Emerson Rosemount MLT 2 Quick start guide

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
itsproductstomeetmanynationalandinternationalstandards.Becausetheseinstruments
are sophisticated technical products, you MUST properly install, use, and maintain
them to ensure they continue to operate within their normal speci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 clari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 speci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 qualied personnel to install, operate, update,
program, and maintain the product.
• When replacement parts are required, ensure that qualied people use replacement
parts speci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 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 qualied 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 [phone]
F [phone]
Internet: www.EmersonProcess.com
Original Instruction Manual for the purpose
of the European Directive 94/9/EC.

TOC-1Emerson Process Management GmbH & Co. OHG
1 Techn. Description
MLT 2 / BINOS100 F
ATEX Instruction Manual
ETC01035
02/2008
Ta b l e o f Co n T e n T s
PREAMBLE ..........................................................................................................................S-1
Denitions............................................................................................................................S-1
Symbols on or inside the instrument................................................................................S-2
Symbols used in this manual.............................................................................................S-3
Terms used in this manual .................................................................................................S-4
Safety instructions..............................................................................................................S-6
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
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 Nonammable 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 Nonammable 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-2 Emerson Process Management GmbH & Co. OHG
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 Modications..............................................................................4-5
4.3 Tests after Modication 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 Modications..............................................................................4-7
4.4 Troubleshooting.....................................................................................................4-8
4.4.1 Pressurization System Not Activated ..................................................................4-8
MLT 2 / BINOS100 F
ATEX Instruction Manual
ETC01035
02/2008
Table of Contents

TOC-3Emerson Process Management GmbH & Co. OHG
1 Techn. Description
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 Certicate..........................................................................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
ETC01035
02/2008
Table of Contents

TOC-4 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS100 F
ATEX Instruction Manual
ETC01035
02/2008
Table of Contents

S-1Emerson Process Management GmbH & Co. OHG
Safety Instructions
MLT 2 / BINOS100 F
ATEX Instruction Manual
ETC01035
02/2008
This instruction manual provides information about installing, operating and maintai-
ning/servicing pressurized BINOS100 F and MLT 2 series gas analyzers in hazardous
(classied) areas and shall be read in conjunction with the standard analyzer instruction
manual only!
This instruction manual covers BINOS100F andMLT2seriesgasanalyzersvariationsand
therefore may describe congurations and/or options not part of your specic analyzer.
The following denitions apply to WARNINGS, CAUTIONS and NOTES found throughout
this publication.
NOTE
Highlights an essential operating procedure, condition or statement.
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.
DEFINITIONS
PREAMBLE

S-2 Emerson Process Management GmbH & Co. OHG
MLT 2 / BINOS100 F
ATEX Instruction Manual
ETC01035
02/2008
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 per-
sonnel when power is removed from the equip-
ment. Certain surfaces may remain hot to the
touch.
more detailled information and instructions are
required and available: Read the instruction
manuals.
SYMBOLS ON OR INSIDE THE INSTRUMENT

S-3Emerson Process Management GmbH & Co. OHG
Safety Instructions
MLT 2 / BINOS100 F
ATEX Instruction Manual
ETC01035
02/2008
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
electronicscomponentssensitiveto electrostatic
discharge
when it is necessary to disconnect equipment
from mains
essential procedures or conditions to be obser-
ved.
Also this symbol may mark an important state-
ment to ensure proper measuring conditions.
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!

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.
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.
Containment System
The part of the analyzer containing the gas
that may constitute an internal source of re-
lease.
Flammable Gas(es)
Gases and gas mixtures are assigned to be
ammable if they might become ignitable
when in a mixture with air.
Area Classication
Zone 1
Where ignitable concentrations of ammable
gases can exist some of the time under nor-
mal 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
classied 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
classied Category 3.
External Explosion Protection
The„External explosionprotection“ servesto
prevent penetration of explosive gas mixtu-
res into the analyzer enclosure. In addition it
avoidsignitiononthesurface.Forthisreason
theanalyzerispurgedwithprotectivegasand
held at an internal overpressure compared to
the surrounding atmosphere.
Explosive Gas(es)
Flammable gases and gas mixtures of a
concentration within the explosion limits and
present in mixture with air.