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Rosemount OCX 8800, Instruction Manual

The Emerson OCX 8800 is a cutting-edge device designed to enhance your user experience. Discover its full potential by referring to the comprehensive Instruction Manual available for free download at manualshive.com. This essential manual provides step-by-step instructions and insightful guidance to optimize your use of the OCX 8800.

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Instruction Manual 

IM-106-880, Rev 2.1 

April 2017 

OCX 8800 

Index-2 

 

 

L 

LOI Components ........................ 4-1 
LOI Keypad ................................ 4-2 
LOI Status Codes ....................... 4-3 

 

M 

Manual Calibration, 

Fieldbus  . . . . . . . . . . . .  5-8, 5-10 

Manual Calibration, HART .......... 5-5 
Manual Calibration, LOI .............. 5-4 
Mapping of PWA .......................... 7-7 
Material Safety Data Sheet . . . A-24 
Menu Tree 

Fieldbus .............................. 6-9 
HART .................................. 6-5 
LOI ...................................... 4-4 

 

N 

Nernst Equation.......................... 1-3 
Network Communication, 

Fieldbus ................................... 7-4 

 

O 

O2 Cell and Heater 

Strut  . . . . . . . . . . . . . .  9-26, 9-28 

O2 Cell and Heater 

Strut Assembly . . 9-11, 9-18, 10-9 

O2 Cell Output Voltage ................ 1-5 
O2 Cell Replacement Kit .......... 9-18 
O2 Cell, Heater, and 

Thermocouple ....................... 9-18 

O2 Cell, Thermocouple, 

& Heater Connections 9-12, 9-27 

OCX Implemented Function 

Blocks ...................................... 7-6 

OCX Removal and Installation . 9-1 
OCX Specifications .................. 1-12 
OCX with Integral Electronics . . 9-2 
Off-Line and On-Line 

Operations ............................... 6-4 

Operating Mode 

Enumerations ........................ 7-18 

Operation Diagram ..................... 1-6 
Oxygen and Cell Output ............. 8-7 

 

P 

Personal Computer (PC) ............ 1-5 
PID Function Block 

Alarm Detection................. 7-43 
Application Information . . 7-44 
Modes ............................... 7-42 
Parameters ....................... 7-36 
Troubleshooting ................ 7-50 

PlantWeb Alerts ......................... 7-6 
Power Up ................................... 3-5 
Pre-Heater ................................ 9-20 
Pre-Heater Alignment ............... 9-21 
Product Matrix .......................... 1-14 
PWA Simulate .......................... 7-10 

R 

Reference Air Tube .................. 9-11 
Remove Eductor ...................... 9-16 
Remove EEprom ...................... 9-29 
Remove Electronics Stack . . . 9-30 
Remove Flash PROM .............. 9-29 
Remove LOI Module and 

Board ..................................... 9-29 

Remove OCX 8800 with 

Integral Electronics .................. 9-2 

Remove OCX with 

Remote Electronics ................. 9-5 

Remove Remote Electronics . . . 9-7 
Remove Solenoid Valves ........... 9-31 
Remove Tube Fittings .............. 9-35 
Repair Sensor Housing ............ 9-10 
Replace Tube Fittings .............. 9-35 
Reset Procedure ...................... 3-14 
Resistance Devices (RTD) ......... 1-4 
Resource Block .......................... 7-6 
Resource Blocks ........................ 7-4 
Returning Material . . . . . . . . . . .C-1 
RTD ............................................ 1-4 

S 

Samole Tube Support .............. 1-10 
Sample and Exhaust 

Tubes  . . . . . . . . . . . . . 9-17, 9-21 

Sample Block Heater 

Rods . . . . . . . . . . . . . . 9-12, 9-27 

 

Selected Distributed 

Control Systems ...................... 1-5 

Sensor Housing 

Components .......................... 10-2 

Sensor Housing 

Disassembly .......................... 9-10 

Sensor Housing 

Enumerations ........................ 7-19 

Sensor Housing Leak Test ......... 9-28 
Sensor Housing Terminals .......... 9-6 
Sensor Housing Type ................ 7-19 
Signal Conversion .................... 7-26 
Simulation ................................ 7-25 
Single Link Fieldbus Network . . 7-5 
Solenoid Power Terminals .........9-34 
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 ........................... 1-12 
Status Handling ........................ 7-29 

Support Resource 

Block Errors ........................... 7-12 

System Configuration ................. 1-4 
System Description .................... 1-3 
System Features ........................ 1-5 
System Operation ...................... 1-6 
System Package ........................ 1-2 

T 

Terminals Insulator ................... 9-28 
Test Gas Values ........................... 3-5 
Total Power Loss ........................ 8-2 
Transducer Block 

Channel Status ........................ 7-22 

Transducer Block 

Enumerations ........................ 7-17 

Transducer Block Errors ........... 7-22 
Transducer Block 

Parameters ............................ 7-13 

Transducer Block Simulate . . . 7-22 
Transducer Blocks ..................... 7-4 
Typical System Installation ......... 1-9 
Typical System Package ............ 1-2 

W 

Warranty Service  . . . . . . . . . . . C-1 

Summary of Contents for OCX 8800

Page 1: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 RosemountTM OCX 8800 Oxygen and Combustibles Transmitter General Purpose Probe with Integral Electronics ...

Page 2: ......

Page 3: ... wall mount or rack mount blowback panel Added coverage of PlantWeb Alert data for OCX 8800 units with FOUNDATION Fieldbus communications Added Appendix B coverage of optional Moore Industries Site Pprogrammable Alarm for OCX 8800 units with HART communications Effective April 2017 Rev 2 1 Page Section Summary Title page Removed Rosemount Analytical logo Updated Emerson logo Page 1 13 Updated Blow...

Page 4: ......

Page 5: ... 3 Configuration and Startup Verify Installation 3 1 Initial Power Up 3 5 Set Test Gas Values 3 5 Calibration Solenoids 3 6 Blowback Feature 3 7 Calibration Verify Feature 3 9 Calibration Tolerance Feature 3 11 COe Purge Zero Feature 3 12 OCX 8800 Reset Procedure 3 14 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...

Page 6: ...rameters 7 13 Transducer Block Enumerations 7 17 Transducer Block Channel Assignments for AI Blocks 7 22 Transducer Block Channel Status 7 22 Transducer Block Simulate 7 23 Support Transducer Block Errors 7 23 Analog Input AI Function Block 7 23 Introduction 7 23 Simulation 7 26 Filtering 7 27 Signal Conversion 7 27 Block Errors 7 28 Modes 7 29 Alarm Detection 7 29 Status Handling 7 29 Advanced Fe...

Page 7: ...7 65 About AMS and DeltaV Software 7 65 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 Maintenance and Service Overview 9 1 OCX 8800 Removal and Installation 9 1 OCX with Integral Electronics 9 2 OCX with Remote Electronics 9 5 Repair Sensor Housin...

Page 8: ...PENDIX A Safety Data Safety Instructions A 2 Safety Data Sheet for Ceramic Fiber Products A 24 High Pressure Gas Cylinders A 30 APPENDIX B SPA with HART Alarm Overview B 1 Description B 1 Installation B 2 Setup B 2 APPENDIX C Return of Materials Returning Material C 1 ...

Page 9: ...ur personnel in the proper installation operation and maintenance of the product Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes Connect all products to the proper electrical and pressure sources To ensure proper performance use qualified personnel to install operate update program and maintain t...

Page 10: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 ii ...

Page 11: ...res and information necessary to install and service the transmitter Before contacting Emerson concerning any questions first consult this manual It describes most situations encountered in your equipment s operation and details necessary action DEFINITIONS The following definitions apply to WARNINGS CAUTIONS and NOTES found throughout this publication NOTE Highlights an essential operating proced...

Page 12: ...ublication is a manual illustration number It is not a part number and is not related to the illustration in any technical manner NOTE Read this manual before working with the product For personal and system safety and for optimum product performance make sure you thoroughly understand the contents before installing using or maintaining this product ...

Page 13: ...s shown in Figure 1 1 Use the product matrix in Table 1 1 at the end of this section to verify your order number The first part of the matrix defines the model The last part defines the various options and features of the OCX 8800 Check the model number against the transmitter features and options making sure options specified by this number are on or included with the unit Use this complete model...

Page 14: ...ypical System Package 1 Instruction Manual 2 Field Communicator Package optional 3 Adapter Plate with Mounting Hardware and Gasket 4 Reference Air and Calibration Set optional 5 Blowback Hardware optional 6 OCX 8800 with Remote Electronics 7 OCX 8800 with Integral Electronics ...

Page 15: ... 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 P2 is the partial pressure of the oxy...

Page 16: ...sponse of the sensor to other combustible gases gives an output that is equivalent to the sensor detecting CO The term COe is used in this manual to describe the sensor output This term indicates that the sensor is calibrated in terms of CO and that the sensor output is equivalent to CO but not specific to CO Dilution air is provided to the COe sensor to ensure there is adequate oxygen to fully ox...

Page 17: ...ation b HART or FOUNDATION fieldbus interface The OCX 8800 s output line transmits a digital signal with the detected oxygen or combustible levels encoded in a digital format This informationcan be accessed through the following Model 375 Field Communicator The handheld field communicator requires Device Description DD software specific to the OCX 8800 The DD software will be supplied with many Mo...

Page 18: ...em The electronics housing contains the CPU and communication boards which convert the sensor inputs into digital output signals The CPU can also initiate and perform calibrations Three test gasses and instrument air can be turned on and off by solenoids Test gas flow to the sensors is regulated by a flow meter between the electronics and sensor housings Instrument air is separated into eductor ai...

Page 19: ...l in situ filters Figure 1 9 shows the optional panel mounted blowback A source of instrument air is required at the OCX 8800 for reference air dilution air and eductor air Since the OCX 8800 is equipped with an in place calibration feature provision should be made for connecting test gas tanks to the OCX 8800 when it is to be calibrated NOTE The electronics module is designed to meet Type 4X and ...

Page 20: ...Laptop with AMS Instrument Air 3 calibration gas lines by customer 300 ft 91 m max Termination in Control Room AMS Figure 1 4 Communication Connections and AMS Application OCX 8800 with Remote Electronics OCX 8800 Sensor Housing Model 375 Field Communicator Signal Output Twisted Pairs OCX 8800 Electronics Housing Customer s Laptop with AMS Instrument Air Termination in Control Room 3 calibration g...

Page 21: ...ter 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 OCX 8800 with REMOTE ELECTRONICS Signal Outputs Twisted Pairs Heater Power Cable up to 150 ft 46 m Pressure Regulator Duct Stack Gases Line Voltage Signal Cable up to 150 ft 46 m 37390064 Low O Test Gas 2 High O Test Gas 2 CO Test Gas ...

Page 22: ...1 10 Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 Figure 1 7 Optional Sample Tube Support ...

Page 23: ...18 NPT 39930006 7 3 186 InSitu Stainless Steel or Hastolloy Filter 102 InSitu High Surface Area Stainless Steel Filter 39930007 CALIBRATION BLOWBACK PANEL OCX 8800 DILUTION GAS CAL GAS SET TO 55 PSIG BLOWBACK AIR PRESSURE REFERENCE AIR PRESSURE OCX88A 35 PSIG OCX88C 45 PSIG PROCESS ANALYTICAL DIVISION 1 440 914 1261 www raihome com 5 00 127 2 2 55 9 6 97 177 16 5 419 1 Wall Mount 6 0 152 4 Wall Mo...

Page 24: ...nting and Mounting Positions Remote Electronics 40 to 158 F 40 to 70 C ambient At temperatures above 158 F 70 C inside instrument housing the infrared keypad will cease to function but the OCX 8800 will continue to operate properly 54 lbs 20 kg 55 lbs 20 5 kg 57 lbs 21 kg 59 lbs 22 kg Flange Sensors Housing Flange Electronics Housing Wall Pipe Materials Probes 316L stainless steel 1300 F 704 C Inc...

Page 25: ... NPT conduit ports when reference air vents are routed to a dry area Certifications Electrical Noise EN 61326 1 Class A Line Voltage Universal 100 to 240 VAC 10 50 to 60 Hz no switches or jumpers required 3 4 14 NPT conduit port Pollution Degree 2 Over Voltage Category II Relative Humidity 5 to 95 non condensing Isolated Output Oxygen 4 20 mAdc 950 ohm maximum with HART or FOUNDATION fieldbus capa...

Page 26: ...dapter Plate 0 must be chosen under Mounting Adapter Probe Side below 1 New Installation Square weld plate with studs 2 Model 218 240 Mounting Plate with Model 218 240 Shield Removed 3 Existing Model 218 240 Support Shield 4 Competitor s Mount 1 5 Model 132 Adapter Plate Code Mounting Hardware Probe Side 0 No Adapter Plate 1 Probe Only ANSI 4 Probe Only DIN Code Electronics Housing NEMA 4X IP66 HA...

Page 27: ...w Rotometers Ref Gas Set w Blowback 4 Cal Gas Flow Rotometers Ref Gas Set w Blowback Panel Mounted OCX88A 11 10 1 1 H3 06 0 0 Example NOTES 1 Provide details of the existing mounting plate as follows Plate with studs Bolt circle diameter number and arrangement of studs stud thread stud height above mounting plate Plate without studs Bolt circle diameter number and arrangement of holes thread depth...

Page 28: ...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 4851B40G02 Wall or Pipe Mounting Kit 1A99784H02 375 Field Communicator with 12 Megabyte buffer model no 375HR1EKLU 6A00171G01 Power line filter kit 6A00288G01 Sample Tube Support 18 in 457 mm 6A00288G02 Sample Tube ...

Page 29: ...nsing point should be selected so the process gas temperature falls within the range of probe material used Figure 2 1 through Figure 2 5 provide mechanical installation references The ambient temperature inside the electronics housing must not exceed 185 F 85 C 2 Check the flue or stack for holes and air leakage The presence of this condition will substantially affect the accuracy of the oxygen a...

Page 30: ... all pneumatic lines prior to installing the OCX 8800 in the stack or ductwork NOTE If process temperatures will exceed 392 F 200 C use anti seize compound on stud threads to ease future removal of the OCX 8800 7 Insert sample and exhaust tubes through the opening in themounting flange and bolt the unit to the flange 8 If insulation is removed to access the duct for OCX 8800 mounting make sure to ...

Page 31: ... 2 1 Installation OCX 8800 with Integral Electronics Table 2 Installation Removal Probe Dim A Dim B 3 ft 6 ft 9 ft 18 in 2235 88 3150 124 2743 108 72 1829 914 36 1321 52 864 34 457 18 Flange Dia DIN ANSI 6 00 152 BOTTOM VIEW B C Dia Dim B Removal Envelope 37390008 Dim A Insertion Depth Flange Dia Hole Dia Allow 9 in 229 mm for Cover Removal Optional In Situ Filter Table 1 Mounting Flange Hole Dia ...

Page 32: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 4 2 Figure 2 2 Installation OCX 8800 with Remote Electronics ...

Page 33: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 2 5 Figure 2 3 Adapter Plate Installation ...

Page 34: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 6 2 Figure 2 4 Wall or Pipe Mounting of Electronics Housing ...

Page 35: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 2 7 Figure 2 5 Installation with Drip Loops Conduit Drip Loops Duct Wall Conduit Drip Loop Conduit Drip Loop Duct Wall 37020004 ...

Page 36: ...3 T6 permanently mounted equipment Disconnect and lock out power before connecting the unit to the power supply Failure to lock out power could result in serious injury or death Install all protective equipment covers and safety ground leads after installation Failure to install covers and ground leads could result in serious injury or death Tomeet the Safety Requirements of IEC 1010 EC requiremen...

Page 37: ...ignal provides all output information and is accessible through a Model 375 handheld communicator Alarm Output Relay Connect any customer supplied relay input to the alarm output relay terminal Use shielded wire and terminate the shield at the electronics housing The alarm output relay terminal is a set of dry no 2 form C contacts with 30 mA 30 VDC capacity Remote Electronics Connections to Sensor...

Page 38: ...Ground Typical for Electronics and Sensor Housing NC COM NO Alarm Output Relay Terminal Block 1 AOUT2 AOUT2 AOUT1 AOUT1 O Signal HART 2 COe Signal Ground Stud Signal Output Terminal Block Power Port 3 4 NPT Signal Port 3 4 NPT External Tooth Lockwasher 1 G G Terminal Block G N L1 EMI Filter Customer Wiring F Fieldbus OUNDATION Not used F Fieldbus OUNDATION HART OR ...

Page 39: ...ED 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 To ground 1 s...

Page 40: ...insulated 2 0 0 25 Typical Heat Shrink Tubing 1 Long 3 16 Size DETAIL A typical on both ends of wiring SIGNAL WIRING OR CABLE ELECTRONICS END PROBE END 0 5 Typ 3 4 NPT Hub Size Liquid tight Strain Relief Connectors Heat Shrink Tubing 2 Long 1 2 Size 4 25 Long Teflon Tubing 0 042 ID Cut off drain wire at probe end of shield 8 Conductors 16 AWG Stranded O 200 C 600 volts Braided shield tinned copper...

Page 41: ... 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 onthe electronics housing and the tee fitting on the sensorhousing 4 One CO gas and two O2 gases are used to calibrate the OCX8800 CO 1000 ppm or up to 4 Balance air O2 low gas 0 4 Balance N2 ...

Page 42: ...r Air In Dilution Air In 4 Dilution Air Flow Meter 0 1 scfh 7 scfh 20 30 psig Recommended 2 Stage Regulators Instrument Air Out 1 2 Instrument Air Supply Electronics Housing Pressure Reguator Filter 35 psig General Purpose CO HI O 2 LO O 2 37390011 Replacement Parts 1 2 Pressure Gage 0 60 psig 275431 03 2 Combination Filter Reg 0 60 psig 1A99422H01 3 Flowmeter 1 10 scfh 771B635H01 4 Flowmeter 0 05...

Page 43: ...B635H01 4 Flowmeter 0 05 0 5 scfh 771B635H08 Reference Air Set and Solenoids Option without COe Zero Function When the reference air set and test gas solenoids are included with your OCX 8800 use the following procedure to install the pneumatic system components 1 Install the reference air set according to the instructions in Reference Air Set Option steps 1 through 3 2 Refer to Figure 2 10 Connec...

Page 44: ... air line between the flow meter outlet port and the CAL GAS inlet fitting on the sensorhousing Reference Air Set and Solenoids Option with COe Zero Function Figure 2 11 shows the piping arrangement for the OCX 8800 with autocalibration when the COe Zero Function is used The arrangement is similar to Figure 2 10 except instrument air is used as the Hi O2 test gas Refer to Section 3 for details of ...

Page 45: ...ng 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 psig and 55 psig pressure regulators The inlet to the 35 psig regulator accepts a 1 8 NPT fitting The inlet to the 55 psig regulator accepts a 1 4 NPT fitting 3 See the upper leg of the instrument air supply Connect the ...

Page 46: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 2 18 Figure 2 12 Pneumatic Installation OCX with Reference Air Set Solenoids Blowback and Autocalibration without COe Zero Function ...

Page 47: ...th COe Zero Function Reference Air Set Solenoids and Blowback Option with COe Zero Function Figure 2 13 shows the piping arrangement for the OCX 8800 with the blowback and autocalibration options when COe Zero Function is used The arrangement is similar to Figure 2 12 except instrument air is used as the Hi O2 test gas Refer to Section 3 for details of this function ...

Page 48: ...on Air Flow Meter 0 1 scfh Electronics Housing Normally Open Solenoid Valve Normally Closed Solenoid Valve Blowback Valve Air Operated Pressure Regulator Filter 35 psig General Purpose 1 2 Actuating Air NOTE During blowback operation states of both solenoid valves change NOTE Wall mount the air operated blowback valve on a suitable mounting plate NOTE Actuating air pressure at blowback valve inlet...

Page 49: ...own in Figure 2 16 Piping arrangement for blowback panel with autocalibration with COe Zero Function is shown in Figure 2 17 Figure 2 15 Pneumatic Installation Blowback Panel without Autocalibration without COe Zero Function Check Valve Sensor Housing Eductor Air In Instrument Air CAL Gas In Reference Air In Dilution Air In CAL Gas Out Dilution Air Out Blowback Air Out Blowback Control Air CAL Gas...

Page 50: ...o Function Check Valve Sensor Housing Eductor Air In Instrument Air CAL Gas In Reference Air In Dilution Air In CAL Gas Out Dilution Air Out Blowback Air Out Blowback Control Air CAL Gas In Instrument Air to Electronics Instrument Air Out Instrument Air Supply Electronics Housing CAL Gas Out Actuating Air 2 Stage Regulators LO O 2 HI O 2 CO 39930004 ...

Page 51: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 2 23 Figure 2 17 Pneumatic Installation Blowback Panel with Autocalibration with COe Zero Function ...

Page 52: ...er possible leave OCX 8800 units running to prevent condensation and premature aging from thermal cycling Upon completing installation make sure that the OCX 8800 is turned on and operating prior to firing up the combustion process Damage can result from having a cold OCX 8800 exposed to the process gases If ducts will be washed down during outages make sure to power down the OCX 8800 units and re...

Page 53: ... 8800 is installed correctly Verify mechanical installation and all electrical and pneumatic connections Refer to Section 2 Installation NOTE During outages and whenever possible leave all OCX 8800 units running to prevent condensation and premature aging from thermal cycling Install all protective equipment covers and safety ground leads after installation Failure to install covers and ground lea...

Page 54: ...nal is internally or externally powered SW2 determines if the COe 4 20 mA signal is internally or externally powered SW3 sets the rail limits for the O2 and COe 4 20 mA signals and configures the sample line heater control circuit All switches are accessible through holes in the electronics box Figure 3 1 OCX 8800 Defaults HART Electronics Remove power from the OCX 8800 before changing defaults If...

Page 55: ... COe 4 20 mA signal rail limit The settings are high 21 1 mA or low 3 5 mA The factory setting is high 21 1 mA Positions 3 and 4 must be set as shown for proper software controlof the device heaters Verify Configuration Fieldbus Electronics There is one switch on the microprocessor board which must be set for the OCX 8800 with fieldbus electronics Figure 3 2 SW3 configures the sample line heater c...

Page 56: ...the solenoid will energize eductor air will begin to flow and the unit will begin normal operation SET TEST GAS VALUES Use Field Communicator or the optional LOI to set test gas values for calibration Refer to Section 4 Using the LOI or Section 6 Field Communicator for more information Setting Test Gas Values with the Field Communicator 1 Use the 375 Field Communicator software to access the HART ...

Page 57: ...entration ppm used for COe test gas CALIBRATION SOLENOIDS The OCX 8800 can be provided with optional calibration solenoids for the purpose of performing autocalibration The solenoids are controlled by the OCX 8800 software and automatically switch in the proper calibration gas during the calibration cycle An OCX 8800 shipped from the factory with calibration solenoids must be configured before aut...

Page 58: ...stalled Configuring Blowback with the Field Communicator HART 1 Use the 375 Field Communicator or AMS software to access theHART menu 2 From the DETAILED SETUP menu select INPUT OUTPUT 3 From the INPUT OUTPUT menu select BLOWBACK 4 From the BLOWBACK select BlBk Enabled Select Yes to enable blowback Also set the following parameters BlBk Intrvl Length of time between blowback events 60 minutes reco...

Page 59: ...lyzer is reading correctly The calibration verify feature flows each calibration gas on demand to verify calibration but does not change the slope or constant of the current calibration This function uses the same gas flow and purge times from the basic calibration setup The calibration verify feature is only valid if the OCX 8800 is supplied with calibration solenoids and the solenoids have been ...

Page 60: ...est gas for the time specified in the calibration setup Flow High COe Gas Flows the COe test gas for the time specified in the calibration setup Purge Gas Initiates a delay for the specified purge time before oxygen combustibles readings are considered valid NOTE A Purge will automatically follow a gas flow Performing a Calibration Verify with the LOI 1 Use the Z pattern to enter the LOI menu tree...

Page 61: ... SETUP menu select O2 CALPARAMS 4 To enable the calibration tolerance feature for the oxygen calibration from the O2 CAL PARAMS select O2 Tol Check Select On to enable the calibration tolerance feature 5 Back out to the CAL SETUP menu select COe CAL PARAMS 6 To enable the calibration tolerance feature for the combustibles calibration from the COe CAL PARAMS select COe TolCheck Select On to enable ...

Page 62: ... and COe zero events When the COe zero feature is used special pneumatic connections are required See Section 2 Pneumatic Installation for details The COe zero feature is only valid if the OCX 8800 is supplied with calibration solenoids and the solenoids have been activated An OCX 8800 shipped from the factory must be configured before the COe zero feature can be implemented This same process must...

Page 63: ...terval Length of time between COe zero events Range is 60 to 480 minutes Default is 60 minutes COe Zero Duration Length of time COe zero gas flows Range is 120 to 600 seconds Default is 120 seconds COe Zero Purge Time Length of time after COe zero is complete before oxygen combustibles readings are considered valid Range is 60 to 180 seconds Default is 60 seconds Total duration of this function is...

Page 64: ...t to update OCX 8800 RESET PROCEDURE Whenever you correct an equipment alarm or fault condition the OCX 8800 will either revert to normal operation or continue to indicate an alarm status condition If the equipment does not revert to normal operation when a fault condition is cleared or if instructed to do so in Section 8 Troubleshooting use the following procedure to reset the OCX 8800 OCX Reset ...

Page 65: ...OI module in the OCX 8800 DISPLAY ORIENTATION The LOI module mounts to a connector on the LOI board The boardis 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 Removed Electronics Sta...

Page 66: ...election Arrow E Lockout Notation Display Window Analytical Status Code Selection Arrows LOI Key Functions The gray top left key will move one level higher in the menu structure When entering parameter values numbers this key moves the cursor to the left The left pointing key also doubles as an Enter key used after the digits of a parameter value are entered and the cursor is moved to its left mos...

Page 67: ... can prevent the LOI from entering lockout This condition can cause uncommanded operations to occur Figure 4 3 Z Pattern Entry LOI Status Codes The LOI display shows a status code in the lower right hand corner ofthe 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 AL Al...

Page 68: ...nd Column Submenus From the first column submenus selecting the right pointing key moves the display into the second column submenus The up and down pointing keys allow the display to move to the second column submenus of the first column submenu selected The left pointing key moves the display back to the first column submenu Third and Fourth Column Submenus From the second column submenus select...

Page 69: ... _____mV Hit E when ready Purge _____s Apply Lo COe Gas Hit E when ready Flow COe Lo _____s ______ _____mV Read COe Lo _____s ______ _____mV Apply Hi COe Gas Hit E when ready Flow COe Hi _____s ______ _____mV Read COe Hi _____s ______ _____mV Hit E when ready Purge _____s Apply Lo O2 Gas Hit E when ready Flow O2 Lo _____s ______ _____mV Read O2 Lo _____s ______ _____mV Apply Hi O2 Gas Hit E when r...

Page 70: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 4 6 Figure 4 4 LOI Menu Tree Sheet 3 of 4 ...

Page 71: ... ___ 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 COe T90 Time ___ seconds Lockout Time ___ seconds Revert Time ___ minutes Luminance ___ PCDC Enable ___ Y N PCNC Enable ___ Y N Alarms CPLD Registers Line Frequency Line Voltage Status PCD Counter Sensor Housing Serial Number PCN Counter Reset De...

Page 72: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 4 8 ...

Page 73: ...tomatic and manual Calibration commands and menus can be accessed by 375 Field Communicator or by the optional 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 375 Field Communicator to set up the OCX 8800 for fully automatic...

Page 74: ...dure to specify a time interval in hours at which the OCX 8800 will automatically calibrate 1 From the DEVICE SETUP screen select DETAILEDSETUP 2 From the DETAILED SETUP screen select CAL SETUP thenselect O2 CAL PARAMS or COE CAL PARAMS 3 If the unit is equipped with calibration solenoids and timed automatic calibrations are desired select Solenoids then select Yes Select No to disable the calibra...

Page 75: ...ic day or time OPERATOR INITIATED AUTOCALIBRATION An operator can initiate an automatic calibration at any time provided that the unit is equipped with calibration solenoids Autocalibration using the optional LOI To initiate a calibration using the LOI perform the following steps on the LOI menu tree Refer to Section 4 Using the LOI for the LOI menu tree 1 From the CALIBRATION menu use the right p...

Page 76: ...l second column submenu 3 From the Cal Control submenu use the right pointing key to selectthe third column Start Cal O2 option 4 Remain at the Start Cal O2 option or use the down pointing key to select the Start Cal COe option or Start Cal Both option The following sequence applies when Start Cal Both isselected 5 Use the right pointing key to start the calibration Turn on the low O2 test gas whe...

Page 77: ...P menu 2 SelectCALIBRATION from the DIAG SERVICE menu 3 Select CAL CONTROL from the CALIBRATIONmenu 4 Select CAL METHODS from the CAL CONTROL menu 5 From the CAL METHODS menu select the type of calibrationdesired O2 Calibration 6 In the first Calibration screen a Loop should be removed from automatic control warning appears Remove the OCX 8800 from any automatic control loops to avoid a potentiall...

Page 78: ... the Setup Press OK when ready 13 Select START CAL STEP CAL to start applying the O2 High Gas The time to apply the test gas is specified by the Gas Time 14 The Calibration Status should be automatically changed to FlowO2Hi and then ReadO2Hi for a period of time During this period if an attempt is made to go the next calibration step by pressing OK and selecting START CAL STEP CAL you will be prom...

Page 79: ... the OCX 8800 fromany automatic control loops to avoid a potantially dangerous operating condition and press OK 7 The main Calibration screen should look like the following Press OKto continue OCX TAG NAME STEP Idle TIME REMAIN 0s COe 0 20 ppm COe DELTA R 0 00 ohm OK NEXT to Select ABORT CANCEL to Exit 8 From the SELECT ACTION screen select START CAL STEP CAL to continue calibration select ABORT C...

Page 80: ...e Calibration using the Field Communicator HART To perform a manual O2 and COe calibration using the Field Communicator or AMS use the following procedure If necessary refer to Section 6 Field Communicator 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 ...

Page 81: ...ssOK when ready 13 Select START CAL STEP CAL to apply the O2 High Gas The time to apply the test gas is specified by the GasTime 14 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 CAL STEP CAL you will be prompted with Oper...

Page 82: ...e calibration or select Calibrate Both Sensors if calibrate both sensors is desired 6 In the calibration screen a Loop should be removed fromautomatic control warning appears Remove the device from any automatic control loops to avoid a potentially dangerous operating condition and press OK 7 The Select Action screen should look like the following From the Select Action screen select Update Displa...

Page 83: ...ied by the GasTime 14 The calibration step will change to Flow O2 High Gas Flow Comb High Gas and then Read O2 High Gas Read Comb High Gas fora period of time 15 Skip over to Step 19 Stop Gas if executing Calibrate O2 Sensoror Calibrate Combustibles Sensor 16 The calibration step will change to Read Comb Low Gas for a period of time When ready Calibration Step will stop at Apply Comb High Gas Swit...

Page 84: ...illamp 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 85: ...he 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 ea...

Page 86: ...imeter to read the milliamp output from the O2 D A converter circuit Connect the positive lead to the AOUT1 terminal and connect the negative lead to the AOUT1 terminal Then press OK at the Field Communicator 7 The Field Communicator displays Setting Fld dev output to 4 mA Press OK Read the O2 millamp output at the digital multimeter Enter the reading at the Field Communicator and press ENTER Sele...

Page 87: ...ect a digital multimeter to read the milliamp output from the COe D A converter circuit Connect the positive lead to the AOUT2 terminal and connect the negative lead to the AOUT2 terminal Then press OK at the HARTcommunicator 7 The Field Communicator displays Setting Fld dev output to 4 mA Press OK Read the COe millamp output at the digital multimeter Enter the reading at the Field Communicator an...

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Page 89: ...ile H indicates the HART protocol The infrared port IrDA lets the 375 Field Communicator interface with the PC IrDA is a PC interface supported for transfer of device descriptions DD software update configurations and application licenses IrDA communication can either be built into the PC or provided through a USB to IrDA adaptor The PC application can either be AMS Suite or 375 Easy Upgrade Progr...

Page 90: ... 375 Lead Set Connecting to a Fieldbus Segment Connect 375 Field Communicator with the supplied lead set in parallel with the device to a Fieldbus segment Figure 6 2 The 375 Field Communicator Fieldbus connections are polarity sensitive an error message displays if the device is connectedincorrectly Explosions can result in death or serious injury Do not make connections to the Field Communicator ...

Page 91: ...Conections Fieldbus Fieldbus Signal OUT1 OCX 8800 Electronics 1 NOTE Devices shown are not to scale Fieldbus Digital Signal Fieldbus Digital Signal Terminal Connectors Terminal Block Terminals Fieldbus Computer Terminal PC Field Communicator Rear Panel Field Communicator Model 375 Lead Set 39710006 ...

Page 92: ... the on line mode the communicator is connected to a fieldbus terminal block NOTE If the Field Communicator is turned on while connected to the fieldbus terminal block an undefined status indication appears while the communicator warms up Wait until the warm up period ends to continue The opening menu displayed on the LCD is different for on line and off line operations When powering up a disconne...

Page 93: ...les Sensor Raw Inputs DEVICE SETUP O2 O2 AO COe COe AO CONTINUED ON SHEET 2 39930012 SV is COe COe AO COe AO Output Variables O2 Raw Inputs COE Raw Inputs DEV Raw Inputs SB T C Board Temp IC CJC Temp Signal O2 Snsor O2 T C O2 Snsor Imp COe Delta V COe Ref V COe Delta R Coe Ref R COe T C RTD Current PV AOUT 4V TV SV PV is O2 O2 AO O2 AO TV is O2 Temp 4V is COe Temp Sensor Limits O2 COe O2 O2 O2 USL...

Page 94: ...rent Cal O2 Slope O2 Constant Sensor Imp Cal COe Slope COe Constant Previous Cal Prev O2 Slope Prev O2 Constant Prev Sensor Imp Prev COe Slope Prev COe Constant Failed Cal Failed O2 Slope Failed O2 Constant Failed COe Slope Failed COe Constant Reset Cal Constant Reset O2 CalConsts Reset COe CalConsts Cal Verify Verify Calibration State TimeRemain O2 COe O2 Loop Test COe Loop Test Loop Test O2 D A ...

Page 95: ...rsion Checksum Build Number Build Date Restart Cntr Detailed Setup Cal Setup Solenoids Gas Time Purge Time O2 Out Tracks O2 High Gas O2 Low Gas O2 Cal Intrv O2 Next Cal Time O2 Tol Check Cal Rec Enable O2 Cal Params Solenoids Gas Time Purge Time COe Out Tracks COe Test Gas COe Cal Intrv COe Next Cal Time COe Slope Warn COe Tol Check Cal Rec Enable COe Cal Params Input Output O2 Analog Output Analo...

Page 96: ...ev Universal Rev Cal Setup O2 Cal Setup Solenoids Gas Time Purge Time O2 Out Tracks O2 Low Gas O2 High Gas O2 Cal Intrvl O2 Next Cal Time O2 Tol Check Cal Rec Enable COe Cal Setup Solenoids Gas Time Purge Time COe Out Tracks COe Test Gas COe Cal Intrvl COe Next Cal Time COe Slope Warn COe Tol Check Cal Rec Enable Input Output O2 URV O2 LRV COe URV COe LRV O2 AO Range COe AO Range O2 Alarm Level CO...

Page 97: ... State Unacknowledge Block Mode Actual Block Mode Target Resource State Fault State Block Error Detailed Status Summary Status Alarm Summary Value Subcode Time Start Alarm State Unacknowledge Master Reset Self Test DD Version Info Transmitter Options PlantWeb Alerts Simulate PWA Simulate Status PWA Status PWA SubStatus Status Methods Manufacturer ID Device Type Device Revision DD Revision Characte...

Page 98: ...Oe Primary Value Range EU at 0 COe Secondary Value Range EU at 100 COe Secondary Value Range EU at 0 COe Sensor Type COe T90 COe Cal Cons COe Slope COe Constant Prev COe Slope Prev COe Constant Failed COe Slope Failed COE Constant O2 Secondary Value COe Secondary Value SB Temp Board Temp CJC Temp O2 Temp Max COe Max SB Temp Max Board Temp Max CJC Temp Max Heater Control O2 Set Point O2 Duty Cycle ...

Page 99: ... Gas Time Purge Time Cal Recommended O2 High Gas O2 Low Gas O2 Cal Interval O2 Next Cal O2 Tolerance Check O2 Sensor Cal Date O2 Sensor Cal Loc O2 Sensor Cal Who Blow Back Blowback State Blowback Enabled Blowback Interval Blowback Duration Blowback Purge Time Initate Blowback Alarm Relay Alarm Relay State Alarm Relay Event1 Alarm Relay Event2 Alarm Relay Event3 Continued with COe Zero Continued fr...

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Page 101: ...the network It has the ability to distribute control among intelligent field devices on the plant floor and digitally communicate that information at high speed that makes FOUNDATIONTM Fieldbus an enablingtechnology EMERSON offers a full range of products from field devices to the DeltaV scalable control system to allow an easy transition to Fieldbus technology The Fieldbus retains the features of...

Page 102: ... a different need Function blocks perform process control functions such as analog input AI and analog output AO functions as well as proportional integral derivative PID functions The standard function blocks provide a common structure for defining function block inputs outputs control parameters events alarms and modes and combining them into a process that can be implemented within a single dev...

Page 103: ... tag Thus the service personnel need only know the tag of the block to access or change the appropriate block parameters Function blocks are also capable of performing short term data collection and storage for reviewing their behavior Device Descriptions Device Descriptions are specified tool definitions that are associated with the function blocks Device descriptions provide for the definition a...

Page 104: ...ation of events There is only one resource block defined for a device For example when the mode of a resource block is out of service it impacts all of the otherblocks Transducer Blocks Transducer blocks connect function blocks to local input output functions They read sensor hardware and write to effector actuator hardware This permits the transducer block to execute as frequently as necessary to...

Page 105: ... to become the LAS The link master that wins the bid begins operating as the LAS immediately upon completion of the bidding process Link masters that do not become the LAS act as basic devices However the link masters can act as LAS backups by monitoring the link for failure of the LAS and then bidding to become the LAS when a LAS failure is detected Only one device can communicate at a time Permi...

Page 106: ...tenance and 3 Advisory Each PWA can be configured for one or more of the three alarm groups The PWA alarms and their severity level default settings are listed in Table7 2 Table 7 2 OCX 8800 PWA PlantWeb Alert Severity Level Default Reserved none Sensor Malfunction Failed Sensor Degraded Failed Thermocouple Malfunction Failed Sensor Heater Malfunction Failed Sensor Heater Over Temperature Failed S...

Page 107: ...ygen cell 2 This problem could be caused by a mechanical failure in the sensor housing or at the electronics An open circuit in the combustible sensor could also cause this alarm Refer to Section 8 Troubleshooting for details Oxygen cells will degrade over time due to aging and corrosion An increasing cell resistance is a good indicator of reduced cell performance As the cell impedance increases t...

Page 108: ...at is too high or too low Check heater wiring check thermocouple wiring or replace the electronics stack Allow instrument several minutes to reach proper temperature or check power supply A heater over temperature out of control problem would generally be caused by the inability of the device to limit power to the heater This could be caused by a shorted triac on the power supply in the electronic...

Page 109: ...g for details 4 ROM Integrity Error NV Writes Resource Block FF A high number of writes has been detected to Deferred 1 NV Writes Device non volatile memory To prevent premature failure Deferred Alerts of the memory the write operations have been deferred The data will be saved on a 6 hour cycle This condition usually exists because a program has been written that writes to Function block paramete...

Page 110: ...PWA active parameters can now be written Device when the PWA The resource block detailed status parameters Alerts simulate mode is and the internal alerts in the Transducer Block active where the PWA active alarms originate can also be written PWA Simulate Setting PWA_SIMULATE to ON allow simulating the PWA parameters FAILED_ACTIVE MAINT_ACTIVE and ADVISE_ACTIVE Allowing Simulating means that thes...

Page 111: ...s Simulation is on the Simulation Switch LED is illuminated When PWA simulation is on the PWA Simulate LED isilluminated Figure 7 4 Simulate PWA Screen 6 If PWA Simulation is on all PWA active parameters and Resource and Transducer Block status parameters are configurable Otherwise they are read only 7 To simulate PlantWeb alerts use the Simulate PWA screens in the Resource Block To simulate block...

Page 112: ...lerts select the alerts listed under Failed Active Maintenance Active and Advisory Active Resource Simulate PWA 7 To simulate block alarms select the alarms listed under Detailed Status in the Resource Block Resource Simulate Status or under Detailed Status in the Transducer Block Transducer Simulate Status 8 Select Resource PWA SubStatus to see the active PWA alarms and masks Select Fail Active M...

Page 113: ...ZER_SW_BUILD_ The build number of the analyzer software NUMBER ANALYZER_SW_ The checksum of the analyzer software CHECKSUM ANALYZER_SW_VERSION The version of the analyzer software BLOCK_ALM See FF 891 section 5 3 BLOCK_ERR See FF 891 section 5 3 BLOWBACK_DURATION 1 5 Seconds The amount of time the blowback solenoid will be on BLOWBACK_ENABLED 0 No 1 Yes Enumerated Enables or disables the automatic...

Page 114: ... reading See FF 903 section 3 3 Ohms The raw value of the combustibles reference input The combustibles cell temperature This is the determined from the value of the combustibles reference RTD The High and Low range limit values the engineering units code and the number of digits to the right of the decimal point for the combustibles cell temperature reading See FF 903 section 3 3 mA Combustible R...

Page 115: ...d as the low gas for calibrating the combustibles sensor O2_CAL_POINT_LO 0 40 The value of the O2 low test gas O2_CELL_IMPEDANCE Ohms The instaneous impedance value for the O2 cell O2_CONSTANT 20 0 20 0 mV The O2 calibration constant O2_FAILED_CONSTANT mV This is the constant value calculated from the last failed O2 calibration O2_FAILED_SLOPE mV Decade This is the slope value calculated from the ...

Page 116: ...SOR_HOUSING_ mV Sensor Housing CJC voltage Valid only with Type 3 sensor TEMP_INPUT SENSOR_HOUSING_ C The highest Sensor Housing temperature read since power on TEMP_MAX SENSOR_HOUSING_TYPE 0 1 2 3 Enumerated This is the Sensor Housing type setting through the DIP switch 0 Type 1 1 Type 2 2 Type3 3 Invalid SOLENOIDS_PRESENT 0 No 1 Yes Enumerated This determines whether a calibration cycle will aut...

Page 117: ...w Gas No 9 Read Comb Low Gas No 10 Apply Comb High Gas Yes If Parameter Solenoids Present is 0 11 Flow Comb High Gas No 12 Read Comb High Gas No 13 Stop Gas Yes If Parameter Solenoids Present is 0 14 Purge No 15 Abort Yes If Parameter Solenoids Present is 0 Calibration Step Command During a calibration the CAL_STATE_STEP command parameter controls the calibration procedure The procedure will progr...

Page 118: ...ions ALARM_RELAY_EVENTDescription Off In Calibration O2 Cell Temp Error O2 Heater Open O2 Cell Bad Cal Failed Cal Warn High Electronics Temp Unit Failure SL Temp Error Comb Cell Temp Error Power Input Error In COe Zero All Operating Mode Table 7 8 Operating Mode Enumerations Operating Mode Description POWER UP WARMUP STABILIZE NORMAL CALIBRATING CALVERIFY BLOWBACK COZERO ALARM SYS FAULT CAL RECOMM...

Page 119: ...libration Verify Status During a running calibration verify procedure the states below reflect the current step that the calibration verify is running in Table 7 11 Calibration Verify State Values VERIFY_STATEDescription Idle Flow High O2 Gas Flow Low O2 Gas Flow High COe Gas Purge Gas Done Calibration Verify Step Control During a calibration the VERIFY_STATE_ STEP command parameters control the c...

Page 120: ... 11 Combustibles Cell Error Mechanical Failure 12 Combustibles Thermocouple Open Mechanical Failure 13 Combustibles Thermocouple Shorted Mechanical Failure 14 Combustibles Thermocouple Reversed Mechanical Failure 15 Combustibles Temperature Low Mechanical Failure 16 Combustibles Temperature High Mechanical Failure 17 Combustibles Temperature Very High Mechanical Failure 18 Combustibles Heater Fail...

Page 121: ...h Electronics Failure 40 Inter board Communication Failure Electronics Failure Reserved for FB Transducer Block Channel Assignments for AI Blocks The following table lists the OCX transducer block I O channels for the AI block Table 7 16 I O Channel Assignments Transducer Block Channel Value Process Variable XD_SCALE UNITS 1 O2 Concentration 2 Combustibles Concentration PPM 3 O2 Cell Temperature C...

Page 122: ... NOT_LIMITED 1 2 Alarm Temperature Low High Cell Bad Error UNCERTAIN SENSOR_CONVERSION_INACCURATE NOT_LIMITED 1 2 System Fault BAD DEVICE_FAILURE NOT_LIMITED 3 4 Powerup Warmup Stablize GOOD NON_SPECIFIC NOT_LIMITED 3 4 Normal GOOD NON_SPECIFIC NOT_LIMITED 3 4 Calibrating Cal Verify Blow Back GOOD NON_SPECIFIC NOT_LIMITED 3 4 Alarm System Fault Temperature Related Alarms T C Open T C Shorted T C R...

Page 123: ...arm condition The Analog Input AI function block processes field device measurements and makes them available to other function blocks The output value from the AI block is in engineering units and contains a status indicating the quality of the measurement The measuring device may have several measurements or derived values available in different channels Use the channel number to define the vari...

Page 124: ...ice manual for information about the specific channels avail able in each device You must configure the CHANNEL parameter before you can configure the XD_SCALE parameter FIELD_VAL 19 Percent The value and status from the transducer block or from the simulated input when simulation is enabled GRANT_DENY 12 None Options for controlling access of host computers and local control panels to operating t...

Page 125: ... or processed by the block ST_REV 01 None The revision level of the static data associated with the function block The revision value will be incremented each time a static parameter value in the block is changed TAG_DESC 02 None The user description of the intended application of the block UPDATE_EVT 20 None This alert is generated by any change to the static data VAR_INDEX 39 of OUT Range The av...

Page 126: ...s OUT_D discrete output that signals a selected alarm condition Figure 7 7 Analog Input Function Block Timing Diagram PV_FTIME Filtering The filtering feature changes the response time of the deviceto smooth variations in output readings caused by rapid changes in input You can adjust the filter time constant in seconds using the PV_FTIME parameter Set the filter time constant to zero to disable t...

Page 127: ...are Root Indirect Square Root signal conversion takes the square root of the value computed with the indirect signal conversion and scales it to the range and units of the PV and OUT parameters PV x EU 100 EU 0 EU 0 OUT_SCALE values When the converted input value is below the limit specified by the LOW_CUT parameter and the Low Cutoff I O option IO_OPTS is enabled True a value of zero is used for ...

Page 128: ...ameter Manual Man The block output OUT may be set manually Automatic Auto OUT reflects the analog input measurement orthe simulated value when simulation is enabled Outof Service O S The block is not processed FIELD_VAL and PV are not updated and the OUT status is set to Bad Out of Service The BLOCK_ERR parameter shows Out of Service In this mode you can make changes to all configurable parameters...

Page 129: ...rm condition In Auto mode OUT reflects the value and status quality of the PV In Man mode the OUT status constant limit is set to indicate that the value is a constant and the OUT status is Good The Uncertain EU range violation status is always set and the PV status is set high or low limited if the sensor limits for conversion are exceeded In the STATUS_OPTS parameter you can select from the foll...

Page 130: ...els depends on the specific application A typical configuration for the AI block involves the following parameters Channel If the device supports more than one measurement verify that the selected channel contains the appropriate measurement or derived value L_TYPE Select Direct when the measurement is already in the engineering units that you want for the block output Select Indirect when you wan...

Page 131: ...e tank The maximum level at the tank is 16 ft The liquid in the tank has a density that makes the level correspond to a pressure of 7 0 psi at the pressure tap Figure7 9 Figure 7 9 Situation 1 Diagram Solution to Situation 1 Table 7 22 lists the appropriate configuration settings and Figure 7 9 illustrates the correct function block configuration Table 7 22 Analog Input Function Diagram for a Pres...

Page 132: ...k is empty is equivalent to 2 0 psi Figure 7 11 Figure 7 11 Situation 2 Diagram 16 ft Empty Tank 0 ft 2 0 psi measured at the transmitter Solution Table 7 23 lists the appropriate configuration settings Table 7 23 Analog Input Function Diagram for a Pressure Transmitter used in Level Measurement Situation 2 Parameter Configured Values L_TYPE Indirect XD_SCALE 2 to 9 psi OUT_SCALE 0 to 16 ft AI Fun...

Page 133: ...itter was calibrated for 0 to 20 in H20 for a flow of 0 to 800 gal min and the transducer was not configured to take the square root of the differential pressure Solution Table 7 24 lists the appropriate configuration settings and Figure 7 12 illustrates the correct function block configuration Table 7 24 Analog Input Function Block Configurationfor a Differential Pressure Measurement L_TYPE Indir...

Page 134: ...or In direct Square Root and cannot be left at ini tial value of 0 3 The actual mode of the Resource block is OOS See Resource Block Diagnostics for cor rective action 4 Block is not scheduled and therefore cannot execute to go to Target Mode Schedule the block to execute 1 FEATURES_SEL does not have Alerts en abled Enable the Alerts bit 2 LIM_NOTIFY is not high enough Set equal to MAX_NOTIFY 3 ST...

Page 135: ...e PID control The block supports mode control signal scaling and limiting feedforward control override tracking alarm limit detection and signal status propagation The block supports two forms of the PID equation Standard and Series You can choose the appropriate equation using the FORM parameter The Standard ISA PID equation is the default selection 1 Standard Out GAIN x e x 1 T s 1 F Series Out ...

Page 136: ...44 None The block alarm is used for all configuration hardware connection failure or system problems in the block The cause of the alert is entered in the sub code field The first alert to become active will set the active status in the sta tus parameter As soon as the Unreported status is cleared by the alert reporting task and other block alert may be reported without clearing the Ac tive status...

Page 137: ... of the alarm a timestamp of occurrence and the state of the alarm LO_LO_LIM 55 EU of PV_SCALE The setting for the alarm limit used to detect the LO LO alarm condition LO_LO_PRI 54 None The priority of the LO LO alarm LO_PRI 52 None The priority of the LO alarm MATH_FORM 73 None Selects equation form series or standard MODE_BLK 05 None The actual target permitted and normal modes of the block Targ...

Page 138: ...ring is applied STATUS_OPTS 14 None Allows you to select options for status handling and processing The support ed status option for the PID block is Target to Manual if Bad IN STRATEGY 03 None The strategy field can be used to identify grouping of blocks This data is not checked or processed by the block ST_REV 01 None The revision level of the static data associated with the function block The r...

Page 139: ...In Auto mode you can also adjust the setpoint limit and the setpoint rate of change using the SP_RATE_UP and SP_RATE_DNparameters In Manual mode the output is entered manually by the operator and is independent of the setpoint In RemoteOutput mode the output is entered by a host computer and is independent of thesetpoint Figure 7 14 illustrates the method for setpoint selection FF_GAIN FF_SCALE Fe...

Page 140: ...ual mode When Track in Manual is False the operator can override the tracking function when the block is in Manual mode Activating the track function causes the block s actual mode to revert to Local Override The TRK_VAL parameter specifies the value to be converted and tracked into the output when the track function is operating The TRK_SCALE parameter specifies the range of TRK_VAL When the TRK_...

Page 141: ... parameter selection When RESET equals zero the equation reduces to an integrator equation with a gain value applied to the error GAIN x e s s Where GAIN proportional gain value e error s laplace operator Reverse and Direct Action To configure the block output action enable the Direct Acting control option This option defines the relationship between a change in PV and the corresponding change in ...

Page 142: ...e PID function block supports the followingmodes Manual Man The block output OUT may be set manually Automatic Auto The SP may be set manually and the block algorithm calculates OUT Cascade Cas The SP is calculated in another block and is provided to the PID block through the CAS_IN connection RemoteCascade RCas The SP is provided by a host computer that writes to the RCAS_IN parameter RemoteOutpu...

Page 143: ...re grouped into five levels of priority Priority Number PriorityDescription 0 The priority of an alarm condition changes to after the condition that caused the alarm is corrected 1 An alarm condition with a priority of 1 is recognized by the system butis not reported to the operator 2 An alarm condition with a priority of 2 is reported to the operator butdoes not require operator attention such as...

Page 144: ...r by moving the output in the appropriate direction The integral term RESET applies a correction based on the magnitude and duration of the error Set the RESET parameter to zero for integral only control To reduce reset action configure the RESET parameter to be a large value The derivative term RATE applies a correction based on the anticipated change in error Derivative control is typically used...

Page 145: ... Good input status is reestablished Application Examples Basic PID Block for Steam Heater Control Situation A PID block is used with an AI block and an AO block to control the flow steam used to heat a process fluid in a heat exchanger Figure 7 15 illustrates the process instrumentation diagram Figure 7 15 PID Function Block Steam Heater Control Solution The PID loop uses TT101 as an input and pro...

Page 146: ... desired temperature range Solution Feedforward control is added to improve the response time of the basic PID control The temperature of the inlet process fluid TT100 is input to an AI function block and is connected to the FF_VAL connector on the PID block Feedforward control is then enabled FF_ENABLE the feedforward value is scaled FF_SCALE and a gain FF_GAIN is determined Figure 7 17 illustrat...

Page 147: ...n the heat exchanger to change The temperature variation will later be sensed by TT101 The temperature controller will modify the valve position to compensate for the steam pressure change The process is slow and causes variations in the product temperature Figure 7 19 illustrates the process instrumentation diagram Figure 7 19 PID Function Block Cascade Control Example AI Function Block OUTOUT IN...

Page 148: ...101 FC 101 TCV 101 Cascade Control with Override You can use the PID function block with other function blocks for complex control strategies Figure 7 21 illustrates the function block diagram for cascade control with override When configured for cascade control with override if one of the PID function blocks connected to the selector inputs is deselected that PID block filters the integral value ...

Page 149: ...k is constant and prevents the integral term from increasing or decreasing Figure 7 21 Function Block Diagram for Cascade Control with Override BKCAL_IN BKCAL_OUT Slave Controller Master Controller CAS_IN PID Function Block OUT PID Function Block IN OUT CAS_IN AO Function Block BKCAL_SEL_1 Configured for High Selection SEL_1 SEL_2 Control Selector Function Block IN_1 OUT PID Function Block BKCAL_S...

Page 150: ...lculation 1 BKCAL_IN a The link is not configured the status would show Not Connected Configure the BKCAL_IN link to the downstream block b The downstream block is sending back a Quality of Bad or a Status of Not Invited See the appropriate downstream blockdiag nostics for corrective action Mode will not change to AUTO Mode will not change to CAS 1 Target mode not set 2 Input 1 Target mode not set...

Page 151: ... not high enough Set equal to MAX_NOTIFY 3 STATUS_OPTS has Propagate Fault Forward bit set This should be cleared to cause an alarm to occur ARITHMETIC ARTHM FUNCTION BLOCK Figure 7 22 Arithmetic ARTHM Function Block IN IN_LO IN_1 IN_2 IN_3 OUT The Arithmetic function block provides the ability to configure a range extension function for a primary input and applies the nine 9 different arithmetic ...

Page 152: ...mit of the compensation input 32 GAIN None The proportional gain multiplier value 22 GAIN_IN_1 None The proportional gain multiplier value for IN_1 24 GAIN_IN_2 None The proportional gain multiplier value for IN_2 26 GAIN_IN_3 None The proportional gain multiplier value for IN_3 12 GRANT_DENY None Options for controlling access of host computers and local control panels to operating tuning and ala...

Page 153: ...scription of the intended application of the block 35 UPDATE_EVT None This alert is generated by any changes to the static data Figure 7 23 Arithmetric Function Block Diagram IN _LO OUT N_1 N_2 N_3 Block Errors Table 7 30 lists the conditions reported in the BLOCK_ERR parameter Table 7 30 BLOCK_ERR Parameters 0 Other The output has a quality of uncertain 1 Block Configuration Error Select type is ...

Page 154: ... condition changes to 0 after the condition that caused the alarm is corrected 1 An alarm condition with a priority of 1 is recognized by the system but is not reported to the operator 2 An alarm condition with a priority of 2 is reported to the operator but does not require operator attention such as diagnostics and system alerts 3 7 Alarm conditions of priority 3 to 7 are advisory alarms of incr...

Page 155: ...curate level indication at widely ranging temperature changing density proves inconvenient The Arithmetic function block allows for the automatic compensation of this change by incorporating gain and bias adjustments to the temperature signal It then applies both the compensated temperature signal and the level signal to a characteristic system equation The result is a level that is a true indicat...

Page 156: ...mpensation Linear Flow Compensation Square Root func PV f func PV f COMP_HI COMP_HI f t 1 t 2 f t 1 t 3 t 2 COMP_LO COMP_LO If there is a divide by zero and the numerator is positive f is set to COMP_HI if the numerator is negative then f is set to COMP_LO The square root of a negative value will equal the negative of the square root of the absolute value Imaginary roots are not supported Flow Com...

Page 157: ... LIM_NOTIFY is not high enough Set equal to MAX_NOTIFY Status Options STATUS_OPTS has the Propagate Fault Forward bit set This must be cleared to cause the alarm to occur INPUT SELECTOR ISEL FUNCTION BLOCK Figure 7 26 Input Selector ISEL Function Block IN_1 IN_2 IN_3 IN_4 DISABLE_1 DISABLE_2 DISABLE_3 DISABLE_4 OP_SELECT OUT SELECTOR IN 1 4 DISABLE 1 4 OP_SELECT TRK_VAL SELECTED OUT Input used in ...

Page 158: ...rmined by source The connection input from another block One of the inputs to be selected from IN_2 12 Determined by source The connection input from another block One of the inputs to be selected from IN_3 13 Determined by source The connection input from another block One of the inputs to be selected from IN_4 14 Determined by source The connection input from another block One of the inputs to b...

Page 159: ...ad 9 Memory Failure A memory failure has occurred in FLASH RAM or EEROM memory 10 Lost Static Data 11 Lost NV Data 12 Readback Check Failed 13 Device Needs Maintenance Now 14 Power Up The device w as just pow ered up 15 Out of Service The actual mode is out of service Modes The ISEL function block supports three modes of operation as defined by the MODE_BLK parameter Manual Man The block output OU...

Page 160: ...uts mid calculates the middle of three inputs or the average of themiddle two inputs if four inputs are defined 1st Good selects the first available good input Hot Backup latches on the selected input and continues to use it until it is bad If DISABLE_N is active the associated input is not used in the selection algorithm If OP_SELECT is set to a value between 1 and 4 the selection type logic is o...

Page 161: ... Selector Function Block Application Example SEL_TYPE Hot Backup IN1 126 F IN2 104 F IN3 112 F IN4 130 F IN1 126 F IN2 104 F IN3 112 F IN4 130 F IN1 126 F IN2 104 F IN3 112 F IN4 130 F To Another Function Block To Another Function Block Table 7 36 Input Selector Function Blocks Time Value IN1 Status Value IN2 Status Value Out Status Selected Value Status T0 Good 20 Good 21 Good 20 Good 1 T1 Bad 20...

Page 162: ...o MAX_NOTIFY 1 Status Options 1 STATUS_OPTS has Propagate Fault Forward bit set This should be cleared to cause an alarm to occur OPERATION WITH EMERSON DELTAV About AMS and DeltaV Software AMS and DeltaV software allows users to manage their instrumentation and to perform on line configurations of their instruments The ability to communicate with instruments and configure instruments on line faci...

Page 163: ...onsist of 3 dll files sym ffo fhx and reg file The files probably will be on a floppy disk or a CD ROM that accompanies your device On CD ROMs delivered together with Emerson analyzers the files are located in the directory Fieldbus Dependent on the existent system use the files of the appropriate subdirectory After answering yes to the first prompt DeltaV will start the installation Figure 7 31 s...

Page 164: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 7 64 ...

Page 165: ...vides facilities for 100 effective grounding and total elimination of groundloops Electrical Noise The OCX 8800 has been designed to operate in the type ofenvironment 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 circuitry of a faulty...

Page 166: ...250 VAC DIAGNOSTIC ALARMS Always install a blocking diode on the customers relay coil Failure to install a blocking diode may create noise spikes and cause faults in the OCXelectronics The OCX 8800 is equipped with a set of alarm relay contacts on the microprocessor board in the electronics housing This set of dry contacts can be connected to any customer supplied relay device 30 VDC 30 mA maximum...

Page 167: ...Check resistance of CJC sensor to ground per Figure 9 9 Replace CJC sensor if resistance is less than 10M Ohms CJC sensor failed Check resistance of CJC sensor per Figure 9 9 Replace CJC sensor if resistance of sensor is not between 100 and 150 Ohms 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 l...

Page 168: ...ection 3 Configuration and Startup to continue operation Incorrect sample block thermocouple wiring Check sample block thermocouple wiring per Figure 8 3 and Figure 9 8 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 packa...

Page 169: ... 3 and Figure 9 9 Check the wiring at the sensor and inside the electronics housing Correct reversed wires fault Perform Reset procedure in Section 3 Configuration and Startup to continue operation Sample block thermocouple wires reversed Check sample block thermocouple wiring per Figure 8 3 and Figure 9 8 Check the wiring at the sensor and inside the electronics housing Correct reversed wires fau...

Page 170: ...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 cause of overload If F3 is not open or if cause of overload cannot be found replace electronics package Sample block heater circuit wiring open Check sample block heater circuit for broken wire or loose connection per Figure 8 3 and Figure 9 8 Re...

Page 171: ...ing portions of the flow path for plugging blowback filter in situ filter eductor outlet path Calibration Gas concentration incorrect orgas bottle empty O2 TOL Error not within 10 of configured O2 test gas COe TOL Error not within 30 of configured CO test gas Table continued on next page Figure 8 2 Oxygen and Cell Output 9 7 5 0 9 0 7 0 5 20 0 20 40 60 80 100 120 ANALYZER OUTPUT MILLIVOLT Cal Warn...

Page 172: ...with line frequency Replace electronics package if they do not agree within 1 Hz 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 Table continued on next page Line Voltage Low AC power line voltage below minimum 85 VAC Probable Cause Recommended Correc...

Page 173: ...ter kit PN 6A00171G01 or high quality line filter for input power Electronics package failure Replace electronics package Electronics package failure Replace electronics package Out Brd Failure Output board failure Probable Cause Recommended Corrective Action Electronics package failure Check power supply voltage and compare with line voltage Replace electronics package if they do not agree within...

Page 174: ...CO T C SB T C SB T C O2 T C O2 O2 CELL O2 CELL YEL BRN BLK RED WHT ORG EXC CO ACT CO ACT CO REF CO REF COe Sensor and Cold Junction Connector J4 O2 Sensor and Thermocouple Connector J5 BLK BLK CJC CJC EXC SHLD To ground 1 screw ELECTRONICS HOUSING SENSOR HOUSING To ground screw Signal Cable Heater Power Cable BLU BLK O2 T C O2 BLK GRN BLK T C CO RED BLK T C SB WHT BLK EXC BLK CJC ORG BLK 2 HTR 1 O...

Page 175: ...n Warning Calibration warning Cal Warning Board Temperature High Electronics temperature maximum exceeded Board Temp Hi 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 Unit Failure Sample Block TemperatureError COe Sensor TemperatureError Power Input Err...

Page 176: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 8 12 ...

Page 177: ...TALLATION 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 clea...

Page 178: ...e the cover from the electronics housing to expose the electronics housing terminal blocks Figure 9 2 5 Disconnect and remove the power leads from the AC power input terminal block and remove the ground lead from the groundstud 6 Disconnect and remove the O2 and COe signal leads from the 4 20 mA signal output terminal block 7 If used disconnect and remove the external relay leads from thealarm out...

Page 179: ... 9 2 Electronics Housing Terminal Blocks Signal Output OR Terminal Block 1 Signal Port 3 4 NPT TOP VIEW 1 2 SIZE EMI Filter G Customer Terminal Block N L1 G Power Port 3 4 NPT G Ground Stud Earth Ground Typical for Electronics and Sensor Housing Wiring Ground Stud External Tooth Lockwasher O Signal AOUT1 Fieldbus AOUT2 COe Signal FOUNDATION Fieldbus 37390013 ...

Page 180: ...tput relayterminal block Figure 9 2 6 Connect the O2 and COe signal leads to the 4 20 mA signal output terminal block 7 Connect the line L1 wire to the L1 terminal and the neutral N wire to the N terminal on the AC power input terminal block 8 Connect the ground lead to the ground stud Secure the connection with two nuts Attach a separate ground lead G wire from the ground stud to the G terminal o...

Page 181: ...ers and close the instrumentair valve 3 Disconnect the calibration gas reference air eductor air and dilution air lines from the sensor housing Figure 9 3 Figure 9 3 OCX with Remote Electronics Duct Stack Sensor Housing Heater Power Cable Signal Cable Signal Outputs AC Power Input Electronics Housing Instrument Air Reference Gas High O2 Test Gas Low O2 Test Gas CO Test Gas 37390044 ...

Page 182: ... and CJC terminal blocks 6 Disconnect the heater power cable from the HTR terminalblocks 7 If moving the sensor housing to another work site disconnectand remove the power and signal cables from the sensor housing 8 Remove insulation to access the mounting bolts Unbolt the sensor housing from the stack and take it to a clean work area 9 Allow the sensor housing to cool to a comfortable workingtemp...

Page 183: ... Housing 1 Turn off power to thesystem 2 Shut off the test gases at the cylinders and close the instrumentair supply valve Figure 9 3 3 Disconnect the test gas and instrument air lines from theremote electronics housing 4 Remove the cover from the electronics housing to expose the electronics housing terminal blocks Figure 9 5 5 Disconnect and remove the power leads from the AC powerinput terminal...

Page 184: ... 9 5 Electronics Housing Terminal Blocks Signal Output OR Terminal Block 1 Signal Port 3 4 NPT TOP VIEW 1 2 SIZE EMI Filter G Customer Terminal Block N L1 G Power Port 3 4 NPT G Ground Stud Earth Ground Typical for Electronics and Sensor Housing Wiring Ground Stud External Tooth Lockwasher O Signal AOUT1 Fieldbus AOUT2 COe Signal FOUNDATION Fieldbus 37390013 ...

Page 185: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 9 9 Figure 9 6 Remote Electronics Housing Cable Connections ...

Page 186: ...layterminal 9 Connect the test gas and instrument air lines to the remote electronics housing Connect the calibration gas line and instrument air line to the remote electronics housing 10 Refer to Figure 9 3 and Figure 9 6 Make sure all test gas lines and electrical connections are complete 11 Install the cover on the electronics housing 12 Turn on the test gasses at the cylinders and open the ins...

Page 187: ...rut Assembly 10 Gasket 11 Screw 12 Heater Clamp 13 Heater Rod 3 7 4 9 5 6 11 10 12 8 13 2 1 Remove O2 Cell and Heater Strut Assembly 1 Remove reference air tube 7 Figure 9 7 from sensor housing 8 2 See Figure 9 8 Disconnect and tag O2 heater wires O2 cell and return wires and thermocouple wires at the sensor housing terminals 3 Remove the O2 cell and heater strut assembly 9 Figure 9 7 from sensor ...

Page 188: ... sample block heater rods 13 out of housing 8 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 Figure 9 8 O2 Cell Thermocouple and Heater Connections O2 Cell Wires O2 Heater Wires Thermocouple Wires O2 ORG RED GRN YEL T C O2 T C CO O2 Cell and Heater Strut Assembly T C SB EXC CJC Sample Block Thermo couple Samp...

Page 189: ... COe sensor assembly 5 eductor fittings 12 and 15 and sensor housing 7 4 Unfasten bayonet connector of COe thermocouple 8 andremove thermocouple 5 Loosen clamp screw of COe band heater 9 until heater rotatesfreely on sensor holder 11 Figure 9 9 COe Sensor Thermocouple and Heater Connections O2 T C O2 RED YEL T C CO CJC Sensor T C SB EXC NOTE All wires at these terminals are in the CJC current loop...

Page 190: ... 2 10 15 6 12 13 16 14 7 1 Insulator 2 Dilution Air Tube 3 COe Extractive Tube 4 Eductor Air Tube 5 COe Sensor Assembly 6 Eductor 7 Sensor Housing 8 COe Thermocouple 9 Heater Insulator 10 COe Band Heater 11 Sensor Holder 12 Eductor Elbow 13 Terminal Block Mounting 14 Eductor Holder 15 Tube Fitting 16 CJC Sensor 37390047 ...

Page 191: ...correct alignment of sensor holder 7 With one wrench holding eductor elbow 12 Figure 9 10 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 9 11 Alignment of COe Sensor Assembly Sensor Holder Flat Matchmark Straightedge Matchmark 37390035 ...

Page 192: ...ats 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 torqueto elbow 12 eductor holder 14 or tube fitting 15 until the thread sealant softens Remove mating parts 12 14 and15 7 Use MEK or methylene chloride solvent to clean thread sealant residue from t...

Page 193: ...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 1 Sensor Housing 2 Sample Tube 3 Exhaust Tube 4 In Situ F...

Page 194: ... 4 will sometimes fuse to the O2 cell 2 2 If the O2 cell is fused to the contact pad push the O2 cell back into the heater tube against spring pressure and quickly twist the O2 cell The cell and contact pad should separate If the contact pad stays fused to the cell a new contact thermocouple assembly 4 must be installed 3 Remove and discard gasket 5 Clean the mating surface of heater tube 3 Remove...

Page 195: ...mocouple adaptor to450 F 232 C minimum b While heating use a flat head screwdriver to apply removaltorque Apply torque until the pipe thread sealant softens Remove and discard the thermocoupleadaptor 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 9 15 ...

Page 196: ...aws with pre heaterport pointing up 3 Install and tighten pre heater 7 Align pre heater to flat ofsensor holder 4 as shown in Figure 9 16 4 Invert sensor holder 4 Figure 9 15 in vise and pour stainlesssteel 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 install ...

Page 197: ...gas passage holes line up with each other in all components 2 Apply a small amount of anti seize compound to the screw threadsand use screws 1 to secure assembly Torque to 35 in lbs 4N 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 bracke...

Page 198: ...reads of eductor 6 Figure 9 17 Do not apply sealant to the first turn of the pipe threads Figure 9 17 Installation of Eductor and COe Sensor 4 3 8 5 1 11 9 2 10 15 6 12 13 16 14 7 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 Term...

Page 199: ...ctor 6 Male port of elbowmust point up and be in line with long axis ofeductor 4 Apply anti seize compound to the external pipe threads ofeductor holder 14 5 Install and tighten eductor holder 14 in sensor housing 7 Align eductor with matchmarks as shown in Figure 9 18 Figure 9 18 Eductor Alignment Matchmarks Eductor Flat Straightedge Matchmark 37390036 ...

Page 200: ... flange as shown in Figure 9 20 Band Heater Insulator 5 Wrap heater insulator 9 around sensor holder 11 Make sure the insulator joint lines up with the band gap of the COe band heater 10 6 Slide COe band heater 10 Figure 9 17 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 Figur...

Page 201: ...efer to Figure 9 21 11 Install and fasten the COe insulator 1 Figure 9 17 around COe sensor assembly 5 All wiring must remain outside of the insulator 12 If terminal block mounting 13 Figure 9 17 was moved reinstallwith two base mounting screws Figure 9 21 COe Sensor Thermocouple and Heater Connections O2 T C O2 RED YEL T C CO CJC Sensor T C SB EXC NOTE All wires at these terminals are in the CJC ...

Page 202: ...Installation of O2 Cell and Heater Strut Assembly 1 Screw 2 Locking Clip 3 Cover 4 O ring 5 Marking Plate 6 Terminal Insulator 7 Reference Air Tube 8 Sensor Housing 9 Heater Strut Assembly 10 Gasket 11 Screw 12 Heater Clamp 13 Heater Rod 3 7 4 9 5 6 11 10 12 8 13 2 1 37390067 ...

Page 203: ...13 heater clamps 12 and screws 11 3 Reconnect the heater rod leads at the sensor housing terminalblocks Figure 9 23 Figure 9 23 O2 Cell Thermocouple and Heater Connections O2 Cell Wires O2 Heater Wires Thermocouple Wires O2 ORG RED GRN YEL T C O2 T C CO O2 Cell and Heater Strut Assembly T C SB EXC CJC Sample Block Thermo couple Sample Block Heater Rods 2 HTR 02 1 2 HTR CO 1 CO REF 2 HTR SB 1 CO AC...

Page 204: ...posite side of insulator 6 and secure with relatedmarking plate 5 3 If removed install cover gasket 4 Screw cover 3 onto sensor housing 8 Tighten cover firmly 4 Align locking clip 2 with gap between cover ribs 5 Loosen screw 1 and slide locking clip 2 fully into gap betweencover ribs Retighten screw 1 Sensor Housing Leak Test 1 Install 1 4 NPT cap on dilution air inlet fitting Install a 1 4 NPT ca...

Page 205: ...ide locking clip 2 awayfrom cover 3 Retighten screw 1 2 With two hands or strap wrench turn cover 3 counterclockwiseto loosen Unthread and removecover 3 Inspect cover gasket 4 for wear or damage Replace cover gasketif damaged Remove Flash PROM 1 Locate Flash PROM access port in electronics stack 5 Figure9 24 2 Use suitable IC removal tool to remove Flash PROM 6 Remove LOI Module and Board 1 Remove...

Page 206: ... 4 O ring 1 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 Remove Electronics Stack 1 Unplug power cable signal cable and solenoid lead connectors from terminals of electronics stack 5 Figure9 24 2 Remove two screws 13 and lockwashers 14 3 Remove electronics stack 5 37390037 ...

Page 207: ...ter wiring at AC power input terminal block on electronic stack 3 Unbolt and remove EMI filter 1 from electronicstack 4 Remove ground wire 2 from terminal block 3 5 Unbolt and remove terminal block 3 from electronic stack Figure 9 25 Removal Installation of EMI Filter Electronics Housing Assembly Install EMI Filter and Terminal Block 1 Install replacement EMI filter 1 Figure 9 25 and or terminal b...

Page 208: ...r terminal block Figure 9 27 Install Electronics Stack 1 Install electronics stack 5 Figure 9 24 and secure with lockwashers 14 and screws 13 2 See Figure 9 26 and Figure 9 27 Reconnect power cable signal cable and solenoid lead connectors to electronics stack terminals Install LOI Module and Board 1 Install LOI board 9 Figure 9 24 and secure with two screws 11 and lockwashers 12 2 Note the locati...

Page 209: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 9 33 Figure 9 26 Electronics Housing Cable Connections ...

Page 210: ...Low O2 Test Gas Instrument Air Install Cover 1 If removed install cover gasket 4 Figure 9 24 Screw cover 3 onto electronics housing Tighten cover firmly Align locking clip 2 withgap between cover ribs 2 Loosen screw 1 and slide locking clip 2 fully into gap betweencover ribs Retighten screw 1 SOL 4 SOL 3 SOL 2 SOL 1 SOL 1 SOL 4 SOL 3 SOL 2 37390033 ...

Page 211: ...ve Tube Fittings The OCX construction includes pipe thread sealant to seal fittings in all ports that pass through to an outer wall of the instrument housing base Use the following instructions to loosen and remove tube fittings that are secured with pipe thread sealant 1 Secure sensor housing 1 Figure 9 28 or electronics housing 2 in soft plastic wood or brass vice jaws 2 To soften the pipe threa...

Page 212: ...e E 3 2 3 3 Install Tube Fittings 1 Verify that the replacement tube fitting is identical to the item removed Special fittings are etched with code markings 2 Apply pipe thread sealant Loctite 567 to the mating threads ofthe 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 sensoror electronics housing 3739...

Page 213: ......

Page 214: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 Section 10 Replacement Parts Sensor Housing page 10 2 Electronics Housing page 10 6 O2 Cell and Heater Strut Assembly page 10 9 ...

Page 215: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 10 3 SENSOR HOUSING Figure 10 1 Sensor Housing Components Sheet 1 of 2 3 2 1 4 5 11 6 9 7 8 10 12 Requires item 13 for assembly 37390072 ...

Page 216: ... 6P00177H01 Heater Insulator Mica 3 4851B46G03 Combustibles Sensor Replacement Kit 4 1A99786H01 Heater Leads Insulator 14 5 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 2 required 13 1A99520H01 Watlube Heater Release A...

Page 217: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 10 5 Figure 10 2 Sensor Housing Components Sheet 2 of 2 ...

Page 218: ... 6A00146G02 Heater Cable Assembly Remote Electronics 40 ft 12 m 6A00146G03 Heater Cable Assembly Remote Electronics 60 ft 18 m 6A00146G04 Heater Cable Assembly Remote Electronics 80 ft 24 m 6A00146G05 Heater Cable Assembly Remote Electronics 100 ft 30 m 6A00146G06 Heater Cable Assembly Remote Electronics 150 ft 45 m 11A 6A00147G01 Signal Cable Assembly Remote Electronics 20 ft 6 m 6A00147G02 Signa...

Page 219: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 10 7 ELECTRONICS HOUSING Figure 10 3 Electronics Housing Components 8 9 10 1 5 4 2 3 7 6 37390054 ...

Page 220: ...noid Valve Test Gas 4 6A00132G01 Electronics Stack HART 6A00387G01 Electronics Stack Fieldbus 5 1A97913H06 Fuse F1 and F6 10 Amp 250 VAC 1A99766H01 Fuse F3 4 Amp 250 VAC 1A99766H02 Fuse F4 8 Amp 250 VAC 6 1A99089H02 Cover Gasket O ring 7 5R10219G01 Cover Blind 7A 5R10199G01 Cover Window 8 6A00115G02 LOI Module 9 1A99112H05 LOI Connector 10 5R10235G01 LOI Board ...

Page 221: ...2 1 April 2017 OCX 8800 10 9 Figure 10 4 EMI Filter and Terminal Block Brown Blue Green Blue Brown Green 1 Green 2 3 Index No Part Number Description 1 1A98467H01 Filter EMI 2 5R10238G01 Ground Wire 3 1A99714H01 Terminal Block 37390083 ...

Page 222: ...ermocouple Assembly 2 5R10211G02 Heater Strut Assembly 3 Ref 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 Standard Sensing Cell 4851B45G03 O2 Cell Replacement Kit High Sulfur Cell Index No Part Number Description 37390055 ...

Page 223: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 10 11 ...

Page 224: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 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 30 ...

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Page 226: ...echanically operated isolating switch If not then another means of disconnecting the equipmentfrom 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 localstandards 7 Where equipment or covers are marked with the symbol to the right hazardous voltages are likely to be present ben...

Page 227: ...y 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 p...

Page 228: ... 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 u...

Page 229: ...sche 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 ...

Page 230: ...e 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 dele...

Page 231: ...nterbrechung 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 Abdeck...

Page 232: ...βάνει 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 εικον...

Page 233: ...asel 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 kohalikelestandarditele 7 Seadmel või ümbristel asuv paremale osutav sümbol tähistab selle all leiduvat ohtlikku pinget Selliste sümbolitega ümbriseid võib eemaldada vaid juhul kui seade on toit...

Page 234: ...tyy myös sisältyä mekaaninen erotuskytkin Jos ei niin jännitesyöttö on pystyttävä katkaisemaan muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi Turvakytkimientai 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 poista...

Page 235: ... 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 suiv...

Page 236: ...usan 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 old...

Page 237: ...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 protezione...

Page 238: ...rtraukiklis 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 239: ...s 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 ti...

Page 240: ...ċċ li jiżola li jaħdem b mod mekkaniku Jekk dan ma jkunx il każ mezz ieħor ta kif it tagħmir jiġi skonnettjat minn mal provvista tad dawl għandu jkun ipprovdut u jkun immrkat b mod ċar li hu hekk Is circuit breakers jew swiċċijiet iridu jkunu konformi ma standard rikonoxxut bħal IEC947 Il wiring kollu jrid ikun konformi ma l istandards lokali jekk ikun hemm 7 Meta t tagħmir jew l għatjien ikunu mm...

Page 241: ...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 242: ...napięcia 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 Podpokrywamilubelementamiurządzeniaoznaczonymi symbolem pokazanym na rysunku po prawej stronie może występować niebezpie...

Page 243: ...erá 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 tipoIEC947 7 Sempre que o equipamento ou as tampas contiverem o símbolo é provável a existência de tensões perigosa...

Page 244: ... 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 kr...

Page 245: ...ikalo 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 po...

Page 246: ...llo 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 equi...

Page 247: ...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 såsomt ex IEC947 7 Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för livsfarlig spänning i närheten Dessa höljen får endast avlägsnas när strömmen...

Page 248: ... inhaled Cristobalite crystalline silica formed at high temperatures above 1800ºF can cause severe respiratory disease SECTION II PHYSICAL DATA APPEARANCE AND ODOR Cream to white colored fiber shapes With or without optional white to gray granular surface coating and or optional black surface coating SPECIFIC WEIGHT 12 25 LB CUBIC FOOT BOILING POINT N A VOLATILES BY WT N A WATER SOLUBILITY N A SEC...

Page 249: ...a vomiting anddiarrhea SKIN Slightly to moderate irritating May cause irritation and inflammation due to mechanical reaction to sharp broken ends of fibers EXPOSURE TO USED CERAMIC FIBER PRODUCT Product which has been in service at elevated temperatures greater than 1800ºF 982ºC may undergo partial conversion to cristobalite a form of crystalline silica which can cause severe respiratory disease P...

Page 250: ...time a material is inhaled into the deep lung While a statistically significant increase in lung tumors was observed following exposure to the highest dose there was no excess lung cancers at the other doses Two rats exposed to 30 mg m3 and one rat exposed to 9 mg m3 developed masotheliomas The International Agency for Research on Cancer IARC reviewed the carcinogenicity data on man made vitreous ...

Page 251: ... approved breathing equipment may be required for non routine and emergency use See Section IX for suitable equipment Pending the results of long term health effects studies engineering control of airborne fibers to the lowest levels attainable is advised VENTILATION Ventilation should be used whenever possible to control or reduce airborne concentrations of fiber and dust Carbon monoxide carbon d...

Page 252: ...C has recently reviewed the animal human and other relevant experimental data on silica in order to critically evaluate and classify the cancer causing potential Based on its review IARC classified crystalline silica as a group 2A carcinogen probable human carcinogen The OSHA permissible exposure limit PEL for cristobalite is 0 05 mg m3 respirable dust The ACGIH threshold limit value TLV for crist...

Page 253: ... 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 or vacuuming should be used to clean the work area If dry vacuuming is used the vacuum must be equipped with HEPA filter Air blowing or dry...

Page 254: ...as where extreme temperatures are prevalent 3 The valve protection cap should be left on each cylinder until it has been secured against a wall or bench or placed in a cylinderstand and is ready to be used 4 Avoid dragging rolling or sliding cylinders even for short distance they should be moved by using a suitablehandtruck 5 Never tamper with safety devices in valves or cylinders 6 Do not store f...

Page 255: ...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 OCX Un...

Page 256: ...a a menu driven selection and calibration procedure Jumper and Switch Settings SPA jumper and switch settings are shown in Figure B 3 If the SPA with HART was factory configured by Emerson 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 jump...

Page 257: ...ters must be configured via a menu driven setup procedure At 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 terminal...

Page 258: ...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 259: ...elected 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 meanspressthe or pushbuttonuntilthedesiredp ar amet er value is shown in the SPAwindow d Proceed through the SPA menu selecting the menu commands and parameter values indicated After completing the sequence in the f...

Page 260: ...ET EGU PV EGU PCT SV EGU CSTM PPM select P select P select M EXIT EGU SCLE INPT PVSCLE PVZERO 0000 PCT PV FULL 25 PCT SCLE SV SET ZERO 0000 P P M SET FULL 1000 PPM EXIT SCLE SCLE DSPL SCLE DSPL SCLE OUT TRIM OUT CONF ALRM PASS WORD CONF EXIT SET ZERO 0000 PCT SET FULL 25 PCT SV DSPL SET ZERO 0000 PPM SET FULL 1000 PPM EXIT DSPL SCLE OUT SET ZERO 4 000 MA SET FULL 20 00 MA EXIT Z FS TRIM OUT TRIM Z...

Page 261: ...the United States call the Emerson Instrument and Valves Response Center using the 1 800 654 RSMT 7768 toll free number This center available 24 hours a day will assist you with any needed information or materials The center will ask for product identification and reason for return and will provide a Return Authorization RMA number The center will also ask for the process material to which the pro...

Page 262: ...Instruction Manual IM 106 880 Rev 2 1 April 2017 OCX 8800 C 2 ...

Page 263: ...Combustibles Sensor 1 4 Communicator Conections Fieldbus 6 3 Component Checklist 1 1 Configuration 3 2 3 4 Configure Simulation from AMS 7 10 D D A Trim Procedures HART 5 14 D A Trim Procedures LOI 5 12 Defaults HART Electronics 3 3 Descriptions of PlantWeb Alert Parameters 7 7 Detailed Status Descriptions 7 20 Device Addressing 7 5 Diagnostic Alarms 8 2 Display Orientation 4 1 E Eductor 9 22 Educ...

Page 264: ...le and Board 9 29 Remove OCX 8800 with Integral Electronics 9 2 Remove OCX with Remote Electronics 9 5 Remove Remote Electronics 9 7 Remove Solenoid Valves 9 31 Remove Tube Fittings 9 35 Repair Sensor Housing 9 10 Replace Tube Fittings 9 35 Reset Procedure 3 14 Resistance Devices RTD 1 4 Resource Block 7 6 Resource Blocks 7 4 Returning Material C 1 RTD 1 4 S Samole Tube Support 1 10 Sample and Exh...

Page 265: ...edy ies for any failure of Rosemount to comply with the warranty provisions whether claims by the purchaser are based in contract or in tort including negligence Rosemount 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 normal wear and te...

Page 266: ...e T 65 777 8211 F 65 777 0947 Gas CSC Emerson com 2017 EmersonAutomationSolutions All rights reserved The Emerson logo is a trademark and service mark of Emerson Electric Co Rosemount is a mark of one of the Emerson family of companies All other marks are property of their respective owners The contents of this publication are presented for information purposes only and while effort has been made ...

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