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HASAxE-IM-HS
User Manual
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Emerson HASAxE-IM-HS User Manual

Instruction Manual
HASAxE-IM-HS 07/2006
Gas Analyzer Series
Instruction Manual
www.EmersonProcess.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
• 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 contained in this document is subject to change without notice.
Edition 2006-07
Emerson Process Management GmbH & Co. OHG
Industriestrasse 1 D-63594 Hasselroth Germany T +49 (0) 6055 884-0 F +49 (0) 6055 884-209 Internet: www.EmersonProcess.com
Instruction Manual
HASAxE-IM-HS 04/2006
X-STREAM

PREAMBLE

This instruction manual provides information about X-STREAM series gas analyzers concerning subassemblies, functions, procedures, installation, operation and maintenance.
This instruction manual covers several X-STREAM series analyzer variations and therefore may describe configurations and/or options not part of your specific analyzer.
Installation and operation of instruments intended to be installed and operated in hazardous areas is not covered by this instruction manual, but part of the specific instruction manual shipped together with such analyzers because of the special requirements for working in hazardous environments!

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication.
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.
Safety Instructions
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.
NOTE
Highlights an essential operating procedure, condition or statement.
Emerson Process Management GmbH & Co. OHG S-1
Instruction Manual
X-STREAM
HASAxE-IM-HS
04/2006
IMPORTANT

Safety Instructions

Wiring and Installation of this Apparatus
The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU st ates should also comply with the following unless superseded by local or National Standards.
1. Adequate earth connections should be made to all earthing points, internal and external, where provided.
2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times.
3. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.
4. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then by trained service personnel only .
5. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.
6. Where equipment or covers are marked with the symbol to the right, refer to the Instruction Manual for instructions.
7. Further graphical symbols used in this product:
Electrostatic discharge (ESD)
Harmful (to Health)!
Explosion Hazard!
Toxic!
Heavy Instrument!
Disconnect from Mains!
All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.
Emerson Process Management GmbH & Co. OHGS-2
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X-STREAM
Safety Instructions
Operating and Maintaining this Apparatus
This instrument has left the factory in com­pliance with all applicable safety regulations. To maintain this operating condition, the user must strictly follow the instructions and consider the warnings in this manual or provided on the instrument.
Before switching on the instrument, verify that the electrical supply voltage matches the instrument´s operating voltage as set in the factory .
Any interruption in the instrument´s ground line, whether inside or outside the instrument, or removal or interruption of its ground line connection, could result in hazardous operating conditions. Intentionally interrupting the instrument´s protective ground is strictly prohi­bited.
Opening cover panels could expose voltage­carrying components. Connectors may also be under voltage. The instrument must be disconnected from all electrical supplies before attempting any calibrations, maintenance operations, repairs or component replacements requiring opening of the instrument. Any calibrations, maintenance operations, or repairs that need the instrument to be opened while connected to electrical supplies should be subject to qualified technicians familiar with the hazards involved only!
Observe all applicable regulations when operating the instrument from an auto­transformer or variac.
Substances hazardous to health may emerge from the instrument‘s exhaust. Please pay attention to the safety of your operation personnel. Protective measures must be taken, if required.
Safety Instructions
Use only fuses of the correct type and current ratings as replacements. Using repaired fuses and short circuiting of fuse holders is prohibited.
Emerson Process Management GmbH & Co. OHG S-3
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Safety Instructions
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04/2006
INTENDED USE STATEMENT
X-Stream series gas analyzers are intended to be used as analyzers for industrial purposes. They must not be used in medical, diagnostic or life support applications nor as safety devices, and no independent agency certifications or approvals are to be implied as covering such applications!
AUTHORIZED PERSONNEL
If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.
SAFETY SUMMARY
T o avoid loss of life, personal injury and damage to this equipment and on-site property , do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training. Save these instructions.
ELECTRICAL SHOCK HAZARD !
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.
TOXIC GASES !
This unit’s exhaust may contain toxic gases such as sulfur dioxide. These gases can cause serious injuries. Aviod inhalation of the exhaust gases at the exhaust fitting.
Connect exhaust outlet to a safe vent. Check vent line and connections for leakage.
Keep all fittings tight to avoid leaks. See section 7-2, page 7-2 for leak test instructions.
Emerson Process Management GmbH & Co. OHGS-4
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X-STREAM
Safety Instructions
EXPLOSION HAZARD !
Do not operate nor install these instruments in hazardous areas with­out additional measures!
HEAVY INSTRUMENTS !
The analyzer variation X-STREAM F, intended to be wall mounted and/or outdoor installed, weighs up to approx. 26 kg (57 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 specified to be used for the weight of the units!
T ake care the wall or stand the unit is intended to be inst alled at is solid and stable to hold the units!
Safety Instructions
HIGH TEMPERATURES !
While working with photometers and/or thermostated components inside the analyzers hot components may be accessible!
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GASES AND GAS CONDITIONING
Take care of the safety instructions applicable for the gases (sample gases and test gases) and for the gas bottles containing these gases!
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Safety Instructions
INJURY HAZARD !
EXPLOSION HAZARD !
Supplying flammable gases of concentrations above the lower explosion limit (LEL) we recommend to utilize one or more of the following measures:
• Purging the housing with inert gas
• Internal tubing with stainless steel
• Flame arrestors at gas input and output fittings
• Intrinsically safe paramagnetical or thermal conductivity sensors
Supplying explosive gases is not permitted ! (Explosive gases are mixtures of flammable gases of concentrations between the explosion limits with air or oxygen).
Before opening gas paths they must be purged with ambient air or neutral gas (N2) to avoid hazards caused by toxic, flammable, explosive or harmful to health sample gas components!
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POWER SUPPLY
V erify the mains voltage at site of inst allation corresponds to the analyzer´s rated voltage as given on the nameplate label!
V erify the safety instruction given by power supply unit manufacturer !
CONNECTING INSTRUMENTS FOR FIXED INSTALLATION
X-STREAM
Safety Instructions
Safety Instructions
Installation and connecting mains and signal cables are subject to qualified 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 qualified personnel only , familiar with the resulting potential risks!
The gas analyzers do not provide a mains power switch and are operable when connected to power.
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.
Cables for external data processing must be double insulated for mains voltage when used inside the instrument! If double insulation is not available signal cables inside the analyzer must be installed in a way that a distance of at least 5 mm is ensured permanently (e.g. by utilizing cable ties).
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These instruments provide a protective earth terminal. To prevent electrical shock 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 hazzard! Intended interruption of protective earth connections is not permitted!
Instruction Manual
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04/2006
Safety Instructions
ELECTRICAL SHOCK HAZARD !
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General Operating Instructions

General Operating Instructions
X-STREAM
DANGER TO LIFE ! EXPLOSION HAZARD ! V erify all gas lines are connected as described within this manual and tight! Improper gas connections may cause explosion, serious injury or death! Exhaust may contain hydrocarbons and other toxic gases, e.g. carbon
monoxide. Carbon monoxide is toxic!
• Indoor installation area has to be clean, free from moisture, excessive vibration and frost­protected.
• T ake care to meet the permissible ambient temperatures as given in the technical data section! Instruments must not be exposed to direct sunlight nor sources of heat. Do not cover venting openings and take care to mount the instrument in a distance to walls not affecting venting.
• Do not interchange gas inlet and outlet! All gases must be conditioned before supplying! When supplying corrosive gases ensure that gas path components are not affected!
• Max. permissible gas pressure: 1,500 hPa (7.5 psig), except with paramagnetic Oxygen sensor (atmospheric pressure;
page 3-17)!
Safety Instructions
• Exhaust lines must be installed in a descending way , need to be pressureless, frost-protected and in compliance with applicable legislative requirements!
• When it is necessary to open gas paths seal the analyzer‘s gas fittings by using PVC caps to avoid pollution of the internal gas path by moisture, dust, etc.
• T o stay in compliance with regulations regarding electromagnetic compatibility it is recommended to use only shielded cables, as optionally available from Emerson Process Management or equivalent. Customer has to take care that the shield is connected in proper way ( section 4-5, page 4-29). Shield and signal connector enclosure need to be conductively connected, submin-d plugs and sockets must be screwed to the analyzer .
• Using external submin-d-to-terminal adaptor elements (option) affects electromagnetic compatibility . In this case the customer has to take measures to stay in compliance and has to declare conformity , when required by legislation (e.g. European EMC Directive).
Emerson Process Management GmbH & Co. OHG S-9
X-STREAM

Magnetically Operated Front Panel

Magnetically Operated Front Panel
Persons with cardiac pacemakers should absolutely avoid magnetic fields !
Negative effects on persons beyond those described above caused by magnetic fields are not known. It is presumed that persons showing allergic reaction on contact with ceramic or metallic material show the same behavior on contact with magnetic material.
Instruction Manual
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DANGER TO LIFE !
Permanent magnets are surrounded by magnetic fields. These magnetic fields can disturb and even destroy sensitive electronic measuring devices, but also mechanical watches, credit cards, etc.
Usually a distance of 20 inch (0.5 m) is enough to avoid damages. All sintered permanent magnets are hard and brittle. Hitting of sintered permanent magnets by the magnetic attraction causes splitting into fragments with many sharp edges. This especially occurs with high energy magnets, and can also cause skin bruises by high attraction.
High energy magnets made of rare-earth materials have to be stored dry, otherwise the surfaces would oxidise. Unprotected operation in a humid environment may cause corrosion. Avoid damaging the protective galvanic coating.
A storage in a hydrogen atmosphere destroys these magnets. A demagnetisation is caused when permanent magnet materials have been exposed in a radioactive radiation for a long time.
For air transportation of magnetic material the IATA instructions have to be observed:
Magnetic fields are not allowed to penetrate the package, if necessary the magnets have to be shorted using a metal plate.
Emerson Process Management GmbH & Co. OHGS-10
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To find information about see chapter
Safety measures ................................................ S
The different instruments designs .................. 1
The instruments technical data ....................... 2
Measuring principles characteristics ............. 3
How to install the instruments.......................... 4
X-STREAM

SHORT FORM GUIDE FOR THIS MANUAL

Software menu structure, how to navigate
and menu entries descriptions ........................ 5
st
1
startup procedures,
checking the instrument‘s setup..................... 6
Basic procedures .............................................. 7
Maintenance procedures ................................. 7
Status messages and troubleshooting .......... 8
Modbus Parameters .......................................... 9
Table of Contents
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TABLE OF CONTENTS
Preamble S-1 Definitions S-1 Safety Instructions S-2
General Operating Instructions ............................................................................................ S-9
Magnetically Operated Front Panel.................................................................................... S-10
Chapter 1 Technical Description 1-1
1-1 Overview .....................................................................................................................1-1
1-2 X-STREAM General Purpose Tabletop or Rack Mount Version ............................ 1-4
1-3 X-STREAM F (Field Housing).................................................................................... 1-6
1-4 Reserved For Future Use ........................................................................................ 1-11
1-5 Gaspath Design ........................................................................................................1-12
1-5-1 Gas Paths Materials .............................................................................................1-12
1-5-2 Safety Filter........................................................................................................... 1-12
1-5-3 Fittings .................................................................................................................. 1-12
1-5-4 Piping.................................................................................................................... 1-12
1-5-5 Gas Path Variations ............................................................................................. 1-13
1-6 Optional Gas Path Components............................................................................. 1-15
1-6-1 Internal Sample Gas Pump ................................................................................. 1-15
1-6-2 Internal Valve Block.............................................................................................1-15
1-6-3 Internal Flow Monitor...........................................................................................1-15
1-6-4 Internal Barometric Pressure Sensor ................................................................ 1-15
1-6-5 Optional Heated Compartment...........................................................................1-16
1-7 Interfaces ..................................................................................................................1-17
1-7-1 Analog Outputs .................................................................................................... 1-17
1-7-2 Modbus Interface ................................................................................................. 1-17
1-7-3 Status Signals (NAMUR) .....................................................................................1-17
1-8 Optional Interfaces................................................................................................... 1-18
1-8-1 Digital Outputs ..................................................................................................... 1-18
1-8-2 Digital Inputs ........................................................................................................ 1-18
1-8-2-1 Remotely Activating a Calibration Procedure using IN 1 to IN 3................. 1-19
1-8-2-2 V alve Control.................................................................................................... 1-20
1-8-2-3 Remote Pump Control .................................................................................... 1-20
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Table of Contents
Chapter 2 Technical Data 2-1
2-1 Common Technical Data ........................................................................................... 2-2
2-2 Model Specific Technical Data.................................................................................. 2-5
2-2-1 X-STREAM GP, GPS Tabletop or Rack Mount Version....................................... 2-5
2-2-1-1 Terminals Version.............................................................................................. 2-6
2-2-1-2 Sockets Version .................................................................................................2-8
2-2-2 X-STREAM F Field Housing................................................................................2-10
2-3 Information on the Nameplate Label ......................................................................2-13
Chapter 3 Measuring Principles 3-1
3-1 Infrared Measurement (IR), Ultraviolet Measurement (UV).....................................3-1
3-1-1 Interference Filter Correlation (IFC) .....................................................................3-1
3-1-2 Opto Pneumatic Measuring Principle .................................................................. 3-3
3-1-3 Technical Implementation..................................................................................... 3-4
3-2 Oxygen Measurement ................................................................................................3-9
3-2-1 Paramagnetic Measurement................................................................................. 3-9
3-2-2 Electrochemical Measurement ........................................................................... 3-11
3-2-3 Special Hints on Oxygen Sensors ..................................................................... 3-13
3-3 Thermal Conductivity Measurement ......................................................................3-14
3-3-1 Principle of Operation.......................................................................................... 3-14
3-3-2 Technical Implementation................................................................................... 3-15
3-4 Measurement Specification ....................................................................................3-16
Table of Contents
Chapter 4 Installation 4-1
4-1 Abstract....................................................................................................................... 4-1
4-2 Gas Conditioning .......................................................................................................4-2
4-3 Electrical Connections ..............................................................................................4-5
4-4 Detailled Installation Instructions ............................................................................. 4-6
4-4-1 X-STREAM GP, X-STREAM GPS...........................................................................4-6
4-4-1-1 Plugs & Sockets Version .................................................................................. 4-7
4-4-1-2 Terminals Version............................................................................................ 4-13
4-4-2 X-STREAM F......................................................................................................... 4-20
4-5 Hints on Wiring Signal Inputs and Outputs........................................................... 4-29
4-5-1 Electrical Connections in General...................................................................... 4-29
4-5-2 Wiring Inductive Loads .......................................................................................4-31
4-5-3 Driving Multiple Loads ........................................................................................ 4-31
4-5-4 Driving High Current Loads................................................................................ 4-32
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Table of Contents
Chapter 5 User Interface and Software Menus 5-1
5-1 Abstract....................................................................................................................... 5-1
5-2 The User Interface...................................................................................................... 5-1
5-2-2 The Status LEDs .................................................................................................... 5-2
5-2-1 The Display............................................................................................................. 5-2
5-2-3 The Keys ................................................................................................................. 5-3
5-2-3-1 Magnetically Operated Front Panel ................................................................. 5-4
5-3 Software...................................................................................................................... 5-5
5-3-1 Power-On Sequence ............................................................................................. 5-5
5-3-2 Measuring Screen .................................................................................................. 5-5
5-3-3 Menu Structure ......................................................................................................5-6
5-3-4 Navigating and Editing..........................................................................................5-6
5-3-5 Access Levels ........................................................................................................ 5-8
5-3-6 Special Screens ..................................................................................................... 5-9
5-4 Menu System ............................................................................................................5-10
5-4-1 Power-On and Measuring Screen ...................................................................... 5-11
5-4-2 Control Menu ........................................................................................................ 5-13
5-4-2-1 Zero Calibration Menu.....................................................................................5-14
5-4-2-2 Span Calibration Menu ................................................................................... 5-15
5-4-2-3 Advanced Calibration Menu ........................................................................... 5-16
5-4-2-4 Calibration Status Screen...............................................................................5-17
5-4-2-5 Apply Gas Menu............................................................................................... 5-18
5-4-2-6 Acknowledgements Menu .............................................................................. 5-19
5-4-3 Setup Menu .......................................................................................................... 5-20
5-4-3-1 Display Setup Menu ........................................................................................5-21
5-4-3-1-1 Display Language Setup Menu .................................................................5-23
5-4-3-1-2 Menu Access Setup Menu..........................................................................5-24
5-4-3-1-3 Component Setup Menu ............................................................................5-25
5-4-3-2 Calibration Setup Menu ..................................................................................5-26
5-4-3-2-1 Calibration Gases Setup Menu ..................................................................5-27
5-4-3-2-2 Interval Time Setup Menu...........................................................................5-28
5-4-3-3 Measurement Setup Menu..............................................................................5-29
5-4-3-3-1 Signal Damping Setup Menu .....................................................................5-30
5-4-3-3-2 Cross Interference Setup Menu.................................................................5-31
5-4-3-3-3 AD Conversion Setup Menu ......................................................................5-32
5-4-3-4 In/Outputs Setup Menu ...................................................................................5-33
5-4-3-4-1 Analog Output Setup Menu........................................................................5-34
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Table of Contents
5-4-3-4-1-1 Analog Output Signal Setup ..................................................................5-35
5-4-3-4-1-2 Analog Output Range Setup..................................................................5-36
5-4-3-4-1-3 Analog Output Signal Scaling Setup ....................................................5-38
5-4-3-4-1-4 Analog Output Signal Trimming ............................................................5-39
5-4-3-4-2 V alve Assignment........................................................................................5-40
5-4-3-5 Installed Options Setup Menu ........................................................................ 5-41
5-4-3-6 Communication Setup Menu..........................................................................5-42
5-4-3-7 Alarms Setup Menu ......................................................................................... 5-43
5-4-3-8 Save-Load Menu ..............................................................................................5-44
5-4-3-9 Miscellaneous Screen.....................................................................................5-46
5-4-4 Status Menu .........................................................................................................5-47
5-4-4-1 Failure Status Screen......................................................................................5-48
5-4-4-2 Check Requests Status Screen..................................................................... 5-49
5-4-4-3 Function Check Status Screen ...................................................................... 5-50
5-4-4-4 Off Spec Status Screen...................................................................................5-51
5-4-4-5 Calibration Status Screen...............................................................................5-52
5-4-4-6 Measurement Status Screen .......................................................................... 5-53
5-4-4-7 Alarms Status Screen .....................................................................................5-54
5-4-5 Info Menu ..............................................................................................................5-55
5-4-5-1 Measuring Range Info Screen........................................................................ 5-56
5-4-5-2 Factory Settings Screen .................................................................................5-57
5-4-5-3 Installed Options Info Screen .........................................................................5-58
Table of Contents
Chapter 6 Initial Startup 6- 1
6-1 Abstract....................................................................................................................... 6-1
6-2 Checking the Instrument's Setup.............................................................................6-2
6-2-1 Instrument's Language Setup.............................................................................. 6-3
6-2-2 Display Information Setup ....................................................................................6-4
6-2-3 Calibration Data Setup ..........................................................................................6-4
6-2-4 Analog Output Setup............................................................................................. 6-7
6-2-5 Concentration Alarms Setup ..............................................................................6-12
Chapter 7 Maintenance 7-1
7-1 Abstract....................................................................................................................... 7-1
7-2 Performing a Leak Test.............................................................................................. 7-2
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Table of Contents
7-3 Calibration Procedures ............................................................................................7-3
7-3-1 Preparing a Calibration .........................................................................................7-4
7-3-2 Manual Calibration................................................................................................. 7-7
7-3-2-1 Manual Zero Calibration.................................................................................... 7-7
7-3-2-2 Manual Span Calibration ..................................................................................7-8
7-3-3 Advanced Calibration..........................................................................................7-10
7-3-3-1 Additional Preparations for Advanced Calibration ...................................... 7-11
7-3-3-2 Zero All Calibration .......................................................................................... 7-14
7-3-3-3 Span All Calibration .........................................................................................7-16
7-3-3-4 Zero & Span All Calibration............................................................................. 7-18
7-3-4 Auto Calibration ................................................................................................... 7-21
7-3-4-1 Additional Preparations for Auto Calibration................................................ 7-21
7-3-4-2 Zero Auto Calibration ......................................................................................7-24
7-3-4-3 Span Auto Calibration .....................................................................................7-26
7-3-4-4 Unattended Auto Calibration.......................................................................... 7-28
7-3-5 Resetting a Calibration........................................................................................7-30
7-3-6 Verifying a Calibration .........................................................................................7-30
7-3-7 Cancelling an Ongoing Calibration....................................................................7-31
7-3-8 Cross Interference Compensation ..................................................................... 7-33
7-4 Replacing the ElectrochemicalSensor .................................................................7-35
7-4-1 Precautions for Sensor Handling ......................................................................7-37
7-4-2 Opening the Analyzer.......................................................................................... 7-38
7-4-2-1 Opening X-STREAM GP / GPS ....................................................................... 7-39
7-4-2-2 Opening X-STREAM F.....................................................................................7-39
7-4-3 Locating the Sensor ...........................................................................................7-40
7-4-4 Sensor Unit Disassembly ................................................................................... 7-41
7-4-5 Sensor Amplifier Adjustment ..............................................................................7-42
7-4-6 Finalizing the Sensor Replacement................................................................... 7-43
7-5 Cleaning the Instrument's Outside.........................................................................7-44
7-6 Save / Restore Configuration Data Sets ................................................................ 7-45
7-6-1 Save CfgData to UserData .................................................................................. 7-46
7-6-2 Restore UserData to CfgData ............................................................................. 7-47
7-6-3 Restore FactData to CfgData..............................................................................7-48
7-6-4 Save / Restore to an External Device................................................................. 7-49
7-6-4-1 Save CfgData to COMPort ..............................................................................7-50
7-6-4-2 Restore COMPort to CfgData .........................................................................7-52
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Table of Contents
X-STREAM
Chapter 8 Troubleshooting 8-1
8-1 Abstract....................................................................................................................... 8-1
8-2 Solving Problems Indicated by Status Messages ..................................................8-2
8-3 Solving Problems Not Indicated by Status Messages ...........................................8-8
8-4 Troubleshooting on Components..........................................................................8-12
8-4-1 Opening X-STREAM GP / GPS............................................................................8-12
8-4-2 Opening X-STREAM F ......................................................................................... 8-12
8-4-3 Measuring Points................................................................................................. 8-13
8-4-3-1 Measuring Points at BKS Board ....................................................................8-13
8-4-3-1-1 Supply voltage +6 V ....................................................................................8-13
8-4-3-1-2 Positive reference voltage..........................................................................8-13
8-4-3-1-3 Negative reference voltage............................................................................. 8-15
8-4-3-1-4 Temperature sensor....................................................................................8-15
8-4-3-1-5 Light barrier signal ......................................................................................8-15
8-4-3-1-6 Analog Preamplifier.....................................................................................8-16
8-4-3-2 Measuring Points at OXS Board (Electrochemical Oxygen Measurement)8-17
8-4-3-2-1 Sensor Signal ..............................................................................................8-17
8-4-4 BKS 20 Board Jumper Configuration................................................................8-18
8-4-5 Fuse on BKS 20 Board .......................................................................................8-19
Table of Contents
Chapter 9 Modbus Functions 9-1
9-1 Abstract....................................................................................................................... 9-1
9-2 Supported Functions ................................................................................................ 9-2
9-3 List of Parameters and Registers ............................................................................. 9-2
9-4 Comparison of Registers and Parameters ............................................................9-17
Chapter 10 Service Information 10-1
10-1 Return of Material..................................................................................................... 10-1
10-2 Customer Service .................................................................................................... 10-2
10-3 T raining ..................................................................................................................... 10-2
Appendix A-1
A-1 Modbus Implementation........................................................................................... A-2
A-2 EC Declaration of Conformity................................................................................ A-12
A-3 Block Diagrams ....................................................................................................... A-13
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Index of Figures
Index of Figures
Fig. 1-1: X-STREAM GP, GPS, front side view......................................................................................................1-4
Fig. 1-2: X-STREAM GP, terminals version, rear side view .................................................................................1-5
Fig. 1-3: X-STREAM GPS, plugs and sockets version, rear side view................................................................1-5
Fig. 1-4: X-STREAM F, front side view & rear side view at carrying handle ......................................................1-7
Fig. 1-5: X-STREAM F, front panel........................................................................................................................1-8
Fig. 1-6: X-STREAM F, bottom view .....................................................................................................................1-9
Fig. 1-7: X-STREAM F, mains and signal terminals (front door removed).......................................................1-10
Fig. 1-8: Single channel or serial tubing ............................................................................................................1-13
Fig. 1-9: Dual channel parallel tubing.................................................................................................................1-12
Fig. 1-10: Single channel or serial tubing, with options ...................................................................................1-14
Fig. 1-1 1: Dual channel parallel tubing, with options ........................................................................................1-15
Fig. 1-12: Optional Heated Compartment ...........................................................................................................1-16
Fig. 1-13: Digital Outputs - Schematic ................................................................................................................1-18
Fig. 1-14: Digital Inputs - Priorities ......................................................................................................................1-19
Fig. 2-1: X-STREAM GP, GPS - dimensions [approx. mm (inch)] .......................................................................2-5
Fig. 2-2: X-STREAM GP , (terminals version) - terminals and fuse holders........................................................2-7
Fig. 2-3: X-STREAM GPS, (sockets version) - power and signals connectors ..................................................2-8
Fig. 2-4: X-STREAM F - dimensions (approx. mm [inch]) .................................................................................2-10
Fig. 2-5: X-STREAM F - mains terminals / fuse holders ....................................................................................2-11
Fig. 2-6: X-STREAM F - signals terminals ..........................................................................................................2-12
Fig. 2-7: Analyzer Nameplate Label (example)...................................................................................................2-13
Fig. 3-1: Absorption Bands of Measured Gases and Transmission of Interference Filters ................................3-2
Fig. 3-2: Gas Detector Design Principle ................................................................................................................3-3
Fig. 3-3: IR Photometer Assembly Principle .........................................................................................................3-5
Fig. 3-4: Photometer Assembly with Pyroelectrical Detector ..............................................................................3-7
Fig. 3-5: IR & UV Photometer Assemblies with Gas Detectors.............................................................................3-8
Fig. 3-6: Paramagnetic Oxygen Detector, Assembly Principle .......................................................................... 3-10
Fig. 3-7: Electrochemical Sensor - Assembly Principle..................................................................................... 3-11
Fig. 3-8: Electrochemical reaction of Oxygen Sensor .......................................................................................3-12
Fig. 3-9: Wheatstone Bridge ................................................................................................................................3-15
Fig. 3-10a: TC cell, exterior view .........................................................................................................................3-15
Fig. 3-10b: TC cell - sectional view......................................................................................................................3-15
Fig. 4-0: Example of gas fittings label...................................................................................................................4-3
Fig. 4-1: Bypass Mode Installation.........................................................................................................................4- 5
Fig. 4-2:Frontal view...............................................................................................................................................4-6
Fig. 4-3: Rear panel - plugs & sockets version .....................................................................................................4-7
Fig. 4-4: Socket X1 - pin assignment ....................................................................................................................4-8
Fig. 4-5: Socket X2 - pin assignment ....................................................................................................................4-9
Fig. 4-7: Plug X3 - pin assignment ......................................................................................................................4-10
Fig. 4-6: Relay status signals, block diagram .....................................................................................................4-10
Fig. 4-8: Socket X4 - pin assignment ..................................................................................................................4-11
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X-STREAM
Index of Figures
Fig. 4-9: IEC mains input plug .............................................................................................................................4-12
Fig. 4-10: Rear panel - terminals version ............................................................................................................4-13
Fig. 4-1 1: Analog Signal Output Terminals ........................................................................................................4-14
Fig. 4-12: Modbus Interface Terminals ................................................................................................................4-15
Fig. 4-14: Relay Status Terminals ........................................................................................................................4-16
Fig. 4-13: Relay status signals, block diagram ...................................................................................................4-16
Fig. 4-15: Digital Input & Output Terminals ........................................................................................................4-17
Fig. 4-16: Mains terminals....................................................................................................................................4-18
Fig. 4-17: X-STREAM F ........................................................................................................................................4-20
Fig. 4-18: X-STREAM F -Allocation of terminals and gas fittings.....................................................................4-21
Fig. 4-19: X-STREAM F - Analog output terminals ............................................................................................4-23
Fig. 4-20: X-STREAM F - Modbus interface terminals .......................................................................................4-24
Fig. 4-22: X-STREAM F - Relay Status Terminals ..............................................................................................4-25
Fig. 4-21: Relay status signals, block diagram ...................................................................................................4-25
Fig. 4-23: Digital Input & Output Terminals ........................................................................................................4-26
Fig. 4-24: Power terminals ...................................................................................................................................4-27
Fig. 4-25: Shielded Signal Cable, shield connected at both ends ....................................................................4-28
Fig. 4-26: Shielded Signal Cable, shield connected at one end .......................................................................4-30
Fig. 4-27: Double-shielded Signal Cable, shields connected at both sides......................................................4-30
Fig. 4-28: Suppressor Diode for Inductive Loads ...............................................................................................4-31
Fig. 4-29: ”Serial” Wiring ....................................................................................................................................4-31
Fig. 4-30: Running Supply Lines "parallel”........................................................................................................4-32
Fig. 4-31: Driving High Current Loads ................................................................................................................4-32
Table of Contents
Fig. 5-1: X-STREAM user interface........................................................................................................................5-1
Fig. 5-2: X-STREAM magnetic tool .......................................................................................................................5-4
Fig. 5-3: X-STREAM Software menu structure ...................................................................................................5-12
Fig. 6-1: Thresholds defining a window..............................................................................................................6-15
Fig. 6-2: HIGH and HIGH-HIGH alarm mode ........................................................................................................6-16
Fig. 6-3: LOW and LOW-LOW alarm mode ........................................................................................................6-17
Fig. 7-1: Leak Testing with U-turn manometer .....................................................................................................7-2
Fig. 7-2: Calibration improvement by variable valve assignments ................................................................... 7-11
Fig. 7-3: Calibration improvement by variable valve assignments ................................................................... 7-21
Fig. 7-3: Graphical Explanation of Interval Time Settings.................................................................................7-28
Fig. 7-4: X-STREAM interior views......................................................................................................................7-38
Fig. 7-5: X-STREAM GP Interior View .................................................................................................................7-40
Fig. 7-6: Cardcage Detail ......................................................................................................................................7-41
Fig. 7-7: Allocation of eO2 Sensor Unit ..............................................................................................................7-40
Fig. 7-8: Purged Box Detail ..................................................................................................................................7-40
Fig. 7-9: Sensor Unit Assembly ...........................................................................................................................7-40
Fig. 7-10: Sensor Block Assembly ......................................................................................................................7-41
Fig. 7-1 1: OXS Board, top view............................................................................................................................7-43
Emerson Process Management GmbH & Co. OHG
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Index of Tables
Fig. 8-0: X-STREAM F interior view with flapped front panel.............................................................................8-8
Fig. 8-1: X-STREAM interior views......................................................................................................................8-12
Fig. 8-2: BKS Board (section), measuring points ...............................................................................................8-13
Fig. 8-3:Light barrier signal .................................................................................................................................8-15
Fig. 8-4: OXS board, assembled, top view..........................................................................................................8-17
Fig. 8-5: BKS board (section) ...............................................................................................................................8-18
Fig. 8-6: Allocation of fuse on BKS board ..........................................................................................................8-19
Index of Tables
Table 1-1: Digital Inputs IN4-IN7, array ................................................................................................................1-20
Table 3-1: Solvent Resistant Sensor: Approved Solvents....................................................................................3-9
Table 3-2: Medium affected Materials within Paramagnetic Oxygen Sensor ...................................................3-10
Table 3-3: Paramagnetic Oxygen Measurement, cross interference by accompanying gases........................3-13
Table 3-4: Electrochemical Oxygen Measurement, cross interference by accompanying gases ...................3-13
Table 3-5: Examples of Specific Thermal Conductivities ..................................................................................3-14
Table 3-6: Gas Components and Measuring Ranges, examples .......................................................................3-16
Table 3-7: Measurement Performance Specifications ........................................................................................3-17
Table 5-1: Analog Output Signal Selection ........................................................................................................5-35
Table 5-2: Analog Output Signal Setting & Operation Modes ..........................................................................5-37
Table 6-1: Analog Output Signals Settings & Operation Modes .......................................................................6-10
Table 6-2: Thresholds influenced by SpanRange parameter.............................................................................6-13
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1-1 Overview

X-STREAM
Chapter 1
Technical Description
Emerson Process Management´s new X­STREAM gas analyzer series key features:
• compact design with easily accessible internal components
• almost identical internal design supports several housing variations covering a wide range of applications
• highly integrated main board, containing all necessary basic functions and interfaces
• microprocessor based multi-language user interface utilizing an alphanumeric li­quid cristal display (LCD) or vacuum fluorescence display (VFD) with measu­ring values and status messages. Outdoor variations provide a magnetically operated impact tested front panel.
• internal wide range power supply for worldwide usage
X-STREAM series analyzers are designed to measure 1 or 2 gas components combining any of the following methods: I R = non-dispersive infrared measurement UV = ultraviolet measurement PO
= paramagnetic Oxygen measurement
2
EO2= electrochemical Oxygen measurement TC = thermal conductivity measurement
For applications with solvent and/or corrosive components in the gas stream special resistant measuring cells are available. For measuring flammable gases special solutions are available too (e.g. intrinsically safe cells).
Standard General Purpose Applications
Several enclosure variations are available:
• T abletop and rack mount versions, full 19“ size, IP 20 protected (acc. to EN 60529).
• NEMA 4X / IP 66 protected field housing for outdoor installation (ambient temperature range +32 to +122°F; 0 to +50 °C, optional
-4 to +122°F; -20 to +50 °C). The analyzer is intended to be wall mounted.
Installation in Hazardous Areas
For installation in hazardous areas the field housing analyzer provides an adapted pressu­rization system (ATEX type approved for Zone 1 or Zone 2 in Europe). Optionally intrinsically safe signal couplers are available, too. A z-purge system permits installation in North­American Zone 2 environments.
A flameproof analyzer variation, designed to be installed in hazardous areas, is suitable for installation in rough environments, too and will be available soon.
CSA-C/US and ATEX approvals for installation in North-Ameri­can and European hazardous areas are pending!
Consult your local sales office for more information.
Note!
This manual does not deal with special conditions for analyzers in hazardous areas, related to installation, operation, maintenance etc. For such applications refer to the
separate instruction manuals, delivered together with the analyzers.
1 Technical Description
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1-1 Overview
The X-STREAM series analyzers offer a wide range of available configurations and options, to be combined according to the selected model:
Measuring principles Up to two out of all offered principles may be combined within one analyzer model to provide best adaption to the application. For a detailled description of available measuring principles: chapter 3.
Gas path design Internal tubing with viton or, optional and depending on application, PFA or stainless steel. In addition one or more of the following options are available:
• Soleniod valve block This option uses 4 internal solenoid valves to control sample, zero, span gas 1 and span gas 2. These gases are fed to the analyzers to provide manual or controlled automatic calibration (initialized by keypad, serial interface or digital inputs).
• Sample pump Maximum flow rate 2.5 l/min
• Barometric Pressure sensor (Measuring range 800 to 1,200 hPa) Facilitates compensation of atmospheric pressure variations to improve precision of results (
measurement specifi­cations, page 3-17). Special sensors for e.g. corrosive gas on request.
• Flow measurement A flow sensor (option) can be used to
monitor gas flow and set alarms.
• Heated box for physical components All the physical components
*)
can optionally be installed inside thermostatted box to minimize influences from ambient tem-perature fluctuations.
For a detailled description of optional gas path components: page 1-16
Interfaces All models may be configured to use several interfaces: St andard:
• analog outputs
• serial interface (RS 485 or RS 232) with Modbus protocol
• status signals (NAMUR; relay outputs)
Optional:
• 8 digital outputs & 7 digital inputs
For a detailled description of optional inter­faces:
page 1-18
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X-STREAM
1-1 Overview
The different X-STREAM their appearance.
T able top and rack mount version (see section 1-2, page 1-5)
series models and
The following sections 1-2 to 1-3 give detailed descriptions for all available configurations.
Field housing (see section 1-3, page 1-7)
1 Technical Description
1-3Emerson Process ManagementGmbH & Co. OHG
X-STREAM
1-2 X-STREAM GP, GPS
1-2 X-STREAM General Purpose
Tabletop or Rack Mount Version
Instruction Manual
HASAxE-IM-HS
05/2006
This basic general purpose version contains all components within a full 19 inch housing and is intended to either be used as rack mountable analyzer or as tabletop instrument after removing two mounting brackets and installing 4 feet (part of an accessory kit). The front panel shows a 4x20 characters alpha­numeric display, a membrane keypad and 3 status LEDs (fig. 1-1). Electrical connections are provided by either screw terminals (version GP , fig. 1-2) or plugs, sockets and mains appliance (version GPS, fig. 1-3) at the instrument's rear side.
Gas fittings are provided at the instrument's rear side, too.
An optional fitting facilitates purging the instrument with inert gas to minimize influences caused by ambient air when measuring low ranges of select gases (e.g. CO, CO
). The in-
2
ert gas may exhaust the analyzer through a
separate fitting (into an exhaust system) or by leakages in the housing (into ambient).
Purging the physical components with air or inert gas may also be needed when measu­ring aggressive and/or flammable gases: In addition to the purge fitting an internal box is installed, covering the physical components. This forces the purge medium to flow around all other (electronic) components before it circulates around the physics and exhausts the analyzer through a separate outlet fitting into an exhaust system. In case of internal leakage this ensures that the aggressive/ flammable gas is not flushed towards the electronics causing hazards of corrosion and/ or explosion and provides operator safety .
Purge medium specifications:
2-1, page 2-4.
1 3456 72
1 4x20 characters alphanumeric display 2 LED (red) 3 LED (red) 4 LED (green)
Fig. 1-1: X-STREAM GP, GPS, front side view
1-4 Emerson Process Management GmbH & Co. OHG
5 "Home" key 6 "Enter" key 7 4 keys for editing and entering menus
Instruction Manual
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X-STREAM
1-2 X-STREAM GP, GPS
1 23456
1 Gas inlet fittings 2 Optional gas inlet fittings 3 Cover for terminals (shown with
transparency)
Fig. 1-2: X-STREAM GP, terminals version, rear side view
1 23 45
4 Input / output signal terminals 5 Mains terminals 6 Mains fuses
1 Technical Description
1 Gas inlet fittings 2 Optional gas inlet fittings 3 Optional purge gas inlet
Fig. 1-3: X-STREAM GPS, plugs and sockets version, rear side view
4 Mains appliance with fuses 5 Signals sockets
1-5Emerson Process ManagementGmbH & Co. OHG
X-STREAM
1-3 X-STREAM F
1-3 X-STREAM F (Field Housing)
Instruction Manual
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05/2006
This IP66 / NEMA 4X protected housing is intended for outside wall mounting: The housing (fig. 1-4) is made of painted stainless steel. Gaskets protect against water and dust.
The front panel is located behind a safety glass providing protection against mechanical impact and shows a 4x20 characters alphanumeric display and 3 status LEDs. The keypad as it is used to operate the tabletop analyzer is re­placed by sensor fields, operated with a mag­netic tool (fig. 1-5).
Electrical connections are provided by internal screw terminals, the cables enter the housing via cable glands located at the instruments bottom side (fig. 1-6).
Gas fittings are located at the instrument's bottom side, too.
The front door opens vertically by 180° provi­ding easy access to internal components. Removing the hinge bolts even allows to completely remove the front door.
inert gas may exhaust the analyzer through a separate fitting (into an exhaust system) or by leakages in the housing (into ambient).
Purging the physical components with air or inert gas may also be needed when measu­ring aggressive and/or flammable gases: In addition to the purge fitting an internal box is installed, covering the physical components. This forces the purge medium to flow around all other (electronic) components before is circulates around the physics and exhausts the analyzer through a separate outlet fitting into an exhaust system. In case of internal leakage this ensures that the aggressive/flammable gas is not flushed towards the electronics causing hazards of corrosion and/or explosion and provides operator safety .
Purge medium specifications: see technical data section (2-1).
An optional fitting facilitates purging the instrument with inert gas to minimize influences caused by ambient air when measuring low ranges of select gases (e.g. CO, CO2). The
Provided with an appropriate pressurization system the X-STREAM F is suitable for installa­tion in hazardous areas.
EXPLOSION HAZARD !
This instruction manual at hand does not deal with X-STREAM analyzers intended to be used in hazardous areas!
Installation, startup and maintenance are described in detail in a separate instruction manual, shipped together with each such analyzer, and are not subject of this current instruction manual!
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X-STREAM
1-3 X-STREAM F
Fig. 1-4: X-STREAM F, front side view & rear side view at carrying handle
HEAVY INSTRUMENT!
X-STREAM F
gas analyzers, designed for wall mounting and/or outdoor
installation may weigh up to 25 kg (57 lbs), depending on installed options! The upper part of the front door is designed to work as a carrying handle,
see fig. 1-4. Use two persons or a suitable lifting device to move or carry the instrument!
1 Technical Description
1-7Emerson Process ManagementGmbH & Co. OHG
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Instruction Manual
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1-3 X-STREAM F
1 345672
1 4x20 characters alphanumeric display 2 LED (red) 3 LED (red) 4 LED (green)
Fig. 1-5: X-STREAM F, front panel
1-8 Emerson Process Management GmbH & Co. OHG
5 "Home" key 6 "Enter" key 7 4 keys for editing and entering menus
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