Emerson Rosemount X-Stream Series Installation and operating instructions

www.EmersonProcess.com
Instruction Manual
HASXEDE-IM-EX
03/2012
Gas Analyzer
X-STREAM Enhanced Series
Flameproof Variation
For Use in Zone 1 and Division 2 Hazardous Areas
Instruction Manual Addendum

ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management (Rosemount Analytical) designs, manufactures and
tests its products to meet many national and international standards. Because these
instruments are sophisticated technical products, you MUST properly install, use, and
maintain them to ensure they continue to operate within their normal specications.
The following instructions MUST be adhered to and integrated into your safety program
when installing, using and maintaining Emerson Process Management (Rosemount
Analytical) products. Failure to follow the proper instructions may cause any one of the
following situations to occur: Loss of life; personal injury; property damage; damage to
this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson Process
Management (Rosemount Analytical) representative for clarication.
• 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.
• When replacement parts are required, ensure that qualied people use replacement
parts specied by Emerson Process Management (Rosemount Analytical).
Unauthorized parts and procedures can affect the product’s performance, place the
safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in re, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place,
except when maintenance is being performed by qualied persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice.
5th edition 03/2012
Original Instruction Manual for the purpose
of the European Directive 94/9/EC.
Rosemount Analytical
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
03/2012
TOC Table of contents
Table of ConTenTs
Introduction S-1
Denitions S-1
Terms used in this instruction manual .......................................... S-2
Symbols used on and inside the unit ........................................... S-3
Symbols used in this manual ................................................. S-4
Safety Instructions S-5
Intended Use Statement..................................................... S-5
General safety notice / Residual risk ........................................... S-5
Special Conditions for Safe Use............................................... S-5
Authorized personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Additional Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
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 Nameplate Label .......................................................1-6
1.7 Technical Data .........................................................1-7
1.8 Measurements Specications ..........................................1-15
1.9 Vapor Recovery Application (Simultaneous Measurement of CH4and Non-CH4).....1-19
Chapter 2 Installation 2-1
2.1 Scope of Supply........................................................2-1
2.2 Installing the Analyzer ...................................................2-2
2.3 Connecting Gas Lines ...................................................2-4
2.3.1 Special Conditions ....................................................2-5
2.3.2 Gas Conditioning...................................................2-7
2.4 Electrical Installation ....................................................2-8
2.4.1 Equipotential bonding conductor ........................................2-20
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
3.4 Symbols and Typographical Conventions ....................................3-4

Emerson Process Management GmbH & Co. OHGTOC-2
X-STREAM XEFD
Instruction Manual
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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
3.9.2 Conguring the Display ................................................3-17
3.9.3 Calibration 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
3.10 Web Browser .........................................................3-28
3.10.1 Connection via network ................................................3-28
3.10.2 Connection to single computer ..........................................3-29
Chapter 4 Service and Maintenance 4-1
4.1 Verications and Tests ...................................................4-3
4.1.1 Routine Tests.........................................................4-3
4.2 Replacement of Parts ...................................................4-6
4.3 Vapor Recovery Application - Special Information ..............................4-8
4.3.1 Determining the converter efciency .......................................4-9
4.3.2 Replacement Instructions ..............................................4-10
4.3.3 Failure Situation .....................................................4-14
4.4 Perform a Calibration...................................................4-15
4.4.1 Manual Zero Calibration ...............................................4-16
4.4.2 Manual Span Calibration ...............................................4-17
4.4.3 Manual Calibration for Vapor Recovery Applications..........................4-18
Chapter 5 Dismounting and Disposal 5-1
5.1 Dismounting and Diposal of the Analyzer ....................................5-1
Appendix A-1
A.1 EC Declaration of Conformity ............................................ A-2
A.2 ATEX EC Type Examination Certicate ..................................... A-3
Table of Contents

Emerson Process Management GmbH & Co. OHG TOC-3
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
03/2012
TOC Table of contents
Table of Figures
A.3 CSA Certicate of Compliance........................................... A-12
A.4 Block Diagram ....................................................... A-19
A.5 Assignment of Terminals and Sockets .................................... A-25
Index of fIgures
Fig. 1-1: Frontal View............................................................................................................1-1
Fig. 1-2: Bottom View............................................................................................................1-2
Fig. 1-3: Nameplate Label Details (exemplary) ....................................................................1-6
Fig. 1-4: Dimensions.............................................................................................................1-7
Fig. 1-5: Signals Terminals..................................................................................................1-13
Fig. 1-6: Power Terminals / Fuse Holders...........................................................................1-14
Fig. 1-7: Vapor Recovery Gas Flow Diagram .....................................................................1-19
Fig. 2-1: Scope of Supply .....................................................................................................2-1
Fig. 2-2: Dimensions.............................................................................................................2-3
Fig. 2-3: Flame arrestor installed into instrument enclosure.................................................2-4
Fig. 2-4: Flame arrestor elements, considering as example FA 01.......................................2-4
Fig. 2-5: Exemplary diagram for a single channel unit with purge option .............................2-5
Fig. 2-6: Exemplary diagram for a single channel instrument for high gas pressure ...........2-6
Fig. 2-7: Label with fastening torques, installed at the instrument .......................................2-6
Fig. 2-8: Allocation of terminals ..........................................................................................2-12
Fig. 2-9: Terminals block X1 - analog signals and relay outputs 1-4 .................................2-14
Fig. 2-10: Terminals block X1 - Modbus interface................................................................2-15
Fig. 2-11: Modbus Interface - Ethernet connector ................................................................2-16
Fig. 2-12: Terminal blocks X4.1 and X4.2 - Digital inputs and outputs .................................2-17
Fig. 2-13: Terminal block X5 - analog inputs........................................................................2-18
Fig. 2-14: Power terminals....................................................................................................2-19
Fig. 2-15: Equipotential bonding conductor terminal ............................................................2-20
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
Fig. 3-5: Web browser logon screen...................................................................................3-30
Fig. 3-6: Web browser measurements screen....................................................................3-30

Emerson Process Management GmbH & Co. OHGTOC-4
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
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Fig. 4-1: Leak Testing with U-tube Manometer (Flame arrestor) ..........................................4-5
Fig. 4-2: Pressure Drop Test.................................................................................................4-5
Fig. 4-3: Vapor recovery application setup............................................................................4-8
Fig. 4-4: Converter assembly................................................................................................4-9
Fig. 4-5: Converter assembly details ....................................................................................4-9
Fig. 4-6: Heated jacket........................................................................................................4-10
Fig. 4-7: Converter, laid open .............................................................................................4-10
Fig. 4-8: Converter lling sequence ....................................................................................4-11
Fig. 4-9: Jacket in converter assembly ..............................................................................4-12
Fig. 4-10: Heated jacket........................................................................................................4-12
Fig. 4-11: Converter metallic cover.......................................................................................4-12
Fig. 4-12: Location of Overtemperature Protection Device...................................................4-13
Index of Figures / Index of Tables
Index of Tables
Tab. 1-1: Generic Analyzer Data ...........................................................................................1-8
Tab. 1-2: Standard Interfaces Data .......................................................................................1-9
Tab. 1-3: Optional Interfaces Data ......................................................................................1-10
Tab. 1-4: Increased Pressure Data .....................................................................................1-12
Tab. 1-5: Purging Gas Data.................................................................................................1-12
Tab. 1-6: Gas Components and Measuring Ranges, examples..........................................1-15
Tab. 1-7: IR, UV, VIS, TCD - Standard and Enhanced Measurement Performance
Specifications......................................................................................................1-16
Tab. 1-8: Trace Moisture - Standard Measurement Performance Specifications................1-16
Tab. 1-9: Oxygen - Standard and Enhanced Measurement Performance Specifications ...1-17
Tab. 1-10: Special Performance Specifications for Gas Purity Measurements.....................1-18
Tab. 3-1: Analog output signals settings and operational modes........................................3-23

Emerson Process Management GmbH & Co. OHG S-1
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
03/2012
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 effectiveness.

Emerson Process Management GmbH & Co. OHGS-2
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
03/2012
Terms Used In This Instruction Manual
ATEX
Directive 94/9/EC, commonly called the
ATEX („Atmosphères Explosibles“) directive,
dealing with equipment intended to be used
in potentially explosive atmospheres.
This directive is valid for equipment to be
sold into and/or installed and operated in the
European Union (EU).
Zone 1
Where ignitable concentrations of ammable
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
Where ignitable concentrations of ammable
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.)
Division 2
Where ignitable concentrations of ammable
gases are not likely to exist under normal
operating conditions (similiar to Zone 2).
Lower Explosion Limit (LEL)
Volume ratio of ammable gas in air below
which an explosive gas atmosphere will not
be formed: the mixture of gas and air lacks
sufcient fuel (gas) to burn.
Upper Explosion Limit (UEL)
Volume ratio of ammable gas in air above
which an explosive gas atmosphere will not
be formed: the mixture of gas and air is too
rich in fuel (decient in oxygen) to burn.
Flammable Gas(es)
Gases and gas mixtures are assigned to be
ammable if they might become ignitable
when in a mixture with air.
Explosive Gas(es)
Flammable Gases and gas mixtures in a mix-
ture with air within the explosive limits.
Intrinsically Safe Cell (IS Cell)
Cells supplied with an intrinsically safe power
signal, approved by a Test Institute, to operate
with explosive gases.
The design ensures the IS cells remains safe
even in case of failure and explosive gases
are not ignited.
Infallible Containment
This term is derived from the standards of
explosion protection especially from the re-
quirements for pressurized housings: thus an
infallible containment can be characterized
by no intended leakage into the gas paths
enabling gas to enter the inner compartment
of the analyzer housing.
Protection Class IP66 / NEMA 4X
Both terms are used to specify conditions for
equipment to be installed outdoor.
IP stands for Ingress Protection, the rst num-
ber species protection against solid objects
(6. = dust tight) while the second number
species the degree of protection against
liquids (.6 = heavy seas).
NEMA stands for National Electrical Manuf-
acturers Association. 4X species a degree
of protection to personnel against incidental
contact with the enclosed equipment; to pro-
vide a degree of protection against falling dirt,
rain, sleet, snow, windblown dust, splashing
water, and hose-directed water; and that will
be undamaged by the external formation of
ice on the enclosure

Emerson Process Management GmbH & Co. OHG S-3
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
03/2012
SSafety Instructions
Symbols Used On And Inside The Unit
This symbol at the instrument ... ... means
dangerous voltages may be accessible. Remo-
ving covers is permitted only, if the instrument is
disconnected from power - and even in this case
by qualied personnel only!
hot surfaces may be accessible. Removing
covers by qualied personnel is permitted only,
if the instrument is disconnected from power.
Nevertheless several surfaces may remain hot
for a limited time.
more detailled information available: see in-
struction manual before proceeding!
more detailled information available: see in-
struction manual before proceeding!
Wherever one or more of the following symbols appear on or inside the instrument, be careful
and read the instructions given in the accompanying manuals!
Strictly observe the given warnings, instructions and information to minimize hazards!

Emerson Process Management GmbH & Co. OHGS-4
X-STREAM XEFD
Instruction Manual
HASXEDE-IM-EX
03/2012
Symbols Used In This Manual
Where one or more of the following symbols appear within this manual, carefully read the rela-
ted information and instructions!
Strictly observe the given warnings, instructions and information to minimize hazards!
This symbol used in the manual ... ... means
dangerous voltages may be exposed
hot surfaces may be exposed
possible danger of explosion
toxic substances may be present
substances harmful to health may be present
indicates notes relating to heavy instruments
electrical components may be destroyed by
electrostatic discharges
units must be disconnected from the power
source
indicates special instructions or information for
operation at low temperatures.
indicates basic conditions or procedures are
being described.
This symbol may also indicate information impor-
tant for achieving accurate measurements.