Emerson Process Management (Rosemount Analytical) designs, manufactures and tests
its products to meet many national and international standards. Because these instruments
are sophisticated technical products, you MUST properly install, use, and maintain
them to ensure they continue to operate within their normal specications. The following
instructions MUST be adhered to and integrated into your safety program when installing,
using and maintaining Emerson Process Management (Rosemount Analytical) products.
Failure to follow the proper instructions may cause any one of the following situations
to occur: Loss of life; personal injury; property damage; damage to this instrument; and
warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson Process
Management (Rosemount Analytical) representative for clarication.
• Follow all warnings, cautions, and instructions marked on and supplied with the
product.
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 specied in the Installation Instructions of the
appropriate Instruction Manual and per applicable local and national codes.
Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualied personnel to install, operate, update,
program, and maintain the product.
• When replacement parts are required, ensure that qualied people use replacement
parts specied by Emerson Process Management (Rosemount Analytical).
Unauthorized parts and procedures can affect the product’s performance, place the
safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in re, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place,
except when maintenance is being performed by qualied persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice.
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 (classied) 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 congurations and/or options not relevant for your specic analyzer.
DEFINITIONS
The following denitions 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. OHGS-1
Emerson Process Management GmbH & Co. OHGS-2
X-STREAM® FN
Instruction Manual
HASANE-IM-ATEX
08/2007
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 Classication
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
sufcient 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 (decient in oxygen) to burn.
Emerson Process Management GmbH & Co. OHGS-3
Emerson Process Management GmbH & Co. OHGS-4
X-STREAM® FN
Instruction Manual
HASANE-IM-ATEX
08/2007
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 certications or approvals are to be implied
as covering such applications!
SAFETY SUMMARY
If this equipment is used in a manner not specied 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 specic for using Non-Incendive X-STREAM FN analyzers in
hazardous (classied) 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 ofce 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 certied to meet the hazardous area classication
that the device was certied to prior to any such component addition,
substitution, or replacement. In addition, the installation of such device or
devices must meet the requirements specied and dened by the hazardous
area classication of the unmodied device.
Any modications to the device not meeting these requirements, will void
the product certication(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 specied 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 (classied) areas must be
considered.
Emerson Process Management GmbH & Co. OHGS-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 specied to be used for the weight of
the units!
Instruction Manual
HASANE-IM-ATEX
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
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08/2007
X-STREAM® FN
Tableof ConTenTs
Preamble S-1
DenitionsS-1
Symbols used in this manual .............................................................................................S-2
Terms used in this manual .................................................................................................S-3
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-3: Power terminals ................................................................................................................................A-6
Fig. A-4: Ethernet connector for Modbus .......................................................................................................A-6
IHV-2Emerson 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 (classied) area of ex zone 2.
X-STREAM FN Analyzers which are certied
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
Instruction Manual
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X-STREAM® FNX-STREAM
®
FN
Instruction manual
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08/2007
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
Classication:
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 fullls the corresponding standard.
Identication Mark (Labeling)
Emerson Process Management GmbH & Co. OHG 1-2
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
Instruction Manual
HASANE-IM-ATEX
08/2007
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 conguration)
Protection class: IP 66 (EN 60529) / NEMA 4X
for outdoor installation analyzer must be
protected against direct sun
Gas ttings: Number: max. 8
Specication: 6/4 mm or 1/4“, stainless
steel, other on request
General Certications (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
Instruction Manual
HASANE-IM-ATEX08/2007
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
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
Instruction Manual
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08/2007
1-4 Measurement Specications
1-4 Measurement Specications
X-STREAM® FNX-STREAM
Gas components
Maximal sample
gas pressure
Sample gas owDepending 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 ofce 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
Instruction manual
HASANE-IM-ATEX
08/2007
Emerson Process Management GmbH & Co. OHG 1-6
Instruction Manual
HASANE-IM-ATEX
08/2007
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 specied 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 sufciently attached and stable
to carry the instrument!
Emerson Process Management GmbH & Co. OHG 2-1
2 Installation
Instruction Manual
HASANE-IM-ATEX08/2007
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
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
Instruction Manual
HASANE-IM-ATEX
08/2007
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
Emerson Process Management GmbH & Co. OHG 2-3
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
®
FN
Instruction Manual
HASANE-IM-ATEX
2-5 Wiring
2-5 Wiring
EXPLOSION DANGER / ELECTRICAL SHOCK HAZARD
Installation and connecting power and signal cables are subject to qualied
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 qualied 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
Instruction Manual
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X-STREAM® FNX-STREAM
Instruction Manual
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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!
Emerson Process Management GmbH & Co. OHG 2-5
2 Installation
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
®
FN
2-5 Wiring
Instruction Manual
HASANE-IM-ATEX
08/2007
• 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 sufciently 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
Emerson Process Management GmbH & Co. OHG 2-6
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
Instruction Manual
HASANE-IM-ATEX
08/2007
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
2 Installation
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
®
FN
Signal inputs / outputs
Analog signal outputs
2-5 Wiring
Instruction Manual
HASANE-IM-ATEX
08/2007
For access to the terminals open the
instrument‘s front door.
Burden: RB ≤ 500 Ω
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!
Emerson Process Management GmbH & Co. OHG 2-8
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
Instruction Manual
HASANE-IM-ATEX
08/2007
Modbus interface
Specication 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 TXD115 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
Emerson Process Management GmbH & Co. OHG 2-9
2 Installation
Instruction Manual
HASANE-IM-ATEX08/2007
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.
Instruction Manual
HASANE-IM-ATEX
08/2007
Note!
Notice, that the modbus screw terminals
( page 4-25) are installed, too, but without
function!
Pin 1Pin 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
Emerson Process Management GmbH & Co. OHG 2-10
Instruction Manual
HASANE-IM-ATEX08/2007
X-STREAM® FNX-STREAM
Instruction Manual
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Relay Status Signals
2-5 Wiring
X-STREAM® FNX-STREAM
Design: potential-free relay contact
Electrical specication: 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); conguration on request
Signal output
(NO); standard
conguration
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
Emerson Process Management GmbH & Co. OHG 2-11
5678
2 Installation
Instruction Manual
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2-5 Wiring
Digital Inputs & Outputs (option)
Design: Open collector (outputs)
Electrical specication:
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 InputsDigital Outputs
Fig. 2-8: Terminal block X4 - Digital Inputs & Outputs
Emerson Process Management GmbH & Co. OHG 2-12
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X-STREAM® FNX-STREAM
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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
Emerson Process Management GmbH & Co. OHG 2-13
®
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Emerson Process Management GmbH & Co. OHG 2-14
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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.
Emerson Process Management GmbH & Co. OHG 3-1
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Inspection, maintenance and service must be carried out by qualied 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 certicate and/or
attach a label to the equipment/analyzer before startup after maintenance
or replacement of parts.
Emerson Process Management GmbH & Co. OHG 4-1
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®
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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 sufcient
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 veried 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
(inuence
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 Modied or Repaired Analyzers
X-STREAM® FNX-STREAM
Modications on X-STREAM FN analyzers
which inuence the integrity of protection type
or analyzer temperature are permissible only
if the modied analyzer are inspected by a
licensed test laboratory or if an authorized
expert has evaluated the modications.
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 inuencing 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
Emerson Process Management GmbH & Co. OHG 4-3
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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 conrmed 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 modications
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
Classied 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
Emerson Process Management GmbH & Co. OHG 4-5
Instruction Manual
®
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HASANE-IM-ATEX
4 Maintenance
FusesData: 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
Emerson Process Management GmbH & Co. OHG 4-6
Instruction Manual
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This chapter includes:
X-STREAM® FN
Appendix
EC Declaration of Conformity
Manufacturer‘s Declaration
Certicate
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
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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
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-3Certicate
A-3Certicate
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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
567891011121314151234
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 1Pin 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
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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X-STREAM® FN
X-STREAM® FN
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 Pacic 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