Rosemount X-STREAM X1 FN Addendum for Non-Incendive Analyzers in Zone 2 Hazardous Area Owner's manual

X-STREAM

®

FN

Addendum for Non-Incendive Analyzers

intended to be used in Hazardous Areas of Zone 2

www.EmersonProcess.com

Instruction Manual

HASANE-IM-ATEX

04/2008

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Emerson Process Management (Rosemount Analytical) designs, manufactures and tests

its products to meet many national and international standards. Because these instruments

are sophisticated technical products, you MUST properly install, use, and maintain

them to ensure they continue to operate within their normal 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.

• 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.

2

nd

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

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Emerson Process Management GmbH & Co. OHG S-1

Safety Instructions

X-STREAM

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Instruction Manual

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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.

PREAMBLE

The following denitions apply to WARNINGS, CAUTIONS and NOTES found throughout

this publication.

DEFINITIONS

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.

NOTE!

Highlights an essential operating procedure, condition or statement.

Highlights an operation or maintenance procedure, practice, condition,

statement, etc.

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

or loss of effectiveness.

Emerson Process Management GmbH & Co. OHGS-2

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Symbols

SYMBOLS USED IN THIS MANUAL

1. Where equipment or covers are marked with the symbol to the right, hazar-

dous 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:

Explosion Hazard!

Harmful (to Health)!

Elektrostatic discharge (ESD)

Toxic!

Heavy Instrument!

Disconnect from Mains!

Emerson Process Management GmbH & Co. OHG S-3

Safety Instructions

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TERMS USED IN THIS MANUAL

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.

Flammable Gas(es)

Gases and gas mixtures are assigned to be

ammable if they might become ignitable

when in a mixture with air.

Terms

Area Classication

Zone 2

In Zone 2 ignitable concentrations of am-

mable gases are not likely to exist under

normal operating conditions.

(A guideline value [not part of a standard]:

less than 10 hours per year.)

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).

Emerson Process Management GmbH & Co. OHGS-4

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Safety Instructions

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 trai-

ning. Save all instructions!

SAFETY SUMMARY

If this equipment is used in a manner not specied in these instructions, protective sy-

stems may be impaired.

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!

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 in-

strument!

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!

SAFETY INSTRUCTIONS

Emerson Process Management GmbH & Co. OHG S-5

Safety Instructions

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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.

Safety Instructions

POSSIBLE EXPLOSION HAZARD

Do not open instrument when energized.

Ensure that external circuitry is disconnected or de-energized before

opening the instrument.

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. OHGS-6

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Safety Instructions

POSSIBLE EXPLOSION HAZARD

Flammable Gases must be intoduced in INFALLIBLE CONTAINMENTS ONLY,

to avoid leakage into internal Analyzer Housing!

HEAVY INSTRUMENT

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!

Take care the wall or stand the unit is intended to be installed at is solid and

stable to hold the units!

IHV-1Emerson Process Management GmbH & Co. OHG

Table of Contents

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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

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-2 Emerson Process Management GmbH & Co. OHG

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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

Emerson Process Management GmbH & Co. OHG 1-1

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1 Technical Description

Chapter 1

Technical Description

1-1 Application and Principle of Operation

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- in-

cendive“ 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 com-

ponents 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 protec-

tion 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 analy-

zer would be no more according to zone 2

but zone 0 requiring special protection me-

thods!

Nevertheless Emerson Process Manage-

ment 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.

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 1-2

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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

Identication Mark (Labeling)

A test sample was approved by an independant test institute according to Guideline (Directive)

94/9/EG („ATEX“) and fullls the corresponding standard.

Protection concept:

Wall-mount eld housing for outdoor installa-

tion with protection method Ex n

Hazardous zone: Zone 2, Gas

Classication:

ATEX Group II, Category 3, Gas,

Ex nAC IIC T4

Temperature class: T4

Underlying standard:

IEC 60079-0:2004 (4

th

Edition)

DIN EN 60079-0:2004

IEC 60079-15:2005 (3

rd

Edition)

DIN EN 60079-15:2005

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1 Technical Description

1-2-2 General Technical Data

1-2 Technical data

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

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

+/- 10 % of the nominal

voltage

!

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

Rated input current

standard 0,75 - 0,35 A max.

with thermostatically controlled physics 2 - 1 A max.

General Certications (Compliances)

Electrical safety

Europe CE, based on EN 61010-1

Elektromagnetic compatibility

Europe CE, based upon EN 61326

other NAMUR

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1-3 X-STREAM Dimensions

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

approx. mm [inch]

Eyebolt detail

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Emerson Process Management GmbH & Co. OHG 1-5

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1 Technical Description

Gas components

Non-ammable gases resp. gas mixtures; concentration does not exceed LEL

(lower explosion limit)

Maximal sample

gas pressure

Atmospheric pressure or <1500 hPa at normal ambient pressure depen-

ding on used measuring principle (see X-STREAM general instruction

manual)

Sample gas ow Depending on measuring principle (see X-STREAM general instruction

manual)

1-4 Measurement Specications

1-5 Infallible Containments

Infallible Containments are based on con-

nections being velded, soldered or designed

as glass-to-metal connections resp. eutectic

or similar methods. The function test for in-

fallible 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.

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 informa-

tion.

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.

• Signal lines need to end in safe or pro-

tected areas (e.g. in a suitable housing

type Ex e).

Gas components

Flammable gases

POSSIBLE EXPLOSION HAZARD

Flammable Gases must be introduced with INFALLIBLE CONTAINMENTS

only!

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2 Installation

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!

Assure that the wall/device for installation is sufciently attached and stable

to carry the instrument!

Chapter 2

Installation

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!

2-1 Abstract

Save operation of Emerson Process Ma-

nagement 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.

2-2 Installation of the Instrument

For installation of the instrument use the de-

scriptions of the X-STREAM analyzor family

general instruction manual. Verify that the

installation site of the instrument is determi-

ned adequately by means of the Figures (see

Fig. 2-1).

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2-3 X-STREAM Dimensions

Figure 2-1: X-STREAM FN - Dimensions

approx. mm [inch]

Eyebolt detail

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2 Installation

2-4 Connections of Gas Pipes

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.

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!

The number of the gas ttings and their allo-

cation 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 moi-

sture, dust etc..

Figure. 2-2: Marking of the gas ttings

(example)

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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!

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 connec-

ted to power.

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Rosemount X-STREAM X1 FN Addendum for Non-Incendive Analyzers in Zone 2 Hazardous Area Owner's manual

Rosemount X-STREAM X1 FN Addendum for Non-Incendive Analyzers in Zone 2 Hazardous Area Owner's manual

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