X-STREAM X1 Flameproof Addendum for Hazardous Area Applications-Orig. Issue
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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 +49 (0) 6055 884-0
F +49 (0) 6055 884-209
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
HASDE-IM-Ex
09/2006
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
HASDE-IM-Ex
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
HASDE-IM-Ex
09/2006
X-STREAM FD
Safety Instructions
Safety Instructions
Emerson Process Management GmbH & Co. OHG S-7
Instruction Manual
HASADE-IM-EX
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
HASADE-IM-EX
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
HASADE-IM-EX
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
HASADE-IM-EX
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
Instruction Manual
X-STREAM FD
HASADE-IM-EX
09/2006
1-5 Technical Data
Interfaces, signal inputs / outputs
2 analog outputs channel 4 (0) - 20 mA (RB < 500 Ω)
(optically isolated; configurable by keypad
start and end concentration user configurable)
Modbus interface RS 485 (2- or 4-wire)
optional RS 232
with or without optical isolation
3 relay outputs (option "status signals“) “Failure”
according NAMUR NE 107 “Maintenance required / Off specification"
“Function check”
dry contact s, max. 30 V; 1 A; 30 W resistive
Digital Inputs and Outputs (option)
7 digital inputs zero calibration ch1 & ch2,
(common ground) span calibration ch1,
span calibration ch2,
open valve V4
open valve V1
open valve V2
open sample gas valve V3 /
switch off sample pump
max. 30 V , internally limited to 2.3 mA
H level: min. 4 V; L level: max. 3 V
8 digital outputs 2 thresholds per channel,
(optically isolated, common ground) sample gas valve,
zero gas valve V4,
span gas valve V1,
span gas valve V2
“Open Collector”, max. 30 V / 30 mA
Gas parameters
X-STREAM Instruction Manual, chapter 3 Measuring Principles
Emerson Process Management GmbH & Co. OHG1-6
Instruction Manual
HASADE-IM-EX
09/2006
X-STREAM FD
1-5 Technical Data
Power Connection
Connection via internal screw terminals near
cable entries, (fig. 1-4).
Cross section: max. 10 AWG (4 mm2), using conductor
sleeves is not required
Cable entry via 1 cable gland, classified IP 68 or suitable
conduit with metric-to-NPT adaptor
Permissible outer cable diameter for power
cord when provided with cable glands: 0.1 1 to 0.5 inch (3-13 mm),
depending on used cable gland sealing ring
Power fuses
The power terminals integrate fuse holders.
Fuse ratings: AC 230 V, 3.15 A, 5x20 mm
324 1
1 Technical Description
1 Power terminals with integrated
fuse holders
2 Protective earth terminal (PE)
Fig. 1-4: X-STREAM FD - power terminals / fuse holders
Emerson Process Management GmbH & Co. OHG 1-7
3 Power cable entry
4 EMI power filter
Instruction Manual
X-STREAM FD
HASADE-IM-EX
09/2006
1-5 Technical Data
Signal inputs / outputs
All signal lines need to be connected to internal
screw terminals (fig. 1-5)
Cross section: max. 12 AWG (2.5 mm2), using conductor
sleeves is not required
Cable entry via 3 cable glands, classified IP 68 or suitable
conduits with metric-to-NPT adaptors
Permissible outer cable diameter for signal
cables when provided with cable glands: 0.1 1 to 0.5 inch (3-13 mm)
depending on used cable gland sealing rings
Available signals: standard: Analog signal outputs
Relay status signals
Modbus interface (RS485; RS 232)
optional: Digital inputs/outputs
Detailed pin assignment 2 Installation
Fig. 1-5: X-STREAM FD - signals terminals
Emerson Process Management GmbH & Co. OHG1-8
Instruction Manual
HASADE-IM-EX
09/2006
Installing and wiring this instrument must comply with all relevant national
legislative requirements and regulations.
Consider all safety instructions within this on hand manual and all associated analyzer instruction manuals!
X-STREAM FD
Chapter 2
Installation
POSSIBLE EXPLOSION HAZARD
POSSIBLE EXPLOSION HAZARD
Installing this instrument requires opening the enclosure and working at
the open instrument. This is permitted only when both no hazardous atmosphere is present and the instrument and connected external circuitry are
de-energized!
Depending on the local regulation, this may require a competent hot work
supervisor to issue a hot work permit.
HEAVY INSTRUMENT
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!
T ake care the wall or stand the unit is intended to be inst alled at is solid and
stable to hold the units!
2 Installation
Emerson Process Management GmbH & Co. OHG 2-1
X-STREAM FD
2-1 Installing the Analyzer
Instruction Manual
HASADE-IM-EX
09/2006
2-1 Installation - Analyzer
Install the analyzer to a stand or a wall by means
of 4 eyebolts, provided at the instruments rear
side.
It is recommended to install the analyzer in an
upright (vertical) position; other orientations
may affect the measuring results.
Eyebolt detail
Fig. 2-1: X-STREAM FD dimensions
All dimensions in mm
[inches in parentheses]
Emerson Process Management GmbH & Co. OHG2-2
Instruction Manual
HASADE-IM-EX
09/2006
2-2 Connecting Gas Lines
X-STREAM FD
2-2 Installation - Gas Lines
Gas inlets and outlets are protected by certified
flame arrestors (FTZU 06 A TEX 0164), supporting stainless steel pipes of either 3.18 mm (1/
8“) or 6.35 mm (1/4“) outer diameter (OD). The
1/4“ fitting may optionally be supplied with a
clamping ring for 6 mm OD pipes.
POSSIBLE EXPLOSION HAZARD
Take care not to damage the threats, this may void the instrument´s safety
and cause hazards!
T ake care to follow the instructions of the separate flame arrestor instruction
manual (HASFAE-IM-H)!
Ensure unused entries remain sealed with approved plugs!
When thightening the fitting, counterhold the
flame arrestor with a wrench placed at the
hexagon (items 5 of fig. 2) next to the cap nut
(items 1, 4) to be tightened.
Always counterhold the flame
arrestor while thightening
fittings; otherwise the flame
arrestor may be damaged!
The instrument provides up to 8 gas inlets and
outlets, depending on the ordered configuration.
Unused entries are plugged by approved plugs.
1
5
2
3
6
5
7
4
1: Gas fitting 1/8“ (inside instrument) *
2: M18 male threat (inside enclosure wall)
3: O-ring
4: Gas fitting 1/4“ or 1/8“ (outside instrument) *
5: Hexagon for counter holding while thightening
6: Hexagon for wrench when mounting into a M18 threat
7: O-ring shoulder
*) FA 01 with 1/4“ (outside instrument) and 1/8“ (inside)
FA 02 with 1/4“ at both ends
FA 03 with 1/8“ at both ends
Fig. 2-2: Flame arrestor installed
into instrument enclosure
Emerson Process Management GmbH & Co. OHG 2-3
Fig. 2-3: Flame arrestor elements,
considering as example FA 01
)
)
2 Installation
X-STREAM FD
Instruction Manual
HASADE-IM-EX
09/2006
2-2 Installation - Gas Lines
Gas fittings are accessible at the instrument‘s
outer bottom side.The number and assignment
of gas inlet and outlet fittings depends on the
application and is given on a label attached to
the analyzer's bottom side adjacent to the
fittings.
For simple installation we recommend to mark
the gas lines according to the marking on the
analyzer label. This avoids confusion during reinstallation when the analyzer had to be
disconnected for whatever reason.
Emerson Process Management GmbH & Co. OHG2-4
Instruction Manual
HASADE-IM-EX
09/2006
2-3 Electrical Installation
Installation and connecting power and signal cables are subject to qualified
personnel only taking into account all applicable standards and legislative
requirements!
Failure to follow may cause warranty invalidation, property damage and/or
personal injury or death!
Installation of these instruments is subject to qualified personnel only,
familiar with the resulting potential risks! Instruments providing screw
terminals for electrical connections may require working near live part!
X-STREAM FD
2-3 Installation - Electrical
ELECTRICAL SHOCK HAZARD
X-STREAM FD gas analyzers do not provide a power switch!
A power switch or circuit breaker (complying 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.
Disconnect instruments with screw terminals from power when working at
power terminals (pull power plug or operate power switch/ circuit breaker in
building installation)!
The analyzers provide a protective earth terminal. T o prevent electrical shock
hazards the instruments must be connected to a protective earth. Therefore
the instruments must be connected to power by using a three wire power
cable with earth conductor!
Any interruption of the earth connector inside or outside the instrument or
disconnecting the earth terminal may cause potential electrical shock
hazzard!
The analyzers do not provide a power switch and are operable when connected to power.
Emerson Process Management GmbH & Co. OHG 2-5
2 Installation
X-STREAM FD
Do not open instrument when energized.
Ensure that external circuitry is disconnected or de-energized before
opening the instrument.
All cables (power and signal) must end (be connected) in either a safe (non-
hazardous) area or in a protecting enclosure (e.g. Ex e junction box)!
Instruction Manual
HASADE-IM-EX
09/2006
2-3 Installation - Electrical
POSSIBLE EXPLOSION HAZARD
SELECT THE CORRECT TYPE OF CABLE ENTRY
Before starting to install the analyzer, verify what type of cable entry is required at your
site of installation:
X-STREAM FD gas analyzers may be equipped with cable glands (regulated e.g. for
installations covered by ATEX) or may be installed with conduits (e.g. in North-America).
INSTALLATION USING CONDUITS
X-STREAM FD analyzers provide metric threads for installing cable entries.
Installing conduits requires using metric-to-NPT adaptors!
To stay compliant with the North-American certification use only the
following type of adaptors:
Redapt AD-U series, st ainless steel with captive o-ring seals,
size male M20 to female 3/4-NPT or 1/2-NPT.
Select a type of conduit according the local code, suitable for above
mentioned adaptors and the site of installation.
During installation follow the instructions provided by the manufacturer of
the conduits!
Unused entries are provided with plugs, secured in place with thread locking
compound!
Emerson Process Management GmbH & Co. OHG2-6
Instruction Manual
HASADE-IM-EX
09/2006
When installing the analyzer in a Hydrogen environment and/or applying
Hydrogen to the analyzer, do not use the standard ADL type cable glands!
Use suitable compound barrier cable glands to stay compliant to EN 60079-14.
During installation follow the instructions provided by the manufacturer of
the glands!
When using the ADL type cable glands: Take care to use the correct cable
gland internal elastomeric ring with an internal diameter supporting the cable
to be used! The supported cable diameters are noted on the sealing ring.
X-STREAM FD
2-3 Installation - Electrical
INSTALLATION USING CABLE GLANDS
Use only cables as specified in the cable glands installation instruction, and
carefully follow the installation instructions!
The next two pages show
• the English section of the ADL type cable
gland installation instructions, reprinted with
the permission of
Cooper Industries
Cooper Menvier Division
CAPRI-CODEC sas .
and
• the English installation instructions for typ e
AD-U adapters, reprinted with the permission
of
Redapt Ltd
Note!
See appendix of this manual for a complete
reprint, and the documentation delivered
together with your analyzer for an original
version of the cable gland or adapter installation instructions, where applicable !
2 Installation
Emerson Process Management GmbH & Co. OHG 2-7
X-STREAM FD
Type AD-U adapter
installation instructions
Instruction Manual
HASADE-IM-EX
09/2006
2-3 Installation - Electrical
Emerson Process Management GmbH & Co. OHG2-8
Instruction Manual
HASADE-IM-EX
09/2006
ADL type cable gland
installation instructions
X-STREAM FD
2-3 Installation - Electrical
The elastomeric sealing
rings, provided together
with the cable gland, are
designed to cover the
diameter ranges
3 to 8 mm
6,5 to 10.5 mm
or
10 to 13 mm.
Emerson Process Management GmbH & Co. OHG 2-9
2 Installation
X-STREAM FD
2-3 Installation - Electrical
The analyzer provides 4 cable entries; unused
entries are provided with plugs, secured in
place with thread locking compound.
The instrument provides internal screw terminals for connecting power and electrical signal
cables. This requires opening the instrument
during installation:
• Unsrew the 20 screws located on the
enclosure flange.
• Flap down the cover part to gain access
to the analyzer inside.
Instruction Manual
HASADE-IM-EX
09/2006
1 Terminals for signal cables
2 Power EMI filter
3 4 cable entries for power and signal cables
4 Power terminals with integrated fuses
1423
Fig. 2-4: X-STREAM FD - allocation of terminals
Preparation of signal cables
All signal cables are to be connected via screw
terminals, located inside the analyzer.
Supported wire cross sections: 24 to 14 A WG (0.2 to 2.5 mm2),
no need to use wire end sleeves
Cable skinning length: 0.354 inch (9 mm)
Hole diameter: 0.05 inch (1.2 mm)
Screw thread: M 2.5
Tightening torque, min: 3.5 in.lb (0.4 Nm)
All cables need to be fed through cable glands
or conduits when entering the instrument and
fixed by the gland cap nut or compound when
connected to the terminals ( warning notes,
page 2-5).
The 3 rear entries are reserved for signal
cables.
To install the cables proceed according to the
installation instruction given in the related
glands or conduits manufacturer documentation.
Emerson Process Management GmbH & Co. OHG2-10
Instruction Manual
HASADE-IM-EX
09/2006
2-3 Installation - Electrical
Signal inputs / outputs
Analog signal outputs
The rightmost 4 terminals (# 1 - 4) of the
terminals row next to the power terminals are
reserved for analog signal outputs.
X-STREAM FD
Burden: RB ≤ 500 Ω
Note!
Take care of the special installation instructions in section 4-5 of the X-STREAM gas
analyzer series manual!
(-) 4 (0) - 20 mA, channel 2
(+) 4 (0) - 20 mA, channel 2
(-) 4 (0) - 20 mA, channel 1
(+) 4 (0) - 20 mA, channel 1
Fig. 2-5: X-STREAM FD - Analog output terminals
2 Installation
Emerson Process Management GmbH & Co. OHG 2-11
X-STREAM FD
2-3 Installation - Electrical
Modbus interface
Specification and driving the interface:
X-STREAM gas analyzer series manual,
chapter 7
Note 1!
Take care of the special installation instructions in section 4-5 of the X-STREAM gas
analyzer series manual!
The leftmost 5 terminals (# 11 - 15) of the
terminals row next to the power terminals are
reserved for the Modbus interface, which can
be either of type RS 232 or RS 485.
Instruction Manual
HASADE-IM-EX
09/2006
Terminal RS 232 RS 485/2w RS 485/4w
11 Common Common Common
12 RXD not used RXD0
13 TXD not used RXD1
14 not used D1 TXD1
15 Common D0 TXD0
Note 2!
X-STREAM analyzers are to be considered
a DTE (Data Terminal Equipment).
Fig. 2-6: X-STREAM FD - Modbus interface terminals
1112131415
Emerson Process Management GmbH & Co. OHG2-12
Instruction Manual
HASADE-IM-EX
09/2006
Relay status Signals
X-STREAM FD
2-3 Installation - Electrical
Design: dry relay contacts
Electrical specification: max. 30 V , 1 A, 30 W
Note!
Take care of the special installation instructions in section 4-5 of the X-STREAM gas
analyzer series manual!
The middle 6 terminals (# 5 - 10) of the
terminals row next to the power terminals are
reserved for the relay status signals.
Signal output (NC);
configuration on
request
Signal output (NO);
factory standard
configuration
Fig. 2-7: Relay status signals, block diagram
Terminal Signal
5 Failure COM
6 Failure NO
7 Maintenance, off-spec COM
8 Maintenance, off-spec NO
9 Function check COM
10 Function check NO
10
9
Fig. 2-8: X-STREAM FD - Relay Status Terminals
Emerson Process Management GmbH & Co. OHG 2-13
5678
2 Installation
Instruction Manual
X-STREAM FD
HASADE-IM-EX
09/2006
2-3 Installation - Electrical
Digital Inputs & Outputs
Design: Open collector (outputs)
Electrical specification:
outputs: max. 30 V , 30 mA
inpu ts: max. 30 V , internally limited to 2.3 mA
H level: min. 4 V; L level: max. 3 V
The leftmost terminal strip is reserved for the
digital inputs and outputs.
Digital Inputs DigitalOutputs
Terminal 15
Terminal 16
Terminal 17
Open V2
Open sample valve or close all
DIG In GND
Terminal 14
Terminal 12
Terminal 13
Open V4
Open V1
Span cal. Ch2
Note!
Take care of the special installation instructions in section 4-5 of the X-STREAM gas
analyzer series manual!
Terminal 7
Terminal 8
Terminal 9
Terminal 10
Terminal 11
V alve V1
V alve V2
DIG Out GND
Zero cal. Ch1 & Ch2
Span cal. Ch1
Terminal 4
Terminal 5
Terminal 6
Ch2: threshold 2
Sample valve
V alve V4
Terminal 1
Terminal 2
Terminal 3
Ch1: threshold 1
Ch1: threshold 2
Ch2: threshold 1
Fig. 2-9: Digital Inputs & Outputs Terminals
Emerson Process Management GmbH & Co. OHG2-14
Instruction Manual
HASADE-IM-EX
09/2006
X-STREAM FD
2-3 Installation - Electrical
Connecting the power cord
The power cord is connected by screw
terminals, located inside analyzer.
Supported wire cross sections: 24 to 12 A WG (0.2 to 4 mm2),
no need to use wire end sleeves
Cable skinning length: 0.315 inch (8 mm)
Hole diameter: 0.05 inch (1.2 mm)
Screw thread: M 3
Tightening torque, min: 4.4 in.lb (0.5 Nm)
To install the cable proceed according to the
installation instruction given in the related
glands or conduits manufacturer documentation (take care of the warning note,
page 2-5).
Insert the power cord through the foremost entry ,
strip the outer insulation, skin and connect the
conductors to the terminals (a descriptive label
is fixed to the filter‘s housing nearby the
terminals), by inserting them from the bottom
sides.
ELECTRICAL SHOCK HAZARD
V erify the power supply at installation site meets the specification given on
the analyzer´s nameplate label, before installing the instrument!
Location
for label
L
N
PE
L= Line
N=Neutral
PE=Protective Earth
Power cord
entry
Fig. 2-10: Power terminals
Verify power cables are disconnected and/or instrument is de-energized
prior to working at the terminals!
Verify the power cord is layed with a distance of at least 1 cm (0.5“) to any
signal cable to ensure proper insulation from signal circuits!
Emerson Process Management GmbH & Co. OHG 2-15
2 Installation
X-STREAM FD
2-3 Installation - Electrical
Connecting an optional equipotential
bonding conductor
The X-STREAM FD enclosure provides an additional terminal for connecting an equipotential
conductor, located at the base part flange´s rear
side (see fig. 2-6), near the nameplate label.
Screw thread: M5
Instruction Manual
HASADE-IM-EX
09/2006
Fig. 2-11: Equipotential bonding conductor terminal
Emerson Process Management GmbH & Co. OHG2-16
Instruction Manual
HASADE-IM-EX
09/2006
2-3 Installation - Electrical
ELECTRICAL SHOCK HAZARD
Before completing the electrical connection of the instrument, verify cables
are inserted and connected in correct manner!
Ensure the earthing conductor is connected!
After all connections are established in correct
manner and verified,
X-STREAM FD
• fix the cables according to the installation
instruction given in the cable gland´s /
conduits manufacturer documentation.
• Install the analyzer´s cover by means of
ALL 20 screws!
Tightening torque: min. 354 in.lb (40 Nm)
POSSIBLE EXPLOSION HAZARD
Do NOT operate the instrument with doors or covers open! This is permitted
only when no hazardous atmosphere is present!
Depending on the local regulation, this may require a competent hot work
supervisor to issue a hot work permit.
Use ALL 20 screws to fix the cover! V iolation may cause an explosion hazard!
Emerson Process Management GmbH & Co. OHG 2-17
2 Installation
X-STREAM FD
Instruction Manual
HASADE-IM-EX
09/2006
2-3 Installation - Electrical
Emerson Process Management GmbH & Co. OHG2-18
Instruction Manual
HASADE-IM-EX
09/2006
X-STREAM FD
Chapter 3
Startup
Once the X-STREAM FD analyzer is installed
correctly and in accordance to the instructions
given in chapter2 „Installation“ it is prepared
for startup.
POSSIBLE EXPLOSION HAZARD
Ensure all covers, plugs and housing parts are in place and secured properly
before supplying power and signal voltages!
Ensure all requirements given
by the clarification sheet for
performing gas analysis within
a flameproof enclosure are
considered BEFORE supplying
gases (see page S-5)!
The sheet also gives instructions for the sequence of
supplying gases during process and analyzer startup .
3 Startup
After all safety aspects are followed and
checked, the instrument may be powered and
operated according the instructions given in the
X-STREAM series instruction manual.
Read this manual for detailled information
about software, parameter settings and more.
Emerson Process Management GmbH & Co. OHG 3-1
X-STREAM FD
Instruction Manual
HASADE-IM-EX
09/2006
3 Startup
Emerson Process Management GmbH & Co. OHG3-2
Instruction Manual
HASADE-IM-EX
09/2006
X-STREAM FD
Chapter 4
Service and Maintenance
Note!
This chapter deals with service and maintenance procedures related to explosion protection only!
More detailled instructions about servicing and maintaining general purpose components of
X-STREAM gas analyzers are subject of the X-STREAM analyzer instruction manual.
POSSIBLE EXPLOSION HAZARD
Inspection, maintenance and service must be carried out considering all
related standards (e.g. EN 60079-17 "Inspection and maintenance of
electrical installations in hazardous areas (other than mines)"
POSSIBLE EXPLOSION HAZARD
Service or replacement of safety related components or requiring to open
the instrument are permitted only if no hazardous atmosphere is present
and both the instrument and connected circuitry are de-energized!
Depending on the local regulation this may require a competent hot work
supervisor to ssue a hot work permit.
POSSIBLE EXPLOSION HAZARD
After maintenance or replacement of parts concerning explosion protection
an authority on explosion protection has to verify that the analyzer still meets
the requirements for explosion protection before it is switched on again.
Parts essential for explosion protection must not be repaired, they must be
replaced if defective!
4 Maintenance
The authority has to issue a certificate for this and/or attach a test label to
the equipment before startup after maintenance or replacement of parts.
Emerson Process Management Manufacturing GmbH & Co. OHG 4-1
X-STREAM FD
FLAMMABLE GASES - POSSIBLE EXPLOSION HAZARD
Leaks may cause explosion when measuring flammable gases!
When measuring flammable gases it is recommended to perform a leak test
on all gas paths, connections and components before startup or applying
power. Leak tests should be carried out on a 2 month's regular basis and
after repair/maintenance.
See the analyzer instruction manual for instructions on how to carry out
leak tests.
Instruction Manual
HASADE-IM-EX
09/2006
4 Service and Maintenance
HAZARDOUS GASES
When measuring flammableand/or toxic gases it is recommended to purge
the system with air or an inert gas, e.g. nitrogen, prior to opening the gas
paths.
Violation may cause an explosion and/or personal injury or death!
POSSIBLE EXPLOSION HAZARD
Modifications affecting the integrity of type of protection (e.g. affixing
addtional threads, replacing the flame arrestors by other model) are NOT
PERMITTED!
Violation may cause an explosion and/or personal injury or death!
Emerson Process Management Manufacturing GmbH & Co. OHG4-2
Instruction Manual
HASADE-IM-EX
09/2006
4-1 Verifications and Tests after Service or Maintenance
4-1 Verifications and Tests after Service or Maintenance
Modifications made on the electrical apparatus
affecting the integrity of the type of protection
or the temperature of the apparatus shall be
permitted only if the modified apparatus is
resubmitted to a testing station.
In the case of repairs affecting the type of
protection, the parts which have been repaired
should be subjected to new routine verifications
and tests. These tests need not necessarily be
made by the manufacturer.
4-1-1 Routine Tests
X-STREAM FD
The following tests shall be performed on a
regular basis:
4-1-1-1 Visual Inspection
The instrument shall be visually checked for
damages to the enclosure and external analyzer components.
4-1-1-2 Tests on Flame Arrestors
Depending on the application flame arrestors
should be checked periodically according the
information given in the flame arrestors
instruction manual.
4 Maintenance
Emerson Process Management Manufacturing GmbH & Co. OHG 4-3
X-STREAM FD
4-2 Replacement of Parts
4-2 Replacement of Parts
POSSIBLE EXPLOSION HAZARD !
Replacement of parts found defective is permitted only by using original
parts!
Violation may cause explosions!
Parts beside the cast enclosure, the safety of the X-STREAM FD relies on:
Cable glands, standard
Type: ADL 1F ISO 20 No. 05 by CAPRI
LCIE 97 ATEX 6006 X
Instruction Manual
HASADE-IM-EX
09/2006
Compound Cable glands (optional)
Metric-to-NPT adapters
Flame arrestors
Internal battery (soldered to electronics board,
not user replaceable)
T ype: to be selected for the installed cable
and with A TEX (EU) or suit able local approval
(outside EU)
Male thread: M20
Available from several manufacturers, e.g.
type CR-X by PeppersCable Glands Limited
Type: AD-U series 316 by Redapt Ltd.
Sira 99ATEX1115U
Male thread: M20
Female thread: as required
Type: FA 01, F A 02, FA 03
by EMERSON PROCESS MANAGEMENT
FTZU 06 ATEX 0164
Type: SL 750 by Tadiran Batteries GmbH
System: SOCl2 / Li
Nom. voltage: 3.6 V
IEC 60086-1 type E cell
Emerson Process Management Manufacturing GmbH & Co. OHG4-4
Instruction Manual
HASADE-IM-EX
09/2006
Enclosure screws
X-STREAM FD
4-2 Replacement of Parts
Material: stainless steel A2
Thread: M16 x 45 ISO 4762– A2
4 Maintenance
Emerson Process Management Manufacturing GmbH & Co. OHG 4-5
X-STREAM FD
Instruction Manual
HASADE-IM-EX
09/2006
4-2 Replacement of Parts
Emerson Process Management Manufacturing GmbH & Co. OHG4-6
Instruction Manual
HASADE-IM-EX
09/2006
Appendix
This chapter contains
ATEX EC Type Examination Certificate A-1, page A-2
EC Declaration of Conformity A-2, page A-3
Cable gland A DL 1F installation instruction A-3, page A-5
Block diagram A-4, page A-6
X-STREAM FD
Appendix
Emerson Process Management GmbH & Co. OHG A-1
X-STREAM FD
A-1 ATEX EC Type Examination Certificate
A-1 ATEX EC Type Examination Certificate
Instruction Manual
HASADE-IM-EX
09/2006
Emerson Process Management GmbH & Co. OHGA-2
Instruction Manual
HASADE-IM-EX
09/2006
A-2 EC Declaration of Conformity
A-2 EC Declaration of Conformity
X-STREAM FD
Appendix
Emerson Process Management GmbH & Co. OHG A-3
X-STREAM FD
Instruction Manual
HASADE-IM-EX
09/2006
Emerson Process Management GmbH & Co. OHGA-4
Instruction Manual
HASADE-IM-EX
09/2006
A-3 Cable gland ADL 1F
installation instruction
(reprinted with the
permission of
Cooper Industries
Cooper Menvier Division
CAPRI-CODEC sas. )
X-STREAM FD
A-3 Cable Gland Installation Instruction
Appendix
Emerson Process ManagementGmbH & Co. OHG A-5
X-STREAM FD
A-4 Block diagram
X-STREAM FD
Instruction Manual
HASADE-IM-EX
09/2006
A-4 Block Diagram
Emerson Process Management GmbH & Co. OHGA-6
Instruction Manual
HASADE-IM-Ex
09/2006
X-STREAM FD
X-STREAM FD
EUROPE
Emerson Process Management GmbH & Co. OHG
Industriestrasse 1
63594 Hasselroth
Germany
T +49 (6055) 884-0
F +49 (6055) 884-209
Internet: www.emersonprocess.de
EUROPE, MIDDLE EAST , AFRICA
Emerson Process Management Shared Services Limited
Heath Place
Bognor Regis
West Sussex PO22 9SH
England
T +44-1243-863121
F +44-1243-845354
Internet: www.emersonprocess.co.uk
Instruction Manual
HASADE-IM-Ex
09/2006
NORTH AMERICA
Emerson Process Management
Rosemount Analytical Inc.
6565P Davis Industrial Parkway
Solon, OH 44139-3922
USA
T +1 (440) 914-1261
F +1 (440) 914-1271
Internet: www.emersonprocess.com
LATIN AMERICA
Emerson Process Management
Rosemount Analytical Inc.
Latin America Headquarters
11100 Brittmoore Park Drive
Houston, TX 77041
USA
T +1 (713) 467-6000
F +1 (713) 827-3329
ASIA - P ACIFIC
Emerson Process Management Asia Pacific Pte Ltd
1 Pandan Crescent
Singapore 128461
T +65 6777 8211
F +65 6777 0947
Internet: www.ap.emersonprocess.com
© 2006 Emerson Process Management GmbH & Co. OHG
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