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Emerson Rosemount OCX8800A Manual

Oxygen and combustibles transmitter
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Manual
00809-0500-4880, Rev AA
December 2022
Rosemount
™
OCX8800A
Oxygen and Combustibles Transmitter

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Summary of Contents for Emerson Rosemount OCX8800A

  • Page 1 Manual 00809-0500-4880, Rev AA December 2022 Rosemount ™ OCX8800A Oxygen and Combustibles Transmitter...
  • Page 2 The information contained in this document is subject to change without notice. NOTICE If a Field Communicator is used with this unit, the software within the Field Communicator may require modification. If a software modification is required, please contact your local Emerson Service Group or National Response Center at 1-800-654-7768. WARNING Physical access Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’...
  • Page 3 Product names used herein are for manufacturer or supplier identification only and may be trademarks/registered trademarks of these companies. Rosemount and the Rosemount logo are registered trademarks of Rosemount. The Emerson logo is a trademark and service mark of Emerson Electric Co.

  • Page 5: Table Of Contents

    4.4 D/A trim procedures......................... 78 ® Chapter 5  Using HART communications................81 5.1 Overview.............................81 5.2 Field Communicator signal connections................81 5.3 Field Communicator PC connections..................84 ® 5.4 HART menu tree........................85 5.5 D/A trim procedures......................... 89 Chapter 6  Calibration........................ 93 6.1 Overview.............................93 6.2 Fully automatic calibration.......................93 6.3 Operator-initiated autocalibration..................95 Rosemount OCX8800A...
  • Page 6 8.7 Transducer block enumerations................... 139 8.8 Analog input (AI) function block....................146 8.9 Proportional/integral/derivative (PID) function block............166 8.10 Arithmetic (ARTHM) function block..................194 8.11 Advanced topics........................203 8.12 Input selector (ISEL) function block..................203 ™ 8.13 Operation with Emerson DeltaV ..................211 Chapter 9  Troubleshoot......................213 9.1 Overview...........................213 9.2 Diagnostic alarms........................215 9.3 Fault isolation.......................... 215 9.4 Alarm relay events........................
  • Page 7 Manual Contents 00809-0500-4880 December 2022 ® Appendix C  SPA with HART alarm..................317 C.1 Overview..........................317 C.2 Description..........................317 C.3 Install............................319 C.4 Setup............................320 Appendix D  Returning material....................327 Rosemount OCX8800A...
  • Page 8 Contents Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 9: Description And Specifications

    Use this complete model number for any correspondence with Emerson. Optional accessories provides a list of accessories for use with the Rosemount OCX8800. Rosemount OCX8800A...
  • Page 10 Manual December 2022 00809-0500-4880 Figure 1-1: Typical System Package A. Quick Start Guide B. Field Communicator package (optional) C. Blowback hardware (optional) D. Adapter plate with mounting hardware and gasket E. Rosemount OCX8800 F. Reference air and calibration set Emerson.com/Rosemount...

  • Page 11: System Overview

    1.2.2  System description Emerson has designed the Rosemount OCX8800 to measure oxygen and combustible concentrations in flue gas temperatures up to 2600 °F (1427 °C). Electrical connections, power, and communications are made through two ¾ national pipe thread (NPT) ports in the flameproof electronics enclosure using fittings and cables provided by the customer.
  • Page 12 The electronics housing may be mounted up to 150 ft. (45.7 m) from the sensor housing. The electronics control both sensor temperatures and provide output signals in one of two ways: Emerson.com/Rosemount...
  • Page 13 Field Communicator: The handheld Field Communicator requires Device Description (DD) software specific to the Rosemount OCX8800. The DD software is supplied with many Field Communicators, but can also be programmed into existing Field Communicators at most Emerson service offices. Refer to Using HART communications for additional information.
  • Page 14 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 the cold sensors causing condensation. Emerson.com/Rosemount...
  • Page 15 ® O. Power supply P. Optional test gas solenoids Q. Instrument air solenoid R. Low O test gas S. High O test gas T. CO test gas U. Instrument air V. Flow meter 50 cc/min. (0.1 scfh) Rosemount OCX8800A...
  • Page 16 185 °F (85 °C). Retain packaging in which the transmitter arrived from the factory in case any components are to be shipped to another site. This packaging haws been designed to protect the product. Emerson.com/Rosemount...
  • Page 17 A. Rosemount OCX8800 with integral electronics B. Instrument air C. Three calibration lines by customer (300 ft. [91 m] maximum) D. Signal output (twisted pairs) E. Termination in control room F. Field Communicator G. Customer's laptop with AMS H. AMS Rosemount OCX8800A...
  • Page 18 D. Instrument air supply (reference gas) E. High O test gas F. Low O test gas G. CO test gas H. Gases I. Duct J. Stack K. Test gas flow meter L. Dilution air flow meter M. Pressure regulator Emerson.com/Rosemount...
  • Page 19 G. Dilution air flow meter H. 4-20 mA outputs (two twisted pairs) I. Line voltage J. Instrument air supply (reference gas) K. Pressure regulator L. High O test gas M. Low O test gas N. CO test gas Rosemount OCX8800A...
  • Page 20 Description and specifications Manual December 2022 00809-0500-4880 Figure 1-6: Optional Sample Tube Support C. 0.75-in. (19 mm) diameter on 7.5-in. (190 mm) diameter B.C., eight places D. 0.75-in. (19 mm) diameter on 4.75-in. (121 mm) diameter B.C., four places Emerson.com/Rosemount...
  • Page 21 114.5 (2907) Figure 1-7: Optional In-Situ Filters A. In-situ stainless steel or Hastelloy filter B. In-situ high surface area stainless steel filter Figure 1-8: Optional Panel Mounted Blowback and Calibration/Reference Air Set (19-in. [482.6 mm] Rack or Wall Mount) Rosemount OCX8800A...

  • Page 22: Specifications

    10 seconds T90 Combustibles 25 seconds T90 1.3.5  Temperature limits Process 32 to 2600 °F (0 to 1427 °C) Sensors housing -40 to 212 °F (-40 to 100 °C) ambient Electronics housing -40 to 149 °F (-40 to 65 °C), ambient Emerson.com/Rosemount...
  • Page 23 Housings mounting Integral electronics Flange Remote electronics Sensors housing: flange Electronics housing: wall/pipe 1.3.8  Materials Probes 316L stainless steel: 1300 °F (704 °C) Inconel 600: 1832 °F (1000 °C) Ceramic: 2600 °F (1427 °C) Enclosures Low copper aluminum Rosemount OCX8800A...
  • Page 24 1.3.17  Electronics housing Type 4X, IP66 with fitting and pipe on reference exhaust port to clean, dry atmosphere, two ¾-14 NPT conduit ports (when reference air vents are routed to a dry area. Emerson.com/Rosemount...

  • Page 25: Ordering Information

    Alarm Alarm output relay - dry contact, form C, 30 mA, 30 Vdc capability 1.3.25  Power consumption 750 W maximum 1.4  Ordering information For ordering information, refer to the Rosemount OCX8800 Oxygen and Combustibles Transmitter Product Data Sheet. Rosemount OCX8800A...
  • Page 26 Description and specifications Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 27: Chapter 2 Install

    You must position the probe so the gas it measures is representative of the process. For best results, position the transmitter near the center of the duct (40 to 60 percent insertion). Longer ducts may require several transmitters since the Rosemount OCX8800A...
  • Page 28 Make the necessary repairs or install the transmitter upstream of any leakage. 2. Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance access to the transmitter. Allow adequate clearance for the removal of the transmitter. Emerson.com/Rosemount...
  • Page 29 D. Flange diameter E. B.C. diameter F. Hole diameter G. See Table 2-2. H. Allow 9 in. (229 mm) for cover removal. I. Bottom view J. Optional in situ filter Table 2-1: 0.06-in. Thick Gasket ANSI 353B18H02 353B45H01 Rosemount OCX8800A...
  • Page 30 9 ft. (2.7 m) 108 in. (2743 mm) 124 in. (3150 mm) Procedure 1. Ensure all components are available to install the transmitter. You may install the transmitter intact as it is received. 2. Weld or bolt adapter plate onto the duct. Emerson.com/Rosemount...
  • Page 31 Manual Install 00809-0500-4880 December 2022 Figure 2-2: Adapter Plate Installation Dimensions are in inches with millimeters in parentheses. Only adapter plate is furnished by Emerson. A. Plate size (see Table 2-4) B. Stud size (see Table 2-4) C. Bolt circle diameter (see...
  • Page 32 Figure 2-3: Installation with Drip Loops A. Duct wall B. Conduit drip loops 5. Where a positive stack pressure exists at the installation site, connect all pneumatic lines prior to installing the transmitter in the stack or ductwork. Emerson.com/Rosemount...

  • Page 33: Electrical Installation

    Disconnect and lock out power before connecting the transmitter to the power supply. WARNING Failure to install covers and ground leads could result in serious injury or death. Install all protective equipment covers and safety ground leads after installation. Rosemount OCX8800A...
  • Page 34 (G wire) to the ground stud in the electronics housing as shown in Figure 2-10. 2.3.3  Connect 4-20 mA signals Connect the 4-20 mA current loop to the 4-20 mA signal output terminals in the electronics housing as shown in Figure 2-10. Emerson.com/Rosemount...
  • Page 35 Fieldbus signal provides all output information and is accessible OUNDATION through a Handheld Communicator. 2.3.7  Alarm output relay Connect any customer-supplied relay input to the alarm output relay terminal. Use shielded wire and terminate the shield at the electronics housing. The alarm Rosemount OCX8800A...
  • Page 36 Install Manual December 2022 00809-0500-4880 output relay terminal is a set of dry, number 2, form C contacts with 30 mA, 30 VDC capacity. Figure 2-4: Alarm Output Relay Terminal Block A. Normally closed B. Common C. Normally open Emerson.com/Rosemount...
  • Page 37 Figure 2-5: 4-20 mA Signal Output Terminal Block A. COe signal B. O signal C. Signal port ¾ national pipe thread (NPT) D. Power port ¾ NPT E. Terminal block F. External tooth lockwasher G. Ground stud H. Customer wiring I. EMI filter Rosemount OCX8800A...
  • Page 38 Remote electronics connections to sensor housing Make the following connections between the remote electronics and sensor housings with the electronics cable ordered with the package (Figure 2-7). Braided cable is available in lengths up to 150 ft (46 m). Emerson.com/Rosemount...
  • Page 39 Housing A. To ground screw B. Heater power connector (J3) C. COe sensor and cold junction connector (J4) D. O sensor and thermocouple connector (J5) E. Heater power cable F. Electronics housing G. Sensor housing H. Signal cable Rosemount OCX8800A...
  • Page 40 T/C sample block (SB) + Black T/C SB - Green T/C O Black T/C O Blue cell + Black cell - Note Interconnect wiring shown is for Rosemount supplied cables. For customer furnished interconnect wiring or cables, refer to Figure 2-8 Figure 2-9. Emerson.com/Rosemount...
  • Page 41 J. Heat shrink tubing 1 in. (25.4 mm) long, 3/16 in. (4.8 mm) size K. Typical on both ends of wiring L. 2.0 ± 0.25 typical M. For RFI/CE compliance, the connector must provide 360 degrees of electrical contact to the cable shield. Rosemount OCX8800A...
  • Page 42 2.3.9  Signal connections Connect the electronics housing terminals to the corresponding terminals in the sensor housing. The twisted wire pairs are numbered on the inner plastic wrapper. Keep twisted pairs together and match the numbers and wire colors. Emerson.com/Rosemount...

  • Page 43: Pneumatic Installation

    K. External tooth locks washer L. Signal port ¾-in. NPT M. Power port ¾-in. NPT 2.4  Pneumatic installation Pneumatic system connections depend on whether reference air set, calibration solenoids, and/or blowback equipment options are equipped on your transmitter. Rosemount OCX8800A...
  • Page 44 5. Connect the output of the test gas sources to the inlet port of the CAL GAS flow meter. Install an air line between the flow meter outlet port and the CAL GAS inlet fitting on the sensor housing. Emerson.com/Rosemount...
  • Page 45 General purpose: 35 psig (2.4 barg) M. 2-in. pressure gauge, 0 to 60 psig (0 to 4.1 barg) N. Combination filter-regulator, 0 to 60 psig (0 to 4.1 barg) O. Flow meter, 1-10 scfh P. Flow meter, 0.05-0.5 scfh Rosemount OCX8800A...
  • Page 46 5. Connect the CAL GAS outlet fitting of the electronics housing to the inlet port of the CAL GAS flow meter. Install an air line between the flow meter outlet port and the CAL GAS inlet fitting on the sensor housing. Emerson.com/Rosemount...
  • Page 47 L. Pressure regulator/filter 35 psig (2.4 barg) for general purpose, 45 psig (3.1 barg) for hazardous areas M. 2-in. pressure gauge 0-60 psig (0 to 4.1 barg) N. Combination filter-reg. 0-60 psig (0 to 4.1 barg) O. Flow meter 1-10 scfh P. Flow meter 0.05-0.5 scfh Q. Calibration gas out Rosemount OCX8800A...
  • Page 48 Reference air set and solenoids option with COe zero function Figure 2-13 shows the piping arrangement for the transmitter with autocalibration when the COe zero function is used. The arrangement is similar to Figure 2-12, except instrument air is used as the high O test gas. Emerson.com/Rosemount...
  • Page 49 O. Flow meter, 1-10 scfh P. Flow meter, 0.05-0.5 scfh Q. Calibration gas out Note If instrument is to be used as the high O calibration gas, the low O and COe calibration gases must also be set to the same pressure. Rosemount OCX8800A...
  • Page 50 Figure 2-14 shows the piping arrangement for the transmitter with the blowback and autocalibration options when COe zero function is used. The arrangement is similar to Figure 2-12 except instrument air is used as the high O test gas. Emerson.com/Rosemount...
  • Page 51 Q. Blowback valve, air operated R. 2-in. pressure gauge, 0 to 60 psig (0 to 4.1 barg) S. Combination filter/regulator, 0 to 60 psig (0 to 4.1 barg) T. Flow meter, 1-10 scfh During blowback operation, states of both solenoid valves change. Rosemount OCX8800A...

  • Page 52: Initial Start-Up

    Upon completing installation, make sure that the transmitter is turned on and operating prior to firing up the combustion process. During outages, and whenever possible, leave the transmitter running to prevent condensation and premature aging from thermal cycling. Emerson.com/Rosemount...

  • Page 53: Configuration And Start-Up

    All switches are accessible through holes in the electronics box. CAUTION Equipment damage If defaults are changed under power, damage to the electronics may occur. Remove power from the transmitter before changing defaults. Verify that the following switch settings are correct for your installation. Rosemount OCX8800A...
  • Page 54 Rail limits: — Open High: 21.1 mA — Closed Low: 3.5 mA SW1: The two settings are internally or externally powering the O 4-20 mA signal. The factory setting is for the O 4-20 mA signal to be internally powered. Emerson.com/Rosemount...
  • Page 55 The switch is accessible through holes in the electronics box. CAUTION Equipment damage If defaults are changed under power, damage to the electronics may occur. Remove power from the transmitter before changing defaults. Rosemount OCX8800A...

  • Page 56: Initial Power Up

    Normal operating temperature for the O cell is 1357 °F (736 °C). Normal operating temperature for the combustibles cell is 572 °F (300 °C). The normal Emerson.com/Rosemount...

  • Page 57: Setting Test Gas Values

    LOW GAS. Enter the percent O used for the low test gas 6. From the TRANSDUCER menu, select COe CAL SETUP. 7. From COe CAL SETUP, select COe Test Gas. Enter the CO concentration (ppm) used for the COe test gas. Rosemount OCX8800A...

  • Page 58: Reset

    3. From the SYSTEM submenu, select the Status submenu. 4. From the Status submenu, select Reset Device. The transmitter resets, and the LOI reverts to the normal operation display. 3.4.2  Reset with Field Communicator Remove the transmitter from the process loop and recycle power. Emerson.com/Rosemount...

  • Page 59: Calibration Solenoids

    00809-0500-4880 December 2022 3.5  Calibration solenoids Emerson can provide the transmitter with optional calibration solenoids for autocalibration. The transmitter's software controls the solenoids, which automatically switch in the proper calibration gas during the calibration cycle. 3.5.1  Configure the calibration solenoids with the Field Communicator - HART ®...
  • Page 60 Blowback Period: Length of time blowback is activated (FIVE seconds recommended). • Blowback Purge Time: Length of time after blowback is complete before oxygen/combustibles readings are considered valid (set as required by the application). • Initiate Blowback: Intiates a blowback event manually. Emerson.com/Rosemount...

  • Page 61: Calibration Verify Feature

    • Blow Bk Period: Length of time blowback in activated. Range is one to five seconds. Default is two seconds. Emerson recommends five seconds. • Blow Bk Purge: Length of time after blowback is complete before oxygen/combustibles readings are considered valid. Range is 0 to 500 seconds.
  • Page 62 A purge automatically follows a gas flow. 3.7.3  Verify calibration with the LOI Procedure 1. Use the Z pattern to enter the LOI menu tree. 2. From the CALIBRATION menu, select Cal Verify. 3. From the Cal Verify menu, select the functions as follows: Emerson.com/Rosemount...

  • Page 63: Calibration Tolerance Feature

    5. Go back to the CAL SETUP menu and select COe CAL PARAMS. 6. To enable the calibration tolerance for the combustibles calibration, from the COe CAL PARAMS menu, select COe Tol Check. Select On to enable the calibration tolerance feature. Rosemount OCX8800A...

  • Page 64: Coe Purge/Zero Feature

    COe zero feature. Switching between the two gases must be manually coordinated between scheduled calibrations and COe zero events. When the COe zero feature is used, special pneumatic connections are required. Emerson.com/Rosemount...
  • Page 65 Valid choices are Yes and No. A Yes choice will cause the COe calibration constant to update. Note At the completion of the COe Zero Function, the COe analog output signal will change if the Zero Update parameter is set to Yes. Rosemount OCX8800A...
  • Page 66 Default is 60 seconds. Total duration of this function is flow time plus purge time. • COe Zero Tracks: Determines if the analog output signals track or hold during the function. Valid choices are None, Both, COe, and O Emerson.com/Rosemount...
  • Page 67 00809-0500-4880 December 2022 • COe Zero Update: Determines if the COe calibration constant is updated at the end of the function. Valid choices are Yes and No. A Yes choice will cause the COe calibration constant to update. Rosemount OCX8800A...
  • Page 68 Configuration and start-up Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 69: Using The Local Operator Interface (Loi)

    4-1. There are four mating connectors on the back of the LOI module that allow the LOI to be oriented as desired. Figure 4-1: LOI components mounting A. Electronics housing (cover removed) B. Electronics stack C. LOI connector D. LOI board E. LOI module Rosemount OCX8800A...

  • Page 70: Local Operator Interface (Loi) Controls

    O signal terminates via a Field Communicator. The transmitter also uses HART ® communications, permitting access to all instrument functionality anywhere the 4-20 mA signal terminates via a HART Field Communicator. Emerson.com/Rosemount...
  • Page 71 Enter key, used after the digits of a parameter value are entered and the cursor is moved to its left-most position. When you touch the Enter key, the new parameter value, if accepted, will appear in the top line of the display. Rosemount OCX8800A...
  • Page 72 CAUTION Excessive dust can prevent the LOI from entering lockout. This condition can cause uncommanded operations to occur. Always clean dust and soil away from the LOI screen each time the LOI is used. Figure 4-3: Z Pattern Entry Emerson.com/Rosemount...

  • Page 73: Local Operator Interface (Loi) Menu Tree

    (after warm-up). Sensors are warming up to operating temperaturs. Warm-Up: The transmitter's heaters are ramping up to operating temperature. 4.3  Local operator interface (LOI) menu tree Figure 4-4 displays the LOI menu tree that is specific to the Rosemount OCX8800. Rosemount OCX8800A...
  • Page 74 Using the local operator interface (LOI) Manual December 2022 00809-0500-4880 Figure 4-4: LOI Menu Tree Emerson.com/Rosemount...
  • Page 75 Manual Using the local operator interface (LOI) 00809-0500-4880 December 2022 Rosemount OCX8800A...
  • Page 76 Using the local operator interface (LOI) Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...
  • Page 77 From the first column submenus, press Right to move the display into the second column submenus. Press Up and Down to move the display to the second column submenus of the first column submenu selected. Press Left to move the display back to the first column submenu. Rosemount OCX8800A...

  • Page 78: D/A Trim Procedures

    4.00 mA output. 6. Read the O milliamp output at the digital multimeter. Use Right to select each digit and use Up and Down to change the value. When the correct value is displayed, use Enter to input the value. Emerson.com/Rosemount...
  • Page 79 5. Connect a digital multimeter to read the milliamp output from the COe D/A converter circuit. Connect the positive lead to the AOUT2+ terminal and connect the negative lead to the AOUT2- terminal. Then press Enter on the LOI. Refer to Figure 2-4, Figure 2-5, and Figure 2-6. Rosemount OCX8800A...
  • Page 80 Then use Enter to input the response. If no, the process repeats from Step When the responses in Step 8 Step 9are yes, the trim procedure is complete. Postrequisites Exit the LOI menu and return the control loop to automatic control. Emerson.com/Rosemount...

  • Page 81: Using Hart ® Communications

    For applications in which the signal line has a load resistance of 250 ohms or more, refer to Method 1: For load resistance ≥ 250 ohms. For applications in which the signal line load is less than 250 ohms, refer to Method 2: For load resistance < ohms. Rosemount OCX8800A...
  • Page 82 NiCad recharger jack in an explosive atmosphere. Procedure 1. Using the supplied lead set, connect the Field Communicator in parallel to the transmitter. 2. Use any wiring termination points in the analog output 4-20 mA signal line. Emerson.com/Rosemount...
  • Page 83 G. Field Communicator rear panel H. Loop connectors Procedure 1. At a convenient point, break the analog output 4-20 mA signal line and install the optional 250 ohm load resistor. Break the signal loop to insert the optional 250 ohm load resistor. Rosemount OCX8800A...

  • Page 84: Field Communicator Pc Connections

    When powering up a disconnected (off-line) Field Communicator, the LCD displays the Main Menu. When powering up a connected (on-line) Field Communicator, the LCD displays the On-line Menu. Refer to the Field Communicator manual for detailed menu information. Emerson.com/Rosemount...

  • Page 85: Hart ® Menu Tree

    Manual Using HART communications ® 00809-0500-4880 December 2022 5.4  HART menu tree ® Figure 5-3 provides a menu tree for the Field Communicator, which is specific to Rosemount OCX8800 applications. Figure 5-3: HART Menu Tree Rosemount OCX8800A...
  • Page 86 Using HART communications Manual ® December 2022 00809-0500-4880 Emerson.com/Rosemount...
  • Page 87 Manual Using HART communications ® 00809-0500-4880 December 2022 Rosemount OCX8800A...
  • Page 88 Using HART communications Manual ® December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 89: D/A Trim Procedures

    The Field Communicator displays Fld dev output 4.00 mA equal to reference meter? 9. Using Up or Down, select 1 Yes or 2 No and press ENTER. If No, the process repeats from Step The Field Communicator displays Setting Fld dev output to 20 mA. 10. Press OK. Rosemount OCX8800A...
  • Page 90 Field Communicator and press ENTER. Select ABORT to exit without changes. The Field Communicator displays Setting Fld dev output to 4 mA. 9. Press OK. The Field Communicator displays Fld dev output 4.00 mA equal to reference meter? Emerson.com/Rosemount...
  • Page 91 The Field Communicator displays Fld output 20.00 mA equal to reference meter? 12. Using Up or Down, select 1 Yes or 2 No. Press ENTER. If No, the process repeats from Step The Field Communicator displays NOTE: Loop may be returned to automatic control. Rosemount OCX8800A...
  • Page 92 Using HART communications Manual ® December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 93: Chapter 6 Calibration

    4. Scroll down to the last item, Use Solenoids. If the transmitter is equipped with calibration solenoids and you want timed automatic calibration, select Yes. 5. Press Up to select O2 Out Tracks. Select Yes or No to determine if the transmitter will update the O lock value. Rosemount OCX8800A...
  • Page 94 6. At the prompt, input a time interval (in hours) at which an automatic O calibration will occur and press ENTER. 7. From the DETAILED SETUP screen, select COE CALIB PARAMS. 8. From the COE CALIB PARAMS menu, select CalIntrvl. Emerson.com/Rosemount...

  • Page 95: Operator-Initiated Autocalibration

    Refer to Calibrate manually using the optional local operator interface (LOI), Calibrate O manually using the Field Communicator: HART , or Calibrate COe ® manually using the Field Communicator: HART ® Rosemount OCX8800A...
  • Page 96 13. Turn off the CO test gas and press Right to start the CO gas purge. When the purge period expires, the LOI display reverts to the normal operation display. If the calibration failed, the display will indicate an alarm condition. Emerson.com/Rosemount...
  • Page 97 O2 LOW GAS parameter in the Setup window. Press OK when ready. 9. Select START/NEXT CALSTEP to start applying the O low gas. The time to apply the test gas is specified by the Gas Time. Rosemount OCX8800A...
  • Page 98 4. From the CAL METHODS menu, select the type of calibration desired: COe Calibration. In the first Calibration screen, a Loop should be removed from automatic control warning appears. 5. Remove the transmitter from any automatic control loops to avoid a potentially dangerous operating condition and press OK. Emerson.com/Rosemount...
  • Page 99 When the purge step is complete, the Calibration Status will be at IDLE if the calibration is sucessful or CAL RECOMMENDED if the calibration has failed.. A Calibration Failed alarm will be set if the calibration has failed. 11. When calibration is complete, select Exit Cal to exit the calibration method. Rosemount OCX8800A...
  • Page 100 2. ABORT CAL — 3. EXIT CAL 8. When the Calibration Status is at the AppO2Low step, switch on O low gas. Verify the O concentration measured matches the O2 LOW GAS parameter in Setup. Press OK when ready. Emerson.com/Rosemount...
  • Page 101 Right key or use the number keypad to select the menu item number. To return to a preceding menu, press the Left key. Procedure 1. To calibrate from Fieldbus, first set the Transducer Block to Out of Service Mode (OOS). Rosemount OCX8800A...
  • Page 102 The time to apply the test gas is specified by the Gas Time. The calibration step will change to Flow O Low Gas/Flow Comb Low Gas and then Read O Low Gas/Read Comb Low Gas for a period of time. When Emerson.com/Rosemount...
  • Page 103 When the Purge step is complete, the Calibration Step will be at Idle . The alarm will be set if the calibration has failed. Calibration Failed 17. When calibration is complete, select Exit to exit the calibration method. Rosemount OCX8800A...
  • Page 104 Calibration Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 105: Chapter 7 Field Communicator

    A minimum 250 ohms resistance must be present in the HART loop for the Field Communicator to function properly. WARNING EXPLOSION Explosions can result in death or serious injury. Do not make connections to the Field Communicator's serial port, digital signal line, or NiCad recharger jack in an explosive atmosphere. Rosemount OCX8800A...
  • Page 106 WARNING EXPLOSION Explosions can result in death or serious injury. Do not make connections to the Field Communicator's serial port, digital signal line, or NiCad recharger jack in an explosive atmosphere. Emerson.com/Rosemount...
  • Page 107 A. Terminal connectors B. Terminal block C. Terminals D. Field Communicator E. Lead set F. Fieldbus signal G. Fieldbus digital signal H. Fieldbus computer terminal (PC) I. Field Communicator rear panel Note Devices shown are not to scale. Rosemount OCX8800A...

  • Page 108: Fieldbus Menu Tree

    Field Communicator Manual December 2022 00809-0500-4880 7.3  Fieldbus menu tree Figure 7-3 displays menu for the Field Communicator using the Fieldbus protocol. This menu is specific to the Hazardous Area Rosemount OCX8800 applications. Emerson.com/Rosemount...
  • Page 109 Manual Field Communicator 00809-0500-4880 December 2022 Refer to the Fieldbus parameter descriptions for the applicable range, units, and description for the Fieldbus menu parameters. Figure 7-3: Fieldbus Menu Tree Rosemount OCX8800A...
  • Page 110 Field Communicator Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...
  • Page 111 Manual Field Communicator 00809-0500-4880 December 2022 Rosemount OCX8800A...
  • Page 112 Field Communicator Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 113: Chapter 8 Foundation ™ Fieldbus

    Fieldbus an enabling technology. OUNDATION Emerson offers a full range of products from field devices to the DeltaV scalable control system to allow an easy transition to Fieldbus technology. The Fieldbus retains the features of the 4-20 mA analog system, including...
  • Page 114 The input snap process ensures that these values do not change during the block execution. New values received for these parameters do not affect the snapped values and will not be used by the function block during the current execution. Emerson.com/Rosemount...
  • Page 115 System management services locate a block by its tag. Thus, the service personnel need only know the tag of the block to access or change the appropriate block parameters. Function blocks are also capable of performing short-term data collection and storage for reviewing their behavior. Rosemount OCX8800A...
  • Page 116 In addition to function blocks, Fieldbus contains two other block types to support the function blocks. These are the resource block and the transducer block. The resource block contains the hardware specific characteristics associated with a device. Transducer blocks couple the function blocks to local input/output functions. Emerson.com/Rosemount...

  • Page 117: Network Communication

    Alarms not only report a status change when a block leaves a particular state, but also report when it returns back to that state. 8.2  Network communication Figure 8-2 illustrates a simple Fieldbus network consisting of a single segment (link). Rosemount OCX8800A...
  • Page 118 LAS. Only the device with the token can communicate. The LAS maintains a list of all devices that need access to the bus. This list is called the Live List. Emerson.com/Rosemount...

  • Page 119: Rosemount Ocx8800 Function Blocks

    Addresses 0 through 15 are reserved for group addressing and for use by the data link layer. For all Emerson Fieldbus devices, addresses 20 through 35 are available to the device. If there are two or more devices with the same address, the first device to start uses its programmed address.

  • Page 120: Resource Block

    The PWA alarms can be Suppressed to mask out failures from annunciation. Sensor Malfunction The Sensor Alerts tab displays one of the following alerts: • Cell Open • Comb Cell Error This alert is active when the sensor is indicating a very high or unexpected output. Emerson.com/Rosemount...
  • Page 121 T/C Shorted 3. O T/C Reversed 4. Comb T/C Open 5. Comb T/C Shorted 6. Comb T/C Reversed 7. S/B T/C Open 8. S/B T/C Shorted 9. S/B T/C Reversed This alert indicates a miswired or faulty thermocouple. Rosemount OCX8800A...
  • Page 122 Diagnose at the transmitter. Refer to Diagnostic alarms for details. Recommended actions 1. Check heater circuit for loose or broken connections. 2. Check thermocouple wiring. 3. Test or replace the heater. Emerson.com/Rosemount...
  • Page 123 3. There are fluctuations or noise in the power supplied to the transmitter. Recommended actions 1. Allow the transmitter several minutes to reach proper temperature. 2. Check power supply. Calibration Error The Calibration Alerts tab may display the following alarms: Rosemount OCX8800A...
  • Page 124 4. ROM Integrity Error The non-volatile parameter storage on the CPU board has become unreliable. Potential cause This alarm generally occurs during start-up. Rarely, the transmitter could be powered down while a parameter is being stored to the non-volatile memory. The Emerson.com/Rosemount...
  • Page 125 2. ADC Reference Error This alert indicates faulty operation of the device electronics. Potential cuase The transmitter continually monitors the analog to digital converter (ADC) for correc operation. Refer to Diagnostic alarms for details. Recommended actions 1. Cycle power. Rosemount OCX8800A...
  • Page 126 This alert may display on the FF/Device Alerts AMS tab. This alert occurs when the PWA simulate mode is active. You can now write the PWA active parameters. You can also write the resource block detailed status parameters and the internal alerts in the transducer block where the PWA active alarms originate. Emerson.com/Rosemount...
  • Page 127 3. Select Enable to enable the simulation feature or Disable to disable the simulation feature. 4. Once the method is complete, select the Simulate PWA tab in the resource block, Figure 8-3. If the simulation is enabled, the PlantWeb Alarm Simulate parameter is configurable; otherwise it is read-only. Rosemount OCX8800A...

  • Page 128: Configure Plantweb Alert (Pwa) Simulation With The Field Communicator

    8.5  Configure PlantWeb alert (PWA) simulation with the Field Communicator Use the following procedure to configure PWA simulation using the Field Communicator. Procedure 1. Run the Transmitter Options method in the resource block (Resource →  Methods) Emerson.com/Rosemount...
  • Page 129 Input Failure: Set whenever there is a communication error between the Fieldbus card and the transmitter. • Simulation Active: Set whenever the Fieldbus Simulate switch is set to On at the Fieldbus card or the Software simulate option is enabled. • Other error: Set whenever XD_ERROR is non-zero. Rosemount OCX8800A...

  • Page 130: Transducer Block

    See FF-891, Section 5.3. BLOCK_ERR See FF-891, Section 5.3. BLOWBACK_DURATION Seconds The amount of time the blowback solenoid will be on. BLOWBACK_ENABLED 0: No Enumerated Enables or disables the 1: Yes automatic blowback cycle. BLOWBACK_INTERVAL 0-32767 Minutes The time between blowback cycles. Emerson.com/Rosemount...
  • Page 131 See FF-903, Sections 3.3 and 4.5. COMB_SENSOR_CAL_WHO See FF-903, Section 3.3. COMB_AUTOCAL_INTERVAL 0-9999 Hours The time between automatic calibrations of the combustibles sensor. COMB_CAL_POINT 0-55000 The value of the combustibles test gas. COMB_CONSTANT -99.0 to 99.0 The combustibles calibration constant. Rosemount OCX8800A...
  • Page 132 The high and low range RANGE limit values, the engineering units code, and the number of digits to the right of the decimal point for the combustibles reading. COMB_PRIMARY_VALUE_TY See FF-903, Section 3.3 COMB_REFERENCE_OHMS Ohms The raw value of the combustibles reference input. Emerson.com/Rosemount...
  • Page 133 Combustible block INPUT thermocouple (T/C) voltage (valid only with Type 3 sensor). COMB_TIME_TO_NEXT 0 - 9999 Hours The time until the next automatic calibration of the combustibles sensor. COMB_TOL_CHECK 0: No Combustible calibration 1: Yes gas tolerance check. Rosemount OCX8800A...
  • Page 134 0 - 16777215 Bit Enum A bit-enumerated value used to communicate the status of the transmitter. (This is similar to the command 48 status bits in HART). ELECTRONICS_TEMP ° C The current temperature reading of the electronics temperature sensor. Emerson.com/Rosemount...
  • Page 135 O calculation. O2_HTR_DUTYCYCLE heater duty cycle. O2_IMPEDANCE_CAL Ohms The impedance value that was calculated as a result of the current successful O calibration. O2_PERCENT_OF_RANGE The percent of range of the current O reading. Rosemount OCX8800A...
  • Page 136 34.5-47.5 mV/Decade The O calibration slope. O2_T90 0-300 Seconds The amount of time that the O process variable will take to reach 90% of the actual process variable. O2_TEMP_MAX ° C The highest O temperature read since power on. Emerson.com/Rosemount...
  • Page 137 SENSOR_HOUSING_TYPE 0, 1, 2, 3 Enumerated This is the sensor housing type setting through the DIP switch. (0 = Type 1, 1 = Type 2, 2 = Type 3, 3 = Invalid) Rosemount OCX8800A...
  • Page 138 Start flow high O , 1 = Start flow lo O , 2 = Start flow high COe, 3 = Purge gas, 6 = No effect) VERIFY_STATE_TIME Seconds Time remaining for the current calibration check state. XD_ERROR See FF-903, Section 3.3. Emerson.com/Rosemount...

  • Page 139: Transducer Block Enumerations

    Read combistibles low gas Apply combustibles high gas Yes, if parameter Solenoids Present is 0.. Flow combustibles high gas Read combustibles high gas Stop gas Yes, if parameter Solenoids Present is 0. Purge Abort Yes, if parameter Solenoids Present is 0. Rosemount OCX8800A...
  • Page 140 BLOWBACK_STATE description Idle Blow Purge Table 8-7: Alarm Event Enumerations ALARM_RELAY_EVENT description In calibration cell temp error heater open cell bad Cal failed Cal warn High electronics temp Unit failure SL temp error Comb cell temp error Power input error Emerson.com/Rosemount...
  • Page 141 CO slope error CO constant error CO tolerance check failed CO slope warning During a running calibration verify procedure, the states below reflect the current step that the calibration verify is running in. Rosemount OCX8800A...
  • Page 142 COZERO_STATE description Idle Flowing Purging Table 8-14: COe out Tracks Enumerations COZERO_OUTTRAK description None Both Table 8-15: Detailed Status Alarm number Description Value of XD_ERROr (see FF-903) No alarm active cell open Mechanical failure cell impedance high Mechanical failure Emerson.com/Rosemount...
  • Page 143 Calibration error Combustibles calibration failed Calibration error Combustibles calibration warning Calibration error calibration recommended Calibration error EEPROM corrupt Data integrity error High electronics temperature Electronics failure ADC timeout error Electronics failure ADC reference error Electronics failure Rosemount OCX8800A...
  • Page 144 1000 ° C 8.7.4  Transducer block channel status The status of channels 1 through 4 are affected by the state of the unit alarm. In all cases, the channel reads what it believes are the correct sensor values. Self- Emerson.com/Rosemount...
  • Page 145 3, 4 Calibrating, Cal GOOD NON_SPECIFIC NOT_LIMITED verify, Blowback 3, 4 Alarm, System fault DEVICE_FAILURE CONSTANT (Temperature related alarms: thermocouple (T/C) open, T/C shorted, T/C reversed, ADC error) 3, 4 Temp low & high GOOD ACTIVE_BLOCK_ NOT_LIMITED ALARM Rosemount OCX8800A...

  • Page 146: Analog Input (Ai) Function Block

    AI block is in engineering units and contains a status indicating the quality of the measurment. The measuring device may have several measurements or derived values available in different channels. Use the channel number to define the variable that the AI block processes. Emerson.com/Rosemount...
  • Page 147 Table 8-19: Definitions of AI Function Block System Parameters Parameter Index number Units Description ACK_OPTION None Used to set auto acknowledgement of alarms. ALARM_HYS Percent The amount the alarm value must return within the alarm limit before the associated active alarm condition clears. Rosemount OCX8800A...
  • Page 148 Active status if the subcode has changed. BLOCK_ERR None This parameter reflects the error status associated with the hardware or software components associated with a block. It is a bit string, so that multiple errors may be shown. Emerson.com/Rosemount...
  • Page 149 HI HI alarm condition. HI_HI_PRI None The priority of the HI HI alarm. HI_LIM EU of PV_SCALE The setting for the alarm limit used to detect the HI alarm condition. HI_PRI None The priority of the HI alarm. Rosemount OCX8800A...
  • Page 150 LO LO alarm condition. LO_LO_PRI None The priority of the LO LO alarm. LO_PRI None The priority of the LO alarm. LOW_CUT If percentage value of transducer input fails below this, PV = 0. Emerson.com/Rosemount...
  • Page 151 STRATEGY None You can use the STRATEGY field to identify grouping of blocks. This data is not checked or processed by the block. Rosemount OCX8800A...
  • Page 152 With simulation enabled, the actual measurement value has no impact on the OUT value or the status. Emerson.com/Rosemount...
  • Page 153 E. PV_Ftime F. IO_opts G. Field_val H. Out_scale XD_scale I. Channel J. Low_cut K. Alarm_hys L. Hi_Hi_Lim Hi_Lim Lo_Lo_Lim Lo_Lim M. Access analog measurement N. Alarm detection O. Simulate P. Convert Q. Cutoff R. Filter S. Status calculation Rosemount OCX8800A...
  • Page 154 The filtering feature changes transmitter's response time to smooth variations in input readings caused by rapid changes in input. You can adjust the filter time constant (in seconds) using the PV_FTIME parameter. Set the filter time constant to zero to disable the filter feature. Emerson.com/Rosemount...
  • Page 155 (PV). This option is useful to eliminate false readings when the differential pressure measurement is close to zero, and it may also be useful with zero-based measurement devices such as flow meters. Rosemount OCX8800A...
  • Page 156 Out of service (O/S): The block is not processed. FIELD_VAL and PV are not updated, and the OUT status is set to Bad: Out of Service. The BLOCK_ERR parameter shows Out of Service. In this mode, you can make changes to all Emerson.com/Rosemount...
  • Page 157 Normally, the status of the PV reflects the status of the measurement value, the operating condition of the I/O card, and any active alarm condition. In Auto mode, OUT reflects the value and status quality of the PV. In Man mode, the OUT status Rosemount OCX8800A...
  • Page 158 VAR_INDEX: Process variability index measured as the integral of average absolute error between PV and its mean value over the previous evaluation period. this index is calculated as a percent of OUT span and is updated at the end of the time period defined by VAR_SCAN. Emerson.com/Rosemount...
  • Page 159 Table 8-21 lists the appropriate configuration settings, and Figure 8-7 illustrates the correct function block configuration. Table 8-21: Analog Input Function Block Configuration for a Typical Temperature Transmitter Parameter Configured values L_TYPE Direct XD_SCALE Not used OUT_SCALE Not used Rosemount OCX8800A...
  • Page 160 The level measurement will be used to control the level of liquid in the tank. The maximum level at the tankis 16 ft. (4.9 m) The liquid in the tank has a density that makes the level correspond to a pressure of 7.0 psi (0.5 BarG) at the pressure tap (Figure 8-8). Emerson.com/Rosemount...
  • Page 161 Table 8-22: Analog Input Function Diagram for a Pressure Transmitter Used in Level Measurement (Situation #1) Parameter Configured values L_TYPE Indirect XD_SCALE 0 to 7 psi (0 to 0.5 BarG) OUT_SCALE 0 to 16 ft (0 to 4.9 m) Rosemount OCX8800A...
  • Page 162 D. Analog output function block Situation #2 The transmitter in situation #1 is installed below the tank in a position where the liquid column in the impulse line, when the tank is empty, is equivalent to 2.0 psi (0.1 BarG) (Figure 8-10). Emerson.com/Rosemount...
  • Page 163 Differential pressure transmitter to measure flow Situation The liquid flow in a line is to be measured using the differential pressure across an orifice plate in the line, and the flow measurement will be used in a flow Rosemount OCX8800A...
  • Page 164 BLOCK_ERR shows the configuration error bit set. Set the following parameters: a) Set CHANNEL to a valid value; do not leave it at the initial value of 0 . b) Set XD_SCALE.UNITS_INDX to match the units in the transducer block channel value. Emerson.com/Rosemount...
  • Page 165 Clear the Propogate Fault Forward bit. Value of output does not make sense Potential cause Linearization type. Recommended action Set L_TYPE to Direct, Indirect, or Indirect Square Root; do not leave it at the initial value of 0 . Rosemount OCX8800A...

  • Page 166: Proportional/Integral/Derivative (Pid) Function Block

    Limit values are outside the OUT_SCALE.EU0 and OUT_SCALE.EU100 values. Recommended action Change OUT_SCALE or set values within range. 8.9  Proportional/integral/derivative (PID) function block The PID function block combines all of the necessary logic to perform proportional/integral/derivative (PID) control. The block supports mode control, Emerson.com/Rosemount...
  • Page 167 OUT = The block output and status. The block supports two forms of the PID equation: Standard and Series. You can choose the appropriate equation using the FORM parameter. The standard ISA PID equation is the default selection. Rosemount OCX8800A...
  • Page 168 Table 8-25: PID Function Block System Parameters Parameter Index number Units Descriptions ACK_OPTION None Used to set auto acknowledgement of alarms. ALARM_HYS Percent The amount the alarm value must return to within the alarm limit before the associated active alarm condition clears. Emerson.com/Rosemount...
  • Page 169 BKCAL_IN EU of OUT_SCALE The analog input value and status from another block's BKCAL_OUT output that is used for backward output tracking for bumpless transfer and to pass limit status. Rosemount OCX8800A...
  • Page 170 Allows you to specify control strategy options. The supported control options for the PID block are Track enable, Track in Manual, SP-PV Track In Man, SP-PV Track In LO or IMAN, Use PV for BCKAL OUT, and Direct Acting. Emerson.com/Rosemount...
  • Page 171 FF_SCALE None The high and low scale values, engineering units code, and number of digits to the right of the decimal point associated with the feedforward value (FF_VAL). GAIN None The proportional gain value. This value cannot equal Rosemount OCX8800A...
  • Page 172 The LO LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm. LO_LO_LIM EU of PV_SCALE The setting for the alarm limit used to detect the LO LO alarm condition. Emerson.com/Rosemount...
  • Page 173 OUT. EU of PV_SCALE The process variable used in block execution. RATE Seconds The derivative action time constant. RCAS_IN EU of PV_SCALE Target setpoint and status that is provided by a supervisory host. Use when mode is RCAS. Rosemount OCX8800A...
  • Page 174 The highest SP value allowed. SP_LO_LIM EU of PV_SCALE The lowest SP value allowed. SP_RATE_DN EU of PV_SCALE per Ramp rate for downward second SP changes. When the ramp rate is set to zero, the SP is used immediately. Emerson.com/Rosemount...
  • Page 175 (TRK_VAL). TRK_VAL EU of TRK SCALE The value (after scaling from TRK_SCALE to OUT_SCALE) applied to OUT in LO mode. Rosemount OCX8800A...
  • Page 176 2.0 degree of freedom PID. UGAMMA Percent Used to set disturbance rejection vs. tracking response action for a 2.0 degree of freedom PID. UPDATE_EVT None This alert is generated by any changes to the static data. Emerson.com/Rosemount...
  • Page 177 Figure 8-14: PID function block schematic A. Feedforward calculation B. Mode C. Setpoint limiting and filtering D. PID equation E. Output limiting F. Gain rate reset G. Scaling and filtering H. Alarm detection I. Operator output J. Convert K. In L. Out Rosemount OCX8800A...
  • Page 178 Set the filter time constant to zero to disable the filter feature. Feedforward calculation The feedforward value (FF_VAL) is scaled (FF_SCALE) to a common range for compatibility with the output scale (OUT_SCALE). A gain value (FF_GAIN) is applied to achieve the total feedforward contribution. Emerson.com/Rosemount...
  • Page 179 PV for BKCAL_OUT option is not selected, the working setpoint (SP_WRK) is used for BKCAL_OUT. You can set control options in Manual or Out of Service mode only. When the mode is set to Auto, the SP will remain at the last value (it will no longer follow the PV). Rosemount OCX8800A...
  • Page 180 The PID function block provides a modified version of feedback reset limiting that prevents windup when output or input limits are encountered and provides the proper behavior in selector applications. 8.9.5  Block errors Table 8-26 lists conditions reported in the BLOCK_ERR parameter. Emerson.com/Rosemount...
  • Page 181 Local Override (LO): The track function is active. OUT is set by TRK_VAL. The BLOCK_ERR parameter shows Out of service. • Initialization Manual (IMan): The output path is not complete (for example, the cascade-to-slave path might not be open). In IMan mode, OUT tracks BKCAL_IN. Rosemount OCX8800A...
  • Page 182 Alarm conditions of priority 8 to 15 are critical alarms of increasing priority. 8.9.8  Status handling Normally, the status of the PV reflects the status of the measurement value, the operating condition of the I/O card, and any active alarm condition. In Auto mode, Emerson.com/Rosemount...
  • Page 183 The integral term RESET applies a correction based on the magnitude and duration of the error. Set the RESET parameter to zero for integral only control. To reduce reset action, configure the RESET parameter to be a large value. Rosemount OCX8800A...
  • Page 184 A PID block is used with an analog input (AI) block and an analog output (AO) block to control the flow steam used to heat a process fluid in a heat exchanger. Figure 8-17 illustrates the process instrumentation diagram. Emerson.com/Rosemount...
  • Page 185 Figure 8-18 illustrates the correct function block configuration. Figure 8-18: PID Function Block for Steam Heater Control Example A. Outlet temperature input B. AI function block C. PID function block D. AO function block E. Out F. In Rosemount OCX8800A...
  • Page 186 (FF_ENABLE), the feedforward value is scaled (FF_SCALE), and a gain (FF_GAIN) is determined. Figure 8-19 illustrates the process instrumentation diagram, and Figure 8-20 illustrates the correct function block configuration. Figure 8-19: PID Function Block Feedforward Example A. Steam supply B. Steam heater C. Condensate Emerson.com/Rosemount...
  • Page 187 The temperature variation will later be sensed by TT101. The temperature controller modifies the valve position to compensate for the steam pressure change. The process is slow and causes variations in the product temperature. Figure 8-21 illustrates the process instrumentation diagram. Rosemount OCX8800A...
  • Page 188 The BKCAL_IN and BKCAL_OUT connections on the PID blocks are used to prevent controller windup on the master loop when the slave loop is in Manual or Automatic mode or it has reached an output constraint. Figure 8-22 illustrates the correct function block configuration. Emerson.com/Rosemount...
  • Page 189 If the instrument connected to the AI block fails, you can place the AI block in Manual mode and set the output to some nominal value for use in the Integrator function block. In this case, IN at the slave PID block is constant and prevents the integral term from increasing or decreasing. Rosemount OCX8800A...
  • Page 190 Refer to Table 8-27 to troubleshoot any problems that you may encounter. Table 8-27: Troubleshooting Symptom Possible causes Corrective action Mode will not leave OOS. 1. Target mode not set. 1. Set target mode to something other than OOS. Emerson.com/Rosemount...
  • Page 191 Quality of or a Status of . See the Not Invited appropriate upstream block diagnostics for corrective action. Mode will not change to CAS. 1. Target mode not set. 1. Set target mode to something other than OOS. Rosemount OCX8800A...
  • Page 192 Mode will not leave out of service (OOS) Mode will not leave out of service (OOS). Mode will not leave IMAN Potential cause The link is not configured; the status shows Not connected. Recommended action Configure the BKCAL_IN link to the downstream block. Emerson.com/Rosemount...
  • Page 193 Recommended action Configure the CAS_IN link to the block. Potential cause The upstream block is sending back a Quality of Bad or a Status of Not Invited. Recommended action See the appropriate upstream block diagnostics for corrective action. Rosemount OCX8800A...

  • Page 194: Arithmetic (Arthm) Function Block

    The arithmetic function block provides the ability to configure a range extension function for a primary input and applies the nine different arithmetic types as compensation to or augmentation of the range extended input. All operations are selected by parameter and input connection. Figure 8-24: Arithmetic (ARTHM) Function Block Emerson.com/Rosemount...
  • Page 195 Bad status Output failure Readback failed Out of , and . Each function block service Other reports none or a subset of these error conditions. COMP_HI_LIM EU of PV Determines the high limit of the compensation input. Rosemount OCX8800A...
  • Page 196 Percent or EU of IN number of outputs is an extensible parameter in some blocks. OUT_HI_LIM EU of OUT_SCALE The maximum output value allowed. supplied by IN OUT_LO_LIM EU of OUT_RANGE The minimum output value allowed. or Supplied by IN Emerson.com/Rosemount...
  • Page 197 TAG_DESC None The user description of the intended application of the block. UPDATE_EVT None This alert is generated by any changes to the static data. Rosemount OCX8800A...
  • Page 198 Condition name and description number Other Block Configuration Error: The BY_PASS parameter is not configured and is set to 0, the SP_HI_LIM is less than the SP_LO_LIM, or the OUT_HI_LIM is less than the OUT_LO_LIM. Link Configuration Error Simulate Active Emerson.com/Rosemount...
  • Page 199 Alarms are grouped into five levels of priority: Priority Priority description number The priority of an alarm condition changes to after the condition that caused the alarm is corrected. Rosemount OCX8800A...
  • Page 200 When IN_(k) is usable: t(k) = GAIN_IN(k) * (BIAS_IN(k) + IN_(k)) • When IN_(k) is not usable, then t(k) gets the value of the last t(k) computed with a usable input. Status handling • IN_x Use Bad • IN_x Use Uncertain • IN_LO Use Uncertain • IN Use Uncertain Emerson.com/Rosemount...
  • Page 201 Figure 8-26 shows the relative temperature effects on a level signal. Figure 8-26: Relative Temperature Effects on Level A. Elevated temperature level B. Indicated level calibrated at ambient temperature C. Level percent D. Milliamp signal Rosemount OCX8800A...
  • Page 202 E. In_1 F. In_2 G. Arithmetic block H. Out I. Arithmetic type = flow comp-linear This application can be applied to very large storage tanks whose contents are subject to thermal expansion and contraction during seasonal changes in temperature. Emerson.com/Rosemount...

  • Page 203: Advanced Topics

    8.11.2  Troubleshoot 8.12  Input selector (ISEL) function block The input selector (ISEL) function block can be used to select the first good, hot backup, maximum, minimum, or average of as many as four input values and Rosemount OCX8800A...
  • Page 204 SELECTED = The selected channel number. • OUT = The block output and status. Figure 8-28 illustrates the internal components of the ISEL block. Table 8-30 lists the ISEL block parameters and their descriptions, units of measure, and index numbers. Emerson.com/Rosemount...
  • Page 205 One of the inputs to be selected from. IN_3 Determined by The connection input from another block. source One of the inputs to be selected from. IN_4 Determined by The connection input from another block. source One of the inputs to be selected from. Rosemount OCX8800A...
  • Page 206 TAG_DESC None The user description of the intended application of the block. UPDATE_EVT None This alert is generated by any change to the static data. Emerson.com/Rosemount...
  • Page 207 Input Failure/Process Variable has Bad Status: One of the inputs is bad or not connected. Output Failure: The output has the quality of Bad. Memory Failure: A memory failure has occured in FLASH, RAM or EEROM memory. Lost Static Data Lost NV Data Readback Check Failed Rosemount OCX8800A...
  • Page 208 (such as diagnostics and system alerts). Alarm conditions of priority through are advisory alarms of increasing priority. 8-15 Alarm conditions of priority are critical alarms of increasing priority. Emerson.com/Rosemount...
  • Page 209 The input selector (ISEL) function block can be used to select the maximum temperature input from four inputs and send it to a proportional/integral/ derivative (PID) function block to control a process water chiller (Figure 8-30) or it Rosemount OCX8800A...
  • Page 210 Figure 8-30: Input Selector Function Block Application Example (SEL_TYPE = max) A. Input selector (ISEL) function block B. To another function block Figure 8-31: Input Selector Function Block Application Example (SEL_TYPE = avg) A. Input selector (ISEL) function block B. To another function block Emerson.com/Rosemount...

  • Page 211: Operation With Emerson Deltav

    Good Good Good Good 8.12.7  Troubleshoot 8.13  Operation with Emerson DeltaV ™ 8.13.1  Install a new device onto a DeltaV system ™ AMS and DeltaV software allows you to manage your instrumentation and to perform on-line configurations of your instruments.
  • Page 212 *.ffo, *fhx, and *.reg files. The files are probably on a floppy disk or a CD- ROM that accompanies your device. On CD-ROMs delivered together with Emerson transmitters the files are located in the directory /Fieldbus. Dependent on the existing system, use the files of the appropriate subdirectory.

  • Page 213: Chapter 9 Troubleshoot

    9.1.2  Electrical noise Emerson has designed the analyzer to operate in the type of environment normally found in a boiler room or control room. Noise suppression circuits are employed on all field terminations and main inputs.
  • Page 214 Figure 9-1: Fuse Locations A. F6 Neutral (N) 10 Amp, 250 Vac B. F1 Line (L1) 10 Amp, 250 Vac C. F3 and COe heater 4 Amp, 250 Vac D. F4 Sample block heater 8 Amp, 250 Vac Emerson.com/Rosemount...

  • Page 215: Diagnostic Alarms

    The potential causes are listed in order of most probable to least probable. Starting with the most probable cause, inspect and test the transmitter to isolate the actual cause; then use the recommended corrective action listed to correct the problem. Rosemount OCX8800A...
  • Page 216 Figure 9-2: Electrical Connections between Electronics and Sensor Housing A. To ground screw B. Heater power connector (J3) C. COe sensor and cold junction connector (J4) D. O sensor and thermocouple connector (J5) E. Heater power cable F. Electronics housing G. Sensor housing H. Signal cable Emerson.com/Rosemount...
  • Page 217 Cold junction connector (CJC)+ Black CJC- Black Execute- Table 9-3: J5 Connections Wire color Connects to Thermocouple (T/C) CO+ Black T/C CO- White T/C sample block (SB)+ Black T/C SB- Green T/C O Black T/C O Blue cell+ Black cell- Rosemount OCX8800A...
  • Page 218 Troubleshoot Manual December 2022 00809-0500-4880 Figure 9-3: Oxygen and Cell Output A. Oxygen concentration (percentage) B. Transmitter output (millivolt) 9.3.1  O2 Sensor R High or O2 Sensor Open Oxygen sensor resistance high, > 5000 ohms or oxygen sensor disconnected. Emerson.com/Rosemount...
  • Page 219 1. Check resistance of COe sensor leads to ground per Figure 10-9. 2. Replace COe sensor if resistance is less than 10M ohms. Potential cause COe sensor failed. Recommended actions 1. Check resistance of both COe sensor elements per Figure 10-9. Rosemount OCX8800A...
  • Page 220 1. Check power supply for line noise or voltage fluctuations. 2. Install power line filter kit (PN 6A00171G01) or high quality line filter for input power. 9.3.5  SB Temp Hi Sample block heater temperature high, > 374 °F (190 °C). Emerson.com/Rosemount...
  • Page 221 Replace electronics package. 9.3.7  COe Temp Very Hi or COe Htr Ramp Rate Combustion sensor heater over maximum temperature, > 752 °F (400 °C). or combustibles sensor heater over maximum temperature ramp rate. Potential cause Incorrect COe heater wiring. Rosemount OCX8800A...
  • Page 222 Incorrect sample block thermocouple wiring. Recommended actions 1. Check sample block thermocouple wiring per Figure 9-2 Figure 10-8 2. Check the wiring at the thermocouple and inside the electronics housing. 3. Correct wiring fault. 4. Perform procedure in Reset to continue operation. Emerson.com/Rosemount...
  • Page 223 Sample block heater thermocouple or thermocouple circuit open. Recommended actions 1. Check sample block thermocouple and circuit wires for breaks or loose connections per Figure 9-2 Figure 10-8. 2. Repair breaks or loose connections or replace failed thermocouple. 3. Perform Reset to continue operation. Rosemount OCX8800A...
  • Page 224 Slow heat up during cold start. Recommended actions 1. Perform Reset to continue operation. 2. If alarm persists, refer to COe Htr Failure. 9.3.14  SB TC Shorted Sample block heater thermocouple shorted. Potential cause Sample block thermocouple or thermocouple circuit shorted. Emerson.com/Rosemount...
  • Page 225 2. Check the wiring at the sensor and inside the electronics housing. 3. Correct reversed-wires fault. 4. Perform Reset to continue operation. 9.3.17  SB TC Reversed Sample block heater thermocouple reversed. Potential cause Sample block thermocouple wires reversed. Rosemount OCX8800A...
  • Page 226 2. Repair broken wire or loose connection. Potential cause heater open. Recommended actions 1. Check resistance of O heater per Figure 10-8. Normal O heater resistance is 62.5 Ohms. 2. Replace O heater if heater is open or has a large resistance. Emerson.com/Rosemount...
  • Page 227 If open, locate and correct cause of overload. • If F3 is not open or if cause of overload cannot be found, replace electronics package. 9.3.21  SB Htr Failure Sample block heater could not reach final temperature. Potential cause Sample block heater circuit wiring open. Rosemount OCX8800A...
  • Page 228 Calibration gas supply low or gas connection leaking. Recommended actions 1. Check calibration gas supplies and connections. 2. Adjust gas pressure and flow. 3. Replenish low calibration gas supplies and tighten or repair loose or leaking connections. 4. When calibration gas supplies are adequate, recalibrate. Emerson.com/Rosemount...
  • Page 229 Slope Warn via HART ® Potential cause Low sample gas flow in sensor housing due to flow path plugging. Recommended action Check the following portions of the flow path for plugging: • Blowback filter • In-situ filter • Eductor outlet path Rosemount OCX8800A...
  • Page 230 Sensor housing exposed to high wind and/or extreme cold temperatures. Recommended action Install sensor housing flange insulator (PN 6P00162H01). Potential cause High noise or voltage fluctuations in power supply. Recommended action 1. Check power supply for line noise or voltage fluctuations. Emerson.com/Rosemount...
  • Page 231 2. Install filter power line kit (PN 6A00171G01) or high quality line filter for input power. 9.3.28  Line Freq Error AC power line frequency out of usable range, < 45 Hz or > 66 Hz. Potential cause High noise or voltage fluctuations in power supply. Rosemount OCX8800A...
  • Page 232 1. Check power supply voltage and compare with line voltage. 2. Replace electronics package if they do not agree within five percent. 9.3.30  Line Voltage High AC power line voltage above maximum, > 278 Vac. Potential cause High noise or voltage fluctuations in power supply. Emerson.com/Rosemount...

  • Page 233: Alarm Relay Events

    9.4  Alarm relay events The transmitter contains an alarm relay that can be configured to activate on one of twelve different groups of events. These event groups and the conditions that trigger them are listed in Table 9-4. Rosemount OCX8800A...
  • Page 234 Temp Hi, SB Temp Very Hi) RTD excitation current error (Ref Curr Err) COe sensor temperature error Combustibles sensor heater temperature low (COe Temp Low) Combustibles sensor heater temperature high (COe Temp Hi, COe Temp Very Hi) RTD excitation current error (Ref curr Err) Emerson.com/Rosemount...
  • Page 235 Alarm relay event Alarms/conditions Power input error AC power line frequency out of usable range (Line Freq Error) AC power line voltage below minimum (Line Voltage Low) AC power line voltage above maximum (Line Voltage Hi) All alarms Any alarm Rosemount OCX8800A...
  • Page 236 Troubleshoot Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 237: Maintenance And Service

    Failure to observe classification guidelines may result in serious injury or death. Observe housing classification guidelines prior to removing cover. 10.2  Removal and installation 10.2.1  Rosemount OCX8800 with integral electronics Remove transmitter Procedure 1. Turn off power to the system. Rosemount OCX8800A...
  • Page 238 Failure to allow adequate time for all internal electrical charges to dissipate can result in serious injury or death. Before removing the cover from the sensor or electronics housing, allow at least 45 minutes to pass after disconnecting power. Emerson.com/Rosemount...
  • Page 239 I. Earth ground typical for electronics and sensor housing J. Ground stud K. Top view (½ size) 5. Disconnect and remove the power leads from the AC power input terminal block and remove the ground lead from the ground stud. Rosemount OCX8800A...
  • Page 240 5. Connect the O and COe signal leads to the 4-20 mA signal output terminal block. 6. Connect the line (L1 wire) to the L1 terminal and the neutral (N wire) to the N terminal on the AC power input terminal block. Emerson.com/Rosemount...
  • Page 241 1. Turn off power to the system. 2. Shut off the test gases at the cylinders and close the instrument air valve. 3. Disconnect the calibration gas, reference air, eductor air, and dilution air lines from the sensor housing, Figure 10-3. Rosemount OCX8800A...
  • Page 242 F. Instrument air (reference gas) G. High O test gas H. Low O test gas I. CO test gas J. Electronics housing K. Duct L. Stack 4. Remove the cover from the sensor housing to expose the sensor housing terminal blocks, Figure 10-4. Emerson.com/Rosemount...
  • Page 243 Figure 10-4: Sensor Housing Terminals A. Heater power cable B. Signal cable C. Sensor housing D. To ground screw Note Wire colors shown are for cables provided by Emerson. Table 10-1: Sensor Housing Terminal Connections Wire color Connects to Black Thermocouple (T/C) O...
  • Page 244 4. Connect the signal cable to O and thermocouple (T/C) terminal blocks and to the CO and CJC terminal blocks, Figure 10-4. Connect the heater power cable to the HTR terminal blocks. Emerson.com/Rosemount...
  • Page 245 2. Shut off the test gases at the cylinders and close the instrument air supply valve, Figure 10-3. 3. Disconnect the test gas and instrument air lines from the remote electronics housing. 4. Remove the cover from the electronics housing to expose the electronics housing terminal blocks, Figure 10-5. Rosemount OCX8800A...
  • Page 246 5. Disconnect and remove the power leads from the AC power input terminal block. Remove the ground lead from the ground stud. 6. Disconnect and remove the O and COe signal leads from the alarm output relay terminal block. Emerson.com/Rosemount...
  • Page 247 B. To ground screw C. COe sensor and CJC connector (J4) D. Electronics housing E. O cell and thermocouple connector (J5) F. Signal cable G. Heater power cable Note Wire colors shown are for cables supplied by Emerson. Rosemount OCX8800A...
  • Page 248 10. If moving the electronics housing to another work site, disconnect and remove the power and signal cables and customer wiring conduits from the housing. 11. Remove the remote electronics housing from its mounting and move it to a suitable work area. Emerson.com/Rosemount...

  • Page 249: Repair Sensor Housing

    Disassemble the transmitter only as needed to replace damaged components. Use the applicable assembly procedures to install replacement parts and reassemble the transmitter. 10.3.1  Disassemble sensor housing Remove cover and terminals insulator Rosemount OCX8800A...
  • Page 250 D. Heater rod E. Sensor housing F. Locking clip G. Screw H. Heater clamp I. Gasket J. Screw K. Marking plate L. Terminal insulator M. Heater strut assembly Procedure 1. Loosen screw and slide locking clip away from cover. Retighten screw. Emerson.com/Rosemount...
  • Page 251 Refer to Figure 10-8. Procedure 1. Remove reference air tube from sensor housing. 2. See Figure 10-8. Disconnect and tag O heater wires, O cell and return wires, and thermocouple wires at the sensor housing terminals. Rosemount OCX8800A...
  • Page 252 G. Sample block heater rods H. Thermal switch I. Sensor housing terminals J. Green K. Orange L. Red M. Yellow N. Thermocouple O O. Thermocouple CO P. Thermocouple sample block Q. CO reference R. Heater sample block S. Heater CO T. Heater O Emerson.com/Rosemount...
  • Page 253 One heater clamp secures each heater rod. 3. Slide sample block heater rods out of housing. Remove COe sensor assembly Procedure 1. Disconnect the COe heater, thermocouple, and sensor wires from the terminal blocks. Refer to Figure 10-9. Rosemount OCX8800A...
  • Page 254 G. CJC sensor H. Red I. Yellow J. Blue K. White L. Thermocouple O M. Thermocouple CO N. Thermocouple sample block O. CO reference P. Heater sample block Q. Heater CO R. Heater 02 2. Remove insulator (A, Figure 10-10). Emerson.com/Rosemount...
  • Page 255 N. Eductor elbow O. Eductor holder P. Sensor housing Note For easier access, you may remove two screws from the base of the terminal block mounting (F) and move the terminal block mounting assembly out of the way. Rosemount OCX8800A...
  • Page 256 10-11. Using a straight edge on the sensor holder flat, as shown, matchmark the upper flange of sensor housing to show the correct alignment of the sensor holder (J). Figure 10-11: Alignment of COe Sensor Assembly A. Matchmark B. Straightedge C. Sensor holder flat Emerson.com/Rosemount...
  • Page 257 Remove the O cell and heater strut assembly (Figure 10-8) and the COe assembly (Figure 10-10) before you start this procedure. Procedure 1. Use a straightedge to matchmark alignment of the eductor flat and elbow, as shown in Figure 10-12. Rosemount OCX8800A...
  • Page 258 2. Unscrew the terminal block mounting ( Figure 10-10). Move the terminal block mounting away from the eductor. 3. Unscrew the eductor holder with eductor and fittings from the sensor housing. 4. Clamp the flats of the eductor in the jaws of the bench vise. Emerson.com/Rosemount...
  • Page 259 Remove sample and exhaust tubes WARNING Burns The tubes are bonded with a thread sealing compound. The compound softens at 450 °F (232 °C). The heated parts can cause severe burns. Use heat resistant gloves when removing the probe or exhaust tube. Rosemount OCX8800A...
  • Page 260 10-13) in soft (plastic, wood, or brass) vice jaws. 2. Use a propane torch to heat the sample tube (C) or exhaust tube (B) to 450 °F (232 °C) minimum. Apply the heat near the threaded end of the tube. Emerson.com/Rosemount...
  • Page 261 Diassemble O cell and heater strut assembly CAUTION Equipment damage Removing the O cell may damage the cell and platinum pad. Do not remove the O cell unless you are certain it needs to be replaced. Rosemount OCX8800A...
  • Page 262 Cell, Heater, and Thermocouple Assembly, Exploded View A. Contact/thermocouple assembly B. Screw C. Lockwasher D. Return wire E. Heater strut assembly F. Strut bracket G. Spring H. Spring clip I. Heater tube J. Gasket K. Test gas passage holes L. O cell M. Screw Emerson.com/Rosemount...
  • Page 263 Transfer match marks to the new assembly. 7. Carefully guide the new contact and thermocouple assembly (A) through the strut bracket (F), spring (G), and spring clip (H) until the spring clip reaches the pencil mark. Rosemount OCX8800A...
  • Page 264 Maintenance and service Manual December 2022 00809-0500-4880 Disassemble COe sensor assembly Procedure 1. Carefully remove screws (I, Figure 10-15), lockwashers (H), and COe sensor (A) from the sensor holder (E). Remove and discard the gasket (F). Emerson.com/Rosemount...
  • Page 265 Manual Maintenance and service 00809-0500-4880 December 2022 Figure 10-15: COe Sensor, Exploded View A. COe sensor B. Pre-heater C. Stainless steel balls D. Plug E. Sensor holder F. Gasket G. Thermocouple adapter H. Lockwasher I. Screw Rosemount OCX8800A...
  • Page 266 Turning the pre-heater in the sensor holder with the stainless steel balls in place will cause permanent damage to the pre-heater. Always remove the stainless steel balls (approximately 200) from the sensor holder before removing or installing the pre-heater. Emerson.com/Rosemount...
  • Page 267 2. Clamp flats of sensor holder (E) in vise jaws with the pre-heater port pointing up. 3. Install and tighten the pre-heater (B). Align the pre-heater to the flat of the sensor holder (E) as shown in Figure 10-17. Figure 10-16: Thermocouple Rosemount OCX8800A...
  • Page 268 5. Install and tighten the plug. CAUTION Equipment damage The resistance temperature device (RTD) elements are fragile, and correct alignment in sensor holder is required for proper Rosemount OCX8800 operation. Use care when installing the combustibles (COe) sensor. Emerson.com/Rosemount...
  • Page 269 Procedure 1. Apply pipe thread sealant (Loctite #567) to the external pipe threads of the eductor (G, Figure 10-18). Do not apply sealant to the first turn of the pipe threads. Rosemount OCX8800A...
  • Page 270 D. Dilution air tube E. CJC sensor F. Terminal block mounting G. Eductor H. Tube fitting I. COe sensor assembly J. Sensor holder K. Heater insulator L. COe thermocouple M. COe band heater N. Eductor elbow O. Eductor holder P. Sensor housing Emerson.com/Rosemount...
  • Page 271 4. Apply anti-seize component to the external pipe threads of eductor holder (O). 5. Install and tighten eductor holder (O) in sensor housing (P). Align eductor with matchmark, as shown in Figure 10-19. Figure 10-19: Eductor Alignment Matchmarks A. Eductor flat B. Straight edge C. Matchmark Rosemount OCX8800A...
  • Page 272 Maintenance and service Manual December 2022 00809-0500-4880 Install COe sensor assembly Figure 10-20: Band Heater Height A. COe sensor B. Insulator C. Band heater Emerson.com/Rosemount...
  • Page 273 Do not allow the eductor elbow to turn. 4. Tighten the sensor holder to align outside flat with matchmark on sensor housing flange, as shown in Figure 10-21. Figure 10-21: COe Sensor Holder Alignment A. Sensor holder flat B. Matchmark C. Straight edge D. Matchmark Rosemount OCX8800A...
  • Page 274 The heater insulator end joint must line up with the band gap of the COe band heater. 10. Reconnect the COe sensor, thermocouple, and heater wires at the sensor housing terminal blocks. Refer to Figure 10-22. Emerson.com/Rosemount...
  • Page 275 N. Thermocouple sample block O. CO reference P. Heater sample block Q. Heater CO R. Heater O 11. Install and fasten the COe insulator (Figure 10-18) around the COe sensor assembly. All wiring must remain outside of the insulator. Rosemount OCX8800A...
  • Page 276 F. Locking clip G. Screw H. Terminal insulator I. Marking plate J. Heater rod K. Gasket L. Screw M. Heater strut assembly Procedure 1. Before installing sample block heater rods, evenly coat the heater rods with Watlube heater release agent. Emerson.com/Rosemount...
  • Page 277 Manual Maintenance and service 00809-0500-4880 December 2022 Figure 10-23 2. Install the heater rods, heater clamps, and screws. 3. Reconnect the heater rod leads at the housing terminal blocks. Rosemount OCX8800A...
  • Page 278 G. Sample block heater rods H. Thermocouple O2 I. Thermocouple CO J. Thermocouple sample block K. CO reference L. Heater sample block M. Heater CO N. Heater O2 O. Sensor housing terminals P. Orange Q. Green R. Red S. Yellow Emerson.com/Rosemount...
  • Page 279 5. Loosen screw and slide locking clip fully into gap between cover ribs. Retighten screw. Leak test sensor housing Procedure 1. Install ¼ national pipe thread (NPT) cap on dilution air fitting. Install a ¼ NPT cap on sample tube (C, Figure 10-13) or plug ¼ NPT sample inlet port. Rosemount OCX8800A...

  • Page 280: Repair Electronics Housing

    Use the assembly procedures that apply to install replacement parts and reassemble the transmitter. 10.4.1  Disassemble electronics housing Remove cover Procedure 1. See Figure 10-25. Loosen screw (L) and slide locking clip (K) away from cover (A). Retighten screw (L). Emerson.com/Rosemount...
  • Page 281 D. Local operator interface (LOI) module E. Screw F. LOI board G. Screw H. Lockwasher I. Solenoid valve (three-way) J. Solenoid valve K. Locking clip L. Screw M. O-ring N. Electronics stack O. Flash PROM P. LOI connector Rosemount OCX8800A...
  • Page 282 Remove solenoid valves Procedure 1. Disconnect solenoid leads from mating terminal connector. 2. Remove top nut of solenoid valve (I or J, Figure 10-25). 3. Remove the solenoid coil assembly and washer. 4. Unthread and remove solenoid valve base. Emerson.com/Rosemount...
  • Page 283 2. Disconnect EMI filter wiring at AC power input terminal block on electronic stack. 3. Unbolt and remove EMI filter (D) from electronic stack. 4. Remove ground wire (E) from terminal block (F). 5. Unbolt and remove terminal block (F) from electronic stack. Rosemount OCX8800A...
  • Page 284 2. Install new solenoid valve base. Be careful not to overtighten. 3. Install new washer and solenoid coil assembly and secure with nut. 4. Connect the solenoid leads to the proper terminations on the solenoid power terminal block (Figure 10-27). Emerson.com/Rosemount...
  • Page 285 A. Top view B. CO test gas C. High O test gas D. Low O test gas E. Instrument air Install electronics stack Procedure 1. Install electronics stack (N, Figure 10-25) and secure with lockwashers (H) and screws (G). Rosemount OCX8800A...
  • Page 286 C. COe and CJC connector (J4) D. O cell and thermocouple connector (J5) E. Signal cable F. Heater cable Note Wire colors shown are for cables supplied by Emerson. Table 10-5: J3 Connections Wire color Connects to Yellow 2 heater CO 1 heater CO Emerson.com/Rosemount...
  • Page 287 10-25) and secure it with two screws (G) and lockwashers (H). 2. Note the location of the LOI connector (P). Plug LOI module (D) and connector into one of the four mating receptacles provided. 3. Install three screws (E) to secure the LOI module. Rosemount OCX8800A...
  • Page 288 Flash PROM corner bevel (A, Figure 10-29) must be in upper left corner of receptacle. 3. Install flash PROM. Install cover Procedure 1. If removed, install cover gasket. a) Screw cover (A, Figure 10-25) onto electronics housing. b) Tighten cover firmly. Emerson.com/Rosemount...

  • Page 289: Replace Tube Fittings

    WARNING Burns The pipe threads are bonded with a pipe thread sealant. The thread sealant softens at 450 °F (232 °C). The heated parts can cause severe burns. Use heat resistant gloves when removing a damaged tube fitting. Rosemount OCX8800A...
  • Page 290 Figure 10-30: Removing Tube Fittings A. Tube fitting (type E) B. Tube fitting C. Tube fitting (type R) D. Sensor housing E. Electronics housing Procedure 1. Secure sensor housing or electronics housing in soft (plastic, wood, or brass) vice jaws. Emerson.com/Rosemount...
  • Page 291 2. Apply pipe thread sealant (Loctite #567) to the mating threads of the tube fitting. Do not apply sealant to the first turn of the external pipe threads. 3. Install and tighten the tube fitting in the mating port of sensor or electronic housing. Rosemount OCX8800A...
  • Page 292 Maintenance and service Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 293: Chapter 11 Replacement Parts

    Manual Replacement parts 00809-0500-4880 December 2022 11  Replacement parts 11.1  Sensor housing Figure 11-1: Sensor Housing Components (Sheet 1 of 2) Rosemount OCX8800A...
  • Page 294 For transmitter with remote electronics: 11 in. (279.4 mm) long. 6P00163H01 COe insulator 1A99746H02 Band heater 1A99749H01 Thermocouple 1A99747H01 Elbow 5R10200H01 Eductor 6A00123G01 CJC sensor (resistance temperature device [RTD] assembly, ring type) 6P00155H02 Insulator 1A98765H02 Heater rod 1A99520H01 Watlube heater release agent Emerson.com/Rosemount...
  • Page 295 Tube, sample, 18 in. (457 mm) 316 stainless steel 5R10183H06 Tube, sample, 18 in. (457 mm) Inconel 600 5R10227G01 Tube, sample, 18 in. (457 mm) ceramic 5R10183H03 Tube, sample, 3 ft. (0.91 m) 316 stainless steel 5R10183H07 Tube, sample, 3 ft. (0.91 m) Inconel Rosemount OCX8800A...
  • Page 296 Signal cable assembly, remote electronics, 80 ft (24 m) 6A00147G05 Signal cable assembly, remote electronics, 100 ft. (30 m) 6A00147G06 Signal cable assembly, remote electronics, 150 ft. (45 m) 1A99762H02 In-situ filter, 10 micron (stainless steel sample tube only) Emerson.com/Rosemount...
  • Page 297 Hasteloy in-situ filter, 10 micron, high temperature (stainless steel and Inconel sample tubes only) 6P00162H01 Flange insulator (optional) 3535B18H02 Flange gasket, ANSI 3553B45H01 Flange gasket, DIN 5R10279G01 Tube fitting, type R 771B870H04 Tube fitting, standard 5R10279G02 Tube fitting, type E Rosemount OCX8800A...

  • Page 298: Electronics Housing

    December 2022 00809-0500-4880 11.2  Electronics housing Figure 11-3: Electronics Housing Components for Rosemount OCX8800 with Integral Electronics Table 11-3: Electronics Housing Components for Rosemount OCX8800 with Integral Electronics Index number Part number Description 1A97902H01 Hose 1A97905H02 Solenoid valve, 3-way Emerson.com/Rosemount...
  • Page 299 Fuse (F1 and F6), 10 amp, 250 Vac 1A99766H01 Fuse (F3), 4 amp, 250 Vac 1A99766H02 Fuse (F4), 8 amp, 250 Vac 1A99089H02 Cover gasket (O-ring) 5R10219G01 Cover, blind 5R10199G01 Cover, window 6A00115G02 Local operator interface (LOI) module 1A99112H05 LOI connector 5R10235G01 LOI board Rosemount OCX8800A...
  • Page 300 Electronics stack, HART Special order Flash PROM, programmed 1A97913H06 Fuse (F1 and F6), 10 amp, 250 Vac 1A99766H01 Fuse (F3), 4 amp, 250 Vac 1A99766H02 Fuse (F4), 8 amp, 250 Vac 1A99089H02 Cover gasket (O-ring) 5R10219G01 Cover, blind 5R10199G01 Cover, window Emerson.com/Rosemount...
  • Page 301 Figure 11-5: EMI Filter and Terminal Block A. Brown B. Blue C. Green D. Filter, EMI E. Ground Wire F. Terminal block Table 11-5: EMI Filter and Terminal Block Parts Index letter Part number Description 1A98467H01 Filter, EMI 5R10238G01 Ground wire 1A99714H01 Terminal block Rosemount OCX8800A...

  • Page 302: Cell And Heater Strut Assembly

    11.3  cell and heater strut assembly Figure 11-6: O Cell and Heater Strut Assembly Table 11-6: O Cell and Heater Strut Assembly Index no. Part number Description 4851B44G01 Contact and thermocouple assembly 5R10211G02 Heater strut assembly 5R10188G01 Heater tube Emerson.com/Rosemount...
  • Page 303 7) Refer to item 7. cell (part of O cell replacement kit, item 7) Refer to item 7. Screw (part of O cell replacement kit, item 7) 4851B45G01 cell replacement kit, standard sensing cell Rosemount OCX8800A...
  • Page 304 Replacement parts Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 305: Appendix A Safety Data

    The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to ensure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or national standards. Rosemount OCX8800A...
  • Page 306 This equipment should only be opened when the power is removed and adequate time as specified on the label or in the Reference Manual has Emerson.com/Rosemount...

  • Page 307: Safety Data Sheet For Ceramic Fiber Products

    • May be irritating to skin, eyes, and respiratory tract. • May be harmful if inhaled. • Cristobalite (crystalline silica) formed at high temperature (above 1800 °F [982 °C]) can cause severe respiratory diseases. Rosemount OCX8800A...
  • Page 308 Exposure to used ceramic fiber product Product which has been at service in elevated temperatures (greater than 1800 °F/982 °C) may undergo partial conversion to cristobalite, a form of crystalline silica which can cause severe respiratory disease (pneumoconiosis). The amount Emerson.com/Rosemount...
  • Page 309 The International Agency for Research on Cancer (IARC) reviewed the carcinogenicity data on man-made vitreous fibers (including ceramic fiber, glasswool, rockwool, and slagwool) in 1987. IARC classified ceramic fibers, fibrous glasswool, and mineral wool (rockwool and slagwool) as possible human carcinogens (Group 2B). Rosemount OCX8800A...
  • Page 310 Use dust suppressant where sweeping if necessary. Avoid clean up procedure which may result in water pollution. (Otherwise, observe Special protection information). Waste disposal methods The transportation, treatment, and disposal of this waste material must be conducted in compliance with all applicable federal, state, and local regulations. Emerson.com/Rosemount...
  • Page 311 [982 °C]) may undergo partial conversion to cristobalite, a form of crystalline silica. This reaction occurs at the furnace lining hot face. As a consequence, this material becomes more friable; take special caution to minimize generation of air- Rosemount OCX8800A...
  • Page 312 HEPA filter. Do not use air blowing or dry sweeping. Use dust suppressing components to clean up light dust. Product packaging may contain product residue. Do not reuse except to re-ship or return ceramic fiber products to the factory. Emerson.com/Rosemount...

  • Page 313: General Precautions For Handling And Storing High Pressure Gas Cylinders

    (52 °C). Never permit a flame to come in contact with any part of a compressed gas cylinder. 8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, take precautions to prevent striking an arc against the cylinder. Rosemount OCX8800A...
  • Page 314 Safety data Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 315: Appendix B Product Certifications

    Product certifications 00809-0500-4880 December 2022 B  Product certifications A copy of the Declaration of Conformity can be found at the end of the Quick Start Guide. The most recent Declaration of Conformity can be found at Emerson.com/ Rosemount. Rosemount OCX8800A...
  • Page 316 Product certifications Manual December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 317: Appendix Cspa With Hart ® Alarm

    It connects to a standard HART field device and provides up to four, fully configurable, contact-closure outputs based on readings of the HART digital data. The four Rosemount OCX8800 alarm outputs recognized by the SPA are Low O High COe, Calibration Status, and OCX Unit Failure. Rosemount OCX8800A...
  • Page 318 SPA with HART alarm Manual ® December 2022 00809-0500-4880 Figure C-1: SPA with HART Alarm A. SPA display window B. Right-hand buttons C. Left-hand buttons Emerson.com/Rosemount...

  • Page 319: Install

    Install Refer to Figure C-2 for the typical interface connections for the Rosemount OCX8800 and the SPA with HART alarm. ® Refer to the Moore Industries SPA user manual for additional information concerning SPA installation, setup, and operation. Rosemount OCX8800A...

  • Page 320: Setup

    C.4.1  Jumper and switch settings If the SPA with HART was factory-configured by Emerson for operation with your ® transmitter, jumper and switch setting adjustments are not required. However, you may use the following procedure to verify that the jumper and switch settings are correct.
  • Page 321 3. Check the position of the failsafe Dip switches. Position the Dip switches as shown in Figure C-3. 4. Check the position of the source current Dip switches. Position the Dip switches as shown in Figure C-3. 5. Reinstall the SPA access cover. Rosemount OCX8800A...
  • Page 322 2. Connect a 90 to 260 Vac or 22 to 300 Vdc power source to the SPA power terminals. When connecting an AC power source, use the AC and ACC (AC Common) terminals. For a DC source, use the AC and ground terminals. Emerson.com/Rosemount...
  • Page 323 Figure C-5 shows the SPA menu, submenu, and parameter values that must be selected to configure the SPA for use with the transmitter. Use the following instructions and selections to properly configure the SPA. Rosemount OCX8800A...
  • Page 324 C-5. The SET HART submenu and related parameter values that must be selected via the front panel buttons on the SPA are to the right of the command window. In the submenu views shown: means press down. means press up. Emerson.com/Rosemount...
  • Page 325 To exit the menu, repeatedly press SELECT to display any main menu command. Then press until CONF EXIT is displayed. Select CONF EXIT. The SPA user manual provides detailed instructions concerning the configuration menu and the submenu structure for each main command. Rosemount OCX8800A...
  • Page 326 SPA with HART alarm Manual ® December 2022 00809-0500-4880 Emerson.com/Rosemount...

  • Page 327: Appendix D Returning Material

    To expedite the return process outside of the United States, contact the nearest Rosemount representative. Within the United States, call the Emerson Instrument and Valves Response Center using the 1-800-654-RSMT (7768) toll-free number. This center, available 24 hours a day, will assist you with any needed information or materials.
  • Page 328 Emerson Terms and Conditions of Sale are available upon request. The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a mark of one of the Emerson family of companies. All other marks are the property of their respective owners.

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