Rosemount OCX 4400 O2 / Combustibles Transmitter-Rev 1.0 Owner's manual

Category
Oxygen Equipment
Type
Owner's manual
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
http://www.processanalytic.com
OCX 4400
OXYGEN/COMBUSTIBLES
TRANSMITTER
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.
Read all instructions prior to installing, operating, and servicing the product.
If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative 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 mainte-
nance of the product.
Install your equipment as specified in the Installation Instructions of the appropriate In-
struction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
To ensure proper performance, use qualified personnel to install, operate, update, program,
and maintain the product.
When replacement parts are required, ensure that qualified people use replacement parts
specified by Rosemount. Unauthorized parts and procedures can affect the product’s per-
formance, 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.
HIGHLIGHTS OF CHANGES
Effective October, 2000 Rev. 1.0.
Page Summary
Throughout Added information on the Blowback option.
Page 1-7 Corrected Figure 1-4.
Page 1-8 Updated specifications.
Page 1-11 Updated Accessories section of Product Matrix.
Page 2-7 Updated Figure 2-5 to include ground stud.
Page 2-8 Updated Figure 2-6 to include shield connections and additional wire
colors.
Page 2-11 Corrected Figure 2-8 piping arrangement.
Page 3-1 Added Initial Power Up instructions for voltage selection.
Page 5-4 through
5-6
Updated Figure 5-3, menu trees for HART communicators.
Page 5-10 Added Line Voltage Selection procedure.
Page 7-1 Added ground stud to removal/replacement instructions.
Page 7-2 Updated Figure 7-1 to include ground stud.
Page 7-4 Updated Figure 7-3 to include shield connections and additional wire
colors.
Page 7-6 Updated Figure 7-4 to include new heater configuration and blowback
option.
Page 7-11 Updated Figure 7-6 to include new instrument air solenoid and vent
tube.
Section 8 Updated troubleshooting information and fault indications.
Section 9 Updated replacement parts table and added new replacement parts.
11-3 through 11-5 Updated Figure 11-3, menu trees for Local Operator Interface.
Appendix C Added Appendix C.
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Rosemount Analytical Inc. A Division of Emerson Process Management i
OCX 4400
TABLE OF CONTENTS
PREFACE........................................................................................................................ P-1
Definitions ........................................................................................................................ P-1
Safety Instructions .......................................................................................................... P-2
1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1
1-1 Component Checklist Of Typical System (Package Contents) ................................. 1-1
1-2 System Overview............................................................................................................ 1-1
1-3 OCX 4400 Specifications............................................................................................... 1-8
2-0 INSTALLATION .............................................................................................................. 2-1
2-1 Mechanical Installation ................................................................................................... 2-1
2-2 Electrical Installation....................................................................................................... 2-6
2-3 Pneumatic Installation .................................................................................................... 2-9
2-4 Startup ............................................................................................................................. 2-9
3-0 STARTUP AND OPERATION ...................................................................................... 3-1
3-1 General ............................................................................................................................ 3-1
4-0 CALIBRATION ................................................................................................................ 4-1
4-1 General ............................................................................................................................ 4-1
4-2 Calibration Methods........................................................................................................ 4-1
5-0 HART/AMS...................................................................................................................... 5-1
5-1 Overview.......................................................................................................................... 5-1
5-2 HART Communicator Signal Line Connections .......................................................... 5-1
5-3 HART Communicator PC Connectiions ....................................................................... 5-2
5-4 Off-Line And On-Line Operations ................................................................................. 5-3
5-5 Menu Tree For HART Communicator/ OCX 4400 Applications ................................ 5-3
5-6 HART Communicator Manual O
2
CAL Method .......................................................... 5-7
5-7 HART Communicator Manual COMB CAL Method.................................................... 5-8
5-8 HART Communicator Manual O
2
And CO CAL Method .......................................... 5-9
5-9 Automatic Calibration Setup Via HART.................................................................... 5-10
5-10 Line Voltage Selection Using HART Communicator ................................................ 5-10
6-0 OPERATION ...................................................................................................................6-1
6-1 Overview.......................................................................................................................... 6-1
6-2 Operation ......................................................................................................................... 6-1
7-0 MAINTENANCE AND SERVICE .................................................................................... 7-1
7-1 Overview.......................................................................................................................... 7-1
7-2 OCX 4400 Removal/Replacement ................................................................................ 7-1
7-3 Sensor Housing Component Replacement .................................................................. 7-5
7-4 Electronics Housing Component Replacement.......................................................... 7-10
8-0 TROUBLESHOOTING .................................................................................................... 8-1
8-1 General ............................................................................................................................ 8-1
8-2 Alarm Output................................................................................................................... 8-1
8-3 Fault Indications.............................................................................................................. 8-1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
ii Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
9-0 RETURN OF MATERIAL .............................................................................................. 9-1
10-0 REPLACEMENT PARTS ............................................................................................. 10-1
11-0 APPENDICES ............................................................................................................... 11-1
Appendix A. Local Operator Interface (LOI) ............................................................. 11-1
Appendix B. SPA With HART Alarm ........................................................................ 11-7
Appendix C. Blowback................................................................................................. 11-8
Appendix D. IS Barrier.............................................................................................. 11-10
12-0 INDEX............................................................................................................................ 12-1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Rosemount Analytical Inc. A Division of Emerson Process Management iii
OCX 4400
LIST OF ILLUSTRATIONS
Figure 1-1. Typical System Package ....................................................................................... 1-2
Figure 1-2. System Operation Diagram ................................................................................... 1-5
Figure 1-3. OCX 440 HART Connections and AMS Application.............................................. 1-6
Figure 1-4. Typical System Installation .................................................................................... 1-7
Figure 2-1. OCX 4400 Installation (with Integral Electronics) .................................................. 2-2
Figure 2-2. OCX 4400 Adapter Plate Dimensions ................................................................... 2-3
Figure 2-3. Adapter Plate Installation....................................................................................... 2-4
Figure 2-4. Installation with Drip Loop and Insulation Removal............................................... 2-5
Figure 2-5. Line Voltage and 4-20 mA Connections ................................................................ 2-7
Figure 2-6. Electrical Connections Between Split-Electronics and Sensor Housing ............... 2-8
Figure 2-7. Air Set, Plant Air Connection ............................................................................... 2-10
Figure 2-8. OCX 4400 Gas Connections ............................................................................... 2-11
Figure 3-1. OCX 4400 Defaults ................................................................................................ 3-0
Figure 5-1. Signal Line Connections, > 250 Ohms Lead Resistance ...................................... 5-1
Figure 5-2. Signal Line Connections, < 250 Ohms Lead Resistance ...................................... 5-2
Figure 5-3. Menu Tree for HART/AMS on the OCX 4400 (Sheet 1 of 3)................................. 5-4
Figure 7-1. Electronics Housing Terminal Blocks .................................................................... 7-2
Figure 7-2. Sensor Housing Terminal Blocks .......................................................................... 7-3
Figure 7-3. Split-Electronics Housing Cable Connections ....................................................... 7-4
Figure 7-4. Sensor Housing, Exploded View ........................................................................... 7-6
Figure 7-5. O
2
Assembly, Exploded View ................................................................................ 7-8
Figure 7-6. Electronics Housing Exploded View .................................................................... 7-11
Figure 7-7. Electronics Box, Exploded View .......................................................................... 7-13
Figure 11-1. LOI Assembly Mounting....................................................................................... 11-1
Figure 11-2. Local Operator Interface (LOI) Assembly ............................................................ 11-2
Figure 11-3. Menu Tree for Local Operator Interface on the OCX 4400 (Sheet 1 of 3) .......... 11-3
Figure 11-4. SPA With HART Alarm ........................................................................................ 11-7
Figure 11-5. Blowback Connections ........................................................................................ 11-9
LIST OF TABLES
Table 1-1. OCX 4400 Specifications....................................................................................... 1-8
Table 1-2. Product Matrix......................................................................................................1-10
Table 1-3. Accessories.......................................................................................................... 1-11
Table 10-1. Replacement Parts .............................................................................................. 10-1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
OCX 4400
PREFACE
The purpose of this manual is to provide a comprehensive understanding of the OCX 4400
Oxygen/Combustibles Transmitter components, functions, installation, and maintenance.
This manual is designed to provide information about the OCX 4400. We recommend that
you thoroughly familiarize yourself with the Introduction and Installation sections before
installing your transmitter.
The introduction presents the basic principles of the transmitter along with its performance
characteristics and components. The remaining sections contain detailed procedures and
information necessary to install and service the transmitter.
Before contacting Rosemount concerning any questions, first consult this manual. It de-
scribes most situations encountered in your equipment’s operation and details necessary
action.
DEFINITIONS
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this
publication.
Highlights an operation or maintenance
procedure, practice, condition, state-
ment, 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, state-
ment, 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 illus-
tration number. It is not a part number, and is not related to the illustration in any technical
manner.
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
P-2 Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
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, hazard-
ous 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. Cer-
tain 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 follow-
ing standards: EN61010-1, IEC417, and ISO3864.
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
OCX 4400
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1-1 COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
A typical Rosemount OCX 4400 Oxygen/
Combustibles Transmitter package should con-
tain the items shown in Figure 1-1. Record the
part number, serial number, and order number
for each component of your system in the table
located on the front page of this manual.
Use the product matrix in Table 1-2 at the end
of this section to verify your order number. The
first part of the matrix defines the model. The
last part defines the various options and fea-
tures of the OCX 4400. Check the model num-
ber against the transmitter features and options,
making sure options specified by this number
are on or included with the unit. Use this com-
plete model number for any correspondence
with Rosemount.
1-2 SYSTEM OVERVIEW
a. Scope
This Instruction Bulletin supplies details
needed to install, startup, operate, and
maintain the Rosemount OCX 4400 Oxy-
gen/ Combustibles Transmitter. Signal con-
ditioning electronics outputs separate 4-20
mA signals representing oxygen (O
2
) and
combustibles (COMB) values. This informa-
tion, plus additional details, can be ac-
cessed with the HART Model 275 handheld
communicator or Asset Management Solu-
tions (AMS) software. An optional local op-
erator interface (LOI) is available to provide
local communication with the electronics.
b. System Description
The Rosemount OCX 4400 Oxygen/
Combustibles Transmitter is designed to
measure oxygen and combustible concen-
trations in flue gas temperatures up to
2600°F (1427°C). The transmitter is close
coupled to the process and requires mini-
mal sample conditioning requirements.
The equipment measures oxygen percent-
age 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 (P1/P2) + C
Where:
1. P2 is the partial pressure of the oxygen in
the measured gas on one side of the cell.
2. P1 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 in-
strument air (20.95% oxygen) as the
reference air.
When the cell is at operating temperature
and there are unequal oxygen concentra-
tions 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 4400 to provide exceptional sensitivity
at low oxygen concentrations.
1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
5
4
6
1
34070023
o
HART
Communicator
FISHER-ROSEMOUNT
TM
MAN 4275A00
English
October 1994
2
3
1. Instruction Bulletin
2. HART
Communicator Package (Optional)
3. Adapter Plate with Mounting Hardware and Gasket
4. OCX 4400 (Shown with Integral Electronics)
5. Reference Air and Calibration Set
6. Blowback Hardware (Optional)
Figure 1-1. Typical System Package
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
OCX 4400
The OCX 4400 measures net oxygen con-
centration in the presence of all the prod-
ucts 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, in-
dicate a lower percentage of oxygen. The
difference will be proportional to the water
content of the sampled gas stream.
The OCX 4400 combustibles sensor is a
catalytic sensor consisting of two Resistant
Temperature Detectors (RTD). One RTD is
the reference element covered with an inert
coating. The other RTD element is active,
coated with a catalyst. As the sample gases
flow by the sensor, the combustible gases
oxidize on the surface of the active element.
The oxidation that occurs produces heat
and a temperature rise in the active ele-
ment. The temperature difference produces
a resistance relationship between the two
elements that is directly proportional to the
concentration of combustibles in the sample
gases.
The catalyst is specifically designed to de-
tect carbon monoxide (CO), but the sensor
responds to other combustible gases. The
sensor is calibrated using carbon monoxide
(CO), thus the output should be expressed
in terms of CO. However, since the sensor
detects other combustible gases, the output
cannot just be labeled CO. The response of
the sensor to other combustible gases gives
an output that is equivalent to the sensor
detecting CO. The term COMB is used in
this manual to describe the sensor output.
This term indicates that the sensor is cali-
brated in terms of CO, and that the sensor
output is equivalent to CO but not specific to
CO.
Dilution air is provided to the COMB sensor
to ensure there is adequate oxygen to fully
oxidize any combustible gases regardless
of the concentration of oxygen in the
process.
c. System Configuration
Transmitters are available in four length op-
tions, 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 mate-
rial options, 316L stainless steel, inconel
600, and ceramic to accommodate higher
temperatures.
The electronics are contained in a separate
housing from the sensors and may be inte-
grally mounted next to the sensor housing
on the probe, or split mounted up to 150
feet away from the probe.
The electronics control both sensor tem-
peratures and provide individual 4-20 mA
isolated outputs that are proportional to the
measured oxygen and combustibles con-
centrations. The power supply can accept
voltages of 100 to 240 VAC and 50 to 60
Hz. The electronics accepts millivolt signals
generated by the sensors and produces the
outputs to be used by remotely connected
devices. The outputs are isolated 4-20 mA
linearized currents. See 3-1b for specific in-
structions upon initial power up.
d. System Features
1. The O
2
cell output voltage and sensi-
tivity increase as the oxygen concen-
tration decreases.
2. HART communication is standard. To
use the HART capability, you must
have either:
(a) A HART Model 275
Communicator.
(b) Asset Management Solutions
(AMS) software for the PC.
3. Oxygen cell and heater/thermocouple
assembly are field replaceable.
1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
4. Electronics are configurable for line
voltages from 100 to 240 VAC. See
Section 3-1b.
5. An operator can calibrate and diagnos-
tically troubleshoot the OCX 4400 in
one of two ways:
(a) HART Interface. Each of the OCX
4400’s 4-20 mA output lines
transmit an analog signal propor-
tional to oxygen or combustible
levels detected. The HART output
is superimposed on the oxygen 4-
20 mA output line only. This infor-
mation can be accessed through
the following:
1 Rosemount Model 275 Hand-
held Communicator - The
handheld communicator re-
quires Device Description
(DD) software specific to the
OCX 4400. The DD software
will be supplied with many
Model 275 units, but can also
be programmed into existing
units at most Fisher-
Rosemount service offices.
Refer to Section 5,
HART/AMS, for additional
information.
2 Personal Computer (PC) -
The use of a personal com-
puter requires AMS software
available from Fisher-
Rosemount.
3 Selected Distributed Control
Systems - The use of distrib-
uted control systems requires
input/output (I/O) hardware
and AMS software which
permit HART
communications.
(b) Optional Local Operator Interface
(LOI). The optional LOI is mounted
to the end of the electronics mod-
ule and allows local communica-
tions with the electronics. Refer to
Appendix A, Local Operator Inter-
face (LOI), for more information.
6. Optional Blowback System. The blow-
back system periodically blows instru-
ment air back through the inlet filter
and out the inlet tube. This clears out
particulate and keeps the inlet filter
from clogging.
e. System Operation
Figure 1-2 shows the relationship between
the components of the OCX 4400. The sen-
sors 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 continu-
ously pulls samples of the process flue gas
through the probe to a chamber in front of
the sensor housing where the sample
passes the O
2
sensor and continues on to
the COMB sensor. Dilution air is provided to
the COMB sensor and reference air to the
O
2
sensor. After the gas sample flows past
the O
2
sensor and through the COMB sen-
sor, it is drawn through the eductor where it
mixes with the eductor air and exits through
exhaust back into the system. The elec-
tronics housing contains the CPU which
converts the sensor inputs into 4-20 mA
analog output signals. The CPU also initi-
ates and performs calibrations. Three test
gasses and instrument air are controlled by
solenoids. Test gas flow to the sensors is
regulated by a rotometer between the elec-
tronics 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.
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
OCX 4400
LOW O2
TEST GAS
COMBUSTIBLES
SENSOR
O2
SENSOR
EDUCTOR
PROBE
EXHAUST
CPU
POWER
SUPPLY
PRESSURE
SENSOR
TEST GAS
SOLENOIDS
INSTRUMENT AIR
SOLENOID
HIGH O2
TEST GAS
HIGH CO
TEST GAS
INSTRUMENT
AIR
DILUTION AIR
REFERENCE AIR
EDUCTOR AIR
ROTOMETER
50 cc/Min.
(0.106 SCFH)
SENSOR
HOUSING
ELECTRONICS
HOUSING
ROTOMETER
5 SCFH
34070001
SAMPLE
GAS
Figure 1-2. System Operation Diagram
1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
f. Handling the OCX 4400
It is important that printed circuit
boards and integrated circuits are
handled only when adequate antistatic
precautions have been taken to pre-
vent possible equipment damage.
The OCX 4400 is designed for indus-
trial application. Treat each compo-
nent of the system with care to avoid
physical damage. The probe may con-
tain components made from ceramics,
which are susceptible to shock when
mishandled.
g. System Considerations
Prior to installing your Rosemount OCX
4400 Oxygen/Combustibles Transmitter,
make sure you have all the components
necessary to make the system installation.
Ensure all the components are properly in-
tegrated to make the system functional.
After verifying that you have all the compo-
nents, select mounting locations and deter-
mine how each component will be placed in
terms of available line voltage, ambient
temperatures, environmental considera-
tions, convenience, and serviceability.
Figure 1-3 shows a typical system wiring. A
typical system installation is illustrated in
Figure 1-4.
A source of instrument air is required at the
OCX 4400 for reference gas, dilution air,
and eductor air. Since the OCX 4400 is
equipped with an in-place calibration fea-
ture, provision should be made for con-
necting test gas tanks to the OCX 4400
when it is to be calibrated.
NOTE
The electronics module is designed to
meet NEMA 4X (IP66) and the elec-
tronic components are rated to tem-
peratures up to 185°F (85°C).
Retain packaging in which the unit ar-
rived from the factory in case any
components are to be shipped to an-
other site. This packaging has been
designed to protect the product.
3 CALIBRATION GAS LINES
BY CUSTOMER
[300 FT (90M) MAX]
INSTRUMENT
AIR
OCX 4400 O2/COMBUSTIBLES TRANSMITTER
WITH INTEGRAL ELECTRONICS
TERMINATION IN
CONTROL ROOM
ASSET MANAGEMENT SOLUTIONS
4-20 MA OUTPUT
(TWISTED PAIRS)
HART MODEL 275
HANDHELD
INTERFACE
CUSTOMER’S LAPTOP
WITH ASSET MANAGEMENT
SOLUTIONS
34070002
Figure 1-3. OCX 440 HART Connections and AMS Application
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7
OCX 4400
INTEGRAL ELECTRONICS
SPLIT-MOUNTED ELECTRONICS
DUCT
DUCT
STACK
STACK
GASES
GASES
HIGH O2 TEST GAS
HIGH O2 TEST GAS
LOW O2 TEST GAS
LOW O2 TEST GAS
LINE VOLTAGE
LINE VOLTAGE
4-20 mA OUTPUTS (2)
4-20 mA OUTPUTS (2)
SPAN COMBUSTIBLES TEST GAS
SPAN COMBUSTIBLES TEST GAS
TEST
GAS
ROTOMETER
TEST
GAS
ROTOMETER
ELECTRONICS
CABLE
(UP TO 150FT)
ADAPTER
PLATE
INSTRUMENT AIR
SUPPLY (REF. GAS)
INSTRUMENT AIR
SUPPLY (REF. GAS)
PRESSURE
REGULATOR
PRESSURE
REGULATOR
34070003
DILUTION AIR
ROTOMETER
DILUTION AIR
ROTOMETER
Figure 1-4. Typical System Installation
1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
1-3 OCX 4400 SPECIFICATIONS
Table 1-1 contains information about the OCX
4400 Oxygen/Combustibles Transmitter oper-
ating characteristics. Use the table to make sure
that available conditions are suitable for the
transmitter before choosing the mounting loca-
tion. Table 1-2 contains the product matrix. Use
the product matrix for ordering information and
specific model number information. Table 1-3
contains information on accessories available
with the OCX 4400.
Table 1-1. OCX 4400 Specifications
Net O
2
Range .................................................. 0-1% to 0-40% O
2
, Fully field selectable
Combustibles ................................................. 0-1000 ppm to 0-5%, Fully field selectable
Accuracy:
Oxygen..................................................... +0.75% of reading or 0.05% O
2
, whichever is greater
Combustibles .......................................... +2% F.S.
System Response to Test Gas:
Oxygen..................................................... 10 sec T90
Combustibles .......................................... 25 sec T90
Temperature Limits:
Process .................................................... 32° to 2600°F (0° to 1427°C)
Sensors.................................................... -40° to 392°F (-40° to 200°C)
Electronics............................................... -40° to 185°F (-40° to 85°C)
1
Nominal and Approximate Shipping Weights:
18 in. (457 mm) package ........................ 54 lbs (24.5 kg)
3 ft (0.91 m) package .............................. 55 lbs (24.5 kg)
6 ft (1.83 m) package .............................. 57 lbs (26 kg)
9 ft (2.74 m) package .............................. 59 lbs (26.8 kg)
Mounting and Mounting Position:
Sensors.................................................... Flange
Electronics............................................... Wall/Pipe
Materials:
Probes...................................................... 316L stainless steel
Inconel 600
Ceramic
Enclosures............................................... Low-copper aluminum
Calibration ...................................................... Semi-automatic or automatic
Calibration Gas Mixtures Recommended.... 0.4% O
2
, Balance N2
8% O
2
, Balance N2
1000 ppm CO, Balance N2
(Ref. test gas kit #1A99119G04)
Calibration Gas Flow ..................................... 5 scfh (2.5 l/m)
Reference Air.................................................. 2 scfh (1 l/m), clean, dry instrument-quality air (20.95% O
2
),
regulated to 35 psi (238 kPa)
Eductor Air...................................................... 5 scfh (2.5 l/m), clean, dry, instrument-quality air
(20.95% O
2
), regulated to 35 psi (238 kPa)
Dilution Air...................................................... 0.1 scfh (0.5 l/m), clean, dry, instrument-quality air
(20.95% O
2
), regulated to 35 psi (238 kPa)
Blowback Air (Optional) ................................ Clean, dry, instrument-quality air (20.95% O
2
), regulated to
55 psi (374 kPa)
1
Operating temperature of electronics inside of electronics housing, as measured by a HART Communicator, or Fisher-
Rosemount Asset Management Solutions Software, or local operator interface.
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9
OCX 4400
Table 1-1. OCX 4400 Specifications (Continued)
Sensors Housing ........................................... NEMA 4X, IP66 with fitting and pipe on reference exhaust
port to clean, dry atmosphere
Two 3/4-14 NPT conduit ports
Electronics Housing ...................................... NEMA 4X, IP66 with fitting and pipe on reference exhaust
port to clean, dry atmosphere
Two 3/4-14 NPT conduit ports
Electrical Noise .............................................. Meets EN 50082-2 Electromagnetic Compatibility Generic
Immunity Std., Part II
Includes ENG 1000 4-R for Electrostatic Discharge 4 Kv
contact, 8 Kv in air
Optionally ENG 1000 4-R “Namur-Increased” 8 Kv contact,
16 Kv in air
Includes IEC 801-4 fast transients-2
Kv on power supply and control lines
Line Voltage.................................................... Universal 100 to 240 VAC, 50 to 60 Hz, Software selectable,
3/4-14 NPT conduit port
Isolated Output:
Oxygen..................................................... 4-20 mAdc, 950 ohm max, with HART capability for O
2
and
COMB
Combustibles .......................................... 4-20 mAdc, 950 ohm max
Logic Signals.................................................. SPA HART Alarm Module (optional)
Low Oxygen Alarm
High Combustibles Alarm
Calibration Status
Unit Failure
Alarm Output Relay (dry contact, 30 mA and 30 VDC
capacity)
Power Consumption Limits:
Heaters..................................................... 650 W nominal max
Electronics............................................... 50 W nominal max
Certification .................................................... CE
FM(Pending)
CSA(Pending)
CENELEC(Pending)
1
Instruction Manual
IB-106-440 Rev. 1.0
October 2000
1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
OCX 4400
Table 1-2. Product Matrix
OCX44A O2 / Combustibles Transmitter
O2 / Combustibles Transmitter IB-106-440
Code Probe Length and Material
00 No Probe or Exhaust Tube
11 18 in. (457 mm) 316 SST up to 1300°F (704°C)
21 18 in. (457 mm) Inconel 600 up to 1832°F (1000°C)
31 18 in. (457 mm) Ceramic up to 2600°F (1426°C)
12 3 ft (0.91 m) 316 SST up to 1300°F (704°C)
22 3 ft (0.91 m) Inconel 600) up to 1832°F (1000°C)
32 3 ft (0.91 m) Ceramic up to 2600°F (1426°C)
13 6 ft (1.83 m) 316 SST up to 1300°F (704°C)
23 6 ft (1.83 m) Inconel 600 up to 1832°F (1000°C)
14 9 ft (2.7 m) 316 SST up to 1300°F (704°C)
Code Probe Mounting Assembly
10 (ANSI 2 in. 150 lb) 6" dia. flange, 4.75" BC with 4 x 0.75" dia. holes
20 (DIN) 185mm dia. flange, 145mm BC with 4 x 18mm dia. holes
30 (JIS) 155mm dia. flange, 130mm BC with 4 x 15mm dia. holes
Code Mounting Hardware - Stack Side
0 No Adapter Plate ("0" must also be chosen under "Mounting Adapter - Probe Side" below)
1 New Installation - Square weld plate with studs
2 Model 218/240 Mounting Plate (with Model 218/240 Shield Removed)
3 Existing Model 218/240 Support Shield
4 Mounting to Other Mounting
(1)
5 Model 132 Adapter Plate
6 Mounting to Ametek WDG-IVC
7 Mounting to Servomex Xendos 2700
8 Mounting to Elsag Bailey SMA-90
Code Mounting Hardware - Probe Side
0 No Adapter Plate
1 Probe Only (ANSI)
4 Probe Only (DIN)
7 Probe Only (JIS)
OCX44A 11 10 1 1 (Cont’d) Example
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Rosemount OCX 4400 O2 / Combustibles Transmitter-Rev 1.0 Owner's manual

Category
Oxygen Equipment
Type
Owner's manual

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