Rosemount X-STREAM X1 Flameproof Addendum for Hazardous Area Applications-Orig. Issue Manuals & Guides

Instruction Manual

HASADE-IM-Ex
09/2006

Flameproof Gas Analyzer

Instruction Manual Addendum for

Hazardous Area Applications

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

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

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

Management (Rosemount Analytical) representative for clarification.

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

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

• Install your equipment as specified in the Installation Instructions of the
appropriate Instruction Manual and per applicable local and national codes.

Connect all products to the proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update,
program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement
parts specified by Emerson Process Management (Rosemount Analytical).
Unauthorized parts and procedures can affect the product’s performance, place the
safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place,
except when maintenance is being performed by qualified persons, to prevent
electrical shock and personal injury.

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

Edition 2006-09

Emerson Process Management GmbH & Co. OHG

Industriestrasse 1
D-63594 Hasselroth
Germany
T [phone]
F [phone]
Internet: www.EmersonProcess.com

Instruction Manual

HASDE-IM-Ex
09/2006

X-STREAM FD

PREAMBLE

This instruction manual provides information about installing, operating and maintaining/
servicing X-STREAM series gas analyzers in hazardous (classified) areas and shall be read
in conjunction with the standard analyzer instruction manual only!

This instruction manual covers several X-STREAM series analyzer variations and therefore
may describe configurations and/or options not part of your specific analyzer.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout
this publication.

Highlights an operation or maintenance procedure, practice, condition, state­ment, etc.

If not strictly observed, could result in injury, death, or long-term health
hazards of personnel.

Highlights an operation or maintenance procedure, practice, condition, state­ment, etc.

Safety Instructions

If not strictly observed, could result in damage to or destruction of equipment,
or loss of effectiveness.

NOTE

Highlights an essential operating procedure, condition or statement.

Emerson Process Management GmbH & Co. OHG S-1

Instruction Manual

X-STREAM FD

Symbols

SYMBOLS USED IN THIS MANUAL

1. Where equipment or covers are marked with the symbol to the right, hazardous
voltages are likely to be present beneath. These covers should only be removed
when power is removed from the equipment — and then by trained service
personnel only .

2. Where equipment or covers are marked with the symbol to the right, there is a
danger from hot surfaces beneath. These covers should only be removed by
trained service personnel when power is removed from the equipment. Certain
surfaces may remain hot to the touch.

3. Where equipment or covers are marked with the symbol to the right, refer to the
Instruction Manual for instructions.

4. Further graphical symbols possibly used in this product:

HASDE-IM-Ex

09/2006

Elektrostatic discharge (ESD)

Harmful (to Health)!

Explosion Hazard!

Toxic!

Heavy Instrument!

Disconnect from Mains!

Emerson Process Management GmbH & Co. OHGS-2

Instruction Manual

HASDE-IM-Ex
09/2006

TERMS USED IN THIS MANUAL

ATEX

Directive 94/9/EC, commonly called the A TE X
(„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).

Area Classification

X-STREAM FD

Terms

Safety Instructions

Zone 1

Where ignitable concentrations of flammable
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.)

Flammable Gas(es)

Gases and gas mixtures are assigned to be
flammable if they might become ignitable when
in a mixture with air.

Lower Explosion Limit (LEL)

Volume ratio of flammable gas in air below
which an explosive gas atmosphere will not be
formed: the mixture of gas and air lacks
sufficient fuel (gas) to burn.

Zone 2

Where ignitable concentrations of flammable
gases are not likely to exist under normal
operating conditions.
(A guideline value [not part of a standard ] is
less than 10 hours per year.)

Upper Explosion Limit (UEL)
Volume ratio of flammable gas in air above
which an explosive gas atmosphere will not be
formed: the mixture of gas and air is too rich in
fuel (deficient in oxygen) to burn.

Emerson Process Management GmbH & Co. OHG S-3

Instruction Manual

X-STREAM FD

Safety Instructions

HASDE-IM-Ex

09/2006

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, and no independent agency certifications or approvals are to be implied as
covering such applications!

SAFETY SUMMARY

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

AUTHORIZED PERSONNEL

T o avoid explosions, loss of life, personal injury and damage to this equipment and on-site
property, do not operate or service this instrument before reading and understanding this
instruction manual and receiving appropriate training.

ADDITIONAL LITERATURE

This manual covers aspects specific for using flameproof X-STREAM FD analyzers in
hazardous (classified) areas, only.

To install, start-up, operate and maintain/service the instrument in a safe manner it is
MANDATORY to read all additional instruction manuals shipped together with the
instrument!

The following instruction manuals are available and/or referenced within this manual at
hand:
HASAxE-IM-HS X-STREAM series instruction manual
HASFAE-IM-H Flame arrestors series instruction manual
The original manufacturer´s cable gland or conduit instruction manual, depending on what
is used.

Contact your local service center or sales office when missing documents.
Save all instructions for future use!

Emerson Process Management GmbH & Co. OHGS-4

Instruction Manual

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Any addition, substitution, or replacement of components installed on or in
this device, must be certified to meet the hazardous area classification that
the device was certified to prior to any such component addition, substitution,
or replacement. In addition, the installation of such device or devices must
meet the requirements specified and defined by the hazardous area
classification of the unmodified device.

Any modifications to the device not meeting these requirements, will void
the product certification(s).

X-STREAM FD

Safety Instructions

Safety Instructions

EXPLOSION HAZARD BY MODIFICATION

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

POSSIBLE EXPLOSION HAZARD
Do not open instrument when energized.
Ensure that external circuitry is disconnected or de-energized before

opening the instrument.
Ensure that all gas connections are made as labeled and are leak free.

Improper gas connections could result in explosion and death.

POSSIBLE EXPLOSION HAZARD

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

If an external flowmeter is required for flow control, legislative requirements
and instructions for installation in hazardous (classified) areas must be
considered.

Emerson Process Management GmbH & Co. OHG S-5

X-STREAM FD

The analyzer model X-STREAM FD, 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!

Use two people and/or suitable tools for transportation and lifting these
instruments!

Take care to use anchors and bolts specified to be used for the weight of
the units!

Instruction Manual

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09/2006

Safety Instructions

HEAVY INSTRUMENT

T ake care the wall or stand the unit is intended to be inst alled at is solid and
stable to hold the units!

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 flameproof 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 please consider the following clarification sheet
released by the European ATEX Notified Body Group (see next page):

Emerson Process Management GmbH & Co. OHGS-6

Instruction Manual

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09/2006

X-STREAM FD

Safety Instructions

Safety Instructions

Emerson Process Management GmbH & Co. OHG S-7

Instruction Manual

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09/2006

X-STREAM FD

TABLE OF CONTENTS

Preamble S-1

Definitions S-1

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

Safety instructions S-4

Chapter 1 Technical Description 1-1

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

1-2 Design Features ......................................................................................................... 1-1

1-3 Protective Measures in Detail ................................................................................... 1-1

1-4 Explosion Protection Compliances ......................................................................... 1-3

1-5 Technical Data............................................................................................................1-4

Table of Contents

Chapter 2 Installation 2-1

2-1 Installing the Analyzer ............................................................................................... 2-2

2-2 Connecting Gas Lines ...............................................................................................2-3

2-3 Electrical Installation.................................................................................................. 2-5

Chapter 3 Startup 3-1

Chapter 4 Service and Maintenance 4-1

4-1 Verifications and Tests after Service or Maintenance ............................................ 4-3

4-1-1 Routine Tests ......................................................................................................... 4-3

4-1-1-1 Visual Inspection ...............................................................................................4-3

4-1-1-2 Tests on Flame Arrestors.................................................................................. 4-3

4-2 Replacement of Parts ................................................................................................ 4-4

Appendix A-1

A-1 ATEX EC Type Examination Certificate .................................................................. A-2

A-2 EC Declaration of Conformity.................................................................................. A-3

A-3 Cable gland ADL 1F installation instruction........................................................... A-5

A-4 Block diagram X-STREAM FD ................................................................................. A-6

Emerson Process Management GmbH & Co. OHG

T-1

Instruction Manual

X-STREAM FD

HASADE-IM-EX

09/2006

Table of Contents

Table of Figures

Fig. 1-1: X-STREAM FD..........................................................................................................................................1-1

Fig. 1-2: X-STREAM FD, bottom view...................................................................................................................1-2

Fig. 1-3: X-STREAM FD - dimensions ...................................................................................................................1-4

Fig. 1-4: X-STREAM FD - power terminals / fuse holders....................................................................................1- 7

Fig. 1-5: X-STREAM F - signals terminals ...........................................................................................................1-8

Fig. 2-1: X-STREAM FD dimensions .....................................................................................................................2-2

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

Fig. 2-3: Flame arrestor elements ..........................................................................................................................2-3

Fig. 2-4: X-STREAM FD - allocation of terminals...............................................................................................2-10

Fig. 2-5: X-STREAM FD - Analog output terminals ........................................................................................... 2-11

Fig. 2-6: X-STREAM FD - Modbus interface terminals ......................................................................................2-12

Fig. 2-7: Relay status signals, block diagram .....................................................................................................2-13

Fig. 2-8: X-STREAM FD - Relay Status Terminals ..............................................................................................2-12

Fig. 2-9: Digital Inputs & Outputs Terminals .......................................................................................................2-14

Fig. 2-10: Power terminals ..................................................................................................................................2-14

Fig. 2-1 1: Equipotential bonding conductor terminal........................................................................................2-16

T-2

Emerson Process Management GmbH & Co. OHG

Instruction Manual

HASADE-IM-EX
09/2006

X-STREAM FD

Chapter 1

Technical Description

1-1 Overview

The new X-STREAM FD gas analyzer is
designed to be used in hazardous areas. Its
flameproof enclosure can be installed at Zone 1
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 FD gas analyzer provides all the
measurement options available for general
purpose instruments, but for installation at
locations where explosive atmosphere might
be present frequently and classified as Zone 1.

The basic concept used is to protect the sur­rounding atmosphere from being ignited if an
internal failure results in high temperatures,
flames or even an explosion.

To provide adequate explosion protection the
X-STREAM FD analyzer features several
protection methods:

• The cast aluminum enclosure is designed to

• withstand an internal explosion,

• extinguish the flames resulting from an

internal explosion (thus preventing a sur­rounding explosive atmoshere from being
ignited).

• Flame arrestors avoide flame transmission
from the gas paths into the surrounding
atmosphere.

• Approved cable glands (option: conduits)
protect the cable inlets and outlets.

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 flange, quenching flames
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 flange.

6

3

1: Enclosure base
2: Screws
3: Enclosure cover
4: Flange
5: Eyebolts for lifting
6: Eyebolts for installation
7: Hinges

Fig. 1-1: X-STREAM FD

Emerson Process Management GmbH & Co. OHG 1-1

2

7

4

5
1

1 Technical Description

X-STREAM FD

Instruction Manual

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09/2006

1-3 Protective Measures in Detail

The only openings penetrating the enclosure
are threads, to be used for gas and cable in­and outlets:

Depending on the measurement application
the instrument provides up to 8 gas in- and
outlets, each protected by an approved flame
arrestor. These arrestors are installed into
threads at the bottom side of the enclosure
base. T wo fitting sizes are available for external
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.

Cables are fed into the enclosure utilizing up
to 4 cable glands, located at the enclosure`s
bottom right side. The approved glands accept
3 different internal elastomeric sealing rings
with different internal diameters, supporting a
wide range of cables.

For installation in North-America cable glands
are replaced by a combination of conduits and
metric-to-NPT thread adapters.

All threads provide a flame path of a length
ensuring that possibly entering flames are extin­guished before reaching the external atmos­phere.

Unused threads must be closed with plugs
when the instrument is operated to ensure
explosion protection.

Note!

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

1: Plugged when not used
2: Gas fitting (part of flame arrestor)
3: Plug
4: Cable gland (or conduits)

1 234

Fig. 1-2: X-STREAM FD, bottom view

Emerson Process Management GmbH & Co. OHG1-2

Instruction Manual

HASADE-IM-EX
09/2006

X-STREAM FD

1-4 Compliances

1-4 Explosion Protection Compliances

This product is available in two different variations, separately certified by agencies for the use in
hazardous (classified) areas:

The one version, to be equipped with metric-to-NPT adapters and conduits, is certified by the
Canadian Standards Association, an "OSHA Nationally Recognized T esting Labor tory" (NRTL), for
USA and Kanada and conforms to the prov isions of ANSI/ISA 60079-0, ANSI/ISA 60079-1, CAN/CSA­E60079-0 and CAN/CSA-60079-1.

The second variation, equipped with cable glands, is certified by Fyzikálnì technický zkušební ústav ,
s.p (FTZÚ), an European Notified 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 CE type examination
certificate.

Depending on the variation, the following certification marks appear on the product's nameplate
label:

USA Class I Zone 1 AEx d IIB + H2 T4
Canada Class I Zone 1 Ex d IIB + H2 T4
Certificate of Compliance:

European Union (EU) A TEX, category 2, Zone 1, Ex d IIB + H2 T4
EC ATEX Type Examination Certificate: FTZU 06 ATEX 0186 X.

Conforms with the provisions of the "Equipment intended for use in Potentially Explosive Atmospheres
(ATEX)“ Directive 94/9/EC, EMC Directive 89/336/EEC and CE Directive 93/68/EEC.

1 Technical Description

Emerson Process Management GmbH & Co. OHG 1-3

X-STREAM FD

1-5 Technical Data

Instruction Manual

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09/2006

1-5 Technical Data

Eyebolt detail

Fig. 1-3: X-STREAM FD - dimensions

All dimensions in mm
[inches in parentheses]

Housing

Permissible ambient temperature range -4 °F to +122 °F ( -20 °C to +50 °C)
Weight: approx. up to 63 kg (139 lbs)

(depending on analyzer configuration)
Protection class: IP 66 (EN 60529) / NEMA 4X

for outdoor installation
Analyzer must not be exposed to direct
sun light

Gas fittings: quantity: max. 8

specification: Flame arrestors
fittings: 6/4 mm or 1/4", stainless steel

Emerson Process Management GmbH & Co. OHG1-4

Instruction Manual

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09/2006

X-STREAM FD

1-5 Technical Data

Site of installation

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

< 70 % r. h. at 104 F (+40 °C)

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

Europe CE, based on EN 61010-1

Electromagnetic compatibility

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

Power supply

Rated input voltage 100 - 240 V 50/60 Hz, wide range input

Power supply voltage fluctuations are
not to exceed +/- 10 % of the nominal
supply voltage!

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

1 Technical Description

Rated input current
standard 0,75 - 0,35 A max.
with thermostated physics 2 - 1 A max.

Emerson Process Management GmbH & Co. OHG 1-5