Emerson X-STREAM Series User manual

www.EmersonProcess.com
Instruction Manual
HASXENE-IM-EX
12/2014
Gas Analyzers
X-STREAM Enhanced Series
Non-Incendive (Ex nA nC) Configuration
for Zone 2 and Division 2 Installations
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 specifications. 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 clarification.
 Follow all warnings, cautions, and instructions marked on and supplied with the
product.
 Inform and educate your personnel in the proper installation, operation, and
maintenance of the product.
 Install your equipment as specified 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 qualified personnel to install, operate, update,
program, and maintain the product.
 When replacement parts are required, ensure that qualified people use replacement
parts specified by 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 fire, electrical hazards, or improper operation.
 Ensure that all equipment doors are closed and protective covers are in place,
except when maintenance is being performed by qualified persons, to prevent
electrical shock and personal injury.
The information within this document
is subject to change without notice.
6th Edition 12/2014
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 Non-Incendive
Instruction Manual
HASXENE-IM-EX
12/2014
TOC Table of contents
TABLE OF CONTENTS
Introduction S-1
Definitions S-1
Terms used in this instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Symbols used on and inside the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-4
Symbols used within this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
Safety Instructions S-6
Intended Use Statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
General Safety Notice / Residual risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Authorized personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Additional Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Chapter 1 Technical Description 1-1
1.1 Analyzer Variations Covered by This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Application and Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.1 Installation Site and Protection Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.2 Nameplate Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.3 General Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.5 Gas Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.6 Measurements Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.7 Infallible Containments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1.8 Instructions for safe use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Chapter 2 Installation 2-1
2.1 Scope of Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.3 Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.4 Mounting the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.5 Connecting Gas Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.6 Gas Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.7 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.7.1 External Equipotential Bonding Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Chapter 3 Startup 3-1
3.1 Safety Instructions and Final Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Performing a Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 Switching On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Emerson Process Management GmbH & Co. OHGTOC-2
X-STREAM Non-Incendive
Instruction Manual
HASXENE-IM-EX
12/2014
3.4 Symbols and 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 Powering 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 Configuring 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 Maintenance Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3 Gas Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.4 Checking Modified or Repaired Analyzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.4.1 Enclosure Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.5 Replacement of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.6 Perform a Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.6.1 Preparing Calibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.6.2 Manual Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.6.3 Manual Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Chapter 5 Dismounting and Disposal 5-1
5.1 Dismounting and Diposal of the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Appendix A-1
A.1 CSA Certificate of Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Table of Contents

Emerson Process Management GmbH & Co. OHG TOC-3
X-STREAM Non-Incendive
Instruction Manual
HASXENE-IM-EX
12/2014
TOC Table of contents
Table of Contents
A.3 Declaration of Decontamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
A.4 Assignment of Plugs and Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18

Emerson Process Management GmbH & Co. OHGTOC-4
X-STREAM Non-Incendive
Instruction Manual
HASXENE-IM-EX
12/2014
INDEX OF TABLES
Tab. 1-1: Gas Components and Measuring Ranges, examples..............................................1-9
Tab. 1-2: IR, UV, VIS, TCD - Measurement Performance Specifications ..............................1-10
Tab. 1-3: Trace Moisture - Measurement Performance Specifications..................................1-10
Tab. 1-4: Oxygen - Measurement Performance Specifications .............................................1-11
Tab. 1-5: Special Performance Specifications for Gas Purity Measurements .......................1-12
Tab. 3-1: Analog output signals settings and operational modes ..........................................3-23
INDEX OF FIGURES
Fig. 1-1: Nameplate Label Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Fig. 1-2: X-STREAM XEFN - dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Fig. 1-3: X-STREAM XDFN - dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fig. 2-1: Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Fig. 2-2: X-STREAM XEFN - dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fig. 2-3: X-STREAM XDFN - dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Fig. 2-4: Labelling of gas connectors (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fig. 2-5: Terminals block X1 - analog signals and relay outputs 1-4 . . . . . . . . . . . . . . . . 2-11
Fig. 2-6: Terminals block X1 - Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Fig. 2-7: Ethernet connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Fig. 2-8: Terminals block X4.1 and X4.2 - digital inputs and outputs . . . . . . . . . . . . . . . . . 2-14
Fig. 2-9: Terminals block X5 - analog input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Fig. 2-10: Power terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Fig. 2-11: Equipotential bonding conductor terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Fig. 3-1: Sealing plug for cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Fig. 3-2: Hexagon socket screw as sealing plug for unused cable inlet openings. . . . . . . . 3-1
Fig. 3-3: Leak Testing with U-turn Manometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fig. 3-4: Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Fig. 3-5: Arrangement of concentration thresholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Fig. 3-6: Ethernet connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Fig. 3-7: Web browser logon screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Fig. 3-8: Web browser measurements screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Fig. 4-1: Assembly for check routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Emerson Process Management GmbH & Co. OHG S-1
X-STREAM Non-Incendive
Instruction Manual
HASXENE-IM-EX
12/2014
SSafety Instructions
This instruction manual provides information about installing, operating and maintaining/
servicing X-STREAM Enhanced series gas analyzers featuring the ignition protection con-
cept Ex nA nC, approved to be used in hazardous (classified) areas of type Zone 2 or Divi-
sion 2. It shall be read in conjunction with the standard analyzer instruction manual only!
This instruction manual covers several analyzer variations and therefore may describe
configurations and/or options not part of your specific analyzer.
Introduction
The following definitions 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 Non-Incendive
Instruction Manual
HASXENE-IM-EX
12/2014
Terms Used In This Instruction Manual
ATEX
Directive 94/9/EC, commonly called the
ATEX („Atmosphères Explosibles“) products
directive.
Flammable Gas(es)
Gases and gas mixtures are assigned to be
flammable if they might become ignitable
when in a mixture with air.
External Explosion Protection
The „External explosion protection“ serves to
prevent penetration of explosive gas mixtu-
res into the analyzer enclosure. In addition it
avoids ignition on the surface. For this reason
the analyzer is purged with protective gas and
held at an internal overpressure compared to
the surrounding atmosphere.
Containment System
The part of the analyzer containing the gas
that may constitute an internal source of re-
lease.
Explosive Gas(es)
Flammable gases and gas mixtures of a
concentration within the explosion limits and
present in mixture with air.
Internal Explosion Protection
The „Internal explosion protection“ serves
to prevent ignition of gas being present in
the analyzer’s Containment System (CS;=
sample gas path).
Dependent on the gas composition several
options are available:
None required (if gas is noncombustible),
dilution by purge gas or/and internal overpres-
sure of the analyzer’s enclosure compared
to the CS.
Enclosure Protection IP66 / Type 4X
To enable outdoor installation, enclosures are
classified based on their enclosure protection.
IP stands for "Ingress Protection". The first
numeral indicates protection of internal
equipment against the ingress of solid foreign
objects (6. = dust tight), while the second
numeral indicates protection of internal
equipment against ingress of water (.6 =
protection against heavy seas or a strong
jet of water).
Type 4X specifies protection against ad-
ditional environmental conditions such as,
corrosion, icing, etc., as specified in NEMA
250 („National Electrical Manufacturers As-
sociation“).
Intrinsically Safe Cell
Special measuring cell for measuring explo-
sive gases, certified by an independent test
house.
Explosive gases are not ignited, even in case
of failure inside the cell.
Divison 2
Abbr. Div. 2, is a hazardous area comparable
to Zone 2. Div. 2 mainly is used in North-
American standards and locations.

Emerson Process Management GmbH & Co. OHG S-3
X-STREAM Non-Incendive
Instruction Manual
HASXENE-IM-EX
12/2014
SSafety Instructions
Zone 1
Where ignitable concentrations of flammable
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 times per year.)
Zone 2
Where ignitable concentrations of flammable
gases are not likely to exist under normal
operating conditions.
(A guideline value [not part of a standard ] is
less than 10 times per year.)
Lower Explosion Limit (LEL)
Volume ratio of flammable gas in air below
which an explosive gas atmosphere will not
be formed: the mixture of gas and air lacks
sufficient fuel (gas) to burn.
Upper Explosion Limit (UEL)
Volume ratio of flammable gas in air above
which an explosive gas atmosphere will not
be formed: the mixture of gas and air is too
rich in fuel (deficient in oxygen) to burn.
Non-Incendive (Ex n)
Within this manual "non-incendive“ stands for
a protection method for equipment marked
Ex nA nC,intended to be installed in hazar-
dous areas, classified Zone 2 or Division 2.
In the following, the term "non-incendive“ is
abbreviated to "Ex n", the code used within
related standards.
Terms

Emerson Process Management GmbH & Co. OHGS-4
X-STREAM Non-Incendive
Instruction Manual
HASXENE-IM-EX
12/2014
Symbols Used On And Inside The Unit
This symbol at the instrument ... ... indicates
dangerous voltages may be accessible. Remo-
ving covers is permitted only, if the instrument is
disconnected from power - and even in this case
by qualified personnel only!
hot surfaces may be accessible. Removing
covers by qualified 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!
Follow these warnings and notes carefully
to minimize risks.
Definitions