Emerson Process Management ETC01035 User 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
th
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.
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.
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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.
P - 5
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
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MLT 2 / BINOS® 100 F
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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MLT 2 / BINOS® 100 F
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
Emerson Process Management Manufacturing GmbH & Co. OHG
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
1 - 5
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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MLT 2 / BINOS® 100 F
1-3-5 Sample Gas Conditions
1-3-5 Sample Gas Conditions
Applicable gases: Nonflammable gases or
gas mixtures which always Flammable gases
remain below LEL
Maximum sample
gas pressure: atmospheric or atmospheric or
<1500 hPa at normal <1500 hPa at normal
atmospheric pressure, atmospheric pressure,
dependend on gas dependend on gas
measuring principle measuring principle
and
overpressure < 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!
Emerson Process Management Manufacturing GmbH & Co. OHG
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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)
Emerson Process Management Manufacturing GmbH & Co. OHG2 - 2
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