Emerson X-STREAM XE User manual

www.EmersonProcess.com
Instruction Manual
HASXEE-IM-HS
10/2012
Gas Analyzers
X-STREAM Enhanced Series
Instruction Manual

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.
6th edition, 10/2012
X-STREAM and IntrinzX are marks of one of the Emerson group of companies.
All other marks are property of their respective owners.
Emerson Process Management GmbH & Co. OHG
Rosemount Analytical
Process Gas Analyzer Center of Excellence
Industriestrasse 1
63594 Hasselroth
Germany
T [phone]
F [phone]

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Instruction Manual
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TOC Table of contents
SHORT FORM GUIDE FOR THIS MANUAL
To nd information about see chapter
Safety instructions ...........................S
The different instruments designs ..............1
The instruments technical data.................2
Measuring principles characteristics ............3
How to install the instruments .................4
1st startup procedures,
checking the instrument´s setup ...............5
Software menu structure, how to navigate
and menu entries descriptions .................6
Basic procedures (e.g. calibration)..............7
Maintenance procedures ......................7
Status messages and troubleshooting ..........8
Modbus parameters ..........................9
Service information ..........................10
Dismounting and disposal of instruments........11
Block diagrams, terminals & connectors..... Appendix
Index .....................................IDX

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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
ADDITIONAL LITERATURE..................................................S-5
Authorized Personnel.......................................................S-6
Notes on Batteries .........................................................S-6
Installing and Connecting the Unit.............................................S-7
Operating and Maintaining This Unit ...........................................S-7
Chapter 1 Technical Description 1-1
1.1 Overview .............................................................1-4
1.1.1 The Front Panel.......................................................1-4
1.2 Conguration of Gas Lines ...............................................1-5
1.2.1 Materials Used .......................................................1-5
1.2.2 Safety Filter..........................................................1-5
1.2.3 Gas Inlets and Outlets..................................................1-5
1.2.4 Tubing ..............................................................1-5
1.2.5 Infallible Containments .................................................1-5
1.2.6 Optional Components for Gas Lines .......................................1-6
1.2.7 Congurations .......................................................1-10
1.3 Interfaces............................................................1-11
1.3.1 Analog Outputs ......................................................1-11
1.3.2 Status Relays .......................................................1-11
1.3.3 Modbus Interface, Ethernet .............................................1-12
1.3.4 Serial Interface ......................................................1-12
1.3.5 USB Interfaces ......................................................1-12
1.3.6 Optional Interfaces ...................................................1-13
1.4 Comparison of the Various X-STREAM Enhanced Analyzer Models..............1-14
1.5 X-STREAM XEGK: ½19 Inch Table-Top Unit.................................1-16
1.6 X-STREAM XEGP: 19 Inch Table-Top or Rackmount Design ....................1-18
1.7 X-STREAM XEXF: Field Housing With (XEF ) Single or (XDF) Dual Compartment ...1-20
1.7.1 Field Housings XEXF for Installation in Hazardous Areas (Ex-Zones & Divisions)...1-24
1.8 X-STREAM XEFD: Cast Aluminum Flameproof Housing .......................1-25

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Chapter 2 Technical Data 2-1
2.1 Common Technical Data .................................................2-2
2.2 Model-Specic Technical Data.............................................2-6
2.2.1 X-STREAM XEGK: ½19 Inch Tabletop Unit .................................2-6
2.2.2 X-STREAM XEGP: 19 Inch Tabletop and Rack-Mount Models . . . . . . . . . . . . . . . . .2-12
2.2.3 X-STREAM XEXF: Field Housing With (XEF) Single or (XDF) Dual Compartment ..2-15
2.2.4 X-STREAM XEFD: Flameproof Housing...................................2-19
2.3 Information on Name Plate ..............................................2-22
Chapter 3 Measuring Principles 3-1
3.1 Infrared Measurement (IR), Ultraviolet Measurement (UV).......................3-1
3.1.1 IntrinzX Technology....................................................3-1
3.1.2 NDIR Detector........................................................3-3
3.1.3 Technical Implementation ...............................................3-4
3.2 Oxygen Measurement ...................................................3-5
3.2.1 Paramagnetic Measurement.............................................3-5
3.2.2 Electrochemical Measurement ...........................................3-8
3.2.3 Electrochemical Trace Oxygen Measurement...............................3-11
3.3 Thermal Conductivity Measurement .......................................3-13
3.3.1 Principle of Operation .................................................3-13
3.3.2 Technical Implementation ..............................................3-14
3.4 Trace Moisture Measurement ............................................3-15
3.4.1 Special Operating Conditions ...........................................3-16
3.4.2 Accompanying Gases .................................................3-17
3.5 Measurement Specications .............................................3-19
Chapter 4 Installation 4-1
4.1 Scope of Supply........................................................4-1
4.2 Introduction ...........................................................4-2
4.3 Gas Conditioning .......................................................4-3
4.4 Gas Connections .......................................................4-5
4.5 Electrical Connections ...................................................4-7
4.6 Analyzer Specic Instructions for Installation..................................4-8
4.6.1 X-STREAM XEGK, X-STREAM XEGP.....................................4-9
4.6.2 X-STREAM XEXF (Single XEF; Dual XDF) ................................4-20
4.7 Notes On Wiring Signal Inputs and Outputs .................................4-32
4.7.1 Electrical Shielding of Cables ...........................................4-32
4.7.2 Wiring Inductive Loads ................................................4-35
4.7.3 Driving High-Current Loads.............................................4-35
4.7.4 Driving Multiple Loads.................................................4-36
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Chapter 5 Startup 5-1
5.1 Introduction ...........................................................5-1
5.2 Symbols and Typographical Conventions ....................................5-2
5.3 Front Panel Elements ...................................................5-3
5.3.1 Display..............................................................5-3
5.3.2 Status Line and Text Message Line........................................5-3
5.3.3 Keys ..............................................................5-4
5.4 Software..............................................................5-6
5.4.1 Access Levels & Codes.................................................5-9
5.4.2 Special Messages....................................................5-10
5.5 Powering Up .........................................................5-10
5.5.1 Boot Sequence ......................................................5-10
5.5.2 Measurement Display .................................................5-10
5.6 Selecting the Language.................................................5-12
5.7 Checking the Settings ..................................................5-13
5.7.1 Installed Options .....................................................5-14
5.7.2 Conguring the Display ................................................5-15
5.7.3 Calibration Setup.....................................................5-16
5.7.4 Setting the Analog Outputs .............................................5-18
5.7.5 Setting Concentration Alarms ...........................................5-23
5.7.6 Backup the Settings ..................................................5-24
5.8 Perform a Calibration ...................................................5-26
Chapter 6 User Interface and Software Menus 6-1
6.1 Symbols and Typographical Conventions ....................................6-1
6.2 Menu System..........................................................6-2
6.2.1 Switching On .........................................................6-4
6.2.2 Control Menu.........................................................6-5
6.2.3 Setup Menu.........................................................6-21
6.2.4 Status Menu .......................................................6-108
6.2.5 Info Menu .........................................................6-122
6.2.6 Service Menu ......................................................6-126
Chapter 7 Maintenance and Other Procedures 7-1
7.1 Introduction ...........................................................7-1
7.2 General Maintenance Information ..........................................7-2
7.3 Performing a Leak Test ..................................................7-4
7.4 Calibration Procedures ..................................................7-5
7.4.1 Preparing Calibrations..................................................7-6
7.4.2 Manual Calibration ...................................................7-18
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7.4.3 Advanced Calibration .................................................7-21
7.4.4 Remote Calibration ...................................................7-35
7.4.5 Unattended Automatic Calibration........................................7-39
7.4.6 Verifying a Calibration .................................................7-42
7.4.7 Restoring a Calibration ................................................7-43
7.4.8 Cancelling an Ongoing Calibration .......................................7-43
7.5 Cross Interference Compensation.........................................7-44
7.6 Replacing Worn Out Sensors ............................................7-49
7.6.1 Safety Instructions....................................................7-49
7.6.2 Opening X-STREAM Analyzers .........................................7-50
7.6.3 Replacing the Electrochemical Oxygen-Sensor .............................7-53
7.6.4 Replacing the Trace Oxygen Sensor......................................7-60
7.6.5 Replacing the Trace Moisture Sensor .....................................7-61
7.7 Cleaning the Instrument´s Outside ........................................7-62
7.8 Save / Restore Conguration Data Sets ....................................7-63
7.8.1 Local Backup - Save ..................................................7-65
7.8.2 Local Backup - Restore................................................7-66
7.8.3 Factory Defaults - Restore .............................................7-67
7.8.4 USB Backup ........................................................7-68
7.8.5 Undo Restore .......................................................7-72
7.9 Handling Log Files.....................................................7-73
7.9.1 Conguring Log Files .................................................7-73
7.9.2 Exporting Log Files ...................................................7-74
7.9.3 Log Files Content ....................................................7-76
7.10 Files on USB Memory Device ............................................7-77
7.10.1 autorun.inf ..........................................................7-77
7.10.2 xe_win_tools.zip .....................................................7-78
7.11 Web Browser .........................................................7-79
7.11.1 Connection Via Network ...............................................7-79
7.11.2 Connection to Single Computer .........................................7-80
Chapter 8 Troubleshooting 8-1
8.1 Abstract ..............................................................8-1
8.2 Solving Problems Indicated by NAMUR Status Messages .......................8-2
8.2.1 Analyzer Related NAMUR Messages ......................................8-3
8.2.2 Channel Related Messages (preceded by Channel Tag, e.g. CO2.1) .............8-8
8.3 Solving Problems Not Indicated by Status Messages ..........................8-12
8.4 Troubleshooting on Components..........................................8-18
8.4.1 Opening X-STREAM Analyzers .........................................8-20
8.4.2 Signal Connectors on XSP Board........................................8-23
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8.4.3 Sample Pump: Replacement of Diaphragm ................................8-24
8.4.4 Paramagnetic Oxygen Cell for Standard Applications: Adjustment of Physical Zero .8-35
8.4.5 Thermal Conductivity Cell: Adjustment of Output Signal.......................8-38
Chapter 9 Modbus Functions 9-1
9.1 Abstract ..............................................................9-1
9.1.1 Modbus TCP/IP .......................................................9-1
9.2 Supported Functions ....................................................9-2
9.3 List of Parameters and Registers - Sorted by Tag Name.........................9-3
9.4 List of Parameters and Registers - Sorted by Daniel Registers...................9-34
Chapter 10 Service Information 10-1
10.1 Return of Material .....................................................10-1
10.2 Customer Service .....................................................10-2
10.3 Training .............................................................10-2
Chapter 11 Dismounting and Disposal 11-1
11.1 Dismounting and Diposal of the Analyzer ...................................11-1
Appendix A-1
A.1 Modbus Specication...................................................A-2
A.2 EC Declaration of Conformity ...........................................A-12
A.3 CSA Certicate of Compliance...........................................A-14
A.4 Block Diagram .......................................................A-21
A.5 Water Vapor: Relationship of Dewpoint, Vol.-% and g/Nm³.....................A-35
A.6 Declaration of Decontamination..........................................A-36
A.7 PLC Quick Reference .................................................A-37
A.8 Assignment of Terminals and Sockets.....................................A-43
A.8.1 Tabletop & Rack Mount Analyzers.......................................A-43
A.8.2 Field Housings......................................................A-44
Index I-1
Table of Contents

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Index of fIgures
Fig. 1-1: X-STREAM Enhanced Front Panel (here X-STREAM XEGP)................1-4
Fig. 1-2: Optional Heated Area...............................................1-8
Fig. 1-3: Suppressed Ranges Options .........................................1-9
Fig. 1-4: Gas Flow Diagram: Single Channel Or in Series .........................1-10
Fig. 1-5: Ethernet Interface Marking..........................................1-12
Fig. 1-6: Serial Interface Marking ............................................1-12
Fig. 1-7: USB Interfaces ...................................................1-12
Fig. 1-8: X-STREAM XEGK - Views..........................................1-17
Fig. 1-9: X-STREAM XEGP - Details .........................................1-19
Fig. 1-10: X-STREAM XEXF Field Housings- Front Views..........................1-21
Fig. 1-11: X-STREAM XEF - Right Side and Bottom View..........................1-22
Fig. 1-12: X-STREAM XEF - Power Supply and Signal Terminals ....................1-23
Fig. 1-13: X-STREAM XEFD - Front View ......................................1-26
Fig. 1-14: X-STREAM XEFD - Bottom View.....................................1-27
Fig. 1-15: X-STREAM XEFD - Terminals .......................................1-28
Fig. 2-1: X-STREAM XEGK - Dimensions ......................................2-6
Fig. 2-2: X-STREAM XEGK - Rear Panel and Handle Variations.....................2-7
Fig. 2-3: UPS 01 Tabletop Power Supply Unit ...................................2-9
Fig. 2-4: UPS 01 Power Supply Unit for Rack Installation .........................2-10
Fig. 2-5: 10 A Tabletop PSU ................................................2-11
Fig. 2-6: X-STREAM XEGP - Dimensions .....................................2-12
Fig. 2-7: X-STREAM XEGP - Power Supply and Signal Connections ................2-14
Fig. 2-8: X-STREAM XEGP - With Screw-Type Terminal Adapters (Top View) .........2-14
Fig. 2-9: X-STREAM XEF - Dimensions.......................................2-15
Fig. 2-10: X-STREAM XDF - Dimensions.......................................2-16
Fig. 2-11: X-STREAM XEXF Field Housings - Power Supply Terminals / Fuse Holders ..2-18
Fig. 2-12: X-STREAM XEXF Field Housings - Signal Terminals .....................2-18
Fig. 2-13: X-STREAM XEFD - Dimensions .....................................2-19
Fig. 2-14: X-STREAM XEFD - Power Supply Terminals / Fuse Holders ...............2-21
Fig. 2-15: X-STREAM XEFD - Signal Terminals..................................2-21
Fig. 2-16: Analyzer Name Plate (examples).....................................2-22
Fig. 3-1: IntrinzX Signal Forms...............................................3-2
Fig. 3-2: Gas Detector Design Principle ........................................3-3
Fig. 3-3: Photometer Assembly Principle .......................................3-4
Fig. 3-4: Paramagnetic Oxygen Sensor - Assembly Principle .......................3-5
Fig. 3-5: Electrochemical O2Sensor - Design Principle ............................3-8

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Fig. 3-6: Electrochemical O2Sensor - Assembly .................................3-8
Fig. 3-7: Electrochemical Reaction of Oxygen Sensor.............................3-9
Fig. 3-8: Cover for EO2 Sensor Block At Rear Panel.............................3-10
Fig. 3-9: Trace Oxygen Sensor Design Principle ................................3-11
Fig. 3-10: Cover for TO2 Sensor Block At Rear Panel .............................3-12
Fig. 3-11: Wheatstone Bridge................................................3-13
Fig. 3-12: TC Cell, Exterior View, Thermal Isolation Removed.......................3-14
Fig. 3-13: TC Cell, Sectional View ............................................3-14
Fig. 3-14: Trace Moisture Sensor Assembly .....................................3-15
Fig. 4-1: X-STREAM Enhanced Analyzers - Scope of Supply .......................4-1
Fig. 4-3: Installation in Bypass Mode ..........................................4-6
Fig. 4-2: Labelling of Gas Connectors (example).................................4-6
Fig. 4-4: X-STREAM XEGK - Rack Mount Version Rear Panel ......................4-9
Fig. 4-5: X-STREAM XEGP - Table Top Version Rear Panel .......................4-10
Fig. 4-6: X-STREAM XEGP - Rear Panel, Terminal Adapters and Front Side Brackets...4-11
Fig. 4-7: Socket X1 - Analog & Digital Outputs 1–4 ..............................4-12
Fig. 4-8: Plug X2 - Serial Interface ...........................................4-13
Fig. 4-9: Conguration of XSTA Terminal Adapter ...............................4-14
Fig. 4-10: Sockets X4.1 and X4.2 - Pin Conguration .............................4-15
Fig. 4-11: Conguration of XSTD Terminal Adapter ...............................4-16
Fig. 4-12: Plug X5 - Analog Inputs ............................................4-17
Fig. 4-13: Conguration of XSTI Terminal Adapter ................................4-18
Fig. 4-14: Power Supply Connectors ..........................................4-19
Fig. 4-15: X-STREAM XEF - Dimensions for Installation...........................4-20
Fig. 4-16: X-STREAM XDF - Dimensions for Installation ..........................4-21
Fig. 4-17: X-STREAM XEXF Field Housings - Terminals, Cable Glands and Gas Fittings .4-22
Fig. 4-18: Terminal Block X1 - Analog Signals and Relay Outputs 1-4 ................4-25
Fig. 4-19: Terminal Block X1 - Serial Interface ...................................4-26
Fig. 4-20: Ethernet Connector ...............................................4-27
Fig. 4-21: X4: Terminal Blocks for Digital Inputs and Outputs........................4-28
Fig. 4-22: Terminal Block X5 - Analog Input Signals ..............................4-29
Fig. 4-23: Power Supply Connections .........................................4-30
Fig. 4-24: Shielded Signal Cable, Shielding Connected At Both Ends. ................4-32
Fig. 4-25: Shielded Signal Cable, Shielding Connected At One end...................4-33
Fig. 4-26: Signal Cable With Double Shielding, Shieldings Connected AtAlternate Ends. .4-33
Fig. 4-27: Shield Connector Terminal With Cable .................................4-34
Fig. 4-28: Suppressor Diode for Inductive Loads. ................................4-35
Fig. 4-29: Driving High-Current Loads .........................................4-35
Index of Figures