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

Category
Oxygen Equipment
Type
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
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-106-440C 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

Category
Oxygen Equipment
Type
Owner's manual

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