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

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG 1 - 1
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
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 approbriate certified
purge system (protection method
„Pressurized Enclosure“ EEx 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:
•EEx p with continuous flow
and
•EEx p with leakage compensation.
Dependent on the sample gas composition
it may be necessary to take care of internal
explosion protection which refers to the
sample gas path (containment system) in
the analyzer.
One of the following protection methods is
used:
•Nonflammable gases and gas
mixtures below the LEL: It must be
ensured that the sample gas in the
containment system always remains
below the lower explosive limit!
•Flammable gases and gas mixtures
may be analyzed 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 when the analyzer
enclosure has an internal overpressure
of > 50 Pa over the pressure in the
containment system. To ensure this
condition a differential pressure switch
is used and connected between
containment system and analyzer
enclosure. In case the pressure
decreases below the level of 50 Pa the
switch is activated and may be used to
activate an alarm or analyzer shut-off.
If more than one switch is needed
because more than one flammable 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. Flame arrestors are required
for all gas inlets and outlets carrying
flammable gases.
•Explosive gases must not be
connected to the analyzer!

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG1 - 2
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
1-2 Instrument Layout
1-2 Unused

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG 1 - 3
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
1-3 Specification
1-3 Specification
1-3-2 Explosion Protection
Concepts:
Category 3: Pressurized enclosure
(EEx p) using simplified
purge with either leakage
compensation mode or
continuous flow
Temperature class: T4
Options: Intrinsically safe (EEx i) digital,
analog, network or Foundation
Fieldbus outputs.
Intrinsically safe (EEx i) para-
magnetic Oxygen sensor or ther-
mal conductivity sensor.
Applicable Standards:
EN 50014:1997 + amendments 1 & 2,
EN 50016:1995,
EN 50020:1994
1-3-3 Pressurization Conditions
Volume of pressurized enclosure:
single enclosure: approx. 56 l
dual enclosure: approx. 112 l
Pre-purge phase:
Duration:
single enclosure: 5 minutes
dual enclosure: 17 minutes
Flow of protective gas:
single enclosure: 8 Nm³/h
dual enclosure: 7 Nm³/h
Minimum overpressure during
operation:
1 mbar against external Ex Zone and
>50 Pa against Containment System if
flammable gases are supplied.
Hazardous area: Zone 2 (Category 3),
1-3-1 Installation Site

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG1 - 4
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
1-3-4 Purge Gas Conditions
1-3-4 Purge Gas Conditions
Purge gas: • Inert gas (e.g. Nitrogen)
• Air (from an ex-free zone)
Temperature: As ambient, but min. 20 °C to 35 °C.
Input pressure at
inlet of EEx p device: • 3,000 to 4,000 hPa (3 to 4 bar)
Minimum internal
overpressure of
the enclosure: • 1 mbar
Maximum internal
overpressure of
the enclosure: • 25 mbar
Pre-purging phase Single enclosure analyzer Dual enclosure analyzer
Duration of
pre-purging phase: 5 min. 17 min.
Flow rate during
pre-purging phase: 8 Nm³/h 7 Nm³/h
(= 133.4 l/min.) (= 117 l/min.)
Flow rate during
pre-purging phase 22 Nm³/h 22 Nm³/h
(@ 25 mbar overpressure): (= 367 l/min.) (= 367 l/min.)
Medium has to be dry and free from
dust, oil, corrosive or aggressive
components!

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG 1 - 5
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
1-3-5 Sample Gas Conditions
Applicable gases: Nonflammable gases or
gas mixtures which always Flammable gases
remain below LEL
Maximum sample
gas pressure: atmospheric or atmospheric or
<1500 hPa at normal <1500 hPa at normal
atmospheric pressure, atmospheric pressure,
dependend on gas dependend on gas
measuring principle measuring principle
and
overpressure < 13 mbar
against surrounding atmosphere
Sample gas flow: for all sample gases refer to the corresponding analyzer data 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
needs to ensure that the pressure within the containment system always remains at minimum
50 Pa below the pressure within the analyzer enclosure. This ensures that in case of a leak the
flammable gas does not enter the enclosure.
An additional differential pressure switch is provided to monitor the pressure difference:
In case the pressure difference decreases below 50 Pa the contact opens.
It is the user’s responsiblity how to use the signal within his system:
The limit of 50 Pa is the least permissible value given by the standards, higher values are
acceptable, too.
Flame arrestors are required for gas inlets and outlets.
Electrical and mechanical connections are shown in section 2 „Installation“.

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG1 - 6
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
1-4 Additional Safety Measures
•Exhaust gas lines must end outside the
hazardous area at a safe point. Sample
gas lines may be returned to the
sampling point.
•If gas exhaust lines end within the
hazardous area gas inlet and outlet
have to be equipped with flame
arrestors.
•The maximum permissible gas
pressure depends on the type of
connected gas. See section 1-3-5 for
detailed information.
1- Additional Safety Measures

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG 2 - 1
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
SECTION 2
Installation
Before starting to install this equipment, read the corresponding sections of the
analyzer’s instruction manual and the manuals of the additional equipment!
Failure to follow the safety instructions could result in serious injury or death.
2-1 General
Proper functioning of the Emerson Process
Management gas analyzers depends on
proper installation. All procedures in this
section, in the corresponding sections of the
analyzer instruction manual and the manuals
of the attached safety devices must be
followed carefully.
2-2 Installation of the Unit
Install the assembled unit as described in
the analyzer’s instruction manual: Refer to
the dimensional drawings in this manual
(fig. 2-1a/b and 2-2a/b) to ensure the
designated location is dimensioned
sufficiently.
The weight of an assembled unit may be up
to approx. 40 kg incl. pressurization system.
Take care to use anchors and
bolts specified to be used for
the weight of the units!
Take care the wall the unit is
intended to be installed at is
solid and stable to hold the
units!

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG2 - 2
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
Fig. 2-1a
Single enclosure analyzer (dimensions in mm)
Standard version w/o pressurization system
2-3 Dimensional Drawings
2-3-1 Single Enclosure Analyzer
2-3 Dimensional Drawings

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG 2 - 3
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
with Category 3 pressurization system
Fig. 2-1b
Single enclosure analyzer (dimensions in mm)
2-3-1 Single Enclosure Analyzer

MLT 2 / BINOS100 F
Emerson Process Management Manufacturing GmbH & Co. OHG2 - 4
ATEX Instruction Manual
HAS8xE-IM-ATEX
January 2004
Fig. 2-2a
Dual enclosure analyzer (dimensions in mm)
Standard version w/o pressurization system
2-3-2 Dual Enclosure Analyzer
2-3-2 Dual Enclosure Analyzer