Page 3 - HIGHLIGHTS OF CHANGES; Page; Revised the text for SW1 and SW2 to read internally powered.
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. Ad...
Page 5 - Instruction Manual; Table of Contents
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www.raihome.com Table of Contents Essential Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iPreface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 7 - Oxygen/Combustibles Transmitter
Instruction Manual IM-106-880, Rev 1.0January 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 standar...
Page 8 - PREFACE; NOTE; SYMBOLS; NOTE TO USERS
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 Install...
Page 9 - Section 1; SYSTEM OVERVIEW; Scope
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Section 1 Description and Specifications Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1S...
Page 11 - is the partial pressure of the oxygen in the reference air on the
Instruction Manual IM-106-880, Rev 1.0January 2007 1-3 OCX 8800 The equipment 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. ...
Page 12 - System Configuration; cell output voltage and sensitivity increase as the oxygen
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 1-4 The catalyst is specifically designed to detect carbon monoxide (CO), but the sensor responds to other combustible gases. The sensor is calibrated using CO, thus the output should be expressed in terms of CO. However, since the sensor ...
Page 13 - System Operation; sensor and continues on to
Instruction Manual IM-106-880, Rev 1.0January 2007 1-5 OCX 8800 5. An operator can calibrate and diagnostically troubleshoot the OCX 8800 using the HART Interface. Each of the OCX 8800's 4-20 mA output lines transmit an analog signal proportional to oxygen or combustible levels detected. The HART ou...
Page 14 - System Considerations; SENSOR
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 1-6 Figure 1-2. System Operation Diagram Handling the OCX 8800 System Considerations Prior to installing your OCX 8800, make sure you have all the components necessary to make the system installation. Ensure all the components are properly...
Page 15 - Connections and AMS Application
Instruction Manual IM-106-880, Rev 1.0January 2007 1-7 OCX 8800 After verifying that you have all the components, select mounting locations and determine how each component will be placed in terms of available line voltage, ambient temperatures, environmental considerations, convenience, and service...
Page 16 - Installation; INTEGRAL
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 1-8 Figure 1-4. Typical System Installation 4-20 mA Outputs (2 Twisted Pairs) Stack OCX 8800 with INTEGRAL ELECTRONICS Duct Gases Line Voltage Adapter Plate Pressure Regulator 37390063 Test Gas Flow Meter Low O Test Gas 2 High O Test Gas 2...
Page 17 - General Purpose OCX
Instruction Manual IM-106-880, Rev 1.0January 2007 1-9 OCX 8800 SPECIFICATIONS General Purpose OCX Specifications Net O 2 Range 0-1% to 0-40% O 2 , fully field selectable Combustibles 0-1000 ppm to 0-5%, fully field selectable Accuracy Oxygen ± 0.75% of reading or 0.05% O 2 (whichever is greater) Co...
Page 21 - Section 2
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Section 2 Installation Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-7Pneumatic Install...
Page 22 - Selecting Location
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 2-2 MECHANICALINSTALLATION Selecting Location 1. The location of the OCX 8800 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The probe must be positioned so the gas it measures is representativ...
Page 23 - flange and bolt the unit to the flange.; Enclosures
Instruction Manual IM-106-880, Rev 1.0January 2007 2-3 OCX 8800 4. Ensure the conduits drop vertically from the OCX 8800 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 (F...
Page 24 - BOTTOM VIEW
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 2-4 Figure 2-1. Installation, OCX 8800 Dim “B” 3 ft 9 ft 6 ft Probe 18 in. Dim “A” (2235) 88 (3150) 124 (2743) 108 72 (1829) (914) 36 (1321) 52 (864) 34 (457) 18 Flange Dia. DIN ANSI 5R10244H02 5R10244H01 6.00 (152) BOTTOM VIEW B.C. Dia. D...
Page 26 - with Drip Loops
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 2-6 Figure 2-3. Installation with Drip Loops 37020004 Conduit Drip Loops Duct Wall Conduit Drip Loop Conduit Drip Loop Duct Wall
Page 28 - One 4-20 mA signal represents the O
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 2-8 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 2-4. NOTE Line voltage, sig...
Page 29 - and 4-20 mA Connections; TOP VIEW
Instruction Manual IM-106-880, Rev 1.0January 2007 2-9 OCX 8800 Figure 2-4. Line Voltage, Earth, and 4-20 mA Connections 37390013 TOP VIEW (1/2 SIZE) Ground Stud Earth Ground Typical for Electronics and Sensor Housing NC COM NO Alarm Output Relay Terminal Block #1 AOUT2+ AOUT2 - AOUT1 -AOUT1+ O Sign...
Page 30 - electronics housing and the tee fitting on the sensor housing.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 2-10 PNEUMATIC INSTALLATION Pneumatic system connections depend on whether reference air set, calibration solenoids, and/or blowback equipment options are equipped on your transmitter. Refer to the following paragraphs and select the optio...
Page 31 - Installation, OCX with Reference
Instruction Manual IM-106-880, Rev 1.0January 2007 2-11 OCX 8800 Figure 2-5. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration) 37390011 Electronics Housing Eductor Air In Sensor Housing Dilution Air In Reference Air In CAL Gas In CAL Gas Flow Meter 7 scfh, 20-30 psig Recom...
Page 32 - Reference Air Set and Solenoids Option
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 2-12 Figure 2-6. Pneumatic Installation, OCX with Reference Air Set and Solenoids (with Autocalibration) Reference Air Set and Solenoids Option When the reference air set and test gas solenoids are included with your OCX 8800, use the foll...
Page 33 - Reference Air Set, Solenoids, and Blowback Option; fitting on the sensor housing.
Instruction Manual IM-106-880, Rev 1.0January 2007 2-13 OCX 8800 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 ...
Page 34 - Blowback with Autocalibration; CAUTION
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 2-14 Figure 2-7. Piping Arrangement, Blowback with Autocalibration 38850004 Pressure regulator with 1/8” inlet port is factoryset for 35 or 45 psig. Regulator with 1/4” inlet portis factory set for 55 psig. If regulators are notinstalled i...
Page 35 - Blowback without Autocalibration
Instruction Manual IM-106-880, Rev 1.0January 2007 2-15 OCX 8800 Figure 2-8. Piping Arrangement, Blowback without Autocalibration 37390005 Check Valve Blowback Valve, Air Operated *Normally ClosedSolenoidValve *NOTE: During blowback operation, states of both solenoid valves change. Electronics Housi...
Page 36 - - Length of time between blowback events.; INITIAL STARTUP
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 2-16 8. Install an air line between the instrument air outlet fitting on the electronics housing and the control air inlet fitting on the air-operated solenoid valve. 9. There are three settings that need to be specified to set up the blow...
Page 37 - Section 3; VERIFY INSTALLATION
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Section 3 Configuration and Startup Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag...
Page 38 - Verify Configuration
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 3-2 Verify Configuration There are three switches on the microprocessor board which are user configurable for the OCX 8800 (Figure 3-1). SW1 determines if the O 2 4-20 mA signal is internally or externally powered. SW2 determines if the CO...
Page 39 - cell is 736°C. Normal
Instruction Manual IM-106-880, Rev 1.0January 2007 3-3 OCX 8800 Figure 3-1. OCX 8800 Defaults INITIAL POWER UP Allow adequate time (approximately 60 minutes) for the heaters to begin operation and for the OCX 8800 to reach normal operating temperature on power up. Normal operating temperature for th...
Page 41 - Section 4; OVERVIEW; -20 mA current loop and a minimum load
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Section 4 Using HART Communications Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1HART Communicator Signal Connections . . . . . . . . . . . . page 4-1HART Communicato...
Page 42 - 50 Ohms Load Resistance; Method 1, for Load Resistance
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 4-2 Figure 4-1. Signal Line Connections, ≥ 250 Ohms Load Resistance Method 1, for Load Resistance ≥ 250 Ohms Refer to Figure 4-1 and the following steps to connect the HART communicator to a signal line 250 ohms or more of load resistance....
Page 43 - line and install the optional 250 ohm load resistor.
Instruction Manual IM-106-880, Rev 1.0January 2007 4-3 OCX 8800 Method 2, for Load Resistance < 250 Ohms Refer to Figure 4-2 and the following steps to connect the HART communicator to a signal line with less than 250 ohms load resistance. 1. At a convenient point, break the oxygen analog output ...
Page 44 - The HART communicator can be operated both off-line and on-line.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 4-4 HART COMMUNICATOR PC CONNECTIONS There is an option to interface the HART communicator with a personal computer. Load the designated AMS software into the PC. Then link the HART communicator to the PC using the interface PC adapter tha...
Page 51 - Section 5
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Section 5 Calibration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-1Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . page 5-1Operator - Init...
Page 59 - Section 6; Use the following procedures to remove or install the OCX 8800.
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Section 6 Maintenance and Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-1OCX 8800 Removal and Installation . . . . . . . . . . . . . . . . . page 6-1Repair Sens...
Page 61 - Terminal Blocks
Instruction Manual IM-106-880, Rev 1.0January 2007 6-3 OCX 8800 Figure 6-2. Electronics Housing Terminal Blocks 37390013 TOP VIEW (1/2 SIZE) Ground Stud Earth Ground Typical for Electronics and Sensor Housing NC COM NO Alarm Output Relay Terminal Block #1 AOUT2+ AOUT2 - AOUT1 -AOUT1+ O Signal 2 COe ...
Page 62 - and COe signal leads to the 4-20 mA signal output
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-4 Install OCX 8800 Observe the following cautions when installing the OCX 8800 in a hot process stack. If the process is shut down and cooled, the transmitter can be installed in the stack prior to connecting the pneumatics and wiring. 1...
Page 63 - Remove Cover and Terminals Insulator
Instruction Manual IM-106-880, Rev 1.0January 2007 6-5 OCX 8800 REPAIR SENSOR HOUSING Use the following procedures to remove damaged components from the OCX 8800 sensor housing and to install new replacement parts. Disassemble the unit only as needed to replace damaged components. Use the assembly p...
Page 64 - Cell
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-6 Figure 6-3. Removal of O 2 Cell and Heater Strut Assembly 5 6 12 11 10 9 1 2 4 3 7 8 13 3 7 39006 7 1. Screw2. Locking Clip3. Cover4. O-ring5. Marking Plate6. Terminal Insulator7. Reference Air Tube8. Sensor Housing9. Heater Strut Asse...
Page 65 - Heater Connections; Remove O; cell and return; Remove Sample Block Heater Rods
Instruction Manual IM-106-880, Rev 1.0January 2007 6-7 OCX 8800 Figure 6-4. O 2 Cell, Thermocouple, and Heater Connections Remove O 2 Cell and Heater Strut Assembly 1. Remove reference air tube (7, Figure 6-3) from sensor housing (8).2. See Figure 6-4. Disconnect and tag O 2 heater wires, O 2 cell a...
Page 66 - Remove COe Sensor Assembly; Thermocouple, and Heater
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-8 2. Loosen screws (11, Figure 6-3) and rotate heater clamps (12) to release heater rods (13). One heater clamp secures each heater rod. 3. Slide sample block heater rods (13) out of housing (8). Remove COe Sensor Assembly 1. Disconnect ...
Page 67 - Unfasten bayonet connector of COe thermocouple (8) and remove
Instruction Manual IM-106-880, Rev 1.0January 2007 6-9 OCX 8800 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. 3. Remove tubes (2, 3, and 4) from COe sensor assembly (5), eductor fittings (12 and 15), and s...
Page 68 - COe Sensor Assembly
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-10 6. See Figure 6-7. Using straightedge on the sensor holder flat, as shown, matchmark upper flange of sensor housing to show correct alignment of sensor holder. 7. With one wrench holding eductor elbow (12, Figure 6-6), and one wrench ...
Page 69 - Remove Eductor; The O
Instruction Manual IM-106-880, Rev 1.0January 2007 6-11 OCX 8800 Remove Eductor The O 2 cell and heater strut assembly (9, Figure 6-3) and the COe sensor assembly (5, Figure 6-6) must be removed before you start this procedure. 1. Use straightedge to matchmark alignment of eductor flat and elbow, as...
Page 70 - and Exhaust Tubes; Remove Sample and Exhaust Tubes
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-12 Figure 6-9. Removal of Sample and Exhaust Tubes Remove Sample and Exhaust Tubes 1. Secure the sensor housing (1, Figure 6-9) in soft (plastic, wood, or brass) vice jaws. 2. Use a propane torch to heat the sample tube (2) or exhaust tu...
Page 71 - Disassemble O
Instruction Manual IM-106-880, Rev 1.0January 2007 6-13 OCX 8800 Figure 6-10. O 2 Cell, Heater, and Thermocouple, Exploded View Disassemble O 2 Cell and Heater Strut Assembly Do not attempt to replace the O 2 cell until all other possibilities for poor performance have been considered. If cell repla...
Page 72 - Disassemble COe Sensor Assembly; If damaged, use the following procedure to remove thermocouple
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-14 Disassemble COe Sensor Assembly 1. Carefully remove screws (1, Figure 6-11), lockwashers (2), and COe sensor (3) from sensor holder (4). Remove and discard gasket (5). 2. If damaged, use the following procedure to remove thermocouple ...
Page 74 - Align COe sensor flat parallel to sensor holder flat, as shown in; Assemble O; tension is present to hold contact pad against O; Install Sample and Exhaust Tubes; a pipe wrench to tighten the tube.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-16 Figure 6-12. COe Sensor and Pre-Heater Alignment 7. Install COe sensor (3), lockwashers (2), and screws (1). Rotate flat of COe sensor (3) to center of sensor holder (4). 8. Align COe sensor flat parallel to sensor holder flat, as sho...
Page 75 - Install Eductor; Eductor and COe Sensor
Instruction Manual IM-106-880, Rev 1.0January 2007 6-17 OCX 8800 Install Eductor If installed, the O 2 cell and heater strut assembly (9, Figure 6-3) must be removed from sensor housing (8), before you install the eductor. 1. Apply pipe thread sealant (Loctite #567) to the external pipe threads of e...
Page 76 - point up and be in line with long axis of eductor.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-18 2. Install and tighten eductor (6) in eductor holder (14).3. Install and tighten elbow (12) on eductor (6). Male port of elbow must point up and be in line with long axis of eductor. 4. Apply anti-seize compound to the external pipe t...
Page 77 - Install COe Sensor Assembly; tighten sensor holder. Do not allow eductor elbow to turn.
Instruction Manual IM-106-880, Rev 1.0January 2007 6-19 OCX 8800 Install COe Sensor Assembly Figure 6-15. Band Heater Height 1. Apply pipe thread sealant (Loctite #567) to the exposed pipe threads of eductor elbow (12, Figure 6-13). Do not apply sealant to the first turn of the pipe threads. 2. Scre...
Page 78 - Holder Alignment
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-20 Figure 6-16. COe Sensor Holder Alignment 37390035 Sensor Holder Flat Matchmark Straightedge Matchmark
Page 79 - Reconnect the COe sensor, thermocouple, and heater wires at the
Instruction Manual IM-106-880, Rev 1.0January 2007 6-21 OCX 8800 10. Reconnect the COe sensor, thermocouple, and heater wires at the sensor housing terminal blocks. Refer to Figure 6-17. 11. Install and fasten the COe insulator (1, Figure 6-13) around COe sensor assembly (5). All wiring must remain ...
Page 80 - Install Sample Block Heater Rods; the heater rods with Watlube heater release agent.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-22 Figure 6-18. Installation of O 2 Cell and Heater Strut Assembly Install Sample Block Heater Rods 1. Before installing sample block heater rods (13, Figure 6-18), evenly coat the heater rods with Watlube heater release agent. 5 6 12 11...
Page 82 - Install O
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-24 Install O 2 Cell and Heater Strut Assembly 1. Rub a small amount of anti-seize compound on both sides of new gasket (10, Figure 6-18). 2. Apply anti-seize compound to threads of O 2 cell and heater strut assembly (9) and sensor housin...
Page 83 - Remove Cover
Instruction Manual IM-106-880, Rev 1.0January 2007 6-25 OCX 8800 REPAIR ELECTRONICS HOUSING Use the following procedures to remove damaged components from the OCX 8800 electronics housing and to install new replacement parts. Disassemble the unit only as needed to replace damaged components. Use the...
Page 84 - Electronics Housing Components; Remove Electronics Stack
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-26 Figure 6-20. Removal/Installation of Electronics Housing Components Remove Electronics Stack 1. Unplug power cable, signal cable, and solenoid lead connectors from terminals of electronics stack (5, Figure 6-20). 2. Remove two screws ...
Page 85 - Remove Solenoid Valves; Installation of EMI Filter; Install EMI Filter and Terminal Block
Instruction Manual IM-106-880, Rev 1.0January 2007 6-27 OCX 8800 Remove Solenoid Valves 1. Disconnect solenoid leads from mating terminal connector.2. Remove top nut of solenoid valve (15 or 16, Figure 6-20). 3. Remove the solenoid coil assembly and washer. 4. Unthread and remove solenoid valve base...
Page 86 - Install Solenoid Valves; and solenoid lead connectors to electronics stack terminals.; Install Flash PROM; Access
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-28 Install Solenoid Valves 1. Disassemble replacement solenoid valve (15 or 16, Figure 6-20).2. Install new solenoid valve base. Be careful not to overtighten. 3. Install new washer and solenoid coil assembly and secure with nut.4. Conne...
Page 87 - Cable Connections; ELECTRONICS HOUSING
Instruction Manual IM-106-880, Rev 1.0January 2007 6-29 OCX 8800 Figure 6-23. Electronics Housing Cable Connections 37390016 REDBLK WHT GRN BLK BLK BLUBLK YEL BRN RED BLK BLK ORG BLK WHT T/C CO+T/C CO- T/C SB+T/C SB-T/C O2+T/C O2- O2 CELL+O2 CELL- SHIELD To Ground Screw GRN ELECTRONICS HOUSING O2 Ce...
Page 88 - Power Terminals; Install Cover
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-30 Figure 6-24. Solenoid Power Terminals Install Cover 1. If removed, install cover gasket (4, Figure 6-20). Screw cover (3) onto electronics housing. Tighten cover firmly. Align locking clip (2) with gap between cover ribs. 2. Loosen sc...
Page 89 - ‘E’ Type Fitting; Remove Tube Fittings
Instruction Manual IM-106-880, Rev 1.0January 2007 6-31 OCX 8800 REPLACE TUBE FITTINGS The OCX transmitter housings have special tube fittings that, if clogged or damaged, must be replaced with the same type of fitting. The special tube fittings have alpha or numeric codes etched on the fitting. Une...
Page 90 - of Tube Fittings; Install Tube Fittings; Special fittings are etched with code markings.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 6-32 Figure 6-25. Removal of Tube Fittings 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 t...
Page 91 - Section 7
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Section 7 Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-1Diagnostic Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-2Fault I...
Page 92 - A blocking diode is required on the customers relay coil.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 7-2 Total Power Loss In the event that the OCX 8800 will not power up at all, check the incoming power supply to make sure power is being delivered to the OCX 8800. If the incoming power supply is good, then check fuses F1 and F6 in the el...
Page 93 - O2 Sensor R High
Instruction Manual IM-106-880, Rev 1.0January 2007 7-3 OCX 8800 FAULT ISOLATION Faults in the OCX 8800 Transmitter are indicated by messages displayed on the HART communicator. Fault indications that can appear are listed in Table 7-1, Troubleshooting. If a fault is indicated on the HART communicato...
Page 96 - ADC Failure; ADC Ref Error; O2 Htr Failure; COe Htr Failure; SB Htr Failure
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 7-6 ADC Failure (Voltage to digital conversion could not complete) ADC Ref Error (Voltage to digital conversion not accurate) Probable Cause Recommended Corrective Action Incorrect wiring between electronics and sensor housings Check all w...
Page 97 - Output; OXYGEN
Instruction Manual IM-106-880, Rev 1.0January 2007 7-7 OCX 8800 Figure 7-2. Oxygen and Cell Output Cal Warning (Calibration warning) Cal Failed (Calibration failed) Probable Cause Recommended Corrective Action Calibration gas supply low or gas connection leaking Check calibration gas supplies and co...
Page 99 - Line Voltage High; Htr Relay Failed; Out Brd Failure
Instruction Manual IM-106-880, Rev 1.0January 2007 7-9 OCX 8800 Line Voltage High (AC power line voltage above maximum, > 278 VAC) Probable Cause Recommended Corrective Action High noise or voltage fluctuations in power supply Check power supply for line noise or voltage fluctuations. Install pow...
Page 101 - Event Groups
Instruction Manual IM-106-880, Rev 1.0January 2007 7-11 OCX 8800 ALARM RELAY EVENTS The OCX 8800 contains an alarm relay that can be configured to activate on one of twelve different groups of events. These event groups, and the conditions that trigger them, are listed in Table 7-2, Alarm Relay Even...
Page 103 - Section 8
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Section 8 Replacement Parts Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-2Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 104 - Components
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 8-2 SENSOR HOUSING Figure 8-1. Sensor Housing Components 37390072 1 5 9 12 (Requires item 13 for assembly) 8 7 10 11 2 3 4 6
Page 110 - and Terminal Block
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 8-8 Figure 8-4. EMI Filter and Terminal Block 1 2 3 37390083 Brown Blue Green Green Green Brown Blue Index No. Part Number Description 1 1A98467H01 Filter, EMI 2 5R10238G01 Ground Wire 3 1A99714H01 Terminal Block
Page 111 - Cell and
Instruction Manual IM-106-880, Rev 1.0January 2007 8-9 OCX 8800 O 2 CELL AND HEATER STRUT ASSEMBLY Figure 8-5. O 2 Cell and Heater Strut Assembly 37390055 2 1 3 4 5 6 7 Index No. Part Number Description 1 4851B44G01 Contact and Thermocouple Assembly 2 5R10211G02 Heater Strut Assembly 3 5R10188G01 He...
Page 113 - Appendix A
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Appendix A Safety Data Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-2Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . page A-24High Pressu...
Page 114 - IMPORTANT
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-2 SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure com...
Page 115 - LEŽITÉ
Instruction Manual IM-106-880, Rev 1.0January 2007 A-3 OCX 8800 D Ů LEŽITÉ Bezpe č nostní pokyny pro zapojení a instalaci za ř ízení Následující bezpe č nostní pokyny se speciáln ě vztahují na všechny č lenské státy EU. Pokyny by m ě ly být p ř ísn ě dodržovány, aby se zajistilo spln ě ní Sm ě rnice...
Page 116 - VIGTIGT
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-4 VIGTIGT Sikkerhedsinstruktion for tilslutning og installering af dette udstyr. Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bø...
Page 117 - BELANGRIJK
Instruction Manual IM-106-880, Rev 1.0January 2007 A-5 OCX 8800 BELANGRIJK Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel. De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan de Laa...
Page 119 - WICHTIG; werden, um der Niederspannungsrichtlinie zu genügen.
Instruction Manual IM-106-880, Rev 1.0January 2007 A-7 OCX 8800 WICHTIG Sicherheitshinweise für den Anschluß und die Installation dieser Geräte.Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der Nieder...
Page 120 - ΣΗΜΑΝΤΙΚΟ
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-8 ΣΗΜΑΝΤΙΚΟ Οδηγιεσ ασφαλειασ για την καλωδιωση και εγκατασταση τησ συσκευησ Οι ακόλουθες οδηγίες ασφαλείας εφαρ µ όζονται ειδικά για όλες τις χώρες µ έλη της Ευρωπαϊκής Κοινότητας . Θα πρέπει να ακολουθούνται αυστηρά ώστε να εξασφαλιστε...
Page 121 - OLULINE TEAVE
Instruction Manual IM-106-880, Rev 1.0January 2007 A-9 OCX 8800 OLULINE TEAVE Juhtmestiku ja seadme paigaldamisega seotud ohutusjuhisedAlljärgnevad ohutusjuhised rakenduvad eriti kõigi Euroopa Liidu liikmesriikide suhtes. Antud juhiseid tuleb täpselt järgida, et kindlustada vastavus madalpinge direk...
Page 122 - TÄRKEÄÄ; sisäisiin ja ulkoisiin.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-10 TÄRKEÄÄ Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa. Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännitedirekt...
Page 124 - FONTOS
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-12 FONTOS Biztonsági el ő írások a készülék vezetékeléséhez és üzembeállításához A következ ő biztonsági el ő írások kifejezetten vonatkoznak az összes EU-tagállamra. Ezeket szigorúan be kell tartani a Kisfeszültség ű irányelvnek való me...
Page 125 - IMPORTANTE
Instruction Manual IM-106-880, Rev 1.0January 2007 A-13 OCX 8800 IMPORTANTE Norme di sicurezza per il cablaggio e l'installazione dello strumento. Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell'Unione Europea, la cui stretta osservanza è richiesta per garantire c...
Page 126 - SVARBU
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-14 SVARBU š io prietaiso laid ų prijungimo ir instaliacijos saugos instrukcijos Toliau išvardinti saugumo reikalavimai taikomi konkre č iai visoms ES šalims nar ė ms. J ų turi b ū ti griežtai paisoma, kad b ū t ų užtikrintai laikomasi Že...
Page 127 - SVAR
Instruction Manual IM-106-880, Rev 1.0January 2007 A-15 OCX 8800 SVAR Ī GI Droš ī bas nor ā d ī jumi š ī s iek ā rtas pievienoš anai un uzst ā d ī š anai Turpm ā kie droš ī bas nor ā d ī jumi attiecas uz vis ā m ES dal ī bvalst ī m. Tie ir stingri j ā iev ē ro, lai nodrošin ā tu atbilst ī bu Zemspri...
Page 128 - tal-kejbils kollha li jintużw iridu jkunu ta' daqs intern tali li; STRUZZJONIJIET TAS-SIGURTÀ GĦALL-WIRING U; IMPORTANTI
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-16 1. Konnessjonijiet adegwati ta' l-ert għandhom isiru għall-punti kollha ta' l-ert, interni u esterni, fejn ikun ipprovdut. 2. Wara l-installazzjoni jew meta tipprova ssolvi xi problema, l-għatjien kollha tas-sigurtà u l-erts tas-sigur...
Page 129 - VIKTIG
Instruction Manual IM-106-880, Rev 1.0January 2007 A-17 OCX 8800 VIKTIG Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret. Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i...
Page 130 - WA; łą
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-18 WA Ż NE! Zalecenia dotycz ą ce bezpiecze ń stwa w zakresie pod łą czania i instalacji tego urz ą dzenia Nast ę puj ą ce zalecenia dotycz ą zw ł aszcza stosowania urz ą dzenia we wszystkich krajach Unii Europejskiej. Nale ż y si ę ś ci...
Page 132 - DÔLEŽITÉ
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-20 DÔLEŽITÉ Bezpe č nostné pokyny pre zapojenie káblov a inš taláciu tohto prístroja Nasledovné bezpe č nostné pokyny sa vzt’ahujú konkrétne na všetky č lenské štáty EÚ. Musia byt’ striktne dodržané, aby sa zaistila zhoda so Smernicou o ...
Page 133 - POMEMBNO; Varnostna navodila za povezavo in vgradnjo naprave
Instruction Manual IM-106-880, Rev 1.0January 2007 A-21 OCX 8800 POMEMBNO Varnostna navodila za povezavo in vgradnjo naprave Naslednja varnostna navodila veljajo za vse države č lanice EU. Zaradi zagotovitve skladnosti z nizkonapetostno direktivo morate navodila strogo upoštevati. V državah, ki niso...
Page 135 - VIKTIGT
Instruction Manual IM-106-880, Rev 1.0January 2007 A-23 OCX 8800 VIKTIGT Säkerhetsföreskrifter för kablage och installation av denna apparat. Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varje avseende för att överensstämma med Lågspännings direktive...
Page 136 - Vitreous Aluminosilicate Fibers with Silicon Dioxide.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-24 SAFETY DATA SHEET FOR CERAMIC FIBER PRODUCTS JULY 1, 1996 SECTION I. IDENTIFICATION PRODUCT NAME Ceramic Fiber Heaters, Molded Insulation Modules and Ceramic Fiber Radiant Heater Panels. CHEMICAL FAMILY Vitreous Aluminosilicate Fibers...
Page 138 - EXPOSURE TO USED CERAMIC FIBER PRODUCT; There is no evidence of any lung disease among those employees; TOXICOLOGY
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-26 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 respirat...
Page 140 - General cleanliness should be followed.
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 A-28 SECTION VIII. SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. NIOSH/MSHA approved breathing equipment may be required for non-routine and emerge...
Page 141 - CONCENTRATION
Instruction Manual IM-106-880, Rev 1.0January 2007 A-29 OCX 8800 IARC 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 ...
Page 143 - Appendix B; Calibration Status, and OCX Unit Failure.
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Appendix B SPA with HART Alarm Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-1Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page...
Page 144 - SPA Interface Connections; INSTALLATION; Jumper and Switch Settings
Instruction Manual IM-106-880, Rev 1.0 January 2007 OCX 8800 B-2 Figure B-2. OCX 8800 and SPA Interface Connections INSTALLATION Refer to Figure B-2 for the typical interface connections for the OCX 8800 and the SPA with HART alarm. Refer to the Moore Industries SPA user's manual for additional info...
Page 145 - and Dip Switch Settings; Configuration/Calibration; If desired, you can connect the 4 to 20 mA O2 signal wires from the
Instruction Manual IM-106-880, Rev 1.0January 2007 B-3 OCX 8800 IN IN Fluke Model 87 Multimeter or equivalent Optional mA AC or DC Power Input AC ACC GND 37390024 250 Ω 950 Ω >< OCX 8800 Figure B-3. SPA Jumper and Dip Switch Settings Figure B-4. SPA Setup for Calibration 2. Verify that the Pas...
Page 149 - Appendix C; RETURNING MATERIAL; Secure a return authorization number from an Emerson Process
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www..raihome.com Appendix C Return of Materials RETURNING MATERIAL If factory repair of defective equipment is required, proceed as follows: 1. Secure a return authorization number from an Emerson Process Management sales office or r...
Page 151 - Index
Instruction Manual IM-106-880, Rev 1.0January 2007 OCX 8800 http://www.raihome.com Index A Accessories . . . . . . . . . . . . . . 1-12Alarm Relay Events . . . . . . . . 7-11Assemble O2 Sensor . . . . . . . 6-16Autocalibration Setup, HART . . 5-1Autocalibration, HART . . . . . . . 5-3 B Band Heater ...
Page 153 - WARRANTY
WARRANTY Rosemount Analytical warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount Analytical shall,...
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