Emerson Process Management BINOS 100 F, BINOS 100 M, BINOS 100, HYDROS 100, BINOS 100 2M User Manual

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Instruction Manual

ETC00781 February 2004

Series 100 Gas Analyzers

BINOS® 100, BINOS® 100 M

BINOS® 100 2M, BINOS® 100 F

OXYNOS® 100, HYDROS® 100

www.EmersonProcess.com

Software Version 5.1x

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

maintenance of the product.

• Install your equipment as specified in the Installation Instructions of the

appropriate Instruction Manual and per applicable local and national codes.

Connect 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 & Co. OHG

Industriestrasse 1 D-63594 Hasselroth Germany T +49 (0) 6055 884-0 F +49 (0) 6055 884-209 Internet: www.EmersonProcess.com

SAFETY SUMMARY

GENERAL

Safety Summary

I. 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, or life support applications, and no independent agency certifications or approvals are to be implied as covering such applications.

II. 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!

Electrostatic Discharge (ESD) !

Explosives !

Hot components !

Toxic !

Risk to health !

Analyzer specific notes for the user !

For additional information to these safety symbols see instruction manual. Strictly follow the related instructions !

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SAFETY SUMMARY

GENERAL

III. General

X To avoid explosion, loss of life, personal injury and damages to this equipment and other

property, all personnel authorized to install, operate and service this equipment should be thoroughly familiar with and strictly follow the instructions in this manual ! Save these instructions !

X If this equipment is used in a manner not specified in these instructions, protective features

may be impaired !

X Correct and safe operation of analyzers calls for appropriate transportation and storage,

expert installation and commissioning as well as correct operation and meticulous maintenance !

X Emerson Process Management does not take responsibility (liability) for the customer´s

failure to comply with these requirements !

X Do not attempt internal service or adjustment unless other person, capable of rendering first

aid and resuscitation, is present !

X 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 !

X Instruments which appear damaged or defective should be made inoperative and secured

against unintended operation until they can be repaired by qualified service personnel.

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SAFETY SUMMARY

GENERAL / GASES AND GAS CONDITIONING (SAMPLE HANDLING)

Do not open instrument when energized ! Component replacement and internal 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 or as 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 without 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.

ETC00781(4) Series 100 e 02/2004

Make sure the wall where the analyzer is intended to be mounted is solid to hold the analyzer!

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SAFETY SUMMARY

GASES AND GAS CONDITIONING (SAMPLE HANDLING) / SUPPLY VOLTAGE

IV.Gases and Gas Conditioning (Sample Handling)

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 (N2) before cleaning or exchanging parts of the gas paths.

V. Supply Voltage

The socket outlet shall be installed near the equipment and shall be easily accessible 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 !

X BINOS® 100(M), BINOS® 100 2M (external PS), HYDROS® 100 and OXYNOS® 100 are

Safety Class III instruments.

Verify correct polarity for 24 V DC operation !

S - 4

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 !

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SAFETY SUMMARY

SUPPLY VOLTAGE

X 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 must be 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 connected to an electrical ground (safety ground) at the power outlet. If the instrument is to be energized via an external power supply, that goes for the power supply too. Any interruption of the protective (grounding) conductor or disconnection of the protective earth terminal will cause a potential shock hazard that could result in personal 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® 100 F ! 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 !

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SAFETY SUMMARY

ANALYZER SPECIFIC NOTES FOR USER

VI. Analyzer specific notes for the user

The installation site for the instrument has to be dry and remain above

freezing point at all times.

The instrument must be exposed neither to direct sunlight nor to strong sources of heat. Be sure to observe the permissible ambient temperature ! For outdoor sites, we recommend 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 !

S - 6

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 that the shield is connected correctly (chapter 29.10). Shield and connectors housing have to be connected conductive. Sub. min. D plugs/sockets 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”.

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SAFETY SUMMARY

BINOS® 100 F SPECIFIC NOTES FOR USE IN HAZARDOUS AREAS (EX ZONES)

VII. BINOS® 100 F specific notes for use in hazardous areas (EX Zones)

Be sure to observe the additional notes, safety precautions and warnings given in the supplemental manual for analyzers intended to be used in hazardous areas. If you do not have the additional manual available, please contact your Emerson Process Management Sales Office!

VII.a Z purge for CSA-C/US Ex Zone 2 Non-Flammable Atmospheres

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 result in explosion,

causing severe personal injury, death or property damage !

Consult factory if flammable samples are to be measured !

Do not open while energized unless it is known that no explosive atmosphere is present !

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SAFETY SUMMARY

Z PURGE FOR CSA-C/US EX ZONE 2 NON-FLAMMABLE ATMOSPHERES

VIII. 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 (N2) before the gas paths are cleaned or parts are replaced.

Hot components may exist at the photometer or in heated versions !

In case of replacing fuses the customer has to be certain that fuses of specified type and rated current are used. It is 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 !

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Cleaning of BINOS® 100 F front panel for EX Zone 1: Danger of electrostatic discharge ! Use damp cloth only for cleaning front panel !

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SAFETY SUMMARY

ADDITIONAL NOTES FOR SERVICE / MAINTENANCE

VIII.a Electrostatic Discharge

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 operation 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).

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SAFETY SUMMARY

ELECTROSTATIC DISCHARGE

IX. Operating Conditions according to DMT Approval

(The following is a reprint of chapter 6 of the supplement I to the DMT reports “IBS/PFG-No. 41300392 NIII” 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 & Co. [now: Emerson Process Management; the editor] are suitable for measuring the concentrations of methane

between 0 and 80 % CH4, of carbon dioxide between 0 and 80 % CO2, 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.-%, if the

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 indicated in this report) and the local operating conditions. Consider the Code of

Pratice No. T032 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.

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SAFETY SUMMARY

OPERATING CONDITIONS ACCORDING TO DMT APPROVAL

X The intervals for the periodical tests must be settled by the person being responsible for

the system´s security and in accordance with the Code of Pratice No. T023 of the Labor

Association of the Chemical Industry "Maintenance of stationary gas warning systems for

explosion protection".

Consider the superproportional dependency of the barometric pressure on the

measured value for CO2.

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.

The pressure and flow values recommended by the manufacturer should be observed.

An external monitoring of the sample gas flow through the analyzer should be provided.

The results of this investigation are based on the systems using software versions “3.03”,

“4.00”, “4.01” and “4.11”. A change of the software version used must be certified by the

Testing Association.

It should be ensured that the system parameters for the analog output have been correctly

adjusted. End of range of low concentration should not be identical or lower than the begin

of range. Disregarding these versions, the measurement range should be adjusted

between 0 to 80 % CH4, 0 to 80 % CO2, 0 to 10 % CO or 0 to 10 % O2 resp. when the systems

are used for explosion protection.

Read and follow the operation and maintenance manual supplied to and certified by PFG.

It is important that the temperature is kept between 5 and 45 °C.

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SAFETY SUMMARY

OPERATING CONDITIONS ACCORDING TO DMT APPROVAL

The analyzer housings must be provided with a permanent type plate indicating the name

of the manufacturer, model number, serial number, and the following reference and date

of testing:

"IBS/PFG-Nr. 41300392" (for CH4, CO2 or CO)

"IBS/PFG-Nr. 41300292" (for O2)

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.

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SAFETY SUMMARY

OPERATING CONDITIONS ACCORDING TO DMT APPROVAL

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SAFETY SUMMARY

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PREFACE

General Overview

The series 100 of analyzers offers multi-component, multi-method analysis. Different measurement methods can be combined in one analyzer. The following measuring methods of the individual measuring channels are possible:

IR = non-dispersive infrared measurement PO2= paramagnetic oxygen measurement EO2= electrochemical oxygen measurement TC = thermal conductivity measurement

All analyzers are designed to measure 1 or 2 gas components except of HYDROS® 100 and OXYNOS® 100 in case of PO2 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):

not in 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 = 1/4 19" housing, ext. PS one or two IR channel BINOS® 100 M = 1/4 19" housing, ext. PS, one IR channel and one EO2 channel BINOS® 100 2M = 1/2 19" housing, one or two IR channel(s) or

internal or external PS, one IR channel and one EO2 channel or

one IR channel and one PO2 channel or one IR channel and one TC channel or one PO2 channel and one TC channel or one EO2 channel and one TC channel or one ot two PO2 channels one ot two EO2 channels one or two TC channels

with standard options: one internal sample gas pump

one internal solenoid valve block one integrated fine dust filter one integrated flow indicator

BINOS® 100 F = field housing, int. PS, measuring channels see BINOS® 100 2M

with standard options: see BINOS® 100 2M (dust filter for GP only) HYDROS® 100 = 1/4 19" housing, ext. PS, one TC channel OXYNOS® 100 = 1/4 19" housing, ext. PS, one or two EO2 channel or

one PO2 channel

P - 2

ETC00781(4) Series 100 e 02/2004

PREFACE

Area Classification

a) General Purpose

All analyzer components are installed into a 1/4 19" housing (BINOS® 100 (M), OXYNOS® 100, HYDROS® 100) or a 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 or as 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 conforming to 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

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PREFACE

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ETC00781(4) Series 100 e 02/2004

CONTENTS

Table of Contents

SAFETY SUMMARY S - 1

I. Intended Use Statement S - 1 II. Safety Symbols S - 1 III. General S - 2 V. Supply Voltage S - 4 VI. Analyzer specific notes for the user S - 6 VII. BINOS® 100 F specific notes for use in hazardous areas (EX Zones) S - 7 VII.a Z purge for CSA-C/US Ex Zone 2 Non-Flammable Atmospheres S - 7 VIII. Additional notes for service / maintenance S - 8 VIIIa Electrostatic Discharge S - 9 IX. Operating Conditions according to DMT Approval S - 10

PREFACE P - 1

General Overview P - 1

a) Software Versions P - 1 b) Housing Versions P - 2

Area Classification P - 3

a) General Purpose P - 3 b) Hazardous Areas P - 3

Ex Zone 2 P - 3 Ex Zone 1 P - 3

1. TECHNICAL DESCRIPTION 1 - 1

1.1 Front Panel 1 - 1

1.2 Rear Panel 1 - 5

1.3 Internal Construction 1 - 11

1.3.1 Internal Gas Paths 1 - 25 a) Gas Path Material 1 - 25 b) Gas Path Layout (internal tubing) 1 - 26

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CONTENTS

2. MEASURING PRINCIPLE 2 - 1

2.1 IR Measurement 2 - 1

2.1.1 Interference Filter Correlation (IFC Principle) 2 - 1

2.1.2 Opto-Pneumatic Measuring Principle 2 - 3

2.1.3 Technique 2 - 5

2.2 Oxygen Measurement 2 - 6

2.2.1 Paramagnetic Measurement 2 - 6

2.2.2 Electrochemical Measurement 2 - 8

2.3 Thermal Conductivity Measurement 2 - 10

2.3.1 Sensor Design 2 - 10

2.3.2 Analysis Cell 2 - 10

2.3.3 Measurement Method 2 - 11

3. PHOTOMETER ASSEMBLY 3 - 1

3.1 Photometer with Pyroelectrical Detector (Solid-state detector) 3 - 1

3.2 Photometer with Gas Detector 3 - 4

5. PREPARATION OF START-UP 5 - 1

5.1 Installation Site 5 - 2

5.2 Gas Conditioning (Sample Handling) 5 - 3

5.2.1 Fine Dust Filter (Option BINOS® 100 2M/F) 5 - 4

5.2.2 Gas Sampling Pump (Option BINOS® 100 2M/F) 5 - 4

5.2.3 Pressure Sensor (Option) 5 - 4

5.2.4 Gas Flow 5 - 4

5.3 Gas Connections 5 - 5

5.3.1 Standard 5 - 5

5.3.2 Internal Solenoid Valves (Option BINOS® 100 2M/F) 5 - 8

5.3.3 Purge gas connection of BINOS® 100 F for Ex zones 5 - 10

5.4 Additional Hints to BINOS® 100 F (Field Housing) 5 - 11

5.4.1 Wall Mounting 5 - 12

5.4.2 Electrical Connections 5 - 13

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CONTENTS

6. SWITCHING ON 6 - 1

6.1 General 6 - 1

6.2 24 V DC Supply 6 - 2

6.3 230/120 V AC Supply 6 - 2

6.3.1 BINOS® 100 2M 6 - 4

6.3.2 BINOS® 100 F 6 - 5

7. KEY FUNCTIONS 7 - 1

7.1 FUNCTION 7 - 2

7.2 ENTER 7 - 4

7.3 INPUT - CONTROL 7 - 6

7.4 PUMP (BINOS® 100 2M/F only) 7 - 7

8. SETTING SYSTEM PARAMETERS 8 - 1

8.1 Pressure Correction 8 - 2

8.2 Cross Compensation (internal) 8 - 2

8.3 Cross Compensation Calibration (internal) 8 - 3

8.4 Hold 8 - 4

8.5 Automatic Calibration 8 - 4

8.6 Tolerance Check 8 - 5

8.7 Display Off 8 - 6

8.8 Analog Signal Outputs 8 - 7

8.9 Flushing Period 8 - 8

8.10 User Code 8 - 8

8.11 Response Time (t90) 8 - 9

8.12 Offset (Begin of range) 8 - 10

8.13 End of Range Value 8 - 11

8.14 Reset 8 - 12

8.15 Program Version 8 - 13

8.16 Serial - No. 8 - 13

8.17 Pump *) 8 - 14

8.18 Pump Control *) 8 - 14

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III

CONTENTS

9. CALIBRATION 9 - 1

9.1 Manual Calibration 9 - 2

9.1.1 Zeroing 9 - 2

9.1.2 Spanning 9 - 4

9.2 Time-Controlled Calibration Mode (Option) 9 - 7

9.2.1 Zeroing 9 - 7

9.2.2 Combined Zeroing and Spanning 9 - 9

9.3 Remote-Controlled Calibration Mode (Option) 9 - 10

10. MEASUREMENT / SWITCHING OFF 10 - 1

10.1 Measurement 10 - 1

10.2 Switching Off 10 - 1

11. DIGITAL OUTPUTS 11 - 1

11.1 Concentration Limits 11 - 2

11.2 Valve Control 11 - 4

11.3 Status Signals (Option non-voltage-carrying relay contacts) 11 - 4

12. SERIAL INTERFACE (OPTION) 12 - 1

12.1 Upgrading Serial Interface / Status Signals 12 - 1

12.2 General 12 - 2

12.3 Start Up 12 - 4

12.3.1 RS 232 C 12 - 4

12.3.2 RS 485 12 - 5

12.3.3 Switching ON/OFF Interface Operation 12 - 6

12.3.4 Setting Interface Parameters 12 - 6

12.4 Telegram Syntax 12 - 8

12.4.1 Start Character ( “$” = Hex 24) 12 - 8

12.4.2 Terminate Character ( “CR” = Hex OD) 12 - 8

12.4.3 Instruction Code 12 - 8

12.4.4 Hyphen Character ( “;” = Hex 3B) 12 - 8

12.4.5 Status Telegram 12 - 9

12.4.6 Numerical Representations 12 - 10

12.4.7 Block Parity Check 12 - 10

12.5 Instruction Syntax 12 - 11

12.5.1 Instruction Listing 12 - 12

12.5.2 Response Telegrams 12 - 13

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CONTENTS

13. DIGITAL INPUTS / FOUNDATION™ FIELDBUS

(BINOS® 100 2M/F OPTION ONLY) 13 - 1

13.1 Digital Inputs 13 - 1

13.1.1 General 13 - 1

13.1.2 Start of Calibration 13 - 1

13.1.3 Valve Control 13 - 2

13.1.4 Pump Control 13 - 2

13.2 Foundation™ Fieldbus *) 13 - 2

14. CROSS COMPENSATION / SETTING OF RESPSONSE TIME

(TC OPTION ONLY) 14 - 1

14.1 Cross Compensation 14 - 1

14.1.1 Preparing Actions 14 - 2

14.1.2 Adjustment Procedure 14 - 3

16. LIST OF FAILURES 16 - 1

17. MEASURING POINTS OF BKS AND OXS 17 - 1

17.1 Measuring points of BKS 17 - 1

17.1.1 Supply Voltage + 6 V 17 - 1

17.1.2 Reference Voltage positive 17 - 1

17.1.4 Motor Drive (for IR channel only) 17 - 2

17.1.5 Temperature Sensor 17 - 3

17.1.6 Light Barrier Signal 17 - 4

17.1.7 Analog Preamplifiering 17 - 5

17.2 Measuring points of OXS (EO2 measurement) 17 - 6

17.2.1 Sensor Signal 17 - 6

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CONTENTS

18. PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS 18 - 1

18.1 Plug Pin Allocation of BKS 18 - 1

18.1.1 IR measurement without oxygen channel 18 - 2

18.1.2 Oxygen Measurement without IR channel 18 - 2

18.1.3 IR / Oxygen Measurement combined 18 - 3

18.1.4 TC Measurement without IR channel 18 - 3

18.1.5 IR / TC Measurement combined 18 - 4

18.1.6 Oxygen / TC Measurement combined 18 - 4

18.2 Plug Pin Allocation OXS (EO2 measurement only) 18 - 5

18.3 Plug Pin Allocation WAP 100 (TC measurement only) 18 - 6

19. JUMPER ALLOCATION OF BKS 19 - 1

21. FINE DUST FILTER (OPTION) 21 - 1

22. LEAK TESTING 22 - 1

23. HOUSING 23 - 1

23.1 Cleaning of Housing Surface 23 - 1

23.2 Opening the Housing 23 - 2

23.2.1 1/4 19" Housing 23 - 2

23.2.2 BINOS® 100 2M 23 - 3 a) Housing Cover 23 - 3 b) Front Panel 23 - 4

23.2.3 BINOS® 100 F (Field Housing) 23 - 5

24. REPLACEMENT AND CLEANING OF PHOTOMETRIC

COMPONENTS 24 - 1

24.1 Taking out the Photometer Assembly 24 - 1

24.2 Light Source Replacement 24 - 2

24.3 Cleaning of Analysis Cells and Windows 24 - 3

24.3.1 Removal of Analysis Cells 24 - 3

24.3.2 Cleaning 24 - 4

24.3.3 Reinstalling the Analysis Cells 24 - 5

24.4 Chopper Replacement 24 - 6

24.5 Reinstalling of the Photometer Assembly 24 - 6

24.6 Physical Zeroing 24 - 7

24.6.1 Standard Photometer (not sealed version) 24 - 7

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 - 3

27.5 Voltage Supply 27 - 9

27.5.1 Electrical Safety 27 - 9

27.5.2 Power Supplies [UPS 01 T / SL10 / SL5] 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 D Plugs, 9 pin 30 - 3

32. FAILURE CHECK LIST 32 - 1

a) Customer Service 32 - 4 b) Training 32 - 4

ETC00781(4) Series 100 e 02/2004

VII

CONTENTS

VIII

ETC00781(4) Series 100 e 02/2004

CONTENTS

ETC00781(4) Series 100 e 02/2004

CONTENTS

ETC00781(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 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

250 ppm

% O para. oxygen sensor

% O

FUNCTION ENTER INPUT - CONTROL

chem.

% O chem. oxygen sensor

paramagnetic

electrochemical

1 - 2

Fig. 1-1: BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 Front view

1 LED display (channel 1) 2 LED display (channel 2) 4 Input setting control key DOWN 5 Input setting control key UP 6 Key ENTER 7 Key FUNCTION 11 Fastening screws for the carrying-strap bracket

or rack-mounting purposes

12 Housing cover fastening screw

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION

FRONT VIEW

Needle valve (option)

% O

1000 ppm

45678391011

Fig. 1-2: BINOS® 100 2M (standard version), front view

1 LED display (channel 1) 2 LED display (channel 2) 3 Function LED for options "Solenoid Valves / Gas Sampling Pump" 4 Input setting control key DOWN 5 Input setting control key UP 6 ENTER key 7 FUNCTION key 8 Key for option “Gas Sampling Pump” 9 Flow indicator (option) 10 Fine dust view filter with needle valve (option) 11 Fastening screws for the carrying strap bracket

or rack-mounting purposes

ETC00781(4) Series 100 e 02/2004

1 - 3

TECHNICAL DESCRIPTION

FRONT VIEW

Wall mounting

holder

Fastener

front panel

Fig. 1-2 for

General Purpose

Operation front panel

Fig. 1-4 for

hazardous areas

(ex zones)

Fig. 1-3: BINOS® 100 F, front view

Front panel

1 - 4

Fig. 1-4: BINOS® 100 F magnetically operated front panel , impact tested, front view

ETC00781(4) Series 100 e 02/2004

1.2 Rear Panel

The rear panels include

R the gas line fittings

R the plug for the electrical supply input

R the subminiature “D” mating socket for the analog signal outputs

TECHNICAL DESCRIPTION

REAR PANEL

R the subminiature “D” plug for the digital outputs (concentration limits / valve control)

R optionally the subminiature “D” mating plug for analog signal inputs

(interference cross compensation, TC only)

R optionally the subminiature “D” mating socket for the RS 232 C / RS 485 interface

R optionally the subminiature “D” mating plug for the status signals (relay outputs)

For BINOS® 100 2M/F only:

R optionally the solenoid valve block

R optionally the terminal strips for the 7 digital inputs

R optionally the terminal strips for the FOUNDATION™ Fieldbus

**)

**) ***)

not in combination with FOUNDATION™ Fieldbus

**)

BINOS® 100 2M with external power supply only

***)

not in combination with RS 232/485 interface

ETC00781(4) Series 100 e 02/2004

1 - 5

TECHNICAL DESCRIPTION

REAR PANEL

K1 K2 K1 K2

OUT

CROSS COMP.

X1 OUTPUT

INTERFACE

24 V

max. W

X2 OUTPUT

12+ 1

X3 OUTPUT

MADE I N GERMANY

1 - 6

Fig. 1-5: BINOS® 100 (M), OXYNOS® 100 (EO2), HYDROS® 100, Rear view

1 Gas inlet line fittings 2 Analog signal output mating socket 3 24 VDC supply input terminal 4 Plug for Digital signal output 5 Gas outlet line fittings 6 Housing cover fastening screws 7 mating socket Serial Interface [RS 232 C / 485] (Option) 8 Plug for Output Relays (Option) 9 Plug for analog signal inputs

(interference cross compensation, HYDROS® 100 only)

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION

REAR PANEL

X2 OUTPUT

INTERFACE

X1 OUTPUT

24 V

max. 40 W

12+1

OUT

X3 OUTPUT

MADE I N GERMANY

ETC00781(4) Series 100 e 02/2004

Fig. 1-6: OXYNOS® 100 (PO2), Rear view

1 - 7

TECHNICAL DESCRIPTION

REAR PANEL

12 34 56789

FLOW

Fig. 1-7: BINOS

100 2M, version A (shown with internal power supply), Rear view with all options

12131416

1 Gas inlet line fitting 22

gas inlet line fitting (option) 3 Gas outlet line fitting 42

gas outlet line fitting (option) 5 Plug for analog signal inputs

(interference cross compensation, TC only) 6 “Solenoid valves”: common gas outlet line fitting 7 “Solenoid valves”: Test gas inlet 1 8 “Solenoid valves”: Test gas inlet 2 9 24 VDC output (max. 2 A, see technical data)

10 Power supply [UPS 01 T (Universal Power Supply)] 11 Plug Power Supply (Mains line) 12 “Solenoid valves”: Zero gas inlet 13 “Solenoid valves”: Sample gas inlet 14 Plug Digital Outputs (threshold contacts) 15 Mating socket Serial Interface [RS 232 C / 485] (option) 16 Mating socket Analog Signal Outputs 17 Plug Output Relays (status signal option)

1 - 8

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION

REAR PANEL

1234 5

K1 K2 K1 K2

IN OUT

X1 OUTPUT

FLOW

IN/OUT

X2 OUTPUT X3 OUTPUT

DURCHFLUSS MAX. 1 L/ MIN

ANALOG I N

SPAN 1

SPAN 2

SAMPLE

ZERO

OUT

24V max.120W

DIGI TAL IN

V+ V-

E1 E2 E3 E4

E5 E6 E7

FB+ FBFB+ FB-

16 15 17 14 13 12

Fig. 1-8: BINOS

100 2M, version B (with external power supply), Rear view with all options

1 Gas inlet line fitting 22

gas inlet line fitting (option) 3 Gas outlet line fitting 42

gas outlet line fitting (option) 5 Plug for analog signal inputs

(interference cross compensation, TC only) 6 “Solenoid valves”: common gas outlet line fitting 7 “Solenoid valves”: Test gas inlet 1 8 “Solenoid valves”: Test gas inlet 2 9 Terminal strips for the 7 Digital Inputs (option)

10 Terminal strips for FOUNDATION™ Fieldbus (option) 11 24 V DC supply input terminal 12 “Solenoid valves”: Zero gas inlet 13 “Solenoid valves”: Sample gas inlet 14 Plug Digital Outputs (threshold contacts) 15 Mating socket Serial Interface 16 Mating socket Analog Signal Outputs 17 Plug Output Relays (status signal option)

**)

[RS 232 C / 485] (option)

1011

ETC00781(4) Series 100 e 02/2004

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

1234 5

OUTIN

X1 OUTPUT

IN/OUT

X2 OUTPUT

FLOW

DURCHFLUSS MAX.1L/MIN

X3 OUTPUT

K2K1K2K1

ANALOG IN

SPAN 1

SPAN 2

SAMPLE

ZERO

OUT

24V 120W

SPAN 1

SPAN 2

OUT

SAMPLE

ZERO

Fig. 1-9: BINOS

14 13

100 2M (special version), Rear view with all options

11 12

1 Gas inlet line fitting channel 1 2 Gas inlet line fitting channel 2 3 Gas outlet line fitting channel 1 4 Gas outlet line fitting channel 2 5 Plug for analog signal inputs

(interference cross compensation, TC only) 6 “Solenoid valves”: common gas outlet line fitting 7 “Solenoid valves”: Test gas inlet 1 8 “Solenoid valves”: Test gas inlet 2 9 (open)

10 (open) 11 24 V DC supply input terminal 12 “Solenoid valves”: Zero gas inlet 13 “Solenoid valves”: Sample gas inlet 14 Plug Digital Outputs (threshold contacts) 15 Mating socket Serial Interface [RS 232 C / 485] (option) 16 Mating socket Analog Signal Outputs 17 Plug Output Relays (status signal option)

1 - 10

ETC00781(4) Series 100 e 02/2004

1.3 Internal Construction

The analyzers includes the following components:

R Depending on analyzer configuration

- one or two IR photometer benches

- one IR photometer and one EO2 sensor

- one IR photometer and one PO2 sensor

- one IR photometer and one TC sensor

- one PO2 sensor and one TC sensor

- one EO2 sensor and one TC sensor

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

- one or two PO2 sensors

- one ot two EO2 sensors

- one or two TC sensors

R 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 barometric pressure to eliminate faulty measurements due to changes in barometric pressure (see technical data).

R 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)].

R BINOS® 100 2M (standard version) / BINOS® 100 F:

Integrated power supply (230/120 V AC).

R 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) at the 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

Gas line fittings

PCB BKS

(channel 2)

Front panel

IR photometer bench (depending on analyzer configuration)

(channel 1)

Pressure sensor (option)

1 - 12

Fig. 1-10: Inside View BINOS® 100

(1 IR channel analyzer, high measuring range with gas detector)

ETC00781(4) Series 100 e 02/2004

Gas line fittings

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Cover metal plate

PCB BKS

IR photometer bench

(depending on analyzer

configuration)

(channel 2)

electrochemical oxygen sensor with PCB “OXS”

(channel 1)

Pressure sensor (option)

ETC00781(4) Series 100 e 02/2004

Front panel

Fig. 1-11: Inside View BINOS® 100 M

(IR channel / electrochemical oxygen measurement)

1 - 13

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Gas line fittings

Security dust filter

O2 sensor

Inlet

Outlet

Heat exchanger

PCB BKS

to Sensor

from Sensor

Heat exchanger view "X" (180° rotate)

1 - 14

Front panel

Fig. 1-12: OXYNOS® 100, Inside View with paramagnetic sensor

ETC00781(4) Series 100 e 02/2004

Gas line fittings

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

channel 2 channel 1

Security dust filter

Pressure sensor (Option)

ETC00781(4) Series 100 e 02/2004

Front panel

Fig. 1-13: OXYNOS® 100, Inside view with electrochemical sensor

1 - 15

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Gas line fittings

PCB BKS

PCB WAP 100

Out

Thermal conductivity sensor

1 - 16

Front panel

Fig. 1-14: HYDROS® 100, Inside view

ETC00781(4) Series 100 e 02/2004

Solenoid valves

(Option)

Power supply option

(UPS 01)

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Gas line fittings

Circuit board BKS

(below physical bench)

IR photometer bench

(depending on analyzer

configuration)

Paramagnetic

oxygen sensor

(depending on analyzer

configuration)

(Channel 1)

(Channel 2)

Electrochemical

oxygen sensor

with circuit board “OXS”

(depending on analyzer

configuration)

(Channel 1)

Pressure sensor

(option)

Gas sampling pump

(option)

Fine dust filter

with integrated

needle valve for regulation of gas flow rate (option)

ETC00781(4) Series 100 e 02/2004

Flow indicator

(option)

Fig. 1-15: Inside View dual-channel BINOS® 100 2M (version A)

(IR channel / oxygen measurement, combined)

1 - 17

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Solenoid valves

(Option)

Power supply option

(UPS 01)

Gas line fittings

Circuit board BKS

(Channel 1)

Electrochemical

oxygen sensor

with circuit board “OXS”

Pressure sensor

(option)

Gas sampling pump

(option)

Fine dust filter

with integrated

needle valve for regulation of gas flow rate (option)

1 - 18

Flow indicator

(option)

Fig. 1-16: Inside View BINOS® 100 2M (version A)

(1 channel oxygen measurement, electrochemical)

ETC00781(4) Series 100 e 02/2004

Solenoid valves

(Option)

Power supply option

(UPS 01)

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Gas line fittings

Circuit board BKS

(below physical bench)

IR photometer bench

(depending on analyzer

configuration)

PCB WAP 100

Thermal conductivity

sensor

(depending on analyzer

configuration)

Electrochemical

oxygen sensor

with circuit board “OXS”

(depending on analyzer

configuration)

Gas sampling pump

(option)

Fine dust filter

with integrated

needle valve for regulation of gas flow rate (option)

ETC00781(4) Series 100 e 02/2004

Flow indicator

(option)

Fig. 1-17: Inside View dual-channel BINOS® 100 2M (version A)

(IR / EO2 , TC / EO2 or IR / TC measurement, combined)

1 - 19

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Solenoid valves

(Option)

Power supply option

(UPS 01)

Gas line fittings

Circuit board BKS

PCB WAP 100

Paramagnetic

oxygens sensor

Thermal conductivity

sensor

Gas sampling pump

(option)

Fine dust filter

with integrated

needle valve for regulation of gas flow rate (option)

(oxygen measurement (paramagnetic) / thermal conductivity measurement, combined)

1 - 20

Flow indicator

(option)

Fig. 1-18: Inside View dual-channel BINOS® 100 2M (version A)

ETC00781(4) Series 100 e 02/2004

Solenoid valves

(Option)

Digital inputs and FOUNDATION™

Fieldbus

(options)

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Gas line fittings

Circuit board BKS

(below physical bench)

IR photometer bench

(depending on analyzer

configuration)

PCB`s WAP 100 and

HEX 01

(intrinsically safe TC

measurement for

potentially explosive

atmosphere,

consult factory)

Thermal conductivity

sensor

(depending on analyzer

configuration)

(Channel 1)

(Channel 2)

Electrochemical

oxygen sensor

with circuit board “OXS”

(depending on analyzer

configuration)

(Channel 1)

Gas sampling pump

(option)

ETC00781(4) Series 100 e 02/2004

Fig. 1-19: Inside View dual-channel BINOS® 100 2M (version B)

(IR channel / oxygen measurement, combined)

1 - 21

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Solenoid valves

(Option)

Digital inputs and FOUNDATION™

Fieldbus

(options)

Gas line fittings

Circuit board BKS

PCB`s WAP 100 and

HEX 01 (intrinsically safe measurement for

potentially explosive

atmosphere,

consult factory)

Paramagnetic

oxygen sensor

Thermal conductivity

sensor

Gas sampling pump

(option)

1 - 22

Fig. 1-20: Inside view dual-channel BINOS® 100 2M w. external P/S (here: version for CAT)

(parmagnetic oxygen measurement & thermal conductivity measurement)

ETC00781(4) Series 100 e 02/2004

Gas line fittings

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Solenoid valves

channel 2

(option)

Solenoid valves

channel 1

(option)

Gas sampling pump

channel 2 (option)

***

IR photometer benches (depending on analyzer

configuration)

Fig. 1-21: Inside View dual-channel BINOS® 100 2M (special version)

ETC00781(4) Series 100 e 02/2004

Gas sampling pump

channel 1

(option)

(two gas sampling pumps and two solenoid valve blocks)

1 - 23

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

Terminal strips

for output / input signals

Power Input Fuses

DC 24 V distribution

Photometer / sensor assembly

is dependening on

analyzer configuration

Power supply

Fig. 1-22: Inside View BINOS® 100 F (field housing)

1 - 24

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

1.3.1 Internal Gas Paths

The materials used for the gas paths are selected according to the application. In marking such selection the diffusion rates of the individual gas components, their corrosivity, and the temperature 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) of the analyzer determine the materials which are used for gas paths and gas fittings.

Safety Dust Filter

All analyzers are equipped with a PTFE safety dust filter. This filter is no substitute for the 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 outlet

(OUT K1)

Gas inlet

(IN K1)

Fig. 1-23: Tubing in series (BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 analyzers)

Gas outlet

Analyzer

Gas inlet

(IN K1)

Gas inlet

(IN K2)

(OUT K1)

Gas outlet

(OUT K2)

1 - 26

Fig. 1-24 Tubing in parallel (BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 analyzers)

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

span gas 1

(SPAN 1 / V1)

span gas 2

(SPAN 2 / V2)

sample gas

(SAMPLE / V3)

zero gas

(ZERO / V4)

Gas outlet

(OUT)

Analyzer

solenoid valves

(Option)

sample gas pump

(Option)

Gas inlet

(IN K1)

Flow indicator,

Filter and throttle

(Options)

not for BINOS® 100 F in hazardous areas

Fig. 1-25: Tubing in series (BINOS® 100 2M analyzers)

(equipped with all options)

Gas outlet (OUT K1)

span gas 1

(SPAN 1 / V1)

not used

span gas 2

(SPAN 2 / V2)

sample gas

sample gas pump

sample gas

zero gas

(Option)

zero gas

(ZERO / V4)

(SAMPLE / V3)

(OUT)

Gas outlet

(OUT)

Gas outlet

(IN K1)

Gas inlet

(IN K2)

Gas inlet

Gas outlet (OUT K1)

Flow indicator

Gas outlet (OUT K2)

Fig. 1-26: Tubing in parallel (special version of BINOS® 100 2M analyzer)

ETC00781(4) Series 100 e 02/2004

(equipped with all options)

1 - 27

TECHNICAL DESCRIPTION

1 - 28

ETC00781(4) Series 100 e 02/2004

MEASURING PRINCIPLE

IR MEASUREMENT

2. Measuring Principle

Depending on the gas to be analyzed different measuring methods will be used.

2.1 IR Measurement

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 concentration independent values. The difference between the two is 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 cell is 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 anywhere 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 CO2 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 passband in 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

IR MEASUREMENT

9075604530150

Transmittance [%]

Reference

4400 460042004000 48003000 3200 3400 3600 3800 5000 5200 5400 5600 5800 6000

Wave Length [nm]

Interference -

Absorption Band

Filter

18 36 54 72 900

Fig. 2-1: Absorption Bands of Sample Gases and Transmittance of the

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 at the 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

IR MEASUREMENT

2.1.2 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

Flow channel with Microflow sensor

CaF2 Window

Gas intake connection

Compensation chamber

ETC00781(1) Series 100 e 10/2001

Fig. 2-2: Principle Design of Gas Detector

2 - 3

MEASURING PRINCIPLE

IR MEASUREMENT

In principle the detector is filled with the infrared active gas to be measured and is only sensitive to this distinct gas with its characteristic absorption spectrum. The absorption chamber is sealed with a window which are transparent for infrared radiation [usually CaF2 (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 radiation passes through the open measurement side of the analysis cell into the detector, a part of it is 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 convert them into the corresponding display format.

2 - 4

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE

123

IR MEASUREMENT

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 influences) and enters the analysis cells. The light transmitted through these cells is focused by filter cells onto the according detector. The preamplified detector output signal is sent to microprocessor circuitry, which converts the analytical signals to results expressed directly in physical concentration units (Vol.-%, ppm, mg/Nm3 etc.).

Light source

Analysis cell measuring side

Analysis cell reference side

MOTOR

Duplex filter disc

Adapter cell (high measuring range)

Analysis cell (undivided)

Filter cell

Preamplifier

Filter cell

Gas detector

ETC00781(1) Series 100 e 10/2001

Pyroelectrical detector (solid-state detector)

Preamplifier

Chopper blade

Fig. 2-3: Principle Representation

2 - 5

MEASURING PRINCIPLE

OXYGEN MEASUREMENT (PO2 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).

% O2 para. = paramagnetic Sensor % O2 chem. = electrochemical Sensor

2.2.1 Paramagnetic Measurement

The determination of O2 concentration is based on the paramagnetic principle (magnetomechanic principle).

Two nitrogen filled (N2 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 a light source to a photodetector, is mounted on this ribbon. A strong permanent magnet especially shaped to produce a strong highly inhomogeneous magnetic field inside the analysis cell, is mounted outside the wall. When oxygen molecules enter the cell, their paramagnetism will cause them to be drawn towards the region of greatest magnetic field strength. The O2 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, will be 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 at the “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 O2 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.

2 - 6

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE

OXYGEN MEASUREMENT (PO2 PARAMAGNETIC PRINCIPLE)

ETC00781(1) Series 100 e 10/2001

Fig. 2-4: Principle Construction of paramagnetic Analysis Cell

1 Permanent magnet 2 Platinum wire 3 Mirror 4 Quartz spheres 5 Wire loop 6 Photodetector 7 Light source 8 Amplifier 9 Display

2 - 7

MEASURING PRINCIPLE

OXYGEN MEASUREMENT (EO2 ELECTROCHEMICAL PRINCIPLE)

2.2.2 Electrochemical Measurement

The determination of O2 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

O - ring (8)

Plastic disc (9)

Plastic top (10)

(1)

(Lead)

(Black)

Thermistor (5)

Acid electrolyte (3)

Sponge disc (7)

Cathode

(2)

Teflon membrane (4)

(Red)

Resistor (6)

(Gold film)

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 at the gold electrode a sponge sheet is inserted on the purged side.

Oxygen molecules diffuse through a non-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 (t90) of the sensor is dependent on the thickness of the Teflon membrane.

2 - 8

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE

OXYGEN MEASUREMENT (EO2 ELECTROCHEMICAL PRINCIPLE)

(Red) (Black)

Thermistor (5)

(-)

Gold-

Cathode (2)

O2 + 4 H+ + 4 e- ¤ 2 H2O

Summary reaktion O

(11)

Electrolyte (3)

(ph 6)

+ 2 Pb ¤ 2 PbO

Resistor (6)

2 Pb + 2 H2O ¤ 2 PbO + 4 H+ + 4 e

Fig. 2-6: Reaction of galvanic cell

(+)

Lead-

Anode (1)

The electric current between the electrodes is proportional to the O2 concentration in the gas mixture to be measured. The signals are measured as ter minal voltages of the resistor (6) and the thermistor (5) for temperature compensation.

The change in output voltages (mV) of the senor (11) represents the oxygen concentration.

Note !

Depending on measuring principle the electrochemical O 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

sensitivity. The output signal will become instabil.

of O

For correct measurement the cells have to be supplied with O We recommend to use the cells in intervall measurement (purge cells with conditioned (dust removal but no drying) ambient air during measurement breaks). If it is 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) will have no influence to measuring value.

cell needs a minimum internal consumption

concentrations of at least 0.1 Vol.-%.

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 (H2), Argon (Ar) or Helium (He), the measurement method of thermal conductivity (TC) will be 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, whereat the 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 - 10

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE

THERMAL 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

ETC00781(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 realized in 100 series. Optional the photometer can be sealed to ambient air. In this case all par ts 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 assembly 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), and the 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) for the selection of spectral bandpass 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 CO2, 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 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 a necked 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

Fig. 3-1: Photometer Assembly with Pyroelectrical Detector

3 - 3

Legends:

03 Chopper Housing 04 / 05 Duplex Filter Disc 06 Zero - Adjustment Baffle (not for sealed photometer) 07 Light Source (thermal radiator) 08 Analysis Cell 1 - 7 mm (spacer ring) 09 Analysis Cell 50 - 200 mm 10 Adapter Cell 14/15 Filter Cell 16 Detector 17 Flange (light source) 18-21 O - Rings 22 Clamp (analysis cells 1-7 mm) 23 (24) Clamping Collar (analysis cells 1-7 mm) 25 Clamp (analysis cells 10-200 mm) 26 Light Source Mounting Screws 27 Mounting Screws for Analysis Cells/Adapter Cells 28 Temperature Sensor

PYROELECTRICAL DETECTOR

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 (N2). To prevent measuring errors by preabsorption, two absorber, fitted to the gas connections of the reference side, absorb CO2 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 ranges 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

3521

ETC00781(4) Series 100 e 02/2004

16 5 4 623

Fig. 3-2: Photometer Assembly 100 Series with Gas Detector

[example above and middle: high measuring ranges,

example below: small measuring ranges.

1 Analysis Cell 2 Filter Cell 3 Gas Detector 4 Holding Device 5 Preamplifier 6 Absorber

3 - 5

PHOTOMETER ASSEMBLY

3 - 6

ETC00781(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: Unscrew transfer safety lock of photometer sliding carriage (Fig. 5-1) ! Lock the system during transport !

Fig. 5-1: BINOS® 100 F, Photometer safety lock

ETC00781(4) Series 100 e 02/2004

5 - 1

PREPARATION

INSTALLATION SITE

5.1 Installation Site

The analyzers must not 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 analyzer as table-top version or as 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 to 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 order to 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).

Exhaust

5 - 2

Overpressure valve

Gas sampling pump

analyzer

Filter

Fig. 5-2: 100 series, Bypass installation

Flow meter

Exhaust

ETC00781(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.

All gases have to be supplied to the analyzers 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.

The gas has to fullfil the following conditions:

It must

R be free of condensable constituents R be free of dust R be free of aggressive constituents which are not compatible with the material of the gas

paths.

R have temperatures and pressures which are within the specifications stated in “Technical

Data” of this manual.

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.

ETC00781(4) Series 100 e 02/2004

5 - 3

PREPARATION

GAS CONDITIONING (SAMPLE HANDLING)

5.2.1 Fine Dust Filter (Option BINOS® 100 2M/F)

A fine dust filter with a pore size of 2 µm 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 l/min., see chapter 7.4). For special solutions with 2 parallel measuring channels and 2 gas sampling pumps consult factory.

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 will then be corrected to 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 max. 1.0 l/min!

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 two 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 !

Permissible gas pressure max. 1,500 hPa !

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.

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 are used to

connect the reference gas.

ETC00781(4) Series 100 e 02/2004

5 - 5

PREPARATION

GAS CONNECTIONS

K1 K2 K1 K2

Gas inlet

fittings

X1 OUTPUT

INTERFACE

24 V

max. W

OUT

CROSS COMP.

12+ 1

Fig. 5-3a: BINOS® 100 (M), OXYNOS® 100 (EO2), HYDROS® 100, gas connections

X2 OUTPUT

INTERFACE

X1 OUTPUT

Gas outlet

fittings

Gas inlet

fittings

5 - 6

24 V

max. 40 W

12+1

X3 OUTPUT

MADE I N GERMANY

Fig. 5-3b: OXYNOS® 100 (PO2), gas connections

OUT

Gas outlet

fittings

ETC00781(4) Series 100 e 02/2004

PREPARATION

GAS CONNECTIONS

Gas inlet

fittings

Gas outlet

fittings

Fig. 5-3c: BINOS® 100 2M, standard gas connections

Wall mounting holder

ETC00781(4) Series 100 e 02/2004

Gas connections

Fig. 5-3d: BINOS® 100 F, standard gas connections

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: All necessary gases have to be connected at the corresponding solenoid valve at an overpressure of 50 - max. 500 hPa. For 2 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:

common gas outlet

(to standard gas inlet K1)

Solenoid valve:

span gas 1

Solenoid valve:

span gas 2

5 - 8

Solenoid valve:

sample gas

Solenoid valve:

zero gas

Fig. 5-4a: BINOS® 100 2M (version A), gas connections with solenoid valve option

ETC00781(4) Series 100 e 02/2004

K1 K2 K1 K2

PREPARATION

GAS CONNECTIONS

Solenoid valve:

span gas 1

IN OUT

X1 OUTPUT

IN/OUT

X2 OUTPUT X3 OUTPUT

DURCHFLUSS MAX.1L/MI N

ANALOG I N

SPAN 1

SPAN 2

SAMPLE

ZERO

OUT

24V max. 1 2

Fig. 5-4b: BINOS® 100 2M (version B), gas connections with solenoid valve option

Solenoid valve:

Span gas 1

channel 1

Solenoid valve:

not used

ANALOG IN

SPAN 1

Solenoid valve:

span gas 2

Solenoid valve:

common gas outlet

(to standard gas inlet K1)

Solenoid valve:

sample gas

Solenoid valve:

zero gas

Solenoid valve:

not used

Solenoid valve:

Span gas 2

channel 2

Solenoid valve:

common gas outlet

channel 1

(to standard gas inlet K1)

Solenoid valve:

sample gas

channel 1

Solenoid valve:

zero gas

channel 1

SPAN 2

SAMPLE

ZERO

OUT

24V 120W

OUT

SPAN 2

SAMPLE

ZERO

Solenoid valve:

Common gas outlet

channel 2

(to standard gas inlet K2)

Solenoid valve:

sample gas

channel 2

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

5 - 9

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

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 of flammable samples into this equipment could result in explosion,

causing severe personal injury, death or property damage !

Consult factory if flammable samples are to be measured !

Z Purge kit is designed for protection against the invasion of 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.

P Connect purge gas (air or N2) 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.

P 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 l/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 scfh (8.5 l/min.). This will provide an enclosure over-pressure of approx. 0.24 inch H2O (0.6 hPa) for continuous purge.

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 - 10

ETC00781(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 (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 CSAC/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 / EExp approved “purge system” for ex zone 1) and in section “Safety Summary, subsection VII.!

ETC00781(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 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 of the units!

Take care the wall the unit is intended to be installed at is solid and stable to hold the units!

550

492

approx. 355

300

332

Glands

(connection cables)

Fig. 5-5: Dimensional sketch / Drill drawing BINOS® 100 F Standard version

[all dimensions in mm]

5 - 12

ETC00781(4) Series 100 e 02/2004

ADDITIONAL HINTS ON BINOS

100 F (FIELD HOUSING)

5.4.2 Electrical Connections

Be sure to observe the safety precautions and warnings !

Verify, that the cable glands together with installed cables are hermetic to ensure protection class IP 65 (according to IEC 60529). The permissible outside diameters of the cables are 7 to 12 mm !

a) Mains Supply

PREPARATION

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.

P Open the analyzers front door.

P Insert the 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

(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) ! 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.

cable glands

for data lines

cable gland

for mains line

Wall mounting

holder

ETC00781(4) Series 100 e 02/2004

Front door

Gas connections

Fig. 5-6: BINOS® 100 F, cable glands for lines (side view from left)

5 - 13

PREPARATION

ADDITIONAL HINTS ON BINOS® 100 F (FIELD HOUSING)

b) Optional Signal Lines

This are analog outputs, digital inputs/outputs and serial interfaces.

P Open the analyzer's front door.

P 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 F !

Use only shielded cables for signal lines! To ensure proper electromagnetic compatibility (EMC) it is recommended to follow the installation steps given below.

All unused cable glands need to be sealed using a sealing plug (part no. ETC00791 or similiar) Unused cable gland openings in the enclosure need to be covered using a special screw (part no. ETC 000790 or similiar).

Cable Gland Assembly Instruction for Shielded Cables

1. Strip the cable insulation

2. Uncover the shielding

5 - 14

3. 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.

5. Stick the fixing

element into the neck and fix the gland.

ETC00791

Cable gland sealing plug

ETC00790

Cable gland allen screw sealing plug

ETC00781(4) Series 100 e 02/2004

PREPARATION

Terminal strips for

data lines

X11

F100.1

F100.2

X10

4321

Interface

Serial out

Terminal strip Interface:

serial interface option

Power supply

ETC00781(4) Series 100 e 02/2004

Fig. 5-7: BINOS® 100 F, Data line connections

Inside view from front (detail, without front door)

5 - 15

PREPARATION

ADDITIONAL HINTS TO BINOS

100 F (FIELD HOUSING)

Terminal strip X2:

analog outputs

Terminal strip X3:

digital outputs

X2 Analog out

X3 Digital out

X1 Status

Tterminal strips

for mains cord

N L

Powerline filter

(connection of L and N of mains line)

5 - 16

Terminal strip X1:

output (status) relays option

Ground conductor pin

(PE mains line)

Fig. 5-8: BINOS® 100 F, Connection data lines / mains line

(inside view, left side panel)

ETC00781(4) Series 100 e 02/2004

SWITCHING ON

GENERAL

6. Switching On

6.1 General

Be sure to observe the safety precautions and warnings !

Once the instrument has been correctly assembled and installed in 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)

Finally either concentration values or error messages will be displayed If as a result of a battery fault the 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:

R entry of the desired system parameters, R 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 24 V DC Supply

The analyzers of series 100 (with except of 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.

P Connect power supply and analyzer (Fig. 6-1, Plug 24 V DC).

Verify correct polarity before operation (Fig. 29-1) !

P Connect mains line and power supply.

Be sure to observe the safety precautions and warnings given by

manufacturer of power supply !

6.3 230/120 V AC Supply

X1 OUTPUT

INTERFACE

X2 OUTPUT

24 V

max. W

12+ 1

X3 OUTPUT

Plug 24 V DC

Input

6 - 2

MADE I N GERMANY

Fig. 6-1a: BINOS® 100 (M), OXYNOS® 100 (EO2), HYDROS® 100, Voltage supply

ETC00781(4) Series 100 e 02/2004

SWITCHING ON

24 V DC SUPPLY

Plug 24 V DC

Input

X2 OUTPUT

INTERFACE

X1 OUTPUT

24 V

max. 40 W

Fig. 6-1b: OXYNOS® 100 (PO2), Voltage supply

OUT

K1 K2 K1 K2

DIGITAL IN

IN OUT

X1 OUTPUT

IN/OUT

X2 OUTPUT X3 OUTPUT

DURCHFLUSS MAX. 1 L/ MIN

ANALOG I N

SPAN 1

SPAN 2

SAMPLE

ZERO

OUT

24V

max.120W

V+ V-

E1 E2

E3 E4

E5 E6 E7

FB+ FBFB+ FB-

Plug 24 V DC

Fig. 6-1c: BINOS® 100 2M (version B) with external power supply, Voltage supply

Input

ETC00781(4) Series 100 e 02/2004

6 - 3

SWITCHING ON

230/120 V AC SUPPLY

6.3.1 BINOS® 100 2M

The analyzer BINOS® 100 2M is optional lly equipped with an internal “autoranging” power supply and is specified for an operating voltage of 230 V AC or 120 V AC resp., 47-63 Hz.

For supply of external components / analyzers there is built in a 24 VDC outlet (a 3-pole XLR flange, female, max. 2 A).

P Connect internal power supply and external components (Fig. 6-2, 24 V DC out).

Verify correct polarity for 24 V DC supply to external components before operation (Section 29.) !

P 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 of your power supply line ! The socket outlet shall be installed near the equipment.

6 - 4

ETC00781(4) Series 100 e 02/2004

SWITCHING ON

230/120 V AC SUPPLY

Socket 24 V DC out

Input

230/120 V AC

POWER

Fig. 6-2: BINOS® 100 2M (version A) shown with internal power supply, Voltage supply

6.3.2 BINOS® 100 F

The analyzer is specified for an operating voltage of 230 V AC or 120 V 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

ETC00781(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 BINOS100® 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 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.

ETC00781(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 in 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: 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

Emerson Process Management BINOS 100 F, BINOS 100 M, BINOS 100, HYDROS 100, BINOS 100 2M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY SUMMARY

I. Intended Use Statement

II. Safety Symbols

III. General

V. Supply Voltage

VI. Analyzer specific notes for the user

VII. BINOS® 100 F specific notes for use in hazardous areas (EX Zones)

VII.a Z purge for CSA-C/US Ex Zone 2 Non-Flammable Atmospheres

VIII. Additional notes for service / maintenance

General Overview

a) Software Versions

b) Housing Versions

Area Classification

a) General Purpose

b) Hazardous Areas

Ex Zone 2

Ex Zone 1

1. Technical Description

1.1 Front Panel

1.2 Rear Panel

1.3.1 Internal Gas Paths

a) Gas Path Material

b) Gas Path Layout (internal tubing)

2. Measuring Principle

2.1 IR Measurement

2.1.1 Interference Filter Correlation (IFC Principle)

2.1.2 Opto-Pneumatic Measuring Principle

2.1.3 Technique

2.2 Oxygen Measurement

2.2.1 Paramagnetic Measurement

2.2.2 Electrochemical Measurement

2.3 Thermal Conductivity Measurement

2.3.1 Sensor Design

2.3.2 Analysis Cell

2.3.3 Measurement Method

3.1 Photometer with Pyroelectrical Detector (Solid-state detector)

3.2 Photometer with Gas Detector

5. Preparation of Start-up

5.1 Installation Site

5.2 Gas Conditioning (Sample Handling)

5.2.1 Fine Dust Filter (Option BINOS® 100 2M/F)

5.2.2 Gas Sampling Pump (Option BINOS® 100 2M/F)

5.2.3 Pressure Sensor (Option)

5.2.4 Gas Flow

5.3 Gas Connections

5.3.3 Purge gas connection of BINOS® 100 F for Ex zones

5.4 Additional Hints to BINOS® 100 F (Field Housing)

5.4.1 Wall Mounting

5.4.2 Electrical Connections

6. Switching On

6.1 General

6.2 24 V DC Supply

6.3 230/120 V AC Supply

6.3.1 BINOS® 100 2M

6.3.2 BINOS® 100 F

7. Key Functions

7.1 FUNCTION