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Instruction Manual

IM-106-880, Rev 1.0
January 2007

OCX 8800

http://www..raihome.com

Section 7

Maintenance and Service

Overview  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-1
OCX 8800 Removal and Installation  . . . . . . . . . . . . . . . . . page 7-1
Repair Sensor Housing   . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-5
Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . page 7-25
Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-31

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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Summary of Contents for OCX 8800

Page 1: ...ihome com Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 Oxygen Combustibles Transmitter Hazardous Area OCX 8800 Oxygen Combustibles Transmitter with Integral Electronics and Local Operator Interface ...

Page 2: ......

Page 3: ...Revised the text for SW1 and SW2 to read internally powered Page 3 3 Revised Figure 3 1 Updated the paragraph Initial Power Up Page A 2 thru A 23 Added note 11 to the safety data section Added additional pages languages Page C 1 Updated the return of materials address Back cover Updated the address blocks ...

Page 4: ......

Page 5: ... 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 the LOI Overview 4 1 Display Orientation 4 1 LOI Controls 4 2 Overview 4 2 LOI Key Functions 4 2 LOI Status Codes 4 3 LOI Menu Tree 4 4 D A Trim Procedures 4 8 SECTION 5 Using HART Communications Overview 5 1 HART Communicator Signal Connections 5 1 HART Co...

Page 6: ...7 31 Install Tube Fittings 7 32 SECTION 8 Troubleshooting Overview 8 1 Grounding 8 1 Electrical Noise 8 1 Electrostatic Discharge 8 1 Total Power Loss 8 2 Diagnostic Alarms 8 2 Fault Isolation 8 3 Alarm Relay Events 8 11 SECTION 9 Replacement Parts Sensor Housing 9 2 Electronics Housing 9 6 O2 Cell and Heater Strut Assembly 9 9 APPENDIX A Safety Data Safety Instructions A 2 Safety Data Sheet for C...

Page 7: ...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 ...

Page 8: ...r 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 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...

Page 9: ...STEM OVERVIEW Scope This Instruction Manual supplies details needed to install startup operate and maintain the OCX 8800 Signal conditioning electronics outputs separate 4 20 mA signals representing oxygen O2 and combustibles COe values This information plus additional details can be accessed with the HART Model 275 375 handheld communicator or Rosemount Analytical AMS software The local operator ...

Page 10: ...uction Manual 2 HART Communicator Package optional 3 Adapter Plate with Mounting Hardware and Gasket 4 Reference Air and Calibration Set 5 Blowback Hardware optional 6 OCX 8800 with Integral Electronics 4 6 1 37390006 2 o HART Communicator FISHER ROSEMOUNTTM MAN 4275A00 English October 1994 3 5 Analytica l ...

Page 11: ... 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 There...

Page 12: ... are 18 in 457 mm 3 ft 0 91 m 6 ft 1 83 m or 9 ft 2 7 m Probes are available in three material options 316L stainless steel inconel 600 and ceramic to accommodate higher temperatures The electronics are contained in a separate housing from the sensors The electronics and sensor housings are integrally mounted The electronics control both sensor temperatures and provide individual 4 20 mA isolated ...

Page 13: ...nt 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 fl...

Page 14: ...Test Gas Solenoids Instrument Air Solenoid High O Test Gas 2 CO Test Gas Instrument Air Dilution Air Reference Air Eductor Air Flow Meter 50 cc min 0 1 scfh SENSOR HOUSING ELECTRONICS HOUSING Flow Meter 7 scfh 37390001 Sample Gas Power Supply It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to prevent possible...

Page 15: ...ed with an in place calibration feature provision should be made for connecting test gas tanks to the OCX 8800 when it is to be calibrated NOTE The electronics module is designed to meet NEMA 4 IP66 and the electronic components are rated to temperatures up to 185 F 85 C Retain packaging in which the unit arrived from the factory in case any components are to be shipped to another site This packag...

Page 16: ...System Installation 4 20 mA Outputs 2 Twisted Pairs Stack OCX 8800 with INTEGRAL ELECTRONICS Duct Gases Line Voltage Adapter Plate Pressure Regulator 37390063 Test Gas Flow Meter Low O Test Gas 2 High O Test Gas 2 Dilution Air Flow Meter CO Test Gas Instrument Air Supply Reference Gas ...

Page 17: ... but the OCX 8800 will continue to operate properly Nominal and Approximate Shipping Weights 18 in 457 mm probe package 54 lbs 20 kg 3 ft 0 91 m probe package 55 lbs 20 5 kg 6 ft 1 83 m probe package 57 lbs 21 kg 9 ft 2 74 m probe package 59 lbs 22 kg Housings Mounting Flange Materials Probes 316L stainless steel 1300 F 704 C Inconel 600 1832 F 1000 C Ceramic 2600 F 1427 C Enclosures Low copper al...

Page 18: ...e 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 Specificati...

Page 19: ...sting 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 H1 HART Communications 2 H2 HART Communications with LOI H3 HART Communications with Calibration Solenoids 2 H4 HART Communications with LOI and Calibration Solenoids Code Electronics Mounti...

Page 20: ...120H02 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 4851B40G01 Wall or Pipe Mounting Kit 1A99784H02 375 HART Communicator ...

Page 21: ...e 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...

Page 22: ...kage The presence of this condition will substantially affect the accuracy of the oxygen and combustibles readings Therefore either make the necessary repairs or install the transmitter up stream of any leakage 3 Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance access to the unit Allow adequate clearance for the removal of the OCX...

Page 23: ...ubes through the opening in the mounting flange and bolt the unit to the flange 7 If insulation is removed to access the duct for OCX 8800 mounting make sure to replace insulation afterward Enclosures The OCX 8800 enclosures are designed to meet ingress conditions of IP66 Each enclosure cover is threaded to its base and sealed with an o ring that isolates the threads from external contaminants Eac...

Page 24: ...8 Dim A Insertion Depth Flange Dia Hole Dia 8 3 211 Allow 9 in 229 mm for Cover Removal Table 2 Installation Removal Optional In Situ Filter Table 1 Mounting Flange Hole Dia 4 Holes equally spaced on B C dia 7 28 185 0 75 19 0 71 18 4 75 121 5 71 145 3535B18H02 3535B45H01 DIN ANSI 0 06 In Thick Gasket Insulate if exposed to adverse weather or extreme temperature changes install a protective housin...

Page 25: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 2 5 OCX 8800 Figure 2 2 Adapter Plate Installation ...

Page 26: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 2 6 Figure 2 3 Installation with Drip Loops 37020004 Conduit Drip Loops Duct Wall Conduit Drip Loop Conduit Drip Loop Duct Wall ...

Page 27: ...n 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 94...

Page 28: ... L terminal and the neutral N wire to the N terminal on the AC power input terminal block in the electronics housing Connect the ground G wire to the ground stud in the electronics housing as shown in Figure 2 4 Connect 4 20 mA Signals Connect the 4 20 mA current loop to the 4 20 mA signal output terminals in the electronics housing as shown in Figure 2 4 Use individual shielded twisted wire pairs...

Page 29: ...1 2 SIZE Ground Stud Earth Ground Typical for Electronics and Sensor Housing NC COM NO Alarm Output Relay Terminal Block 1 AOUT2 AOUT2 AOUT1 AOUT1 O Signal 2 COe Signal Ground Stud 4 20 mA Signal Output Terminal Block Power Port 3 4 NPT Signal Port 3 4 NPT External Tooth Lockwasher 1 G G Terminal Block N G L1 EMI Filter Customer Wiring ...

Page 30: ...s housing and to the inlet side of the dilution air flow meter 2 Connect the dilution air flow meter output to the dilution air inlet fitting on the sensor housing 3 Install an air line between the instrument air outlet fitting on the electronics housing and the tee fitting on the sensor housing 4 One CO gas and two O2 gases are used to calibrate the OCX 8800 CO 1000 ppm or 4 O2 low gas 0 4 O2 hig...

Page 31: ...ibration 37390011 Electronics Housing Eductor Air In Sensor Housing Dilution Air In Reference Air In CAL Gas In CAL Gas Flow Meter 7 scfh 20 30 psig Recommended Dilution Air Flow Meter 0 1 scfh Instrument Air Supply Pressure Reguator Filter 35 psig General Purpose 45 psig Hazardous Area 2 Stage Regulators CO HI O 2 LO O 2 Instrument Air Out ...

Page 32: ... 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 3 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 Electronics Housing Dilution Air In Reference Air In CAL Gas In...

Page 33: ... set calibration gas solenoids and blowback options are included with your transmitter use the following procedure to install the pneumatic system components 1 Connect the calibration gas sources according to the instructions in the previous paragraph Reference Air Set and Solenoids Option steps 2 through 5 2 Connect a clean dry instrument quality supply of air 20 95 O2 to the 35 45 psig and 55 ps...

Page 34: ...lenoid Valve Electronics Housing Eductor Air In Sensor Housing Dilution Air In Reference Air In Cal Gas Flow Meter 7 scfh 20 30 psig Recommended Dilution Air Flow Meter 0 1 scfh Instrument Air Supply Pressure Regulator Filter 35 psig General Purpose 45 psig Hazardous Area CAL Gas Out Instrument Air Pressure Regulator Filter 55 psig Normally Open Solenoid Valve 2 Stage Regulators CO HI O 2 LO O 2 C...

Page 35: ...s Flow Meter 7 scfh 20 30 psig Recommended Dilution Air Flow Meter 0 1 scfh Instrument Air Supply Pressure Regulator Filter 35 psig General Purpose 45 psig Hazardous Area 2 Stage Regulators CO HI O 2 LO O 2 Instrument Air Pressure Regulator Filter 55 psig Normally Open Solenoid Valve Pressure regulator with 1 8 inlet port is factory set for 35 or 45 psig Regulator with 1 4 inlet port is factory se...

Page 36: ...s required by the application These settings are available through HART from the DEVICE SETUP DETAILED SETUP OUTPUT CONDITIONS BLOWBACK menu Using the LOI these settings are accessible from the SYSTEM INPUT OUTPUT BLOWBACK menu INITIAL STARTUP Observe the following Caution and Note Refer to Section 3 Configuration and Startup for OCX 8800 startup information NOTE During outages and whenever possib...

Page 37: ...ctrical 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 ...

Page 38: ...ttings 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...

Page 39: ...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 1 2 3 4 Internal O 4 20 mA is Internally Powered 2 External O 4 20 mA Requires an External Power Supply Default 2 O 21 1 mA 3 5 mA 2 O 4 20 mA Signal Rail Limits High 21 1 mA Low 3 5 mA 2 COe 4 20 mA Signal Rail Limit...

Page 40: ...b Setup select O2 High Gas Enter the percent O2 used for the high O2 test gas 4 Select the down arrow and the next selection will be O2 Low Gas Enter the percent O2 used for the low O2 test gas 5 Select the down arrow several times to display COe Test Gas Enter the CO concentration ppm used for COe test gas OCX 8800 RESET PROCEDURE Whenever you correct an equipment alarm or fault condition the OCX...

Page 41: ...d operation of the LOI module in the OCX 8800 DISPLAY ORIENTATION The LOI module mounts to a connector on the LOI board The board is installed on the end of the electronics stack in the electronics housing Figure 4 1 There are four mating connectors on the back of the LOI module that allow the LOI to be oriented as desired by the user Figure 4 1 LOI Components Mounting Electronics Housing Cover Re...

Page 42: ...ove one level higher in the menu structure When entering parameter values numbers this key moves the cursor to the left The left pointing key also doubles as an Enter key used after the digits of a parameter value are entered and the cursor is moved to its left most position When the Enter key is touched the new parameter value if accepted will appear in the top line of the display The blue bottom...

Page 43: ...lso user configurable Figure 4 3 Z Pattern Entry LOI Status Codes The LOI display shows a status code in the lower right hand corner of the display There are nine status codes to indicate the existing status of the device during operation The status code descriptions are shown in Table 4 1 Table 4 1 LOI Status Codes 37390057 E Analytical 3 4 1 2 CODE DESCRIPTION AL Alarm The device is in a recover...

Page 44: ...rst column submenu Third and Fourth Column Submenus From the second column submenus selecting the right pointing key moves the display into the third column submenus The third column submenu may be another menu or a list of parameters The up and down pointing keys allow the display to move to the different parameters or menus The third or fourth column submenu may be a parameter list When a parame...

Page 45: ...y Hit E when ready Hit E when ready Apply Lo COe Gas Flow COe Lo _____s ______ _____mV Read COe Lo _____s ______ _____mV Hit E when ready Apply Hi COe Gas Flow COe Hi _____s ______ _____mV Read COe Hi _____s ______ _____mV Purge _____s Hit E when ready Hit E when ready Apply Lo O2 Gas Flow O2 Lo _____s ______ _____mV Read O2 Lo _____s ______ _____mV Apply Hi O2 Gas Flow O2 Hi _____s ______ _____mV...

Page 46: ...r 1 Event Trigger 2 Event Trigger 3 Event All COe Temp Sample Pr Sen Sample Ln Temp Unit Fail Hi Elect Temp Calib Fail O2 Cell Bad O2 Htr Open O2 Cell Temp In Calibrtn Off Calib Setup Blowback Alarm Relay Analog 37390017 O2 Type 20 4 mA COe Type 20 4 mA COe Range HI ___ppm Trim COe Out procedure O2 Range Hi ___ O2 Range Lo ___ O2 AlarM Level ___mA Trim O2 Out procedure COe Range Lo ___ppm COe Alar...

Page 47: ... COe Slope ___ ppm ohm Version Checksum Build Number Build Date Parameters Software 37390056 CONTINUED FROM SHEET 3 Restart Count SW Err File SW Err Line SW Err Number Revert Time ___ minutes O2 T90 Time ___ seconds Luminance ___ PCDC Enable ___ Y N Lockout Time ___ seconds PCNC Enable ___ Y N Alarms CPLD Registers Line Frequency Line Voltage Status PCD Counter Sensor Housing Serial Number PCN Cou...

Page 48: ...llamp output at the digital multimeter Use the right pointing key to select each digit and use the up and down pointing keys to change the value When the correct value is displayed use the Enter key to input the value 7 The LOI displays 20 mA Meter The trim program inputs the design equivalent signal for a 20 00 mA output Read the O2 millamp output at the digital multimeter Use the right pointing ...

Page 49: ...the digital multimeter Use the right pointing key to select each digit and use the up and down pointing keys to change the value When the correct value is displayed use the Enter key to input the value 7 The LOI displays 20 mA Meter The trim program inputs the design equivalent signal for a 20 00 mA output Read the COe millamp output at the digital multimeter Use the right pointing key to select e...

Page 50: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 4 10 ...

Page 51: ...unicator accomplishes its task using a Frequency Shift Keying FSK technique With the use of FSK high frequency digital communication signals are superimposed on the 4 20 mA oxygen output signal The communicator does not disturb the 4 20 mA signal since no net energy is added to the loop HART information is not available on the COe output signal The HART communicator may be interfaced with a person...

Page 52: ... the HART communicator in parallel to the OCX 8800 Use any wiring termination points in the oxygen analog output 4 20 mA signal line Loop Connectors O 4 20 mA Signal Line 2 HART Communicator Model 275 375 RL 250Ω Analog Output Device HART Communicator Rear Panel Lead Set 37390023 4 20 mA Terminal Block in Electronics Housing A OUT 1 A OUT 1 1 Do not make connections to the HART communicator s seri...

Page 53: ...located on the rear panel of the HART communicator Figure 5 2 Signal Line Connections 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 250 OHM Load Resistor See Note 37390021 The signal loop must be broken to insert the optional 250 ohm loa...

Page 54: ...erations are those in which the communicator is not connected to the OCX 8800 Off line operations can include interfacing the HART communicator with a PC Refer to applicable HART documentation regarding HART PC applications In the on line mode the communicator is connected to the oxygen 4 20 mA analog output signal line The communicator is connected in parallel to the OCX 8800 or in parallel to th...

Page 55: ...AO COe COe AO CONTINUED ON SHEET 2 37390038 SV is COe COe AO COe AO VIEW OUTPUT VARS VIEW O2 RAW VAL VIEW COE RAW VAL VIEW DEV RAW VAL SB T C Brd Temp IC CJC Temp S O2 Snsr O2 T C O2 Snsr R O2 Snsr RS COe DeltV COe RefV COe DeltaR Coe RefR COe T C RTD Curr PV AOUT 4V TV SV PV is O2 O2 AO O2 AO TV is O2 Temp 4V is COe Temp VIEW DEV LIMITS O2 SB TEMP BOARD TEMP COE O2 O2 O2 USL O2 LSL SB Temp SB TC ...

Page 56: ...ev Prev VERIFY CALIB Verify Calibration Status TimeRemain O2 COe BlBk State Blowback BLOWBACK MAX TEMP O2TempMax COeTempMax SBTempMax BrdTempMax CJCTempMax O2 Prop O2 Int O2 DutyCyc O2 SetPt O2 Temp HEATER PID O2 PID COE PID SB PID COe Prop Int DutyCyc SetPt Temp COe COe COe COe SB Prop SB Int SB DutyCyc SB SetPt SB Temp 37390039 Line Freq Line Volt PCN Counter PCD Counter Status group 4 RTD Curre...

Page 57: ...Tm BlBk State ANALOG OUTPUT ALARM RELAY DEVICE PARAMS LOI PARAMS O2 CALIB PARAMS BLOWBACK COe AO Type COe URV COe LRV COe Alarm Level O2 ANALOG OUTPUT COe ANALOG OUTPUT O2OutTracks O2 High Gas O2 Low Gas Gas Time Purge Time Solenoids O2 CalIntv O2NxtCalTm COeOutTracks COe Test Gas Gas Time Purge Time Solenoids COe CalIntv COeNxtCalTm COe Slope Warn O2 Slope O2 Const O2 T90 COe Slope COe Const COe ...

Page 58: ... CONTINUED FROM SHEET 3 37390041 Tag Poll addr Dev id Num req preams Fld dev rev Universal rev DEVICE CONFIG COE CALIB O2OutTracks O2 High Gas O2 Low Gas Gas Time Purge Time Solenoids O2 CalIntv O2NxtCalTm COeOutTracks COe Test Gas Gas Time Purge Time Solenoids COe CalIntv COeNxtCalTm COe Slope Warn COE DEVICE CONFIG DEVICE CONFIG Trig 1 Event Trig 2 Event Trig 3 Event BlBk Enabled BlBk Intrvl BlB...

Page 59: ... from the O2 D A coverter circuit Connect the positive lead to the AOUT1 terminal and connect the negative lead to the AOUT1 terminal Then press OK at the HART communicator 6 The HART 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 HART communicator and press ENTER Select ABORT to exit without changes 7 The...

Page 60: ...milliamp output from the COe D A coverter circuit Connect the positive lead to the AOUT2 terminal and connect the negative lead to the AOUT2 terminal Then press OK at the HART communicator 6 The HART 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 HART communicator and press ENTER Select ABORT to exit with...

Page 61: ...omatic and manual Calibration commands and menus can be accessed by HART AMS or by the LOI FULLY AUTOMATIC CALIBRATION If the OCX 8800 is equipped with calibration solenoids the unit can be programmed to automatically calibrate without any operator action Refer to the following paragraphs for using the LOI or HART AMS to set up the OCX 8800 for fully automatic calibration Autocalibration Setup usi...

Page 62: ...s desired between automatic calibrations 8 Use the down pointing key to select the next item O2 Next Cal Enter the amount of time in hours until the next automatic calibration Select the left pointing key three times to move back to the LOI operating display Autocalibration Setup using HART NOTE Automatic calibration is only available on units equipped with calibration solenoids Use the following ...

Page 63: ... item either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number To return to a preceding menu press the left arrow key 6 From the O2 CALIB PARAMS screen select CalIntrvl 7 At the prompt input a time interval in hours at which an automatic O2 calibration will occur and press ENTER 8 From the DETAILED SETUP ...

Page 64: ...type of calibration desired O2 Calibration COe Calibration or O2 and COe Calibration MANUAL CALIBRATION If a unit is not equipped with calibration solenoids a calibration must be performed by an operator following prompts from the unit Refer to the following paragraphs for manual calibration Manual Calibration using the LOI Use the following procedure to perform a manual calibration with the LOI I...

Page 65: ... key to start the CO gas purge 15 When the purge period expires the LOI display reverts to the normal operation display If the calibration failed the display will indicate an alarm condition Manual O2 Calibration using HART To perform a manual O2 calibration using the HART communicator or AMS use the following procedure If necessary refer to Section 5 Using HART Communications for the HART menu tr...

Page 66: ...en 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 Fl...

Page 67: ...ion screen should look like the following Press OK to continue OCX TAG NAME STATUS Idle TIME REMAIN 0s COe 0 20 ppm 0 00 mV OK NEXT to Select ABORT CANCEL to Exit 5 From the SELECT ACTION screen select START NEXT CALSTEP to continue calibration select ABORT CAL to abort calibration or EXIT CAL to exit calibration Select one item from the list and press ENTER OCX TAG NAME SELECT ACTION 1 START NEXT...

Page 68: ...l to exit the calibration method Manual O2 and COe Calibration using HART To perform a manual O2 and COe calibration using the HART communicator or AMS use the following procedure If necessary refer to Section 5 Using HART Communications for the HART menu tree NOTE To select a menu item either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number...

Page 69: ...hen 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 Operato...

Page 70: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 6 10 ...

Page 71: ... 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...

Page 72: ...erminal block 7 If used disconnect and remove the external relay leads from the alarm output relay terminal block 8 Disconnect and remove customer power and signal wire conduits and wiring from the electronics housing 9 Remove insulation to access the sensor housing mounting bolts Unbolt the OCX 8800 from the stack and take it to a clean work area 10 Allow the unit to cool to a comfortable working...

Page 73: ... SIZE Ground Stud Earth Ground Typical for Electronics and Sensor Housing NC COM NO Alarm Output Relay Terminal Block 1 AOUT2 AOUT2 AOUT1 AOUT1 O Signal 2 COe Signal Ground Stud 4 20 mA Signal Output Terminal Block Power Port 3 4 NPT Signal Port 3 4 NPT External Tooth Lockwasher 1 G G Terminal Block N G L1 EMI Filter Customer Wiring ...

Page 74: ...d Secure the connection with two nuts Attach a separate ground lead G wire from the ground stud to the G terminal on the power input terminal block 8 Install the cover on the electronics housing 9 Restore power to the system Allow OCX to reach normal operating temperature before installing in a hot process stack 10 Bolt the OCX 8800 to the stack and install insulation Refer to Figure 7 1 and make ...

Page 75: ...se the assembly procedures that apply to install replacement parts and reassemble the unit Sensor Housing Disassembly Remove Cover and Terminals Insulator 1 Loosen screw 1 Figure 7 3 and slide locking clip 2 away from cover Retighten screw 1 2 With two hands or strap wrench turn cover 3 counterclockwise to loosen Unthread and remove cover 3 Inspect cover o ring 4 for wear or damage Replace cover o...

Page 76: ...l and Heater Strut Assembly 5 6 12 11 14 15 10 9 1 2 4 3 7 8 13 37390066 1 Screw 2 Locking Clip 3 Cover 4 O ring 5 Marking Plate 6 Terminal Insulator 7 Reference Air Tube 8 Sensor Housing 9 Heater Strut Assembly 10 Gasket 11 Screw 12 Heater Clamp 13 Heater Rod 14 Insulator 15 Thermal Switch 15 ...

Page 77: ...ng terminals 3 Remove the O2 cell and heater strut assembly 9 Figure 7 3 from sensor housing 8 Remove and discard gasket 10 Remove Sample Block Heater Rods 1 Disconnect sample block heater rod wires from terminal block Refer to Figure 7 4 O2 Thermocouple Wires ORG RED T C O2 T C CO T C SB EXC CJC O Cell Wires 2 O Heater Wires 2 Return Wire O Cell and Heater Strut Assembly 2 CO REF CO ACT Sensor Ho...

Page 78: ... thermal switch Remove COe Sensor Assembly 1 Disconnect COe heater thermocouple and sensor wires from terminal blocks Refer to Figure 7 5 2 Remove insulator 1 Figure 7 6 Figure 7 5 COe Sensor Thermocouple and Heater Connections O2 RED T C O2 T C CO T C SB EXC CJC COe Sensor Wires COe Heater Wires COe Sensor Assembly CO REF CO ACT Sensor Housing Terminals HTR 02 HTR SB 2 2 1 YEL 37390018 HTR 02 2 1...

Page 79: ...et 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 7 6 Removal of COe Sensor Assembly 1 5 6 7 8 9 10 11 12 13 14 1 Insulator 2 Dilution Air Tube 3 COe Extractive Tube 4 Eductor Air Tube 5 COe Sensor Assembly 6 Eductor 7 Sensor Housing 8 COe Thermocouple 9 Heater Insulator 10 COe Band Heater 11...

Page 80: ...w correct alignment of sensor holder 7 With one wrench holding eductor elbow 12 Figure 7 6 and one wrench on flats of sensor holder 11 unthread and remove COe sensor assembly 5 Do not allow eductor elbow to turn 8 Slide band heater 10 and heater insulator 9 from sensor holder 11 Figure 7 7 Alignment of COe Sensor Assembly 37390035 Sensor Holder Flat Matchmark Straightedge Matchmark ...

Page 81: ...s of eductor 6 in jaws of bench vise 5 Use a propane torch to heat the eductor 6 to 450 F 232 C minimum Apply the heat near the screw threads 6 While heating the eductor 6 use wrench to apply removal torque to elbow 12 eductor holder 14 or tube fitting 15 until the thread sealant softens Remove mating parts 12 14 and 15 7 Use MEK or methylene chloride solvent to clean thread sealant residue from t...

Page 82: ...val torque to part being removed Apply torque until the pipe thread sealant softens Remove and discard the used sample tube 2 exhaust tube 3 or in situ filter 4 4 Use MEK or methylene chloride solvent to clean thread sealant residue from the internal pipe threads in the housing Refer to applicable MSDS sheet for solvent handling precautions 37390048 1 2 3 4 1 Sensor Housing 2 Sample Tube 3 Exhaust...

Page 83: ...f the contact pad stays fused to the cell a new contact thermocouple assembly 4 must be installed 3 Remove and discard gasket 5 Clean the mating surface of heater tube 3 Remove burrs and raised surfaces with a block of wood and crocus cloth 4 Remove screws 6 lockwashers 7 return wire 8 and heater strut assembly 9 5 If replacing contact and thermocouple assembly 4 use a pencil to mark location of s...

Page 84: ...or to 450 F 232 C minimum b While heating use a flat head screwdriver to apply removal torque Apply torque until the pipe thread sealant softens Remove and discard the thermocouple adaptor c Use MEK or methylene chloride solvent to clean thread sealant residue from the internal pipe threads in the sensor holder Refer to applicable MSDS sheet for solvent handling precautions Figure 7 11 COe Sensor ...

Page 85: ...aws with pre heater port pointing up 3 Install and tighten pre heater 7 Align pre heater to flat of sensor holder 4 as shown in Figure 7 12 4 Invert sensor holder 4 Figure 7 11 in vise and pour stainless steel balls 9 into plug port Press down on stainless steel balls and tap sensor holder with plastic hammer to compact balls in pre heater chamber 5 Install and tighten plug 8 6 Lubricate and insta...

Page 86: ...e assembly Torque to 35 in lbs 4 N m 3 Carefully slide O2 heater strut assembly 9 into heater tube 3 4 Press down on the back plate of strut bracket 12 to ensure spring 11 tension is present to hold contact pad against O2 cell 2 5 Secure strut bracket 12 and return wire 8 with four screws 6 and lockwashers 7 Make sure return wire 8 is tightly fastened This is the ground side connection for the O2 ...

Page 87: ...hreads of eductor 6 Figure 7 13 Do not apply sealant to the first turn of the pipe threads Figure 7 13 Installation of Eductor and COe Sensor 37390047 1 5 6 7 8 9 10 11 12 13 14 1 Insulator 2 Dilution Air Tube 3 COe Extractive Tube 4 Eductor Air Tube 5 COe Sensor Assembly 6 Eductor 7 Sensor Housing 8 COe Thermocouple 9 Heater Insulator 10 COe Band Heater 11 Sensor Holder 12 Eductor Elbow 13 Termin...

Page 88: ...ctor 6 Male port of elbow must point up and be in line with long axis of eductor 4 Apply anti seize compound to the external pipe threads of eductor holder 14 5 Install and tighten eductor holder 14 in sensor housing 7 Align eductor with matchmarks as shown in Figure 7 14 Figure 7 14 COe Sensor Parts Alignment 37390036 Eductor Flat Matchmark Straightedge ...

Page 89: ...e insulator joint lines up with the band gap of the COe band heater 10 6 Slide COe band heater 10 Figure 7 13 up onto sensor holder 11 Do not tighten the band heater at this time Heater must rotate freely around sensor holder 7 Check for proper height of COe heater thermocouple Figure 7 12 Thread bayonet connector up or down to adjust height 8 Install and fasten thermocouple 8 Figure 7 13 9 Positi...

Page 90: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 7 20 Figure 7 16 COe Sensor Holder Alignment 37390035 Sensor Holder Flat Matchmark Straightedge Matchmark ...

Page 91: ... outside of the insulator 12 If terminal block mounting 13 Figure 7 13 was moved reinstall with two base mounting screws Figure 7 17 COe Sensor Thermocouple and Heater Connections O2 RED T C O2 T C CO T C SB EXC CJC COe Sensor Wires COe Heater Wires COe Sensor Assembly CO REF CO ACT Sensor Housing Terminals HTR 02 HTR SB 2 2 1 YEL 37390018 HTR 02 2 1 HTR CO 1 WHT BLU RED RED WHT COe Thermocouple W...

Page 92: ...alling sample block heater rods 13 Figure 7 18 evenly coat the heater rods with Watlube heater release agent 5 6 12 11 14 15 10 9 1 2 4 3 7 8 13 37390066 1 Screw 2 Locking Clip 3 Cover 4 O ring 5 Marking Plate 6 Terminal Insulator 7 Reference Air Tube 8 Sensor Housing 9 Heater Strut Assembly 10 Gasket 11 Screw 12 Heater Clamp 13 Heater Rod 14 Insulator 15 Thermal Switch 15 ...

Page 93: ...ator 14 3 Install the heater rods 13 heater clamps 12 and screws 11 4 Reconnect the heater rod leads at the sensor housing terminal blocks Figure 7 19 O2 Thermocouple Wires ORG RED T C O2 T C CO T C SB EXC CJC O Cell Wires 2 O Heater Wires 2 Return Wire O Cell and Heater Strut Assembly 2 CO REF CO ACT Sensor Housing Terminals HTR 02 HTR SB 2 GRN 2 1 YEL 37390069 HTR 02 2 1 Sample Block Heater Rods...

Page 94: ...d install cover gasket 4 Screw cover 3 onto sensor housing 8 Tighten cover firmly 4 To comply with explosion proof requirements the cover gasket 4 must be compressed For hazardous area applications verify that the cover gasket is compressed 5 Align locking clip 2 with gap between cover ribs 6 Loosen screw 1 and slide locking clip 2 fully into gap between cover ribs Retighten screw 1 Sensor Housing...

Page 95: ...e locking clip 2 away from cover 3 Retighten screw 1 2 With two hands or strap wrench turn cover 3 counterclockwise to loosen Unthread and remove cover 3 Inspect cover gasket 4 for wear or damage Replace cover gasket if damaged Remove Flash PROM 1 Locate Flash PROM access port in electronics stack 5 Figure 7 20 2 Use suitable IC removal tool to remove Flash PROM 6 Remove LOI Module and Board 1 Rem...

Page 96: ...d connectors from terminals of electronics stack 5 Figure 7 20 2 Remove two screws 13 and lockwashers 14 3 Remove electronics stack 5 37390037 1 Screw 2 Locking Clip 3 Cover 4 O ring 5 Electronics Stack 6 Flash PROM 7 Screw 8 LOI Module 9 LOI Board 10 LOI Connector 11 Screw 12 Lockwasher 13 Screw 14 Lockwasher 15 Solenoid Valve 3 way 16 Solenoid Valve 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A na ly...

Page 97: ...move solenoid valve base Remove EMI Filter and Terminal Block 1 Disconnect EMI filter wiring Figure 7 21 at terminal block 3 2 Disconnect EMI filter wiring at AC power input terminal block on electronic stack 3 Unbolt and remove EMI filter 1 from electronic stack 4 Remove ground wire 2 from terminal block 3 5 Unbolt and remove terminal block 3 from electronic stack Figure 7 21 Removal Installation...

Page 98: ...stall electronics stack 5 Figure 7 20 and secure with lockwashers 14 and screws 13 2 See Figure 7 23 and Figure 7 24 Reconnect power cable signal cable and solenoid lead connectors to electronics stack terminals Install LOI Module and Board 1 Install LOI board 9 Figure 7 20 and secure with two screws 11 and lockwashers 12 2 Note the location of the LOI connector 10 Plug LOI module 8 and connector ...

Page 99: ... O2 T C O2 O2 CELL O2 CELL SHIELD To Ground Screw GRN ELECTRONICS HOUSING O2 Cell Thermocouple Connector J5 COe Sensor CJC Connector J4 EXC CO ACT CO ACT CO REF CO REF CJC CJC EXC Heater Power Cable Signal Cable NOTE Wire colors shown are for cables supplied by Emerson Process Management 1 1 1 1 1 1 To Ground Screw SHLD Heater Power Connector J3 1 2HTR SB 1HTR O2 1HTR SB 2HTR CO 1HTR CO 2HTR O2 WH...

Page 100: ... locking clip 2 with gap between cover ribs 2 To comply with explosion proof requirements cover gasket 4 must be compressed For hazardous area applications verify that the cover gasket is compressed 3 Loosen screw 1 and slide locking clip 2 fully into gap between cover ribs Retighten screw 1 37390033 Instrument Air SOL 1 CO Test Gas High O Test Gas 2 Low O Test Gas 2 SOL 4 SOL 3 SOL 2 TOP VIEW SOL...

Page 101: ...neral 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 sealan...

Page 102: ...are etched with code markings 2 Apply pipe thread sealant Loctite 567 to the mating threads of the tube fitting Do not apply sealant to the first turn of the external pipe threads 3 Install and tighten the tube fitting in the mating port of sensor or electronics housing 37390071 5 3 4 3 6 1 1 Sensor Housing 2 Electronics Housing 3 Tube Fitting 4 Tube Fitting Type 13 6 Tube Fitting Type F Tube Fitt...

Page 103: ... system provides facilities for 100 effective grounding and total elimination of ground loops Electrical Noise The OCX 8800 has been designed to operate in the type of environment normally found in a boiler room or control room Noise suppression circuits are employed on all field terminations and main inputs When fault finding evaluate the electrical noise being generated in the immediate circuitr...

Page 104: ...ronics housing This set of dry contacts can be connected to any customer supplied relay device 30 VDC 30 mA maximum A blocking diode is required on the customers relay coil Any fault condition in the OCX 8800 will trip the alarm relay The optional SPA with HART programmable alarm indicates LOW O2 HIGH COe Calibration Status and Unit Failure For more information refer to Appendix B SPA with HART Al...

Page 105: ...cell impedance is greater than 5000 ohms and no ground fault is indicated replace O2 cell with cell replacement kit Ref Current Err RTD excitation current error Probable Cause Recommended Corrective Action Loose or open lead or circuit wire connection for COe sensor or CJC sensor current loop Check all COe and CJC sensor current loop wiring per Figure 8 3 and Figure 7 5 Correct wiring faults COe s...

Page 106: ...per Figure 8 3 and Figure 7 5 Check the wiring at the thermocouple and inside the electronics housing Correct wiring fault Perform Reset procedure in Section 3 Configuration and Startup to continue operation Electronics package failure Replace electronics package SB Temp Very Hi Sample block heater over maximum temperature 260ºC SB Htr Rmp Rate Sample block heater over maximum temperature ramp rat...

Page 107: ...ted Sample block heater thermocouple shorted Probable Cause Recommended Corrective Action Sample block thermocouple or thermocouple circuit shorted Check sample block thermocouple and circuit wires for short circuit condition per Figure 8 3 and Figure 7 4 Repair shorted wiring or replace failed thermocouple Perform Reset procedure in Section 3 Configuration and Startup to continue operation Slow h...

Page 108: ...heater circuit for broken wire or loose connection per Figure 8 3 and Figure 7 5 Repair broken wire or loose connection COe heater open Check resistance of COe heater per Figure 7 5 Normal COe heater resistance is 97 7 Ohms Replace COe heater if heater is open or has a large resistance Heater electronics failure Check heater fuse F3 in electronics housing per Figure 8 1 If open locate and correct ...

Page 109: ...l impedance is less than 5000 ohms check for cell housing ground fault Repair ground fault If cell impedance is greater than 5000 ohms and no ground fault is indicated replace O2 cell Flow calibration gas to the O2 cell Read the cell millivolt output Plot the cell millivolt output and the calibration gas O2 concentration on the chart shown in Figure 8 2 If the plotted values do not fall on the slo...

Page 110: ...luctuations Install power line filter kit PN 6A00171G01 or high quality line filter for input power SB Temp Low Sample block heater temperature low 150ºC Probable Cause Recommended Corrective Action Sensor housing exposed to high wind and or extreme cold temperatures Install sensor housing flange insulator PN 6P00162H01 High noise or voltage fluctuations in power supply Check power supply for line...

Page 111: ...lure Check power supply voltage and compare with line voltage Replace electronics package if they do not agree within 5 Htr Relay Failed Heater relay failure Probable Cause Recommended Corrective Action High noise or voltage fluctuations in 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 ...

Page 112: ...SHIELD To ground screw GRN BLK WHT BLK YEL RED BLU WHT BLK BLK GRN BLK BLK BLK ORG WHT RED BLK BRN To ground screw GRN ELECTRONICS HOUSING SENSOR HOUSING Heater Power Cable Signal Cable O Sensor and Thermocouple Connector J5 2 COe Sensor and Cold Junction Connector J4 EXC CO ACT CO ACT CO REF CO REF CJC CJC EXC O2 HTR O2 HTR CO HTR SB CO REF CO ACT CJC T C SB T C CO T C O2 1 1 1 1 1 To ground scre...

Page 113: ...bration failed Cal Failed Calibration Warning Calibration warning Cal Warning Board Temperature High Electronics temperature maximum exceeded Board Temp Hi Unit Failure Any non recoverable or heater relay off alarm O2 Temp Hi O2 Temp Very Hi COe Temp Hi COE Temp Very Hi SB Temp Hi SB Temp Very Hi O2 Htr Ramp Rate COe Htr Rmp Rate SB Htr Ramp Rate O2 TC Shorted O2 TC Reversed COe TC Shorted COe TC ...

Page 114: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 8 12 ...

Page 115: ...nstruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 http www raihome com Section 9 Replacement Parts Sensor Housing page 9 2 Electronics Housing page 9 6 O2 Cell and Heater Strut Assembly page 9 9 ...

Page 116: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 9 2 SENSOR HOUSING Figure 9 1 Sensor Housing Components 37390073 1 14 2 15 3 4 5 6 7 9 16 12 Requires item 13 for assembly 8 10 11 ...

Page 117: ... Sensor Replacement Kit 4 1A99786H01 Heater Leads Insulator 11 inches long 5 6P00163H01 COe Insulator 6 1A99746H02 Band Heater 7 1A99749H01 Thermocouple 8 1A99747H01 Elbow 9 5R10200H01 Eductor 10 6A00123G01 CJC Sensor RTD assembly ring type 11 6P00155H02 Insulator 12 1A98765H02 Heater Rod 13 1A99520H01 Watlube Heater Release Agent 14 9886A15H01 Thermal Switch Insulator 15 5R10268H02 Thermal Switch...

Page 118: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 9 4 Figure 9 2 Sensor Housing Components 37390088 1 12 2 14 16 5 6 7 19 4 3 9 8 15 13 10 18 19 ...

Page 119: ...3 ft 0 91 m Ceramic 5R10183H04 Tube Sample 6 ft 1 83 m 316 Stainless steel 5R10183H08 Tube Sample 6 ft 1 83 m Inconel 600 5R10183H05 Tube Sample 9 ft 2 7 m 316 Stainless steel 5R10183H09 Tube Sample 9 ft 2 7 m Inconel 600 6 5R10183H01 Tube Exhaust 7 1A68017H02 COe Extractive 8 5R10185H08 Dilution Air Tube 9 5R10185H03 Eductor Drive Air Tube 10 5R10185H04 Reference Air Tube 11 Not Used 12 6A00144G0...

Page 120: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 9 6 ELECTRONICS HOUSING Figure 9 3 Electronics Housing Components 37390054 7 9 1 3 2 5 6 4 8 10 11 ...

Page 121: ...lenoid Valve Test Gas 4 6A00132G01 Electronics Stack HART 5 Special Order Flash PROM Programmed 6 1A97913H06 Fuse F1 and F6 10 Amp 250 VAC 1A99766H01 Fuse F3 4 Amp 250 VAC 1A99766H02 Fuse F4 8 Amp 250 VAC 7 1A99089H02 Cover Gasket O ring 8 5R10219G01 Cover Blind 8A 5R10199G01 Cover Window 9 6A00115G02 LOI Module 10 1A99112H05 LOI Connector 11 5R10235G01 LOI Board ...

Page 122: ...1 0 January 2007 OCX 8800 9 8 Figure 9 4 EMI Filter and Terminal Block 1 2 3 37390083 Brown Blue Green Green Green Brown Blue Index No Part Number Description 1 1A98467H01 Filter EMI 2 5R10238G01 Ground Wire 3 1A99714H01 Terminal Block ...

Page 123: ...055 2 1 3 4 5 6 7 Index No Part Number Description 1 4851B44G01 Contact and Thermocouple Assembly 2 5R10211G02 Heater Strut Assembly 3 5R10188G01 Heater Tube 4 Ref Gasket part of O2 Cell Replacement Kit item 7 5 Ref O2 Cell part of O2 Cell Replacement Kit item 7 6 Ref Screw part of O2 Cell Replacement Kit item 7 7 4851B45G01 O2 Cell Replacement Kit ...

Page 124: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 9 10 ...

Page 125: ...880 Rev 1 0 January 2007 OCX 8800 http www raihome com Appendix A Safety Data Safety Instructions page A 2 Safety Data Sheet for Ceramic Fiber Products page A 24 High Pressure Gas Cylinders page A 29 Atex Clarification page A 31 ...

Page 126: ... mechanically operated isolating switch If not then another means of disconnecting the equipment from the supply must be provided and clearly marked as such Circuit breakers or switches must comply with a recognized standard such as IEC947 All wiring must conform with any local standards 7 Where equipment or covers are marked with the symbol to the right hazardous voltages are likely to be present...

Page 127: ...ory Jistič může také obsahovat mechanický odpojovač Pokud ho neobsahuje musí být zajištěn a jasně označen jiný způsob odpojení zařízení od zdroje Jističe nebo přepínače musí odpovídat uznávaným normám např IEC947 Všechna zapojení musí odpovídat místním normám 7 Je li zařízení nebo kryt označen symbolem na pravé straně pravděpodobně se uvnitř nachází nebezpečné napětí Tyto kryty by měly být sejmuty...

Page 128: ...t kontakt Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og mærkes som sådan Afbrydere eller kontakter skal overholde en kendt standard som IEC947 7 Hvor udstyr eller dæksler er mærket med dette symbol er farlige spændinger normalt forekom mende bagved Disse dæksler bør kun afmonteres når forsyningsspændingen er frakoblet og da kun af instrueret servicepersonale 8 Hvor ...

Page 129: ...che schakelaar bevatten Zoniet moet een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook duidelijk zo zijn aangegeven Stroomonderbrekers of schakelaars moeten onderworpen zijn aan een erkende standaard zoals IEC947 7 Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning aanwezig Deze deksels mogen enkel verwijderd worden nadat de v...

Page 130: ...de schakelaar Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen Zekeringen en schakelaars dienen te voldoen aan een erkende standaard zoals IEC 947 7 Waar de apparatuur of de beschermdeksels kappen gemarkeerd zijn met het volgende symbool kunnen zich hieronder spanning voerende del...

Page 131: ... Unterbrechung der Spannungszufuhr gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden Ein solcher Mechanismus zur Spannungsunterbrechung muß mit den Normen und Richtlinien für die allgemeine Installation von Elektrogeräten wie zum Beispiel der IEC947 übereinstimmen 7 Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet die eine gefährliche Netzspannung Spannung führen Die Abde...

Page 132: ...µβάνει µηχανικό διακόπτη αποµόνωσης Εάν δεν περιλαµβάνει τότε άλλα µέσα αποσύνδεσης της συσκευής από την τροφοδοσία πρέπει να παροχηθούν και να σηµανθούν σαφώς ως τέτοια Οι ασφαλειοδιακόπτες ή διακόπτες πρέπει να συµµορφώνονται µε αναγνωρισµένα πρότυπα όπως το IEC947 Όλες οι καλωδιώσεις πρέπει να συµµορφώνονται µε τα τοπικά πρότυπα 7 Όπου συσκευές ή καλύµµατα είναι σηµασµένα µε το σύµβολο που εικο...

Page 133: ...tasel juhul peab seadme toiteallikast lahtiühendamiseks olema teine ja selgelt osutatud moodus Automaatkorgid või lülitid peavad vastama tunnustatud standarditele nagu nt IEC947 Kogu juhtmestik peab vastama kohalikele standarditele 7 Seadmel või ümbristel asuv paremale osutav sümbol tähistab selle all leiduvat ohtlikku pinget Selliste sümbolitega ümbriseid võib eemaldada vaid juhul kui seade on to...

Page 134: ...tyy myös sisältyä mekaaninen erotuskytkin Jos ei niin jännitesyöttö on pystyttävä katkaisemaan muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi Turvakytkimien tai kat kaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä 7 Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla hengenvaarallisen suuruinen jännite Suojaa ei saa poist...

Page 135: ...les conducteurs en cas d anomalie Ce disjoncteur doit également pouvoir être actionné manuellement de façon mécanique Dans le cas contraire un autre système doit être mis en place afin de pouvoir isoler l appareil et doit être signalisé comme tel Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telle IEC947 7 Lorsque les équipements ou les capots affichent le symbole suiva...

Page 136: ...ikusan működtethető áramtalanító kapcsolót is Ellenkező esetben biztosítani kell a berendezés elektromos hálózatról történő lekapcsolásának más módját és ezt világosan jelezni kell A megszakítóknak vagy kapcsolóknak meg kell felelniük egy elismert szabványnak például az IEC947 szabványnak Az összes vezetéknek meg kell felelnie az összes helyi szabványnak 7 Ha a berendezés vagy a burkolata a jobb o...

Page 137: ...i di circuito in caso di guasto Tale interruttore dovrà inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione dell alimentazione chiaramente identificabile Gli interruttori dovranno essere conformi agli standard riconosciuti quali IEC947 7 Il simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza di elevati voltaggi Tali coperchi di protezio...

Page 138: ...ertraukiklis taip pat gali turėti mechaniškai veikiantį įzoliavimo jungiklį Jeigu ne tuomet turi būti nurodytos kitos įrenginio atjungimo priemonės ir aiškai pažymėtos kad jos tokios yra Automatiniai perjungikliai ar jungikliai turi atitikti pripažintus standartus tokius kaip IEC947 Visi laidai turi atitikti visus vietinius standartus 7 Kur įrenginys ar dangos yra pažymėti simboliu dešinėje žemiau...

Page 139: ...padeves un tā atbilstoši un skaidri jāmarķē Slēdžiem jāatbilst kādam vispāratzītam standartam piemēram IEC947 Visai elektroinstalācijai jāatbilst vietējiem standartiem 7 Vietās kur iekārta vai tās pārsegi ir marķēti ar labajā pusē norādīto simbolu visticamāk zem tiem ir bīstams spriegums Šos pārsegus drīkst noņemt tikai tad ja iekārta ir atvienota no strāvas padeves un šos darbus drīkst veikt tika...

Page 140: ...q il lemin x aktarx li jkun hemm vultaġġi perikolużi taħthom Dawn l għatjien għandhom jitneħħew biss meta titneħħa l provvista tad dawl mit tagħmir u minn ħaddiema tal manutenzjoni mħarrġa biss 8 Meta t tagħmir jew l għatjien ikunu mmarkati bis simbolu fuq il lemin ikun hemm periklu mill uċuħ jaħarqu li jkun hemm taħthom Dawn l għatjien għandhom jitneħħew biss minn ħaddiema tal manutenzjoni mħarrġ...

Page 141: ...yningen Dersom det ikke er en mekanisk operert bryter installert må det være en annen måte å isolere utstyret fra spenningsforsyningen og denne måten må være tydelig merket Kretsbrytere eller kontakter skal oppfylle kravene i en annerkjent standard av typen IEC947 eller tilsvarende 7 Der hvor utstyr eller deksler er merket med symbol for farlig spenning er det sannsynlig at disse er tilstede bak d...

Page 142: ...ięcia W przeciwnym razie należy zapewnić i jasno oznaczyć inną możliwość odłączenia urządzenia od zasilania Wyłączniki automatyczne oraz odłączniki powinny być zgodne z uznawanymi standardami takimi jak norma IEC947 Wszystkie przewody muszą być zgodne z lokalnymi przepisami 7 Pod pokrywami lub elementami urządzenia oznaczonymi symbolem pokazanym na rysunku po prawej stronie może występować niebezp...

Page 143: ...derá também conter um interruptor de isolamento accionado manualmente Caso contrário deverá ser instalado qualquer outro meio para desligar o equipamento da energia eléctrica devendo ser assinalado convenientemente Os disjuntores ou interruptores devem obedecer a uma norma reconhecida tipo IEC947 7 Sempre que o equipamento ou as tampas contiverem o símbolo é provável a existência de tensões perigo...

Page 144: ...Ak nie musí byt poskytnutý iný spôsob odpojenia zariadenia od siet ového napájania a tento spôsob musí byt zreteľne označený Prerušovače obvodu alebo spínače musia byt v zhode s uznanou normou ako napr IEC947 Všetky káblové pripojenia musia vyhovovat akýmkoľvek miestnym normám 7 Tam kde je zariadenie alebo kryty označené symbolom na pravej strane sa pravdepodobne nachádza nebezpečné napätie Tieto ...

Page 145: ...tikalo lahko vključuje tudi mehansko izolacijsko stikalo V nasprotnem primeru morajo biti zagotovljeni in jasno označeni drugi načini za izklop opreme iz napajanja Odklopna in druga stikala morajo biti skladna z uveljavljenimi standardi kot je IEC947 Vsa napeljava mora biti skladna z lokalnimi standardi 7 V opremi ali pod pokrovi ki so označeni s simbolom na desni je prisotna nevarna napetost Te p...

Page 146: ...fallo Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio 7 Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa dicho alojamiento solamente se abrira una vez que se haya interrumpido la alimentacion electrica al equipo asimismo la intervencion sera llevada a cabo por personal entrenado para estas labores 8 Cuando las tapas o el eq...

Page 147: ...are Om så inte är fallet måste ett annat förfarande för att frånskilja utrustningen från strömförsörjning tillhandahållas och klart framgå genom markering Säkring eller omkopplare måste överensstämma med en gällande standard såsom t ex IEC947 7 Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för livsfarlig spänning i närheten Dessa höljen får endast avlägsnas när strömme...

Page 148: ...ia Drive Columbia MO 65202 573 814 1300 ext 5170 573 474 9402 HEALTH HAZARD SUMMARY WARNING Possible cancer hazard based on tests with laboratory animals May be irritating to skin eyes and respiratory tract May be harmful if inhaled Cristobalite crystalline silica formed at high temperatures above 1800ºF can cause severe respiratory disease SECTION II PHYSICAL DATA APPEARANCE AND ODOR Cream to whi...

Page 149: ...ZARDS 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 Abrasive action may cause damage to outer surface of eye INHALATION May cause respiratory tract irritation Repeated or prolonged breathing of particles of respirable size may cause inflammation of the lu...

Page 150: ...e 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 4 Pleural plaques thickening along the chest wall have been observed in a small number of employees who had a long duration of employment There are several occupational and...

Page 151: ...culties administer oxygen until medical assistance can be rendered INGESTION Do not induce vomiting Get medical attention if irritation persists SKIN CONTACT Do not rub or scratch exposed skin Wash area of contact thoroughly with soap and water Using a skin cream or lotion after washing may be helpful Get medical attention if irritation persists SECTION VI REACTIVITY DATA STABILITY CONDITIONS TO A...

Page 152: ...les to prevent eye contact Do not wear contact lenses when working with this substance Have eye baths readily available where eye contact can occur 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 s...

Page 153: ...ayed with water before removal to suppress airborne dust As water evaporates during removal additional water should be sprayed on surfaces as needed Only enough water should be sprayed to suppress dust so that water does not run onto the floor of the work area To aid the wetting process a surfactant can be used After RCF removal is completed dust suppressing cleaning methods such as wet sweeping o...

Page 154: ...y to be used 4 Avoid dragging rolling or sliding cylinders even for short distance they should be moved by using a suitable handtruck 5 Never tamper with safety devices in valves or cylinders 6 Do not store full and empty cylinders together Serious suckback can occur when an empty cylinder is attached to a pressurized system 7 No part of cylinder should be subjected to a temperature higher than 52...

Page 155: ... FLAMEPROOF ENCLOSURE Special conditions apply to using a flameproof enclosure analyzer under the scope of the European Directive for Equipment used in Explosive Atmosphere Directive 94 9 EEC ATEX To stay compliant to the directive please consider the following clarification sheet released by the European ATEX Notified Body Group ...

Page 156: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 A 32 ...

Page 157: ...he OCX 8800 DESCRIPTION The Moore Industries SPA with HART Alarm Figure B 1 is a 4 wire line or mains powered site programmable digital process alarm It connects to a standard HART field device and provides up to four fully configurable contact closure outputs based on readings of the HART digital data The four OCX 8800 alarm outputs recognized by the SPA are Low O2 High COe Calibration Status and...

Page 158: ...igure B 3 If the SPA with HART was factory configured by Emerson Process Management for operation with your OCX 8800 jumper and switch setting adjustments are not required However you may use the following procedure to verify that the jumper and switch settings are correct Adjust or verify jumper and switch settings as follows 1 Refer to Figure B 3 Turn the SPA over and slide the access cover out ...

Page 159: ...t the end of the configuration procedure the SPA analog output signal is calibrated to insure valid communications 1 See Figure B 4 Connect a calibrated ammeter Fluke Model 87 or equivalent accurate to 0 025 to the SPA analog output terminals Observe polarity 2 Connect a 90 to 260 VAC or 22 to 300 VDC power source to the SPA power terminals When connecting an AC power source use the AC and ACC AC ...

Page 160: ...hand pushbutton scrolls up or down through the SPA command menu a submenu or parameter values list c Pressing the VIEW pushbutton displays rail limits and alarm relay configurations There are five sequential displays in the VIEW mode While in the VIEW mode the up down and SELECT pushbuttons are disabled NOTE In the VIEW mode you can scroll through and display the output zero and full scale setting...

Page 161: ...lected via the front panel pushbuttons on the SPA c In the submenu views shown means press the down pushbutton means press the up pushbutton means press the SELECT pushbutton one time means press the or pushbutton until the desired parameter value is shown in the SPA window d Proceed through the SPA menu selecting the menu commands and parameter values indicated After completing the sequence in th...

Page 162: ...PV EGU Ü ô PCT Ü SV EGU Ü ô CSTM Ü ô PPM select P select P select M Ü EXIT EGU Ü SCLE INPT Ü PV SCLE Ü PV ZERO ô 0000 PCT Ü PV FULL ô 25 PCT Ü SCLE SV Ü SET ZERO ô 0000 PPM Ü SET FULL ô 1000 PPM Ü EXIT SCLE Ü SCLE DSPL Ü PV DSPL Ü SET ZERO Ü ô 0000 PCT Ü SET FULL Ü ô 25 PCT Ü SV DSPL Ü SET ZERO Ü ô 0000 PPM Ü SET FULL Ü ô 1000 PPM Ü EXIT DSPL Ü SCLE OUT Ü SET ZERO Ü ô 4 000 MA Ü SET FULL Ü ô 20 00...

Page 163: ...the equipment has been operating housing weather vibration dust etc c Site from which equipment was removed d Whether warranty or nonwarranty service is requested e Complete shipping instructions for return of equipment f Reference the return authorization number 4 Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Emerson Process Manag...

Page 164: ...Instruction Manual IM 106 880 Rev 1 0 January 2007 OCX 8800 C 2 ...

Page 165: ... Connections 1 7 HART PC Connections 5 4 HART Signal Connections 5 1 HART Signal Line Connections 5 2 5 3 Hazardous Area OCX 8800 1 11 4 2 Heater Strut Assembly 7 16 I Install Eductor 7 17 Install Electronics Stack 7 28 Install Flash PROM 7 28 Install Integral OCX 8800 7 4 Install LOI Module 7 28 Install Solenoid Valves 7 28 Install Tube Fittings 7 32 Instrument Air 1 7 L LK Notation 4 3 LOI board...

Page 166: ...nals 7 30 SPA Configuration Menu B 6 SPA Front Panel B 4 SPA Interface Connections B 2 SPA Setup for Calibration B 3 SPA with HART Alarm B 1 Specifications 1 9 SW1 3 2 SW2 3 2 SW3 3 2 System Configuration 1 4 System Description 1 1 System Features 1 4 System Operation 1 5 System Overview 1 1 System Package 1 2 T Terminals Insulator 7 24 Test Gas Values 3 4 Thermal Switch 7 8 Total Power Loss 8 2 T...

Page 167: ...es for any failure of Rosemount Analytical to comply with the warranty provisions whether claims by the purchaser are based in contract or in tort including negligence Rosemount Analytical does not warrant equipment against normal deterioration due to environment Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of n...

Page 168: ...7 3329 ASIA PACIFIC Emerson Process Management Asia Pacific Private Limited 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65 6 777 8211 F 65 6 777 0947 E analytical ap emersonprocess com ROSEMOUNT ANALYTICAL EUROPE Emerson Process Management Gmbh co OHG Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884 209 WORLD HEADQUARTERS Emerson Process Management Rosemount...

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