BINOS 100 F & MLT 2
Addendum for Pressurized Analyzers intended to be used
in Hazardous Areas
Zone 1: All Versions
Zone 2: Non-Flammable Gases Only
th
4
Edition 08/2005
www.EmersonProcess.com
BINOS 100 F & MLT 2 Addendum Zone 1 & 2Instruction Manual
ETC01035
08/2005
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 maintainthem 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.
Industriestrasse 1
D-63594 Hasselroth
Germany
T +49 (0) 6055 884-0
F +49 (0) 6055 884-209
Internet: www.EmersonProcess.com
ATEX Instruction Manual
ETC01035
August 2005
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. The analyzers are EC type
certified, documented by the EC Type Examination Certificates
LCIE 03 ATEX 6010 X and LCIE 03 ATEX 6011 X
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
P - 1
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
IMPORT ANT
SAFETY INSTRUCTIONS
SAFETY SUMMARY
If this equipment is used in a manner not specified in these instructions, protective
systems may be impaired.
DANGER TO LIFE !
Before installing, operating or working at Products described in this
manual read this and all other related manuals!
EXPLOSION HAZARD !
Instruments described in this manual are intended to be installed and
operated at hazardous locations. Doing so may be permitted only taking
into account special legal conditions not described in this manual!
Ensure all safety devices and the pressurization unit are safe and
operating properly to operate the analyzers in a safe manner!
Failure to follow the proper instructions may cause an explosion!
DANGER TO LIFE !
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.
Emerson Process Management Manufacturing GmbH & Co. OHG
P - 3
MLT 2 / BINOS® 100 F
Products described in this manual shall not be supplied with explosive
gases!
ATEX Instruction Manual
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Safety Instructions
EXPLOSION HAZARD !
EXPLOSION HAZARD !
Instruments inclusive EEx p unit may weigh up to 40 kg (depending on
installed options)!
Do not use the attached EEx p unit or the external valve as a handle for
transportation or lifting the instrument! Failure to follow may loosen or
damage the devices and impair the safety of the whole instrument!
EXPLOSION HAZARD !
When the analyzer is out of order or if the pressurization unit shuts off all
non-intrinsically safe inputs and outputs connected to external equipment
MUST be shut off too!
This ensures that no hazardous voltages are present within the analyzer
enclosure when not pressurized.
AUTHORIZED PERSONNEL
T o 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 FOR FUTURE USE.
Emerson Process Management Manufacturing GmbH & Co. OHGP - 4
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TERMS USED IN THIS MANUAL
ATEX
Directive 94/9/EC, commonly called the
ATEX („Atmosphères Explosibles“)
products directive.
Area Classification
MLT 2 / BINOS® 100 F
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.
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.
Containment System
The part of the analyzer containing the gas
that may constitute an internal source of
release.
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
and/or
•internal overpressure of the analyzer’s
enclosure compared to the CS.
Lower Explosion Limit (LEL)
V olume 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.
Emerson Process Management Manufacturing GmbH & Co. OHG
Upper Explosion Limit (UEL)
V olume 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
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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.
Pressurization modes
„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.
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.
„Leakage Compensation“
In EEx p „leakage compensation mode“ just
as much protective gas is used to hold the
required overpressure compared to
atmospheric.
Flammable Gas(es)
Gases and gas mixtures are assigned to be
flammable if they might become ignitable
when in a mixture with air.
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MLT 2 / BINOS® 100 F
Emerson Process Management Manufacturing GmbH & Co. OHG
A-3-3BINOS® 100 F ...................................................................................................A-23
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SECTION 1
Technical Description
1-1Application 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 appropriate certified
pressurization system (protection method
„Pressurized Enclosure“ EEx p) they can be
installed and operated in hazardous areas
of Category 2 or Category 3.
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 using an analyzer with
pressurization method „leakage
compensation“ 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 using an analyzer with
pressurization method „leakage
compensation“ or „continuous flow“
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 forces
the purging unit to disconnect the
analyzer from it’s power supply . If more
than one switch is needed because
more than one flammable gas is
supplied to the analyzer, the cont acts 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!
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MLT 2 / BINOS® 100 F
1-2Unused
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1-2 Instrument Layout
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1-3 Specification
1-3Specification
1-3-1Installation Site
Hazardous area:Zone 1 (Category 2)
orZone 2 (Category 3),
dependent on purge system
1-3-2Explosion Protection
MLT 2 / BINOS® 100 F
Concepts:
Category 2 : Pressurized enclosure
(EEx p) with either leakage
compensation mode or
continuous flow
Category 3:Pressurized enclosure
(EEx p) using simplified
purge with either leakage
compensation mode or
continuous flow
EN 50014:1997 + amendments 1 & 2,
EN 50016:1995,
EN 50020:1994
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MLT 2 / BINOS® 100 F
1-3-43 Description of Pressurization Systems
1-3-3Description of Pressurization Systems
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An internal overpressure inside the protected housing prevents outer (possibly explosive) atmosphere to enter.
Instruments intended to be installed in Zone
1 are automatically prepurged before power
is supplied. This ensures that all possibly
explosive atmosphere present inside the
instrument is removed. The prepurge
process is controlled by the pressurization
control unit which also acitivates switching
on the analyzer when the prepurge phase
has elapsed.
While the Zone 2 unit mainly consists of a
pressure monitor with alarm contacts the
Zone 1 unit contains a purge gas inlet valve
(proportional valve), a controller unit with
microprocessor and an outlet valve (high
pressure version only). The controller unit
permanently monitors the parameters (e.g.
prepurge phase, purge gas flow, internal
overpressure, and more) and therefore
ensures safe operation. A separate instruction manual provides more detailled information.
The Zone 1 system is available in two
differing variations due to different
requirements for measuring flammable and
non-flammable gases:
Measuring non-flammable gases:
The system provides an internal overpressure of 14 mbar during operation.
Measuring flammable gases:
The standard configuration is designed to
hold an internal overpressure of 90 mbar.
Optionally 14 mbar may be adjusted if it is
ensured that the gas pressure within the
Containment System is allways below
12 mbar.
In addition one differential pressure switch
is installed within any gas path to ensure the
instrument‘s overpressure is always at least
50 Pa (0.5 mbar) above the pressure in the
containment system.
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Single Enclosure
Dual Enclosure (volume
Dual Enclosure (volume
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January 2004
Depending on which system is used, different parameters apply:
MLT 2 / BINOS® 100 F
ApplicationMode of Ope ration
Zon e 1Pre p urge Ph ase
for measuring Duration:10 min14 min
flamm able gasesPurge gas cons um ption:1,75 Nm³/h1,92 Nm³/h
max i m um overpressure:95 mbar95 mbar
Measuri ng Mode
Internal overpress ure:90mbar90 mbar
Flow rat e (leakage rate):<= 3 l/min<= 4, 5 l /min
Zon e 1Pre p urge Ph ase
for measuring Duration:4 min6 min
non-flamm able gasesP urge gas consumption:6,8 Nm³/ h9,2 Nm³/h
max i m um overpressure:25 mbar25 mbar
Measuri ng Mode
Internal overpressure:14 mbar14 mbar
Flow rat e (leakage rate):<= 3 l/min<= 4, 5 l /min
ApplicationMode of Ope ra tion
(volume approx . 56 l)
Single Enclosure
(volume approx . 56 l)
approx . 112 l)
approx . 112 l)
Zone 2Pre p urge Ph ase
for mea suri n gDuration:5 min17 min
non-flamm able gasesP urge gas consumption:8 Nm³/h7 Nm³/h
Minimum overpressure in all enclosures:
•1 mbar against external atmosphere and
•50 Pa against containment system when measuring flammable gases
Emerson Process Management Manufacturing GmbH & Co. OHG
max i m um overpressure:25 mbar25 mbar
Measuri ng Mode
Internal overpres sure:1 m bar1 mbar
Flow rat e (leakage rate):<= 22Nm ³/ h<= 22 Nm ³/ h
1 - 5
MLT 2 / BINOS® 100 F
1-3-4 Purge Gas Conditions
1-3-4Purge 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:• 2.000 to 4.000 hPa (2 to 4 bar)
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MLT 2 / BINOS® 100 F
1-3-5 Sample Gas Conditions
1-3-5Sample Gas Conditions
Applicable gases:Nonflammable gases or
gas mixtures which alwaysFlammable gases
remain below LEL
Maximum sample
gas pressure:atmospheric oratmospheric or
<1500 hPa at normal<1500 hPa at normal
atmospheric pressure,atmospheric pressure,
dependend on gasdependend on gas
measuring principlemeasuring principle
Sample gas flow:for all sample gases refer to the corresponding analyzer data sheet
1-3-6Differential 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 must be provided to monitor the pressure difference.
The switch’s electric contact has to be connected to the purge system. In case the pressure
difference decreases below 50 Pa the contact opens and the purge system shuts down the
analyzer.
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“.
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MLT 2 / BINOS® 100 F
January 2004
1-3-7 Equivalent Safety Devices
1-3-7Equivalent Safety Devices
It is recommended to order and use the pressurization systems provided and
specified by Emerson Process Management.
It is the responsibility of the operator/owner to choose and install a pressurization
system other than recommended by Emerson Process Management!
In no case Emerson Process Management is held responsible for any damage,
personal injury etc. resulting from choosing different pressurization systems!
In principle it is possible to use other
equivalent pressurization systems as
described in this manual, as long as they
meet the following requirements:
• Device is ATEX approved
• Adjustable pre-purge phase
• Minimum purge flow rate :
7 Nm3/h resp. 8 Nm3/h
• Limited purge gas pressure during the
pre-purging phase: < 25 mbar
• Input pressure for purge gas supply:
2 ... 4 bar
• Relay contacts for all-pole disconnection
of the analyzer from power supply
• Relay contacts for disconnecting additional external equipment
• Connection facility for bypass key switch,
providing intrinsically safe signal for
scanning the key switch
• For units connected to flammable
gases, only:
Connection facility for differential
pressure switch, providing intrinsically
safe signal for scanning the switch
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1-4 Additional Safety Measures
1-4Additional 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.
MLT 2 / BINOS® 100 F
Emerson Process Management Manufacturing GmbH & Co. OHG
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MLT 2 / BINOS® 100 F
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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.
2-1General
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 .
Instruments inclusive
EEx p unit may weigh up
to 40 kg (depending on
installed options)!
Use two person and/or
suitable tools for transportation and lifting these
instruments!
2-2Installation 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.
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!
EXPLOSION HAZARD !
Do not use the attached EEx p unit or the external valve as a handle for
transportation or lifting the instrument! Failure to follow may loosen or
damage the devices and impair safety of the whole instrument!
Emerson Process Management Manufacturing GmbH & Co. OHG
Single enclosure analyzer (approx. dimensions in mm)
Emerson Process Management Manufacturing GmbH & Co. OHG2 - 2
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MLT 2 / BINOS® 100 F
2-3-1 Single Enclosure Analyzer
Standard Version
1
Version „increased pressure“
2
with category 3 EEx p system
with category 2 EEx p system
Fig. 2-1b
Single enclosure analyzer (approx. dimensions in mm)
Emerson Process Management Manufacturing GmbH & Co. OHG
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MLT 2 / BINOS® 100 F
2-3-2 Dual Enclosure Analyzer
2-3-2Dual Enclosure Analyzer
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Standard version w/o purging system
with category 3 purging system
Fig. 2-2a
Dual enclosure analyzer (approx. dimensions in mm)
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MLT 2 / BINOS® 100 F
2-3-2 Dual Enclosure Analyzer
1
Fig. 2-2b
Dual enclosure analyzer (approx. dimensions in mm)
Emerson Process Management Manufacturing GmbH & Co. OHG
Standard-Ausführung
Standard Version
Ausführung „erhöhter Innendruck“
2
Version „increased pressure“
with category 2 purging system
2 - 5
MLT 2 / BINOS® 100 F
2-4 Connection of Sample Gas and Protective Gas (Purge Gas)
2-4Connection of Sample Gas and
Protective Gas (Purge Gas)
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When the analyzer with assembled EEx p
safety device has been fixed, connect the
gas lines according the diagram (fig. 2-3).
The following conditions must be observed
for trouble free operation:
•The operator must ensure the minimum
pressure of the protective gas at the
point of installation.
A pressure of 2,000 ... 4,000 hPa
(2...4 bar) must be applied to the
protective gas inlet of the EEx p safety
device.
2-4-1Hints on Flammable Gases
•When applying flammable gases (either
as sample gas or span gas) the
corresponding gas inlets and outlets
must be equipped with flame arrestors.
•T o avoid internal release of flammable
gases the minimum pressure specified
for the pressurized enclosure is at least
50 Pa higher than the maximum
pressure specified for the containment
system. A differential pressure switch is
provided with the system to operate if
the pressure difference falls below
50 Pa.
•The EEx safety device is delivered with
fixed basic parameters. The minimum
purge gas pressure is preset to 1 mbar
for standard applications. Useful
modifications such as increasing the
max. purge gas pressure must only be
done after studying the appropriate
sections of the manual of the EEx p
safety device.
•Flammable sample gas must not be
supplied to the analyzer until the prepurging phase has ended.
•For Category 2 equipment the switch
is connected to the pressurization
system to disconnect the complete unit
from power in case of a failure (refer
to circuit diagrams in the appendix).
The 50 Pa limit is the value
defined by the associated
standards. It is not allowed
to decrease this value but
higher values are allowed .
Category 3 equipment:
The purpose(s) for which the differential pressure switch is used (i.e. to
disconnect power or to sound an alarm or otherwise maintain the safety of
the installation) is the responsibility of the user!
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2-4-1 Hints on Flammable Gases
Installing Flame Arrestors
Flame arrestors shipped together with the
instrument are to be mounted to the gas
fittings plate utilizing the associated steel
pipes. Up to 8 flame arrestors may be
installed by aligning the as shown in fig.
2-3.
Take care of placing and fixing the
swivel nuts correctly!
Untightened connections (especially at
the analyzer side of the arrestors) may
cause malfunction!
MLT 2 / BINOS® 100 F
Fig. 2-3
Single and installed flame arrestors
T ake care of the possible formation of flammable mixtures due to the possibility
of air penetration into the containment system and the resulting additional
precautions that may be necessary.
Read and take into account the separate flame arrestor documentation,
shipped together with the instrument!
Emerson Process Management Manufacturing GmbH & Co. OHG
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MLT 2 / BINOS® 100 F
2-4-2 MLT 2 Gas Flow Diagrams
2-4-2MLT 2 Gas Flow Diagrams
2-4-2-1 Gas Flow Diagram for Nonflammable Gases or
Flammable Gases diluted below 1/4 LEL
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Fig. 2-4a
Gas Flow Diagram
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MLT 2 / BINOS® 100 F
2-4-2 MLT 2 Gas Flow Diagrams
2-4-2-2 Gas Flow Diagrams for Nondiluted Flammable Gases
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Fig. 2-4b
Gas Flow Diagram
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MLT 2 / BINOS® 100 F
2-4-2 MLT 2 Gas Flow Diagrams
2-4-2-2 Gas Flow Diagrams for Nondiluted Flammable Gases (cont’d)
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Fig. 2-4c
Gas Flow Diagram
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2-4-3 BINOS® 100 F Gas Flow Diagrams
2-4-3BINOS® 100 F Gas Flow Diagrams
2-4-3-1 Gas Flow Diagram for Nonflammable Gases or
Flammable Gases diluted below 1/4 LEL
MLT 2 / BINOS® 100 F
Fig. 2-4d
Gas Flow Diagram
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MLT 2 / BINOS® 100 F
2-4-3 BINOS® 100 F Gas Flow Diagrams
2-4-3-2 Gas Flow Diagrams for Nondiluted Flammable Gases
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Fig. 2-4e
Gas Flow Diagram
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MLT 2 / BINOS® 100 F
2-4-3 BINOS® 100 F Gas Flow Diagrams
2-4-3-2 Gas Flow Diagrams for Nondiluted Flammable Gases (cont’d)
Emerson Process Management Manufacturing GmbH & Co. OHG
Fig. 2-4f
Gas Flow Diagram
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MLT 2 / BINOS® 100 F
2-4-3 BINOS® 100 F Gas Flow Diagrams
2-4-3-2 Gas Flow Diagrams for Nondiluted Flammable Gases (cont’d)
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Fig. 2-4g
Gas Flow Diagram
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2-5 Safety Device Settings
2-5Safety Device Settings
MLT 2 / BINOS® 100 F
The EEx safety device is delivered with fixed
basic parameters. The purge gas pressure
is preset to 1 hPa (rel.; for non-flammable
gases). Useful modifications such as
increasing the max. purge gas pressure
must only be done after studying the
appropriate sections of the manual of the
EEx p safety device.
2-6Special Remarks and Instructions
General
It is not allowed to change
the internal purge medium
path.
Category 2
Category 2 equipment is provided with a key
switch which bypasses the purge system
and switches off the automatic monitoring
facility . It is therefore also possible to switch
on the pressurized system with the housing
door open for setting work resp. to keep the
analyzer powered even if the front door is
opened.
The use of this switch is
intended for maintenance
purposes only!
As the parameters are selected to be in
conformance with the type test results, some
of them are not allowed to be changed!
This applies to the pre-purge time, which is
adjusted to ensure a 5 times volume
exchange within the analyzer enclosure at a
preset purge medium flow!
When maintenance work has been finished
is has to be verified that the switch is turned
off!
The purge system M code, preset to 0001,
must be replaced by an individual code
which must then be entered.
The purge system by-pass code, preset to
0002, must be replaced by an individual
code, unequal Zero.
This facility should however
only be used when it has
been ascertained that there is
no explosive atmosphere in
the vicinity of the unit (fire
safety certificate).
Emerson Process Management Manufacturing GmbH & Co. OHG
For instructions on how to change the
codes see the separate pressurization
instruction manual!
2 - 15
MLT 2 / BINOS® 100 F
2-7 Electrical Connections
2-7Electrical Connections
Installation of and connecting
the power supply lines and
signal lines is permitted to
qualified personnel only!
The standard EN 60079-14
„Electrical Installations in
Hazardous Areas“ and all
related standards have to be
observed.
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.
ATEX Instruction Manual
ETC01035
August 2005
•All connections have to be done accor-
ding to the schematics delivered together
with the equipment.
•A mains switch or ciruit-breaker must be
provided at the building installation.
• The equipment enclosure must be
connected to an earthing or equipotential
bonding conductor.
•All cables introduced into the enclosure
must be kept as short as possible.
• The cable glands are designed to fix
single cables only , with diameters from 7
to 12 mm. Special inserts are available
on request to fix thinner or multiple cables
within one gland.
•Mains power terminals are suitable for
cables up to 2.5 mm2 cross section.
•Use only shielded cables for signal lines!
To ensure proper electromagnetic
compatibility (EMC) it is recommended
to follow the installation steps given in
section 2-7-1!
•Cables carrying intrinsically safe (EEX i)
signals need adequate marking. When
running such cables take into
consideration the requirements given in
the related standards (minimum distance
to non-IS cables etc.). If running in
minimum distance is not possible
clearance may be achieved utilizing solid insulation of suitable thickness.
Emerson Process Management Manufacturing GmbH & Co. OHG2 - 16
ATEX Instruction Manual
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2-7-1Cable Gland Assembly Instruction
MLT 2 / BINOS® 100 F
1. Strip the cable
insulation
2. Uncover the
shielding
3. Feed cable through
gland nut and into
fixing element
4. Put the shielding net
over the element the
way that it covers the
o-ring 2 mm.
2-7-2Signal Inputs and Outputs
Signal inputs and outputs by default are nonintrinsically safe!
DIN rail installable converters (option) are
available to provide intrinsically safe signals
5. Stick the fixing
element into the
neck and fix the
gland.
(contact your local sales office for detailled
information).
EXPLOSION HAZARD !
When the analyzer is out of order or if the pressurization unit shuts off all
non-intrinsically safe inputs and outputs connected to external equipment
MUST be shut off too!
This ensures that no hazardous voltages are present within the analyzer
enclosure when not pressurized.
Emerson Process Management Manufacturing GmbH & Co. OHG
2 - 17
MLT 2 / BINOS® 100 F
2-7-2 Category 2 Equipment
2-7-2Category 2 Equipment Mains Connection
ATEX Instruction Manual
ETC01035
August 2005
The mains power line cord has to be
connected to the pressurization control unit,
terminals 16, 18 and PE (fig. 2-4).
Verify that the mains voltage
at the point of installation
meets the analyzer nominal
voltage!
Terminal 16
PE terminal
Fig. 2-5
T erminal location inside control unit
Terminal 18
Emerson Process Management Manufacturing GmbH & Co. OHG2 - 18
ATEX Instruction Manual
ETC01035
August 2005
2-7-3 Category 3 Equipment Mains Connection
2-7-3Category 3 Equipment Mains Connection
MLT 2 / BINOS® 100 F
The mains power line cord has to be
connected to the terminals provided at the
analyzer enclosure’s inner left side, near the
EMC line filter (fig. 2-5).
Verify that the mains voltage
at the point of installation
meets the analyzer nominal
voltage!
EMC line filter
Fig. 2-6
T erminal location inside analyzer
Emerson Process Management Manufacturing GmbH & Co. OHG
Terminals
2 - 19
MLT 2 / BINOS® 100 F
2-7-4 Category 3 Equipment Alarm Contacts
2-7-4Category 3 Equipment Alarm Contact s
ATEX Instruction Manual
ETC01035
August 2005
The Category 3 pressure monitor provides
alarm contacts activated when the pressure
inside the analyzer enclosure is outside the
limits.
This alarm loop operates in normally closed
connection mode.
The contacts are allowed to be connected
to signal circuitry (amplifier, relay) providing
output signals according NAMUR/
EN 50227 resp. [EEx ib] IIC only. The
standard specifies all essential data and
operating conditions.
Consult factory for applicable circuitry which
is available from various manufacturers.
0
3
1
2
Fig. 2-7
Pressure monitor: T erminal allocationand signal connection
Emerson Process Management Manufacturing GmbH & Co. OHG2 - 20
ATEX Instruction Manual
ETC01035
January 2004
MLT 2 / BINOS® 100 F
SECTION 3
Startup
Startup can only be done properly by personnel being familiar with the contents
of all applicable manuals and related instructions!
Especially the warnings provided by the documentation have to be observed!
3-1Final Check
Make sure that the analyzer and the related
pressurization system have been setup as
described in section 2 and all covers and
doors are closed and fixed.
All unused cable glands need to be sealed
using the supplied approved sealing plug
(part no. ETC00791; fig. 3-1)
Unused cable gland openings in the
enclosure need to be covered using a
special screw (part no. ETC 000790; fig. 3-2).
Fig. 3-1
Cable gland sealing plug
Use only the components listed
above as these are A TEX approved
for use in hazardous areas!
3-2Switching On
In a next step the analyzer may be powered
by opening the purge gas supply and
switching on the power supply .
Emerson Process Management Manufacturing GmbH & Co. OHG
Fig. 3-2
Cable gland hexagon socket screw sealing plug
3 - 1
MLT 2 / BINOS® 100 F
ATEX Instruction Manual
ETC01035
January 2004
Emerson Process Management Manufacturing GmbH & Co. OHG3 - 2
ATEX Instruction Manual
ETC01035
August 2005
MLT 2 / BINOS® 100 F
SECTION 4
Maintenance
After maintenance or replacement of parts concerning explosion protection an
authority on explosion protection has to verify that the analyzer still meets the
requirements for explosion protection before it is switched on again.
If parts essential for explosion protection are repaired they have to be routine
tested!
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.
4-1Maintenance Interval
T o ensure the performance and safety of the
equipment it has to be checked on a regular
basis, at least once a year. S pecial care has
to be taken for the EEx p saftey device and
parts ensuring explosion protection (e.g.
gaskets).
4-2Gasanalyzer
Refer to the associated manual for detailed
information on maintenance, replacement of
parts and how to carry out a containment
system leak test.
4-3Pressurization Systems and
Other Additional Equipment
Refer to the associated manuals for detailed
information on maintenance and
replacement of parts.
It is the operators/owners
responsibility to extend the
maintenance interval with
respect to negative
influences of gases or
environment on materials in
contact with the sample gas
or ensuring explosion
protection (e.g. gaskets).
Defective parts relevant for
the explosion protection
must only be replaced by original Emerson Process Management spare parts!
Unauthorized parts and
procedures can affect the
product’s performance, place
the safe operation of your
process at risk and affect the
explosion protection!
Emerson Process Management Manufacturing GmbH & Co. OHG
4 - 1
MLT 2 / BINOS® 100 F
4-4 Verifications and Tests
4-4Verifications and Tests on
Modified or Repaired Electrical
Apparatus
ATEX Instruction Manual
ETC01035
August 2005
Modifications made on the electrical
apparatus affecting the integrity of the type
of protection 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 of electrical apparatus
affecting the type of protection, the parts
which have been repaired should be
subjected to new routine verifications and
tests. These test s need not necessarily be
made by the manufacturer.
4-4-1System with 14 mbar Operating Pressure
4-4-1-1 Preparations
Required tools:
•Manometer with full scale between 50
•Pressure regulator to reduce the pressure
and 100 mbar and resolution of
0.1 mbar.
•Flow meter with full scale between 5
•Equipment for flow regulation
•1 plug to seal the purge gas outlet
and 10 l/min, resolution 0.1 l/min.
•T est gas: Compressd air or Nitrogen,
•1 plug to seal gas outlet (size 6 mm)
pressure reduced to max. 1,500 hPa.
To carry out the routine tests the following
steps have to be performed:
•Disconnect the analyzer and the
•Disconnect one of the containment
pressurization unit from power.
•Seal the purge medium outlet at the
pressurization unit (1“ opening at the left
side).
•Disconnect the containment system
gas connectors from the external gas
lines.
•Connect an external source of
to values of 25 resp. 37.5 mbar.
(size 1“)
system gas connectors inside the
analyzer and seal the other one.
(Remark: Now it must be possible set
the enclosure under pressure by
applying an external gas (e.g.
compressed air) to the gas connector.)
compressed air as described in the
drawing on the next page (fig. 4-1).
Emerson Process Management Manufacturing GmbH & Co. OHG4 - 2
ATEX Instruction Manual
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MLT 2 / BINOS® 100 F
4-4 Verifications and Tests
Fig. 4-1
Setup for routine tests
4-4-1-2 Overpressure Test
A pressure of 37.5 mbar (= 1.5 times the
maximum overpressure specified) has to be
applied to the pressurized enclosure. T o do
this the following has to be performed:
•Carefully apply a pressure of 37.5 mbar
to the enclosure and hold this pressure
for a period of 2 minutes +/- 10 seconds.
The test is considered to be satisfactory if
no permanent deformation occures which
would invalidate the type of protection.
Keep the modifications to carry out the
leakage test (sec. 4-4-1-3).
4-4-1-3 Leakage Test
The leakage of the enclosure has to be
measured with an overpressure of 25 mbar
applied to the pressurized enclosure. T o do
this the following steps have to be
performed:
•Make sure the modifications as
described in the section 4-4-1-1are still
existent.
•Apply an overpressure of 25 mbar to
the analyzer enclosure and take the
reading of the flow meter.
The test is considered to be satisfacotry if
the measured value is acceptable
compared to the following values.
Acceptable flow values are:
• single analyzer: 3 l/minute maximum
• dual analyzer: 4.5 l/minute maximum
Emerson Process Management Manufacturing GmbH & Co. OHG
4 - 3
MLT 2 / BINOS® 100 F
4-4 Verifications and Tests
4-4-2System with 90 mbar Operating Pressure
4-4-2-1 Preparations
Required tools:
•Manometer with full scale between
150 and 200 mbar and resolution of
0.1 mbar.
•Flow meter with full scale between 5
and 10 l/min, resolution 0.1 l/min.
•T est gas: Compressd air or Nitrogen,
pressure reduced to max. 1,500 hPa.
•Pressure regulator to reduce the pressure
•Equipment for flow regulation
•1 plug to seal the purge gas outlet
•1 plug to seal gas outlet (size 6 mm)
ATEX Instruction Manual
ETC01035
August 2005
to values of 95 resp. 143 mbar.
(size 1“)
To carry out the routine tests the following
steps have to be performed:
•Disconnect the analyzer and the
pressurization unit from power.
•Seal the purge medium outlet at the
pressurization unit (1“ opening at the left
side).
•Disconnect the containment system
gas connectors from the external gas
lines.
•Disconnect one of the containment
system gas connectors inside the
analyzer and seal the other one.
(Remark: Now it must be possible set
the enclosure under pressure by
applying an external gas (e.g.
compressed air) to the gas connector.)
•Connect an external source of
compressed air as described in the
drawing on the next page (fig. 4-2).
Emerson Process Management Manufacturing GmbH & Co. OHG4 - 4
ATEX Instruction Manual
ETC01035
August 2005
MLT 2 / BINOS® 100 F
4-4 Verifications and Tests
Fig. 4-2
Setup for routine tests
4-4-2-2 Overpressure Test
A pressure of 143 mbar (= 1.5 times the
maximum overpressure specified) has to be
applied to the pressurized enclosure. T o do
this the following has to be performed:
•Carefully apply a pressure of 37.5 mbar
to the enclosure and hold this pressure
for a period of 2 minutes +/- 10 seconds.
The test is considered to be satisfactory if
no permanent deformation occures which
would invalidate the type of protection.
Keep the modifications to carry out the
leakage test (sec. 4-4-2-3).
4-4-2-3 Leakage Test
The leakage of the enclosure has to be
measured with an overpressure of 95 mbar
applied to the pressurized enclosure. T o do
this the following steps have to be
performed:
•Make sure the modifications as
described in the section 4-4-2-1are still
existent.
•Apply an overpressure of 95 mbar to
the analyzer enclosure and take the
reading of the flow meter.
The test is considered to be satisfacotry if
the measured value is acceptable
compared to the following values.
Acceptable flow values are:
• single analyzer: 3 l/minute maximum
• dual analyzer: 4.5 l/minute maximum
Emerson Process Management Manufacturing GmbH & Co. OHG
4 - 5
MLT 2 / BINOS® 100 F
4-4 Verifications and Tests
4-4-3Removal of Modifications
Remove all the modifications described in
section 4-4-1 resp. 4-4-2. T ake special care
of the gas connections to be tightend.
ATEX Instruction Manual
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Emerson Process Management Manufacturing GmbH & Co. OHG4 - 6
ATEX Instruction Manual
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APPENDIX
A-1EC Declarations of Conformity
MLT 2 / BINOS® 100 F
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 1
MLT 2 / BINOS® 100 F
A-1 EC Declarations of Conformity
ATEX Instruction Manual
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Emerson Process Management Manufacturing GmbH & Co. OHGA- 2
ATEX Instruction Manual
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MLT 2 / BINOS® 100 F
A-1 EC Declarations of Conformity
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 3
MLT 2 / BINOS® 100 F
A-1 EC Declarations of Conformity
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A-2-1 Category 2 Certificate
A-2EC Type Examination Certificates
A-2-1Category 2 Certificate
MLT 2 / BINOS® 100 F
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 5
MLT 2 / BINOS® 100 F
A-2-1 Category 2 Certificate
ATEX Instruction Manual
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ATEX Instruction Manual
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MLT 2 / BINOS® 100 F
A-2-1 Category 2 Certificate
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 7
MLT 2 / BINOS® 100 F
A-2-1 Category 2 Certificate
ATEX Instruction Manual
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Emerson Process Management Manufacturing GmbH & Co. OHGA- 8
ATEX Instruction Manual
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MLT 2 / BINOS® 100 F
A-2-1 Category 2 Certificate
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 9
MLT 2 / BINOS® 100 F
A-2-2Category 3 Certificate
ATEX Instruction Manual
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ATEX Instruction Manual
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MLT 2 / BINOS® 100 F
A-2-2 Category 3 Certificate
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 11
MLT 2 / BINOS® 100 F
A-2-2 Category 3 Certificate
ATEX Instruction Manual
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MLT 2 / BINOS® 100 F
A-2-2 Category 3 Certificate
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 13
MLT 2 / BINOS® 100 F
A-2-2 Category 3 Certificate
ATEX Instruction Manual
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Emerson Process Management Manufacturing GmbH & Co. OHGA- 14
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A-3Circuit Diagrams
A-3-1ML T 2, single
MLT 2 / BINOS® 100 F
A-3 Circuit Diagrams
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 15
MLT 2 / BINOS® 100 F
A-3-1 ML T 2 Circuit Diagrams
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MLT 2 / BINOS® 100 F
A-3-1 ML T 2 Circuit Diagrams
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 17
MLT 2 / BINOS® 100 F
A-3-1 ML T 2 Circuit Diagrams
ATEX Instruction Manual
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A-3-2MLT 2, dual
MLT 2 / BINOS® 100 F
A-3-2 ML T 2 Circuit Diagrams
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 19
MLT 2 / BINOS® 100 F
A-3-2 ML T 2 Circuit Diagrams
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MLT 2 / BINOS® 100 F
A-3-2 ML T 2 Circuit Diagrams
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 21
MLT 2 / BINOS® 100 F
A-3-2 ML T 2 Circuit Diagrams
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A-3-2 BINOS® 100 F Circuit Diagrams
A-3-3BINOS® 100 F
MLT 2 / BINOS® 100 F
Emerson Process Management Manufacturing GmbH & Co. OHG
A- 23
MLT 2 / BINOS® 100 F
A-3-2 BINOS® 100 F Circuit Diagrams
ATEX Instruction Manual
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August 2005
Emerson Process Management Manufacturing GmbH & Co. OHGA- 24
BINOS 100 F & MLT 2 Addendum Zone 1 & 2
WORLD HEADQUARTERS
ROSEMOUNT ANAL YTICAL EUROPE
Emerson Process Management
GmbH & Co. OHG
Industriestrasse 1
63594 Hasselroth
Germany
T 49 6055 884 0
F 49 6055 884209
Emerson Process Management
Rosemount Analytical Inc.
6565 P Davis Industrial Parkway
Solon, OH 44139 USA
T 440.914.1261
Toll Free in US and Canada 800.433.6076
F 440.914.1271
e-mail: gas.csc@EmersonProcess.com
www.raihome.com
GAS CHROMAT OGRAPHY CENTER
AND LATIN AMERICA
Emerson Process Management
Rosemount Analytical Inc.
11100 Brittmoore Park Drive
Houston, TX 77041
T 713 467 6000
F 713 827 3329
Instruction Manual
ETC01035
08/2005
EUROPE, MIDDLE EAST AND AFRICA
Emerson Process Management
Shared Services Limited
Heath Place
Bognor Regis
West Sussex PO22 9SH
England
T 44 1243 863121
F 44 1243 845354
ASIA-PACIFIC
Emerson Process Management
Asia Pacific Private Limited
1 Pandan Crescent
Singapore 128461
Republic of Singapore
T 65 6 777 8211
F 65 6 777 0947
e-mail: analytical@ap.emersonprocess.com