Emerson HAS8xE-IM-ATEX User Manual

Instruction Manual

HAS8xE-IM-A TEX
08/2004

Instruction Manual

BINOS 100 F & MLT 2
Addendum for Pressurized Analyzers
intended to be used in
Hazardous Areas classified Zone 2

rd

Edition 08/2004

3

www.EmersonProcess.com

BINOS 100 F & MLT 2 Addendum for Zone 2 Instruction Manual

HAS8XE-IM-ATEX

08/2004

ESSENTIAL INSTRUCTIONS

READ THIS P AGE BEFORE PROCEEDING!

Emerson Process Management (Rosemount Analytical) designs, manufactures and test s
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 specifications. 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 specified 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.

• T o 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 W ARRANTY. 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. Misprints
reserved.

1st Edition 11/2003 2nd Edition 01/2004

3rd Edition 08/2004

© 2003-2004 by Emerson Process Management

Emerson Process Management
GmbH & Co. OHG

Industriestrasse 1
D-63594 Hasselroth
Germany
T [phone]
F [phone]
Internet: www.EmersonProcess.com

ATEX Instruction Manual

HAS8xE-IM-ATEX
January 2004

The purpose of this manual is to provide additional information
concerning the components, functions, installation and maintenance of
EEx p pressurized MLT 2 and BINOS
installed and operated at hazardous locations, classified Zone 2, to
measure FLAMMABLE, but NON-EXPLOSIVE gases or gas mixtures.

The user should become thoroughly familiar with the operation of this
equipment before operating it.

Some sections may describe equipment not used in your configuration.

This ATEX instruction manual is a supplement to the analyzers standard
instruction manual! In addition to this manual, the manuals of all devices
necessary for operating the system must be observed. Read all manuals
completely to be familiar with the operation of this equipment at
hazardous locations.

PREFACE







100 F analyzers intended to be

MLT 2 / BINOS 100 F

Some technical specifications in this manual may be different to those
in the associated manuals for the analyzers and additional equipment.
In this case the technical specifications listed in this manual are valid
only.

Emerson Process Management Manufacturing GmbH & Co. OHG

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MLT 2 / BINOS 100 F

The following definitions apply to WARNINGS, CAUTIONS and NOTES found
throughout this publication.

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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.

Highlights an essential operating
procedure, condition or statement.

Highlights an operation or
maintenance procedure,
practice, condition,
statement, etc. If not strictly
observed, could result in
damage to or destruction of
equipment, or loss of
effectiveness.

NOTE

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MLT 2 / BINOS 100 F

IMPORTANT

SAFETY INSTRUCTIONS

SAFETY SUMMARY

If this equipment is used in a manner not specified in these instructions, protective
systems may be impaired.

PRODUCTS DESCRIBED IN THIS MANUAL SHALL NOT BE
SUPPLIED WITH EXPLOSIVE GASES!

PRODUCTS DESCRIBED IN THIS MANUAL ARE NOT
DESIGNED FOR USE IN ANY LIFE SUPPORT AND/OR
SAFETY EQUIPMENT WHERE FAILURE TO PERFORM CAN
REASONABLY BE EXPECTED TO RESULT IN PERSONAL
INJURY OR DEATH.

AUTHORIZED PERSONNEL

To avoid 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.
SAVE THESE INSTRUCTIONS.

Emerson Process Management Manufacturing GmbH & Co. OHG

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MLT 2 / BINOS 100 F

TERMS USED IN THIS MANUAL

ATEX

Directive 94/9/EC, commonly called the
ATEX („Atmosphères Explosibles“)
products directive.

Area Classification

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January 2004

Zone 1

Where ignitable concentrations of
flammable gases can exist some of the time
under normal operating conditions.
(A guideline value [not part of a standard ]
is 10 to 1.000 hours per year.)
Equipment to be used in Zone 1 has to be
classified Category 2.

Explosion Protection
External Explosion Protection

The „External explosion protection“ serves
to prevent penetration of explosive gas
mixtures into the analyzer enclosure. In
addition it avoids ignition on the surface. For
this reason the analyzer is purged with
protective gas and held at an internal
overpressure compared to the surrounding
atmosphere.

Zone 2

Where 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.)
Equipment to be used in Zone 2 has to be
classified Category 3.

Internal Explosion Protection

The „Internal explosion protection“ serves to
prevent ignition of gas being present in the
analyzer’s Containment System (CS;=
sample gas path).
Dependent on the gas composition several
options are available:
None required (if gas is noncombustible),
dilution by purge gas or/and internal
overpressure of the analyzer’s enclosure
compared to the CS.

Containment System

The part of the analyzer containing the gas that may constitute an internal source of release.

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.

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MLT 2 / BINOS 100 F

Terms used in this manual

Flammable Gas(es)

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

Protective Gas

Air or inert gas used for purging and
maintaining an overpressure and, if
required, dilution.

Pre-Purging

The pre-purging phase serves to remove any
combustible gas out of the analyzer’s
enclosure prior to switching on the analyzer.
During this time the housing is purged with
5 times its own volume.

Explosive Gas(es)

Gases and gas mixtures are assigned to be
explosive if they consist of a flammable gas
in a mixture with air and the concentration is
inbetween the explosive limits.

Dilution

The continuous supply of a protective gas,
after purging, at such a rate that the
concentration of a flammable mixture inside
the pressurized enclosure is maintained at
a value outside the explosive limits except
in a dilution area.

Pressurization Modes

Pressurization mode „Continuous
Flow“

In EEx p „continuous flow mode“ the
protective gas flows with higher rates
through the enclosure. Flow rates are
calculated to hold an overpressure of > 1
mbar compared to atmospheric.

Emerson Process Management Manufacturing GmbH & Co. OHG

Pressurization mode „Leakage
Compensation“

In EEx p „leakage compensation mode“ just
as much protective gas is used to hold an
overpressure of > 1 mbar compared to
atmospheric.

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MLT 2 / BINOS 100 F

TABLE OF CONTENTS

Preface P-1

Definitions ..................................................................................................................... P-2

Safety Instructions ...................................................................................................... P-3

Terms used in this manual ........................................................................................... P-4

SECTION 1

Technical Description 1-1

1-1 Application and Principle of Operation .......................................................... 1-1

1-2 unused .............................................................................................................. 1-2

1-3 Specification .................................................................................................... 1-3

1-3-1 Installation Site ................................................................................................... 1-3

1-3-2 Explosion Protection .......................................................................................... 1-3

1-3-3 Pressurization Conditions ................................................................................... 1-3

1-3-4 Purge Gas Conditions ........................................................................................ 1-4

1-3-5 Sample Gas Conditions ..................................................................................... 1-5

1-3-6 Differential Pressure Monitoring ......................................................................... 1-5

1-4 Additional Safety Measures ............................................................................ 1-6

SECTION 2

Installation 2-1

2-1 General ............................................................................................................. 2-1

2-2 Installation of the Unit...................................................................................... 2-1

2-3 Dimensional Drawings .................................................................................... 2-2

2-3-1 Single Enclosure Analyzer .................................................................................. 2-2

2-3-2 Dual Enclosure Analyzer ..................................................................................... 2-4

2-4 Connection of Sample Gas and Protective Gas (Purge Gas) ....................... 2-6

2-4-1 Hints on Flammable Gases ................................................................................ 2-7

2-4-2 MLT 2 Gas Flow Diagrams ................................................................................. 2-8

2-4-3 BINOS® 100 F Gas Flow Diagrams .................................................................. 2-10

2-5 Safety Device Settings .................................................................................. 2-13

2-6 Special Remarks and Instructions ............................................................... 2-13

2-7 Electrical Connections .................................................................................. 2-14

2-7-1 Cable Gland Assembly Instruction for Shielded Cables ..................................... 2-14

2-7-2 Mains Connection............................................................................................. 2-15

2-7-2-1 Purge System .................................................................................................. 2-15

2-7-2-2 Analyzer ........................................................................................................... 2-17

2-7-3 Pressurization System Alarm Contacts ............................................................. 2-17

2-7-4 Differential Pressure Switch(es) ....................................................................... 2-18

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January 2004

SECTION 3

Startup 3-1

3-1 Final Check ...................................................................................................... 3-1

3-2 Switching On .................................................................................................... 3-1

SECTION 4

Maintenance 4-1

4-1 Maintenance Interval ....................................................................................... 4-1

4-2 Gasanalyzer ..................................................................................................... 4-1

4-3 Pressurization Systems and Other Additional Equipment ........................... 4-2

4-4 Verifications and Tests on Modified or Repaired Electrical Apparatus ....... 4-2

4-4-1 Preparations ...................................................................................................... 4-2

4-4-2 Overpressure Test .............................................................................................. 4-3

4-4-3 Leakage Test ..................................................................................................... 4-3

4-4-4 Removal of Modifications ................................................................................... 4-4

APPENDIX A-1

A-1 Declarations .....................................................................................................A-1

A-2 Circuit Diagrams .............................................................................................. A-3

A-2-1 MLT 2, single ...................................................................................................... A-3

A-2-2 MLT 2, dual ......................................................................................................... A-7

A-2-3 BINOS® 100 F .................................................................................................. A-11

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SECTION 1

Technical Description

1-1 Application and Principle of Operation

MLT 2 / BINOS 100 F

The gas analyzers of type BINOS 100 F
and MLT 2 are intended to measure gas
components within gas mixtures. In
combination with an approbriate certified
purge system (protection method
„Pressurized Enclosure“ EEx p) they can be
installed and operated in hazardous areas
of Zone 2.
Pressurization acts as external explosion
protection and prevents external explosive
atmosphere to penetrate into the analyzer
by holding the enclosure at an overpressure
compared to the surrounding
The type of purge system used varies
dependent on the area where the analyzer
is intended to be installed. Both systems
offer two modes of operation:

• EEx p with continuous flow
and

• EEx p with leakage compensation.

Dependent on the sample gas composition
it may be necessary to take care of internal
explosion protection which refers to the
sample gas path (containment system) in
the analyzer.

One of the following protection methods is
used:

• Nonflammable gases and gas
mixtures below the LEL: It must be

ensured that the sample gas in the
containment system always remains
below the lower explosive limit!

• Flammable gases and gas mixtures

may be analyzed when the sample gas
is diluted below ¼ LEL outside the
analyzer, so the resulting sample gas
is to be categorized „nonflammable“.
The diluting system must ensure that the
gas in the containment system always
remains below ¼ LEL.

• Flammable gases and gas mixtures

may be analyzed when the analyzer
enclosure has an internal overpressure
of > 50 Pa over the pressure in the
containment system. To ensure this
condition a differential pressure switch
is used and connected between
containment system and analyzer
enclosure. In case the pressure
decreases below the level of 50 Pa the
switch is activated and may be used to
activate an alarm or analyzer shut-off.

If more than one switch is needed
because more than one flammable gas
is supplied to the analyzer, the contacts
of these switches have to be connected
in series. Purge medium may be inert
gas or air. Flame arrestors are required
for all gas inlets and outlets carrying
flammable gases.

• Explosive gases must not be
connected to the analyzer!

Emerson Process Management Manufacturing GmbH & Co. OHG

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MLT 2 / BINOS 100 F

1-2 Unused

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1-2 Instrument Layout

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1-3 Specification

1-3 Specification

1-3-1 Installation Site

Hazardous area: Zone 2 (Category 3),

1-3-2 Explosion Protection

MLT 2 / BINOS 100 F

Concepts:

Category 3: Pressurized enclosure

(EEx p) using simplified
purge with either leakage
compensation mode or
continuous flow

Temperature class: T4

1-3-3 Pressurization Conditions

Volume of pressurized enclosure:

single enclosure: approx. 56 l
dual enclosure: approx. 112 l

Pre-purge phase:

Duration:
single enclosure: 5 minutes
dual enclosure: 17 minutes

Options: Intrinsically safe (EEx i) digital,

analog, network or Foundation
Fieldbus outputs.

Intrinsically safe (EEx i) para­magnetic Oxygen sensor or ther­mal conductivity sensor.

Applicable Standards:

EN 50014:1997 + amendments 1 & 2,
EN 50016:1995,
EN 50020:1994

Flow of protective gas:

single enclosure: 8 Nm³/h
dual enclosure: 7 Nm³/h

Minimum overpressure during
operation:

1 mbar against external Ex Zone and

>50 Pa against Containment System if

flammable gases are supplied.

Emerson Process Management Manufacturing GmbH & Co. OHG

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MLT 2 / BINOS 100 F

1-3-4 Purge Gas Conditions

1-3-4 Purge Gas Conditions

Purge gas: • Inert gas (e.g. Nitrogen)

• Air (from an ex-free zone)

Temperature: As ambient, but min. 20 °C to 35 °C.

Medium has to be dry and free from
dust, oil, corrosive or aggressive
components!

Input pressure at
inlet of EEx p device: • 3,000 to 4,000 hPa (3 to 4 bar)

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Minimum internal
overpressure of
the enclosure: • 1 mbar

Maximum internal
overpressure of
the enclosure: • 25 mbar

Pre-purging phase Single enclosure analyzer Dual enclosure analyzer

Duration of
pre-purging phase: 5 min. 17 min.

Flow rate during
pre-purging phase: 8 Nm³/h 7 Nm³/h

(= 133.4 l/min.) (= 117 l/min.)

Flow rate during
pre-purging phase 22 Nm³/h 22 Nm³/h
(@ 25 mbar overpressure): (= 367 l/min.) (= 367 l/min.)

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MLT 2 / BINOS 100 F

1-3-5 Sample Gas Conditions

1-3-5 Sample Gas Conditions

Applicable gases: Nonflammable gases or

gas mixtures which always Flammable gases
remain below LEL

Maximum sample

gas pressure: atmospheric or atmospheric or

<1500 hPa at normal <1500 hPa at normal
atmospheric pressure, atmospheric pressure,
dependend on gas dependend on gas
measuring principle measuring principle

and

overpressure < 13 mbar
against surrounding atmosphere

Sample gas flow: for all sample gases refer to the corresponding analyzer data sheet

1-3-6 Differential Pressure Monitoring

For analyzers connected to flammable gases (either sample gas or span gas) the operator
needs to ensure that the pressure within the containment system always remains at minimum
50 Pa below the pressure within the analyzer enclosure. This ensures that in case of a leak the
flammable gas does not enter the enclosure.
An additional differential pressure switch is provided to monitor the pressure difference:
In case the pressure difference decreases below 50 Pa the contact opens.

It is the user’s responsiblity how to use the signal within his system:
The limit of 50 Pa is the least permissible value given by the standards, higher values are
acceptable, too.
Flame arrestors are required for gas inlets and outlets.
Electrical and mechanical connections are shown in section 2 „Installation“.

Emerson Process Management Manufacturing GmbH & Co. OHG

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MLT 2 / BINOS 100 F

1- Additional Safety Measures

1-4 Additional Safety Measures

• Exhaust gas lines must end outside the
hazardous area at a safe point. Sample
gas lines may be returned to the
sampling point.

• If gas exhaust lines end within the
hazardous area gas inlet and outlet
have to be equipped with flame
arrestors.

• The maximum permissible gas
pressure depends on the type of
connected gas. See section 1-3-5 for
detailed information.

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MLT 2 / BINOS 100 F

SECTION 2

Installation

Before starting to install this equipment, read the corresponding sections of the

analyzer’s instruction manual and the manuals of the additional equipment!
Failure to follow the safety instructions could result in serious injury or death.

2-1 General

Proper functioning of the Emerson Process
Management gas analyzers depends on
proper installation. All procedures in this
section, in the corresponding sections of the
analyzer instruction manual and the manuals
of the attached safety devices must be
followed carefully.

2-2 Installation of the Unit

Install the assembled unit as described in
the analyzer’s instruction manual: Refer to
the dimensional drawings in this manual
(fig. 2-1a/b and 2-2a/b) to ensure the
designated location is dimensioned
sufficiently.
The weight of an assembled unit may be up
to approx. 40 kg incl. pressurization system.

Take care to use anchors and
bolts specified to be used for
the weight of the units!

Take care the wall the unit is
intended to be installed at is
solid and stable to hold the
units!

Emerson Process Management Manufacturing GmbH & Co. OHG

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