Rosemount X-STREAM X1 FN Addendum for Non-Incendive Analyzers in Zone 2 Hazardous Area Applications-2nd Ed. Manuals & Guides

Instruction Manual
HASANE-IM-ATEX 04/2008
Addendum for Non-Incendive Analyzers
intended to be used in Hazardous Areas of Zone 2
X-STREAM® FN
www.EmersonProcess.com
X-STREAM® FN
Emerson Process Management (Rosemount Analytical) designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain
them to ensure they continue to operate within their normal specications. The following
instructions MUST be adhered to and integrated into your safety program when installing, using and maintaining Emerson Process Management (Rosemount Analytical) products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson Process
Management (Rosemount Analytical) representative for clarication.
• Follow all warnings, cautions, and instructions marked on and supplied with the
product.
Instruction Manual
HASANE-IM-ATEX 08/2007

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!
• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
• Install your equipment as specied in the Installation Instructions of the
appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualied personnel to install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualied people use replacement parts specied by Emerson Process Management (Rosemount Analytical).
Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in re, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place,
except when maintenance is being performed by qualied persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice. 2nd Edition 04/2008
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
HASANE-IM-ATEX 08/2007
X-STREAM® FN

PREAMBLE

This instruction manual provides information about installing, operating and maintaining/ servicing Non-Incendive X-STREAM FN series gas analyzers in hazardous (classied) areas and shall be read in conjunction with the standard analyzer instruction manual only!
This instruction manual covers all X-STREAM FN series analyzer variations and therefore
may describe congurations and/or options not relevant for your specic analyzer.

DEFINITIONS

The following denitions apply to WARNINGS, CAUTIONS and NOTES found throughout
this publication.
Highlights an operation or maintenance procedure, practice, condition, statement, etc.
If not strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition, statement, etc.
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
Emerson Process Management GmbH & Co. OHGS-2
X-STREAM® FN
Instruction Manual
HASANE-IM-ATEX
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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.
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:
Elektrostatic discharge (ESD)
Harmful (to Health)!
Explosion Hazard!
Toxic!
Heavy Instrument!
Disconnect from Mains!
Instruction Manual
HASANE-IM-ATEX 08/2007

TERMS USED IN THIS MANUAL

ATEX
Directive 94/9/EC, commonly called the ATEX („Atmosphères Explosibles“) directive, dealing with equipment intended to be used in potentially explosive atmosphere. This directive is valid for equipment to be sold into and/or installed and operated in the European Union (EU).
Area Classication
X-STREAM® FN
Terms
Safety Instructions
Zone 2
In Zone 2 ignitable concentrations of am­mable gases are not likely to exist under normal operating conditions. (A guideline value [not part of a standard]: less than 10 hours per year.)
Flammable Gas(es)
Gases and gas mixtures are assigned to be
ammable if they might become ignitable
when in a mixture with air.
Lower Explosion Limit (LEL)
Volume ratio of ammable gas in air below
which an explosive gas atmosphere will not be formed: the mixture of gas and air lacks
sufcient fuel (gas) to burn.
Upper Explosion Limit (UEL)
Volume ratio of ammable gas in air above
which an explosive gas atmosphere will not be formed: the mixture of gas and air is too
rich in fuel (decient in oxygen) to burn.
Emerson Process Management GmbH & Co. OHG S-3
Emerson Process Management GmbH & Co. OHGS-4
X-STREAM® FN
Instruction Manual
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Safety Instructions

SAFETY INSTRUCTIONS
INTENDED USE STATEMENT
X-STREAM FN 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 certications or approvals are to be implied
as covering such applications!
SAFETY SUMMARY
If this equipment is used in a manner not specied in these instructions, protective sy­stems may be impaired.
AUTHORIZED PERSONNEL
To avoid personal injury and loss of property, do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate trai­ning. Save all instructions!
ADDITIONAL LITERATURE
This manual covers aspects specic for using Non-Incendive X-STREAM FN analyzers in hazardous (classied) 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
Contact your local service center or sales ofce when missing documents.
Save all instructions for future use!
Instruction Manual
HASANE-IM-ATEX 08/2007
X-STREAM® FN
Safety Instructions
EXPLOSION HAZARD BY MODIFICATION
Any addition, substitution, or replacement of components installed on or
in this device, must be certied to meet the hazardous area classication that the device was certied to prior to any such component addition,
substitution, or replacement. In addition, the installation of such device or
devices must meet the requirements specied and dened by the hazardous area classication of the unmodied device.
Any modications to the device not meeting these requirements, will void the product certication(s).
Contact Emerson Process Management‘s customer service center for return authorization.
POSSIBLE EXPLOSION HAZARD Do not open instrument when energized. Ensure that external circuitry is disconnected or de-energized before
opening the instrument.
Safety Instructions
Before opening the instrument ensure the waiting time, as specied on the
label at the analyzer´s enclosure, has elapsed! 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 owmeter is required for ow control, legislative requirements and instructions for installation in hazardous (classied) areas must be
considered.
Emerson Process Management GmbH & Co. OHG S-5
X-STREAM® FN
The analyzer model X-STREAM FN, to which this manual relates, intended to be wall mounted and/or outdoor installed, weighs up to approx. 26 kg (58 lbs), depending on included options!
Use two people and/or suitable tools for transportation and lifting these instruments!
Take care to use anchors and bolts specied to be used for the weight of
the units!
Instruction Manual
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08/2007
Safety Instructions
HEAVY INSTRUMENT
Take care the wall or stand the unit is intended to be installed at is solid and stable to hold the units!
POSSIBLE EXPLOSION HAZARD
Flammable Gases must be intoduced in INFALLIBLE CONTAINMENTS ONLY, to avoid leakage into internal Analyzer Housing!
Emerson Process Management GmbH & Co. OHGS-6
Instruction Manual
HASANE-IM-ATEX 08/2007
X-STREAM® FN
Table of ConTenTs
Preamble S-1
Denitions S-1
Symbols used in this manual .............................................................................................S-2
Terms used in this manual .................................................................................................S-3
Safety instructions ..............................................................................................................S-4
Chapter 1 Technical Description 1-1
1-1 Application and Principle of Operation ............................................................... 1-1
1-2 Technical Data ........................................................................................................1-2
1-2-1 Installation Site and Protection Method ........................................................... 1-2
1-2-2 General Technical Data ...................................................................................... 1-3
1-3 X-STREAM Dimensions .........................................................................................1-4
1-4 MeasurementSpecications ................................................................................1-5
1-5 Infallible Containments .........................................................................................1-5
1-6 Additional Safety Measures .................................................................................. 1-5

Table of Contents

Chapter 2 Installation 2-1
2-1 Abstract ..................................................................................................................2-1
2-2 Installation of the Instrument ................................................................................2-1
2-3 X-STREAM Dimensions .........................................................................................2-2
2-4 Connections of Gas Pipes ....................................................................................2-3
2-5 Wiring ......................................................................................................................2-4
2-5-1 Cable Gland Assembly Instruction for Shielded Cables ................................ 2-6
Chapter 3 Startup 3-1
3-1 Final Check .............................................................................................................3-1
3-2 Switching On .......................................................................................................... 3-1
Chapter 4 Maintenance 4-1
4-1 Maintenance Instructions......................................................................................4-2
4-2 Gas Paths ...............................................................................................................4-2
4-3 CheckModiedorRepairedAnalyzers .............................................................. 4-3
IHV-1Emerson Process Management GmbH & Co. OHG
Instruction Manual
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08/2007
Table of Contents
4-4 Enclosure Leakage Test ....................................................................................... 4-3
4-4-1 Preparation..........................................................................................................4-3
4-4-2 Run Leakage Test ..............................................................................................4-4
4-4-3 Startup after Test Procedure ............................................................................. 4-4
4-5 Replacement of Components ............................................................................... 4-5
Appendix A-1
A-1 EC Declaration of Conformity ...............................................................................A-2
A-2 Manufacturer‘s Declaration ..................................................................................A-3
A-3 Certicate ...............................................................................................................A-4
A-4 Block diagram ........................................................................................................A-5
A-5 Assignment of Plugs and Terminals ....................................................................A-6

Index of fIgures

Fig. 1-1: X-STREAM FN - Dimensions ..............................................................................................................1-4
Fig. 2-1: X-STREAM FN - Dimensions ..............................................................................................................2-2
Fig. 2-2: Marking of the gas ttings (example) ...............................................................................................2-3
Fig. 2-3: Terminal block X1 - Analog outputs .................................................................................................2-8
Fig. 2-4: Terminal block X2 - Modbus interface ..............................................................................................2-9
Fig. 2-5: X-STREAM FN - Modbus over ethernet connector ........................................................................2-10
Fig. 2-6: Relay status signals ......................................................................................................................... 2-11
Fig. 2-7: Terminal block X3 - Relay Status Terminals ..................................................................................2-11
Fig. 2-8: Terminal block X4 - Digital Inputs & Outputs .................................................................................2-12
Fig. 2-9: Power terminals ................................................................................................................................2-13
Fig. 3-1: Sealing Plug for Cable Connections .................................................................................................3-1
Fig. 3-2: Hexagon Socket Screw used as Sealing Plug .................................................................................3-1
Fig. 4-1: Assembly for check routines .............................................................................................................4-4
Fig. A-1: Terminals strip 1 ................................................................................................................................ A-6
Fig. A-2: Terminals strip 2 ................................................................................................................................ A-6
Fig. A-3: Power terminals ................................................................................................................................A-6
Fig. A-4: Ethernet connector for Modbus .......................................................................................................A-6
IHV-2 Emerson Process Management GmbH & Co. OHG
Instruction Manual
HASANE-IM-ATEX 08/2007
Chapter 1
Technical Description

1-1 Application and Principle of Operation

X-STREAM® FNX-STREAM
The Gas Analyzer model X-STREAM FN has been developed to enable the measurement of gas components in hazardous areas (Ex zones): X-STREAM FN is assembeled with selected components (method of protection: „Non- in­cendive“ Ex n) to be installed and operated in
hazardous (classied) area of ex zone 2. X-STREAM FN Analyzers which are certied
according to EN 60079-15, protection method Ex n „Non-Incendive“, do not include com­ponents by design which may create arcs, sparks or hot spots under normal operation conditions. That is why they cannot ignite an explosive atmosphere being eventually present. The advantage of the Non-Incendive protec­tion type versus other protection methods is that no other means need to be provided such as purge gas for pressurized systems.
The used method of protection is suitable for Zone 2 applications only. According to this
ammable/explosive gases are not allowed or
just for a short while in the ambient of these components.
This is especially true for the measurement
of ammable gases: Measuring ammables gases with standard
tubings (containments) would enable those gases to pass off into the housing in case of leakages. Together with the air being present an explosive mixture would be built. As a result of the tight enclosure and the missing exchange with the surrounding atmosphere the explosive mixture would be available for a long time. The categorization of the internal compartment of the X-STREAM FN analy­zer would be no more according to zone 2 but zone 0 requiring special protection me­thods!
Nevertheless Emerson Process Manage­ment has designed infallible containments to
enable the measurement of ammable gases
in X-STREAM FN Analyzers: These are gas paths designed as „technically
tight“ due to the construction ( 1-5, Page 1-5). Using those infallible containments in a proper way enables the use to avoid the
leakage of ammable gases into the analyzer
and the formation of explosive atmosphere.
1 Technical Description
EXPLOSION DANGER MEASURING FLAMMABLE GASES
Flammable Gases must be introcuced into INFALLIBLE CONTAINMENTS ONLY thus avoiding internal leakages!
Such Containments are available on request.
Emerson Process Management GmbH & Co. OHG 1-1
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X-STREAM® FNX-STREAM
®
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1-2 Technical Data

1-2 Technical Data 1-2-1 Installation Site and Protection Method

Permissible ambient temperature -20 °C (-4 °F) to +50 °C (122 °F), other on request
Permissible storage temperature -20 °C (68 °F) to +70 °C (158 °F) Permissible humidity (non-condensing) < 90 % r. F. at +20 °C (68 °F)
< 70 % r. F. at +40 °C (104 °F) Pollution degree 2
Installation category I I Altitude 0 to 2000 m (6560 ft.) Höhe über N.N. Ambient atmosphere The Analyzer may not be
used in corro-
sive atmosphere
Protection concept: Wall-mount eld housing for outdoor installa-
tion with protection method Ex n
Hazardous zone: Zone 2, Gas
Underlying standard:
IEC 60079-0:2004 (4th Edition) DIN EN 60079-0:2004 IEC 60079-15:2005 (3
rd
Edition)
DIN EN 60079-15:2005
Classication:
ATEX Group II, Category 3, Gas,
Ex nAC IIC T4 Temperature class: T4
A test sample was approved by an independant test institute according to Guideline (Directive)
94/9/EG („ATEX“) and fullls the corresponding standard.
Identication Mark (Labeling)
Emerson Process Management GmbH & Co. OHG 1-2
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X-STREAM® FNX-STREAM
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1-2 Technical data

1-2-2 General Technical Data

For further technical data consult X-STREAM general instruction manual.
Voltage supply
Rated input voltage 100 - 240 V 50/60 Hz, Wide range input
Power supply voltage uctation must
not exceed voltage
Input voltage range 85 - 264 V , 47 - 63 Hz
!
X-STREAM® FNX-STREAM
+/- 10 % of the nominal
Rated input current standard 0,75 - 0,35 A max. with thermostatically controlled physics 2 - 1 A max.
Housing
Weight: up to 26 kg
(depending on analyzer conguration)
Protection class: IP 66 (EN 60529) / NEMA 4X for outdoor installation analyzer must be protected against direct sun
Gas ttings: Number: max. 8 Specication: 6/4 mm or 1/4“, stainless
steel, other on request
General Certications (Compliances)
Electrical safety Europe CE, based on EN 61010-1
Elektromagnetic compatibility Europe CE, based upon EN 61326 other NAMUR
1 Technical Description
Emerson Process Management GmbH & Co. OHG 1-3
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X-STREAM® FNX-STREAM
®
FN

1-3 X-STREAM Dimensions

1-3 X-STREAM Dimensions
Instruction manual
HASANE-IM-ATEX
Eyebolt detail
08/2007
approx. mm [inch]

Fig. 1-1: X-STREAM FN - Dimensions

Emerson Process Management GmbH & Co. OHG 1-4
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X-STREAM® FNX-STREAM
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1-4 Measurement Specications
1-4 Measurement Specications
X-STREAM® FNX-STREAM
Gas components
Maximal sample gas pressure
Sample gas ow Depending on measuring principle (see X-STREAM general instruction
Gas components
Flammable Gases must be introduced with INFALLIBLE CONTAINMENTS only!

1-5 Infallible Containments

Infallible Containments are based on con­nections being velded, soldered or designed as glass-to-metal connections resp. eutectic or similar methods. The function test for in­fallible containments is performed according to the legislation guidline EN 60079-2. Thus it makes sure that no leakage may occur in the gas paths enabling gas to enter the inner compartment of the analyzer housing.
Non-ammable gases resp. gas mixtures; concentration does not exceed LEL
(lower explosion limit) Atmospheric pressure or <1500 hPa at normal ambient pressure depen-
ding on used measuring principle (see X-STREAM general instruction manual)
manual)
Flammable gases
POSSIBLE EXPLOSION HAZARD
The X-STREAM FN Analyzer can be used for
measurement of ammable gases if the gas paths for sample gas (and ammable cal gas)
are designed as infallible containment. Infallible containments are availble for thermal conductivity while Infrared/Ultraviolet method is under construction. Consult factory or EMERSON sales ofce for further informa­tion.
1 Technical Description

1-6 Additional Safety Measures

Gas outlets need to be located at a safe
location ouside hazard area. Sample gas tubings may be connected to the sample inlet.
If sample gas oulets are located inside
hazardous areas ame arrestors have
to be provided for gas inlet and outlet.
Emerson Process Management GmbH & Co. OHG 1-5
Signal lines need to end in safe or pro-
tected areas (e.g. in a suitable housing type Ex e).
®
FN
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POSSIBLE EXPLOSION HAZARD AND MORTAL DANGER
Read the corresponding sections of the Analyzer Instruction Manual and all Addendum Manuals before performing the Installation !
Disregarding of the Security Advices can lead to explosion, physical injury or death!
X-STREAM® FNX-STREAM
Chapter 2
Installation

2-1 Abstract

Save operation of Emerson Process Ma­nagement gas analyzers requires a proper installation. Therefor all procedures that are described in this section as well as those of the analogous sections of the X-STREAM analyzor family general instruction manual need to be followed strictly.
HEAVY INSTRUMENT
X-STREAM FN Analyzers intended to be wall mounted and/or outdoor installed weigh up to 26 kg (58 lbs), depending on the chosen options!
Use two persons and/or suitable tools for transportation and lifting these instruments!
Take care to use anchors and bolts specied to be used for the weight of
the instruments!

2-2 Installation of the Instrument

For installation of the instrument use the de­scriptions of the X-STREAM analyzor family general instruction manual. Verify that the installation site of the instrument is determi­ned adequately by means of the Figures (see Fig. 2-1).
Assure that the wall/device for installation is sufciently attached and stable
to carry the instrument!
Emerson Process Management GmbH & Co. OHG 2-1
2 Installation
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X-STREAM® FNX-STREAM
®
FN

2-3 X-STREAM Dimensions

2-3 X-STREAM Dimensions
Instruction Manual
HASANE-IM-ATEX
Eyebolt detail
08/2007
approx. mm [inch]
Figure 2-1: X-STREAM FN - Dimensions
Emerson Process Management GmbH & Co. OHG 2-2
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X-STREAM® FNX-STREAM
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2-4 Connections of Gas Pipes

2-4 Connections of Gas Pipes
TOXIC GAS HAZARDS
Take care that all external gas pipes are connected in the described way and that they are gastight to avoid leakages!
Faulty connected gas pipes lead to explosion hazard or even to mortal danger!
Emissions may contain hydrocarbon or other toxic components (e.g. carbon monoxide)! Carbon monoxide may cause headache, sickness, unconsciousness and death. Don‘t take a breathe of the emissions!
X-STREAM® FNX-STREAM
Don‘t confuse gas inlet and outlet! All introduced gases need to be previously conditioned! If aggressive gases are introduced into the instrument it needs to be assured that the gas paths don‘t get damaged!
More information is available in the X-STREAM general instruction manual, page 4-2 ff.
The number of the gas ttings and their allo­cation may vary depending on the installated options.
All gas ttings are marked and located at the
rear side of the analyzer.
If it‘s necessary to open the gas paths, the
gas ttings need to be tightened with PVC-
caps to prevent contamination through moi­sture, dust etc..
Figure. 2-2: Marking of the gas ttings
(example)
2 Installation
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X-STREAM® FNX-STREAM
®
FN
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2-5 Wiring

2-5 Wiring
EXPLOSION DANGER / ELECTRICAL SHOCK HAZARD
Installation and connecting power and signal cables are subject to qualied personnel only taking into account all applicable standards and legislative requirements!
The standard EN 60079-14 „Electrical installations in [gas explosion] hazardous areas“ und all corresponding standards must be taken into account.
Failure to follow may cause warranty invalidation, property damage and/or personal injury or death!
08/2007
Installation of these instruments is subject to qualied personnel only,
familiar with the resulting potential risks! Instruments providing screw terminals for electrical connections may require working near live part!
X-STREAM FN 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. To 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 2-4
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X-STREAM® FNX-STREAM
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Do NOT open instrument during operation before having made sure that ambient atmosphere is not hazardous (explosive)!explosive)!
2-5 Wiring
POSSIBLE EXPLOSION HAZARD
X-STREAM® FNX-STREAM
POSSIBLE EXPLOSION HAZARD
If the analyzer is powered and shall be opened (e.g. for troubleshooting) make sure that ambient atmosphere is not hazardous (explosive) beforeexplosive) before servicing internal components (this is valid also for example for the exchange of fuses!)
Terminal tags and screwed connections with signals being not intrinsically safe may be disconnected when energized!
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X-STREAM® FNX-STREAM
®
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2-5 Wiring
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• All gas ttings have to be executed accor­ding to the circuit diagrams handed over with the instrument.
• A mains switches or circuit breakers have to be provided at the installation site.
• The housing needs to be connected to a ground or a potential equalization conduc­tor.
• All cabels that are introduced into the housing need to be kept as short as pos­sible.
• The cable connectors are intended for se-
• Use shielded cables only for signal li­nes! To ensure electromagnetic compa­tibility (EMC) we recommend attending the installation commands in section 2-5-1.
• Cables for intrinsically safe (Ex i) signals need to get marked adequately. For passing the cables take care of the requirements of the corresponding standards (minimum distance to cables being not intrinsically safe etc.). If the minimum distance can‘t be
hold a sufciently thick rm isolation needs
to be applied.
veral cables with a diameter of 7 to 12 mm. Special adapters that allow the mounting of thinner or multiple cables in one connection can be delivered on request.
• Supply terminals are intended for cables with a cross section of up to 2,5 mm2.

2-5-1 Cable Gland Assembly Instruction for Shielded Cables

1. Strip the cabel insu­lation
2. Uncover the shiel-
ding
3. Feed cable through gland nut and into
xing element
4. Put the shielding net over the element the way that it co­vers the o-ring 2 mm (0.08 in).
5. Stick the fixing ele­ment into the neck
and x the gland
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X-STREAM® FNX-STREAM
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2-5 Wiring
Preparation of signal cables
All signal cables are to be connected via screw terminals, located inside the analy­zer. The instruments inner components are
Supported wire cross sections: 24 to 14 AWG (0.2 bis 2.5 mm2), no need to use wire end sleeves
Cable skinning lenght: 0.354 inch (9 mm) Hole diameter: 0.05 inch (1.2 mm) Screw thread: M2.5
accessible after loosening the two fasteners at it‘s upper end and opening the front door downwards.
X-STREAM® FNX-STREAM
Tightening torque, min: 3.5 in.lb (0.4 Nm)
All cables need to be fed through cable glands
when entering the instrument and xed by the
gland nut when connected to the terminals.
The cable glands provide strain-relief and protection against EMI (Electro Magnetic In­terference) when installed properly.
Emerson Process Management GmbH & Co. OHG 2-7
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X-STREAM® FNX-STREAM
®
FN
Signal inputs / outputs Analog signal outputs
2-5 Wiring
Instruction Manual
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For access to the terminals open the instrument‘s front door.
Burden: RB 500
The rightmost 4 terminals (# 1-4) of the ter­minals row next to the power terminals are reserved for analog signal outputs.
Note!
Take care of the special installation instruc­tions in section 4-5 and the cable gland as­sembly instruction on page 2-6!
(-) 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. 2-3: Terminal block X1 - Analog outputs

ELECTRICAL SHOCK HAZARD
Take care that electricity cables are not connected and/or the analyzer is not energized during operation!
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X-STREAM® FNX-STREAM
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Modbus interface
Specication and driving the interface:
X-STREAM general instruction manual
Chapter 9
2-5 Wiring
X-STREAM® FNX-STREAM
Note 1!
Take care of the special installation instruc­tions in section 4-5 of X-STREAM general instruction manual and of the cable gland assembly instruction on page 2-6!
For accessing the terminals open the instrument‘s front door.
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).
The leftmost 5 terminals (# 11 - 15) of the terminals row next to the power terminals are reserved for the Modbus interface.
1112131415

Fig. 2-4: Terminal block X2 - Modbus interface

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X-STREAM® FNX-STREAM
®
FN
2-5 Wiring
Optional RJ45 connection
If installed, the optional RJ45 connector is located on the BKS main board, in the upper part of the instrument. To install this connection one has to insert a cable without connector through the cable inlet.
Once the open end is inside the instrument, the plug connector can be attached: We recommend using a VARIOSUB RJ45 QUICK-ON plug connector (PHOENIX CONTACT), as supplied together with the instrument, not requiring special tools. See the separate installation instruction, provided together with the plug connector for informa­tion on how to install it.
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Note!
Notice, that the modbus screw terminals ( page 4-25) are installed, too, but without function!
Pin 1 Pin 8

Fig. 2-5: X-STREAM FN - Modbus over ethernet connector

Pin Signal 1 TX+ 2 TX­ 3 RX+ 6 RX­ other not used
RJ45 connector on
main board BKS
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Relay Status Signals
2-5 Wiring
X-STREAM® FNX-STREAM
Design: potential-free relay contact Electrical specication: max. 30 V , 1 A, 30 W
Note!
Take care of the special installation instruc­tions in section 4-5 and of the cable gland assembly instruction on page 2-6!
For accessing the terminals open the instrument‘s front door. 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); congurati­on on request
Signal output (NO); standard
conguration

Fig. 2-6: Relay status signals

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. 2-7: Terminal block X3 - Relay Status Terminals

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2-5 Wiring
Digital Inputs & Outputs (option)
Design: Open collector (outputs) Electrical specication: outputs: max. 30 V , 30 mA inputs: max. 30 V , internally limited to 2.3 mA H level: min. 4 V; L level: max. 3 V
For accessing the terminals open the instru­ments front door. The leftmost terminal strip is reserved for the digital inputs and outputs.
Terminal 9
Terminal 10
Terminal 11
Terminal 12
Terminal 13
Terminal 14
Terminal 15
Terminal 16
Terminal 17
DIG Out GND
Zero cal. Ch1 & Ch2
Span cal. Ch1
Span cal, Ch2
Valve V4
Valve V1
Valve V2
Sample valve or pump
DIG In GND
Terminal 6
Terminal 7
Terminal 8
Valve V4
Valve V1
Valve V2
Note!
Take care of the special installation instruc­tions in section 4-5 of the X-STREAM Basis Instruction Manual and of the cable gland assembly instruction on page 2-6!
Terminal 1
Terminal 2
Terminal 3
Terminal 4
Terminal 5
*)
When making use of the
Ch1 -threshold 1
Ch1 -threshold 2
Ch2 -threshold 1
Ch2 -threshold 2
Sample valve
*)
range switching option, this output is assigned a range indicator ( X-STREAM general instruction manual, section 7-7-5, page 7-57)
Digital Inputs Digital Outputs

Fig. 2-8: Terminal block X4 - Digital Inputs & Outputs

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X-STREAM® FNX-STREAM
2-5 Wiring
Connecting the power cable
The power cable is connected by screw ter­minals, located inside the analyzer.
Supported wire cross section: 24 to 12 AWG (0.2 to 4 mm2), no need to use wire end sleeves
Cable skinning lenght: 8 mm (0.315 inch) hole diameter: 1.2 mm (0.05 inch) Screw thread: M 3 Tightening torque, min: 0.5 Nm (4.4 in.lb)
ELECTRICAL SHOCK HAZARDELECTRICAL SHOCK HAZARD
Take care that the power cable is not connected and/or the analyzer is not energized during operation!
The distance between power and signal cables must exceed 1 cm (0.4 in)!
Insert the power cable through the foremost cable gland, strip the outer insulation, skin and connect the conductors to the terminals (a
descriptive label is xed to the lter‘s housing
nearby the terminals).
When done, x the power cable by tightening
the outer cable gland nut.
L
Location for label
N
PE
Power cable gland
2 Installation

Fig. 2-9: Power terminals

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Chapter 3
Startup
POSSIBLE EXPLOSION HAZARD Startup, operation and service must not be performed before reading and
understanding all instructions! Especially all warnings in the manual have to be taken into account!

3-1 Final Check

Ensure that the analyzer has been installed according to the descriptions in section 2 and that all covers and doors are closed and fastened. All unused cable connections need to be closed with the provided permissible sealing plug (part no. ETC00791; Fig. 3-1) Unused openings for cable connections in the housing need to be closed with a special screw (part no. ETC00790; Fig. 3-2).
X-STREAM® FNX-STREAM
3 Startup

Fig. 3-1: Sealing Plug for Cable Connections

POSSIBLE EXPLOSION HAZARD
Use these above mentioned ATEX-approved components only!
Fig. 3-2: Hexagon Socket Screw as Sealing
Plug for unused Cable Connection Openings

3-2 Switching On

Now the analyzer can be switched on.
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Inspection, maintenance and service must be carried out by qualied personnel
only considering all related standards and legal requirements! Especially the standard EN 60079-17 „Inspection and maintenance
of electrical installations in [gas explosion] hazardous areas“ and all corresponding standards have to be taken into account.
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. If parts being essential for explosion protection are repaired, they must undergo a routine test!
X-STREAM® FNX-STREAM
Chapter 4
Maintenance
POSSIBLE EXPLOSION HAZARDPOSSIBLE EXPLOSION HAZARD
4 Maintenance
The authority for explosion protection has to issue a certicate and/or
attach a label to the equipment/analyzer before startup after maintenance or replacement of parts.
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X-STREAM® FNX-STREAM
®
FN

4-1 Maintenance Instructions

4 Maintenance
Instruction Manual
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To assure instrument performance and safety the analyzer has to be checked regularly but at least once a year. During maintenance especially those part being relevant for explosion protection have to be taken into account. For X-STREAM FN this does include parti­cularly the enclosure and the corresponding sealings. The sealings have to be checked
on damage and they need to show sufcient
effectiveness ( Leakage test, 4-4). During maintenance the optional gas sampling pump has to be evaluated that moving parts do not grind or hook on creating sparks thereby. Internal connectors have to be regarded ac-
cordingly. They need to be xed to draw no
sparks during operation.
Due to visual inspection of the internal part of
the analyzer especially the electrical compo-
nents it must be veried that no components
are overloaded. Otherwise they may become hot and thus become a danger of ignition (an indication for overloaded components is for example discoloration).
The user/owner has to take responsibility to modify the maintenance interval regarding the conditions at site
(inuence
of gases or ambient atmosphere on material being in contact with sample/cal gas or which are re­levant for
explosion protection
[e.g. enclosure sealing]).
POSSIBLE EXPLOSION HAZARD
Replacement of defective parts being relevant for explosion protection must be done with original
The use
of not suitable parts or procedures may reduce performance or
jeopardize the safe process operation and affect Explosion Protection! Section 4-5 of this manual includes a listing of parts being relevant for Explo-
sion Protection.

4-2 Gas Paths

Detailled Information about maintenance, re­placement of components and accomplishment of a gas paths leakage test are available in
Emerson Process Management
the X-STREAM gas analyzer series general instruction manual.
Emerson Process Management GmbH & Co. OHG 4-2
parts only!
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4 Maintenance
4-3 Check Modied or Repaired Analyzers
X-STREAM® FNX-STREAM
Modications on X-STREAM FN analyzers which inuence the integrity of protection type
or analyzer temperature are permissible only
if the modied analyzer are inspected by a
licensed test laboratory or if an authorized
expert has evaluated the modications.

4-4 Enclosure Leakage Test 4-4-1 Preparation Required Tools:

Pressure gauge with a measuring range
of 50 und 100 mbar (0.7 to 1.5 psig; re­solution of 0.1 mbar/ 0.0015 psig).
Flow meter with a measuring range of 5 to 10 l/min;
Span gas: Instrumental air or nitrogen;
pressure reduced to 1.500 mbar
(22 psig).
To run the test procedure the following pre­parations have to be encountered:
Disconnect or de-ernergize the analy-
zer.
Disconnect containment system ttings
from external gas pipes.
Disconnect one containment system gas
tting inside the analyzer and close the other tting.
(Remark: Now it need to be possible
to pressurize the housing supplying an external gas (e.g. compressed air) to the gas inlet.)
Supply compressed air from an external
source as described on sketch of the following page, (Fig. 4-1).
resolution of
0.1 l/min.
In case of repair inuencing the protection
type, the repaired parts should be drawn to suitable check routines and must be con­trolled. These inspections need not to be carried out from the supplier necessarily.
Pressure regulator to reduce pressure to
25 mbar (0.4 psig)
Equipment for ow control
1 plug to shut off the gas outlet
(size: 6 mm/ 1/4“)
The compressed air must be dry and free from dust, oil and corrosive components!
4 Maintenance
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Fig. 4-1: Assembly for check routines

4-4-2 Run Leakage Test

The housing needs to be controlled on leaka­ges with a pressure of 25 mbar (0.4 psig). The following steps have to be provided:
Modify like described on chapter 4-4-1.
Supply a pressure of 25 mbar to the ana-
lyzer housing and take care of the ow
meter display.
The test is conrmed if the measured value
does not exceed the following max. value:
Permissible ow: 3 l/min max.

4-4-3 Startup after Test Procedure

All in section 4-4-1 described modications have to be cancelled.
Especially the gas ttings‘ tight assemblies
need to be checked.
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4 Maintenance

4-5 Replacement of Components

POSSIBLE EXPLOSION HAZARDPOSSIBLE EXPLOSION HAZARD
Replacement of defective parts must be carried out with original parts only!
Neglection may cause Explosion Hazard!
Components which are important for X-STREAM FN safety:
X-STREAM® FNX-STREAM
Internal Battery (soldered on circuit board, not to be replaced by the user)
Type: SL 750Type: SL 750 Supplier: Tadiran Batteries GmbH System: SOCl2 / Li Rated voltage: 3,6 V
Classied to IEC 60086-1: Typ E
Optional internal Gas Sampling Pump
Type: 113.095.103.1, 113.095.100.0 Supplier: ASF Thomas, WISA
Relays (soldered on circuit board, not to be replaced by the user. These components must not be exchanged individually!)
Diverse types and suppliers
4 Maintenance
All internal Connections and Screw Terminals Diverse types and suppliers
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Fuses Data: 3,15 AT; 250V Type: 215 (5x20 mm)
Supplier: Wickmann / Littlefuse
Safety holder
Type: UK 5 - HESI Supplier: Phoenix
Mini fuse (on circuit board BKS) Data: 4 AT; 250 V
Type: 372 Supplier: Wickmann / Littlefuse
08/2007
Fuse holder with cap
Type: 571 with 575 Supplier: Wickmann / Littlefuse
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This chapter includes:
X-STREAM® FN

Appendix

EC Declaration of Conformity
Manufacturer‘s Declaration
Certicate
Block diagram
Assignment of Terminals and Sockets
A-1, page A-2
A-2, page A-3
A-3, page A-4
A-4, page A-5
A-5, page A-6
A Appendix
Emerson Process Management GmbH & Co. OHG A-1
Emerson Process Management GmbH & Co. OHG A-2
X-STREAM® FN
Instruction Manual
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A-1 EC Declaration of Conformity

A-1 EC Declaration of Conformity
Emerson Process Management GmbH & Co. OHG A-3
Instruction Manual
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X-STREAM® FN
A Appendix

A-2 Manufacturer‘s Declaration

A-2 Manufacturer‘s Declaration
X-STREAM® FN
Gewerbestr. 28 87600 Kaufbeuren Germany
PrüfbescheinigungPrüfbescheinigung
Certificate Certificate
Antragsteller: Emerson Process Management GmbH & Co. OHGAntragsteller: Emerson Process Management GmbH & Co. OHG
Applicant: Industriestraße 1, 63594 Hasselroth – Germany Applicant: Industriestraße 1, 63594 Hasselroth – Germany
Produkt Typ: Gas AnalyzerProdukt Typ: Gas Analyzer
Product type: Product type:
Modell: X-STREAM FN Modell: X-STREAM FN
Model:Model:
Ein repräsentatives Testmuster des o.g Models bestand die Prüfung nach Ein repräsentatives Testmuster des o.g Models bestand die Prüfung nach
A representative Test Sample of above stated model passed the tests according to A representative Test Sample of above stated model passed the tests according to
Norm: IEC 60079-15:2005 (3
rd
Edition) and DIN EN 60079-15:2005Norm: IEC 60079-15:2005 (3
Standard: and IEC 60079-0:2004 (4
th
Edition) and DIN EN 60079-0:2004 Standard: and IEC 60079-0:2004 (4
rd
Edition) and DIN EN 60079-15:2005
th
Edition) and DIN EN 60079-0:2004
II 3 GATEX Kennzeichnung: ATEX Kennzeichnung:
ATEX marking: Ex nAC IIC T4
Technische Daten: 100 – 240Vac; 50/60Hz; 2A
Ratings:
Bericht Nr: 05KFS106
Report No.:
Zertifikat Nr. 06 – 088 – 2
Certificate No.
Datum: 12. Juli 2006
Issued:
Zertifizierstelle: Horst Haug
Certificate Placement: Horst Haug
Dieses Zertifikat hat eine Gültigkeit von 3 Jahren ab Ausstellungsdatum.
This Certificate is valid for 3 years from date of issue.
A-3Certicate
A-3 Certicate
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A-4 Block diagram
X-STREAM® FN

A-4 Block diagram

Appendix
Emerson Process Management GmbH & Co. OHG
A-5
X-STREAM® FN
A-5 Assignment of Plugs and Terminals
56789101112131415 1234

A-5 Assignment of Plugs and TerminalsAssignment of Plugs and Terminals

Terminal 16
Terminal 17
Terminal 14
Terminal 15
Terminal 12
Terminal 13
Terminal 11
Terminal 9
Terminal 10
Terminal 7
Terminal 8
Terminal 5
Terminal 6
Terminal 3
Terminal 4
Terminal 1
Terminal 2
Instruction Manual
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Terminal RS 232 RS 485/2d RS 485/4d
11 Common Common Common 12 RXD not used RXD0 13 TXD not used RXD1 14 not used D1 TXD1 15 Common D0 TXD0

Fig. A-1: Terminals strip 1Terminals strip 1

Modbus interface
Pin 1 Pin 8
Terminal Signal
5 6 7 8 9 10
Failure COM Failure NO Maintenance, off-spec COMMON Maintenance, off-spec NO Function check COMMON Function check NO
Relay outputs
Terminal Signal
1 (+) 4 (0) - 20 mA, ch 1 2 (-) 4 (0) - 20 mA, ch 1 3 (+) 4 (0) - 20 mA, ch 2 4 (-) 4 (0) - 20 mA, ch 2
Burden: RB 500
Analog outputs
Pin Signal
1 TX+ 2 TX­ 3 RX+ 6 RX­ other not used

Fig. A-2: Terminals strip 2

Valve V4
Valve V1
Valve V2
Open sample valve, close all, or pump on/off
DIG inputs COMMON
Digital Inputs Digital Outputs
Protective Earth PE
Ch1 & Ch2: Zero cal.
Ch1: Span cal.
Ch2: Span cal.
Valve V2
DIG outputs COMMON
Valve V4
Valve V1
Ch2: threshold 1
Ch2: threshold 2
Sample valve
Ch1: threshold 1
Ch1: threshold 2
*)
*)
With optional range switching this output is used as range indicator.
Line L
Neutral N
Note:
Line and neutral terminals with built­in fuse holders

Fig. A-4: Ethernet connector for ModbusEthernet connector for Modbus

Fig. A-3: Power terminals

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WORLD HEADQUARTERS
ROSEMOUNT ANALYTICAL 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
NORTH AMERICA Emerson Process Management Rosemount Analytical Inc.
6565P Davis Industrial Parkway Solon, OH 44139 USA T +1 (440) 914-1261 Toll Free in US and Canada (800) 433-6076 F +1 (440) 914-1271 e-mail: gas.csc@EmersonProcess.com Internet: www.raihome.com
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GAS CHROMATOGRAPHY CENTER and LATIN AMERICA Emerson Process Management Rosemount Analytical Inc.
11100 Brittmoore Park Drive Houston, TX 77041 USA T +1 (713) 467-6000 F +1 (713) 827-3329
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
ASIA - PACIFIC
Emerson Process Management Asia Pacic Pte Ltd
1 Pandan Crescent Singapore 128461 T +65 (6777) 8211 F +65 (6777) 0947 e-mail: analytical@ap.emerson.com Internet: www.ap.emersonprocess.com
© Emerson Process Management GmbH & Co. OHG 2007
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