Emerson Research X-STREAM Series Installation and operating instructions

www.emerson.com
Instruction Manual
HASXEDE-IM-EX
07/2017
Gas Analyzer
X-STREAM Enhanced Series
Flameproof Variation
For Use in Zone 1 and Division 2 Hazardous Areas
Instruction Manual Addendum
10th Edition

ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson (Rosemount) 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

MUST be adhered to and integrated into your safety program when installing, using and
maintaining Emerson (Rosemount) products. Failure to follow the proper instructions
may cause any one of the following situations to occur: Loss of life; personal injury;
property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson
(Rosemount) representative
• Follow all warnings, cautions, and instructions marked on and supplied with the
product.
• Inform and educate your personnel in the proper installation, operation, and
maintenance of the product.
• Install your equipment as specied in the Installation Instructions of the
appropriate Instruction Manual and per applicable local and national codes.
Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualied personnel to install, operate, update,
program, and maintain the product.
• 

󰀨
and VOID YOUR WARRANTY
hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place,
except when maintenance is being performed by qualied persons, to prevent
electrical shock and personal injury.

10th edition 07/2017
Original Instruction Manual for the purpose
of the European Directive 2014/34/EU.
Rosemount
Process Gas Analyzer Center of Excellence
Emerson Process Management GmbH & Co. OHG
Industriestrasse 1
63594 Hasselroth
Germany
T [phone]
F [phone]

Emerson Process Management GmbH & Co. OHG
TOC-1
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
TOC Table of contents

Introduction S-1
Denitions S-1
Terms used in this instruction manual .......................................... S-2
 ........................................... S-3
 ................................................. S-4
Safety Instructions S-5
Intended Use Statement..................................................... S-5
General safety notice / Residual risk ........................................... S-5
Additional Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Authorized personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Special Conditions for Safe Use............................................... S-7
Chapter 1
Technical Description 1-1
1.1 Overview .............................................................1-1
1.2 Design Features........................................................1-1
1.3 Protective Measures in Detail .............................................1-2
1.4 High Pressure Option / Purge Option .......................................1-3
1.5 Explosion Protection Compliances .........................................1-4
1.5.1 Special Conditions for Safe Use ..........................................1-5
 ..............................................1-6
1.7 Technical Data .........................................................1-7
  ............................................1-15
1.9 Vapor Recovery Application (Simultaneous Measurement of CH4and Non-CH4).....1-20
Chapter 2
Installation 2-1
2.1 Scope of Supply........................................................2-1
2.2 Installing the Analyzer ...................................................2-2
2.3 Gas Conditioning .......................................................2-4
2.4 Gas Connections .......................................................2-6
2.4.1 Special Conditions ....................................................2-9
2.5 Electrical Installation ...................................................2-11
  .........................................2-23

Emerson Process Management GmbH & Co. OHG
TOC-2
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
Chapter 3
Start up 3-1
3.1 Final Check ...........................................................3-1
3.2 Performing a Leak Test ..................................................3-2
3.3 Switching On ..........................................................3-3
  Typographical Conventions ....................................3-4
3.5 Front Panel Elements ...................................................3-5
3.5.1 Display..............................................................3-5
3.5.2 Status Line and Text message line ........................................3-5
3.5.3 Keys 3-6
3.6 Software..............................................................3-8
3.6.1 Access Levels & Codes ...............................................3-11
3.6.2 Special Messages ....................................................3-12
3.7 Start up .............................................................3-12
3.7.1 Boot Sequence ......................................................3-12
3.7.2 Measurement Display .................................................3-12
3.8 Language Settings.....................................................3-14
3.9 Checking the Settings ..................................................3-15
3.9.1 Installed Options .....................................................3-16
  Display ................................................3-17
  Setup.....................................................3-18
3.9.4 Setting the Analog Outputs .............................................3-20
3.9.5 Setting Concentration Alarms ...........................................3-25
3.9.6 Backup the Settings ..................................................3-26
 Browser .........................................................3-28
3.10.1 Connection via network ................................................3-28
3.10.2 Connection to single computer ..........................................3-29
3.11 Start the measurement .................................................3-31
Chapter 4
Service and Maintenance 4-1
  ...................................................4-3
4.1.1 Routine Tests.........................................................4-3
4.2 Replacement of Parts ...................................................4-7
4.3 Vapor Recovery Application – Special Information .............................4-9
 󰀩 ......................................4-10
4.3.2 Replacement Instructions See additional instruction manual .................4-11
4.3.3 Failure Situation .....................................................4-12
4.4 Perform a C...................................................4-13
Table of Contents

Emerson Process Management GmbH & Co. OHG
TOC-3
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
TOC Table of contents
Table of Figures
  ...............................................4-14
  ...............................................4-15
 ..........................4-16
Chapter 5
Dismounting and Disposal 5-1
5.1 Dismounting and Diposal of the Analyzer ....................................5-1
Appendix A-1
A.1 Assignment of Terminals and Sockets ..................................... A-2

Fig. 1-1: Frontal View............................................................................................................1-1
Fig. 1-2: Bottom View............................................................................................................1-2
  ....................................................................1-6
Fig. 1-4: Dimensions.............................................................................................................1-7
Fig. 1-6: Signals Terminals..................................................................................................1-13
Fig. 1-5: Signals Terminals..................................................................................................1-13
Fig. 1-7: Power Terminals / Fuse Holders...........................................................................1-14
Fig. 1-8: Vapor Recovery Gas Flow Diagram .....................................................................1-20
Fig. 2-1: Scope of Supply .....................................................................................................2-1
Fig. 2-2: Dimensions.............................................................................................................2-3
  ....................................................................................2-7
 ...................................................................2-7
Fig. 2-5: Flame arrestor installed into instrument enclosure.................................................2-8
Fig. 2-6: Flame arrestor elements, considering as example FA 01.......................................2-8
Fig. 2-7: Exemplary diagram for a single channel unit with purge option .............................2-9
Fig. 2-8: Exemplary diagram for a single channel instrument for high gas pressure .........2-10
 .....................................2-10
Fig. 2-10: Allocation of terminals ..........................................................................................2-15
 ..................................2-17
 ................................................................2-18
  ...............................................................2-19

Emerson Process Management GmbH & Co. OHG
TOC-4
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
 .................................2-20
 X5 – analog inputs.......................................................................2-21
Fig. 2-16: Power terminals....................................................................................................2-22
  ............................................................2-23
Fig. 3-1: Leak Testing with U-turn Manometer......................................................................3-2
Fig. 3-2: Front panel .............................................................................................................3-5
Fig. 3-3: Arrangement of concentration thresholds.............................................................3-25
Fig. 3-4: Ethernet connectors .............................................................................................3-28
 ...................................................................................3-30
 ....................................................................3-30
  ..........................................4-6
Fig. 4-2: Pressure Drop Test.................................................................................................4-6
Fig. 4-3: Vapor recovery application setup............................................................................4-9
Fig. 4-4: Location of Overtemperature Protection Device...................................................4-12
Index of Figures / Index of Tables

  ..........................................................................................1-8
 ......................................................................................1-9
  .....................................................................................1-10
  ....................................................................................1-12
  ...............................................................................................1-12
  ........................................1-15
 
Performance Specifications ................................................................................1-16
 ..............1-16
 .1-17
 2S – Standard Measurement Performance Specifications ...............................1-18
 2...............................1-18
 .............................1-19
 .......................................3-23

Emerson Process Management GmbH & Co. OHG
S-1
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
SSafety Instructions
This instruction manual provides information about installing, operating and maintaining/
servicing X-STREAM series ame proof gas analyzers in hazardous (classied) areas and
shall be read in conjunction with the basic analyzer instruction manual only!
This instruction manual covers several X-STREAM series ame proof gas analyzer varia-
tions and therefore may describe congurations and/or options not part of your specic
analyzer.
INTRODUCTION
The following denitions apply to WARNINGS, CAUTIONS and NOTES found throughout
this publication.
DEFINITIONS
NOTE!
Highlights an essential operating procedure, condition or statement.
HIGHLIGHTS AN OPERATION OR MAINTENANCE PROCEDURE,
PRACTICE, CONDITION, STATEMENT, ETC.
If not strictly observed, could result in injury, death, or long-term health
hazards of personnel.
HIGHLIGHTS AN OPERATION OR MAINTENANCE PROCEDURE,
PRACTICE, CONDITION, STATEMENT, ETC.
If not strictly observed, could result in damage to or destruction of
equipment, or loss of e󰀨ectiveness.

Emerson Process Management GmbH & Co. OHG
S-2
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
Terms Used InThis Instruction Manual
ATEX
Directive 2014/34/EU, commonly called the


in potentially explosive atmospheres.
       
sold into and/or installed and operated in the
European Union (EU).
Containment System
-

source of release into the Ex d enclosure.
Division 2

gases are not likely to exist under normal
operating conditions (similiar to Zone 2).
Explosive Gas Atmosphere

of gas or vapor with air under atmospher-
ic conditions, which after ignition permits

Flammable Gas or Vapor
Gas or vapor which, when mixed with air in
certain proportions, will form an explosive gas

in the X-STREAM gas analyzers inside the con-

Infallible Containment
This term is derived from the standards of
explosion protection especially from the re-
quirements for pressurized housings: thus an
 
 

of the analyzer housing.
Lower Explosion Limit (LEL)

which an explosive gas atmosphere will not

󰀩
Lower Flammable Limit (LFL)

-

Protection Class IP66 / NEMA 4X
Both terms are used to specify conditions for

IP -

(6. = dust tight  
     
liquids (.6 = heavy seas).
NEMA stands for National Electrical Manu-
facturers Association. 4X
of protection to personnel against incidental
contact with the enclosed equipment; to pro-
vide a degree of protection against falling dirt,

water, and hose-directed water; and that will

ice on the enclosure.
Upper Explosion Limit (UEL)

which an explosive gas atmosphere will not


Zone 1

gases can exist some of the time under nor-
mal operating conditions.
(A guideline value [not part of a standard] is
10 to 1.000 hours per year.)
Zone 2

gases are not likely to exist under normal
operating conditions.
(A guideline value [not part of a standard ] is
less than 10 hours per year.)

Emerson Process Management GmbH & Co. OHG
S-3
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
SSafety Instructions
Symbols Used On And Inside The Unit
 ... means
dangerous voltages -
ing covers is permitted only, if the instrument is
disconnected from power – and even in this case

hot surfaces    

if the instrument is disconnected from power.
Nevertheless several surfaces may remain hot
for a limited time.
more detailled information available: see in-

more detailled information available: see in-



Strictly observe the given warnings, instructions and information to minimize hazards!

Emerson Process Management GmbH & Co. OHG
S-4
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
Symbols Used InThis Manual
-

Strictly observe the given warnings, instructions and information to minimize hazards!
 ... means
dangerous voltages
hot surfaces 
 danger of explosion
toxic substances
substances harmful to health
indicates notes relating to heavy instruments
     
electrostatic discharges
   disconnected from the power
source
indicates special instructions or information for
operation at low temperatures.
     

-
ant for achieving accurate measurements.

Emerson Process Management GmbH & Co. OHG
S-5
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
SSafety Instructions
SAFETY INSTRUCTIONS
Intended Use Statement



             -
             
X-STREAM Enhanced




-

With a special option maximum sample gas pressure in the containment system is 1500 hPa

an internal release of oxygen in concentrations greater than that found in air or other oxidizer are

Sample gases are allowed to contain Oxygen only up to 21%.



type plate.
It is not allowed to measure sample gas which is explosive frequently or over long periods.

sample gas only.
General Safety Notice / Residual Risk


Despite of incoming goods inspections, production control, routine tests and application of state-



•  
the user.
•  
•  


operating, maintaining and servicing the analyzer.

Emerson Process Management GmbH & Co. OHG
S-6
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
Safety Instructions
Additional Literature
This manual covers aspects specic for using ameproof X-STREAM XEFD gas analyzers
in hazardous (classied) areas, only.
For comprehensive information on operating and maintain/service the instrument in a safe
manner it is MANDATORY to read all additional instruction manuals, if not provided as
printed version, see the accompanying USB stick for an electronic version (PDF)!

HASXEE-IM-HS X-STREAM Enhanced series instruction manual
 

󰀩
SAVE ALL INSTRUCTIONS FOR FUTURE USE!
Authorized Personnel

analyzer.
Authorized personnel for installing, operating, servicing and maintaining the analyzer are instructed


 󰀨
 
• follow the instruction manual.
Operators must
 
 
work,
• know the safety mechanisms and regulations.
To avoid personal injury and loss of property, do not install, operate, maintain or service this instru-


Emerson Process Management GmbH & Co. OHG
S-7
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
SSafety Instructions
Safety Instructions
SPECIAL CONDITIONS FOR SAFE USE
• 
-
󰀨
from relevant minimum and maximum


is necessary to contact the manufacturer.
•        
proof enclosure special fasteners with

used.
• 


1100 hPa to 1500 hPa and enclosure has

device.
• 

devices, if the sample gas concentration is


• Vapor recovery application: Pressure of
gases not to exceed 1100 hPa. concen-

• 

EN 60079-14.
• Depending on the particular application
all appropriate safety instructions men-
     
considered.
EXPLOSION HAZARD BY CONNECTIONS
Consider the waiting time statement on the front door label before opening,
if the analyzer is congured with selected measurement principles!
Do not open instrument when energized.
Ensure that external circuitry is disconnected or de-energized before
opening the instrument.
Ensure that all gas connections are made as labeled and are leak free.
Improper gas connections could result in explosion and death.

Emerson Process Management GmbH & Co. OHG
S-8
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
Safety Instructions
EXPLOSION HAZARD BY MODIFICATION
Any addition, substitution, or replacement of components installed on or
in this device, must be certied to meet the hazardous area classication
that the device was certied to prior to any such component addition,
substitution, or replacement. In addition, the installation of such device or
devices must meet the requirements specied and dened by the hazardous
area classication of the unmodied device.
Any modications to the device not meeting these requirements, will void
the product certication(s).
EXPLOSION HAZARD BY INTERNAL BATTERY
This analyzer contains an internal battery!
Do NOT OPEN the analyzer enclosure if explosive atmosphere may be present!
Disregarding may cause explosion even if the analyzer is de-energized!
ELECTRICAL SHOCK HAZARD
Installation, and connecting mains and signal cables are subject to qualied
personnel only, taking into account all applicable standards and legislative
requirements!
Failure to follow may cause warranty invalidation, property damage and/or
personal injury or death! Connecting mains and signal cables to internal
srew terminals requires working at open housing near life parts!
Installation of this instrument is subject to qualied personnel only, familiar
with the resulting potential risks!
The gas analyzers do not provide a mains switch! A mains switch or circuit
breaker (to comply with IEC 60947-1 /-3) has to be provided in the building
installation. This switch has to be installed near by analyzer, must be easily
operator accessible and has to be assigned as disconnector for the analyzer.

Emerson Process Management GmbH & Co. OHG
S-9
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
SSafety Instructions
Safety Instructions
EXPLOSION and ELECTRICAL SHOCK HAZARD BY INSTALLATION
These instruments provide a protective earth terminal. To prevent electrical
shock and explosion hazards, the instrument must be connected to a
protective earth.
Therefore the instrument has to be connected to mains by using a three
wire mains cable with earth conductor!
Any interruption of the earth connector inside or outside the instrument
or disconnecting the earth terminal may cause potential electrical shock
hazard!
Intended interruption of protective earth connections is not permitted!
EXPLOSION HAZARD BY DAMAGED FLAME PATHS
Take care to not damage the housing nor threads, and to not produce
scratches on the ange, as threads and ange function as ame paths!
Violation may result in explosion and personal injury!
Repair of the amepaths is not intended.
ELECTRICAL SHOCK HAZARD WHEN CONNECTING TO MAINS
Before connecting the analyzer to mains power, please read the chapter on
safety warnings and the following instructions carefully.

Emerson Process Management GmbH & Co. OHG
S-10
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
Safety Instructions
ELECTRICAL SHOCK HAZARD WHEN OPERATED OPENED
Do not operate without covers secure. Do not open while energized.
Installation requires access to live parts which can cause death or serious
injury.
For safety and proper performace this instrument must be connected to a
properly grounded three-wire source of power.
Violation may cause explosion and personnel injury!
EXPLOSION HAZARD WHEN OPEN
Do NOT operate the instrument with doors or covers open! This is permitted
only when no hazardous atmosphere is present! Depending on the local
regulation, this may require a competent hot work supervisor to issue a
hot work permit.
Use ALL 20 screws with the respective torque to x the cover!
Violation may cause an explosion hazard!
EXPLOSION HAZARD BY HIGH PRESSURE
Risk of internal overpressure under leakage conditions!
For normal operation up to 1100 hPa (1.45 psig) sample gas pressure the
maximum ow into the containment system is 1.5 lpm for ammable gases.
For high pressure option up to 1500 hPa (7.25 psig) the maximum ow into
the enclosure is 1.0 lpm. The sum of gas ows into the enclosure including
purge gas ows not not exceed 2 l/min. Make sure to close gas supplies
before you open the front cover.
Take care of special conditions for safe use, and gas parameter specications!

Emerson Process Management GmbH & Co. OHG
S-11
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
SSafety Instructions
Safety Instructions
EXPLOSION AND ELECTRICAL SHOCK HAZARD
All cables (power and signal) must end (be connected) in either a safe (non-
hazardous) area or in a protecting enclosure (e.g. Ex e junction box)!
The power and signal cables must be separated by a distance of minimum
1 cm (0.4 in) inside and outside the analyzer!
EXPLOSION HAZARD
Startup, operation and service must not be performed, before reading and
understanding all instructions!
Especially all warnings in this and the associated manuals have to be
considered! Inspection, maintenance and service must be carried out
considering all related standards e.g. for “Inspection and maintenance of
electrical installations in hazardous areas” or “Equipment repair, overhaul
and reclamation“.
EXPLOSION HAZARD: VAPOR RECOVERY APPLICATION
Consider the waiting time statement on the front door label before opening!
Disregarding the waiting time statement may result in explosion!
Temperatures of components for this application installed into the analyzer
exceed the analyzer’s temperature classication for hazardous areas! This
option is only possible for -20°C to 50°C ambient temperature and for non-
ammable sample gas.

Emerson Process Management GmbH & Co. OHG
S-12
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
Safety Instructions
HEAVY INSTRUMENT HAZARD
X-STREAM XEFD analyzers, to which this manual relates, intended
to be wall mounted and/or outdoor installed, weigh up to approx. 63 kg
(139 lbs), depending on included options!
Use two people and/or suitable tools for transportation and lifting these
instruments!
Take care to use anchors and bolts specied to be used for the weight of
the units!
Take care the wall or stand the unit is intended to be installed at is solid
and stable to hold the units!
HIGH TEMPERATURES HAZARD
While working at internal components hot surfaces may be accessible, even
after the instrument has been disconnected from power!
HAZARD TO LIFE AND EXPLOSION HAZARD BY EXHAUST GASES
Exhaust gases may contain hydrocarbons and other toxic gases such as
carbon monoxide.
Faulty gas connections may lead to explosion and death.
Ensure that all gas connections are connected as labelled and airtight.

Emerson Process Management GmbH & Co. OHG
S-13
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
SSafety Instructions
Safety Instructions
HIGH TEMPERATURES
Hot parts may be exposed when working on photometers and/or
heated components in the unit.
CRUSHING HAZARD
Take care of crushing hazard when closing the front door of analyzer eld
housings!
Keep out of the closing area between enclosure cover and base!
OPERATION AT LOW TEMPERATURES
When operating an instrument at temperatures below 0 °C (32 °F), do
NOT apply gas nor operate the internal pump before the warmup time has
elapsed!
Violation may result in condensation inside the gas paths or damaged
pump diaphragm!

Emerson Process Management GmbH & Co. OHG
S-14
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
07/2017
General Operating Notes
GENERAL OPERATING NOTES
 
.
 

• Gas inlets and -
plied to the unit. When using this unit with corrosive sample gases, ensure that these gases
do not contain components harmful to the gas lines.
          
pressure up to 1500 hPa (7.25 psig) consider special ordering code and special conditions

          

 
PVC caps to avoid polluting the internal gas lines with condensate, dust, etc.
 -


• -
closure.
• 
to perform leak tests regularly.
FLAMMABLE GASES – EXPLOSION HAZARD
Leaks may cause explosion when measuring ammable gases!
When measuring ammable gases it is recommended to perform a leak test
on all gas paths, connections and components before startup or applying
power. Leak tests should be carried out on a 2 month’s regular basis and
after repair/maintenance.
See the analyzer instruction manual for instructions on how to carry out
leak tests.