Emerson Process Management HASX2E-IM-HS User Manual
Instruction Manual
HASX2E-IM-HS
02/2012
Gas Analyzers
X-STREAM X2 Series
Instruction Manual
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 specications.
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 clarication.
• 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 specied 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 qualied personnel to install, operate, update,
program, and maintain the product.
• When replacement parts are required, ensure that qualied people use replacement
parts specied 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 qualied persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice.
10th edition, 02/2012
X-STREAM and IntrinzX are marks of one of the Emerson group of companies.
All other marks are property of their respective owners.
Rosemount Analytical
Process Gas Analyzer Center of Excellence
Emerson Process Management GmbH & Co. OHG
Industriestrasse 1
D-63594 Hasselroth
Deutschland
T +49 (0) 6055 884-0
F +49 (0) 6055 884-209
www.emersonprocess.de
Instruction Manual
HASX2E-IM-HS
02/2012
SHORT FORM GUIDE FOR THIS MANUAL
X-STREAM X2
To nd information about see chapter
Safety instructions ..................................................... S
The different instruments designs
The instruments technical data
Measuring principles characteristics
How to install the instruments
st
startup procedures,
1
.............................1
..................................2
........................3
...................................4
checking the instrument´s setup ..............................5
Software menu structure, how to navigate
and menu entries descriptions
Basic procedures (e.g. calibration)
..................................6
............................7
Table of contents
TOC
Maintenance procedures
Status messages and troubleshooting
Modbus parameters
Service information
....................................................10
Block diagrams, terminals & connectors
Index of phrases
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........................................................IDX
............................................7
.....................8
...................................................9
................. A
Instruction Manual
X-STREAM X2
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02/2012
Table of ConTenTs
Introduction S-1
Denitions S-1
Terms Used in This Instruction Manual .........................................S-2
Symbols Used on and Inside the Unit
Symbols Used in This Manual ................................................S-4
Safety Instructions S-5
Intended Use Statement..................................................... S-5
General Safety Notice / Residual Risk ..........................................S-5
Authorized Personnel.......................................................S-6
Additional Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Installing and Connecting the Unit .............................................S-7
Operating and Maintaining This Unit ........................................... S-7
.......................................... S-3
Chapter 1 Technical Description 1-1
1.1 Overview .............................................................1-3
1.1.1 The Front Panel.......................................................1-3
1.2 Conguration of Gas Lines ...............................................1-4
1.2.1 Materials Used .......................................................1-4
1.2.2 Safety Filter..........................................................1-4
1.2.3 Inlets and Outlets .....................................................1-4
1.2.4 Pipework ............................................................1-4
1.2.5 Infallible Containments .................................................1-4
1.2.6 Optional Components for Gas Lines.......................................1-5
1.2.7 Alternative Congurations ...............................................1-8
1.3 Interfaces.............................................................1-9
1.3.1 Analog Outputs .......................................................1-9
1.3.2 Status Relays ........................................................1-9
1.3.3 Optional Interfaces ...................................................1-10
1.4 Comparison of the Various X-STREAM Analyzer Models .......................1-12
1.5 X-STREAM X2GK: ½19 Inch Table-Top Unit.................................1-14
1.6 X-STREAM X2GP: 19 Inch Table-Top or Rackmount Design ....................1-17
1.7 X-STREAM X2XF: Field Housing With (XLF) Single Or (XXF) Dual Compartment....1-20
1.7.1 Field Housing for Installation in Hazardous Areas (Ex-Zones) ..................1-26
1.8 X-STREAM X2FD: Cast Aluminum Flameproof Housing........................1-27
Chapter 2 Technical Data 2-1
2.1 Common Technical Data .................................................2-2
2.2 Model-Specic Technical Data.............................................2-5
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Table of Contents
2.2.1 X-STREAM X2GK: ½19 Inch Table-Top Unit.................................2-5
2.2.2 X-STREAM X2GP: 19 Inch Table-Top and Rack-Mount Models ................2-12
2.2.3 X-STREAM X2XF: Single (XLF) or Dual (XXF) Compartment Field Housing.......2-15
2.2.4 X-STREAM X2FD: Flameproof Housing...................................2-19
2.3 Information on Name Plate ..............................................2-22
X-STREAM X2
Table of contents
Chapter 3 Measuring Principles 3-1
3.1 Infrared Measurement (IR), Ultraviolet Measurement (UV).......................3-1
3.1.1 IntrinzX Technology....................................................3-1
3.1.2 NDIR Detector........................................................3-3
3.1.3 Technical Implementation ...............................................3-4
3.2 Oxygen Measurement ...................................................3-5
3.2.1 Paramagnetic Measurement.............................................3-5
3.2.2 Electrochemical Measurement ...........................................3-8
3.2.3 Electrochemical Trace Oxygen Measurement...............................3-11
3.3 Thermal Conductivity Measurement .......................................3-13
3.3.1 Principle of Operation .................................................3-13
3.3.2 Technical Implementation ..............................................3-14
3.4 Trace Moisture Measurement ............................................3-15
3.4.1 Special Operating Conditions ...........................................3-16
3.4.2 Accompanying Gases .................................................3-17
3.5 Measurement Specications .............................................3-19
Chapter 4 Installation 4-1
4.1 Scope of Supply........................................................4-1
4.2 Introduction ...........................................................4-2
4.3 Gas Conditioning .......................................................4-3
4.4 Gas Connections .......................................................4-5
4.5 Electrical Connections ...................................................4-7
4.6 Analyzer Specic Instructions for Installation..................................4-8
4.6.1 X-STREAM X2GK.....................................................4-9
4.6.2 X-STREAM X2GP....................................................4-15
4.6.3 X-STREAM X2XF Field Housings (single XLF; Dual XXF).....................4-23
4.7 Notes On Wiring Signal Inputs and Outputs .................................4-34
4.7.1 Electrical Shielding of Cables ...........................................4-34
4.7.2 Wiring Inductive Loads ................................................4-37
4.7.3 Driving High-Current Loads.............................................4-37
4.7.4 Driving Multiple Loads.................................................4-38
TOC
Chapter 5 Startup 5-1
5.1 Introduction ...........................................................5-1
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5.2 Front Panel Elements ...................................................5-2
5.2.1 Display..............................................................5-3
5.2.2 Status LED ..........................................................5-3
5.2.3 Keys 5-4
5.3 Symbols Used .........................................................5-6
5.4 Software..............................................................5-7
5.4.1 Navigating and Editing .................................................5-7
5.4.2 Access Levels ........................................................5-9
5.4.3 Special Messages....................................................5-10
5.5 Powering Up .........................................................5-11
5.5.1 Boot Sequence ......................................................5-11
5.5.2 Measurement Display .................................................5-11
5.6 Selecting the Language.................................................5-12
5.7 Checking the Settings ..................................................5-13
5.7.1 Installed Options .....................................................5-14
5.7.2 Conguring the Display................................................5-16
5.7.3 Calibration Setup.....................................................5-17
5.7.4 Setting the Analog Outputs .............................................5-20
5.7.5 Setting Concentration Alarms ...........................................5-28
5.7.6 Backing Up the Settings ...............................................5-34
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Chapter 6 User Interface and Software Menus 6-1
6.1 Symbols Used .........................................................6-2
6.2 Menu System..........................................................6-3
6.2.1 Startup..............................................................6-4
6.2.2 Control Menu.........................................................6-5
6.2.3 Setup Menu.........................................................6-14
6.2.4 Status Menu ........................................................6-50
6.2.5 Info Menu ..........................................................6-61
Chapter 7 Maintenance and Other Procedures 7-1
7.1 Introduction ...........................................................7-1
7.2 General Maintenance Information ..........................................7-2
7.3 Performing a Leak Test ..................................................7-4
7.4 Calibration Procedures ..................................................7-5
7.4.1 Preparing Calibrations..................................................7-7
7.4.2 Manual Calibration ...................................................7-17
7.4.3 Advanced Calibration .................................................7-20
7.4.4 Remote Calibration ...................................................7-31
7.4.5 Unattended Automatic Calibration........................................7-36
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Table of Contents
7.4.6 Resetting a Calibration ................................................7-39
7.4.8 Cancelling an Ongoing Calibration .......................................7-40
7.5 Replacing Worn Out Sensors ............................................7-42
7.5.1 Safety Instructions....................................................7-42
7.5.2 Opening X-STREAM Analyzers..........................................7-43
7.5.3 Replacing the Electrochemical Oxygen Sensor .............................7-46
7.5.4 Replacing the Trace Oxygen Sensor......................................7-53
7.5.5 Replacing the Trace Moisture Sensor.....................................7-54
7.6 Cleaning the Instrument´s Outside ........................................7-55
7.7 Save / Restore Conguration Data Sets ....................................7-56
7.7.1 Save CfgData to UserData .............................................7-58
7.7.2 Restore UserData to CfgData ...........................................7-59
7.7.3 Copy FactData to CfgData .............................................7-60
7.7.4 Save / Restore CfgData to External Device ................................7-61
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Table of contents
TOC
Chapter 8 Troubleshooting 8-1
8.1 Abstract ..............................................................8-1
8.2 Solving Problems Indicated by Status Messages ..............................8-2
8.2.1 Analyzer Related Messages .............................................8-3
8.2.2 Channel Related Messages (preceded by Channel Tag, e.g. CO2.1) .............8-6
8.3 Solving Problems Not Indicated by Status Messages.........................8-11
8.4 Troubleshooting on Components..........................................8-17
8.4.1 Opening X-STREAM Analyzers .........................................8-19
8.4.2 Signal Connectors on XSP Board........................................8-21
8.4.3 Sample Pump: Replacement of Diaphragm ................................8-22
8.4.4 Paramagnetic Oxygen Cell: Adjustment of Physical Zero......................8-33
8.4.5 Thermal Conductivity Cell: Adjustment of Output Signal.......................8-36
Chapter 9 Modbus Functions 9-1
9.1 Abstract ..............................................................9-1
9.1.1 Modbus TCP/IP .......................................................9-1
9.2 Supported Functions ....................................................9-2
9.3 List of Parameters and Registers - Sorted by Tag Name.........................9-2
9.4 List of Parameters and Registers - Sorted by Daniel Registers...................9-22
Chapter 10 Service Information 10-1
10.1 Return of Material .....................................................10-1
10.2 Customer Service .....................................................10-2
10.3 Training .............................................................10-2
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Chapter 11 Dismounting and Disposal 11-1
11.1 Dismounting and Diposal of the Analyzer ...................................11-1
Appendix A-1
A.1 Modbus Specication...................................................A-2
A.2 EC Declaration of Conformity ...........................................A-12
A.3 CSA Certicate of Compliance...........................................A-14
A.4 Block Diagram .......................................................A-21
A.5 Water Vapor: Relationship of Dewpoint, Vol.-% and g/Nm³..................... A-34
A.6 Declaration of Decontamination..........................................A-35
A.7 Assignment of Terminals and Sockets..................................... A-37
Index I-1
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X-STREAM X2
Table of figures
Fig. 1-1: X-STREAM Front Panel (here the X-STREAM X2GP) ...........................................1-3
Fig. 1-2: Optional Heated Area .............................................................................................1-7
Fig. 1-3: Gas Flow Diagram: Single Channel or in Series ....................................................1-8
Fig. 1-4: Serial Interface Marking ........................................................................................1-10
Fig. 1-5: X-STREAM X2GK - Views ....................................................................................1-16
Fig. 1-6: X-STREAM X2GP - Views ....................................................................................1-19
Fig. 1-7: X-STREAM X2XF Field Housings - Front Views ..................................................1-22
Fig. 1-8: X-STREAM X2XF Field Housings - Front Panel ..................................................1-23
Fig. 1-9: X-STREAM XLF - Bottom and Side View .............................................................1-24
Fig. 1-10: X-STREAM XLF - Power Supply and Signal Terminals ........................................1-25
Fig. 1-11: X-STREAM X2FD - Front View ............................................................................1-29
Fig. 1-12: X-STREAM X2FD - Front Panel ...........................................................................1-30
Fig. 1-13: X-STREAM X2FD - Bottom View ..........................................................................1-30
Fig. 1-14: X-STREAM X2FD - Terminals ..............................................................................1-31
Table of contents
TOC
Fig. 2-1: X-STREAM X2GK - Dimensions ............................................................................2-5
Fig. 2-2: X-STREAM X2GK - Rear Panel and Handle Variations .........................................2-6
Fig. 2-3: UPS 01 T Power Supply Unit ..................................................................................2-9
Fig. 2-4: 10 A Table-Top PSU ..............................................................................................2-10
Fig. 2-5: X-STREAM X2GP - Dimensions ...........................................................................2-12
Fig. 2-6: X-STREAM X2GP - Power Supply and Signal Connections ................................2-14
Fig. 2-7: X-STREAM X2GP - Signal Connections With Screw-Type Terminal Adapters ....2-14
Fig. 2-8: X-STREAM XLF - Dimensions .............................................................................2-15
Fig. 2-9: X-STREAM XXF - Dimensions .............................................................................2-16
Fig. 2-10: X-STREAM X2XF Field Housings - Power Supply Terminals / Fuse Holders ......2-18
Fig. 2-11: X-STREAM X2XF Field Housings - Signal Terminals .........................................2-18
Fig. 2-12: X-STREAM X2FD - Dimensions ...........................................................................2-19
Fig. 2-13: X-STREAM X2FD - Power Supply Terminals / Fuse Holders ...............................2-20
Fig. 2-14: X-STREAM X2FD - Signal Terminals ...................................................................2-21
Fig. 2-15: Analyzer Name Plate (examples) .........................................................................2-22
Fig. 3-1: IntrinzX Signal Forms .............................................................................................3-2
Fig. 3-2: Gas Detector Design Principle ...............................................................................3-3
Fig. 3-3: Photometer Assembly Principle ..............................................................................3-4
Fig. 3-4: Paramagnetic Oxygen Sensor - Assembly Principle ..............................................3-5
Fig. 3-5: Electrochemical Sensor - Assembly Principle ........................................................ 3-8
Fig. 3-6: Electrochemical O2 Sensor - Assembly ..................................................................3-8
Fig. 3-7: Electrochemical Reaction of Oxygen Sensor ........................................................3-9
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Index of Figures
Fig. 3.8 Cover for EO2 Sensor Block At Rear Panel .........................................................3-10
Fig. 3.9 Trace Oxygen Sensor Design Principle ................................................................3-11
Fig. 3.10 Cover for TO2 Sensor Block At Rear Panel ..........................................................3-12
Fig. 3-11: Wheatstone Bridge ...............................................................................................3-13
Fig. 3-12: TC Cell, Exterior View, Thermal Isolation Removed .............................................3-14
Fig. 3-13: TC Cell, Sectional View ........................................................................................3-14
Fig. 3-14: Trace Moisture Sensor Assembly .........................................................................3-15
Fig. 4-1: X-STREAM X2 Analyzers - Scope of Supply ..........................................................4-1
Fig. 4-3: Installation in Bypass Mode ....................................................................................4-6
Fig. 4-2: Labelling of Gas Connectors (example) .................................................................4-6
Fig. 4-4: X-STREAM X2GK - Front Panel .............................................................................4-9
Fig. 4-5: X-STREAM X2GK - Rear Panel ...........................................................................4-10
Fig. 4-6: Socket X1 - Pin Conguration ..............................................................................4-11
Fig. 4-7: Plug X2 - Modbus Interface ..................................................................................4-12
Fig. 4-8: Socket X4 - Pin Conguration .............................................................................4-13
Fig. 4-9: Power In Connectors ............................................................................................4-14
Fig. 4-10: X-STREAM X2GP - Front View ............................................................................4-15
Fig. 4-11: X-STREAM X2GP - Rear Panel, Model With Signal Plugs and Sockets..............4-16
Fig. 4-12: X-STREAM X2GP - Rear Panel, With Terminal Adapters and Brackets ..............4-17
Fig. 4-13: Socket X1 - Analog & Digital Outputs 1-4 ............................................................4-18
Fig. 4-14: Plug X2 - Modbus Interface ..................................................................................4-19
Fig. 4-15: Conguration of XSTA Terminal Adapter ..............................................................4-20
Fig. 4-16: Sockets X4.1 and X4.2 - Pin Conguration .........................................................4-21
Fig. 4-17: Conguration of XSTD Terminal Adapter ..............................................................4-22
Fig. 4-18: X-STREAM XLF ..................................................................................................4-23
Fig. 4-19: X-STREAM XXF ..................................................................................................4-24
Fig. 4-20: X-STREAM X2XF Field Housings - Terminals, Cable Glands and Gas Fittings ...4-25
Fig. 4-21: Terminal Block X1 - Analog Signals and Relay Outputs 1-4 ................................4-28
Fig. 4-22: Terminal Block X1 - Modbus Interface ..................................................................4-29
Fig. 4-23: X-STREAM X2XF Field Housings - Ethernet Connector ......................................4-30
Fig. 4-24: Terminal Blocks for Digital Inputs and Outputs .....................................................4-31
Fig. 4-25: Power Supply Connections ..................................................................................4-32
Fig. 4-26: Shielded Signal Cable, Shielding Connected At Both Ends. ................................4-34
Fig. 4-27: Shielded Signal Cable, Shielding Connected At One end. ...................................4-35
Fig. 4-28: Signal Cable With Double Shielding, Shieldings Connected At Alternate Ends. ..4-35
Fig. 4-29: Shield Connector Terminal With Cable .................................................................4-36
Fig. 4-30: Suppressor Diode for Inductive Loads. ................................................................4-37
Fig. 4-31: Driving High-Current Loads ..................................................................................4-37
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Index of Figures
Fig. 4-32: Loads in Series .....................................................................................................4-38
Fig. 4-33: Loads in Parallel ...................................................................................................4-38
Fig. 5-1: X-STREAM Front Panel .........................................................................................5-2
Fig. 5-2: Limits Dening a Window for Valid Concentrations ..............................................5-31
Fig. 5-3: High Pre-Alarm and Main Alarm ...........................................................................5-32
Fig. 5-4: Low Pre-Alarm and Main Alarm ............................................................................5-33
Fig. 6-1: X-STREAM Software Menu Structure ....................................................................6-3
Fig. 7-1: Leak Testing With U-Turn Manometer ....................................................................7-4
Fig. 7-2: Calibration Improvement by Variable Valve Assignments .....................................7-10
Fig. 7-3: Internal Valves Assignments .................................................................................7-13
Fig. 7-4: Zero All Calibration Procedure Flow Chart ........................................................... 7-22
Fig. 7-5: Span All Calibration Procedure Flow Diagram ..................................................... 7-25
Fig. 7-6: Zero Span All Calibration Procedure Flow Diagram .............................................7-28
Fig. 7-7: Digital Inputs - Initializing Calibrations ..................................................................7-33
Fig. 7-8: Graphical Explanation of Interval Time Settings ...................................................7-37
Fig. 7-9: X-STREAM X2GP .................................................................................................7-43
Fig. 7-10: X-STREAM X2GK ................................................................................................7-43
Fig. 7-11: X-STREAM X2 Field Housings and X2FD - How to Open ...................................7-44
Fig. 7-12: Location of the EO2 Sensor Unit ..........................................................................7-49
Fig. 7-13: Sensor Unit Design ...............................................................................................7-50
Fig. 7-14: Sensor At Rear Panel ...........................................................................................7-51
Fig. 7-15: OXS Board, Top View ...........................................................................................7-51
Fig. 7-16: Trace Moisture Sensor Assembly Separated .......................................................7-54
Fig. 7-17: Relationship of Supported Data Sets and Where to Find Further Information .....7-57
Fig. 7-18: Service Port Connector - Serial RS 232 Interface ................................................7-61
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TOC
Fig. 8-1: X-STREAM X2GP .................................................................................................8-19
Fig. 8-2: X-STREAM X2GK ................................................................................................8-19
Fig. 8-3: X-STREAM X2 Field Housings and X2FD - How to Open ...................................8-20
Fig. 8-4: XSP - Allocation of Signal Connectors..................................................................8-21
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index of Tables
Tab. 3-1: Paramagnetic Sensor -
Tab. 3-2: Solvent Resistant Paramagnetic Sensor - Approved Solvents ...............3-7
Tab. 3-3: Solvent Resistant Paramagnetic Sensor - Medium Affected Materials ........3-7
Tab. 3-4: Electrochemical Oxygen Measurement -
Tab. 3-5: Examples of Specific Thermal Conductivities ...........................3-13
Tab. 3-6: Dew Points and Water Content (at 1013 HPa) ..........................3-16
Tab. 3-7: Limitations on Gases ..............................................3-17
Tab. 3-8: Gas Components and Measuring Ranges, Examples ....................3-19
Tab. 3-9: IR, UV, VIS, TCD - Measurement Performance Specifications ..............3-20
Tab. 3-10: Oxygen - Standard Measurement Performance Specifications .............3-21
Tab. 3-11: Trace Moisture - Standard Measurement Performance Specifications ........3-22
Tab. 3-12: Special Performance Specifications for Gas Purity Measurements ..........3-22
Tab. 5-1: Analog Output Signals - Settings and Operational Modes .................5-21
Tab. 5-2: Analog Outputs - Scaling (examples) .................................5-27
Tab. 5-3: Influence of “SpanRange” Parameter on Concentration Alarm Limits ........5-29
Tab. 6-1: Analog Output Signals: Settings and Operational Modes ..................6-32
Tab. 6-2: Options for Digital Outputs .........................................6-38
Tab. 6-3: Options for Digital Inputs ...........................................6-40
Tab. 6-4: Parameter IntSHS Options .........................................6-42
Cross Interferences (examples) .....................3-6
Cross Interference by Gases ........3-10
Tab. 7-1: Digital Inputs Priorities ............................................7-32
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X-STREAM X2
INTRODUCTION
The instruction manual contains information about the component assembly, function,
installation, operation and maintenance of the X-STREAM® X2 series gas analyzers.
The manual covers several X-STREAM analyzer models and so many contain information
about congurations and/or options not appliccable to your analyzer.
The installation and operation of units for use in explosive environments is not covered
in this manual.
Analyzers intended to be used in such environments are supplied with further instruction
manuals, which should be consulted in addition to this.
DEFINITIONS
The following denitions explain the use of the terms WARNING, CAUTION and NOTE in
this manual.
Safety Instructions
S
Indicates an operational or maintenance procedure, a process, a condition,
an instruction, etc.
Failure to comply may result in injury, death or permanent health risk.
Indicates an operational or maintenance procedure, a process, a condition,
an instruction, etc.
Failure to comply may result in damage to or destruction of the instrument,
or impaired performance.
NOTE!
Indicates an imperative operational procedure,
or an important condition or instruction.
Emerson Process Management GmbH & Co. OHG S-1
X-STREAM X2
TERMS USED IN THIS INSTRUCTION MANUAL
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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.
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 species protection against solid objects
(6. = dust tight) while the second number
species the degree of protection against
liquids (.6 = heavy seas).
NEMA stands for National Electrical Manuf-
acturers Association. 4X species 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 (decient in oxygen) to burn.
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
sufcient fuel (gas) to burn.
NAMUR
NAMUR is an international user association of
automation technology in process industries.
This organisation has issued experience reports and working documents, called recommendations (NE) and worksheets (NA).
Emerson Process Management GmbH & Co. OHGS-2
Instruction Manual
HASX2E-IM-HS
02/2012
X-STREAM X2
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 qualied personnel only!
hot surfaces may be accessible. Removing
covers by qualied 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 X2
HASX2E-IM-HS
02/2012
SYMBOLS USED IN THIS MANUAL
Wherever one or more of the following symbols are used in this instruction manual, read the
accompanying information and instructions carefully.
Follow these warnings and notes carefully
to minimize risk.
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
Instruction Manual
HASX2E-IM-HS
02/2012
X-STREAM X2
SAFETY INSTRUCTIONS
INTENDED USE STATEMENT
X-STREAM series gas analyzers are intended to be used as analyzers for industrial purposes. They must not be used in medical, diagnostic or life support applications nor as
safety devices.
Using X-STREAM XE analyzers as safety devices, requiring redundant design or SIL clas-
sication, is also not permitted.
No independent agency certications or approvals are to be implied as covering such
applications!
Safety Instructions
S
GENERAL SAFETY NOTICE / RESIDUAL RISK
If this equipment is used in a manner not specied in these instructions, protective sy-
stems 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.
Emerson Process Management GmbH & Co. OHG S-5
Instruction Manual
X-STREAM X2
Safety Instructions
HASX2E-IM-HS
02/2012
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 qualied 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 instrument before reading and understanding this instruction manual and receiving
appropriate training.
ADDITIONAL LITERATURE
This manual covers aspects important for installation and startup of X-STREAM X2 gas
analyzers.
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, check for a accompanying USB stick with an electronic version (PDF)!
The following additional instruction manuals are available or referenced within this manual:
• HASX2E-SFM-HS X-STREAM X2 short form manual
• HASICx-IM-H Infallible containment instruction manual
• Separate manuals for Hazardous Area applications
Contact your local service center or sales ofce when missing documents.
SAVE ALL INSTRUCTIONS FOR FUTURE USE!
Emerson Process Management GmbH & Co. OHGS-6
Instruction Manual
HASX2E-IM-HS
02/2012
Safety Instructions
X-STREAM X2
INSTALLING AND CONNECTING THE UNIT
The following notices should be carefollowed to ensure compliance with the low voltage directive.
1.
Suitable grounding connections should be made at all connectors provided for this purpose.
2. All safety covers and grounding connections must be properly reinstated after maintenance
work or troubleshooting.
3. A fuse should be provided at the installation site which will completely disconnect the unit
in case of failure. Installing an isolating switch may also be benecial. In either case, these
components must be constructed to conform to recognised norms.
Safety Instructions
S
OPERATING AND MAINTAINING THIS UNIT
On leaving our factory, this instrument confor-
med to all applicable safety directives.
In order to preserve this state of affairs, the
operator must take care to follow all the instructions and notes given in this manual and
on the unit.
Before switching on the unit, ensure that the
local nominal mains voltage corresponds to
the factory-set operational voltage of this
unit.
Any interruption of the protective earth connections, whether inside or outside of the unit,
may result in exposure to the risk of electricity .
Deliberately disconnected the protective earth
is therefore strictly forbidden.
Removing covers may expose components
conducting electric current. Connectors may
also be energised. The unit should therefore
be disconnected from the power supply before
any kind of maintenance, repair or calibration
work requiring access to the inside of the
unit.
Only trained personnel who are aware of
the risk involved may work on an open and
energized unit.
Fuses may only be replaced by fuses of an
identical type and with identical ratings. It is
forbidden to use repair fuses or to bypass
fuses.
Take note of all applicable regulations when
using this unit with an autotransformer or a
variable transformer.
Substances hazardous to health may escape
from the unit’s gas outlet. This may require
additional steps to be taken to guarantee the
safety of operating staff.
Emerson Process Management GmbH & Co. OHG S-7
X-STREAM X2
The units described in this manual may not be used in explosive atmospheres
without additional safety measures.
Do not operate without covers secure. Do not open while energized.
Installation requires access to live parts which can cause death or serious
injury.
Instruction Manual
HASX2E-IM-HS
02/2012
Safety Instructions
EXPLOSION HAZARD
ELECTRICAL SHOCK HAZARD
For safety and proper performace this instrument must be connected to a
properly grounded three-wire source of power.
Emerson Process Management GmbH & Co. OHGS-8
Instruction Manual
HASX2E-IM-HS
02/2012
This unit’s exhaust may contain toxic gases such as (but not limited
to) e.g. sulfur dioxide. These gases can cause serious injuries.
Avoid inhaling exhaust gases.
Connect the exhaust pipe to a suitable ue and inspect the pipes regularly
for leaks.
All connections must be airtight to avoid leaks. See section 7.2, page 7-2
for instructions on performing a leak test.
X-STREAM X2
Safety Instructions
TOXIC GASES
Safety Instructions
S
HEAVY INSTRUMENT
The models intended for outside and wall mounted use (X-STREAM XLF,
XXF and X2FD) weigh between 26 kg (57 lb) and 63 kg (139 lb), depending
on version and options installed.
Two people and/or lifting equipment is required to lift and carry these units.
Take care to use anchors and bolts specied 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 support the weight!
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-9
X-STREAM X2
Safety Instructions
GASES AND PREPARATION OF GASES
GASES HAZARDOUS TO HEALTH
Follow the safety precautions for all gases (sample and span gases) and
gas cylinders.
Before opening the gas lines, they must be purged with air or neutral gas
) to avoid danger from escaping toxic, ammable, exposive or hazardous
(N
2
gases.
Instruction Manual
HASX2E-IM-HS
02/2012
EXPLOSIVE GASES
When supplying ammable gases with concentrations of more than ¼ of
the lower explosion limit, we RECOMMEND implementing one or more
additional safety measures:
• purging the unit with inert gas
• stainless steel internal pipes
• ame arrestors on gas inlets and outlets
• inherently safe or failsafe measuring cells
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!
Emerson Process Management GmbH & Co. OHGS-10
Instruction Manual
HASX2E-IM-HS
02/2012
Power supply
X-STREAM X2
Safety Instructions
Ensure that the local power voltage where the unit is to be installed,
corresponds to the unit’s nominal voltage as given on the name plate
label.
CONNECTING UNITS FOR PERMANENT INSTALLATION
Only qualied personnel following all applicable and legal regulations
may install the unit and connect it to power and signal cables. Failure to
comply may invalidate the unit’s warranty and cause exposure to the risk
of damage, injury or death.
This unit may only be installed by qualied personnel familiar with the
possible risks.
Working on units equipped with screw-type terminals for electrical
connections may require the exposure of energized components.
Wall-mounted units have no power switch and are operational when
connected to a power supply . The operating company is therefore required
to have a power switch or circuit breaker (as per IEC 60947-1/-3) available
on the premises. This must be installed near the unit, easily accessible to
operators and labelled as a power cut-off for the analyzer.
Safety Instructions
S
ADDITIONAL NOTES FOR UNITS WITH SCREW-TYPE TERMINALS
Cables for external data processing must be double-insulated against mains
power.
If this is not possible, cables must be laid in such a way as to guarantee
a clearance of at least 5 mm from power cables. This clearance must be
permanently secured (e.g. with cable ties)
Emerson Process Management GmbH & Co. OHG S-11
Instruction Manual
X-STREAM X2
HASX2E-IM-HS
02/2012
General Operating Notes
General operating notes
EXPLOSION HAZARD
Exhaust gases may contain hydrocarbons and other toxic gases such as
carbon monoxide. Carbon monoxide is toxic.
Faulty gas connections may lead to explosion and death.
Ensure that all gas connections are connected as labelled and airtight.
• 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. Admissable ambient
temperatures (see technical details) must be adhered to.
• Gas inlets and outlets must not be interchanged.All gases must be supplied to the unit already
processed. When using this unit with corrosive sample gases, ensure that these gases do
not contain components harmful to the gas lines.
• Admissable gas pressure for sample and test gases is 1500 hPa.
• 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 shiel-
ding is correctly tted ( section 4.5, page 4-31). Shielding and terminal housing must be
electrically connected; submin-D plugs and sockets must be screwed to the unit.
• When using optional external adapters (submin-D to screw-type terminal), protection from
electromagnetic interference can no longer be guaranteed (CE compliance pursuant to EMC
guidelines). In this case the customer or operating company functions as a maker of a system
and must therefore ensure and declare compliance with EMC guidelines.
Emerson Process Management GmbH & Co. OHGS-12
Instruction Manual
HASX2E-IM-HS
02/2012
X-STREAM X2
Chapter 1
Technical description
The following are the main features of the new
Emerson Process Management X-STREAM
gas analyzers in brief:
• compact design with easily accessible
internal components
• customizable for a wide range of applications: different housings are avail-
able while internal construction remains
largely identical
• multilingual microprocessor-controlled
user interface with liquid crystal (LCD)
or vacuum ourescent display (VFD) to
indicate measurement value and status
messages
• units for outdoor use are optionally supplied with an impact tested front panel
• widerange power supply unit for worldwi-
1
de use without modication (
⁄2 19in units
with internal or external PSUs)
X-STREAM X2 gas analyzers can measure
up to four different gas components by mul-
tiple combinations of the following analyzing
techniques (restrictions apply to ½19in units):
IR = non-dispersive infrared analysis
Special congurations (e.g. intrinsically safe
or infallible measuring cells) for the analysis
of combustible gases are also available.
Chapter 3 contains a detailed descrip-
tion of the various measuring techniques.
Standard applications
The use of different housings allow X-
STREAM analyzers to be tailored to the many
different applications:
• Tabletop units in ½19in modular design,
with IP 20 protection class
• Tabletop and rackmountable units in 19
in modular design, with IP 20 protection
class
• Stainless steel wallmountable field
housing with IP 66 / NEMA 4X protection
class for outdoor use (operating temperature -20°C to +50°C).
• Cast aluminium wallmountable field
housing with IP 66 / NEMA 4X protection
class for outdoor use (operating temperature -20°C to +50°C).
The various analyzer types are described in
more detail in section 1.4, page 1-12ff.
Technical Description
1
UV = ultraviolet analysis
pO
=
paramagnetic oxygen analysis
2
eO
=
electrochemical oxygen analysis
2
tO2 = electrochemical trace oxygen analysis
TC = thermal conductivity analysis
Installation in hazardous areas
X-STREAM analyzers in eld housings, when
tted with various protective devices, can
also be installed and operated in hazardous
environments. Available options are:
• Non-incendive assembly (Ex nA nC) for
tH
O = trace moisture measurement
2
Modied resistant measuring cells are avai-
installation in Zone 2 and Division 2 for the
measurement of non-ammable gases.
lable for use with corrosive gases and/or
gases containing solvents.
• Pressurized enclosure conforming to
ATEX directive 94/9/EC, for installation
in zone 2.
Emerson Process Management GmbH & Co. OHG 1-1
X-STREAM X2
Instruction Manual
HASX2E-IM-HS
02/2012
1 Technical Description
• Simplified purge system (Z-purge) for
installation in North American Div 2 environments.
The cast aluminium eld housing (Ex d) is
designed to withstand an explosion and
intended to be used in hazardous areas of
Zone 1. Its robust design with NEMA 4X / IP
66 protection also enables the installation in
rough environments outside hazardous areas.
More information about analyzers for hazardous areas can
be obtained from your Emerson
Process Management sales
ofce.
Note!
These instructions do not detail the installa-
tion or operation of X-STREAM analyzers in
hazardous areas. If you intend to use your
analyzer for such purposes, we would
draw your attention to the separate instruction manuals supplied with analyzers
for use in hazardous areas.
Further features (in parts options):
• Congurable measurement display
• gas values and/or secondary measure-
ments (e. g. ow)
• single or dual pages
• Congurable measurement units
• supports conversion factors from ppm
to several other, even user specic units
• 3 independent software access levels
• protection against unauthorized chan-
ging of congurations
• password protected
• to be separately activated
• Unattended zero and span calibrations
• calibrations without user interaction
• Backup and restore analyzer congura-
tions to/from protected internal memory.
Emerson Process Management GmbH & Co. OHG1-2
Instruction Manual
HASX2E-IM-HS
02/2012
1.1 Overview
X-STREAM X2
1.1 Overview
All X-STREAM gas analyzers feature an
easy-to-use alphanumeric user interface,
which displays measurement values, status
and error messages, and menus for the input
of parameters.
1.1.1 The Front Panel
All X-STREAM gas analyzers feature an
alphanumeric LCD display with 4x20 characters, showing measurement and status
information.
Wall-mounted units can, as an alternative, be
tted with a vacuum uorescent display, incre-
asing legibility in brighter environments.
The
display can also be protected with an impact
tested glass panel.
All analyzer types also feature three LEDs on
the front panel which display status information in addition to the plain text messages.
For ease of use, the operator can select one
of ve languages for the display (currently
available: English, French, German, Italian
and Spanish).
The colors of the LEDs are based on the
NAMUR NE 44 specifications. The LEDs
are activated in accordance with the NE 107
standards, and indicate “Failure”, “Function
check”, “Out of specication” and “Maintenance
request”. For further information, see
chapter 8, page 8-1.
The analyzer software is operated by means
of only six keys.
Technical Description
1
1 3 4 5 6 72
1 4x20 character alphanumeric display
2 LED (red)
3 LED (red)
4 LED (green)
Fig. 1-1: X-STREAM Front Panel (here the X-STREAM X2GP)
Emerson Process Management GmbH & Co. OHG 1-3
5 “Measure“ key
6 “Enter” key
7 4 keys for settings and menu navigation
X-STREAM X2
Instruction Manual
HASX2E-IM-HS
02/2012
1.2 Conguration of Gas Lines
1.2 Configuration of Gas Lines
Various materials are available to allow the
analyzer to be customized to your needs.
The materials used are selected based on
the characteristics of the sample gas, e.g.
diffusion rate, corrosiveness, temperature
and pressure.
1.2.1 Materials Used
The physical and chemical properties of the
sample gas as well as the conditions under
which measurement takes place inuence the
choice of materials. Among those available
are Viton
®
, PFA and stainless steel.
1.2.2 Safety Filter
The analyzers are generally tted with an
internal stainless-steel lter. This lter is not
a replacement for any dust lter in the prepa-
ration of the gas, but represents a last line of
defence.
1.2.3 Inlets and Outlets
Rackmounted and tabletop devices are tted
with PVDF inlets and outlets (ø 6/4 mm) as
standard. Alternatively, Swagelok™ or stain-
less steel ttings (ø 6/4 mm or ¼ in can be
tted.
Wall-mounted eld housings are supplied
with Swagelok™ or stainless steel ttings (ø
6/4 mm or ¼ in) ausgestattet.
Other materials available on request.
X-STREAM X2FD units are always supplied
with ame arrestors and stainless steel ttings
(ø 6/4 mm or ¼ in).
1.2.4 Pipework
Unless otherwise specied, the analyzers
are supplied with Viton® or PVDF piping (ø
6/4 mm or ¼ in). Other materials (e.g. stain-
less steel) can be used, depending on the
application.
1.2.5 Infallible Containments
Infallible containments are gas lines which,
due to their design, can be regarded as per-
manently technically tight. This is achieved
by, for example, welded joints, or metallically
sealing joints (e.g. tap connectors and bin-
ders), providing they are seldom disconnec-
ted. Gas lines congured in this manner can
be used for measuring noxious, ammable
and explosive gases. At the time of going
to press, infallible containments for thermal
conductivity analysis (TC) are available; other
analysis methods are projected. Further in-
formation about infallible containments can
be found in the separate instruction manual
supplied with these units.
Infallible containments do not
render it unnecessary to test for
leaks regularly, e.g. following
lengthy breaks in service, substantial alterations, repairs and
modications.
Read the separate instruction
manual giving detailed instructions on the conguration, operation and maintenance of units
fitted with infallible containments.
Emerson Process Management GmbH & Co. OHG1-4
Instruction Manual
HASX2E-IM-HS
02/2012
1.2 Conguration of Gas Lines
1.2.6 Optional Components for Gas Lines
X-STREAM X2
The analyzers can, as an option, be tted with
further components. Not all components are
available for all analyzer types:
• internal sample gas pump
• internal valve block
• internal ow sensors
• internal ow monitor switch
• internal barometric pressure meters
• internal temperature sensors.
1.2.6.1 Internal Sample Gas Pump
An internal sample gas pump is used when
the sample gas is under insufcient pressure.
It ensures a constant ow of sample gas (max.
2.5 l/min through the analyzer).
When in internal pump is tted, the relevant
parameter in the software setup dialog is set
to Yes ( 6.2.3.5, page 6-43). The pump
can be controlled either manually through a
software menu or optionally by a digital input.
1.2.6.2 Internal Valve Block
The use of an internal valve block allows all
necessary gas lines (zero gas, span gas,
sample gas) to remain permanently connected to the analyzer. Valves are then activated
automatically when required (e.g. during au-
tomatic calibration).
When an internal valve block is tted, this is
shown in the relevant software setup dialog
as either Internal or Int+Ext (
page 6-43). The valves are controlled by
either a software menu, optionally by digital
input, or automatically during autocalibration.
Depending on the model, up to two valve
bocks can be tted.
6.2.3.5,
1.2.6.3 Internal Flow Sensor
Up to two internal ow sensors can measure
the ow of gas and can activate an alarm si-
gnal in the event of a failure. The alarm level
for ow sensors is operator adjustable to up
to 2000 ml/min. Depending on the model, up
to two sensors can be tted and evaluated
separately.
When a sensor is tted, the relevant parame-
ter in the software setup dialog is set to Yes
(
6.2.3.5, page 6-43).
If the current ow rate is too low, a status
message is displayed and the parameter
under CHECK REQUESTS.. is set to Yes
( Chapter 8 “Troubleshooting”).
1.2.6.4 Internal Flow Monitor Switch
An internal ow switch monitors the gas ow
and activates an alarm signal in case it is not
sufcient. The alarm level for the internal ow
switch is xed and not operator adjustable.
Additional external switches may used and
connected via digital inputs. All tted ow
switches are evaluated to share a common
alarm.
When an internal ow switch is tted, the relevant parameter in the software setup dialog
is set to Yes (
If the current ow rate is too low, a status
message is displayed and the parameter
under CHECK REQUESTS.. is set to Yes
( Chapter 8 “Troubleshooting”).
6.2.3.5, page 6-43).
Technical Description
1
Emerson Process Management GmbH & Co. OHG 1-5
X-STREAM X2
1.2 Conguration of Gas Lines
1.2.6.5 Internal Barometric Pressure Sensor
The inuence of varying atmospheric pres-
sure can be compensated for by the use of
an internal barometric pressure sensor (
measurement specication, page 3-17).
If such a sensor is installed in the unit, the
related menu shows the entry Internal (
6.2.3.5, page 6-43).
1.2.6.6 Internal Temperature Sensors
Instruction Manual
HASX2E-IM-HS
02/2012
The inuence of varying temperatures can
be compensated for by the use of internal
temperature sensors (
measurement
specication, page 3-17 ).
Depending on the conguration of the unit or
the demands of the application, temperature
sensors can measure the unit’s internal temperature or selected measurement channel
components.
If such sensors are installed in the unit, this is
indicated in the installed options menu (
6.2.3.5, page 6-43).
Emerson Process Management GmbH & Co. OHG1-6
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