Emerson HASXEDE-IM-EX User Manual

Instruction Manual

HASXEDE-IM-EX 03/2012

Gas Analyzer

X-STREAM Enhanced Series

Flameproof Variation

For Use in Zone 1 and Division 2 Hazardous Areas

Instruction Manual Addendum

www.EmersonProcess.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Emerson Process Management (Rosemount Analytical) designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and

maintain them to ensure they continue to operate within their normal specications.

The following instructions MUST be adhered to and integrated into your safety program when installing, using and maintaining Emerson Process Management (Rosemount Analytical) products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Emerson Process

Management (Rosemount Analytical) representative for clarication.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.

• Install your equipment as specied in the Installation Instructions of the

appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources.

• To ensure proper performance, use qualied personnel to install, operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualied people use replacement parts specied by Emerson Process Management (Rosemount Analytical).

Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike

substitutions may result in re, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place,

except when maintenance is being performed by qualied persons, to prevent

electrical shock and personal injury.

The information contained in this document is subject to change without notice.

5th edition 03/2012

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

Original Instruction Manual for the purpose of the European Directive 94/9/EC.

Instruction Manual

HASXEDE-IM-EX 03/2012

X-STREAM XEFD

Table of ConTenTs

Introduction S-1

Denitions S-1

Terms used in this instruction manual .......................................... S-2

Symbols used on and inside the unit ........................................... S-3

Symbols used in this manual ................................................. S-4

Safety Instructions S-5

Intended Use Statement..................................................... S-5

General safety notice / Residual risk ........................................... S-5

Special Conditions for Safe Use............................................... S-5

Authorized personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6

Additional Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6

Chapter 1 Technical Description 1-1

1.1 Overview .............................................................1-1

1.2 Design Features........................................................1-1

1.3 Protective Measures in Detail .............................................1-2

1.4 High Pressure Option / Purge Option .......................................1-3

1.5 Explosion Protection Compliances .........................................1-4

1.5.1 Special Conditions for Safe Use ..........................................1-5

1.6 Nameplate Label .......................................................1-6

1.7 Technical Data .........................................................1-7

1.8 Measurements Specications ..........................................1-15

1.9 Vapor Recovery Application (Simultaneous Measurement of CH4 and Non-CH4) .....1-19

Table of contents

TOC

Chapter 2 Installation 2-1

2.1 Scope of Supply........................................................2-1

2.2 Installing the Analyzer ...................................................2-2

2.3 Connecting Gas Lines ...................................................2-4

2.3.1 Special Conditions ....................................................2-5

2.3.2 Gas Conditioning...................................................2-7

2.4 Electrical Installation ....................................................2-8

2.4.1 Equipotential bonding conductor ........................................2-20

Chapter 3 Start up 3-1

3.1 Final Check ...........................................................3-1

3.2 Performing a Leak Test ..................................................3-2

3.3 Switching On ..........................................................3-3

3.4 Symbols and Typographical Conventions ....................................3-4

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Table of Contents

3.5 Front Panel Elements ...................................................3-5

3.5.1 Display..............................................................3-5

3.5.2 Status Line and Text message line ........................................3-5

3.5.3 Keys 3-6

3.6 Software..............................................................3-8

3.6.1 Access Levels & Codes................................................3-11

3.6.2 Special Messages ....................................................3-12

3.7 Start up .............................................................3-12

3.7.1 Boot Sequence ......................................................3-12

3.7.2 Measurement Display .................................................3-12

3.8 Language Settings .....................................................3-14

3.9 Checking the Settings ..................................................3-15

3.9.1 Installed Options .....................................................3-16

3.9.2 Conguring the Display ................................................3-17

3.9.3 Calibration Setup.....................................................3-18

3.9.4 Setting the Analog Outputs .............................................3-20

3.9.5 Setting Concentration Alarms ...........................................3-25

3.9.6 Backup the Settings ..................................................3-26

3.10 Web Browser .........................................................3-28

3.10.1 Connection via network ................................................3-28

3.10.2 Connection to single computer ..........................................3-29

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Chapter 4 Service and Maintenance 4-1

4.1 Verications and Tests ...................................................4-3

4.1.1 Routine Tests.........................................................4-3

4.2 Replacement of Parts ...................................................4-6

4.3 Vapor Recovery Application - Special Information ..............................4-8

4.3.1 Determining the converter efciency .......................................4-9

4.3.2 Replacement Instructions ..............................................4-10

4.3.3 Failure Situation .....................................................4-14

4.4 Perform a Calibration...................................................4-15

4.4.1 Manual Zero Calibration ...............................................4-16

4.4.2 Manual Span Calibration ...............................................4-17

4.4.3 Manual Calibration for Vapor Recovery Applications..........................4-18

Chapter 5 Dismounting and Disposal 5-1

5.1 Dismounting and Diposal of the Analyzer ....................................5-1

Appendix A-1

A.1 EC Declaration of Conformity ............................................ A-2

A.2 ATEX EC Type Examination Certicate ..................................... A-3

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Table of Figures

A.3 CSA Certicate of Compliance........................................... A-12

A.4 Block Diagram ....................................................... A-19

A.5 Assignment of Terminals and Sockets .................................... A-25

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Index of fIgures

Fig. 1-1: Frontal View ............................................................................................................1-1

Fig. 1-2: Bottom View ............................................................................................................1-2

Fig. 1-3: Nameplate Label Details (exemplary) ....................................................................1-6

Fig. 1-4: Dimensions .............................................................................................................1-7

Fig. 1-5: Signals Terminals ..................................................................................................1-13

Fig. 1-6: Power Terminals / Fuse Holders ...........................................................................1-14

Fig. 1-7: Vapor Recovery Gas Flow Diagram .....................................................................1-19

Table of contents

TOC

Fig. 2-1: Scope of Supply .....................................................................................................2-1

Fig. 2-2: Dimensions .............................................................................................................2-3

Fig. 2-3: Flame arrestor installed into instrument enclosure .................................................2-4

Fig. 2-4: Flame arrestor elements, considering as example FA 01 .......................................2-4

Fig. 2-5: Exemplary diagram for a single channel unit with purge option .............................2-5

Fig. 2-6: Exemplary diagram for a single channel instrument for high gas pressure ...........2-6

Fig. 2-7: Label with fastening torques, installed at the instrument .......................................2-6

Fig. 2-8: Allocation of terminals ..........................................................................................2-12

Fig. 2-9: Terminals block X1 - analog signals and relay outputs 1-4 .................................2-14

Fig. 2-10: Terminals block X1 - Modbus interface ................................................................2-15

Fig. 2-11: Modbus Interface - Ethernet connector ................................................................2-16

Fig. 2-12: Terminal blocks X4.1 and X4.2 - Digital inputs and outputs .................................2-17

Fig. 2-13: Terminal block X5 - analog inputs ........................................................................2-18

Fig. 2-14: Power terminals ....................................................................................................2-19

Fig. 2-15: Equipotential bonding conductor terminal ............................................................2-20

Fig. 3-1: Leak Testing with U-turn Manometer ......................................................................3-2

Fig. 3-2: Front panel .............................................................................................................3-5

Fig. 3-3: Arrangement of concentration thresholds .............................................................3-25

Fig. 3-4: Ethernet connectors .............................................................................................3-28

Fig. 3-5: Web browser logon screen ...................................................................................3-30

Fig. 3-6: Web browser measurements screen ....................................................................3-30

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Index of Figures / Index of Tables

Fig. 4-1: Leak Testing with U-tube Manometer (Flame arrestor) ..........................................4-5

Fig. 4-2: Pressure Drop Test .................................................................................................4-5

Fig. 4-3: Vapor recovery application setup............................................................................4-8

Fig. 4-4: Converter assembly ................................................................................................4-9

Fig. 4-5: Converter assembly details ....................................................................................4-9

Fig. 4-6: Heated jacket ........................................................................................................4-10

Fig. 4-7: Converter, laid open .............................................................................................4-10

Fig. 4-8: Converter lling sequence ....................................................................................4-11

Fig. 4-9: Jacket in converter assembly ..............................................................................4-12

Fig. 4-10: Heated jacket ........................................................................................................4-12

Fig. 4-11: Converter metallic cover .......................................................................................4-12

Fig. 4-12: Location of Overtemperature Protection Device ...................................................4-13

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Index of Tables

Tab. 1-1: Generic Analyzer Data ...........................................................................................1-8

Tab. 1-2: Standard Interfaces Data .......................................................................................1-9

Tab. 1-3: Optional Interfaces Data ......................................................................................1-10

Tab. 1-4: Increased Pressure Data .....................................................................................1-12

Tab. 1-5: Purging Gas Data .................................................................................................1-12

Tab. 1-6: Gas Components and Measuring Ranges, examples ..........................................1-15

Tab. 1-7: IR, UV, VIS, TCD - Standard and Enhanced Measurement Performance

Specifications ......................................................................................................1-16

Tab. 1-8: Trace Moisture - Standard Measurement Performance Specifications ................1-16

Tab. 1-9: Oxygen - Standard and Enhanced Measurement Performance Specifications ...1-17

Tab. 1-10: Special Performance Specifications for Gas Purity Measurements .....................1-18

Tab. 3-1: Analog output signals settings and operational modes ........................................3-23

Emerson Process Management GmbH & Co. OHGTOC-4

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X-STREAM XEFD

INTRODUCTION

This instruction manual provides information about installing, operating and maintaining/ servicing X-STREAM series ame proof gas analyzers in hazardous (classied) areas and shall be read in conjunction with the basic analyzer instruction manual only!

This instruction manual covers several X-STREAM series ame proof gas analyzer varia-

tions and therefore may describe congurations and/or options not part of your specic

analyzer.

DEFINITIONS

Safety Instructions

The following denitions 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.

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

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Terms Used In This Instruction Manual

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ATEX

Directive 94/9/EC, commonly called the

ATEX („Atmosphères Explosibles“) directive, dealing with equipment intended to be used

in potentially explosive atmospheres.

This directive is valid for equipment to be

sold into and/or installed and operated in the European Union (EU).

Division 2

Where ignitable concentrations of ammable

gases are not likely to exist under normal operating conditions (similiar to Zone 2).

Explosive Gas(es)

Flammable Gases and gas mixtures in a mixture with air within the explosive limits.

Flammable Gas(es)

Gases and gas mixtures are assigned to be ammable if they might become ignitable

when in a mixture with air.

Infallible Containment

This term is derived from the standards of explosion protection especially from the requirements for pressurized housings: thus an

infallible containment can be characterized by no intended leakage into the gas paths enabling gas to enter the inner compartment

of the analyzer housing.

Intrinsically Safe Cell (IS Cell)

Cells supplied with an intrinsically safe power

signal, approved by a Test Institute, to operate

with explosive gases. The design ensures the IS cells remains safe

even in case of failure and explosive gases are not ignited.

Lower Explosion Limit (LEL)

Volume ratio of ammable gas in air below

which an explosive gas atmosphere will not

be formed: the mixture of gas and air lacks sufcient fuel (gas) to burn.

Protection Class IP66 / NEMA 4X

Both terms are used to specify conditions for

equipment to be installed outdoor. IP stands for Ingress Protection, the rst num-

ber species protection against solid objects (6. = dust tight) while the second number species the degree of protection against

liquids (.6 = heavy seas). NEMA stands for National Electrical Manuf-

acturers Association. 4X species a degree of protection to personnel against incidental contact with the enclosed equipment; to provide a degree of protection against falling dirt,

rain, sleet, snow, windblown dust, splashing

water, and hose-directed water; and that will

be undamaged by the external formation of

ice on the enclosure

Upper Explosion Limit (UEL)

Volume ratio of ammable gas in air above

which an explosive gas atmosphere will not

be formed: the mixture of gas and air is too rich in fuel (decient in oxygen) to burn.

Zone 1

Where ignitable concentrations of ammable

gases can exist some of the time under normal operating conditions.

(A guideline value [not part of a standard ] is 10 to 1.000 hours per year.)

Zone 2

Where ignitable concentrations of ammable

gases are not likely to exist under normal operating conditions.

(A guideline value [not part of a standard ] is less than 10 hours per year.)

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X-STREAM XEFD

Symbols Used On And Inside The Unit

Wherever one or more of the following symbols appear on or inside the instrument, be careful and read the instructions given in the accompanying manuals!

Strictly observe the given warnings, instructions and information to minimize hazards!

This symbol at the instrument ... ... means

dangerous voltages may be accessible. Remo- ving covers is permitted only, if the instrument is disconnected from power - and even in this case

by qualied personnel only! hot surfaces may be accessible. Removing

covers by qualied personnel is permitted only,

if the instrument is disconnected from power. Nevertheless several surfaces may remain hot for a limited time.

more detailled information available: see in-

struction manual before proceeding!

more detailled information available: see in-

struction manual before proceeding!

Safety Instructions

Emerson Process Management GmbH & Co. OHG S-3

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Symbols Used In This Manual

Where one or more of the following symbols appear within this manual, carefully read the related information and instructions!

Strictly observe the given warnings, instructions and information to minimize hazards!

This symbol used in the manual ... ... means

dangerous voltages may be exposed

hot surfaces may be exposed

possible danger of explosion

toxic substances may be present

substances harmful to health may be present

indicates notes relating to heavy instruments

electrical components may be destroyed by

electrostatic discharges

units must be disconnected from the power source

indicates special instructions or information for operation at low temperatures.

indicates basic conditions or procedures are being described.

This symbol may also indicate information impor-

tant for achieving accurate measurements.

Emerson Process Management GmbH & Co. OHGS-4

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X-STREAM XEFD

SAFETY INSTRUCTIONS

Intended Use Statement

X-STREAM XE 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.

Using X-STREAM XE analyzers as safety devices is prohibited where redundancy and/or SIL classication or equivalent is needed.

No independent agency certications or approvals are to be implied as covering such applications!

Safety Instructions

General Safety Notice / Residual Risk

If this equipment is used in a manner not specied in these instructions, protective systems may be impaired.

Despite of incoming goods inspections, production control, routine tests and application of state-

of-the-art measuring and test methods, an element of risk remains when operating a gas analyzer! Even when operated as intended and observing all applicable safety instructions, some residual

risks remain, including, but not limited to, the following:

• An interruption of the protective earth line, e.g. in an extension cable, may result in risk to

the user.

• Live parts are accessible when operating the instrument with doors open or covers removed.

• The emission of gases hazardous to health may even be possible when all gas connections have been correctly made.

Avoid exposure to the dangers of these residual risks by taking particular care when installing,

operating, maintaining and servicing the analyzer.

SPECIAL CONDITIONS FOR SAFE USE

• Only specied screws M16x45 ISO 4762 A2-70 as specied in the maintenance section of this manual shall be used (spare

part # 42716945).

• Vapor recovery application:

Pressure of gases not to exceed 1100 hPa.

Concentrations of gases must be below

25 % LEL.

• The ame joints correspond to the drawing

No. 4.271-7112/1 and do not comply with

the dimensions mentioned into the Tab. 1 and Tab. 2 of EN 60079-1 ed.2.

• The gas path for the sample gas shall be equipped with additional appropriate ame arrestors in case of gas pressure above

1100 hPa to 1500 hPa.

• Appropriate certied cable glands shall be

used in accordance with IEC/EN 60079-14

Emerson Process Management GmbH & Co. OHG S-5

• Depending on the particular application all approbriate safety instructions mentioned

in this instruction manual on hand must

be considered!

• Take special care of formation of ammable gas at the outlet of breathing and/or

purging devices, if the sample gas con-

centration is above 25% LEL! If need be, such outlets have to end in a safe area!

Instruction Manual

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Safety Instructions

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Authorized Personnel

In-depth specialist knowledge is an absolutely necessary condition for working with and on the

analyzer.

Authorized personnel for installing, operating, servicing and maintaining the analyzer are instructed

and trained qualied personnel of the operating company and the manufacturer.

It is the responsibility of the operating company to

• train staff,

• observe safety regulations,

• follow the instruction manual.

Operators must

• have been trained,

• have read and understood all relevant sections of the instruction manual before commencing

work,

• know the safety mechanisms and regulations.

To avoid personal injury and loss of property, do not install, operate, maintain or service this instru-

ment before reading and understanding this instruction manual and receiving appropriate training.

Additional Literature

This manual covers aspects specic for using ameproof X-STREAM XEFD gas analyzers in hazardous (classied) areas, only.

For comprehensive information on operating and maintain/service the instrument in a safe manner it is MANDATORY to read all additional instruction manuals, if not provided as printed version, see the accompanying USB stick for an electronic version (PDF)!

The following instruction manuals are available and/or referenced within this manual at hand:

HASXEE-IM-HS X-STREAM XE series instruction manual

HASICx-IM-H Infallible Containment The original manufacturer's cable gland or conduit instruction manual, depending on what is used.

Contact your local service center or sales ofce when missing documents.

SAVE ALL INSTRUCTIONS FOR FUTURE USE!

Emerson Process Management GmbH & Co. OHGS-6

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Consider the waiting time statement on the front door label before opening,

if the analyzer is congured with selected measurement principles!

Do not open instrument when energized.

Ensure that external circuitry is disconnected or de-energized before opening the instrument.

Ensure that all gas connections are made as labeled and are leak free. Improper gas connections could result in explosion and death.

X-STREAM XEFD

Safety Instructions

EXPLOSION HAZARD BY CONNECTIONS

Safety Instructions

EXPLOSION HAZARD BY MODIFICATION

Any addition, substitution, or replacement of components installed on or

in this device, must be certied to meet the hazardous area classication that the device was certied to prior to any such component addition,

substitution, or replacement. In addition, the installation of such device or

devices must meet the requirements specied and dened by the hazardous area classication of the unmodied device.

Any modications to the device not meeting these requirements, will void the product certication(s).

Contact Emerson Process Management‘s customer service center for return authorization.

EXPLOSION HAZARD BY SAMPLE HANDLING

The X-STREAM analyzer may utilize not only sample gas but one or more pressurized carrier gases and/or calibration gases.

If an external owmeter is required for ow control, legislative requirements and instructions for installation in hazardous (classied) areas must be

considered.

Emerson Process Management GmbH & Co. OHG S-7

X-STREAM XEFD

Installation, and connecting mains and signal cables are subject to qualied

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 qualied 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.

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Safety Instructions

ELECTRICAL SHOCK HAZARD

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.

EXPLOSION and ELECTRICAL SHOCK HAZARD BY INSTALLATION

These instruments provide a protective earth terminal. To prevent electrical shock and explosion 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 hazard!

Intended interruption of protective earth connections is not permitted!

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Take care to not damage the housing nor threads, and to not produce

scratches on the ange, as threads and ange function as ame paths!

Violation may result in explosion and personal injury!

Before connecting the analyzer to mains power, please read the chapter on safety warnings and the following instructions carefully.

X-STREAM XEFD

Safety Instructions

EXPLOSION HAZARD BY DAMAGED FLAME PATHS

Safety Instructions

ELECTRICAL SHOCK HAZARD WHEN CONNECTING TO MAINS

ELECTRICAL SHOCK HAZARD WHEN OPERATED OPENED

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.

Violation may cause explosion and personnel injury!

EXPLOSION HAZARD WHEN OPEN

Do NOT operate the instrument with doors or covers open! This is permitted only when no hazardous atmosphere is present! Depending on the local regulation, this may require a competent hot work supervisor to issue a hot work permit.

Use ALL 20 screws to x the cover!

Violation may cause an explosion hazard!

Emerson Process Management GmbH & Co. OHG S-9

X-STREAM XEFD

Risk of internal overpressure under leakage conditions!

For the purge or high sample gas option, take care to limit the total of purge

gas ow and highest ow of sample gas lines into the instrument to max.

2 l/min!

Take care of special conditions for safe use, and gas parameter specications

( S-11 and 1-12 )!

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Safety Instructions

EXPLOSION HAZARD BY HIGH PRESSURE

EXPLOSION AND ELECTRICAL SHOCK HAZARD

All cables (power and signal) must end (be connected) in either a safe (nonhazardous) area or in a protecting enclosure (e.g. Ex e junction box)!

The power and signal cables must be separated by a distance of minimum 1 cm (0.4 in) inside and outside the analyzer!

EXPLOSION HAZARD

Startup, operation and service must not be performed, before reading and understanding all instructions!

Especially all warnings in this and the associated manuals have to be considered! Inspection, maintenance and service must be carried out considering all related standards e.g. for „Inspection and maintenance of electrical installations in hazardous areas“ or „Equipment repair, overhaul and reclamation“.

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Consider the waiting time statement on the front door label before opening!

X-STREAM XEFD

Safety Instructions

EXPLOSION HAZARD: VAPOR RECOVERY APPLICATION

Disregarding the waiting time statement may result in explosion!

Temperatures of components for this application installed into the analyzer

exceed the analyzer's temperature classication for hazardous areas!

HEAVY INSTRUMENT HAZARD

X-STREAM XEFD analyzers, to which this manual relates, intended to be wall mounted and/or outdoor installed, weigh up to approx. 63 kg (139 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 specied to be used for the weight of

the units!

Take care the wall or stand the unit is intended to be installed at is solid and stable to hold the units!

Safety Instructions

HIGH TEMPERATURES HAZARD

While working at internal components hot surfaces may be accessible, even after the instrument has been disconnected from power!

HOW TO STAY IN COMPLIANCE WITH THE

EUROPEAN DIRECTIVE 94/9/EC ("ATEX") WHEN PERFORMING GAS

ANALYSIS WITHIN A FLAMEPROOF ENCLOSURE.

Special conditions apply to using a ameproof enclosure analyzer under the scope of the

"European Directive for Equipment used in Explosive Atmosphere" (Directive 94/9/EC;

ATEX). To stay compliant with the directive, consider the following clarication sheet released by the European ATEX Notied Body Group (see next page):

Emerson Process Management GmbH & Co. OHG S-11

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Safety Instructions

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This analyzer contains an internal battery!

X-STREAM XEFD

Safety Instructions

EXPLOSION HAZARD BY INTERNAL BATTERY

Safety Instructions

Do NOT OPEN the analyzer enclosure if explosive atmosphere may be present!

Disregarding may cause explosion even if the analyzer is de-energized!

CRUSHING HAZARD

Take care of crushing hazard when closing the front door of analyzer eld

housings!

Keep out of the closing area between enclosure cover and base!

OPERATION AT LOW TEMPERATURES

When operating an instrument at temperatures below 0 °C (32 °F), do NOT apply gas nor operate the internal pump before the warmup time has elapsed!

Violation may result in condensation inside the gas paths or damaged pump diaphragm!

HIGH TEMPERATURES

Hot parts may be exposed when working on photometers and/or heated components in the unit.

Emerson Process Management GmbH & Co. OHG S-13

X-STREAM XEFD

GENERAL OPERATING NOTES

HAZARD TO LIFE AND EXPLOSION HAZARD BY EXHAUST GASES

Exhaust gases may contain hydrocarbons and other toxic gases such as carbon monoxide.

Faulty gas connections may lead to explosion and death.

Ensure that all gas connections are connected as labelled and airtight.

Instruction Manual

HASXEDE-IM-EX

03/2012

General Operating Notes

• The unit must be installed in a clean and dry area, protected from strong vibrations and frost

• The unit must not be exposed to direct sunlight and sources of heat. Admissible ambient temperatures (see technical details) must be adhered to.

• Gas inlets and outlets must not be interchanged.All gases must be conditioned, before sup-

plied to the unit. When using this unit with corrosive sample gases, ensure that these gases do not contain components harmful to the gas lines.

• Admissable pressure for all applied gases is 1500 hPa (consider special conditions for safe use)!.

• Exhaust lines must be laid inclined downwards, depressurized, protected from frost and according to applicable regulations.

• If it is necessary to disconnect the gas lines, the unit’s gas connectors must be sealed with

PVC caps to avoid polluting the internal gas lines with condensate, dust, etc.

• To ensure electromagnetic compatibility (EMC), only shielded cables (supplied by us on request, or of equivalent standard) may be used. The customer must ensure that the shielding is correctly tted. Shielding must be electrically connected.

Emerson Process Management GmbH & Co. OHGS-14

Instruction Manual

HASXEDE-IM-EX 03/2012

1.1 Overview

X-STREAM XEFD

Chapter 1

Technical Description

The new X-STREAM ameproof gas analyzers are designed to be used in hazardous areas. The flameproof enclosure can be

installed at Zone 1 and Division 2 locations without the need of any additional protective measures, e.g. purge gas supply.

1.2 Design Features

Packaged into a cast aluminum enclosure, the X-STREAM XEFD gas analyzer provides

all the measurement options available for general purpose instruments, but for installation

at locations, where explosive gas atmosphere might be present frequently (Zone 1) or occasionally (Zone 2, Division 2).

The basic concept used to protect the surrounding atmosphere from being ignited, if an

internal failure results in high temperatures,

ames or even an explosion, is to keep the

explosion inside the enclosure and quench all

ames possibly passing through the ange.

To provide adequate explosion protection the

X-STREAM ameproof analyzer feature:

•

a cast aluminum enclosure, designed to

• withstand an internal explosion,

• quench ames resulting from an internal

explosion (thus preventing a surroun-

ding explosive atmoshere from being

ignited).

• ame arrestors avoiding ame transmissi-

on from the gas paths into the surrounding atmosphere.

• approved cable glands (option: conduits), protecting the cable inlets and outlets.

Techn. Description

1: Enclosure base

2: Screws

3: Enclosure cover

Fig. 1-1: Frontal View

Emerson Process Management GmbH & Co. OHG 1-1

4: Flange

5: Eyebolts for lifting

6: Hinges

X-STREAM XEFD

1.3 Protective Measures in Detail

The cast aluminum enclosure consists of two

parts: base and cover, connected by hinges.

The area where the two parts are in contact

is designed to work as a ange, quenching ames entering the small path between them.

When operated, the analyzer enclosure has to

be closed and secured by 20 screws evenly arranged all over the ange. The ame path between the ange parts is manufactured with very low tolerances and best atness, to ensure the function of quenching ames.

For this reason, it is of particular importance

to keep the anges surfaces free of scratches and other damages!

The only openings penetrating the enclosure

are threads, to be used for gas and cable in-

and outlets: Depending on the measurement application

the instrument provides up to 8 gas in- and

outlets, each protected by an approved ame

arrestor. These arrestors are installed into

threads at the bottom side of the enclosure base. Two tting sizes are available for ex-

ternal connection of gas pipes with 3.18 mm (1⁄8") or 6.35 mm (1⁄4") outer diameter (OD).

Instruction Manual

HASXEDE-IM-EX

03/2012

Optionally a clamping ring for 6 mm OD may be used, replacing the 6.35 mm version.

Cables are fed into the enclosure utilizing up to 4 cable glands, located at the enclosure`s bottom right side. The approved glands ac-

cept 3 different internal elastomeric sealing rings with different internal diameters, sup-

porting a wide range of cables. For installation in North America cable glands

are replaced by a combination of conduits and

metric-to-NPT thread adapters.

All threads are designed to act as a ame

path of a length ensuring that possibly entering flames are quenched before exiting to the external atmosphere. For this reason, avoid to damage the threads, neither externally nor internally!

Unused threads must be closed with plugs

when the instrument is operated to ensure explosion protection.

Note!

See the X-STREAM series instruction manuals for more information about common gas analyzers features, and special features of the X-STREAM XEFD.

Fig. 1-2: Bottom View

1 2 3 4

1: Plugged when not used

2: Gas tting (part of ame arrestor)

3: Plug

4: Cable gland (or conduits)

Emerson Process Management GmbH & Co. OHG1-2

Instruction Manual

HASXEDE-IM-EX 03/2012

1.4 High Pressure Option / Purge Option

Normally ameproof housings are permitted

to operate under atmospheric conditions only, that is within an ambient pressure range between 800 and 1100 hPa.

For analyzers this pressure range also applies to the gas pressure within the containment system. While the lower limit is not critical,

the higher is, because it lowers the permitted sample gas (and calibration gases) pressures by 400 hPa, compared to general purpose

analyzers. This results in higher requirements for the sample handling system, as it has to safely reduce the process gas pressure to the permitted range.

Another aspect to take care for when ope-

rating ameproof analyzers is the option of

applying a purge gas to the enclosure when

measuring low concentrations of gases, being constituent of the ambient air: The ambient air

inside the analyzer enclosure cross interfe-

rese with the sample gas and inuences the

measuring results. By purging the housing with a gas free of the measured component,

this can be avoided, but could increase the

pressure inside the analyzer and so would violate the atmospheric pressure condition.

X-STREAM ameproof analyzers have been subjected to additional tests to support both

situations:

X-STREAM XEFD

Higher gas pressure is specied to be within

the range of 1100 hPa to 1500 hPa. The maxi-

mum permitted ow is 1,5 l/min, depending on

the installed measurement system lower limits may apply.

The gas paths need additionally to be protected by suitable inline ame arrestors, designed and

approved for the applied higher gas pressure

and for the area of installation. These ame arrestors need to be installed outside the analyzer and in addition to the ame arrestors provided by the analyzer.

Note!

The external inline flame arrestors are not

subject of the analyzer certication and may

be provided by the customer, or optionally by EMERSON PROCESS MANAGEMENT.

A separate analyzer ame arrestor has to be installed, operating as a breathing device and

so limiting the increase of pressure in the enclosure in case of internal leakage.

Purging the housing with clean gas when measuring low concentrations

The maximum permitted gas ow is 2 l/min. The gas must be supplied via a separate ame arrestor. Another ame arrestor must be installed, operating as a breathing device and so limiting

the increase of pressure in the enclosure.

Techn. Description

• higher sample and calibration gas pres-

sures

as well as

• purging the housing with a gas for best

measuring results at low concentrations.

To permit this, special additional conditions

must be taken into account:

High sample and calibration gas pressures

Emerson Process Management GmbH & Co. OHG 1-3

When making use of any of above mentioned options, take care of the special conditions given in the technical data section, and in chapter 2 (installation instructions)!

EXPLOSION HAZARD

X-STREAM XEFD

1.5 Compliances

1.5 Explosion Protection Compliances

Instruction Manual

HASXEDE-IM-EX

03/2012

These products are available in two different variations, separately certied by agencies for the use in hazardous (classied) areas:

The one variation, to be equipped with cable glands, is certied by Fyzikálně technický zkušební ústav, s.p (FTZÚ), an European Notied Body under the Directive 94/9/EC („ATEX“) and conforms to the provisions of

EN 60079-0 and EN 60079-1. See appendix for a copy of the EC type examination

certicate. The second variation, to be equipped with

metric-to-NPT adapters and conduits (these components are not part of the instrument

certication), is certied by the Canadian Standards Association, an „OSHA Nationally Recognized Testing Laboratory“ (NRTL), for

Canada and USA and conforms to the provisions of CAN/CSA-E60079-0:02 (R2006), CAN/CSA-E60079-1:02 (R2006), ANSI/ ISA-12.00.01-2002 (IEC 60079-0 Mod), ANSI/ ISA-12.22.01-2002 (IEC 60079-1 Mod). Furthermore, these X-STREAM X2FD analyzers

are certied for use in Class I, Division 2,

Group BCD T3 areas.

See appendix for a copy of the CSA Certicate

of Compliance.

The following certication markings apply to

the products:

European Union (EU, ATEX)

Category 2, Zone 1: Ex d IIB+H2 T4 Gb

EC ATEX Type Examination Certicate:

FTZU 08 ATEX 0028 X.

IECEx

Ex d IIB+H2 T4 Gb

Conforms to the provisions of the „Equipment intended for use in Potentially Explosive At-

mospheres (ATEX)“ Directive 94/9/EC, EMC

Directive 2004/108/EC and CE Directive 93/68/EEC.

USA

Class I, Zone 1, AEx d IIB+H2 T3 Class I, Division 2, Group BCD T3

IECEx certication enables worldwide approvals with minimized need of testing.

Canada

Class I, Zone 1, Ex d IIB+H2 T3

Certicate of Compliance 1714037X

Emerson Process Management GmbH & Co. OHG1-4

Instruction Manual

HASXEDE-IM-EX 03/2012

1.5 Compliances

1.5.1 Special Conditions for Safe Use

X-STREAM XEFD

• Only screws M16x45 ISO 4762 A2-70 as specied in the maintenance section of this manual shall be used (spare part #

42716945).

• The ame joints correspond to the drawing

No. 4.271-7112/1 and do not comply with

the dimensions mentioned into the Tab. 1 and Tab. 2 of EN 60079-1 ed.2.

• The gas path for the sample gas shall be equipped with additional appropriate ame arrestors in case of gas pressure above

1100 hPa to 1500 hPa.

• Appropriate certied cable glands shall be

used in accordance with IEC/EN 60079-14.

• Vapor Recovery application:

Pressure of gases not to exceed 1100 hPa.

Concentration of gases must be below

25 % LEL.

• Depending on the particular application all approbriate safety instructions mentioned

in this instruction manual on hand must

be considered!

• Take special care of formation of ammable gas at the outlet of breathing and/or

purging devices, if the sample gas con-

centration is above 25% LEL! If need be, such outlets have to end in a safe area!

Techn. Description

Emerson Process Management GmbH & Co. OHG 1-5

Instruction Manual

X-STREAM XEFD

1.6 Nameplate Label

CSA-C/US versionATEX version

Area Description Area Description

The analyzer´s electrical data, manufac-

turing data and serial number

Manufacturer address

HASXEDE-IM-EX

03/2012

Certication Data

Area classication

Protection concepts

Additional Division Marking, if applicable

Certicate numbers

Other

IECEx /

EU (ATEX)

II other than mines 2 Category 2 Equipm. (Zone 1) G for explosive Gas atmosphere Ex Explosion protected

d ameproof IIB+H

Group II, Gas Group B

plus Hydrogen

T4 Temperature Class (135 °C) Gb Equipment Protection Level

Ambient Temperature Range

amb

IP66, Type 4X Enclosure Rating

(outdoor use)

IECEx FTZU 08.0004X FTZU 08 ATEX 0028 X

CE mark, number of Notied

Body for Quality assessment

North America (CSA)

Class I Flammable gases, vapors or liquids

Zone 1 Zone 1 areas

AEx Explosion protected (US) Ex Explosion protected (CAN) d ameproof IIB+H

Group II, Gas Group B

plus Hydrogen T3 Temperature Class (200 °C)

Ambient Temperature Range

amb

IP66, Type 4X Enclosure Rating

(outdoor use)

Class I Flammable gases, vapors or liquids

Division 2 Division 2 areas Groups BCD all Gases, except

Acetylene T3 Temperature Class (200 °C)

1714037X

Instruction note where to install the explosion proof seal

Additional warning: Do not open the instrument while energized. Consult manual!

Fig. 1-3: Nameplate Label Details (exemplary)

Emerson Process Management GmbH & Co. OHG1-6

Instruction Manual

HASXEDE-IM-EX 03/2012

1.7 Technical Data

X-STREAM XEFD

1.7 Technical Data

Transport lugs to be removed after installation

Techn. Description

Flame arrestors with gas ttings

(enclosure threads: M18 x 1.5)

Fig. 1-4: Dimensions

Housing

Permissible operating ambient temperature range

Permissible storing ambient temperature range

Weight

Cable inlets

(enclosure threads; M20 x 1.5)

Eyebolt detail

All dimensions in mm [inches in brackets]

-30 °C to +50 °C (-22 °F to +122 °F)

-30 °C to +70 °C (-22 °F to +158 °F)

approx. up to 63 kg (139 lbs), (depending on analyzer conguration)

Protection class

Emerson Process Management GmbH & Co. OHG 1-7

IP 66 (EN 60529) / Type 4X for outdoor installation.

Analyzer must not be exposed to direct sun light

X-STREAM XEFD

1.7 Technical Data

Site of installation

Humidity (non-consending)

Pollution degree 2 Installation category II Altitude 0 to 6560 ft (2000 m) above sea level

Sourrounding atmosphere

General Purpose Compliances

Electrical safety

Canada / USA

< 90 % r.h. at +20 °C (68 °F) < 70 % r.h. at +40 °C (104 °F)

Analyzers must not be operated in corrosive atmosphere

CSA-C/US, based on CAN/CSA-C22.2 No. 61010-1-04 / UL 61010-1, 2nd Edition

Instruction Manual

HASXEDE-IM-EX

03/2012

Europe

CE, based on EN 61010-1

Electromagnetic compatibility

Europe CE, based on EN 61326 Australia C-Tick others NAMUR

Power supply

Rated input voltage

100 - 240 V 50 / 60 Hz Input voltage range 85 - 264 V 47 - 63 Hz Nominal input current

standard 1.3 - 0,7 A with temperature control 3 - 1.5 A

Gas connections

Quantity max. 8

Specication

ame arrestors with ttings

Sizes connections: 6/4 mm or 1⁄4“, stainless steel

Tab. 1-1: Generic Analyzer Data

Emerson Process Management GmbH & Co. OHG1-8

Instruction Manual

HASXEDE-IM-EX 03/2012

1.7 Technical Data

Standard interfaces

electrical

up to 5 analog outputs

(standard: 1 analog output per channel)

4 relay outputs

2 Modbus interfaces Ethernet (RJ45 sockets), 10/100 MBit

specication

function

electrical

specication

function

specication USB 1.0

4 (0)–20 mA (RB ≤ 500 Ω) optically isolated from each other and from analy-

zer electronics

user-congurable activation and deactivation of

concentration levels support for NAMUR NE 43 operation modes, con-

gurable via keypad and Modbus

dry contacts max. load. 30 V; 1 A; 30 W resistive

Each output can be congured to provide any of

the functions listed in chapter 6 of the X-STREAM XE instruction manual. These functions include,

but are not limited to

NAMUR NE 107 status signals 'Failure', 'Main-

tenance request', 'Out of specication', 'Function

check', concentration alarms, control signals for external valves or pumps,

and many more

X-STREAM XEFD

Techn. Description

1 USB connector type A,

2 USB ports

function

Tab. 1-2: Standard Interfaces Data

Emerson Process Management GmbH & Co. OHG 1-9

for connecting external storage devices

1 USB connector type mini AB, for connecting external computers

X-STREAM XEFD

Optional interfaces

Digital I/O board

7 or 14 digital inputs

9 or 18 additional relay outputs

1.7 Technical Data

max. 30 V, internally limited to 2.3 mA

electrical

specication

HIGH: min. 4 V; LOW: max. 3 V

common GND

Each input can be congured to any of

the functions listed in chapter 6 of the X-STREAM XE instruction manual, e. g.

function

Dry relay change-over contacts can be

electrical

used as NO or NC

specication

max. load. 30 V; 1 A; 30 W resistive Each output can be congured to provi-

de any of the functions listed in chapter 6 of the X-STREAM XE instruction manual

These functions include, but are not limited to

function

NAMUR NE 107 status signals 'Failure', 'Maintenance request', 'Out of specication', 'Function check',

concentration alarms, control signals for external valves or

pumps, and many more

Instruction Manual

HASXEDE-IM-EX

03/2012

Open valve Activate sample gas pump

Zero calibrate all channels Span calibrate all channels Zero and span calibrate all channels Abort calibration

Tab. 1-3: Optional Interfaces Data

Emerson Process Management GmbH & Co. OHG1-10

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