Rosemount Manual: MLT2 CEMS Ex p Manual Addendum for Pressurized Analyzers | Rosemount Manuals & Guides
ATEX Instruction Manual
ETC01035
2015/10
MLT 2 CEMS Ex p
Manual Addendum for Pressurized Analyzers
intended to be used in Hazardous Areas Zone 2
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 specifi cations. 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 clarifi cation.
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 specifi ed 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 qualifi ed personnel to install, operate, update,
program, and maintain the product.
When replacement parts are required, ensure that qualifi ed people use replacement
parts specifi ed 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 fi 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 qualifi ed persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice.
10th edition 2015-10
Emerson Process Management
GmbH & Co. OHG
Rosemount Analytical
Process Gas Analyzer Center of Excellence
Industriestrasse 1
63594 Hasselroth, Germany
T +49 6055 884 0
F +49 6055 884 209
Original Instruction Manual for the purpose
of the European Directive 94/9/EC.
ATEX Instruction Manual
ETC01035
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MLT 2 CEMS Ex p
TABLE OF CONTENT
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
ADDITIONAL LITERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
Defi nitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Symbols used on and inside the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3
Symbols used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-4
Terms used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Intended use statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
General safety notice / Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Authorized personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-8
CHAPTER 1
Technical Description 1-1
1.1 Application and Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Description of Pressurization System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.1 Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.2 Explosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.3 Electrical and Mechanical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.3.4 Purge Gas Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.3.5 Overpressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.6 Sample gas specifi cations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Nameplate Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table of Content
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.5 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.5.1 Cable Gland Assembly Instruction for Shielded Cables . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.5.2 Power Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
CHAPTER 3
Startup 3-1
3.1 Final Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Switching On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
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Table of Contents
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Chapter 4
Maintenance 4-1
4.1 Routine Tests in General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.1.1 Routine Tests Inteval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Pressurization System and
other accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.4 Test the Relief Valve´s Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.3 Tests after Working on the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.3.2 Overpressure Test .......................................................................................................4-6
4.3.3 Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.3.4 Test the Relief Valve´s Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.3.5 Removal of Modifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.3.6 Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.4 Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.5.1 Overpressure is not generated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
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PREAMBLE
This instruction manual provides additional information about installing, operating and maintaining/servicing pressurized ML T 2 series gas analyzers for zone 2 in hazardous (classifi ed) areas.
Operators must be familiar with operating these analyzers, before startup.
This instruction manual covers ML T 2 series gas analyzers variations and therefore may describe
confi gurations and/or options not part of your specifi c analyzer.
This ATEX instruction manual is an addendum to the basic instruction manual and covers aspects
of explosion protection and safety equipment only! To safely operate these instruments, you have
to read and understand all associated manuals, including those of additional components!
If specifi cations or data provided by this manual differ from those given in the associated manuals,
latter are superseded by this manual.
ADDITIONAL LITERATURE
This manual covers aspects specifi c for using pressurized MLT 2 series gas analyzers
analyzers in hazardous (classifi ed) areas, only.
T o 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 confi guration, shipped with your analyzer:
90002929 MLT Hardware instruction manual
HAS3xE-IM-SW39 MLT Software instruction manual (rev. 3.9.x or later)
User´s Manual F 840 Pressurized Enclosure System F840, Revision 2, 2012 or Revi-
sion 0, 2015
SAVE ALL INSTRUCTIONS FOR FUTURE USE!
Contact your local service center or sales offi ce when missing documents.
Safety Instructions
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DEFINITIONS
The following defi nitions 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.
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.
REMARK
Highlights an essential operating
procedure, condition or statement
NOTE
Highlights an important statement.
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SYMBOLS USED ON AND INSIDE THE UNIT
Wherever one or more of the following symbols appear on or inside the instrument, be careful
and read the instructions given in the accompanying manuals!
Follow these warnings and notes carefully
to minimize risks.
This symbol at the instrument ... ... indicates
dangerous voltages may be accessible. Removing covers is permitted only, if the instrument is
disconnected from power - and even in this case
by qualifi ed personnel only!
hot surfaces may be accessible. Removing
covers by qualifi ed personnel is permitted only,
if the instrument is disconnected from power.
Nevertheless several surfaces may remain hot
for a limited time.
Safety Instructions
more detailled information available: see in-
struction manual before proceeding!
more detailled information available: see instruction manual before proceeding!
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SYMBOLS USED IN THIS MANUAL
Wherever one or more of the following symbols are used in this instruction manual, read the
accompanying information and instructions carefully.
Follow these warnings and notes carefully
to minimize risk.
This symbol used in the manual ... ... means
dangerous voltages may be exposed
hot surfaces may be exposed
possible danger of explosion
toxic substances may be present
substances harmful to health may be present
indicates notes relating to heavy instruments
electrical components may be destroyed by
electrostatic discharges
units must be disconnected from the power
source
indicates special instructions or information for
operation at low temperatures.
indicates basic conditions or procedures are
being described.
This symbol may also indicate information important for achieving accurate measurements.
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TERMS USED IN THIS MANUAL
MLT 2 CEMS Ex p
ATEX
Directive 94/9/EC, (respectivly directive
2014/34/EU, valid from 20.04.2016) commonly called the ATEX („Atmosphères Explosibles“) products directive.
Area Classifi cation
Zone 1
Where ignitable concentrations of fl ammable
gases can exist some of the time under normal operating conditions.
Equipment to be used in Zone 1 has to be
classifi ed Category 2.
Zone 2
Where ignitable concentrations of fl ammable
gases are not likely to exist under normal
operating conditions.
Equipment to be used in Zone 2 has to be
classifi ed Category 3.
Containment System
part of the analyzer containing the fl ammable
substance that may constitute an internal
source of release
Pressurization
technique of guarding against the ingress of
the external atmosphere into an enclosure by
maintaining a protective gas therein at a pressure above that of the external atmosphere.
Pressurization system
grouping of safety devices and other components used to pressurize and monitor or control
a pressurized enclsoure.
Safety Instructions
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, vapors or mixtures thereof that are
apable of being ignited
Purging
in a pressurized enclosure, the operation of
passing a quantity of protective gas through
the enclosure and ducts, so that the concentration of the explosive gas atmosphere is
brought to a safe level.
Purge mode „Leakage Compensation“
In Ex p „leakage compensation mode“ just
as much protective gas is used to hold an
overpressure of > 1 mbar compared to atmospheric.
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Terms used in this manual
Lower Explosion Limit (LEL)
Volume ratio of fl ammable gas in air below
which an explosive gas atmosphere will not
be formed.
Upper Explosion Limit (UEL)
Volume ratio of fl 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 (defi cient in oxygen) to burn.
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Protective Gas
Air or inert gas used for purging and maintaining an overpressure and, if required, dilution
and purging.
Overpressure
pressure above ambient pressure within a
pressurized enclosure.
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SAFETY INSTRUCTIONS
INTENDED USE STATEMENT
MLT 2 series gas analyzers are intended to be used as analyzers for industrial purposes.
They must not be used in medical, diagnostic or life support applications nor as safety
devices.
Using ML T 2 analyzers as safety devices, requiring redundant design or SIL classifi cation,
is also not permitted.
No independent agency certifi cations or approvals are to be implied as covering such
applications!
GENERAL SAFETY NOTICE / RESIDUAL RISK
If this equipment is used in a manner not specifi ed in these instructions, protective systems
may be impaired or hazards can arise, resulting in explosion, loss of life, personal injury
and damage to this equipment and on-site property.
Despite of incoming goods inspections, production control, routine tests and application
of state-of-the-art measuring and test methods, an element of risk remains when operating
a gas analyzer!
Even when operated as intended and observing all applicable safety instructions some
residual risks remain, including, but not limited to, the following:
• Explosion protection measures may become ineffective on the occurence of
• 1 failure (for Category 3 instruments)!
• The emission of gases hazardous to health may even be possible when all gas connections have been correctly made.
Avoid exposure to the dangers of these residual risks by taking particular care when installing, operating, maintaining and servicing the analyzer.
Safety Instructions
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Safety Instructions
AUTHORIZED PERSONNEL
In-depth specialist knowledge is an absolutely necessary condition for working with and
on the analyzer.
Authorized personnel for installing, operating, servicing and maintaining the analyzer are
instructed and trained qualifi ed personnel of the operating company and the manufac-
turer.
It is the responsibility of the operating company to
• train staff,
• observe safety regulations,
• follow the instruction manual.
Operators must
• have been trained,
• have read and understood all relevant sections of the instruction manual before
commencing work,
• know the safety mechanisms and regulations.
10/2015
T o avoid explosions, loss of life, personal injury and damage to this equipment and on-site
property, do not install, operate, maintain or service this instrument before reading and
understanding this instruction manual and receiving appropriate training.
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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!
MLT 2 CEMS Ex p
Safety Instructions
EXPLOSION HAZARD
EXPLOSION HAZARD WHEN OPEN
Do not open while explosive atmosphere may be present!
EXPLOSION HAZARD
Products covered by this manual are intended to be installed and operated
in hazardous areas. This is permitted only, considering all relevant national
legislative requirements and regulations, not listed within this manual.
Make sure, that all safety devices and the pressurization unit are working
properly, to ensure safe operation of the analyzer!
Violating may cause explosions!
EXPLOSION HAZARD
Safety Instructions
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!
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EXPLOSION HAZARD WHEN SHUT OFF / BATTERY
When the analyzer is out of order or if the pressurization unit shuts off due
to a failure, all 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. Note that for data backup purposes some
circuitry on the CPU board continuously is powered by a battery!
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Safety Instructions
EXPLOSION HAZARD DURING MAINTENANCE
Disconnect the system from voltage before open the doors. Don‘t open the
analyzer when explosive atmosphere can be present
EXPLOSION HAZARD BY MODIFICATION
Any addition, substitution, or replacement of components installed on or
in this device, must be certifi ed to meet the hazardous area classifi cation
that the device was certifi ed to prior to any such component addition,
substitution, or replacement. In addition, the installation of such device or
devices must meet the requirements specifi ed and defi ned by the hazardous
area classifi cation of the unmodifi ed device.
Any modifi cations to the device not meeting these requirements, will void
the product certifi cation(s).
Contact Emerson Process Management‘s customer service center for return
authorization.
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