Emerson X-STREAM Series Bedienungsanleitung

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 +49 6055 884 0

F +49 6055 884 209

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

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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

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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

Inhaltsverzeichnis

Andere Emerson Messgerät Handbücher

Emerson

Emerson Rosemount 8700 Series Konfigurationshandbuch

Emerson

Emerson Rosemount WPG: Rosemount SPG Bedienungsanleitung

Emerson

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