Rosemount OCX 4400 O2 / Combustibles Transmitter Hazardous Area-Orig. Issue Owner's manual

Instruction Manual

IB-106-440C Original Issue

February 2003

http://www.processanalytic.com

OCX 4400

HAZARDOUS AREA

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.

Instruction Manual

IB-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management i

OCX 4400 HAZARDOUS AREA

TABLE OF CONTENTS

PREFACE............................................................................................................................1

Definitions ............................................................................................................................1

Safety Instructions ...............................................................................................................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 Initial Startup.................................................................................................................. 2-11

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 Connections ........................................................................... 5-3

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 Isolation. ................................................................................................................. 8-1

Instruction Manual

IB-106-440C Original Issue

February 2003

ii Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400 HAZARDOUS AREA

9-0 RETURN OF MATERIAL .............................................................................................. 9-1

10-0 REPLACEMENT PARTS ............................................................................................. 10-1

11-0 APPENDICES ............................................................................................................... 11-1

Appendix A Local Operator Interface (LOI) ................................................................... A-1

Appendix B SPA with HART Alarm ............................................................................... B-1

Appendix C Blowback....................................................................................................C-1

Appendix D IS Barrier....................................................................................................D-1

12-0 INDEX............................................................................................................................ 12-1

Instruction Manual

IB-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management iii

OCX 4400 HAZARDOUS AREA

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. Wall or Pole Mounting of Electronics Housing....................................................... 2-4

Figure 2-5. Installation with Drip Loops.................................................................................... 2-5

Figure 2-6. Line Voltage and 4-20 mA Connections ................................................................ 2-7

Figure 2-7. Electrical Connections Between Split-Electronics and Sensor Housing ............... 2-8

Figure 2-8. Pneumatic Installation, OCX with Reference Air Set (without Autocalibration)..... 2-9

Figure 2-9. Pneumatic Installation, OCX with Reference Air Set and

Solenoids (with Autocalibration) .......................................................................... 2-10

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. Fuses, Exploded View ......................................................................................... 7-12

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 8-1. Troubleshooting ..................................................................................................... 8-2

Table 10-1. Replacement Parts .............................................................................................. 10-1

Instruction Manual

IB-106-440C Original Issue

February 2003

iv Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400 HAZARDOUS AREA

Instruction Manual

IB-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management P-1

OCX 4400 HAZARDOUS AREA

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-106-440C Original Issue

February 2003

P-2 Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400 HAZARDOUS AREA

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-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

OCX 4400 HAZARDOUS AREA

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 back cover of this manual.

Use the product matrix in Table 1-2 at the end

of this section to verify your order number. The

first part of the matrix defines the model. The

last part defines the various options and 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). 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

Category 2, Zone 1, Group IIB +H2 T3 per-

manently mounted equipment. The trans-

mitter is close coupled to the process and

requires minimal sample conditioning re-

quirements.

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 (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 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-106-440C Original Issue

February 2003

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400 HAZARDOUS AREA

5

4

6

1

37020025

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-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

OCX 4400 HAZARDOUS AREA

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 3-1c and 3-1d for

specific instructions 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-106-440C Original Issue

February 2003

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400 HAZARDOUS AREA

4. Electronics are automatically config-

ured for line voltages from 100 to 240

VAC.

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 communica-

tions.

(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 flameproof housings. The sensor

housing and probe mounts to a duct or pro-

cess 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 sam-

ple passes the O

2

sensor and continues on

to the COMB sensor. Dilution air is provided

to the COMB sensor and reference air to

the O

2

sensor. After the gas sample flows

past the O

2

sensor and through the COMB

sensor, it is drawn through the eductor

where it mixes with the eductor air and exits

through exhaust back into the system. The

electronics housing contains the CPU which

converts the sensor inputs into 4-20 mA

analog output signals. The CPU can also

initiate and perform calibrations. Three test

gasses and instrument air can be turned on

and off by solenoids. Test gas flow to the

sensors is regulated by a rotometer be-

tween the electronics and sensor housings.

Instrument air is separated into eductor air,

reference air, and dilution air. The instru-

ment 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-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

OCX 4400 HAZARDOUS AREA

LOW O2

TEST GAS

COMBUSTIBLES

SENSOR

O2

SENSOR

EDUCTOR

PROBE

EXHAUST

CPU

POWER

SUPPLY

PRESSURE

SENSOR

OPTIONAL

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.

(0.1 SCFH)

SENSOR

HOUSING

ELECTRONICS

HOUSING

ROTOMETER

5 SCFH

37020001

SAMPLE

GAS

Figure 1-2. System Operation Diagram

1

Instruction Manual

IB-106-440C Original Issue

February 2003

1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400 HAZARDOUS AREA

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 air, 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 (IP55) 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-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7

OCX 4400 HAZARDOUS AREA

INTEGRAL ELECTRONICS

SPLIT-MOUNTED ELECTRONICS

DUCT

STACK

GASES

HIGH O2 TEST GAS

LOW O2 TEST GAS

LINE VOLTAGE

4-20 mA OUTPUTS (2)

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-106-440C Original Issue

February 2003

1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400 HAZARDOUS AREA

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

1

Accuracy:

Oxygen..................................................... +0.75% of reading or 0.05% O

2

, whichever is greater

Combustibles .......................................... +2% F.S.

System Response to Test Gas:

Oxygen..................................................... 25 sec T90

Combustibles .......................................... 30 sec T90

Temperature Limits:

Process .................................................... 32° to 2600°F (0° to 1427°C)

Sensors Housing .................................... 32° to 392°F (0° to 200°C)

2

Electronics Housing ............................... 32° to 185°F (0° to 85°C)

2

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 N

2

(Ref. test gas bottles kit #1A99119G04) 8% O

2

, Balance N

2

1000 ppm CO, Balance N

2

NOTES:

(1)

Combustibles sensor is calibrated with CO gas. Sensor may be calibrated with H

2

gas. Use in methane service is not

recommended.

(2)

Operating temperature of electronics inside of electronics housing, as measured by a HART Communicator, or Emerson

Process Management Asset Management Solutions (AMS) Software, or local operator interface. Operation below 0°C

(32°F) requires that sensor housing be insulated.

Instruction Manual

IB-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9

OCX 4400 HAZARDOUS AREA

Table 1-1. OCX 4400 Specifications (Continued)

Calibration Gas Flow ..................................... 5 scfh (2.5 l/m)

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

2

),

regulated to 45 psi (310 kPa)

Eductor Air...................................................... 5 scfh (2.5 l/m), clean, dry, instrument-quality air

(20.95% O

2

), regulated to 45 psi (310 kPa)

Dilution Air...................................................... 0.1 scfh (0.5 l/m), clean, dry, instrument-quality air

(20.95% O

2

), regulated to 45 psi (310 kPa)

Blowback Air (Optional) ................................ Clean, dry, instrument-quality air (20.95% O

2

),

regulated to 55 psi (374 kPa)

Sensor and Electronics Housings ............... NEMA 4X, IP55 with fitting and pipe on reference exhaust

port to clean, dry atmosphere, two 3/4-14 NPT conduit ports

Electrical Noise .............................................. Meets EN 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

Alarm Output Relay ....................................... No. 2, form C, double-pole, double-throw, 30 Vdc, 2 Amp,

(software assignable)

Logic Signals.................................................. SPA HART Alarm Module (optional)

Low Oxygen Alarm

High Combustibles Alarm

Calibration Status

Unit Failure

Power Consumption Limits:

Heaters..................................................... 650 W nominal max

Electronics............................................... 50 W nominal max

Certification .................................................... CE

FM (Pending)

CSA (Pending)

CENELEC EEX d IIB+H2, Sensor Housing T3,

Electronics Housing T6

CENELEC EEX d ia IIB+H2, Sensor Housing T3,

Electronics Housing T6 (with IS Barrier option)

NOTE:

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

notice.

1

Instruction Manual

IB-106-440C Original Issue

February 2003

1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

OCX 4400 HAZARDOUS AREA

Table 1-2. Product Matrix

OCX44C O2 / Combustibles Transmitter - Flameproof

O2 / Combustibles Transmitter IB-106-440C

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)

OCX44C 11 10 1 1 (Cont’d) Example

Instruction Manual

IB-106-440C Original Issue

February 2003

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-11

OCX 4400 HAZARDOUS AREA

Table 1-2. Product Matrix (Continued)

Cont'd Code Electronic Housing - NEMA 4X, IP55 HART Communications

01 Basic Unit

02 Local Operator Interface

2

03 Calibration Solenoids

04 IS Barrier

3

05 Local Operator Interface and Calibration Solenoids

06 Local Operator Interface and IS Barrier

3

07 Calibration Solenoids and IS Barrier

3

08 Local Operator Interface and Calibration Solenoids and IS Barrier

3

Code Electronic Mounting

01 Integral to Sensor Housing Electronics

02 Split Electronics and no cable

03 Split Electronics and 20 ft (6m) cable

04 Split Electronics and 40 ft (12m) cable

05 Split Electronics and 60 ft (18m) cable

06 Split Electronics and 80 ft (24m) cable

07 Split Electronics and 100 ft (30m) cable

08 Split Electronics and 150 ft (45m) cable

Code Accessories

00 None

01 Cal. Gas Rotometers, Flow Rotometers, and Ref. Gas Set

11 Blowback Option and Cal. Gas Rotometers, Flow Rotometers, and Ref. Gas Set

Cont’d 08 01 11 Example

NOTES:

(1)

Where possible, specify SPS number; otherwise, provide details of the existing mounting plate as follows:

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

Plate without studs Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.

(2)

If the Local Operator Interface (LOI) is not implemented, remote access and functionality available via HART Communica-

tions (Model 275 Handheld Communicator) with Oxygen/Combustibles Device Description (DD) required.

(3)

If the IS Barrier option is selected, customer must also purchase the Moore Industries SPA (1A99292H01), current repeater

backplane and adpater kit (p/n 1A99698G01) to maintain the 4 – 20 mA combustibles output.

Table 1-3. Accessories

PART NUMBER DESCRIPTION

1A99119H01 Oxygen Bottle 0.4%, balance N

2

1A99119H02 Oxygen Bottle 8.0%, balance N

2

1A99119H06 CO Bottle 1000 PPM and air, balance N

2

1A99120H02 Regulator for Oxygen (may need 2)

1A99120H03 Regulator for COMB

1A99119G06 Wall mount bracket for gas bottles

1A99119G05 Test gas regulators kit

1A99119G04 Test gas bottles kit

1A99292H01

Moore Industries SPA for Low O

2

Alarm, High

COMB Alarm, Calibration Status, and Unit Fail

275D9EI5D0000 275 HART Communicator with 12 Meg buffer

1

Instruction Manual

IB-106-440C Original Issue

February 2003

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

OCX 4400 HAZARDOUS AREA

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Rosemount OCX 4400 O2 / Combustibles Transmitter Hazardous Area-Orig. Issue Owner's manual

Rosemount OCX 4400 O2 / Combustibles Transmitter Hazardous Area-Orig. Issue Owner's manual

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