Flameproof Gas Analyzer - emerson.com€¦ · Flameproof Gas Analyzer Instruction Manual Addendum...

Flameproof Gas AnalyzerInstruction Manual Addendum for

Hazardous Area Applications

www.EmersonProcess.com

Instruction ManualHASADE-IM-Ex07/2007

ESSENTIAL INSTRUCTIONSREAD 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 clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.

• Install your equipment as 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 qualified personnel to install, operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process Management (Rosemount Analytical). Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without notice.

Emerson Process Management GmbH & Co. OHGIndustriestrasse 1D-63594 HasselrothGermanyT +49 (0) 6055 884-0F +49 (0) 6055 884-209Internet: www.EmersonProcess.com

3rd edition 2007-072nd edition 2007-041st edition 2006-07

Instruction ManualHASDE-IM-Ex04/2007

Emerson Process Management GmbH & Co. OHG S-1

Safe

ty In

stru

ctio

ns

X-STREAM FD

This instruction manual provides information about installing, operating and maintaining/servicing X-STREAM series gas analyzers in hazardous (classified) areas and shall be read in conjunction with the standard analyzer instruction manual only!

This instruction manual covers several X-STREAM series analyzer variations and therefore may describe configurations and/or options not part of your specific analyzer.

PREAMBLE

The following definitions 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.

NOTEHighlights 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.

Instruction ManualHASDE-IM-Ex

04/2007

Emerson Process Management GmbH & Co. OHGS-2

X-STREAM FDSymbols

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. Certain surfaces may remain hot to the touch.

3. Where equipment or covers are marked with the symbol to the right, refer to the Instruction Manual for instructions.

4. Further graphical symbols possibly used in this product:

SYMBOLS USED IN THIS MANUAL

Explosion Hazard!

Harmful (to Health)!

Elektrostatic discharge (ESD)

Toxic!

Heavy Instrument!

Disconnect from Power!



Safe

ty In

stru

ctio

ns

X-STREAM FD

TERMS USED IN THIS MANUAL

ATEXDirective 94/9/EC, commonly called the ATEX („Atmosphères Explosibles“) directive, dealing with equipment intended to be used in potentially explosive atmospheres.This directive is valid for equipment to be sold into and/or installed and operated in the European Union (EU).

Area ClassificationZone 1Where ignitable concentrations of flammable gases can exist some of the time under nor-mal operating conditions. (A guideline value [not part of a standard ] is 10 to 1.000 hours per year.)

Zone 2Where ignitable concentrations of flammable gases are not likely to exist under normal operating conditions. (A guideline value [not part of a standard ] is less than 10 hours per year.)

Lower Explosion Limit (LEL)Volume ratio of flammable gas in air below which an explosive gas atmosphere will not be formed: the mixture of gas and air lacks sufficient fuel (gas) to burn.

Upper Explosion Limit (UEL)Volume ratio of flammable gas in air above which an explosive gas atmosphere will not be formed: the mixture of gas and air is too rich in fuel (deficient in oxygen) to burn.

Flammable Gas(es)Gases and gas mixtures are assigned to be flammable if they might become ignitable when in a mixture with air.

Terms


04/2007


X-STREAM FDSafety Instructions

AUTHORIZED PERSONNELTo avoid explosions, loss of life, personal injury and damage to this equipment and on-site property, do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training.

SAFETY SUMMARYIf this equipment is used in a manner not specified in these instructions, protective sy-stems may be impaired.

INTENDED USE STATEMENTX-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, and no independent agency certifications or approvals are to be implied as covering such applications!

ADDITIONAL LITERATURE

This manual covers aspects specific for using flameproof X-STREAM FD analyzers in hazardous (classified) areas, only.

To install, start-up, operate and maintain/service the instrument in a safe manner it is MANDATORY to read all additional instruction manuals shipped together with the instru-ment!

The following instruction manuals are available and/or referenced within this manual at hand:HASAxE-IM-HS X-STREAM series instruction manualHASFAE-IM-H Flame arrestors series instruction manualThe original manufacturer´s cable gland or conduit instruction manual, depending on what is used.

Contact your local service center or sales office when missing documents. Save all instructions for future use!

SAFETY INSTRUCTIONS



Safe

ty In

stru

ctio

ns

X-STREAM FD

EXPLOSION HAZARD BY MODIFICATIONAny addition, substitution, or replacement of components installed on or in this device, must be certified to meet the hazardous area classification that the device was certified to prior to any such component addition, substitution, or replacement. In addition, the installation of such device or devices must meet the requirements specified and defined by the hazardous area classification of the unmodified device. Any modifications to the device not meeting these requirements, will void the product certification(s).Contact Emerson Process Management‘s customer service center for return authorization.

POSSIBLE EXPLOSION HAZARDThe X-STREAM analyzer may utilize not only sample gas but one or more pressurized carrier gases and/or calibration gases.If an external flowmeter is required for flow control, legislative requirements and instructions for installation in hazardous (classified) areas must be considered.

Safety Instructions

POSSIBLE EXPLOSION HAZARDDo not open instrument when energized.Ensure that external circuitry is disconnected or de-energized before opening the instrument.Ensure that all gas connections are made as labeled and are leak free. Improper gas connections could result in explosion and death.


04/2007



HOW TO STAY IN COMPLIANCE WITH THEEUROPEAN DIRECTIVE 94/9/EC ("ATEX") WHEN PERFORMING GAS

ANALYSIS WITHIN A FLAMEPROOF ENCLOSURE.

Special conditions apply to using a flameproof enclosure analyzer under the scope of the"European Directive for Equipment used in Explosive Atmosphere" (Directive 94/9/EC; ATEX). To stay compliant to the directive please consider the following clarification sheet released by the European ATEX Notified Body Group (see next page):

HEAVY INSTRUMENTThe analyzer model X-STREAM FD, to which this manual relates, intended to be wall mounted and/or outdoor installed, weighs up to approx. 63 kg (139 lbs), depending on included options!Use two people and/or suitable tools for transportation and lifting these instruments!Take care to use anchors and bolts specified to be used for the weight of the units!Take care the wall or stand the unit is intended to be installed at is solid and stable to hold the units!



Safe

ty In

stru

ctio

ns



04/2007


X-STREAM FD

TOC-1Emerson Process Management GmbH & Co. OHG

Tabl

e of

Con

tent

s

Instruction ManualHASDE-IM-Ex04/2007 X-STREAM FD

Table of ConTenTs

Preamble S-1

Definitions S-1Symbols used in this manual .............................................................................................S-2Terms used in this manual .................................................................................................S-3Safety instructions ..............................................................................................................S-4

Chapter 1 Technical Description 1-11-1 Overview ................................................................................................................. 1-11-2 Design Features ..................................................................................................... 1-11-3 Protective Measures in Detail ............................................................................... 1-11-4 Explosion Protection Compliances...................................................................... 1-31-5 Technical Data ........................................................................................................ 1-4

Chapter 2 Installation 2-12-1 Installing the Analyzer ........................................................................................... 2-22-2 Connecting Gas Lines ........................................................................................... 2-32-3 Electrical Installation ............................................................................................. 2-5

Chapter 3 Startup 3-1

Chapter 4 Service and Maintenance 4-14-1 Verifications and Tests after Service or Maintenance ........................................ 4-34-1-1 Routine Tests ...................................................................................................... 4-34-1-1-1 Visual Inspection ............................................................................................ 4-34-1-1-2 Tests on Flame Arrestors .............................................................................. 4-34-2 Replacement of Parts ............................................................................................ 4-4

Appendix A-1A-1 EC Declaration of Conformity ...............................................................................A-2A-2 ATEX EC Type Examination Certificate ...............................................................A-3A-3 Cable gland ADL 1F installation instruction ........................................................A-7A-4 Block diagram X-STREAM FD ...............................................................................A-8A-5 Assignment of Terminals and Socket .................................................................A-9

TOC-2 Emerson Process Management GmbH & Co. OHG


04/2007X-STREAM FDTable of Contents

Table of figuresFig. 1-1: X-STREAM FD .....................................................................................................................................1-1Fig. 1-2: X-STREAM FD, bottom view ..............................................................................................................1-2Fig. 1-3: X-STREAM FD - dimensions .............................................................................................................1-4Fig. 1-4: X-STREAM FD - power terminals / fuse holders ..............................................................................1-7Fig. 1-5: X-STREAM FD - signals terminals ....................................................................................................1-8

Fig. 2-1: X-STREAM FD dimensions ................................................................................................................2-2Fig. 2-2: Flame arrestor installed into instrument enclosure ........................................................................2-3Fig. 2-3: Flame arrestor elements, considering as example FA 01 ...............................................................2-3Fig. 2-4: X-STREAM FD - allocation of terminals ..........................................................................................2-10Fig. 2-5: X-STREAM FD - Analog output terminals .......................................................................................2-12Fig. 2-6: X-STREAM FD - Modbus interface terminals .................................................................................2-13Fig. 2-7: X-STREAM F - Modbus over ethernet connector ...........................................................................2-14Fig. 2-9: X-STREAM FD - Relay Status Terminals ........................................................................................2-15Fig. 2-8: Relay status signals, block diagram ..............................................................................................2-15Fig. 2-10: Digital Inputs & Outputs Terminals ...............................................................................................2-16Fig. 2-11: Power terminals ..............................................................................................................................2-17Fig. 2-12: Equipotential bonding conductor terminal ..................................................................................2-18

Fig. A-1: Terminals strip 1 ................................................................................................................................ A-9Fig. A-2: Terminals strip 2 ................................................................................................................................ A-9Fig. A-3: Power terminals ................................................................................................................................ A-9Fig. A-4: Ethernet connector for Modbus ....................................................................................................... A-9

X-STREAM FD

Emerson Process Management GmbH & Co. OHG 1-1

Instruction ManualHASADE-IM-EX07/2007

1 T

echn

ical

Des

crip

tion

Chapter 1 Technical Description

1-1 OverviewThe new X-STREAM FD gas analyzer is de-signed to be used in hazardous areas. Its fla-meproof enclosure can be installed at Zone 1 locations without the need of any additional protective measures, e.g. purge gas supply.

1-2 Design FeaturesPackaged into a cast aluminum enclosure, the X-STREAM FD gas analyzer provides all the measurement options available for general purpose instruments, but for installation at lo-cations where explosive atmosphere might be present frequently and classified as Zone 1.

The basic concept used is to protect the sur-rounding atmosphere from being ignited if an internal failure results in high temperatures, flames or even an explosion.

To provide adequate explosion protection the X-STREAM FD analyzer features several protection methods:

Fig. 1-1: X-STREAM FD

1-3 Protective Measures in DetailThe cast aluminum enclosure consists of two parts: base and cover, connected by hinges.The area where the two parts are in contact is designed to work as a flange, quenching flames entering the small path between them. When operated, the analyzer enclosure has to be closed and secured by 20 screws evenly arranged all over the flange.

• The cast aluminum enclosure is designed to• withstand an internal explosion,• extinguish the flames resulting from an

internal explosion (thus preventing a sur-rounding explosive atmoshere from being ignited).

• Flame arrestors avoide flame transmission from the gas paths into the surrounding atmosphere.

• Approved cable glands (option: conduits) protect the cable inlets and outlets.

1: Enclosure base2: Screws3: Enclosure cover4: Flange 5: Eyebolts for lifting6: Eyebolts for installation7: Hinges

1

2

3

5

4

6

7

X-STREAM FD

Emerson Process Management GmbH & Co. OHG1-2

Instruction ManualHASADE-IM-EX

07/2007

1-3 Protective Measures in Detail

The only openings penetrating the enclosure are threads, to be used for gas and cable in- and outlets:

Depending on the measurement application the instrument provides up to 8 gas in- and outlets, each protected by an approved flame arrestor. These arrestors are installed into threads at the bottom side of the enclosure base. Two fitting sizes are available for ex-ternal connection of gas pipes with 3.18 mm (1/8“) or 6.35 mm (1/4“) outer diameter (OD). Optionally a clamping ring for 6 mm OD may be used, replacing the 6.35 mm version.

Cables are fed into the enclosure utilizing up to 4 cable glands, located at the enclosure`s bottom right side. The approved glands accept 3 different internal elastomeric sealing rings with different internal diameters, supporting a wide range of cables.

For installation in North-America cable glands are replaced by a combination of conduits and metric-to-NPT thread adapters.

All threads provide a flame path of a length ensuring that possibly entering flames are extin-guished before reaching the external atmos-phere.

Unused threads must be closed with plugs when the instrument is operated to ensure explosion protection.

Note!See the X-STREAM series instruction manual for more information about common X-STREAM series gas analyzers features and special features of the X-STREAM FD.

Fig. 1-2: X-STREAM FD, bottom view

1: Plugged when not used2: Gas fitting (part of flame arrestor)3: Plug4: Cable gland (or conduits)

1 2 3 4

X-STREAM FD



1 T

echn

ical

Des

crip

tion

1-4 Compliances

1-4 Explosion Protection CompliancesThis product is available in two different variations, separately certified by agencies for the use in hazardous (classified) areas:The one version, to be equipped with metric-to-NPT adapters and conduits (these components are not part of the instrument certification), is certified by the Canadian Standards Association, an „OSHA Nationally Recognized Testing Labor tory“ (NRTL), for Canada and USA and conforms to the provisions of CAN/CSA-E60079-0:02 (R2006), CAN/CSA-E60079-1:02 (R2006), ANSI/ISA-12.00.01-2002 (IEC 60079-0 Mod), ANSI/ISA-12.22.01-2002 (IEC 60079-1 Mod). The second variation, to be equipped with cable glands, is certified by Fyzikálně technický zkušební ústav, s.p (FTZÚ), an European Notified Body under the Directive 94/9/EC („ATEX“) and conforms to the provisions of EN 60079-0 and EN 60079-1. See appendix for a copy of the CE type examination certificate.

Depending on the variation, the following certification markings apply to the product:

USA Class I, Zone 1, AEx d IIB + H2 T3Canada Class I, Zone 1, Ex d IIB + H2 T3

European Union (EU) ATEX, category 2, Zone 1, Ex d IIB + H2 T4EC ATEX Type Examination Certificate: FTZU 06 ATEX 0186.

Conforms with the provisions of the „Equipment intended for use in Potentially Explosive Atmosphe-res (ATEX)“ Directive 94/9/EC, EMC Directive 89/336/EEC and CE Directive 93/68/EEC.

X-STREAM FD



07/2007

1-5 Technical Data

1-5 Technical Data

Fig. 1-3: X-STREAM FD - dimensions

approx. in mm [inches]

Cable inlets (enclosure threads; M20 x 1.5)

Flame arrestors with gas fittings (enclosure threads: M18 x 1.5)

Eyebolt detail

HousingPermissible ambient temperature range -22 F to 122 F ( -30 °C to +50 °C)Weight: approx. up to 139 lbs (63 kg) (depending on analyzer configuration)Protection class: IP 66 (EN 60529) / NEMA 4X for outdoor installation Analyzer must not be exposed to direct sun light Gas fittings: quantity: max. 8 specification: flame arrestors with fittings 6/4 mm or 1/4“, stainless steel

X-STREAM FD



1 T

echn

ical

Des

crip

tion

1-5 Technical Data

Site of installationHumidity (non condensing) < 90 % r. h. at 68 F (+20 °C) < 70 % r. h. at 104 F (+40 °C)Pollution degree 2 Installation category I IAltitude 0 to 6560 ft (2000 m) above sea level Sourrounding atmosphere Analyzers must not be operated in corrosive atmosphere.

Power supplyRated input voltageated input voltage 100 - 240 V 50/60 Hz, wide range input Power supply voltage fluctuations are not to exceed +/- 10 % of the nominal supply voltage! Input voltage range 85 - 264 V , 47 - 63 Hz Rated input current standard 0,75 - 0,35 A max. with thermostated physics 2 - 1 A max.

General Purpose CompliancesElectrical safety CAN / USA CSA-C/US, based on CAN/CSA-C22.2 No. 61010-1-04 / UL 61010-1, 2nd Edition Europe CE, based on EN 61010-1 Electromagnetic compatibility Europe CE, based on EN 61326 other NAMUR

X-STREAM FD



07/2007

1-5 Technical Data

Gas parameters X-STREAM Instruction Manual, chapter 3 Measuring Principles

Interfaces, signal inputs / outputs2 analog outputs channel 4 (0) - 20 mA (RB < 500 Ω) (optically isolated; configurable by keypad start and end concentration user configurable)

Modbus interface RS 485 (2- or 4-wire) optional: RS 232 with or without optical isolation Ethernet (RJ45 socket)

3 relay outputs (option „status signals“) “Failure” according NAMUR NE 107 “Maintenance required / Off specification“ “Function check” dry contacts, max. 30 V; 1 A; 30 W resi-stive

Digital Inputs and Outputs (option)

7 digital inputs zero calibration ch1 & ch2, (common ground) span calibration ch1, span calibration ch2, open valve V4 open valve V1 open valve V2 open sample gas valve V3 / switch off sample pump

max. 30 V, internally limited to 2.3 mA H level: min. 4 V; L level: max. 3 V

8 digital outputs 2 thresholds per channel, (optically isolated, common ground) sample gas valve, zero gas valve V4, span gas valve V1, span gas valve V2 “Open Collector”, max. 30 V / 30 mA

X-STREAM FD



1 T

echn

ical

Des

crip

tion

Fig. 1-4: X-STREAM FD - power terminals / fuse holders

1-5 Technical Data

Power ConnectionConnection via internal screw terminals near cable entries, (fig. 2-8). Cross section: max. 10 AWG (4 mm2), using conductor sleeves is not required Cable entry via 1 cable gland, classified IP 68 or suitable conduit with metric-to-NPT adaptorPermissible outer cable diameter for power cord when provided with cable glands: 0.11 to 0.5 inch (3-13 mm), depending on used cable gland sealing ring

Power fusesThe power terminals integrate fuse holders. Fuse ratings: AC 230 V, 3.15 A, 5x20 mm

1 Power terminals with integrated fuse holders 2 Protective earth terminal (PE)

3 Power cable entry 4 EMI power filter

324 1

X-STREAM FD



07/2007

Fig. 1-5: X-STREAM FD - signals terminals

1-5 Technical Data

Signal inputs / outputsAll signal lines need to be connected to internal screw terminals (fig. 1-5), except the optional RJ45 ethernet connector.

Cross section: max. 12 AWG (2.5 mm2), using conductor sleeves is not required Cable entry via 3 cable glands, classified IP 68 or suitable conduits with metric-to-NPT adaptorsPermissible outer cable diameter for signal cables when provided with cable glands: 0.11 to 0.5 inch (3-13 mm) depending on used cable gland sealing rings

Available signals: standard: Analog signal outputs Relay status signals Modbus interface (RS232; RS 485) optional: Digital inputs/outputs Modbus RJ45 ethernet connectorDetailed pin assignment 2 Installation

The optional ethernet connector (RJ45),located on the electronics

main board BKS


Instruction ManualHASADE-IM-EX07/2007 X-STREAM FD

2 In

stal

latio

n

Chapter 2 Installation

POSSIBLE EXPLOSION HAZARDInstalling and wiring this instrument must comply with all relevant national legislative requirements and regulations.Consider all safety instructions within this on hand manual and all associa- ted analyzer instruction manuals!

POSSIBLE EXPLOSION HAZARDInstalling this instrument requires opening the enclosure and working at the open instrument. This is permitted only when both no hazardous atmosphere is present and the instrument and connected external circuitry are de-energized!Depending on the local regulation, this may require a competent hot work supervisor to issue a hot work permit.

HEAVY INSTRUMENTThe analyzer model X-STREAM FD, to which this manual relates, intended to be wall mounted and/or outdoor installed, weighs up to approx. 63 kg (139 lbs), depending on included options!Use two people and/or suitable tools for transportation and lifting these instruments!Take care to use anchors and bolts specified to be used for the weight of the units!Take care the wall or stand the unit is intended to be installed at is solid and stable to hold the units!



07/2007X-STREAM FD

2-1 Installing the AnalyzerInstall the analyzer to a stand or a wall by means of 4 eyebolts, provided at the instru-ments rear side.It is recommended to install the analyzer in an

2-1 Installation - Analyzer

Fig. 2-1: X-STREAM FD dimensions

upright (vertical) position; other orientations may affect the measuring results.

Eyebolt detail

All dimensions in mm [inches in brackets]

Flame arrestors with gas fittings Electrical connections

Note!Add 15 [0.59] to left and right side to include hinges.



2 In

stal

latio

n

1

2

3

4

5

5

67

2-2 Installation - Gas Lines

2-2 Connecting Gas LinesGas inlets and outlets are protected by cer-tified flame arrestors (FTZU 06 ATEX 0164), suppor-ting stainless steel pipes of either 3,18 mm (1/8“) or 6,35 mm (1/4“) outer diameter (OD). The 1/4“ fitting may optionally be supplied with a clamping ring for 6 mm OD pipes.

Fig. 2-2: Flame arrestor installed into instrument enclosure

1: Gas fitting 1/8“ (inside instrument) *)

2: M18 male threat (inside enclosure wall)3: O-ring4: Gas fitting 1/4“ or 1/8“ (outside instrument) *)

5: Hexagon for counter holding while thightening6: Hexagon for wrench when mounting into a M18 threat7: O-ring shoulder

*) FA 01 with 1/4“ (outside instrument) and 1/8“ (inside) FA 02 with 1/4“ at both ends FA 03 with 1/8“ at both ends

Fig. 2-3: Flame arrestor elements, considering as example FA 01

POSSIBLE EXPLOSION HAZARDTake care not to damage the threats, this may void the instrument´s safety and cause hazards!Take care to follow the instructions of the separate flame arrestor instruction manual (HASFAE-IM-H)!Ensure unused entries remain sealed with approved plugs!

When thightening the fitting, counterhold the flame arrestor with a wrench placed at the hexagon (items 5 of fig. 2) next to the cap nut (items 1, 4) to be tightened.

Always counterhold the flame arrestor while thightening fit-tings; otherwise the flame arre-stor may be damaged!

The instrument provides up to 8 gas inlets and outlets, depending on the ordered configura-tion. Unused entries are closed by approved plugs.



07/2007X-STREAM FD2-2 Installation - Gas Lines

Gas fittings are accessible at the instrument‘s outer bottom side.The number and assign-ment of gas inlet and outlet fittings depends on the application and is given on a label at-tached to the analyzer‘s bottom side adjacent to the fittings.

For simple installation we recommend to mark the gas lines according to the marking on the analyzer label. This avoids confusion during re-installation when the analyzer had to be disconnected for whatever reason.



2 In

stal

latio

n

2-3 Electrical Installation

2-3 Installation - Electrical

ELECTRICAL SHOCk H AZARDInstallation and connecting power and signal cables are subject to qualified personnel only taking into account all applicable standards and legislative requirements!Failure to follow may cause warranty invalidation, property damage and/or personal injury or death!Installation of these instruments is subject to qualified personnel only, familiar with the resulting potential risks! Instruments providing screw terminals for electrical connections may require working near live part!X-STREAM FD 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.



07/2007X-STREAM FD

INSTALLATION USING CONDUITSX-STREAM FD analyzers provide metric threads for installing cable entries. Installing conduits requires using metric-to-NPT adaptors!To stay compliant with the North-American certification use only flameproof certified adaptors, e.g. the following type: Redapt AD-U series, stainless steel with captive o-ring seals, size male M20 x 1.5 to female 3/4-NPT or 1/2-NPT.Select a type of conduit according the local code, suitable for above mentioned adaptors and the site of installation. During installation follow the instructions provided by the manufacturer of the conduits!Unused entries must be provided with flameproof plugs, secured in place with thread locking compound!

POSSIBLE EXPLOSION HAZARDDo not open instrument when energized.Ensure that external circuitry is disconnected or de-energized before opening the instrument.All cables (power and signal) must end (be connected) in either a safe (non-hazardous) area or in a protecting enclosure (e.g. Ex e junction box)!

SELECT THE CORRECT TYPE OF CABLE ENTRYBefore starting to install the analyzer, verify what type of cable entry is required at your site of installation: X-STREAM FD gas analyzers may be equipped with cable glands (regulated e.g. for instal-lations covered by ATEX) or may be installed with conduits (e.g. in North-America).




2 In

stal

latio

n

• the English section of the ADL type cable gland installation instructions, reprinted with the permission of

Cooper IndustriesCooper Menvier DivisionCAPRI-CODEC sas .


INSTALLATION USING CABLE GLANDS When installing the analyzer in a Hydrogen environment and/or applying Hydrogen to the analyzer, do not use the standard ADL type cable glands! Use suitable compound barrier cable glands to stay compliant to EN 60079-14. During installation follow the instructions provided by the manufacturer of the glands!When using the ADL type cable glands: Take care to use the correct cable gland internal elastomeric ring with an internal diameter supporting the cable to be used! The supported cable diameters are noted on the sealing ring.Use only cables as specified in the cable glands installation instruction, and carefully follow the installation instructions!

The next two pages show

and

• the English installation instructions for type AD-U adapters, reprinted with the permis-sion of

Redapt LtdNote!See appendix of this manual for a complete reprint, and the documentation delivered together with your analyzer for an original version of the cable gland or adapter instal-lation instructions, where applicable !



07/2007X-STREAM FD2-3 Installation - Electrical

Type AD-U adapter installation instructions



2 In

stal

latio

n


The elastomeric sealing rings, provided together with the cable gland, are designed to cover the diameter ranges

3 to 8 mm6,5 to 10.5 mm or10 to 13 mm.

ADL type cable gland in-stallation instructions



07/2007X-STREAM FD

Fig. 2-4: X-STREAM FD - allocation of terminals

1 Terminals for signal cables2 Power EMI filter3 4 cable entries for power and signal cables4 Power terminals with integrated fuses5 Ethernet connector (option)


Unused entries during installation have to be provided with plugs, secured in place with thread locking compound.

Installation under CSA certification requires the use of approved conduits and suitable metric-to-NPT adaptors. .

The instrument provides internal screw termi-nals for connecting power and signal cables. This requires opening the instrument during installation:• Unsrew the 20 screws located on the

enclosure flange. • Flap down the cover part to gain access

to the analyzer inside.

The analyzer provides 4 cable entries and is shipped with selected sets of plugs and glands or adaptors, depending on the ordered analyzer configuration:The default set consists of • 1 gland/adaptor for the power cord• 1 gland/adaptor for one signal cable • 3 plugs for unused entries, taking into

account an installation without even one signal cable.

1 42 35



2 In

stal

latio

n


Installation with conduitsEnsure all required parts are available: Adaptors, suitable conduits, plugs for not used entries and compound (see accessory kit).Place some locking compound onto the male thread of the required number of adaptors and install them into the related cable entries:The 3 rear entries are reserved for signal cables, the first one is for the power cord.Ensure the explosionproof seal is placed at the analyzer enclosure or within 2“ from enclosure.All cables need to be fed properly through conduits when entering the instrument and connected to the terminals ( warning notes, page 2-5). To seal the cable entries proceed according to the installation instruction given in the related conduits manufacturer documentation.Seal unused entries utilizing flameproof certi-fied plugs, also provided with some compound on their threads.

All signal cables are to be connected via screw terminals, except the optional ethernet connector, located inside the analyzer.

Preparation of signal cables

Supported wire cross sections: 24 to 14 AWG (0,2 to 2,5 mm2), no need to use wire end sleevesCable skinning length: 0.354 inch (9 mm)Hole diameter: 0.05 inch (1,2 mm)Screw thread: M 2,5 Tightening torque, min: 3.5 in.lb (0,4 Nm)

Installation with cable glandsEnsure all required parts are available: Cable glands, plugs for not used entries and compound (see accessory kit).Place some locking compound onto the male thread of the required number of cable glands body parts and install them according the manufacturers instruction into the related cable entry:The 3 rear entries are reserved for signal cables, the first one is for the power cord.All cables need to be fed properly through the cable glands when entering the instrument and connected to the terminals ( warning notes, page 2-5). To seal the cable entries proceed according to the installation instruction given in the related cable glands manufacturer documentation.Seal unused entries utilizing the plugs, also provided with some compound on their th-reads.




Signal inputs / outputs

Analog signal outputs

The rightmost 4 terminals (# 1 - 4) of the ter-minals row next to the power terminals are reserved for analog signal outputs.

Fig. 2-5: X-STREAM FD - Analog output terminals

Note!Take care of the special installation instruc-tions in section 4-5 of the X-STREAM gas analyzer series manual!

(-) 4

(0) -

20

mA

, cha

nnel

2(+

) 4 (0

) - 2

0 m

A, c

hann

el 2

(-) 4

(0) -

20

mA

, cha

nnel

1(+

) 4 (0

) - 2

0 m

A, c

hann

el 1

Burden: RB ≤ 500 Ω



2 In

stal

latio

n

Modbus interfaceSpecification and driving the interface:

X-STREAM gas analyzer series manual, chapter 7.

Note 1!Take care of the special installation instruc-tions in section 4-5 of the X-STREAM gas analyzer series manual!

The leftmost 5 terminals (# 11 - 15) of the terminals row next to the power terminals are reserved for the Modbus interface, which can be either of type RS 232 or RS 485.

Note 2!X-STREAM analyzers are to be considered a DTE (Data Terminal Equipment).

Fig. 2-6: X-STREAM FD - Modbus interface terminals

1112131415

Terminal RS 232 RS 485/2w RS 485/4w 11 Common Common Common 12 RXD not used RXD0 13 TXD not used RXD1 14 not used D1 TXD1 15 Common D0 TXD0





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 connetor through the cable inlet.

Once the open end is inside the instrument, the plug connector can be installed: We recommend using a VARIOSUB RJ45 QUICKON plug connector (PHOENIX CON-TACT), as supplied together with the instru-ment, not requiring special tools. See the separate installation instruction, provided together with the plug connector for informa-tion on how to install it.

Optional Modbus RJ45 connection

RJ45 connector on main board BKS

Pin Signal 1 TX+ 2 TX- 3 RX+ 6 RX- other not used

Pin 1 Pin 8

Fig. 2-7: X-STREAM F - Modbus over ethernet connector

Note!Notice, that the modbus screw terminals ( page 2-12) are installed, too, but wit-hout function!



2 In

stal

latio

n

Relay status SignalsDesign: dry relay contacts Electrical specification: max. 30 V , 1 A, 30 W

Fig. 2-8: Relay status signals, block diagram


Signal output (NC); configurati-on on request

Signal output (NO); factory standard configu-ration

Fig. 2-9: X-STREAM FD - Relay Status Terminals

The middle 6 terminals (# 5 - 10) of the ter-minals row next to the power terminals are reserved for the relay status signals.

5 Failure COM 6 Failure NO 7 Maintenance, off-spec COM 8 Maintenance, off-spec NO 9 Function check COM 10 Function check NO

Terminal Signal

5678910




07/2007X-STREAM FD

Digital Inputs & Outputs

The leftmost terminal strip is reserved for the digital inputs and outputs.

Fig. 2-10: Digital Inputs & Outputs Terminals

Design: Open collector (outputs) Electrical specification: 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


Ch1: threshold 1

Ch1: threshold 2

Ch2: threshold 1

Ch2: threshold 2

Sam

ple valveValve V

4Valve V

1Valve V

2D

IG O

ut GN

DZero cal. C

h1 & C

h2S

pan cal. Ch1

Span cal. C

h2O

pen V4

Open V

1O

pen V2

Open sam

ple valve or close allD

IG In G

ND

Terminal 1

Terminal 2

Terminal 3

Terminal 4

Terminal 5

Terminal 6

Terminal 7

Terminal 8

Terminal 9

Terminal 10

Terminal 11

Terminal 12

Terminal 13

Terminal 14

Terminal 15

Terminal 16

Terminal 17

Digital Inputs DigitalOutputs




2 In

stal

latio

n

Connecting the power cordThe power cord is connected by screw termi-nals, located inside analyzer.Supported wire cross sections: 24 to 12 AWG (0,2 to 4 mm2), no need to use wire end sleevesCable skinning length: 0.315 inch (8 mm)Hole diameter: 0.05 inch (1,2 mm)Screw thread: M 3 Tightening torque, min: 4.4 in.lb (0,5 Nm)

To install the cable proceed according to the installation instructions for either conduits or cable glands, given on page 2-11.

Insert the power cord through the foremost entry, strip the outer insulation, skin and connect the conductors to the terminals (a descriptive label is fixed to the filter‘s housing nearby the terminals), by inserting them from the bottom sides.


ELECTRICAL SHOCk HAZARDVerify the power supply at installation site meets the specification given on the analyzer´s nameplate label, before installing the instrument!Verify power cables are disconnected and/or instrument is de-energized prior to working at the terminals!Verify the power cord is layed with a distance of at least 1 cm (0.5“) to any signal cable to ensure proper insulation from signal circuits!

L

PE

N

Power cord entry

Location for label

L= LineN=NeutralPE=Protective Earth

Fig. 2-11: Power terminals



07/2007X-STREAM FD

Connecting an optional equipotential bonding conductor

The X-STREAM FD enclosure provides an additional terminal for connecting an equi-potential conductor, located at the base part flange´s rear side (see fig. 2-6), near the nameplate label.

Screw thread: M5

Fig. 2-12: Equipotential bonding conductor terminal




2 In

stal

latio

n

After all connections are established in correct manner and verified, • fix the cables according to the installati-

on instruction given in the cable glands/ conduits manufacturer documentation.

• Install the analyzer´s cover by means of ALL 20 screws! Tightening torque: min. 354 in.lb (40 Nm)


POSSIBLE EXPLOSION HAZARDDo NOT operate the instrument with doors or covers open! This is permitted only when no hazardous atmosphere is present!Depending on the local regulation, this may require a competent hot work supervisor to issue a hot work permit.Use ALL 20 screws to fix the cover! Violation may cause an explosion hazard!

ELECTRICAL SHOCk HAZARDBefore completing the electrical connection of the instrument, verify cables are inserted and connected in correct manner!Ensure the earthing conductor (protective earth; PE) is connected!


X-STREAM FD

3 St

artu

p


Chapter 3 Startup

Once the X-STREAM FD analyzer is installed correctly and in accordance to the instruc-tions given in chapter2 „Installation“ it is prepared for startup.

POSSIBLE EXPLOSION HAZARDEnsure all covers, plugs and housing parts are in place and secured properly before supplying power and signal voltages!

Ensure all requirements given by the clarification sheet for performing gas analysis within a flameproof enclosure are considered BEFORE supplying gases (see page S-5)!The sheet also gives instruc-tions for the sequence of supply-ing gases during process and analyzer startup .

After all safety aspects are followed and checked, the instrument may be powered and operated according the instructions given in the X-STREAM series instruction manual. Read this manual for detailled information about software, parameter settings and more.


X-STREAM FDInstruction Manual

HASADE-IM-EX04/2007

3 Startup


X-STREAM FD

4 M

aint

enan

ce


Chapter 4 Service and Maintenance

POSSIBLE EXPLOSION HAZARDInspection, maintenance and service must be carried out considering all related standards (e.g. EN 60079-17 „Inspection and maintenance of electrical installations in hazardous areas (other than mines)“ ).

POSSIBLE EXPLOSION HAZARDService or replacement of safety related components or requiring to open the instrument are permitted only if no hazardous atmosphere is present and both the instrument and connected circuitry are de-energized!Depending on the local regulation this may require a competent hot work supervisor to issue a hot work permit.

POSSIBLE EXPLOSION HAZARDAfter maintenance or replacement of parts concerning explosion protection an authority on explosion protection has to verify that the analyzer still meets the requirements for explosion protection before it is switched on again.Parts essential for explosion protection must not be repaired, they must be replaced if defective!The authority has to issue a certificate for this and/or attach a test label to the equipment before startup after maintenance or replacement of parts.

Note!This chapter deals with service and maintenance procedures related to explosion protection only!More detailled instructions about servicing and maintaining general purpose components of X-STREAM gas analyzers are subject of the X-STREAM analyzer instruction manual.



HASADE-IM-EX07/2007

4 Service and Maintenance

FLAMMABLE GASES - POSSIBLE EXPLOSION HAZARDLeaks may cause explosion when measuring flammable gases!When measuring flammable gases it is recommended to perform a leak test on all gas paths, connections and components before startup or applying power. Leak tests should be carried out on a 2 month‘s regular basis and after repair/maintenance.See the analyzer instruction manual for instructions on how to carry out leak tests.

HAZARDOUS GASESWhen measuring flammableand/or toxic gases it is recommended to purge the system with air or an inert gas, e.g. nitrogen, prior to opening the gas paths.Violation may cause an explosion and/or personal injury or death!

POSSIBLE EXPLOSION HAZARDModifications affecting the integrity of type of protection (e.g. affixing addtional threads, replacing the flame arrestors by other model) are NOT PERMITTED!Violation may cause an explosion and/or personal injury or death!


X-STREAM FD

4 M

aint

enan

ce


Modifications made on the electrical appara-tus affecting the integrity of the type of protec-tion or the temperature of the apparatus shall be permitted only if the modified apparatus is resubmitted to a testing station. In the case of repairs affecting the type of protection, the parts which have been re-paired should be subjected to new routine verifications and tests. These tests need not necessarily be made by the manufacturer.

4-1 Verifications and Tests after Service or Maintenance

4-1 Verifications and Tests after Service or Maintenance

4-1-1 Routine TestsThe following tests shall be performed on a regular basis:

4-1-1-1 Visual InspectionThe instrument shall be visually checked for damages to the enclosure and external ana-lyzer components.

4-1-1-2 Tests on Flame ArrestorsDepending on the application flame arrestors should be checked periodically according the information given in the flame arrestors instruction manual.



HASADE-IM-EX07/2007

4-2 Replacement of Parts


POSSIBLE EXPLOSION HAZARD !Replacement of parts found defective is permitted only by using original parts!Violation voids the approvals and may cause explosions!

Parts beside the cast enclosure, the safety of the X-STREAM FD relies on:Cable glands, standard for ATEX approved analyzers Type: ADL 1F ISO 20 No. 05 by CAPRI LCIE 97 ATEX 6006 X Compound Cable glands (optional) for ATEX approved analyzers Type: to be selected for the installed cable and with ATEX (EU) or suitable local approval (outside EU) Male thread: M20 x 1.5 Available from several manufacturers, e.g. type CR-X by PeppersCable Glands LimitedCable entries stopping plugs for ATEX approved analyzers Type: 120209 by CAPRI Male thread: M20 x 1.5 98 ATEX 0001U

Metric-to-NPT adapters for CSA approved analyzers Any flameproof certified type Male thread: M20 x 1.5 Female thread: 1/2“ or 3/4“ per request e.g. Type: AD-U series by Redapt Ltd. CSA certificate 1248014


X-STREAM FD

4 M

aint

enan

ce



Cable entries stopping plugs for CSA approved analyzers Any flameproof certifed type Male thread: M20 x 1.5 e.g. Type: PD-U by Redapt Ltd. CSA certificate 1248014Flame arrestors Type: FA 01, FA 02, FA 03 by EMERSON PROCESS MANAGEMENT FTZU 06 ATEX 0164 Enclosure screws Material: stainless steel A2-70 Thread: M16 x 45 ISO 4762 A2Thread locking adhesive Type: ML® 5249 by DELOInternal battery (soldered to electronics board, not user replaceable) Type: SL 750 by Tadiran Batteries GmbH System: SOCl2 / Li Nom. voltage: 3.6 VNom. voltage: 3.6 V IEC 60086-1 type E cell



HASADE-IM-EX07/2007


Emerson Process Management GmbH & Co. OHG A-1


App

endi

x

X-STREAM FD

Appendix

This chapter contains

EC Declaration of Conformity A-1, page A-2

ATEXECTypeExaminationCerti.cate A-2, page A-3

Cable gland ADL 1F installation instruction A-3, page A-7

Block diagram A-4, page A-8

Assignment of Terminals and Socket A-5, page A-9

Emerson Process Management GmbH & Co. OHGA-2


07/2007X-STREAM FD

A-1 EC Declaration of Conformity

A-1 EC Declaration of Conformity



App

endi

x

X-STREAM FD

A-2 ATEXECTypeExaminationCerti.cate

A-2ATEXECTypeExaminationCertificate



07/2007X-STREAM FDA-2ATEXECTypeExaminationCertificate



App

endi

x

X-STREAM FDA-2ATEXECTypeExaminationCertificate



07/2007X-STREAM FD

X-STREAM FD


App

endi

x


A-3 Cable gland ADL 1F installation instruction

(reprinted with the permission of

Cooper IndustriesCooper Menvier DivisionCAPRI-CODEC sas. )

A-3 Cable Gland Installation Instruction

X-STREAM FD



07/2007

A-4 Block diagram X-STREAM FD

A-4 Block Diagram

X-STREAM FD


App

endi

x


A-5 Assignment of Terminals and Socket

Fig. A-1: Terminals strip 1

Modbus interface

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

56789101112131415 1234

Burden: RB ≤ 500 Ω

1 (+) 4 (0) - 20 mA, ch 1 2 (-) 4 (0) - 20 mA, ch 1 3 (+) 4 (0) - 20 mA, ch 2 4 (-) 4 (0) - 20 mA, ch 2

Terminal Signal

Analog outputs

Failure COMFailure NOMaintenance, off-spec COMMONMaintenance, off-spec NOFunction check COMMONFunction check NO

5 6 7 8 9 10

Terminal Signal

Relay outputsFig. A-2: Terminals strip 2

Line L

Protective Earth PE

Neutral N

Fig. A-3: Power terminals

Note!Line and neutral terminals with built-in fuse holders

Fig. A-4: Ethernet connector for Modbus

Pin 1 Pin 8

Pin Signal 1 TX+ 2 TX- 3 RX+ 6 RX- andere nicht verwendet

*) With optional range switching this output is used as range indicator ( X-STREAM series instruction manual, section 7-7-5, page 7-58)

A-5 Assignment of Terminals and Socket

Terminal 1

Terminal 2

Terminal 3

Terminal 4

Terminal 5

Terminal 6

Terminal 7

Terminal 8

Terminal 9

Terminal 10

Terminal 11

Terminal 12

Terminal 13

Terminal 14

Terminal 15

Terminal 16

Terminal 17

Ch1: threshold 1

*)

Ch1: threshold 2

Ch2: threshold 1

Ch2: threshold 2

Sam

ple valve

Valve V4

Valve V1

Valve V2

DIG

outputs CO

MM

ON

Ch1 &

Ch2: Zero cal.

Ch1: S

pan cal.

Ch2: S

pan cal.

Valve V4

Valve V1

Valve V2

Open sam

ple valve, close all, or pump on/off

DIG

inputs CO

MM

ON

Digital Inputs Digital Outputs

X-STREAM FD



07/2007

Instruction ManualHASADE-IM-Ex04/2007 X-STREAM FD

Instruction ManualHASADE-IM-Ex

04/2007X-STREAM FD

© 2007 Emerson Process Management GmbH & Co. OHG

WORLD HEADQUARTERS

ASIA-PACIFICEmerson Process ManagementAsia Pacific Private Limited1 Pandan CrescentSingapore 128461Republic of SingaporeT 65 6 777 8211F 65 6 777 0947e-mail: [email protected]

EUROPE, MIDDLE EAST AND AFRICAEmerson Process ManagementShared Services LimitedHeath PlaceBognor RegisWest Sussex PO22 9SHEnglandT 44 1243 863121F 44 1243 845354

ROSEMOUNT ANALYTICAL EUROPE Emerson Process ManagementGmbH & Co. OHGIndustriestrasse 163594 HasselrothGermanyT 49 6055 884 0F 49 6055 884209

GAS CHROMATOGRAPHY CENTERAND LATIN AMERICAEmerson Process ManagementRosemount Analytical Inc.11100 Brittmoore Park DriveHouston, TX 77041T 713 467 6000F 713 827 3329

Emerson Process ManagementRosemount Analytical Inc.6565 P Davis Industrial ParkwaySolon, OH 44139 USAT 440.914.1261Toll Free in US and Canada 800.433.6076F 440.914.1271e-mail: [email protected]

Flameproof Gas Analyzer - emerson.com€¦ · Flameproof Gas Analyzer Instruction Manual Addendum...

Documents

Transcript of Flameproof Gas Analyzer - emerson.com€¦ · Flameproof Gas Analyzer Instruction Manual Addendum...