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
Hazardous Areas classified Zone 2
3rd Edition 08/2004
Instruction Manual
HAS8xE-IM-ATEX
08/2004

BINOS 100 F & MLT 2 Addendum for Zone 2 InstructionManual
HAS8XE-IM-ATEX
08/2004
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-alike substitutionsmayresult 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 11/2003 2nd Edition 01/2004
3rd Edition 08/2004
©2003-2004 by Emerson Process Management

ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004 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, classified Zone 2, to
measure FLAMMABLE, but NON-EXPLOSIVE gases or gas mixtures.
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
HAS8xE-IM-ATEX
January 2004
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,
statement, 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,
statement, etc. If not strictly
observed, could result in
damage to or destruction of
equipment, or loss of
effectiveness.
The following definitions apply to WARNINGS, CAUTIONS and NOTES found
throughout this publication.
DEFINITIONS

ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004 MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG P - 3
IMPORTANT
SAFETY INSTRUCTIONS
SAFETY SUMMARY
If this equipment is used in a manner not specified in these instructions, protective
systems may be impaired.
AUTHORIZED PERSONNEL
To avoid loss of life, personal injury and damage to this equipment and on-site property,
do not operate or service this instrument before reading and understanding this
instruction manual and receiving appropriate training.
SAVE THESE INSTRUCTIONS.
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.
PRODUCTS DESCRIBED IN THIS MANUAL SHALL NOT BE
SUPPLIED WITH EXPLOSIVE GASES!

MLT 2 / BINOS100 F
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
Emerson Process Management Manufacturing GmbH & Co. OHGP - 4
TERMS USED IN THIS MANUAL
ATEX
Directive 94/9/EC, commonly called the
ATEX („Atmosphères Explosibles“)
products directive.
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.
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.
Containment System
The part of the analyzer containing the gas that may constitute an internal source of release.
Lower Explosion Limit (LEL)
Volume ratio of flammable gas in air below
which an explosive gas atmosphere will not
be formed: the mixture of gas and air lacks
sufficient fuel (gas) to burn.
Upper Explosion Limit (UEL)
Volume ratio of flammable gas in air above
which an explosive gas atmosphere will not
be formed: the mixture of gas and air is too
rich in fuel (deficient in oxygen) to burn.
Area Classification
Zone 1
Where ignitable concentrations of
flammable gases can exist some of the time
under normal operating conditions.
(A guideline value [not part of a standard ]
is 10 to 1.000 hours per year.)
Equipment to be used in Zone 1 has to be
classified Category 2.
Zone 2
Where ignitable concentrations of
flammable gases are not likely to exist under
normal operating conditions.
(A guideline value [not part of a standard ] is
less than 10 hours per year.)
Equipment to be used in Zone 2 has to be
classified Category 3.
Explosion Protection

ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004 MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG P - 5
Terms used in this manual
Dilution
The continuous supply of a protective gas,
after purging, at such a rate that the
concentration of a flammable mixture inside
the pressurized enclosure is maintained at
a value outside the explosive limits except
in a dilution area.
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.
Flammable Gas(es)
Gases and gas mixtures are assigned to be
flammable if they might become ignitable
when in a mixture with air.
Pressurization 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.
Pressurization mode „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
Explosive Gas(es)
Gases and gas mixtures are assigned to be
explosive if they consist of a flammable gas
in a mixture with air and the concentration is
inbetween the explosive limits.

MLT 2 / BINOS100 F
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
Emerson Process Management Manufacturing GmbH & Co. OHGP - 6

ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004 MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG i - 1
TABLE OF CONTENTS
Preface P-1
Definitions ..................................................................................................................... P-2
Safety Instructions ...................................................................................................... P-3
Terms used in this manual ........................................................................................... P-4
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 Pressurization Conditions ................................................................................... 1-3
1-3-4 Purge Gas Conditions ........................................................................................ 1-4
1-3-5 Sample Gas Conditions ..................................................................................... 1-5
1-3-6 Differential Pressure Monitoring ......................................................................... 1-5
1-4 Additional Safety Measures ............................................................................ 1-6
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 ................................................................................ 2-7
2-4-2 MLT 2 Gas Flow Diagrams ................................................................................. 2-8
2-4-3 BINOS®100 F Gas Flow Diagrams .................................................................. 2-10
2-5 Safety Device Settings .................................................................................. 2-13
2-6 Special Remarks and Instructions ............................................................... 2-13
2-7 Electrical Connections .................................................................................. 2-14
2-7-1 Cable Gland Assembly Instruction for Shielded Cables ..................................... 2-14
2-7-2 Mains Connection............................................................................................. 2-15
2-7-2-1 Purge System .................................................................................................. 2-15
2-7-2-2 Analyzer ........................................................................................................... 2-17
2-7-3 Pressurization System Alarm Contacts ............................................................. 2-17
2-7-4 Differential Pressure Switch(es) ....................................................................... 2-18

MLT 2 / BINOS100 F
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
Emerson Process Management Manufacturing GmbH & Co. OHGi - 2
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 ........................... 4-2
4-4 Verifications and Tests on Modified or Repaired Electrical Apparatus ....... 4-2
4-4-1 Preparations ...................................................................................................... 4-2
4-4-2 Overpressure Test .............................................................................................. 4-3
4-4-3 Leakage Test ..................................................................................................... 4-3
4-4-4 Removal of Modifications ................................................................................... 4-4
APPENDIX A-1
A-1 Declarations ..................................................................................................... A-1
A-2 Circuit Diagrams .............................................................................................. A-3
A-2-1 MLT 2, single ...................................................................................................... A-3
A-2-2 MLT 2, dual ......................................................................................................... A-7
A-2-3 BINOS®100 F .................................................................................................. A-11