OCX 4400 OXYGEN/COMBUSTIBLES TRANSMITTER

Transcription

1 Instruction Manual OXYGEN/COMBUSTIBLES TRANSMITTER

2 ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Rosemount Analytical 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 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 Rosemount Analytical 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 Rosemount. 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. Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH T (330) F (330) gas.csc@emersonprocess.com

3 Page Throughout Pages 1-4, 1-5 Pages 1-8, 1-9 Page 2-1 HIGHLIGHTS OF CHANGES Effective January, 2003 Rev. 2.0 Summary Changed IB revision number and release date. Identified test gas solenoids as optional equipment. Updated specifications and specification notes. Expanded drip loop usage to vertical and horizontal installations. Page 2-2 Component view corrections to Figure 2-1. Page 2-4 Revised adapter plate view, Figure 2-3, to simplify recommendations. Added new Figure 2-4 to show electronics housing wall/pole mounting kit. Page 2-5 Expanded drip loop usage to vertical and horizontal installations. Page 2-6 Added reference to Appendix D for OCX with IS Barrier wiring. Revised alarm relay contact description. Page 2-8 Corrected electrical wiring diagram discrepancies in Figure 2-7. Page 2-9 Revised paragraph 2-3 to link installation instructions to applicable equipment options. Revised/changed Figure 2-8 to show pneumatic installation requirements for OCX with reference air option (only). Page 2-10 Revised Figure 2-9 to show pneumatic installation requirements for OCX with reference air and cal gas solenoid options. Page 2-11 Deleted CAUTION paragraph from NOTE. Page 3-0 Revised Figure 3-1 to correctly identify location of SW1 and SW2. Page 3-1 Revised Initial Power Up procedure. Page 7-3 Corrected electrical wiring diagram discrepancies in Figure 7-2. Page 7-4 Corrected electrical wiring diagram discrepancies in Figure 7-3. Page 7-6 Revised Figure 7-4 to clarify location of exhaust tube during assembly and to include parts availability note. Page 7-8 Revised Figure 7-5 to include parts availability note. Page 7-11 Revised Figure 7-6 to include parts availability note. Pages 7-12 thru 7-14 Deleted replacement procedures for electronics package components. Added electronics package replacement procedure. Revised Figure 7-7 and fuse replacement procedure. Page 8-1 Revised paragraph 8-3 to describe new troubleshooting table. Page 8-2 Replaced fault listings with troubleshooting table. Pages 10-1, 10-2 Corrected discrepancies in Table 10-1, Replacement Parts. Page 11-1 Revised Section 11 list of Appendices A, B, C, and D. Pages A-3 thru A-6 Revised/corrected LOI menu tree displays. Pages B-1 thru B-6 Added SPA setup instructions. Pages C-1, C-2 Revised/clarified blowback installation instructions and illustration. Pages D-1, D-2 Added IS Barrier installation/wiring instructions and illustration.

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5 Instruction Manual TABLE OF CONTENTS PREFACE...1 Definitions...1 Safety Instructions DESCRIPTION AND SPECIFICATIONS Component Checklist of Typical System (Package Contents) System Overview Specifications INSTALLATION Mechanical Installation Electrical Installation Pneumatic Installation Initial Startup STARTUP AND OPERATION General CALIBRATION General Calibration Methods HART/AMS Overview HART Communicator Signal Line Connections HART Communicator PC Connections Off-Line and On-Line Operations Menu Tree for HART Communicator/ Applications HART Communicator Manual O 2 CAL Method HART Communicator Manual COMB CAL Method HART Communicator Manual O 2 and CO CAL Method Automatic Calibration Setup Via HART Line Voltage Selection using HART Communicator OPERATION Overview Operation MAINTENANCE AND SERVICE Overview Removal/Replacement Sensor Housing Component Replacement Electronics Housing Component Replacement TROUBLESHOOTING General Alarm Output Fault Isolation Rosemount Analytical Inc. A Division of Emerson Process Management i

6 Instruction Manual 9-0 RETURN OF MATERIAL REPLACEMENT PARTS APPENDICES Appendix A Local Operator Interface (LOI)... A-1 Appendix B SPA with HART Alarm... B-1 Appendix C Blowback...C-1 Appendix D IS Barrier...D INDEX ii Rosemount Analytical Inc. A Division of Emerson Process Management

7 Instruction Manual LIST OF ILLUSTRATIONS Figure 1-1. Typical System Package Figure 1-2. System Operation Diagram Figure 1-3. OCX 440 HART Connections and AMS Application Figure 1-4. Typical System Installation Figure 2-1. Installation (with Integral Electronics) Figure 2-2. Adapter Plate Dimensions Figure 2-3. Adapter Plate Installation Figure 2-4. Wall or Pole Mounting of Electronics Housing Figure 2-5. Installation with Drip Loops Figure 2-6. Line Voltage and 4-20 ma Connections Figure 2-7. Electrical Connections Between Split-Electronics and Sensor Housing Figure 2-8. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration) Figure 2-9. Pneumatic Installation, OCX with Reference Air Set and Solenoids (with Autocalibration) Figure 3-1. Defaults Figure 5-1. Signal Line Connections, > 250 Ohms Lead Resistance Figure 5-2. Signal Line Connections, < 250 Ohms Lead Resistance Figure 5-3. Menu Tree for HART/AMS on the (Sheet 1 of 3) Figure 7-1. Electronics Housing Terminal Blocks Figure 7-2. Sensor Housing Terminal Blocks Figure 7-3. Split-Electronics Housing Cable Connections Figure 7-4. Sensor Housing, Exploded View Figure 7-5. O 2 Assembly, Exploded View Figure 7-6. Electronics Housing Exploded View Figure 7-7. Fuses, Exploded View LIST OF TABLES Table 1-1. Specifications Table 1-2. Product Matrix Table 1-3. Accessories Table 8-1. Troubleshooting Table Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management iii

8 Instruction Manual iv Rosemount Analytical Inc. A Division of Emerson Process Management

9 Instruction Manual PREFACE The purpose of this manual is to provide a comprehensive understanding of the Oxygen/Combustibles Transmitter components, functions, installation, and maintenance. This manual is designed to provide information about the. 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 Rosemount 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. 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. NOTE Highlights an essential operating procedure, condition, or statement. : EARTH (GROUND) TERMINAL : PROTECTIVE CONDUCTOR TERMINAL : RISK OF ELECTRICAL SHOCK : WARNING: REFER TO INSTRUCTION BULLETIN 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. Rosemount Analytical Inc. A Division of Emerson Process Management P-1

10 Instruction Manual 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 compliance with the Low Voltage Directive. Non- EU states should also comply with the following unless superseded by local or National Standards. 1. Adequate earth connections should be made to all earthing points, internal and external, where provided. 2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times. 3. Mains supply cords should comply with the requirements of IEC227 or IEC All wiring shall be suitable for use in an ambient temperature of greater than 75 C. 5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage. 6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from 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 local standards. 7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment and then only by trained service personnel. 8. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch. 9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions. 10. All graphical symbols used in this product are from one or more of the following standards: EN , IEC417, and ISO3864. P-2 Rosemount Analytical Inc. A Division of Emerson Process Management

11 Instruction Manual SECTION 1 DESCRIPTION AND SPECIFICATIONS 1-1 COMPONENT CHECKLIST OF TYPICAL SYSTEM (PACKAGE CONTENTS) A typical Rosemount Oxygen/ Combustibles Transmitter package should contain the items shown in Figure 1-1. Record the part number, serial number, and order number for each component of your system in the table located on the back cover of this manual. Use the product matrix in Table 1-2 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. 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 Rosemount. 1-2 SYSTEM OVERVIEW a. Scope This Instruction Bulletin supplies details needed to install, startup, operate, and maintain the Rosemount Oxygen/ Combustibles Transmitter. Signal conditioning electronics outputs separate 4-20 ma signals representing oxygen (O 2 ) and combustibles (COMB) values. This information, plus additional details, can be accessed with the HART Model 275 handheld communicator or Asset Management Solutions (AMS) software. An optional local operator interface (LOI) is available to provide local communication with the electronics. b. System Description The Rosemount Oxygen/ Combustibles Transmitter is designed to measure oxygen and combustible concentrations in flue gas temperatures up to 2600 F (1427 C). The transmitter is close coupled to the process and requires minimal sample conditioning requirements. 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. When operated at the proper temperature, the millivolt output of the cell is given by the following Nernst equation: Where: EMF = KT log10 (P 1 /P 2 ) + C 1. P 2 is the partial pressure of the oxygen in the measured gas on one side of the cell. 2. P 1 is the partial pressure of the oxygen in the reference air on the opposite side of the cell. 3. T is the absolute temperature. 4. C is the cell constant. 5. K is an arithmetic constant. NOTE For best results, use clean, dry instrument air (20.95% oxygen) as the reference air. When the cell is at operating temperature and there are unequal oxygen concentrations across the cell, oxygen ions will travel from the high oxygen partial pressure side to the low oxygen partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mv per decade. The output is proportional to the inverse logarithm of the oxygen concentration. Therefore, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the to provide exceptional sensitivity at low oxygen concentrations. Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

12 Instruction Manual 1 5 MAN 4275A00 English October 1994 HART o Communicator FISHER-ROSEMOUN TM Instruction Bulletin 2. HART Communicator Package (Optional) 3. Adapter Plate with Mounting Hardware and Gasket 4. (Shown with Integral Electronics) 5. Reference Air and Calibration Set 6. Blowback Hardware (Optional) Figure 1-1. Typical System Package 1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

13 Instruction Manual The measures net oxygen concentration in the presence of all the products of combustion, including water vapor. Therefore, it may be considered an analysis on a wet basis. In comparison with older methods, such as the portable apparatus, which provides an analysis on a dry gas basis, the wet analysis will, in general, indicate a lower percentage of oxygen. The difference will be proportional to the water content of the sampled gas stream. The combustibles sensor is a catalytic sensor consisting of two Resistant Temperature Detectors (RTD). One RTD is the reference element covered with an inert coating. The other RTD element is active, coated with a catalyst. As the sample gases flow by the sensor, the combustible gases oxidize on the surface of the active element. The oxidation that occurs produces heat and a temperature rise in the active element. The temperature difference produces a resistance relationship between the two elements that is directly proportional to the concentration of combustibles in the sample gases. The catalyst is specifically designed to detect carbon monoxide (CO), but the sensor responds to other combustible gases. The sensor is calibrated using carbon monoxide (CO), thus the output should be expressed in terms of CO. However, since the sensor detects other combustible gases, the output cannot just be labeled CO. The response of the sensor to other combustible gases gives an output that is equivalent to the sensor detecting CO. The term COMB 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 COMB sensor to ensure there is adequate oxygen to fully oxidize any combustible gases regardless of the concentration of oxygen in the process. c. System Configuration Transmitters are available in four length options, giving the user the flexibility to use a penetration appropriate to the size of the stack or duct. The length options are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), or 9 ft (2.7 m). Probes are available in three material options, 316L stainless steel, inconel 600, and ceramic to accommodate higher temperatures. The electronics are contained in a separate housing from the sensors and may be integrally mounted next to the sensor housing on the probe, or split mounted up to 150 feet away from the probe. The electronics control both sensor temperatures and provide individual 4-20 ma isolated outputs that are proportional to the measured oxygen and combustibles concentrations. The power supply can accept voltages of 100 to 240 VAC and 50 to 60 Hz. The electronics accepts millivolt signals generated by the sensors and produces the outputs to be used by remotely connected devices. The outputs are isolated 4-20 ma linearized currents. See 3-1c and 3-1d for specific instructions upon initial power up. d. System Features 1. The O 2 cell output voltage and sensitivity increase as the oxygen concentration decreases. 2. HART communication is standard. To use the HART capability, you must have either: (a) A HART Model 275 Communicator. (b) Asset Management Solutions (AMS) software for the PC. 3. Oxygen cell and heater/thermocouple assembly are field replaceable. Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

14 Instruction Manual 4. Electronics are automatically configured for line voltages from 100 to 240 VAC. 5. An operator can calibrate and diagnostically troubleshoot the in one of two ways: (a) HART Interface. Each of the OCX 4400 s 4-20 ma output lines transmit an analog signal proportional to oxygen or combustible levels detected. The HART output is superimposed on the oxygen 4-20 ma output line only. This information can be accessed through the following: 1 Rosemount Model 275 Handheld Communicator - The handheld communicator requires Device Description (DD) software specific to the. The DD software will be supplied with many Model 275 units, but can also be programmed into existing units at most Fisher- Rosemount service offices. Refer to Section 5, HART/AMS, for additional information. 2 Personal Computer (PC) - The use of a personal computer requires AMS software available from Fisher- Rosemount. 3 Selected Distributed Control Systems - The use of distributed control systems requires input/output (I/O) hardware and AMS software which permit HART communications. (b) Optional Local Operator Interface (LOI). The optional LOI is mounted to the end of the electronics module and allows local communications with the electronics. Refer to Appendix A, Local Operator Interface (LOI), for more information. 6. Optional Blowback System. The blowback system periodically blows instrument air back through the inlet filter and out the inlet tube. This clears out particulate and keeps the inlet filter from clogging. e. System Operation Figure 1-2 shows the relationship between the components of the. The sensors and the electronics are contained in separate housings. The sensor housing and probe mounts to a duct or process wall so that the probe protrudes into the flue gas stream. An air powered eductor continuously pulls samples of the process flue gas through the probe to a chamber in front of the sensor housing where the sample passes the O 2 sensor and continues on to the COMB sensor. Dilution air is provided to the COMB sensor and reference air to the O 2 sensor. After the gas sample flows past the O 2 sensor and through the COMB sensor, it is drawn through the eductor where it mixes with the eductor air and exits through exhaust back into the system. The electronics housing contains the CPU which converts the sensor inputs into 4-20 ma analog 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 rotometer between the electronics and sensor housings. Instrument air is separated into eductor air, reference air, and dilution air. The instrument air solenoid does not allow air flow until the heaters are up to temperature. This minimizes the amount of sampled process flue gas being pulled into cold sensors causing condensation. 1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

15 Instruction Manual SENSOR HOUSING ELECTRONICS HOUSING COMBUSTIBLES SENSOR CPU POWER SUPPLY PRESSURE SENSOR LOW O2 TEST GAS HIGH O2 TEST GAS PROBE O2 SENSOR OPTIONAL TEST GAS SOLENOIDS HIGH CO TEST GAS SAMPLE GAS EDUCTOR INSTRUMENT AIR SOLENOID INSTRUMENT AIR ROTOMETER 5 SCFH EDUCTOR AIR EXHAUST REFERENCE AIR DILUTION AIR ROTOMETER 50 CC/MIN. (0.1 SCFH) Figure 1-2. System Operation Diagram Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

16 Instruction Manual f. Handling the It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to prevent possible equipment damage. The is designed for industrial application. Treat each component of the system with care to avoid physical damage. The probe may contain components made from ceramics, which are susceptible to shock when mishandled. g. System Considerations Prior to installing your Rosemount OCX 4400 Oxygen/Combustibles Transmitter, make sure you have all the components necessary to make the system installation. Ensure all the components are properly integrated to make the system functional. 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 serviceability. Figure 1-3 shows a typical system wiring. A typical system installation is illustrated in Figure 1-4. A source of instrument air is required at the for reference air, dilution air, and eductor air. Since the is equipped with an in-place calibration feature, provision should be made for connecting test gas tanks to the when it is to be calibrated. NOTE The electronics module is designed to meet NEMA 4X (IP55) and the electronic components are rated to temperatures up to 185 F (85 C). Retain packaging in which the unit arrived from the factory in case any components are to be shipped to another site. This packaging has been designed to protect the product. O2/COMBUSTIBLES TRANSMITTER WITH INTEGRAL ELECTRONICS HART MODEL 275 HANDHELD INTERFACE 4-20 MA OUTPUT (TWISTED PAIRS) CUSTOMER S LAPTOP WITH ASSET MANAGEMENT SOLUTIONS INSTRUMENT AIR 3 CALIBRATION GAS LINES BY CUSTOMER [300 FT (90M) MAX] TERMINATION IN CONTROL ROOM ASSET MANAGEMENT SOLUTIONS Figure 1-3. OCX 440 HART Connections and AMS Application Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

17 Instruction Manual INTEGRAL ELECTRONICS GASES ADAPTER PLATE STACK DUCT TEST GAS ROTOMETER DILUTION AIR ROTOMETER 4-20 ma OUTPUTS (2) LINE VOLTAGE SPAN COMBUSTIBLES TEST GAS LOW O2 TEST GAS HIGH O2 TEST GAS INSTRUMENT AIR SUPPLY (REF. GAS) PRESSURE REGULATOR SPLIT-MOUNTED ELECTRONICS GASES STACK DUCT ELECTRONICS CABLE (UP TO 150FT) TEST GAS ROTOMETER 4-20 ma OUTPUTS (2) LINE VOLTAGE DILUTION AIR ROTOMETER INSTRUMENT AIR SUPPLY (REF. GAS) PRESSURE REGULATOR SPAN COMBUSTIBLES TEST GAS LOW O2 TEST GAS HIGH O2 TEST GAS Figure 1-4. Typical System Installation Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7

18 Instruction Manual 1-3 SPECIFICATIONS Table 1-1 contains information about the OCX 4400 Oxygen/Combustibles Transmitter operating characteristics. Use the table to make sure that available conditions are suitable for the transmitter before choosing the mounting location. Table 1-2 contains the product matrix. Use the product matrix for ordering information and specific model number information. Table 1-3 contains information on accessories available with the. Table 1-1. Specifications Net O 2 Range % to 0-40% O 2, Fully field selectable Combustibles ppm to 0-5%, Fully field selectable 1 Accuracy: Oxygen % of reading or 0.05% O 2, whichever is greater Combustibles... +2% F.S. System Response to Test Gas: Oxygen sec T90 Combustibles sec T90 Temperature Limits: Process to 2600 F (0 to 1427 C) Sensors Housing to 392 F (0 to 200 C) 2 Electronics Housing to 185 F (0 to 85 C) 2 Nominal and Approximate Shipping Weights: 18 in. (457 mm) package lbs (24.5 kg) 3 ft (0.91 m) package lbs (24.5 kg) 6 ft (1.83 m) package lbs (26 kg) 9 ft (2.74 m) package lbs (26.8 kg) Mounting and Mounting Position: Sensors... Flange Electronics... Wall/Pipe Materials: Probes... Enclosures... Calibration L stainless steel Inconel 600 Ceramic Low-copper aluminum Semi-automatic or automatic Calibration Gas Mixtures Recommended % O 2, Balance N 2 (Ref. test gas bottles kit #1A99119G04) 8% O 2, Balance N ppm CO, Balance N 2 NOTES: (1) Combustibles sensor is calibrated with CO gas. Sensor may be calibrated with H2 gas. Use in methane service is not recommended. (2) Operating temperature of electronics inside of electronics housing, as measured by a HART Communicator, or Emerson Process Management Asset Management Solutions (AMS) Software, or local operator interface. Operation below 0 C (32 F) requires that sensor housing be insulated. 1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

19 Instruction Manual Table 1-1. Specifications (Continued) Calibration Gas Flow... 5 scfh (2.5 l/m) Reference Air... 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O 2 ), regulated to 35 psi (241 kpa) Eductor Air... 5 scfh (2.5 l/m), clean, dry, instrument-quality air (20.95% O 2 ), regulated to 35 psi (241 kpa) Dilution Air scfh (0.5 l/m), clean, dry, instrument-quality air (20.95% O 2 ), regulated to 35 psi (241 kpa) Blowback Air (Optional)... Clean, dry, instrument-quality air (20.95% O 2 ), regulated to 55 psi (374 kpa) Sensors Housing... NEMA 4X, IP55 with fitting and pipe on reference exhaust port to clean, dry atmosphere, two 3/4-14 NPT conduit ports Electronics Housing... NEMA 4X, IP55 with fitting and pipe on reference exhaust port to clean, dry atmosphere, two 3/4-14 NPT conduit ports Electrical Noise... Meets EN Electromagnetic Compatibility Generic Immunity Std., Part II Includes ENG R for Electrostatic Discharge 4 Kv contact, 8 Kv in air Optionally ENG R Namur-Increased 8 Kv contact, 16 Kv in air Includes IEC fast transients-2 Kv on power supply and control lines Line Voltage... Universal 100 to 240 VAC, 50 to 60 Hz, software selectable, 3/4-14 NPT conduit port Isolated Output: Oxygen madc, 950 ohm max, with HART capability for O 2 and COMB Combustibles madc, 950 ohm max Alarm Output Relay... No. 2, form C, double-pole, double-throw, 2A, 30 Vdc, (software assignable) Logic Signals... Power Consumption Limits: Heaters... Electronics... Certification... SPA HART Alarm Module (optional) Low Oxygen Alarm High Combustibles Alarm Calibration Status Unit Failure 650 W nominal max 50 W nominal max CE FM(Pending) CSA(Pending) CENELEC(Pending) NOTE: All static performance characteristics are with operating variables constant. Specifications subject to change without notice. Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9

20 Instruction Manual Table 1-2. Product Matrix OCX44A O2 / Combustibles Transmitter O2 / Combustibles Transmitter IB Code Probe Length and Material 00 No Probe or Exhaust Tube in. (457 mm) 316 SST up to 1300 F (704 C) in. (457 mm) Inconel 600 up to 1832 F (1000 C) in. (457 mm) Ceramic up to 2600 F (1426 C) 12 3 ft (0.91 m) 316 SST up to 1300 F (704 C) 22 3 ft (0.91 m) Inconel 600) up to 1832 F (1000 C) 32 3 ft (0.91 m) Ceramic up to 2600 F (1426 C) 13 6 ft (1.83 m) 316 SST up to 1300 F (704 C) 23 6 ft (1.83 m) Inconel 600 up to 1832 F (1000 C) 14 9 ft (2.7 m) 316 SST up to 1300 F (704 C) Code Probe Mounting Assembly 10 (ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes 20 (DIN) 185mm dia. flange, 145mm BC with 4 x 18mm dia. holes 30 (JIS) 155mm dia. flange, 130mm BC with 4 x 15mm dia. holes Code Mounting Hardware - Stack Side 0 No Adapter Plate ("0" must also 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 Mounting to Other Mounting (1) 5 Model 132 Adapter Plate 6 Mounting to Ametek WDG-IVC 7 Mounting to Servomex Xendos Mounting to Elsag Bailey SMA-90 Code Mounting Hardware - Probe Side 0 No Adapter Plate 1 Probe Only (ANSI) 4 Probe Only (DIN) 7 Probe Only (JIS) OCX44A (Cont d) Example 1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

21 Instruction Manual Table 1-2. Product Matrix (Continued) Cont'd Code Electronic Housing - NEMA 4X, IP55 HART Communications 01 Basic Unit 02 Local Operator Interface 2 03 Calibration Solenoids 04 IS Barrier 3 05 Local Operator Interface and Calibration Solenoids 06 Local Operator Interface and IS Barrier 3 07 Calibration Solenoids and IS Barrier 3 08 Local Operator Interface and Calibration Solenoids and IS Barrier 3 Code Electronic Mounting 01 Integral to Sensor Housing Electronics 02 Split Electronics and no cable 03 Split Electronics and 20 ft (6m) cable 04 Split Electronics and 40 ft (12m) cable 05 Split Electronics and 60 ft (18m) cable 06 Split Electronics and 80 ft (24m) cable 07 Split Electronics and 100 ft (30m) cable 08 Split Electronics and 150 ft (45m) cable Code Accessories 00 None 01 Cal. Gas Rotometers, Flow Rotometers, and Ref. Gas Set 11 Blowback Option and Cal. Gas Rotometers, Flow Rotometers, and Ref. Gas Set Cont d Example NOTES: (1) Where possible, specify SPS number; otherwise, 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 of stud mounting plate with accessories. (2) If the Local Operator Interface (LOI) is not implemented, remote access and functionality available via HART Communications (Model 275 Handheld Communicator) with Oxygen/Combustibles Device Description (DD) required. (3) If the IS Barrier option is selected, customer must also purchase the Moore Industries SPA (1A99292H01), current repeater backplane and adpater (intrinsic safety barrier kit p/n 1A99698G01) to maintain the 4 20 ma combustibles output. Table 1-3. Accessories PART NUMBER DESCRIPTION 1A99119H01 Oxygen Bottle 0.4%, balance N 2 1A99119H02 Oxygen Bottle 8.0%, balance N 2 1A99119H06 CO Bottle 1000 PPM and air, balance N 2 1A99120H02 Regulator for Oxygen (may need 2) 1A99120H03 Regulator for COMB 1A99119G06 Wall mount bracket for gas bottles 1A99119G05 Test gas regulators kit 1A99119G04 Test gas bottles kit 1A99292H01 Moore Industries SPA for Low O 2 Alarm, High COMB Alarm, Calibration Status, and Unit Fail 275D9EI5D HART Communicator with 12 Meg buffer Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-11

22 Instruction Manual 1-12 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

23 Instruction Manual SECTION 2 INSTALLATION Before installing this equipment, read the Safety instructions for the wiring and installation of this apparatus at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury or death. readings. Therefore, either make the necessary repairs or install the transmitter upstream of any leakage. 3. 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. 2-1 MECHANICAL INSTALLATION a. Selecting Location 1. The location of the 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 representative of the process. Best results are normally obtained if the transmitter is positioned near the center of the duct (40-60% 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. The sensing 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 and combustibles Do not allow the temperature of the electronics housing to exceed 185 F (85 C) or damage to the electronics may result. b. Installation 1. Ensure all components are available to install the. 2. The may be installed intact as it is received. 3. Weld or bolt adapter plate (Figure 2-3) onto the duct. 4. For systems with split electronics, use the pole or wall mounting hardware as shown in Figure 2-4 to mount the electronics housing. Choose a location not to exceed the length of the electronics cable ordered. 5. For integral electronics installations, ensure the system cable drops vertically from the and the conduit is routed below the level of the housings. Drip loops minimize the possibility that moisture will damage the electronics (Figure 2-5). Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

24 Instruction Manual NOTE If process temperatures will exceed 392 F (200 C), use anti-seize compound on stud threads to ease future removal of the. 6. Insert sample and exhaust tubes through the opening in the mounting flange and bolt the unit to the flange. 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, make sure to replace insulation afterward. NOTE: ALL DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES. INSULATE IF EXPOSED TO AMBIENT WEATHER CONDITIONS THK GASKET ANSI JIS DIN 3535B18H B46H B45H01 DIM B DIM A TABLE 2. INSTALLATION/REMOVAL PROBE 18 IN. 3 FT 6 FT 9 FT DIM "A" 16 (406) 34 (864) 70 (1778) 106 (2692) DIM "B" (822) (1280) (2184) (3108) FLANGE DIA HOLE DIA (4) HOLES EQ SP ON B.C. DIA. TABLE 1. MOUNTING FLANGE ANSI DIN JIS 4512C17H C19H C18H (153) (185) (155) (20) (18) (15) 4.75 (121) 5.71 (145) 5.12 (130) TOP VIEW Figure 2-1. Installation (with Integral Electronics) Installation Rosemount Analytical Inc. A Division of Emerson Process Management

25 Instruction Manual ADAPTER PLATE* DIMENSIONS FOR DIMENSIONS IN. (mm) ANSI (P/N 4512C34G01) DIN (P/N 4512C36G01) JIS (P/N 4512C35G01) "A" 6.00 (153) 7.5 (191) 6.50 (165) "B" THREAD (M-16 x 2) (M-12 x 1.75) "C" DIA 4.75 (121) (145) (130) *PART NUMBERS FOR ADAPTER PLATES INCLUDE ATTACHING HARDWARE. A NOTE: DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES. 45 o DIA (63.5) C A B ADAPTER PLATE FOR INSTALLATION. SEE FIGURE STUDS, LOCKWASHERS AND NUTS EQUALLY SPACED ON C DIA B.C. Figure 2-2. Adapter Plate Dimensions Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3

26 Instruction Manual INSTALLATION FOR METAL WALL STACK OR DUCT INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION NOTE: ONLY ADAPTER PLATE IS FURNISHED BY ROSEMOUNT. DIMENSIONS IN INCHES WITH MILLIMETERS IN PARENTHESES. BOLT ADAPTER PLATE TO OUTSIDE WALL SURFACE MASONRY STACK WALL 2.50 [63.5] MIN DIA HOLE IN WALL FIELD WELD PIPE TO ADAPTER PLATE STACK OR DUCT METAL WALL WELD OR BOLT ADAPTER PLATE TO METAL WALL OF STACK OR DUCT. JOINT MUST BE AIRTIGHT. JOINT MUST BE AIRTIGHT PIPE 3.00 SCHEDULE 40, SLEEVE LENGTH OPTIONAL Figure 2-3. Adapter Plate Installation NOTE: * INDICATES ITEMS ARE INCLUDED IN MOUNTING KIT P/N 4851B40G01. *POLE MOUNTING CLAMP ELECTRONICS HOUSING *WALL OR POLE MOUNT BRACKET AND SCREWS WALL MOUNTING BOLTS OR LAG SCREWS (4 EACH BY CUSTOMER) 1/4-20 UNC X 2 IN. M-F STANDOFFS RECOMMENDED FOR REAR PIPING CLEARANCE WHEN WALL MOUNTING (4 EACH BY CUSTOMER) Figure 2-4. Wall or Pole Mounting of Electronics Housing Installation Rosemount Analytical Inc. A Division of Emerson Process Management

27 Instruction Manual CONDUIT DRIP LOOPS DUCT WALL CONDUIT DRIP LOOP CONDUIT DRIP LOOP DUCT WALL Figure 2-5. Installation with Drip Loops Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5

28 Instruction Manual 2-2 ELECTRICAL INSTALLATION All wiring must conform to local and national codes. For reference, factory wired solenoid power connections are shown in Figure 2-6. Disconnect and lock out power before connecting the unit to the power supply. 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. To meet the Safety Requirements of IEC 1010 (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) 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 CE compliance, ensure a good connection exists between the mounting flange bolts and earth. a. Connect Line Voltage The is software configured for 100 to 240 VAC line voltage at 50 to 60 Hz. The power supply requires no setup. Connect the line, or L wire, to the L terminal, and the neutral, or N wire, to the N terminal on the AC power input terminal block in the electronics housing. Connect the ground, or G wire, to the ground stud in the electronics housing. Secure the connection with two nuts. Attach a separate line from the ground stud to the G terminal on the power input terminal block. NOTE Make sure line voltage is correctly set. See paragraph 3-1c for instructions. b. Connect 4-20 ma Signals Connect the 4-20 ma current loop to the 4-20 ma signal output terminals in the electronics housing. If the isolation barrier option is provided, refer to Appendix D for alternate wiring instructions. 1. Oxygen (O 2 ) 4-20 ma Signal. One 4-20 ma signal represents the O 2 value. Superimposed on the O 2 signal is the HART information accessible through a Model 275 Handheld Communicator or AMS software. The O 2 signal is at the AOUT 1 terminals. 2. Combustibles (COMB) 4-20 ma Signal. Another 4-20 ma signal at the AOUT 2 terminals represents the COMB value. HART information is not available on the COMB signal. c. Alarm Output Relay Connect any customer supplied relay input to the alarm output relay terminal. The alarm output relay terminal is a set of dry, no. 2, form C, double-pole, double-throw contacts with 30 ma and 24 VDC capacity. d. Split-Electronics Connections to Sensor Housing If the is configured with splitelectronics, make the following connections between the electronics and sensor housings with the electronics cable ordered with the package (Figure 2-7). Braided cable is available in lengths up to 150 ft. (45 m). 1. Thermocouple Connections. Connect the electronics housing sensor/thermocouple 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 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

29 Instruction Manual Connect the twisted pair wire shields to the shield terminals. 2. Heater Power Connections. Use the purple, orange, black, gray, brown, and red stranded wires in the electronics cable to connect power to the three SOLENOID POWER TERMINAL BLOCK (FACTORY WIRED) ELECTRONICS HOUSING (COVER REMOVED) 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 2-7. LO O2 GND HI O2 GND HI COMB GND INST AIR GND ALARM OUTPUT RELAY TERMINAL PRESSURE SENSOR HI COMB SOLENOID HI O2 SOLENOID LO O2 SOLENOID INST AIR SOLENOID NC COMMON SENSOR INPUT HEATER THERMOCOUPLE, AND HEATER POWER INPUT PORT (FROM SENSOR HOUSING) 4-20 ma SIGNAL OUTPUT TERMINAL BLOCK NO AOUT 2+ AOUT 2- AOUT 1- AOUT ma SIGNAL OUTPUT PORT COMB 4-20 ma SIGNAL O ma SIGNAL F1 POWER SUPPLY FUSE F2 HEATER FUSE AC POWER INPUT PORT AC POWER INPUT TERMINAL BLOCK L N G GROUND STUD TWO NUTS Figure 2-6. Line Voltage and 4-20 ma Connections Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7

30 Instruction Manual SPLIT-ELECTRONICS HOUSING (COVER REMOVED) PRESSURE SENSOR HEATER POWER TERMINAL BLOCK ELECTRONICS CABLE PORT PURPLE ORANGE BLACK GRAY BROWN RED CABLE GROUND STUD SL HEATER L2 O2 CELL HEATER L2 COMB CELL HEATER L2 SENSOR/THERMOCOUPLE TERMINAL BLOCK (1) (2) (3) (4) (5) (6) YELLOW RED SHIELD YELLOW RED BLUE WHITE SHIELD GREEN WHITE YELLOW WHITE SHIELD RED WHITE PRESSURE SENSOR FACTORY WIRED WHITE GREEN RED BLACK ELECTRONICS CABLE (UP TO 150 FT) NOTE: KEEP TWISTED PAIRS TOGETHER O2 T/C + O2 T/C - GND SL T/C + SL T/C - O2 MV + O2 MV - GND COMB ACTIVE + COMB ACTIVE - COMB REF + COMB REF - GND COMB DRIVE COMB RETURN PR SENSOR - PR SENSOR PR SRC PR SRC RTN SL HEATER L2 O2 CELL HEATER L2 COMB CELL HEATER L2 (1) (2) (3) (4) (5) (6) YELLOW RED YELLOW RED BLUE WHITE GREEN WHITE YELLOW WHITE RED WHITE SENSOR/THERMOCOUPLE TERMINAL BLOCK ELECTRONICS CABLE PORT PURPLE ORANGE BLACK GRAY BROWN RED HEATER POWER TERMINAL BLOCK O2 T/C + O2 T/C - SL T/C + SL T/C - O2 MV + O2 MV - RED WHITE BLUE COMB ACTIVE + COMB ACTIVE - COMB REF + COMB REF - COMB DRIVE COMB RETURN PROBE SENSOR HOUSING (COVER REMOVED) Figure 2-7. Electrical Connections Between Split-Electronics and Sensor Housing Installation Rosemount Analytical Inc. A Division of Emerson Process Management

31 Instruction Manual 2-3 PNEUMATIC INSTALLATION Pneumatic system connections depend on which options are equipped on your transmitter. Refer to paragraphs 2-3a, 2-3b, and 2-3c, and select the paragraph that applies to your OCX transmitter configuration. a. 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. 1. Refer to Figure 2-8. 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 rotometer. 2. Connect the dilution air rotometer 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. Do not use 100% nitrogen as an O 2 low gas. It is suggested that O 2 low gas be between 0.4% and 2.0% O 2. 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. One CO gas and two O 2 gases are used to calibrate the : CO ppm or 4%, O 2 low gas - 0.4%, O 2 high gas - 8%. Connect the output of the test gas sources to the inlet port of the CAL GAS rotometer. Install an air line between the rotometer outlet port and the CAL GAS inlet fitting on the sensor housing. SENSOR HOUSING EDUCTOR AIR IN CAL GAS IN REFERENCE AIR IN DILUTION AIR IN CAL GAS FLOW METER 5 SCFH PSIG RECOMMENDED ( ( DILUTION AIR FLOW METER 0.1 SCFH HI CO HI O 2 LO O 2 2-STAGE REGULATORS ELECTRONICS HOUSING INSTRUMENT AIR SUPPLY PRESSURE REGULATOR/FILTER 35 PSIG Figure 2-8. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration) Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9

32 Instruction Manual SENSOR HOUSING CAL GAS FLOW METER 5 SCFH PSIG ( RECOMMENDED ( EDUCTOR AIR IN CAL GAS IN REFERENCE AIR IN DILUTION AIR IN ELECTRONICS HOUSING DILUTION AIR FLOW METER 0.1 SCFH PRESSURE REGULATOR/FILTER 35 PSIG INSTRUMENT AIR SUPPLY 2-STAGE REGULATORS HI CO HI O 2 LO O Figure 2-9. Pneumatic Installation, OCX with Reference Air Set and Solenoids (with Autocalibration) 2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

33 Instruction Manual b. Reference Air Set and Solenoids When the reference air set and test gas solenoids are included with your OCX, use the following procedure to install the pneumatic system components. 1. Install the reference air set according to the instructions in paragraph 2-3a, steps 1 through Refer to Figure 2-9. Connect the O 2 low gas source to the CAL GAS LO O 2 inlet fitting on the electronics housing. Install a shutoff valve and pressure regulator with gage in the O 2 low supply line, as shown. 3. Connect the O 2 high gas source to the CAL GAS HI O 2 inlet fitting. Install a shutoff valve and pressure regulator with gage in the O 2 high supply line. 4. Connect the CO high gas to the CAL GAS HI COMB 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 rotometer. Install an air line between the rotometer outlet port and the CAL GAS inlet fitting on the sensor housing. c. Reference Air, Solenoids, and Blowback When the reference air set, calibration gas solenoids, and blowback options are included with your OCX transmitter, use the following procedure to install the pneumatic system components. 1. Connect the calibration gas sources according to the instructions in paragraph 2-3b, steps 2 through Use the instructions in Appendix C to install the reference air set and blowback system components. Upon completing installation, make sure that the is turned on and operating prior to firing up the combustion process. Damage can result from having a cold exposed to the process gases. NOTE During outages, and whenever possible, leave units running to prevent condensation and premature aging from thermal cycling. 2-4 INITIAL STARTUP Observe the preceding Caution and Note. Refer to Section 3, STARTUP AND OPERA- TION, for startup information. Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11

34 Instruction Manual O 2 COMB SECTION 3 SWITCH DEFAULT POSITIONS SHOWN 21.1 ma 3.5 ma CLOSED SW O ma/3.5 ma: O ma SIGNAL RAIL LIMITS: HIGH ma LOW ma COMB 21.1 ma/3.5 ma: COMB 4-20 ma SIGNAL RAIL LIMITS: HIGH ma LOW ma FUSE F2 INTERNAL: O ma IS INTERNALLY POWERED (DEFAULT) SW1 EXTERNAL: O ma REQUIRES AN EXTERNAL POWER SUPPLY INTERNAL: COMB 4-20 ma IS INTERNALLY POWERED (DEFAULT) SW2 EXTERNAL: COMB 4-20 ma REQUIRES AN EXTERNAL POWER SUPPLY Figure 3-1. Defaults 3-0 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

35 Instruction Manual SECTION 3 STARTUP AND OPERATION Install all protective equipment covers and safety ground leads before equipment startup. Failure to install covers and ground leads could result in serious injury or death. 3-1 GENERAL a. Verify Installation Ensure the is installed correctly. Verify mechanical installation and all electrical and pneumatic connections (Section 2, INSTALLATION). NOTE During outages, and whenever possible, leave all units running to prevent condensation and premature aging from thermal cycling. Make sure that the is turned on and operating prior to firing up the combustion process. Damage can result from having a cold exposed to the process gases. b. Verify Configuration There are three switches on the microprocessor board which are user configurable for the (Figure 3-1). SW1 determines if the O ma signal is internally or externally powered. SW2 determines if the COMB 4-20 ma signal is internally or externally powered. SW3 sets the rail limits for the O 2 and COMB 4-20 ma signals and configures the sample line heater control circuit. All switches are accessible through holes in the electronics box. Remove power from the before changing defaults. If defaults are changed under power, damage to the electronics may occur. 1. SW1. The two settings are internally or externally powering the O ma signal. The factory setting is for the O ma signal to be internally powered. 2. SW2. The two settings are internally or externally powering the COMB 4-20 ma signal. The factory setting is for the COMB 4-20 ma signal to be internally powered. 3. SW3. The factory sets this switch as follows: (a) Position 1 determines the O ma signal rail limit. The settings are high, 21.1 ma, or low, 3.5 ma. The factory setting is at low, 3.5 ma. (b) Position 2 determines the COMB 4-20 ma signal rail limit. The settings are high, 21.1 ma, or low, 3.5 ma. The factory setting is at high, 21.1 ma. (c) Position 3 is not used. (d) Position 4 is not used. Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-1

36 Instruction Manual c. Initial Power Up Allow adequate time for the heaters to begin operation and for the OCX transmitter to reach normal operating temperature on power up. Normal operating temperature for the O 2 cell is 736 C. Normal operating temperature for the combustibles cell is 300 C. The normal sample line temperature is 130 C. Upon initial power up of the, and any time supply voltage to the unit changes, the power input voltage must be verified in the software to ensure proper operation of the heaters. The input voltage is set as follows: 1. Remove the housing cover from the electronics housing. 2. Remove fuse F2 from the electronics box. See Figure 3-1 for the location of fuse F2. 3. Replace the electronics housing cover. 4. Apply power to the Oxygen/Combustibles Transmitter. 5. If using the HART handheld communicator, connect the communicator to the transmitter. 6. If using the HART communicator, select: Device Setup > Detailed Setup > Line Voltage. If using the LOI, select: Setup > Parameters > Line Voltage. 7. Set the line voltage to the appropriate value: 100, 110, or If using the HART communicator, press F4 for Enter and then F2 for send. If using the LOI, press the right arrow to enter the value. 9. Remove power from the electronics. 10. Remove the electronics housing cover and install fuse F Install the electronics housing cover and restore power to the electronics. d. Set Test Gas Values Using HART/AMS or optional LOI, set the test gas values for calibration. Refer to Section 5, HART/AMS or Appendix A, Local Operator Interface for more information. 1. HART/AMS. If using HART/AMS, from the DETAILED SETUP menu, select O 2 CALIBRATION. (a) From O 2 CALIBRATION, select High TG. Enter the percentage of O 2 used for the high O 2 test gas. (b) From O 2 CALIBRATION, select Low TG. Enter the percentage of O 2 used for the low O 2 test gas. (c) From the DETAILED SETUP menu, select COMB CALIBRATION. (d) From COMB CALIBRATION, select High TG. Enter the percentage of CO used for high COMB test gas. 2. LOI. If using the LOI, from the SETUP menu select CALIBRATION. (a) From CALIBRATION, select O 2 High Gas. Enter the percentage of O 2 used for the high O 2 test gas. (b) Select the down arrow and the next selection will be O 2 Low Gas. Enter the percentage of O 2 used for the low O 2 test gas. (c) Select the down arrow again and the next selection will be Comb High Gas. Enter the percentage of O 2 used for the combustibles span gas. 3-2 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

37 Instruction Manual SECTION 4 CALIBRATION 4-1 GENERAL During a calibration, two calibration gases with known O 2 concentrations and one calibration gas with a known COMB concentration are applied to the. Slope and constant values are calculated to determine if the is correctly measuring net concentrations of O 2 and combustibles in the industrial process. Before calibrating the, verify that the calibration gas parameters are correct by setting the test gas values used when calibrating the unit (Refer to Section 3, STARTUP AND OP- ERATION). 4-2 CALIBRATION METHODS There are three types of calibration methods available to the ; automatic, operatorinitiated automatic, and manual. Calibration commands and menus can be accessed by HART/AMS or by the optional LOI. a. Automatic Calibration If the is equipped with calibration solenoids, the unit can be programmed to automatically calibrate without any operator action. Refer to Section 5, HART/AMS for information on automatic calibration setup via HART/AMS. Refer to Appendix A for information on automatic calibration setup via LOI. b. Operator Initiated-Automatic Calibration An operator can initiate an automatic calibration at any time provided that the unit is equipped with calibration solenoids. 1. HART/AMS. To initiate an automatic calibration using HART/AMS, perform the following steps on the HART/AMS menu tree. Refer to Figure 5-3 for the complete HART/AMS menu tree. (a) Select DIAG/SERVICE from DE- VICE SETUP menu. (b) Select CALIBRATE from the DIAG/SERVICE menu. (c) Select PERFORM CAL from CALI- BRATE menu. (d) Select CAL from PERFORM CAL menu. (e) Select the type of calibration desired: O 2 Cal method, COMB Cal method, or O 2 and COMB Cal method from CAL menu. 2. LOI. To initiate a calibration using the LOI, perform the following steps on the LOI menu tree. Refer to APPENDIX A for complete LOI menu tree. (a) From the CALIBRATE menu, use the right-pointing arrow to select DO CALIBRATION. (b) Select O2, COMBUSTIBLES, or BOTH sensors for calibration. Use the right-pointing arrow to access the calibration window. (c) At the prompt, use the rightpointing arrow to initiate automatic calibration. c. Manual Calibration If a unit is not equipped with calibration solenoids, a calibration must be performed by an operator following prompts from the unit. Refer to Section 5, HART/AMS for information on manual calibration with HART/AMS. Refer to APPENDIX A for information on manual calibration with LOI. Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-1

38 Instruction Manual 4-2 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management

39 Instruction Manual SECTION 5 HART/AMS 5-1 OVERVIEW The HART Communicator is a handheld communications interface device. It provides a common communications link to all microprocessor-based instruments that are HART compatible. The handheld communicator contains an 8 x 21 character liquid crystal display (LCD) and 25 keys. A pocket-sized manual, included with the HART Communicator, details the specific functions of all the keys. To interface with the, the HART Communicator requires a termination point along the O ma current loop and a minimum load resistance of 250 ohms between the communicator and the power supply. The HART Communicator accomplishes its task using a frequency shift keying (FSK) technique. With the use of FSK, high-frequency digital communication signals are superimposed on the 4-20 ma oxygen output signal. The communicator does not disturb the 4-20 ma signal since no net energy is added to the loop. HART information is not available on the COMB output signal ma TERMINAL BLOCK IN ELECTRONICS HOUSING The HART Communicator may be interfaced with a personal computer (PC), providing special software has been installed. To connect the HART Communicator to a PC, an interface adapter is required. Refer to the proper HART Communicator documentation in regard to the PC interface option. 5-2 HART COMMUNICATOR SIGNAL LINE CONNECTIONS The HART Communicator can connect to the oxygen analog output signal line at any wiring termination in the O ma current loop. There are two methods of connecting the HART Communicator to the signal line. For applications in which the signal line has a load resistance of 250 ohms or more, refer to method 1. For applications in which the signal line load resistance is less than 250 ohms, refer to method 2. a. Method 1, For Load Resistance 250 Ohms. Refer to Figure 5-1 and the following steps to connect the HART Communicator to a signal line 250 ohms or more of load resistance. RL 250Ω A OUT 1 - A OUT 1 + O ma SIGNAL LINE ANALOG OUTPUT DEVICE LOOP CONNECTORS SERIAL PORT & BATTERY CHARGER MUST NOT BE USED IN HAZARDOUS AREAS LOOP CONNECTORS USE INTERFACE ONLY SERIAL PORT HART COMMUNICATOR HART COMMUNICATOR REAR PANEL LEAD SET Figure 5-1. Signal Line Connections, > 250 Ohms Load Resistance Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-1

40 Instruction Manual Explosions can result in death or serious injury. Do not make connections to the HART Communicator s serial port, 4-20 ma signal lines, or NiCad recharger jack in an explosive atmosphere. Using the supplied lead set, connect the HART Communicator in parallel to the OCX Use any wiring termination points in the oxygen analog output 4-20 ma signal line. b. Method 2, For Load Resistance 250 Ohms Refer to Figure 5-2 and the following steps to connect the HART Communicator to a signal line with less than 250 ohms load resistance. Explosions can result in death or serious injury. Do not make connections to the HART Communicator s serial port, 4-20 ma signal lines, or NiCad recharger jack in an explosive atmosphere. 1. At a convenient point, break the oxygen analog output 4-20 ma signal line and install the optional 250 ohm load resistor. 2. Plug the load resistor into the loop connectors (located on the rear panel of the HART Communicator) ma TERMINAL BLOCK IN ELECTRONICS HOUSING NOTE: THE SIGNAL LOOP MUST BE BROKEN TO INSERT THE OPTIONAL 250 OHM LOAD RESISTOR. RL < 250Ω A OUT 1 - A OUT 1 + O ma SIGNAL LINE ANALOG OUTPUT DEVICE LOOP CONNECTORS USE INTERFACE SERIAL PORT & BATTERY LOOP CONNECTORS ONLY CHARGER MUST SERIAL PORT NOT BE USED IN HAZARDOUS AREAS 250 OHM LOAD RESISTOR (NOTE 1) HART COMMUNICATOR HART COMMUNICATOR REAR PANEL Figure 5-2. Signal Line Connections, 250 Ohms Load Resistance 5-2 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

41 Instruction Manual 5-3 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 that connects to the serial port (on the communicator rear panel). Refer to the proper HART Communicator documentation in regard to the PC interface option. 5-4 OFF-LINE AND ON-LINE OPERATIONS The HART Communicator can be operated both off-line and on-line. a. Off-line operations are those in which the communicator is not connected to the OCX Off-line operations can include interfacing the HART Communicator with a PC. (Refer to applicable HART documentation regarding HART/PC applications.) b. In the on-line mode, the communicator is connected to the oxygen 4-20 ma analog output signal line. The communicator is connected in parallel to the or in parallel to the 250 ohm load resistor. c. The opening menu displayed on the LCD is different for on-line and off-line operations. When powering up a disconnected (off-line) communicator, the LCD will display the Main Menu. When powering up a connected (online) communicator, the LCD will display the On-line Menu. Refer to the HART Communicator manual for detailed menu information. 5-5 MENU TREE FOR HART COMMUNICATOR/ APPLICATIONS This section consists of a menu tree for the HART Communicator. This menu is specific to applications. Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-3

42 Instruction Manual PROCESS VARIABLES VIEW FLD DEV VARS VIEW FLD DEV mv O2 O2 temp Electronics temp COMB COMB temp SL temp Pressure O2 mv O2 temp mv Elec temp V COMB Act mv COMB Ref mv Pressure V SL temp mv Status Group 1 O2 Thermocouple Error O2 Cell Temperature Low O2 Cell Temperature High O2 Cell Temperature Very High O2 Heater Open O2 Cell Open O2 Cell Bad O2 Slope Error Status Group 2 O2 Constant Error O2 Calibration Failed Landusky Error High Electronics Temperature EEPROM Corrupt DEVICE SETUP O2 O2 AO COMB COMB AO DIAG/SERVICE STATUS Status Group 3 Status Group 4 Sample Line Thermocouple Error Sample Line Temperature Low Sample Line Temperature High Sample Line Temperature Very High Sample Pressure Low Absolute Combustibles Cell Error Combustibles Cell Chamber Temperature Low Combustibles Cell Chamber Temperature High Combustibles Cell Chamber Temperature Very High Combustibles Slope Error CO Constant Error CO Cal Failed AO Saturated O2 AO Saturated COMB AO Saturated AO Fixed Max Electronics Temp O2 AO Fixed COMB AO Fixed LOOP TEST O2 Loop test method COMB Loop test method CALIBRATE PERFORM CAL Cal methods O2 Optrak TG? COMB Optrak TG? CalState O2 Cal method COMB Cal method O2 and COMB Cal method (CONTINUED ON SHEET 2) CAL STATUS LAST CAL CONSTANTS RESET CAL CONSTANTS CalState TimeRemain Present O2 Present COMB O2 Cal slope O2 Cal Const O2 Cell Imp COMB Slope COMB Const Reset O2 constants Reset COMB constants D/A TRIM O2 D/A trim method COMB D/A trim method Figure 5-3. Menu Tree for HART/AMS on the (Sheet 1 of 3) 5-4 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

43 Instruction Manual (CONTINUED FROM SHEET 1) Tag BASIC SETUP SELECT RANGE O2 URV COMB URV DEVICE INFORMATION Dev id Descriptor Message Date Final asmbly num O2 Snsr s/n COMB Snsr s/n S/W VERSION INFO Ver Chk sum Bld num Bld date SENSORS O2 O2 O2 Temp Electronics temp O2 mv O2 Temp mv Elec temp V DETAILED SETUP COMB COMB COMB TEMP COMB ACT MV COMB REF MV SL TEMP SL temp mv Pressure Pressure V SIGNAL CONDITION O2 % range COMB % range O2 AO OUTPUT CONDITION ANALOG OUTPUT O2 Analog Output O2 Alrm typ O2 Range 3.5 ma 21.1 ma COMB AO COMB Analog Output COMB Alrm typ 3.5 ma 21.1 ma HART OUTPUT Poll addr Num req preams COMB Range (CONTINUED ON SHEET 3) LINE VOLTAGE (CONTINUED ON SHEET 3) Figure 5-3. Menu Tree for HART/AMS on the (Sheet 2 of 3) Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-5

44 Instruction Manual (CONTINUED FROM SHEET 2) DETAILED SETUP (CONTINUED FROM SHEET 2) O2 SETUP O2 CALIBRATION SLOPE O2 CONST O2 T90 High TG Low TG OPtrak TG? TG Time Purge Time Sol. Present Cal Intrvl h Next Cal Time h OP Locks OP Tracks COMB SLOPE COMB SETUP COMB CONST COMB T90 COMB CALIBRATION ALARM RELAY BLOWBACK High TG OPtrak TG? TG Time Purge Time Sol. Present Cal Intrvl h Next Cal Time h EVENT 1 EVENT 2 EVENT 3 Alarm State Enabled Interval Duration Purge Time State Do Blowback OP Locks OP Tracks None In Cal O2 Temp O2 Heater O2 Cell Bad Cal Failed Hi Elect Temp Unit Fail SL Temp SL Pressure Comb Temp All REVIEW DEVICE INFORMATION CAL INFO Manufacturer Model Dev id Tag Descriptor Message Date Final asmbly num O2 Snsr s/n COMB Snsr s/n Fld dev rev Hardware rev Software rev Universal rev O2 Cal Info COMB Cal Info OPtrak TG? TG Time Purge Time Low TG High TG Slope O2 const O2 cell Imp OPtrak TG? TG Time Purge Time High TG COMB slope COMB const DEVICE CONFIG O2 Device Config COMB Device Config SLOPE O2 CONST O2 T90 COMB SLOPE OUTPUT CONFIG O2 URV COMB URV Poll addr Num req preams COMB CONST COMB T Figure 5-3. Menu Tree for HART/AMS on the (Sheet 3 of 3) 5-6 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

45 Instruction Manual 5-6 HART COMMUNICATOR MANUAL O 2 CAL METHOD To perform a manual O 2 calibration using the HART Communicator, use the following procedure. If necessary, use the menu tree in Figure 5-3 (sheet 1 of 3) for reference. 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 number. To return to a preceding menu, press the left arrow key. a. From the PERFORM CAL screen, select menu item 1, CAL, then menu item 1, O 2 Cal method to access the O 2 calibration method. Failure to remove the from automatic control loops prior to performing this procedure may result in a dangerous operating condition. b. In the first O 2 CAL method screen, a Loop should be removed from automatic control warning appears. Remove the from any automatic control loops to avoid a potentially dangerous operating condition and press OK. c. The next several screens indicate the calibration status. At each of the following status prompts, select menu item 2, NEXT CAL STEP: COMPLETE APPLY LOW O 2 GAS LOW O 2 GAS FLOW d. At this point, select menu item 4, EXIT, to leave the O2 CAL procedure. e. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O2, as the calibration status updates. f. When CALSTATE displays APPLY HIGH O 2 GAS, return to the O 2 CAL procedure. When the Loop should be removed from automatic control warning appears, press OK. g. At the APPLY HIGH O 2 GAS status prompt, select menu item 2, NEXT CAL STEP. When the status displays HIGH O 2 GAS FLOW, select menu item 4, EXIT, to leave the O 2 CAL procedure. h. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O 2, as the calibration status updates. i. When CALSTATE displays STOP GAS, return to the O 2 CAL procedure. j. When the Loop should be returned to automatic control message appears, return the to the automatic control loops previously removed and press OK. k. At the STOP GAS status prompt, select menu item 2, NEXT CAL STEP. When the status displays PURGING, select menu item 4, EXIT, to leave the O 2 CAL procedure. l. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O 2, as the calibration status updates. m. When CALSTATE displays COMPLETE, the calibration is finished. Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-7

46 Instruction Manual 5-7 HART COMMUNICATOR MANUAL COMB CAL METHOD To perform a manual combustibles calibration using the HART Communicator, use the following procedure. If necessary, use the menu tree in Figure 5-3 (sheet 1 of 3) for reference. 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 number. To return to a preceding menu, press the left arrow key. a. From the PERFORM CAL screen, select menu item 1, CAL, then select menu item 2, COMB Cal method to access the combustibles calibration method. Failure to remove the from automatic control loops prior to performing this procedure may result in a dangerous operating condition. b. In the first COMB CAL method screen, a Loop should be removed from automatic control warning appears. Remove the OCX 4400 from any automatic control loops to avoid a potentially dangerous operating condition and press OK. c. The next several screens indicate the calibration status. At each of the following status prompts, select menu item 2, NEXT CAL STEP: COMPLETE APPLY HIGH O 2 GAS HIGH O2 GAS FLOW d. At this point, select menu item 4, EXIT, to leave the COMB CAL procedure. e. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 4, PRESENT COMB, as the calibration status updates. f. When CALSTATE displays APPLY COM- BUSTIBLES GAS, return to the O 2 CAL procedure. When the Loop should be removed from automatic control warning appears, press OK. g. At the APPLY COMBUSTIBLES GAS status prompt, select menu item 2, NEXT CAL STEP. When the status displays COM- BUSTIBLES GAS FLOW, select menu item 4, EXIT, to leave the COMB CAL procedure. h. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 4, PRESENT COMB, as the calibration status updates. i. When CALSTATE displays STOP GAS, return to the COMB CAL procedure. j. When the Loop should be returned to automatic control message appears, return the to the automatic control loops previously removed and press OK. k. At the STOP GAS status prompt, select menu item 2, NEXT CAL STEP. When the status displays PURGING, select menu item 4, EXIT, to leave the COMB CAL procedure. l. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT COMB, as the calibration status updates. m. When CALSTATE displays COMPLETE, the calibration is finished. 5-8 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

47 Instruction Manual 5-8 HART COMMUNICATOR MANUAL O 2 AND CO CAL METHOD To perform a manual O 2 and COMB calibration using the HART Communicator, use the following procedure. If necessary, use the menu tree in Figure 5-3 (sheet 1 of 3) for reference. 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 number. To return to a preceding menu, press the left arrow key. a. From the PERFORM CAL screen, select menu item 1, CAL, then menu item 3, O 2 and COMB Cal method to access the O 2 and COMB calibration method. Failure to remove the from automatic control loops prior to performing this procedure may result in a dangerous operating condition. b. In the first O 2 CAL method screen, a Loop should be removed from automatic control warning appears. Remove the from any automatic control loops to avoid a potentially dangerous operating condition and press OK. c. The next several screens indicate the calibration status. At each of the following status prompts, select menu item 2, NEXT CAL STEP: COMPLETE APPLY LOW O 2 GAS LOW O 2 GAS FLOW d. At this point, select menu item 4, EXIT, to leave the O 2 CAL procedure. e. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O 2, as the calibration status updates. f. When CALSTATE displays APPLY HIGH O 2 GAS, return to the O 2 and COMB CAL procedure. When the Loop should be removed from automatic control warning appears, press OK. g. At the APPLY HIGH O 2 GAS status prompt, select menu item 2, NEXT CAL STEP. When the status displays HIGH O 2 GAS FLOW, select menu item 4, EXIT, to leave the O 2 and COMB CAL procedure. h. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O 2, as the calibration status updates. i. When CALSTATE displays APPLY COM- BUSTIBLES GAS, return to the O 2 and COMB CAL procedure. When the Loop should be removed from automatic control warning appears, press OK. j. At the APPLY COMBUSTIBLES GAS status prompt, select menu item 2, NEXT CAL STEP. When the status displays COM- BUSTIBLES GAS FLOW, select menu item 4, EXIT, to leave the O 2 and COMB CAL procedure. k. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 4, PRESENT COMB, as the calibration status updates. l. When CALSTATE displays STOP GAS, return to the O 2 and COMB CAL procedure. m. When the Loop should be returned to automatic control message appears, return the to the automatic control loops previously removed and press OK. Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-9

48 Instruction Manual n. At the STOP GAS status prompt, select menu item 2, NEXT CAL STEP. When the status displays PURGING, select menu item 4, EXIT, to leave the O 2 and COMB CAL procedure. o. From the PERFORM CAL screen, view menu item 4, CALSTATE, to monitor the calibration status as it updates. Or, access the CALIBRATE screen and select menu item 2, CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; menu item 3, PRESENT O 2, and menu item 4, PRESENT COMB, as the calibration status updates. p. When CALSTATE displays COMPLETE, the calibration is finished. 5-9 AUTOMATIC CALIBRATION SETUP VIA HART NOTE Automatic calibration is only available on units equipped with calibration solenoids. Use the following procedure to specify a time interval (in hours) at which the will automatically calibrate the. To disable the automatic calibration feature for oxygen or combustibles, enter a 0 for the CAL INTRVL for both O 2 and COMB. If desired, the NEXT CAL TIME can be changed to synchronize a calibration at a specific day or time. When setting automatic calibration times, the CAL INTRVL and the NEXT CAL TIME should be set so that O 2 and combustibles are NOT calibrated simultaneously. 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 number. To return to a preceding menu, press the left arrow key. a. From the DEVICE SETUP screen, select DETAILED SETUP. b. From the DETAILED SETUP screen, select O 2 CALIBRATION. From the O 2 CALIBRA- TION screen, select menu item 7, CAL INTRVL. c. At the prompt, input a time interval (in hours) at which an automatic O 2 calibration will occur and press ENTER. d. From the DETAILED SETUP screen, select COMB CALIBRATION. e. From the COMB CALIBRATION screen, select menu item 7, CAL INTRVL. f. At the prompt, input a time interval (in hours) at which an automatic COMB calibration will occur and press ENTER LINE VOLTAGE SELECTION USING HART COMMUNICATOR Use the procedure in paragraph 3-1c to select or change the line voltage configuration using the HART Communicator HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management

49 Instruction Manual SECTION 6 OPERATION 6-1 OVERVIEW Once the is installed, set up, and calibrated properly, the unit is ready for operation. 6-2 OPERATION Before the can begin normal operation, all heaters must be up to temperature before the unit begins to take measurements of the sample gas. During normal operation, the unit will perform continuous measurements of the sample gas. The unit is performing properly if there are no alarms present. If the unit is equipped with an LOI, the normal operating display will show a value for Oxygen and Combustible concentrations measured. If an LOI is not used, values for Oxygen and Combustibles are available through HART. Rosemount Analytical Inc. A Division of Emerson Process Management Operation 6-1

50 Instruction Manual 6-2 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

51 Instruction Manual SECTION 7 MAINTENANCE AND SERVICE 7-1 OVERVIEW This section contains the procedures to maintain and service the. 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 be removed from the stack for all service activities. The unit should be allowed to cool and be taken to a clean work area. Failure to comply may cause severe burns. Disconnect and lock out power before working on any electrical components. There may be voltage up to 264 VAC. 7-2 REMOVAL/REPLACEMENT a. with Integrally Mounted Electronics 1. Remove. (a) Turn off power to the system. (b) Shut off the calibration gases at the cylinders and the instrument air. (c) Disconnect the calibration gas and instrument air lines from the electronics housing. (d) Remove the cover from the electronics housing to expose the electronics housing terminal blocks, Figure 7-1. (e) Disconnect and remove the two power leads from the AC power input terminal block and the ground lead from the ground stud. (f) Disconnect and remove the O 2 and COMB 4-20 ma signal leads from the 4-20 ma signal output terminal block. (g) If used, disconnect and remove the external relay leads from the alarm output relay terminal. (h) Remove insulation to access the mounting bolts. Unbolt the OCX 4400 from the stack and take it to a clean work area. (i) Allow the unit to cool to a comfortable working temperature. 2. Replace. (a) Bolt the to the stack and install insulation. Remove cover on electronics housing. (b) If used, connect external relay leads to the alarm output relay terminal, Figure 7-1. (c) Connect the O 2 and COMB 4-20 ma signal leads to the 4-20 ma signal output terminal block. (d) Connect the line, or L wire, to the L terminal, and the neutral, or N wire, to the N terminal on the AC power input terminal block in the electronics housing. Connect the ground, or G wire, to the ground stud in the electronics housing. Secure the connection with two nuts. Attach a separate line from the ground stud to the G terminal on the power input terminal block. Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-1

52 Instruction Manual (e) Replace cover on electronics housing. (f) Connect the calibration gasses and instrument air lines to the electronics housing. (g) Turn on the calibration gasses at the cylinders and turn on instrument air. (h) Restore power to the system. ELECTRONICS HOUSING (COVER REMOVED) 4-20 ma SIGNAL OUTPUT TERMINAL BLOCK AC POWER INPUT TERMINAL BLOCK ALARM OUTPUT RELAY TERMINAL GROUND STUD AOUT 2+ AOUT 2- AOUT 1- AOUT 1+ L N G TWO NUTS NO COMMON NC COMB 4-20 ma SIGNAL O ma SIGNAL Figure 7-1. Electronics Housing Terminal Blocks Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

53 Instruction Manual SENSOR HOUSING (COVER REMOVED) SL HEATER L2 O2 CELL HEATER L2 COMB CELL HEATER L2 EMI BOOT HEATER POWER TERMINAL BLOCK ELECTRONICS CABLE (TO ELECTRONICS HOUSING) SENSOR/THERMOCOUPLE TERMINAL BLOCK (1) (2) (3) (4) (5) (6) YELLOW RED YELLOW RED BLUE WHITE GREEN WHITE YELLOW WHITE RED WHITE PURPLE ORANGE BLACK GRAY BROWN RED ELECTRONICS CABLE PORT O2 T/C + O2 T/C - PROBE SL T/C + SL T/C - O2 MV + O2 MV - RED WHITE BLUE COMB ACTIVE + COMB ACTIVE - COMB REF + COMB REF - COMB DRIVE COMB RETURN Figure 7-2. Sensor Housing Terminal Blocks b. with Split Mounted Electronics 1. Remove Sensor Housing. (a) Turn power off to the system. (b) Shut off the calibration gases at the cylinders and the instrument air. (c) Disconnect calibration gas, reference air, eductor air, and dilution air lines from the sensor housing. (d) Remove the cover from the sensor housing to expose the sensor housing terminal blocks, Figure 7-2. (e) Disconnect the electronics cable from sensor/thermocouple terminal block and the heater power terminal block. (f) Remove insulation to access the mounting bolts. Unbolt the sensor housing from the stack and take it to a clean work area. (g) Allow the sensor housing to cool to a comfortable working temperature. 2. Replace Sensor Housing (a) Bolt the sensor housing to the stack and install insulation. (b) With the cover removed, connect the electronics cable to sensor/ thermocouple terminal block and the heater power terminal block, Figure 7-2. Install sensor housing cover. (c) Connect the calibration gas, reference air, eductor air, and dilution air lines to the sensor housing. (d) Turn on the calibration gases at the cylinders and instrument air. (e) Restore power to the system. Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-3

54 Instruction Manual SPLIT-ELECTRONICS HOUSING (COVER REMOVED) HEATER POWER TERMINAL BLOCK ELECTRONICS CABLE PORT PURPLE ORANGE BLACK GRAY BROWN RED SENSOR/THERMOCOUPLE TERMINAL BLOCK SL HEATER L2 O2 CELL HEATER L2 COMB CELL HEATER L2 ELECTRONICS CABLE (UP TO 150 FT) NOTE: KEEP TWISTED PAIRS TOGETHER (1) (2) (3) (4) (5) (6) YELLOW RED YELLOW RED BLUE WHITE O2 T/C + O2 T/C - GND SL T/C + SL T/C - O2 MV + O2 MV - GND GREEN WHITE YELLOW WHITE COMB ACTIVE + COMB ACTIVE - COMB REF + COMB REF - Figure 7-3. Split-Electronics Housing Cable Connections GND RED WHITE COMB DRIVE COMB RETURN PRESSURE SENSOR FACTORY WIRED PR SENSOR - PR SENSOR PR SRC PR SRC RTN Remove Split-Electronics Housing. (a) Turn power off to the system. (b) Shut off the calibration gases at the cylinders and the instrument air. (c) Disconnect the three calibration gas input lines and instrument air line from the split-electronics housing. Disconnect the calibration gas outlet and instrument air outlet lines from the split-electronics housing. (d) Remove the cover from the electronics housing to expose the electronics housing terminal blocks, Figure 7-1. (e) Disconnect and remove the two power leads from the AC power input terminal block. Remove the ground lead from the ground stud. (f) Disconnect and remove the O 2 and COMB 4-20 ma signal leads from the 4-20 ma signal output terminal block. (g) If used, disconnect and remove the external relay leads from the alarm output relay terminal. (h) Disconnect the electronics cable from sensor/thermocouple terminal block and the heater power terminal block, Figure 7-3. (i) Remove the split-electronics housing from mounting and move to a suitable work area. 7-4 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

55 Instruction Manual 4. Replace Split-Electronics Housing. (a) Mount split-electronics housing on wall or pole within distance of electronics cable used. Remove cover. (b) Connect electronics cable to the sensor/thermocouple and heater power terminal blocks, Figure 7-3. (c) Connect the line, or L wire, to the L terminal, and the neutral, or N wire, to the N terminal on the AC power input terminal block in the electronics housing. Connect the ground, or G wire, to the ground stud in the electronics housing. Secure the connection with two nuts. Attach a separate line from the ground stud to the G terminal on the power input terminal block. (d) Connect the O 2 and COMB 4-20 ma signal leads to the 4-20 ma signal output terminal block. (e) If used, connect external relay leads to the alarm output relay terminal. (f) Replace cover on electronics housing. (g) Connect the three calibration gas input lines and the instrument air input line to the split-electronics housing. Connect the calibration gas outlet line and instrument air outlet line to the split-electronics housing. (h) Turn on the calibration gasses at the cylinders and instrument air. (i) Restore power to the system. 7-3 SENSOR HOUSING COMPONENT REPLACEMENT Each of the following procedures details how to remove and replace a specific component located in the sensor housing of the. a. O 2 Cell Replacement This paragraph covers oxygen sensing cell replacement. Do not attempt to replace the cell until all other possibilities for poor performance have been considered. If cell replacement is needed, order the O 2 cell replacement kit (Table 10-1). The O 2 cell replacement kit contains an O 2 cell and flange assembly, gaskets, socket head cap screws, and anti-seize compound. The items are carefully packaged to preserve precise surface finishes. Do not remove items from the packaging until they are ready to be used. Use heat-resistant gloves and clothing when removing the. Do not attempt to work on any sensor housing components until they have cooled to room temperature. Components can be as hot as 2600 F (1427 C). This can cause severe burns. Disconnect and lock out power before working on any electrical components. There may be voltage up to 264 VAC. Do not remove the O 2 cell unless certain it needs to be replaced. Removal may damage the cell and platinum pad. Only remove the O 2 cell if it is to be replaced. 1. Follow the instructions in paragraph 7-2a.1 to remove the from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.1 to remove the sensor housing. 2. Remove sensor housing cover (1, Figure 7-4). 3. Remove reference air tube (2) from sensor housing (24). 4. Disconnect and tag all O 2 assembly (3) wire leads from the sensor housing terminal blocks. 5. Remove the O 2 assembly (3) from sensor housing (24). Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-5

56 Instruction Manual NOTES: 1. NOT ALL ITEMS IDENTIFIED ARE AVAILABLE FOR SALE. SEE SECTION 10, REPLACEMENT PARTS, FOR A LIST OF AVAILABLE PARTS. 2. EXHAUST TUBE (30) MUST BE INSTALLED IN FLANGE PORT NEAREST TO THE BLOWBACK FILTER HOUSING Cover 2. Reference Air Tube 3. O 2 Assembly 4. Gasket 5. Internal Ring 6. Eductor Air Tube 7. Dilution Air Tube 8. Screw 9. Washer 10. Bracket 11. COMB Extractive Tube 12. Heater 13. Screw 14. Plate 15. COMB Sensor 16. Gasket 17. Preheater 18. Thermocouple 19. Heater 20. Heater Clamp 21. Connector 22. Eductor 23. COMB Sensor Holder 24. Sensor Housing 25. Sample Tube 26. Sample Filter 27. Adapter 28. Check Valve (w/ blowback only) 29. Plug (w/out blowback) 30. Exhaust Tube 30 BLOWBACK FILTER HOUSING Figure 7-4. Sensor Housing, Exploded View 7-6 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

57 Instruction Manual 6. Remove four allen cap screws (14, Figure 7-5) from O 2 cell (13) and remove O 2 cell and gasket (12). The cell flange has a notch that may be used to gently pry the flange away from heater tube (11). Note that the pad on the end of contact/thermocouple assembly (4) will sometimes fuse to O 2 cell (13). If the O 2 cell is fused to the contact pad, push the O 2 cell back into the heater tube (against spring pressure) and quickly twist the O 2 cell. The cell and contact pad should separate. If the contact pad stays fused to the cell, a new contact/thermocouple assembly must be installed. 7. Remove and discard gasket (12). Clean the mating surface of heater tube (11). Remove burrs and raised surfaces with a block of wood and crocus cloth. 8. Rub a small amount of anti-seize compound on both sides of new gasket (12). 9. Assemble O 2 cell (13), gasket (12), and heater tube (11). Make sure the calibration gas passage holes line up with each other in all components. Apply a small amount of anti-seize compound to the screw threads and use screws (14) to secure assembly. Torque to 35 in-lbs (4 N m). 10. Apply anti-seize compound to threads of O 2 assembly (3, Figure 7-4) and sensor housing (24). Replace graphoil gasket (4) with new gasket in kit. Reinstall O 2 assembly in sensor housing. 11. Reconnect the wire leads from O 2 assembly (3) to the sensor housing terminal blocks. Refer to Figure 7-2 if necessary. 12. Replace reference air tube (2) in sensor housing (24). Ensure that the open end of reference air tube extends into O 2 assembly (3). 13. Follow the instructions in paragraph 7-2a.2 to install the into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b Turn on power and after the stabilizes, calibrate the unit. If new components have been installed, repeat calibration after 24 hours of operation. b. O 2 Heater Strut Assembly and Contact/Thermocouple Assembly Replacement This paragraph covers O 2 heater strut and contact/thermocouple replacement. If heater strut or contact/thermocouple replacement is needed, order the replacement parts from Table Use heat-resistant gloves and clothing when removing the. Do not attempt to work on any sensor housing components until they have cooled to room temperature. Components can be as hot as 2600 F (1427 C). This can cause severe burns. Disconnect and lock out power before working on any electrical components. There may be voltage up to 264 VAC. 1. Follow the instructions in paragraph 7-2a.1 to remove the from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.1 to remove the sensor housing. 2. Remove sensor housing cover (1, Figure 7-4). 3. Remove reference air tube (2) from sensor housing (24). 4. Disconnect and tag O 2 assembly (3) wire leads from the sensor housing terminal blocks. 5. Remove four screws (1, Figure 7-5) and washers (2) securing O 2 heater strut assembly (3) to heater tube (11). The spring tension should release and the heater strut assembly moves up. 6. Carefully slide heater strut assembly (3) out of heater tube (11). Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-7

58 Instruction Manual 4 NOTE: NOT ALL ITEMS IDENTIFIED ARE AVAILABLE FOR SALE. SEE SECTION 10, REPLACEMENT PARTS, FOR A LIST OF AVAILABLE PARTS Screw 2. Washer 3. O 2 Heater Strut Assembly 4. Contact/Thermocouple Assembly 5. Strut Bracket 6. Spring 7. Spring Clip 8. Screw 9. Washer 10. Heater Assembly 11. Heater Tube 12. Gasket 13. O 2 Cell 14. Cap Screw 15. Cell Kit (includes 12, 13, and 14) Figure 7-5. O 2 Assembly, Exploded View 7-8 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

59 Instruction Manual Use care when handling contact and thermocouple assembly. The ceramic rod in this assembly is fragile. 7. If replacing contact/thermocouple assembly (4), use a pencil to mark location of spring clip (7) before removing. Squeeze tabs on spring clip to remove. Retain spring clip and spring (6); replace if damaged. 8. While carefully handling new contact and thermocouple assembly (4), lay old assembly next to new one. Transfer pencil marks to new assembly. 9. Carefully guide new contact and thermocouple assembly (4) through strut bracket (5), spring (6), and spring clip (7) until spring clip reaches pencil mark. 10. Carefully slide new O 2 heater strut assembly (3) into heater tube (11). Press down on the back plate of strut bracket (5) to ensure spring (6) tension is present to hold contact pad against O 2 cell (13). Secure with four screws (1) and washers (2). 11. Reconnect the O 2 assembly wire leads to the sensor housing terminal blocks. Refer to Figure 7-2 if necessary. 12. Replace reference air tube (2, Figure 7-4) in sensor housing (24). Ensure the open end of the reference air tube extends into O 2 assembly (3). 13. Replace sensor housing cover (1). 14. Follow the instructions in paragraph 7-2a.2 to install the into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.2. c. COMB Sensor Replacement This paragraph covers combustible sensor replacement. Do not attempt to replace the sensor until all other possibilities for poor performance have been considered. If sensor replacement is needed, order the combustibles sensor replacement kit from Table Use heat-resistant gloves and clothing when removing the. Do not attempt to work on any sensor housing components until they have cooled to room temperature. Components can be as hot as 2600 F (1427 C). This can cause severe burns. Disconnect and lock out power before working on any electrical components. There may be voltage up to 264 VAC. 1. Follow the instructions in paragraph 7-2a.1 to remove the from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.1 to remove the sensor housing. 2. Remove sensor housing cover (1, Figure 7-4). 3. Disconnect and tag the four wire leads from COMB sensor (15) to the sensor/thermocouple terminal block. 4. Remove two screws (13) securing plate (14) to holder (23). Remove the plate. 5. Remove old COMB sensor (15) and gasket (16). Replace with new COMB sensor and gasket from replacement kit. Use care when handling the new combustibles sensor. The RTDs are fragile. 6. Secure new COMB sensor (15) with plate (14) to holder (23) with two screws (13). 7. Reconnect the four wire leads from COMB sensor (15) to the sensor/thermocouple terminal block. Refer to Figure 7-2 if necessary. 8. Replace sensor housing cover (1, Figure 7-4). 9. Follow the instructions in paragraph 7-2a.2 to install the into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.2. Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-9

60 Instruction Manual 10. Turn on power and monitor COMB sensor output. After the stabilizes, calibrate the unit. If new components have been installed, repeat calibration after 24 hours of operation. 7-4 ELECTRONICS HOUSING COMPONENT REPLACEMENT Each of the following procedures details how to remove and replace a specific component located in the electronics housing of the OCX Disconnect and lock out power before working on any electrical components. There may be voltage up to 264 VAC. a. Solenoid Replacement The has three optional calibration gas solenoids (HI COMB, HI O 2, LO O 2 ) and a standard, 3-way instrument air solenoid. Use the following procedure to replace one of four solenoids (11, Figure 7-6) in the electronics housing. The replacement procedure for all solenoids is similar. 1. Follow the instructions in paragraph 7-2a to remove the from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.3 to remove the electronics housing. 2. Tag and disconnect wire leads from solenoid (11, Figure 7-6) to be replaced at the solenoid power terminal block. 3. Remove top nut of solenoid (11) securing the coil assembly and washer to the solenoid base. Remove the coil assembly, including the leads, and washer. Place a 13/16 in. deep socket over the solenoid base and remove from electronics housing base (12). When installing a solenoid, do not overtighten. Damage to the solenoid may occur. 4. Install the new solenoid base. Be careful not to overtighten. Install the new washer and coil assembly and secure with the top nut. 5. Connect the leads to the proper terminations on the solenoid power terminal block. Refer to Figure 2-6 if necessary. 6. Follow the instructions in paragraph 7-2a.2 to install the into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.4 to install electronics housing. b. Pressure Sensor Replacement Use the following procedure to replace pressure sensor (10, Figure 7-6). 1. Follow the instructions in paragraph 7-2a to remove the from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.3 to remove the electronics housing. 2. Tag and remove pressure sensor (10) leads from sensor/thermocouple terminal block. 3. Place a 3/4 in. deep socket over pressure sensor (10) and remove from electronics housing base (12). When installing the pressure sensor, do not overtighten. Damage to the pressure sensor may occur. 4. Install new pressure sensor (10) into electronics housing base (12). 5. Connect leads to the proper terminations on the sensor/thermocouple terminal block. Refer to Figure 2-7 if necessary Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

61 Instruction Manual NOTES: NOT ALL ITEMS IDENTIFIED ARE AVAILABLE FOR SALE. SEE SECTION 10, REPLACEMENT PARTS, FOR A LIST OF AVAILABLE PARTS Cover 2. Screw 3. Local Operator Interface 4. Washers 5. Spacer 6. Connector 7. Electronics Package 8. Screw 9. Washer 10. Solenoid 11. Housing Base 12. Fitting 13. Screw 14. Nameplate 15. Instrument Air Solenoid 16. Vent Tube Figure 7-6. Electronics Housing Exploded View 6. Follow the instructions in paragraph 7-2a.2 to install the into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.4 to install electronics housing. c. Electronics Package Replacement Use the following procedure to replace the electronics package (7, Figure 7-6). 1. Follow the instructions in paragraph 7-2a.1 to remove the from the stack or duct. If removing a splitmounted unit, follow the instructions in paragraph 7-2b.3 to remove the electronics housing. 2. Disconnect and tag wire leads from solenoids and the pressure sensor to the solenoid power and sensor/ thermocouple terminal blocks. Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 7-11

62 Instruction Manual 3. If replacing components on an integral electronics mounted unit, disconnect and tag wire leads from the sensor housing at the sensor/thermocouple, heater power, and solenoid power terminal blocks. 4. Remove four screws (8, Figure 7-6) and washers (9) securing electronics box (7) to electronics housing base (12). Remove the electronics package. 5. If equipped, install local operator interface (3, Figure 7-6) to electronics package (7) with three screws (2), double washers (4), spacers (5), and connector (6). 6. If replacing components on an integral electronics mounted unit, connect wire leads from the sensor housing to sensor/thermocouple, heater power, and solenoid power terminal blocks. 7. Connect wire leads from the solenoids and the pressure sensor to the solenoid power and sensor/thermocouple terminal blocks. 8. Follow the instructions in paragraph 7-2a.2 to install the into the stack or duct. If installing a splitmounted unit, follow the instructions in paragraph 7-2b.4 to install electronics housing. d. Fuse Replacement The has two fuses (1 and 3, Figure 7-7). The power supply fuse, F1, is to the left of the AC power terminal block. The heater fuse, F2, is to the right of the AC power terminal block. Both fuses are accessible through holes in the electronics box. Refer to Table 10-1 for replacement fuse specifications. Perform the following procedure to check or replace fuses. Disconnect and lock out power before working on any electrical components. There may be voltage up to 264 VAC. 1. Turn off power to the system. 2. Remove electronics housing cover (1, Figure 7-6). 3. Remove fuseholder (2, Figure 7-7) by pushing in and turning 1/4 turn counterclockwise. Remove fuse (1 or 3). 4. After checking or replacing fuse (1 or 3), install fuseholder (2) by pushing in and turning 1/4 turn clockwise. ELECTRONICS HOUSING 1. Fuse Heater, F2 2. Fuse Holder 3. Fuse Power Supply, F1 3 1 Figure 7-7. Fuses, Exploded View Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

63 Instruction Manual SECTION 8 TROUBLESHOOTING Install all protective equipment covers and safety ground leads after troubleshooting. Failure to install covers and ground leads could result in serious injury or death. 8-1 GENERAL The troubleshooting section describes how to identify and isolate faults that may develop in the. When troubleshooting the OCX 4400, reference the following information. a. Grounding It is essential that adequate grounding precautions are taken when installing the system. Thoroughly check both the probe and electronics to ensure the grounding quality has not degraded during fault finding. The system provides facilities for 100% effective grounding and the total elimination of ground loops. b. Electrical Noise The has been designed to operate in the type of environment 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 system. Also, ensure all cable shields are connected to earth. c. Loose Integrated Circuits The uses a microprocessor and supporting integrated circuits (IC). If the electronics are handled roughly during installation or located where subjected to severe vibration, the ICs could work loose. Before troubleshooting the system, ensure all ICs are fully seated. d. Electrostatic Discharge Electrostatic discharge can damage the ICs used in the electronics. Before removing or handling the processor board or the ICs, ensure you are at ground potential. 8-2 ALARM OUTPUT a. The 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, 2 Amp maximum. Any fault condition in the OCX 4400 will trip the alarm relay. b. The optional SPA with HART programmable alarm indicates LOW O 2, HIGH COMB, Calibration Status, and Unit Failure. For more information refer to Appendix B, SPA with HART Alarm. 8-3 FAULT ISOLATION Faults in the Transmitter are indicated by messages displayed on the HART communicator or LOI. Fault indications that can appear are listed in the PROBLEM column of Table 8-1, Troubleshooting. If a fault is indicated on the HART communicator or LOI, locate the fault indication in the PPO- BLEM column of Table 8-1. For each fault listed, there are related PROBABLE CAUSES and RECOMMENDED CORRECTIVE ACTIONS. The PROBABLE CAUSES are listed in the order of most probable to least probable. Starting with the most probable cause, inspect and test the unit to isolate the actual cause, then use the RECOMMENDED CORRECTIVE ACTION listed to correct the problem. Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 8-1

64 Instruction Manual Table 8-1. Troubleshooting PROBLEM PROBABLE CAUSE RECOMMENDED CORRECTIVE ACTION O 2 Thermocouple Error (thermocouple voltage out of limits) O 2 Cell Temperature Low (< 726 C) O 2 Cell Temperature High (> 746 C) or Very High (> 820 C) O 2 Heater Open O 2 Cell Circuit Open or O 2 Cell Bad O 2 thermocouple or thermocouple circuit open O 2 thermocouple or thermocouple circuit shorted O 2 thermocouple wires reversed Sensor housing exposed to wind or very cold temperatures. O 2 cell heater open Heater electronics failure Transmitter in warmup mode High noise in OCX power supply Electronics package power supply failure O 2 heater or heater circuit wiring open. Transmitter in powerup or warm-up mode Loose or open O 2 cell lead or circuit wire connection O 2 cell failure Very low O 2 concentration in process gas Check O 2 thermocouple and circuit wires for breaks or loose connection. Repair break or loose connection or replace failed thermocouple. Cycle OCX power to resume operation. Check O 2 thermocouple and thermocouple circuit wires for short circuit condition. Repair shorted wiring or replace faulty thermocouple. Cycle OCX power to resume operation. Check O 2 thermocouple wiring per Figure 2-7. Correct reversed-wires fault. Cycle OCX power to resume operation. Install sensor housing insulating jacket. Check O 2 cell heater circuit for broken wire or loose connection. Repair broken wire or loose connection. Check heater fuse F2 in electronics housing. If open, locate and correct cause of overload. If F2 is not open or if cause of overload cannot be found, replace electronics package. During warm-up, heater temperature rise may surpass heater control response. Cycle power to resume operation. Check power supply for line noise or voltage surges. Install high quality line filter if high noise or voltages are indicated. Replace electronics package. Check O 2 cell heater circuit for broken wire or loose connection. Repair broken wire or loose connection. Check resistance of the O 2 cell heater; heater resistance should be less than 100 ohms. Replace heater if heater coil circuit is open. During power-up and warm-up, low heater temperature give false O 2 indication. Cycle power to resume operation. Check O 2 cell tip and cell circuit wires for breaks or loose connection. Repair cell lead wire break or loose connection. Check O 2 cell impedance value at LOI (see Figure A-3, sheet 2). If cell impedance is zero, replace O 2 cell. If cell impedance is less than 500 ohms, check for cell housing ground fault. Repair ground fault. If cell impedance is greater than 500 ohms and no ground fault is indicated, replace O 2 cell. Cycle power to resume operation. 8-2 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

65 Instruction Manual Table 8-1. Troubleshooting (Continued) PROBLEM PROBABLE CAUSE RECOMMENDED CORRECTIVE ACTION O 2 Slope Error (O 2 slope > 57.5 or < 34.5 mv/dec) O 2 Constant Error (> 20 mv or < 20 mv) or O 2 Calibration Failed High Electronics Temperature (> 85 C) EEPROM Corrupt Sample Line Thermocouple Error (voltage out of limits) Calibration gas supply low or gas connection leaking O 2 cell degraded O 2 cell failure Calibration gas supply low or gas connection leaking O 2 cell degraded O 2 cell failure Electronics housing exposed high ambient temperature. Unit powered down during calibration parameter storage EEPROM failure Sample line thermocouple wires reversed. Sample line thermocouple or thermocouple circuit open. Sample line thermocouple or wiring circuit shorted. Check calibration gas supplies and connections. Adjust gas pressure and flow. Replenish low calibration gas supplies and tighten or repair loose or leaking connections. When calibration gas supplies are adequate, recalibrate. Recalibrate the OCX. Check O 2 cell impedance value at LOI (see Figure A-3, sheet 2). If cell impedance is zero, replace O 2 cell. If cell impedance is less than 500 ohms, check for cell housing ground fault. Repair ground fault. If cell impedance is greater than 500 ohms and no ground fault is indicated, replace O 2 cell. Check calibration gas supplies and connections. Adjust gas pressure and flow. Replenish low calibration gas supplies and tighten or repair loose or leaking connections. When calibration gas supplies are adequate, recalibrate. Recalibrate the OCX. Check O 2 cell impedance value at LOI (see Figure A-3, sheet 2). If cell impedance is zero, replace O 2 cell. If cell impedance is less than 500 ohms, check for cell housing ground fault. Repair ground fault. If cell impedance is greater than 500 ohms and no ground fault is indicated, replace O 2 cell. Insulate housing from source of high temperature and/or install cooling fan to remove heat from housing. Cycle OCX power to resume operation. With power on, wait five minutes, cycle power and recalibrate the OCX. Replace EEPROM. Check thermocouple wiring per Figure 2-7. Correct reversed-wires fault. Cycle OCX power to resume operation. Check thermocouple and thermocouple circuit wires for breaks or loose connection. Repair break or loose connection or replace failed thermocouple. Cycle OCX power to resume operation. Check thermocouple and thermocouple circuit wires for short circuit condition. Repair shorted wiring or replace faulty thermocouple. Cycle OCX power to resume operation. Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 8-3

66 Instruction Manual Table 8-1. Troubleshooting (Continued) PROBLEM PROBABLE CAUSE RECOMMENDED CORRECTIVE ACTION Sample Line Temperature Low (< 155 C; unit not in warmup mode) Sample Line Temperature High (> 195 C) or Very High (> 220 C) Combustibles Cell Error (cell temp. < 40 C; mv or > 400 C; mv ref. side or active side) Combustibles Temperature Low (< 290 C; unit not in warmup mode) Combustibles Temperature High (> 310 C) or Very High (> 400 C) Sensor housing exposed to wind or very cold temperatures. Sample line heater open Heater electronics failure Transmitter in warmup mode High noise in OCX power supply Electronics package power supply failure COMB sensor circuit wiring COMB sensor RTD shorted or open (reference or active) Electronics package power supply failure Sensor housing exposed to wind or very cold temperatures. COMB cell heater open Heater electronics failure Transmitter in warmup mode Large rise in COMB concentration. High noise in OCX power supply Electronics package power supply failure Install sensor housing insulating jacket. Check sample line heater circuit for broken wire or loose connection. Repair broken wire or loose connection. Check heater fuse F2 in electronics housing. If open, locate and correct cause of overload. If F2 is not open or if cause of overload cannot be found, replace electronics package. During warm-up, heater temperature rise may surpass heater control response. Cycle power to resume operation. Check power supply for line noise or voltage surges. Install high quality line filter if high noise or voltages are indicated. Replace electronics package. Check COMB sensor circuit for broken wire or loose connection. Repair broken wire or loose connection. Check RTD resistance (lead to ground) of reference and active RTDs. If either RTD is open or shorted to ground, replace COMB sensor. Replace electronics package. Install sensor housing insulating jacket. Check COMB cell heater circuit for broken wire or loose connection. Repair broken wire or loose connection. Check heater fuse F2 in electronics housing. If open, locate and correct cause of overload. If F2 is not open or if cause of overload cannot be found, replace electronics package. During warm-up, heater temperature rise may surpass heater control response. Cycle power to resume operation. High temperature rise in cell may surpass heater control response. Cycle power to resume operation. Check power supply for line noise or voltage surges. Install high quality line filter if high noise or voltages are indicated. Replace electronics package. 8-4 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

67 Instruction Manual Table 8-1. Troubleshooting (Continued) PROBLEM PROBABLE CAUSE RECOMMENDED CORRECTIVE ACTION Combustibles Slope Error (< 0 or > 3000 ppm/mv) or Combustibles Constant Error or Combustibles Calibration Failed (slope error during last calibration) Calibration gas supply low or gas connection leaking O 2 cell degraded O 2 cell failure Check calibration gas supplies and connections. Adjust gas pressure and flow. Replenish low calibration gas supplies and tighten or repair loose or leaking connections. When calibration gas supplies are adequate, recalibrate. Recalibrate the OCX. Check O 2 cell impedance value at LOI (see Figure A-3, sheet 2). If cell impedance is zero, replace O 2 cell. If cell impedance is less than 500 ohms, check for cell housing ground fault. Repair ground fault. If cell impedance is greater than 500 ohms and no ground fault is indicated, replace O 2 cell. Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 8-5

68 Instruction Manual 8-6 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

69 Instruction Manual SECTION 9 RETURN OF MATERIAL 9-1 If factory repair of defective equipment is required, proceed as follows: a. Secure a return authorization number from a Rosemount Analytical Sales Office or representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted. In no event will Rosemount be responsible for equipment returned without proper authorization and identification. b. Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to insure that no additional damage will occur during shipping. c. In a cover letter, describe completely: 1. The symptoms from which it was determined that the equipment is faulty. 2. The environment in which the equipment has been operating (housing, weather, vibration, dust, etc.). 3. Site from which equipment was removed. 4. Whether warranty or nonwarranty service is requested. 5. Complete shipping instructions for return of equipment. 6. Reference the return authorization number. d. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Rosemount Return Authorization, prepaid, to: Rosemount Analytical Inc. RMR Department 1201 N. Main Street Orrville, Ohio If warranty service is requested, the defective unit will be carefully inspected and tested at the factory. If failure was due to conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount's option, and an operating unit will be returned to the customer in accordance with shipping instructions furnished in the cover letter. For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions. Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 9-1

70 Instruction Manual 9-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

71 Instruction Manual SECTION 10 REPLACEMENT PARTS Table Replacement Parts FIGURE and INDEX No. PART NUMBER DESCRIPTION 1-1, 2 275D9EI5D HART Communicator with 12 meg buffer 1-1, B30G02 Adapter Plate 218 w/shield to ANSI OCX 1-1, B30G08 FLG Adapter Assembly, 132 to ANSI OCX 1-1, B31G01 OCX/132 Adapter Plate (DIN) 1-1, 5 263C152G01 Reference Gas Set, includes: 771B635H01 Flowmeter, SCFH 771B635H08 Flowmeter, SCFH 1A99422H01 Pressure Regulator/Filter, 0 60 psig Pressure Gage, 2 in., 0 60 psi 1-1, 6 1A99518G01 Blowback Kit B41G01 Cable, 20 ft. (6m) NEMA B41G02 Cable, 40 ft. (12m) NEMA B41G03 Cable, 60 ft. (18m) NEMA B41G04 Cable, 80 ft. (24m) NEMA B41G05 Cable, 100 ft. (30m) NEMA B41G06 Cable, 150 ft. (45m) NEMA B18H02 ANSI Gasket 2-8 1A99119G05 Test Gas Regulator Kit 2-8 1A99119G04 Test Gas Bottles Kit 2-8 1A99119H01 Oxygen Bottle 0.4%, Balance N A99119H02 Oxygen Bottle 8.0%, Balance N A99119H06 CO Bottle 1000 ppm, Balance N A99120H02 Regulator for Oxygen 2-8 1A99120H03 Regulator for Combustibles 1A99119G06 Wall Mount Bracket for Gas Bottles (not shown) 7-4, 1 5R10219G01 Cover, Sensor Housing 7-4, 3 and 7-5, B45G01 O 2 Cell Replacement Kit 7-4, 12 1A99371H01 Combustibles Chamber Heater 7-4, 13 thru B46G01 Combustibles Sensor Replacement Kit 7-4, 18 1A98151H03 Sample Line Thermocouple Assembly 7-4, 19 1A99371H02 Sample Line Heater 7-4, 25 5R10183H02 Tube, Sample, 18 in. (457mm) 316 Stainless steel 7-4, 25 5R10183H06 Tube, Sample, 18 in. (457mm) Inconel , 25 5R10227G01 Tube, Sample, 18 in. (457mm) Ceramic 7-4, 25 5R10183H03 Tube, Sample, 3 ft. (0.91m) 316 Stainless steel 7-4, 25 5R10183H07 Tube, Sample, 3 ft. (0.91m) Inconel , 25 5R10227G02 Tube, Sample, 3 ft. (0.91m) Ceramic 7-4, 25 5R10183H04 Tube, Sample, 6 ft. (1.83m) 316 Stainless steel 7-4, 25 5R10183H08 Tube, Sample, 6 ft. (1.83m) Inconel , 25 5R10183H05 Tube, Sample, 9 ft. (2.7m) 316 Stainless steel 7-4, 26 5R10246H02 Filter, 20 micron 7-4, 30 5R10183H01 Tube, Exhaust Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 10-1

72 Instruction Manual Table Replacement Parts (Continued) FIGURE and INDEX No. PART NUMBER DESCRIPTION 7-5, 3 5R10211G01 Heater Strut Assembly 7-5, B44G01 Contact and Thermocouple Assembly 7-6, 1 5R10199G01 Cover, Electronics Housing 7-6, B49G02 Local Operator Interface 7-6, 7 5R10214G01 Electronics Package 7-6, 11 1A97905H01 Solenoid Valve, Cal. Gas 7-6, 16 1A97905H02 Solenoid Valve, Instrument Air 7-7, 1 1A97913H18 Heater Fuse, Slo-Blo, 6.3 amp, 250 VAC, F2 7-7, 3 1A97913H04 Power Supply Fuse, Slo-Blo, 1.0 amp, 250 VAC, F1 B-1 1A99292H01 Moore Industries SPA for HART Alarm C-1 1A99339H03 Blowback Valve, Air Operated D-1 1A99376H01 IS Barrier Module, Model MTL 5046 D-1 1A99698G01 Intrinsic Safety Barrier Kit 10-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

73 Instruction Manual SECTION 11 APPENDICES APPENDIX A APPENDIX B APPENDIX C APPENDIX D LOCAL OPERATOR INTERFACE (LOI) SPA WITH HART ALARM BLOWBACK IS BARRIER Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 11-1

74 Instruction Manual 11-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

75 Instruction Manual Appendix A Rev 2.0 APPENDIX A LOCAL OPERATOR INTERFACE (LOI) A-1 FORWARD This appendix describes the installation and operation of the Local Operator Interface (LOI) for the. A-2 INSTALLATION The LOI mounts to the LOI connector on the LOI board located at the end of the electronics box in the electronics housing of an Oxygen/Combustibles Transmitter Figure A-1. There are four matching connectors on the back of the LOI assembly that allow the LOI to be oriented as desired by the user. ELECTRONIC HOUSING (COVER REMOVED) LOI CONNECTOR LOI ASSEMBLY LOI BOARD ELECTRONICS BOX Figure A-1. LOI Assembly Mounting Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-1

76 Instruction Manual Appendix A Rev. 2.0 A-3 OPERATION The LOI assembly, Figure A-2, allows local communication with the electronics. The LOI uses infrared sensors near the selection arrows to move the cursor between menus and menu items. The LCD display window shows the operating display, which consists of the O 2 % and COMB ppm, current menu, or item selected. When a blinking cursor is displayed, the UP or DOWN arrows can be used to increase or decrease the value for that item. SELECTION ARROWS LCD DISPLAY WINDOW A-4 LOI MENU TREE This section consists of a menu tree for the LOI on the, Figure A-3. This menu is specific to the. a. First Column Sub-Menus From the operating display, O 2 % and COMB ppm, the left-pointing arrow is the only option to move into the first column sub-menus of the LOI menu tree. The first column contains three sub-menus: SENSOR DATA, Figure A-3 sheet 1 of 3, CALIBRATE, sheet 2 of 3, and SETUP, sheet 3 of 3. From the operating display, SENSOR DATA is displayed when the right arrow is selected. Use the up or downpointing arrow to move to the other first column sub-menus. b. Second Column Sub-Menus From the first column sub-menus, selecting the right-pointing arrow moves the display into the second column sub-menus. The up and down-pointing arrows allow the display to move to the second column sub-menus of the first column sub-menu selected. The left-pointing arrow moves the display back to the first column sub-menu. c. Third, and Fourth Column Sub-Menus SELECTION ARROWS Figure A-2. Local Operator Interface (LOI) Assembly From the second column sub-menus, selecting the right-pointing arrow moves the display into the third column sub-menus. The third column sub-menu may be another menu or a list of parameters. The up and down-pointing arrows allow the display to move to the different parameters or menus. The third or fourth column may be a parameter list. When a parameter list is displayed, the cursor will blink. The up and down-pointing arrows select the value for the parameter displayed. A-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

77 Instruction Manual Appendix A Rev 2.0 Temp/ Pressure O2 Sensor dgc Comb Sensor dgc Sample Block Temp dgc Sample Block Press psi Electronics Max Elect Temp dgc O2% X.XX% Comb % XXX Sensor O2 Sensor mv ppm Data O2 Sensor T/C mv Comb Delta mv Voltages Comb Reference mv Elect Temp V Smpl Blok T/C mv Smpl Line Pres V Output Values O2 Analog % Comb Analog % O2 Analog ma ma Comb Analog ma ma (CONTINUED ON SHEET 2) Figure A-3. Menu Tree for Local Operator Interface on the (Sheet 1 of 3) Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-3

78 Instruction Manual Appendix A Rev. 2.0 (CONTINUED FROM SHEET 1) Calibrate Do Calibrate O2 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 ready Flow O2 Hi s % mv Read O2 Hi s % mv Hit E when ready Purge s O2 Calibration Pass/Fail Combustibles Apply Lo CO Gas Hit E when ready Flow CO Lo s % mv Read CO Lo s % mv Apply Hi CO Gas Hit E when ready Flow CO Hi s % mv Read CO Hi s % mv Hit E when ready Purge s (CONTINUED ON SHEET 3) NOTE: Hit E when ready prompt is displayed during semiautomatic calibration only (when Setup Calibration value Got Solenoids = n ). Both 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 ready Flow O2 Hi s % mv Read O2 Hi s % mv Hit E when ready Purge s Apply Lo CO Gas Hit E when ready Flow CO Lo s % mv Read CO Lo s % mv Apply Hi CO Gas Hit E when ready Flow CO Hi s % mv Read CO Hi s % mv Hit E when ready Purge s View Constants Calib Status Latest Calib Prev Calib Calibrate Step Calibrate Time O2 Next Calib O2 Slope O2 Constant Comb Next Cal Comb Slope Comb Constant O2 Slope mv/d O2 Constant mv O2 Cell Imped Comb Slope ppm/mv Comb Constant mv Pre O2 Slope mv/d Pre O2 Const mv Pre Co Slope ppm/mv Pre Co Const mv Figure A-3. Menu Tree for Local Operator Interface (LOI) on the (Sheet 2 of 3) A-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

79 Instruction Manual Appendix A Rev 2.0 (CONTINUED FROM SHEET 2) SETUP CALIBRATION O2 High Gas % O2 O2 Low Gas % O2 Comb Test Gas % O2 Got Solenoids Yes/No O2 Output Tracks Yes/No Comb Out Tracks Yes/No O2 Cal Interval XDXH O2 Next Cal XH Comb Cal Interval XDXH Comb Next Cal XH Gas Time 0:00 Purge Time 0:00 PARAMETERS Line voltage O2 Slope mv/d O2 Constant mv Comb Slope Comb Constant BLOWBACK Blow Bk Present Yes/No Blow Bk Intvl min Blow Bk Durat sec Blow Bk Purge 999 sec Do Blow Back Yes/No ALARM RELAY ANALOG OUTPUTS Trigger 1 Event Trigger 2 Event Trigger 3 Event O2 Type 20-4 ma 4-20 ma Comb Type 20-4 ma 4-20 ma HART Off All Comb Temp Sample Pr Sen Sample Ln Temp Unit Fail Hi Elect Temp Calib Fail O2 Cell Bad O2 Htr Open O2 Cell Temp In Calibrtn Off O2 Range 0-VAR (40% Max.) Comb Range 50,000 ppm Do O2 Out Trim Do COMB Out Trim SOFTWARE Version Checksum Build Number Build Date Test Code Figure A-3. Menu Tree for Local Operator Interface (LOI) on the (Sheet 3 of 3) A-5 AUTOMATIC CALIBRATION SETUP Use the following procedure to setup the OCX 4400 with the LOI for automatic calibration. If necessary, use the menu tree in Figure A-3 for reference. The unit must be equipped with calibration solenoids to use automatic calibration. NOTE Automatic calibration is only available on units equipped with calibration solenoids. a. From the operating display use the rightpointing arrow to select SETUP first column sub-menu. b. From the SETUP first column sub-menu, use the right-pointing arrow to select the CALIBRATION second column sub-menu. c. From the CALIBRATION second column sub-menu, use the right-pointing arrow to select the third column parameter list. Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-5

80 Instruction Manual Appendix A Rev. 2.0 d. Scroll down to the forth item Got Solenoids. If the unit is equipped with calibration solenoids and timed automatic calibration is desired, select Yes. e. Use the down-pointing arrow to select the next item O 2 Output Tracks. Select Yes or No to determine if updates to the O 2 lock value will take place. f. Use the down-pointing arrow to select the next item Comb Out Tracks. Select Yes or No to determine if updates to the COMB lock value will take place. g. Use the down-pointing arrow to select the next item O 2 Cal Interval. Enter the amount of time in days and hours that is desired between automatic calibrations. h. Use the down-pointing arrow to select the next item O 2 Next Cal. Enter the amount of time in hours until the next automatic calibration. Select the left-pointing arrow three times to move back to the operating display. A-6 MANUAL CALIBRATION WITH LOI Use the following procedure to perform a manual calibration with the LOI. If necessary, refer to the menu tree in Figure A-3 if needed. Once the manual calibration procedure is initiated by the LOI, a series of prompts will appear giving instructions to the operator. a. Use the right-pointing arrow to select the CALIBRATE first column sub-menu. b. From the CALIBRATE sub-menu use the right-pointing arrow to select the DO CALIBRATION second column sub-menu. c. From the DO CALIBRATION sub-menu use the right-pointing arrow to select the third column O 2 sensor calibrate option. d. Remain at the O 2 sensor option or use the down-pointing arrow to calibrate COM- BUSTIBLES or BOTH sensors. (The following sequence applies when BOTH sensors are selected.) e. Use the right-pointing arrow to start the calibration. Turn on the low O 2 test gas, when prompted by Apply Lo O 2 Gas. f. Press the right-pointing arrow when the low O 2 test gas is applied. The calibration data changes as the calibration proceeds. g. Press the right-pointing arrow when the low O 2 reading is stable. Turn off the low O 2 test gas and turn on the high O 2 test gas as prompted by Apply Hi O 2 Gas. h. Press the right-pointing arrow when the high O 2 test gas is applied. The calibration data changes as the calibration proceeds. i. Press the right-pointing arrow when the high O 2 reading is stable. Turn off the high O 2 test gas. Press the right-pointing arrow to start the high O 2 gas purge. j. When the Purge period expires, the LOI displays O 2 Calibration Pass or Fail. (Calibration Fail exits the program.) k. Press the right-pointing arrow to start combustibles calibration. Turn on the low CO test gas, when prompted. l. Press the right-pointing arrow when the low CO test gas is applied. The calibration data changes as the calibration proceeds. m. Press the right-pointing arrow when the low CO reading is stable. Turn off the low CO test gas and turn on the high CO test gas when prompted. n. Press the right-pointing arrow when the high CO test gas is applied. The calibration data changes as the calibration proceeds. o. Turn off the high CO test gas and press the right-pointing arrow to start the high CO gas purge. p. When the Purge period expires, the LOI displays CO Calibration Pass or Fail. A failure reapplies the last good calibration parameters for O 2 /combustibles sensing. A-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

81 Instruction Manual Appendix B Rev 2.0 APPENDIX B SPA WITH HART ALARM B-1 FORWARD This appendix describes the SPA with HART Alarm option available for the. B-2 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, contactclosure outputs based on readings of the HART digital data. The four outputs from the OCX 4400 which are recognized by the SPA are Low O 2, High COMB, Calibration Status, and OCX Unit Failure. Electrostatic discharge (ESD) protection is required to avoid damage to the SPA electronic circuits. 1. Refer to Figure B-3. Turn the SPA over and slide the access cover out. Before changing any jumper or switch position, take adequate precautions to avoid an electrostatic discharge. B-3 INSTALLATION Refer to Figure B-2 for the typical interface connections for the and the SPA with HART alarm. Refer to the Moore Industries user s manual provided with the SPA for additional information concerning SPA installation, setup, and operation. B-4 SETUP Setup of the SPA for communication with the includes setting internal jumpers and dip switches and configuring the SPA operating parameters via a menu-driven selection and calibration procedure. a. Jumper and Switch Settings SPA jumper and switch settings are shown in Figure B-3. If the SPA with HART was factoryconfigured by Rosemount Analytical for operation with your, 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 jumper and switch settings as follows: Figure B-1. SPA With HART Alarm Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-1

82 F1 F2 F3 F4 Instruction Manual Appendix B Rev 2.0 > 250Ω R < 950Ω 4-20 ma O 2 SIGNAL LOOP HART MODEL 275 HANDHELD COMMUNICATOR CUSTOMERS DCS, PLC, or PC with AMS SOFTWARE ANALOG OUTPUT IN IN 4-20 ma or 0-24 vdc EVENT RECORDER, AUDIBLE ALARM, OR OTHER ANALOG DEVICE Figure B-2. and SPA Interface Connections NOTICE REMOVE THIS PANEL FOR SERVICE ACCESS. STATIC SENSITIVE. USE CAUTION WHEN CHANGING JUMPERS ACCESS COVER SPA BOTTOM VIEW SOURCE CURRENT DIP SWITCHES PASSWORD JUMPER PINS FAILSAFE DIP SWITCHES SWITCHES SHOWN IN CORRECT POSITION PASSWORD ON PASSWORD OFF SWITCHES SHOWN IN CORRECT POSITION Figure B-3. SPA Jumper and Dip Switch Settings B-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

83 Instruction Manual Appendix B Rev Verify that the PASSWORD jumper is set to the OFF position. If the jumper is in the ON position, reposition the jumper. 3. Check the position of the FAILSAFE dip switches. Position the dip switches as shown in Figure B Check the position of the SOURCE CURRENT dip switches. Position the dip switches as shown in Figure B Reinstall the SPA access cover. b. Configuration/Calibration. Prior to operation, the SPA operating parameters must be configured via a menudriven 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 terminals. When connecting an AC power source, use the AC and ACC (AC Common) terminals. For a DC source, use the AC and Ground terminals. 3. If desired, you can connect the 4 to 20 ma O 2 signal wires from the OCX 4400 analog output terminal block to the SPA INput terminals. (The OCX must be operational to transmit the O 2 signal. Observe polarity.) NOTE The O 2 signal connection is not required for SPA configuration or calibration. The OCX interface will allow you to observe the O 2 signal level when the SPA configuration procedure is completed. FLUKE MODEL 87 MULTIMETER OR EQUIVALENT ma OPTIONAL > < 250Ω 950Ω IN IN AC ACC GND AC or DC POWER INPUT Figure B-4. SPA Setup for Calibration Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-3

84 Instruction Manual Appendix B Rev Observe the front panel of the SPA, Figure B-5: (a) A process value display in the SPA display window indicates that the SPA is operational. Four pushbuttons are located below the display window. (b) Pressing a left-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 SE- LECT pushbuttons are disabled. NOTE In the VIEW mode, you can scroll through and display the output zero and full scale settings and the alarm relay trip points and configurations. (d) Pressing the SELECT pushbutton selects the displayed menu or submenu command or selects a displayed parameter variable. SPA DISPLAY WINDOW LEFT-HAND PUSHBUTTONS RIGHT-HAND PUSHBUTTONS Figure B-5. SPA Front Panel B-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

85 Instruction Manual Appendix B Rev Figure B-6 shows the SPA menu, submenus, and parameter values that must be selected to configure the SPA for use with the. 6. Use the following instructions and selections shown in Figure B-6 to properly configure the SPA. (a) Press the SELECT pushbutton. Observe the display window on the SPA front panel. The display window should read SET HART. (b) See the SET HART command in Figure B-6. To the right of the command window is the SET HART submenu and related parameter values that must be selected via the front panel pushbuttons on the SPA. (c) In the submenu views shown in Figure B-6, means press the down pushbutton. means press the up pushbutton. (d) means press the SELECT pushbutton one time. means press the or pushbutton until the desired parameter value is shown in the SPA window. (e) Proceed through the SPA menu, selecting the menu commands and parameter values indicated in Figure B-6. After completing the sequence in the first column, go to the top of the second column and continue. (f) To exit the menu, repeatedly press SELECT to display any main menu command. Then, press or until CONF EXIT is displayed. Select CONF EXIT. (g) Detailed instructions concerning the configuration menu and the submenu structure for each main command are provided in the SPA user s manual. Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-5

86 Instruction Manual Appendix B Rev 2.0 SET HART SGNL SRCE FLT SRCE CONF OPTS SET MSTR PRIM SET FUCT NRML NUM VARS 02 NUM TRYS 03 EXIT HART SGNL SRCE AOUT SRCE SV AL2 SRCE PV AL3 SRCE PV AL4 SRCE PV EXIT SRCE FLT SRCE CONF OPTS SET LINR LINR OFF PV SCLE AUTO DSPL EGU CSTM PPM (select P, select P, select M) DSPL SRCE SV AL2 SEL AL2 FLT SET FAIL FAIL LOW EXIT OPTS SET EGU SCLE INPT SCLE DSPL SCLE OUT TRIM OUT CONF ALRM PV DSPL SET ZERO 0000 PCT SET FULL 25 PCT SV DSPL SET ZERO 0000 PPM SET FULL 1000 PPM EXIT DSPL SCLE OUT SET ZERO MA SET FULL MA EXIT Z/FS TRIM OUT TRIM ZERO MA TRIM FULL MA EXIT TRIM CONF ALRM Refer to SPA manual for settings or PASS WORD SET EGU PV EGU PCT SV EGU CSTM PPM (select P, select P, select M) EXIT EGU SCLE INPT PASS WORD CONF EXIT SCLE INPT PV SCLE PV ZERO 0000 PCT PV FULL 25 PCT SCLE SV SET ZERO 0000 PPM SET FULL 1000 PPM EXIT SCLE SCLE DSPL CONF EXIT SPA setup complete; observe process value display. SCLE DSPL Figure B-6. SPA Configuration Menu for Communication B-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

87 Instruction Manual Appendix C Rev 2.0 APPENDIX C BLOWBACK C-1 FORWARD This appendix describes the operation of the blowback option for the Oxygen/ Combustibles Transmitter. The blowback system blows instrument air back through the inlet filter and out the inlet tube of the transmitter. This removes built up dirt and particulate from the filer and inlet line. The blowback option is normally used in systems that have a dirty process stream. C-2 INSTALLATION Installing an Oxygen/Combustibles Transmitter with the blowback option requires the addition of air operated blowback valve, regulator and gage, and check valve. Figure C-1 shows the piping arrangement for the Oxygen/Combustibles Transmitter with the blowback and autocalibration options. Figure C-2 shows the piping arrangement for the Oxygen/Combustibles Transmitter with the blowback option without autocalibration (without test gas solenoids). 1. Connect a clean, dry, instrumentquality supply of air (20.95% O 2 ) 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. 2. See the upper leg of the instrument air supply. Connect the output of the 35 psi regulator/filter to one port of the normally-closed air-operated solenoid valve, and to the inlet side of the dilution air rotometer. 3. Connect the dilution air rotometer output to the DILUTION AIR inlet fitting on the sensor housing. C-3 SETUP 4. Install an instrument air line between the open port of the normally-open airoperated solenoid valve and the tee fitting on the sensor housing. 5. Connect the output of the 55 psi regulator/filter to one port of the normallyopen air-operated solenoid valve, and to the instrument air inlet on the back of the electronics housing. 6. Install an air line between the open port of the normally-closed air-operated solenoid valve and the check valve inlet fitting on the sensor housing. 7. 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. There are three settings that need to be specified to set up the blowback option. These are the blowback interval, duration, and purge time. These settings are available through HART from the Device Setup > Detailed Setup > Blowback menu. Using the LOI, these settings are accessible from the Setup > Blowback menu. Interval Length of time between blowback events. (60 minutes recommended.) Duration Length of time blowback air is activated. (5 seconds recommended.) Purge Time Length of time after blowback is complete before oxygen/ combustibles readings are considered valid. (Set as required by the application.) Rosemount Analytical Inc. A Division of Emerson Process Management Appendices C-1

88 Instruction Manual Appendix C Rev 2.0 CAL GAS FLOW METER 5 SCFH PSIG ( RECOMMENDED CHECK VALVE ( EDUCTOR AIR IN SENSOR HOUSING CAL GAS IN REFERENCE AIR IN DILUTION AIR IN INSTRUMENT AIR Pressure regulator with 1/8 inlet port is factory set for 35 psig. Regulator with 1/4 inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the will not work. ELECTRONICS HOUSING BLOWBACK VALVE, AIR OPERATED DILUTION AIR FLOW METER 0.1 SCFH AIR PRESSURE REGULATOR/FILTER * * NORMALLY OPEN SOLENOID VALVE NORMALLY CLOSED SOLENOID VALVE 35 PSIG 55 PSIG INSTRUMENT AIR SUPPLY 2-STAGE REGULATORS AIR PRESSURE REGULATOR/FILTER HI CO HI O 2 LO O 2 NOTE: DURING OPERATION, STATE OF NORMALLY-OPEN AND NORMALLY-CLOSED SOLENOID VALVES CHANGE Figure C-1. Piping Arrangement, Blowback with Autocalibration C-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

89 Instruction Manual Appendix C Rev 2.0 CHECK VALVE EDUCTOR AIR IN SENSOR HOUSING REFERENCE AIR IN CAL GAS FLOW METER 5 SCFH PSIG ( RECOMMENDED CAL GAS IN DILUTION AIR IN ( 2-STAGE REGULATORS HI CO HI O 2 LO O 2 INSTRUMENT AIR ELECTRONICS HOUSING BLOWBACK VALVE, AIR OPERATED DILUTION AIR FLOW METER 0.1 SCFH AIR PRESSURE REGULATOR/FILTER * * NORMALLY OPEN SOLENOID VALVE NORMALLY CLOSED SOLENOID VALVE 35 PSIG 55 PSIG INSTRUMENT AIR SUPPLY Pressure regulator with 1/8 inlet port is factory set for35 psig. Regulator with 1/4 inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the will not work. AIR PRESSURE REGULATOR/FILTER NOTE: DURING OPERATION, STATE OF NORMALLY-OPEN AND NORMALLY-CLOSED SOLENOID VALVES CHANGE. Figure C-2. Piping Arrangement, Blowback without Autocalibration Rosemount Analytical Inc. A Division of Emerson Process Management Appendices C-3

90 Instruction Manual Appendix C Rev 2.0 C-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

91 Instruction Manual Appendix D Rev 2.0 APPENDIX D IS BARRIER D-1 DESCRIPTION A twisted pair of signal wires provide communication from the Transmitter to the customer s analog devices (alarms, PC, DCS, etc.). In normal operation, the signal wires carry a low-voltage, 4 to 20 milliamp analog signal. An OCX equipment fault, however, could generate a higher energy signal at the transmitter output terminals. Where the OCX analog signal is transmitted through hazardous areas, failure to use IS barriers could allow higher energy signals to ignite combustible gases or materials. The Transmitter is available with an IS barrier option. The IS barrier limits the energy (voltage and current) that can be produced at the analog output terminals of the transmitter. Whenever the OCX with IS barrier protection is selected, the customer s devices must also be IS barrier protected to avoid transmitting a feedback energy surge through the OCX signal wires. The recommended interface for connecting the with IS barrier protection to the customer s analog devices is shown in Figure D-1. The MTL Model 44041A Current Repeater with adapter and BPS 04 Backplane (intrinsic barrier kit) has been selected by Rosemount Analytical to protect against feedback from the customer s equipment through the O 2 signal loop. Notice that an SPA with HART alarm is included in the IS barrier interconnect diagram. The SPA unit is necessary to decode the 4 to 20 ma combustibles (COMB) concentration signal or line fault detection signals superimposed on the O 2 analog signal. Without the SPA, only the O 2 analog signal would be available for input to the customer s analog devices. Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-1

92 F1 F2 F3 F4 Instruction Manual Appendix D Rev 2.0 NON-HAZARDOUS AREA ELECTRONICS HOUSING ISOLATING DRIVER MTL PWR VDC O SIGNAL ma SIGNAL OUTPUT TERMINAL BLOCK AOUT 2 AOUT 2 AOUT 1 AOUT 1 HART MODEL 275 HANDHELD COMMUNICATOR Ω O SIGNAL LOOP 4-20 ma 2 HAZARDOUS AREA CUSTOMER S EQUIPMENT NON-HAZARDOUS AREA MOORE INDUSTRIES SITE-PROGRAMMABLE HART LOOP MONITOR AND ALARM IN IN ANALOG OUTPUT ADAPTER I I CURRENT REPEATER MTL 4041A EVENT RECORDER, AUDIBLE ALARM OR OTHER ANALOG DEVICE INTRINSIC SAFETY BARRIER KIT P/N 1A99698G VDC PWR IN MTL BACKPLANE BPS 04 > 250Ω R < 950Ω O 2 SIGNAL 4-20 ma AC/DC PWR IN DCS or PC with AMS SOFTWARE Figure D-1. IS Barrier Interface Diagram D-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management