Rosemount X-STREAM Enhanced-1st Ed. Owner's manual

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www.EmersonProcess.com
Instruction Manual
HASXEE-IM-HS
04/2010
Gas Analyzer Series
Instruction Manual
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 speciî‚¿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 clariî‚¿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 speciî‚¿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 î‚¿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 qualiî‚¿ed persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice.
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
1
st
edition, 2010-04
X-STREAM and IntrinzX are marks of one of the Emerson group of companies.
All other marks are property of their respective owners.
Emerson Process Management GmbH & Co. OHG TOC-1
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
TOC
Table of contents
SHORT FORM GUIDE FOR THIS MANUAL
To î‚¿nd Information About See Chapter
Safety Instructions
. . . . . . . . . . . . . . . . . . . . . . . . . . . S
The Different Instruments Designs
. . . . . . . . . . . . . . 1
The Instruments Technical Data
. . . . . . . . . . . . . . . . 2
Measuring Principles Characteristics
. . . . . . . . . . . 3
How to Install the Instruments
. . . . . . . . . . . . . . . . . 4
1
st
Startup Procedures,
Checking the Instrument´s Setup . . . . . . . . . . . . . . . 5
Software Menu Structure, How to Navigate
and Menu Entries Descriptions
. . . . . . . . . . . . . . . . . 6
Basic Procedures (e.g. Calibration)
. . . . . . . . . . . . . 7
Maintenance Procedures
. . . . . . . . . . . . . . . . . . . . . . 7
Status Messages and Troubleshooting
. . . . . . . . . . 8
Modbus Parameters
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Information
. . . . . . . . . . . . . . . . . . . . . . . . . .10
Dismounting and Disposal of Instruments
. . . . . . .11
Block Diagrams, Terminals & Connectors
. . . . . . . . A
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IDX
Emerson Process Management GmbH & Co. OHGTOC-2
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
Table of ConTenTs
Introduction S-1
Deî‚¿nitions S-1
Terms Used in This Instruction Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Symbols Used on and Inside the Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3
Symbols Used in This Manual
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-4
Safety Instructions S-5
Intended Use Statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
General Safety Notice / Residual Risk
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
Authorized Personnel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Disposal of Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Installing and Connecting the Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Operating and Maintaining This Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Chapter 1 Technical Description 1-1
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.1.1 The Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.2 Conî‚¿guration of Gas Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.1 Materials Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.2 Safety Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.3 Gas Inlets and Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.4 Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.5 Infallible Containments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2.6 Optional Components for Gas Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.2.7 Alternative Conî‚¿gurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.3.1 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.3.2 Status Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.3.3 Modbus Interface, Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1.3.4 Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1.3.5 USB Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1.3.6 Optional Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1.4 Comparison of the Various X-STREAM Analyzer Models . . . . . . . . . . . . . . . . . . . . . . .1-13
1.5 X-STREAM XEGC: ½ 19 Inch Table-Top Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
1.6 X-STREAM XEGP: 19 Inch Table-Top or Rackmount Design . . . . . . . . . . . . . . . . . . . .1-17
1.7 X-STREAM XEF/XDF: Field Housing With Single Or Dual Compartment. . . . . . . . . . .1-19
1.7.1 Field Housings for Installation in Hazardous Areas (Ex-Zones) . . . . . . . . . . . . . . . . .1-23
1.8 X-STREAM XEFD: Cast Aluminum Flameproof Housing . . . . . . . . . . . . . . . . . . . . . . .1-24
Emerson Process Management GmbH & Co. OHG TOC-3
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
TOC
Table of contents
Chapter 2 Technical Data 2-1
2.1 Common Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2 Model-Speciî‚¿c Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.2.1 X-STREAM XEGC: ½ 19 Inch Tabletop Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.2.2 X-STREAM XEGP: 19 Inch Tabletop and Rack-Mount Models . . . . . . . . . . . . . . . . .2-12
2.2.3 X-STREAM XEF/XDF: Single/Dual Compartment Field Housing . . . . . . . . . . . . . . . .2-15
2.2.4 X-STREAM XEFD: Flameproof Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
2.3 Information on Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Chapter 3 Measuring Principles 3-1
3.1 Infrared Measurement (IR) / Ultraviolet Measurement (UV) . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.1 IntrinzX Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.2 NDIR Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.1.3 Technical Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.2 Oxygen Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3.2.1 Paramagnetic Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3.2.2 Electrochemical Measurement (I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3.2.3 Special Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3.3 Thermal Conductivity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3.3.1 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3.3.2 Technical Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3.4 Measurement Speciî‚¿cation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Chapter 4 Installation 4-1
4.1 Scope of Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 Gas Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.4 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.5 Analyzer Speciî‚¿c Instructions for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.5.1 X-STREAM XEGC, X-STREAM XEGP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.5.2 X-STREAM XEF, X-STREAM XDF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4.6 Notes On Wiring Signal Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
4.6.1 Electrical Shielding of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
4.6.2 Wiring Inductive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
4.6.3 Driving High-Current Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
4.6.4 Driving Multiple Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35
Chapter 5 Startup 5-1
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Symbols and Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.3 Front Panel Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Table of Contents
Emerson Process Management GmbH & Co. OHGTOC-4
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
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5.3.1 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.3.2 Status Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.3.3 Keys 5-4
5.4 Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5.4.1 Access Levels & Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5.4.2 Special Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.5 Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.5.1 Boot Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.5.2 Measurement Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.6 Selecting the Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5.7 Checking the Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5.7.1 Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5.7.2 Conî‚¿guring the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5.7.3 Calibration Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5.7.4 Setting the Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5.7.5 Setting Concentration Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
5.7.6 Backup the Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
5.8 Perform a Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
Chapter 6 User Interface and Software Menus 6-1
6.1 Symbols and Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 Menu System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6.2.1 Switching On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6.2.2 Control Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6.2.3 Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
6.2.4 Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-108
6.2.5 Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-122
6.2.6 Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-126
Chapter 7 Maintenance and Other Procedures 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2 General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.3 Performing a Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.4 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
7.4.1 Preparing Calibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
7.4.2 Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
7.4.3 Advanced Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
7.4.4 Remote Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
7.4.5 Unattended Automatic Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
7.4.6 Verifying a Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
Table of Contents
Emerson Process Management GmbH & Co. OHG TOC-5
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
TOC
Table of contents
7.4.8 Restoring a Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
7.4.7 Cancelling an Ongoing Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
7.5 Replacing the Electrochemical Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42
7.5.1 General Hints on Handling the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
7.5.2 Opening X-STREAM Analyzers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46
7.5.3 Locating the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-48
7.5.4 Disassembling the Sensor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49
7.5.5 Adjusting the Output Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50
7.5.6 Finalizing the Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
7.6 Cleaning the Instrument´s Outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-52
7.7 Save / Restore Conî‚¿guration Data Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53
7.7.1 Local Backup - Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55
7.7.2 Local Backup - Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57
7.7.3 Factory Defaults - Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
7.7.4 USB Backup - Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
7.7.5 USB Backup - Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-64
7.7.6 Undo Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-66
7.8 Handling Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
7.8.1 Conî‚¿guring Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
7.8.2 Exporting Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-68
7.8.3 Log Files Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-70
7.9 Files on USB Memory Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71
7.9.1 autorun.inf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71
7.9.2 xe_win_tools.zip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-72
7.10 Web Browser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-73
Chapter 8 Troubleshooting 8-1
8.1 Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.2 Solving Problems Indicated by NAMUR Status Messages . . . . . . . . . . . . . . . . . . . . . . .8-2
8.2.1 Analyzer Related NAMUR Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
8.2.2 Channel Related Messages (preceded by Channel Tag, e.g. CO2.1) . . . . . . . . . . . . .8-8
8.3 Solving Problems Not Indicated by Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
8.4 Troubleshooting on Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18
8.4.1 Opening X-STREAM Analyzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-20
8.4.2 Signal Connectors on XSP Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-22
8.4.3 Sample Pump: Replacement of Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-23
8.4.4 Paramagnetic Oxygen Cell for Standard Applications: Adjustment of Physical Zero .8-34
8.4.5 Thermal Conductivity Cell: Adjustment of Output Signal. . . . . . . . . . . . . . . . . . . . . . .8-37
Table of Contents
Emerson Process Management GmbH & Co. OHGTOC-6
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
Chapter 9 Modbus Functions 9-1
9.1 Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
9.1.1 Modbus TCP/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
9.2 Supported Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2
9.3 List of Parameters and Registers - Sorted by Tag Name. . . . . . . . . . . . . . . . . . . . . . . . .9-2
9.4 List of Parameters and Registers - Sorted by Daniel Registers. . . . . . . . . . . . . . . . . . .9-31
Chapter 10 Service Information 10-1
10.1 Return of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
10.2 Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10.3 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
Chapter 11 Dismounting and Disposal 11-1
11.1 Dismounting and Diposal of the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
Appendix A-1
A.1 Modbus Speciî‚¿cation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.2 EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
A.3 CSA Certiî‚¿cate of Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
A.4 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
A.5 Water Vapor: Relationship of Dewpoint, Vol.-% and g/Nm³ . . . . . . . . . . . . . . . . . . . . . A-34
A.6 Declaration of Decontamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-35
A.7 PLC Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-36
A.8 Assignment of Terminals and Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-43
A.8.1 Tabletop & Rack Mount Analyzers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-43
A.8.2 Field Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-44
Table of Contents
Emerson Process Management GmbH & Co. OHG TOC-7
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
TOC
Table of contents
Index of Tables
Tab. 3-1: Standard Paramagnetic Sensor -
Cross Interference by Gases .................................3-6
Tab. 3-2: Solvent Resistant Paramagnetic Sensor - Approved Solvents .................................3-7
Tab. 3-3: Solvent Resistant Paramagnetic Sensor - Medium Affected Materials ...................3-7
Tab. 3-4: Solvent Resistant Paramagnetic Sensor -
Cross Interference by Gases ................... 3-7
Tab. 3-5: Electrochemical Oxygen Measurement -
Cross Interference by Gases ..................3-10
Tab. 3-6: Examples of Specific Thermal Conductivities .........................................................3-11
Tab. 3-7: Gas Components and Measuring Ranges, Examples
...........................................3-13
Tab. 3-8: General Measurement Performance Specifications ...............................................3-14
Tab. 3-9: Special Performance Specifications for Gas Purity Measurements .......................3-15
Tab. 5-1: Analog Output Signals Settings and Operation Modes
..........................................5-21
Tab. 6-1: Analog Output Failure Modes
.................................................................................6-66
Tab. 7-1: Digital Inputs Priorities ............................................................................................7-33
Emerson Process Management GmbH & Co. OHGTOC-8
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
Index of fIgures
Fig. 1-1: X-STREAM Front Panel (here the X-STREAM XEGP) ..........................................1-3
Fig. 1-2: Optional Heated Area .............................................................................................1-8
Fig. 1-3: Gas Flow Diagram: Single Channel Or in Series ...................................................1-9
Fig. 1-4: Ethernet Interface Marking ...................................................................................1-11
Fig. 1-5: Serial Interface Marking ........................................................................................1-11
Fig. 1-6: USB Interfaces .....................................................................................................1-11
Fig. 1-7: X-STREAM XEGC - Views ...................................................................................1-16
Fig. 1-8: X-STREAM XEGP - Details ..................................................................................1-18
Fig. 1-9: X-STREAM XEF / XDF- Front Views ....................................................................1-20
Fig. 1-10: X-STREAM XEF - Right Side and Bottom View ...................................................1-21
Fig. 1-11: X-STREAM XEF - Power Supply and Signal Terminals .......................................1-22
Fig. 1-12: X-STREAM XEFD - Front View ...........................................................................1-25
Fig. 1-13: X-STREAM XEFD - Bottom View .........................................................................1-26
Fig. 1-14: X-STREAM XEFD - Terminals ..............................................................................1-27
Fig. 2-1: X-STREAM XEGC - Dimensions ............................................................................2-6
Fig. 2-2: X-STREAM XEGC - Connectors and Fuse ............................................................2-6
Fig. 2-3: X-STREAM XEGC - Rack Mounting Options .........................................................2-7
Fig. 2-4: UPS 01 Tabletop Power Supply Unit ......................................................................2-9
Fig. 2-5: UPS 01 Power Supply Unit for Rack Installation ..................................................2-10
Fig. 2-6: 10 A Tabletop PSU ................................................................................................2-11
Fig. 2-7: X-STREAM XEGP - Dimensions ..........................................................................2-12
Fig. 2-8: X-STREAM XEGP - Power Supply and Signal Connections ................................2-14
Fig. 2-9: X-STREAM XEGP - Signal Connections With Screw-Type Terminal Adapters ....2-14
Fig. 2-10: X-STREAM XEF - Dimensions .............................................................................2-15
Fig. 2-11: X-STREAM XDF - Dimensions .............................................................................2-16
Fig. 2-12: X-STREAM XE Field Housing - Power Supply Terminals / Fuse Holders ..........2-18
Fig. 2-13: X-STREAM XE Field Housing - Signal Terminals .................................................2-18
Fig. 2-14: X-STREAM XEFD - Dimensions ..........................................................................2-19
Fig. 2-15: X-STREAM XEFD - Power Supply Terminals / Fuse Holders ..............................2-21
Fig. 2-16: X-STREAM XEFD - Signal Terminals ...................................................................2-21
Fig. 2-17: Analyzer Name Plate (examples) .........................................................................2-22
Fig. 3-1: IntrinzX Signal Forms .............................................................................................3-2
Fig. 3-2: Gas Detector Design Principle ...............................................................................3-3
Fig. 3-3: Photometer Assembly Principle ..............................................................................3-4
Fig. 3-4: Paramagnetic Oxygen Sensor - Assembly Principle ..............................................3-5
Fig. 3-5: Electrochemical Sensor - Design Principle .............................................................3-8
Emerson Process Management GmbH & Co. OHG TOC-9
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Table of contents
Fig. 3-6: Electrochemical Sensor - Assembly .......................................................................3-8
Fig. 3-7: Electrochemical Reaction of Oxygen Sensor ........................................................3-9
Fig. 3-8: Wheatstone Bridge ...............................................................................................3-11
Fig. 3-9: TC Cell, Exterior View, Thermal Isolation Removed .............................................3-12
Fig. 3-10: TC Cell, Sectional View ........................................................................................3-12
Fig. 4-1: X-STREAM XE Analyzers - Scope of Supply .........................................................4-1
Fig. 4-2: Labelling of Gas Connectors (example) .................................................................4-4
Fig. 4-3: Installation in Bypass Mode ....................................................................................4-5
Fig. 4-4: X-STREAM XEGC - Table Top Version Rear Panel ...............................................4-8
Fig. 4-5: X-STREAM XEGP - Table Top Version Rear Panel ................................................4-9
Fig. 4-6: X-STREAM XEGP - Rear Panel, With Terminal Adapters and Brackets ..............4-10
Fig. 4-7: Socket X1 - Analog & Digital Outputs 1-4 ............................................................4-11
Fig. 4-8: Plug X2 - Serial Interface ......................................................................................4-12
Fig. 4-9: Conî‚¿guration of XSTA Terminal Adapter ..............................................................4-13
Fig. 4-10: Sockets X4.1 and X4.2 - Pin Conî‚¿guration .........................................................4-14
Fig. 4-11: Conî‚¿guration of XSTD Terminal Adapter ..............................................................4-15
Fig. 4-12: Plug X5 - Analog Inputs ........................................................................................4-16
Fig. 4-13: Conî‚¿guration of XSTI Terminal Adapter ...............................................................4-17
Fig. 4-14: 24 V DC in Connector, Pin Conî‚¿guration .............................................................4-18
Fig. 4-15: X-STREAM XEF - Dimensions for Installation .....................................................4-19
Fig. 4-16: X-STREAM XDF - Dimensions for Installation ....................................................4-20
Fig. 4-17: X-STREAM XE Field Housing - Terminals, Cable Glands and Gas Connectors ..4-21
Fig. 4-18: Terminal Block X1 - Analog Signals and Relay Outputs 1-4 ................................4-24
Fig. 4-19: Terminal Block X1 - Serial Interface .....................................................................4-25
Fig. 4-20: X-STREAM XEF - Ethernet Connector .................................................................4-26
Fig. 4-21: X4: Terminal Blocks for Digital Inputs and Outputs...............................................4-27
Fig. 4-22: Terminal Block X5 - Analog Input Signals ............................................................4-28
Fig. 4-23: Power Supply Connections ..................................................................................4-29
Fig. 4-24: Shielded Signal Cable, Shielding Connected At Both Ends. ................................4-31
Fig. 4-25: Shielded Signal Cable, Shielding Connected At One end. ...................................4-32
Fig. 4-26: Signal Cable With Double Shielding, Shieldings Connected At Alternate Ends. ..4-32
Fig. 4-27: Shield Connector Terminal With Cable .................................................................4-33
Fig. 4-28: Suppressor Diode for Inductive Loads. ................................................................4-34
Fig. 4-29: Driving High-Current Loads ..................................................................................4-34
Fig. 4-30: Common Line .......................................................................................................4-35
Fig. 4-31: Loads in Parallel ...................................................................................................4-35
Fig. 5-1: X-STREAM XE Front Panel ....................................................................................5-3
Index of Figures
Emerson Process Management GmbH & Co. OHGTOC-10
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
Fig. 5-2: Arrangement of Concentration Thresholds ...........................................................5-23
Fig. 6-1: X-STREAM XE Software Menu Structure ..............................................................6-2
Fig. 6-2: Measurement Display Elements ...........................................................................6-25
Fig. 6-3: Usage of Labels and Tags ...................................................................................6-31
Fig. 6-4: Measurement Display With Labels and Tags (example).......................................6-99
Fig. 6-5: USB File System Structure .................................................................................6-104
Fig. 7-1: Leak Testing With U-Turn Manometer ....................................................................7-4
Fig. 7-2: Calibration Improvement by Variable Valve Assignments .....................................7-10
Fig. 7-3: Internal Valves Assignments .................................................................................7-12
Fig. 7-4: Zero All Calibration Procedure Flow Diagram ......................................................7-23
Fig. 7-5: Span All Calibration Procedure Flow Diagram .....................................................7-26
Fig. 7-6: Zero&Span All Calibration Procedure Flow Diagram ............................................7-28
Fig. 7-7: Digital Inputs - Initializing Calibrations ..................................................................7-34
Fig. 7-8: Graphical Explanation of Interval Time Settings ...................................................7-38
Fig. 7-9: X-STREAM XEGP ................................................................................................7-46
Fig. 7-10: X-STREAM XEGC ................................................................................................7-46
Fig. 7-11: X-STREAM Field Housings - Interior Views .........................................................7-47
Fig. 7-12: Location of the EO2 Sensor Unit ..........................................................................7-48
Fig. 7-13: Sensor Unit Design ...............................................................................................7-49
Fig. 7-14: OXS Board, Top View ...........................................................................................7-50
Fig. 7-15: Locking Device Details .........................................................................................7-51
Fig. 7-16: Relations of Supported Data Sets, and Where to Find Further Information .........7-54
Fig. 7-17: USB File System Structure ...................................................................................7-61
Fig. 7-18: Subdirectory for Log Files .....................................................................................7-69
Fig. 7-19: Example of Log File ..............................................................................................7-70
Fig. 7-20: USB File System Structure ...................................................................................7-71
Fig. 7-21: Autorun.inf Template .............................................................................................7-71
Fig. 7-22: Ethernet Connectors .............................................................................................7-73
Fig. 7-23: Web Browser Logon Screen .................................................................................7-74
Fig. 7-24: Web Browser Measurements Screen ...................................................................7-74
Fig. 8-1: X-STREAM XEF, XDF and XEFD, Opened With Visible Front Panel...................8-12
Fig. 8-2: X-STREAM XEGP ................................................................................................8-20
Fig. 8-3: X-STREAM XEGC ................................................................................................8-20
Fig. 8-4: X-STREAM Field Housings - Interior Views .........................................................8-21
Fig. 8-5: XSP - Allocation of Signal Connectors..................................................................8-22
Index of Figures
Emerson Process Management GmbH & Co. OHG S-1
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
S
Safety Instructions
The instruction manual contains information about the component assembly, function,
installation, operation and maintenance of the X-STREAM
®
series gas analyzers.
The manual covers several X-STREAM analyzer models and so may contain information
about conî‚¿gurations and/or options not applicable to your analyzer.
The installation and operation of units for use in explosive (hazardous) environments is
not covered in this manual.
Analyzers intended to be used in such environments are supplied with further instruction
manuals, which should be consulted in addition to this.
INTRODUCTION
The following deî‚¿nitions apply to the terms WARNING, CAUTION and NOTE, and the sym-
bol , as used in this manual.
DEFINITIONS
NOTE!
Indicates an imperative operational procedure, an important condition or instruction.
Indicates an operational or maintenance procedure, a process, a condition,
an instruction, etc.
Failure to comply may result in injury, death or permanent health risk.
Indicates an operational or maintenance procedure, a process, a condition,
an instruction, etc.
Failure to comply may result in damage to or destruction of the instrument,
or impaired performance.
The symbol
, together with a page number ( 6-5 ) or chapter headline ( Startup )
refers to more information, provided on the indicated page or chapter.
Emerson Process Management GmbH & Co. OHGS-2
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
TERMS USED IN THIS INSTRUCTION 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
sufî‚¿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 (deî‚¿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.
Explosive Gas(es)
Flammable Gases and gas mixtures in a mix-
ture with air within the explosive limits.
Intrinsically Safe Cell (IS Cell)
Cells supplied with an intrinsically safe power
signal, approved by a Test Institute, to operate
with explosive gases.
The design ensures the IS cells remains safe
even in case of failure and explosive gases
are not ignited.
Infallible Containment
This term is derived from the standards of
explosion protection especially from the re-
quirements for pressurized housings: thus an
infallible containment can be characterized
by no intended leakage out of the gas paths
enabling gas to enter the inner compartment
of the analyzer housing.
NAMUR
NAMUR is an international user association of
automation technology in process industries.
This organisation has issued experience re-
ports and working documents, called recom-
mendations (NE) and worksheets (NA).
Protection Class IP66 / NEMA 4X
Both terms are used to specify conditions for
equipment to be installed outdoor.
IP stands for Ingress Protection, the î‚¿rst num-
ber speciî‚¿es protection against solid objects
(6. = dust tight) while the second number
speciî‚¿es the degree of protection against
liquids (.6 = heavy seas).
NEMA stands for National Electrical Manuf-
acturers Association. 4X speciî‚¿es a degree
of protection to personnel against incidental
contact with the enclosed equipment; to pro-
vide a degree of protection against falling dirt,
rain, sleet, snow, windblown dust, splashing
water, and hose-directed water; and that will
be undamaged by the external formation of
ice on the enclosure
Emerson Process Management GmbH & Co. OHG S-3
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
S
Safety Instructions
This symbol attached to the unit ... ... means
dangerous voltages may be exposed. Covers
may only be removed when power to the unit is
disconnected, and only be trained personnel.
hot surfaces may be exposed. Covers may
only be removed by trained personnel and when
power is disconnected. Certain surfaces may
remain hot.
further information and instructions are re-
quired: read the instruction manual.
SYMBOLS USED ON AND INSIDE THE UNIT
Emerson Process Management GmbH & Co. OHGS-4
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
This symbol used in the manual ... ... means
dangerous voltages may be exposed
hot surfaces may be exposed
possible danger of explosion
toxic substances may be present
substances harmful to health may be present
indicates notes relating to heavy instruments
electrical components may be destroyed by
electrostatic discharges
units must be disconnected from the power
source
indicates basic conditions or procedures are
being described.
This symbol may also indicate information impor-
tant for achieving accurate measurements.
SYMBOLS USED IN THIS MANUAL
Wherever one or more of the following symbols are used in this instruction manual, read the
accompanying information and instructions carefully.
Follow these warnings and notes carefully
to minimize risk.
Emerson Process Management GmbH & Co. OHG S-5
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
S
Safety Instructions
INTENDED USE STATEMENT
X-STREAM series gas analyzers are intended to be used as analyzers for industrial pur-
poses. They must not be used in medical, diagnostic or life support applications nor as
safety devices.
Using X-STREAM XE analyzers as safety devices, requiring redundant design or SIL clas-
siî‚¿cation, is also not permitted.
No independent agency certiî‚¿cations or approvals are to be implied as covering such
applications!
GENERAL SAFETY NOTICE / RESIDUAL RISK
If this equipment is used in a manner not speciî‚¿ed in these instructions, protective sy-
stems may be impaired.
Despite of incoming goods inspections, production control, routine tests and application
of state-of-the-art measuring and test methods, an element of risk remains when operating
a gas analyzer!
Even when operated as intended and observing all applicable safety instructions some
residual risks remain, including, but not limited to, the following:
• An interruption of the protective earth line, e.g. in an extension cable, may result in
risk to the user.
• Live parts are accessible when operating the instrument with doors open or covers
removed.
• The emission of gases hazardous to health may even be possible when all gas con-
nections have been correctly made.
Avoid exposure to the dangers of these residual risks by taking particular care when in-
stalling, operating, maintaining and servicing the analyzer.
SAFETY INSTRUCTIONS
Emerson Process Management GmbH & Co. OHGS-6
X-STREAM XE
Instruction Manual
HASXEE-IM-HS
04/2010
DISPOSAL OF BATTERIES
• This instrument contains a Li battery (button cell) of type CR 2032.
• The battery is soldered and usually does not need to be replaced during the
instrument´s lifetime.
• At the end of lifetime, the instrument must be disposed in compliance with the wast
regulations. The disposal specialist then has to disassemble the instrument and
dispose the battery in compliance with the regulations.
AUTHORIZED PERSONNEL
In-depth specialist knowledge is an absolutely necessary condition for working with and
on the analyzer.
Authorized personnel for installing, operating, servicing and maintaining the analyzer are
instructed and trained qualiî‚¿ed personnel of the operating company and the manufac-
turer.
It is the responsibility of the operating company to
• train staff,
• observe safety regulations,
• follow the instruction manual.
Operators must
• have been trained,
• have read and understood all relevant sections of the instruction manual before
commencing work,
• know the safety mechanisms and regulations.
To avoid personal injury and loss of property, do not install, operate, maintain or service
this instrument before reading and understanding this instruction manual and receiving
appropriate training.
Safety Instructions
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Rosemount X-STREAM Enhanced-1st Ed. Owner's manual

Type
Owner's manual

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