Emerson Rosemount OCX 8800 User manual

Quick Start Guide
00825-0100-4880, Rev AC
October 2019
Rosemount™ OCX8800 Oxygen and
Combustibles Transmitter
with 4–20 mA HART® Protocol

Essential instructions
Emerson designs, manufactures, and tests its products to meet many national and international
standards. Because these instruments are sophisticated technical products, you must properly install,
use, and maintain them to ensure they continue to operate within their normal specifications. The
following instructions must be adhered to and integrated into your safety program when installing,
using, and maintaining Emerson products.
•Read all instructions prior to installing, operating, and servicing the product.
•Install equipment as specified in the installation instructions of the appropriate Reference Manual
and per applicable local and national codes. Connect all products to the proper electrical and
pressure sources.
Symbols
Earth (ground) terminal
Protective conductor terminal
Risk of electrical shock
Refer to reference manual.
Contents
Description and specifications......................................................................................................3
Installation................................................................................................................................... 5
Configuration and startup.......................................................................................................... 33
Using the LOI..............................................................................................................................41
Calibration................................................................................................................................. 44
Product certifications................................................................................................................. 53
Declaration of Conformity..........................................................................................................58
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1 Description and specifications
1.1 Component checklist
A typical Rosemount OCX8800 Oxygen/Combustibles Transmitter package
should contain the items shown in Figure 1-1.
Check the model number of your Rosemount OCX8800 against the
transmitter features and options, making sure options specified by this
number are on or included with the unit. Use this complete model number
for any correspondence with Emerson.
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Figure 1-1: Typical System Package
A. Quick Start Guide
B. Adapter plate with mounting hardware and gasket
C. Reference air and calibration set (optional)
D. Blowback hardware (optional)
E. Rosemount OCX8800 with remote electronics
F. Rosemount OCX8800 with integral electronics
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2 Installation
2.1 Product safety
WARNING
EXPLOSIONS
The Rosemount OCX8800 may explode if used in hazardous areas.
The Rosemount OCX88A can be installed in general purpose areas only.
Do not install the Rosemount OCX88A in hazardous areas.
To maintain explosion-proof protection of the Rosemount OCX88C in
hazardous areas, all cable entry devices and blanking elements for
unused apertures must be certified flameproof, suitable for the
conditions of use, and properly installed.
To maintain explosion-proof protection of the Rosemount OCX88C in
hazardous areas, the sensor housing must not be mounted to any
surface or flange that exceeds 383 °F (195 °C).
To maintain explosion-proof protection of the Rosemount OCX88C in
hazardous areas, the sample entering the sensor housing must not
exceed 383 °F (195 °C).
WARNING
PHYSICAL ACCESS
Unauthorized personnel may potentially cause significant damage to and/or
misconfiguration of end users’ equipment. This could be intentional or
unintentional and needs to be protected against.
2.2 Mechanical installation
2.2.1 Select a location
The location of the transmitter in the stack or flue is important for maximum
accuracy in the oxygen analyzing process. You must position the probe so
the gas it measures is representative of the process.
For best results, position the transmitter near the center of the duct (40- 60
percent insertion). Longer ducts may require several transmitters since the
oxygen and combustibles can vary due to stratification. A point too near the
wall of the duct or the inside radius of a bend may not provide a
representative sample because of the very low flow conditions. Select the
sensing point so the process gas temperature falls within the range of probe
material used. The ambient temperature inside the electronics housing
must not exceed 185 °F (85 °C).
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CAUTION
Damage to the electronics may result.
Do not allow the temperature of the electronics housing to exceed 185 °F
(85 °C).
CAUTION
Failure to connect the pneumatic lines can allow the flow of contaminants
into the transmitter's ports.
Whenever a positive stack pressure exists at the installation site, be sure to
connect all pneumatic lines prior to installing the transmitter in the stack or
ductwork.
Procedure
1. Check the flue or stack for holes and air leakage.
The presence of this condition will substantially affect the accuracy of
the oxygen and combustibles readings. Make the necessary repairs
or install the transmitter upstream of any leakage.
2. Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance access to the unit.
Allow adequate clearance for the removal of the transmitter.
2.2.2 Install
Procedure
1. Ensure all components are available to install the transmitter.
Refer to Figure 1-1. You may install the transmitter intact as it is
received.
2. Weld or bolt adapter plate onto the duct.
3. Use the pipe or wall mounting hardware to mount a remote
electronics housing.
Choose a location that does not exceed the length of the electronics
cable ordered.
4. Ensure the conduits drop vertically from the transmitter and the
conduit is routed below the level of the conduit ports on the housing
to form a drip loop.
Drip loops minimize the possibility that moisture will damage the
electronics.
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5. Where a positive stack pressure exists at the installation site, connect
all pneumatic lines prior to installing the transmitter 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 transmitter.
6. Insert sample and exhaust tubes through the opening in the
mounting flange and bolt the unit to the flange.
Note
Uninsulated stacks or ducts may cause ambient temperatures in the
electronics housing to exceed 185 °F (85 °C) and damage the
electronics.
7. If insulation is removed to access the duct for mounting the
transmitter, make sure to replace insulation afterward.
2.3 Electrical installation
All wiring must conform to local and national codes. Figure 2-1 shows
factory wired solenoid power connections.
WARNING
Failure to install covers and ground leads could result in serious injury or
death.
Install all protective equipment covers and safety ground leads after
installation.
WARNING
To meet the Safety Requirements of IEC 61010 (EC requirement), and
ensure safe operation of this equipment, connection to the main electrical
power supply must be made through a circuit breaker (min 10 A) in close
proximity and marked for this equipment which will disconnect all current-
carrying conductors during a fault situation. This circuit breaker should also
include a mechanically operated isolating switch. If not, then another
external means of disconnecting the supply from the equipment should be
located close by. Circuit breakers or switches must comply with a recognized
standard such as IEC 947.
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WARNING
The transmitter may explode in hazardous areas.
All cable entry devices and blanking elements for unused apertures must
be certified flameproof, suitable for the conditions of use, and properly
installed.
The sensor housing must not be mounted to any surface or flange that
exceeds 383 °F (195 °C).
The sample entering the sensor housing must not exceed 383 °F (195
°C).
Note
To maintain proper earth grounding, ensure a positive connection exists
between the sensor housing, the electronics housing, and earth. The
connecting ground wire must be 14 AWG minimum. Refer to Figure 2-1.
Note
Line voltage, signal, and relay wiring must be rated for at least 221 °F
(105 °C).
2.3.1 Electrical connections
Make electrical connections, power, and communications to the electronics
enclosure through two ¾ NPT ports in the enclosure, using fittings and
cables provided by the customer. Cable installation must meet NEC, IEC,
and/or other applicable national or local codes for Class I, Zone 1, IIB +H2
T3/T6 permanently mounted equipment.
2.3.2 Connect line voltage
The transmitter operates on 100 to 240 Vac line voltage at 50 to 60 Hz. The
power supply requires no setup. Connect the line (L wire) to the L terminal
and the neutral (N wire) to the N terminal on the AC power input terminal
block in the electronics housing. Connect the ground (G wire) to the ground
stud in the electronics housing as shown in Figure 2-1.
2.3.3 Connect output signals
The transmitter comes with two 4-20 mA signals with HART® on the oxygen
O2 signal.
Connect the output terminals in the electronics housing as shown in Figure
2-1. Use individual shielded twisted wire pairs. Terminate the shield at the
electronics housing.
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2.3.4 Oxygen (O2) 4-20 mA signal
One 4-20 mA signal represents the O2 value. Superimposed on the O2 signal
is the FOUNDATION Fieldbus information accessible through a handheld
communicator or AMS Device Manager software. The O2 signal is at the
AOUT 1 terminals.
2.3.5 Combustibles equivalent (COe) 4-20 mA signal
Another 4-20 mA signal at the AOUT 2 terminals represents the COe value.
2.3.6 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.
2.3.7 Remote electronics connections to sensor housing
Make the following connections between the remote electronics and sensor
housings with the electronics cable ordered with the package (Figure 2-2).
Braided cable is available in lengths up to 150 ft. (46 m).
Note
Interconnect wiring shown is for Rosemount supplied cables. For customer
furnished interconnect wiring or cables, refer to Figure 2-3.
2.3.8 Signal connections
Connect the electronics housing terminals to the corresponding terminals in
the sensor housing. The twisted wire pairs are numbered on the inner plastic
wrapper. Keep twisted pairs together and match the numbers and wire
colors shown in Figure 2-2.
2.3.9 Heater power connections
Use the blue, white, orange, black, red, and yellow stranded wires in the
heater power cable to connect power to the three heaters in the sensor
housing. Match the wire colors to the corresponding heater power terminal
blocks in the sensor and electronics housings as shown in Figure 2-2.
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Figure 2-1: Line Voltage, Earth, and 4-20 mA Connections
A. Alarm output relay terminal block
B. FOUNDATION™ Fieldbus
C. HART®
D. Signal output terminal block
E. Ground stud
F. Earth ground typical for electronics and sensor housing
G. Ground
H. Customer wiring
I. Terminal block
J. EMI filter
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K. External tooth locks washer
L. Signal port ¾ NPT
M. Power port ¾ NPT
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Figure 2-2: Electrical Connections Between Remote Electronics and
Sensor Housing
A. Heater power connector (J3)
B. Heater power cable
C. O2 sensor and thermocouple connector (J5)
D. To ground screw
E. COe sensor and cold junction connector (J4)
F. Electronics housing
G. Sensor housing
H. Signal cable
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Figure 2-3: Signal Wiring or Cable
Note
For RFI/CE compliance, the connector must provide 360 degrees of electrical
contact to the cable shield.
A. Strip wire ends 3/16-in. typical
B. Stud size #10
C. Heat shrink tubing 2-in. long ½-in. size
D. 7.0-in. long Teflon® tubing, 0.042-in. ID (Cut off drain wire at probe end
of shield.)
E. ¾ NPT hub size, liquid-tight strain relief connector
F. Heat shrink tubing 2-in. long ½-in. size
G. Eight twisted pairs 24 AWG, stranded, insulated, tinned copper
conductors, 400 °F (200 °C), 300 volts, with overall braid of 34 AWG
tinned copper, uninsulated drain wire
H. Ferrule, uninsulated
I. Overall cable length
J. Heat shrink tubing 1-in. long, 3/16-in. size
K. Typical on both ends of wiring
L. 2.0 ± 0.25 typical
M. See Note.
N. Electronics end
O. Probe end
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Figure 2-4: Heater Wiring or Cable
A. Strip wire ends 3/16-in. typical
B. Green, 16 AWG
C. Stud size #10
D. Heat shrink tubing 2-in. long, ½-in. size
E. 2.0 ± .25 typical
F. 4.25-in. long Teflon tubing, 0.042-in. ID. (Cut off drain wire at probe end
of shield).
G. ¾ NPT hub size, liquid-tight strain relief connectors
H. Heat shrink tubing 2-in. long, ½-in. size
I. Eight Conductors, 16 AWG, stranded, 400 °F (200°C), 600 volts. Braided
shield - tinned copper, 90 percent coverage with 18 AWG 24 tinned
copper, uninsulated, drain wire.
J. Ferrule, uninsulated
K. Green, 16 AWG
L. Stud size #6
M. Electronics end
N. Probe end
2.4 Pneumatic installation
Pneumatic system connections depend on whether reference air set,
calibration solenoids, and/ or blowback equipment options are equipped on
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your transmitter. Refer to the following sections and select the option that
applies to your transmitter configuration.
2.4.1 Reference air set option (only)
When no options or only the reference air set option is equipped, use the
following procedure to install the pneumatic system components.
Procedure
1. Refer to Figure 2-5. Connect the reference air set (regulator/filter and
pressure gage) to the instrument air inlet on the electronics housing
and to the inlet side of the dilution air flow meter.
2. Connect the dilution air flow meter output to the dilution air inlet
fitting on the sensor housing.
3. Install an air line between the instrument air outlet fitting on the
electronics housing and the tee fitting on the sensor housing.
Note
Do not use 100 percent nitrogen as an O2 low gas. It is suggested
that O2 low gas be between 0.4 percent and 2.0 percent O2. Do not
use gases with hydrocarbon concentrations of more than 40 parts
per million. Failure to use proper gases will result in erroneous
readings.
4. Use one CO gas and two O2 gases to calibrate the transmitter.
•CO: 1000 ppm or up to four percent, balance air
•O2 low gas: 0.4 percent , balance N2
•O2 high gas: eight percent, balance N2
5. Connect the output of the test gas sources to the inlet port of the
CAL GAS flow meter. Install an air line between the flow meter outlet
port and the CAL GAS inlet fitting on the sensor housing.
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Figure 2-5: Pneumatic Installation, Rosemount OCX8800 with Reference
Air Set without Autocalibration
A. Sensor housing
B. Eductor air in
C. Electronics housing
D. Calibration gas in
E. Reference air in
F. Dilution air in
G. Dilution air flow meter 0.1 scfh
H. Instrument air out
I. Calibration gas flow meter (7 scfh, 20-30 psig recommended)
J. Two-stage regulators
K. Instrument air supply
L. Pressure regulator/filter 35 psig - general purpose, 45 psig - hazardous
area
M. Two-in. pressure gauge 0-60 psig
N. Combination filter-reg. 0-60 psig
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O. Flow meter 1-10 scfh
P. Flow meter 0.05-0.5 scfh
2.4.2 Reference air set and solenoids option without COe zero function
When the reference air set and test gas solenoids are included with your
transmitter, use the following procedure to install the pneumatic system
components.
Procedure
1. Install the reference air set according to the instructions in Reference
air set option (only), steps Step 1 through Step 3.
2. Refer to Figure 2-6. Connect the O2 low gas source to the CAL GAS LO
O2 inlet fitting on the electronics housing. Install a shutoff valve and
pressure regulator with gage in the O2 low supply line, as shown.
3. Connect the O2 high gas source to the CAL GAS HI O2 inlet fitting.
Install a shutoff valve and pressure regulator with gage in the O2 high
supply line.
4. Connect the CO high gas to the CAL GAS HI COe inlet fitting. Install a
shutoff valve and pressure regulator with gage in the CO high supply
line.
5. Connect the CAL GAS outlet fitting of the electronics housing to the
inlet port of the CAL GAS flow meter. Install an air line between the
flow meter outlet port and the CAL GAS inlet fitting on the sensor
housing.
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Figure 2-6: Pneumatic Installation, Rosemount OCX8800 with Reference
Air Set, Solenoids, and Autocalibration, without COe Zero Function
A. Sensor housing
B. Eductor air in
C. Electronics housing
D. Calibration gas in
E. Reference air in
F. Dilution air in
G. Dilution air flow meter 0.1 scfh
H. Instrument air out
I. Calibration gas flow meter (7 scfh, 20-30 psig recommended)
J. Two-stage regulators
K. Instrument air supply
L. Pressure regulator/filter 35 psig - general purpose, 45 psig - hazardous
area
M. Two-in. pressure gauge 0-60 psig
N. Combination filter-reg. 0-60 psig
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O. Flow meter 1-10 scfh
P. Flow meter 0.05-0.5 scfh
Q. Calibration gas out
2.4.3 Reference air set and solenoids option with COe zero function
Figure 2-7 shows the piping arrangement for the transmitter with
autocalibration when the COe Zero Function is used. The arrangement is
similar to Figure 2-6 except instrument air is used as the Hi O2 test gas. Refer
to Configuration and startup for details of this function.
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Figure 2-7: Pneumatic Installation, Rosemount OCX8800 with Reference
Air Set, Solenoids, and Autocalibration, with COe Zero Function
A. Sensor housing
B. Eductor air in
C. Electronics housing
D. Calibration gas in
E. Reference air in
F. Dilution air in
G. Dilution air flow meter 0.1 scfh
H. Instrument air out
I. Calibration gas flow meter (7 scfh, 20-30 psig recommended)
J. Two-stage regulators
K. Instrument air supply
L. Pressure regulator/filter 35 psig - general purpose, 45 psig - hazardous
area
M. Two-in. pressure gauge 0-60 psig
N. Combination filter-reg. 0-60 psig
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