Emerson Rosemount BINOS 100 F User manual

www.EmersonProcess.com
Instruction Manual
BINOS 100 F & MLT 2
Addendum for Pressurized Analyzers intended to be used
in HazardousAreas
Zone 1: All Versions
Zone 2: Non-Flammable Gases Only
4th Edition 08/2005
Instruction Manual
ETC01035
08/2005

BINOS 100 F & MLT 2 Addendum Zone 1 & 2 InstructionManual
ETC01035
08/2005
Emerson Process Management
GmbH & Co. OHG
Industriestrasse 1
D-63594 Hasselroth
Germany
T [phone]
F [phone]
Internet: www.EmersonProcess.com
ESSENTIALINSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management (RosemountAnalytical) designs, manufactures and tests
itsproductstomeetmanynationalandinternationalstandards.Becausetheseinstruments
are sophisticated technical products, you MUST properly install, use, and maintain
them to ensure they continue to operate within their normal specifications. The following
instructionsMUST be adhered to and integrated into yoursafety program when installing,
using and maintaining Emerson Process Management (RosemountAnalytical) products.
Failure to follow the proper instructions may cause any one of the following situations to
occur:Loss oflife;personal injury;propertydamage;damageto thisinstrument;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 forclarification.
•Followallwarnings, cautions,andinstructionsmarkedonandsuppliedwiththeproduct.
•Inform and educate your personnel in the proper installation, operation, and
maintenance of the product.
•Installyour equipmentas specified in the InstallationInstructions ofthe appropriate
InstructionManual and per applicablelocal and nationalcodes.Connect allproducts
totheproper electrical and pressure sources.
•Toensureproperperformance,usequalifiedpersonneltoinstall,operate,update,program,
andmaintain the product.
•Whenreplacement partsarerequired, ensure thatqualifiedpeople usereplacementparts
specifiedby Emerson ProcessManagement(Rosemount Analytical). Unauthorizedparts
and procedures can affect the product’s performance, place the safe operation of your
processat risk, and VOIDYOUR WARRANTY.Look-alikesubstitutionsmay result infire,
electricalhazards, or improperoperation.
•Ensurethatall equipmentdoorsare closedandprotective coversarein place,except
when maintenance is being performed by qualified persons, to prevent electrical
shockand 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 Edition08/2005
©2003-2005 by Emerson Process Management

ATEX Instruction Manual
ETC01035
August2005 MLT 2 / BINOS®100 F
Emerson Process Management Manufacturing GmbH & Co. OHG P-1
PREFACE
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®®
®®
®100 F analyzers intended to be
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.
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.

MLT 2 / BINOS®100 F ATEX Instruction Manual
ETC01035
August2005
Emerson Process Management Manufacturing GmbH & Co. OHGP-2
NOTE
Highlights an essential operating
procedure, condition or statement.
Highlights an operation or
maintenance procedure,
practice, condition, state-
ment, etc. If not strictly
observed, could result in
injury, death, or long-term
health hazards of personnel.
Highlights an operation or
maintenance procedure,
practice, condition, state-
ment, etc. If not strictly
observed, could result in
damage to or destruction of
equipment, or loss of
effectiveness.
DEFINITIONS
The following definitions apply to WARNINGS, CAUTIONS and NOTES found
throughoutthispublication.

ATEX Instruction Manual
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August2005 MLT 2 / BINOS®100 F
Emerson Process Management Manufacturing GmbH & Co. OHG P-3
IMPORTANT
SAFETY INSTRUCTIONS
SAFETYSUMMARY
If this equipment is used in a manner not specified in these instructions, protective
systems may be impaired.
Before installing, operating or working at Products described in this
manual read this and all other related manuals!
DANGER TO LIFE !
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!
EXPLOSION HAZARD !
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.
DANGER TO LIFE !

MLT 2 / BINOS®100 F ATEX Instruction Manual
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Emerson Process Management Manufacturing GmbH & Co. OHGP-4
Safety Instructions
Products described in this manual shall not be supplied with explosive
gases!
EXPLOSION HAZARD !
AUTHORIZEDPERSONNEL
Toavoid 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.
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-intrinsicallysafe 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.
EXPLOSION HAZARD !

ATEX Instruction Manual
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August2005 MLT 2 / BINOS®100 F
Emerson Process Management Manufacturing GmbH & Co. OHG P-5
TERMSUSEDINTHISMANUAL
ATEX
Directive 94/9/EC, commonly called the
ATEX („Atmosphères Explosibles“)
productsdirective.
Area Classification
Zone 1
Where ignitable concentrations of
flammablegasescanexistsomeofthetime
undernormaloperating 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.
Zone 2
Where ignitable concentrations of
flammablegasesarenotlikelytoexistunder
normaloperatingconditions.
(Aguidelinevalue[notpartofastandard]is
lessthan 10 hoursper year.)
Equipment to be used in Zone 2 has to be
classified Category 3.
External Explosion Protection
The „External explosion protection“ serves
to prevent penetration of explosive gas
mixtures into the analyzer enclosure. In
additionit avoidsignitiononthesurface.For
this reason the analyzer is purged with
protective gas and held at an internal
overpressurecomparedto the surrounding
atmosphere.
Internal Explosion Protection
The„Internalexplosionprotection“servesto
prevent ignition of gas being present in the
analyzer’s Containment System (CS;
= sample gas path).
Dependentonthe gascompositionseveral
options are available:
•None required (if gas is noncom-
bustible),
•dilution by purge gas
and/or
•internaloverpressureof the analyzer’s
enclosure compared to the CS.
Containment System
Thepartof theanalyzer containingthegas
that may constitute an internal source of
release.
Explosion Protection
Lower Explosion Limit (LEL)
Volume ratio of flammable gas in air below
whichanexplosivegasatmospherewill not
be formed: the mixture of gas and air lacks
sufficientfuel(gas)to burn.
Upper Explosion Limit (UEL)
Volume ratio of flammable gas in air above
whichanexplosivegasatmospherewill not
be formed: the mixture of gas and air is too
richinfuel (deficient inoxygen)toburn.

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Emerson Process Management Manufacturing GmbH & Co. OHGP-6
Terms used in this manual
Dilution
The continuous supply of a protective gas,
after purging, at such a rate that the
concentrationofaflammablemixtureinside
the pressurized enclosure is maintained at
a value outside the explosive limits except
in a dilution area.
Pre-Purging
Thepre-purgingphaseservestoremoveany
combustible gas out of the analyzer’s
enclosureprior toswitchingontheanalyzer.
Flammable Gas(es)
Gasesandgasmixturesareassignedtobe
flammable if they might become ignitable
whenina mixture withair.
„Leakage Compensation“
InEExp „leakage compensationmode“just
as much protective gas is used to hold the
required overpressure compared to
atmospheric.
„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.
Protective Gas
Air or inert gas used for purging and
maintaining an overpressure and, if
required,dilution.
Pressurization modes

ATEX Instruction Manual
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August2005 MLT 2 / BINOS®100 F
Emerson Process Management Manufacturing GmbH & Co. OHG P-7

ATEX Instruction Manual
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August2005 MLT 2 / BINOS®100 F
Emerson Process Management Manufacturing GmbH & Co. OHG i - 1
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

ATEX Instruction Manual
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January2004 MLT 2 / BINOS®100 F
Emerson Process Management Manufacturing GmbH & Co. OHG 1- 1
SECTION 1
Technical Description
1-1 Application and Principle of Operation
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
„PressurizedEnclosure“EExp)theycanbe
installed and operated in hazardous areas
of Category 2 or Category 3.
Pressurization acts as external explosion
protectionand prevents externalexplosive
atmosphere to penetrate into the analyzer
byholdingtheenclosureatanoverpressure
comparedtothe 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:
•EExpwithcontinuous flow
and
•EEx p with leakage compensation.
Dependentonthesample gas composition
itmaybe necessarytotake care ofinternal
explosion protection which refers to the
sample gas path (containment system) in
theanalyzer.
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
belowthe lowerexplosivelimit!
•Flammable gases and gas mixtures
maybeanalyzedusingananalyzerwith
pressurization method „leakage
compensation“whenthesamplegasis
diluted below ¼ LEL outside the
analyzer, so the resulting sample gas
is to be categorized „nonflammable“.
Thedilutingsystemmustensurethatthe
gas in the containment system always
remains below ¼ LEL.
•Flammable gases and gas mixtures
maybeanalyzedusingananalyzerwith
pressurization method „leakage
compensation“ or „continuous flow“
when the analyzer enclosure has an
internal overpressure of > 50 Pa over
thepressureinthecontainmentsystem.
To ensure this condition a differential
pressureswitchisusedandconnected
between containment system and
analyzer enclosure. In case the
pressure decreases below the level of
50Pa theswitchisactivatedandforces
the purging unit to disconnect the
analyzerfromit’spowersupply.Ifmore
than one switch is needed because
more than one flammable gas is
suppliedtotheanalyzer,thecontactsof
these switches have to be connected
in series. Purge medium may be inert
gasorair.Flamearrestorsarerequired
for all gas inlets and outlets carrying
flammablegases.
•Explosive gases must not be
connected to the analyzer!

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1-2 Instrument Layout
1-2 Unused

ATEX Instruction Manual
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January2004 MLT 2 / BINOS®100 F
Emerson Process Management Manufacturing GmbH & Co. OHG 1- 3
1-3 Specification
1-3 Specification
1-3-2 Explosion Protection
Concepts:
Category 2 : Pressurized enclosure
(EEx p) with either leakage
compensation mode or
continuousflow
Category 3: Pressurized enclosure
(EEx p) using simplified
purge with either leakage
compensation mode or
continuousflow
Temperature class: T4
Options: Intrinsically safe (EEx i) digital,
analog, network or Foundation
Fieldbusoutputs.
Intrinsically safe (EEx i) para-
magneticOxygensensororther-
malconductivitysensor.
Applicable Standards:
EN 50014:1997 + amendments 1 & 2,
EN 50016:1995,
EN 50020:1994
Hazardous area: Zone 1 (Category 2)
or Zone2(Category3),
dependent on purge system
1-3-1 Installation Site

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1-3-3 Description of Pressurization Systems
1-3-43 Description of Pressurization Systems
An internal overpressure inside the pro-
tectedhousingpreventsouter (possibly ex-
plosive)atmosphereto enter.
Instrumentsintendedto be installedinZone
1are automaticallyprepurgedbeforepower
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
Zone1unitcontains a purgegas inletvalve
(proportional valve), a controller unit with
microprocessor and an outlet valve (high
pressure version only). The controller unit
permanentlymonitorsthe parameters (e.g.
prepurge phase, purge gas flow, internal
overpressure, and more) and therefore
ensuressafeoperation.Aseparateinstruc-
tion manual provides more detailled infor-
mation.
The Zone 1 system is available in two
differing variations due to different
requirementsformeasuringflammableand
non-flammablegases:
Measuring non-flammable gases:
The system provides an internal over-
pressure 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
isinstalled withinanygaspathtoensurethe
instrument‘soverpressureis always atleast
50Pa (0.5 mbar)above the pressurein the
containmentsystem.

ATEX Instruction Manual
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Depending on which system is used, diffe-
rentparametersapply:
Application Mode of Operation
Single Enclosure
(volume approx. 56 l)
Dual Enclosure (volume
approx. 112 l)
Zone 1 Prepurge Phase
for measuring Duration: 10 min 14 min
flammable gases Purge gas consumption: 1,75 Nm³/h 1,92 Nm³/h
maximum overpressure: 95 mbar 95 mbar
Measuring Mode
Internal overpressure: 90mbar 90 mbar
Flow rate (leakage rate): <= 3 l/min <= 4,5 l/min
Zone 1 Prepurge Phase
for measuring Duration: 4 min 6 min
non-flammable gases Purge gas consumption: 6,8 Nm³/h 9,2 Nm³/h
maximum overpressure: 25 mbar 25 mbar
Measuring Mode
Internal overpressure: 14 mbar 14 mbar
Flow rate (leakage rate): <= 3 l/min <= 4,5 l/min
Application Mode of Operation Single Enclosure (volume approx. 56 l)
Dual Enclosure (volume
approx. 112 l)
Zone 2 Prepurge Phase
for measuring Duration: 5 min 17 min
non-flammable gases Purge gas consumption: 8 Nm³/h 7 Nm³/h
maximum overpressure: 25 mbar 25 mbar
Measuring Mode
Internal overpressure: 1 mbar 1 mbar
Flow rate (leakage rate): <= 22Nm³/h <= 22 Nm³/h
Minimum overpressure in all enclosures:
•1 mbar against external atmosphere and
•50Pa againstcontainment system whenmeasuring flammablegases

MLT 2 / BINOS®100 F ATEX Instruction Manual
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Emerson Process Management Manufacturing GmbH & Co. OHG1- 6
1-3-4 Purge Gas Conditions
1-3-4 Purge Gas Conditions
Purge gas: • Inert gas (e.g. Nitrogen)
• Air(from an ex-freezone)
Temperature:As ambient, but min. 20 °C to 35 °C.
Inputpressureat
inlet of EEx p device: • 2.000 to 4.000 hPa (2 to 4 bar)
Medium has to be dry and free from
dust, oil, corrosive or aggressive
components!

ATEX Instruction Manual
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Emerson Process Management Manufacturing GmbH & Co. OHG 1- 7
1-3-5 Sample Gas Conditions
Applicable gases: Nonflammablegases or
gasmixtureswhichalways Flammable gases
remain below LEL
Maximumsample
gas pressure: atmospheric or atmospheric or
<1500 hPa at normal <1500 hPa at normal
atmosphericpressure, atmospheric pressure,
dependend on gas dependend on gas
measuringprinciple measuring principle
and overpressure < 85 mbar
(optional < 12 mbar)
againstsurroundingatmosphere
Sample gas flow: for all samplegases referto thecorresponding analyzerdata sheet
1-3-5 Sample Gas Conditions
1-3-6 Differential Pressure Monitoring
For analyzers connected to flammable gases (either sample gas or span gas) the operator
needstoensure thatthepressure within thecontainmentsystemalwaysremainsat minimum
50Pabelowthepressurewithinthe analyzer enclosure. Thisensures thatin caseof aleak the
flammablegasdoes notenterthe enclosure.
Anadditionaldifferentialpressure switch mustbeprovidedtomonitor the pressuredifference.
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.
Electricalandmechanical connectionsareshownin section2„Installation“.

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1-3-7 Equivalent Safety Devices
1-3-7 Equivalent Safety Devices
In principle it is possible to use other
equivalent pressurization systems as
described in this manual, as long as they
meetthefollowingrequirements:
•Device is ATEX approved
•Adjustablepre-purgephase
•Minimumpurgeflow rate:
7 Nm3/h resp. 8 Nm3/h
•Limited purge gas pressure during the
pre-purging phase: < 25 mbar
•Inputpressureforpurge gas supply:
2 ... 4 bar
•Relaycontactsforall-poledisconnection
oftheanalyzerfrompower supply
•Relay contacts for disconnecting additi-
onalexternalequipment
•Connectionfacilityforbypasskeyswitch,
providing intrinsically safe signal for
scanningthekeyswitch
•For units connected to flammable
gases, only:
Connection facility for differential
pressure switch, providing intrinsically
safesignal for scanningtheswitch
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!

ATEX Instruction Manual
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January2004 MLT 2 / BINOS®100 F
Emerson Process Management Manufacturing GmbH & Co. OHG 1- 9
1-4 Additional Safety Measures
•Exhaustgaslinesmustendoutsidethe
hazardousareaatasafepoint.Sample
gas lines may be returned to the
samplingpoint.
•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
detailedinformation.
1-4 Additional Safety Measures