Manual: BINOS 100 F and MLT 2 Addendum for Pressurized Analyzers in Hazardous Area Applications-6th Ed. | Rosemount
Rosemount Manual: BINOS 100 F and MLT 2 Addendum for Pressurized Analyzers in Hazardous Area Applications-6th Ed. | Rosemount Manuals & Guides
ATEX Instruction Manual
ETC01035
February 2008
MLT 2 and BINOS® 100 F
Manual Upgrade for Pressurized Analyzers
intended to be used in Hazardous Areas
www.EmersonProcess.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management (Rosemount Analytical) designs, manufactures and tests
its products to meet many national and international standards. Because these instruments
are sophisticated technical products, you MUST properly install, use, and maintain
them to ensure they continue to operate within their normal specications. 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 clarication.
• 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 specied in the Installation Instructions of the
appropriate Instruction Manual and per applicable local and national codes.
Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualied personnel to install, operate, update,
program, and maintain the product.
• When replacement parts are required, ensure that qualied people use replacement
parts specied by Emerson Process Management (Rosemount Analytical).
Unauthorized parts and procedures can affect the product’s performance, place the
safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in re, 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 qualied persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice.
6th edition 2008/02
5th edition 2007/09
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
Original Instruction Manual for the purpose
of the European Directive 94/9/EC.
ATEX Instruction Manual
ETC01035
02/2008
MLT 2 / BINOS 100 F
Ta b l e o f Co n T e n T s
PREAMBLE ..........................................................................................................................S-1
Denitions
Symbols on or inside the instrument
Symbols used in this manual
Terms used in this manual .................................................................................................S-4
Safety instructions
CHAPTER 1 Technical Description 1-1
1.1 Application and Principle of Operation ...............................................................1-1
1.2 Description of Pressurization System .................................................................1-4
1.3 Technical Data ........................................................................................................1-5
1.3.1 Installation Site ...................................................................................................1-5
1.3.2 Explosion Protection..........................................................................................1-5
1.3.3 Electrical and Mechanical Data .........................................................................1-6
1.3.4 Pressurization Gas and Sample Gas Conditions ............................................1-7
1.3.5 Purge Gas Conditions ........................................................................................1-8
1.3.6 Differential Pressure Monitoring .......................................................................1-8
1.3.7 Infallible Containments ......................................................................................1-8
1.3.8 Nameplate Label .................................................................................................1-9
1.3.9 Equivalent Safety Devices ...............................................................................1-10
1.4 Additional Safety Measures ................................................................................ 1-11
............................................................................................................................S-1
................................................................................S-2
.............................................................................................S-3
..............................................................................................................S-6
CHAPTER 2 Installation 2-1
2.1 General....................................................................................................................2-2
2.2 Installing the Intrument .........................................................................................2-2
2.3 Dimensions.............................................................................................................2-3
2.4 Connecting Sample and Protective Gases ..........................................................2-7
2.4.1 Instructions for Handling Flammable Gases ...................................................2-7
2.4.2 MLT 2 Gas Flow Diagrams ................................................................................. 2-9
2.4.2.1 For Nonammable or Flammable Gases diluted below 1/4 LEL ................2-9
2.4.2.2 For Nondiluted Flammable Gases ..............................................................2-10
2.4.3 BINOS® 100 F Gas Flow Diagrams .................................................................. 2-12
2.4.3.1 For Nonammable or Fammable Gases diluted below 1/4 LEL ...............2-12
2.4.3.2 For Nondiluted Flammable Gases ..............................................................2-13
2.5 Adjusting the Pressurization System ................................................................2-15
2.6 Special Instructions .............................................................................................2-15
2.7 Electrical Connections ........................................................................................2-16
TOC-1Emerson Process Management GmbH & Co. OHG
1 Techn. Description
TOC-2 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
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02/2008
Table of Contents
2.7.1 Cable Gland Assembly Instruction for Shielded Cables ..............................2-17
2.7.2 Signal Inputs and Outputs ...............................................................................2-17
2.7.3 Category 2 Equipment Mains Connection .....................................................2-18
2.7.4 Power Connection Category 3 Analyzer ........................................................2-19
2.7.4.1 Pressurization Control Unit .........................................................................2-20
CHAPTER 3 Startup 3-1
3.1 Final Check .............................................................................................................3-1
3.2 Switching On ..........................................................................................................3-2
3.2.1 Category 2 System .............................................................................................3-2
3.2.2 Category 3 System .............................................................................................3-2
CHAPTER 4 Maintenance 4-1
4.1 Routine Tests in General .......................................................................................4-2
4.1.1 Routine Tests Interval ....................................................................................... 4-2
4.1.2 Visual Inspections ..............................................................................................4-2
4.1.3 Close Examination .............................................................................................4-2
4.1.4 Detail Examination ............................................................................................4-2
4.2 Routine Tests .........................................................................................................4-3
4.2.1 Gasanalyzer, Analytical Function .....................................................................4-3
4.2.2 Gasanalyzer, Ex Protection ...............................................................................4-3
4.2.3 Differential Pressure Switch (Option) ...............................................................4-3
4.2.4 Pressurization System andother accessories .................................................4-3
4.2.5 Differential Pressure Switch ..............................................................................4-4
4.2.5.1 Preparation .....................................................................................................4-4
4.2.5.2 Differential Pressure Switch Test .................................................................4-5
4.2.5.3 Removal of Modications ..............................................................................4-5
4.3 Tests after Modication or Repair ........................................................................4-6
4.3.1 Analyzer Housing ...............................................................................................4-6
4.3.1.1 Preparation .....................................................................................................4-6
4.3.1.2 Overpressure Test ..........................................................................................4-7
4.3.1.3 Leak Test .........................................................................................................4-7
4.3.1.4 Removal of Modications ..............................................................................4-7
4.4 Troubleshooting .....................................................................................................4-8
4.4.1 Pressurization System Not Activated ..................................................................4-8
TOC-3Emerson Process Management GmbH & Co. OHG
1 Techn. Description
MLT 2 / BINOS 100 F
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Table of Contents
APPENDIX A-1
A.1 EC Declarations of Conformity .............................................................................A-2
A.1.1 Category 2 Equipment .......................................................................................A-2
A.1.2 Category 3 Equipment .......................................................................................A-4
A.2 EC Type Examination Certicate ..........................................................................A-6
A.3 Manufacturer´s Declaration ................................................................................A-13
A.4 Circuit Diagrams, Cat. 2 Equipment ...................................................................A-14
A.4.1 MLT 2, single .....................................................................................................A-14
A.4.2 MLT 2, dual ........................................................................................................A-18
A.4.3 BINOS® 100 F ....................................................................................................A-22
A.5 Circuit Diagrams, Cat. 3 Equipment ...................................................................A-24
A.5.1 MLT 2, single .....................................................................................................A-24
A.5.2 MLT 2, dual ........................................................................................................A-28
A.5.3 BINOS® 100 F ....................................................................................................A-32
In d e x o f fI g u r e s
Fig. 1-1: Analyzer with Category 2 Pressurization System .......................................................................1-2
Fig. 1-2: Analyzer with Category 3 Pressurization System .......................................................................1-3
Fig. 1-3: Nameplate Label Details ................................................................................................................1-9
Fig. 2-1: Cat. 3 Single Enclosure Analyzer (Dimensions in mm) ..............................................................2-3
Fig. 2-2: Cat. 3 Dual Enclosure Analyzer (Dimensions in mm) .................................................................2-4
Fig. 2-3: Cat. 2 Single Enclosure Analyzer (Dimensions in mm) ..............................................................2-5
Fig. 2-4: Cat. 2 Dual Enclosure Analyzer (Dimensions in mm) .................................................................2-6
Fig. 2-3: Single and installed 8 ame arrestors ........................................................................................2-8
Fig. 2-6: Mains Terminals Inside Analyzer ................................................................................................2-19
Fig. 2-7: Mains Terminals Inside Control Unit ..........................................................................................2-20
Fig. 3-1: Cable gland sealing plug ...............................................................................................................3-1
Fig. 3-2: Cable gland hexagon socket screw sealing plug ......................................................................3-1
Fig. 4-1: Setup for Differential Pressure Switch Tests ..............................................................................4-5
Fig. 4-2: Setup for Enclosure Tests .............................................................................................................4-7
MLT 2 / BINOS 100 F
ATEX Instruction Manual
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Table of Contents
TOC-4 Emerson Process Management GmbH & Co. OHG
ATEX Instruction Manual
ETC01035
02/2008
MLT 2 / BINOS 100 F
PREAMBLE
This instruction manual provides information about installing, operating and maintaining/servicing pressurized BINOS
100 F and MLT 2 series gas analyzers in hazardous
(classied) areas and shall be read in conjunction with the standard analyzer instruction
manual only!
This instruction manual covers BINOS
100 F and MLT 2 series gas analyzers variations and
therefore may describe congurations and/or options not part of your specic analyzer.
DEFINITIONS
The following denitions apply to WARNINGS, CAUTIONS and NOTES found throughout
this publication.
Highlights an operation or maintenance procedure, practice, condition,
statement, etc. which, if not strictly observed, could result in injury, death,
or long-term health hazards of personnel.
Safety Instructions
Highlights an operation or maintenance procedure, practice, condition,
statement, etc. which, if not strictly observed, could result in minor or
moderate injury or damage to or destruction of equipment, or loss of
effectiveness.
NOTE
Highlights an essential operating procedure, condition or statement.
S-1Emerson Process Management GmbH & Co. OHG
S-2 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
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02/2008
SYMBOLS ON OR INSIDE THE INSTRUMENT
This symbol appearing on or inside the
instrument ...
... signals
hazardous voltages are likely to be present.
Covers should only be removed when power
is removed from the equipment — and then by
trained service personnel only.
hot surfaces are likely to be present. Covers
should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the
touch.
more detailled information and instructions are
required and available: Read the instruction
manuals.
S-3Emerson Process Management GmbH & Co. OHG
Safety Instructions
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
SYMBOLS USED IN THIS MANUAL
Where one or more of the following symbos appear in this instruction manual, carefully read the
given informations and instructions!
Observe the given warnings and instructions to avoid risks!
Where this symbol appears in the manual... ... information is provided about
hazardous voltages likely to be present
high temperatures likely to be present
hazards of explosion likely to be present
toxic substances likely to be present
substances harmful to health likely to be
present
how to handle heavy instruments
electronics components sensitive to electrostatic
discharge
when it is necessary to disconnect equipment
from mains
essential procedures or conditions to be observed.
Also this symbol may mark an important statement to ensure proper measuring conditions.
S-4 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
TERMS USED IN THIS MANUAL
ATEX
Directive 94/9/EC, commonly called the
ATEX („Atmosphères Explosibles“) products
directive.
Area Classication
Zone 1
Where ignitable concentrations of ammable
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
classied Category 2.
Zone 2
Where ignitable concentrations of ammable
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
classied Category 3.
Containment System
The part of the analyzer containing the gas
that may constitute an internal source of release.
Explosive Gas(es)
Flammable gases and gas mixtures of a
concentration within the explosion limits and
present in mixture with air.
Flammable Gas(es)
Gases and gas mixtures are assigned to be
ammable if they might become ignitable
when in a mixture with air.
Dilution
The continuous supply of a protective gas,
after purging, at such a rate that the con-
centration of a ammable mixture inside the
pressurized enclosure is maintained at a
value outside the explosive limits except in a
dilution area.
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.
S-5Emerson Process Management GmbH & Co. OHG
Safety Instructions
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
Terms used in this manual
Internal Explosion Protection
The „Internal explosion protection“ serves
to prevent ignition of gas being present in
the analyzer’s Containment System (CS;=
sample gas path).
Dependent on the gas composition several
options are available:
None required (if gas is noncombustible),
dilution by purge gas or/and internal overpressure of the analyzer’s enclosure compared
to the CS.
Lower Explosion Limit (LEL)
Volume ratio of ammable gas in air below
which an explosive gas atmosphere will not
be formed: the mixture of gas and air lacks
sufcient fuel (gas) to burn.
Protective Gas
Air or inert gas used for purging and maintaining an overpressure and, if required, dilution.
Purge mode „Leakage Compensation“
In EEx p „leakage compensation mode“ just
as much protective gas is used to hold an
overpressure of > 1 mbar compared to atmospheric.
Pre-Purging
The pre-purging phase serves to remove any
combustible gas out of the analyzer’s enclosure prior to switching on the analyzer. During
this time the housing is purged with 5 times
its own volume.
Purge mode „Continuous Flow“
In EEx p „continuous ow mode“ the protec-
tive gas ows with higher rates through the
enclosure. Flow rates are calculated to hold
an overpressure of > 1 mbar compared to
atmospheric.
Upper Explosion Limit (UEL)
Volume ratio of ammable gas in air above
which an explosive gas atmosphere will not
be formed: the mixture of gas and air is too
rich in fuel (decient in oxygen) to burn.
S-6 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
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SAFETY INSTRUCTIONS
INTENDED USE STATEMENT
Emerson series gas analyzers described herein are intended to be used as analyzers for
industrial purposes. They must not be used in medical, diagnostic or life support appli-
cations nor as safety devices, and no independent agency certications or approvals are
to be implied as covering such applications!
SAFETY SUMMARY
If this equipment is used in a manner not specied in these instructions, protective systems may be impaired.
AUTHORIZED PERSONNEL
To avoid explosions, loss of life, personal injury and damage to this equipment and on-site
property, do not operate or service this instrument before reading and understanding this
instruction manual and receiving appropriate training.
ADDITIONAL LITERATURE
This manual covers aspects specic for using pressurized BINOS
gas analyzers analyzers in hazardous (classied) areas, only.
To install, start-up, operate and maintain/service the instrument in a safe manner it is
MANDATORY to read all additional instruction manuals shipped together with the instrument!
The following instruction manuals are available and/or referenced within this manual at
hand and, depending on your system´s conguration, shipped with your analyzer:
90002929 MLT Hardware instruction manual
HAS3xE-IM-SW39 MLT Software instruction manual (rev. 3.9.x or later)
HAS1xE-IM-HS BINOS 100 series instruction manual
HASICE-IM-H Infallible Containment instruction manual
User´s Manual F 850 S Zone 1 Pressurized Enclosure System User´s Manual
User´s Manual F 840 Zone 2 Pressurized Enclosure System User´s Manual
SAVE ALL INSTRUCTIONS FOR FUTURE USE!
Contact your local service center or sales ofce when missing documents.
100 F and MLT 2 series
S-7Emerson Process Management GmbH & Co. OHG
Safety Instructions
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
Safety Instructions
EXPLOSION HAZARD
Read all instruction manuals (including versions for auxiliary equipment)
before installing this instrument!
Violating safety instruction can cause explosion and/or injury, death, or
long-term health hazards of personnel!
HEAVY INSTRUMENT
The analyzer to which this manual relates, intended to be wall mounted
and/or outdoor installed, weighs up to approx. 40 kg, depending on included
options!
Use two people and/or suitable tools for transportation and lifting these
instruments!
Take care to use anchors and bolts specied 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!
Don´t use the attached pressurization unit´s components as a transportation
handle!
EXPLOSION HAZARD
Operating an open instrument or an instrument with disabled pressurization
system for maintenance requires a hot work permit to be issued to ensure,
the surrounding atmosphere is safe to operate the instrument!
Using the bypass key is permitted for maintenance only!
S-8 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
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Installing and wiring this instrument must comply with all relevant national
legislative requirements and regulations.
Consider all safety instructions within this on hand manual and all associated analyzer instruction manuals!
Safety Instructions
EXPLOSION HAZARD
POSSIBLE EXPLOSION HAZARD
Do NOT operate the instrument with doors or covers open! This is permitted
only when no hazardous atmosphere is present!
Depending on the local regulation, this may require a competent hot work
supervisor to issue a hot work permit.
EXPLOSIONS HAZARD
When installing optional ame arrestors take care to properly x the tube
ttings for leak free installation!
Fittings not tight enough (especially those at the enclosure side of the
ame arrestors) may increase safety of the whole equipment and can cause
explosions!
Read and follow the accompanying ame arrestor´s instructions!
The operator should take into account the possibility of air penetrating
the containment system through a leak and the formation of explosive
atmosphere. Additional safety measures may be required for safe
operation!
S-9Emerson Process Management GmbH & Co. OHG
Safety Instructions
MLT 2 / BINOS 100 F
ATEX Instruction Manual
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02/2008
Safety Instructions
ELECTRICAL SHOCk HAZARD
Installation and connecting power and signal cables are subject to qualied
personnel only taking into account all applicable standards and legislative
requirements! Especially the standard EN 60079-14 „Electrical Installations
in Hazardous Areas“ and all related standards have to be observed.
Failure to follow may cause warranty invalidation, property damage and/or
personal injury or death!
Installation of these instruments is subject to qualied personnel only,
familiar with the resulting potential risks! Instruments providing screw
terminals for electrical connections may require working near live part!
Analyzers described in this manual do not provide a power switch!
A power switch or circuit breaker (complying with IEC 60947-1/-3) has to be
provided in the building installation. This switch has to be installed near
by analyzer, must be easily operator accessible and has to be assigned as
disconnector for the analyzer.
Disconnect instruments with screw terminals from power when working at
power terminals (pull power plug or operate power switch/ circuit breaker
in building installation)!
The analyzers provide a protective earth terminal. To prevent electrical
shock hazards the instruments must be connected to a protective earth.
Therefore the instruments must be connected to power by using a three
wire power cable with earth conductor!
Any interruption of the earth connector inside or outside the instrument
or disconnecting the earth terminal may cause potential electrical shock
hazzard!
The analyzers do not provide a power switch and are operable when connected to power.
S-10 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
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Installing this instrument requires opening the enclosure and working at
the open instrument. This is permitted only when no hazardous atmosphere
is present!
Depending on the local regulation, this may require a competent hot work
supervisor to issue a hot work permit.
Safety Instructions
EXPLOSION HAZARD
ELECTRICAL SHOCk HAZARD
Verify the power supply at installation site meets the specication given on
the analyzer´s nameplate label, before installing the instrument!
Verify power cables are disconnected and/or instrument is de-energized
prior to working at the terminals!
Verify the power cord is layed with a distance of at least 1 cm (0.5“) to any
signal cable to ensure proper insulation from signal circuits!
ELECTRICAL SHOCk HAZARD
Before completing the electrical connection of the instrument, verify cables
are inserted and connected in proper way!
Ensure the earthing conductor (protective earth; PE) is connected!
S-11Emerson Process Management GmbH & Co. OHG
Safety Instructions
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
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Safety Instructions
EXPLOSION HAZARD
When the analyzer is out of order or if the pressurization unit shuts off
due to a failure 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.
HIGH PRESSURE HAZARD
The maximum inlet purge gas pressure at the inlet valve must not exceed
6900 hPa (6,9 bar)!
Higher pressure may damage the analyzer enclosure in case of failure of
the inlet valve!
Take care to externally limit the maximum inlet purge gas pressure!
ATEX Instruction Manual
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02/2008
CHAPTER 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 certied pressurization system
(protection method „Pressurized Enclosure“
Ex p) they can be installed and operated in
hazardous areas of Zone 2.
Pressurization acts as external explosion
protection and prevents external explosive
atmosphere to penetrate into the analyzer
by holding the enclosure at an overpressure
compared to the surrounding
The type of purge system used varies dependent on the area where the analyzer is
intended to be installed. Both systems offer
two modes of operation:
• Ex p with continuous ow
and
• Ex 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 has to differentiate between the following
measurement applications:
• Nonammable gases and gas mixtu-
res 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 compen sation“ 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 above
the pressure in the containment system.
To ensure this condition a differential
pressure switch is used and connected between containment system and
analyzer enclosure, activating an alarm
contact in case the pressure decreases
below the level of 50 Pa. For Category 2
instruments the purging unit disconnects
the analyzer from it’s power supply and
starts a prepurge phase. For Category 3
instruments the operator has to ensure
the alarm signal is interpreted in a proper
way. If more than one switch is needed
because more than one ammable gas is
supplied to the analyzer, the contacts of
these switches have to be connected in
series. Purge medium may be inert gas
or air.
Depending on the measured gas and
methode infallible containments may be
used, so differential pressure switches
become redundant.
1 Techn. Description
1-1Emerson Process Management GmbH & Co. OHG
1-2 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
1.1 Application and Principle of Operation
1 2 3 4 5 1 2 3 4 5687 7
1 Purge gas inlet
2 Pressure relief valve (on bottom or optional on top side)
3 Purge gas outlet
4 Control unit
5 Analzer front door
6 Analyzer physics door (dual enclosure MLT 2 only)
7 Cable inlets
8 Gas ttings
Fig. 1-1: Analyzer with Category 2 Pressurization System
1-3Emerson Process Management GmbH & Co. OHG
1 Techn. Description
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
1.1 Application and Principle of Operation
1 2 3 4 5 1 2 3 4 5687 7
1 Purge gas inlet
2 Pressure relief valve (on bottom or optional on top side)
3 Purge gas outlet
4 Control unit
5 Analzer front door
6 Analyzer physics door (dual enclosure MLT 2 only)
7 Cable inlets
8 Gas ttings
Fig. 1-2: Analyzer with Category 3 Pressurization System
1-4 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
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02/2008
1.2 Description of Pressurization System
1.2 Description of Pressurization System
The intention of a pressurized analyzer is to
keep out of the instrument a surrounding potentially explosive atmosphere by providing
an internal overpressure. The pressurization
system consists of a gas inlet valve, control unit
with micro processor and a bypass switch (Cat
2 only). The control unit monitors all relevant
parameters (pre-purge phase, purge medium
flow, internal overpressure, and more) and
ensures safe operation.
Category 2 analyzers, to be installed in Zone 1
are automatically pre-purged before the power
supply is activated. This ensures a potentially
explosive atmosphere is ushed out. The pre-
purge phase is controlled by the micro processor
unit, which also activates the power supply for
the analyzer when the pre-purge phase has
elapsed or disconnects the analyzer from power
supply in case of failure. It´s internal design has
redundant components to ensure safe operation
even in case of 1 failure.
The main difference of a Category 3 pressu-
rization unit for Zone 2 installation is, that this
unit does not control the analyer´s power supply (e.g. in case of a failure the analyzer is not
disconnected), pre-purging is only optional and
the internal controller design is not as redundant
(safe operation without failure). If an infallible
containment is available for the specic appli-
cation, it can be used for measuring ammable
gases. But, measuring ammable gases utilizing
a differential pressure switch is not permitted: In
this case a Zone 1 instrument has to be used.
The different gaspath designs for measuring
ammable or non-ammable gases also inuence the intruments operation parameters:
Measuring non-ammable gases:
The pressurization system provides an internal
overpressure of 14 mbar. The acceptable samp-
le gas pressure complies with the specications
of an analyzer for non-hazardous (general purpose) areas.
Measuring ammable gases utilizing a diffe-
rential pressure switch:
The internal overpressure is adjusted to
14 mbar. The opertor has to ensure the gas
pressure (sample gas, calibration gases) inside
the containment system remains below 12 mbar,
due to the fact that there is a differential pressure switch installed in each gas path containing
ammable gas. Limiting the gas pressure ensures the pressure inside the instrument is always
at minimum 50 Pa (0,5 mbar) above the con-
tainment pressure. This conguration ensures
that in case of a gas path leak ammable gas
cannot enter the analyzer enclosure.
In case the pressure difference is less than the
given values (due to a failure), the control unit
disconnects the analyzer power supply and
starts pre-purging.
EXPLOSION HAZARD
The operator has to ensure that in case the analyzer is disconnected from
its power supply, applied external signals are disconnected, too, if they are
not intrinsically safe!
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1 Techn. Description
MLT 2 / BINOS 100 F
ATEX Instruction Manual
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02/2008
1.3 Technical Data
1.3 Technical Data
1.3.1 Installation Site
Hazardous area (dependent on pressurization system): Zone 1, Gas or Zone 2, Gas
Permissible ambient temperature range: -20 °C to +40 °C
Permissible ambient storage temperature range: -20 °C to +60 °C
Humidity (non condensing): < 90 % r. h. at +20 °C
< 70 % r. h. at +40 °C
Pollution degree: 2
Installation category: II
Altitude: 0 to (2000 m) above sea level
Surrounding atmosphere Analyzers must not be operated in
corrosive atmosphere.
1.3.2 Explosion Protection
Concepts:
Category 2 :
Category 3:
Temperature class: T4
Analyzer markings:
Options
Infallible containment.
: Intrinsically safe (Ex i) digital, ana-
Pressurized enclosure (Ex px)
with either leakage compensa-
tion mode or continuous ow
Pressurized enclosure (Ex pz)
using simplified purge with
either leakage compensation
mode or continuous ow
dependent on pressurization system
and intended installation site´s
classication (see page 1-9 for
detailled infomation)
log or network outputs.
Intrinsically safe (Ex i) paramagne-
tic Oxygen sensor.
Applicable Standards:
Cat. 2: EN 60079-0 (2004),
EN 60079-2 (2004),
EN 60079-11 (2007)
Cat. 3: EN 60079-0 (2004),
EN 60079-2 (2004),
1-6 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
1.3 Technical Data
1.3.3 Electrical and Mechanical Data
For data not listed see the separate analyzer´s
instruction manual.
Power Supply
HAZARD BY WRONG INPUT VOLTAGE !
Applying a rated voltage other than specied on the analyzer´s nameplate
label may cause an explosion, injury or damage to the installation.
Pressurized analyzers for hazardous locations do NOT provide wide range power
supplies! This type of analyzers is always setup for a specic rated input voltage,
see nameplate label!
Ensure the voltage at site of installation meets the rated analyzer input
voltage!
Rated input voltage: 110 V~, 120 V~, 220 V~ or 230 V~,
48 ... 62 Hz
Rated power: 700 VA max
Housing
Weight: approx. up to 40 kg
(depending on analyzer conguration)
Protection class: IP 54 (EN 60529)
(IP65 if purge gas outlet is protected
accordingly, e.g. by a connected pipe)
for outdoor installation
Analyzer must not be exposed to direct
sun light
Gas ttings, except of the pressurization unit: quantity: max. 8
specication: 6/4 mm or 1/4",
stainless steel
Pressurization Unit Specic Data
See separate instruction manual
1-7Emerson Process Management GmbH & Co. OHG
1 Techn. Description
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
1.3 Technical Data
1.3.4 Pressurization Gas and Sample Gas Conditions
Single Enclosure
Application Mode of Operation
Measurement of Pre-purging
ammable gases with Duration: 4 min 6 min
differential pressure
switch Gas ow: 6,8 Nm³/h 9,2 Nm³/h
Maximum
overpressure: 25 mbar 25 mbar
Measuring
Internal overpressure: 14 mbar 14 mbar
Gas ow (leakage
maximum sample gas
pressure: 12 mbar 12 mbar
Measurement of Pre-purging
non-ammable gases Duration: 4 min 6 min
Gas ow: 6,8 Nm³/h 9,2 Nm³/h
Maximum
overpressure: 25 mbar 25 mbar
(Volume: approx. 56 l)
rate): <= 3 l/min (180 l/h) <= 4,5 l/min (270 l/h)
Dual Enclosure
(Volume: approx. 112 l)
Measuring
Internal overpressure: 14 mbar 14 mbar
Gas ow (leakage
rate): <= 3 l/min (180 l/h) <= 4,5 l/min (270 l/h)
maximum sample gas
pressure:
see analyzer instruction manual
1-8 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
1.3 Technical Data
1.3.5 Purge Gas Conditions
Purge gas: •Inert gas (e.g. Nitrogen)
•Air (from an ex-free area)
Temperature: As ambient, but min. +20 °C to +35 °C.
Medium has to be dry and free from
dust, oil, corrosive or aggressive
components!
Rated input pressure at inlet of Ex p device: 2000 to 4000 hPa (2 to 4 bar)
Maximum input pressure at inlet of Ex p device: 6900 hPa (6,9 bar)
Minimum internal overpressure of the enclosure: 1 mbar
Maximum internal overpressure of the enclosure
during operation: 25 mbar
1.3.6 Differential Pressure Monitoring
For analyzers connected to ammable 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 ammable 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
1.3.7 Infallible Containments
Infallible containments may be used alterna-
tively for measuring ammable gases instead
of using differential pressure monitoring:
Infallible containments are designed and
built using joints made by welding, brazing,
glass to metal sealing, eutectic or comparable
methods. This ensures that the containment
does not have any intentional leakage into
the pressurized enclosure and supersedes
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 lowest permissible
value given by the standards, higher values
are acceptable, too.
Electrical and mechanical connections are
shown in section 2 „Installation“.
the differential pressure switch and the „50 Pa
overpressure condition“ (see 1.3.6).
Infallible containments are currently available
for the measuring principle TC (thermal con-
ductivity). Pls. contact your local sales ofce
for more information.
If your analyzer provides an infallible contain-
ment, see the associated manual for more
information.
1-9Emerson Process Management GmbH & Co. OHG
1 Techn. Description
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
1.3.8 Nameplate Label
1.3 Technical Data
Fig. 1-3: Nameplate Label Details
(example)
Area Description Area Description
The analyzer´s electrical data and serial
number: digits 3 to 5 show manufacturing date („mmy“), e.g. 097 = 09 2007
The maximum gas input pressure to be
applied to the containment system, if the
analyzer is congured to measure ammable
gases
Manufacturer address, CE mark, number of Notied Body for Quality assement and
certication data:
Zone 1 Zone 2
Area classication
Protection concepts
Certicate number
II other than mines
2 Category 2 Equipm. (Zone 1)
G for explosive Gas atmosphere
Ex Explosion protected
[ia] or ia Intrinsically safe output
(depending on type of internal
components)
px Zone 1 pressurization system
IIC Group II, Gas Group C
T4 Temperature Class (135 °C)
LCIE 03 ATEX 6010 X Manufacturers Declaration, not
The measuring channel data (components & ranges)
The purge medium data to be observed
to comply with the certicate, the maxi-
mum leakage ow rate and the volume
of the enclosure
II other than mines
3 Category 3 Equipm. (Zone 2)
G for explosive Gas atmosphere
Ex Explosion protected
[ia] or ia Intrinsically safe output
(depending on type of internal
components)
pz Zone 2 pressurization system
IIC Group II, Gas Group C
T4 Temperature Class (135 °C)
shown on the nameplate label
1-10 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
1.3.9 Equivalent Safety Devices
An explosion may result of using a pressurization system other than
recommended by Emerson Process Management!
It is the responsibility of the operator/owner to choose and install such
systems not provided and specied 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!
1.3 Technical Data
EXPLOSION HAZARD
In principle it is possible to use other equivalent pressurization systems than described
in this manual, as long as they meet the following requirements:
• Device is ATEX approved
• Adjustable pre-purge phase
• Minimum purge ow rate :
6,8 Nm3/h resp. 9,2 Nm³/h
• Limited purge gas pressure during the pre-
purging phase: < 25 mbar
• Input pressure for purge gas supply:
2 ... 4 bar
Category 2 equipment:
• 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 measuring ammable gases,
only:
Connection facility for differential pressure
switch, providing intrinsically safe signal for
scanning the switch.
1-11Emerson Process Management GmbH & Co. OHG
1 Techn. Description
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
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 ame arrestors.
• The maximum permissible gas pressure
depends on the type of installed measu-
ring principle and classication of gas
(ammable / nonammable). See section
1.3.4 for detailed information.
The maximum inlet purge gas pressure at the inlet valve must not exceed
6900 hPa (6,9 bar)!
Higher pressure may damage the analyzer enclosure in case of failure of
the inlet valve!
MLT 2 / BINOS 100 F
ATEX Instruction Manual
ETC01035
02/2008
1-12 Emerson Process Management GmbH & Co. OHG
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