Instruction/ maintenance manual of the product HYDROS 100 Emerson Process Management
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Instruction Manual ETC00781 February 2004 Series 100 Gas Analyzers BINOS ® 100, BINOS ® 100 M BINOS ® 100 2M, BINOS ® 100 F OXYNOS ® 100, HYDROS ® 100 www.
ESSENTIAL INSTRUCTIONS READ THIS P AGE BEFORE PROCEEDING! Emerson Process Management (Rosemount Analytical) designs, manufactures and tests its products to meet many national and international standards.
SAFETY SUMMARY S - 1 ETC00781(4) Series 100 e 02/2004 Safety Summary I. Intended Use Statement The series 100 instr uments are intended for use an industrial measurement de vice only .
SAFETY SUMMARY S - 2 ETC00781(4) Series 100 e 02/2004 GENERAL III. General X T o a void e xplosion, loss of life , personal injur y and damages to this equipment and other proper ty , all personnel au.
SAFETY SUMMARY S - 3 ETC00781(4) Series 100 e 02/2004 GENERAL / GASES AND GAS CONDITIONING (SAMPLE HANDLING) Do not open instrument when energized ! Component replacement and inter nal adjustments req.
SAFETY SUMMARY S - 4 ETC00781(4) Series 100 e 02/2004 GASES AND GAS CONDITIONING (SAMPLE HANDLING) / SUPPLY VOLTAGE I V . Gases and Gas Conditioning (Sample Handling) Be sure to observe the safety reg.
SAFETY SUMMARY S - 5 ETC00781(4) Series 100 e 02/2004 X BINOS ® 100 2M (internal PS) and BINOS ® 100 F are Safety Class 1 instruments The analyzer is pro vided with a protective ear th ter minal. T o pre vent shoc k hazard, the instr ument chassis and cabinet must be connected to an electrical ground.
SAFETY SUMMARY S - 6 ETC00781(4) Series 100 e 02/2004 VI . Analyzer specific notes for the user The installation site for the instrument has to be dry and remain above freezing point at all times. The instrument must be exposed neither to direct sunlight nor to strong sources of heat.
SAFETY SUMMARY S - 7 ETC00781(4) Series 100 e 02/2004 VII. BINOS ® 100 F specific notes for use in hazardous areas (EX Zones) Be sure to observe the additional notes, safety precautions and warnings given in the supplemental manual for analyzers intended to be used in hazardous areas.
SAFETY SUMMARY S - 8 ETC00781(4) Series 100 e 02/2004 VIII. Additional notes for service / maintenance Do not open instrument when energized ! Component replacement and internal adjustments requires s.
SAFETY SUMMARY S - 9 ETC00781(4) Series 100 e 02/2004 VIII.a Electrostatic Discharge The electronic par ts of the analyzer can be irreparab ly damaged if e xposed to e lectro s tatic d ischarge (ESD). The instr ument is ESD protected when the cov ers hav e been secured and saf ety precautions obser v ed.
SAFETY SUMMARY S - 10 ETC00781(4) Series 100 e 02/2004 IX . Operating Conditions according to DMT Approval (The f ollowing is a reprint of chapter 6 of the supplement I to the DMT repor ts “IBS/PFG-No .
SAFETY SUMMARY S - 11 ETC00781(4) Series 100 e 02/2004 X The intervals for the periodical tests must be settled by the person being responsible for the system´s security and in accordance with the Code of Pratice No.
SAFETY SUMMARY S - 12 ETC00781(4) Series 100 e 02/2004 X The analyzer housings must be provided with a permanent type plate indicating the name of the manufacturer , model number , serial number , and the following reference and date of testing: "IBS/PFG-Nr .
SAFETY SUMMARY S - 13 ETC00781(4) Series 100 e 02/2004 OPERATING CONDITIONS ACCORDING TO DMT APPROVAL.
SAFETY SUMMARY S - 14 ETC00781(4) Series 100 e 02/2004.
P - 1 PREFACE ETC00781(4) Series 100 e 02/2004 PREF ACE General Overview The ser ies 100 of analyz ers offers multi-component, m ulti-method analysis. Different measure- ment methods can be combined in one analyzer .
P - 2 PREFACE ETC00781(4) Series 100 e 02/2004 b) Housing Versions Different housing v ersions are deliv ered (for detailed inf or mations see price list): BINOS ® 100 = 1/4 19" housing, ext. PS one or tw o IR channel BINOS ® 100 M = 1/4 19" housing, ext.
P - 3 PREFACE ETC00781(4) Series 100 e 02/2004 Area Classification a) General Purpose All analyzer components are installed into a 1/4 19" housing (BINOS ® 100 (M), O XYNOS ® 100, HYDROS ® 100) or a 1/2 19" enclosure (BINOS ® 100 2M), 3 height units .
P - 4 PREFACE ETC00781(4) Series 100 e 02/2004.
CONTENTS I ETC00781(4) Series 100 e 02/2004 T able of Content s SAFETY SUMMAR Y S - 1 I . Intended Use Statement S - 1 I I . Safety Symbols S - 1 III. General S - 2 V. Supply Voltage S - 4 VI . Analyzer specific notes for the user S - 6 VII. BINOS® 100 F specific notes for use in hazardous areas (EX Zones) S - 7 VII.
CONTENTS II ETC00781(4) Series 100 e 02/2004 2. MEASURING PRINCIPLE 2 - 1 2.1 IR Measurement 2 - 1 2.1.1 Interference Filter Correlation (IFC Principle) 2 - 1 2.1.2 Opto-Pneumatic Measuring Principle 2 - 3 2.1.3 Technique 2 - 5 2.2 Oxygen Measurement 2 - 6 2.
CONTENTS III ETC00781(4) Series 100 e 02/2004 6. SWITCHING ON 6 - 1 6. 1 General 6 - 1 6.2 24 V DC Supply 6 - 2 6.3 230/120 V AC Supply 6 - 2 6.3.1 BINOS® 100 2M 6 - 4 6.3.2 BINOS® 100 F 6 - 5 7. KEY FUNCTIONS 7 - 1 7 .1 FUNCTION 7 - 2 7 . 2 ENTER 7 - 4 7.
CONTENTS IV ETC00781(4) Series 100 e 02/2004 9. CALIBRA TION 9 - 1 9.1 Manual Calibration 9 - 2 9.1.1 Zeroing 9 - 2 9.1.2 Spanning 9 - 4 9.2 Time-Controlled Calibration Mode (Option) 9 - 7 9.2.1 Zeroing 9 - 7 9.2.2 Combined Zeroing and Spanning 9 - 9 9.
CONTENTS V ETC00781(4) Series 100 e 02/2004 13. DIGIT AL INPUTS / FOUNDA TION ™ FIELDBUS (BINOS ® 100 2M/F OPTION ONL Y) 13 - 1 13.1 Digital Inputs 13 - 1 13.1.1 General 13 - 1 13.1.2 Start of Calibration 13 - 1 13.1.3 Valve Control 13 - 2 13.1.4 Pump Control 13 - 2 13.
CONTENTS VI ETC00781(4) Series 100 e 02/2004 18. PLUG PIN ALLOCA TION OF PRINTED CIRCUIT BOARDS 18 - 1 18.1 Plug Pin Allocation of BKS 18 - 1 18.1.1 IR measurement without oxygen channel 18 - 2 18.1.2 Oxygen Measurement without IR channel 18 - 2 18.1.
CONTENTS VII ETC00781(4) Series 100 e 02/2004 24.6.2 Sealed Photometer (Option) 24 - 8 25. CHECKING / REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 1 25.1 Checking the Sensor 25 - 2 25.2 Replacing the Sensor 25 - 3 25.2.1 Remove the old Sensor 25 - 3 a) Oxygen Measurement without IR - channel 25 - 3 b) IR / Oxygen Measurement combined 25 - 5 25.
CONTENTS VIII ETC00781(4) Series 100 e 02/2004.
CONTENTS IX ETC00781(4) Series 100 e 02/2004.
CONTENTS X ETC00781(4) Series 100 e 02/2004.
1 - 1 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 1. T echnical Description The different analyzers are based on the same internal main components and differ only by available options and enclosures.
1 - 2 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-1: BINOS ® 100 (M), OXYNOS ® 100, HYDROS ® 100 Front view 1 LED display (channel 1) 2 LED display (channel 2) 4 Input setting con.
1 - 3 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-2: BINOS ® 100 2M (standard version), front view 1 LED display (channel 1) 2 LED display (channel 2) 3 Function LED for options &qu.
1 - 4 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-3: BINOS ® 100 F, front view FRONT VIEW Fig. 1-4: BINOS ® 100 F magnetically operated front panel , impact tested, front view Front panel Fastener front panel Wall mounting holder Operation front panel Fig.
1 - 5 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 REAR PANEL *) not in combination with FOUNDATION ™ Fieldbus **) BINOS ® 100 2M with external power supply only ***) not in combination with RS 232/485 interface 1.
1 - 6 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-5: BINOS ® 100 (M), OXYNOS ® 100 (EO 2 ), HYDROS ® 100, Rear view 1 Gas inlet line fittings 2 Analog signal output mating socket .
1 - 7 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-6: OXYNOS ® 100 (PO 2 ), Rear view 1 Gas inlet line fittings 2 Analog signal output mating socket 3 24 VDC supply input terminal 4 .
1 - 8 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-7: BINOS ® 100 2M, version A (shown with internal power supply) , Rear view with all options 1 Gas inlet line fitting 22 nd gas inl.
1 - 9 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-8: BINOS ® 100 2M, version B (with external power supply), Rear view with all options 1 Gas inlet line fitting 22 nd gas inlet line.
1 - 10 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 REAR PANEL Fig. 1-9: BINOS ® 100 2M (special version) , Rear view with all options 1 Gas inlet line fitting channel 1 2 Gas inlet line fi.
1 - 11 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 1.3 Internal Construction The analyzers includes the f ollowing components: R Depending on analyzer configuration - one or two IR photomet.
1 - 12 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-10: Inside View BINOS ® 100 (1 IR channel analyzer, high measuring range with gas detector) INTERNAL CONSTRUCTION Gas line fitting.
1 - 13 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-11: Inside View BINOS ® 100 M (IR channel / electrochemical oxygen measurement) INTERNAL CONSTRUCTION Gas line fittings PCB BKS Co.
1 - 14 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-12: OXYNOS ® 100, Inside View with paramagnetic sensor INTERNAL CONSTRUCTION Security dust filter PCB BKS O 2 sensor Heat exchange.
1 - 15 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Front panel Fig. 1-13: OXYNOS ® 100, Inside view with electrochemical sensor INTERNAL CONSTRUCTION Security dust filter Gas line fittings.
1 - 16 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Front panel Fig. 1-14: HYDROS ® 100, Inside view INTERNAL CONSTRUCTION Gas line fittings PCB BKS PCB WAP 100 Thermal conductivity sensor .
1 - 17 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-15: Inside View dual-channel BINOS ® 100 2M (version A) (IR channel / oxygen measurement, combined) INTERNAL CONSTRUCTION Circuit .
1 - 18 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-16: Inside View BINOS ® 100 2M (version A) (1 channel oxygen measurement, electrochemical) INTERNAL CONSTRUCTION (Channel 1) Circu.
1 - 19 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-17: Inside View dual-channel BINOS ® 100 2M (version A) (IR / EO 2 , TC / EO 2 or IR / TC measurement, combined) INTERNAL CONSTRUC.
1 - 20 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-18: Inside View dual-channel BINOS ® 100 2M (version A) (oxygen measurement (paramagnetic) / thermal conductivity measurement, com.
1 - 21 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-19: Inside View dual-channel BINOS ® 100 2M (version B) (IR channel / oxygen measurement, combined) INTERNAL CONSTRUCTION (Channel.
1 - 22 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-20: Inside view dual-channel BINOS ® 100 2M w. external P/S (here: version for CAT) (parmagnetic oxygen measurement & thermal .
1 - 23 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-21: Inside View dual-channel BINOS ® 100 2M (special version) (two gas sampling pumps and two solenoid valve blocks) INTERNAL CONS.
1 - 24 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 INTERNAL CONSTRUCTION Fig. 1-22: Inside View BINOS ® 100 F (field housing) Power Input Fuses Terminal strips for output / input signals P.
1 - 25 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 1.3.1 Internal Gas Paths The materials used for the gas paths are selected according to the application.
1 - 26 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 b ) Gas Path Layout (internal tubing) The pr inciple v ar ious possib le layouts of the internal gas lines are summar iz ed in the follo wing figures. Fig. 1-23: Tubing in series (BINOS ® 100 (M), OXYNOS ® 100, HYDROS ® 100 analyzers) Fig.
1 - 27 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004 Fig. 1-25: Tubing in series (BINOS ® 100 2M analyzers) (equipped with all options) Fig. 1-26: Tubing in parallel (special version of BINO.
1 - 28 TECHNICAL DESCRIPTION ETC00781(4) Series 100 e 02/2004.
MEASURING PRINCIPLE 2 - 1 ETC00781(1) Series 100 e 10/2001 2. Measuring Principle Depending on the gas to be analyzed different measuring methods will be used. 2.1 IR Measurement The analyzers are non-dispersiv e infrared photometers (NDIR) using measurement of selectiv e absor ption in a column of gas.
MEASURING PRINCIPLE 2 - 2 ETC00781(1) Series 100 e 10/2001 Fig. 2-1: Absorption Bands of Sample Gases and Transmittance of the Interference Filters used The signal generation happens b y a pyroelectrical (solid-state) detector . The detector records the incoming IR radiation.
MEASURING PRINCIPLE 2 - 3 ETC00781(1) Series 100 e 10/2001 Gas intake connection Absorption chamber Compensation chamber 2.1.2 Opto-Pneumatic Measuring Principle A ther mal radiator generates the infr ared radiation passing through a chopper wheel.
MEASURING PRINCIPLE 2 - 4 ETC00781(1) Series 100 e 10/2001 In principle the detector is filled with the infrared active gas to be measured and is only sensitive to this distinct gas with its characteristic absor ption spectrum.
MEASURING PRINCIPLE 2 - 5 ETC00781(1) Series 100 e 10/2001 2.1.3 Technique The broadband emission from two IR sources (in the case of dual channel analyzers) passes through the chopper blade , then, i.
MEASURING PRINCIPLE 2 - 6 ETC00781(1) Series 100 e 10/2001 2.2 Oxygen Measurement Depending on analyzer model diff erent measur ing methods will be used. The installed type of oxygen sensor is to identify at the channel code (see Fig. 1-1). % O 2 para.
MEASURING PRINCIPLE 2 - 7 ETC00781(1) Series 100 e 10/2001 OXYGEN MEASUREMENT (PO 2 PARAMAGNETIC PRINCIPLE) Fig. 2-4: Principle Construction of paramagnetic Analysis Cell 1 Permanent magnet 2 Platinum.
MEASURING PRINCIPLE 2 - 8 ETC00781(1) Series 100 e 10/2001 OXYGEN MEASUREMENT (EO 2 ELECTROCHEMICAL PRINCIPLE) 2.2.2 Electrochemical Measurement The deter mination of O 2 concentrations is based on the principle of a galv anic cell. The principle str ucture of the oxygen sensor is sho wn in Fig.
MEASURING PRINCIPLE 2 - 9 ETC00781(1) Series 100 e 10/2001 OXYGEN MEASUREMENT (EO 2 ELECTROCHEMICAL PRINCIPLE) Fig. 2-6: Reaction of galvanic cell The electric current between the electrodes is propor tional to the O 2 concentration in the gas mixture to be measured.
MEASURING PRINCIPLE 2 - 10 ETC00781(1) Series 100 e 10/2001 2.3 Thermal Conductivity Measurement T o measure gases like Hydrogen (H 2 ), Argon (Ar) or Helium (He), the measurement method of ther mal conductivity (TC) will be used.
MEASURING PRINCIPLE 2 - 11 ETC00781(1) Series 100 e 10/2001 2.3.3 Measurement Method The entire measurement cell is thermostatted to a temperature of up to 75 °C. The f our sensors are electrically heated to a higher temperature and the signal of the Wheatstone Br idge is monitored.
MEASURING PRINCIPLE 2 - 12 ETC00781(1) Series 100 e 10/2001 THERMAL CONDUCTIVITY (TC) MEASUREMENT.
3 - 1 PHOTOMETER ASSEMBLY ETC00781(4) Series 100 e 02/2004 3. Photometer Assembly Depending on gas component and measur ing range , different photometer assemb lies will be realized in 100 series. Optional the photometer can be sealed to ambient air .
3 - 2 PHOTOMETER ASSEMBLY ETC00781(4) Series 100 e 02/2004 This e xtremely simple and windowless design enab les easy cleaning of the cells in the ev ent of contamination.
3 - 3 PHOTOMETER ASSEMBLY ETC00781(4) Series 100 e 02/2004 PYROELECTRICAL DETECTOR Fig. 3-1: Photometer Assembly with Pyroelectrical Detector Legends: 03 Chopper Housing 04 / 05 Duplex Filter Disc 06 .
3 - 4 PHOTOMETER ASSEMBLY ETC00781(4) Series 100 e 02/2004 3. 2 Photometer with Gas Detector Fig. 3-2 shows schematically the photometer assemb ly . This assembly is similar to the assemb ly with pyroelectrical detector .
3 - 5 PHOTOMETER ASSEMBLY ETC00781(4) Series 100 e 02/2004 GAS DETECTOR Fig. 3-2: Photometer Assembly 100 Series with Gas Detector [example above and middle: high measuring ranges, example below: small measuring ranges.
3 - 6 PHOTOMETER ASSEMBLY ETC00781(4) Series 100 e 02/2004.
PREPARATION 5 - 1 ETC00781(4) Series 100 e 02/2004 5. Prep aration of S tart-up Please check the package and its contents immediately upon receipt. If any item is damaged or lost y ou are requested to notify the contractor to under take a damage sur ve y and repor t the loss or damage to us immediately .
PREPARATION 5 - 2 ETC00781(4) Series 100 e 02/2004 5.1 Installation Site The analyzers m ust not operate in e xplosive atmosphere without supplementar y protectiv e measures ! F ree flow of air into a.
PREPARATION 5 - 3 ETC00781(4) Series 100 e 02/2004 5. 2 Gas Conditioning (Sample Handling) The conditioning of the sample gas is of greatest impor tance f or the successful operation of any analyzer according to e xtractiv e method.
PREPARATION 5 - 4 ETC00781(4) Series 100 e 02/2004 5.2.1 Fine Dust Filter (Option BINOS ® 100 2M/F) A fine dust filter with a pore size of 2 µ m may optionally be integrated into the BINOS ® 100 2M/F front panel (Fig.
PREPARATION 5 - 5 ETC00781(4) Series 100 e 02/2004 5.3 Gas Connections The installed gas connections are depending on gas analyzer specification and model. All fittings are clearly marked. The fittings are located on the rear panel of the instrument or on the left bottom side.
PREPARATION 5 - 6 ETC00781(4) Series 100 e 02/2004 Fig. 5-3a: BINOS ® 100 (M), OXYNOS ® 100 (EO 2 ), HYDROS ® 100, gas connections GAS CONNECTIONS Fig. 5-3b: OXYNOS ® 100 (PO 2 ), gas connections Gas inlet fittings Gas outlet fittings Gas inlet fittings Gas outlet fittings IN T E R F A C E X1 OU TPUT OUT IN K1 K2 K1 K2 CROSS COMP.
PREPARATION 5 - 7 ETC00781(4) Series 100 e 02/2004 GAS CONNECTIONS Fig. 5-3d: BINOS ® 100 F, standard gas connections Fig. 5-3c: BINOS ® 100 2M, standard gas connections Gas outlet fittings Gas inle.
PREPARATION 5 - 8 ETC00781(4) Series 100 e 02/2004 5.3.2 Internal Solenoid Valves (BINOS ® 100 2M/F Option) For operation with optional internal solenoid valves, the following indications have to be considered: All necessar y gases hav e to be connected at the corresponding solenoid valv e at an ov er pressure of 50 - max.
PREPARATION 5 - 9 ETC00781(4) Series 100 e 02/2004 Fig. 5-4b: BINOS ® 100 2M (version B), gas connections with solenoid valve option Fig. 5-4c: BINOS ® 100 2M (special version), gas connections with.
PREPARATION 5 - 10 ETC00781(4) Series 100 e 02/2004 PURGE GAS CONNECTIONS OF BINOS ® 100 F / CONTINUOUS PURGE 5.3.3 Purge gas connection of BINOS ® 100 F for Ex zones a) A TEX Applications Refer to the supplemental manual for installing analyzers in hazardous areas where A TEX is applicable.
PREPARATION 5 - 11 ETC00781(4) Series 100 e 02/2004 PURGE GAS CONNECTIONS OF BINOS ® 100 F / Z PURGE 5. 4 Additional Hints to BINOS ® 100 F (Field Housing) In the field housing version BINOS ® 100 F all componets are incorporated into a protection housing going conform to DIN-standard protection class IP 65 (appro x.
PREPARATION 5 - 12 ETC00781(4) Series 100 e 02/2004 Fig. 5-5: Dimensional sketch / Drill drawing BINOS ® 100 F Standard version [all dimensions in mm] 5.4.1 Wall Mounting This housing is designed for wall mounting. Location of fixing points: see Fig.
PREPARATION 5 - 13 ETC00781(4) Series 100 e 02/2004 5.4.2 Electrical Connections Be sure to obser v e the safety precautions and w ar nings ! V erify , that the cable glands together with installed cab les are her metic to ensure protection class IP 65 (according to IEC 60529).
PREPARATION 5 - 14 ETC00781(4) Series 100 e 02/2004 b) Optional Signal Lines This are analog outputs, digital inputs/outputs and serial interfaces. P Open the analyzer's front door . P Inser t the cable through the cab le glands (Fig. 5-6 and 5-5) into the housing.
PREPARATION 5 - 15 ETC00781(4) Series 100 e 02/2004 Fig. 5-7: BINOS ® 100 F, Data line connections Inside view from front (detail, without front door) Terminal strip Interface: serial interface option Terminal strips for data lines Power supply Int erface Seri al out 4 3 2 1 X10 2 1 X11 X9 1 1 F100 .
PREPARATION 5 - 16 ETC00781(4) Series 100 e 02/2004 Fig. 5-8: BINOS ® 100 F, Connection data lines / mains line (inside view, left side panel) ADDITIONAL HINTS TO BINOS ® 100 F (FIELD HOUSING) X2 A .
6 - 1 SWITCHING ON ETC00781(4) Series 100 e 02/2004 6. Switching On 6.1 General Be sure to obser v e the safety precautions and w ar nings ! Once the instrument has been correctly assembled and installed in accordance with the general instructions given in section 5.
6 - 2 SWITCHING ON ETC00781(4) Series 100 e 02/2004 6. 2 24 V DC Supply The analyzers of series 100 (with e xcept of BINOS ® 100 F and BINOS ® 100 2M with inter nal po wer supply) are specified for an operating v oltage of 24 V DC . This v oltage has to be provided via a 3-pole XLR flange (male).
6 - 3 SWITCHING ON ETC00781(4) Series 100 e 02/2004 24 V ma x . 4 0 W 2+ 3 OUT IN X1 OU T PUT X2 OUT PUT IN T E R F A C E Fig. 6-1b: OXYNOS ® 100 (PO 2 ), Voltage supply Fig. 6-1c: BINOS ® 100 2M (version B) with external power supply, Voltage supply 24 V DC SUPPLY Plug 24 V DC Input OUT SPAN 2 SPAN 1 ANAL OG I N 3 2 1 ZE RO SAMPL E 24V m ax .
6 - 4 SWITCHING ON ETC00781(4) Series 100 e 02/2004 6.3.1 BINOS ® 100 2M The analyzer BINOS ® 100 2M is optional lly equipped with an internal “autoranging” power supply and is specified for an oper ating voltage of 230 V AC or 120 V AC resp ., 47-63 Hz.
6 - 5 SWITCHING ON ETC00781(4) Series 100 e 02/2004 Socket 24 V DC out Input 230/120 V AC POWER Fig. 6-2: BINOS ® 100 2M (version A) shown with internal power supply, Voltage supply 6.3.2 BINOS ® 100 F The analyzer is specified f or an operating v oltage of 230 V AC or 120 V A C resp .
6 - 6 SWITCHING ON ETC00781(4) Series 100 e 02/2004.
7 - 1 KEY FUNCTIONS ETC00781(4) Series 100 e 02/2004 7. Key Functions By default the analyzer is operated and programmed by using the membrane keypad with its four keys (see Fig. 1-1 and 1-2, Item 4 to 7). If either the BINOS100 ® 2M or BINOS 100 F analyzer is equipped with an internal pump, the fifth key “PUMP” is activated by software.
7 - 2 KEY FUNCTIONS ETC00781(4) Series 100 e 02/2004 7 .1 FUNCTION Pressing this ke y (Fig. 1-1 and 1-2, Item 3) addresses the individual analyz er functions in sequence. Merely addressing an analyzer function will not initiate an analyzer action or operation.
7 - 3 KEY FUNCTIONS ETC00781(4) Series 100 e 02/2004 Only with Option RS 232 C/485 Serial Interface Only in combination of internal solenoid valves or digit al outputs and external solenoid valves , and if Auto = 1 The following analyzer functions and their sequences (see also Fig.
7 - 4 KEY FUNCTIONS ETC00781(4) Series 100 e 02/2004 7 . 2 ENTER The ENTER - key (Fig. 1-1 and 1-2, Item 4) is used for the transfer of (keyed-in) numerical data to the corresponding operating parameters and f or the initiation of cer tain operations, such as zeroing and spanning.
7 - 5 KEY FUNCTIONS ETC00781(4) Series 100 e 02/2004 KEY FUNCTION OVERVIEW Fig. 7-1: 100 Series Operating Function Matrix Actual Nominal 0..-1 0.-1 0 - 1 CodE 0..-.1 t-AS. t-AS CodE PrES SYS.- CodE C.-On C.CAL Hold PArA tol. Auto d.OFF L-0 tPur t90.1 CodE t90.
7 - 6 KEY FUNCTIONS ETC00781(4) Series 100 e 02/2004 7.3 INPUT - CONTROL This keys (Fig. 1-1 and 1-2, Item 5 and 6) are used for the adjustment of the individual input parameter values. A single press on either key will change the current value by +/- 1.
7 - 7 KEY FUNCTIONS ETC00781(4) Series 100 e 02/2004 7. 4 PUMP (BINOS ® 100 2M/F only) Optionally there is built-in a gas sampling pump (pumping rate max. 2,5 l/min.) into analyzers of type BINOS ® 100 2M/F . The pump can be switched on and switched off by either • the key “PUMP” at the front panel [Fig.
7 - 8 KEY FUNCTIONS ETC00781(4) Series 100 e 02/2004.
8 - 1 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 8 . Setting System Parameters Push the ke y until the text appears. Press the ke y If the Code had not already been entered, there will.
8 - 2 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 8.1 Pressure Correction T o eliminate faulty measurements due to changes in barometric pressure or sample gas pressure, the operator is off ered the oppor tunity to enter the current pressure expressed in hPa (mbar) in a range of 800 to 1,300 hP a.
8 - 3 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 8.3 Cross Compensation Calibration (internal) Deter mination of cross compensation correction f actors is perfo r med dur ing the span adjustment. Pure test gases are required f or this operation.
8 - 4 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 8. 4 Hold The analyzer function HOLD is used to lock the analog signal outputs and the concentration limits during a calibration procedure to hold the last measured values. Input value 0: The outputs remain unlocked.
8 - 5 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 8.6 Tolerance Check The tolerance function is for the activ ation and deactivation of the toler ance check procedure f or v ar ious calibration gases.
8 - 6 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 8.7 Display Off Entering "1" will tur n the DISPLA Y off about 1 to 2 minutes after the last ke y was pressed.
8 - 7 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 ANALOG SIGNAL OUTPUTS Fig. 8-1: Pin assignments mating socket X 2 (analog signal outputs) 1 ⊥ ⊥ ⊥ ⊥ ⊥ (V DC) 2 0 (2) - 10 V D.
8 - 8 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 8. 9 Flushing Period F or calibration, the gas paths must be supplied with sufficient calibration gas. The flushing period has to be fix ed adequate; perf or m calibration only after a suitab le flushing per iod (the calibration gas flow should be identical with sample gas flo w).
8 - 9 SETTING SYSTEM PARAMETERS ETC00781(4) Series 100 e 02/2004 8.11 Response Time (t 90 ) F or some types of analysis an alteration of the analyzer damping f actor , i.e. its electrical response time, t 90 , ma y be required. The operator is off ered the option of selecting an optimal response time for each application.
8 - 10 ENTRY OF SYSTEM PARAMETERS ETC00265(4) Series 100 e 02/2004 OFFSET (BEGIN OF RANGE) 8.12 Offset (Begin of range) The operator is here off ered the oppor tunity to introduce a scale offset f or the analog signal output (begin of range).
8 - 11 ENTRY OF SYSTEM PARAMETERS ETC00265(4) Series 100 e 02/2004 END OF RANGE VALUE 8.13 End of Range Value The operator is here off ered the oppor tunity to introduce a full scale range f or the analog signal output. Example: For an analyz er concentration range of 0 - 25 % it is desired to measure only concentrations in the range 0 - 15 %.
8 - 12 ENTRY OF SYSTEM PARAMETERS ETC00265(4) Series 100 e 02/2004 8.14 Reset The reset operation restores the settings of the analyz er to the parameters and calibration f actors set in our factory at the time of its manuf acture.
8 - 13 ENTRY OF SYSTEM PARAMETERS ETC00265(4) Series 100 e 02/2004 8.15 Program Version The Program V ersion (No . of the installed software - v ersion) will be display ed. Press the ke y 8.16 Serial - No. The Serial - No. will be display ed. (Please note this number for fur ther contact with our f actor y- maintenace, service, etc.
8 - 14 ENTRY OF SYSTEM PARAMETERS ETC00265(4) Series 100 e 02/2004 8.17 Pump *) This displa y shows the status of gas sampling pump . If the function is enabled in “Pump Control” (“P .Ctl. ”, see chapter 8.18), the pump can be switching On or Off via this input.
CALIBRATION 9 - 1 ETC00781(4) Series 100 e 02/2004 9. Calibration T o insure correct measurement results, z eroing and spanning should be carr ied out once a week. Spanning can be perf or med only after zeroing bef ore. For the calibration procedure the analyzer has to be supplied with unpressurized test gases through the respective gas inlets (cf.
CALIBRATION 9 - 2 ETC00781(4) Series 100 e 02/2004 9.1 Manual Calibration 9.1.1 Zeroing Zeroing will set the actually measured gas concentration to “zero”. Push the ke y until the display sho ws (Zeroing channel 1) or (Zeroing channel 2) resp . Press the ke y There will appear Use the ke ys to select the correct user - code and enter using.
CALIBRATION 9 - 3 ETC00781(4) Series 100 e 02/2004 Push the key The nominal value or will be display ed. If the actual and nominal zero levels match, the next function can be selected using the FUNCTION ke y (without zeroing).
CALIBRATION 9 - 4 ETC00781(4) Series 100 e 02/2004 9.1.2 Spanning V er ification of the span calibration is essential f or accurate concentration measurement. Spanning can be performed only after zeroing has been done. Spanning will set the actually measured gas concentration to the entered “span gas setpoint”.
CALIBRATION 9 - 5 ETC00781(4) Series 100 e 02/2004 Push the key until the display sho ws (Spanning channel 1) or (Spanning channel 2) resp . Press the ke y Enter the correct user code , if not already entered The displays will now show resp . The actual concentration - le vel will be displa yed.
CALIBRATION 9 - 6 ETC00781(4) Series 100 e 02/2004 The actual measuring value resp . will be displayed Quit the calibration mode by pressing the FUNCTION - key (nominal value is entered without span calibration) or push again to star t spanning . As soon as spanning has finished, the display indicates the actual measuring value resp .
CALIBRATION 9 - 7 ETC00781(4) Series 100 e 02/2004 9.2 T ime-Controlled Calibration Mode (Option) A time-controlled calibration only can be done with internal or separate e xter nal solenoid valv es via digital outputs. The automatic function of the analyzer m ust also be activated correctly (cf .
CALIBRATION 9 - 8 ETC00781(4) Series 100 e 02/2004 If the correct user code has not yet been entered, the displays show Use the ke ys to select the correct user - code and enter using It appears Y ou can enter a time inter val (hours), when an automatic z eroing has to be perf or med.
CALIBRATION 9 - 9 ETC00781(4) Series 100 e 02/2004 9.2.2 Combined Zeroing and Spanning With this function a span calibration will be performed after completion of zeroing.
CALIBRATION 9 - 10 ETC00781(4) Series 100 e 02/2004 9.3 Remote-Controlled Calibration Mode (Option) A remote-controlled calibration requires internal solenoid valves or external solenoid valves controled via digital outputs. Additional the correct test gas setpoint has to be set first (manually: chapter 9.
10 - 1 MEASUREMENT/SWITCHING OFF MEASUREMENT ETC00781(1) Series 100 e 10/2001 10 . Measurement / Switching Off 10.1 Measurement Analyzer w ar ming-up after s witching on takes about 15 to 50 minutes , depending on the installed detectors ! P Supply sample gas to the gas inlet fitting (chapter 5.
10 - 2 MEASUREMENT/SWITCHING OFF SWITCHING OFF ETC00781(1) Series 100 e 10/2001 Before switching off the analyzer purge all the gas lines for about 5 minutes with zero gas (N 2 ) or adequate conditioned air .
DIGITAL OUTPUTS 11 - 1 ETC00781(4) Series 100 e 02/2004 Fig. 11-1: Pin Assignments X 3 (Digital Outputs) 11 . Digital Outputs All standard digital outputs are available on plug X 3 at the rear panel. The maximum output load is 30 V DC / 30 mA (“Open Collector”).
DIGITAL OUTPUTS 11 - 2 ETC00781(4) Series 100 e 02/2004 CONCENTRATION LIMITS 11.1 Concentration Limits One upper and one lower concentration limit can be assigned for each channel, freely selectable by the operator within the available concentration range.
DIGITAL OUTPUTS 11 - 3 ETC00781(4) Series 100 e 02/2004 LIMIT VALUES The displays show upper limit channel 1 Use the keys to set the limit value. Press the ke y to enter the v alue. Now the displays show lower limit channel 2 Use the keys to set the limit value.
DIGITAL OUTPUTS 11 - 4 ETC00781(4) Series 100 e 02/2004 VALVE CONTROL / STATUS SIGNALS (OPTION) Fig. 11-2: Pin Assignments X 1 (Status Signals) 11.2 Valve Control Optional external solenoid valves have to be connected to plug X 3 on the rear panel to be controlled by the analyz er .
SERIAL INTERFACE (OPTION) 12 - 1 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 12 . Serial Interface (Option) 12.1 Upgrading Serial Interface / Status Signals (status signals only: PCB BSI 10, Catalog - No . : 43 001 590, RS 232 - Interf ace: PCB BSI 10 with PCB SIF 232, Catalog - No .
SERIAL INTERFACE (OPTION) 12 - 2 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 12.2 General The analyzer is equipped with a serial interf ace enabling communication with a host computer . The host computer can call up , prescr ibe, or alter parameters as w ell as initiate analyzer operations, using standardiz ed protocols.
SERIAL INTERFACE (OPTION) 12 - 3 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical T o av oid detecting transmission errors , the host computer can inser t a message -length par ity byte immediately preceding the terminate character f or verification by the analyz er .
SERIAL INTERFACE (OPTION) 12 - 4 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 12.3 Start Up The analyzer has been set in our f actor y to RS 232 C or RS 485 interface via the plugged PCB SIF 232 or SIF 485 on the PCB BSI 10. The parameter 232c has also been set to 0 = NO or 1 = YES in the SIP (Ser ial Interf ace P arameters) line.
SERIAL INTERFACE (OPTION) 12 - 5 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 12.3.2 RS 48 5 Configure 2- or 4-wire operation via solder bridge LB 1 of PCB SIF 485 before mounting the PCB . Connecting of [1 - 2] 2-wire-operation is selected. Connecting of [2 - 3] 4-wire-operation is activ e.
SERIAL INTERFACE (OPTION) 12 - 6 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 12.3.3 Switching ON/OFF Interface Operation The analyzer ma y be set to either “online” or “offline” status . This setting may be perf or med either from the ke ypad or via telegram input.
SERIAL INTERFACE (OPTION) 12 - 7 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical All entries are made using the keys and Press the ke y until appears, then push the ke y The unit is now ready f or code entr y , if such has not already been perf or med.
SERIAL INTERFACE (OPTION) 12 - 8 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 12.4 Telegram Syntax T elegrams are assemb led as follo ws: 12.4.1 Start Character ( “$” = Hex 24) If the star t character is missing, this will result in transmission of an appropriate status telegram by the analyz er .
SERIAL INTERFACE (OPTION) 12 - 9 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 12.4.5 Status Telegram If telegram syntax is f aulty , or analyzer is unab le to act upon an instr uction receiv ed, then the analyzer will transmit a status teleg ram to the host computer .
SERIAL INTERFACE (OPTION) 12 - 10 ETC00781(4) Series 100 e 02/2004 12.4.6 Numerical Representations T elegrams ma y contain integers or real numbers. The f or mats for these numbers are subject to the f ollowing restrictions.
SERIAL INTERFACE (OPTION) 12 - 11 ETC00781(4) Series 100 e 02/2004 12.5 Instruction Syntax Code definitions: RP: receiv e par ameters analyz er is accepting v alues SP: send parameters analyzer is sending values RI: receive instructions k: channel numbers 0 to 2 m: r ange number w: v alue <ID>: analyzer ID - no .
SERIAL INTERFACE (OPTION) 12 - 12 ETC00781(4) Series 100 e 02/2004 12.5.1 Instruction Listing Instruction syntax: Instr uction description: $ID;001;k;LPB<CR> R I stand-by status (all valv es clo.
SERIAL INTERFACE (OPTION) 12 - 13 ETC00781(4) Series 100 e 02/2004 12.5.2 Response Telegrams Response telegrams f ollo w with the same syntax as the appropiate (SP-) commands (see 12.
SERIAL INTERFACE (OPTION) 12 - 14 ETC00781(4) Series 100 e 02/2004 12.5.2.2 Pump Status (Instruction 008) *) The response telegram f or instr uction “$ID;008;LPB<CR> SP Pump status” shows as f ollows: $ID;008;w;LPB<CR> with w = pump status 0: Pump Off 1: Pump On RESPONSE TELEGRAMS *) BINOS ® 100 2M/F from program version 5.
DIGITAL INPUTS / FOUNDATION ™ FIELDBUS (OPTIONS) 13 - 1 ETC00781(4) Series 100 e 02/2004 13 . Digit al Inputs / Foundation ™ Fieldbus (BINOS ® 100 2M/F option only) Be sure to observe the saf ety measures for all w or kings at the analyzer! 13.1 Digital Inputs 13.
DIGITAL INPUTS / FOUNDATION ™ FIELDBUS (OPTIONS) 13 - 2 ETC00781(4) Series 100 e 02/2004 13.1.3 Valve Control The inputs “E4 to E7” are lev el sensitive with descending priority . That means “E4” has highest prior ity and “E7” has lowest priority .
14 - 1 CROSS COMPENSATION / SETTING OF RESPSONSE TIME (TC ONLY) ETC00781(4) Series 100 e 02/2004 14 . Cross Compensation / Setting of Resp sonse time (TC Option only) 14.
14 - 2 CROSS COMPENSATION / SETTING OF RESPSONSE TIME (TC ONLY) ETC00781(4) Series 100 e 02/2004 14.1.1 Preparing Actions The adjustment procedure for alteration the factory settings of cross compensa.
14 - 3 CROSS COMPENSATION / SETTING OF RESPSONSE TIME (TC ONLY) ETC00781(4) Series 100 e 02/2004 14.1.2 Adjustment Procedure P Switch on the TC analyz er (chapter 6.) and all analyzers used f or measur ing interf er ing gas components. P P erform zeroing and spanning of all rele vant measuring channels.
14 - 4 CROSS COMPENSATION / SETTING OF RESPSONSE TIME (TC ONLY) ETC00781(4) Series 100 e 02/2004.
Error Code Possible Reasons Check / Correct 16 - 1 LIST OF FAILURES ETC00781(4) Series 100 e 02/2004 1 6 . List of Failures Some of the f ailures which may arise dur ing measurement will be repor ted on the displays in f orms of error codes.
Error Code Possible Reasons Check / Correct 16 - 2 LIST OF FAILURES ETC00781(4) Series 100 e 02/2004 Battery buffer faulty. The EPROM default values were charged. 1. Jumper not or incorrect plugged. 2. Positive or negative reference voltage absent. 3.
Error Code Possible Reasons Check / Correct 16 - 3 LIST OF FAILURES ETC00781(4) Series 100 e 02/2004 1. Incorrect zero gas in use. 2. IR channel: Photometer section contaminated. 3. Analyzer not calibrated. 1. Incorrect nominal value. 2. Incorrect span gas in use.
Error Code Possible Reasons Check / Correct 16 - 4 LIST OF FAILURES ETC00781(4) Series 100 e 02/2004 Parameter ABS. does not set to “0”. Time out for XON of serial interface. 1. Measuring range failure. 2. Connection faulty. 3. Pressure sensor faulty.
Error Code Possible Reasons Check / Correct 16 - 5 LIST OF FAILURES ETC00781(4) Series 100 e 02/2004 3. Gas pressure subject to excessive fluctuations. 4. Oxygen senor / detector not connected. 5. Electrochemical oxygen sensor is already consumed. 6. IR channel: Light source not connected or faulty.
Error Code Possible Reasons Check / Correct 16 - 6 LIST OF FAILURES ETC00781(4) Series 100 e 02/2004 9. Barometric pressure effects. 10. Temperature below the dew point in the gas paths. 11. Faulty A/D converter. 1. Incorrect response time ( t 90 time) settings.
Error Code Possible Reasons Check / Correct 16 - 7 LIST OF FAILURES ETC00781(4) Series 100 e 02/2004 1. Needle valve is not opened (Option) 2. Sample gas pump (Option) is not switched on 3. Membrane of pump is defective 4. Sample gas pump is defective 5.
Error Code Possible Reasons Check / Correct 16 - 8 LIST OF FAILURES ETC00781(4) Series 100 e 02/2004.
MEASURING POINTS OF BKS AND OXS 17 - 1 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 17 . Measuring Point s of BKS and OXS 17.1 Measuring points of BKS All measuring points are measured against ground (X 1 1 / X 28 or X 29) ! 17.
MEASURING POINTS OF BKS AND OXS 17 - 2 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 17.1.3 Reference Voltage negative Measuring point: X 12 Measuring device: D VM Signal: inv erse [ref erence voltage positiv e] The diff erence between negativ e reference v oltage and positive ref erence v oltage must be no more than 10 mV (U ref.
MEASURING POINTS OF BKS AND OXS 17 - 3 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 17.1.5 Temperature Sensor Measuring point: X 8 Measuring device: D VM Signal: appro x.
MEASURING POINTS OF BKS AND OXS 17 - 4 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 17.1.6 Light Barrier Signal Measuring point: Plug 9, pin 2 Measuring de vice: Oscilloscope Signal: square i.
MEASURING POINTS OF BKS AND OXS 17 - 5 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical MEASURING POINTS OF OXS 17.1.7 Analog Preamplifiering a) p aramagnetic oxygen measurement Measuring point: X 25 channel 1 Measuring device: D VM Signal: A t z ero gas purge: 0 V dc (± 50 mV) At ambient air (appro x.
MEASURING POINTS OF BKS AND OXS 17 - 6 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical Fig. 17-2: PCB “OXS”, assembled, horizontal projection 17.
PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS 18 - 1 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical Front panel X 16 X 18 X 1 17 8 P1 P2 X 9 1 X 3 14 X 2 1 1 1 X 5 1 X 6 J 9 1 X 7 Marked Marked X 36 EPROM (at BAF 01) Option BAF 01 P 1 EPROM (D 30 at BKS) 18 .
PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS 18 - 2 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 18.1.1 IR measurement without oxygen channel X 2 Chopper X 3 (4/5) Light source channel 1 X 3.
PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS 18 - 3 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 18.1.3 IR / Oxygen Measurement combined X 2 Chopper X 3 (4/5) Light source channel 2 X 5 Oxygen sensor X 6 IR detector (channel 2) X 7 T emperature sensor (chopper) X 9 Light barr ier (chopper) 18.
PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS 18 - 4 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 18.1.5 IR / T C Measurement combined X 2 Chopper X 3 (4/5) Light source channel 2 X 5 TC sensor (from PCB W AP 100, cable P15, 5 pin connector)) X 6 IR detector (channel 2) X 7 T emperature sensor (chopper) X 9 Light barr ier (chopper) 18.
PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS 18 - 5 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical PCB “OXS” Cable “P 1” Connection Oxygen sensor (Pin-base“P 2”) View A ↓ ↓ ↓ ↓ ↓ View A: PCB OXS assembled, horizontal projection Fig.
PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS 18 - 6 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical P 2 1 P 18 orange blue green yellow 1 P 16 1 P 10 P 15 PLUG PIN ALLOCATION OF WAP 100 (TC MEASURMENT) 18.
JUMPER ALLOCATION OF BKS 19 - 1 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical 19 . Jumper Allocation of BKS J 1 A/D con v ersion star t channel 1 J 2 A/D con v ersion star t channel 2 (open f or 1 channel analyzer) J 6 W atchdog signal J 7 Buff er Batter y Fig.
JUMPER ALLOCATION OF BKS 19 - 2 ETC00781(1) Series 100 e 10/2001 Rosemount Analytical.
FINE DUST FILTER (OPTION) 21 - 1 ETC00781(4) Series 100 e 02/2004 Fig. 21-1: Fine Dust Filter 2 1 . Fine Dust Filter (Option) The optional fine dust filter (see Fig. 1-2) should be checked in intervals appropriate to the type of process and application.
21 - 2 FINE DUST FILTER (OPTION) ETC00781(4) Series 100 e 02/2004.
22 - 1 LEAK TESTING ETC00781(4) Series 100 e 02/2004 Fig. 22-1: Leak Testing with an U - Tube - Manometer P Install a waterfilled U - tube manometer at the sample gas outlet; P Install a shut-off valv e at the sample gas inlet.
22 - 2 LEAK TESTING ETC00781(4) Series 100 e 02/2004.
HOUSING 23 - 1 ETC00781(4) Series 100 e 02/2004 23. Housing 23.1 Cleaning of Housing Surface For cleaning the analyzer housing surface use a soft, fluff free cloth and all purpose detergent.
HOUSING 23 - 2 ETC00781(4) Series 100 e 02/2004 OPENING THE HOUSING (1/4 19" HOUSING) 23.2 Opening the Housing The housing must be opened f or checking the electrical connections and for replacement or cleaning of any of theinternal components of the analyzer .
HOUSING 23 - 3 ETC00781(4) Series 100 e 02/2004 23.2.2 BINOS ® 100 2M a) Housing Cover P Disconnect all voltage supplies . P Unscrew f astening scre ws for rac k mounting / front frame if necessar y (Fig. 1-2, Item 11). Remov e analyzer out of rac k or remov e the front mounting frame and carr ying strap to rear .
HOUSING 23 - 4 ETC00781(4) Series 100 e 02/2004 b) Front Panel P Opening housing cov er (Item 23.2.2 a). P Unscrew the 6 f astening scre ws at both housing sides (Fig. 23-2) P Remov e front panel to the front carefully . If the optional components fine dust filter and flow meter are mounted at front panel - take care of gas lines (see Fig.
HOUSING 23 - 5 ETC00781(4) Series 100 e 02/2004 OPENING THE HOUSING (BINOS ® 100 F) Fig. 23-3: BINOS ® 100 F (Field housing) (fastener for front panel) 23.2.3 BINOS ® 100 F (Field Housing) P Open all 4 fasteners with a square key (Fig. 23-3) P Carefully swing out the front panel to the right side.
HOUSING 23 - 6 ETC00781(4) Series 100 e 02/2004.
24 - 1 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS ETC00781(4) Series 100 e 02/2004 24 . Replacement and Cleaning of Photometric Components 24.1 Taking out the Photometer Assembly P Open the analyzer housing (cf.
REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS 24 - 2 ETC00781(4) Series 100 e 02/2004 24.2 Light Source Replacement P Open the analyzer housing (cf . chapter 23). P TT ak e the photometer assembly out of the analyzer housing (see chapter 24.1). P Remov e the two light source mounting scre ws (shown in Fig.
24 - 3 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS ETC00781(4) Series 100 e 02/2004 24.3 Cleaning of Analysis Cells and Windows 24.3.1 Removal of Analysis Cells P Open the analyzer housing (cf . chapter 23). P T ake the photometer assemb ly out of the analyzer housing (see chapter 24-1).
REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS 24 - 4 ETC00781(4) Series 100 e 02/2004 24.3.2 Cleaning a ) Windows The windows on the filter cell, chopper housing, the adapter cell resp . analysis cell ma y be cleaned with a soft, lint-free cloth.
24 - 5 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS ETC00781(4) Series 100 e 02/2004 24.3.3 Reinstalling the Analysis Cells a) For analysis cells of lengths 1 mm and 7 mm P Place the O-rings on the adapter cell and filter cell. P Fit the components together .
REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS 24 - 6 ETC00781(4) Series 100 e 02/2004 24.4 Chopper Replacement P Open the analyzer housing (cf. chapter 23). P T ake the photometer assemb ly out of the analyzer housing (see chapter 24.1). P Remov e the light source(s) from chopper housing (see chapter 24.
24 - 7 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS ETC00781(4) Series 100 e 02/2004 24.6 Physical Zeroing Adjustment of the ph ysical zero - lev el will only be required if a light source, a filter cell, or an analysis cell hav e been replaced or repositionned.
REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS 24 - 8 ETC00781(4) Series 100 e 02/2004 24.6.2 Sealed Photometer (Option) P Slightly loosen the light source mounting screws (sho wn in Fig. 24-1 as Item 5) or the temperature sensor (sho wn in Fig. 24-1 as Item 3) resp .
CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 1 ETC00781(4) Series 100 e 02/2004 2 5 . Checking / Replacing an Electrochemical Oxygen Sensor On account of the measuring principle the oxygen sensor has a limited life time.
CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 2 ETC00781(4) Series 100 e 02/2004 CHECKING THE SENSOR Fig. 25-1: PCB “OXS”, assembled, horizontal projection 25.1 Checking the Sensor Replace the sensor , if the v oltage is less than 70 % of the initial output voltage .
CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 3 ETC00781(4) Series 100 e 02/2004 REPLACING THE SENSOR 25.2 Replacing the Sensor Be sure to obser ve the saf ety measures ! 25.2.1 Remove the old Sensor a) Oxygen Measurement without IR - channel P Open the analyzer housing (see chapter 23.
CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 4 ETC00781(4) Series 100 e 02/2004 P T ake out the complete suppor t (see Fig. 25-1) to the top of the analyzer . P Disconnect the connector f or the sensor from “P2” of circuit board “O XS” (see Fig.
CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 5 ETC00781(4) Series 100 e 02/2004 b) IR / Oxygen Measurement combined P Open the analyzer housing (see chapter 23.). P Disconnect the connector f or the sensor from “P2” of circuit board “O XS” (see Fig.
CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 6 ETC00781(4) Series 100 e 02/2004 25.2.2 Removing the Sensor P T ake the consumed sensor out of the fitting. P T ake off the stopper from new sensor and place the ne w sensor into the fitting, so that the name plate is at the top of the sensor .
CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 7 ETC00781(4) Series 100 e 02/2004 BASIC SETTINGS Fig. 25-5: PCB “OXS”, assembled, view at component side 25.2.4 Basic settings for the Oxygen Sensor P Supply ambient air to the analyzer (appro x.
CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 - 8 ETC00781(4) Series 100 e 02/2004.
TECHNICAL DATA 27 - 1 ETC00781(4) Series 100 e 02/2004 2 7 . T echnical Data Certifications EN 61326, EN 61010-1 (for measurment of non flammable gases or non explosive gases resp. (< 50 % LEL). NAMUR, CSA-C/US, Higher concentrations require supplementary C-Tick, PAC, GOSSTANDART protective measures !) Suitability tests TÜV Nord mbH, report no.
TECHNICAL DATA 27 - 2 ETC00781(4) Series 100 e 02/2004 27.2 Housing Gas connections Standard 6/4 mm PVDF Option: 6/4 mm or 1/4", ss additional fittings on request BINOS ® (M)/ OXYNOS ® / HYDROS ® 100 max. 4 fittings BINOS ® 100 2M max. 9 fittings BINOS ® 100 F (standard version) max.
TECHNICAL DATA 27 - 3 ETC00781(4) Series 100 e 02/2004 27.3 Signal Inputs / Outputs, Interfaces 2 analog outputs per channel 0 - 10 V and 0 - 20 mA (R B < 500 W) [(optically isolated: 2 channels, c.
TECHNICAL DATA 27 - 4 ETC00781(4) Series 100 e 02/2004 Fig. 27-2: Dimensional sketch BINOS ® 100 2M (dimensions in [mm]) Fig. 27-1: Dimensional sketch BINOS ® 100 (M) / OXYNOS ® 100 / HYDROS ® 100 (dimensions in [mm]) 112 19 462. 6 52 . 5 213 128.
TECHNICAL DATA 27 - 5 ETC00781(4) Series 100 e 02/2004 Fig. 27-3: Dimensional sketch/ Drill drawing BINOS ® 100 F Single Section Housing for General Purpose Applications (dimensions in mm) Fig.
TECHNICAL DATA 27 - 6 ETC00781(4) Series 100 e 02/2004 27.4 Gas Related Specifications For information about measuring components and ranges of the actual analyzer refer to the nameplate label, which is located on the left or right side of the analyzer cover (all table top and rack mount versions) or inside the front door (BINOS 100 F).
TECHNICAL DATA 27 - 7 ETC00781(4) Series 100 e 02/2004 Cross sensitivities electrochemical oxygen measurement: paramagnetic oxygen measurement: Not for use with sample gases containing 100 % Gas zerol.
TECHNICAL DATA 27 - 8 ETC00781(4) Series 100 e 02/2004 GENERAL SPECIFICATIONS 27.5 Voltage Supply BINOS ® 100 (M) / OXYNOS ® 100 / HYDROS ® 100 / BINOS ® 100 2M (external power supply) Input 3-pol.
TECHNICAL DATA 27 - 9 ETC00781(4) Series 100 e 02/2004 VOLTAGE SUPPLY 27.5.2 Power Supplies [UPS 01 T ( U niversal P ower S upply) / SL5 / SL10] Input (UPS/SL5/ SL10 ) plug / terminal s / terminal s N.
TECHNICAL DATA 27 - 10 ETC00781(4) Series 100 e 02/2004 Fig. 27-7: Dimensional sketch SL10 (Front view) [mm] Fig. 27-8: Front view SL 5 Fig. 27-9: Side view SL10/SL5 Fig. 27-10: Dimensional sketch UPS 01 T (Universal Power Supply) , table-top version rack module turn around 90° [all dimensions in mm, without cable and plugs] 275.
REPLACING THE EPROM 28 - 1 ETC00781(4) Series 100 e 02/2004 28 . Replacing the EPROM The EPROM may be easily replaced by a new unit when faulty or update the software. The EPROM - replacement procedure is as f ollows: P Disconnect the analyzer from the source of electric power .
REPLACING THE EPROM 28 - 2 ETC00781(4) Series 100 e 02/2004.
CABLES AND CORDS 30 - 1 ETC00781(4) Series 100 e 02/2004 3 0 . Cables and Cords T o stay in conf or mance with EMC requirements use our shielded data cables (optionally available) or equivalent data cables only! The operator has to ensure that the cable shield is connected in correct manner (chapter 29.
CABLES AND CORDS 30 - 2 ETC00781(4) Series 100 e 02/2004 230/120 V AC INPUT / ANALOG SIGNAL OUTPUT *) BINOS ® 100 2M/F from program version 5.0 or hoigher only 30.
CABLES AND CORDS 30 - 3 ETC00781(4) Series 100 e 02/2004 30.3 Data / Signal Lines 30.3.1 Sub D Sockets, 9 pin The following cables are availble for analog signal outputs (X2 Output) and RS 232/485 ser.
CABLES AND CORDS 30 - 4 ETC00781(4) Series 100 e 02/2004.
32 - 1 ETC00781(4) Series 100 e 02/2004 17. Analog Output absent RR 18. Fluctuating display without error RR 19. Response time to long RR 20. Chopper has loud noise R 21. Measuring values to high RR 22. Measuring values to low RR 23. Misalignment Display/Analog output RR 24.
32 - 2 ETC00781(4) Series 100 e 02/2004 Additional tests of electronics (see chapter 17): 33. Supply voltage + 6 V incorrect R 34 Reference voltage positive incorrect R 35 Reference voltage negative incorrect R 36. Motor drive incorrect R 37. Light barrier signal incorrect R 3 8.
32 - 3 ETC00781(4) Series 100 e 02/2004 If factory repair of defective equipment is required, proceed as follows: 1 . Secure a return authorization from a Emerson Process Management Sales Office or Representative before returning the equipment.
32 - 4 ETC00781(4) Series 100 e 02/2004 Customer Service For order administr ation, replacement par ts, applicaton assistance , on-site or f actor y repair , service or maintenance contract information, contact: In Europe: Emerson Process Management Manufacturing GmbH & Co.
Series 100 Gas Analyzers Instruction Manual ETC00781 02/2004 ASIA - P ACIFIC Emerson Process Management Asia Pacific Pte Ltd 1 Pandan Crescent Singapore 128461 T el +65 6777 821 1 Fax +65 6777 0947 Internet: www .
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