Emerson Rosemount OCX 8800 User manual

Quick Start Guide
00825-0100-4880, Rev AE
July2023
Rosemount™ OCX8800 Oxygen and
Combustibles Transmitter
with 4–20 mA HART® Protocol

Safety information
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. You must adhere to the following instructions and integrate them
into your safety program when installing, using, and maintaining Emerson's Rosemount
products.
WARNING
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.
WARNING
Install equipment as specified in the installation instructions of the appropriate manual and
per local and national codes. connect all products to the proper electrical and pressure
sources.
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.
Physical security is an important part of any security program and fundamental to protecting
your system. Restrict physical access by unauthorized personnel to protect end users' assets.
This is true for all systems used within the facility.
Symbols
Earth (ground) terminal
Protective conductor terminal
Risk of electrical shock
Refer to manual.
Contents
Description and specifications................................................................................................... 5
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Installation.................................................................................................................................... 6
Configuration and startup........................................................................................................ 30
Using the local operator interface (LOI)..................................................................................38
Calibration...................................................................................................................................41
Product certifications................................................................................................................ 49
Declaration of Conformity........................................................................................................ 53
China RoHS table........................................................................................................................55
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1 Description and specifications
1.1 Component checklist
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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2 Installation
2.1 Product safety
WARNING
Safety instructions
Failure to follow the safety instructions could result in serious injury
or death.
Before installing this equipment, read Safety information.
WARNING
Hazardous areas
The Rosemount OCX88A can be installed in general purpose areas
only. The Rosemount Xi Advanced Electronics can be installed in
general purpose areas only.
Do not install the Rosemount OCX88A in hazardous areas.
Do not install the Rosemount Xi in hazardous areas or in the
vicinity of flammable liquids.
WARNING
Hazardous areas
The Rosemount OCX88C 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).
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WARNING
Electrical shock
Failure to install covers and ground leads could result in serious
injury or death.
Install all protective equipment covers and ground leads after
installation.
If external loop power is used, the power supply must be a safety
extra low voltage (SELV) type.
Note
Plug all unused ports on the probe housing and Rosemount Xi
enclosure with a suitable filling.
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 to 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.
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.
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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 transmitter.
Allow adequate clearance for the removal of the transmitter.
2.2.2 Install the transmitter
Procedure
1. Ensure all components are available to install the transmitter.
You can 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.
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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.
Figure 2-1: Installation with drip loops
A. Duct wall
B. Conduit drip loops
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.
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CAUTION
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.
CAUTION
Uninsulated stacks or ducts may cause ambient temperatures
in the electronics housing to exceed 185 °F (85 °C) and
damage the electronics.
If insulation is removed to access the duct for mounting the
transmitter, make sure to replace the insulation afterward.
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 2-2 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.
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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
(minimum 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.
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 2-2.
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-in. 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 2-2.
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 2-2.
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Use individual shielded twisted wire pairs. Terminate the shield at the
electronics housing.
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 HART® 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.
HART® information is not available on the COe signal.
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,
number 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.
Braided cable is available in lengths up to 150 ft (46 m).
Note
Interconnect wiring shown is for Emerson-supplied cables.
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.
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.
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Figure 2-2: 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
K. External tooth locks washer
L. Signal port ¾ NPT
M. Power port ¾ NPT
2.4 Pneumatic installation
Pneumatic system connections depend on whether reference air
set, calibration solenoids, and/or blowback equipment options are
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equipped on 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 2-3. Connect the reference air set (regulator/
filter and pressure gauge) 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.
CAUTION
Failure to use proper gases will result in erroneous readings.
Do not use 100 percent nitrogen as an O2 low gas.
Emerson recommends using O2 low gas between 0.4
percent and 2.0 percent O2.
Do not use gases with hydrocarbon concentrations of more
than 40 parts per million.
4. Use one CO gas and two O2 gases to calibrate the transmitter.
•CO: 1000 ppm or up to 4 percent, balance air
•O2 low gas: 0.4 percent , balance N2
•O2 high gas: 8 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 2-3: 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 to 30 psig [1.4 to 2.1 barg]
recommended)
J. Two-stage regulators
K. Instrument air supply
L. Pressure regulator/filter
General purpose: 35 psig (2.4 barg)
Hazardous area: 45 psig (3.1 barg)
M. 2-in. pressure gauge, 0 to 60 psig (0 to 4.1 barg)
N. Combination filter-regulator, 0 to 60 psig (0 to 4.1 barg)
O. Flow meter, 1-10 scfh
P. Flow meter, 0.05-0.5 scfh
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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), Step1 through Step3.
2. Refer to Figure 2-4. 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 gauge 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
gauge 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 gauge 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 2-4: 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 to 30 psig [1.4 to 2.1 barg]
recommended)
J. Two-stage regulators
K. Instrument air supply
L. Pressure regulator/filter 35 psig (2.4 barg) for general purpose, 45
psig (3.1 barg) for hazardous areas
M. 2-in. pressure gauge 0-60 psig (0 to 4.1 barg)
N. Combination filter-reg. 0-60 psig (0 to 4.1 barg)
O. Flow meter 1-10 scfh
P. Flow meter 0.05-0.5 scfh
Q. Calibration gas out
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2.4.3 Reference air set and solenoids option with COe zero function
Figure 2-5 shows the piping arrangement for the transmitter
with autocalibration when the COe zero function is used. The
arrangement is similar to Figure 2-4, except instrument air is used
as the high O2 test gas.
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Figure 2-5: 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 [1.4 to 2.1 barg]
recommended)
J. Two-stage regulators
K. Instrument air supply
L. Pressure regulator/filter 35 psig (2.4 barg) for general purpose, 45
psig (3.1 barg) for hazardous areas
M. 2-in. pressure gauge, 0-60 psig (0 to 4.1 barg)
N. Combination filter-regulator, 0-60 psig (0 to 4.1 barg)
O. Flow meter, 1-10 scfh
P. Flow meter, 0.05-0.5 scfh
Q. Calibration gas out
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Note
If instrument is to be used as the high O2 calibration gas, the low O2
and COe calibration gases must also be set to the same pressure.
2.4.4 Reference air set, solenoids, and blowback option with COe
zero function
Figure 2-6 shows the piping arrangement for the transmitter with
the blowback and autocalibration options when COe zero function is
used. The arrangement is similar to Figure 2-4 except instrument air
is used as the high O2 test gas.
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