Emerson Rosemount OCX 8800 User manual

http://www.raihome.com
Instruction Manual
IM-106-880, Rev 1.0
January 2007
OCX 8800
Oxygen/Combustibles Transmitter
Hazardous Area OCX 8800 Oxygen/Combustibles Transmitter
with Integral Electronics and Local Operator Interface

HIGHLIGHTS OF CHANGES
Effective January, 2007 Rev 1.0
Page Summary
Page 2-19 Revised Figure 2-11.
Page 3-2 Revised the text for SW1 and SW2 to read internally powered.
Page 3-3 Revised Figure 3-1. Updated the paragraph Initial Power Up.
Page A-2 thru A-23 Added note 11 to the safety data section. Added additional pages/languages.
Page C-1 Updated the return of materials address.
Back cover Updated the address blocks.

Instruction Manual
IM-106-880, Rev 1.0
January 2007 OCX 8800
http://www.raihome.com
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
SECTION 1
Description and
Specifications
Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SECTION 2
Installation
Mechanical
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
SECTION 3
Configuration and
Startup
Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
OCX 8800 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
SECTION 4
Using the LOI
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Display Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
LOI Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
LOI Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
LOI Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
LOI Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
SECTION 5
Using HART
Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
HART Communicator Signal Connections. . . . . . . . . . . . . . . . . . . . . . 5-1
HART Communicator PC Connections . . . . . . . . . . . . . . . . . . . . . . . . 5-4
HART Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
SECTION 6
Calibration
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Instruction Manual
IM-106-880, Rev 1.0
January 2007
OCX 8800
TOC-2
SECTION 7
Maintenance and Service
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
OCX 8800 Removal
and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
OCX with
Integral Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Sensor Housing Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Sensor Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Electronics Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Electronics Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Remove Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Install Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
SECTION 8
Troubleshooting
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Total Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Diagnostic Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Alarm Relay Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
SECTION 9
Replacement Parts
Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
O2 Cell and Heater Strut Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
APPENDIX A
Safety Data
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . . A-24
High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-29
Atex Clarification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-31
APPENDIX B
SPA with HART Alarm
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
APPENDIX C
Return of Materials
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Instruction Manual
IM-106-880, Rev 1.0
January 2007 OCX 8800
http://www.raihome.com
OCX 8800
Oxygen/Combustibles Transmitter
ESSENTIAL
INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management designs, manufactures and tests its products
to meet many national and international standards. Because these
instruments are sophisticated technical products, you MUST properly install,
use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and
integrated into your safety program when installing, using, and maintaining
Emerson’s Rosemount Analytical products. Failure to follow the proper
instructions may cause any one of the following situations to occur: Loss of
life; personal injury; property damage; damage to this instrument; and
warranty invalidation.
•Read all instructions prior to installing, operating, and servicing the
product.
• If you do not understand any of the instructions, contact your
Emerson Process Management representative for clarification.
•Follow all warnings, cautions, and instructions marked on and
supplied with the product.
•Inform and educate your personnel in the proper installation,
operation, and maintenance of the product.
•Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes.Connect all products to the proper electrical and
pressure sources.
• To ensure proper performance, use qualified personnel to install,
operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson Process Management.
Unauthorized parts and procedures can affect the product's
performance, place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire,
electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers
are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.
The information contained in this document is subject to change without
notice.
If a Model 275/375 Universal HART®Communicator is used with this unit, the software
within the Model 275/375 may require modification. If a software modification is required,
please contact your local Emerson Process Management Service Group or National
Response Center at 1-800-654-7768.

Instruction Manual
IM-106-880, Rev 1.0
January 2007
OCX 8800
ii
PREFACE The purpose of this manual is to provide a comprehensive understanding of
the OCX 8800 components, functions, installation, and maintenance.
We recommend that you thoroughly familiarize yourself with the Introduction
and Installation sections before installing your transmitter.
The introduction presents the basic principles of the transmitter along with its
performance characteristics and components. The remaining sections contain
detailed procedures and information necessary to install and service the
transmitter.
Before contacting Emerson Process Management concerning any questions,
first consult this manual. It describes most situations encountered in your
equipment's operation and details necessary action.
DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES
found throughout this publication.
NOTE
Highlights an essential operating procedure, condition, or statement.
SYMBOLS
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a
manual illustration number. It is not a part number, and is not related to the
illustration in any technical manner.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETI
N

Instruction Manual
IM-106-880, Rev 1.0
January 2007 OCX 8800
http://www..raihome.com
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-9
COMPONENT
CHECKLIST
A typical OCX 8800 Oxygen/Combustibles Transmitter package should
contain the items shown in Figure 1-1.
Use the product matrix in Table 1-1 at the end of this section to verify your
order number. The first part of the matrix defines the model. The last part
defines the various options and features of the OCX 8800. Check the model
number against the transmitter features and options, making sure options
specified by this number are on or included with the unit. Use this complete
model number for any correspondence with Emerson Process Management.
A list of accessories for use with the OCX 8800 is provided in Table 1-2.
SYSTEM OVERVIEW Scope
This Instruction Manual supplies details needed to install, startup, operate,
and maintain the OCX 8800. Signal conditioning electronics outputs separate
4-20 mA signals representing oxygen (O2) and combustibles (COe) values.
This information, plus additional details, can be accessed with the HART
Model 275/375 handheld communicator or Rosemount Analytical AMS
software. The local operator interface (LOI) also provides a communications
interface with the electronics.
System Description
The OCX 8800 is designed to measure oxygen and combustible
concentrations in flue gas temperatures up to 2600°F (1427°C). Electrical
connections, power and communications are made through two 3/4 NPT ports
in the flameproof electronics enclosure using fittings and cables provided by
the customer. Cable installation must meet NEC, IEC and/or other applicable
national or local codes for Class I, Zone 1, Group IIB +H2 T3/T6 permanently
mounted equipment. The transmitter is close coupled to the process and
requires minimal sample conditioning requirements.

Instruction Manual
IM-106-880, Rev 1.0
January 2007
OCX 8800
1-2
Figure 1-1. Typical System Package
1. Instruction Manual
2. HART®Communicator Package (optional)
3. Adapter Plate with Mounting Hardware and Gasket
4. Reference Air and Calibration Set
5. Blowback Hardware (optional)
6. OCX 8800 with Integral Electronics
4
6
1
37390006
2
o
HART Communicator
FISHER-ROSEMOUNT
TM
MAN 4275A00
English
October 1994
3
5
Analytica
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