Emerson X-STREAM X2 Instruction Manual

Instruction Manual

HASXMDE-IM-EX
03/2012

Gas Analyzer

X-STREAM X2 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.

6th edition 03/2012

Rosemount Analytical
Process Gas Analyzer Center of Excellence
Emerson Process Management GmbH & Co. OHG

Industriestrasse 1
D-63594 Hasselroth
Deutschland
T [phone]
F [phone]
www.emersonprocess.de

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

Instruction Manual

HASXMDE-IM-EX
03/2012

X-STREAM X2FD

Table of ConTenTs

Preamble S-1

Denitions S-1

Terms used in this 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 ............................................1-14

1.9 Vapor Recovery Application (Simultaneous Measurement of CH4 and Non-CH4) ....1-18

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 ...................................................2-5

2.3.1 Special Conditions ...................................................2-6

2.3.2 Gas Conditioning ....................................................2-8

2.4 Electrical Installation ....................................................2-9

Chapter 3 Startup 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 used .........................................................3-4

Emerson Process Management GmbH & Co. OHG TOC-1

Instruction Manual

X-STREAM X2FD

Table of Contents

3.5 The user interface ......................................................3-5

3.5.1 Display ............................................................3-6

3.5.2 Status LED .........................................................3-6

3.5.3 Keys 3-7

3.6 Software .............................................................3-9

3.6.1 Navigating and editing ................................................3-9

3.6.2 Access levels ...................................................... 3-11

3.6.3 Special messages ...................................................3-12

3.7 Powering up .........................................................3-13

3.7.1 Boot sequence .....................................................3-13

3.7.2 Measurement display ................................................3-13

3.8 Selecting the language .................................................3-14

3.9 Calibrating the analyzer ................................................3-15

3.9.1 Preparing Calibrations ...............................................3-16

3.9.2 Manual Calibration ..................................................3-18

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Chapter 4 Service and Maintenance 4-1

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

4.1.1 Routine Tests on Analyzer .............................................4-3

4.1.2 Tests on Flame Arrestors ..............................................4-4

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 Calibration ..................................................4-16

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

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

A.4 Block diagram ........................................................A-19

A.5 Assignment of Terminals and Sockets .....................................A-24

Emerson Process Management GmbH & Co. OHGTOC-2

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X-STREAM X2FD

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 ..................................................1-12

Fig. 1-6: Power terminals / fuse holders ........................................1-13

Fig. 1-7: Vapor Recovery Gas Flow Diagram ....................................1-18

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

Fig. 2-2: Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Fig. 2-3: Flame arrestor installed into instrument enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Fig. 2-4: Flame arrestor elements, exemplarly considering FA 01 .....................2-5

Fig. 2-5: Exemplary diagram for a single channel unit with purge option ................2-6

Fig. 2-6: Exemplary diagram for a single channel instrument for high gas pressure ......2-7

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

Fig. 2-8: Allocation of terminals ..............................................2-13

Fig. 2-9: Terminals block X1 - analog signals and relay outputs 1-4 ..................2-15

Fig. 2-10: Terminals block X1 - Modbus interface ................................2-16

Fig. 2-11: Modbus Interface - Ethernet connector ................................2-17

Fig. 2-12: Terminal blocks X4.1 and X4.2 - Digital inputs and outputs ................2-18

Fig. 2-13: Power terminals ..................................................2-19

Fig. 2-14: Equipotential bonding conductor terminal ..............................2-20

Table of Contents

TOC

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

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

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 ................................................4-10

Fig. 4-5: Converter assembly details ..........................................4-10

Fig. 4-6: Heated jacket .....................................................4-11

Fig. 4-7: Converter, laid open ................................................4-11

Fig. 4-8: Converter lling sequence ...........................................4-12

Fig. 4-9: Jacket in converter assembly ........................................4-13

Fig. 4-10: Heated jacket ....................................................4-13

Fig. 4-11: Converter metallic cover ...........................................4-13

Fig. 4-12: Location of Overtemperature Protection Device .........................4-14

Emerson Process Management GmbH & Co. OHG TOC-3

Instruction Manual

X-STREAM X2FD

HASXMDE-IM-EX

03/2012

Index of Tables

Tab. 1-1: Gas Components and Measuring Ranges, examples ......................1-14

Tab. 1-2: NDIR/UV/VIS, TCD - Standard Measurement Performance Specications .....1-15

Tab. 1-3: Trace Moisture - Standard Measurement Performance Specications .........1-15

Tab. 1-4: Oxygen - Standard Measurement Performance Specications ..............1-16

Tab. 1-5: Special Performance Specications for Gas Purity Measurements ...........1-17

Emerson Process Management GmbH & Co. OHGTOC-4

Instruction Manual

HASXMDE-IM-EX
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X-STREAM X2FD

PREAMBLE

This instruction manual provides information about installing, operating and maintaining/
servicing X-STREAM X2 series 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 X2FD series analyzer variations and

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

Safety Instructions

DEFINITIONS

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.

S

NOTE

Highlights an essential operating procedure, condition or statement.

Emerson Process Management GmbH & Co. OHG S-1

X-STREAM X2FD

Instruction Manual

HASXMDE-IM-EX

03/2012

TERMS USED IN THIS MANUAL

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.)

Emerson Process Management GmbH & Co. OHGS-2

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X-STREAM X2FD

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

S

Emerson Process Management GmbH & Co. OHG S-3

Instruction Manual

X-STREAM X2FD

HASXMDE-IM-EX

03/2012

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 X2FD

SAFETY INSTRUCTIONS

Intended Use Statement

X-STREAM X2 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 X2 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.

S

• 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

X-STREAM X2FD

Safety Instructions

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03/2012

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 X2FD 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:

HASX2E-IM-HS X-STREAM X2 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

Instruction Manual

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Do not open instrument when energized.

X-STREAM X2FD

Safety Instructions

POSSIBLE EXPLOSION HAZARD

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.

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.

Safety Instructions

S

EXPLOSION HAZARD

The X-STREAM X2FD 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 X2FD

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.

Instruction Manual

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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

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!

Emerson Process Management GmbH & Co. OHGS-8

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Temperatures inside an analyzer for VAPOR RECOVERY applications

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

Special conditions apply to handling and operating this analyzer, consider
the safety instructions at the beginning of this manual!

The analyzer model X-STREAM X2FD, to which this manual relates, intended
to be wall mounted and/or outdoor installed, weighs up to approx. 63 kg
(139 lbs), depending on included options!

X-STREAM X2FD

Safety Instructions

EXPLOSION HAZARD BY HOT COMPONENTS

Safety Instructions

S

HEAVY INSTRUMENT

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!

HIGH TEMPERATURES

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

, even

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 to 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-9

X-STREAM X2FD

Instruction Manual

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Safety Instructions

Emerson Process Management GmbH & Co. OHGS-10

Instruction Manual

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1.1 Overview

X-STREAM X2FD

Chapter 1

Technical Description

The new X-STREAM X2FD gas analyzer is

designed to be used in hazardous areas.
Its ameproof 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 X2FD 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 X2FD analyzer features:

•

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

3

5

2

6

Fig. 1-1: Frontal View

Emerson Process Management GmbH & Co. OHG 1-1

4

1

1: Enclosure base

2: Screws
3: Enclosure cover
4: Flange

5: Eyebolts for lifting

6: Hinges

X-STREAM X2FD

1.3 Protective Measures in Detail

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 only ope-

nings penetrating the enclosure are threads,

to be used for gas and cable in- and outlets:

Instruction Manual

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

For installation in North America cable glands
are replaced by a combination of conduits and

metric-to-NPT thread adapters.

All threads provide a ame path of a length
ensuring that possibly entering ames are
quenched before reaching the external at-

mosphere.

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).
Optionally a clamping ring for 6 mm OD may
be used, replacing the 6,35 mm version.

Unused threads must be closed with plugs

when the instrument is operated to ensure
explosion protection.

Note!

See the X-STREAM X2 series instruction
manual for more information about common
X-STREAM X2 series gas analyzers fea­tures and special features of the X-STREAM
X2FD.

1: Plugged when not used

2: Gas tting (part of ame arrestor)

3: Plug

4: Cable gland (or conduits)

Fig. 1-2: Bottom view

1 2 3 4

Emerson Process Management GmbH & Co. OHG1-2

Instruction Manual

HASXMDE-IM-EX
03/2012

1.4 High Pressure Option / Purge Option

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 X2FD analyzers have been
subjected to additional tests to support both

situations:

X-STREAM X2FD

ximum 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, de-

signed 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 ame 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

thus 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

1

• 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:

Higher sample and calibration gas pres­sures

Higher gas pressure is specied to be within

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

Emerson Process Management GmbH & Co. OHG 1-3

EXPLOSION HAZARD

When making use of any of
above mentioned options, take
care of the special conditions
for safe use given on the next
page!

X-STREAM X2FD

1.5 Compliances

1.5 Explosion Protection Compliances

Instruction Manual

HASXMDE-IM-EX

03/2012

This product is available in two different varia­tions, separately certied by agencies for the
use in hazardous (classied) areas:

The one version, 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 analy-

zers 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

HASXMDE-IM-EX
03/2012

1.5 Compliances

1.5.1 Special conditions for safe use

X-STREAM X2FD

• 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).

• 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.

Concentrations 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

1

Emerson Process Management GmbH & Co. OHG 1-5

Instruction Manual

X-STREAM X2FD

1.6 Nameplate Label

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

HASXMDE-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

2

plus Hydrogen

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

Ambient Temperature Range

T

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

2

plus Hydrogen
T3 Temperature Class (200 °C)

Ambient Temperature Range

T

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

HASXMDE-IM-EX
03/2012

1.7 Technical Data

X-STREAM X2FD

1.7 Technical Data

Transport lugs to be removed after installation

Techn. Description

1

Flame arrestors with gas ttings

(enclosure threads: M18 x 1.5)

(enclosure threads; M20 x 1.5)

Cable inlets

Eyebolt detail

All dimensions in mm
[inches in brackets]

Fig. 1-4: Dimensions

Housing

Permissible operating ambient temperature range -30 °C to +50 °C (-22 F to +122 F)
Permissible storing ambient temperature range -30 °C to +70 °C (-22 F to +158 F)

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

Protection class:

IP 66 (EN 60529) / Type 4X for outdoor in-

stallation (if applicable, see nameplate label !)
Analyzer must not be exposed to direct

sun light

Gas ttings: quantity: max. 8
specication: ame arrestors with ttings

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

Emerson Process Management GmbH & Co. OHG 1-7

Instruction Manual

X-STREAM X2FD

HASXMDE-IM-EX

1.7 Technical Data

Site of installation

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

Pollution degree 2
Installation category I I

Altitude 0 to 6560 ft (2000 m) above sea level
Sourrounding atmosphere Analyzers must not be operated in

corrosive atmosphere.

General Purpose Compliances

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

03/2012

Europe CE, based on EN 61010-1

Electromagnetic compatibility
Europe CE, based on EN 61326

other NAMUR

Power supply

Rated input voltage 100 - 240 V 50/60 Hz, wide range input
Power supply voltage uctuations are

not to exceed +/- 10 % of the nominal

supply voltage!

Input voltage range 85 - 264 V , 47 - 63 Hz

Nominal input current
standard 1.3 - 0.7 A max.
with temperature control 3 - 1.5 A max.

Emerson Process Management GmbH & Co. OHG1-8

Instruction Manual

HASXMDE-IM-EX
03/2012

1.7 Technical Data

Interfaces, signal inputs / outputs

up to 4 analog outputs channel 4 (0) - 20 mA (RB < 500 Ω)
(Standard: 1 analog output per channel) optically isolated from each other and
from other electronic components;

user-congurable activation and
deactivation concentration levels;
support for NAMUR NE 43 operation

modes, congurable via keypad and
Modbus

4 relay outputs dry contacts,
max. load. 30 V; 1 A; 30 W resistive

X-STREAM X2FD

Techn. Description

1

Each output can be congured to one of the
following functions: NAMUR NE 107 status signal

“Failure”

“Out of specication”
“Function check”

Control signals for

external valve V1 ... V8,
external sample gas valve
external pump
Zoom status for analog outputs

Optional interfaces for all models

1 Modbus interface RS 485 (2 or 4 wire)

optional:
RS 232
Ethernet (RJ45 socket)

Digital inputs and outputs

“Maintenance request”

1 of 2 concentration limits per channel,

7 or 14 digital outputs max. 30 V, internally limited to 2.3 mA
HIGH: min. 4 V; LOW: max. 3 V
(common GND)

Emerson Process Management GmbH & Co. OHG 1-9

Instruction Manual

X-STREAM X2FD

HASXMDE-IM-EX

03/2012

1.7 Technical Data

Each input can be congured to one of the
following functions: Open valve V1 ... V8
Open sample gas valve

Activate sample gas pump
Zero calibrate all channels

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

Zoom analog output 1
Zoom analog output 2
Zoom analog output 3
Zoom analog output 4

9 or 18 additional relay outputs dry contacts,
max. load. 30 V; 1 A; 30 W resistive

Each output can be congured to one of the

following functions: NAMUR NE 107 status signal

“Failure”

“Maintenance request”
“Out of specication”
“Function check”

1 of 2 concentration limits per channel,
Control signals for

external valve V1 ... V8,
external sample gas valve
external pump
Zoom status display for analog outputs

Emerson Process Management GmbH & Co. OHG1-10

Instruction Manual

HASXMDE-IM-EX
03/2012

1.7 Technical Data

High sample and calibration gas pressures

X-STREAM X2FD

High gas pressure
care

Maximum ow 1,5 l/min.

Special conditions:
tected by suitable inline ame arrestors, designed
and approved for the applied higher gas
pressure. These inline ame arrestors need to be
installed outside the analyzer and in addition

to the ame arrestors provided by the analy
zer. A separate analyzer ame arrestor has
be installed, operating as a breathing device.

Connection of breathing device:
(exhaust) can be open to the ambience of the

analyzer, if the measured gas concentration is
below 25 % V-V LEL. Otherwise it must end
in a safe area.

Purging the housing with clean gas when e.g. measuring low concentrations

Maximum gas ow 2 l/min.

Permitted purge medium: Inert gas or air. Dry, clean, free of corrosives
or components containing solvents, and free
of components to be measured.
Its temperature must correspond to the am­ bient temperature of the analyzer, but be at
least within the range 20–35 °C (68–95 °F).

Above 1100 hPa to max. 1500 hPa (take

of the measurement principles limits!)

The gas paths need additionally to be pro-

to

The external output of the breathing device

Techn. Description

1

Special conditions:

ame arrestor. Another ame arrestor must
be installed, operating as a breathing device.

Connection of breathing device: The external output of the breathing device
(exhaust) can be open to the ambience of the

analyzer if inert gas is used as purge medium.
If air is used, the output must end in a safe
area, if the measured gas concentration is above
25 % V-V LEL.

Take care of special conditions for safe use (

Emerson Process Management GmbH & Co. OHG 1-11

The medium must be supplied via a separate

S-5 or 1-5 ) !

Instruction Manual

X-STREAM X2FD

HASXMDE-IM-EX

1.7 Technical Data

Signal inputs and outputs

All signal cables are connected to internal
screw-type terminals (g. 1-5), except the optional RJ45 ethernet connector.

Cable cross-section: max. 1.5 mm2 (14 AWG),

end sleeves not required.

Cable entry via three IP 68 cable glands or conduits

03/2012

Permissible cable outer diameter:

see cable gland / conduit specication

Available signals: standard: Analog signal outputs

Relay status signals
Modbus interface (RS232; RS 485)
optional: Digital inputs/outputs

Modbus RJ45 ethernet connector
Detailed terminals conguration „Chapter 2

Installation“

Fig. 1-5: Signals terminals

Note!

Depending on the actual analyzer conguration
not all shown terminals may be provided!

Emerson Process Management GmbH & Co. OHG1-12

Instruction Manual

HASXMDE-IM-EX
03/2012

X-STREAM X2FD

1.7 Technical Data

Power Connection

Connection via internal screw terminals near
cable entries, (g. 1-6).
Cross section: max. 4 mm2 (10 AWG), end sleeves not
required

Cable entry via 1 cable gland, classied IP 68 or suitable
conduit with metric-to-NPT adaptor

Permissible outer cable diameter for power
cord:

see cable gland / conduit specication

Power supply fuses

The power terminals integrate fuse holders.
Fuse ratings: AC 230 V / T 4 A / 5x20 mm

1 Power terminals with integrated
fuse holders
2 Protective earth terminal (PE)

3 Power cable entry
4 EMI power supply lter

4

Techn. Description

1

1

3

2

Fig. 1-6: Power terminals / fuse holders

Emerson Process Management GmbH & Co. OHG 1-13

Instruction Manual

X-STREAM X2FD

HASXMDE-IM-EX

03/2012

1.8 Measurements Specications

1.8 Measurements Specications

Sample gas components and measuring ranges (standard congurations)

In total, more than 60 gases are detectable, so the following table gives an overview only.
Consult with Emerson for gases / congurations not listed.
Not all data is applicable to all analyzer variations. The sample gas(es) and measuring ranges
for your specic analyzer are given by the order acknowledgement and on the analyzer's name
plate label.

Acetone
Acetone
Acetylene C2H
Ammonia NH
Argon Ar TCD 0–50 % 0–100 %

Carbon dioxide CO
Carbon monoxide CO IR 0–10 ppm

Chlorine Cl
Ethane C2H
Ethanol
Ethylene C2H
Helium He TCD 0–10 % 0–100 %
Hexane
Hydrogen

Hydrogen Sulde H2S UV 0–2 % 0–10 %
Hydrogen Sulde H2S IR 0–10 % 0–100 %

Methane CH
Methanol
n–Butane C4H
Nitrogen dioxide
Nitrogen monoxide NO IR 0–100 ppm 0–100 %
Nitrous oxide N2O IR 0–100 ppm 0–100 %

Oxygen O
Oxygen O
Oxygen, Trace O

Propane C3H
Propylene C3H
Sulfur dioxide SO
Sulfur dioxide SO
Sulfur hexauoride SF
Toluene
Vinyl chloride C2H3Cl IR 0–1000 ppm 0–2 %
Water vapor

Water vapor, Trace

1

Dew point below ambient

temperature

Gas component Principle

1

1

1

1

4

1

1

1

CH3COCH
CH3COCH

2

3

2

2

6

C2H5OH IR 0–1000 ppm 0–10 %

4

C6H

14

H

2

4

CH3OH IR 0–1000 ppm 0–10 %

1

NO

C7H

10

2

2

2

2

8

6

2

2

6

8

H2O IR 0–1000 ppm 0–8 %

1

H2O capacitive 0–100 ppm 0–3000 ppm

2

Higher concentrations
decrease sensor lifetime

3

3

UV 0–400 ppm 0–3 %

IR 0–500 ppm 0–3 %
IR 0–3 % 0–100 %
IR 0–100 ppm 0–100 %

IR 0–5 ppm

UV 0–300 ppm 0–100 %

IR 0–1000 ppm 0–100 %

IR 0–400 ppm 0–100 %

IR 0–100 ppm 0–10 %

TCD 0–1 % 0–100 %

IR 0–100 ppm 0–100 %

IR 0–800 ppm 0–100 %

UV 0–25 ppm

electrochem. 0–5 % 0–25 %

paramagn. 0–1 % 0–100 %

electrochem. 0–10 ppm 0–10 000 ppm

IR 0–1000 ppm 0–100 %
IR 0–400 ppm 0–100 %

UV 0–25 ppm

IR 0–1 % 0–100 %
IR 0–5 ppm

UV 0–300 ppm 0–5 %

3

Special Specs

or Conditions

Lowest

Range

5

5

3

3

3

Daily zero calibration re­quired for ranges below

lowest standard specs range

Standard Specs

(see Tab. 1-2 – 1-4)

Lowest

Range

0–50 ppm 0–100 %
0–50 ppm 0–100 %

0–50 ppm 0–10 %

0–50 ppm 0–1 %

0–20 ppm 0–2 %

4

Special "renery" applica­tion with 0–1% H2 in N2

available

Highest

Range

2

5

see Tab. 1-5

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

Emerson Process Management GmbH & Co. OHG1-14