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Emerson Process Management Series 100 Gas Analyzers HYDROS 100 User's Manual

1. INTERNAL CONSTRUCTION Gas line fittings EE FE oe a Solenoid valves a N t y T Option SI PN m 5 no Circuitboard BKS Powersupplyoptian d below physical bench UPS 01 IR photometer bench Ez o depending on analyzer configuration LT PCB WAP 100 Electrochemical i oxygen sensor i with circuit board OXS depending on analyzer configuration sid e o E e o Thermal conductivity sensor depending on analyzer fe HER configuration al o 5c Gas sampling pump option Ao 10 g a NES A FILTERELEMENT 2um 42 707 676 Fine dustfilter 2 with integrated So q Flow indicator needle valve for option regulation of gas flow rate option Fig 1 17 Inside View dual channel BINOS 100 2M version A IR EO TC EO orlR TC measurement combined ETC00781 4 Series 100
2. INTERNAL CONSTRUCTION Gas line fittings af dlo cn r i nO Solenoid valves U Option Miti 2 T m AX 1 2 E Circuitboard BKS Digitalinputs and d below physical bench FOUNDATIONTM E Fieldbus IR photometer bench options depending on analyzer configuration Cena and Electrochemical 8 O G oxygen sensor HEX 01 EE intrinsically safe TC o pun 2 pee Be depending on analyzer measurement for configuration potentially explosive 9 i i SU atmosphere EMO a de consultfactory OR Channel2 Channel1 1 H E Th d Channel 1 b ermal conductivity sensor A depending on analyzer configuration a fe Gas sampling pump option Fig 1 19 Inside View dual channel BINOS 100 2M version B IR channel oxygen measurement combined 00781 4 Series 100 e 02 2004 1 21 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Gas line fit
3. Zeroing channel 1 Zeroing channel 2 5 Spanning channel 1 d Spanning channel 2 RIUSCIRE q Interval Time for automatic Zeroing Only in combination of internal solenoid valves or digital outputs andexternal solenoid valves and E Interval Time for automatic Spanning if Auto 1 llILL I e w E Entry of concentration limits All 3 lo Entry of system parameters FORT GG a a 11 5 Only with Option RS 232 C 485 Serial Entry of serial interface parameters M A sue Interface SS Ss is SDS SSD ETC00781 4 Series 100 e 02 2004 7 3 KEY FUNCTIONS ENTER 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 for the initiation of certain operations such as zeroing and spanning First time the ENTER key is pressed within the function sequences following the sequences from Zeroing 0 1 to the interface parameter SIP the display will show the message This indicates that for safety reasons a password user code CODE must be entered in order to enable access to the specific level If a wrong
4. INTERNAL CONSTRUCTION span gas 1 SPAN 1 V1 gt Analyzer span gas 2 Si solenoid valves 7 SPAN 2 V2 fili Option Gas outlet gt OUT K1 sample gas gt lt V SAMPLE V3 el sample gas pump Option 4 PN o zero gas fa Z Flow indicator ZERO V4 z 7 VA Ls Filter and throttle Options Gas outlet Gas inlet OUT IN K1 not for BINOS 100 F in hazardous areas Fig 1 25 Tubing in series BINOS 100 2M analyzers equipped with all options o 2 5 DT Ou Do OT Sal 5 O C 3 ga Od x S X E EZ Su 00 8z o Sa NN SE c D Sk o V V V Gas outlet V 72 V V as outle A EE gt LA PAR LA ds OUT K1 e V Flow indicator Gas outlet sample gas pump OUT K2 Option e i L lt 5 _ V V NY au Y X HX HX X J N o 2 gt Si d s o c aa 3 o W on rg 5 z en OD zx 20 2 T nO 92 gx EZ de GE a 25 NO o Fig 1 26 Tubing in parallel special version of BINOS 100 2M analyzer equipped with all options ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION 00781 4 Series 100 e 02 2004 1 28 4 MEASURING PRINCIPLE IRMEASUREMEN
5. REAR PANEL 1 2 3 4 6 5 8 9 josss 9 X1 OUTPU gel FLOW 10 MAX 1L MIN X3 OUTPUI 11 FN al Fig 1 7 BINOS 100 2M version A shown with internal power supply Rear view with all options 11 12 13 14 15 16 17 Gas inlet line fitting 2 gas inlet line fitting option Gas outlet line fitting 2 gas outlet line fitting option Plugforanalog signal inputs interference cross compensation TC only Solenoid valves common gas outlet line fitting Solenoid valves Test gas inlet 1 Solenoid valves Test gas inlet 2 24 VDC output max 2 A see technical data Power supply UPS 01 T Universal Power Supply Plug Power Supply Mains line Solenoid valves Zero gas inlet Solenoid valves Sample gas inlet Plug Digital Outputs threshold contacts Mating socket Serial Interface RS 232 C 485 option Mating socket Analog Signal Outputs Plug Output Relays status signal option ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION REAR PANEL ve O fil v IOF Et e LIO O ES E6 t LH E7 Ny FB m IM LV
6. X1 OUTPU 4 JURCHFLUSS MAX 1L MIN X3 OUTPUT f 7 O VY RE 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 100F The analyzer is specified for an operating voltage of 230 V AC or 120V AC resp 47 63 Hz Built in power supply manual switch between 230 120 VAC is either power supply of type SL5 or of type SL10 Once the instrument has been correctly assembled and installed in accordance with the general instructions given in section 5 5 3 3 and 5 4 the equipment is ready for operation The analyzer is switched on by providing the required voltage ETC00781 4 Series 100 e 02 2004 6 5 SWITCHING ON 6 6 00781 4 Series 100 e 02 2004 KEY FUNCTIONS 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 BINOS 100 2M or BINOS 100 F analyzer is equipped with an internal pump the fifth key PUMP is activated by software see Fig 1 2 Item 8 and chapter 7 4 BINOS 100 F for use in rough surroundings may optionally be equipped with a touch screen keypad without fifth key for gas sampling pump In this case the pump
7. 1 5 1 interfering gas 1 20 1 GND interfering gas 1 5 9 gt interfering gas 2 4 gt 1 GND interfering gas 2 5 not used 1 6 6 o interfering gas 3 o 1 GND interfering gas 3 8 not used 6 9 9 a not used T dE Fig 14 1 Pin assignments Cross Comp Analog In TC Option analog signal inputs for interference compensation ETC00781 4 Series 100 e 02 2004 14 1 CROSS COMPENSATION SETTING OF RESPSONSE TIME TC ONLY CROSS COMPENSATION 14 1 1 Preparing Actions The adjustment procedure for alteration the factory settings of cross compensation is as follows The number of interfering gases and the type of analog input signal is selected by configuring solder bridges on the printed circuit boards WAP 100 TC signal processing and BSE 01 analog input signals O Openthe analyzer housing cf Section 23 O Remove the PCB s and check and or alter the solder bridges cf table 14 1 Analog Input PCBWAP 100 PCB BSE 01 LB 9 LB8 LB 1 LB 9 LB 6 LB 7 LB2 LB 6 Signal LB 13 LB 12 LB 3 LB 12 0 1VDC 1 2 open open closed 0 10VDC 1 2 open open open 0 20 1 2 closed closed 0 2 1V DC 2 3 closed open closed 2 10V DC 2 3 closed open open 4 20mA 2 3 closed closed closed not used open open open open Table 14 1 Solder bridges TC option analog signal inputs for cross compensation
8. 6 amp Fig 23 1 BINOS 100 2M Fastening screws housing cover ETCO00781 4 Series 100 e 02 2004 23 3 HOUSING OPENING THE HOUSING BINOS 100 2M b Front Panel O Opening housing cover Item 23 2 2 O Unscrew the 6 fastening screws at both housing sides Fig 23 2 O Remove front panel to the front carefully 1 If the optional components fine dust filter and flow meter are mounted at front panel take care of gas lines see Fig 1 2 Closing the housing is performed in reverse order 1 Do not squeeze gas lines Fasteningscrews front panel n PS HIT Fig 23 2 BINOS 100 2M Fastening screws front panel viewed without options filter and flow sensor 2 3 4 ETC00781 4 Series 100 e 02 2004 HOUSING OPENING THE HOUSING BINOS 100 F 23 2 3 BINOS 100 F Field Housing O Open all 4 fasteners with a square key Fig 23 3 O Carefully swing out the front panel to the right side O Pulloutthe phometer slide in cart to the front carefully Photometer components may be hot Closing the housing is performed in reverse order Fastener for front panel Fastener for front panel Fig 23 3 BINOS 100 F Field housing fastener for front panel ETC00781 4 Series 100 e 02 2004 23 5 HOUSING 23 6 00781 4 Series 100 e 02 2004 REPLACEMENT AND CLEANING O
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10. 27 4 Fig 27 2 Dimensional sketch BINOS 100 2M dimensions mm ETC00781 4 Series 100 e 02 2004 TECHNICAL DATA 550 492 approx 355 EE TE ora 1 1 7 95 pes uw e N x 9 9 8 o caes QOO bd d Pa NI Se E gi A Glands N p connection cables Gas connections Fig 27 3 Dimensional sketch Drill drawing BINOS 100 F Single Section Housing for General Purpose Applications dimensions in mm 30 Soc e Al PURGE IN d A 2 9 TA t IS SI Ko D z 25 E E 2 o S 7 5 3 z E ks ul E d DE e steli Ga DOE 38 Fig 27 4 Dimensional sketch BINOS 100 with Continuous Purge for CENELEC Ex Zone 1 Applications or with Z purge for CSA C US Ex Zone 2 Non Flammable Atmospheres ETC00781 4 Series 100 e 02 2004 27 5 TECHNICAL DATA 27 4 Gas Related Specifications For information about measuring components and ranges ofthe 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 See chapter 27 for information about how to read a name plate label Available Measuring Components and Ranges s
11. LIST OF FAILURES Possible Reasons Check Correct Flashing Channel 1 Channel2 A D Conversion End Signal absent Temperature compensation interferred Battery buffer faulty The EPROM default values were charged Jumper not or incorrect plugged Positive or negative reference voltage absent Light barrier signal absent IR channel Chopper drive inoperative Supply voltage internal 6 V DC absent Start up of A D conversion in temperature channel absent Supply voltage internal 6 V DC absent Check if Jumper J 7 is plugged see chapter 19 Exchange battery if battery voltage 3 5 V BKS Jumper J7 plugged The error is clearing after depressing any key or with serial interface instruction 627 Channel 1 Check Jumper J1 Channel 2 Check Jumper J2 see chapter 18 Switch analyzer off and then on again Check reference voltage see chapter 17 1 2 17 1 3 Check connection X9 light barrier see chapter 18 Check measuring point 17 1 6 Check connection X2 chopper drive see chapter 18 Check measuring point 17 1 4 Check measuring point 17 1 1 Switch analyzer off andthen on again Check measuring point 17 1 1 ETCO0781 4 Series 100 e 02 2004 LIST OF FAILURES Possible Reasons Check
12. Red Black o 11 Thermistor 5 Resistor 6 Gold Lead Cathode 2 x Anode 1 4 AN S cR Tea N N N EN gt Pa Se SN Pow E CS 4 4 amp gt 2 H O 2 Pb 2 H O gt 2 PbO 4 H 4 Electrolyte 3 e NA Summary reaktion O 2 Pb gt 2 PbO Fig 2 6 Reaction of galvanic cell The electric current between the electrodes is proportional to the O concentration in the gas mixture to be measured The signals are measured as terminal voltages of the resistor 6 and the thermistor 5 fortemperature compensation The change in output voltages mV of the senor 11 represents the oxygen concentration Note Depending on measuring principle the electrochemical O cell needs a minimum internal consumption of oxygen residual humidity avoids drying of the cell Supply cells continuously with dry sample gas of low grade oxygen concentration or with oxygen free sample gas could result a reversible detuning of O sensitivity The output signal will become instabil For correct measurement the cells have to be supplied with O concentrations of at least 0 1 Vol We recommend to use the cells in intervall measurement purge cells with conditioned dust removal but no drying ambient air during measurement breaks If itis necessary to interrupt oxygen supply for several hours or days the cell has to regenerate Supply cell for about one day
13. i 7 A Im 1 0 N DU Ss AS N CONTENTS 9 CALIBRATION 9 1 Manual Calibration 9 1 1 Zeroing 9 1 2 Spanning 9 2 Time Controlled Calibration Mode Option 9 2 1 Zeroing 9 2 2 Combined Zeroing and Spanning 9 3 Remote Controlled Calibration Mode Option 10 MEASUREMENT SWITCHING OFF 10 1 Measurement 10 2 Switching Off 11 DIGITAL OUTPUTS 11 1 Concentration Limits 11 2 Valve Control 11 3 Status Signals Option non voltage carrying relay contacts 12 SERIAL INTERFACE OPTION 12 3 Upgrading Serial Interface Status Signals 12 2 12 3 Start Up 12 3 1 RS 232 C 12 3 2 RS 485 12 3 3 Switching ON OFF Interface Operation 12 3 4 Setting Interface Parameters 12 4 Telegram Syntax 12 4 1 Start Character Hex 24 12 4 2 Terminate Character CR Hex OD 12 4 3 Instruction Code 12 4 4 Hyphen Character 5 Hex 3B 12 4 5 Status Telegram 12 4 6 Numerical Representations 12 4 7 Block Parity Check 12 5 Instruction Syntax 12 5 1 Instruction Listing 12 5 2 Response Telegrams 9 1 9 2 9 2 9 4 9 7 9 7 9 9 9 10 10 1 10 1 10 1 11 1 nia 2 did 11 4 12 1 12 gt 1 12 2 id 4 12 4 12 5 12 6 12 6 12 8 12 8 12 8 12 8 126 8 12 9 12 10 12 10 10211 12 12 12 13 00781 4 Series 100 e 02 2004 CONTENTS 13 DIGITAL INPUTS FOUNDATION FIELDBUS BINOS 100 2M F
14. FB 16 17 14 6 13 12 11 10 Fig 1 8 BINOS 100 2M version B with external power supply Rear view with all options ETC00781 4 Series 100 e 02 2004 qr Gas inlet line fitting 2 gas inlet line fitting option Gas outlet line fitting 2 gas outlet line fitting option Plug for analog signal inputs interference cross compensation TC only Solenoid valves common gas outletline fitting Solenoid valves Test gas inlet 1 Solenoid valves Test gas inlet 2 Terminal strips for the 7 Digital Inputs option Terminal strips for FOUNDATION Fieldbus option 24V DC supply input terminal Solenoid valves Zero gas inlet Solenoid valves Sample gas inlet Plug Digital Outputs threshold contacts Mating socket Serial Interface RS 232 C 485 option Mating socket Analog Signal Outputs Plug Output Relays status signal option only possible if serial interface RS 232 485 is not request only possible if FOUNDATION Fieldbus is not request 1 9 TECHNICAL DESCRIPTION REAR PANEL J ANALOG IN A pa X2 OUTPUT ls 9 FLOW MAX 1L MIN X3 OUTPUT of 5 16
15. TECHNICAL DESCRIPTION REAR PANEL N E e 1 0 9 0 5 e n e e our e CROSS COMP X1 OUTPUT 7 INTERFACE X2 OUTPUT X3 OUTPUT Fig 1 5 BINOS 100 M OXYNOS 100 EO HYDROS 100 Rear view Gas inlet line fittings Analog signal output mating socket 24VDC supply input terminal Plug for Digital signal output Gas outlet line fittings Housing cover fastening screws mating socket Serial Interface RS 232 C 485 Option Plugfor Output Relays Option Plugforanalog signal inputs interference cross compensation HYDROS 100 only o o 00 a ON 00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION REAR PANEL 4 X2 OUTPUT INTERFACE X1 OUTPUT G 6 O OJ OUTPUT Fig 1 6 OXYNOS 100 PO Rear view Gas inlet line fittings Analog signal output mating socket 24 VDC supply input terminal Plugfor Digital signal output Gas outlet line fittings Housing coverfastening screws mating socket Serial Interface RS 232 C 485 Option Plugfor Output Relays Option o NOOA ETC00781 4 Series 100 e 02 2004 1 7 TECHNICAL DESCRIPTION
16. E Do 9 eo A Ir channel 2 channel1 ij EF HT i C Frontpanel IR photometer bench depending on analyzer configuration Pressure sensor option 1 IR channel analyzer high measuring range with gas detector 00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Gas line fittings DIL DI LI i no bd LJLL Tim po popu E S AA J Cover metal plate PCBBKS TET IR photometer bench cm electrochemical depending on analyzer e oxygen sensor configuration ie oso ha with PCB OXS S TIE ad o _ JA ak Toe LF 5 5 se 95 OUT u _ channel2 channel 1 H IFTE dA Em ES T T i Pressure sensor n p LI Front panel Fig 1 11 Inside View BINOS 100 IR channel electrochemical oxygen measurement 00781 4 Series 100
17. O Reinstall the PCB s and correctly replace any connector 14 2 ETC00781 4 Series 100 e 02 2004 CROSS COMPENSATION SETTING OF RESPSONSE TIME TC ONLY CROSS COMPENSATION 14 1 2 Adjustment Procedure O Switch on the TC analyzer chapter 6 and all analyzers used for measuring interfering gas components O Perform zeroing and spanning of all relevant measuring channels O Connect the gas paths of all analyzers in series and purge with zero gas N nitrogen O Connect the analog signals of the analyzers used for measureing interfering gas components to the respective analog input Fig 14 1 of the TC analyzer The following steps have to be executed for each interfering gas seperately O Supply the maximum concentration of the respective interfering gas maximum concentration should be full scale of the analyzer measuring the interfering gas For external analyzers with different measuring ranges be sure that the analog signal 2 connected to the TC analyzer is related to the highest measuring range and that this measuring range does not change while adjusting the cross compensation O Adjustthe correlated potentiometers of the PCB WAP 100 to setthe analog signal output of TC measurement to Zero The potentiometer assignments is as follows Interfering gas analoginput1 Q1 R 71 Interfering gas analoginput2 Q2 R 84 Interfering gas analoginput3 118 Purge with zero gas N nitrogen c
18. O FOUNDATION Fieldbus chapter 13 2 A calibration will be performed as described in either chapter 9 1 single channel zeroing or spanning orin chapter 9 2 2 combined zeroing and spanning depending on startcommand 9 1 0 ETC00781 4 Series 100 e 02 2004 MEASUREMENT SWITCHING OFF MEASUREMENT 10 Measurement Switching Off 10 1 Measurement 2 Analyzer warming up after switching on takes about 15 to 50 minutes depending on the installed detectors O Supply sample gas to the gas inlet fitting chapter 5 3 O Switching on optional sample gas pump c f chapter 7 4 O Adqgjust the gas flow rate with optional needle valve within the specified rate The analyzer must be in the analysis mode i e the displays must show XXX X Note If another mode has been selected the analyzer will automatically return to the analysis display when a period of 60 120 seconds has elapsed after the last key actuation or after the last completion of an operation The analyzer will remain at analysis display until another mode is selected Note for analyzers with electrochemical O cell On account of the measuring principle the electrochemical O cell needs a minimum internal consumption of oxygen residual humidity avoids the cell running dry Continuously supplying cells with dry sample gas of low grade oxygen concentration or with oxygen free sample gas could result a reversible change of O sensitivity
19. For operation with optional internal or external solenoid valves the solenoid valves are activated automatically by the respective function via digital outputs If the analyzer is in calibration mode a digital status signal calibration may be set see chapter 11 3 Zeroing For zeroing the analyzer has to be flushed with nitrogen N or adequate zerogas e g synth air or conditionned air Spanning The span gas concentration should be in a range of 80 110 of full scale range For lower span gas concentrations the measuring accuracy could be decreased for sample gas concentrations which are above the span gas concentration Spanning for oxygen measurement can be done using ambient air as span gas if the oxygen concentration is known and constant When using span gas mixtures the entry for C Cal must be set to 0 see chapter 8 3 If there is no built in pressure sensor the correct pressure must be entered before 2 performing the calibration if you want to have the possibility of pressure correction see chapter 8 1 ETC00781 4 Series 100 e 02 2004 9 1 CALIBRATION MANUAL ZEROING 9 1 Manual Calibration 9 1 1 Zeroing Zeroing will set the actually measured gas concentration to zero Push the key until the display shows Zeroing channel 1 or play XXXX g U e Zeroing channel 2 resp XXXX Press the key i
20. SIP parameter On L 1 for online status SIP parameter On L 0 for offline status Telegram setting Instructioncode6 sets analyzer online status Instructioncode 7 sets analyzer offline status If the analyzer is set to offline status it will accept only instruction code 6 All other instructions will be ignored and result in transmission of appropriate status telegrams 12 3 4 Setting Interface Parameters Agreement of interface parameters between analyzer and host computer is a fundamental requirement for communication without errors The following analyzer parameters are concerned L baudrate 600 1 200 2 400 4 800 9 600 19 200 38 400 bits s L databits 8 L stop bits 2 L paritybit none L echo mode on off received characters will be retransmitted immediately 1 LPB test on off message length parity check L ID no 0 to 99 device ID no in RS 485 mode 12 6 00781 1 Series 100 e 10 2001 Rosemount Analytical FISHER ROSEMOUNT SERIAL INTERFACE OPTION START UP INTERFACE PARAMETER and Press the key until then push the key ETC00781 1 Series 100 e 10 2001 LR All entries are made using the keys AM ENTER FUNCTION ENTER a appears a The unit is now ready for c
21. The BINOS 100 F field housing has no switch with disconnect function The customer has to provide a switch or circuit breaker into his installation This switch has to be installed near by analyzer must be easily attainable for operator and has to be charaterized as disconnector for analyzer Front door cable glands gt E for data lines V pl T cable gand for mains line 1 Wall mounting POLI Gas connections holder i Hi Fig 5 6 BINOS 100 F cable glands for lines side view from left ETC00781 4 Series 100 e 02 2004 5 1 3 PREPARATION ADDITIONAL HINTS ON BINOS 100 F FIELD HOUSING b Optional Signal Lines This are analog outputs digital inputs outputs and serial interfaces O Opentheanalyzer s front door O Insert the cable through the cable glands Fig 5 6 and 5 5 into the housing Connection is to be done to the respective terminal strips Fig 5 7 and 5 8 Assignment see chapter 2 Cables to external dataprocessing have to be double insulated against mains voltage for analyzer BINOS 100 compatibility EMC it is recommended to follow the installation steps given Use only shielded cables for signal lines To ensure proper electromagnetic below All unused cable glands need to be sealed using a sealing plug part no 00791 or similiar Unused cable gland openings in the enclosure need to be covered using a
22. 09 10 14 15 16 17 18 21 22 23 24 25 26 27 28 il Chopper Housing Duplex Filter Disc Zero Adjustment Baffle not for sealed photometer Light Source thermal radiator Analysis Cell 1 7 mm spacer ring Analysis Cell 50 200 mm Adapter Cell Filter Cell Detector Flange light source O Rings Clamp analysis cells 1 7 mm Clamping Collar analysis cells 1 7 mm Clamp analysis cells 10 200 mm Light Source Mounting Screws Mounting Screws for Analysis Cells Adapter Cells Temperature Sensor YHOLOALAC IVOIHLOd THOHAd A18W3SSV JILIINOLOHd PHOTOMETER ASSEMBLY GAS DETECTOR 3 2 Photometer with Gas Detector Fig 3 2 shows schematically the photometer assembly This assembly is similar to the assembly with pyroelectrical detector The analysis cells are separated into two halves by means of an internal wall along its axis and both ends are sealed with windows This divided the analysis cell in measuring side and reference side Sample gas is flowing through measuring side while the closed reference side contains inert gas To prevent measuring errors by preabsorption two absorber fitted to the gas connections of the reference side absorb CO parts The filter cell has a single stage conical shape The gas detector is connected by a shielded cable to the separate preamplifier For small measuring ran
23. If necessary enter the test gas setpoint value taken from the manufacturer s certificate on the gas bottle INPUT CONTROL using the keys A VI ETCO00781 4 Series 100 e 02 2004 9 5 CALIBRATION MANUAL SPANNING The actual measuring value one XXX X resp XXXX will be displayed Quit the calibration mode by pressing the FUNCTION key nominal value is entered without span calibration or push ENTER again to start spanning As soon as spanning has finished the display indicates the actual measuring value SN XXXX resp E XXXX will be displayed The keyboard will only be released after another flushing period and t time If Hold 1 the analog signal outputs and the concentration limits are released too To leave calibration mode press FUNCTION When using span gas mixtures the entry for C Cal must be set to 0 see chapter 8 3 If there is no built in pressure sensor the correct pressure must be entered before performing the calibration if you want to make use of pressure correction see chapter 8 1 00781 4 Series 100 e 02 2004 CALIBRATION AUTOMATIC ZEROING OPTION 9 2 Time Controlled Calibration Mode Option Atime controlled calibration only can be done with internal or separate external solenoid valves via digital outputs The automatic fu
24. SAFETY SUMMARY GENERAL Safety Summary l Intended Use Statement The series 100 instruments are intended for use an industrial measurement device only It is not intended for use in medical diagnostic orlife support applications and no independent agency certifications or approvals are to be implied as covering such applications Il Safety Symbols Several symbols attached to the analyzer or printed in the instruction manual are used to point out special sources of danger Source of danger See Operation Manual gt 4 Electrostatic Discharge ESD A Explosives Hot components AN Toxic Risk to health 1 Analyzer specific notes for the user gt For additional information to these safety symbols see instruction manual Strictly follow the related instructions ETC00781 4 Series 100 e 02 2004 S 1 SAFETY SUMMARY GENERAL General To avoid explosion loss of life personal injury and damages to this equipment and other property all personnel authorizedto install operate and service this equipment should be thoroughly familiar with and strictly follow the instructions in this manual Save these instructions If this equipmentis used in a manner not specified in these instructions protective features may be impaired Correct and safe operation of analyzers calls for appropriate transportation and storage expertinstallation and commissioning as wel
25. The output signal will become unstable For correct measurement the cells have to be supplied with O concentrations of at least 0 1 Vol Werecommendto use the cells in intervall measurement purge cells with conditioned removal of dust but no drying ambient air during measurement breaks If itis necessary to interrupt oxygen supply for several hours or days the cell has to regenerate Supply cell for about one day with ambient air Temporary flushing with nitrogen N for less than 1 h e g analyzer zeroing does not influence the measuring quality 00781 1 Series 100 e 10 2001 10 1 10 2 Switching Off MEASUREMENT SWITCHING OFF SWITCHING OFF Before switching off the analyzer purge all the gas lines for about 5 minutes with zero gas N or adequate conditioned air The full procedure for shutting down is as follows conditioned ambient air before closing the gas line fittings for transport or Y For analyzers with electrochemical O cell purge all gas lines with depositing the analyzer O Supply zero gas to the gas inlet fitting O Switch on the optional sample gas pump see chapter 7 4 O Adjust the gas flow rate with optional needle valve within the specified rate O Wait 5 minutes O Switch Off by disconnecting the voltage supply O ShutOffthe gas supply O Closeallgasline fittings immediately 10 2 00781 1 Series 100 e 10 2001 DIGITAL OUTPUTS 11 Digital Outputs All standard digita
26. for example 40 C could be the half life time and measured concentrations Note On account of the measuring principle the electrochemical O2 cell needs a minimum internal consumption of oxygen residual humidity avoids the cell running dry Continuously supplying cells with dry sample gas of low grade oxygen concentration or with oxygen free sample gas could result a reversible change of O2 sensitivity The output signal will become unstable For correct measurement the cells have to be supplied with O2 concentrations of at least 0 1 Vol We recommend to use the cells in intervall measurement purge cells with conditioned removal of dust but no drying ambient air during measurement breaks If itis necessary to interrupt oxygen supply for several hours or days the cell has to regenerate supply cell for about one day with ambient air Temporary flushing with nitrogen N2 for less than 1 h e g analyzer zeroing does not influence the measuring quality For analyzers with electrochemical O cell purge all analyzer gas lines with conditioned ambient air before closing the gas line fittings for transport or depositing the analyzer ETCO00781 4 Series 100 e 02 2004 25 CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR CHECKING THE SENSOR 25 1 A Checking the Sensor Alas Replace the sensor if the voltage is less than 70 of the initial output voltage The check requires a digital voltmeter DVM with a range of
27. 10 2001 18 Plug Pin Allocation of Printed Circuit Boards 0000000601 Z lt a w g Marked X1 mumumuumum 00n00X3 1 1 4 Front panel Fig 18 1 PCB BKS Plug Pin Allocation principle drawing 18 1 PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS PLUG PIN ALLOCATION OF BKS Rosemount Analytical FISHER ROSEMOUNT 18 1 1 IRmeasurement without oxygen channel X2 Chopper X3 4 5 Light source channel 1 X3 1 2 Light source channel 2 X5 IR detector channel 1 X6 IR detector channel 2 X7 Temperature sensor chopper X9 Light barrier chopper 18 1 2 Oxygen Measurement without IR channel X5 Oxygen sensor channel 1 atelectrochemical measurement PCB OXS cable P1 5 pin connector X7 Oxygen sensor channel 2 atelectrochemical measurement PCB OXS cable P1 5 pin connector X7 Temperature sensor atelectrochemical measurement PCB OXS cable P1 2 pin connector 18 2 00781 1 Series 100 e 10 2001 Rosemount Analytical FISHER ROSEMOUNT PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS PLUG PIN ALLOCATION OF BKS X2 X3 4 5 X5 X6 X7 9 In preparation ETC00781 1 Series 100 e 10 2001 18 1 3 IR Oxygen Measurement combined Chopper Light source channel 2 Oxygen sensor IR detector channel 2 Temperature sensor chopper Light barrier chopper 18 1 4 TC Measurement wi
28. 2 Opto Pneumatic Measuring Principle A thermal radiator generates the infrared radiation passing through a chopper wheel This radiation alternately passes through a filter cell and reaches the measuring and reference side of the analysis cell with equal intensity After passing another filter cell the radiation reaches the pneumatic detector The pneumatic detector compares and evaluates the radiation from the measuring and reference sides and converts them into voltage signals proportional to their intensity via a preamplifier The detector consists of a gas filled absorption and a compensation chamber which are interconnected via a flow channel Absorption chamber CaF Window Gas intake connection Flow channel with Microflow sensor Compensation chamber Fig 2 2 Principle Design of Gas Detector ETC00781 1 Series 100 e 10 2001 2 3 MEASURING PRINCIPLE IRMEASUREMENT In principle the detector is filled with the infrared active gas to be measured andis only sensitive to this distinct gas with its characteristic absorption spectrum The absorption chamberis sealed with a window which are transparent for infrared radiation usually CaF Calcium fluoride When the IR radiation passes through the reference side of the analysis cell into the detector no preabsorption occurs Thus the gas inside the absorption chamber is heated expands and some of it passes through the flow channel into the compensation chamber When the IR ra
29. E 2 Ft 7 O N Eii Plug 24 V DC Input Fig 6 1c BINOS 100 2M version B with external power supply Voltage supply ETC00781 4 Series 100 e 02 2004 SWITCHING ON 230 120 V AC SUPPLY 6 3 1 5 100 2M The analyzer BINOS 100 2M is optional lly equipped with an internal autoranging power supply and is specified for an operating voltage of 230 V AC or 120 V AC resp 47 63 Hz For supply of external components analyzers there is builtina24 VDC outlet a 3 pole XLR flange female max 2 O Connect internal power supply and external components Fig 6 2 24 V DC out 24VDC supply to external components analyzers with the internal power A supply of BINOS 100 2M requires a fuse to be connected in series to the consumer which limits the current consumption to max 2 A Verify correct polarity for 24 V DC supply to external components before X operation Section 29 O Connect mains line and internal power supply Fig 6 2 V AC in Verify beforehand that the line voltage stated on the power supply meets that N of your power supply line The socket outlet shall be installed near the equipment 6 4 00781 4 Series 100 e 02 2004 SWITCHING ON 230 120 V AC SUPPLY Socket 24 V DC out
30. In Europe Emerson Process Management Manufacturing GmbH amp Co OHG Service Department Germany 49 6055 884 470 472 In US Rosemount Analytical Inc Process Analytic Division Customer Service Center 1 800 433 6076 In Asia Pacific Emerson Process Management Asia Pacific Pte Limited 1 Pandan Crescent Singapore 128461 65 6 777 8211 32 4 00781 4 Series 100 e 02 2004 Series 100 Gas Analyzers Instruction Manual ETC00781 02 2004 EUROPE Emerson Process Management MFG GmbH amp Co OHG Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884 209 Internet www emersonprocess de EUROPE MIDDLE EAST AFRICA Emerson Process Management Shared Services Limited Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 Internet www emersonprocess co uk NORTH AMERICA Rosemount Analytical Inc Process Analytic Division 1201 N Main St Orrville OH 44667 0901 T 1 330 682 9010 F 1 330 684 4434 Internet www emersonprocess com LATIN AMERICA Emerson Process Management Ltda Avenida Hollingsworth 325 Iporanga Sorocabe SP 18087 000 Brazil T 55 152 38 3788 F 55 152 38 3300 Internet www emersonprocess com br ASIA PACIFIC Emerson Process Management Asia Pacific Pte Ltd 1 Pandan Crescent Singapore 128461 Tel 65 6777 8211 Fax 65 6777 0947 Internet www ap emersonprocess com Emerson Pro
31. Inc Process Analytic Division Customer Service Center 1 800 433 6076 In Asia Pacific Emerson Process Management Asia Pacific Pte Limited 1 Pandan Crescent Singapore 128461 65 6 777 8211 If warranty service is expected the defective unit will be carefully inspected and tested at the factory If failure was due to conditions listed in the standard Rosemount warranty the defective unit will be repaired or replaced at Rosemount s option and an operating unit will be returned to the customer in accordance with shipping instructions furnished in the cover letter For equipment no longer under warranty the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions ETC00781 4 Series 100 e 02 2004 32 3 SERVICES Customer Service For order administration replacement parts applicaton assistance on site or factory repair service or maintenance contract information contact In Europe Emerson Process Management Manufacturing GmbH amp Co OHG Service Department Germany 49 6055 884 470 472 In US Rosemount Analytical Inc Process Analytic Division Customer Service Center 1 800 433 6076 In Asia Pacific Emerson Process Management Asia Pacific Pte Limited 1 Pandan Crescent Singapore 128461 65 6 777 8211 Training A comprehensive Factory Training Program of operator and service classes is available For a copy of the training schedule contact
32. OPTION ONLY 13 1 13 1 1 13 1 2 13 1 3 13 1 4 13 2 Digital Inputs General Start of Calibration Valve Control Pump Control Foundation Fieldbus 14 CROSS COMPENSATION SETTING OF RESPSONSE TIME TC OPTION ONLY 14 1 14 1 1 14 1 2 Cross Compensation Preparing Actions Adjustment Procedure 16 LIST OF FAILURES 17 MEASURING POINTS OF BKS AND OXS 17 1 17 1 1 17 1 2 17 1 4 17 1 5 17 1 6 17 1 7 17 2 17 2 1 Measuring points of BKS Supply Voltage 6 V Reference Voltage positive Motor Drive for IR channel only Temperature Sensor Light Barrier Signal Analog Preamplifiering Measuring points of OXS EO2 measurement Sensor Signal ETC00781 4 Series 100 e 02 2004 14 Ni N Nub cd wx 1 14 ide 14 1 2 3 md gt a CONTENTS 18 PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS 18 1 Plug Pin Allocation of BKS 18 1 1 IR measurement without oxygen channel 18 1 2 Oxygen Measurement without IR channel 18 1 3 IR Oxygen Measurement combined 18 1 4 TC Measurement without IR channel 18 1 5 IR TC Measurement combined 18 1 6 Oxygen TC Measurement combined 18 2 Plug Pin Allocation OXS 2 measurement only 18 3 Plug Pin Allocation WAP 100 TC measurement only 19 JUMPER ALLOCATION OF BKS 21 FINE DUST FILTER OPTION 22 LEAK TESTING 23 HOUSING 23 1 Cleaning of Housing Surface 23 2 Opening the Hou
33. OXYNOS 100 HYDROS 100 Front view LED display channel 1 LED display channel 2 Input setting control key DOWN Input setting control key UP Key ENTER Key FUNCTION Fastening screws for the carrying strap bracket orrack mounting purposes 12 Housing cover fastening screw YO 1 nD 1 2 00781 4 Series 100 02 2004 TECHNICAL DESCRIPTION FRONT VIEW Needle valve option 1 2 2 2 2 AT ni _ Ei 1000 SPAN 1 0 SAMPLE 3 O SPAN 2 ERO o PUMP j PUMP UNCTION ENTER NPUT CONTROI o gt Na uh x J J F M 2 11 10 9 3 8 7 6 5 4 Fig 1 2 BINOS 100 2M standard version front view LED display channel 1 LED display channel 2 Function LED for options Solenoid Valves Gas Sampling Pump Input setting control key DOWN Input setting control key UP ENTER key FUNCTION key Key for option Gas Sampling Pump Flow indicator option Fine dust view filter with needle valve option Fastening screws for the carrying strap bracket orrack mounting purposes O 0 ON DO gt gt ETC00781 4 Series 100 02 2004 1 3 TECHNICAL DESCRIPTION FRONT VIEW Wall mounting holder Fig 1 2 for General Purpose Fastener front panel Operation front p
34. SL5 SL 10 Nominal voltage Input voltage UPS 515 or SL10 Input power UPS or SL5 51110 Fuses UPS internal Output Output voltage UPS 515 51 70 Output power UPS 515 SL10 Dimensions UPS Rack module Installation depth with plug cable UPS table top module SL5 mountable on DIN supporting rails TS35 SL10 mountable on DIN supporting rails TS35 ETCO00781 4 Series 100 e 02 2004 plug terminal s terminal s 230 120 V AC 50 60 Hz 196 264 V AC and 93 132 V AC 47 63 Hz with autoranging manual switch max 350 VA max 700 VA T 3 15A 250V 2 pcs 3 pole XLR Flange female UPS terminals SL10 SL5 24 V DC max 5 0A max 5 0A max 10 0A max 120 W max 120 W max 240 W 19 3 HU 21 DU min 400 mm see Fig 27 10 125 x 65 x 103 mm HxWxD see Fig 27 8 and 27 9 125 x 122 x 103 mm HxWxD see Fig 27 7 and 27 9 27 9 TECHNICAL DATA E 115 Voc 230 Voc 24 Vdc 10 A Blectronealy protected 115 230Voc 2 6 1 44 50 60 2 a ne NL OG CIMO Fig 27 7 Fig 27 8 Fig 27 9 Dimensional sketch SL10 Front view mm Front view SL 5 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
35. according to CENELEC EN 50014 with touch screen keypad Optionally we can provide additional intrinsically safe I O s and or ex interface relays couplers For European ex zone 2 a simplified pressurization is installed and individual approval is provided An EExp approved purge system for European ex zone 1 both according to CENELEC EN 50016 or with Z Purge for measurement of non flammable gases in hazardous areas according to CSA C US for North American Ex zone 2 is another option Be sure to observe the additional notes safety precautions and warnings given in the individual manuals simplified pressurization for ex zone 2 N EExp approved purge system for ex zone 1 and in section Safety Summary subsection VII 00781 4 Series 100 e 02 2004 5 11 PREPARATION ADDITIONAL HINTS ON BINOS 100 F FIELD HOUSING 5 4 1 Wall Mounting This housing is designed for wall mounting Location of fixing points see Fig 5 5 Lift or carry housing with at least 2 persons because of the high weight of field A housing BINOS 100 F approx 30 35 kg for standard housing For easy transport use a suitable cart Lift points are labeled Labels showing down side for transport Do not use electronics of optional purge system as handle Take care to use anchors and bolts specified to be used for the weight N of the units Take care the wall the unit is intended to be installed at is solid
36. an error message will appear see chapter 16 By default the error message will be erased after 2 3 minutes Setting the tolerance check parameter to 2 will hold the error message till either a correct calibration has been performed or the analyzer has been resetted Input value 0 Tolerance check is deactivated Input value 1 Tolerance check is activated error message will be erased after 2 3 minutes Input value 2 Tolerance check is enabled error message is held INPUT CONTROL Change values using A V ETCO00781 4 Series 100 e 02 2004 8 5 SETTING SYSTEM PARAMETERS DISPLAY OFF C3 EL T 8 7 Display Off gt lt Entering 1 will turn the DISPLAY off about 1 to 2 minutes after the last key was pressed Pressing any key will turn the display on again Input value 0 Display is always turned on Input value 1 Display is will be automatically turned of INPUT CONTROL Change values using A VI 8 z 6 ETC00781 4 Series 100 e 02 2004 SETTING SYSTEM PARAMETERS ANALOG SIGNAL OUTPUTS X The analog signal outputs optically isolated are brought out to a 9 pin sub miniature D connector X2 on the analyzer rear panel Refer to the wiring hints in chapter 29 10 8 8 Analog Signal Outputs Input value 0 Output signal is 0 10 Vdc Option O 1Vdc 0 20 Input value 1 Output signal is 2 10 Vdc Option 0 2 1 Vdc 4 20 mA life zero
37. analyzer determine the materials which are usedfor gas paths and gas fittings Safety Dust Filter All analyzers are equipped with a PTFE safety dust filter This filter is no substitute forthe necessary dust filter to be provided with sample handling systems described in chapter 5 2 Fittings As standard the analyzers are provided with PVDF fittings 6 4 mm The analyzers can be delivered with swagelok fittings stainless steel 6 4 mm or 1 4 as option Additional fittings are delivered as special options Tubing As standard the analyzers are provided with Viton tubings or PTFE tubings 6 4 mm Additional tubings e g stainless steel are delivered as special options ETC00781 4 Series 100 e 02 2004 1 25 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION b Gas Path Layout internal tubing The principle various possible layouts of the internal gas lines are summarized in the following figures Analyzer Gas inlet gt IN K1 Gas outlet gt OUT K1 Fig 1 23 Tubing in series BINOS 100 M OXYNOS 100 HYDROS 100 analyzers Analyzer Gas inlet Gas outlet OUTK1 5 Gas outlet OUT K2 IN K1 Gas inlet IN K2 Fig 1 24 Tubing in parallel BINOS 100 M OXYNOS 100 HYDROS 100 analyzers ETCO0781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION
38. 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 Input value 1 The outputs will be locked INPUT CONTROL Change values using A VI and 5 8 5 Automatic Calibration For operation with optional internal or external solenoid valves it can be selected ifthere a time controlled automatic resp a remote controlled calibration is possible or not in combination with solenoid valves controlled via digital outputs Input value 0 Time controlled remote controlled calibration is not possible Input value 1 Time controlled remote controlled calibration is possible INPUT CONTROL Change values using A V 8 4 ETC00781 4 Series 100 e 02 2004 SETTING SYSTEM PARAMETERS TOLERANCE CHECK 8 6 Tolerance Check X The tolerance functionis forthe activation and deactivation ofthe tolerance check procedure for various calibration gases If the tolerance check procedure has been activated the microprocessor will verify during calibration procedures whether the used calibration gas shows a deviation of more than 10 96 from measuring range of zero zero level or more than 10 ofthe nominal concentration value enteredresp span If this tolerance is exceeded no calibration will be performed and
39. and stable to hold the units 550 492 approx 355 IE x e x o amp 85 gt ES bf M E 4 5g e Glands ai a connection cables Gas connections Fig 5 5 Dimensional sketch Drill drawing BINOS 100 F Standard version all dimensions in mm ETC00781 4 Series 100 e 02 2004 PREPARATION ADDITIONAL HINTS ON BINOS 100 F FIELD HOUSING 5 4 2 Electrical Connections Be sure to observe the safety precautions and warnings to ensure protection class IP 65 according to IEC 60529 The permissible outside diameters of the cables are 7 to 12 mm Verify that the cable glands together with installed cables are hermetic a MainsSupply The analyzer is rated for an operating voltage of 230 V AC or 120 V AC 47 63 Hz The built in power supply is either of type SL5 or of type SL10 and provides a switch to manually select the nominal voltage Openthe analyzers front door O Insertthe mains line through the cable glands Fig 5 6 or 5 5 into the housing Connect L N and PE to the terminals located nearby the powerline filter Fig 5 8 Verify that the line voltage given on the identification plate N front door inside complies with that of your power supply line Verify that the position of the power supply s voltage selector switch complies with the voltage of your power supply line Fig 27 7 27 8 and 5 8
40. are installed into a 1 4 19 housing BINOS 100 M OXYNOS 100 HYDROS 100 ora 1 2 19 enclosure BINOS 100 2M 3 height units These housings are go conform to DIN standard protection class IP 20 The housings are available as rack mountable oras table top versions The table top housings are fitted with an additional carrying handle and additional rubber feets Additionally we can deliver a field housing version BINOS 100 F All componets are installed into a protection housing conformingto DIN standard protection class IP 65 approx NEMA 4 4X This enclosure is designed for wall mounting b Hazardous Areas For installation in hazardous areas special versions of BINOS 100 F are avaliable with adapted options and specifications These versions are not subject of this manual except the variation with Z purge For all other analyzer versions intended to be used in hazardous areas pls refer to the separate manuals Ex Zone 2 The BINOS 100 F is equipped with Pressurization system for ATEX EX Zone 2 Applications Z purge for CSA C US EX Zone 2 Non Flammable Atmospheres Ex Zone 1 The BINOS 100 F is equipped with Pressurization system for ATEX EX Zone 1 Applications ETCO00781 4 Series 100 e 02 2004 P 3 PREFACE P 4 00781 4 Series 100 e 02 2004 CONTENTS Table of Contents SAFETY SUMMARY l Il Ill V VI VII Intended Use Statement Safety Symbols General S
41. are used to connectthe reference gas ETC00781 4 Series 100 e 02 2004 5 5 PREPARATION GAS CONNECTIONS O O K1 K2 K1 K2 Gasinlet 0 0 9 Gas outlet fittings Nn E Qui 9 fittings Tem 9 X1 OUTPUT INTERFACE N 00000 7A ma W N OOO00 JA max W Fig 5 3a BINOS 100 M OXYNOS 100 EO HYDROS 100 gas connections X2 OUTPUT 0000 00000 3 4 serene _ MADE INGERMANY 52 24V max 40W Doo 2 Fig 5 3b OXYNOS 100 PO gas connections Gas inlet fittings Gas outlet fittings 00781 4 Series 100 e 02 2004 PREPARATION GAS CONNECTIONS 0 Hc GS LCS 89 GE 2 Gas inlet Gas outlet fittings NE EMT fittings O X1 OUTPUT AA GD SRI 39 GE IN OU Ve E 0o00 fy foooo WY OLITRITT Fig 5 3c BINOS 100 2M standard gas connections D 5 o D E E gt F amp F GA d oO I Ve lt o gt z Es E CODE Gas connections Fig 5 3d BINOS 100 F standard gas connections ETC00781 4 Series 100 e 02 2004 5 7 PREPARATION GAS CONNECTIONS 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 Allne
42. channel 2 XXXX Use the keys and for the entry Note The specifications of the analyzer written in the data sheet are only for OFS 0 and END full scale range set in our factory Itis part of customer to enter logical values for OFS and END 8 1 0 ETC00265 4 Series 100 e 02 2004 ENTRY OF SYSTEM PARAMETERS END OF RANGE VALUE sno 8 13 End of Range Value XXXX The operator is here offered the opportunity to introduce a full scale range for the analog signal output Example For an analyzer concentration range of 0 25 it is desired to measure only concentrations in the range 0 15 If the operator enters here the value 15 the analog signal outputs of 10 1 V 20 mA will then correspond to a gas concentration of 15 96 The displayed values are not affected Use the keys A forthe entry Ent ibility f h 2 ntr OSS or cnanne il XXXX Use the keys and for the entry Note The specifications of the analyzer written in the data sheet are only for OFS 0 and END full scale range set in our factory It is part of customer to enter logical values for OFS and END ETC00265 4 Series 100 e 02 2004 8 11 ENTRY OF SYSTEM PARAMETERS RESET RES 8 14 Reset XXXX Theresetoperation restores the settings ofthe analyzertothe parameters and calibration factors set in our factory atthe ti
43. desired system parameters L calibration of the analyzer Note The X s shown in the display indicate a number or combinations of numbers ETC00781 4 Series 100 e 02 2004 6 1 SWITCHING ON 24 V DC SUPPLY 6 2 24V DC Supply The analyzers of series 100 with exceptof BINOS 100 F and BINOS 100 2M with internal power supply are specified for an operating voltage of 24 V DC This voltage has to be provided via a 3 pole XLR flange male The DC supply voltage has to be provided by one of the optional power supplies VSE 2000 UPS 01 T DP 157 SL5 SL10 or an equivalent power supply O Connect power supply and analyzer Fig 6 1 Plug 24 V DC Verify correct polarity before operation Fig 29 1 O Connectmains line and power supply Be sure to observe the safety precautions and warnings given by manufacturer of power supply 6 3 230 120 V AQ Dupelx e wy X1 OUTPUT INTERFACE lt 00000 X2 OUTPUT Plug 24 V DC Input X3 OUTPUT 95 Fig 6 1a BINOS 100 M OXYNOS 100 HYDROS 100 Voltage supply 6 2 ETC00781 4 Series 100 e 02 2004 SWITCHING ON 24 V DC SUPPLY X2 OUTPUT INTERFACE X1 OUTPUT Plug 24 V DC Input OUT Fig 6 1b OXYNOS 100 PO Voltage supply TERRE Casas
44. e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Gas line fittings im im _ zai 1 Solenoid valves um x Option Ho RN Circuitboard BKS Power supply option UPS 01 ee c PCB WAP 100 Thermal conductivity sensor Paramagnetic oxygens sensor Gas sampling pump option option gm Fine dustfilter e Wilhaintegrated Flowindicator needle valve for option regulation of gas flow rate option Fig 1 18 Inside View dual channel BINOS 100 2M version A oxygen measurement paramagnetic thermal conductivity measurement combined ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION
45. mounting flange from the light source and position it on the new light source O Forsealed version with pyroelectrical detector only Remove the tight baffle zero level adjustment baffle from the light source and position it in the new light source O Forsealed version only Place the O rings on the adapter cell and filter cell O Insertthe new light source and flange in the same position as the old one O Insertand tighten the two light source mounting screws shown in Fig 24 1 as Item 5 orthe temperature sensor shown in Fig 24 1 as Item 3 resp O Reinstall the photometer assembly see chapter 24 5 O Performthe physical zeroing procedure see chapter 24 6 24 2 ETC00781 4 Series 100 e 02 2004 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS REMOVAL OF ANALYSIS CELLS 24 3 Cleaning of Analysis Cells and Windows 24 3 1 Removal of Analysis Cells N O Open the analyzer housing cf chapter 23 O the photometer assembly out of the analyzer housing see chapter 24 1 a For analysis cells of lengths 1 mm and 7 mm O Remove the clamp Fig 24 2 Item 2 O Remove the clamping collar and the filter cell with signal detector assembly b For analysis cells of lengths 50 mm 200 mm Remove the clamp Fig 24 2 Item 3 Remove the filter cell with signal detector assembly Remove the mounting screws shown in Fig 24 2 Item 4 Remove the analysis cell body from the chopper housing 242
46. not the front panel with a dry cloth afterwards ETC00781 4 Series 100 e 02 2004 23 1 HOUSING OPENING THE HOUSING 1 4 19 HOUSING 23 2 Openingthe Housing The housing must be opened for checking the electrical connections and for replacement or cleaning of any of theinternal components of the analyzer N Be sure to observe chapter VIII of the safety measures 23 2 4 1 419 Housing O Disconnectall voltage supplies O Table top analyzers only Remove the rubber feet Unscrew the screws shown Fig 1 1 Item 8 Remove the front mounting frame and carrying strap to rear O Unscrew the screws shown in Fig 1 1 Item 7 and Figs 1 5 and 1 6 Item 6 O Remove the analyzer housing top cover panel Closing the housing is performed in reverse order 2 3 22 ETC00781 4 Series 100 e 02 2004 HOUSING OPENING THE HOUSING BINOS 100 2M 23 2 2 BINOS 100 2M a Housing Cover Disconnectall voltage supplies Unscrew fastening screws for rack mounting front frame if necessary Fig 1 2 Item 11 Remove analyzer out of rack or remove the front mounting frame and carrying strap to rear Unscrew the respective fastening screws at both housing sides Fig 23 1 Remove the respective housing top cover panel Closing the housing is performed in reverse order fastening screws housing cover LUUD
47. only Schuko plug Other locations Use cords with an IEC60320 female at one end and an appropriate plug at the other end to meet your local requirements Power cords must have a separate grounding conductor In case of doubt contact your local Emerson Process Management sales office to order an appropriate cord 30 3 Power Supply for Wall Mounted Analyzers BINOS 100 F Power cords must have a separate grounding conductor Variation 1 Use cords with an appropriate plug at the one end to meet your local requirements and single conductors at the other end to be connected to the terminals inside the analyzer In case of doubt contact your local Emerson Process Management sales office to order an appropriate cord Variation 2 30 2 For permanently connected equipment use cords rated to meet your local requirements and single conductors at the other end to be connected to the terminals inside the analyzer In case of doubt contact your local Emerson Process Management sales office to order an appropriate cord BINOS 100 2M F from program version 5 0 or hoigher only 00781 4 Series 100 e 02 2004 CABLES AND CORDS 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 serial interface option Interface or X4 Output ETC ACC 101 shielded cable 2 m both ends sub D plug and one terminal adaptor ETC ACC 102 shie
48. or additional failure description 32 2 ETC00781 4 Series 100 e 02 2004 FACTORY REPAIRFAILURE CHECKLIST 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 Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted 2 n no event will Rosemount be responsible for equipment without proper authorization and identification 3 Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage will occur during shipping 4 Ina cover letter describe completely a The symptoms that determined the equipment is faulty b The environment in which the equipment was operating housing weather vibration dust etc Site from which equipment was removed Whether warranty service or nonwarranty service is requested Complete shipping instructions for the return of the equipment Enclose the completed check list 5 Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in a Rosemount Return Authorization prepaid to Doo In Europe Emerson Process Management Manufacturing GmbH amp Co OHG Service Department Germany 49 6055 884 470 472 In US Rosemount Analytical
49. then on again c Lightbarrier not connected see chapter 18 1 d Broken cable of light barrier or faulty light barrier exchange chopper e BKS faulty exchange BKS Possible reasons oxygen measurement without IR channel a Solder bridge LB 18 not closed b BKS faulty exchange BKS 17 4 00781 1 Series 100 e 10 2001 Rosemount Analytical FISHER ROSEMOUNT MEASURING POINTS OF BKS AND OXS MEASURING POINTS OF OXS Measuring point Signal Failure Possible reasons a IRmeasurement Measuring point Measuring device Signal Failure Possible reasons ETC00781 1 Series 100 e 10 2001 Measuring device 17 1 7 Analog Preamplifiering a paramagnetic oxygen measurement X 25 channel 1 DVM At zero gas purge 0 V dc 50 mV At ambient air approx 21 Vol O 500 mV dc 50 mV No signal or incorrect measuring values a oxygensensor not connected see chapter 18 b oxygen sensor faulty exchange sensor BKS faulty exchange BKS X 25 channel 1 not for analyzer with oxygen measurement X 27 channel 2 DVM At zero gas purge dc 100 mV There should be a minimum difference of 600 mV measuring ranges lt 1000 ppm difference 500 mV between zeropoint voltage and sensitivity voltage No signal or incorrect measuring values a Detectornot connected see chapter 18 b Detector faulty exchange detector BKS faulty exchange B
50. with ambient air Temporary flushing with nitrogen N for less than 1 h e g analyzer zeroing will have no influence to measuring value ETC00781 1 Series 100 e 10 2001 2 9 MEASURING PRINCIPLE THERMAL CONDUCTIVITY TC MEASUREMENT 2 3 Thermal Conductivity Measurement To measure gases like Hydrogen H Argon Ar or Helium He the measurement method of thermal conductivity TC willbe used 2 3 1 Sensor Design The sensor consists of four small PT 100 resistors arranged in a Wheatstone Bridge which is mounted into a block made of either aluminum stainless steel or hastelloy depending on the application e g stainless steel hastelloy for corrosive gases The block is thermostatted to supress influence of external temperature change Fig 2 7 Thermal conductivity sensor 2 3 2 Analysis Cell Both the volume of the block and the mass of the resistors have been minimized on order to obtain short response time The block contains two gas paths for sample and reference gas whereatthe reference gas path is closed for standard applications Always two sensors are located in the sample and the reference gas path The resistors are full glass packaged to withstand agressive gases The material in contact with the gases are glass Gold Aluminum stainless steel and Hastelloy so a high resistance against corrosion by agressive gases is provided by this cell 2 1 0 00781 1 Series 100 e 10 2001 MEASURING PRINCIPLE TH
51. x I I olo 2 F q OO x Terminal strip X1 Ground conductor pin output status relays option PE mains line Fig 5 8 BINOS 100 F Connection data lines mains line inside view left side panel 5 1 6 ETC00781 4 Series 100 e 02 2004 SWITCHING ON GENERAL 6 Switching On 6 1 General N Be sure to observe the safety precautions and warnings Once the instrument has been correctly assembled and installed accordance with the general instructions given in section 5 the equipment is ready for operation The equipment is switched on by providing the required voltage The presence of the supply voltage will be indicated by the illumination of the LED displays Upon connection of the supply voltage the analyzer will perform a self diagnostic test routine First the actual program version will be shown analyzers without fieldbus or analyzers with fieldbus XXX XXX Finally either concentration values or error messages will be displayed Ifasaresultofa battery faultthe default values were charged this will be shown by a flushing batt This message will disappear after depressing any key Analyzer warming up takes about 15 to 50 minutes depending on the installed detectors Before starting an analysis however the following should be performed L entry of the
52. 0 10 Vol O 0 10 Vol 2 For information about the configuration 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 How to read a name plate label Analyzer type and measuring prinziples EMERSON ROSEMOUNT Process Management Analytical Serial number Typ BINOS 100 IR IR SN 1234567890 Channel 1 Component and CO FS 1000ppm CO2 FS 100ppm Channel 2 Component and full scale range 9 Signal 4 20 2 10V full scale range PFG Nr 41300392 Made in Germany Analog output settings DMT approvalnumber if applicable 27 1 Options Pressure sensor Measuring range 800 1 100 hPa Fine dust filter BINOS 100 2M F Filter material PTFE Pore size approx 2mm Sample gas pump BINOS 100 2M F Pumping rate max 2 5 l min Suction pressure min 900 hPa Lifetime max 5 000 hours ETCO00781 4 Series 100 e 02 2004 27 1 TECHNICAL DATA HOUSING OPTIONS 27 2 Housing Gas connections 5 OXYNOS HYDROS 100 BINOS 100 2M BINOS 100 F standard version Dimensions Weight depending on analyzer configuration BINOS M OXYNOS HYDROS 100 BINOS 100 2M BINOS 100 F standard version Protection class BINOS M 2M OXYNOS HYDROS BINOS 100 F standard version Permissible ambient temperature Humid
53. 0 baud echo mode may also be activated The analyzer software is configured such as that telegrams may be sent to the host computer at time intervals of 150 ms and greater ETC00781 1 Series 100 e 10 2001 12 3 SERIAL INTERFACE OPTION Rosemount Analytical START UP FISHER ROSEMOUNT 12 3 Start Up The analyzer has been set in our factory 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 setto 0 NOor 1 YESin the SIP Serial Interface Parameters line Interconnection to the interface is via the 9 pin socket Interface or X4 Output on the analyzer rear panel Observe the wiring hints in chapter 29 10 12 3 1 RS 232 This interface requires shielded cable having at least three internal conductors Q w GND o _ RxD oO Te TxD O n notused GND o gt not used not used o gt not used gt not used Hd 82 gt Fig 12 2 Pin Assignments RS 232 Interface 12 4 00781 1 Series 100 e 10 2001 Rosemount Analytical SERIAL INTERFACE OPTION FISHER ROSEMOUNT START UP 12 3 2 RS 485 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 w
54. 0 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Gas line fittings PCB WAP 100 PCBBKS Thermal conductivity sensor Frontpanel Fig 1 14 HYDROS 100 Inside view 1 1 6 ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Gas line fittings mando loda Solenoid valves Option a O Circuitboard BKS 2 Power supply option below physical bench UPS 01 Lo IR photometer bench S depending on analyzer configuration Electrochemical Ei oxygen sensor wwe with circuit board OXS d di E NN depen ing on yzer a 11 2 configuration Channel2 Channel1 t o 6 Channel 1 E ti S 2 E Paramagnetic _ presse sensor oxygen sensor option _ SA D u depending on analyzer JA EM configuration c7 Cp Md CO 6 4 lal Gas sampling pump option A 46 H N En _ ES EP no
55. 15 17 14 6 13 12 11 12 13 Fig 1 9 BINOS 100 2M special version Rear view with all options AON Oo 11 12 13 14 15 16 17 Gas inlet line fitting channel 1 Gas inlet line fitting channel 2 Gas outlet line fitting channel 1 Gas outlet line fitting channel 2 Plug for analog signal inputs interference cross compensation TC only Solenoid valves common gas outlet line fitting Solenoid valves Test gas inlet 1 Solenoid valves Test gas inlet 2 open open 24V DC supply inputterminal Solenoid valves Zero gas inlet Solenoid valves Sample gas inlet Plug Digital Outputs threshold contacts Mating socket Serial Interface RS 232 C 485 option Mating socket Analog Signal Outputs Plug Output Relays status signal option ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION 1 3 Internal Construction The analyzers includes the following components d Depending on analyzer configuration oneortwo IR photometer benches onelR photometer and one EO sensor onelR photometer and one PO sensor onelR photometer and one TC sensor one sensor and one TC sensor one EO sensor and one TC sensor oneortwo PO sensors oneottwo EO sensors oneortwoTC sensors Optionally one pressure sensor range of 800 to 1 100 hPa The concentration values computed by the analyzer will then be corrected to reflect the barom
56. 1D 626 LPB lt CR gt ID 627 LPB lt CR gt 1D 645 0 LPB lt CR gt 1D 646 w LPB lt CR gt BINOS 100 2M F from program version 5 0 is required 12 12 Instruction description RI stand by status all valves closed RI sample gas valve open RI zero gas valve open RI span gas valve open RI on line status RI off line status SP pump status RI pump status w 0 pump Off w 1 pump On SP at full scale range SP t response time RP t response time SP preflushing period zero gas RP preflushing period zero gas SP preflushing period Span gas RP preflushing period span gas SP concentration SP span gas concentration RP span gas concentration SP status messages SP serial number t 0 max 10 characters channel identification t 1 ch 1 t 2 ch 2 SP gas component Rl automatic zeroing Hl automatic spanning RI automatic zeroing amp spanning SP E Prom Software version SP failure message possible error batt is clearing by read out SP pressure value SP solenoid valve status w 1 samplegas valve w 2 zerogas valve w 4 spangas 1 w 8 spangas 2 00781 4 Series 100 e 02 2004 SERIAL INTERFACE OPTION RESPONSE TELEGRAMS 12 5 2 Response Telegrams Response telegrams follow with the same syntax as the appropiate SP commands see 12 5 12 5 2 1Status Messages Instruction 030 The response telegram for instruction ID 030 LPB lt CR gt SP Status messag
57. 2004 CROSS COMPENSATION SETTING OF RESPSONSE TIME TC ONLY CROSS COMPENSATION 14 Compensation Setting of Respsonse time TC Option only 14 1 Cross Compensation For gas mixtures of two gas components binary gas mixtures with different thermal conductivities the analyzer may be calibrated to directly show the concentration of one of the gas component The same is applicable for quasi binary gas mixtures of more than two components with only a single component the component to be measured of varying concentration The compostition of the remainder of the gas mixture remains constant in time Forthe more common case that more than one component of a sample gas mixture has varying concentrations the result of this measuring principle is non selective i e it will not be unambiguously related to the true concentration of the gas component of interest If the concentrations of interfering gas components are detected by using other gas analyzers and the analytical signals thus obtained are supplied to the analyzer via rear panel plug CROSS COMP Item 9 of Fig 1 5 or Analog In Item 5 of Fig 1 7 and 1 8 then the disturbing effects of any interfering gas component may be electronically compensated The analyzer is designed for compensating up to 3 interfering gas components Possible signal inputs are 0 0 2 1 V 0 2 10V or0 4 20 mA Observe the wiring hints in chapter 29 10
58. 25 3 O Fix the sensor with a cable tie to the support see Fig 25 3 O Connecttheconnector forthe sensorto P2 of circuit board OXS see Fig 25 5 chapter 18 O Insert the complete support see Fig 25 3 into the analyzer and fix it with the two allen screws fastening screws see Fig 25 2 O Reconnectall gas lines to the fittings see Fig 25 2 and Fig 25 3 Do not interchange gas inlets and gas outlets O Reconnectall electrical connections between OXS and BKS X5 and X7 see chapter 18 O Performaleakage test see chapter 22 and set the sensor see chapter 25 2 4 b Combined IR Oxygen Measurement O Putthe fitting with the new sensor onto the support move to the stop and fix it with the two fastening screws see Fig 25 4 O Connecttheconnectorforthe sensorto P2 of circuit board OXS see Fig 25 5 chapter 18 O Performaleakage test see chapter 22 and setthe sensor see chapter 25 2 4 25 6 ETC00781 4 Series 100 e 02 2004 CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR BASIC SETTINGS 25 2 4 Basic settings for the Oxygen Sensor Afas O Supply ambient air to the analyzer approx 21 Vol O and switch on see chapter 6 O Connect the DVM to the measuring points Tp 1 Signal and Tp 2 L of the PCB OXS mounted directly at the connection block Fig 25 1 see also Fig 25 2 1 11 1 13 1 15 to 1 17 and 1 19 O Setthe signal to 3 36 V DC 5 mV with potentiometer R
59. 3 27 5 Voltage Supply 27 9 21 5 1 Electrical Safety 27 9 27 5 2 Power Supplies UPS 01 T SL10 515 27 9 28 REPLACING THE EPROM 28 1 30 CABLES AND CORDS 30 1 30 1 24 V DC Supply Cable 30 1 30 2 230 120 V AC Input BINOS 100 2M UPS power supply 30 2 30 3 Power Supply for Wall Mounted Analyzers BINOS 100 F 30 2 30 3 Data Signal Lines 30 3 30 3 1 Sub D Sockets 9 pin 30 3 30 3 2 Sub Plugs 9 pin 30 3 2 FAILURE CHECK LIST 32 1 a Customer Service 32 4 b Training 32 4 ETC00781 4 Series 100 e 02 2004 VII CONTENTS VIII 00781 4 Series 100 e 02 2004 CONTENTS 00781 4 Series 100 e 02 2004 CONTENTS X 00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION FRONT VIEW 1 Technical Description The different analyzers are based on the same internal main components and differ only by available options and enclosures BINOS 100 M OXYNOS 100 HYDROS 100 1 4 19 enclosures BINOS 100 2M 1 2 19 enclosure All analyzer components are installed into enclosure 3 height units tall These housings are classified protection class IP 20 The housings are available as rack mountable or as table top versions The table top housings are fitted with an additional carrying handle and additional rubber feets BINOS 100 F field housing wall mountable Additional we can deliver a field housing version All components are installed
60. 4 5 4 1 5 4 2 Installation Site Gas Conditioning Sample Handling Fine Dust Filter Option BINOS 100 2M F Gas Sampling Pump Option BINOS 100 2M F Pressure Sensor Option Gas Flow Gas Connections Standard Internal Solenoid Valves Option BINOS 100 2M F Purge gas connection of BINOS 100 F for Ex zones Additional Hints to BINOS 100 F Field Housing Wall Mounting Electrical Connections 2 1 2 1 2 1 2 3 2 5 2 6 2 6 2 8 2 10 2 10 2 10 2 11 3 1 3 1 3 4 5 1 5 2 5 3 5 4 5 4 5 4 5 4 5 5 5 5 5 8 5 10 5 11 5 12 1 i 00781 4 Series 100 e 02 2004 CONTENTS 6 6 1 6 2 6 3 6 3 1 6 3 2 7 7 1 te 7 3 7 4 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 8 10 8 11 8 12 8 13 8 14 8 15 8 16 8 17 8 18 SWITCHING ON General 24 V DC Supply 230 120 V AC Supply BINOS 100 2M BINOS 100 F KEY FUNCTIONS FUNCTION ENTER INPUT CONTROL PUMP BINOS 100 2M F only SETTING SYSTEM PARAMETERS Pressure Correction Cross Compensation internal Cross Compensation Calibration internal Hold Automatic Calibration Tolerance Check Display Off Analog Signal Outputs Flushing Period User Code Response Time t90 Offset Begin of range End of Range Value Reset Program Version Serial No Pump Pump Control ETC00781 4 Series 100 e 02 2004 6 6 6 6 6 O A N N I
61. 4 Fig 25 5 of the corresponding circuit board OXS Note Do not change this setting for this sensor again O Switch offthe analyzer and close the analyzer housing see chapter 23 Slide the module into platform if necessary O Acomplete recalibration of the instrument mustbe performed after a sensor replacement Potentiometer R4 Tp 1 Tp2 a Podre 2 EG 99 LB3 JO o LB2 C2 R5 4 P3 o R9 ng 0 0 0 OOOO R2 LB4 LB1 Connection oxygen sensor P2 Fig 25 5 PCB OXS assembled view at component side ETC00781 4 Series 100 e 02 2004 25 7 CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 8 ETC00781 4 Series 100 e 02 2004 TECHNICAL DATA 27 Technical Data Certifications EN 61326 EN 61010 1 for measurment of non flammable gases or non explosive gases resp lt 50 LEL NAMUR CSA C US Higher concentrations require supplementary C Tick PAC GOSSTANDART protective measures Suitability tests T V Nord mbH report no 95CU054 B TUV Bavaria report no 1563793 Carbon monoxide CO TI Air 13 BImSchV Oxygen TI Air 13 BImSchV 17 BImSchV DMT IBS PFG No 41300392NIII 41300292NIII CO CH 0 80 Vol CO 0 200 ppm
62. 5 V DC O O Open the housing see chapter 23 Switch On the analyzer see chapter 6 Supply ambient air to the analyzer approx 21 Vol O Connect the DVM to the measuring points Tp 1 Signal and Tp 2 L of the PCB OXS mounted directly at the connection block Fig 25 1 see also Fig 25 2 1 11 1 13 1 15 to 1 17 and 1 19 The measuring signal should be in a range of 2 4V DC to 3 36 V DC Note If the measuring value is lower than 2 4V at gas flow with ambient air the sensor is consumed Replace the sensor 25 2 Tp 1 Tp2 _ 2 Pi 99 E C1 9 Ny d ella a E pe C3 o 8d o Um Jof a L82 c2 6 TP4 e Ee TP5 RQ RB EOS 050505020 E Fig 25 1 PCB OXS assembled horizontal projection 00781 4 Series 100 e 02 2004 25 2 CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR REPLACING THE SENSOR Replacing the Sensor N a to observe the safety measures 25 2 1 Remove the old Sensor a ETC00781 4 Series 100 e 02 2004 Oxygen Measurement without IR channel Open the analyzer housing see chapter 23 Disconnect all electrical connections between the PCBs OXS and BKS X5 X6 and X7 see chapter 18 Remove all gas lines from the sensors Unsc
63. 529 Only analyzers with gas detector O Remove preamplifier from analysis cell C3 ww TU UJ 3 Fig 24 2 Photometer Assembly 2 channel photometer side view Filter cell with signal detector assembly Clamp with clamping collar Clamp Mounting screws for analysis cells of lengths 50 200 mm a ETC00781 4 Series 100 e 02 2004 24 3 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS CLEANING 24 3 2 Cleaning a Windows The windows on the filter cell chopper housing the adapter cell resp analysis cell may be cleaned with a soft lint free cloth Use a highly volatile alcohol for the cleaning procedure To remove any remaining lint and dust particles blow off the cleaned components with nitrogen N b non divided analysis cells The analysis cell may be cleaned with a soft lint free cloth Use a highly volatile alcohol for the cleaning procedure To remove any remaining lint and dust particles blow off analysis cell with nitrogen N C dividedanalysis cells If pollution is visible in the analysis cell it can be removed with suitable solvents e g acetone or spirit Afterwards the analysis cell has to be flushed with an alcohol which evaporates easily and dried by blowing nitrogen 2 Max pressure in analysis cell 1 500 hPa 24 4 ETC00781 4 Series 100 e 02 2004 REPLACEMENT AND CLEANING OF PHOTOMETRIC C
64. 6 1 or 24 6 2 24 6 1 Standard Photometer notsealed version O Slightly loosen the light source mounting screws shown in Fig 24 1 as Item 5 or the temperature sensor shown in Fig 24 1 as Item 3 resp for channel 1 or channel 2 O Setthe zero level precisely to 0 V 100 mV by turning the corresponding light source If the turning of the light source is not sufficient the zero point can be adjusted by sliding the zero level adjustment baffle Fig 24 1 item 4 O Tightenthe light source mounting screws shown in Fig 24 1 as Item 5 orthe temperature sensor shown in Fig 24 1 as Item 3 resp for channel 1 or channel 2 Whenthe physical zeroing has been correctly set perform an electrical zeroing see chapter 9 ETC00781 4 Series 100 e 02 2004 24 7 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS PHYSICAL ZEROING 24 6 2 Sealed Photometer Option O Slightly loosen the light source mounting screws shown in Fig 24 1 as Item 5 or the temperature sensor shown in Fig 24 1 as Item 3 resp for channel 1 or channel 2 O Setthe zero level precisely to O V 100 mV by turning the corresponding light source O Forphotometer with pyroelectrical detector only To enable physical zero level adjustment one out of three different fix apertures zero level adjustment aperture are installed inside the light source For simple replacement the aperture is fixed inside the source with a magnet If turning the li
65. 7 digital inputs They are available at terminals on the rear side of the analyzer Fig 1 8 Item 9 The inputs are active only if the analyzer is equipped with built in solenoid valve block or if the solenoid valves are connected to the digital outputs see chapter 29 5 1 Observe the wiring hints in chapter 29 10 V O 5 VDC eT ol E1 Q start zero calibration channel 1 amp 2 E2 Q start span calibration channel 1 E3 O start span calibration channel 2 E4 O open zero gas valve ES O open span gas valve 1 E6 open span gas valve 2 ODI Er close sample gas valve sample gas pump off Fig 13 1 Terminal assignments Digital Inputs The analyzer may be controlled by either control voltages or floating contacts A low signal has to be lt 1 4 V dc a high signal has to be gt 3 5 V dc max 30V dc Reference point is terminal V 1 To work with floating contacts customer can use the intrinsic safe output voltage of 5 V DC at terminal V 13 1 2 StartofCalibration Inputs E1 to E3 The analyzer will start a calibration procedure if control signal changes from low level to high level These inputs have a higher priority than inputs E4 to E7 ETC00781 4 Series 100 e 02 2004 1 3 1 DIGITAL INPUTS FOUNDATION FIELDBUS OPTIONS 13 1 3 Valve Control The inputs E4 to E7 are level sensi
66. 8 00781 4 Series 100 e 02 2004 CALIBRATION AUTOMATIC ZEROING AND SPANNING OPTION 9 2 2 Combined Zeroing and Spanning With this function a span calibration will be performed after completion of zeroing Press the key a Lame XXXX Press the key Enter the correct user code if not already entered until the message appears ES The displays will now show You can enter atime interval hours when a automatic zeroing and after that a spanning has to be performed Point of reference is the current time Range of accepted entries 0 999 hours Note If the entry is 0 zero the time controlled calibration is switched off INPUT CONTROL Entry is performed using A VI followed by After entry of interval calibration will be done automatically atthe end ofthe enteredtime interval ETC00781 4 Series 100 e 02 2004 9 9 CALIBRATION 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 setfirst manually chapter 9 1 2 serial interface option chapter 12 5 The automatic function of the analyzer must also be activated correctly cf chapter 8 5 A calibration can be started via O serialinterface option chapter 12 5 O digital inputs option chapter 13 1
67. A D converter Exchange BKS Incorrect response time Check the value for t time t time settings see chapter 8 11 Pumping rate inadequate The feeder line between the sampling point and the analyzer is too long Use a larger external pump consider adding a bypass line to the process stream for sampling purposes see chapter 5 1 Response time too long t time 3 Contamination of the gas Check gas paths and gas paths conditionning to contamination Clean gas paths and exchange the filter elements ETC00781 4 Series 100 e 02 2004 LIST OF FAILURES Possible Reasons Check Correct Needle valve is not opened Option No gas flow ETCO00781 4 Series 100 e 02 2004 Sample gas pump Option is not switched on Membrane of pump is defective Sample gas pump is defective Solenoid valves defective Option Contamination of the gas lines Open needle valve Option see Fig 1 2 Press key PUMP Exchange membrane of the pump Exchange sample gas pump Check the valve face of the solenoid valves and exchange if necessary Exchange solenoid valves Check gas lines including filters to contamination Clean the gas lines and exchange the filter elements 16 7 LIST OF FAILURES ETC00781 4 Series 100 e 02 2004 16 8 4 Rosemount Analytical MEASURING POINTS OF BKS AND OXS FISHER ROSEMOUNT M
68. BINOS 100 2M F ONLY 74 PUMP BINOS 100 2M F only b Optionally there is built in a gas sampling pump pumping rate max 2 5 l min into analyzers of type BINOS 100 2 The pump can be switched on and switched off by either e the key PUMP at the front panel Fig 1 2 Item 8 standard BINOS 100 2M F only e the keypad System Parameter PUMP chapter 8 17 e via optional RS 232 485 instructions chapter 12 5 e via optional FOUNDATION Fieldbus instructions chapter 13 2 or e via optional digital inputs chapter 13 1 Optional the status of gas sampling pump is output via a digital status signal Pump see Item 11 3 If the pump is turned on a green LED PUMP Fig 1 2 Item 3 will light up at the front panel BINOS 100 2M from program version 5 0 is required notin combination with FOUNDATION Fieldbus 9 not in combination with RS 232 485 interface ETC00781 4 Series 100 e 02 2004 7 7 KEY FUNCTIONS 7 8 00781 4 Series 100 e 02 2004 SETTING SYSTEM PARAMETERS 8 Setting System Parameters Push the key until the text appears Press the key a ESTES SS CE RU E re eh ete cc LC M ILL 11 If the Code had not already been entered there willappear INPUT CONTROL Use the keys A V to select the Code and then using The display wi
69. Correct Channel2 Tolerance error Zero gas value differs more than 10 of measuring range from zero Channel 1 Channel2 Tolerance error Span gas value differs more than 10 from nominal value Channel 1 J Channel 2 Measuring value more than 10 over full scale range ETC00781 4 Series 100 e 02 2004 Incorrect zero gas in use IR channel Photometer section contaminated Analyzer not calibrated Incorrect nominal value Incorrect span gas in use IR channel Photometer section contaminated Analyzer not calibrated Concentration of measuring gas too high Check zero gas in use Checkanalysiscell and windows for contamination Cleaning of contaminated parts see chapter 24 3 Switch off the tolerance check before starting an adjustment see chapter 8 6 Enter the correct nominal value certification of span gas bottle see chapter 9 1 2 Check span gas in use Use another or a new gas bottle Enter the correct nominal value Checkanalysiscell and windows for contamination Cleaning of contaminated parts see chapter 24 3 Switch off the tolerance check before starting an adjustment see chapter 8 6 Check concentration of measuring gas Us
70. EASURING POINTS OF BKS 17 Measuring Points of BKS and OXS 2 Be sure to observe the safety measures 17 4 Measuring points of BKS All measuring points are measured against ground X 11 X 28 or X 29 17 1 1 Supply Voltage 6 V Measuringpoint X 14 Measuring device DVM Signal 6V DC 10 200 mV adjust with Potentiometer R 90 if necessary Failure No signal Possiblereasons a Voltage supply is absent b Voltage supply lt 9V or polarity reversal c BKSfaulty 17 1 2 Reference Voltage positive Measuringpoint X 10 Measuring device DVM Signal 5 535 V DC x 60 mV Front panel Fig 17 1 PCB BKS measuring points principle drawing ETC00781 1 Series 100 e 10 2001 17 1 MEASURING POINTS OF BKS AND OXS Rosemount Analytical MEASURING POINTS OF BKS FISHER ROSEMOUNT 17 1 3 17 1 4 17 2 Reference Voltage negative Measuringpoint X 12 Measuring device DVM Signal inverse reference voltage positive Thedifference between negative reference voltage and positive reference voltage must be no more than 10 mV U U lt 10mV ref pos ref neg If the difference is bigger exchange BKS Motor Drive for IR channel only Measuring point LB 1 Measuring device Oscilloscope Signal square impuls U 6 V 0 3 V frequency 1152 Hz 20 Hz Failure No signal or incorrect frequency Possible reasons a
71. ENERAL SPECIFICATIONS 27 5 Voltage Supply BINOS 100 OXYNOS 100 HYDROS 100 BINOS 100 2M external power supply Input Voltage Supply 3 pole XLR Flange male lockable 24 V DC 5 96 DC voltage supplied by optional power supplies SL5 SL10 both for rack mounting only or UPS 01 T orequivalent power supply Power Consumption analyzer itself BINOS 100 2M internal power supply Input integrated power supply Power Consumption Outputto external consumers Available power supply to external consumers BINOS 100 Input Internal power supply Power consumption Fuses internal 27 5 1 Electrical Safety Over voltage category Pollution degree Safety Class alll O s 27 8 BINOS 100 M lt 20W OXYNOS 100 40W HYDROS 100 35W BINOS 100 2M 120W plug UPS input voltage see chapter 27 5 2 max 240 VA 3 poliger XLR Flange female max 2 0 A depends onintemal configuration terminal strips SL5 input voltage see chapter 27 5 2 max 350 VA T 3 15 A 250 V 2 pieces 2 2 for BINOS 100 M OXYNOS 100 HYDROS 100 BINOS 100 2M ext PS instruments 1 for BINOS 100 2M int PS BINOS 100 F instruments SELV voltage optically isolated to electrical supply 00781 4 Series 100 e 02 2004 VOLTAGE SUPPLY TECHNICAL DATA 27 5 2 Power Supplies UPS 01 T Universal Power Supply SL5 SL10 Input UPS
72. ERMAL CONDUCTIVITY TC MEASUREMENT 2 3 3 Measurement Method The entire measurement cell is thermostatted to a temperature of up to 75 C The four sensors are electrically heated to a higher temperature and the signal of the Wheatstone Bridge is monitored Depending on the thermal conductivity of the gases that pass the cell the temperature of the sensors in contact with the gas changes and thus their electrical resistance This changes the output signal of the Wheatstone Bridge and electronic circuitry processes this signal to obtain standardized signal amplitudes and transmits these to both an indicator instrument and to the signal output connector ETC00781 1 Series 100 e 10 2001 2 11 MEASURING PRINCIPLE THERMAL CONDUCTIVITY TC MEASUREMENT 2 12 00781 1 Series 100 e 10 2001 PHOTOMETER ASSEMBLY PYROELECTRICAL DETECTOR 3 Photometer Assembly Depending on gas component and measuring range different photometer assemblies will be realizedin 100 series Optionalthe photometer can be sealed to ambient air In this case all parts are sealed with O rings The entire photometer assembly is mounted as a unit on the main circuit board BKS by means of a bracket The main circuit board is inserted into guide rails in the analyzer housing to which the front panel membrane keypad and the rear panel are assembled 3 1 Photometer with Pyroelectrical Detector Solid state detector Fig 3 1 shows the schematical photometer as
73. ETC00781 4 Series 100 e 02 2004 CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR REPLACING THE SENSOR b IR Oxygen Measurement combined O Open the analyzer housing see chapter 23 Disconnect the connector for the sensor from P2 of circuit board OXS see Fig 25 5 O Unscrew both fastening screws for the fitting see Fig 25 4 and remove the fitting completely with the sensor Gas connections Fastening screws Fitting Front panel Fig 25 4 Inside View BINOS 100 2M combined IR Oxygen Measurement assembly similar in BINOS 100 M ETC00781 4 Series 100 e 02 2004 25 5 CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR REPLACE REINSTALL THE SENSOR 25 2 2 Removing the Sensor O Takethe consumed sensor out of the fitting O Take off the stopper from new sensor and place the new sensor into the fitting so that the name plate is at the top of the sensor O Close the consumed sensor with the stopper and send it back to our factory 25 2 3 Reinstalling the Sensor a Oxygen Measurement without IR channel O Putthe fitting with the new sensor onto the support move to the stop and screw with the two fastening screws phillips screws see Fig
74. Exhaust X Flowmeter Filter LA gt Gas sampling pump Fig 5 2 100 series Bypass installation 00781 4 Series 100 e 02 2004 PREPARATION GAS CONDITIONING SAMPLE HANDLING 5 2 Gas Conditioning Sample Handling The conditioning of the sample gas is of greatest importance for the successful operation of any analyzer according to extractive method If corrosive gases are inserted into the instrument ithas is to be verified that there Y All gases have to be supplied to the analyzers as conditionned gases are no gas components which may damage the gas path components The gas has to fullfil the following conditions It must befree of condensable constituents be free of dust be free of aggressive constituents which are not compatible with the material of the gas paths have temperatures and pressures which are within the specifications stated in Technical Data of this manual 1 d a a Inflammable or explosive gas mixtures may not be introduced into the analyzers without supplementary protective measures When analysing vapours the dewpoint of the sample gas has to be at least 10 C below the ambient temperature in order to avoid the precipitation of condensate in the gas paths Suitable gas conditionning hardware may be supplied or recommended for specific analytical problems and operating conditions ETCO00781 4 Series 100 e 02 2004 PREPARATION GAS CONDITIONI
75. F PHOTOMETRIC COMPONENTS REMOVAL OF THE PHOTOMETER ASSEMBLY 24 Replacement and Cleaning of Photometric Components 24 1 Taking out the Photometer Assembly N 5 4 ETC00781 4 Series 100 e 02 2004 Open the analyzer housing cf chapter 23 Disconnectallelectrical connections between photometer assembly and electronic unit and disconnect all gas lines from the photometer assembly O Onlyanalyzers with gas detector Remove preamplifier Fig 3 2 Item 5 from holding device Fig 3 2 Item 4 Remove the two screws shown in Fig 24 1 as Item 1 Take the photometer assembly out of the analyzer housing 2 Fig 24 1 Analyzer Photometer Assembly 2 channel IR analyzer viewed from the front panel side Fastening screw photometer assembly mounting bracket Light source with mounting flange Temperature sensor Zero level adjustment baffle not for sealed version Light source mounting screw Oa A 24 1 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS LIGHT SOURCE REPLACEMENT A 24 2 Light Source Replacement a O Open the analyzer housing cf chapter 23 O TTake the photometer assembly out of the analyzer housing see chapter 24 1 O Remove the two light source mounting screws shown in Fig 24 1 as Item 5 or the temperature sensor shown in Fig 24 1 as Item 3 resp O Remove the light source together with its mounting flange O Remove the
76. FISHER ROSEMOUNT 18 3 Plug Pin Allocation WAP 100 TC measurement only P2 24V DC supply from PCB BKS P1 or P2 Terminals P 18 to sensor Cable P15 5 pin connector PCB BKS X 5 sensor signal P16 heater of sensor 10 BSE 01 analog input for cross compensation 2 58 18 1 10 P10 e e e P16 n of A P15 ol 2 Fig 18 3 WAP 100 Plug Pin Allocation principle drawing 1 8 6 ETC00781 1 Series 100 10 2001 FISHER ROSEMOUNT 19 Jumper Allocation of BKS J1 A D conversion start channel 1 42 A D conversion start channel 2 open for 1 channel analyzer J6 Watchdog signal J7 Buffer Battery Front panel Fig 19 1 PCB BKS Jumper Allocation principle drawing ETC00781 1 Series 100 e 10 2001 1 9 1 JUMPER ALLOCATION OF BKS Rosemount Analytical FISHER ROSEMOUNT 1 9 29 00781 1 Series 100 e 10 2001 FINE DUST FILTER OPTION 21 Fine Dust Filter Option LA The optional fine dust filter see Fig 1 2 should be checked in intervals appropriate to the type of process and application If the filter element shows contamination the element should be replaced immediately with a new unit To avoid risks by explosive toxic or unhealthy gas components purge the gas lines with ambient air or nitrogen N b
77. Instruction Manual ETC00781 February 2004 Series 100 Gas Analyzers BINOS 100 BINOS 100 M BINOS 100 2M BINOS 100 F OXYNOS 100 HYDROS 100 Software Version 5 1x ROSEMOUNT 5 Analytical EMERSON Process Management www EmersonProcess com ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING Emerson Process Management Rosemount Analytical designs manufactures and tests its products to meet many national and international standards Because these instruments are sophisticated technical products you MUST properly install use and maintain them to ensure they continue to operate within their normal specifications 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 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 maintena
78. KS 17 5 MEASURING POINTS OF BKS AND OXS Rosemount Analytical FISHER ROSEMOUNT 17 2 Measuring points of OXS electrochemical oxygen measurement 17 2 1 Sensor Signal Measuring device DVM Measuring point 1 Signal Tp 2 1 Signal At ambient air approx 21 Vol O 700 mV to 1000 mV Failure No signal or faulty voltage Possible reasons a Oxygen sensor not connected to PCB OXS b PCB OXS not connected faulty Oxygen sensor faulty orconsumed d BKS faulty Note Ifthe measuring value is lower than lt 700 mV at gas flow with ambientair the sensor is consumed Exchange the sensor Tp2 ca 00000000 00000000 R5 a O Fig 17 2 PCB OXS assembled horizontal projection 17 6 00781 1 Series 100 e 10 2001 Rosemount Analytical FISHER ROSEMOUNT PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS PLUG PIN ALLOCATION OF BKS P 1 or P2 X1 X16 X18 J9 X 36 D 30 1 2 Be sure to observe the safety measures 18 1 Plug Pin Allocation of BKS 24V DC supply to optional internal consumer heater of paramagn O sensor e g Front panel BXF P8 Digital Outputs parallel Analog Outputs Option BSI 10 Status signals and serial interface resp Option BAF 01 Pressure sensor PCB at Option BAF 01 Connector for pressure sensor ETC00781 1 Series 100 e
79. NG SAMPLE HANDLING 5 2 1 Fine Dust Filter Option BINOS 100 2M F A fine dust filter with a pore size of 2 um may optionally be integrated into the BINOS 100 2M F front panel Fig 1 2 Item 10 not for 2 channel analyzers with parallel gas paths and for BINOS 100 F analyzers used in hazardous area Ex zones 5 2 2 Gas Sampling Pump Option BINOS 100 2M F Optional BINOS 100 2M F can be equipped with a gas sampling pump pumping rate max 2 5 I min see chapter 7 4 For special solutions with 2 parallel measuring channels 2 gas sampling pumps consult factory 1 Lifetime max 5 000 hours of operation 5 2 3 Pressure Sensor Option It is possible to integrate a pressure sensor with a range of 800 1 100 hPa The concentration values computed by the analyzer willthen be correctedto reflect the barometric pressure to eliminate faulty measurements due to changes in barometric pressure See technical data chapter 27 5 2 4 Gas Flow The gas flow rate should be within the range 0 2 l min to max 1 5 l min A constant flow rate of about 1 l min is recommended The allowed gas flow rate for analyzers with paramagnetic oxygen sensor and for BINOS 100 F analyzers used in hazardous area Ex zones is 1 01 BINOS 100 2M F with an optional fine dust filter see chapter 5 2 1 allow to adjust the flow with a screw driver via an optional integrated throttle It is possible to integrate up to tw
80. OMPONENTS REINSTALLING OF ANALYSIS CELLS 24 3 3 Reinstalling the Analysis Cells a For analysis cells of lengths 1 mm and 7 mm Place the O rings on the adapter cell and filter cell Fitthe components together Install the clamping collars with the clamp and tighten it b Analysis cells of lengths 50 mm 200 mm O O Place the O ring on the chopper housing side of the cell body Position the cell body in place and fasten it using the two mounting screws Fig 24 2 Item 4 Place the O ring on the filter cell Fit the filter cell on the cell body Install the clamp and tighten Only analyzer with gas detector O Assembly preamplifierto analysis cell Then O Reinstall the photometer assembly see chapter 24 5 ETC00781 4 Series 100 e 02 2004 24 5 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS CHOPPER REPLACEMENT REINSTALLING OF THE PHOTOMETER ASSEMBLY 24 4 24 5 24 6 Chopper Replacement Open the analyzer housing cf chapter 23 Take the photometer assembly out of the analyzer housing see chapter 24 1 Remove the light source s from chopper housing see chapter 24 2 Remove the analysis cell s from chopper housing see chapter 24 3 1 Remove the analysis cell s from chopper housing see chapter 24 3 1 Reinstall the analysis cell s to new chopper housing see chapter 24 3 3 Insert the light source s to new chopper housing See chapter 24 2 Re
81. T 2 Measuring Principle Depending on the gas to be analyzed different measuring methods will be used 2 1 IRMeasurement The analyzers are non dispersive infrared photometers NDIR using measurement of selective absorption in a column of gas The measuring effect derived from absorption of infrared radiation is due to the gas being measured The gas specific wavelengths of the absorption bands characterize the type of gas while the strength of the absorption gives a measure of the concentration of the component measured Due to a rotation chopper wheel the radiation intensities coming from measuring and reference side of the analysis cell produce periodically changing signals within the detector The detector signal amplitude thus alternates between concentration dependent and concentra tion independent values The difference between the twois a reliable measure of the concentration of the absorbing gas component Dependent on measuring component and measuring concentration two different measuring methods will be used 2 1 1 Interference Filter Correlation IFC Principle The undivided analysis cellis alternately illuminated with filtered light concentrated in one of two spectral separated wave length ranges One of these two spectrally separated wave length bands is chosen to coincide with an absorption band of the sample gas and the other is chosen such that none of the gas constituents expected to be encountered in practice absorbs a
82. an be performed only after zeroing has been done Spanning will set the actually measured gas concentration to the entered span gas setpoint Note span gas concentration should be in a range of 80 110 of full scale range For lower span gas concentrations the measuring accuracy could be decreased for sample gas concentrations which are above the span gas concentration Spanning for oxygen measurement can be done using ambient air as span gas if the oxygen concentration is known and constant When using span gas mixtures the entry for C Cal must be set to 0 see chapter 8 3 If there is no built in pressure sensor the correct pressure must be entered before 1 performing the calibration if you want to make use of pressure correction see chapter 8 1 9 4 ETC00781 4 Series 100 e 02 2004 CALIBRATION MANUAL SPANNING Push the key a zl a until the display shows Spanning channel 1 or XXXX E Spanning channel 2 resp XXX X Press the key Enter the correct user code if not already entered E IP Boda The displays will now show The actual concentration level will be displayed Wait at least the entered flushing period and t time to go by Push the key The test gas setpoint a resp XXXX will be displayed
83. and 13 too These signals are floating contacts with a maximum load of 30V 1A 30W Observe the wiring hints in chapter 29 10 p 1 5 o A gt OK open Failure closed OK closed Failure open Measure open Calibration closed Measure closed Calibration open Pump OFF open Pump ON closed OK Failure Common Measure Calibration Common Gas sampling pump Common Pump OFF closed Pump ON open Fig 11 2 Pin Assignments X 1 Status Signals BINOS 100 2M F with software revision 5 0 or higher only 11 4 ETC00781 4 Series 100 e 02 2004 Rosemount Analytical FISHER ROSEMOUNT SERIAL INTERFACE OPTION RETROFITTING 12 1 status signals only RS 232 Interface RS 485 Interface washers and the screws Threated bolt Rear panel PCB BSI 10 Code pin see chapter 28 ETC00781 1 Series 100 e 10 2001 12 Seriallnterface Option Upgrading Serial Interface Status Signals PCB BSI 10 Catalog No 43 001 590 PCB BSI 10 with PCB SIF 232 Catalog No CH 000 069 PCB BSI 10 with PCB SIF 485 Catalog No CH 000 070 see chapter 12 3 2 too 1 Be sure to observe the safety measures O Switch off the analyzer and open the housing see 23 J9 Fig 12 1 Installation of PCB BSI 10 O Mountthe circuit board to the threated bolts at the rear panel and
84. and plugs 27 10 00781 4 Series 100 e 02 2004 REPLACING THE EPROM 28 Replacingthe EPROM The EPROM may be easily replaced by a new unit when faulty or update the software The EPROM replacement procedure is as follows O Disconnect the analyzer from the source of electric power O Open the housing see chapter 23 O Remove jumper J7 for the battery buffering see the chapter 19 O Pull out the EPROM chapter 18 1 Align the EPROM with respect to the socket before re insertion EPROM The EPROM is aligned correctly if the mark points to the front panel O Insertthe EPROM O Reconnect jumper J7 see the chapter 19 A O Reconnect the instrument to the source of electric power and switch it on see chapter 6 the displays must show a flashing batt All stored data have now been replaced by default values All user and application data such as system parameters threshold values etc must be re entered 2 A complete re calibration of the instrument see chapter 9 must be performed after an EPROM replacement ETCO00781 4 Series 100 e 02 2004 28 1 REPLACING THE EPROM 28 2 00781 4 Series 100 e 02 2004 CABLES AND CORDS 24 V DC INPUT OUTPUT 30 t t t Cables and Cords To stay in conformance with EMC requirements use our shielded data cables optionally available or equivalent data cables only The operato
85. anel Fig 1 4 for hazardous areas ex zones Front panel Fig 1 3 BINOS 100 F front view SPAN 1 O SAMPLE 3 SPAN 2 0 ZERO 4 5 PUMP SWITCH CTRL FUNCTION ENTER INPUT CONTROL f AN a A LY Y Fig 1 4 BINOS 100 F magnetically operated front panel impact tested front view 1 4 ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION REAR PANEL 1 2 Rear Panel The rear panels include L thegasline fittings L the plug for the electrical supply input L the subminiature D mating socket for the analog signal outputs L the subminiature D plug for the digital outputs concentration limits valve control L optionally the subminiature D mating plug for analog signal inputs interference cross compensation TC only L optionally the subminiature mating socket for the RS 232 C RS 485 interface L optionally the subminiature D mating plug for the status signals relay outputs For BINOS 100 2M F only L optionally the solenoid valve block L optionally the terminal strips for the 7 digital inputs L optionally the terminal strips for the FOUNDATION Fieldbus not in combination with FOUNDATION Fieldbus 7 BINOS 100 2M with external power supply only 9 not in combination with RS 232 485 interface ETC00781 4 Series 100 e 02 2004 1 5
86. arge Use damp cloth only for cleaning front panel ETC00781 4 Series 100 e 02 2004 SAFETY SUMMARY ADDITIONAL NOTES FOR SERVICE MAINTENANCE A Milla Electrostatic Discharge Alas The electronic parts of the analyzer can be irreparably damaged if exposed to electrostatic discharge ESD The instrument is ESD protected when the covers have been secured and safety precautions observed When the housing is open the internal components are not ESD protected anymore Although the electronic parts are reasonable safe to handle you should be aware of the following considerations Best ESD example is when you walked across a carpet and then touched an electrical grounded metal doorknob The tiny spark which has jumped is the result of electrostatic discharge ESD You prevent ESD by doing the following Remove the charge from your body before opening the housing and maintain during work with opened housing that no electrostatic charge can be built up Ideally you are opening the housing and working at an ESD protecting workstation Here you can wear a wrist trap However if you do not have such a workstation be sure to do the following procedure exactly Discharge the electric charge from your body Do this by touching a device that is grounded electrically any device that has a three prong plug is grounded electrically when it is plugged into a power receptacle This should be done several times during the ope
87. at the analyzer see chapter 12 3 4 12 1 0 00781 4 Series 100 e 02 2004 SERIAL INTERFACE OPTION INSTRUCTION SYNTAX 12 5 Instruction Syntax Code definitions RP receive parameters analyzer is accepting values SP send parameters analyzer is sending values Ri receive instructions k channel numbers 0 to 2 m range number W value ID analyzer ID no for RS 485 mode of operation follows start character LPB message length parity byte CR terminate character Receipt of any instruction codes not listed in the following section will be acknowledged by transmittal of status code 106 Future expansions will make use of code numbers not currently in use ETCO0781 4 Series 100 e 02 2004 12 11 SERIAL INTERFACE OPTION INSTRUCTIONLIST 12 5 1 Instruction Listing Instruction syntax 1D 001 k LPB lt CR gt 1D 002 k LPB lt CR gt 1D 003 k LPB lt CR gt 1D 005 m k LPB lt CR gt ID 006 LPB lt CR gt ID 007 LPB lt CR gt 1D 008 LPB lt CR gt 1D 009 w LPB lt CR gt 1D 011 m k LPB lt CR gt 1D 013 k LPB lt CR gt 1D 014 w k LPB lt CR gt 1D 017 k LPB lt CR gt 1ID 018 w k LPB lt CR gt 1D 019 k LPB lt CR gt 1ID 020 w k LPB lt CR gt 1D 023 k LPB lt CR gt 1ID 028 m k LPB lt CR gt ID 029 m w k LPB lt CR gt 1D 030 LPB lt CR gt 1D 031 t _LPB lt CR gt 1D 603 k LPB lt CR gt 1D 604 k LPB lt CR gt ID 605 k LPB CR 1D 606 0 LPB lt CR gt
88. ation character Upon receipt of the terminate character the analyzer attempts to evaluate the current contents of its input buffer as a valid telegram If the syntax of the transmitted telegram is correct the analyzer will transmit a response telegram to the host computer This consists of the start character an instruction code requested data a block parity byte and the termination character Ifthe syntaxofthetransmittedtelegram was not correct the analyzer willtransmita status telegram containing an error message to the host computer Each terminate character reception thus initiates an analyzer response 12 2 ETC00781 1 Series 100 e 10 2001 Rosemount Analytical SERIAL INTERFACE OPTION FISHER ROSEMOUNT GENERAL To avoid detecting transmission errors the host computer can insert a message length parity byte immediately preceding the terminate character for verification by the analyzer The analyzer invariably transmits message length parity bytes immediately preceding termination characters The elapsed time between the reception of start characters and termination characters is not limited by the analyzer i e there are no time out periods If the host computer transmits any new characters before the analyzer has responded to the preceding telegram the analyzer s input buffer will reject them i e these characters will be ignored by the analyzer The transmission rate may be set between 600 and 38 40
89. by It is important that the temperature is kept between 5 and 45 C ETC00781 4 Series 100 e 02 2004 5 11 SAFETY SUMMARY OPERATING CONDITIONS ACCORDING TO DMT APPROVAL The analyzer housings must be provided with a permanent type plate indicating the name ofthe manufacturer model number serial number and the following reference and date oftesting IBS PFG Nr 41300392 for CO or CO IBS PFG Nr 41300292 for Other designation requirements such as these according to ElexV are still valid With this type plate the manufacturer conformes that the features and technical data of the delivered system are identical with those described in this report Any system which is not provided with such a type plate does not go conform with this report The chapter 6 of this report must be included in the operation and maintenance manual The manufacturer has to supply the customer with a copy of this report if required A print of the report in an abridged version requires the agreement of PFG The results included in this report may not be altered in publications produced by the manufacturer ETC00781 4 Series 100 e 02 2004 SAFETY SUMMARY OPERATING CONDITIONS ACCORDING TO DMT APPROVAL 00781 4 Series 100 e 02 2004 SAFETY SUMMARY S 14 ETC00781 4 Series 100 e 02 2004 PREFACE PREFACE General Overview The series 100 of analy
90. c0 0 0 L S O N AX O SIQI reunuon enjoy auuey9 3ueunsn py 9A97 0197 L 00 sSSOSHGAH F 01170 L 0 3000 1 0 001 sSONIA IN 00 SONIA d 001 5 001 sSONIA NOILONNI SILNA dN NMOG oseo al 25 YONOL umos 3009 ab ion Matrix Operating Funct ries 100 Se Fig 7 1 ETCO00781 4 Series 100 e 02 2004 KEY FUNCTIONS INPUT CONTROL INPUT CONTROL 7 3 INPUT CONTROL A V 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 UP ZX increase current value by 1 DOWN UA decrease current value by 1 If either of these keys is held pressed the value will be altered continuously Altering rate starts with the slower rate and shifts automatically to the faster rate When the minimum value is reached the analyzer will automatically revert to the slower rate in order to facilitate entering the minimum value For any parameter a tolerance range is defined which has to be considered when entering parameter values In addition all values are plausibility checked as added protection against operator errors 2 If within about 60 120 seconds no further keys have been pressed the analyzer will automatically revertto the analysis display 7 6 ETC00781 4 Series 100 e 02 2004 KEY FUNCTIONS PUMP
91. cated in this report and the local operating conditions Consider the Code of Pratice No 032 of the Labor Association of the Chemical Industry Usage of stationary gas warning systems for explosion protection Verify that the explosion protection requirements are met when using the gas warning system Depending on the situation it must be verified that the preset values are low enough to allow the system to activate the necessary protection and emergency measures and thus to prevent any critical situations in a minimum period of time When at system installation a release of one or both measuring components in the ambient air might occur its influence on the measuring result should be proved A sealed cell or an external housing purging with sample free air of measuring gases can be used if required The operability of the alarms and the displays of each system should be tested with clean air and test gas after the initial operation after each long time interruption and periodically The tightness of gas pathes should also be tested The tests must be documented by keeping accounts 5 1 0 ETC00781 4 Series 100 e 02 2004 SAFETY SUMMARY OPERATING CONDITIONS ACCORDING TO DMT APPROVAL 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 T023 of the Labor Association of the Chemical Industry Maintenan
92. ce of stationary gas warning systems for explosion protection Consider the superproportional dependency of the barometric pressure on the measured value for CO The system control with serial interfaces described in this operation manual have not been subject to this investigation Sample gas condensation in analyzer components must be prevented by taking the necessary steps When the system is used with aggressive gases it is to be verified that there are no gas components which might damage the gas path components Appropriate dust filters must precede the used systems and flow values recommended by the manufacturer should be observed An external monitoring of the sample gas flow through the analyzer should be provided Theresultsofthis investigation are based on the systems using software versions 3 03 4 00 4 01 and 4 11 Achange of the software version used must be certified by the Testing Association lishouldbeensuredthatthe system parameters forthe analog output have been correctly adjusted End of range oflow concentration should not be identical orlowerthan the begin of range Disregarding these versions the measurement range should be adjusted between 0 to 80 Oto 80 CO Oto 10 COor 0 to 10 O resp when the systems are used for explosion protection Readand follow the operation and maintenance manual supplied to and certified
93. cess Management Manufacturing GmbH amp Co OHG 2004 ws ST EMERSON
94. cessary gases have to be connected atthe corresponding solenoid valve at an overpressure of 50 max 500 hPa For2 channel analyzer with parallel gas paths we can deliver a special solution with 2 valve blocks Be sure to observe the safety regulations for the respective gases sample gas and test gases span gases and the gas bottles The test gas containers have to be set up according to the valid regulations If a solenoid valve is open there is illuminated a green LED Fig 1 2 Item 3 at the front panel Solenoid valve lz V x common gas outlet to standard gas inlet K1 WM o N 00000 Solenoid valve S c has span gas 1 X1 OUTPUT a SUB SE ae Ge DURCHFLUSS 4 Ge X4 INMOUT A MAX IL MIN _ 5 5 Solenoid valve span gas 2 X3 OUTPUT r DE i l 5 Solenoid valve Lh sample gas GE cin LU NDA 2 E Solenoid valve zero gas Fig 5 4a BINOS 100 2M version A gas connections with solenoid valve option 5 8 00781 4 Series 100 e 02 2004 PREPARATION GAS CONNECTIONS Solenoid valve MAXAL MN span gas 1 Solenoid valve span gas 2 Solenoid valve common gas outlet to standard gas inlet K1 Solenoid valve sample gas Solenoid va
95. d There will appear Use the keys to select the correct user code and enter using o U XXXX XXXX The displays will now show The actual zero level will be displayed Wait at least the entered flushing period and ty time to go by 9 2 ETC00781 4 Series 100 e 02 2004 CALIBRATION MANUAL ZEROING Push the key The nominal value will be displayed If the actual and nominal zero levels match the next function can be selected using the FUNCTION key without zeroing If the two values dismatch press the key 8B Ue will be displayed XXX X XXX To start zeroing press again As soon as zeroing has finished the display indicates The actual measuring value ru resp will be displayed XKXX the actual measuring value The keyboard will only be released after another flushing period and t time If Hold 1 the analog signal outputs and the concentration limits are released too To leave calibration mode press a ETC00781 4 Series 100 e 02 2004 9 3 CALIBRATION MANUAL SPANNING 9 1 2 Spanning Verification of the span calibration is essential for accurate concentration measurement Spanning c
96. d to install the instrument in a protective cabinet At least the instrument has to be protected against rain e g shelter Do not interchange gas inlets and gas outlets All gases have to be supplied to the analyzer as conditionned gases If corrosive gases are inserted into the instrument it has is to be verified that there are no gas components which may damage the gas path components Ensure that all gas connections are made as labeled and are leak free Improper gas connections could result in explosion and death The unit s exhaust may contain hydrocarbons and other toxic gases such as carbon monoxide Carbon monoxide is highly toxic Permissible gas pressure of sample gas test gases max 1 500 hPa The exhaust gas lines have to be mounted in a declining descending pressureless and frost free and according to the valid emission legislation In case it is necessary to open the gas paths close the analyzers gas connections with PVC caps immediatly to avoid pollution of gas paths BINOS 100 F lift points are labeled Labels showing down side for transport Do not use electronics of the optional pressurization system as handle Use only optional delivered cables from our factory or equivalent shielded cables to be in agreement with the CE conformity The customer has to prove thatthe shield is connected correctly chapter 29 10 Shield and connectors housing have to be connected conductive Sub min D plugs s
97. diation passes through the open measurement side of the analysis Cell into the detector a partof itis absorbed depending on sample gas concentration The gas in the absorption chamber then is heated less than in the case of radiation coming from reference side Absorption chamber gas become colder gas pressure in the absorption chamber is reduced and some gas of compensation chamber passes through the flow channel into the absorption chamber The flow channel geometry is designed in such a way that it hardly impedes the gas flow by restriction Due to the radiation of chopper wheel the different radiation intensities lead to periodically repeated flow pulses within the detector The microflow sensor evaluates this flow and converts it into electrical voltages The electronics which follow evaluate the signals and convertthem into the corresponding display format 2 4 00781 1 Series 100 e 10 2001 MEASURING PRINCIPLE IRMEASUREMENT 2 1 3 Technique The broadband emission from two IR sources in the case of dual channel analyzers passes through the chopper blade then if IFC through combinations of interference filters if optopneumatic principle depending on application through an optical filter reduction of influ ences and enters the analysis cells The light transmitted through these cells is focused by filter cells onto the according detector The preamplified detector output signalis sentto microprocessor circuitry which co
98. e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Gas line fittings Security dustfilter O sensor ms Frontpanel Fig 1 12 OXYNOS 100 Inside View with paramagnetic sensor Outlet to Sensor from Sensor Heat exchanger view X 180 rotate Heat exchanger PCB BKS 00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Gas line fittings LDA OCL Ce Im ULI UU N lt DI p Security dustfilter channel2 channel 1 2 Pressure sensor DT Option EA A Y Front panel Fig 1 13 OXYNOS 100 Inside view with electrochemical sensor 00781 4 Series 10
99. e another analyzer suitable for the concentration range involved LIST OF FAILURES Possible Reasons Check Correct Pressure sensor defective EPROM Checksummary defective Test for RAM IC s defective Analog output absent Fluctuating or erroneous display Time out for XON of serial interface Measuring range failure Connection faulty Pressure sensor faulty EPROM faulty BKS faulty RAM IC s BKS faulty BKS faulty Leakage into gas circuit Ambient air contains gas constituent to be measured in excessive concentration At drive of serial interface XON character is absent Time out 60 s pressure not into the sensor measuring range 800 1 100 hPa Check connection P1 at BAF 01 pressure sensor see chapter 18 Exchange pressure sensor Exchange EPROM see chapter 28 Exchange BKS Exchange BKS Exchange BKS Perform a leakage check see chapter 22 Replace absorber materialforthe light sources and chopper housing Use sealed photometer Option Flush out the analyzer 00781 4 Series 100 e 02 2004 LIST OF FAILURES Possible Reasons Check Correct Gas pressure subject to 3 Check the gas lines preceding and excessive fluctuations following the sensor c
100. e shut off valve and verify that following a brief period required for pressure equilibrium that the height of the water column does not drop over a period of about 5 minutes Any external devices such as sample gas cooling hardware dustfilters etc should be checked in the course of leak testing Overpressure max 500 hPa For analyzers with parallel gas paths leak testing must be performed for each gas path separately ETC00781 4 Series 100 e 02 2004 22 1 LEAKTESTING 22 2 00781 4 Series 100 e 02 2004 HOUSING CLEANING OF HOUSING SURFACE 23 Housing 23 1 Cleaning of Housing Surface For cleaning the analyzer housing surface use a soft fluff free cloth and all purpose detergent O Disconnectall voltage supplies To avoid risks by explosive toxic or unhealthy gas components first purge the gas lines with ambient air or nitrogen N before cleaning or replacing parts of the gas paths 1 If itis necessary to disconnect the gas connections the gas line fittings of the analyzer have to be closed with PVC caps before cleaning to avoid pollution O Moisten the soft fluff free cloth with the cleaning solution mixture of 3 parts water 1 part all purpose detergent max 1 Be sure to use moisted but wet cloth only Be sure that no liquid can drop into the housing inside O Clean the analyzer housing surface with the damped cloth O Ifrequired rub off the housing but
101. ector Light source Amplifier Display 0 0 NODO gt ON ETC00781 1 Series 100 10 2001 2 7 MEASURING PRINCIPLE OXYGEN MEASUREMENT EO ELECTROCHEMICAL PRINCIPLE 2 2 2 Electrochemical Measurement The determination of O concentrations is based on the principle of a galvanic cell The principle structure of the oxygen sensor is shown in Fig 2 5 Lead wire Anode Lead wire Cathode Anode Lead O ring 8 Plastic disc 9 Plastictop 10 Resistor 6 Thermistor 5 Acid electrolyte 3 Sponge disc 7 Gold film Teflon membrane 4 Fig 2 5 Structure of electrochemical Oxygen Sensor The oxygen senor incorporate a lead gold oxygen cell with a lead anode 1 and a gold cathode 2 using a specific acid electrolyte To avoide moisture losses atthe gold electrode a sponge sheet is inserted on the purged side Oxygen molecules diffuse through anon porous Teflon membrane 4 into the electrochemical cell and are reduced at the gold cathode Water results from this reaction On the anode lead oxide is formed which is transferred into the electrolyte The lead anode is regenerated continuously and the electrode potential therefore remains unchanged for a long time The rate of diffusion and so the response time t of the sensor is dependent on the thickness of the Teflon membrane 2 8 ETC00781 1 Series 100 10 2001 MEASURING PRINCIPLE OXYGEN MEASUREMENT EO ELECTROCHEMICAL PRINCIPLE
102. efore cleaning or replacing parts of the gas paths O Remove the glass filter cover and unscrew the mounting bracket switch off optional gas sampling pump before O Replace contaminated filter element using only new units Order No 42 707 676 Dispose contaminated filter elements in accordance with applicable regulations Filter elements are single use disposable items Do not clean and replace used filter elements use new replacements only O Reinstall mounting bracket and close filter with the glass cover see Fig 21 1 O Performa leak testing see Item 22 Filter element Glass cover Mounting bracket Fig 21 1 Fine Dust Filter ETCO0781 4 Series 100 e 02 2004 21 1 FINE DUST FILTER OPTION 21 2 ETC00781 4 Series 100 02 2004 LEAK TESTING 22 LeakTesting Testing for gas leakage should be performed at bimonthly intervals and always immediately after any repair or replacement of gasline components is performed The test procedure is as follows Analyzer Overpressure Valve approx 50 hPa Water TT Fig 22 1 Leak Testing with an U Tube Manometer O _ Install a waterfilled U tube manometer at the sample gas outlet O _ Install a shut off valve at the sample gas inlet Admit air into the instrument at the shut off valve until the entire analyzer is subjected to an overpressure of 50 hPa approximately 500 mm water column see Fig 22 1 Close th
103. ell Eliminate any restrictions found beyond the gas outlet fitting Reduce pumping rate or flow rate Oxygen senor detector Check connections not connected BKS X5 Oxygen sensor detector channel 1 BKS X6 detectorchannel 1 channel2 see 18 Electrochemical oxygen Exchange sensor see 25 sensor is already consumed IR channel Checkconnection Light source not connected BKS X3 1 2 light source channel 1 or faulty BKS X3 4 5 light source channel 2 Fluctuating or see 18 erroneous display Light source is cold For dual IR channel analyzer interchange the two light sources Replace the suspect light source see 24 2 Faulty analog Check measuring point 17 1 7 or preamplifiering 17 2 1 resp Contamination of the gas Checkanalysiscell and windows for paths contamination Cleaning of contaminated parts see 24 3 Check gas paths and gas conditionning to contamination ETCO00781 4 Series 100 e 02 2004 LIST OF FAILURES Possible Reasons Check Correct Barometric pressure 9 Enter the correct value for effects barometric pressure see chapter 8 1 Pressure sensor faulty E 37 Temperature below the Check the temperature of the gas dew point in the gas paths paths and eliminate any reason of condensation Fluctuating or erroneous display Maintain all temperatures at values at least 10 C above the dew point of sample gas Faulty
104. enter with the a key The displays show Lele lower limit channel 1 XXXX INPUT CONTROL Use the keys A V to set the limit value Push the key to enter the value 11 2 00781 4 Series 100 e 02 2004 DIGITAL OUTPUTS LIMIT VALUES The displays show Use the keys Press the key Now the displays show Use the keys Press the key The displays show Use the keys Press the key Press the displays show INPUT CONTROL gt Niel ENTER mis XX ENTER FUNCTION XXX gt lt gt lt gt lt gt lt a ZAR gt lt gt lt The analyzer is now back in the analysis display ETC00781 4 Series 100 e 02 2004 upper limit channel 1 to set the limit value to enter the value lower limit channel 2 to set the limit value to enter the value upper limit channel 2 to set the limit value to enter the value until DIGITAL OUTPUTS VALVE CONTROL STATUS SIGNALS OPTION 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 analyzer Observe the wiring hints in chapter 29 10 11 3 Status Signals Option non voltage carrying relay contacts Three optional status signals are available on the 9 pin subminiature D plug X 1 on the rear panel of the analyzer see chapter 7 4 9
105. erator may specify another password user code Set the code using Please take care for filing the user code 8 2 8 00781 4 Series 100 e 02 2004 SETTING SYSTEM PARAMETERS RESPONSE TIME T oo 8 11 Response Time t so XX For some types of analysis an alteration ofthe analyzer damping factor i e its electrical response time t may be required The operator is offered the option of selecting an optimal response time for each application The range of accepted values is 2 60 sec INPUT CONTROL Change values using A VI X a Input indicator for channel 2 gt lt INPUT CONTROL Change values using A V a 00781 4 Series 100 e 02 2004 8 9 ENTRY OF SYSTEM PARAMETERS OFFSET BEGIN OF RANGE DES XXXX The operatoris here offered the opportunity to introduce a scale offset for the analog signal output begin of range 8 12 Offset Begin of range Example For an analyzer concentration range of 0 25 it is desired to measure only concentrations in the range 10 25 If the operator enters here the value 10 the analog signal outputs of or2 0 2 V 4 mA will then correspond to a gas concentration of 10 96 The displayed values are not affected Effect the entry using uro Entry possibility for
106. ersonal injury Deliberate disconnection is inadmissible prohibited The analyzer BINOS 100 F field housing has no switch with disconnect function The customer has to provide a switch or circuit breaker into his installation This switch has to be installed near by analyzer must be easily attainable for operator and has to be characterized as disconnector for analyzer Cables to external data processing have to be double insulated against mains voltage for analyzer BINOS 100F Use cables suitable for intrinsic safe applications only Install internal data lines that they have a distance to mains voltage lines of at least 5 mm This distance has to be valid permanently e g via cable holder 24 VDC supply to external components analyzers with the internal power supply of BINOS 100 2M requires a fuse to be connected in series to the consumer which limits the current consumption to max 2 A Verify correct polarity for 24 V DC supply of external components gt gt gt ETC00781 4 Series 100 e 02 2004 5 5 SAFETY SUMMARY ANALYZER SPECIFIC NOTES FOR USER Vi Analyzer specific notes for the user t Ee The installation site for the instrument has to be remain above freezing point at all times The instrument must be exposed neither to direct sunlight nor to strong sources of heat Be sure to observe the permissible ambient temperature For outdoor sites we recommen
107. es shows as follows 1D 030 a b c _LPB lt CR gt This means a OK Status 0 Relay without power 1 Relay active b Value of variable calibration O Relay without power gt 0 Relay active b Meaning No Calibration Zeroing channel 1 Zeroing channel 2 Zeroing channel 1 2 Spanning channel 1 Spanning channel 2 Spanning channel 1 2 Spanning channel 1 first then channel 2 reserved reserved Waiting for flushing time and ty response time 0 OAH WN Oo c Gas sampling pump 0 Relay without power 1 Relay active pump OFF pump ON BINOS 100 2M F from program version 5 0 is required ETCO00781 4 Series 100 e 02 2004 12 13 SERIAL INTERFACE OPTION RESPONSE TELEGRAMS 12 5 2 2 Pump Status Instruction 008 Theresponse telegram for instruction 1D 008 LPB CR SP Pump status shows asfollows 1D 008 w LPB CR with w 2 pump status 0 Pump Off 1 Pump On BINOS 100 2M F from program version 5 0 is required 12 14 ETC00781 4 Series 100 e 02 2004 DIGITAL INPUTS FOUNDATION FIELDBUS OPTIONS DIGITAL INPUTS 13 Digital Inputs Foundation Fieldbus BINOS 100 2M F option only 2 Be sure to observe the safety measures for all workings at the analyzer 13 1 Digital Inputs 13 1 1 General To remotely control different conditions of analyzer BINOS 100 2M F the analyzer can optionally be equipped with
108. etric pressure to eliminate faulty measurements due to changes in barometric pressure see technical data Optionally one gas sampling pump BINOS 100 2M F only see chapter 7 4 and 8 17 pumping rate maxi 2 5 l min special solution with 2 pumps with parallel gas paths BINOS 100 2M standard version BINOS 100 F Integrated power supply 230 120 V AC Optionally solenoid valve unit BINOS 100 2M F only special solution with 2 valve blocks with parallel gas paths For this case there are built in 4 8 solenoid valves Sample Gas Zero Gas Span Gas 1 Span Gas 2 atthe analyzer For manual or automatical adjustment the zero gas and the span gases will be fed to the solenoid valves controlled by the analyzer If a solenoid valve is open there is illuminated a green LED Fig 1 2 Item 3 at the front panel ETC00781 4 Series 100 e 02 2004 1 11 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Cover metal plate PCBBKS Gas line fittings e T Bc Fig 1 10 Inside View BINOS 100 e ED pn s S pH O
109. fittings ETC00781 4 Series 100 e 02 2004 3 1 PHOTOMETER ASSEMBLY PYROELECTRICAL DETECTOR This extremely simple and windowless design enables easy cleaning of the cells in the event of contamination The only optical surfaces which also might become contaminated are the chopper windows and the windows of the filter cells these are accessible upon removal of the cell body The filter cell 14 15 has anecked conical shape for optimal adaptation of the analysis cell beam cross sectional profile to the active area of the detectors For high measurement ranges up to 100 an adapter cell 10 is required The use of a spacer ring 08 creates an analysis cell in the space between the exit window of the adapter cell and the entrance window of the filter cell 3 2 ETC00781 4 Series 100 e 02 2004 1002 2092 001 seues vy 18200019 40 99 9q 8911 99 00144d A quie SS y J9JouioJouyd L DIS J N Pe EE 2222 T 5 RY Legends 03 04 05 06 07 08
110. fix it using the O Connect the signal cable to connector J9 BKS paying attention to the coding pin Rear panel 1 2 19 analyzers 1 4 19 analyzers O For upgrading a serial interface insert the EPROM delivered together with the board 12 1 SERIAL INTERFACE OPTION Rosemount Analytical GENERAL FISHER ROSEMOUNT 12 2 General The analyzer is equipped with a serial interface enabling communication with a host computer The host computer can call up prescribe or alter parameters as well as initiate analyzer operations using standardized protocols The optional BSI 10 plugin circuit board constitutes the hardware interface This may be configured as RS 232 C or RS 485 interface The RS 485 interface permits networking several analyzers Each analyzer may then be addressed using an assignment numerical ID code Communication is always initiated by the host computer i e analyzer behave passively until the host computer requests information from them or demands commencement of an action Communications use so called telegrams being exchanged between the host computer and the analyzer s Syntax for these telegrams is established in protocols Telegrams always commence with the start character immediately followed by a three digit instruction code Subsequent elements of telegrams are segregated by the hyphen character The final element of all telegrams transmitted must be the CR termin
111. flammable gases into enclosure from outside atmosphere only It does not provide protection against the release of inflammable gases contained in the sample gas via internal leakages O Connect purge gas air or to the BINOS 100 F inlet via 1 4 O D tube connection see Fig 27 4 Outlet is done via 3 8 O D fitting with analyzer specific insert throttle O Use purge gas supply under pressure of 58 psig 4 bar 5 000 hPa abs This will provide a flow rate approx 55 scfh 26 I min At this flow rate five case volumes of purge gas will pass through the instrument in 11 minutes After 11 minutes reduce the pressure to 5 1 psig 350 mbar 1 350 hPa abs resulting in a flow rate of approx 18 8 5 l min This will provide an enclosure over pressure of approx 0 24 inch H O 0 6 hPa for continuous purge 2 Pressure inside the housing must not exceed 5 hPa at normal operation or 10 hPa for a short time of less than 1 2 hour resp 5 1 0 00781 4 Series 100 e 02 2004 PREPARATION 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 approx NEMA 4 4X This housing is designed for wall mounting For installation in hazardous areas the BINOS 100 F is equipped with an impact tested front panel
112. ges the preamplifier is mounted at the analysis cell For high measuring ranges the preamplifier is mounted at two holding clamps 3 4 ETC00781 4 Series 100 e 02 2004 PHOTOMETER ASSEMBLY GAS DETECTOR e T E zi ob 6 A w So Y Pi i O O y L Fig 3 2 Photometer Assembly 100 Series with Gas Detector example above and middle high measuring ranges example below small measuring ranges Analysis Cell Filter Cell Gas Detector Holding Device Preamplifier Absorber ETC00781 4 Series 100 e 02 2004 3 5 q BON PHOTOMETER ASSEMBLY 3 6 00781 4 Series 100 e 02 2004 PREPARATION 5 Preparation of Start up Please check the package and its contents immediately upon receipt If any item is damaged or lost you are requested to notify the contractor to undertake a damage survey and report the loss or damage to us immediately BINOS 100 F 1 Unscrew transfer safety lock of photometer sliding carriage Fig 5 1 Lock the sys
113. ght source is not sufficient use another fix aperture zero level adjustment aperture see item 24 2 and again turn the light source O Tighten the light source mounting screws shown in Fig 24 1 as Item 5 or the temperature sensor shown in Fig 24 1 as Item 3 resp for channel 1 or channel 2 When the physical zeroing has been set correctly perform an electrical zeroing see chapter 9 24 8 00781 4 Series 100 e 02 2004 CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR 25 Checking Replacing an Electrochemical Oxygen Sensor On account of the measuring principle the oxygen sensor has a limited life time The life time of the oxygen sensor depends on the sensor itself and on the measured oxygen concentration and is calculated as follows sensor time hours O concentration life time The so called sensor time operation without oxygen at 20 C is approx 900 000 hours for sensors with a response time of about 12 s approx 450 000 hours for sensors with a response time of about 6s The sensors have the following life time at approx 21 Oxygen and 20 C approx 42 857 hours approx 5 years for sensors with a response time of about 12 s approx 21 428 hours approx 2 5 years for sensors with a response time of about 6 s Note The values given above are presented as guidelines only The actual values are depending on operation temperatures the result of higher temperatures
114. heck the zero point and start a zero calibration via keypad again if necessary Supply the maximum concentration of the respective interfering gas again and perform a fine setting of zero point using the corrrelated potentiometers of PCB WAP 100 When the adjustment has been finished O Closetheanalyzer housing cf Section 23 ETCO00781 4 Series 100 e 02 2004 14 3 CROSS COMPENSATION SETTING OF RESPSONSE TIME TC ONLY 14 4 ETC00781 4 Series 100 e 02 2004 LIST OF FAILURES 16 List of Failures Some of the failures which may arise during measurement will be reported on the displays in forms of error codes When such a failure arises the display s will show the concentration value alternating with B ERROR Note Ifthere is an error message a digital status signal Failure can be given optional see Item 10 3 1 Be sure to observe the safety measures for all workings atthe analyzer Possible Reasons Check Correct Displays are switched OFF 1 Press any key Check parameter dOFF see chapter 8 7 No Display Voltage supply absent Check connection mains line PS Check external power supply Check electrical supply see Fig 1 5 and 1 6 Item 3 Fig 1 7 to 1 9 Item 10 BINOS 100 F Check internal fuses F1 and F2 Connection front panel BKS Check connection absent BKB BKS X1 see chapter 18 1 ETC00781 4 Series 100 e 02 2004
115. hen oxygen molecules enter the cell their paramagnetism will cause them to be drawn towards the region of greatest magnetic field strength The O molecules thus exert different forces which produce a torque acting on the sphere arrangement and the suspended dumbbell along with the mirror mounted on its suspension ribbon willbe angulary rotated away from the equilibrium position The mirror then will deflect an incident light beam onto the photodetector which itself produces an electric voltage The electric signal is amplified and fed back to a conducting coil atthe dumbbell forcing the suspended spheres back to the equilibrium position The current required to generate the restoring torque to return the dumbbell to its equilibrium position is a direct measure of the O concentration in the gas mixture The complete analysis cell consists of analysis chamber permanent magnet processing electronics and a temperature sensor The sensor itself is thermostat controlled up to approx 55 C For warming up the measuring gas is conducted via a heat exchanger Optionally we have built in a solvent resistant cell or an intrinsic safe cell for potentially explosive atmosphere Da 6 00781 1 Series 100 e 10 2001 MEASURING PRINCIPLE OXYGEN MEASUREMENT PO PARAMAGNETIC PRINCIPLE Fig 2 4 Principle Construction of paramagnetic Analysis Cell Permanent magnet Platinum wire Mirror Quartz spheres Wireloop Photodet
116. his display 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 Display Entry of 0 gas sampling pump is Off Display Entry of 1 gas sampling pump is On Entry is performed using followed by X In this item you can determine the input for pump control 8 18 Pump Control Entry of 0 pump control via front panel key Entry of 1 pump control via system parameter PUMP chapter 8 17 Entry of 2 pump control via optional digital input Item 13 1 Entry is performed using A V followed by Push the key until XXXX the displays show XK XXX The analyzer now is back in the analysis mode BINOS 100 2M F with software version 5 0 or higher only 8 14 ETC00265 4 Series 100 e 02 2004 CALIBRATION 9 Calibration To insure correct measurement results zeroing and spanning should be carried out once a week Spanning can be performed only after zeroing before For the calibration procedure the analyzer has to be supplied with unpressurized test gases through the respective gas inlets cf chapter 5 3 at a gas flow rate of about 1 I min the same as with sample gas 1 After switching on the analyzer wait at least approx 15 to 50 minutes depending on installed detectors before admit gas to the analyzer Note
117. id integer value numerical value outside defined range invalid failure status code instruction can not be done here failure in transmitted character zeroing running spanning running invalid realnumber automatic calibration mode off parameter outside defined range preflushing period is running XXX instruction code ID device ID no in RS 485 mode LPB message length parity byte lt CR gt terminate character ETC00781 1 Series 100 e 10 2001 12 9 SERIAL INTERFACE OPTION NUMERICAL REPRESENTATION BLOCK PARITY CHECK 12 4 6 Numerical Representations Telegrams may contain integers or real numbers The formats for these numbers are subjectto the following restrictions Integers maximum value 2 6 1 positive numbers only accepted no decimal points allowed Real maximum of 6 digits accepted no alphabetic characters e g 2 2E 6 allowed analyzer output is 6 digit real numbers 12 4 7 BlockParity Check The master control computer may insert a message length parity byte into telegrams These invariably consist of two characters The message length parity byte is the cumulatively EXCLUSIVE OR correlation of all previously transmitted characters of the telegram line Representation is in hexadecimal format For example ifthe decimal value should be decimal 13 this will be represented by the two characters OD i e 030H and 044H The verification procedure may be enabled or disabled
118. install the photometer assembly see chapter 24 5 A Reinstalling ofthe Photometer Assembly N Insert the photometer assembly into the analyzer housing and fasten in position using the mounting bracket screws Fig 24 1 Item 1 O Onlyanalyzers with gas detector Insert preamplifier Fig 3 2 Item 5 to holding device Fig 3 2 Item 4 Reconnect all gas lines to the assembly Reconnectall electrical connections between the photometer assembly and the electronic unit see chapter 18 Perform a leakage test see chapter 22 Perform the physical zeroing procedure see chapter 24 6 ETC00781 4 Series 100 e 02 2004 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS PHYSICAL ZEROING 24 6 PhysicalZeroing Adjustment of the physical zero level will only be required ifa light source a filter cell or an analysis cell have been replaced or repositionned 2 Be sure to observe the safety measures Take care of the photometer temperature Photometers heat up when powered Needed for the adjustment are a digital voltmeter DVM with a range of 2 VDC and a mm hexagon wrench SW 3 O Switch onthe analyzer cf chapter 6 O Admitzero gasto the analyzer O Connectthe DVM to the measuring points X25 and X28 L for channel1 IR measurementonly X27 andX28 1 for channel1 Combined Oxygen IR measurement channel 2 IR measurement only Depending on the installed photometer model continue with step 24
119. internal 6 V DC absent see chapter 17 1 1 b uP do not work da Is the EPROM insert correctly see chapter 28 2 Perform a RESET see chapter 8 14 3 BKS faulty exchange BKS 00781 1 Series 100 e 10 2001 Rosemount Analytical MEASURING POINTS OF BKS AND OXS FISHER ROSEMOUNT MEASURING POINTS OF BKS 17 1 5 Temperature Sensor Measuringpoint 8 Measuring device DVM Signal approx 0 500 mV DC at ambient temperature Failure Signal gt 3 5 V DC Possible reasons IR measurement or paramagnetic oxygen measurement a Temperature sensor not connected see chapter 18 1 b Temperature sensorfaulty exchange sensor c Broken cable of temperature sensor exchange sensor d BKS faulty exchange BKS Possible reasons electrochemical oxygen measurement a Temperature sensor not connected see chapter 18 2 b PCB OXS faulty exchange OXS d PCB BKS faulty exchange BKS ETC00781 1 Series 100 e 10 2001 17 3 MEASURING POINTS OF BKS AND OXS Rosemount Analytical MEASURING POINTS OF BKS FISHER ROSEMOUNT 17 1 6 Light Barrier Signal Measuring point Plug 9 pin 2 Measuring device Oscilloscope Signal square impulse U 6 0 3 V Frequency 24 Hz 0 1 Hz Failure No signal Possible reasons IR measurement a Chopper not connected see chapter 18 1 b Chopper inoperative switch analyzer off and
120. into a protective enclosure classified IP 65 acc IEC 60529 approx NEMA 4 4X This enclosure is designed for wall mounting An magnetically operated impact tested front panel is available as an option Special versions are available for installation in hazardous areas which meet the requirements of either ATEX Europe CENELEC outside Europe or North America CSA C US Z purge The special conditions for operating ATEX analyzers are described in a supplemental manual 1 1 Front Panel The front panel includes the LED displays for both analysis channels and all of the analyzer operating controls The BINOS 100 2M and BINOS 100 F front panels show status LEDs for the options Solenoid Valves and Gas Sampling Pump and include a key PUMP to switch on and off the gas sampling pump The front panels of BINOS 100 2M and BINOS 100 F may be equipped with an optional fine dust filter with integrated needle valve or and a flow meter for general purpose applications only These options are not available if BINOS 100 F is intended to be used in hazardous areas EX Zones or if IP 65 is required ETC00781 4 Series 100 e 02 2004 1 1 TECHNICAL DESCRIPTION FRONT VIEW GB 12 EG la O paramagnetic para oxygen sensor EE O electrochemical chem oxygen sensor FUNCTION ENTER INPUT CONTROL 7 4 2 Fig 1 1 BINOS 100 M
121. ire operation is active Switch on network termination via soldering bridges at both ends of interface connection For network operation with several analyzers via RS485 interface termination has to be done at both ends of network connection only For the other analyzers the soldering bridges have to be open Close soldering bridge LB2 for 2 wire operation For 4 wire operation close LB2 and LB3 1 o _ GND 259 55 RD 3 o RxD 4 o TxD 5 0 2 TD 0 1 not used not used 8 Oo notused 9 0 used Fig 12 3 Pin Assignments RS 485 Interface In contrastto RS 232 C operation simultaneous transmission and receptionis notimplemented in this standard This would not result in damage to the electronics but could lead to destroy of data The analyzer behaves passively in this mode of operation i e it keeps its transceiver set for reception wheneveritis nottransmitting Since the time periodsfortransmission and reception are controlled by protocols data collisions are excluded ETC00781 1 Series 100 e 10 2001 12 5 SERIAL INTERFACE OPTION Rosemount Analytical START UP INTERFACE PARAMETER FISHER ROSEMOUNT 12 3 3 Switching ON OFF Interface Operation The analyzer may be setto either online or offline status This setting may be performed either from the keypad or via telegram input Keyboard setting
122. is controlled via software menu Operator guidance prompts will appear on the 4 digit LED displays Battery buffering of the stored parameters prevents their loss in the absense of voltage supply ETCO00781 4 Series 100 e 02 2004 7 1 KEY FUNCTIONS FUNCTION 7 1 FUNCTION Pressing this key Fig 1 1 and 1 2 Item 3 addresses the individual analyzer functions sequence Merely addressing an analyzer function will not initiate an analyzer action or operation The analyzer will stay in measurement mode until the ENTER key is pressed Remark concerning the optional touch screen keypad To avoid unintended keypad activation all the keys are secured by an additional user code This code has to be entered each time before leaving the measurement display 2 After pressing the FUNCTION key the text Code appears in the upper display and the following keys have to be pressed within a time period of 20 seconds DOWN UP ENTER FUNCTION Pressing the correct sequence shows the text Code in the lower display too and menu scrolling is enabled If the correct code is not entered within the time period of 20 seconds menu scrolling will still be locked and the measurement display is shown again 7 2 ETC00781 4 Series 100 e 02 2004 KEY FUNCTIONS The following analyzer functions and their sequences see also Fig 7 1 are shown
123. ity non condensing Rain drop splash water Explosive atmosphere Altitude 27 2 Standard 6 4 mm PVDF Option 6 4 mm or 1 4 ss additional fittings on request max 4 fittings max 9 fittings max 6 fittings see dimensional sketches Fig 27 1 approx 4 7kg approx 10 12 kg approx 30 35 kg according to DIN standard 40050 IP 20 IP 65 NEMA4 4X 5 Cto 40 C higher ambient temperatures 45 C on request lt 90 rel humidity at 20 C lt 70 rel humidity at 40 C The analyzer must not be exposed to rain or drop splash water The analyzer must not be operated in explosive atmosphere without supplementary protective measures 0 2000 m above sea level ETC00781 4 Series 100 e 02 2004 TECHNICAL DATA SIGNAL OUTPUTS INTERFACES 27 3 Signal Inputs Outputs Interfaces 2 analog outputs per channel optically isolated 2 channels common ground offset begin of range and end of range are free programmable Option 3 analog inputs Option for TC for electronic cross compensation of up to 3 interfering components external signals 8 digital outputs parallel optically isolated 7 digital inputs parallel Option serial interface Option optically isolated notin combination with field bus FOUNDATION fieldbus Option 3 output relays Option status signals ETC00781 4 Series 100 e 02 2004 0 10 V and 0 20 mA x 500 W O
124. l as correct operation and meticulous maintenance Emerson Process Management does not take responsibility liability for the customer s failure to comply with these requirements Do notattempt internal service or adjustment unless other person capable of rendering first aid and resuscitation is present Because of the danger of introducing additional hazards do not perform any unauthorized modification to the instrument Return the instrument to a Emerson Process Management Sales and Service office for service or repair to ensure that safety features are maintained Instruments which appear damaged or defective should be made inoperative and secured against unintended operation until they can be repaired by qualified service personnel 00781 4 Series 100 e 02 2004 SAFETY SUMMARY GENERAL GASES AND GAS CONDITIONING SAMPLE HANDLING Pee BP gt gt gt Do not open instrument when energized Component replacement andinternal adjustments requires servicing by qualified personnel only Read this instruction manual before attempting to operate the instrument Be sure to observe the additional notes safety precautions and warnings given in the instruction manual Operate analyzer as table top version oras rack mountable version built in only except of BINOS 100 F designed for wall mounting only Do not operate the instrument in the presence of flammable gases or explosive atmosphere withou
125. l outputs are available on plug X 3 at the rear panel The maximum output load is 30 V DC 30 mA Open Collector Observe the wiring hints in chapter 29 10 O Limits channel 2 max Limits channel 2 min o Limits channel 1 max o o Limits channel 1 min At gt Valve control span gas 2 Valve control span gas 1 Valve control zero gas Valve control sample gas 9 Fig 11 1 Pin Assignments 3 Digital Outputs 00781 4 Series 100 e 02 2004 11 1 DIGITAL OUTPUTS 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 The last right decimal point of the related display will start to flash whenever a concentration limit value is reached Additional digital signal outputs for the concentration limits are available at plug X 3 on the rear panel Open Collector max 30 V DC 30 mA Press the key until the text appears Press the key Corr ene 5 If the correct user code has not yet been entered the message appears INPUT CONTROL Press the keys to select the correct user code AM CRA a_i _ e a
126. lded cable 2 m both ends sub D plug ETC ACC 103 terminal adaptor with sub D socket 9 pin and screw terminals 30 3 2 Sub D Plugs 9 pin The following cables are availble for digital signal outputs X3 Output status signal option relay outputs X1 Output and analog signal input option TCD Cross Comp or Analog In ETC ACC 104 shielded cable 2 m both ends sub D socket and one terminal adaptor ETC ACC 105 shielded cable 2 m both ends sub D socket ETC ACC 106 terminal adaptor with sub D plug 9 pin and screw terminals ETCO00781 4 Series 100 e 02 2004 30 E 3 CABLES AND CORDS 30 4 00781 4 Series 100 e 02 2004 FAILURE CHECKLIST 32 Failure Check List If you experience failures with your analyzer pls take this checklist to mark the failure s before contacting our service department or sending back the unit together with copy of this list The enclosed information may speed up trouble shooting and result in cost reduction Some failures may need to mark more than one of the following items Serial No to be found on the name plate label Measuring range gas channel 1 Software Version No k 10 11 12 13 14 15 16 No Display defective BATT is flushing E 11 is flushing E 12 is flushing E 14 is flushing E 16 is flushing E 17 is flushing E 18 is flushing E 19 is flushing E 20 is flushing E 21 i
127. le to disconnect the device from the socket outlet Verify whether the line voltage stated on the instrument or power supply is in accordance with that of your mains line Be sure to observe the safety precautions and warnings given by manufacturer of power supply BINOS 100 M BINOS 100 2M external PS HYDROS 100 and OXYNOS 100 are Safety Class Ill instruments PPP Verify correct polarity for 24 V DC operation Use only power supply VSE 2000 UPS 01 T DP 157 SL5 SL10 DP 157 and SL for rack installation only or equivalent power supplies to keep the instrument safe If using equivalent power supplies they must have SELV output voltage ETC00781 4 Series 100 e 02 2004 SAFETY SUMMARY SUPPLY VOLTAGE BINOS 100 2M internal PS and BINOS 100 F are Safety Class 1 instruments The analyzer is provided with a protective earth terminal To prevent shock hazard the instrument chassis and cabinet mustbe connected to an electrical ground The instrument must be connected to the AC power supply mains through a three conductor power cable with the third wire firmly A connected to an electrical ground safety ground at the power outlet Ifthe instrumentis to be energized via an external power supply that goes for the power supply too Any interruption of the protective grounding conductor or disconnection ofthe protective earth terminal will cause a potential shock hazard that could resultin p
128. llnow show C ETC00781 4 Series 100 e 02 2004 8 1 SETTING SYSTEM PARAMETERS PRESSURE CORRECTION CROSS COMPENSATION INTERNAL lla 8 1 Pressure Correction XXXX To eliminate faulty measurements due to changes in barometric pressure or sample gas pressure the operator is offered the opportunity to enterthe current pressure expressed in hPa mbar in a range of 800 to 1 300 hPa The concentration values computed by the analyzer will then be corrected to reflect the barometric pressure or sample gas pressure resp entry INPUT CONTROL Input values using A V and LJ Itis possible to integrate a pressure sensor with a range of 800 1 100 hPa The concentration values computed by the analyzer will then be corrected to reflect the barometric pressure to eliminate faulty measurements due to changes in barometric 2 pressure see technical data In this case it is not possible to enter pressure value manually In attempting to enter pressure value manually the analyzer will automatically revert to the display of measured pressure value X This control permits switching the electronic cross compensation feature on and off The cross compensation feature is designed minimize mutual interferences between the two gases e g CO and CO measured by the analyzer 8 2 Cross Compensation internal Input value 0 cross compensation is disabled Inpu
129. lve Zero gas Fig 5 4b BINOS 100 2M version B gas connections with solenoid valve option Solenoid valve Solenoid valve Span gas 1 channel 1 Solenoid valve not used Solenoid valve common gas outlet channel 1 to standard gas inlet K1 LE 2 Solenoid valve sample gas channel 1 E not used Solenoid valve Span gas 2 channel 2 Solenoid valve Common gas outlet channel 2 to standard gas inlet K2 Solenoid valve sample gas channel 2 Solenoid valve zero gas channel 1 Solenoid valve zero gas channel 2 Fig 5 4c BINOS 100 2M special version gas connections with 2 solenoid valve blocks ETC00781 4 Series 100 e 02 2004 PREPARATION PURGE GAS CONNECTIONS OF BINOS 100 F CONTINUOUS PURGE 5 3 3 Purge gas connection of BINOS 100 F for Ex zones a ATEX Applications N Refer to the supplemental manual for installing analyzers in hazardous areas where ATEX is applicable b Z purge for CSA C US Ex Zone 2 Non Flammable Atmospheres This analyzer is not designed for analysis of flammable sample Introduction offlammable samples into this equipment could resultin explosion A 1 causing severe personal injury death or property damage Consult factory ifflammable samples are to be measured Z Purge kitis designed for protection against the invasion of
130. me of its manufacture Thisis equivalentto switching off the electrical supply line and switching offthe battery buffering of the RAM s by removing the battery jumper J7 All parameters and calibration factors entered by the user will be lost whenever a reset operation is performed The currently valid user identification code must be entered before a reset will be executed this will preventinadvertent resets Entry is performed using A VI followed by a Whenever a reset operationis initiated the analyzer operating program will be restarted just as itis when the instrument is first switched on see chapter 6 1 Jumper J6 which activates the watchdog circuitry must be inserted if the reset operation is to be correctly executed 8 12 ETC00265 4 Series 100 e 02 2004 ENTRY OF SYSTEM PARAMETERS PROGRAM VERSION SERIAL NUMBER alll 8 15 Program Version XXX The Program Version No of the installed software version will be displayed Press the key a sil XX XX The Serial No will be displayed Please note this number for further contact with our factory maintenace service etc Push the key SS Continuation of Serial No XX Press the key 8 16 Serial No ETC00265 4 Series 100 e 02 2004 8 13 ENTRY OF SYSTEM PARAMETERS GAS SAMPLING PUMP 8 17 Pump a T
131. mode INPUT CONTROL Change values using A VI and Note The begin of range concentration OFS and the end of range concentration END are freely programmable see chapter 8 12 and 8 13 Fortypeof voltage output standard oroption please referto order confirmation or identification label 1 0 1 VDC 2 0 0 2 10 V DC Option 0 0 2 1 V DC channel 1 1 3 0 0 4 20 channel 1 lt 500 4 0 2 10 DC Option 0 0 2 1 V DC channel 2 5 0 4 20 mA channel 2 lt 500 5 777777 1 mA 8 9 T Fig 8 1 Pin assignments mating socket X 2 analog signal outputs ETC00781 4 Series 100 e 02 2004 8 7 SETTING SYSTEM PARAMETERS FLUSHING PERIOD USER CODE XX For calibration the gas paths must be supplied with sufficient calibration gas The flushing period has to be fixed adequate perform calibration only after a suitable flushing period the calibration gas flow should be identical with sample gas flow 8 9 Flushing Period This period may be set within the range 0 99 sec depending on calibration conditions INPUT CONTROL Change values using A VI and 5 BL rm 8 10 User Code gt lt gt lt gt lt gt lt Factory default setting is 1 To prevent parameter alterations by unauthorized persons the op
132. nce 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 all products to the proper electrical and pressure sources To ensure proper performance use qualified personnel to install operate update program and maintain the product When replacement parts are required ensure that qualified people use replacement parts specified 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 fire 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 qualified persons to prevent electrical shock and personal injury The information contained in this document is subject to change without notice 1 Edition 10 2001 3 Edition 01 2003 2 Edition 11 2002 4 Edition 02 2004 Emerson Process Management Manufacturing GmbH amp Co OHG SET Industriestrasse 1 gt D 63594 Hasselroth Germany Q te T 49 0 6055 884 0 x 7 SO 5001204 eS F 49 0 6055 884 209 Cert Reg No 254969 QM Internet www EmersonProcess com EM E RSON Process Management
133. nction of the analyzer must also be activated correctly cf chapter 8 5 With this function the analyzer can perform an automatic calibration at preset time intervals The displays of the analyzer shows additional the functions t AO and t AS using the FUNCTION key Note Foratime controlled calibration procedure the test gases must be supplied through solenoid valves controlled by the analyzer in order to ensure the supply of test gases in correct sequence If the test gas concentration has changed the correct setpointis to enter first see chapter 9 1 2 9 2 1 Zeroing Push the key C R Press the key until the displays show ETCO00781 4 Series 100 e 02 2004 9 T CALIBRATION AUTOMATIC ZEROING OPTION If the correct user code has not yet been entered the displays show Use the keys to select the correct user code and enter using Itappears XXX You can enter a time interval hours when an automatic zeroing has to be performed Point of reference is the current time Range of accepted entries 0 999 hours Note If the entry is 0 zero the time controlled calibration is deactivated INPUT CONTROL Entry is performed using AJ VI followed by After entry of interval zeroing will be done automatically at the end of the entered time interval 9
134. nverts the analytical signals to results expressed directly in physical concentra tion units Vol ppm mg Nm etc Light source Ne Ds 1 Duplexfilter disc Adapter cell high measuring range Analysis cell Analysis cell measuring side undivided Analysis cell reference side z Filter cell Preamplifier m Filter cell Pyroelectrical detector solid state detector Gas detector Preamplifier Chopper blade 8 Fig 2 3 Principle Representation ETC00781 1 Series 100 e 10 2001 25 5 MEASURING PRINCIPLE OXYGEN MEASUREMENT PO PARAMAGNETIC PRINCIPLE 2 2 Oxygen Measurement Depending on analyzer model different measuring methods will be used The installed type of oxygen sensor is to identify at the channel code see Fig 1 1 O para paramagnetic Sensor O chem electrochemical Sensor 2 2 1 Paramagnetic Measurement The determination of O concentration is based on the paramagnetic principle magneto mechanic principle Two nitrogen filled N is diamagnetic quartz spheres are arranged in a dumbbell configuration and suspended free to rotate on a thin platinum ribbon in a cell A small mirror that reflects a light beam coming from alight source to a photodetector is mounted on this ribbon A strong permanent magnet especially shaped to produce a strong highly inhomo geneous magnetic field inside the analysis cell is mounted outside the wall W
135. nywhere within the band The spectral transmittance curves of the interference filters used in the 100 series analyzer and the spectral absorption of the gases CO and CO are shown in Fig 2 1 It can be seen that the absorption bands of these gases each coincide with the passbands of one of the interference filters The fourth interference filter used for generating a reference signal has its passbandin a spectral region where none of these gases absorb Most of the other gases of interest also do not absorb within the passband of this reference filter ETC00781 1 Series 100 e 10 2001 2 1 MEASURING PRINCIPLE IRMEASUREMENT Absorption Band Transmittance Interference Filter Transmittance Reference A r x 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000 Wave Length nm Fig 2 1 Absorption Bands of Sample Gases and Transmittance ofthe Interference Filters used The signal generation happens by a pyroelectrical solid state detector The detector records the incoming IR radiation This radiation intensity is reduced by the absorption of the gas atthe corresponding wave lengths By comparing the intensity at measuring and reference wave length an alternating voltage signal is developed This signal results from cooling and heating of the pyroelectrical material of the detector 2 2 ETC00781 1 Series 100 e 10 2001 MEASURING PRINCIPLE IRMEASUREMENT 2 1
136. o flow indicators into the BINOS 100 2M F front panel Fig 1 2 to 1 4 5 4 ETC00781 4 Series 100 e 02 2004 PREPARATION GAS CONNECTIONS 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 The exhaust gas lines have to be mounted in a declining pressureless and frost free way and according to the valid emission legislation Do not interchange gas inlets and gas outlets Ensure that all gas connections are made as labeled and are leak free Improper gas connections could result in explosion and death The unit s exhaust may contain hydrocarbons and other toxic gases such as carbon monoxide Carbon monoxide is highly toxic Permissible gas pressure max 1 500 hPa p ata 5 3 1 Standard Configuration Depending on analyzer version the following gas connections are installed in Gas inlet out Gas outlet K 1 measuring channel 1 K 2 measuring channel 2 Zero gas and span gas are introduced directly via the sample gas inlet The test gas containers have to be set up according to the current legislation 2 x Be sure to observe the safety regulations for the respective gases sample gas and test gases span gases and the gas bottles for HYDROS 100 with open reference side of sensor the gas fittings of channel 2
137. ockets have to be screwed to the analyzer The analyzer excepting BINOS 100 F is not in agreement with the CE conformity if optional terminal strip adapters are used In this case CE conformity must be declared by customer as manufacturer of system ETC00781 4 Series 100 e 02 2004 SAFETY SUMMARY BINOS 100 F SPECIFIC NOTES FOR USE IN HAZARDOUS AREAS EX ZONES Vil BINOS 100 F specific notes for use in hazardous areas EX Zones AN 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 If you do not have the additional manual available please contact your Emerson Process Management Sales Office Vila Z purge for CSA C US Ex Zone 2 Non Flammable Atmospheres AL This enclosure shall not be opened unless the area is known to be free of flammable materials or unless all devices within have been de energized Upon start up or after loss of continuous dilution requiring switching off the electrical supply purge for 11 minutes with flow rate approx 55 scfh 26 l min see chapter 5 3 3 unless the internal atmosphere is known to be well below the lower explosive limit LEL This analyzer is not designed for analysis of flammable sample Introduction of flammable samples into this equipment could resultin explosion Causing severe personal injury death or property damage Consult fac
138. ode entry if such has not already been performed off line status 1 line status Each device is assigned a device number for operation through the RS 485 interface 0 99 Select interface type 0 RS 485 1 RS232C Set baud rate O 4 800 1 2 400 2 1 200 3 600 4 9 600 5 19 200 6 38 400 Echo mode operation O OFF 1 ON Message block parity check U OFF 1 12 7 SERIAL INTERFACE OPTION Rosemount Analytical TELEGRAMSYNTAX FISHER ROSEMOUNT 12 4 Telegram Syntax Telegrams are assembled as follows 12 4 4 Start Character Hex 24 If the start character is missing this will result in transmission of an appropriate status telegram by the analyzer 12 4 2 Terminate Character CR Hex OD If the terminate character is missing no decoding of the transmitted information will be performed and the analyzer will not respond No response message will be transmitted 12 4 3 Instruction Code Each instruction is assigned a unique three digit numerical instruction code If a received instruction code should be other than three digits in length or contain non numerical ASCII characters the analyzer will transmit an appropriate status telegram Reception of unassigned instruction codes will also result in the transmittal of a status telegram Inthe RS 232 C mode of operation the instruction code immediately follows the start character inthe RS 485 mode of operati
139. ome components ranges may not be available with all analyzer versions Argon Ar Carbon dioxide CO ppm Carbon monoxide ppm Ethylene ppm Helium P Methane Yo n Butane Yo Oxygen m n Propylene Yo Propane Yo Toluene Other components and configurations on request Dewpoint must not exceed ambient temperature Non standard specifications 27 6 00781 4 Series 100 e 02 2004 TECHNICAL DATA Measuring System Specifications Values refer to the lowest ranges Standard ranges with better specs 19694 19699 lt 2 per week lt 1 96 per week 196594 lt 5599 0 2 1 5 l min Detection limit Linearity Zero point drift Span sensitivity drift Repeatability Total response time ts Permissible gas flow Influence of gas flow Max pressure 1 500 hPa abs Influence of pressure At constant temperature lt 0 10 96 per hPa 2 0 15 96 hPa at 2 lt 0 01 per hPa 2 lt 0 015 hPa at CO 5 C to 40 C 19 With pressure compensation 9 Permissible ambient temperature Influence of temperature at constant pressure zero point On span sensitivity Thermostat control Heating up time lt 1 per 10K 596 5to 40 C Approx 15 to 50 minutes 9 1 Relatedtofullscale atsystem parameter 4 Constantpressure andtemperature END final value set in our fact
140. on the start character is followed by a two digit device identification code the separator character and a three digit instruction code in this order 12 4 4 Hyphen Character Individual elements of a telegram line are separated by this hyphen character Missing hyphen characters can lead to misinterpretations of telegrams and will result in transmission of an appropriate status telegram 12 8 ETC00781 1 Series 100 e 10 2001 Rosemount Analytical SERIAL INTERFACE OPTION FISHER ROSEMOUNT STATUS TELEGRAM 12 4 5 Status Telegram If telegram syntax is faulty or analyzer is unable to act upon an instruction received then the analyzer will transmit a status telegram to the host computer These status telegrams are listed here for reference 1D 000 S100 LPB lt CR gt 1D 000 S101 LPB lt CR gt 1D 000 S102 LPB lt CR gt 1D 000 S103 LPB lt CR gt ID xxx S104 LPB lt CR gt ID xxx S105 LPB lt CR gt ID xxx S106 LPB lt CR gt ID xxx S107 LPB lt CR gt ID xxx S108 LPB lt CR gt ID xxx S109 LPB lt CR gt ID xxx S110 LPB lt CR gt ID xxx S111 LPB lt CR gt ID xxx S112 LPB lt CR gt ID xxx S113 LPB lt CR gt ID xxx S114 LPB lt CR gt ID xxx S115 LPB lt CR gt ID xxx S116 LPB lt CR gt ID xxx S117 LPB lt CR gt unrecognized instruction code LP byte in error start character missing input buffer overflow analyzer offline status text line too long undefined instruction inval
141. ory and OFS 0 5 Dependentonintegrated photometerbench 2 Relatedto measuring value 6 Paramagneticoxygen measurement PO 3 Fromgasanalyzerinletat 1 0 l min gas flow 7 dependentonmeasurementrange electr 2 s Cross sensitivities electrochemical oxygen measurement Not for use with sample gases containing FCH s inorganic gases with chlorines andfluorines Not for Ozone H S 100 ppm NH 20 ppm ETCO00781 4 Series 100 e 02 2004 19604 lt 1 14 lt 2 per week 7 lt 1 96 per week 7 196592 lt 5 s 99 Approx 12 s 99 0 2 1 0 Vmin 0 2 1 5 l min 19699 29504 195 09 lt 2 96 per week 7 lt 1 96 per week 7 19692 3S lt ty x 20s 9 0 2 1 0 l min 0 1 l min 1969215 Atm pres 9 lt 1 500 hPa abs 9 lt 1 500 hPa abs lt 0 10 per hPa 2 lt 0 10 per hPa 2 0 01 96 per hPa lt 0 01 per hPa 5 C to 40 C 9 5 Cto 40 C 0 lt 1 10 lt 1 10 Approx 55 C 9 12 None 9 Approx 50 minutes 9 lt 1 per10Kin 1h lt 2 per 10K in 1h Approx 75 C 12 Approx 15 minutes 8 Pressuresensorrequired 9 Electrochemicaloxygen measurement EO notforuse with sample gas containing FCHC s 10 Higher ambienttemperatures 45 C on request 11 Starting from 20 C to 5 C or to 40 C 12 Sensor cell only paramagnetic oxygen measurement 100 Gas zerolevel effect O TECHNICAL DATA G
142. password is entered the CODE display will remain and the display will be reset to the value 0 When the correct password has been entered access to the specific level is permitted 1 This password CODE has a factory setting value 1 7 4 ETC00781 4 Series 100 e 02 2004 KEY FUNCTIONS KEY FUNCTION OVERVIEW bz 0c 61 8 LI 9 S v e OL 6 8 1 9 4 Y 4 0 gt a OTT PONTO 00996 9 002 2 sJajawesed a9ejuazui eluas aeo E opa orou MITO 0096 p 009 0 qg oyog pnya 9262 oN P heuo 3po9 dis L qd T VIVd ON 8 S UNOS D Nd 53 ePu3 2540 1 540 2 061 1061 IP00 indi 0 1 40 101 IVO O 40 2 6344 3P09 SAS indui 101 u09 dund 59 44 Jeddn yBiq snes dund pjoysesyy Jomo MO UO 242 LUO LUO 1 z Wed jo jenas O N S sindino 11ui 0 plousel Kejdsip wed a91h9p jouaquinu jenas 04 5 pron 1 2 1 10 77 Hb 3999 q fejdsip 1 wesboJd ON d ejep uoijeoniqe jo
143. r 2 10 Vand 4 20 lt 500 W adjustable via keyboard 0 0 2 1 V and 0 4 20 mA R x 500 W 0 10V 0 20mA 2 10V 4 20mA 0 1Vor0 2 1V 2threshold contacts per channel Sample gas valve Zero gas valve Span gas valve 1 Span gas valve 2 dual channel only Open Collector max 30 V DC 30 mA Zero gas calibration ch 1 amp ch 2 Span gas calibration ch 1 Span gas calibration ch 2 open Zero gas valve open Span gas valve 1 open Span gas valve 2 dual channel only close Sample gas valve sample gas pump Off Description see chapter 13 and 29 8 RS 232 C or RS 485 2 or 4 wire support not in combination with serial interface Measure Calibration Failure Analyzer Sample Gas Pump On Off non voltage carrying contacts max 30V 1A 30W 27 3 TECHNICAL DATA Diagram dimensions without 24 VDC elbow socket approx 30 mm 402 19 8 4 3 3 4 20 377 14 106 3 400 417 Fig 27 1 Dimensional sketch BINOS 100 M OXYNOS 100 HYDROS 100 dimensions in mm A 0 0 lg ROS co f N J SPAN 1 o SAMPLE 3 q ed ICI J XY v 0 213 gt e X9 19 462 6 52 5 4 Pit lt
144. r has to ensure that the cable shield is connected in correct manner chapter 29 10 Shield and connector s housing have to be electrically linked and the housing screwed to the analyzer Analyzers with external terminal adaptors option do not meet the EMC requirements if the adaptors are not installed in a shielding enclosure In this case the customer acts like a manufacturer of system and has to confirm conformance The standard terminal adaptors inside BINOS 100 F and optional terminal adaptors for other BINOS 100 series analyzers connect the submin D connector pins to terminals of the same denominator submin D pin 1 is connected to terminal 1 pin 2 to terminal 2 so pin assignments given in this manual do not change when using adaptors 30 1 24V DC Supply Cable NGA ACC PS5 Power supply cable for connection of 100 series with UPS BINOS 100 2M 1 m one elbow socket one straight plug NGA ACC PS6 Power supply cable for connection of 100 series with UPS BINOS 100 2M 2 m one elbow socket one straight plug NGA ACC PS7 Power supply cable for connection of 100 series with 5 A 10 A power supply 2 m one side elbow socket other side 3 single conductors ETCO00781 4 Series 100 e 02 2004 30 1 CABLES AND CORDS 230 120 V AC INPUT ANALOG SIGNAL OUTPUT 30 2 230 120 V AC Input BINOS 100 2M UPS power supply 03 861 008 t Supply voltage cord to connect a BINOS 100 2M with mains 1 m for Germany
145. ration with opened housing especially after leaving the service site because the movement on a low conducting floors or in the air might cause additional ESDs ETC00781 4 Series 100 e 02 2004 S 9 SAFETY SUMMARY ELECTROSTATIC DISCHARGE IX Operating Conditions according to DMT Approval The following is a reprint of chapter 6 of the supplement to the DMT reports IBS PFG No 41300392 and IBS PFG No 41300292 NIII about the performance test of the stationary gas analyzers BINOS 100 M 2M and OXYNOS 100 According to the system version and measuring results included in this report the stationary gas analyzers BINOS 100 M 2M from Fisher Rosemount GmbH amp Co now Emerson Process Management the editor are suitable for measuring the concentrations of methane between 0 and 80 CH of carbon dioxide between O and 80 CO of carbon monoxid between 0 200 ppm CO and 0 10 Vol CO and the stationary gas analyzers BINOS 100 M 2M and OXYNOS 100 are suitable for measuring of oxygen between 0 10 Vol ifthe features and system version go conform with the details contained in the enclosed documents as Stated in this report if the analysis system is operated accordingly and if the following requirements are met When using the gas warning system it must be ensured that the permissible variations will not be exceeded taking into account the systematic failures of the measuring signals as indi
146. rew both allen screws fastening screws see Fig 25 2 Gas connections e Fastening srew Ort Fastening srew Front panel Fig 25 2 Inside View BINOS 100 2M Oxygen Measurement without IR channel assembly similar in OXYNOS 100 EO 25 3 CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR REPLACING THE SENSOR O Take out the complete support see Fig 25 1 to the top of the analyzer O Disconnect the connector for the sensor from P2 of circuit board OXS see Fig 25 5 O Outthrough the cable tie see Fig 25 3 O Unscrew both fastening screws for the fitting phillips screws see Fig 25 3 O Remove the fitting including the sensor see Fig 25 3 Connectorfor Sensor otentiometer R4 PCBOXS gt gt gas outlet nmm SA uy Gas connections 2 a E LL Sensor A E gas inlet Cable tie Pitung Fastening screw Sensor name plate fitting phillips screw Fig 25 3 Sensor support BINOS 100 2M Oxygen Measurement without IR channel 25 4
147. s flushing E 22 is flushing E 27 is flushing E 37 is flushing E 38 is flushing E 39 is flushing ETC00781 4 Series 100 e 02 2004 D DL D D D D DU D DULDU ULUuL 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 channel 2 Analog Output absent Fluctuating display without error Response time to long Chi CH1 CH1 Chopper has loud noise Measuring values to high Measuring values to low Misalignment Display Analog output Limiting values function incorrect Adjustment not possible Analyzer drift CH1 CH1 CH1 CH1 Transverse sensitivity to high Contamination of analyzer Condensation CH1 CH1 Overhaul complete analyzer with cost estimate Removal of failures with cost estimate Og 02 08 E Removal of failures without cost estimate J 32 1 FAILURE CHECKLIST Additional tests of electronics see chapter 17 33 Supply voltage 6 V incorrect 34 Reference voltage positive incorrect 35 Reference voltage negative incorrect 36 Motor drive incorrect 37 Light barrier signal incorrect 38 Temperature sensor incorrect 39 Supply voltage 18 V incorrect L DD O 40 Analog preamplifiering incorrect 41 Are you satisfied with the services offered by Emerson Process Management Yes o No o If no give us a short comment please Comment
148. sampling pump Le gy lil depending on analyzer channel 2 option D configuration A TT All ls Y t o 6 i BTEL sl up i e Gas sampling pump o ENO channel 1 ol ee ee ibe A option LT Bc WR N Fig 1 21 Inside View dual channel BINOS 100 2M special version two gas sampling pumps and two solenoid valve blocks ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Terminal strips Power Input Fuses for output input signals P DC 24 V distribution Photometer sensor assembly is dependening on analyzer configuration Power supply Fig 1 22 Inside View BINOS 100F field housing 1 24 ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION 1 3 1 Internal Gas Paths The materials usedforthe gas paths are selected according to the application In marking such selectionthe diffusion rates ofthe individual gas components their corrosivity and the tempera ture and pressure of the sampled gas must be taken into account a Gas Path Material The physical and chemical properties of the sampled gas and the operating conditions temperature and pressure ofthe
149. sembly for dual channel operation The base element for the photometer assembly is the chopper housing 03 upon which the light source thermal radiator 07 the analysis cell cuvette 09 andthe signal detection unit filter cell 14 15 pyroelectrical solid state detector with integrated preamplifier 16 are all mounted The chopper housing also incorporates the duplex filters 04 05 forthe selection of spectral band pass ranges from the broadband emission of the light sources Between the two halves of the chopper housing 03 which are sealed together with an O ring is the chopper blade driven by a stepping motor Both the chopper housing and the motor encapsulation are hermetically sealed with respect to the ambient in order to prevent entry of gases such as atmospheric CO which could produce background absorptivity preabsorption leading to drift effects An absorber material provides for constant removal of any traces of CO which may enter the interior of the chopper housing via diffusion The chopper housing additionally incorporates a photoelectric gate for providing a reference signal for the phase angle of the chopper blade plus a temperature sensor 28 for monitoring continuously the photometer assembly temperature This temperature information is used by the signal processing electronics for the compensation of thermal effects The analysis cells are merely aluminum tubes equipped with sample gas inlet and outlet
150. sing 23 2 1 1 4 19 Housing 23 2 2 BINOS 100 2M a Housing Cover b Front Panel 23 2 3 BINOS 100 F Field Housing 24 REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS 24 1 Taking out the Photometer Assembly 24 2 Light Source Replacement 24 3 Cleaning of Analysis Cells and Windows 24 3 1 Removal of Analysis Cells 24 3 2 Cleaning 24 3 3 Reinstalling the Analysis Cells 24 4 Chopper Replacement 24 5 Reinstalling of the Photometer Assembly 24 6 Physical Zeroing 24 6 1 Standard Photometer not sealed version VI LI Ss Aa N j 23 23 23 23 23 23 23 23 A 24 24 24 24 24 24 24 24 24 24 24 NN DODO TOP WWD ETC00781 4 Series 100 e 02 2004 CONTENTS 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 2 2 Removing the Sensor 25 6 25 2 3 Reinstalling the Sensor 25 6 a Oxygen Measurement without IR channel 25 6 b Combined IR Oxygen Measurement 25 6 25 2 4 Basic settings for the Oxygen Sensor 25 7 27 TECHNICAL DATA 27 1 27 1 Options 27 1 27 2 Housing 27 1 27 3 Signal Inputs Outputs Interfaces 27 2 27 4 General Specifications 27
151. special screw part no ETC 000790 or similiar Cable Gland Assembly Instruction for Shielded Cables 1 Strip the cable insulation 2 Uncover the shielding w Feed cable through gland nut and into fixing element 4 Put the shielding net over the element the way that it covers the o ring 2 mm sa o 5 Stick the fixing element into the neck and fix the gland 00791 Cable gland sealing plug ETC00790 Cable gland allen screw sealing plug ETC00781 4 Series 100 e 02 2004 PREPARATION Terminal strips for data lines OL L Interface Serial out E 00 1 O CTS F100 1 F100 2 7 Terminal strip Interface serial interface option Power supply Fig 5 7 BINOS 100 F Data line connections Inside view from front detail without front door ETC00781 4 Series 100 e 02 2004 PREPARATION ADDITIONAL HINTS TO BINOS 100 F FIELD HOUSING Terminal strip X2 Terminal strip Tterminal strips Powerline filter analog outputs digital outputs for mains cord connection of L and N of mains line di S E lt N x E 8 o 2 a ll
152. t supplementary protective measures Hot components may exist at the photometer or in heated versions BINOS 100 F The analyzer has a weight of approx 30 35 kg Lift or carry this unit with at least 2 persons For easy transport use a Suitable cart or comparable tools Verify that the cable fittings with installed cables are hermetic to be in agreement with protection class IP 65 according to DIN standard 40050 The permissible outside diameters of the cables are 7 to 12 mm The analyzer is intended to be wall mounted Use bolts which are suitable for the weight of the unit and appropriate anchors Make sure the wall where the analyzer is intended to be mounted is solid to hold the analyzer ETC00781 4 Series 100 e 02 2004 5 3 SAFETY SUMMARY GASES AND GAS CONDITIONING SAMPLE HANDLING SUPPLY VOLTAGE IV Gases and Gas Conditioning Sample Handling gt ES Ep Be sure to observe the safety regulations for the gases sample gas and test gases span gases and the gas bottles Inflammable or explosive gas mixtures must not be purged into the instrument without supplementary protective measures To avoid risks for the operators by explosive toxic or unhealthy gas components first purge the gas lines with ambient air or nitrogen N before cleaning or exchanging parts of the gas paths V Supply Voltage PPP The socket outlet shall be installed near the equipment and shall be easily accessib
153. t value 1 cross compensation is enabled INPUT CONTROL Change values using A V 8 2 ETC00781 4 Series 100 e 02 2004 SETTING SYSTEM PARAMETERS CROSS COMPENSATION CALIBRATION INTERNAL X Determination of cross compensation correction factors is performed during the span adjustment Pure test gases are required for this operation Once cross compensation corrections have been determined span adjustments may be performed using test gas mixtures 8 3 Cross Compensation Calibration internal Input value 0 spanning without cross compensation correction test gas mixtures Input value 1 spanning with cross compensation correction pure test gases INPUT CONTROL Change values using A V To perform a calibration with cross compensation correction proceed as follows First perform a zeroing for both analysis channels see chapter 9 1 1 Then perform a spanning for both analysis channels as described in chapter 9 1 2 Repeat spanning for the analysis channel that has been spanned first Use pure test gases only The values entered as described in chapters 8 2 and 8 3 must be 1 for 2 performing a calibration with cross compensation correction 1 When using test gas mixtures C Cal must be set to 0 ETC00781 4 Series 100 e 02 2004 8 3 SETTING SYSTEM PARAMETERS HOLD AUTOMATIC CALIBRATION 8 4 Hold The
154. tem during transport c LF Fig 5 1 BINOS 100 F Photometer safety lock 00781 4 Series 100 e 02 2004 PREPARATION INSTALLATION SITE 5 1 Installation Site t A t Theanalyzers mustnot operate in explosive atmosphere without supplementary protective measures Free flow of air into and out of the analyzers ventilation slits must not be hindered by nearby objects or walls Operate analyzerastable top version oras rack mountable version built in only except of BINOS 100 F designed for wall mounting only The installation site for the analyzers has to be dry and remain above freezing point at all times The analyzers must be exposed neither to direct sunlight nor to strong sources of heat Be sure to observe the permissible ambient temperatures c f chapter 27 Technical Data For outdoor installation we recommend install the analyzers in a protective cabinet At least the analyzers has to be protected against rain e g shelter The BINOS 100 series analyzer has to be installed as near as possible to the sample point in order to avoid low response time caused by long sample gas lines In orderto decrease the response time a sample gas pump with a matching high pumping rate may be used while the analyzers has to be operated in the bypass mode or by an overflow valve to prevent too high flow and too high pressure Fig 5 2 gt Exhaust analyzer
155. th optional 7 digital inputs Version 5 11 with optional 7 digital inputs and optional FOUNDATION Fieldbus notin combination with FOUNDATION Fieldbus not in combination with RS 232 485 interface ETC00781 4 Series 100 e 02 2004 P 1 PREFACE b Housing Versions Different housing versions are delivered for detailed informations see price list BINOS 100 BINOS 100 M BINOS 100 2M BINOS 100 F HYDROS 100 OXYNOS 100 1 4 19 housing ext PS 1 4 19 housing ext PS 1 2 19 housing internal or external PS with standard options field housing int PS with standard options 1 4 19 housing ext PS 1 4 19 housing ext PS one or two IR channel one IR channel and one EO channel one or two IR channel s or one IR channel and one EO channel or one IR channel and one PO channel or one IR channel and one TC channel or one PO channel and one TC channel or one EO channel and one TC channel or one ot two PO channels one ot two EO channels one or two TC channels one internal sample gas pump one internal solenoid valve block one integrated fine dust filter one integrated flow indicator measuring channels see BINOS 100 2M see BINOS 100 2M dust filter for GP only one TC channel one or two EO channel or one PO channel 00781 4 Series 100 e 02 2004 PREFACE Area Classification a General Purpose All analyzer components
156. thout IR channel 18 3 PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS Rosemount Analytical PLUG PIN ALLOCATION OF BKS FISHER ROSEMOUNT 18 1 5 IR TC Measurement combined X2 Chopper X3 4 5 Light source channel 2 X5 TC sensor from PCB WAP 100 cable P15 5 pin connector X6 IR detector channel 2 X7 Temperature sensor chopper X9 Light barrier chopper 18 1 6 Oxygen TC Measurement combined In preparation 1 8 4 00781 1 Series 100 e 10 2001 Rosemount Analytical PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS FISHER ROSEMOUNT PLUG PIN ALLOCATION OF OXS ELECTROCHEMICAL O MEASURMENT 18 2 PlugPin Allocation OXS electrochemical oxygen measurement only Pin base P2 Oxygensensor Cable P1 5 pin connector PCB BKS X 5 sensor signal Cable P1 pin connector PCB BKS X 7 temperature sensor not used for combination with IR measurement View A PCB OXS assembled horizontal projection N1 Ed E So mmm s Connection PCB Oxygensensor OXS ViewA Pin base P2 GR NNNSNNSSSSSSSISSISSSSS Fig 18 2 PCB OXS ETC00781 1 Series 100 e 10 2001 1 8 5 PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS Rosemount Analytical PLUG PIN ALLOCATION OF WAP 100 TC MEASURMENT
157. tings Solenoid valves Option Circuit board BKS Digital inputs and FOUNDATION Fieldbus options PCB s WAP 100 and HEX 01 intrinsically safe measurement for potentially explosive atmosphere consult factory hermal conductivity sensor Paramagnetic oxygen sensor HP Gas sampling pump option Fig 1 20 Inside view dual channel BINOS 100 2M w external P S here version for CAT parmagnetic oxygen measurement amp thermal conductivity measurement ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Gas line fittings Momo TE e _ Caan Solenoid valves ka Fo channel 2 ca option O S S 8 F o L SL JO Solenoid valves e channel 1 U U option 2 IR photometer benches Gas
158. tive with descending priority That means E4 has highest priority and E7 has lowest priority At input E4 open zero gas valve a high signal opens the zero gas valve and closes all the other valves no matter of the signal levels at E5 to E7 A high signal at E5 opens the span gas valve closes all the other valves if E4 has low level no matter of the signal levels at E6 E7 Input E7 has a special logic A low level opens and a high level closes the sample gas valve whereat the inputs E4 to have to be at low level 13 1 4 Pump Control For the case that the optional gas sampling pump is controlled via digital input see chapter 8 18 this is done using input E7 too A low level on E7 switches on and a high signal switches off the gas sampling pump irrespective of the signals at E1 to 13 2 FOUNDATION Fieldbus For communication via FOUNDATION Fieldbus terminals are available at the analyzer s rear side Fig 1 8 Item 9 For exact description see separate FOUNDATION Fieldbus specific manual Observe the wiring hints in chapter 29 10 FB JO Fieldbus FB JO Fieldbus FB Fieldbus FB O Fieldbus Fig 13 2 Terminal strip assignments Fieldbus connection only possible if serial interface RS 232 485 is not request 1 3 22 00781 4 Series 100 e 02
159. tory if flammable samples are to be measured Do not open while energized unless itis known that no explosive atmosphere is present ETC00781 4 Series 100 e 02 2004 5 7 SAFETY SUMMARY Z PURGE FOR CSA C US EX ZONE 2 NON FLAMMABLE ATMOSPHERES Vill Additional notes for service maintenance Do not open instrument when energized Component replacement and internal adjustments requires servicing by qualified personnel only Always disconnect power discharge circuits and remove external voltage sources before troubleshooting repair or replacement of component Any work inside the instrument without switching off the power must be performed by a specialist who is familiar with the related danger only To avoid a danger to the operators by explosive toxic or unhealthy gas components first purge the gas lines with ambient air or nitrogen N before the gas paths are cleaned or parts are replaced Hot components may exist at the photometer or in heated versions Incase of replacing fuses the customer has to be certain that fuses of specified type and rated current are used Itis prohibited to use repaired fuses or defective fuse holders or to short circuit fuse carriers fire hazard Do not open BINOS 100 F for use in hazardous areas EX Zones while energized unless it is known that no explosive atmosphere is present Cleaning of BINOS 100 F front panel for EX Zone 1 Danger of electrostatic disch
160. upply Voltage Analyzer specific notes for the user BINOS 100 F specific notes for use in hazardous areas EX Zones Z purge for CSA C US Zone 2 Non Flammable Atmospheres VIII Additional notes for service maintenance Milla Electrostatic Discharge IX Operating Conditions according to DMT Approval PREFACE General Overview a b Software Versions Housing Versions Area Classification a b General Purpose Hazardous Areas Ex Zone 2 Ex Zone 1 TECHNICAL DESCRIPTION Front Panel Rear Panel Internal Construction Internal Gas Paths a Gas Path Material b Gas Path Layout internal tubing ETC00781 4 Series 100 e 02 2004 S 1 S 1 S 1 S 2 5 4 5 6 5 7 5 7 5 8 5 9 S 10 P 1 P 1 P 1 P 2 P 3 P 3 P 3 P 3 P 3 1 1 le 4 1 5 ied 1 25 je 35 1 26 CONTENTS 2 MEASURING PRINCIPLE 2 1 2 11 2 1 2 2 1 3 2 2 2 21 2 2 2 2 3 2 3 1 2 3 2 2 3 3 IR Measurement Interference Filter Correlation IFC Principle Opto Pneumatic Measuring Principle Technique Oxygen Measurement Paramagnetic Measurement Electrochemical Measurement Thermal Conductivity Measurement Sensor Design Analysis Cell Measurement Method 3 PHOTOMETER ASSEMBLY 3 1 3 2 Photometer with Pyroelectrical Detector Solid state detector Photometer with Gas Detector 5 PREPARATION OF START UP 5 1 5 2 5 2 1 5 2 2 5 2 3 5 2 4 5 3 5 3 1 5 3 2 5 3 3 5
161. w m Fine dustfilter Q Pi with integrated E NA Flow indicator needle valve for option regulation of gas flow rate option Fig 1 15 Inside View dual channel BINOS 100 2M version A IR channel oxygen measurement combined ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION INTERNAL CONSTRUCTION Solenoid valves Option Gas line fittings TT lo Power supply option UPS01 Fine dustfilter with integrated needle valve for regulation of gas flow rate option option Fig 1 16 Inside View BINOS 100 2M version A 1channeloxygen measurement electrochemical MOIN mer T Circuit board BKS Channel 1 fl 5 Electrochemical i oxygen sensor 1 with circuit board OXS Eh Pressure sensor I option 6 CARO Pi beg 04 Gas sampling pump option 548 PQ 2 fey BL L FILTERELEMENT Zum LS 42 707 676 FLOW WPN N Flow indicator ETC00781 4 Series 100 e 02 2004 TECHNICAL DESCRIPTION
162. zers offers multi component multi method analysis Different measure ment methods can be combined in one analyzer The following measuring methods of the individual measuring channels are possible R non dispersive infrared measurement PO paramagnetic oxygen measurement EO electrochemical oxygen measurement TC thermalconductivity measurement All analyzers are designed to measure 1 or 2 gas components except of HYDROS 100 and OXYNOS 100 in case of PO measurement both 1 channel only a Software Versions Different software versions and analyzer options are available BINOS 100 M OXYNOS 100 HYDROS 100 1 4 19 housing external power supply Version 4 11 with optional RS 232 485 Interface according to DMT Approval Version 5 10 with optional RS 232 485 Interface BINOS 100 2M 1 2 19 housing internal power supply Version 4 11 with optional RS 232 485 Interface according to DMT Approval Version 5 10 with optional RS 232 485 Interface BINOS 100 2M 1 2 19 housing external power supply Version 4 11 with optional RS 232 485 Interface according to DMT Approval Version 5 10 with optional RS 232 485 Interface and or with optional 7 digital inputs Version 5 11 with optional 7 digital inputs and FOUNDATION Fieldbus BINOS 100 F field housing internal power supply Version 4 11 with optional RS 232 485 Interface according to DMT Approval Version 5 10 with optional RS 232 485 Interface and or wi

Emerson Process Management Series 100 Gas Analyzers HYDROS 100 User's Manual

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