Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Oxygen/Combustibles Transmitter General Purpose OCX 8800 Oxygen/Combustibles Analyzer with Remote Electronics http://www.raihome.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Table of Contents Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual OCX 8800 IM-106-880 Original Issue February 2005 SECTION 6 Maintenance and Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 OCX 8800 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 OCX with Remote Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 OCX 8800 Oxygen/Combustibles Transmitter ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications.
Instruction Manual IM-106-880 Original Issue February 2005 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.
Instruction Manual IM-106-880 Original Issue February 2005 Section 1 OCX 8800 Description and Specifications Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-9 COMPONENT CHECKLIST A typical OCX 8800 Oxygen/Combustibles Transmitter package should contain the items shown in Figure 1-1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 1-1. Typical System Package 1 An a lytic al MAN 4275A00 English October 1994 4 Communicator HART o FISHER-ROSEMOUNTTM 2 3 5 1. Instruction Manual 2. HART®Communicator Package (optional) 3. Adapter Plate with Mounting Hardware and Gasket 4. Reference Air and Calibration Set 5. Blowback Hardware (optional) 6.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 The equipment measures oxygen percentage by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output of the cell is given by the following Nernst equation: EMF = KT log10 (P1/P2) + C Where: 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 5. 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.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 1-2. System Operation Diagram SENSOR HOUSING ELECTRONICS HOUSING CPU COe Combustibles Sensor HART Board Power Supply Probe Sample Gas Low O2 Test Gas Optional Test Gas Solenoids O2 Sensor Eductor Instrument Air Solenoid High O2 Test Gas CO Test Gas Instrument Air Flow Meter 7 scfh Eductor Air Exhaust Dilution Air Flow Meter 50 cc/min. (0.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 After verifying that you have all the components, select mounting locations and determine how each component will be placed in terms of available line voltage, ambient temperatures, environmental considerations, convenience, and serviceability. Figure 1-3 shows a typical system wiring. Simplified installations for the OCX 8800 are shown in Figure 1-4.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 1-4.
Instruction Manual IM-106-880 Original Issue February 2005 SPECIFICATIONS OCX 8800 General Purpose OCX Specifications Net O2 Range Combustibles Accuracy Oxygen Combustibles System Response to Test Gas Oxygen Combustibles Temperature Limits Process Sensors Housing Electronics Housing 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.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Specifications Sensors Housing Electronics Housing Electrical Noise Certifications NEMA 4, IP66 with fitting and pipe on reference exhaust port to clean, dry atmosphere, two 3/4-14 NPT conduit ports NEMA 4, IP66 with fitting and pipe on reference exhaust port to clean, dry atmosphere, two 3/4-14 NPT conduit ports EN 61326-1, Class A C Line Voltage Pollution Degree Over Voltage Category Relative Humidity Isolated Output Oxygen Combustibl
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Table 1-1. Product Matrix - General Purpose OCX 8800 OCX88A O2/Combustibles Transmitter Code 00 11 21 31 12 22 32 13 23 14 24 Probe Length and Material No Probe or Exhaust Tube 18 in. (457 mm) 316 SST 18 in. (457 mm) Inconel 600 18 in. (457 mm) Ceramic 3 ft (0.91 m) 316 SST 3 ft (0.91 m) Inconel 600 3 ft (0.91 m) Ceramic 6 ft (1.83 m) 316 SST 6 ft (1.83 m) Inconel 600 9 ft (2.7 m) 316 SST 9 ft (2.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Table 1-2. Accessories PART NUMBER 1A99119H01 1-12 DESCRIPTION Oxygen test gas bottle; 0.4% O2, balance N2 1A99119H02 Oxygen test gas bottle; 8.
Instruction Manual IM-106-880 Original Issue February 2005 Section 2 OCX 8800 Installation Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-8 Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-14 Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 MECHANICAL INSTALLATION Selecting Location 1. The location of the OCX 8800 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The probe must be positioned so the gas it measures is representative of the process. Best results are normally obtained if the transmitter is positioned near the center of the duct (40-60% insertion).
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 4. Use the pipe or wall mounting hardware as shown in Figure 2-3 to mount the electronics housing. Choose a location not to exceed the length of the electronics cable ordered. 5. Ensure the conduits drop vertically from the OCX 8800 and the conduit is routed below the level of the conduit ports on the housing to form a drip loop. Drip loops minimize the possibility that moisture will damage the electronics (Figure 2-4). 6.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-1. Installation, OCX 8800 NOTE All dimensions are in inches with millimeters in parentheses. Insulate if exposed to adverse weather or extreme temperature changes, install a protective housing and/or insulation around the unit. Flange Dia. B.C. Dia. Hole Dia. Table 1. Mounting Flange DIN ANSI 5R10244H01 5R10244H02 Flange 7.28 6.00 Dia. (185) (152) 0.75 0.71 Hole Dia. (19) (18) (4) Holes 4.75 5.71 equally (121) (145) spaced on B.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-2. Adapter Plate Installation NOTE: Dimensions are in inches with millimeters in parentheses. Only adapter plate is furnished by Rosemount Analytical. Adapter Plate Kit - Mounting Dimensions *Type Part Number Plate Size "A" Stud Size "B" Bolt Circle Dia. “C" ANSI (P/N 4512C34G01) 6.00 (152) 5/8 -11 UNC - 2A 4.75 (121) DIN (P/N 4512C36G01) 7.50 (191) (M-16 x 2.0 - 6g) 5.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-3. Wall or Pipe Mounting of Electronics Housing Note: * Indicates items are included in mounting kit P/N 4851B40G01. *Pipe Mounting Clamp 1/4-20 UNC x 2 in. M-F Standoffs. Recommended for rear piping clearance when wall mounting.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-4.
Instruction Manual OCX 8800 ELECTRICAL INSTALLATION IM-106-880 Original Issue February 2005 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.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 NOTE To maintain proper earth grounding, ensure a positive connection exists between the sensor housing, the electronics housing, and earth. The connecting ground wire must be 14 AWG minimum. Refer to Figure 2-5. NOTE Line voltage, signal, and relay wiring must be rated for at least 105ºC (221ºF). Electrical Connections Electrical connections, power and communications are made to the electronic enclosure.
Instruction Manual OCX 8800 IM-106-880 Original Issue February 2005 Remote Electronics Connections to Sensor Housing Make the following connections between the electronics and sensor housings with the electronics cable ordered with the package (Figure 2-6). Braided cable is available in lengths up to 150 ft. (46 m). NOTE Interconnect wiring shown is for Rosemount Analytical supplied cables. For customer furnished interconnect wiring or cables, refer to Figure 2-7.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-5.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 #1 2HTR CO 1HTR CO 2HTR O2 1HTR O2 2HTR SB 1HTR SB YEL RED BLK ORG WHT BLU SHIELD GRN Figure 2-6.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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 contact to the cable shield. ELECTRONICS END 7.25 ±0.10 Strip Wire Ends 3/16” Typical Heat Shrink Tubing 2” Long 1/2” Size PROBE END 12.5 ±0.10 3/4 NPT Hub Size, Liquid-tight Strain Relief Connector 10.375 ±0.10 Heat Shrink Tubing 2” Long 1/2” Size 0.5 Typ.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-8. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration) Sensor Housing CAL Gas In Reference Air In ( CAL Gas Flow Meter 7 scfh, 20-30 psig Recommended ( Dilution Air In Dilution Air Flow Meter 0.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-9. Pneumatic Installation, OCX with Reference Air Set and Solenoids (with Autocalibration) Sensor Housing CAL Gas In ( ( CAL Gas Flow Meter 7 scfh, 20-30 psig Recommended Reference Air In Eductor Air In Dilution Air In CAL Gas Out Instrument Air Out Dilution Air Flow Meter 0.
Instruction Manual OCX 8800 IM-106-880 Original Issue February 2005 4. Connect the CO high gas to the CAL GAS HI COe inlet fitting. Install a shutoff valve and pressure regulator with gage in the CO high supply line. 5. Connect the CAL GAS outlet fitting of the electronics housing to the inlet port of the CAL GAS flow meter. Install an air line between the flow meter outlet port and the CAL GAS inlet fitting on the sensor housing.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-10. Piping Arrangement, Blowback with Autocalibration ( ( Cal Gas Flow Meter 7 scfh, 20-30 psig Recommended CAUTION Pressure regulator with 1/8” inlet port is factory set for 35 or 45 psig. Regulator with 1/4” inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the OCX 8800 will not work.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 2-11. Piping Arrangement, Blowback without Autocalibration CAUTION Check Valve Sensor Housing Pressure regulator with 1/8” inlet port is factory set for 35 or 45 psig. Regulator with 1/4” inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the OCX 8800 will not work.
Instruction Manual OCX 8800 IM-106-880 Original Issue February 2005 8. Install an air line between the instrument air outlet fitting on the electronics housing and the control air inlet fitting on the air-operated solenoid valve. 9. There are three settings that need to be specified to set up the blowback option. These are the blowback interval, duration, and purge time. Interval - Length of time between blowback events. (60 minutes recommended.) Duration - Length of time blowback air is activated.
Instruction Manual IM-106-880 Original Issue February 2005 Section 3 OCX 8800 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 . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 COe O2 Figure 3-1. OCX 8800 Defaults Open 21.1 mA Switch Default Postions Shown 3.5 mA 1 Open Closed 2 3 4 Closed O2 21.1 mA/3.5 mA: O2 4-20 mA Signal Rail Limits: Open High - 21.1 mA Closed Low - 3.5 mA SW3 3 4 1 2 COe 21.1 mA/3.5 mA: COe 4-20 mA Signal Rail Limits: Open High- 21.1 mA Closed Low - 3.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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 1. Use the HART communicator or AMS software to access the HART menu. 2. From the DETAILED SETUP menu, select O2 CALIB PARAMS. 3. From O2 CALIB PARAMS, select O2 High Gas. Enter the percent O2 used for the high O2 test gas. 4. From O2 CALIB PARAMS, select Low TG.
Instruction Manual IM-106-880 Original Issue February 2005 Section 4 OCX 8800 Using HART Communications Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1 HART Communicator Signal Connections . . . . . . . . . . . . page 4-1 HART Communicator PC Connections . . . . . . . . . . . . . . . page 4-4 HART Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-5 D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 4-1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Method 2, for Load Resistance < 250 Ohms Refer to Figure 4-2 and the following steps to connect the HART communicator to a signal line with less than 250 ohms load resistance. Do not make connections to the HART communicator's serial port, 4-20 mA signal lines, or NiCad recharger jack in an explosive atmosphere. Explosions can result in death or serious injury. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 HART COMMUNICATOR PC CONNECTIONS There is an option to interface the HART communicator with a personal computer. Load the designated AMS software into the PC. Then link the HART communicator to the PC using the interface PC adapter that connects to the serial port (on the communicator rear panel). Refer to the proper HART communicator documentation in regard to the PC interface option.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 HART MENU TREE This section consists of a menu tree for the HART communicator. This menu is specific to OCX 8800 applications. Figure 4-3.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 4-3.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 4-3.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 4-3.
Instruction Manual IM-106-880 Original Issue February 2005 D/A TRIM PROCEDURES OCX 8800 O2 D/A trim procedure using HART/AMS Use the following procedure to perform the O2 D/A trim procedure using the HART communicator or AMS. 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. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 COe D/A trim procedure using HART/AMS Use the following procedure to perform the COe D/A trim procedure using the HART communicator or AMS. Refer to the HART menu tree, Figure 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. 1.
Instruction Manual IM-106-880 Original Issue February 2005 Section 5 OCX 8800 Calibration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-1 Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . page 5-1 Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . page 5-3 Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual OCX 8800 IM-106-880 Original Issue February 2005 4. Select O2 CalIntrvl (O2 calibration interval) and enter the desired time in hours between automatic O2 calibrations. Select COE Callintrvl and enter the desired time between automatic COe calibrations. To disable automatic calibration for O2 and COe, enter 0 for both CalIntrvl parameters. 5.
Instruction Manual IM-106-880 Original Issue February 2005 OPERATOR - INITIATED AUTOCALIBRATION OCX 8800 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. 1. Select DIAG/SERVICE from DEVICE SETUP menu. 2.
Instruction Manual OCX 8800 IM-106-880 Original Issue February 2005 5. From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT CAL to exit calibration. Select one item from the list and press ENTER. OCX: TAG NAME SELECT ACTION 1. START/NEXT CALSTEP 2. ABORT CAL 3. EXIT CAL 6. When the Calibration Status is at the AppO2Low step, switch on O2 Low Gas. Verify the O2 concentration measured matches the O2 LOW GAS parameter in the Setup.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Manual COe Calibration using HART To perform a manual COe calibration using the HART communicator or AMS, use the following procedure. If necessary, refer to Section 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.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 9. The Calibration Status should be automatically changed to FlowCOeHi and then ReadCOeHi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time. The Next Cal Step command is not accepted at this time. 10. When ready, Calibration Status will stop at STOP GAS.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 5. From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT CAL to exit calibration. Select one from the list and press ENTER. OCX: TAG NAME SELECT ACTION 1. START/NEXT CALSTEP 2. ABORT CAL 3. EXIT CAL 6. When the Calibration Status is at the AppO2Low step, switch on O2 Low Gas. Verify the O2 concentration measured matches the O2 LOW GAS parameter in Setup.
Instruction Manual OCX 8800 5-8 IM-106-880 Original Issue February 2005
Instruction Manual IM-106-880 Original Issue February 2005 Section 6 OCX 8800 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 . . . . . . . . . . . . . . . . . . . . .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 OCX with Remote Electronics Remove Sensor Housing 1. Turn off power to the system. 2. Shut off the test gasses at the cylinders and close the instrument air valve. 3. Disconnect the calibration gas, reference air, eductor air, and dilution air lines from the sensor housing, Figure 6-1. Figure 6-1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 4. Remove the cover from the sensor housing to expose the sensor housing terminal blocks, Figure 6-2. 5. Disconnect the signal cable from the O2 and T/C terminal blocks, and from the CO and CJC terminal blocks. 6. Disconnect the heater power cable from the HTR terminal blocks. 7. If moving the sensor housing to another work site, disconnect and remove the power and signal cables from the sensor housing. 8.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Install Sensor Housing 1. Connect the test gas, reference air, eductor air, and dilution air lines to the sensor housing. 2. Remove the sensor housing cover. 3. If removed, install the power and signal cables and the customer power and signal conduits and wiring at the sensor housing. 4. Connect the signal cable to O2 and T/C terminal blocks and to the CO and CJC terminal blocks, Figure 6-2.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-3.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 2HTR CO 1HTR CO 2HTR O2 1HTR O2 2HTR SB 1HTR SB SHIELD #1 YEL RED BLK ORG WHT BLU GRN Figure 6-4.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Install Remote Electronics Housing 1. Mount remote electronics housing on wall or pipe within distance of signal and heater cables in use. 2. Remove the electronics housing cover. 3. If removed, install the power and signal cables and the customer power and signal conduits and wiring at the electronics housing. 4.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 REPAIR SENSOR HOUSING 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. Sensor Housing Disassembly Remove Cover and Terminals Insulator 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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 Gasket Screw Heater Clamp Heater Rod 3 7 4 9 5 6 11 10 12 8 13 2 1 37390067 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-6.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 2. Loosen screws (11, Figure 6-5) and rotate heater clamps (12) to release heater rods (13). One heater clamp secures each heater rod. 3. Slide sample block heater rods (13) out of housing (8). Remove COe Sensor Assembly 1. Disconnect COe heater, thermocouple, and sensor wires from terminal blocks. Refer to Figure 6-7. 2. Remove insulator (1, Figure 6-8).
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 NOTE For easier access, you may remove two screws from base of terminal block mounting (13) and move terminal block assembly out of the way. 3. Remove tubes (2, 3, and 4) from COe sensor assembly (5), eductor fittings (12 and 15), and sensor housing (7). 4. Unfasten bayonet connector of COe thermocouple (8) and remove thermocouple. 5. Loosen clamp screw of COe band heater (9) until heater rotaters freely on sensor holder (11). Figure 6-8.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 6. 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. 7. 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. 8. Slide band heater (10) and heater insulator (9) from sensor holder (11). Figure 6-9.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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. 1. Use straightedge to matchmark alignment of eductor flat and elbow, as shown in Figure 6-10. Figure 6-10. Eductor Alignment Matchmarks Eductor Flat Straightedge 37390036 Matchmark 2. Unscrew terminal block mounting (13, Figure 6-8).
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-11. Removal of Sample and Exhaust Tubes Remove Sample and Exhaust Tubes Use heat resistant gloves when removing the probe tube or exhaust tube. The tubes are bonded with a thread sealing compound. The compound softens at 450°F (232°C). The heated parts can cause severe burns. 1. Secure the sensor housing (1, Figure 6-11) in soft (plastic, wood, or brass) vice jaws. 2.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-12. O2 Cell, Heater, and Thermocouple, Exploded View Do not remove the O2 cell unless you are certain it needs to be replaced. Removal may damage the cell and platinum pad. Remove the O2 cell for cell replacement only. Disassemble O2 Cell and Heater Strut Assembly Do not attempt to replace the O2 cell until all other possibilities for poor performance have been considered.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Disassemble COe Sensor Assembly 1. Carefully remove screws (1, Figure 6-13), lockwashers (2), and COe sensor (3) from sensor holder (4). Remove and discard gasket (5). 2. If damaged, use the following procedure to remove thermocouple adaptor (6) from sensor holder (4): a. Use a propane torch to heat the thermocouple adaptor to 450°F (232°C), minimum. b. While heating, use a flat-head screwdriver to apply removal torque.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Always remove the stainless steel balls (approximately 200) from sensor holder before removing or installing pre-heater. Turning pre-heater in the sensor holder with the stainless steel balls in place will cause permanent damage to the pre-heater. 3. If pre-heater (7) is to be removed, clamp flats of sensor holder (4) in vise jaws with plug (8) pointing up. Remove plug.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-14. COe Sensor and Pre-Heater Alignment COe SENSOR ASSEMBLY TOP VIEW THERMOCOUPLE Sensor Holder Sensor Holder Flat Pre-Heater Flat Sensor Holder Flat 37390034 2 to 2-1/4 in. (51 to 57 mm) COe Sensor Flat 7. Install COe sensor (3), lockwashers (2), and screws (1). Rotate flat of COe sensor (3) to center of sensor holder (4). 8. Align COe sensor flat parallel to sensor holder flat, as shown in Figure 6-14.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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. 1. 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 4 3 5 8 1 11 9 2 15 10 6 12 13 16 14 1. 2. 3. 4. 5. 6. 7. 8.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 2. Install and tighten eductor (6) in eductor holder (14). 3. Install and tighten elbow (12) on eductor (6). Male port of elbow must point up and be in line with long axis of eductor. 4. Apply anti-seize compound to the external pipe threads of eductor holder (14). 5. Install and tighten eductor holder (14) in sensor housing (7). Align eductor with matchmarks, as shown in Figure 6-16. Figure 6-16.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Install COe Sensor Assembly Figure 6-17. Band Heater Height COe Sensor 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 of the pipe threads. 2. Screw sensor holder (11) onto eductor elbow (12). 0.37 in. (9,4 mm) 3. With wrenches on eductor elbow (12) and on flats of sensor holder (11), tighten sensor holder.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-18.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 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 Gasket Screw Heater Clamp Heater Rod 3 7 4 9 5 6 11 10 12 8 13 2 1 37390067 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Install Sample Block Heater Rods 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-21. O2 Cell, Thermocouple, and Heater Connections O2 Cell Wires Thermocouple Wires + Return Wire O2 Heater Wires + + + O2 ORG RED GRN YEL T/C O2 + + + - - 2 HTR 02 1 2 HTR HTRCO 02 1 2 HTR SB 1 O2 Cell and Heater Strut Assembly T/C SB + Sample Block - EXC Thermocouple - Sample Block Heater Rods CJC + CO REF + CO ACT + + EXC 37390068 Sensor Housing Terminals T/C CO + 2.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Install O2 Cell and Heater Strut Assembly 1. Rub a small amount of anti-seize compound on both sides of new gasket (10, Figure 6-20). 2. Apply anti-seize compound to threads of O2 cell and heater strut assembly (9) and sensor housing (8). 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 .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 REPAIR ELECTRONICS HOUSING 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. Electronics Housing Disassembly Remove Cover 1. See Figure 6-22.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-22. Removal/Installation of Electronics Housing Components 3 13 6 14 5 15 4 16 1. Screw 2. Locking Clip 3. Cover 4. O-ring 5. Electronics Stack 6. Flash PROM 7. thru 12. Not used 13. Screw 14. Lockwasher 15. Solenoid Valve (3 way) 16. Solenoid Valve 2 37390037 1 Remove Electronics Stack 1. Unplug power cable, signal cable, and solenoid lead connectors from terminals of electronics stack (5, Figure 6-22). 2.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Remove Solenoid Valves 1. Disconnect solenoid leads from mating terminal connector. 2. Remove top nut of solenoid valve (15 or 16, Figure 6-22). 3. Remove the solenoid coil assembly and washer. 4. Unthread and remove solenoid valve base. Remove EMI Filter and Terminal Block 1. Disconnect EMI filter wiring (Figure 6-23) at terminal block (3). 2. Disconnect EMI filter wiring at AC power input terminal block on electronic stack. 3.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Install Solenoid Valves 1. Disassemble replacement solenoid valve (15 or 16, Figure 6-22). 2. Install new solenoid valve base. Be careful not to overtighten. 3. Install new washer and solenoid coil assembly and secure with nut. 4. Connect the solenoid leads to the proper terminations on the solenoid power terminal block (Figure 6-26). Install Electronics Stack 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 2HTR CO 1HTR CO 2HTR O2 1HTR O2 2HTR SB 1HTR SB SHIELD #1 YEL RED BLK ORG WHT BLU GRN Figure 6-25.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-26. Solenoid Power Terminals SOL 2 SOL 3 SOL 4 SOL 1 TOP VIEW SOL 4 CO Test Gas SOL 3 SOL 2 High O2 Test Gas Low O2 Test Gas SOL 1 Instrument Air #1 37390033 #1 Install Cover 1. 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. 2.
Instruction Manual OCX 8800 REPLACE TUBE FITTINGS IM-106-880 Original Issue February 2005 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. ‘E’ Type Fitting The ‘E’ type fitting is an eductor drive air fitting for the OCX 8800 general purpose sensor housing.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 6-27. Removal of Tube Fittings 5 3 4 1. 2. 3. 4. 5. Sensor Housing Electronics Housing Tube Fitting Tube Fitting (Type R) Tube Fitting (Type E) 1 3 3 Install Tube Fittings 37390070 3 2 1. Verify that the replacement tube fitting is identical to the item removed. Special fittings are etched with code markings. 2. Apply pipe thread sealant (Loctite #567) to the mating threads of the tube fitting.
Instruction Manual OCX 8800 6-36 IM-106-880 Original Issue February 2005
Instruction Manual IM-106-880 Original Issue February 2005 Section 7 OCX 8800 Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-1 Diagnostic Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-2 Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-3 Alarm Relay Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Total Power Loss In the event that the OCX 8800 will not power up at all, check the incoming power supply to make sure power is being delivered to the OCX 8800. If the incoming power supply is good, then check fuses F1 and F6 in the electronics housing. Refer to Figure 7-1 for fuse locations. Figure 7-1.
Instruction Manual IM-106-880 Original Issue February 2005 FAULT ISOLATION OCX 8800 Faults in the OCX 8800 Transmitter are indicated by messages displayed on the HART communicator. Fault indications that can appear are listed in Table 7-1, Troubleshooting. If a fault is indicated on the HART communicator, locate the fault indication in Table 7-1. For each fault listed, there are related Probable Causes and Recommended Corrective Actions.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 SB Temp Hi (Sample block heater temperature high, > 190ºC) Probable Cause Recommended Corrective Action High noise in OCX power supply Check power supply for line noise or voltage fluctuations. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 SB TC Open (Sample block heater thermocouple open) Probable Cause Recommended Corrective Action Sample block thermocouple or thermocouple circuit open Check sample block thermocouple and circuit wires for breaks or loose connections per Figure 7-3 and Figure 6-6. Repair breaks or loose connections or replace failed thermocouple. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 ADC Failure (Voltage to digital conversion could not complete) ADC Ref Error (Voltage to digital conversion not accurate) Probable Cause Recommended Corrective Action Incorrect wiring between electronics and sensor housings Electronics package failure Check all wiring between the electronics and sensor housings per Figure 7-3. Correct wiring faults. Replace electronics package.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Cal Warning (Calibration warning) Cal Failed (Calibration failed) Probable Cause Recommended Corrective Action Calibration gas supply low or gas connection leaking Check calibration gas supplies and connections. Adjust gas pressure and flow. Replenish low calibration gas supplies and tighten or repair loose or leaking connections. When calibration gas supplies are adequate, recalibrate.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Board Temp Hi (Electronics temperature maximum exceeded, > 85ºC) Probable Cause Recommended Corrective Action Electronics housing exposed to high ambient temperature Insulate housing from source of high temperature and/or install cooling fan to remove heat from housing. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Line Voltage High (AC power line voltage above maximum, > 278 VAC) Probable Cause Recommended Corrective Action High noise or voltage fluctuations in power supply Electronics package failure Check power supply for line noise or voltage fluctuations. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power. Check power supply voltage and compare with line voltage.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 #1 2HTR CO 1HTR CO 2HTR O2 1HTR O2 2HTR SB 1HTR SB YEL RED BLK ORG WHT BLU SHIELD GRN Figure 7-3.
Instruction Manual IM-106-880 Original Issue February 2005 ALARM RELAY EVENTS OCX 8800 The OCX 8800 contains an alarm relay that can be configured to activate on one of twelve different groups of events. These event groups, and the conditions that trigger them, are listed in Table 7-2, Alarm Relay Event Groups. Table 7-2.
Instruction Manual OCX 8800 7-12 IM-106-880 Original Issue February 2005
Instruction Manual IM-106-880 Original Issue February 2005 Section 8 OCX 8800 Replacement Parts Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-2 Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-6 O2 Cell and Heater Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . page 8-9 http://www.processanalytic.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 SENSOR HOUSING Figure 8-1.
Instruction Manual IM-106-880 Original Issue February 2005 Index No.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 8-2.
Instruction Manual IM-106-880 Original Issue February 2005 Index No. Part Number 1 2 3 1A99089H02 5R10246H02 1A98448H02 OCX 8800 Description Cover Gasket (O-ring) Blowback Filter O-ring 4 5R10247H01 Adaptor 5 5R10183H02 Tube, Sample, 18 in. (457 mm) 316 Stainless steel 5R10183H06 Tube, Sample, 18 in. (457 mm) Inconel 600 5R10227G01 Tube, Sample, 18 in. (457 mm) Ceramic 5R10183H03 Tube, Sample, 3 ft. (0.91 m) 316 Stainless steel 5R10183H07 Tube, Sample, 3 ft. (0.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 ELECTRONICS HOUSING Figure 8-3.
Instruction Manual IM-106-880 Original Issue February 2005 Index No.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure 8-4. EMI Filter and Terminal Block Blue Brown Blue Green Brown Green Green 1 37390083 2 3 8-8 Index No.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 O2 CELL AND HEATER STRUT ASSEMBLY Figure 8-5. O2 Cell and Heater Strut Assembly 1 2 3 4 37390055 7 5 6 Index No.
Instruction Manual OCX 8800 8-10 IM-106-880 Original Issue February 2005
Instruction Manual IM-106-880 Original Issue February 2005 Appendix A OCX 8800 Safety Data Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-2 Ceramic Fiber Products Material Safety Data Sheet . . . . page A-15 High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . page A-21 http://www.raihome.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 BELANGRIJK Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel. De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 VIGTIGT Sikkerhedsinstruktion for tilslutning og installering af dette udstyr. Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bør også følges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder. 1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse forefindes.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 BELANGRIJK Veiligheidsinstructies voor de bedrading en installatie van dit apparaat. Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving anders voorschrijft. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 TÄRKEÄÄ Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa. Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive) yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta, elleivät kansalliset standardit estä sitä. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 IMPORTANT Consignes de sécurité concernant le raccordement et l'installation de cet appareil. Les consignes de sécurité ci-dessous s'adressent particulièrement à tous les états membres de la communauté européenne. Elles doivent être strictement appliquées afin de satisfaire aux directives concernant la basse tension.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 WICHTIG Sicherheitshinweise für den Anschluß und die Installation dieser Geräte. Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der Niederspannungsrichtlinie zu genügen. Nichtmitgliedsstaaten der europäischen Gemeinschaft sollten die national gültigen Normen und Richtlinien einhalten. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 IMPORTANTE Norme di sicurezza per il cablaggio e l'installazione dello strumento. Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell'Unione Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all'Unione Europea, salvo quanto disposto dalle vigenti normative locali o nazionali. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 VIKTIG Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret. Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder. 1.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 IMPORTANTE Instruções de segurança para ligação e instalação deste aparelho. As seguintes instruções de segurança aplicam-se especificamente a todos os estados membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tensão. Relativamente aos estados que não pertençam à UE, deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação local a tiver substituído.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 IMPORTANTE Instrucciones de seguridad para el montaje y cableado de este aparato. Las siguientes instrucciones de seguridad, son de aplicacion especifica a todos los miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension. 1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en aquellos terminales previstos al efecto. 2.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 VIKTIGT Säkerhetsföreskrifter för kablage och installation av denna apparat. Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varje avseende för att överensstämma med Lågspännings direktivet. Icke EU medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala eller nationella föreskrifter. 1.
Instruction Manual OCX 8800 A-14 IM-106-880 Original Issue February 2005
Instruction Manual IM-106-880 Original Issue February 2005 CERAMIC FIBER PRODUCTS MATERIAL SAFETY DATA SHEET OCX 8800 JULY 1, 1996 SECTION I. IDENTIFICATION PRODUCT NAME Ceramic Fiber Heaters, Molded Insulation Modules and Ceramic Fiber Radiant Heater Panels. CHEMICAL FAMILY Vitreous Aluminosilicate Fibers with Silicon Dioxide. CHEMICAL NAME N.A. CHEMICAL FORMULA N.A. MANUFACTURER'S NAME AND ADDRESS Watlow Columbia 2101 Pennsylvania Drive Columbia, MO 65202 573-814-1300, ext.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 SECTION IV. FIRE AND EXPLOSION DATA FLASH POINT: NONE FLAMMABILITY LIMITS: N.A. EXTINGUISHING MEDIA Use extinguishing agent suitable for type of surrounding fire. UNUSUAL FIRE AND EXPLOSION HAZARDS / SPECIAL FIRE FIGHTING PROCEDURES N.A. SECTION V. HEALTH HAZARD DATA THRESHOLD LIMIT VALUE (See Section III) EFFECTS OF OVER EXPOSURE • EYE - Avoid contact with eyes. Slightly to moderately irritating.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 3) A statistical "trend" was observed in the exposed population between the duration of exposure to RCF and a decrease in some measures of pulmonary function. These observations are clinically insignificant. In other words, if these observations were made on an individual employee, the results would be interpreted as being within the normal range.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 SECTION VI. REACTIVITY DATA STABILITY/CONDITIONS TO AVOID Stable under normal conditions of use. HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID N.A. INCOMPATIBILITY/MATERIALS TO AVOID Incompatible with hydrofluoric acid and concentrated alkali. HAZARDOUS DECOMPOSITION PRODUCTS N.A. SECTION VII.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 SECTION IX. SPECIAL PRECAUTIONS PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING General cleanliness should be followed. The Toxicology data indicate that ceramic fiber should be handled with caution. The handling practices described in this MSDS must be strictly followed.
Instruction Manual OCX 8800 IM-106-880 Original Issue February 2005 If airborne fiber or cristobalite concentrations are not known, as minimum protection, use NIOSH/MSHA approved half face, air-purifying respirator with HEPA filter cartridges. Insulation surface should be lightly sprayed with water before removal to suppress airborne dust. As water evaporates during removal, additional water should be sprayed on surfaces as needed.
Instruction Manual IM-106-880 Original Issue February 2005 HIGH PRESSURE GAS CYLINDERS OCX 8800 GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed Gases" published in 1981 Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202 Used by Permission 1. Never drop cylinders or permit them to strike each other violently. 2.
Instruction Manual OCX 8800 A-22 IM-106-880 Original Issue February 2005
Instruction Manual IM-106-880 Original Issue February 2005 Appendix B OCX 8800 SPA with HART Alarm Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure B-2. OCX 8800 and SPA Interface Connections HART Model 275/375 Handheld Communicator OCX 8800 > R < 250 Ω 950 Ω Customers DCS, PLC, or PC with AMS Software 4-20 mA O2 Signal Loop Analog Output IN IN 4-20 mA or 0-24 vdc 37390022 Event Recorder, Audible Alarm, or other Analog Device INSTALLATION Refer to Figure B-2 for the typical interface connections for the OCX 8800 and the SPA with HART alarm.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure B-3. SPA Jumper and Dip Switch Settings NOTICE REMOVE THIS PANEL FOR SERVICE ACCESS. STATIC SENSITIVE. USE CAUTION WHEN CHANGING JUMPERS Access Cover SPA - Bottom View Source Current Dip Switches (shown in correct position) Figure B-4. SPA Setup for Calibration Password OFF Failsafe Dip Switches (shown in correct position) 2. Verify that the Password Jumper is set to the OFF position.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 NOTE The O2 signal connection is not required for SPA configuration or calibration. The OCX interface will allow you to observe the O2 signal level when the SPA configuration procedure is completed. 4. Observe the front panel of the SPA, Figure B-5: a. A process value display in the SPA display window indicates that the SPA is operational. Four pushbuttons are located below the display window. b.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 5. Figure B-6 shows the SPA menu, submenus, and parameter values that must be selected to configure the SPA for use with the OCX 8800. Use the following instructions and selections shown to properly configure the SPA. a. Press the SELECT pushbutton. Observe the display window on the SPA front panel. The display window should read SET HART. b. See the SET HART command in Figure B-6.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Figure B-6.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Appendix C Return of Materials RETURNING MATERIAL If factory repair of defective equipment is required, proceed as follows: 1. Secure a return authorization number from a Rosemount Analytical sales office or representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount Analytical instructions or it will not be accepted.
Instruction Manual OCX 8800 C-2 IM-106-880 Original Issue February 2005
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Index A Accessories . . . . . . . . . . . . . . 1-12 Alarm Relay Events . . . . . . . . 7-11 Assemble O2 Sensor . . . . . . . 6-19 Autocalibration Setup, HART . . 5-1 Autocalibration, HART . . . . . . . 5-3 B Band Heater Height . . . . . . . . 6-22 Blowback System . . . . . . 1-5, 2-17 Blowback with Autocalibration . . . . . . . . . . . 2-18 Blowback without Autocalibration . . . . . . . . . . . 2-19 C Cable Connections . . . . . . . .
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Selected Distributed Control Systems . . . . . . . . . . . 1-5 Sensor Housing Components . . . . . . . . . . 8-2, 8-4 Sensor Housing Disassembly . . . . . . . . . . . . . . 6-8 Sensor Housing Leak Test . . . 6-27 Sensor Housing Terminals . . . . 6-3 Solenoid Power Terminals . . . 6-33 SPA Configuration Menu . . . . . . B-6 SPA Front Panel . . . . . . . . . . . . B-4 SPA Interface Connections . . . .
WARRANTY Rosemount Analytical warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount Analytical shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts.
Instruction Manual IM-106-880 Original Issue February 2005 OCX 8800 Rosemount Analytical and the Rosemount Analytical logotype are registered trademarks of Rosemount Analytical Inc. HART is a registered trademark of the HART Communications Foundation. All other marks are the property of their respective owners. Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 6565P Davis Industrial Parkway Solon, OH 44139 T (440) 914 1261 F (440) 914 1271 E gas.csc@emersonprocess.
