Rosemount OCX 8800 O2 / Combustibles Transmitter Hazardous Area Instruction manual

Instruction Manual

IM-106-880, Rev 1.0

January 2007

OCX 8800

Oxygen/Combustibles Transmitter

Hazardous Area OCX 8800 Oxygen/Combustibles Analyzer with Remote Electronics http://www.raihome.com

Page

Page 2-19

Page 3-2

Page 3-3

Page A-2 thru A-23

Page C-1

Back cover

HIGHLIGHTS OF CHANGES

Effective January, 2007 Rev 1.0

Summary

Revised Figure 2-11.

Revised the text for SW1 and SW2 to read internally powered.

Revised Figure 3-1. Updated the paragraph Initial Power Up.

Added note 11 to the safety data section. Added additional pages/languages.

Updated the return of materials address.

Updated the address blocks.


IM-106-880, Rev 1.0

January 2007

OCX 8800

Table of Contents

SECTION 1

Description and

Specifications

SECTION 2

Installation

SECTION 3

Configuration and

Startup

SECTION 4

Using HART

Communications

SECTION 5

Calibration

SECTION 6

Maintenance and Service

Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Mechanical

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

OCX 8800 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

HART Communicator Signal Connections. . . . . . . . . . . . . . . . . . . . . . 4-1

HART Communicator PC Connections . . . . . . . . . . . . . . . . . . . . . . . . 4-4

HART Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

OCX 8800 Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

OCX with

Remote Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Sensor Housing Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Sensor Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Electronics Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6-28 http://www.raihome.com

OCX 8800

SECTION 7

Troubleshooting

SECTION 8

Replacement Parts

APPENDIX A

Safety Data

APPENDIX B

SPA with HART Alarm

APPENDIX C

Return of Materials


IM-106-880, Rev 1.0

January 2007

Electronics Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Remove Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Install Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Total Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Diagnostic Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Alarm Relay Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

O2 Cell and Heater Strut Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . . A-24

High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29

Atex Clarification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

TOC-2


IM-106-880, Rev 1.0

January 2007

ESSENTIAL

INSTRUCTIONS

OCX 8800

OCX 8800

Oxygen/Combustibles Transmitter

READ THIS PAGE BEFORE PROCEEDING!

Emerson Process Management designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install,

use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining

Emerson’s Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your

Emerson Process Management representative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation,

operation, and maintenance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and

national codes. Connect all products to the proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process Management.

Unauthorized parts and procedures can affect the product's performance, place the safe operation of your process at risk, and

VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without notice.

If a Model 275/375 Universal HART ® Communicator is used with this unit, the software within the Model 275/375 may require modification. If a software modification is required, please contact your local Emerson Process Management Service Group or National

Response Center at 1-800-654-7768.

http://www.raihome.com

ii

OCX 8800

PREFACE

DEFINITIONS

SYMBOLS


IM-106-880, Rev 1.0

January 2007

The purpose of this manual is to provide a comprehensive understanding of the OCX 8800 components, functions, installation, and maintenance.

We recommend that you thoroughly familiarize yourself with the Introduction and Installation sections before installing your transmitter.

The introduction presents the basic principles of the transmitter along with its performance characteristics and components. The remaining sections contain detailed procedures and information necessary to install and service the transmitter.

Before contacting Emerson Process Management concerning any questions, first consult this manual. It describes most situations encountered in your equipment's operation and details necessary action.

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.


IM-106-880, Rev 1.0

January 2007

Section 1

COMPONENT

CHECKLIST

SYSTEM OVERVIEW

OCX 8800

Description and Specifications

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-9

A typical OCX 8800 Oxygen/Combustibles Transmitter package should contain the items shown in Figure 1-1.

Use the product matrix in Table 1-1 at the end of this section to verify your order number. The first part of the matrix defines the model. The last part defines the various options and features of the OCX 8800. Check the model number against the transmitter features and options, making sure options specified by this number are on or included with the unit. Use this complete model number for any correspondence with Emerson Process Management.

A list of accessories for use with the OCX 8800 is provided in Table 1-2.

Scope

This Instruction Manual supplies details needed to install, startup, operate, and maintain the OCX 8800. Signal conditioning electronics outputs separate

4-20 mA signals representing oxygen (O

2

) and combustibles (COe) values.

This information, plus additional details, can be accessed with the HART

Model 275/375 handheld communicator or Rosemount Analytical AMS software.

System Description

The OCX 8800 is designed to measure oxygen and combustible concentrations in flue gas temperatures up to 2600°F (1427°C). Electrical connections, power and communications are made through two 3/4 NPT ports in the flameproof electronics enclosure using fittings and cables provided by the customer. Cable installation must meet NEC, IEC and/or other applicable national or local codes for Class I, Zone 1, Group IIB +H2 T3/T6 permanently mounted equipment. The transmitter is close coupled to the process and requires minimal sample conditioning requirements.

http://www..raihome.com

OCX 8800

Figure 1-1. Typical System Package

4

6

1-2

3

1. Instruction Manual

2. HART

®

Communicator Package (optional)

3. Adapter Plate with Mounting Hardware and Gasket

4. Reference Air and Calibration Set

5. Blowback Hardware (optional)

6. OCX 8800 with Remote Electronics

5


IM-106-880, Rev 1.0

January 2007

1

MAN 4275A00

English

October 1994

HART Communicator o

Ana lytic al

2


IM-106-880, Rev 1.0

January 2007

OCX 8800

The equipment measures oxygen percentage by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output of the cell is given by the following Nernst equation:

EMF = KT log10 (P

1

/P

2

) + C

Where:

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 OCX 8800 to provide exceptional sensitivity at low oxygen concentrations.

The OCX 8800 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 OCX 8800 combustibles sensor is a catalytic sensor consisting of two

Resistance Devices (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.

1-3

OCX 8800


IM-106-880, Rev 1.0

January 2007

The catalyst is specifically designed to detect carbon monoxide (CO), but the sensor responds to other combustible gases. The sensor is calibrated using

CO, thus the output should be expressed in terms of CO. However, since the sensor 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 COe 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 COe sensor to ensure there is adequate oxygen to fully oxidize any combustible gases regardless of the concentration of oxygen in the process.

System Configuration

Transmitters are available in four lengths, 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. The electronics housing may be mounted up to 150 feet away from the sensor housing.

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. Refer to

Section 3, Configuration and Startup for specific instructions upon initial power up.

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. HART Model 275/375 Communicator.

b. AMS software for the PC.

3. Oxygen cell and heater/thermocouple assembly are field replaceable.

4. Electronics are automatically configured for line voltages from 100 to

240 VAC.

1-4


IM-106-880, Rev 1.0

January 2007

OCX 8800

5. An operator can calibrate and diagnostically troubleshoot the OCX 8800 using the HART Interface. Each of the OCX 8800's 4-20 mA output lines transmit an analog signal proportional to oxygen or combustible levels detected. The HART output is superimposed on the oxygen 4-20 mA output line only. This information can be accessed through the following:

• Model 275/375 Handheld Communicator - The handheld communicator requires Device Description (DD) software specific to the OCX 8800. The DD software will be supplied with many

Model 275/375 units, but can also be programmed into existing units at most Emerson Process Management service offices.

Refer to Section 4, Using HART Communications, for additional information.

• Personal Computer (PC) - The use of a personal computer requires AMS software available from Emerson Process

Management.

• Selected Distributed Control Systems - The use of distributed control systems requires input/output (I/O) hardware and AMS software which permit HART communications.

6. Optional Blowback System. The blowback system periodically blows instrument air back through the sample line filter and out the sample tube. This clears out particulate and keeps the sample line filter from clogging.

System Operation

Figure 1-2 shows the relationship between the components of the OCX 8800.

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 COe sensor. Dilution air is provided to the COe sensor and reference air to the O

2

sensor. After the gas sample flows past the O

2

sensor and through the COe 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 and HART boards which convert 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 flow meter 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.

1-5

OCX 8800

Figure 1-2. System Operation Diagram

SENSOR

HOUSING

COe

Combustibles

Sensor

Sample

Gas

Probe

Exhaust

O

2

Sensor

Eductor

ELECTRONICS

HOUSING

CPU

HART

Board

Power

Supply

Optional

Test Gas

Solenoids

Instrument Air

Solenoid


IM-106-880, Rev 1.0

January 2007

Low O

2

Test Gas

High O

2

Test Gas

CO

Test Gas

Instrument

Air

Flow Meter

7 scfh

Eductor Air

Reference Air

Dilution Air

Flow Meter

50 cc/min.

(0.1 scfh)

Handling the OCX 8800

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 OCX 8800 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.

System Considerations

Prior to installing your OCX 8800, make sure you have all the components necessary to make the system installation. Ensure all the components are properly integrated to make the system functional.

1-6


IM-106-880, Rev 1.0

January 2007

Figure 1-3. OCX 8800 HART

Connections and AMS Application

OCX 8800

Sensor Housing

OCX 8800

After verifying that you have all the components, select mounting locations and determine how each component will be placed in terms of available line voltage, ambient temperatures, environmental considerations, convenience, and serviceability. Figure 1-3 shows a typical system wiring. Simplified installations for the OCX 8800 are shown in Figure 1-4.

A source of instrument air is required at the OCX 8800 for reference air, dilution air, and eductor air. Since the OCX 8800 is equipped with an in-place calibration feature, provision should be made for connecting test gas tanks to the OCX 8800 when it is to be calibrated.

NOTE

The electronics module is designed to meet NEMA 4 (IP66) 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.

HART

Model 275/375

Handheld

Communicator

4-20 mA Output

(Twisted Pairs)

OCX 8800

Electronics Housing

Customer’s Laptop with AMS

Instrument

Air

3 calibration gas lines by customer

[300 ft (91 m) max.)

Termination in

Control Room

AMS

1-7

OCX 8800

Figure 1-4. Typical System

Installation

Gases

Heater

Power Cable

[up to 150 ft (46 m)]

Signal Cable

[up to 150 ft (46 m)]

Stack

Dilution

Air

Flow

Meter

Duct

OCX 8800 with

REMOTE

ELECTRONICS


IM-106-880, Rev 1.0

January 2007

Test Gas

Flow Meter

4-20 mA Outputs

(2 Twisted Pairs)

Line Voltage

Pressure

Regulator

Instrument Air

Supply

(Reference Gas)

CO Test Gas

1-8


IM-106-880, Rev 1.0

January 2007

SPECIFICATIONS

OCX 8800

Hazardous Area OCX

Specifications

Net O

2

Range

Combustibles

Accuracy

Oxygen

Combustibles

System Response to

Test Gas

Oxygen

Combustibles

Temperature Limits

Process

Sensors Housing

Electronics Housing

0-1% to 0-40% O

2

, fully field selectable

0-1000 ppm to 0-5%, fully field selectable

± 0.75% of reading or 0.05% O

2

(whichever is greater)

± 2% range

10 sec T90

25 sec T90

32° to 2600°F (0° to 1427°C)

-40° to 212°F (-40° to 100°C), ambient

-40° to 149°F (-40° to 65°C), ambient

-40° to 185°F (-40° to 85°C), internal - operating temperature of electronics inside instrument housing, as measured by a HART communicator or AMS software

Nominal and Approximate

Shipping Weights

18 in. (457 mm) probe package

3 ft (0.91 m) probe package



Mounting and Mounting

Positions

Sensors Housing

Electronics Housing

Materials

Probes

54 lbs (20 kg)

55 lbs (20.5 kg)

57 lbs (21 kg)

59 lbs (22 kg)

Flange

Wall/Pipe

Enclosures

Calibration

Calibration Gas Mixtures

Recommended

(Ref. test gas bottles kit #1A99119G04)

Calibration Gas Flow

Reference Air

316L stainless steel - 1300°F (704°C)

Inconel 600 - 1832°F (1000°C)

Ceramic - 2600°F (1427°C)

Low-copper aluminum

Semi-automatic or automatic

0.4% O

2

8% O

2

, Balance N2

, Balance N2

1000 ppm CO, Balance Air

Eductor Air

Dilution Air

Blowback Air (optional)

7 scfh (3.3 l/m)

2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O

2 regulated to 45 psi (310 kPa)

),

5 scfh (2.5 l/m), clean, dry, instrument-quality air 20.95% O


),

0.1 scfh (0.5 l/m), clean, dry, instrument-quality air (20.95% O


)

Clean, dry, instrument-quality air (20.95% O

2

), regulated to 55 psi

(379 kPa)

Table continued on next page

1-9

OCX 8800


IM-106-880, Rev 1.0

January 2007

Specifications

Sensors Housing

Electronics Housing

Electrical Noise

Certifications

NEMA 4, IP66 with fitting and pipe on reference exhaust port to clean, dry atmosphere, two 3/4-14 NPT conduit ports

NEMA 4, IP66 with fitting and pipe on reference exhaust port to clean, dry atmosphere, two 3/4-14 NPT conduit ports

EN 61326-1, Class A

Sensor Housing

0344 II 2 G

KEMA 04 ATEX 2308

EEx d IIB+H2 T3

C US

2005.1602514

CLASS 1, ZONE 1

Ex d IIB+H2 T3

AEx D IIB+H2 T3

TYPE 4 / IP66

APPROVED

CLASS 1, ZONE 1

AEx D IIB+H2 T3

TYPE 4 / IP66

Electronics Housing

Line Voltage

Pollution Degree

Over Voltage Category

Relative Humidity

Isolated Output

Oxygen

Combustibles

Alarm

Power Consumption

II

0344 II 2 G

KEMA 04 ATEX 2308

EEx d IIB+H2 T6 IP66

C US

2005.1602514

CLASS 1, ZONE 1

Ex d IIB+H2 T6

AEx D IIB+H2 T6

TYPE 4 / IP66

APPROVED

CLASS 1, ZONE 1

AEx D IIB+H2 T3

TYPE 4 / IP66

Universal 100 to 240 VAC ±10%, 50 to 60 Hz, no switches or jumpers required, 3/4-14 NPT conduit port

2

5 to 95% (non-condensing)

4-20 mAdc, 950 ohm maximum, with HART capability

4-20 mAdc, 950 ohm maximum

Alarm output relay - dry contact, form C, 30 mA, 30VDC capacity

750 W maximum

NOTE

All static performance characteristics are with operating variables constant. Specifications subject to change without notice.

1-10


IM-106-880, Rev 1.0

January 2007

OCX 8800

Table 1-1. Product Matrix - Hazardous Area OCX 8800

OCX88C O

2

/Combustibles Transmitter - Flameproof

32

13

23

14

24

Code Probe Length and Material

00

11

No Probe or Exhaust Tube

18 in. (457 mm) 316 SST

21

31

12

22

18 in. (457 mm) Inconel 600

18 in. (457 mm) Ceramic

3 ft (0.91 m) 316 SST

3 ft (0.91 m) Inconel 600

3 ft (0.91 m) Ceramic

6 ft (1.83 m) 316 SST

6 ft (1.83 m) Inconel 600

9 ft (2.7 m) 316 SST

9 ft (2.7 m) Inconel 600 up to 1300°F (704°C) up to 2600°F (1427°C) up to 2600°F (1427°C) up to 1300°F (704°C) up to 1832°F (1000°C) up to 2600°F (1427°C) up to 1300°F (704°C) up to 1832°F (1000°C) up to 1300°F (704°C) up to 1832°F (1000°C)

Code Probe Mounting Assembly

10

20

(ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes

(DIN) 185 mm dia. flange, 145 mm BC with 4 x 18 mm dia. holes

2

3

4

5

Code Mounting Hardware - Stack Side

0 No Adapter Plate (“0” must be chosen under “Mounting Adapter - Probe Side” below)

1 New Installation - Square weld plate with studs

Model 218/240 Mounting Plate (with Model 218/240 Shield Removed)

Existing Model 218/240 Support Shield

Special Mounting (1)

Model 132 Adapter Plate

Code Mounting Hardware - Probe Side

0 No Adapter Plate

1

2

Probe Only (ANSI)

Probe Only (DIN)

Code Electronics Housing - Communications

H1 HART Communications (2)

H2

H3

H4

HART Communications with LOI

HART Communications with Calibration Solenoids (2)

HART Communications with LOI and Calibration Solenoids

Code Electronics Mounting

02 Remote Electronics and no cable

Code Accessories

00

01

None

Flow meters & Ref. Air Set

02

03

11

12

13

In-Situ Filter (Stainless Steel only)

In-Situ Filter (SST), Flow meters & Ref. Air Set

Flow meters, and Ref. Air Set with Blowback

In-Situ Filter (SST) with Blowback

In-Situ Filter (SST), Flow meters & Ref. Air Set with Blowback

OCX88C 11 10 1 1 H2 02 02 Example

NOTES:

(1)

Provide details of the existing mounting plate as follows:

Plate with studs

Plate without studs

Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate.

Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.

(2)

If the LOI is not implemented, remote access and functionality available via HART Communications (Model 275/375 Handheld Communicator) with Oxygen/Combustibles Device Description (DD) required.

1-11

OCX 8800

Table 1-2. Accessories


IM-106-880, Rev 1.0

January 2007

PART NUMBER

1A99119H01

1A99119H02

1A 99119H07

1A99120H02

1A99120H03

1A99119G06

1A99119G05

1A99119G04

1A99292H01

1A99339H03

1A99784H02

6A00171G01

DESCRIPTION

Oxygen test gas bottle; 0.4% O

2

, balance N

2

Oxygen test gas bottle; 8.0% O

2

, balance N

2

CO test gas bottle; 1000 ppm CO, balance air

Regulator for Oxygen (may need 2)

Regulator for CO test gas

Wall mount bracket for test gas bottles

Test gas regulators kit

Test gas bottles kit

Moore Industries SPA for Low O

2

Calibration Status, and Unit Fail

Alarm, High COe Alarm,

Blowback valve, air operated

375 HART Communicator with 12 Megabyte buffer, model no. 375HR1EKLU

Power line filter kit

1-12


IM-106-880, Rev 1.0

January 2007

Section 2

OCX 8800

Installation

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-8

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-14

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-20

Before installing this equipment, read the "Safety instructions for the wiring and installation of this apparatus" in Appendix A: Safety Data. Failure to follow the safety instructions could result in serious injury or death.

To maintain explosion-proof protection of the OCX 8800 in hazardous areas, all cable entry devices and blanking elements for unused apertures must be certified flameproof, suitable for the conditions of use and properly installed.

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sensor housing must not be mounted to any surface or flange that exceeds 200ºC (392ºF).

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sample entering the sensor housing must not exceed 200ºC (392ºF).


OCX 8800

MECHANICAL

INSTALLATION


IM-106-880, Rev 1.0

January 2007

Selecting Location

1. The location of the OCX 8800 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The probe must be positioned so the gas it measures is 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 2-4 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 readings. Therefore, either make the necessary repairs or install the transmitter up stream 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 OCX 8800.

Do not allow the temperature of the electronics housing to exceed 185°F (85°C) or damage to the electronics may result.

Whenever a positive stack pressure exists at the installation site, be sure to connect all pneumatic lines prior to installing the OCX 8800 in the stack or ductwork. Failure to connect the pneumatic lines can allow the flow of contaminants into the OCX 8800 ports.

Before installing the OCX 8800 into a hot stack or ductwork, make sure that the OCX 8800 is turned on and at normal operating temperature. Exposing a cold OCX transmitter to hot process gases can cause permanent damage to the equipment.

Installation

1. Ensure all components are available to install the OCX 8800.

2. The OCX 8800 may be installed intact as it is received.

3. Weld or bolt adapter plate (Figure 2-2) onto the duct.

2-2


IM-106-880, Rev 1.0

January 2007

OCX 8800

4. Use the pipe or wall mounting hardware as shown in Figure 2-3 to mount the electronics housing. Choose a location not to exceed the length of the electronics cable ordered.

5. Ensure the conduits drop vertically from the OCX 8800 and the conduit is routed below the level of the conduit ports on the housing to form a drip loop. Drip loops minimize the possibility that moisture will damage the electronics (Figure 2-4).

6. Where a positive stack pressure exists at the installation site, connect all pneumatic lines prior to installing the OCX 8800 in the stack or ductwork.

NOTE

If process temperatures will exceed 392°F (200°C), use anti-seize compound on stud threads to ease future removal of the OCX 8800.

7. 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.

8. If insulation is removed to access the duct for OCX 8800 mounting, make sure to replace insulation afterward.

Enclosures

The OCX 8800 enclosures are designed to meet ingress conditions of IP66.

Each enclosure cover is threaded to its base and sealed with an o-ring that isolates the threads from external contaminants.

Each cover is secured by a clip attached to the base that engages the cover between the ribs of the cover sidewall. The clip is held in place by an Allen head cap screw and lockwasher mounted in a recess. Cover removal and installation requires an Allen wrench to loosen and tighten the screw.

2-3

OCX 8800

Figure 2-1. Installation, OCX 8800

NOTE

All dimensions are in inches with millimeters in parentheses.

Insulate if exposed to adverse weather or extreme temperature changes, install a protective housing and/or insulation around the unit.

Flange Dia.

B.C. Dia.

Hole Dia.

See Table 1


IM-106-880, Rev 1.0

January 2007

Table 1. Mounting Flange

Flange

Dia.

Hole

Dia.

ANSI

5R10244H01

6.00

(152)

0.75

(19)

DIN

5R10244H02

7.28

(185)

0.71

(18)

(4) Holes equally spaced on

B.C. dia

4.75

(121)

5.71

(145)

Removal Envelope

Dim “B”

Insertion Depth

Dim “A”

See Table 2

SENSOR HOUSING

Table 2. Installation/Removal

Probe

18 in.

3 ft

6 ft

9 ft

Dim "A”

18

(457)

36

(914)

72

(1829)

108

(2743)

Dim "B”

34

(864)

52

(1321)

88

(2235)

124

(3150)

Allow 9 in.

(229 mm) for

Cover Removal

ELECTRONICS HOUSING

Optional

In Situ FIilter

8.3

(211)

0.06 In. Thick Gasket

ANSI 3535B18H02

DIN 3535B45H01

2-4


IM-106-880, Rev 1.0

January 2007

Figure 2-2. Adapter Plate Installation

OCX 8800

2-5

OCX 8800

Figure 2-3. Wall or Pipe Mounting of Electronics Housing

Note: * Indicates items are included in mounting kit P/N 4851B40G01.

*Pipe

Mounting

Clamp

*Wall or Pipe

Mounting Bracket and Screws


IM-106-880, Rev 1.0

January 2007

Electronics

Housing

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)

2-6


IM-106-880, Rev 1.0

January 2007

Figure 2-4. Installation with Drip Loops

Conduit Drip Loops Duct Wall

Conduit Drip Loop Conduit Drip Loop

Duct Wall

OCX 8800

2-7

OCX 8800

ELECTRICAL

INSTALLATION


IM-106-880, Rev 1.0

January 2007

All wiring must conform to local and national codes. For reference, factory wired solenoid power connections are shown in Figure 2-5.

Disconnect and lock out power before connecting the unit to the power supply. Failure to lock out power could result in serious injury or death.

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) in close proximity and marked for this equipment which will disconnect all current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 947.

To maintain explosion-proof protection of the OCX 8800 in hazardous areas, all cable entry devices and blanking elements for unused apertures must be certified flameproof, suitable for the conditions of use and properly installed.

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sensor housing must not be mounted to any surface or flange that exceeds 200ºC (392ºF).

To maintain explosion-proof protection of the OCX88C in hazardous areas, the sample entering the sensor housing must not exceed 200ºC (392ºF).

2-8


IM-106-880, Rev 1.0

January 2007

OCX 8800

NOTE

To maintain proper earth grounding, ensure a positive connection exists between the sensor housing, the electronics housing, and earth. The connecting ground wire must be 14 AWG minimum. Refer to Figure 2-5.

NOTE

Line voltage, signal, and relay wiring must be rated for at least 105ºC (221ºF).

Electrical Connections

Electrical connections, power and communications are made to the electronic enclosure. The connections are made through two 3/4 NPT ports in the enclosure using fittings and cables provided by the customer. Cable installation must meet NEC, IEC and/or other applicable national or local codes for Class I, Zone 1, IIB +H2 T3/T6 permanently mounted equipment.

Connect Line Voltage

The OCX 8800 operates on 100 to 240 VAC line voltage at 50 to 60 Hz. The power supply requires no setup. Connect the line (L wire) to the L terminal, and the neutral (N wire) to the N terminal on the AC power input terminal block in the electronics housing. Connect the ground (G wire) to the ground stud in the electronics housing as shown in Figure 2-5.

Connect 4-20 mA Signals

Connect the 4-20 mA current loop to the 4-20 mA signal output terminals in the electronics housing as shown in Figure 2-5. Use individual shielded twisted wire pairs. Terminate the shield at the electronics housing.

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 275/375

Handheld Communicator or AMS software. The O terminals.

2

signal is at the AOUT 1

COe 4-20 mA Signal

Another 4-20 mA signal at the AOUT 2 terminals represents the COe value. HART information is not available on the COe signal.

Alarm Output Relay

Connect any customer-supplied relay input to the alarm output relay terminal.

Use shielded wire and terminate the shield at the electronics housing. The alarm output relay terminal is a set of dry, no. 2, form C, contacts with 30 mA,

30 VDC capacity.

2-9

OCX 8800


IM-106-880, Rev 1.0

January 2007

Remote Electronics Connections to Sensor Housing

Make the following connections between the electronics and sensor housings with the electronics cable ordered with the package (Figure 2-6). Braided cable is available in lengths up to 150 ft. (46 m).

NOTE

Interconnect wiring shown is for Rosemount Analytical supplied cables. For customer furnished interconnect wiring or cables, refer to Figure 2-7.

Signal Connections

Connect the electronics housing terminals to the corresponding terminals in the sensor housing. The twisted wire pairs are numbered on the inner plastic wrapper. Keep twisted pairs together and match the numbers and wire colors shown in Figure 2-6.

Heater Power Connections

Use the blue, white, orange black, red, and yellow stranded wires in the heater power cable to connect power to the three heaters in the sensor housing. Match the wire colors to the corresponding heater power terminal blocks in the sensor and electronics housings as shown in Figure 2-6.

2-10


IM-106-880, Rev 1.0

January 2007

Figure 2-5. Line Voltage, Earth, and 4-20 mA Connections

OCX 8800

#1

NC

COM

NO


Terminal Block

4-20 mA Signal Output

Terminal Block

COe Signal

{

{

AOUT2+

AOUT2 -

AOUT1 -

AOUT1+

#1

Signal Port

3/4 NPT

EMI Filter

TOP VIEW

(1/2 SIZE)

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

Customer

Wiring

G N L1

G

Terminal

Block

Ground

Stud

G

Power Port

3/4 NPT

External Tooth

Lockwasher

2-11

OCX 8800

Figure 2-6. Electrical Connections Between Remote Electronics and Sensor Housing

YEL

RED

BLK

ORG

WHT

BLU

Heater Power

Connector (J3)

#1

2HTR CO

1HTR CO

2HTR O

2

1HTR O

2

2HTR SB

1HTR SB

To ground screw

#1


IM-106-880, Rev 1.0

January 2007

#1 #1

RED

BLK

WHT

BLK

GRN

BLK

BLU

BLK

#1

Thermocouple

Connector (J5)

T/C CO+

T/C CO-

T/C SB+

T/C SB-

T/C O2+

T/C O2-

O2 CELL+

O2 CELL-

SHLD

YEL

BRN

BLK

RED

WHT

ORG

BLK

BLK

To ground screw

#1

EXC+

CO ACT+

CO ACT-

CO REF+

CO REF-

CJC+

CJC-

EXC-

COe Sensor and

Cold Junction

Connector (J4)


SENSOR HOUSING

To ground screw

2-12


IM-106-880, Rev 1.0

January 2007

OCX 8800

Figure 2-7. Customer-Furnished

Interconnect Wiring or Cables

SIGNAL WIRING OR CABLE

NOTE: For RFI/CE compliance, the connector must provide 360 degrees of electrical contact to the cable shield.

ELECTRONICS END

7.25

±0.10

Heat Shrink

Tubing

2” Long

1/2” Size

3/4 NPT Hub Size,

Liquid-tight

Strain Relief

Connector

Heat Shrink

Tubing

2” Long

1/2” Size

Strip Wire

Ends 3/16”

Typical 0.5

Typ.

Stud Size

#10

7.25 ±0.10

9.25 ±0.10

ELECTRONICS END

4.0 ±0.10

PROBE END

12.5 ±0.10

10.375 ±0.10

8.625 ±0.10

6.875 ±0.10

A

See Note

2.0 ±0.25

Typical

7.0” Long Teflon Tubing,

0.042” ID (Cut off drain wire at probe end of shield).

Overall Cable Length

By Customer

150’ Maximum

See Note

8 twisted pairs 24 AWG, stranded, insulated, tinned copper o conductors, 200 C, 300 volts, with overall braid of 34 AWG tinned copper, 90% coverage and 24 AWG tinned copper, uninsulated drain wire.

3.875

±0.10

4.625

±0.10

5.375

±0.10

6.125

±0.10

Ferrule,

Uninsulated

# 1

# 2

Heat Shrink Tubing

1” Long, 3/16” Size

DETAIL

A

(typical on both ends of wiring)

HEATER WIRING OR CABLE

3/4 NPT Hub Size,

Liquid-tight

Strain Relief

Connectors

Heat Shrink Tubing


Heat Shrink Tubing


PROBE END

5.5 ±0.10

Ferrule, Uninsulated

0.5

Typ.

Strip Wire

Ends 3/16”

Typical

Green,

16 AWG

Stud Size

#10 4.5 ±0.10

2.0 ±0.25 Typical

4.25” Long Teflon Tubing,

0.042” ID. (Cut off drain wire at probe end of shield).

Green, 16 AWG

8 Conductors, 16 AWG, Stranded,

O

200 C, 600 volts.

Braided shield - tinned copper, 90% coverage with 18 AWG 24 tinned copper, uninsulated, drain wire.

Stud Size #6

2-13

OCX 8800

PNEUMATIC

INSTALLATION


IM-106-880, Rev 1.0

January 2007

Pneumatic system connections depend on whether reference air set, calibration solenoids, and/or blowback equipment options are equipped on your transmitter. Refer to the following paragraphs and select the option that applies to your transmitter configuration.

.

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 flow meter.

2. Connect the dilution air flow meter output to the dilution air inlet fitting on the sensor housing.

3. Install an air line between the instrument air outlet fitting on the electronics housing and the tee fitting on the sensor housing.

Do not use 100% nitrogen as an O

0.4% and 2.0% O

2

2

low gas. It is suggested that O

2

low gas be between

. 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 OCX 8800:

CO - 1000 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 flow meter. Install an air line between the flow meter outlet port and the CAL GAS inlet fitting on the sensor housing.

2-14


IM-106-880, Rev 1.0

January 2007

Figure 2-8. Pneumatic

Installation, OCX with Reference

Air Set (without Autocalibration)

OCX 8800

Sensor

Housing

Eductor

Air In

CAL Gas In

Reference Air In

Dilution Air In

Dilution Air

Flow Meter

0.1 scfh

Instrument

Air Out

(

CAL Gas

Flow Meter

7 scfh, 20-30 psig

Recommended

2-Stage

Regulators

Instrument

Air Supply

Pressure Reguator/Filter

35 psig - General Purpose

45 psig - Hazardous Area

(

Electronics

Housing

2-15

OCX 8800

Figure 2-9. Pneumatic

Installation, OCX with Reference

Air Set and Solenoids (with

Autocalibration)


IM-106-880, Rev 1.0

January 2007

Sensor

Housing

(

CAL Gas

Flow Meter

7 scfh, 20-30 psig

Recommended

(

Eductor

Air In

Reference

Air In

CAL Gas In

Dilution

Air In

Dilution Air

Flow Meter

0.1 scfh

Electronics

Housing

Instrument

Air Supply

Pressure Regulator/Filter



2-Stage

Regulators

Reference Air Set and Solenoids Option

When the reference air set and test gas solenoids are included with your

OCX 8800, use the following procedure to install the pneumatic system components.

1. Install the reference air set according to the instructions in Reference Air

Set Option, steps 1 through 3.

2. Refer to Figure 2-9. Connect the O

O

2

2

low gas source to the CAL GAS LO

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

Install a shutoff valve and pressure regulator with gage in the O supply line.

2

high gas source to the CAL GAS HI O2 inlet fitting.

2

high

2-16


IM-106-880, Rev 1.0

January 2007

OCX 8800

4. Connect the CO high gas to the CAL GAS HI COe inlet fitting. Install a shutoff valve and pressure regulator with gage in the CO high supply line.

5. Connect the CAL GAS outlet fitting of the electronics housing to the inlet port of the CAL GAS flow meter. Install an air line between the flow meter outlet port and the CAL GAS inlet fitting on the sensor housing.

Reference Air Set, Solenoids, and Blowback Option

The blowback system blows instrument air back through the blowback filter and out the sample tube of the transmitter. This removes built up dirt and particulate from the filter and sample line. The blowback option is normally used in systems that have a dirty process stream.

Installing an OCX 8800 with the blowback option requires the addition of air operated blowback valve, regulator and gage, and check valve.

Figure 2-10 shows the piping arrangement for the OCX 8800 with the blowback and autocalibration options. Figure 2-11 shows the piping arrangement for the OCX 8800 with the blowback option, but without autocalibration (without test gas solenoids).

When the reference air set, calibration gas solenoids, and blowback options are included with your transmitter, use the following procedure to install the pneumatic system components.

1. Connect the calibration gas sources according to the instructions in the previous paragraph “Reference Air Set and Solenoids Option”, steps 2 through 5.

2. Connect a clean, dry, instrument-quality supply of air (20.95% O

2

) to the

35/45 psig and 55 psig pressure regulators. The inlet to the 35/45 psig regulator accepts a 1/8" NPT fitting. The inlet to the 55 psig regulator accepts a 1/4" NPT fitting.

3. See the upper leg of the instrument air supply. Connect the output of the

35/45 psi regulator/filter to one port of the normally-closed air-operated solenoid valve, and to the inlet side of the dilution air flow meter.

4. Connect the dilution air flow meter output to the DILUTION AIR inlet fitting on the sensor housing.

5. Install an instrument air line between the open port of the normally-open air-operated solenoid valve and the tee fitting on the sensor housing.

6. Connect the output of the 55 psi regulator/filter to one port of the normally-open air-operated solenoid valve, and to the instrument air inlet on the back of the electronics housing.

7. 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.

2-17

OCX 8800

Figure 2-10. Piping Arrangement,

Blowback with Autocalibration

Cal Gas Flow Meter

( 7 scfh, 20-30 psig

Recommended

(

Check

Valve

Tee - (3 x 1/4 in.

Tube Unions)

Check Valve

Sensor

Housing


IM-106-880, Rev 1.0

January 2007

CAUTION

Pressure regulator with 1/8” inlet port is factory set for 35 or 45 psig. Regulator with 1/4” inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the OCX 8800 will not work.

2-Stage

Regulators

Eductor Air In

Electronics

Housing

*Normally

Open

Solenoid

Valve

Vacuum

Gage

Reference

Air In

Dilution Air In

Instrument Air

Dilution

Air Flow Meter

0.1 scfh

*Normally

Closed

Solenoid

Valve




Blowback Valve,

Air Operated

*NOTE: During blowback operation, states of both solenoid valves change.

NOTE: Wall mount the air-operated blowback valve on a suitable mounting plate.

Instrument

Air Supply

Pressure

Regulator/Filter

55 psig

2-18


IM-106-880, Rev 1.0

January 2007

Figure 2-11. Piping Arrangement,

Blowback without Autocalibration

OCX 8800

Check Valve

Sensor

Housing

CAUTION

Pressure regulator with 1/8” inlet port is factory set for 35 or 45 psig. Regulator with 1/4” inlet port is factory set for 55 psig. If regulators are not installed in correct locations, the OCX 8800 will not work.

( Cal Gas Flow Meter (

7 scfh, 20-30 psig

Recommended

Eductor Air In

CAL Gas In

Reference Air In

Dilution Air In

Instrument Air

2-Stage

Regulators

Dilution

Air Flow Meter

0.1 scfh

Electronics

Housing

*Normally

Open

Solenoid

Valve

*Normally

Closed

Solenoid

Valve




Blowback Valve,

Air Operated

*NOTE: During blowback operation, states of both solenoid valves change.

NOTE: Wall mount the air-operated blowback valve on a suitable mounting plate.

Instrument

Air Supply

Pressure

Regulator/Filter

55 psig

2-19

OCX 8800

INITIAL STARTUP


IM-106-880, Rev 1.0

January 2007

8. Install an air line between the instrument air outlet fitting on the electronics housing and the control air inlet fitting on the air-operated solenoid valve.

9. There are three settings that need to be specified to set up the blowback option. These are the blowback interval, duration, and purge time.

Interval - Length of time between blowback events.

(60 minutes recommended.)

Duration - Length of time blowback air is activated.

(5 seconds recommended.)

Purge - Length of time after blowback is complete before oxygen/combustibles readings are considered valid.

(Set as required by the application.)

These settings are available through HART from the DEVICE SETUP >

DETAILED SETUP > OUTPUT CONDITIONS > BLOWBACK menu.

Observe the following Caution and Note. Refer to Section 3: Configuration and Startup, for OCX 8800 startup information.

Upon completing installation, make sure that the OCX 8800 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold OCX 8800 exposed to the process gases.

If ducts will be washed down during outages, make sure to power down the OCX 8800 units and remove them from the wash area.

NOTE

During outages, and whenever possible, leave OCX 8800 units running to prevent condensation and premature aging from thermal cycling.

2-20


IM-106-880, Rev 1.0

January 2007

Section 3

OCX 8800

Configuration and Startup

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1

Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3

Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-4

OCX 8800 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . page 3-4

VERIFY INSTALLATION

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.

Ensure the OCX 8800 is installed correctly. Vertify mechanical installation and all electrical and pneumatic connections. Refer to Section 2, Installation.

Make sure that the OCX 8800 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold OCX 8800 exposed to the process gases.

NOTE

During outages, and whenever possible, leave all OCX 8800 units running to prevent condensation and premature aging from thermal cycling.


OCX 8800


IM-106-880, Rev 1.0

January 2007

Verify Configuration

There are three switches on the microprocessor board which are user configurable for the OCX 8800 (Figure 3-1). SW1 determines if the O

2

4-20 mA signal is internally or externally powered. SW2 determines if the COe 4-20 mA signal is internally or externally powered. SW3 sets the rail limits for the

O

2

and COe 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 OCX 8800 before changing defaults. If defaults are changed under power, damage to the electronics may occur.

Verify that the following switch settings are correct for your OCX 8800 installation:

SW1 The two settings are internally or externally powering the O

2 mA signal. The factory setting is for the O

2 powered.

4-20

4-20 mA signal to be internally

SW2 The two settings are internally or externally powering the COe 4-20 mA signal. The factory setting is for the COe 4-20 mA signal to be internally powered.

SW3 The factory sets this switch as follows:

• Position 1 determines the O

2

4-20 mA signal rail limit. The settings are high, 21.1 mA, or low, 3.5 mA. The factory setting is low, 3.5 mA.

• Position 2 determines the COe 4-20 mA signal rail limit. The settings are high, 21.1 mA, or low, 3.5 mA. The factory setting is high, 21.1 mA.

• Positions 3 and 4 must be set as shown for proper software control of the device heaters.

3-2


IM-106-880, Rev 1.0

January 2007

Figure 3-1. OCX 8800 Defaults

OCX 8800

Open

Closed

Open

Switch

Default Postions

Shown

21.1 mA

3.5 mA

1 2 3 4

Closed

SW3

1 2

3 4

Open

Closed

Rail Limits:

High - 21.1 mA

Low - 3.5 mA

COe 21.1 mA/3.5 mA:

Open

Closed

COe 4-20 mA Signal

Rail Limits:

High- 21.1 mA

Low - 3.5 mA

1 2 3 4

Internal:

COe 4-20 mA is Internally

Powered

SW2

External:

COe 4-20 mA

Requires an External

Power Supply

(Default)

INITIAL POWER UP

Internal: is Internally

Powered

SW1

External:

Requires an External

Power Supply

(Default)

Allow adequate time (approximately 60 minutes) for the heaters to begin operation and for the OCX 8800 to reach normal operating temperature on power up. Normal operating temperature for the O

2

cell is 736°C. Normal operating temperature for the combustibles cell is 300°C. The normal sample line temperature is 170°C. During this time the eductor air solenoid will remain closed so no sample is pulled through the analyzer. When the OCX reaches operating temperature the solenoid will energize, eductor air will begin to flow, and the unit will begin normal operation.

3-3

OCX 8800

SET TEST GAS VALUES

OCX 8800 RESET

PROCEDURE


IM-106-880, Rev 1.0

January 2007

Use HART/AMS to set test gas values for calibration. Refer to Section 4,

Using HART Communications for more information.

Setting Test Gas Values with HART

1. Use the HART communicator or AMS software to access the HART menu.

2. From the DETAILED SETUP menu, select O2 CALIB PARAMS.

3. From O2 CALIB PARAMS, select O2 High Gas. Enter the percent O used for the high O

2

test gas.

2

4. From O2 CALIB PARAMS, select Low TG. Enter the percent O for the low O

2

test gas.

2

used

5. From the DETAILED SETUP menu, select COe CALIB PARAMS.

6. From COe CALIB PARAMS, select COe Test Gas. Enter the CO concentration (ppm) used for COe test gas.

Whenever you correct an equipment alarm or fault condition, the OCX 8800 will either revert to normal operation or continue to indicate an alarm status condition. If the equipment does not revert to normal operation when a fault condition is cleared, or if instructed to do so in Section 7, Troubleshooting, use the following procedure to reset the OCX 8800.

OCX Reset with HART

Remove the OCX 8800 from the process loop and recycle power.

3-4


IM-106-880, Rev 1.0

January 2007

Section 4

OCX 8800

Using HART Communications

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1

HART Communicator Signal Connections . . . . . . . . . . . . page 4-1

HART Communicator PC Connections . . . . . . . . . . . . . . . page 4-4

HART Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-5

D/A Trim Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-9

OVERVIEW

HART COMMUNICATOR

SIGNAL CONNECTIONS

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 OCX 8800, the HART communicator requires a termination point along the O

2

4-20 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 COe output signal.

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.

The HART communicator can connect to the OCX 8800 oxygen analog output signal line at any wiring termination in the O

2

4-20 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.


OCX 8800

Figure 4-1. Signal Line Connections,

≥ 250 Ohms Load Resistance

4-20 mA Terminal Block in


1

A OUT 1 +

A OUT 1 -

RL 250 Ω


IM-106-880, Rev 1.0

January 2007

Analog Output Device

Loop

Connectors

HART

Communicator

Model 275/375

Lead Set

HART Communicator

Rear Panel

Method 1, for Load Resistance ≥ 250 Ohms

Refer to Figure 4-1 and the following steps to connect the HART communicator to a signal line 250 ohms or more of load resistance.

Do not make connections to the HART communicator's serial port, 4-20 mA signal lines, or

NiCad recharger jack in an explosive atmosphere. Explosions can result in death or serious injury.

Using the supplied lead set, connect the HART communicator in parallel to the OCX 8800. Use any wiring termination points in the oxygen analog output

4-20 mA signal line.

4-2


IM-106-880, Rev 1.0

January 2007

OCX 8800

Method 2, for Load Resistance < 250 Ohms

Refer to Figure 4-2 and the following steps to connect the HART communicator to a signal line with less than 250 ohms load resistance.

Do not make connections to the HART communicator's serial port, 4-20 mA signal lines, or

NiCad recharger jack in an explosive atmosphere. Explosions can result in death or serious injury.

Figure 4-2. Signal Line Connections,

< 250 Ohms Load Resistance

4-20 mA Terminal Block in


1

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).

RL <250

Ω

O 4-20 mA Signal Line

2

A OUT 1 +

A OUT 1 -

Analog Output Device

Loop

Connectors

HART Communicator

Rear Panel

250 OHM

Load Resistor

(See Note)

HART

Communicator

Model 275/375

NOTE: The signal loop must be broken to insert the optional 250 ohm load resistor.

4-3

OCX 8800


IM-106-880, Rev 1.0

January 2007

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.

Off-line and On-line Operations

The HART communicator can be operated both off-line and on-line.

Off-line operations are those in which the communicator is not connected to the OCX 8800. Off-line operations can include interfacing the HART communicator with a PC. (Refer to applicable HART documentation regarding

HART/PC applications.)

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

OCX 8800 or in parallel to the 250 ohm load resistor.

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 (on-line) communicator, the LCD will display the On-line Menu. Refer to the HART communicator manual for detailed menu information.

4-4


IM-106-880, Rev 1.0

January 2007

HART MENU TREE

OCX 8800

This section consists of a menu tree for the HART communicator. This menu is specific to OCX 8800 applications.

Figure 4-3. HART Menu Tree

(Sheet 1 of 4)

DEVICE SETUP

O2

O2 AO

COe

COe AO

PROCESS

VARIABLES

(CONTINUED ON

SHEET 2)

VIEW DEV VARS

VIEW DEV

RAW VAL

VIEW OUTPUT

VARS

VIEW DEV

LIMITS

SV

TV

4V

VIEW O2 RAW VAL

VIEW COE RAW VAL

VIEW DEV RAW VAL

PV-AOUT

O2

COE

BOARD TEMP

SB TEMP

O2

COe

O2 Temp

COe Temp

SB Temp

Brd Temp

CJC Temp

O2 Snsr

O2 T/C

O2 Snsr R

O2 Snsr RS

COe DeltV

COe RefV

COe DeltaR

Coe RefR

COe T/C

RTD Curr

SB T/C

Brd Temp IC

CJC Temp S

PV is

O2

O2 AO

O2 AO %

SV is

COe

COe AO

COe AO %

TV is

O2 Temp

4V is

COe Temp

O2

O2

O2 USL

O2 LSL

O2 TEMP

O2 Temp

O2 T/C USL

O2 T/C LSL

COE

COe

COe USL

COe LSL

COE TEMP

COe Temp

COe T/C USL

COe T/C LSL

Brd Temp

Brd TC USL

Brd TC LSL

SB Temp

SB TC USL

SB TC LSL

4-5

OCX 8800

Figure 4-3. HART Menu Tree (Sheet 2 of 4)

(CONTINUED FROM

SHEET 1 )

DIAG/SERVICE

STATUS

HW STATUS

Operate Mode

Status group 1

Status group 2

Status group 3

Status group 4

Status group 5

Status group 6

AO saturated

AO fixed

Model Number

Snsr Housing

CPLD REGS

Line Freq

Line Volt

PCN Counter

PCD Counter

LOOP TEST

D/A TRIM

O2 D/A Trim

COe D/A Trim

PERFORM

CAL

CALIBRATE

CAL

STATUS

CAL VALUES

VERIFY CALIB

BLOWBACK

MAX TEMP

HEATER PID

PREV CAL

VALUES

FAILED CAL

VALUES

RESET CAL

CONST

Verify Calibration

Status

TimeRemain

O2

COe

BlBk State

Blowback

O2TempMax

COeTempMax

SBTempMax

BrdTempMax

CJCTempMax

O2 PID

COE PID

SB PID

(CONTINUED ON

SHEET 3)

4-6

O2 Prop

O2 Int

O2 DutyCyc

O2 SetPt

O2 Temp

COe Prop

COe Int

COe

COe

COe

DutyCyc

SetPt

Temp

SB Prop

SB Int

SB DutyCyc

SB SetPt

SB Temp


IM-106-880, Rev 1.0

January 2007

O2 AO Saturated

COe AO Saturated

O2 AO Fixed

COe AO Fixed

BCSR0

BCSR1

BCSR2

BCSR3

BCSR4

BCSR5

O2 Loop Test

COe Loop Test

(procedures)

CAL METHODS

O2OutTracks

COeOutTracks

Cal Step

Cal Time

O2

COe

Cal Step

Cal Time

O2 Slope

O2 Const

O2 Snsr R

COe Slope

COe Const

Prev O2 Slope

Prev

Prev

O2 Const

O2 Snsr R

Prev

Prev

COe Slope

COe Const

Bad O2 Slope

Bad O2 Const

Bad COe Slope

Bad COe Const

Reset O2 CalConsts

Reset COe CalConsts

Status group 1

O2 T/C Open

O2 T/C Shorted

O2 T/C Reversed

ADC Failure

Line Freq Error

O2 Htr Failure

O2 Temp Very Hi

Board Temp Hi

Status group 2

O2 Temp Low

O2 Temp Hi

O2 Snsr Open

O2 Snsr R Hi

EEPRM Chksm Fail

O2 Htr Ramp Rate

COe Htr Ramp Rate

SB Htr Ramp Rate

Status group 3

Cal Failed

Cal Warning

SB T/C Open

SB T/C Shorted

SB Temp Low

SB Temp Hi

SB Temp Very Hi

ADC Ref Error

Status group 4

RTD Current Err

COe Temp Low

COe Temp Hi

COe Temp Very Hi

COe T/C Open

COe T/C Shorted

COe T/C Reversed

SB T/C Reversed

Status group 5

COe Htr Failure

SB Htr Failure

Line Voltage Low

Line Voltage Hi

Htr Relay Failed

Output Board Failure

Status group 6

O2 Slope Error

O2 Constant Error

O2 Cal Failed

COe Slope Error

COe Constant Error

COe Cal Failed

O2 Calibration

COe Calibration

O2 and COe Calib


IM-106-880, Rev 1.0

January 2007


(Sheet 3 of 4)

(CONTINUED FROM

SHEET 2)

DEVICE

INFORMATION

BASIC SETUP

HART

INFORMATION

S/W VERSION

INFO

DETAILED

SETUP

OUTPUT

CONDITION

O2 CALIB

PARAMS

COe CALIB

PARAMS

DEVICE

PARAMS

(CONTINUED ON

SHEET 4)

LOI

PARAMS

OCX 8800

BLOWBACK

O2OutTracks

O2 High Gas

O2 Low Gas

Gas Time

Purge Time

Solenoids

O2 CalIntv

O2NxtCalTm

COeOutTracks

COe Test Gas

Gas Time

Purge Time

Solenoids

COe CalIntv

COeNxtCalTm

COe Slope Warn

O2 Slope

O2 Const

O2 T90

COe Slope

COe Const

COe T90

PCNC Enable

PCDC Enable

User Intface

Luminance

Lockout Time

Revert Time

Date

Descriptor

Message

Final asmbly num

O2 Sensor s/n

COe Sensor s/n

Tag

Poll addr

Dev id

Num req preams

Fld dev rev

Version

Chksum

Bld Num

Bld Date

Restart Cntr

ANALOG

OUTPUT

O2 ANALOG

OUTPUT

COe ANALOG

OUTPUT

ALARM

RELAY

O2 AO Type

O2 URV

O2 LRV

O2 Alarm Level

COe AO Type

COe URV

COe LRV

COe Alarm Level

Trig 1 Event

Trig 2 Event

Trig 3 Event

Alarm State

BlBk Enabled

BlBk Intrvl

BlBk Period

BlBk PurgeTm

BlBk State

4-7

OCX 8800


(Sheet 4 of 4)

(CONTINUED FROM

SHEET 3)

REVIEW DEVICE

INFORMATION

HART

INFORMATION

Manufacturer

Model

Date

Descriptor

Message

Final asmbly num

O2 Sensor s/n

COe Sensor s/n

Hardware rev

Software rev

Tag

Poll addr

Dev id

Num req preams

Fld dev rev

Universal rev

O2 CALIB

CAL INFO

COE CALIB

DEVICE

CONFIG

O2 DEVICE

CONFIG

COE DEVICE

CONFIG

DEVICE CONFIG

O2OutTracks

O2 High Gas

O2 Low Gas

Gas Time

Purge Time

Solenoids

O2 CalIntv

O2NxtCalTm

COeOutTracks

COe Test Gas

Gas Time

Purge Time

Solenoids

COe CalIntv

COeNxtCalTm

COe Slope Warn

O2 Slope

O2 Const

O2 T90

COe Slope

COe Const

COe T90

Trig 1 Event

Trig 2 Event

Trig 3 Event

BlBk Enabled

BlBk Intrvl

BlBk Period

BlBk PurgeTm

PCNC Enable

PCDC Enable

Luminance

Lockout Time

Revert Time


IM-106-880, Rev 1.0

January 2007

OUTPUTS

CONFIG

O2 URV

O2 LRV

COe URV

COe LRV

O2 AO Type

COe AO Type

O2 Alarm Level

COe Alarm Level

4-8


IM-106-880, Rev 1.0

January 2007

OCX 8800

D/A TRIM PROCEDURES O

2

D/A trim procedure using HART/AMS

Use the following procedure to perform the O

2

D/A trim procedure using the

HART communicator or AMS. Refer to the HART menu tree, Figure 4-3.

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.

1. From the DIAG/SERVICE menu, select D/A TRIM. The HART communicator displays O2 D/A Trim.

2. Press the right arrow key to start the procedure. (If you wish to exit D/A

Trim with no changes, select ABORT.)

3. The HART communicator displays WARNING: Loop should be

removed from automatic control. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

4. Remove the electronics housing cover.

5. Refer to Figure 2-5. Connect a digital multimeter to read the milliamp output from the O

2

D/A coverter circuit. Connect the positive lead to the

AOUT1+ terminal and connect the negative lead to the AOUT1- terminal. Then, press OK at the HART communicator.

6. The HART communicator displays Setting Fld dev output to 4 mA.

Press OK. Read the O

2 millamp output at the digital multimeter. Enter the reading at the HART communicator and press ENTER. (Select

ABORT to exit without changes).


Press OK. Read the O

2 millamp output at the digital multimeter. Enter the reading at the HART communicator and press ENTER. (Select



Press OK.

9. The HART communicator displays Fld dev output 4.00 mA equal to

reference meter? Using the up or down arrow, select 1 Yes or 2 No and Press ENTER. If No, the process repeats from step 6.


Press OK.



12. The HART communicator displays NOTE: Loop may be returned to

automatic control.

4-9

OCX 8800


IM-106-880, Rev 1.0

January 2007

COe D/A trim procedure using HART/AMS

Use the following procedure to perform the COe D/A trim procedure using the

HART communicator or AMS. Refer to the HART menu tree, Figure 4-3.

NOTE



1. From the DIAG/SERVICE menu, select D/A TRIM. The HART communicator displays O2 D/A Trim. Press the up or down arrow to select COe D/A Trim.

2. Press the right arrow key to start the procedure. (If you wish to exit D/A

Trim with no changes, select ABORT.)

3. The HART communicator displays WARNING: Loop should be

removed from automatic control. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.


5. Refer to Figure 2-5. Connect a digital multimeter to read the milliamp output from the COe D/A coverter circuit. Connect the positive lead to the AOUT2+ terminal and connect the negative lead to the AOUT2- terminal. Then, press OK at the HART communicator.


Press OK. Read the COe millamp output at the digital multimeter. Enter the reading at the HART communicator and press ENTER. (Select



Press OK. Read the COe millamp output at the digital multimeter. Enter the reading at the HART communicator and press ENTER. (Select



Press OK.




Press OK.



12. The HART communicator displays NOTE: Loop may be returned to

automatic control.

4-10


IM-106-880, Rev 1.0

January 2007

Section 5

OVERVIEW

FULLY AUTOMATIC

CALIBRATION

OCX 8800

Calibration

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-1

Fully Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . page 5-1

Operator - Initiated Autocalibration . . . . . . . . . . . . . . . . . page 5-3

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-3

During a calibration, two calibration gases with known O

2

concentrations and one calibration gas with a known COe concentration are applied to the OCX

8800. Slope and constant values are calculated to determine if the OCX 8800 is correctly measuring net concentrations of O industrial process.

2

and combustibles in the

Before calibrating the OCX 8800, verify that the calibration gas parameters are correct by setting the test gas values used when calibrating the unit. Refer to Section 3, Configuration and Startup.

There are three calibration methods available to the OCX 8800; automatic, operator-initiated automatic, and manual. Calibration commands and menus can be accessed by HART/AMS.

If the OCX 8800 is equipped with calibration solenoids, the unit can be programmed to automatically calibrate without any operator action. Refer to the following paragraphs for using HART/AMS to set up the OCX 8800 for fully automatic calibration.

Autocalibration Setup using 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

OCX 8800 will automatically calibrate.

1. From the DEVICE SETUP screen, select DETAILED SETUP.

2. From the DETAILED SETUP screen, select O2 CALIB PARAMS or

COE CALIB PARAMS.

3. If the unit is equipped with calibration solenoids and timed automatic calibrations are desired, select Solenoids, then select Yes. Selct No to disable the calibration solenoids.


OCX 8800


IM-106-880, Rev 1.0

January 2007

4. Select O2 CalIntrvl (O

2

calibration interval) and enter the desired time in hours between automatic O

2

calibrations. Select COE Callintrvl and enter the desired time between automatic COe calibrations. To disable automatic calibration for O

2 parameters.

and COe, enter 0 for both CalIntrvl

5. If desired, the O2NxtCalTm and the COeNxtCalTm (next calibration time) parameters can be changed to synchronize a calibration at a specific day or time.

When setting automatic calibration times, CalIntrvl and NxtCalTm should be set so that O and COe are NOT calibrated simultaneously.

2

NOTE



6. From the O2 CALIB PARAMS screen, select CalIntrvl.

7. At the prompt, input a time interval (in hours) at which an automatic O calibration will occur and press ENTER.

2

8. From the DETAILED SETUP screen, select COE CALIB PARAMS.

9. From the COE CALIB PARAMS menu, select CalIntrvl.

10. At the prompt, input a time interval (in hours) at which an automatic COe calibration will occur and press ENTER.

5-2


IM-106-880, Rev 1.0

January 2007

OCX 8800

OPERATOR - INITIATED

AUTOCALIBRATION

MANUAL CALIBRATION

An operator can initiate an automatic calibration at any time provided that the unit is equipped with calibration solenoids.

Autocalibration using HART

To initiate an automatic calibration using HART/AMS, perform the following steps on the HART menu tree. Refer to Section 4, Using HART

Communications, for the HART menu tree.

1. Select DIAG/SERVICE from DEVICE SETUP menu.

2. Select CALIBRATE from the DIAG/SERVICE menu.

3. Select PERFORM CAL from the CALIBRATE menu.

4. Select CAL METHODS from the PERFORM CAL menu.

5. From the CAL METHODS menu, select the type of calibration desired:

O2 Calibration, COe Calibration, or O2 and COe 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 the following paragraphs for manual calibration.

Manual O

2

Calibration using HART

To perform a manual O

2

calibration using the HART communicator or AMS, use the following procedure. If necessary, refer to Section 4, Using HART


NOTE



1. From the DIAG/SERVICE menu, select CALIBRATION. From the

CALIBRATION menu, select PERFORM CAL.

2. From the PERFORM CAL menu, select CAL METHODS. Select O2

CALIBRATION to start O

2

calibration.

3. In the first O

2

Calibration screen, a Loop should be removed from

automatic control warning appears. Remove the OCX 8800 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

4. The main Calibration screen should look like the following. Press OK to continue.

OCX: TAG NAME

STATUS: Idle

TIME REMAIN: 0s

O2: 0.4 %, 85.95mV

OK/NEXT to Select

ABORT/CANCEL to Exit

5-3

OCX 8800


IM-106-880, Rev 1.0

January 2007

5. From the SELECT ACTION screen, select START/NEXT CALSTEP to continue calibration, select ABORT CAL to abort calibration or EXIT

CAL to exit calibration. Select one item from the list and press ENTER.

OCX: TAG NAME

SELECT ACTION

1. START/NEXT CALSTEP

2. ABORT CAL

3. EXIT CAL

6. When the Calibration Status is at the AppO2Low step, switch on O

Low Gas. Verify the O

2

2

concentration measured matches the O2 LOW

GAS parameter in the Setup. Press OK when ready.

7. Select Start/Next Cal Step to start applying the O

2 to apply the test gas is specified by the Gas Time.

Low Gas. The time

8. The Calibration Status should be automatically changed to FlowO2Low and then ReadO2Low for a period of time. During this period, if an attempt is made to go to the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step

command is not accepted at this time. The Next Cal Step command is not accepted at this time.

9. When ready, Calibration Status will stop at the AppO2Hi. Switch off the

O

2

Low Gas and switch on the O

2

High Gas. Verify the O

2

concentration measured matches the O2 HIGH GAS parameter in the Setup. Press

OK when ready.



High Gas. The time

11. The Calibration Status should be automatically changed to FlowO2Hi and then ReadO2Hi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting

Start/Next Cal Step, you will be prompted with Operator step


12. When ready, Calibration Status will stop at STOP GAS. Switch off the

O

2

High Gas. Press OK when ready. Select Start/Next Cal Step to start purging gas. The time to purge gas is specified by the Purge Time.

13. When the Purge step is complete, the Calibration Status will be at IDLE if the calibration is successful or CAL RECOMMENDED if the calibration has failed. A Calibration Failed alarm will be set if the calibration has failed.

14. When calibration is complete. Select Exit Cal to exit the calibration method.

5-4


IM-106-880, Rev 1.0

January 2007

OCX 8800

Manual COe Calibration using HART

To perform a manual COe calibration using the HART communicator or AMS, use the following procedure. If necessary, refer to Section 4, Using HART


NOTE





2. From the PERFORM CAL menu, select CAL METHODS. Select COe

CALIBRATION to start COe calibration.

3. In the first COe Calibration screen, a Loop should be removed from



OCX: TAG NAME

STATUS: Idle

TIME REMAIN: 0s

COe: 0.20 ppm, 0.00 mV




CAL to exit calibration. Select one item from the list and press ENTER.

OCX: TAG NAME

SELECT ACTION


2. ABORT CAL

3. EXIT CAL

6. The unit samples reference air as the COe Low Gas. The Calibration

Status should automatically change to ReadCOLow for a period of time.

During this period, if an attempt is made to go to the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step command is not accepted at this time.

The Next Cal Step command is not accepted at this time.

7. When ready, Calibration Status will stop at the AppCOeHi. Switch on the COe High Gas. Verify the COe concentration measured matches the

COe HIGH GAS parameter in the Setup. Press OK when ready.

8. Select Start/Next Cal Step to start applying the COe High Gas. The time to apply the test gas is specified by the Gas Time.

5-5

OCX 8800


IM-106-880, Rev 1.0

January 2007

9. The Calibration Status should be automatically changed to FlowCOeHi and then ReadCOeHi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting Start/Next Cal Step, you will be prompted with Operator step



COe High Gas. Press OK when ready. Select Start/Next Cal Step to start purging gas. The time to purge gas is specified by the Purge Time.

11. When the Purge step is complete, the Calibration Status will be at IDLE if the calibration is successful or CAL RECOMMENDED if the calibration has failed. A Calibration Failed alarm will be set if the calibration has failed.

12. When calibration is complete. Select Exit Cal to exit the calibration method.

Manual O

2

and COe Calibration using HART

To perform a manual O

2

and COe calibration using the HART communicator or AMS, use the following procedure. If necessary, refer to Section 4, Using

HART Communications, for the HART menu tree.

NOTE





2. From the PERFORM CAL menu, select CAL METHODS. Select 02 &

COe CALIBRATION to start O

2

and COe calibration.

3. In the first Calibration screen, a Loop should be removed from



OCX: TAG NAME

STATUS: Idle

TIME REMAIN: 0s

O2: 0.4 %, 85.95mV

COe: 0.20 ppm, 0.00 mV



5-6


IM-106-880, Rev 1.0

January 2007

OCX 8800


CAL to exit calibration. Select one from the list and press ENTER.

OCX: TAG NAME

SELECT ACTION


2. ABORT CAL

3. EXIT CAL

6. When the Calibration Status is at the AppO2Low step, switch on O

Low Gas. Verify the O

2

2

concentration measured matches the O2 LOW

GAS parameter in Setup. Press OK when ready.



Low Gas. The time

8. The Calibration Status should automatically change to FIowO2Low and then ReadO2Low for a period of time. During this period, if an attempt is made to go to the next calibration step by pressing OK and selecting



9. When ready, Calibration Status will stop at AppO2Hi. Switch off the O

Low Gas and switch on the O

2

High Gas. Verify the O

2

concentration measured matches the O2 HIGH GAS parameter in Setup. Press OK when ready.

2

10. Select Start/Next Cal Step to apply the O

2 the test gas is specified by the Gas Time.

High Gas. The time to apply

11. The Calibration Status should automatically change to FlowO2Hi, then

ReadO2Hi, and then ReadCOeLo for a period of time. During this period, if an attempt is made to go the next calibration step by pressing

OK and selecting Start/Next Cal Step, you will be prompted with

Operator step command is not accepted at this time. The Next Cal

Step command is not accepted at this time.

12. When ready, Calibration Status will stop at AppCOeHi. Switch off the O

2

High Gas and switch on the COe Gas. Verify the COe concentration measured matches the COe TEST GAS parameter in the Setup. Press

OK when ready.

13. Select Start/Next Cal Step to start applying the COe Gas. The time to apply the test gas is specified by the Gas Time.

14. The Calibration Status should automatically change to FlowCOeHi and then ReadCOeHi for a period of time. During this period, if an attempt is made to go the next calibration step by pressing OK and selecting




COe gas. Press OK when ready. Select Start/Next Cal Step to start purging gas. The time to purge gas is specified by Purge Time.

5-7

OCX 8800


IM-106-880, Rev 1.0

January 2007

5-8


IM-106-880, Rev 1.0

January 2007

Section 6

OVERVIEW

Maintenance and Service

OCX 8800

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-1

OCX 8800 Removal and Installation . . . . . . . . . . . . . . . . . page 6-1

Repair Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-8

Repair Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . page 6-28

Replace Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-34

This section contains the procedures to maintain and service the OCX 8800.

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 OCX 8800 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.

OCX 8800 REMOVAL

AND INSTALLATION

Observe housing classification guidelines prior to removing cover. Failure to observe classification guidelines may result in serious injury or death.

Use the following procedures to remove or install the OCX 8800. http://www..raihome.com

OCX 8800

OCX with

Remote Electronics


IM-106-880, Rev 1.0

January 2007

Remove Sensor Housing

1. Turn off power to the system.

2. Shut off the test gasses at the cylinders and close the instrument air valve.

3. Disconnect the calibration gas, reference air, eductor air, and dilution air lines from the sensor housing, Figure 6-1.

Figure 6-1. OCX with

Remote Electronics

Duct

Sensor

Housing

Heater

Power Cable

Signal Cable

Stack

Eductor Air

Air

Ref erence

Dilution

Air

Test

Gas

Instrument Air

Electronics

Housing

4-20 mA

Outputs

AC Power

Input

Instrument Air

(Reference Gas)

CO Test Gas

6-2


IM-106-880, Rev 1.0

January 2007

OCX 8800

4. Remove the cover from the sensor housing to expose the sensor housing terminal blocks, Figure 6-2.

5. Disconnect the signal cable from the O

2 from the CO and CJC terminal blocks.

and T/C terminal blocks, and

6. Disconnect the heater power cable from the HTR terminal blocks.

7. If moving the sensor housing to another work site, disconnect and remove the power and signal cables from the sensor housing.

8. Remove insulation to access the mounting bolts. Unbolt the sensor housing from the stack and take it to a clean work area.

9. Allow the sensor housing to cool to a comfortable working temperature.

Figure 6-2. Sensor

Housing Terminals

NOTE: Wire colors shown are for cables supplied by Emerson Process

Management.

SENSOR HOUSING

To

Ground

Screw

6-3

OCX 8800


IM-106-880, Rev 1.0

January 2007

Install Sensor Housing

1. Connect the test gas, reference air, eductor air, and dilution air lines to the sensor housing.

2. Remove the sensor housing cover.

3. If removed, install the power and signal cables and the customer power and signal conduits and wiring at the sensor housing.

4. Connect the signal cable to O

2

and T/C terminal blocks and to the CO and CJC terminal blocks, Figure 6-2. Connect the heater power cable to the HTR terminal blocks.

5. Refer to Figure 6-1 and make sure all test gas lines and electrical connectors are complete.

6. Install the sensor housing cover.

7. Restore power to the system. Allow OCX to reach normal operating temperature before installing in a hot process stack.

8. Insert and bolt the sensor housing in the stack and install insulation.

9. Turn on the test gases at the cylinders and open the instrument air supply valve.

Remove Remote Electronics Housing

1. Turn off power to the system.

2. Shut off the test gases at the cylinders and close the instrument air supply valve, Figure 6-1.

3. Disconnect the test gas and instrument air lines from the remote electronics housing.

4. Remove the cover from the electronics housing to expose the electronics housing terminal blocks, Figure 6-3.

5. Disconnect and remove the power leads from the AC power input terminal block. Remove the ground lead from the ground stud.

6. Disconnect and remove the O signal output terminal block.

2

and COe signal leads from the 4-20 mA

7. If used, disconnect and remove the external relay leads from the alarm output relay terminal block.

8. Disconnect the signal cable leads from O

2

cell and thermocouple connector (J4), and from COe and CJC connector (J5), Figure 6-4.

9. Disconnect the heater cable leads from the heater power connector

(J3).

10. If moving the electronics housing to another work site, disconnect and remove the power and signal cables and customer wiring conduits from the housing.

11. Remove the remote electronics housing from its mounting and move it to a suitable work area.

6-4


IM-106-880, Rev 1.0

January 2007

Figure 6-3. Electronics Housing

Terminal Blocks

OCX 8800

#1

NC

COM

NO


Terminal Block

4-20 mA Signal Output

Terminal Block

COe Signal

{

{

AOUT2+

AOUT2 -

AOUT1 -

AOUT1+

#1

Signal Port

3/4 NPT

EMI Filter

TOP VIEW

(1/2 SIZE)

Ground Stud

Earth Ground

Typical for Electronics and

Sensor Housing

Customer

Wiring

G N L1

G

Terminal

Block

Ground

Stud

G

Power Port

3/4 NPT

External Tooth

Lockwasher

6-5

OCX 8800

Figure 6-4. Remote Electronics

Housing Cable Connections

#1

YEL

RED

BLK

ORG

WHT

BLU

Heater Power

Connector (J3)

2HTR CO

1HTR CO

2HTR O

2

1HTR O

2

2HTR SB

1HTR SB

#1

#1

To

Ground

Screw

#1


IM-106-880, Rev 1.0

January 2007

Signal Cable

Heater

Power Cable

RED

BLK

WHT

BLK

GRN

BLK

BLU

BLK

#1

T/C CO+

T/C CO-

T/C SB+

T/C SB-

T/C O2+

T/C O2-

O2 CELL+

O2 CELL-

O2 Cell

& Thermocouple

Connector (J5)

SHLD

COe Sensor

& CJC

Connector (J4)

YEL

BRN

BLK

RED

WHT

ORG

BLK

BLK

#1

To Ground

Screw

EXC+

CO ACT+

CO ACT-

CO REF+

CO REF-

CJC+

CJC-

EXC-


NOTE: Wire colors shown are for cables supplied by Emerson Process Management.

6-6


IM-106-880, Rev 1.0

January 2007

OCX 8800

Install Remote Electronics Housing

1. Mount remote electronics housing on wall or pipe within distance of signal and heater cables in use.


3. If removed, install the power and signal cables and the customer power and signal conduits and wiring at the electronics housing.

4. Connect the signal cable leads to the O

2

cell and thermocouple connector (J4), and to the COe and CJC connector (J5), Figure 6-4.

5. Connect the heater cable leads to the heater power connector (J3).

6. Connect the line (L1 wire) to the L1 terminal, and the neutral (N wire) to the N terminal on the AC power input terminal block, Figure 6-4.

7. Connect the ground lead to the ground stud. Secure the connection with two nuts. Attach a separate ground lead (G wire) from the ground stud to the G terminal on the power input terminal block.

8. If used, connect external relay leads to the alarm output relay terminal.

9. Connect the test gas and instrument air lines to the remote electronics housing. Connect the calibration gas line and instrument air line to the remote electronics housing.

10. Refer to Figure 6-1 and Figure 6-4. Make sure all test gas lines and electrical connections are complete.

11. Install the cover on the electronics housing.

12. Turn on the test gasses at the cylinders and open the instrument air valve.

13. Restore power to the system.

6-7

OCX 8800

REPAIR SENSOR

HOUSING

Sensor Housing

Disassembly


IM-106-880, Rev 1.0

January 2007

Use the following procedures to remove damaged components from the OCX

8800 sensor housing and to install new replacement parts. Disassemble the unit only as needed to replace damaged components. Use the assembly procedures that apply to install replacement parts and reassemble the unit.

Remove Cover and Terminals Insulator

1. Loosen screw (1, Figure 6-5) and slide locking clip (2) away from cover.

Retighten screw (1).

2. With two hands or strap wrench, turn cover (3) counterclockwise to loosen. Unthread and remove cover.

3. Inspect cover o-ring (4) for wear or damage. Replace cover o-ring if damaged.

4. Unsnap terminal marking plates (5) and remove terminal insulator (6).

6-8


IM-106-880, Rev 1.0

January 2007

Figure 6-5. Removal of O

2 and Heater Strut Assembly

Cell

1. Screw

2. Locking Clip

3. Cover

4. O-ring

5. Marking Plate

6. Terminal Insulator

7. Reference Air Tube

8. Sensor Housing

9. Heater Strut Assembly

10. Gasket

11. Screw

12. Heater Clamp

13. Heater Rod

14. Insulator

15. Thermal Switch

9

14

11

10

12

15 5

6

4

8

1

2

3

15

13

OCX 8800

7

6-9

OCX 8800

Figure 6-6. O

2

Cell,

Thermocouple, and

Heater Connections


IM-106-880, Rev 1.0

January 2007

O2

-

+

2

HTR 02

1

2

HTR SB

1

2

1

ORG

GRN

RED

YEL

Thermocouple Wires

+

+

+

-

+

T/C O2

-

+

T/C CO

+

-

+

T/C SB

Sample

Block

Thermocouple

-

EXC

+

CJC

Assembly

+

Sample Block

Heater Rods

-

+

CO REF

-

+

CO ACT

+ EXC

Thermal

Switch

Remove O

2

Cell and Heater Strut Assembly

1. Remove reference air tube (7, Figure 6-5) from sensor housing (8).

2. See Figure 6-6. Disconnect and tag O

2

heater wires, O

2

cell and return wires, and thermocouple wires at the sensor housing terminals.

3. Remove the O

2

cell and heater strut assembly (9, Figure 6-5) from sensor housing (8). Remove and discard gasket (10).

Remove Sample Block Heater Rods

1. Disconnect sample block heater rod wires from terminal block. Refer to

Figure 6-6.

6-10


IM-106-880, Rev 1.0

January 2007

Figure 6-7. COe Sensor,

Thermocouple, and Heater

Connections

OCX 8800

2. Loosen screws (11, Figure 6-5) and rotate heater clamps (12) to release heater rods (13). One heater clamp secures each heater rod.

3. Slide sample block heater rods (13) out of housing (8).

4. To replace thermal switch (15), remove insulator (14). Disconnect heater wires. Unscrew and remove thermal switch.

Remove COe Sensor Assembly

1. Disconnect COe heater, thermocouple, and sensor wires from terminal blocks. Refer to Figure 6-7.

2. Remove insulator (1, Figure 6-8).

O2

2

HTR 02

1

2

HTR SB

1

2

1

+

-

CJC Sensor

RED

YEL

-

+

CO REF

-

+

CO ACT

+ EXC

COe Heater Wires

COe Sensor Wires

COe Thermocouple Wires

-

+

T/C O2

-

+

T/C CO

-

+

T/C SB

- EXC

-

+

CJC

NOTE: All wires at these terminals are in the CJC current loop.

COe Sensor

Assembly

6-11

OCX 8800

Figure 6-8. Removal of

COe Sensor Assembly

10

8

12

14

5

11

9

15

6

13

16

7


IM-106-880, Rev 1.0

January 2007

NOTE

For easier access, you may remove two screws from base of terminal block mounting (13) and move terminal block assembly out of the way.

3. Remove tubes (2, 3, and 4) from COe sensor assembly (5), eductor fittings (12 and 15), and sensor housing (7).

4. Unfasten bayonet connector of COe thermocouple (8) and remove thermocouple.

5. Loosen clamp screw of COe band heater (9) until heater rotaters freely on sensor holder (11).

1

2

3

4

1. Insulator

2. Dilution Air Tube

3. COe Extractive Tube

4. Eductor Air Tube

5. COe Sensor Assembly

6. Eductor

7. Sensor Housing

8. COe Thermocouple

9. Heater Insulator

10. COe Band Heater

11. Sensor Holder

12. Eductor Elbow

13. Terminal Block Mounting

14. Eductor Holder

15. Tube Fitting

16. CJC Sensor

6-12


IM-106-880, Rev 1.0

January 2007

OCX 8800

6. See Figure 6-9. Using straightedge on the sensor holder flat, as shown, matchmark upper flange of sensor housing to show correct alignment of sensor holder.

7. With one wrench holding eductor elbow (12, Figure 6-8), and one wrench on flats of sensor holder (11), unthread and remove COe sensor assembly (5). Do not allow eductor elbow to turn.

8. Slide band heater (10) and heater insulator (9) from sensor holder (11).

Figure 6-9. Alignment of

COe Sensor Assembly

Sensor

Holder

Flat

Matchmark

Straightedge

Matchmark

6-13

OCX 8800


IM-106-880, Rev 1.0

January 2007

Figure 6-10. Eductor Alignment

Matchmarks

Remove Eductor

The O

2

cell and heater strut assembly (9, Figure 6-5) and the COe sensor assembly (5, Figure 6-8) must be removed before you start this procedure.

1. Use straightedge to matchmark alignment of eductor flat and elbow, as shown in Figure 6-10.

Eductor Flat

Straightedge

Matchmark

2. Unscrew terminal block mounting (13, Figure 6-8). Move terminal block mounting away from eductor (6).

3. Unscrew eductor holder (14) with eductor (6) and fittings (12 and 15) from sensor housing (7).

4. Clamp flats of eductor (6) in jaws of bench vise.

Use heat resistant gloves when removing mating parts from the eductor. The mating parts are bonded with a thread sealing compound. The compound softens at 450°F (232°C). The heated parts can cause severe burns.

5. Use a propane torch to heat the eductor (6) to 450°F (232°C), minimum.

Apply the heat near the screw threads.

6. While heating the eductor (6), use wrench to apply removal torque to elbow (12), eductor holder (14), or tube fitting (15) until the thread sealant softens. Remove mating parts (12, 14, and 15).

7. Use MEK or methylene chloride solvent to clean thread sealant residue from the pipe threads of the mating parts. Refer to applicable MSDS sheet for solvent handling precautions.

6-14


IM-106-880, Rev 1.0

January 2007

Figure 6-11. Removal of Sample and Exhaust Tubes

Remove Sample and Exhaust Tubes

OCX 8800

Use heat resistant gloves when removing the probe tube or exhaust tube. The tubes are bonded with a thread sealing compound. The compound softens at 450°F (232°C). The heated parts can cause severe burns.

1. Secure the sensor housing (1, Figure 6-11) in soft (plastic, wood, or brass) vice jaws.

2. Use a propane torch to heat the sample tube (2) or exhaust tube (3) to

450°F (232°C), minimum. Apply the heat near the threaded end of the tube.

3. While heating the tube, use a pipe wrench to apply removal torque to part being removed. Apply torque until the pipe thread sealant softens.

Remove and discard the used sample tube (2), exhaust tube (3), or in-situ filter (4).

4. Use MEK or methylene chloride solvent to clean thread sealant residue from the internal pipe threads in the housing. Refer to applicable MSDS sheet for solvent handling precautions.

1

2 3

1. Sensor Housing

2. Sample Tube

3. Exhaust Tube

4. In Situ Filter

4

6-15

OCX 8800


IM-106-880, Rev 1.0

January 2007

Figure 6-12. O

View

2

Cell, Heater, and Thermocouple, Exploded

1

4

12

11

10

2

6

7

8

9

1. Screw

3. Heater Tube

4. Contact/

Thermocouple

Assembly

5. Gasket

6. Screw

7. Lockwasher

8. Return Wire

9. Heater Strut

Assembly

10. Spring Clip

11. Spring

12. Strut Bracket

3

5

Test Gas

Passage

Holes

Do not remove the O

2

cell unless you are certain it needs to be replaced. Removal may damage the cell and platinum pad. Remove the O

2

cell for cell replacement only.

Disassemble O

2


Do not attempt to replace the O

O

2

2

cell until all other possibilities for poor performance have been considered. If cell replacement is needed, order the

cell replacement kit (Refer to Section 8, Replacement Parts).

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 package until they are ready to be used.

1. Remove the four allen cap screws (1, Figure 6-12) from the O

2

cell (2).

Remove the O

2

cell. The cell flange has a notch that may be used to gently pry the flange away from heater tube (3).

NOTE

The pad on the end of contact/thermocouple assembly (4) will sometimes fuse to the O

2

cell (2).

2. 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 (4) must be installed.

3. Remove and discard gasket (5). Clean the mating surface of heater tube (3). Remove burrs and raised surfaces with a block of wood and crocus cloth.

Use care when handling contact and thermocouple assembly. The ceramic rod in this assembly is fragile.

4. Remove screws (6), lockwashers (7), return wire (8), and heater strut assembly (9).

5. If replacing contact and thermocouple assembly (4), use a pencil to mark location of spring clip (10) before removing. Squeeze tabs on spring clip to remove. Retain spring clip and spring (11); replace if damaged.

6. While carefully handling new contact and thermocouple assembly (4) lay old assembly next to new one. Transfer match marks to new assembly.

7. Carefully guide new contact and thermocouple assembly (4) through strut bracket (12), spring (11), and spring clip (10) until spring clip reaches pencil mark.

6-16


IM-106-880, Rev 1.0

January 2007

OCX 8800

Disassemble COe Sensor Assembly

1. Carefully remove screws (1, Figure 6-13), lockwashers (2), and COe sensor (3) from sensor holder (4). Remove and discard gasket (5).

2. If damaged, use the following procedure to remove thermocouple adaptor (6) from sensor holder (4): a. Use a propane torch to heat the thermocouple adaptor to 450°F

(232°C), minimum. b. While heating, use a flat-head screwdriver to apply removal torque.

Apply torque until the pipe thread sealant softens. Remove and discard the thermocouple adaptor.

c. Use MEK or methylene chloride solvent to clean thread sealant residue from the internal pipe threads in the sensor holder. Refer to applicable MSDS sheet for solvent handling precautions.


Exploded View

1

2

3

7

5

6 9

8

4 1. Screw

2. Lockwasher

3. COe Sensor

4. Sensor Holder

5. Gasket

6. Thermocouple Adapter

7. Pre-Heater

8. Plug

9. Stainless Steel Balls

6-17

OCX 8800

Sensor Housing

Assembly


IM-106-880, Rev 1.0

January 2007

Always remove the stainless steel balls (approximately 200) from sensor holder before removing or installing pre-heater. Turning pre-heater in the sensor holder with the stainless steel balls in place will cause permanent damage to the pre-heater.

3. If pre-heater (7) is to be removed, clamp flats of sensor holder (4) in vise jaws with plug (8) pointing up. Remove plug. Unclamp sensor holder and pour stainless steel balls (9) into a container.

NOTE

Pre-heater should only be removed when pre-heater or sensor holder is damaged. If removal is not required, leave the pre-heater installed in the sensor holder.

4. Unthread and remove pre-heater (7).

5. Use a cleaning solvent to thoroughly clean stainless steel balls (9) and pre-heater chamber in sensor housing (4). Refer to applicable MSDS sheet for solvent handling precautions.

Assemble COe Sensor Assembly

Always remove the stainless steel balls (approximately 200) from sensor holder before removing or installing pre-heater. Turning pre-heater in the sensor holder with the stainless steel balls in place will cause permanent damage to the pre-heater.

1. If pre-heater (7, Figure 6-13) was removed, apply pipe thread sealant

(Loctite #567) to the external pipe threads of pre-heater (7) and plug (8).

Do not apply sealant to the first turn of the pipe threads.

2. Clamp flats of sensor holder (4) in vise jaws with pre-heater port pointing up.

3. Install and tighten pre-heater (7). Align pre-heater to flat of sensor holder (4) as shown in Figure 6-14.

4. Invert sensor holder (4, Figure 6-13) in vise and pour stainless steel balls (9) into plug port. Press down on stainless steel balls and tap sensor holder with plastic hammer to compact balls in pre-heater chamber.

5. Install and tighten plug (8).

Use care when installing the combustibles (COe) sensor. The RTD elements are fragile and correct alignment in sensor holder is required for proper OCX operation.

6. Lubricate and install COe sensor gasket (5). Apply anti-seize compound to threads of screws (1).

6-18


IM-106-880, Rev 1.0

January 2007

Figure 6-14. COe Sensor and

Pre-Heater Alignment

OCX 8800

THERMOCOUPLE

2 to 2-1/4 in.

(51 to 57 mm)

Sensor

Holder

Flat

Sensor

Holder

COe

SENSOR ASSEMBLY

TOP VIEW

COe Sensor

Flat

Pre-Heater

Flat

Sensor

Holder

Flat

7. Install COe sensor (3), lockwashers (2), and screws (1). Rotate flat of

COe sensor (3) to center of sensor holder (4).

8. Align COe sensor flat parallel to sensor holder flat, as shown in

Figure 6-14. Tighten screws (1, Figure 6-13).

9. If replacing thermocouple adaptor (6), apply anti-seize to the pipe threads. Install and tighten thermocouple adaptor.

Assemble O

2

Sensor and Heater Strut Assembly

1. See Figure 6-12. Assemble O components.

2

cell (2), gasket (5), and heater tube (3).

Make sure the test gas passage holes line up with each other in all

2. Apply a small amount of anti-seize compound to the screw threads and use screws (1) to secure assembly. Torque to 35 in-lbs (4 N·m).

3. Carefully slide O

2

heater strut assembly (9) into heater tube (3).

4. Press down on the back plate of strut bracket (12) to ensure spring (11) tension is present to hold contact pad against O

2

cell (2).

5. Secure strut bracket (12) and return wire (8) with four screws (6) and lockwashers (7). Make sure return wire (8) is tightly fastened. This is the ground side connection for the O

2

cell.

Install Sample and Exhaust Tubes

1. See Figure 6-11. Apply pipe thread sealant (Loctite #567) to the replacement sample tube (2) or exhaust tube (3) pipe threads. Do not apply sealant to the first turn of the pipe threads.

2. Thread the sample tube (2) or exhaust tube (3) into the housing (1). Use a pipe wrench to tighten the tube.

3. If used, install and tighten in-situ filter (4).

6-19

OCX 8800

Figure 6-15. Installation of

Eductor and COe Sensor

10

8

12

14

5

11

9

15

6

13

16

7


IM-106-880, Rev 1.0

January 2007

Install Eductor

If installed, the O

2

cell and heater strut assembly (9, Figure 6-5) must be removed from sensor housing (8), before you install the eductor.

1. Apply pipe thread sealant (Loctite #567) to the external pipe threads of eductor (6, Figure 6-15). Do not apply sealant to the first turn of the pipe threads.

4

3

1

2

1. Insulator

2. Dilution Air Tube

3. COe Extractive Tube

4. Eductor Air Tube

5. COe Sensor Assembly

6. Eductor

7. Sensor Housing

8. COe Thermocouple

9. Heater Insulator

10. COe Band Heater

11. Sensor Holder

12. Eductor Elbow

13. Terminal Block Mounting

14. Eductor Holder

15. Tube Fitting

16. CJC Sensor

6-20


IM-106-880, Rev 1.0

January 2007

OCX 8800

2. Install and tighten eductor (6) in eductor holder (14).

3. Install and tighten elbow (12) on eductor (6). Male port of elbow must point up and be in line with long axis of eductor.

4. Apply anti-seize compound to the external pipe threads of eductor holder (14).

5. Install and tighten eductor holder (14) in sensor housing (7). Align eductor with matchmarks, as shown in Figure 6-16.

Figure 6-16. COe Sensor

Parts Alignment

Eductor Flat

Straightedge

Matchmark

6-21

OCX 8800


IM-106-880, Rev 1.0

January 2007

Figure 6-17. Band Heater Height

COe Sensor

0.37 in.

(9,4 mm)

Install COe Sensor Assembly

1. Apply pipe thread sealant (Loctite #567) to the exposed pipe threads of eductor elbow (12, Figure 6-15). Do not apply sealant to the first turn of the pipe threads.

2. Screw sensor holder (11) onto eductor elbow (12).

3. With wrenches on eductor elbow (12) and on flats of sensor holder (11), tighten sensor holder. Do not allow eductor elbow to turn.

4. Tighten sensor holder (11) to align outside flat with matchmark on sensor housing flange, as shown in Figure 6-18.

Band Heater Insulator

The heater insulator prevents current leakage between the band heater and the sensor holder. Failure to properly install the insulator may cause the device to trip a ground fault interrupt circuit.

5. Wrap heater insulator (9) around sensor holder (11). Make sure the insulator joint lines up with the band gap of the COe band heater (10).

6. Slide COe band heater (10, Figure 6-15) up onto sensor holder (11). Do not tighten the band heater at this time. Heater must rotate freely around sensor holder.

7. Check for proper height of COe heater thermocouple (Figure 6-14).

Thread bayonet connector up or down to adjust height.

8. Install and fasten thermocouple (8, Figure 6-15).

9. Position band heater as shown in Figure 6-17 and Figure 6-18 and tighten band heater clamp screw. The heater insulator (9) end joint must line up with the band gap of the COe band heater (10).

6-22


IM-106-880, Rev 1.0

January 2007

Figure 6-18. COe Sensor

Holder Alignment

Sensor

Holder

Flat

Matchmark

Straightedge

Matchmark

OCX 8800

6-23

OCX 8800


Thermocouple, and Heater

Connections


IM-106-880, Rev 1.0

January 2007

10. Reconnect the COe sensor, thermocouple, and heater wires at the sensor housing terminal blocks. Refer to Figure 6-19.

11. Install and fasten the COe insulator (1, Figure 6-15) around COe sensor assembly (5). All wiring must remain outside of the insulator.

12. If terminal block mounting (13, Figure 6-15) was moved, reinstall with two base mounting screws.

O2

2

HTR 02

1

2

HTR SB

1

2

1

+

-

CJC Sensor

RED

YEL

-

+

CO REF

-

+

CO ACT

+ EXC

COe Heater Wires

COe Sensor Wires

COe Thermocouple Wires

-

+

T/C O2

-

+

T/C CO

-

+

T/C SB

- EXC

-

+

CJC

NOTE: All wires at these terminals are in the CJC current loop.

COe Sensor

Assembly

6-24


IM-106-880, Rev 1.0

January 2007

Figure 6-20. Installation of O

2 and Heater Strut Assembly

Cell

1. Screw

2. Locking Clip

3. Cover

4. O-ring

5. Marking Plate

6. Terminal Insulator

7. Reference Air Tube

8. Sensor Housing

9. Heater Strut Assembly

10. Gasket

11. Screw

12. Heater Clamp

13. Heater Rod

14. Insulator

15. Thermal Switch

3

OCX 8800

15

7

9

14

11

10

12

15 5

6

4

8

13

1

2

Install Sample Block Heater Rods

1. Before installing sample block heater rods (13, Figure 6-20), evenly coat the heater rods with Watlube heater release agent.

6-25

OCX 8800

Figure 6-21. O

2

Cell,

Thermocouple, and

Heater Connections


IM-106-880, Rev 1.0

January 2007

O2

-

+

2

HTR 02

1

2

HTR SB

1

2

1

ORG

GRN

RED

YEL

Thermocouple Wires

+

+

+

-

+

T/C O2

-

+

T/C CO

+

-

+

T/C SB

Sample

Block

Thermocouple

-

EXC

+

CJC

Assembly

+

Sample Block

Heater Rods

-

+

CO REF

-

+

CO ACT

+ EXC

Thermal

Switch

2. If thermal switch (15) was removed, install thermal switch on mating heater clamp (12), connect wires of heater rods (13), and install insulator (14).

3. Install the heater rods (13), heater clamps (12), and screws (11).

4. Reconnect the heater rod leads at the sensor housing terminal blocks,

(Figure 6-21).

6-26


IM-106-880, Rev 1.0

January 2007

OCX 8800

Install O

2


1. Rub a small amount of anti-seize compound on both sides of new gasket (10, Figure 6-20).

2. Apply anti-seize compound to threads of O

2 assembly (9) and sensor housing (8).

cell and heater strut

Stripped threads on the O

2

cell and heater strut assembly can allow gas leakage. Gas leakage can affect the O

2

measurements and calibration. Avoid over-tightening the O and heater strut assembly .

2

cell

3. Install O

2

cell and heater strut assembly (9) in sensor housing (8). Snug up, but do not over-tighten the assembly.

4. Reconnect the lead wires from O

2

cell, heater, and thermocouple to the sensor housing terminal blocks. Refer to Figure 6-21.

5. Install reference air tube (7, Figure 6-20) in sensor housing (8). Make sure that the open end of reference air tube extends into heater tube of

O

2

cell and heater strut assembly (9).

Install Terminals Insulator and Cover

1. Install insulator (6, Figure 6-20) over uppermost terminal blocks.

Position one side of insulator against terminal blocks and snap terminal marking plate (5) to mating stand-off.

2. Position opposite side of insulator (6) and secure with related marking plate (5).

3. If removed, install cover gasket (4). Screw cover (3) onto sensor housing (8). Tighten cover firmly.

4. To comply with explosion-proof requirements, the cover gasket (4) must be compressed. For hazardous area applications, verify that the cover gasket is compressed.

5. Align locking clip (2) with gap between cover ribs.

6. Loosen screw (1) and slide locking clip (2) fully into gap between cover ribs. Retighten screw (1).

Sensor Housing Leak Test

1. Install 1/4 NPT cap on dilution air inlet fitting. Install a 1/4 NPT cap on sample tube (2, Figure 6-11) or plug 1/4 NPT sample inlet port. Capped or plugged ports must be air tight.

2. If not in place, install exhaust tube (3, Figure 6-11) in exhaust port according to the instructions provided.

3. Connect a calibrated manometer to the CAL GAS inlet port.

4. Connect and apply clean instrument air at 35 psig (241 kPa gage) to the instrument air inlet fitting.

5. Observe the manometer reading. The reading should be from 10 to 13 inches, Water Column. Locate and correct leaks if the reading is less than 10 inches WC.

6-27

OCX 8800

REPAIR ELECTRONICS

HOUSING


Disassembly


IM-106-880, Rev 1.0

January 2007

Use the following procedures to remove damaged components from the OCX

8800 electronics housing and to install new replacement parts. Disassemble the unit only as needed to replace damaged components. Use the assembly procedures that apply to install replacement parts and reassemble the unit.

Remove Cover

1. See Figure 6-22. Loosen screw (1) and slide locking clip (2) away from cover (3). Retighten screw (1).

2. With two hands or strap wrench, turn cover (3) counterclockwise to loosen. Unthread and remove cover.

3. Inspect cover gasket (4) for wear or damage. Replace cover gasket if damaged.

Remove Flash PROM

Electrostatic discharge (ESD) protection is required to avoid damage to the electronic circuits.

1. Locate Flash PROM access port in electronics stack (5, Figure 6-22).

2. Use suitable IC removal tool to remove Flash PROM (6).

6-28


IM-106-880, Rev 1.0

January 2007

Figure 6-22. Removal/Installation of

Electronics Housing Components

OCX 8800

3

1. Screw

2. Locking Clip

3. Cover

4. O-ring

5. Electronics Stack

6. Flash PROM

7. thru 12. Not used

13. Screw

14. Lockwasher

15. Solenoid Valve (3 way)

16. Solenoid Valve

6

5

4

14

13

15

16

2

1

Remove Electronics Stack

1. Unplug power cable, signal cable, and solenoid lead connectors from terminals of electronics stack (5, Figure 6-22).

2. Remove two screws (13) and lockwashers (14).

3. Remove electronics stack (5).

6-29

OCX 8800

Figure 6-23. Removal/

Installation of EMI Filter


IM-106-880, Rev 1.0

January 2007

Remove Solenoid Valves

1. Disconnect solenoid leads from mating terminal connector.

2. Remove top nut of solenoid valve (15 or 16, Figure 6-22).

3. Remove the solenoid coil assembly and washer.

4. Unthread and remove solenoid valve base.

Remove EMI Filter and Terminal Block

1. Disconnect EMI filter wiring (Figure 6-23) at terminal block (3).

2. Disconnect EMI filter wiring at AC power input terminal block on electronic stack.

3. Unbolt and remove EMI filter (1) from electronic stack.

4. Remove ground wire (2) from terminal block (3).

5. Unbolt and remove terminal block (3) from electronic stack.

Brown

Blue

Green

Blue

Brown

Green

Green

1


Assembly

2

3

Install EMI Filter and Terminal Block

1. Install replacement EMI filter (1, Figure 6-23) and/or terminal block (3) on electronic stack.

2. Refer to wiring details in Figure 6-23. Connect EMI filter wiring and ground wire (2) at terminal block (3).

3. Connect EMI filter wiring at AC power input terminal block on electronic stack.

6-30


IM-106-880, Rev 1.0

January 2007

Figure 6-24. Flash PROM

Alignment

Corner

Bevel

OCX 8800

Install Solenoid Valves

1. Disassemble replacement solenoid valve (15 or 16, Figure 6-22).

2. Install new solenoid valve base. Be careful not to overtighten.

3. Install new washer and solenoid coil assembly and secure with nut.

4. Connect the solenoid leads to the proper terminations on the solenoid power terminal block (Figure 6-26).

Install Electronics Stack

1. Install electronics stack (5, Figure 6-22) and secure with lockwashers

(14) and screws (13).

2. See Figure 6-25 and Figure 6-26. Reconnect power cable, signal cable, and solenoid lead connectors to electronics stack terminals.

Install Flash PROM

Flash

PROM

Electrostatic discharge (ESD) protection is required to avoid damage to the electronic circuits.

1. Locate Flash PROM access port in electronics stack (5, Figure 6-22).

2. See Figure 6-24. Align Flash PROM (6, Figure 6-22) with mating receptacle in access port of electronics stack as shown. Flash PROM corner bevel must be in upper left corner of receptacle.

3. Install Flash PROM (6).

Access

Port

6-31

OCX 8800


Cable Connections

YEL

#1

RED

BLK

ORG

WHT

BLU

Heater Power

Connector (J3)

2HTR CO

1HTR CO

2HTR O

2

1HTR O

2

2HTR SB

1HTR SB

#1

#1

To

Ground

Screw

#1


IM-106-880, Rev 1.0

January 2007

Signal Cable

Heater

Power Cable

RED

BLK

WHT

BLK

GRN

BLK

T/C CO+

T/C CO-

T/C SB+

T/C SB-

T/C O2+

T/C O2-

BLU

BLK

#1

O2 CELL+

O2 CELL-

O2 Cell

& Thermocouple

Connector (J5)

SHLD

COe Sensor

& CJC

Connector (J4)

YEL

BRN

BLK

RED

WHT

ORG

BLK

BLK

#1

To Ground

Screw

EXC+

CO ACT+

CO ACT-

CO REF+

CO REF-

CJC+

CJC-

EXC-


NOTE: Wire colors shown are for cables supplied by Emerson Process Management.

6-32


IM-106-880, Rev 1.0

January 2007

Figure 6-26. Solenoid

Power Terminals

OCX 8800

TOP VIEW

SOL 4

SOL 2

SOL 1

CO Test Gas

Instrument Air

#1

#1

Install Cover

1. If removed, install cover gasket (4, Figure 6-22). Screw cover (3) onto electronics housing. Tighten cover firmly. Align locking clip (2) with gap between cover ribs.

2. To comply with explosion-proof requirements, cover gasket (4) must be compressed. For hazardous area applications, verify that the cover gasket is compressed.

3. Loosen screw (1) and slide locking clip (2) fully into gap between cover ribs. Retighten screw (1).

6-33

OCX 8800

REPLACE TUBE

FITTINGS

Remove Tube Fittings


IM-106-880, Rev 1.0

January 2007

The OCX transmitter housings have special tube fittings that, if clogged or damaged, must be replaced with the same type of fitting. The special tube fittings have alpha or numeric codes etched on the fitting. Unetched tube fittings are standard 1/4 inch, stainless steel fittings.

‘F’ Type Fitting

The ‘F’ type fitting is a flame arrestor fitting used in all OCX 8800 hazardous area housings. The flame arrestor fitting prohibits spark or flame conduction from the housing. It requires a thread sealing compound

(Loctite 567) and at least five threads engagement.

‘13’ Type Fitting

This fitting is an eductor drive air fitting for the OCX 8800 hazardous area housing. This is a 1/8 inch tube fitting with a built-in 0.013 inch restrictor orifice. It seats in a threaded base port inside the housing.

‘R’ Type Fitting

The ‘R’ type fitting is a reference air line fitting for the general purpose and hazardous area sensor housings. This is a 1/4 inch tube fitting with a built-in 0.007 inch restrictor orifice.

The OCX construction includes pipe thread sealant to seal fittings in all ports that pass through to an outer wall of the instrument housing base. Use the following instructions to loosen and remove tube fittings that are secured with pipe thread sealant.

Use heat resistant gloves when removing a damaged tube fitting. The pipe threads are bonded with a pipe thread sealant. The thread sealant softens at 450°F (232°C). The heated parts can cause severe burns.

1. Secure sensor housing (1, Figure 6-27) or electronics housing (2) in soft

(plastic, wood, or brass) vice jaws.

2. To soften the pipe thread sealant, use a propane torch to heat the tube fitting (3, 4, 5, or 6) to 450°F (232°C), minimum.

3. While heating the tube fitting, use a wrench to apply removal torque until the pipe thread sealant softens. Remove and discard the used fitting.

4. Use MEK or methylene chloride solvent to clean thread sealant residue from the internal pipe threads in the housing. Refer to applicable MSDS sheet for solvent handling precautions.

6-34


IM-106-880, Rev 1.0

January 2007

Figure 6-27. Removal of Tube Fittings

1. Sensor Housing

2. Electronics Housing

3. Tube Fitting

4 . Tube Fitting (Type R)

5 . Tube Fitting (Type 13)

6. Tube Fitting (Type F)

4

3

5

OCX 8800

1

6

2

3

3

3

Install Tube Fittings 1. Verify that the replacement tube fitting is identical to the item removed.

Special fittings are etched with code markings.

2. Apply pipe thread sealant (Loctite #567) to the mating threads of the tube fitting. Do not apply sealant to the first turn of the external pipe threads.

3. Install and tighten the tube fitting in the mating port of sensor or electronics housing.

6-35

OCX 8800


IM-106-880, Rev 1.0

January 2007

6-36


IM-106-880, Rev 1.0

January 2007

Section 7

OCX 8800

Troubleshooting

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-1

Diagnostic Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-2

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-3

Alarm Relay Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-11

OVERVIEW

Grounding

Electrical Noise

Electrostatic Discharge

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.

The troubleshooting section describes how to identify and isolate faults that may develop in the OCX 8800. When troubleshooting the OCX 8800, reference the following information.

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 total elimination of ground loops.

The OCX 8800 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. Ensure all cable shields are connected to earth.

Electrostatic discharge can damage ICs in the electronics. Before removing or handling the processor board or the ICs, ensure you are at ground potential.


OCX 8800

Total Power Loss

Figure 7-1. Fuse Locations


IM-106-880, Rev 1.0

January 2007

In the event that the OCX 8800 will not power up at all, check the incoming power supply to make sure power is being delivered to the OCX 8800. If the incoming power supply is good, then check fuses F1 and F6 in the electronics housing. Refer to Figure 7-1 for fuse locations.

F6

Neutral (N)

10 Amp, 250 VAC

F1

Line (L1)

10 Amp, 250 VAC

F3

O2 and COe Heater

4 Amp, 250 VAC

F4

Sample Block Heater

8 Amp, 250 VAC

DIAGNOSTIC ALARMS

Always install a blocking diode on the customers relay coil. Failure to install a blocking diode may create noise spikes and cause faults in the OCX electronics.

The OCX 8800 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, 30 mA maximum. A blocking diode is required on the customers relay coil.

Any fault condition in the OCX 8800 will trip the alarm relay. The optional SPA with HART programmable alarm indicates LOW O2, HIGH COe, Calibration

Status, and Unit Failure. For more information refer to Appendix B - SPA with

HART Alarm.

7-2


IM-106-880, Rev 1.0

January 2007

OCX 8800

FAULT ISOLATION Faults in the OCX 8800 Transmitter are indicated by messages displayed on the HART communicator. Fault indications that can appear are listed in

Table 7-1, Troubleshooting.

If a fault is indicated on the HART communicator, locate the fault indication in

Table 7-1. 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.

Table 7-1. Troubleshooting

O2 Sensor R High (Oxygen sensor resistance high, > 5000 Ohms)

O2 Sensor Open (Oxygen sensor disconnected)

Probable Cause

Loose or open O

2

cell circuit connection

O

2

cell degraded or failed

Recommended Corrective Action

Check O

2

cell circuit wires for breaks or loose connections. Repair lead wire break or loose connections.

Check O

2

cell impedance by reading the O2 Snsr R value via HART (see Figure 4-3, sheet 2). If cell impedance is zero, replace O

2

cell with cell replacement kit. If cell impedance is less than 5000 ohms, check for cell housing ground fault. Repair ground fault. If cell impedance is greater than 5000 ohms and no ground fault is indicated, replace O

2

cell with cell replacement kit.

Ref Current Err (RTD excitation current error)

Probable Cause

Loose or open lead or circuit wire connection for

COe sensor or CJC sensor current loop

COe sensor grounded

COe sensor failed

CJC sensor grounded

CJC sensor failed


Check all COe and CJC sensor current loop wiring per Figure 7-3 and Figure 6-7.

Correct wiring faults.

Check resistance of COe sensor leads to ground per Figure 6-7. Replace COe sensor if resistance is less than 10M Ohms.

Check resistance of both COe sensor elements per Figure 6-7. Replace COe sensor if resistance of sensor element is not between 100 and 250 Ohms.

Check resistance of CJC sensor to ground per Figure 6-7. Replace CJC sensor if resistance is less than 10M Ohms.

Check resistance of CJC sensor per Figure 6-7. Replace CJC sensor if resistance of sensor is not between 100 and 150 Ohms.

O2 Temp Hi (Oxygen sensor heater temperature high, > 750ºC)

Probable Cause

High noise in OCX power supply


Check power supply for line noise or voltage fluctuations. Install power line filter kit

(PN 6A00171G01) or high quality line filter for input power.

COe Temp Hi (Combustion sensor heater temperature high, 310ºC)

Probable Cause






7-3

OCX 8800


IM-106-880, Rev 1.0

January 2007

SB Temp Hi (Sample block heater temperature high, > 190ºC)

Probable Cause





O2 Temp Very Hi (Oxygen sensor heater over maximum temperature, > 820ºC)

O2 Htr Rmp Rate (Oxygen sensor heater over maximum temperature ramp rate)

Probable Cause

Incorrect O

2

heater wiring

Incorrect O

2

thermocouple wiring

Electronics package failure


Check O

2

heater wiring per Figure 7-3 and Figure 6-6. Check the wiring at the heater and inside the electronics housing. Correct wiring fault. Perform Reset procedure in

Section 3, Configuration and Startup to continue operation.

Check O

2

thermocouple wiring per Figure 7-3 and Figure 6-6. Check the wiring at the thermocouple and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Replace electronics package.

COe Temp Very Hi (Combustion sensor heater over maximum temperature, > 400ºC)

COe Htr Rmp Rate (Combustibles sensor heater over maximum temperature ramp rate)

Probable Cause

Incorrect COe heater wiring

Incorrect COe thermocouple wiring



Check COe heater wiring per Figure 7-3 and Figure 6-7. Check the wiring at the heater and inside the electronics housing. Correct wiring fault. Perform Reset procedure in

Section 3, Configuration and Startup to continue operation.

Check COe thermocouple wiring per Figure 7-3 and Figure 6-7. Check the wiring at the thermocouple and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.


SB Temp Very Hi (Sample block heater over maximum temperature, > 260ºC)

SB Htr Rmp Rate (Sample block heater over maximum temperature ramp rate)

Probable Cause

Incorrect sample block heater wiring

Incorrect sample block thermocouple wiring



Check sample block heater wiring per Figure 7-3 and Figure 6-6. Check the wiring at the heater and inside the electronics housing. Correct wiring fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

Check sample block thermocouple wiring per Figure 7-3 and Figure 6-6. Check the wiring at the thermocouple and inside the electronics housing. Correct wiring fault.

Perform Reset procedure in Section 3, Configuration and Startup to continue operation.


O2 TC Open (Oxygen sensor heater thermocouple open)

Probable Cause

O

2

thermocouple or thermocouple circuit open


Check O

2

thermocouple and circuit wires for breaks or loose connections per Figure 7-3 and Figure 6-6. Repair breaks or loose connections or replace failed thermocouple.


COe TC Open (Combustibles sensor heater thermocouple open)

Probable Cause

Combustibles sensor thermocouple open


Check thermocouple resistance (lead to ground) of reference and active thermocouples per Figure 7-3 and Figure 6-7. If either thermocouple is open or shorted to ground, replace combustibles sensor.


7-4


IM-106-880, Rev 1.0

January 2007

OCX 8800

SB TC Open (Sample block heater thermocouple open)

Probable Cause

Sample block thermocouple or thermocouple circuit open


Check sample block thermocouple and circuit wires for breaks or loose connections per

Figure 7-3 and Figure 6-6. Repair breaks or loose connections or replace failed thermocouple. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

O2 TC Shorted (Oxygen sensor heater thermocouple shorted)

Probable Cause

O

2

thermocouple or thermocouple circuit shorted

Slow heatup during cold start


Check O

2

thermocouple and circuit wires for short circuit condition per Figure 7-3 and

Figure 6-6. Repair shorted wiring or replace failed thermocouple. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.


If alarm persists, refer to the O2 Htr Failure alarm procedure.

COe TC Shorted (Combustibles sensor heater thermocouple shorted)

Probable Cause

Combustibles sensor thermocouple shorted



Check thermocouple resistance (lead to ground) of reference and active thermocouples per Figure 7-3 and Figure 6-7. If either thermocouple is open or shorted to ground, replace combustibles sensor.


If alarm persists, refer to the COe Htr Failure alarm procedure.

SB TC Shorted (Sample block heater thermocouple shorted)

Probable Cause

Sample block thermocouple or thermocouple circuit shorted



Check sample block thermocouple and circuit wires for short circuit condition per

Figure 7-3 and Figure 6-6. Repair shorted wiring or replace failed thermocouple.



If alarm persists, refer to the SB Htr Failure alarm procedure.

O2 TC Reversed (Oxygen sensor heater thermocouple reversed)

Probable Cause

O

2

thermocouple wires reversed


Check O

2

thermocouple wiring per Figure 7-3 and Figure 6-6. Check the wiring at the sensor and inside the electronics housing. Correct reversed-wires fault. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

COe TC Reversed (Combustibles sensor block heater thermocouple reversed)

Probable Cause

Combustibles thermocouple wires reversed


Check combustibles thermocouple wiring per Figure 7-3 and Figure 6-7. Check the wiring at the sensor and inside the electronics housing. Correct reversed-wires fault.


SB TC Reversed (Sample block heater thermocouple reversed)

Probable Cause

Sample block thermocouple wires reversed


Check sample block thermocouple wiring per Figure 7-3 and Figure 6-6. Check the wiring at the sensor and inside the electronics housing. Correct reversed-wires fault.



7-5

OCX 8800


IM-106-880, Rev 1.0

January 2007

ADC Failure (Voltage to digital conversion could not complete)

ADC Ref Error (Voltage to digital conversion not accurate)

Probable Cause

Incorrect wiring between electronics and sensor housings



Check all wiring between the electronics and sensor housings per Figure 7-3. Correct wiring faults.


O2 Htr Failure (Oxygen sensor heater could not reach final temperature)

Probable Cause

O

2

heater circuit wiring open

O

2

heater open

Heater electronics failure


Check O

2

cell heater circuit for broken wire or loose connection per Figure 7-3 and

Figure 6-6. Repair broken wire or loose connection.

Check resistance of O

2

Ohms. Replace O

2

heater per Figure 6-6. Normal O

2

heater resistance is 62.5

heater if heater is open or has a large resistance.

Check heater fuse F3 in electronics housing per Figure 7-1. If open, locate and correct cause of overload. If F3 is not open, or if cause of overload cannot be found, replace electronics package.

COe Htr Failure (Combustibles sensor heater could not reach final temperature)

Probable Cause

COe heater circuit wiring open

COe heater open



Check COe heater circuit for broken wire or loose connection per Figure 7-3 and

Figure 6-7. Repair broken wire or loose connection.

Check resistance of COe heater per Figure 6-7. Normal COe heater resistance is 97.7

Ohms. Replace COe heater if heater is open or has a large resistance.


SB Htr Failure (Sample block heater could not reach final temperature)

Probable Cause

Sample block heater circuit wiring open

Sample block heater open


Sensor housing exposed to high wind and/or extreme cold temperatures


Check sample block heater circuit for broken wire or loose connection per Figure 7-3 and Figure 6-6. Repair broken wire or loose connection.

Check resistance of sample block heater per Figure 6-6. Normal sample block heater resistance is 36.4 Ohms each (18.2 Ohms with both heaters in parallel). Replace sample block heater if heater is open or has a large resistance.


If above probable causes are not causing the SB heater failure, install flange insulator

(PN 6P00162H01).


7-6


IM-106-880, Rev 1.0

January 2007

OCX 8800

Cal Warning (Calibration warning)

Cal Failed (Calibration failed)

Probable Cause

Calibration gas supply low or gas connection leaking

O

2

cell degraded or failed

COe sensor degraded

Low sample gas flow in sensor housing due to flow path plugging


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.

Check O

2

cell impedance by reading the O2 Snsr R value via HART (see Figure 4-3, sheet 2). If cell impedance is zero, replace O

2

cell. If cell impedance is less than 5000 ohms, check for cell housing ground fault. Repair ground fault. If cell impedance is greater than 5000 ohms and no ground fault is indicated, replace O

2

cell.

Flow calibration gas to the O

2

cell. Read the cell millivolt output. Plot the cell millivolt output and the calibration gas O

2

concentration on the chart shown in Figure 7-2. If the plotted values do not fall on the slope line shown in Figure 7-2, replace the O

2

cell.

Replace COe sensor or increase warning level (SYSTEM, CALIB SETUP, COe Slope

Warn via HART.)

Check the following portions of the flow path for plugging:

• blowback filter

• in-situ filter

• eductor outlet path


Figure 7-2. Oxygen and Cell

Output

20

(23)

9

10

8

7

6

5

4

3

2

(73)

1

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

-20 0 20 40 60 80 100

ANALYZER OUTPUT (MILLIVOLT)

120

7-7

OCX 8800


IM-106-880, Rev 1.0

January 2007

Board Temp Hi (Electronics temperature maximum exceeded, > 85ºC)

Probable Cause

Electronics housing exposed to high ambient temperature


Insulate housing from source of high temperature and/or install cooling fan to remove heat from housing. Perform Reset procedure in Section 3, Configuration and Startup to continue operation.

EEPRM Chksm Fail (Non-volatile parameter storage corrupted)

Probable Cause

Unit powered down during calibration parameter storage

Flash PROM failure


Perform Reset procedure in Section 3, Configuration and Startup. Recalibrate the OCX and check/trim analog outputs.


O2 Temp Low (Oxygen sensor heater temperature low, < 710ºC)

Probable Cause


High noise or voltage fluctuations in power supply


Install sensor housing flange insulator (PN 6P00162H01).

Check power supply for line noise or voltage fluctuations. Install filter power line kit


COe Temp Low (Combustion sensor heater temperature low, < 290ºC)

Probable Cause







SB Temp Low (Sample block heater temperature low, < 150ºC)

Probable Cause







Line Freq Error (AC power line frequency out of usable range, < 45 Hz or > 66 Hz)

Probable Cause


AC power line frequency is outside the usable range of the OCX universal power supply





Correct power supply frequency. AC power line frequency must be between 50 and

60 Hz.

Check power supply frequency with a calibrated oscilloscope or frequency meter and compare with line frequency. Replace electronics package if they do not agree within

1 Hz.

Line Voltage Low (AC power line voltage below minimum, < 85 VAC)

Probable Cause






Check power supply voltage and compare with line voltage. Replace electronics package if they do not agree within 5%.


7-8


IM-106-880, Rev 1.0

January 2007

OCX 8800

Line Voltage High (AC power line voltage above maximum, > 278 VAC)

Probable Cause






Check power supply voltage and compare with line voltage. Replace electronics package if they do not agree within 5%.

Htr Relay Failed (Heater relay failure)

Probable Cause







Out Brd Failure (Output board failure)

Probable Cause




7-9

OCX 8800

Figure 7-3. Electrical Connections Between Electronics and Sensor Housing

YEL

RED

BLK

ORG

WHT

BLU

Heater Power

Connector (J3)

#1

2HTR CO

1HTR CO

2HTR O

2

1HTR O

2

2HTR SB

1HTR SB

To ground screw

#1


IM-106-880, Rev 1.0

January 2007

#1 #1

RED

BLK

T/C CO+

T/C CO-

WHT

BLK

GRN

BLK

T/C SB+

T/C SB-

T/C O2+

T/C O2-

BLU

BLK

O2 CELL+

O2 CELL-

#1

O Sensor and

2

Thermocouple

Connector (J5)

SHLD

YEL

BRN

BLK

RED

WHT

ORG

BLK

BLK

To ground screw

#1

EXC+

CO ACT+

CO ACT-

CO REF+

CO REF-

CJC+

CJC-

EXC-

COe Sensor and

Cold Junction

Connector (J4)


SENSOR HOUSING

To ground screw

7-10


IM-106-880, Rev 1.0

January 2007

OCX 8800

ALARM RELAY EVENTS The OCX 8800 contains an alarm relay that can be configured to activate on one of twelve different groups of events. These event groups, and the conditions that trigger them, are listed in Table 7-2, Alarm Relay Event

Groups.

Table 7-2. Alarm Relay

Event Groups

Alarm Relay Event Alarms/Conditions

O

2

In Calibration

Temperature Error

Unit Failure

Calibration in progress

Oxygen sensor heater temperature low (O2 Temp Low)

Oxygen sensor heater temperature high (O2 Temp Hi,

O2 Temp Very Hi)

RTD excitation current error (Ref Curr Err)

Oxygen sensor heater could not reach final temperature

Heater Failure

(O2 HTR Failure)

Combustibles sensor heater could not reach final temperature

(COe Htr Failure)

Sample Block sensor heater could not reach final temperature

O

2

Sensor Error

Calibration Failure

Calibration Warning

(SB Htr Failure)

Oxygen sensor resistance high (O2 Sensor R High)

Oxygen sensor disconnected (O2 Sensor Open)

Calibration failed (Cal Failed)

Calibration warning (Cal Warning)

Board Temperature High Electronics temperature maximum exceeded (Board Temp Hi)

Any non-recoverable or heater relay off alarm (O2 Temp Hi,

O2 Temp Very Hi, COe Temp Hi, COE Temp Very Hi,

SB Temp Hi, SB Temp Very Hi, O2 Htr Ramp Rate,

COe Htr Rmp Rate, SB Htr Ramp Rate, O2 TC Shorted,

O2 TC Reversed, COe TC Shorted, COe TC Reversed,

SB TC Shorted, SB TC Reversed, ADC Failure,

ADC Ref Error, Board Temp Hi, EEPRM Chksm Fail,

Line Freq Error, Line Voltage Low, Line Voltage Hi,

Htr Relay Failed, Out Brd Fail)

Sample Block

Temperature Error

COe Sensor

Temperature Error

Power Input Error

All Alarms

Sample block heater temperature low (SB Temp Low)

Sample block heater temperature high (SB Temp Hi,

SB Temp Very Hi)


Combustibles sensor heater temperature low (COe Temp Low)

Combustibles sensor heater temperature high (COe Temp Hi,

COe Temp Very Hi)


AC power line frequency out of usable range (Line Freq Err)

AC power line voltage below minimum (Line Voltage Low)

AC power line voltage above maximum (Line Voltage Hi)

Any alarm

7-11

OCX 8800


IM-106-880, Rev 1.0

January 2007

7-12


IM-106-880, Rev 1.0

January 2007

Section 8

OCX 8800

Replacement Parts

Sensor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-2

Electronics Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-6

O2 Cell and Heater Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . page 8-9 http://www..raihome.com

OCX 8800

SENSOR HOUSING

Figure 8-1. Sensor Housing

Components

1

3

2

14

15

4

7

8

6

9

10

5

11


IM-106-880, Rev 1.0

January 2007

16

12

(Requires item 13 for assembly)

8-2


IM-106-880, Rev 1.0

January 2007

Index No.

11

12

13

14

9

10

7

8

15

5

6

3

4

1

2

Part Number

5R10190G02

6P00177H01

4851B46G03

1A99786H01

6P00163H01

1A99746H02

1A99749H01

1A99747H01

5R10200H01

6A00123G01

6P00155H02

1A98765H02

1A99520H01

9886A15H01

5R10268H02

O

2

Cell and Heater Assembly

Heater Insulator, Mica

Combustibles Sensor Replacement Kit

Heater Leads Insulator, 11 inches long

COe Insulator

Band Heater

Thermocouple

Elbow

Eductor

CJC Sensor (RTD assembly, ring type)

Insulator

Heater Rod

Watlube Heater Release Agent

Thermal Switch Insulator

Thermal Switch

Description

OCX 8800

8-3

OCX 8800

Figure 8-2. Sensor Housing

Components


IM-106-880, Rev 1.0

January 2007

1

14

2

3

7

5

6

4

8

9

18

19 16

15

19

10

13

12

11, 11A

8-4


IM-106-880, Rev 1.0

January 2007

Index No.

3

4

1

2

5

15

16

18

19

12

13

14

10

11

8

9

6

7

11A

Part Number

6A00146G02

6A00146G03

6A00146G04

6A00146G05

6A00146G06

6A00147G01

6A00147G02

6A00147G03

6A00147G04

6A00147G05

6A00147G06

6A00144G01

6P00162H01

3535B18H02

3535B45H01

5R10279G01

771B870H04

5R10279G03

5R10267G01

1A99089H02

5R10246H02

1A98448H02

5R10247H01

5R10183H02

5R10183H06

5R10227G01

5R10183H03

5R10183H07

5R10227G02

5R10183H04

5R10183H08

5R10183H05

5R10183H09

5R10183H01

1A68017H02

5R10185H08

5R10185H03

5R10185H04

6A00146G01

Description

Cover Gasket (O-ring)

Blowback Filter

O-ring

Adaptor

Tube, Sample, 18 in. (457 mm) 316 Stainless steel

Tube, Sample, 18 in. (457 mm) Inconel 600

Tube, Sample, 18 in. (457 mm) Ceramic

Tube, Sample, 3 ft. (0.91 m) 316 Stainless steel

Tube, Sample, 3 ft. (0.91 m) Inconel 600

Tube, Sample, 3 ft. (0.91 m) Ceramic





Tube, Exhaust

COe Extractive

Dilution Air Tube

Eductor Drive Air Tube

Reference Air Tube

Heater Cable Assembly, Remote Electronics, 20 ft (6 m)






Signal Cable Assembly, Remote Electronics, 20 ft (6 m)






In-situ Filter Kit

Flange Insulator (optional)

Flange Gasket, ANSI

Flange Gasket, DIN

Tube Fitting, Type "R"

Tube Fitting, Standard

Tube Fitting, Type "13"

Tube Fitting, Flame Arrestor, Type “F”

OCX 8800

8-5

OCX 8800

ELECTRONICS

HOUSING


Components

7

8

6

5

4


IM-106-880, Rev 1.0

January 2007

1

3

2

8-6


IM-106-880, Rev 1.0

January 2007

Index No.

5

6

3

4

1

2

7

8

8A

Part Number

1A97902H01

1A97905H02

1A97905H01

6A00132G01

Special Order

1A97913H06

1A99766H01

1A99766H02

1A99089H02

5R10219G01

5R10199G01

Hose

Solenoid Valve, 3-Way

Solenoid Valve, Test Gas

Electronics Stack, HART

Flash PROM, Programmed

Fuse (F1 and F6), 10 Amp, 250 VAC

Fuse (F3), 4 Amp, 250 VAC

Fuse (F4), 8 Amp, 250 VAC

Cover Gasket (O-ring)

Cover, Blind

Cover, Window

Description

OCX 8800

8-7

OCX 8800

Figure 8-4. EMI Filter and Terminal Block


IM-106-880, Rev 1.0

January 2007

Brown

Blue

Green

Green

1

Blue

Brown

Green

Index No.

1

2

3

Part Number

1A98467H01

5R10238G01

1A99714H01

Filter, EMI

Ground Wire

Terminal Block

3

2

Description

8-8


IM-106-880, Rev 1.0

January 2007

O

2

CELL AND HEATER

STRUT ASSEMBLY

Figure 8-5. O

2

Cell and

Heater Strut Assembly

1

3

4

7

Index No.

1

2

3

4

5

6

7

Part Number

4851B44G01

5R10211G02

5R10188G01

Ref

Ref

Ref

4851B45G01

5

6

Description

Contact and Thermocouple Assembly

Heater Strut Assembly

Heater Tube

Gasket (part of O

2

Cell Replacement Kit, item 7)

O

2

Cell (part of O

2


Screw (part of O

2


O

2

Cell Replacement Kit

2

OCX 8800

8-9

OCX 8800


IM-106-880, Rev 1.0

January 2007

8-10


IM-106-880, Rev 1.0

January 2007

Appendix A Safety Data

OCX 8800

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-2

Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . page A-24

High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-29

Atex Clarification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-31 http://www..raihome.com

OCX 8800


IM-106-880, Rev 1.0

January 2007

SAFETY INSTRUCTIONS

IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING

AND INSTALLATION OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure 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

IEC245.

4. 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: EN61010-1, IEC417, and ISO3864.

11. Where equipment or labels are marked "Do Not Open While Energized" or similar, there is a danger of ignition in areas where an explosive atmosphere is present. This equipment should only be opened when power is removed and adequate time as specified on the label or in the instruction manual has been allowed for the equipment to cool down - and then only by trained service personnel.

A-2


IM-106-880, Rev 1.0

January 2007

OCX 8800

DŮLEŽITÉ

Bezpečnostní pokyny pro zapojení a instalaci zařízení

Následující bezpečnostní pokyny se speciálně vztahují na všechny členské státy EU. Pokyny by měly být přísně dodržovány, aby se zajistilo splnění Směrnice o nízkém napětí. Pokud nejsou pokyny nahrazeny místními či národními normami, měly by je dodržovat i nečlenské státy EU.

1. U všech zemnicích bodů, interních a externích, by mělo být vytvořeno odpovídající uzemnění.

2. Po instalaci nebo odstranění problémů musí být vyměněny všechny bezpečnostní kryty a uzemnění. Vždy musí být zajištěna integrita všech zemnicích svorek.

3. Sí˙ové kabely by měly odpovídat požadavkům normy IEC227 nebo

IEC245.

4. Všechna zapojení by měla být vhodná pro použití při vnějších teplotách nad 75 °C.

5. Všechna použitá kabelová hrdla by měla mít takové vnitřní rozměry, aby zajistila odpovídající zakotvení kabelu.

6. Správnou činnost zařízení zajistíte, vytvoříte-li připojení k napájecímu zdroji pouze přes jistič, který v případě poruchy odpojí všechny obvody s konduktory. Jistič může také obsahovat mechanický odpojovač.

Pokud ho neobsahuje, musí být zajištěn a jasně označen jiný způsob odpojení zařízení od zdroje. Jističe nebo přepínače musí odpovídat uznávaným normám, např. IEC947. Všechna zapojení musí odpovídat místním normám.

7. Je-li zařízení nebo kryt označen symbolem na pravé straně, pravděpodobně se uvnitř nachází nebezpečné napětí. Tyto kryty by měly být sejmuty pouze po odpojení zařízení od zdroje - a to pouze kvalifikovaným zaměstnancem.

8. Je-li zařízení nebo kryt označen symbolem na pravé straně, povrch zařízení může být velmi horký. Tyto kryty by měly být sejmuty pouze kvalifikovaným zaměstnancem po odpojení zařízení od zdroje. Některé povrchy mohou být stále horké.

9. Je-li zařízení nebo kryt označen symbolem na pravé straně, přečtěte si nejprve instrukce v návodu k obsluze.

10. Všechny grafické symboly používané u výrobku pocházejí z následujících norem: EN61010-1, IEC417 a

ISO3864.

11. Pokud je zařízení nebo štítky označeno varováním „Je-li zařízení pod napětím, neotvírejte jej“ či podobným, může dojít ve výbušném prostředí ke vznícení. Zařízení lze otevřít pouze po jeho odpojení od zdroje a ponechání dostatečného času na vychladnutí, jak je uvedeno na štítku nebo v návodu k obsluze - a to pouze kvalifikovaným zaměstnancem.

A-3

OCX 8800


IM-106-880, Rev 1.0

January 2007

VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.

Følgende sikkerhedsinstruktioner gælder specifikt i alle

EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af

Lavsspændingsdirektivet og bør også følges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse forefindes.

2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og jordforbindelser reetableres.

3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.

4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur højere end 75°C.

5. Alle benyttede kabelforskruninger skal have en intern dimension, så passende kabelaflastning kan etableres.

6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse mod indirekte berøring gennem afbryder (min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsitua-tion. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og mærkes som sådan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947.

7. Hvor udstyr eller dæksler er mærket med dette symbol, er farlige spændinger normalt forekom-mende bagved.

Disse dæksler bør kun afmonteres, når forsyningsspændingen er frakoblet - og da kun af instrueret servicepersonale.

8. Hvor udstyr eller dæksler er mærket med dette symbol, forefindes meget varme overflader bagved. Disse dæksler bør kun afmonteres af instrueret servicepersonale, når forsyningsspænding er frakoblet.

Visse overflader vil stadig være for varme at berøre i op til 45 minutter efter frakobling.

9. Hvor udstyr eller dæksler er mærket med dette symbol, se da i betjeningsmanual for instruktion.

10. Alle benyttede grafiske symboler i dette udstyr findes i

én eller flere af følgende standarder:- EN61010-1,

IEC417 & ISO3864.

11. Når udstyr eller etiketter er mærket "Må ikke åbnes, mens udstyret tilføres strøm” eller lignende, er der fare for antændelse i områder, hvor der er en eksplosiv atmosfære. Dette udstyr må kun åbnes, når strømkilden er fjernet, og der er gået tilstrækkelig tid til, at udstyret er kølet ned. Den nødvendige tid hertil er angivet på etiketten eller i brugervejledningen. Udstyret må kun åbnes af en faglært person.

A-4


IM-106-880, Rev 1.0

January 2007

OCX 8800

BELANGRIJK

Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.

De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de

EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low Voltage Directive) te verzekeren.

Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften.

1. Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten, intern en extern.

2. Na installatie of controle moeten alle veiligheidsdeksels en -aardingen terug geplaatst worden. Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven.

3. Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.

4. Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen, hoger dan 75°C.

5. Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd is.

6. Om de veilige werking van dit toestel te verzekeren, moet de voeding door een stroomonderbreker gevoerd worden (min 10A) welke alle draden van de voeding moet onderbreken. De stroomonderbreker mag een mechanische schakelaar bevatten. Zoniet moet een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten onderworpen zijn aan een erkende standaard zoals IEC947.

7. Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning aanwezig. Deze deksels mogen enkel verwijderd worden nadat de voedingsspanning werd afgelegd en enkel door getraind onderhoudspersoneel.

8. Waar toestellen of deksels aangegeven staan met het symbool is er gevaar voor hete oppervlakken. Deze deksels mogen enkel verwijderd worden door getraind onderhoudspersoneel nadat de voedingsspanning verwijderd werd. Sommige oppper-vlakken kunnen 45 minuten later nog steeds heet aanvoelen.

9. Waar toestellen of deksels aangegeven staan met het symbool gelieve het handboek te raadplegen.

10. Alle grafische symbolen gebruikt in dit produkt, zijn afkomstig uit een of meer van devolgende standaards:

EN61010-1, IEC417 en ISO3864.

11. Op plaatsen waar uitrusting of etiketten zijn voorzien van een melding als "Niet openen bij aanwezigheid van spanning" bestaat er brandgevaar in omgevingen waar een explosieve atmosfeer aanwezig is. Deze uitrusting mag uitsluitend worden geopend wanneer het niet meer onder spanning staat en de uitrusting gedurende de voorgeschreven tijd op het etiket of in de handleiding is afgekoeld - en dan uitsluitend door voldoende opgeleid onderhoudspersoneel.

A-5

OCX 8800


IM-106-880, Rev 1.0

January 2007

BELANGRIJK

Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.

Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving anders voorschrijft.

1. Alle voorziene interne- en externe aardaansluitingen dienen op adequate wijze aangesloten te worden.

2. Na installatie, onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels /kappen en aardingen om reden van veiligheid weer aangebracht te worden.

3. Voedingskabels dienen te voldoen aan de vereisten van de normen

IEC 227 of IEC 245.

4. Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven 75°C.

5. Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankering van de kabel wordt verkregen.

6. Om een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats te vinden via een meerpolige automatische zekering (min.10A) die alle spanningvoerende geleiders verbreekt indien een foutconditie optreedt. Deze automatische zekering mag ook voorzien zijn van een mechanisch bediende schakelaar. Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars dienen te voldoen aan een erkende standaard zoals IEC 947.

7. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder spanning voerende delen bevinden die gevaar op kunnen leveren. Deze beschermdeksels/ kappen mogen uitsluitend verwijderd worden door getraind personeel als de spanning is afgeschakeld.

8. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder hete oppervlakken of onderdelen bevinden. Bepaalde delen kunnen mogelijk na 45 min. nog te heet zijn om aan te raken.

9. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, dient men de bedieningshandleiding te raadplegen.

10. Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende standaarden:

EN 61010-1, IEC 417 & ISO 3864.

11. Op plaatsen waar uitrusting of etiketten zijn voorzien van een melding als

"Niet openen bij aanwezigheid van spanning" bestaat er brandgevaar in omgevingen waar een explosieve atmosfeer aanwezig is. Deze uitrusting mag uitsluitend worden geopend wanneer het niet meer onder spanning staat en de uitrusting gedurende de voorgeschreven tijd op het etiket of in de handleiding is afgekoeld - en dan uitsluitend door voldoende opgeleid onderhoudspersoneel.

A-6


IM-106-880, Rev 1.0

January 2007

OCX 8800

WICHTIG

Sicherheitshinweise für den Anschluß und die Installation dieser Geräte.

Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der Niederspannungsrichtlinie zu genügen.

Nichtmitgliedsstaaten der europäischen Gemeinschaft sollten die national gültigen Normen und Richtlinien einhalten.

1. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden.

2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerät müssen alle Sicherheitsabdeckungen und Erdungen wieder installiert werden. Die

Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gestört sein.

3. Die Netzspannungsversorgung muß den Anforderungen der IEC227 oder IEC245 genügen.

4. Alle Verdrahtungen sollten mindestens bis 75°C ihre Funktion dauerhaft erfüllen.

5. Alle Kabeldurchführungen und Kabelverschraubungen sollten in Ihrer

Dimensionierung so gewählt werden, daß diese eine sichere

Verkabelung des Gerätes ermöglichen.

6. Um eine sichere Funktion des Gerätes zu gewährleisten, muß die

Spannungsversorgung über mindestens 10 A abgesichert sein. Im

Fehlerfall muß dadurch gewährleistet sein, daß die

Spannungsversorgung zum Gerät bzw. zu den Geräten unterbrochen wird. Ein mechanischer Schutzschalter kann in dieses System integriert werden. Falls eine derartige Vorrichtung nicht vorhanden ist, muß eine andere Möglichkeit zur Unterbrechung der Spannungszufuhr gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden.

Ein solcher Mechanismus zur Spannungsunterbrechung muß mit den

Normen und Richtlinien für die allgemeine Installation von

Elektrogeräten, wie zum Beispiel der IEC947, übereinstimmen.

7. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, die eine gefährliche (Netzspannung) Spannung führen. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde.

Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen.

8. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, in bzw. unter denen heiße Teile vorhanden sind. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen. Bis 45 Minuten nach dem Unterbrechen der Netzzufuhr können derartig Teile noch über eine erhöhte Temperatur verfügen.

9. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, bei denen vor dem Eingriff die entsprechenden Kapitel im Handbuch sorgfältig durchgelesen werden müssen.

10. Alle in diesem Gerät verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgend aufgeführten Standards:

EN61010-1, IEC417 & ISO3864.

11. Wenn Geräte oder Etiketten mit dem Hinweis "Nicht unter Spannung

öffnen" oder ähnlichen Hinweisen versehen sind, besteht in explosionsgefährdeten Umgebungen Entzündungsgefahr. Das Gerät darf nur geöffnet werden, wenn es nicht ans Stromnetz angeschlossen und entsprechend der Zeitangaben auf dem Etikett bzw. in der

Betriebsanleitung ausreichend abgekühlt ist. Das Gerät darf nur von geschultem Service-Personal geöffnet werden.

A-7

OCX 8800


IM-106-880, Rev 1.0

January 2007

ΣΗΜΑΝΤΙΚΟ

Οδηγιεσ ασφαλειασ για την καλωδιωση και εγκατασταση τησ συσκευησ

Οι ακόλουθες οδηγίες ασφαλείας εφαρµόζονται ειδικά για όλες τις χώρες

µέλη της Ευρωπαϊκής Κοινότητας. Θα πρέπει να ακολουθούνται αυστηρά ώστε να εξασφαλιστεί η συµβατότητα µε τις οδηγίες για τη Χαµηλή Τάση.

Χώρες που δεν είναι µέλη της Ευρωπαϊκής Κοινότητας θα πρέπει επίσης

να ακολουθούν τις οδηγίες, εκτός εάν αυτές αντικαθίστανται από τα

Τοπικά ή Εθνικά πρότυπα.

1. Επαρκείς συνδέσεις γείωσης θα πρέπει να γίνονται σε όλα τα σηµεία

γείωσης, εσωτερικά και εξωτερικά, όπου υπάρχουν.

2. Μετά την εγκατάσταση ή την αντιµετώπιση σφαλµάτων, όλα τα καλύµµατα

ασφαλείας και οι γειώσεις ασφαλείας πρέπει να επανεγκαθίστανται. Η καλή

κατάσταση όλων των ακροδεκτών γείωσης πρέπει να συντηρείται διαρκώς.

3. Τα καλώδια τροφοδοσίας πρέπει να πληρούν τις απαιτήσεις των IEC227 ή IEC245.

4. Όλες οι καλωδιώσεις θα πρέπει να είναι κατάλληλες για χρήση σε

θερµοκρασία χώρου υψηλότερη από 75°C.

5. Όλοι οι στυπιοθλίπτες θα πρέπει να είναι τέτοιων εσωτερικών

διαστάσεων, ώστε να παρέχουν επαρκή στερέωση των καλωδίων.

6. Για τη διασφάλιση ασφαλούς λειτουργίας αυτής της συσκευής, η σύνδεση

τροφοδοσίας θα πρέπει να γίνεται µόνο µέσω ασφαλειοδιακόπτη, ο

οποίος θα αποσυνδέει όλους τους ηλεκτροφόρους αγωγούς των

κυκλωµάτων, στη διάρκεια κατάστασης σφάλµατος. Ο ασφαλειοδιακόπτης

µπορεί επίσης να περιλαµβάνει µηχανικό διακόπτη αποµόνωσης. Εάν δεν

περιλαµβάνει, τότε άλλα µέσα αποσύνδεσης της συσκευής από την

τροφοδοσία πρέπει να παροχηθούν και να σηµανθούν σαφώς ως τέτοια.

Οι ασφαλειοδιακόπτες ή διακόπτες πρέπει να συµµορφώνονται µε

αναγνωρισµένα πρότυπα όπως το IEC947. Όλες οι καλωδιώσεις πρέπει

να συµµορφώνονται µε τα τοπικά πρότυπα.

7. Όπου συσκευές ή καλύµµατα είναι σηµασµένα µε το

σύµβολο που εικονίζεται δεξιά, επικίνδυνες τάσεις

ενυπάρχουν κάτω από αυτά. Αυτά τα καλύµµατα θα

πρέπει να αφαιρούνται µόνο όταν έχει αφαιρεθεί η

τροφοδοσία από τη συσκευή - και στην περίπτωση αυτή,

µόνο από ειδικευµένο τεχνικό προσωπικό.


σύµβολο που εικονίζεται δεξιά, υπάρχει κίνδυνος από

καυτές επιφάνειες κάτω από αυτά. Τέτοια καλύµµατα θα

πρέπει να αφαιρούνται µόνο από ειδικευµένο τεχνικό

προσωπικό, όταν έχει αφαιρεθεί η τροφοδοσία από τη

συσκευή. Κάποιες επιφάνειες µπορούν να παραµένουν ζεστές στην αφή.


σύµβολο που εικονίζεται δεξιά, ανατρέξτε στις οδηγίες

χρήσης της συσκευής.

10. Όλα τα γραφικά σύµβολα που χρησιµοποιούνται σε αυτό

το προϊόν είναι από ένα ή περισσότερα από τα εξής

πρότυπα: EN61010-1, IEC417 και ISO3864.

11. Όπου συσκευή ή ετικέτα είναι σηµασµένη µε την ένδειξη "Μην ανοίγετε ενώ

βρίσκεται σε λειτουργία" ή άλλη παρόµοια, υπάρχει κίνδυνος ανάφλεξης σε

περιοχές µε εκρηκτική ατµόσφαιρα. Ο παρών εξοπλισµός πρέπει να

ανοίγεται µόνο όταν είναι εκτός ρεύµατος και αφού παρέλθει ο κατάλληλος

χρόνος που αναγράφεται στην ετικέτα ή στο εγχειρίδιο οδηγιών ώστε να

ψυχθεί και µόνο από εκπαιδευµένο προσωπικό συντήρησης.

A-8


IM-106-880, Rev 1.0

January 2007

OCX 8800

OLULINE TEAVE

Juhtmestiku ja seadme paigaldamisega seotud ohutusjuhised

Alljärgnevad ohutusjuhised rakenduvad eriti kõigi Euroopa Liidu liikmesriikide suhtes. Antud juhiseid tuleb täpselt järgida, et kindlustada vastavus madalpinge direktiiviga. Euroopa Liitu mittekuuluvad riigid peavad samuti alljärgnevaid juhiseid järgima, va juhul, kui on olemas vastavad kohalikud riiklikud standardid.

1. Ettenähtud maanduspunktide, nii sisemiste kui väliste jaoks tuleb tagada nõuetekohased maaühendused.

2. Pärast paigaldamist või rikketuvastust tuleb kõik turvaümbrised ja turvamaandused uuesti oma kohale seada. Kõigis olukordades tuleb säilitada kõigi maandusklemmide terviklikkus.

3. Toitejuhtmed peavad vastama IEC227 või IEC245 nõuetele.

4. Kogu juhtmestik peab sobima kasutamiseks üle 75°C õhutemperatuuri juures.

5. Kõik juhtmetihendid peavad sisemõõtmete poolest tagama nõuetekohased kaabliühendused.

6. Seadme ohutu töötamise tagamiseks peab ühendus toiteallikaga toimuma vaid läbi automaatkorgi, mis veaolukorras lülitab välja kõik voolukandjad. Automaatkorgil võib olla ka mehhaaniliselt reguleeritav lahklüliti. Vastasel juhul peab seadme toiteallikast lahtiühendamiseks olema teine ja selgelt osutatud moodus. Automaatkorgid või -lülitid peavad vastama tunnustatud standarditele nagu nt IEC947. Kogu juhtmestik peab vastama kohalikele standarditele.

7. Seadmel või ümbristel asuv paremale osutav sümbol tähistab selle all leiduvat ohtlikku pinget. Selliste sümbolitega ümbriseid võib eemaldada vaid juhul, kui seade on toiteallikast lahti ühendatud ning ka siis ainult vastavate oskustega spetsialisti poolt.

8. Seadmele või ümbristele märgitud paremale osutava sümboli all valitseb kuumadest pindadest tulenev oht.

Nimetatud sümbolitega ümbriseid võib eemaldada vaid vastavate oskustega spetsialist, kui seade on toiteallikast lahti ühendatud. Teatud pinnad võivad puudutamise jaoks liiga kuumad olla.

9. Seadmel või ümbristel leiduva paremale osutava sümboli korral vt juhiste jaoks Toimimisjuhendit.

10. Kõik selle toote juures kasutatavad graafilised sümbolid lähtuvad ühest või enamast järgmistest standarditest:

EN61010-1, IEC417 ja ISO3864.

11. Kui seadmele või siltidele on kirjutatud "Ärge avage voolutarbimine korral" vms, valitseb plahvatusohtlikus keskkonnas süttimise oht.

Seadet võib avada ainult siis, kui toide on lahti ühendatud ning seadmel on võimaldatud sildil või kasutusjuhendis osutatud aja jooksul maha jahtuda -- ning ka sellisel juhul ainult vastavate oskustega spetsialisti poolt.

A-9

OCX 8800


IM-106-880, Rev 1.0

January 2007

TÄRKEÄÄ

Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa.

Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin

(Low Voltage Directive) yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta, elleivät kansalliset standardit estä sitä.

1. Riittävät maadoituskytkennät on tehtävä kaikkiin maadoituspisteisiin, sisäisiin ja ulkoisiin.

2. Asennuksen ja vianetsinnän jälkeen on kaikki suojat ja suojamaat asennettava takaisin pai-koilleen. Maadoitusliittimen kunnollinen toiminta täytyy aina ylläpitää.

3. Jännitesyöttöjohtimien täytyy täyttää IEC227 ja IEC245 vaatimukset.

4. Kaikkien johdotuksien tulee toimia >75°C lämpötiloissa.

5. Kaikkien läpivientiholkkien sisähalkaisijan täytyy olla sellainen että kaapeli lukkiutuu kun-nolla kiinni.

6. Turvallisen toiminnan varmistamiseksi täytyy jännitesyöttö varustaa turvakytkimellä (min 10A), joka kytkee irti kaikki jännitesyöttöjohtimet vikatilanteessa. Suojaan täytyy myös sisältyä mekaaninen erotuskytkin.

Jos ei, niin jännitesyöttö on pystyttävä katkaisemaan muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi. Turvakytkimien tai kat-kaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä.

7. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla hengenvaarallisen suuruinen jännite. Suojaa ei saa poistaa jänniteen ollessa kytkettynä laitteeseen ja poistamisen saa suorittaa vain alan asian-tuntija.

8. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla kuuma pinta. Suojan saa poistaa vain alan asiantuntija kun jännite-syöttö on katkaistu. Tällainen pinta voi säilyä kosketuskuumana jopa 45 mi-nuuttia.

9. Mikäli laite tai kosketussuoja on merkitty tällä merkillä katso lisäohjeita käyt-töohjekirjasta.

10. Kaikki tässä tuotteessa käytetyt graafiset symbolit ovat yhdestä tai useammasta seuraavis-ta standardeista:

EN61010-1, IEC417 & ISO3864.

11. Jos laitteessa tai tarrassa on merkintä "Älä avaa, kun virta on kytketty" tai vastaava, räjähdysvaarallisissa tiloissa on syttymisen vaara. Nämä laitteet voidaan avata vain silloin, kun virta ei ole kytkettynä ja laitteen on annettu jäähtyä tarrassa tai oppaassa määritetyn ajan. Tällöinkin laitteet saa avata vain koulutettu huoltohenkilökunta.

A-10


IM-106-880, Rev 1.0

January 2007

OCX 8800

IMPORTANT

Consignes de sécurité concernant le raccordement et l'installation de cet appareil.

Les consignes de sécurité ci-dessous s'adressent particulièrement à tous les états membres de la communauté européenne. Elles doivent

être strictement appliquées afin de satisfaire aux directives concernant la basse tension. Les états non membres de la communauté européenne doivent également appliquer ces consignes sauf si elles sont en contradiction avec les standards locaux ou nationaux.

1. Un raccordement adéquat à la terre doit être effectuée à chaque borne de mise à la terre, interne et externe.

2. Après installation ou dépannage, tous les capots de protection et toutes les prises de terre doivent être remis en place, toutes les prises de terre doivent être respectées en permanence.

3. Les câbles d'alimentation électrique doivent être conformes aux normes

IEC227 ou IEC245.

4. Tous les raccordements doivent pouvoir supporter une température ambiante supérieure à 75°C.

5. Tous les presse-étoupes utilisés doivent avoir un diamètre interne en rapport avec les câbles afin d'assurer un serrage correct sur ces derniers.

6. Afin de garantir la sécurité du fonctionnement de cet appareil, le raccordement à l'alimentation électrique doit être réalisé exclusivement au travers d'un disjoncteur (minimum 10A.) isolant tous les conducteurs en cas d'anomalie. Ce disjoncteur doit également pouvoir être actionné manuellement, de façon mécanique. Dans le cas contraire, un autre système doit être mis en place afin de pouvoir isoler l'appareil et doit

être signalisé comme tel. Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telle IEC947.

7. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des tensions dangereuses sont présentes. Ces capots ne doivent

être démontés que lorsque l'alimentation est coupée, et uniquement par un personnel compétent.

8. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des surfaces dangereusement chaudes sont présentes. Ces capots ne doivent être démontés que lorsque l'alimentation est coupée, et uniquement par un personnel compétent.

Certaines surfaces peuvent rester chaudes jusqu'à

45 mn.

9. Lorsque les équipements ou les capots affichent le symbole suivant, se reporter au manuel d'instructions.

10. Tous les symboles graphiques utilisés dans ce produit sont conformes à un ou plusieurs des standards suivants: EN61010-1, IEC417 & ISO3864.

11. Les équipements comportant une étiquette avec la mention " Ne pas ouvrir sous tension " ou toute autre mention similaire peuvent créer un risque d'incendie dans les environnements explosifs. Ces équipements ne doivent être ouverts que lorsqu'ils sont hors tension et que la durée de refroidissement requise indiquée sur l'étiquette ou dans le manuel d'instructions s'est écoulée. En outre ils ne doivent être ouverts que par un personnel qualifié.

A-11

OCX 8800


IM-106-880, Rev 1.0

January 2007

FONTOS

Biztonsági előírások a készülék vezetékeléséhez és üzembeállításához

A következő biztonsági előírások kifejezetten vonatkoznak az összes

EU-tagállamra. Ezeket szigorúan be kell tartani a Kisfeszültségű irányelvnek való megfelelés biztosításához. A nem EU-tagállamok szintén tartsák be a következőket, kivéve ha a helyi és nemzeti szabványok azt másként nem írják elő.

1. A megfelelő földelést biztosítani kell az összes rendelkezésre álló földelési ponton, legyen az belső vagy külső.

2. Az üzembeállítás vagy hibaelhárítás után az összes biztonsági burkolatot és biztonsági földvezetéket ki kell cserélni. A földelőkapcsok sértetlenségét mindig biztosítani kell.

3. A tápvezetékeknek eleget kell tenniük az IEC227 vagy IEC245 szabványokban megfogalmazott követelményeknek.

4. Az összes vezetéknek alkalmasnak kell lennie a 75 °C-nál magasabb környezeti hőmérséklet melletti használatra.

5. Az összes használt kábelvezető tömszelencének olyan belső méretűnek kell lennie, hogy biztosítsák a kábelek megfelelő lekötését.

6. A berendezés biztonságos működésének biztosításához az elektromos hálózathoz való csatlakozást csak megszakítón keresztül szabad megvalósítani, amely az összes áramot szállító vezetéket bontja hibahelyzet esetén. A megszakító magában foglalhat egy mechanikusan működtethető áramtalanító kapcsolót is. Ellenkező esetben biztosítani kell a berendezés elektromos hálózatról történő lekapcsolásának más módját,

és ezt világosan jelezni kell. A megszakítóknak vagy kapcsolóknak meg kell felelniük egy elismert szabványnak, például az IEC947 szabványnak.

Az összes vezetéknek meg kell felelnie az összes helyi szabványnak.

7. Ha a berendezés vagy a burkolata a jobb oldalon látható szimbólummal jelzett, alatta valószínűleg veszélyes feszültség van jelen. Az ilyen burkolat csak a berendezés áramtalanítása után távolítható el - és csak képzett szervizszakember végezheti el.

8. Ha a berendezés vagy a burkolata a jobb oldalon látható szimbólummal jelzett, fenn áll a veszélye, hogy alatta forró felületek találhatóak. Az ilyen burkolatot csak képzett szervizszakember távolíthatja el a berendezés áramtalanítása után. Bizonyos felületek

érintésre forróak maradhatnak.

9. Ha a berendezés vagy a burkolata a jobb oldalon látható szimbólummal jelzett, tekintse meg az

Üzemeltetési útmutató arra vonatkozó utasításait.

10. A terméken használt grafikus szimbólumok a következő szabványok legalább egyikéből származnak:

EN61010-1, IEC417 és ISO3864.

11. Ha a berendezésen vagy a címkéken a „Ne nyissa ki bekapcsolt

állapotban” vagy hasonló felhívás szerepel, robbanásveszélyes környezetben fennáll a gyulladás veszélye. Ez a berendezés csak

áramtalanítás után nyitható ki, a címkén vagy a kezelési útmutatóban szereplő, a berendezés lehűlését biztosító megfelelő idői ráhagyás után -

és csak képzett szervizszakember végezheti el.

A-12


IM-106-880, Rev 1.0

January 2007

OCX 8800

IMPORTANTE

Norme di sicurezza per il cablaggio e l'installazione dello strumento.

Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell'Unione Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all'Unione Europea, salvo quanto disposto dalle vigenti normative locali o nazionali.

1. Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra interni ed esterni, dove previsti.

2. Dopo l'installazione o la localizzazione dei guasti, assicurarsi che tutti i coperchi di protezione siano stati collocati e le messa a terra siano collegate. L'integrità di ciscun morsetto di terra deve essere costantemente garantita.

3. I cavi di alimentazione della rete devono essere secondo disposizioni

IEC227 o IEC245.

4. L'intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore a 75°C.

5. Le dimensioni di tutti i connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggio al cavo.

6. Per garantire un sicuro funzionamento dello strumento il collegamento alla rete di alimentazione principale dovrà essere eseguita tramite interruttore automatico (min.10A), in grado di disattivare tutti i conduttori di circuito in caso di guasto. Tale interruttore dovrà inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione dell'alimentazione, chiaramente identificabile. Gli interruttori dovranno essere conformi agli standard riconosciuti, quali IEC947.

7. Il simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza di elevati voltaggi.

Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento.

8. Il simbolo riportato sullo strumento o sui coperchi di protezione indica rischio di contatto con superfici ad alta temperatura. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento. Alcune superfici possono mantenere temperature elevate per oltre 45 minuti.

9. Se lo strumento o il coperchio di protezione riportano il simbolo, fare riferimento alle istruzioni del manuale

Operatore.

10. Tutti i simboli grafici utilizzati in questo prodotto sono previsti da uno o più dei seguenti standard: EN61010-1,

IEC417 e ISO3864.

11. L'indicazione "Non aprire sotto tensione" o simili sull'apparecchiatura o sulle etichette segnala il pericolo di accensione nelle aree in cui è presente un'atmosfera esplosiva. L'apparecchiatura può essere aperta solo quando l'alimentazione è scollegata ed è trascorso il tempo indicato sull'etichetta o nel manuale delle istruzioni per consentirne il raffreddamento. L'operazione può essere effettuata esclusivamente da personale dell'assistenza qualificato.

A-13

OCX 8800


IM-106-880, Rev 1.0

January 2007

SVARBU

š

io prietaiso laidų prijungimo ir instaliacijos saugos instrukcijos

Toliau išvardinti saugumo reikalavimai taikomi konkrečiai visoms ES

šalims narėms. Jų turi būti griežtai paisoma, kad būtų užtikrintai laikomasi Žemos įtampos direktyvos. Ne ES narės taip pat turi laikytis toliau pateikiamų reikalavimų nebent juos pakeičia vietiniai ar

Nacionaliniai standartai.

1. Turi būti atliktas tinkamas įžeminimas visuose įžeminimo taškuose, vidiniuose ir išoriniuose, kur numatyta.

2. Visos apsauginės dangos ir įžemikliai po instaliacijos ar remonto turi būti pakeisti. Visų įžeminimo terminalų vientisumo priežiūra turi būti atliekama nuolat.

3. Matinimo tinklo laidai turi atitikti IEC227 ar IEC245 reikalavimus.

4. Visi laidai turi būti tinkami naudojimui aplinkos temperatūtoje, aukštesnėje nei 75°C.

5. Visi naudojamų kabelių riebokšliai turi būti tokių vidinių matmenų, kad būtų galimas tinkamas kabelio pritvirtinimas.

6. Saugaus šio prietaiso veikimo užtikrinimui, prijungimas prie maitinimo tinklo turi būti atliekamas tik per automatinį pertraukiklį, kuris atjungs visas grandines nešančius konduktorius linijos gedimo metu.

Automatinis pertraukiklis taip pat gali turėti mechaniškai veikiantį įzoliavimo jungiklį. Jeigu ne, tuomet turi būti nurodytos kitos įrenginio atjungimo priemonės, ir aiškai pažymėtos, kad jos tokios yra.

Automatiniai perjungikliai ar jungikliai turi atitikti pripažintus standartus, tokius kaip IEC947. Visi laidai turi atitikti visus vietinius standartus.

7. Kur įrenginys ar dangos yra pažymėti simboliu dešinėje, žemiau turi būti pavojinga įtampa. Šios dangos turi būti nuimamos tik tada, kai srovė yra pašalinta iš įrenginio - ir tik tuomet tai turi atlikti apmokytas personalas.

8. Ten kur įrenginys ar dangos yra pažymėti simboliu dešinėje, ten yra pavojus nuo karštų paviršių apačioje.

Šios dangos gali būti nuimamos tik apmokyto personalo, kai srovė yra pašalinta iš įrenginio. Tam tikri paviršiai gali išlikti karšti liečiant.

9. Ten kur įrenginys ar dangos yra pažymėti simboliu dėšinėje, žr. nurodymus Valdymo instrukcijose.

10. Visi grafiniai simboliai naudojami šiam produktui yra iš vieno ar daugiau toliau išvardintų standartų:

EN61010-1, IEC417, ir ISO3864.

11. Ten, kur įrenginys ar etiketės yra pažymėti "Neatidaryti esant srovės tiekimui" ar panašiai, yra užsidegimo pavojus tose vietose, kur yra sprogstamoji atmosfera. Šis įrenginys gali būti atidarytas tuomet, kai yra pašalinta srovė, ir praėjęs atitinkamas laikas, nurodytas etiketėje ar valdymo instrukcijoje, pakankamas įrenginio ataušimui - ir tai tik apmokyto personalo.

A-14


IM-106-880, Rev 1.0

January 2007

OCX 8800

SVARĪGI

Droš ības norādījumi š īs iekārtas pievienoš anai un uzstādīš anai

Turpmākie drošības norādījumi attiecas uz visām ES dalībvalstīm. Tie ir stingri jāievēro, lai nodrošinātu atbilstību Zemsprieguma direktīvai.

Turpmāk norādītais jāievēro arī valstīs, kas nav ES dalībvalstis, ja vien

šos norādījumus neaizstāj vietējie vai valsts standarti.

1. Visi pieejamie iekšējie un ārējie zemējuma punkti ir atbilstoši jāiezemē.

2. Pēc uzstādīšanas vai problēmu risināšanas visi drošības pārsegi un drošības zemējuma savienojumi ir jāpievieno atpakaļ. Visiem zemējuma savienojumiem vienmēr jābūt iezemētiem.

3. Elektropadeves vadiem jāatbilst IEC227 vai IEC245 prasībām.

4. Visai elektroinstalācijai jābūt piemērotai lietošanai apkārtējā temperatūrā, kas pārsniedz 75°C.

5. Visu izmantoto kabeļu blīvju iekšējiem izmēriem jābūt tādiem, lai atbilstoši nostiprinātu kabeli.

6. Lai nodrošinātu šīs iekārtas drošu darbību, savienojums ar elektropadeves tīklu jāizveido, izmantojot slēdzi, kas kļūmes gadījumā atvienos visas ķēdes, kurās ir vadītāji. Slēdzī var būt iestrādāts arī mehānisks pārtraucējslēdzis. Ja tāda nav, tad ir jāuzstāda cita veida ierīce iekārtas atvienošanai no strāvas padeves un tā atbilstoši un skaidri jāmarķē. Slēdžiem jāatbilst kādam vispāratzītam standartam, piemēram,

IEC947. Visai elektroinstalācijai jāatbilst vietējiem standartiem.

7. Vietās, kur iekārta vai tās pārsegi ir marķēti ar labajā pusē norādīto simbolu, visticamāk, zem tiem ir bīstams spriegums. Šos pārsegus drīkst noņemt tikai tad, ja iekārta ir atvienota no strāvas padeves, – un šos darbus drīkst veikt tikai atbilstoši apmācīti remontdarbu darbinieki.

8. Vietās, kur iekārta vai tās pārsegi ir marķēti ar labajā pusē norādīto simbolu, apdraudējumu izraisa zem tiem esošās karstās virsmas. Šos pārsegus drīkst noņemt tikai atbilstoši apmācīti remontdarbu darbinieki, kad iekārta ir atvienota no strāvas padeves. Iespējams, dažas virsmas arī pēc iekārtas atvienošanas paliks karstas.

9. Ja iekārta vai pārsegi ir marķēti ar labajā pusē esošo simbolu, skatiet operatora rokasgrāmatā ietvertos norādījumus.

10. Visi šajā izstrādājumā izmantotie grafiskie simboli atbilst vienam vai vairākiem no šiem standartiem: EN61010-1,

IEC417 un ISO3864.

11. Ja iekārtai vai uzlīmēm ir marķējums "Neatvērt, kamēr pieslēgta strāvai" vai tamlīdzīga norāde, tas nozīmē, ka sprādzienbīstamā vidē ir uzliesmošanas bīstamība. Šo iekārtu drīkst atvērt tikai tad, ja ir atvienota strāva un ir nogaidīts iekārtas atdzišanai nepieciešamais laiks, kas norādīts uzlīmē vai ekspluatācijas rokasgrāmatā, – un šos darbus drīkst veikt tikai atbilstoši apmācīti remontdarbu darbinieki.

A-15

OCX 8800


IM-106-880, Rev 1.0

January 2007

IMPORTANTI

STRUZZJONIJIET TAS-SIGURTÀ GĦALL-WIRING U

L-INSTALLAZZJONI TAT-TAGĦMIR

L-istruzzjonijiet tas-sigurtà japplikaw speċifikament għall-Istati Membri ta' l-UE. Dawn għandhom jiġu osservati b'mod strett biex tkun żgurata lkonformità mad-Direttiva dwar il-Vultaġġ Baxx. Stati li mhumiex membri ta' l-UE għandhom ukoll ikunu konformi ma' dan li ġej ħlief jekk dawn ikunu sostituti mill-Istandards lokali jew Nazzjonali.

1. Konnessjonijiet adegwati ta' l-ert għandhom isiru għall-punti kollha ta' l-ert, interni u esterni, fejn ikun ipprovdut.

2. Wara l-installazzjoni jew meta tipprova ssolvi xi problema, l-għatjien kollha tas-sigurtà u l-erts tas-sigurtà għandhom jitpoġġew lura f'posthom.

L-integrità tat-terminali kollha ta' l-ert għandha tinżamm f'kull ħin.

3. Il-wajers tal-provvista tad-dawl għandhom ikunu konformi ml-ħtiġijiet ta'

IEC227 jew IEC245.

4. Il-wiring kollu għandu jkun adattat għall-użu f'temperatura ta' l-ambjent ta' iktar minn 75°C.

5. Il-glands tal-kejbils kollha li jintużw iridu jkunu ta' daqs intern tali li jipprovdu ankoraġġ adegwat lill-kejbil.

6. Biex tiżgura t-tħaddim sigur ta' dan it-tagħmir, il-konnessjoni mal-provvista tad-dawl għandha ssir biss permezz ta' circuit breaker li jiskonnetta l-kondutturi kollha li jkunu jġorru ċ-ċirkuwiti f'sitwazzjoni meta jkun hemm il-ħsara. Is-circuit breaker jista wkoll jinkludi swiċċ li jiżola li jaħdem b'mod mekkaniku. Jekk dan ma jkunx il-każ, mezz ieħor ta' kif it-tagħmir jiġi skonnettjat minn mal-provvista tad-dawl għandu jkun ipprovdut, u jkun immrkat b'mod ċar li hu hekk. Is-circuit breakers jew swiċċijiet iridu jkunu konformi ma' standard rikonoxxut bħal IEC947. Il-wiring kollu jrid ikun konformi ma' l-istandards lokali, jekk ikun hemm.

7. Meta t-tagħmir jew l-għatjien ikunu mmarkati bis-simbolu fuq il-lemin, x'aktarx li jkun hemm vultaġġi perikolużi taħthom. Dawn l-għatjien għandhom jitneħħew biss meta titneħħa l-provvista tad-dawl mit-tagħmir - u minn ħaddiema tal-manutenzjoni mħarrġa biss.

8. Meta t-tagħmir jew l-għatjien ikunu mmarkati bis-simbolu fuq il-lemin, ikun hemm periklu mill-uċuħ jaħarqu li jkun hemm taħthom. Dawn l-għatjien għandhom jitneħħew biss minn ħaddiema tal-manutenzjoni mħarrġa meta titneħħa l-provvista tad-dawl mit-tagħmir. Ċerti wċuħ jistgħu jibqgħu jaħarqu meta tmisshom.

9. Meta t-tagħmir jew l-għatjien ikunu mmarkati bis-simbolu fuq il-lemin, irreferi għall-Manwal ta' l-Operatur għall-istruzzjonijiet.

10. Is-simboli grafiċi kollha użati f'dan il-prodott huma minn wieħed jew iktar mill-istandards li ġejjin: EN61010-1, IEC417, u ISO3864.

11. Fejn it-tagħmir u t-tikketti huma mmarkati bil-kliem “Tiftaħx Meta

Jkun Enerġizzat” jew kliem simili, hemm periklu ta' nar f'żoni fejn atmosfera esplossiva hi preżenti. It-tagħmir għandu jinfetaħ biss meta l-provvista tad-dawl tkun mitfija u jkun għadda ħin biżżejjed, kif speċifikat fuq it-tikketta jew fil-manwal ta' l-istruzzjonijiet, biex it-tagħmir ikun kesaħ

– u t-tagħmir għandu jinfetaħ biss minn staff li jkun imħarreġ.

A-16


IM-106-880, Rev 1.0

January 2007

OCX 8800

VIKTIG

Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret.

Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder.

1. Passende jordforbindelser må tilkobles alle jordingspunkter, interne og eksterne hvor disse forefinnes.

2. Etter installasjon eller feilsøking skal alle sikkerhetsdeksler og jordforbindelser reetableres. Jordingsforbindelsene må alltid holdes i god stand.

3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.

4. Alle ledningsforbindelser skal være konstruert for en omgivelsestemperatur høyere en 750°C.

5. Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnåes.

6. For å oppnå sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom en strømbryter (minimum 10A) som vil bryte spenningsforsyningen til alle elektriske kretser ved en feilsituasjon. Strømbryteren kan også inneholde en mekanisk operert bryter for å isolere instrumentet fra spenningsforsyningen. Dersom det ikke er en mekanisk operert bryter installert, må det være en annen måte

å isolere utstyret fra spenningsforsyningen, og denne måten må være tydelig merket. Kretsbrytere eller kontakter skal oppfylle kravene i en annerkjent standard av typen IEC947 eller tilsvarende.

7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell.

8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. Noen overflater kan være for varme til å berøres i opp til 45 minutter etter spenningsforsyning frakoblet.

9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til instruksjonsmanualen for instrukser.

10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av følgende standarder: EN61010-1, IEC417

& ISO3864.

11. Når utstyr eller merkelapper bærer advarselen "Må ikke åpnes under spenning" eller lignende, innbærer det fare for eksplosjon i områder med en eksplosiv atmosfære. Utstyret skal bare åpnes når det ikke er noen strømtilførsel, og etter at det har hatt tilstrekkelig tid til å kjøle ned, som spesifisert på merkelappen eller i håndboken. Selv da skal utstyret bare åpnes av erfarne serviceteknikere.

A-17

OCX 8800


IM-106-880, Rev 1.0

January 2007

WAŻNE!

Zalecenia dotyczące bezpieczeństwa w zakresie podłączania i instalacji tego urządzenia

Następujące zalecenia dotyczą zwłaszcza stosowania urządzenia we wszystkich krajach Unii Europejskiej. Należy się ściśle do nich stosować w celu zapewnienia zgodności z dyrektywą niskonapięciową.

W przypadku instalacji urządzenia w krajach nienależących do Unii

Europejskiej należy również przestrzegać poniższych zaleceń, chyba że są one zastąpione lokalnymi lub ogólnokrajowymi standardami.

1. Urządzenie należy podłączyć kablem uziemiającym do wszystkich punktów uziemienia (wewnętrznych i zewnętrznych).

2. Po instalacji lub czynnościach serwisowych należy zamknąć wszystkie pokrywy zabezpieczające i ponownie podłączyć uziemienie. Należy pilnować, by nie doszło do przerwania uziemienia.

3. Przewody zasilające powinny być zgodne z wymaganiami normy

IEC227 lub IEC245.

4. Wszystkie przewody powinny być odpowiednie do użytku w środowisku o temperaturze wyższej niż 75°C.

5. Wszystkie dławnice powinny mieć wymiary wewnętrzne zapewniające pewne umocowanie przewodów.

6. W celu zapewnienia bezpiecznej pracy urządzenie należy podłączyć do sieci tylko za pośrednictwem wyłącznika automatycznego, który w razie awarii odłączy wszystkie obwody, w których przepływa prąd. Wyłącznik automatyczny może być również wyposażony w mechaniczny odłącznik napięcia. W przeciwnym razie należy zapewnić i jasno oznaczyć inną możliwość odłączenia urządzenia od zasilania. Wyłączniki automatyczne oraz odłączniki powinny być zgodne z uznawanymi standardami, takimi jak norma IEC947. Wszystkie przewody muszą być zgodne z lokalnymi przepisami.

7. Pod pokrywami lub elementami urządzenia oznaczonymi symbolem pokazanym na rysunku po prawej stronie może występować niebezpieczne napięcie elektryczne.

Te pokrywy mogą być zdejmowane tylko po odłączeniu zasilania, wyłącznie przez odpowiednio przeszkolonych pracowników serwisu.

8. Pod pokrywami lub elementami urządzenia oznaczonymi symbolem pokazanym na rysunku po prawej stronie znajdują się gorące powierzchnie. Te pokrywy mogą być zdejmowane tylko po odłączeniu zasilania, wyłącznie przez odpowiednio przeszkolonych pracowników serwisu. Niektóre powierzchnie mogą pozostać nagrzane przez pewien czas po odłączeniu zasilania.

9. W przypadku sprzętu oraz pokryw oznaczonych symbolem pokazanym na rysunku po prawej stronie należy zapoznać się ze wskazówkami w Instrukcji operatora i stosować się do nich.

10. Wszystkie symbole graficzne zastosowane do oznaczenia produktu pochodzą z następujących norm: EN61010-1,

IEC417 lub ISO3864.

11. Oznaczenie „Nie otwierać, gdy urządzenie jest pod napięciem” lub podobne oznaczenia informują o ryzyku zapłonu w miejscach, gdzie występuje zagrożenie wybuchem. Urządzenie należy otwierać tylko po odłączeniu zasilania i po upływie czasu na ostygnięcie urządzenia oznaczonego na etykiecie lub w instrukcji obsługi. Urządzenie mogą otwierać wyłącznie odpowiednio przeszkoleni pracownicy serwisu.

A-18


IM-106-880, Rev 1.0

January 2007

OCX 8800

IMPORTANTE

Instruções de segurança para ligação e instalação deste aparelho.

As seguintes instruções de segurança aplicam-se especificamente a todos os estados membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tensão.

Relativamente aos estados que não pertençam à UE, deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação local a tiver substituído.

1. Devem ser feitas ligações de terra apropriadas a todos os pontos de terra, internos ou externos.

2. Após a instalação ou eventual reparação, devem ser recolocadas todas as tampas de segurança e terras de protecção. Deve manter-se sempre a integridade de todos os terminais de terra.

3. Os cabos de alimentação eléctrica devem obedecer às exigências das normas IEC227 ou IEC245.

4. Os cabos e fios utilizados nas ligações eléctricas devem ser adequados para utilização a uma temperatura ambiente até 75ºC.

5. As dimensões internas dos bucins dos cabos devem ser adequadas a uma boa fixação dos cabos.

6. Para assegurar um funcionamento seguro deste equipamento, a ligação ao cabo de alimentação eléctrica deve ser feita através de um disjuntor (min. 10A) que desligará todos os condutores de circuitos durante uma avaria. O disjuntor poderá também conter um interruptor de isolamento accionado manualmente. Caso contrário, deverá ser instalado qualquer outro meio para desligar o equipamento da energia eléctrica, devendo ser assinalado convenientemente. Os disjuntores ou interruptores devem obedecer a uma norma reconhecida, tipo IEC947.

7. Sempre que o equipamento ou as tampas contiverem o símbolo, é provável a existência de tensões perigosas.

Estas tampas só devem ser retiradas quando a energia eléctrica tiver sido desligada e por Pessoal da

Assistência devidamente treinado.

8. Sempre que o equipamento ou as tampas contiverem o símbolo, há perigo de existência de superfícies quentes.

Estas tampas só devem ser retiradas por Pessoal da

Assistência devidamente treinado e depois de a energia eléctrica ter sido desligada. Algumas superfícies permanecem quentes até 45 minutos depois.

9. Sempre que o equipamento ou as tampas contiverem o símbolo, o Manual de Funcionamento deve ser consultado para obtenção das necessárias instruções.

10. Todos os símbolos gráficos utilizados neste produto baseiam-se em uma ou mais das seguintes normas:

EN61010-1, IEC417 e ISO3864.

11. Sempre que o equipamento ou as etiquetas apresentarem o aviso "Não abrir quando ligado à corrente" ou semelhante, existe um risco de ignição em atmosferas explosivas. Este equipamento só deve ser aberto depois de desligado da corrente eléctrica e o tempo de arrefecimento adequado especificado na etiqueta ou no manual de instruções ter decorrido.

O equipamento só pode ser aberto por técnicos qualificados.

A-19

OCX 8800


IM-106-880, Rev 1.0

January 2007

DÔLEŽITÉ

Bezpečnostné pokyny pre zapojenie káblov a inš taláciu tohto prístroja

Nasledovné bezpečnostné pokyny sa vzt’ahujú konkrétne na všetky členské štáty EÚ. Musia byt’ striktne dodržané, aby sa zaistila zhoda so

Smernicou o nízkom napätí. Štáty, ktoré nie sú členskými štátmi EÚ by mali nasledovné pokyny taktiež dodržiavat’, pokiaľ nie sú nahradené miestnymi alebo národnými normami.

1. Adekvátne uzemnenia musia byt’ vykonané na všetkých bodoch uzemnenia, interných aj externých, tam, kde sú poskytnuté.

2. Po inštalácii alebo riešení problémov musia byt’ všetky bezpečnostné kryty a bezpečnostné uzemnenia vymenené. Integrita všetkých uzemňovacích terminálov musí byt’ vždy zachovaná.

3. Káble siet’ového napájania musia byt’ v zhode s požiadavkami IEC227 alebo IEC245.

4. Všetky káblové pripojenia by mali byt’ vhodné pre používanie v teplote okolia vyššej, ako 75°C.

5. Všetky použité káblové priechodky musia mat’ také vnútorné rozmery, aby poskytovali adekvátne uchopenie kábla.

6. Pre zaistenie bezpečnej prevádzky tohto zariadenia musí byt’ pripojenie k siet’ovému napájaniu zapojené len cez prerušovač obvodu, ktorý počas poruchovej situácie odpojí všetky obvody elektrických vodičov.

Prerušovač obvodu by mal obsahovat’ aj mechanicky ovládaný úsekový vypínač. Ak nie, musí byt’ poskytnutý iný spôsob odpojenia zariadenia od siet’ového napájania a tento spôsob musí byt’ zreteľne označený.

Prerušovače obvodu alebo spínače musia byt’ v zhode s uznanou normou, ako napr. IEC947. Všetky káblové pripojenia musia vyhovovat’ akýmkoľvek miestnym normám.

7. Tam, kde je zariadenie alebo kryty označené symbolom na pravej strane, sa pravdepodobne nachádza nebezpečné napätie. Tieto kryty by sa mali odoberat’ len vtedy, keď je zariadenie odpojené od elektrickej energie a len vyškoleným servisným personálom.

8. Tam, kde je zariadenie alebo kryty označené symbolom na pravej strane, existuje nebezpečenstvo horúcich povrchov. Tieto kryty by mali byt’ odstraňované len vyškoleným servisným personálom, pričom je zariadenie odpojené od elektrickej energie. Určité povrchy môžu ostat’ horúce na dotyk.

9. V miestach, kde je zariadenie alebo kryty označené symbolom na pravej strane, si kvôli pokynom pozrite

Operátorskú príručku.

10. Všetky obrázkové symboly použité pri tomto produkte zodpovedajú jednej alebo viacerým nasledujúcim normám: EN61010-1, IEC417 a ISO3864.

11. V miestach, kde je zariadenie alebo značky označené nápisom

"Neotvárat’ pod elektrickým prúdom" alebo podobné, existuje nebezpečenstvo vznietenia v oblastiach s prítomnost’ou výbušného ovzdušia. Toto zariadenie sa smie otvárat’ len v prípade odpojenia od elektrického napájania a ponechania zariadenia vychladnút’ po dobu uplynutia dostatočného času tak, ako je to uvedené na štítku alebo v návode na použitie - a len vyškoleným servisným personálom.

A-20


IM-106-880, Rev 1.0

January 2007

OCX 8800

POMEMBNO

Varnostna navodila za povezavo in vgradnjo naprave

Naslednja varnostna navodila veljajo za vse države članice EU. Zaradi zagotovitve skladnosti z nizkonapetostno direktivo morate navodila strogo upoštevati. V državah, ki niso članice EU, je treba upoštevati tudi naslednje smernice, razen če jih ne zamenjujejo lokalni ali nacionalnimi standardi.

1. Do vseh ozemljitvenih točk, notranjih in zunanjih, ki so na voljo, morajo biti speljane ustrezne ozemljitvene povezave.

2. Po vgradnji ali odpravljanju težav je treba namestiti vse varnostne pokrove in zaščitne ozemljitve. Brezhibnost vseh ozemljitvenih priključkov je treba nenehno preverjati.

3. Omrežni napajalni kabli morajo biti skladni z zahtevami standarda

IEC227 ali IEC245.

4. Vsa napeljava mora biti primerna za uporabi pri temperaturi okolja, višji od 75 °C.

5. Notranje dimenzije kabelskih tesnilk morajo zagotavljati ustrezno pritrditev kablov.

6. Za zagotovitev varnega delovanja opreme mora biti povezava z omrežnim napajanjem vzpostavljena prek odklopnega stikala, ki v primeru napake izklopi vse tokokroge s prevodniki. Odklopno stikalo lahko vključuje tudi mehansko izolacijsko stikalo. V nasprotnem primeru morajo biti zagotovljeni in jasno označeni drugi načini za izklop opreme iz napajanja.

Odklopna in druga stikala morajo biti skladna z uveljavljenimi standardi, kot je IEC947. Vsa napeljava mora biti skladna z lokalnimi standardi.

7. V opremi ali pod pokrovi, ki so označeni s simbolom na desni, je prisotna nevarna napetost. Te pokrove je dovoljeno odstraniti samo, če je napajanje opreme izklopljeno. To lahko izvaja samo usposobljeno servisno osebje.

8. Pri opremi ali pod pokrovi, ki so označeni s simbolom na desni, so prisotne nevarne vroče površine. Te pokrove lahko odstranjuje samo usposobljeno servisno osebje.

Napajanje opreme mora biti izklopljeno. Določene površine so lahko vroče.

9. Pri opremi ali pokrovih, ki so označeni s simbolom na desni, si za navodila oglejte priročnik za upravljanje.

10. Vsi uporabljeni grafični simboli so iz enega ali več naslednjih standardov: EN61010-1, IEC417 in ISO3864.

11. Če je na opremi ali oznakah navedeno "Ne odpirajte, če je pod napetostjo" ali podobno opozorilo, je na območjih z eksplozivnim ozračjem prisotna nevarnost vžiga. To opremo je dovoljeno odpirati samo, če je napajanje izklopljeno in je poteklo dovolj časa, da se oprema ohladi, kot je navedeno na oznaki ali v priročniku z navodili.

Opremo lahko odpira samo usposobljeno servisno osebje.

A-21

OCX 8800


IM-106-880, Rev 1.0

January 2007

IMPORTANTE

Instrucciones de seguridad para el montaje y cableado de este aparato.

Las siguientes instrucciones de seguridad, son de aplicacion especifica a todos los miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension.

1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en aquellos terminales previstos al efecto.

2. Una vez finalizada las operaciones de mantenimiento del equipo, se deben volver a colocar las cubiertas de seguridad aasi como los terminales de tierra. Se debe comprobar la integridad de cada terminal.

3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245.

4. Todo el cableado sera adecuado para una temperatura ambiental de

75ºC.

5. Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables.

6. Para un manejo seguro del equipo, la alimentacion electrica se realizara a traves de un interruptor magnetotermico ( min 10 A ), el cual desconectara la alimentacion electrica al equipo en todas sus fases durante un fallo. Los interruptores estaran de acuerdo a la norma IEC

947 u otra de reconocido prestigio.

7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa, dicho alojamiento solamente se abrira una vez que se haya interrumpido la alimentacion electrica al equipo asimismo la intervencion sera llevada a cabo por personal entrenado para estas labores.

8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con alta temperatura, por tanto se abrira una vez que se haya interrumpido la alimentacion electrica al equipo por personal entrenado para estas labores, y al menos se esperara unos 45 minutos para enfriar las superficies calientes.

9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el manual de instrucciones.

10. Todos los simbolos graficos usados en esta hoja, estan de acuerdo a las siguientes normas EN61010-1,

IEC417 & ISO 3864.

11. Cuando el equipo o las etiquetas tienen la indicación " No abrir mientras reciba energía" u otra similar, existe el peligro de ignición en zonas donde haya un ambiente explosivo. Este equipo sólo debe ser abierto por personal de servicio cualificado después de apagarlo y dejar pasar el intervalo de tiempo correspondiente indicado en la etiqueta o el manual de instrucciones para que el equipo se enfríe.

A-22


IM-106-880, Rev 1.0

January 2007

OCX 8800

VIKTIGT

Säkerhetsföreskrifter för kablage och installation av denna apparat.

Följande säkerhetsföreskrifter är tillämpliga för samtliga

EU-medlemsländer. De skall följas i varje avseende för att

överensstämma med Lågspännings direktivet. Icke EU medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala eller nationella föreskrifter.

1. Tillämplig jordkontakt skall utföras till alla jordade punkter, såväl internt som externt där så erfordras.

2. Efter installation eller felsökning skall samtliga säkerhetshöljen och säkerhetsjord återplaceras. Samtliga jordterminaler måste hållas obrutna hela tiden.

3. Matningsspänningens kabel måste överensstämma med föreskrifterna i

IEC227 eller IEC245.

4. Allt kablage skall vara lämpligt för användning i en omgivningstemperatur högre än 75ºC.

5. Alla kabelförskruvningar som används skall ha inre dimensioner som motsvarar adekvat kabelförankring.

6. För att säkerställa säker drift av denna utrustning skall anslutning till huvudströmmen endast göras genom en säkring (min 10A) som skall frånkoppla alla strömförande kretsar när något fel uppstår. Säkringen kan även ha en mekanisk frånskiljare. Om så inte är fallet, måste ett annat förfarande för att frånskilja utrustningen från strömförsörjning tillhandahållas och klart framgå genom markering. Säkring eller omkopplare måste överensstämma med en gällande standard såsom t ex IEC947.

7. Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för livsfarlig spänning i närheten.

Dessa höljen får endast avlägsnas när strömmen ej är ansluten till utrustningen - och då endast av utbildad servicepersonal.

8. När utrustning eller hölje är markerad med vidstående symbol föreligger risk för brännskada vid kontakt med uppvärmd yta. Dessa höljen får endast avlägsnas av utbildad servicepersonal, när strömmen kopplats från utrustningen. Vissa ytor kan vara mycket varma att vidröra även upp till 45 minuter efter avstängning av strömmen.

9. När utrustning eller hölje markerats med vidstående symbol bör instruktionsmanualen studeras för information.

10. Samtliga grafiska symboler som förekommer i denna produkt finns angivna i en eller flera av följande föreskrifter:- EN61010-1, IEC417 & ISO3864.

11. För utrustning som markerats med föreskrifter som "Öppna inte när strömmen är på", eller liknande, råder explosionsrisk när det förekommer explosiva ångor. Utrustningen får endast öppnas efter att strömmen stängts av och efter att utrustningen fått svalna under så lång tid som anges i instruktionsboken. Öppnandet får endast utföras av utbildad servicepersonal.

A-23

OCX 8800

SAFETY DATA SHEET

FOR CERAMIC FIBER

PRODUCTS


IM-106-880, Rev 1.0

January 2007

JULY 1, 1996

SECTION I. IDENTIFICATION

PRODUCT NAME

Ceramic Fiber Heaters, Molded Insulation Modules and Ceramic Fiber

Radiant Heater Panels.

CHEMICAL FAMILY

Vitreous Aluminosilicate Fibers with Silicon Dioxide.

CHEMICAL NAME

N.A.

CHEMICAL FORMULA

N.A.

MANUFACTURER'S NAME AND ADDRESS

Watlow Columbia

2101 Pennsylvania Drive

Columbia, MO 65202

573-814-1300, ext. 5170

573-474-9402

HEALTH HAZARD SUMMARY WARNING

• Possible cancer hazard based on tests with laboratory animals.

• May be irritating to skin, eyes and respiratory tract.

• May be harmful if inhaled.

• Cristobalite (crystalline silica) formed at high temperatures (above

1800ºF) can cause severe respiratory disease.

SECTION II. PHYSICAL DATA

APPEARANCE AND ODOR

Cream to white colored fiber shapes. With or without optional white to gray granular surface coating and/or optional black surface coating.

SPECIFIC WEIGHT: 12-25 LB./CUBIC FOOT

BOILING POINT: N.A.

VOLATILES (% BY WT.): N.A.

WATER SOLUBILITY: N.A.

A-24


IM-106-880, Rev 1.0

January 2007

OCX 8800

SECTION III. HAZARDOUS INGREDIENTS

MATERIAL, QUANTITY, AND THRESHOLD/EXPOSURE LIMIT VALUES

Aluminosilicate (vitreous) 99+ % 1 fiber/cc TWA

CAS. No. 142844-00-0610 fibers/cc CL

Zirconium Silicate0-10% 5 mg/cubic meter (TLV)

Black Surface Coating**0 - 1% 5 mg/cubic meter (TLV)

Armorphous Silica/Silicon Dioxide0-10% 20 mppcf (6 mg/cubic meter)

PEL (OSHA 1978) 3 gm cubic meter

(Respirable dust): 10 mg/cubic meter,

Intended TLV (ACGIH 1984-85)

**Composition is a trade secret.

SECTION IV. FIRE AND EXPLOSION DATA

FLASH POINT: None

FLAMMABILITY LIMITS: N.A.

EXTINGUISHING MEDIA

Use extinguishing agent suitable for type of surrounding fire.

UNUSUAL FIRE AND EXPLOSION HAZARDS / SPECIAL FIRE

FIGHTING PROCEDURES

N.A.

SECTION V. HEALTH HAZARD DATA

THRESHOLD LIMIT VALUE

(See Section III)

EFFECTS OF OVER EXPOSURE

• EYE - Avoid contact with eyes. Slightly to moderately irritating.

Abrasive action may cause damage to outer surface of eye.

• INHALATION - May cause respiratory tract irritation. Repeated or prolonged breathing of particles of respirable size may cause inflammation of the lung leading to chest pain, difficult breathing, coughing and possible fibrotic change in the lung (Pneumoconiosis).

Pre-existing medical conditions may be aggravated by exposure: specifically, bronchial hyper-reactivity and chronic bronchial or lung disease.

• INGESTION - May cause gastrointestinal disturbances. Symptoms may include irritation and nausea, vomiting and diarrhea.

• SKIN - Slightly to moderate irritating. May cause irritation and inflammation due to mechanical reaction to sharp, broken ends of fibers.

A-25

OCX 8800


IM-106-880, Rev 1.0

January 2007

EXPOSURE TO USED CERAMIC FIBER PRODUCT

Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) may undergo partial conversion to cristobalite, a form of crystalline silica which can cause severe respiratory disease

(Pneumoconiosis). The amount of cristobalite present will depend on the temperature and length of time in service. (See Section IX for permissible exposure levels).

SPECIAL TOXIC EFFECTS

The existing toxicology and epidemiology data bases for RCF's are still preliminary. Information will be updated as studies are completed and reviewed. The following is a review of the results to date:

EPIDEMIOLOGY

At this time there are no known published reports demonstrating negative health outcomes of workers exposed to refractory ceramic fiber (RCF). Epidemiologic investigations of RCF production workers are ongoing.

1. There is no evidence of any fibrotic lung disease (interstitial fibrosis) whatsoever on x-ray.

2. There is no evidence of any lung disease among those employees exposed to RCF that had never smoked.

3. A statistical "trend" was observed in the exposed population between the duration of exposure to RCF and a decrease in some measures of pulmonary function. These observations are clinically insignificant.

In other words, if these observations were made on an individual employee, the results would be interpreted as being within the normal range.

4. Pleural plaques (thickening along the chest wall) have been observed in a small number of employees who had a long duration of employment. There are several occupational and non-occupational causes for pleural plaque. It should be noted that plaques are not

"pre-cancer" nor are they associated with any measurable effect on lung function.

TOXICOLOGY

A number of studies on the health effects of inhalation exposure of rats and hamsters are available. Rats were exposed to RCF in a series of life-time nose-only inhalation studies. The animals were exposed to 30,

16, 9, and 3 mg/m3, which corresponds with approximately 200, 150,

75, and 25 fibers/cc.

Animals exposed to 30 and 16 mg/m3 were observed to have developed a pleural and parenchymal fibroses; animals exposed to 9 mg/m3 had developed a mild parenchymal fibrosis; animals exposed to the lowest dose were found to have the response typically observed any time a material is inhaled into the deep lung. While a statistically significant increase in lung tumors was observed following exposure to the highest dose, there was no excess lung cancers at the other doses.

Two rats exposed to 30 mg/m3 and one rat exposed to 9 mg/m3 developed masotheliomas.

A-26


IM-106-880, Rev 1.0

January 2007

OCX 8800

The International Agency for Research on Cancer (IARC) reviewed the carcinogenicity data on man-made vitreous fibers (including ceramic fiber, glasswool, rockwool, and slagwool) in 1987. IARC classified ceramic fiber, fibrous glasswool and mineral wool (rockwool and slagwool) as possible human carcinogens (Group 2B).

EMERGENCY FIRST AID PROCEDURES

• EYE CONTACT - Flush eyes immediately with large amounts of water for approximately 15 minutes. Eye lids should be held away from the eyeball to insure thorough rinsing. Do not rub eyes. Get medical attention if irritation persists.

• INHALATION - Remove person from source of exposure and move to fresh air. Some people may be sensitive to fiber induced irritation of the respiratory tract. If symptoms such as shortness of breath, coughing, wheezing or chest pain develop, seek medical attention. If person experiences continued breathing difficulties, administer oxygen until medical assistance can be rendered.

• INGESTION - Do not induce vomiting. Get medical attention if irritation persists.

• SKIN CONTACT - Do not rub or scratch exposed skin. Wash area of contact thoroughly with soap and water. Using a skin cream or lotion after washing may be helpful. Get medical attention if irritation persists.

SECTION VI. REACTIVITY DATA

STABILITY/CONDITIONS TO AVOID

Stable under normal conditions of use.

HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID

N.A.

INCOMPATIBILITY/MATERIALS TO AVOID

Incompatible with hydrofluoric acid and concentrated alkali.

HAZARDOUS DECOMPOSITION PRODUCTS

N.A.

SECTION VII. SPILL OR LEAK PROCEDURES

STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED

Where possible, use vacuum suction with HEPA filters to clean up spilled material. Use dust suppressant where sweeping if necessary.

Avoid clean up procedure which may result in water pollution. (Observe

Special Protection Information Section VIII.)

WASTE DISPOSAL METHODS

The transportation, treatment, and disposal of this waste material must be conducted in compliance with all applicable Federal, State, and Local regulations.

A-27

OCX 8800


IM-106-880, Rev 1.0

January 2007

SECTION VIII. SPECIAL PROTECTION INFORMATION

RESPIRATORY PROTECTION

Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. NIOSH/MSHA approved breathing equipment may be required for non-routine and emergency use. (See Section IX for suitable equipment).

Pending the results of long term health effects studies, engineering control of airborne fibers to the lowest levels attainable is advised.

VENTILATION

Ventilation should be used whenever possible to control or reduce airborne concentrations of fiber and dust. Carbon monoxide, carbon dioxide, oxides of nitrogen, reactive hydrocarbons and a small amount of formaldehyde may accompany binder burn off during first heat. Use adequate ventilation or other precautions to eliminate vapors resulting from binder burn off. Exposure to burn off fumes may cause respiratory tract irritation, bronchial hyper-reactivity and asthmatic response.

SKIN PROTECTION

Wear gloves, hats and full body clothing to prevent skin contact. Use separate lockers for work clothes to prevent fiber transfer to street clothes. Wash work clothes separately from other clothing and rinse washing machine thoroughly after use.

EYE PROTECTION

Wear safety glasses or chemical worker's goggles to prevent eye contact. Do not wear contact lenses when working with this substance.

Have eye baths readily available where eye contact can occur.

SECTION IX. SPECIAL PRECAUTIONS

PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING

General cleanliness should be followed.

The Toxicology data indicate that ceramic fiber should be handled with caution. The handling practices described in this MSDS must be strictly followed. In particular, when handling refractory ceramic fiber in any application, special caution should be taken to avoid unnecessary cutting and tearing of the material to minimize generation of airborne dust.

It is recommended that full body clothing be worn to reduce the potential for skin irritation. Washable or disposable clothing may be used. Do not take unwashed work clothing home. Work clothes should be washed separately from other clothing. Rinse washing machine thoroughly after use. If clothing is to be laundered by someone else, inform launderer of proper procedure. Work clothes and street clothes should be kept separate to prevent contamination.

Product which has been in service at elevated temperatures (greater than 1800°F/982°C) may undergo partial conversion to cristobalite, a form of crystalline silica. This reaction occurs at the furnace lining hot face. As a consequence, this material becomes more friable; special caution must be taken to minimize generation of air-borne dust. The amount of cristobalite present will depend on the temperature and length in service.

A-28


IM-106-880, Rev 1.0

January 2007

OCX 8800

IARC has recently reviewed the animal, human, and other relevant experimental data on silica in order to critically evaluate and classify the cancer causing potential. Based on its review, IARC classified crystalline silica as a group 2A carcinogen (probable human carcinogen).

The OSHA permissible exposure limit (PEL for cristobalite is 0.05 mg/m3 (respirable dust). The ACGIH threshold limit value (TLV) for cristobalite is 0.05 mg/m3 (respirable dust) (ACGIH 1991-92). Use

NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. The minimum respiratory protection recommended for given airborne fiber or cristobalite concentrations are:

CONCENTRATION

HIGH PRESSURE GAS

CYLINDERS

If airborne fiber or cristobalite concentrations are not known, as minimum protection, use NIOSH/MSHA approved half face, air purifying respirator with HEPA filter cartridges.

Insulation surface should be lightly sprayed with water before removal to suppress airborne dust. As water evaporates during removal, additional water should be sprayed on surfaces as needed. Only enough water should be sprayed to suppress dust so that water does not run onto the floor of the work area. To aid the wetting process, a surfactant can be used.

After RCF removal is completed, dust suppressing cleaning methods, such as wet sweeping or vacuuming, should be used to clean the work area. If dry vacuuming is used, the vacuum must be equipped with

HEPA filter. Air blowing or dry sweeping should not be used. Dust suppressing components can be used to clean up light dust.

Product packaging may contain product residue. Do not reuse except to reship or return Ceramic Fiber products to the factory.

GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH

PRESSURE GAS CYLINDERS

• Edited from selected paragraphs of the Compressed

Gas Association's "Handbook of Compressed Gases" published in 1981

Compressed Gas Association

1235 Jefferson Davis Highway

Arlington, Virginia 22202

Used by Permission

1. Never drop cylinders or permit them to strike each other violently.

A-29

OCX 8800


IM-106-880, Rev 1.0

January 2007

2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent.

3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in a cylinder stand, and is ready to be used.

4. Avoid dragging, rolling, or sliding cylinders, even for short distance; they should be moved by using a suitable handtruck.

5. Never tamper with safety devices in valves or cylinders.

6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is attached to a pressurized system.

7. No part of cylinder should be subjected to a temperature higher than

52°C (125°F). A flame should never be permitted to come in contact with any part of a compressed gas cylinder.

8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions must be taken to prevent striking an arc against the cylinder.

A-30


IM-106-880, Rev 1.0

January 2007

ATEX CLARIFICATION

OCX 8800

ATEX COMPLIANT GAS ANALYSIS PERFORMED WITHIN A

FLAMEPROOF ENCLOSURE

Special conditions apply to using a flameproof enclosure analyzer under the scope of the “European Directive for Equipment used in Explosive

Atmosphere” (Directive 94/9/EEC; ATEX). To stay compliant to the directive please consider the following clarification sheet released by the European

ATEX Notified Body Group:

A-31

OCX 8800


IM-106-880, Rev 1.0

January 2007

A-32


IM-106-880, Rev 1.0

January 2007

Appendix B SPA with HART Alarm

OCX 8800

OVERVIEW

DESCRIPTION

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-2

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-2

This section describes the SPA with HART Alarm option for the OCX 8800.

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, contact-closure outputs based on readings of the HART digital data. The four

OCX 8800 alarm outputs recognized by the SPA are Low O

2

Calibration Status, and OCX Unit Failure.

, High COe,

Figure B-1. SPA with

HART Alarm http://www..raihome.com

OCX 8800

Figure B-2. OCX 8800 and

SPA Interface Connections

R

>

<

250

950

OCX 8800


IM-106-880, Rev 1.0

January 2007

IN

HART

Model 275/375

Handheld

Communicator

IN

Analog Output

Customers

DCS, PLC, or

PC with AMS

Software

4-20 mA or

0-24 vdc

Event Recorder,

Audible Alarm, or other

Analog Device

INSTALLATION

SETUP

Refer to Figure B-2 for the typical interface connections for the OCX 8800 and the SPA with HART alarm. Refer to the Moore Industries SPA user's manual for additional information concerning SPA installation, setup, and operation.

Setup of the SPA for communication with the OCX 8800 includes setting internal jumpers and dip switches and configuring the SPA operating parameters via a menu-driven selection and calibration procedure.

Jumper and Switch Settings

SPA jumper and switch settings are shown in Figure B-3. If the SPA with

HART was factory-configured by Emerson Process Management for operation with your OCX 8800, 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:

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-2


IM-106-880, Rev 1.0

January 2007

Figure B-3. SPA Jumper and Dip Switch Settings

SPA - Bottom View

NOTICE

REMOVE THIS PANEL

FOR SERVICE ACCESS.

STATIC SENSITIVE.

USE CAUTION WHEN

CHANGING JUMPERS

Access Cover

OCX 8800

Source Current Dip Switches

(shown in correct position)

Password

ON

Password

Jumper Pins

Password

OFF

Failsafe Dip Switches

(shown in correct position)

Figure B-4. SPA Setup for

Calibration

OCX

8800

Optional

Fluke Model 87

Multimeter or equivalent mA

>

<

250

950

Ω

IN IN

2. 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-3.

4. Check the position of the Source Current Dip Switches. Position the dip switches as shown in Figure B-3.

5. Reinstall the SPA access cover.

Configuration/Calibration

Prior to operation, the SPA operating parameters must be configured via a menu-driven 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 O2 signal wires from the

OCX 8800 analog output terminal block to the SPA Input terminals. (The

OCX must be operational to transmit the O2 signal. Observe polarity.)

AC or DC

Power Input

AC

ACC

GND

B-3

OCX 8800

Figure B-5. SPA Front Panel


IM-106-880, Rev 1.0

January 2007

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 configuration procedure is completed.

signal level when the SPA

4. 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 SELECT 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

B-4


IM-106-880, Rev 1.0

January 2007

OCX 8800

5. Figure B-6 shows the SPA menu, submenus, and parameter values that must be selected to configure the SPA for use with the OCX 8800. Use the following instructions and selections shown 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:

means press the down pushbutton. means press the up pushbutton. means press the SELECT pushbutton one time.

means press the or pushbutton until the desired parameter value is shown in the SPA window.

d. Proceed through the SPA menu, selecting the menu commands and parameter values indicated. After completing the sequence in the first column, go to the top of the second column and continue.

e. To exit the menu, repeatedly press SELECT to display any main menu command. Then, press or until CONF EXIT is displayed.

Select CONF EXIT.

f. Detailed instructions concerning the configuration menu and the submenu structure for each main command are provided in the SPA user's manual.

B-5

OCX 8800

Figure B-6. SPA Configuration Menu for OCX 8800 Communication


IM-106-880, Rev 1.0

January 2007

SET

HART

Ü SET MSTR Ü ô PRIM

Ü SET FUCT Ü ô NRML

Ü NUM VARS Ü ô 02

Ü NUM TRYS Ü ô 03

Ü EXIT HART Ü SGNL SRCE

SGNL

SRCE

Ü AOUT SRCE Ü ô SV

Ü AL2 SRCE Ü ô PV



Ü EXIT SRCE Ü FLT SRCE

FLT

SRCE

ê CONF OPTS

SCLE INPT

SCLE

DSPL

SCLE

OUT

Ü PV DSPL

Ü SET ZERO Ü ô 0000 PCT

Ü SET FULL Ü ô 25 PCT

Ü SV DSPL

Ü SET ZERO Ü ô 0000 PPM

Ü SET FULL Ü ô 1000 PPM

Ü EXIT DSPL Ü SCLE OUT

Ü SET ZERO Ü ô 4.000 MA

Ü SET FULL Ü ô 20.00 MA

Ü EXIT Z/FS

Ü TRIM OUT

TRIM

OUT

Ü TRIM ZERO Ü ô 4.000 MA

Ü TRIM FULL Ü ô 20.00 MA

Ü EXIT TRIM Ü CONF ALRM

CONF

OPTS

Ü SET LINR Ü ô LINR OFF

Ü PV SCLE Ü ô AUTO

Ü DSPL EGU Ü ô CSTM Ü ô PPM

(select P, select P, select M)

Ü DSPL SRCE Ü ô SV

Ü AL2 SEL Ü AL2 FLT

ê SET FAIL Ü FAIL LOW

ê EXIT OPTS Ü SET EGU

SET

EGU

Ü PV EGU Ü ô PCT

Ü SV EGU Ü ô CSTM Ü ô PPM

(select P, select P, select M)

Ü EXIT EGU Ü SCLE INPT

CONF

ALRM

Refer to

SPA manual for settings or

ê PASS WORD

PASS

WORD

ê CONF EXIT

SCLE

INPT

Ü PV SCLE Ü PV ZERO ô 0000 PCT

Ü PV FULL ô 25 PCT

Ü SCLE SV Ü SET ZERO ô 0000 PPM

Ü SET FULL ô 1000 PPM

Ü EXIT SCLE Ü SCLE DSPL

CONF

EXIT

Ü SPA setup complete; observe process value display.

SCLE DSPL

B-6


IM-106-880, Rev 1.0

January 2007

Appendix C Return of Materials

OCX 8800

RETURNING MATERIAL If factory repair of defective equipment is required, proceed as follows:

1. Secure a return authorization number from an Emerson Process

Management sales office or representative before returning the equipment. Equipment must be returned with complete identification in accordance with Emerson Process Management instructions or it will not be accepted.

In no event will Emerson Process Management be responsible for equipment returned without proper authorization and identification.

2. Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to ensure that no additional damage will occur during shipping.

3. In a cover letter, describe completely: a. The symptoms from which it was determined that the equipment is faulty.

b. The environment in which the equipment has been operating

(housing, weather, vibration, dust, etc.).

c. Site from which equipment was removed.

d. Whether warranty or nonwarranty service is requested.

e. Complete shipping instructions for return of equipment.

f. Reference the return authorization number.

4. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Emerson Process

Management Return Authorization, prepaid, to:

Emerson Process Management

RMR Department

Daniel Headquarters

11100 Britmore Park Drive

Houston, TX 77041

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 Analytical warranty, the defective unit will be repaired or replaced at Emerson Process Management'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.


OCX 8800


IM-106-880, Rev 1.0

January 2007

C-2


IM-106-880, Rev 1.0

January 2007

OCX 8800

Index

A

Accessories . . . . . . . . . . . . . . 1-12

Alarm Relay Events . . . . . . . . 7-11

Assemble O2 Sensor . . . . . . . 6-19

Autocalibration Setup, HART . . 5-1

Autocalibration, HART . . . . . . . 5-3

B

Band Heater Height . . . . . . . . 6-22

Blowback System . . . . . . 1-5, 2-17

Blowback with Autocalibration 2-18

Blowback without Autocalibration 2-19

C

Cable Connections . . . . . . . . . . 6-6

Cell Output . . . . . . . . . . . . . . . . 7-7

COe Band Heater . . . . . . . . . . 6-14

COe Sensor Assembly . 6-11, 6-17,

6-18, . . . . . . . . . . . . . . . . . . . 6-22

COe Sensor Holder Alignment 6-23

COe Sensor Parts . . . . . . . . . . 6-21

COe Sensor, Thermocouple, and Heater Connections . . . . . . . . . . . 6-24

Combustibles Sensor . . . . . . . . 1-3

Component Checklist . . . . . . . . 1-1

Configuration . . . . . . . . . . . . . . 3-2

D

D/A Trim Procedure . . . . . . . . . 5-8

Defaults . . . . . . . . . . . . . . . . . . . 3-3

Diagnostic Alarms . . . . . . . . . . . 7-2

E

Eductor . . . . . . . . . . . . . 6-14, 6-20

Eductor Holder . . . . . . . . . . . . 6-14

Electrical Noise . . . . . . . . . . . . . 7-1

Electronics Housing Components 8-6

Electronics Housing Disassembly 6-28

Electronics Housing Terminal Blocks

6-5

Electrostatic Discharge . . . . . . . 7-1

Essential Instructions . . . . . . . . . . i

F

Factory Repair . . . . . . . . . . . . . C-1

Fault Indications . . . . . . . . . . . . 7-3

Fault Isolation . . . . . . . . . . . . . . 7-3

Fitting, ‘F’ Type . . . . . . . . . . . . 6-34

Fitting, ‘R’ Type . . . . . . . . . . . . 6-34

Fittng, ‘13’ Type . . . . . . . . . . . . 6-34

Fuse Locations . . . . . . . . . . . . . 7-2

G

Grounding . . . . . . . . . . . . . . . . . 7-1

H

Handling . . . . . . . . . . . . . . . . . . 1-6

HART Communicator . . . . . . . . 4-1

HART Connections . . . . . . . . . . 1-7

HART PC Connections . . . . . . . 4-4

HART Signal Connections . . . . . 4-1

HART Signal Line Connections 4-2,

4-3

Hazardous Area OCX 8800 . . 1-11

Heater Strut Assembly . . . . . . 6-19

I

Install Eductor . . . . . . . . . . . . . 6-20

Install Electronics Stack . . . . . . 6-31

Install Flash PROM . . . . . . . . . 6-31

Install Remote Electronics . . . . . 6-7

Install Sensor Housing . . . . . . . 6-4

Install Solenoid Valves . . . . . . 6-31

Install Tube Fittings . . . . . . . . . 6-35

Instrument Air . . . . . . . . . . . . . . 1-7

M

Manual Calibration, HART 5-3, 5-5, 5-6

Material Safety Data Sheet . . .A-24

N

Nernst Equation . . . . . . . . . . . . 1-3

O

O2 Cell and Heater Strut 6-25, 6-27

O2 Cell and Heater Strut Assembly

6-9, . . . . . . . . . . . .6-10, 6-16, 8-9

O2 Cell Output Voltage . . . . . . . 1-4

O2 Cell Replacement Kit . . . . . 6-16

O2 Cell, Heater, and Thermocouple

6-16

O2 Cell, Thermocouple, and Heater

Connections . . . . . . . . 6-10, 6-26

OCX with Remote Electronics . .6-2

Operation Diagram . . . . . . . . . .1-6

Oxygen and Cell Output . . . . . .7-7

P

Personal Computer (PC) . . . . . .1-5

Power Up . . . . . . . . . . . . . . . . . .3-3

Pre-Heater . . . . . . . . . . . . . . . .6-18

Pre-Heater Alignment . . . . . . .6-19

Product Matrix . . . . . . . . . . . . . 1-11

R

Reference Air Tube . . . . . . . . .6-10

Removal and Installation . . . . . .6-1

Remove Eductor . . . . . . . . . . .6-14

Remove EEprom . . . . . . . . . . .6-28

Remove Electronics Stack . . . .6-29

Remove Flash PROM . . . . . . .6-28

Remove Remote Electronics . . .6-4

Remove Sensor Housing . . . . . .6-2

Remove Solenoid Valves . . . . .6-30

Remove Tube Fittings . . . . . . .6-34

Repair Sensor Housing . . . . . . .6-8

Replace Tube Fittings . . . . . . .6-34

Reset Procedure . . . . . . . . . . . .3-4

Resistance Devices (RTD) . . . .1-3

Returning Material . . . . . . . . . . C-1

RTD . . . . . . . . . . . . . . . . . . . . . .1-3

S

Sample and Exhaust Tubes 6-15, 6-19

Sample Block Heater Rods 6-10, 6-25

Selected Distributed Control Systems

1-5

Sensor Housing Components 8-2, 8-4

Sensor Housing Disassembly . .6-8

Sensor Housing Leak Test . . . .6-27

Sensor Housing Terminals . . . . .6-3

Solenoid Power Terminals . . . .6-33

SPA Configuration Menu . . . . . B-6

SPA Front Panel . . . . . . . . . . . B-4

SPA Interface Connections . . . B-2 http://www.raihome.com

OCX 8800

SPA Setup for Calibration . . . . . B-3

SPA with HART Alarm . . . . . . . B-1

Specifications . . . . . . . . . . . . . . 1-9

SW1 . . . . . . . . . . . . . . . . . . . . . 3-2

SW2 . . . . . . . . . . . . . . . . . . . . . 3-2

SW3 . . . . . . . . . . . . . . . . . . . . . 3-2

System Configuration . . . . . . . . 1-4

System Description . . . . . . . . . . 1-1

System Features . . . . . . . . . . . . 1-4

System Operation . . . . . . . . . . . 1-5

System Overview . . . . . . . . . . . 1-1

System Package . . . . . . . . . . . . 1-2

T

Terminals Insulator . . . . . . . . . 6-27

Test Gas Values . . . . . . . . . . . . 3-4

Thermal Switch . . . . . . . . . . . . 6-11

Total Power Loss . . . . . . . . . . . . 7-2

Transmitter Package . . . . . . . . . 1-1

Typical System Installation . . . . 1-8

Typical System Package . . . . . . 1-2

W

Warranty Service . . . . . . . . . . . C-1


IM-106-880, Rev 1.0

January 2007

Index-2

WARRANTY

Rosemount Analytical warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount Analytical shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount Analytical with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER

WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED

(INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR

PURPOSE).

The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure of Rosemount Analytical to comply with the warranty provisions, whether claims by the purchaser are based in contract or in tort (including negligence).

Rosemount Analytical does not warrant equipment against normal deterioration due to environment. Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the warranty period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be subject to the same warranty as is extended to Rosemount Analytical by the original manufacturer.

At the time of installation it is important that the required services are supplied to the system and that the electronic controller is set up at least to the point where it is controlling the sensor heater. This will ensure, that should there be a delay between installation and full commissioning that the sensor being supplied with ac power and reference air will not be subjected to component deterioration.

3885

1/07

OCX 8800


IM-106-880, Rev 1.0

January 2007

Rosemount Analytical and the Rosemount Analytical logotype are registered trademarks of Rosemount Analytical Inc.

HART is a registered trademark of the HART Communications Foundation.

All other marks are the property of their respective owners.

WORLD HEADQUARTERS

Emerson Process Management

Rosemount Analytical Inc.

6565P Davis Industrial Parkway

Solon, OH 44139

T 440 914 1261

T 800 433 6076

F 440 914 1262

E [email protected]

ROSEMOUNT ANALYTICAL EUROPE


Gmbh & co. OHG

Industriestrasse 1

63594 Hasselroth

Germany

T 49 6055 884 0

F 49 6055 884 209

EUROPE, MIDDLE EAST, AFRICA


Shared Services Limited

Heath Place

Bognor Regis

West Sussex PO22 9SH

England

T 44 1243 863121

F 44 1243 845354 http://www.raihome.com

GAS CHROMATOGRAPHY

CENTER AND LATIN AMERICA


Rosemount Analytical Inc.

11100 Brittmoore Park Drive

Houston, TX 77041

T 713 467 6000

F 713 827 3329

ASIA-PACIFIC


Asia Pacific Private Limited

1 Pandan Crescent

Singapore 128461

Republic of Singapore

T 65 6 777 8211

F 65 6 777 0947

E analytical@ ap.emersonprocess.com

© 2007 Emerson Process Management. All rights reserved.

Rosemount OCX 8800 O2 / Combustibles Transmitter Hazardous Area Instruction manual

OCX 8800

Oxygen/Combustibles Transmitter

HIGHLIGHTS OF CHANGES

Table of Contents

OCX 8800

Oxygen/Combustibles Transmitter

Section 1

Description and Specifications

OCX 8800 with

REMOTE

ELECTRONICS

Section 2

Installation

TOP VIEW

(1/2 SIZE)

ELECTRONICS HOUSING

SENSOR HOUSING

SIGNAL WIRING OR CABLE

A

A

HEATER WIRING OR CABLE

CAUTION

CAUTION

Section 3

Configuration and Startup

Section 4

Using HART Communications

Section 5

Calibration

Section 6

Maintenance and Service

SENSOR HOUSING

TOP VIEW

(1/2 SIZE)

THERMOCOUPLE

COe

SENSOR ASSEMBLY

TOP VIEW

ELECTRONICS HOUSING

TOP VIEW

Section 7

Troubleshooting

ANALYZER OUTPUT (MILLIVOLT)

ELECTRONICS HOUSING

SENSOR HOUSING

Section 8

Replacement Parts

Appendix A Safety Data

IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING

AND INSTALLATION OF THIS APPARATUS

DŮLEŽITÉ

VIGTIGT

BELANGRIJK

BELANGRIJK

WICHTIG

ΣΗΜΑΝΤΙΚΟ

OLULINE TEAVE

TÄRKEÄÄ

IMPORTANT

FONTOS

IMPORTANTE

SVARBU

š

SVARĪGI

IMPORTANTI

STRUZZJONIJIET TAS-SIGURTÀ GĦALL-WIRING U

L-INSTALLAZZJONI TAT-TAGĦMIR

1. Konnessjonijiet adegwati ta' l-ert għandhom isiru għall-punti kollha ta' l-ert, interni u esterni, fejn ikun ipprovdut.

2. Wara l-installazzjoni jew meta tipprova ssolvi xi problema, l-għatjien kollha tas-sigurtà u l-erts tas-sigurtà għandhom jitpoġġew lura f'posthom.

L-integrità tat-terminali kollha ta' l-ert għandha tinżamm f'kull ħin.

3. Il-wajers tal-provvista tad-dawl għandhom ikunu konformi ml-ħtiġijiet ta'

IEC227 jew IEC245.

4. Il-wiring kollu għandu jkun adattat għall-użu f'temperatura ta' l-ambjent ta' iktar minn 75°C.

5. Il-glands tal-kejbils kollha li jintużw iridu jkunu ta' daqs intern tali li jipprovdu ankoraġġ adegwat lill-kejbil.

7. Meta t-tagħmir jew l-għatjien ikunu mmarkati bis-simbolu fuq il-lemin, x'aktarx li jkun hemm vultaġġi perikolużi taħthom. Dawn l-għatjien għandhom jitneħħew biss meta titneħħa l-provvista tad-dawl mit-tagħmir - u minn ħaddiema tal-manutenzjoni mħarrġa biss.

9. Meta t-tagħmir jew l-għatjien ikunu mmarkati bis-simbolu fuq il-lemin, irreferi għall-Manwal ta' l-Operatur għall-istruzzjonijiet.

10. Is-simboli grafiċi kollha użati f'dan il-prodott huma minn wieħed jew iktar mill-istandards li ġejjin: EN61010-1, IEC417, u ISO3864.

11. Fejn it-tagħmir u t-tikketti huma mmarkati bil-kliem “Tiftaħx Meta