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ATEX Instruction Manual

ETC01035
August 2005

MLT 2 / BINOS

®

100 F

Emerson Process Management Manufacturing GmbH & Co. OHG

A- 5

A-2-1

Category 2 Certificate

A-2

EC Type Examination Certificates

A-2-1 Category 2 Certificate

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Summary of Contents for Rosemount BINOS 100 F

Page 1: ...om Instruction Manual BINOS 100 F MLT 2 Addendum for Pressurized Analyzers intended to be used in Hazardous Areas Zone 1 All Versions Zone 2 Non Flammable Gases Only 4th Edition 08 2005 Instruction Manual ETC01035 08 2005 ...

Page 2: ...semount Analytical representative for clarification 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 specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes Connect a...

Page 3: ...X 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...

Page 4: ...rocedure 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 ...

Page 5: ...ts 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...

Page 6: ...opriate 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 or...

Page 7: ...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 composi...

Page 8: ...the analyzer s enclosure prior to switching on the analyzer Flammable Gas es Gases and gas mixtures are assigned to be flammable if they might become ignitable when in a mixture with air Leakage Compensation In EEx p leakage compensation mode 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 ga...

Page 9: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG P 7 ...

Page 10: ... 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 Ga...

Page 11: ...l 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...

Page 12: ...e 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 using an analyzer with pressurization method leakage compensation when the sample gas is diluted below LEL outside the analyzer so the resulting sample gas is to be categorized nonflammable Thedilutin...

Page 13: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 January 2004 Emerson Process Management Manufacturing GmbH Co OHG 1 2 1 2 Instrument Layout 1 2 Unused ...

Page 14: ...ategory 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 Hazardous a...

Page 15: ...portional valve a controller unit with microprocessor and an outlet valve high pressure version only The controller unit permanently monitors the parameters e g prepurge phase purge gas flow internal overpressure and more and therefore ensures safe operation Aseparate instruc tion manual provides more detailled infor mation The Zone 1 system is available in two differing variations due to differen...

Page 16: ... Zone 1 Prepurge Phase for measuring Duration 4 min 6 min non flammable gases Purge gas consumption 6 8 Nm h 9 2 Nm 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...

Page 17: ... OHG 1 6 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 2 000 to 4 000 hPa 2 to 4 bar Medium has to be dry and free from dust oil corrosive or aggressive components ...

Page 18: ...ntial 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 must be provided ...

Page 19: ...ction of the analyzer from power supply Relay contacts for disconnecting additi onal external equipment Connection facility for bypass key switch providing intrinsically safe signal for scanning the key switch For units connected to flammable gases only Connection facility for differential pressure switch providing intrinsically safe signal for scanning the switch It is recommended to order and us...

Page 20: ...s 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 4 Additional Safety Measures ...

Page 21: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 January 2004 Emerson Process Management Manufacturing GmbH Co OHG 1 10 ...

Page 22: ...ollowed 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 Take care to use anchors and bolts specified to be used for the weight of the units Take care the wall or stand the unit is intended to be inst...

Page 23: ...035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG 2 2 Fig 2 1a Single enclosure analyzer approx dimensions in mm Standard version w o purging system 2 3 Dimensional Drawings 2 3 1 Single Enclosure Analyzer 2 3 Dimensional Drawings ...

Page 24: ...100 F Emerson Process Management Manufacturing GmbH Co OHG 2 3 2 3 1 Single Enclosure Analyzer with category 2 EEx p system with category 3 EEx p system Standard Version Version increased pressure 2 1 Fig 2 1b Single enclosure analyzer approx dimensions in mm ...

Page 25: ...August 2005 Emerson Process Management Manufacturing GmbH Co OHG 2 4 Fig 2 2a Dual enclosure analyzer approx dimensions in mm Standard version w o purging system with category 3 purging system 2 3 2 Dual Enclosure Analyzer 2 3 2 Dual Enclosure Analyzer ...

Page 26: ...son Process Management Manufacturing GmbH Co OHG 2 5 with category 2 purging system Fig 2 2b Dual enclosure analyzer approx dimensions in mm 2 3 2 Dual Enclosure Analyzer Standard Ausführung Standard Version Ausführung erhöhter Innendruck Version increased pressure 2 1 ...

Page 27: ...fety device Flammable sample gas must not be supplied to the analyzer until the pre purging phase has ended 2 4 1 Hints on Flammable Gases When applying flammable gases either as sample gas or span gas the corresponding gas inlets and outlets must be equipped with flame arrestors To avoid internal release of flammable gases the minimum pressure specified for the pressurized enclosure is at least 5...

Page 28: ... Fig 2 3 Single and installed flame arrestors Installing Flame Arrestors Flame arrestors shipped together with the instrument are to be mounted to the gas fittings plate utilizing the associated steel pipes Up to 8 flame arrestors may be installed by aligning the as shown in fig 2 3 Take care of placing and fixing the swivel nuts correctly Untightened connections especially at the analyzer side of...

Page 29: ...1035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG 2 8 2 4 2 MLT 2 Gas Flow Diagrams 2 4 2 1 Gas Flow Diagram for Nonflammable Gases or Flammable Gases diluted below 1 4 LEL 2 4 2 MLT 2 Gas Flow Diagrams Fig 2 4a Gas Flow Diagram ...

Page 30: ...n Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG 2 9 2 4 2 MLT 2 Gas Flow Diagrams 2 4 2 2 Gas Flow Diagrams for Nondiluted Flammable Gases Fig 2 4b Gas Flow Diagram ...

Page 31: ...TEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG 2 10 2 4 2 MLT 2 Gas Flow Diagrams 2 4 2 2 Gas Flow Diagrams for Nondiluted Flammable Gases cont d Fig 2 4c Gas Flow Diagram ...

Page 32: ...NOS 100 F Emerson Process Management Manufacturing GmbH Co OHG 2 11 2 4 3 1 Gas Flow Diagram for Nonflammable Gases or Flammable Gases diluted below 1 4 LEL 2 4 3 BINOS 100 F Gas Flow Diagrams 2 4 3 BINOS 100 F Gas Flow Diagrams Fig 2 4d Gas Flow Diagram ...

Page 33: ...TEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG 2 12 2 4 3 2 Gas Flow Diagrams for Nondiluted Flammable Gases 2 4 3 BINOS 100 F Gas Flow Diagrams Fig 2 4e Gas Flow Diagram ...

Page 34: ...l ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG 2 13 2 4 3 BINOS 100 F Gas Flow Diagrams 2 4 3 2 Gas Flow Diagrams for Nondiluted Flammable Gases cont d Fig 2 4f Gas Flow Diagram ...

Page 35: ... Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG 2 14 2 4 3 BINOS 100 F Gas Flow Diagrams 2 4 3 2 Gas Flow Diagrams for Nondiluted Flammable Gases cont d Fig 2 4g Gas Flow Diagram ...

Page 36: ...y 2 Category 2 equipment is provided with a key switch which bypasses the purge system and switches off the automatic monitoring facility It is therefore also possible to switch on the pressurized system with the housing door open for setting work resp to keep the analyzer powered even if the front door is opened The use of this switch is intended for maintenance purposes only This facility should...

Page 37: ...n Use only shielded cables for signal lines To ensure proper electromagnetic compatibility EMC it is recommended to follow the installation steps given in section 2 7 1 Cables carrying intrinsically safe EEX i signals need adequate marking When running such cables take into consideration the requirements given in the related standards minimum distance to non IS cables etc If running in minimum dis...

Page 38: ...ent into the neck and fix the gland 2 7 2 Signal Inputs and Outputs Signal inputs and outputs by default are non intrinsically safe DIN rail installable converters option are available to provide intrinsically safe signals When the analyzer is out of order or if the pressurization unit shuts off all non intrinsically safe inputs and outputs connected to external equipment MUST be shut off too This...

Page 39: ...quipment Mains Connection 2 7 2 Category 2 Equipment The mains power line cord has to be connected to the pressurization control unit terminals 16 18 and PE fig 2 4 Fig 2 5 Terminal location inside control unit Terminal 16 Terminal 18 PE terminal Verify that the mains voltage at the point of installation meets the analyzer nominal voltage ...

Page 40: ...ction 2 7 3 Category 3 Equipment Mains Connection The mains power line cord has to be connected to the terminals provided at the analyzer enclosure s inner left side near the EMC line filter fig 2 5 Fig 2 6 Terminal location inside analyzer Terminals EMC line filter Verify that the mains voltage at the point of installation meets the analyzer nominal voltage ...

Page 41: ...e inside the analyzer enclosure is outside the limits This alarm loop operates in normally closed connection mode The contacts are allowed to be connected to signal circuitry amplifier relay providing output signals according NAMUR EN 50227 resp EEx ib IIC only The standard specifies all essential data and operating conditions Consult factory for applicable circuitry which is available from variou...

Page 42: ...on system have been setup as described in section 2 and all covers and doors are closed and fixed All unused cable glands need to be sealed using the supplied approved sealing plug part no ETC00791 fig 3 1 Unused cable gland openings in the enclosure need to be covered using a specialscrew partno ETC000790 fig 3 2 Fig 3 1 Cable gland sealing plug Fig 3 2 Cable gland hexagon socket screw sealing pl...

Page 43: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 January 2004 Emerson Process Management Manufacturing GmbH Co OHG 3 2 ...

Page 44: ...to be taken for the EEx p saftey device and parts ensuring explosion protection e g gaskets It is the operators owners responsibility to extend the maintenance interval with respect to negative influences of gases or environment on materials in contact with the sample gas or ensuring explosion protection e g gaskets 4 1 Maintenance Interval 4 2 Gasanalyzer Refer to the associated manual for detail...

Page 45: ...n unit from power Seal the purge medium outlet at the pressurization unit 1 opening at the left side Disconnect the containment system gas connectors from the external gas lines Disconnect one of the containment system gas connectors inside the analyzer and seal the other one Remark Now it must be possible set the enclosure under pressure by applying an external gas e g compressed air to the gas c...

Page 46: ...tisfacotry if the measured value is acceptable compared to the following values Acceptable flow values are singleanalyzer 3l minutemaximum dualanalyzer 4 5l minutemaximum 4 4 1 2 Overpressure Test A pressure of 37 5 mbar 1 5 times the maximum overpressure specified has to be applied to the pressurized enclosure To do this the following has to be performed Carefully apply a pressure of 37 5 mbar to...

Page 47: ...he other one Remark Now it must be possible set the enclosure under pressure by applying an external gas e g compressed air to the gas connector Connect an external source of compressed air as described in the drawing on the next page fig 4 2 4 4 2 System with 90 mbar Operating Pressure Required tools Manometer with full scale between 150 and 200 mbar and resolution of 0 1 mbar Flow meter with ful...

Page 48: ...tisfacotry if the measured value is acceptable compared to the following values Acceptable flow values are singleanalyzer 3l minutemaximum dualanalyzer 4 5l minutemaximum 4 4 2 2 Overpressure Test A pressure of 143 mbar 1 5 times the maximum overpressure specified has to be applied to the pressurized enclosure To do this the following has to be performed Carefully apply a pressure of 37 5 mbar to ...

Page 49: ... August 2005 Emerson Process Management Manufacturing GmbH Co OHG 4 6 4 4 3 Removal of Modifications Remove all the modifications described in section 4 4 1 resp 4 4 2 Take special care of the gas connections to be tightend 4 4 Verifications and Tests ...

Page 50: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 1 APPENDIX A 1 EC Declarations of Conformity ...

Page 51: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 2 A 1 EC Declarations of Conformity ...

Page 52: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 3 A 1 EC Declarations of Conformity ...

Page 53: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 4 A 1 EC Declarations of Conformity ...

Page 54: ...nstruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 5 A 2 1 Category 2 Certificate A 2 EC Type Examination Certificates A 2 1 Category 2 Certificate ...

Page 55: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 6 A 2 1 Category 2 Certificate ...

Page 56: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 7 A 2 1 Category 2 Certificate ...

Page 57: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 8 A 2 1 Category 2 Certificate ...

Page 58: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 9 A 2 1 Category 2 Certificate ...

Page 59: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 10 A 2 2 Category 3 Certificate ...

Page 60: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 11 A 2 2 Category 3 Certificate ...

Page 61: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 12 A 2 2 Category 3 Certificate ...

Page 62: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 13 A 2 2 Category 3 Certificate ...

Page 63: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 14 A 2 2 Category 3 Certificate ...

Page 64: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 15 A 3 Circuit Diagrams A 3 1 MLT 2 single A 3 Circuit Diagrams ...

Page 65: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 16 A 3 1 MLT 2 Circuit Diagrams ...

Page 66: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 17 A 3 1 MLT 2 Circuit Diagrams ...

Page 67: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 18 A 3 1 MLT 2 Circuit Diagrams ...

Page 68: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 19 A 3 2 MLT 2 dual A 3 2 MLT 2 Circuit Diagrams ...

Page 69: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 20 A 3 2 MLT 2 Circuit Diagrams ...

Page 70: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 21 A 3 2 MLT 2 Circuit Diagrams ...

Page 71: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 22 A 3 2 MLT 2 Circuit Diagrams ...

Page 72: ...ATEX Instruction Manual ETC01035 August 2005 MLT 2 BINOS 100 F Emerson Process Management Manufacturing GmbH Co OHG A 23 A 3 2 BINOS 100 F Circuit Diagrams A 3 3 BINOS 100 F ...

Page 73: ...MLT 2 BINOS 100 F ATEX Instruction Manual ETC01035 August 2005 Emerson Process Management Manufacturing GmbH Co OHG A 24 A 3 2 BINOS 100 F Circuit Diagrams ...

Page 74: ...nada 800 433 6076 F 440 914 1271 e mail gas csc EmersonProcess com www raihome com GAS CHROMATOGRAPHY CENTER AND LATIN AMERICA Emerson Process Management Rosemount Analytical Inc 11100 Brittmoore Park Drive Houston TX 77041 T 713 467 6000 F 713 827 3329 EUROPE MIDDLE EAST AND AFRICA Emerson Process Management Shared Services Limited Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 8...

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