anti-seize compound on both sides of new gasket (10, Figure 6-20).

Apply anti-seize compound to threads of O2 cell and heater strut assembly (9) and sensor housing (8).

Install O2 cell and heater strut assembly (9) in sensor housing (8). Snug up, but do not over-tighten the assembly.

Reconnect the lead wires from O2 cell, heater, and thermocouple to the sensor housing terminal blocks. Refer to Figure 6-21.

Install reference air tube (7, Figure 6-20) in sensor housing (8). Make sure that the open end of reference air tube extends into heater tube of O2 cell and heater strut assembly (9).

Install Terminals Insulator and Cover

Install insulator (6, Figure 6-20) over uppermost terminal blocks. Position one side of insulator against terminal blocks and snap terminal marking plate (5) to mating stand-off.

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

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

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

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

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

Sensor Housing Leak Test

Install 1/4 NPT cap on dilution air inlet fitting. Install a 1/4 NPT cap on sample tube (2, Figure 6-11) or plug 1/4 NPT sample inlet port. Capped or plugged ports must be air tight.

If not in place, install exhaust tube (3, Figure 6-11) in exhaust port according to the instructions provided.

Connect a calibrated manometer to the CAL GAS inlet port.

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

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

Stripped threads on the O2 cell and heater strut assembly can allow gas leakage. Gas leakage can affect the O2 measurements and calibration. Avoid over-tightening the O2 cell and heater strut assembly.

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REPAIR ELECTRONICS HOUSING

Electronics Housing Disassembly

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

Remove Cover

See Figure 6-22. Loosen screw (1) and slide locking clip (2) away from cover (3). Retighten screw (1).

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

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

Remove Flash PROM

Locate Flash PROM access port in electronics stack (5, Figure 6-22).

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

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

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Figure 6-22. Removal/Installation of Electronics Housing Components

Screw

Locking Clip

Cover

O-ring

Electronics Stack

Flash PROM

thru 12. Not used

13.

Screw

14.

Lockwasher

15.

Solenoid Valve (3 way)

16.

Solenoid Valve

Remove Electronics Stack

Unplug power cable, signal cable, and solenoid lead connectors from terminals of electronics stack (5, Figure 6-22).

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

Remove electronics stack (5).

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Remove Solenoid Valves

Disconnect solenoid leads from mating terminal connector.

Remove top nut of solenoid valve (15 or 16, Figure 6-22).

Remove the solenoid coil assembly and washer.

Unthread and remove solenoid valve base.

Remove EMI Filter and Terminal Block

Disconnect EMI filter wiring (Figure 6-23) at terminal block (3).

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

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

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

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

Figure 6-23. Removal/ Installation of EMI Filter

Brown

Blue Green

Blue Brown

Green

Electronics Housing Assembly

Install EMI Filter and Terminal Block

Install replacement EMI filter (1, Figure 6-23) and/or terminal block (3) on electronic stack.

Refer to wiring details in Figure 6-23. Connect EMI filter wiring and ground wire (2) at terminal block (3).

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

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Install Solenoid Valves

Disassemble replacement solenoid valve (15 or 16, Figure 6-22).

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

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

Connect the solenoid leads to the proper terminations on the solenoid power terminal block (Figure 6-26).

Install Electronics Stack

Install electronics stack (5, Figure 6-22) and secure with lockwashers (14) and screws (13).

See Figure 6-25 and Figure 6-26. Reconnect power cable, signal cable, and solenoid lead connectors to electronics stack terminals.

Figure 6-24. Flash PROM Alignment

Install Flash PROM

Corner

Bevel

Flash PROM

Access

Port

Locate Flash PROM access port in electronics stack (5, Figure 6-22).

See Figure 6-24. Align Flash PROM (6, Figure 6-22) with mating receptacle in access port of electronics stack as shown. Flash PROM corner bevel must be in upper left corner of receptacle.

Install Flash PROM (6).

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

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Figure 6-25. Electronics Housing Cable Connections

YEL RED BLK ORG WHT BLU

Heater Power

Connector (J3)

2HTR CO 1HTR CO 2HTR O

1HTR O

2HTR SB 1HTR SB

Ground

Screw

#1 #1

RED

BLK

WHT BLK GRN

BLK BLU

BLK

T/C CO+ T/C CO-

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

O2 CELL+ O2 CELL-

YEL

BRN

BLK

RED WHT ORG

COe Sensor

& CJC

Connector (J4)

EXC+ CO ACT+ CO ACT-

CO REF+ CO REF-

O2 Cell

& Thermocouple

Connector (J5)

SHLD

BLK

To Ground

Screw

CJC+ CJCEXC-

ELECTRONICS HOUSING

Signal Cable

Heater Power Cable

NOTE: Wire colors shown are for cables supplied

by Emerson.

GRN SHIELD

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SOL 3

Figure 6-26. Solenoid Power Terminals

CO Test Gas

TOP VIEW

High O2 Test Gas Low O2 Test Gas

Instrument Air

Install Cover

If removed, install cover gasket (4, Figure 6-22). Screw cover (3) onto electronics housing. Tighten cover firmly. Align locking clip (2) with gap between cover ribs.

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

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

SOL 4

SOL 3 SOL 2

SOL 1

SOL

1 SOL

4 SOL

3 SOL

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REPLACE TUBE FITTINGS

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

‘F’ Type Fitting

The ‘F’ type fitting is a flame arrestor fitting used in all OCX 8800

hazardous area housings. The flame arrestor fitting prohibits spark or flame conduction from the housing. It requires a thread sealing compound (Loctite 567) and at least five threads engagement.

‘13’ Type Fitting

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

‘R’ Type Fitting

The ‘R’ type fitting is a reference air line fitting for the general purpose and

hazardous area sensor housings. This is a 1/4 inch tube fitting with a built-in 0.007 inch restrictor orifice.

Remove Tube Fittings The OCX construction includes pipe thread sealant to seal fittings in all ports

that pass through to an outer wall of the instrument housing base. Use the following instructions to loosen and remove tube fittings that are secured with pipe thread sealant.

Secure sensor housing (1, Figure 6-27) or electronics housing (2) in soft (plastic, wood, or brass) vice jaws.

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

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

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

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

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Figure 6-27. Removal of Tube Fittings

Sensor Housing

Electronics Housing

Tube Fitting

Tube Fitting (Type R)

Tube Fitting (Type 13)

Tube Fitting (Type F)

Install Tube Fittings 1. Verify that the replacement tube fitting is identical to the item removed.

Special fittings are etched with code markings.

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

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

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

Specifications and Main Features

Frequently Asked Questions

User Manual