Emerson Rosemount BINOS 100 F, Rosemount MLT 2 Instruction Manual

Instruction Manual
ETC01035 08/2005
Instruction Manual
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
4
Edition 08/2005
www.EmersonProcess.com
BINOS 100 F & MLT 2 Addendum Zone 1 & 2 Instruction 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 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 03/2003 2nd Edition 01/2004 3rd Edition 08/2004
4th Edition 08/2005 © 2003-2005 by Emerson Process Management
Emerson Process Management GmbH & Co. OHG
Industriestrasse 1 D-63594 Hasselroth Germany T +49 (0) 6055 884-0 F +49 (0) 6055 884-209 Internet: www.EmersonProcess.com
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.
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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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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.
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MLT 2 / BINOS® 100 F
Products described in this manual shall not be supplied with explosive gases!
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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.
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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.
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.
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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TABLE OF CONTENTS

PREFACE P-1
Definitions....................................................................................................................... P-3
Safety Instructions........................................................................................................P-3
Terms used in this manual ............................................................................................ P-5
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 Description of Pressurization Systems .......................................................... 1-4
1-3-4 Purge Gas Conditions ...................................................................................... 1-6
1-3-6 Differential Pressure Monitoring...................................................................... 1-6
1-3-5 Sample Gas Conditions.................................................................................... 1-7
1-3-7 Equivalent Safety Devices ............................................................................... 1-9
1-4 Additional Safety Measures ............................................................................. 1-9
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 .............................................................................. 2-6
2-4-2 MLT 2 Gas Flow Diagrams................................................................................ 2-8
2-4-3 BINOS® 100 F Gas Flow Diagrams ................................................................ 2-11
2-5 Safety Device Settings ................................................................................... 2-15
2-6 Special Remarks and Instructions ................................................................ 2-15
2-7 Electrical Connections ................................................................................... 2-16
2-7-1 Cable Gland Assembly Instruction................................................................ 2-17
2-7-2 Signal Inputs and Outputs ............................................................................. 2-17
2-7-2 Category 2 Equipment Mains Connection ................................................... 2-18
2-7-3 Category 3 Equipment Mains Connection ................................................... 2-19
2-7-4 Category 3 Equipment Alarm Contacts ........................................................ 2-20
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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 ........................... 4-1
4-4 Verifications and Tests on Modified or Repaired Electrical Apparatus ....... 4-2
4-4-1 System with 14 mbar Operating Pressure...................................................... 4-2
4-4-1-1 Preparations ...................................................................................................... 4-2
4-4-1-2 Overpressure Test ............................................................................................ 4-3
4-4-1-3 Leakage Test ..................................................................................................... 4-3
4-4-2 System with 90 mbar Operating Pressure...................................................... 4-4
4-4-2-1 Preparations ...................................................................................................... 4-4
4-4-2-2 Overpressure Test ............................................................................................ 4-5
4-4-2-3 Leakage Test ..................................................................................................... 4-5
4-4-3 Removal of Modifications................................................................................. 4-6
APPENDIX A-1
A-1 EC Declarations of Conformity........................................................................ A-1
A-2 EC Type Examination Certificates ...................................................................A-5
A-2-1 Category 2 Certificate ....................................................................................... A-5
A-2-2 Category 3 Certificate ..................................................................................... A-10
A-3 Circuit Diagrams .............................................................................................A-15
A-3-1 MLT 2, single enclosure..................................................................................A-15
A-3-2 MLT 2, dual enclosure.....................................................................................A-19
A-3-3 BINOS® 100 F ...................................................................................................A-23
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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 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

1-2 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 1 (Category 2)
or Zone 2 (Category 3),
dependent on purge system

1-3-2 Explosion 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
Temperature class: T4
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
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1-3-43 Description of Pressurization Systems

1-3-3 Description 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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Depending on which system is used, diffe­rent parameters apply:
MLT 2 / BINOS® 100 F
Application Mode of Ope ration
Zon e 1 Pre p urge Ph ase for measuring Duration: 10 min 14 min flamm able gases Purge gas cons um ption: 1,75 Nm³/h 1,92 Nm³/h
max i m um overpressure: 95 mbar 95 mbar
Measuri ng Mode
Internal overpress ure: 90mbar 90 mbar
Flow rat e (leakage rate): <= 3 l/min <= 4, 5 l /min
Zon e 1 Pre p urge Ph ase for measuring Duration: 4 min 6 min non-flamm able gases P urge gas consumption: 6,8 Nm³/ h 9,2 Nm³/h
max i m um overpressure: 25 mbar 25 mbar
Measuri ng Mode
Internal overpressure: 14 mbar 14 mbar
Flow rat e (leakage rate): <= 3 l/min <= 4, 5 l /min
Application Mode of Ope ra tion
(volume approx . 56 l)
Single Enclosure
(volume approx . 56 l)
approx . 112 l)
approx . 112 l)
Zone 2 Pre p urge Ph ase for mea suri n g Duration: 5 min 17 min non-flamm able gases P urge gas consumption: 8 Nm³/h 7 Nm³/h
Minimum overpressure in all enclosures:
1 mbar against external atmosphere and
50 Pa against containment system when measuring flammable gases
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max i m um overpressure: 25 mbar 25 mbar
Measuri ng Mode
Internal overpres sure: 1 m bar 1 mbar
Flow rat e (leakage rate): <= 22Nm ³/ h <= 22 Nm ³/ h
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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: 2.000 to 4.000 hPa (2 to 4 bar)
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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 < 85 mbar (optional < 12 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 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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1-3-7 Equivalent Safety Devices
1-3-7 Equivalent 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

1-4 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.
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.

2-1 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 .
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!

2-2 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.
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!
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MLT 2 / BINOS® 100 F

2-3 Dimensional Drawings

2-3 Dimensional Drawings 2-3-1 Single Enclosure Analyzer

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Standard version w/o purging system
Fig. 2-1a
Single enclosure analyzer (approx. dimensions in mm)
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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)
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MLT 2 / BINOS® 100 F

2-3-2 Dual Enclosure Analyzer

2-3-2 Dual 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)
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Standard-Ausführung Standard Version
Ausführung „erhöhter Innendruck“
2
Version „increased pressure“
with category 2 purging system
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MLT 2 / BINOS® 100 F

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

2-4 Connection 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.

2-4-1 Hints 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!
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MLT 2 / BINOS® 100 F

2-4-2 MLT 2 Gas Flow Diagrams

2-4-2 MLT 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

2-4-3 BINOS® 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
Emerson Process Management Manufacturing GmbH & Co. OHG
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ATEX Instruction Manual
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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ATEX Instruction Manual
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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August 2005
Fig. 2-4g
Gas Flow Diagram
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2-5 Safety Device Settings

2-5 Safety 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.

2-6 Special 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

2-7 Electrical 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.
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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.
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2-7-1 Cable 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.

2-7-2 Signal 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.
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MLT 2 / BINOS® 100 F
2-7-2 Category 2 Equipment

2-7-2 Category 2 Equipment Mains Connection

ATEX Instruction Manual
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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
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2-7-3 Category 3 Equipment Mains Connection

2-7-3 Category 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
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MLT 2 / BINOS® 100 F

2-7-4 Category 3 Equipment Alarm Contacts

2-7-4 Category 3 Equipment Alarm Contact s
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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
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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!

3-1 Final 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!

3-2 Switching 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
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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.

4-1 Maintenance 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).

4-2 Gasanalyzer

Refer to the associated manual for detailed information on maintenance, replacement of parts and how to carry out a containment system leak test.
4-3 Pressurization 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
4-4 Verifications and Tests on
Modified or Repaired Electrical Apparatus
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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.

4-4-1 System 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).
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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

4-4-2 System 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).
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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
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MLT 2 / BINOS® 100 F
4-4 Verifications and Tests

4-4-3 Removal 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.
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APPENDIX

A-1 EC 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
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MLT 2 / BINOS® 100 F
A-1 EC Declarations of Conformity
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MLT 2 / BINOS® 100 F
A-1 EC Declarations of Conformity
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A-2-1 Category 2 Certificate

A-2 EC Type Examination Certificates A-2-1 Category 2 Certificate
MLT 2 / BINOS® 100 F
Emerson Process Management Manufacturing GmbH & Co. OHG
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MLT 2 / BINOS® 100 F
A-2-1 Category 2 Certificate
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MLT 2 / BINOS® 100 F
A-2-1 Category 2 Certificate
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MLT 2 / BINOS® 100 F
A-2-1 Category 2 Certificate
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MLT 2 / BINOS® 100 F
A-2-1 Category 2 Certificate
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MLT 2 / BINOS® 100 F

A-2-2 Category 3 Certificate

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MLT 2 / BINOS® 100 F
A-2-2 Category 3 Certificate
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MLT 2 / BINOS® 100 F
A-2-2 Category 3 Certificate
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MLT 2 / BINOS® 100 F
A-2-2 Category 3 Certificate
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MLT 2 / BINOS® 100 F
A-2-2 Category 3 Certificate
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A-3 Circuit Diagrams A-3-1 ML T 2, single
MLT 2 / BINOS® 100 F

A-3 Circuit Diagrams

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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
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MLT 2 / BINOS® 100 F
A-3-1 ML T 2 Circuit Diagrams
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A-3-2 MLT 2, dual
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
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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
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A-3-2 BINOS® 100 F Circuit Diagrams

A-3-3 BINOS® 100 F

MLT 2 / BINOS® 100 F
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MLT 2 / BINOS® 100 F
A-3-2 BINOS® 100 F Circuit Diagrams
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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
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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
© Emerson Process Management GmbH & Co. OHG 2007
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