Rosemount BINOS 100 Series Analyzers including OXYNOS 100, HYDROS 100 and CAT 100-5th Ed. Manuals & Guides

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Instruction Manual

HAS1xE-IM-HS April 2008

BINOS® 100 Series Gas Analyzers

OXYNOS® 100, HYDROS® 100, CAT 100

BINOS® 100, BINOS® 100 M

BINOS® 100 2M, BINOS® 100 F

www.EmersonProcess.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Emerson Process Management 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 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 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.

· T o ensure proper performance, use qualified personnel to inst all, operate, update, program, and maintain the product.

· When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process Management. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR W ARRANTY. 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. 3rd Edition 2/2007 4th Edition 12/2007

5th Edition 4/2008

Emerson Process Management 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

Instruction Manual

HAS1xE-IM-HS 03/2005

This instruction manual provides information about BINOS® 100 series gas analyzers concerning subassemblies, functions, procedures, installation, operation and maintenance.

This instruction manual covers several BINOS® 100 series analyzer variations and therefore may describe configurations and/or options not part of your specific analyzer.

Installation and operation of instruments intended to be installed and operated in HAZARDOUS AREAS is NOT COVERED by this instruction manual, but part of the specific instruction manual shipped together with such analyzers because of the special requirements for working in hazardous environments!

BINOS® 100 Series

PREAMBLE

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc.

If not strictly observed, could result in injury , death, or longterm health hazards of personnel.

NOTE

Highlights an essential operating procedure, condition or statement.

Highlights an operation or maintenance procedure, practice, condition, statement, etc.

If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

Emerson Process Management Manufacturing GmbH & Co. OHG S-I

Instruction Manual

HAS1xE-IM-HS

BINOS® 100 Series

IMPORTANT

SAFETY INSTRUCTIONS

WIRING AND INSTALLATION OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Volt age Directive. Non-EU states should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external, where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times.

3. T o ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect a fault situation. The circuit breaker may also include a mechanically operated isolating switch. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.

all circuits carrying conductors during

03/2005

4. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then by trained service personnel only .

5. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.

6. Where equipment or covers are marked with the symbol to the right, refer to the Instruction Manual for instructions.

7. Further graphical symbols used in this product:

Elektrostatic discharge (ESD)

Harmful (to Health)!

Explosion Hazard!

Toxic!

Heavy Instrument!

Disconnect from Mains!

All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

Emerson Process Management Manufacturing GmbH & Co. OHGS-II

Instruction Manual

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OPERATING AND MAINTAINING THIS APPARATUS

BINOS® 100 Series

SAFETY INSTRUCTIONS

This instrument has left the factory in compliance with all applicable safety regulations. To maintain this operating condition, the user must strictly follow the instructions and consider the warnings in this manual or provided on the instrument.

Before switching on the instrument, verify that the electrical supply voltage matches the instrument´s operating voltage as set in the factory .

Any interruption in the instrument´s ground line, whether inside or outside the instrument, or removal or interruption of its ground line connection, could result in hazardous operating conditions. Intentionally interrupting the instrument´s protective ground is strictly prohibited.

Opening cover panels could expose voltagecarrying components. Connectors may also be under voltage. The instrument must be disconnected from all electrical supplies before attempting any calibrations, maintenance operations, repairs or component replacements requiring opening of the instrument. Any calibrations, maintenance operations, or repairs that need the instrument to be opened while connected to electrical supplies should be subject to qualified technicians familiar with the hazards involved only!

Observe all applicable regulations when operating the instrument from an autotransformer or variac.

Substances hazardous to health may emerge from the instrument‘s exhaust. Please pay attention to the safety of your operation personnel. Protective measures must be taken, if required.

Use only fuses of the correct type and current ratings as replacements. Using repaired fuses and short circuiting of fuse holders is prohibited.

Emerson Process Management Manufacturing GmbH & Co. OHG S-III

Instruction Manual

BINOS® 100 Series

SAFETY INSTRUCTIONS

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INTENDED USE STATEMENT

BINOS ® 100 series gas analyzers are intended to be used as analyzers for industrial

purposes. They must not be used in medical, diagnostic or life support applications, and no independent agency certifications or approvals are to be implied as covering such applications!

SAFETY SUMMARY

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

may be impaired.

AUTHORIZED PERSONNEL

T o avoid loss of life, personal injury and damage to this equipment and on-site property , do

not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training. Save these instructions.

ELECTRICAL SHOCK HAZARD !

Do not operate without covers secure. Do not open while energized. Installation requires access to live parts which can cause death or serious injury.

For safety and proper performace this instrument must be connected to a properly grounded three-wire source of power.

TOXIC GASES !

This unit’s exhaust may contain toxic gases such as sulfur dioxide. These gases can cause serious injuries.

Aviod inhalation of the exhaust gases at the exhaust fitting. Connect exhaust outlet to a safe vent. Check vent line and connections for leakage. Keep all fittings tight to avoid leaks. See section 9-2, page 9-3 for leak test information.

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Instruction Manual

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Do not operate nor install these instruments in hazardous areas without additional measures!

BINOS® 100 F and CAT 100 -- HEAVY INSTRUMENTS !

The analyzer variations BINOS mounted and/or outdoor installed weigh up to 30 kg resp. 70 kg, depending on included options!

SAFETY INSTRUCTIONS

EXPLOSION HAZARD !

100 F and CAT 100 intended to be wall

BINOS® 100 Series

Use two person and/or suitable tools for transportation and lifting these instruments!

Take care to use anchors and bolts specified to be used for the weight of the units!

T ake care the wall or stand the unit is intended to be inst alled at is solid and stable to hold the units!

HIGH TEMPERATURES !

While working at photometers and/or thermostated components inside the analyzers hot components may be accessible!

Emerson Process Management Manufacturing GmbH & Co. OHG S-V

BINOS® 100 Series

SAFETY INSTRUCTIONS

GASES AND GAS CONDITIONING

T ake care of the safety instructions applicable for the gases (sample gases and test gases) and for the gas bottles containing these gases!

Before opening gas paths they must be purged with ambient air or neutral gas (N2) to avoid hazards caused by toxic, flammable, explosive or harmful to health sample gas components!

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EXPLOSION HAZARD !

Supplying flammable gases of concentrations above 25 % of lower explosion limit (LEL) we recommend to utilize one or more of the following measures:

• Purging the housing with inert gas

• Internal tubing with stainless steel

• Flame arrestors at gas input and output fittings

• Intrinsically safe paramagnetical or thermal conductivity sensors

Supplying explosive gases is not permitted !

Emerson Process Management Manufacturing GmbH & Co. OHGS-VI

Instruction Manual

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SAFETY INSTRUCTIONS

POWER SUPPLY

V erify the mains voltage at site of inst allation corresponds to the analyzer´s rated voltage as given on the nameplate label!

V erify the safety instruction given by power supply unit manufacturer !

Instruments with External Power Supply Unit

BINOS® 100 Series

The mains socket has to be nearby the power supply unit and easily accessible! Disconnecting from mains requires unplugging the power plug!

To comply with the CE mark requirements use only power supply units of type VSE 2000, UPS 01 T, DP 157, SL5, SL10 (DP 157 and SL for rack installation only) or equivalent units. Equivalent units must provide SELV output voltages!

Verify proper polarity when connecting DC 24 V operated analyzers !

Instruments with Internal Power Supply Unit

ELECTRICAL SHOCK HAZARD !

These instruments provide a protective earth terminal. To prevent electrical shock hazards the instrument must be connected to a protective earth. Therefore the instrument has to be connected to mains by using a three wire mains cable with earth conductor!

Any interruption of the earth connector inside or outside the instrument or disconnecting the earth terminal may cause potential electrical shock hazzard! Intended interruption of protective earth connections is not permitted!

Emerson Process Management Manufacturing GmbH & Co. OHG S-VII

BINOS® 100 Series

ADDITIONAL HINTS FOR MODELS BINOS® 100 F AND CA T 100

Installation and connecting mains and signal cables are subject to qualified personnel only taking into account all applicable standards and legislative requirements!

Failure to follow may cause warranty invalidation, property damage and/or personal injury or death! Mains and signal cables need to be connected to internal srew terminals requiring to work at open housing near life parts!

Instruction Manual

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SAFETY INSTRUCTIONS

Installation of this instrument is subject to qualified personnel only , familiar with the resulting potential risks!

These gas analyzer do not provide a mains power switch and are operable when connected to power.

These gas analyzers do not provide a mains switch! A mains switch or circuit breaker has to be provided in the building installation. This switch has to be installed near by analyzer , must be easily operator accessible and has to be assigned as disconnector for the analyzer.

ADDITIONAL HINTS FOR MODEL BINOS® 100 F

Cables for external data processing must be double insulated for mains voltage when used inside the instrument! If double insulation is not available signal cables inside the analyzer must be installed in a way that a distance of at least 5 mm is ensured permanently (e.g. by utilizing cable ties).

Emerson Process Management Manufacturing GmbH & Co. OHGS-VIII

Instruction Manual

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Supplying external components utilizing the DC 24 V power output provided by the BINOS® 100 2M internal power supply unit requires a fuse to be connected in series to the load limiting the power to 2 A max!

Verify proper DC 24 V polarity when connecting any external load!

BINOS® 100 Series

SAFETY INSTRUCTIONS

ADDITIONAL HINTS FOR MODEL BINOS® 100 2M

Emerson Process Management Manufacturing GmbH & Co. OHG S-IX

BINOS® 100 Series

General Operating Instructions

General operating instructions

DANGER TO LIFE ! EXPLOSION HAZARD ! V erify all gas lines are connected as described within this manual and tight! Improper gas connections may cause explosion, serious injury or death! Exhaust may contain hydrocarbons and other toxic gases, e.g. carbon

monoxide. Carbon monoxide is toxic!

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• Installation area has to be clean, free from moisture, excessive vibration and frost-protected. T ake care to meet the permissible ambient temperatures as given in the technical data section! Instruments must not be exposed to direct sunlight, fluorescent lamps nor sources of heat.For outdoor installation it is recommended to mount the instruments into a cabinet. At least sheltering against rain is required. Do not cover venting openings and take care to mount the instrument in a distance to walls not affecting venting.

• Do not interchange gas inlet and outlet! All gases must be conditioned before supplying! When supplying corrosive gases ensure that gas path components are not affected!

• Max. permissible gas pressure: 1,500 hPa, except with integrated valve blocks (see hint at page 3-4) and/or paramagnetic Oxygen sensor (see page 2-15)!

• Exhaust lines must be installed in a descending way , need to be pressureless, frost-protected and in compliance with applicable legislative requirements!

• When it is necessary to open gas paths seal the analyzer‘s gas fittings by using PVC caps to avoid pollution of the internal gas path by moisture, dust, etc.

• T o stay in compliance with regulations regarding electromagnetic compatibility it is recommended to use only shielded cables, as optionally available from Emerson Process Management or equivalent. Customer has to take care that the shield is connected in proper way (see section 3-5). Shield and signal connector enclosure need to be conductively connected, submin-d plugs and sockets must be screwed to the analyzer.

• Using external submin-d-to-terminal adaptor elements (option) affects electromagnetic compatibility . In this case the customer has to take measures to stay in compliance and has to declare conformity , when required by legislation (e.g. European EMC Directive).

Emerson Process Management Manufacturing GmbH & Co. OHGS-X

Instruction Manual

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Magnetically Operated Front Panel

Persons with cardiac pacemakers should absolutely avoid magnetic fields !

Negative effects on persons beyond those described above caused by magnetic fields are not known. It is presumed that persons showing allergic reaction on contact with ceramic or metallic material show the same behavior on contact with magnetic material.

BINOS® 100 Series

DANGER TO LIFE !

Permanent magnets are surrounded by magnetic fields. These magnetic fields can disturb and even destroy sensitive electronic measuring devices, but also mechanical watches, credit cards, etc.

Usually a distance of 0.5 m is enough to avoid damages. All sintered permanent magnets are hard and brittle. Hitting of sintered permanent magnets by the magnetic attraction causes splitting into fragments with many sharp edges. This especially occurs with high energy magnets, and can also cause skin bruises by high attraction.

High energy magnets made of rare-earth materials have to be stored dry, otherwise the surfaces would oxidise. Unprotected operation in a humid environment may cause corrosion. Avoid damaging the protective galvanic coating.

A storage in a hydrogen atmosphere destroys these magnets. A demagnetisation is caused when permanent magnet materials have been exposed in a radioactive radiation for a long time.

For air transportation of magnetic material the IATA instructions have to be observed:

Magnetic fields are not allowed to penetrate the package, if necessary the magnets have to be shorted using a metal plate.

Emerson Process Management Manufacturing GmbH & Co. OHG S-XI

BINOS® 100 Series

Instruction Manual

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Emerson Process Management Manufacturing GmbH & Co. OHGS-XII

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

Table of Contents

PREAMBLE ................................................................................................................... I

DEFINITIONS ................................................................................................................... I

SAFETY INSTRUCTIONS..................................................................................................II

CHAPTER 1 TECHNICAL DESCRIPTION................................................................... 1-1

1-1 General Description................................................................................................................1-1

1-2 BINOS® 100, BINOS® 100 M, OXYNOS® 100, HYDROS® 100.............................................. 1-5

1-3 BINOS® 100 2M ......................................................................................................................1-9

1-4 BINOS® 100 F.......................................................................................................................1-15

1-5 CAT 100 ................................................................................................................................ 1-22

1-6 Internal Gas Paths ................................................................................................................ 1-30

1-6-1 Gas Paths Materials ........................................................................................................... 1-30

1-6-2 Safety Filter.........................................................................................................................1-30

1-6-3 Fittings.................................................................................................................................1-30

1-6-4 Piping .................................................................................................................................. 1-30

1-6-5 Gas Path Variations............................................................................................................ 1-31

1-7 Technical Data ...................................................................................................................... 1-34

1-7-1 Common Technical Data .................................................................................................... 1-34

1-7-2 Model Specific Data ............................................................................................................ 1-36

1-7-2-1 BINOS® 100, BINOS® 100 M, OXYNOS® 100, HYDROS® 100 .......................................1-36

1-7-2-2 BINOS® 100 2M................................................................................................................ 1-41

1-7-2-3 BINOS® 100 F .................................................................................................................. 1-48

1-7-2-4 CAT 100 ........................................................................................................................... 1-55

1-7-2-5 External Power Supply Unit for Tabletop and Rack Mount Analyzers.............................. 1-63

1-7-2-6 5 A Power Supply Unit for DIN Rail Installation ............................................................... 1-65

1-7-2-7 External 10A Power Supply Unit for DIN Rail Installation .................................................1-67

1-7-2-8 10 A Tabletop Power Supply Unit .................................................................................... 1-69

1-7-3 Specifications at the Nameplate Label ............................................................................... 1-70

CHAPTER 2 MEASURING PRINCIPLES..................................................................... 2-1

2-1 Infrared Measurement (IR)...................................................................................................... 2-1

2-1-1 Interference Filter Correlation (IFC)...................................................................................... 2-1

2-1-2 Opto Pneumatic Measuring Principle................................................................................... 2-3

2-1-3 Technical Implementation .....................................................................................................2-4

2-2 Oxygen Measurement ............................................................................................................2-9

2-2-1 Paramagnetic Measurement ................................................................................................ 2-9

2-2-2 Electrochemical Measurement .......................................................................................... 2-11

2-2-3 Special Hints on Oxygen Sensors ..................................................................................... 2-13

2-3 Thermal Conductivity Measurement..................................................................................... 2-14

2-3-1 Principle of Operation ......................................................................................................... 2-14

2-3-2 Technical Implementation ...................................................................................................2-15

2-4 Measurement Specification ..................................................................................................2-16

Emerson Process Management Manufacturing GmbH & Co. OHG TOC-1

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Table of Contents

CHAPTER 3 INST ALLATION....................................................................................... 3-1

3-1 Abstract................................................................................................................................... 3-1

3-2 Gas Conditioning .................................................................................................................... 3-2

3-3 Gas Connections....................................................................................................................3-3

3-4 Analyzer Specific Instructions ................................................................................................. 3-5

3-4-1 1/4 19" Instruments ............................................................................................................... 3-5

3-4-2 1/2 19" Instruments ............................................................................................................... 3-9

3-4-3 BINOS® 100 F ..................................................................................................................... 3-14

3-4-4 CAT 100 .............................................................................................................................. 3-21

3-5 Wiring Signal Terminals ........................................................................................................ 3-27

3-5-1 Electrical Connections in General ...................................................................................... 3-27

3-5-2 Wiring Inductive Loads ....................................................................................................... 3-29

3-5-3 Driving Multiple Loads ........................................................................................................3-29

3-5-4 Driving High Current Loads ................................................................................................ 3-30

CHAPTER 4 OPERA TION........................................................................................... 4- 1

4-1 Abstract................................................................................................................................... 4-1

4-2 Button "FUNCTION"................................................................................................................4-4

4-3 Button "ENTER"......................................................................................................................4-6

4-4 Buttons "INPUT - CONTROL" ................................................................................................ 4-6

4-5 Button "PUMP"........................................................................................................................ 4-7

4-6 Software Menu Structure ........................................................................................................ 4-7

4-7 Magnetically Operated Front Panel ........................................................................................ 4-9

4-7-1 Front Panel Elements ........................................................................................................... 4-9

4-7-2 Accessory ............................................................................................................................. 4-9

4-7-3 Operating the Front Panel................................................................................................... 4-10

4-7-4 Storing the Actuator Tool..................................................................................................... 4-11

CHAPTER 5 ST ARTUP ............................................................................................... 5-1

5-1 Abstract................................................................................................................................... 5-1

5-2 Software Menu Structure ........................................................................................................ 5-2

5-3 Checking System Parameter Settings...................................................................................5-3

5-3-1 Menu "System Parameter" .................................................................................................. 5-3

5-3-2 Menu "Druckkorrektur" ........................................................................................................ 5-4

5-3-3 Menu "Internal Cross Compensation´" ................................................................................ 5-4

5-3-4 Menu "Calibrate Cross Compensation" ..............................................................................5-5

5-3-5 Menu "Hold" ......................................................................................................................... 5-6

5-3-6 Menu "Automatic Calibration"..............................................................................................5-6

5-3-7 Menu "Tolerance Check"..................................................................................................... 5-7

5-3-8 Menu "Display Off" .............................................................................................................. 5-8

5-3-9 Menu "Gas Path Purge Time" ............................................................................................. 5-9

5-3-10 Menu "Access Code" ..........................................................................................................5-9

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Table of Contents

5-3-11 Menus "Response Time t90"........................................................................................... 5-10

5-3-12 Menu "Reset"..................................................................................................................... 5-11

5-3-13 Menu "Software Revision" ................................................................................................. 5-12

5-3-14 Menus "Analyzer Serial Number"......................................................................................5-12

5-3-15 Menu "Pump Status" *) ...................................................................................................... 5-13

5-3-16 Menu "Pump Control" *) ....................................................................................................5-13

5-4 Analog Outputs .................................................................................................................... 5-14

5-4-1 Menu "Life-Zero for Analog Outputs"................................................................................. 5-15

5-4-2 Menu "Adjusting Analog Outputs"......................................................................................5-16

5-4-3 Menu "Analog Output Offset" ............................................................................................5-18

5-4-4 Menu "Analog Output Upper Limit".................................................................................... 5-19

5-5 Digital Outputs ............................................................................................................. ......... 5-20

5-5-1 Concentration Threshold Operation Modes ....................................................................... 5-20

5-5-2 Setting Concentration Thresholds ...................................................................................... 5-24

5-5-3 Valve Control ....................................................................................................................... 5-26

5-5-4 Wiring Digital Outputs.........................................................................................................5-26

5-6 Calibration Procedures.........................................................................................................5-27

5-6-1 Manual Calibration .............................................................................................................. 5-28

5-6-1-1 Zero Calibration ................................................................................................................5-28

5-6-1-2 Sp an Calibration...............................................................................................................5-30

5-6-2 Time Controlled Calibration ................................................................................................ 5-32

5-6-2-1 Zero Calibration ................................................................................................................5-32

5-6-2-2 Combined Zero and Span Calibration.............................................................................. 5-34

5-7 Remote Calibration (Option)................................................................................................. 5-35

5-8 Measuring ............................................................................................................................ 5-36

5-9 Taking Out of Operation ........................................................................................................ 5-37

CHAPTER 6 DESCRIPTION OF OPTIONS ................................................................. 6-1

6-1 Relay Status Signals ........................................................................................................ ....... 6-2

6-2 Serial Interface........................................................................................................................6-3

6-2-1 Enabling / Disabling Serial Interface.....................................................................................6-5

6-2-2 Configuring the Interface....................................................................................................... 6-5

6-2-3 Communication.....................................................................................................................6-7

6-2-3-1 Telegram Syntax ................................................................................................................ 6-8

6-2-3-2 Status Telegram ................................................................................................................. 6-9

6-2-3-3 Number Formats .............................................................................................................. 6-10

6-2-3-4 Longitudinal Parity Test .................................................................................................... 6-10

6-2-3-5 Command Syntax ............................................................................................................ 6-10

6-2-3-6 List of Available Commands ............................................................................................ 6-11

6-2-3-7 Reply Telegrams .............................................................................................................. 6-12

6-2-3-7-1 Status Messages (Command 030) ................................................................................ 6-12

6-2-5-7-2 Pump Status (Command 008) *).................................................................................... 6-13

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Table of Contents

6-3 Option Digital Inputs / Foundation™ Fieldbus ...................................................................... 6-14

6-3-1 Digital Inputs .......................................................................................................................6-14

6-3-2 Starting a Calibration Procedure......................................................................................... 6-15

6-3-3 Valve Control ....................................................................................................................... 6-15

6-3-4 Pump Control......................................................................................................................6-15

6-3-5 Foundation™ Fieldbus.......................................................................................................6-16

6-4 Cross Compensation (TCD) ................................................................................................ 6-17

6-5 Fine Dust Filter / Needle Valve...........................................................................................6-18

6-5-1 Fine Dust Filter....................................................................................................................6-18

6-5-2 Needle Valve....................................................................................................................... 6-18

6-6 Flowmeter.............................................................................................................................6-19

CHAPTER 7 BUG FIXING ........................................................................................... 7-1

7-1 Error Codes ............................................................................................................................ 7-1

7-2 Other Problems ...................................................................................................................... 7-6

CHAPTER 8 TROUBLESHOOTING ON ELECTRONICS............................................ 8-1

8-1 Getting Access to Internal Analyzer Components .................................................................. 8-2

8-1-1 BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 ............................................................. 8-2

8-1-2 BINOS® 100 2M ....................................................................................................................8-8

8-1-3 BINOS® 100 F..................................................................................................................... 8-14

8-1-4 CAT 100 .............................................................................................................................. 8-16

8-2 Measuring Points .................................................................................................................. 8-23

8-2-1 Measuring Points at BKS ...................................................................................................8-23

8-2-1-1 Supply voltage +6 V ......................................................................................................... 8-23

8-2-1-2 Positive reference voltage................................................................................................ 8-23

8-2-1-4 Temperature sensor ......................................................................................................... 8-25

8-2-1-3 Negative reference voltage .............................................................................................. 8-25

8-2-1-5 Light barrier signal............................................................................................................ 8-25

8-2-1-6 Analog Preamplifier ..........................................................................................................8-26

8-2-2 Measuring Points at OXS (Electrochemical Oxygen Measurement) ............................... 8-27

8-2-2-1 Sensor Signal................................................................................................................... 8-27

8-3 Position and Assignment of Connectors on Electronics Boards.......................................8-28

8-3-1 BKS .....................................................................................................................................8-28

8-3-1-1 IR Measurement w/o Oxygen Sensor.............................................................................. 8-29

8-3-1-2 Oxygen Measurement w/o IR .......................................................................................... 8-29

8-3-1-3 Combination of IR and Oxygen Measurement................................................................ 8-29

8-3-1-4 TCD w/o IR channel......................................................................................................... 8-29

8-3-1-5 Combined IR and TCD Measurement ............................................................................ 8-30

8-3-1-6 Combined Oxygen and TCD Measurement .................................................................... 8-30

8-3-2 OXS (Electrochemical Oxygen Measurement) ................................................................. 8-31

8-3-3 WAP 100 (TC Measurement) ............................................................................................. 8-32

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Table of Contents

8-4 BKS 20 Jumper Configuration..............................................................................................8-33

CHAPTER 9 MAINTENANCE ...................................................................................... 9-1

9-1 Replacing the Fine Dust Filter ................................................................................................ 9-2

9-2 Leak Testing ............................................................................................................................ 9-3

9-3 Cleaning the Analyzer´s Outside ............................................................................................9-4

9-4 Replacing the Electrochemical Oxygen Sensor .................................................................... 9-5

9-4-1 Analyzer with Oxygen Measurement only, no IR Channel................................................... 9-6

9-4-2 Analyzer with Combined IR and Oxygen measurement......................................................9-7

9-4-3 Replacing the Sensor ........................................................................................................... 9-7

9-4-4 Reassembling the Sensor Unit ............................................................................................. 9-8

9-4-5 Sensor Amplifier Adjustment ................................................................................................ 9-8

9-5 Magnetically Operated Front Panel ........................................................................................ 9-9

APPENDIX A-1

A-1 Block Diagrams ......................................................................................................................A-2

A-1-1 BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 ............................................................ A -2

A-1-2 BINOS® 100 2M ................................................................................................................... A-3

A-1-3 BINOS® 100 F ...................................................................................................................... A-4

A-1-4 CAT 100............................................................................................................................... A-5

A-2 Declarations of Conformity .....................................................................................................A-9

A-2-1 BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 ............................................................ A -9

A-2-2 BINOS® 100 2M ................................................................................................................. A-10

A-2-3 BINOS® 100 F .....................................................................................................................A-11

A-2-4 CAT 100............................................................................................................................. A-12

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Instruction Manual

BINOS® 100 Series

HAS1xE-IM-HS

03/2005

T able of Illustrations

CHAPTER 1 TECHNICAL DESCRIPTION

Fig. 1-1: BINOS® 100 (M), OXYNOS® 100, HYDROS® 100, front side view ...................................... 1-6

Fig. 1-2: BINOS® 100 (M), OXYNOS® 100 (EO2), HYDROS® 100, rear side view............................1-7

Fig. 1-3: OXYNOS® 100 (PO2), rear side view...................................................................................1-8

Fig. 1-4: BINOS® 100 2M (standard version) front side view............................................................ 1-11

Fig. 1-5: BINOS® 100 2M, variation A (internal power supply) Rear side view with all options........1-12

Fig. 1-6: BINOS® 100 2M, variation B (external power supply) Rear side view with all options ...... 1-13

Fig. 1-7: BINOS® 100 2M (special variation), Rear side view with all options .................................1-14

Fig. 1-8: BINOS® 100 F Standard version, front side view................................................................ 1-18

Fig. 1-9: BINOS® 100 F Standard front panel incl. sample handling options....................................1-19

Fig. 1-10: BINOS® 100 FMagnetically operated front panel (option)...................................................1-20

Fig. 1-1 1: BINOS® 100 F Interior view (without components)............................................................ 1-21

Fig. 1-12: CAT 100 Exterior view......................................................................................................... 1-25

Fig. 1-13: CAT 100 (Dome and extender housing removed)..............................................................1-26

Fig. 1-14: CAT 100 Front panel ........................................................................................................... 1-27

Fig. 1-15: CAT 100 Junction box, interior view...................................................................................1-28

Fig. 1-16: CAT 100 Gas fittings and assignment ................................................................................ 1-29

Fig. 1-17: Single channel or serial tubing............................................................................................1-31

Fig. 1-18: Dual channel parallel tubing ................................................................................................ 1-31

Fig. 1-19: Single channel resp. serial tubing, with options.................................................................. 1-32

Fig. 1-20: Parallel tubing, with options ................................................................................................ 1-33

Fig. 1-21: BINOS® 100 (M) / OXYNOS® 100 / HYDROS® 100 dimensions........................................ 1-36

Fig. 1-22: Pin assignment 24 V DC input plug....................................................................................1-37

Fig. 1-23: Socket X2 pin assignment (analog signal outputs; standard) ............................................ 1-37

Fig. 1-26: Plug Analog IN pin assignment (cross compensation; option).......................................... 1-38

Fig. 1-25: Plug X3 pin assignment (digital outputs; standard) ............................................................ 1-38

Fig. 1-24: Connecting digital outputs................................................................................................... 1-38

Fig. 1-27: Socket X4 pin assignment (serial interface; option) ......................................................... 1-39

Fig. 1-28: Relay status signals, block diagram................................................................................... 1-40

Fig. 1-29: Plug X1 pin assignment (relay status signals; option)........................................................ 1-40

Fig. 1-30: BINOS® 100 2M dimensions...............................................................................................1-41

Fig. 1-31a: Pin assignment 24 V DC input plug ....................................................................................1-42

Fig. 1-31b: Pin assignment 24 V DC output socket.............................................................................. 1-42

Fig. 1-31c: IEC mains input plug...........................................................................................................1-42

Fig. 1-32: Socket X2 pin assignment (analog signal outputs; standard) ............................................ 1-43

Fig. 1-34: Plug Analog IN pin assignment (cross compensation; option).......................................... 1-44

Fig. 1-34: Plug X3 pin assignment (digital outputs; standard) ............................................................ 1-44

Fig. 1-33: Connecting digital outputs................................................................................................... 1-44

Fig. 1-36: Socket X4 pin assignment (serial interface; option) ......................................................... 1-45

Fig. 1-38: Plug X1 pin assignment (relay status signals; option)........................................................ 1-46

Fig. 1-37: Relay status signals, block diagram................................................................................... 1-46

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Fig. 4-1: BINOS® 100 (M), OXYNOS® 100, HYDROS Fig. 4-2: BINOS® 100 2M (standard version) front sid

Instruction Manual

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BINOS® 100 Series

T able of Illustrations

Fig. 1-39: Digital inputs (option), terminal assignment .......................................................................1-47

Fig. 1-40: Foundation™ Fieldbus (option), terminal assignment ........................................................ 1-47

Fig. 1-41: BINOS® 100 F dimensions .................................................................................................1-48

Fig. 1-42: Screw terminals for mains .................................................................................................. 1-48

Fig. 1-43: 9-pole adaptor element for signal cables; submin-d to screw terminals ...........................1-50

Fig. 1-44: Pin assignment adaptor element X 2 (analog signal outputs; standard)........................... 1-51

Fig. 1-45: Pin assignment adaptor element X3 (digital outputs; standard)........................................ 1-52

Fig. 1-47: Pin assignment adaptor element Analog IN (cross compensation; option) ...................... 1-52

Fig. 1-46: Connecting digital outputs................................................................................................... 1-52

Fig. 1-48: Pin assignment adaptor element X4 (serial interface; option).......................................... 1-53

Fig. 1-49: Relay status signals, block diagram................................................................................... 1-53

Fig. 1-50: Pin assignment adaptor X1 (relay status signals; option) ................................................. 1-53

Fig. 1-51: Digital inputs (option), terminal assignment .......................................................................1-55

Fig. 1-52: Foundation™ Fieldbus (option), terminal assignment ........................................................ 1-55

Fig. 1-53: CAT 100 dimensions................................................................................................... ........ 1-55

Fig. 1-54: CAT 100 junction box, interior view..................................................................................... 1-56

Fig. 1-55: Connecting digital outputs................................................................................................... 1-59

Fig. 1-56: Relay status signals, block diagram................................................................................... 1-61

Fig. 1-57: Power supply UPS 01 / 01 T dimensions........................................................................... 1-64

Fig. 1-58a: IEC mains input plug ........................................................................................................... 1-64

Fig. 1-58b: 24 V DC output socket Pin assignment.............................................................................. 1-64

Fig. 1-59: Power Supply SL05Dimensions......................................................................................... 1-67

Fig. 1-60: Power Supply SL 10 Dimensions ....................................................................................... 1-68

Fig. 1-61: 10 A Tabletop Power Supply Dimensions ........................................................................... 1-69

Fig. 1-62: Analyzer Nameplate Label (example)................................................................................. 1-70

CHAPTER 2 MEASURING PRINCIPLES

Fig. 2-1: Absorption bands of measured gases and transmission of interference filters................... 2-2

Fig. 2-2: Gas detector design principle............................................................................................... 2-3

Fig. 2-3: IR photometer assembly principle........................................................................................ 2-5

Fig. 2-4: Photometer assembly with pyroelectrical detector, dual channel ........................................ 2-7

Fig. 2-5: Photometer assembly with gas detector.............................................................................. 2-8

Fig. 2-6: Paramagnetic Oxygen detector, assembly principle.......................................................... 2-11

Fig. 2-7: Electrochemical sensor, assembly principle ...................................................................... 2-11

Fig. 2-8: Electrochemical reaction of Oxygen sensor ......................................................................2-12

Fig. 2-9: TC cell, Wheatstone Bridge ............................................................................................ .... 2-13

Fig. 2-10a: TC cell, exterior view, thermal isolation removed ............................................................... 2-15

Fig. 2-10b: TC cell, sectional view ........................................................................................................ 2-15

CHAPTER 3 INST ALLATION

Fig. 3-1: Bypass Mode Installation ...................................................................................................... 3-5

Fig. 3-2: BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 Dimensions........................................... 3-6

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100, front side view ...................................... 4-1

Instruction Manual

BINOS® 100 Series

HAS1xE-IM-HS

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T able of Illustrations

Fig. 3-3: BINOS® 100 (M), OXYNOS® 100 (EO2), HYDROS® 100 rear panel ................................... 3-6

Fig. 3-4: OXYNOS® 100 (PO2), rear panel......................................................................................... 3-8

Fig. 3-5: BINOS® 100 2M Dimensions .............................................................................................. 3-10

Fig. 3-6: BINOS® 100 2M, variation a (with internal power supply) Rear panel with all options .....3-10

Fig. 3-8: BINOS® 100 2M , special variation, Rear panel with all options ........................................ 3-12

Fig. 3-7: BINOS® 100 2M, variation b (with external power supply), Rear panel with all options ....3-13

Fig. 3-9: BINOS® 100 F Dimensions ................................................................................................ 3-15

Fig. 3-10: BINOS® 100 F, View at cable glands ................................................................................. 3-17

Fig. 3-1 1: BINOS® 100 F Power supply and power distribution.......................................................... 3-18

Fig. 3-12: Adaptor element, 9 pole ...................................................................................................... 3-19

Fig. 3-13a: BINOS® 100 F, Location of adaptor elements.................................................................... 3-20

Fig. 3-13b: BINOS® 100 F, Gas fittings at analyzer’s bottom side ....................................................... 3-20

Fig. 3-14: CAT 100, Dimensions......................................................................................................... 3-24

Fig. 3-15: CAT 100, Junction box, interior view................................................................................... 3-24

Fig. 3-16: CAT 100, Assignment of gas fittings and analyzer’s bottom view at gas fittings............... 3-27

Fig. 3-17: Shielded Signal Cable, shield connected at both ends ...................................................... 3-27

Fig. 3-19: Double-shielded Signal Cable, shields connected at both sides ....................................... 3-29

Fig. 3-18: Shielded Signal Cable, shield connected at one end ......................................................... 3-29

Fig. 3-20: Suppressor Diode for Inductive Loads ............................................................................... 3-29

Fig. 3-21: ”Serial” Wiring ..................................................................................................................... 3-30

Fig. 3-22: Running Supply Lines "Parallel”.......................................................................................... 3-30

Fig. 3-23: Driving High Current Loads................................................................................................. 3-30

CHAPTER 4 OPERA TION

Fig. 4-1: BINOS® 100 (M), OXYNOS® 100, HYDROS® 100, front side view ...................................... 4-1

Fig. 4-2: BINOS® 100 2M (standard version) front side view............................................................. 4-2

Fig. 4-3: Magnetically operated front panel ......................................................................................... 4-3

Fig. 4-4: BINOS® 100 Software Menus ............................................................................................... 4-5

Fig. 4-5: BINOS® 100 Series Software Menu Structure...................................................................... 4-8

Fig. 4-6: Magnetically operated frontpanel (CA T 100 version)............................................................ 4-9

Fig. 4-7: Magnetic actuator.................................................................................................................. 4-9

Fig. 4-8: Magnetic actuator, view at magnets .....................................................................................4-9

Fig. 4-9: Sensor details ..................................................................................................................... 4-10

Fig. 4-10: Vertically aligned, activating UP key.................................................................................... 4-11

Fig. 4-1 1: Horizontally aligned, activating DOWN key ........................................................................ 4-11

Fig. 4-12: Actuator stored when not in use ......................................................................................... 4-12

CHAPTER 5 ST ARTUP

Fig. 5-1: Software Menu Structure ......................................................................................................5-2

Fig. 5-2: Pin Assignment Socket X 2 (analog outputs) .................................................................... 5-14

Fig. 5-3: Thresholds defining a window ............................................................................................ 5-21

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BINOS® 100 Series

Table of Illustrations

Fig. 5- 4: HIGH and HIGH-HIGH alarm mode..................................................................................... 5-22

Fig. 5- 5: LOW and LOW-LOW alarm mode ................................................................................... 5-23

Fig. 5-7: Digital Outputs - External Wiring ........................................................................................ 5-26

Fig. 5-6: Pin Assignment X3 (digital outputs) ................................................................................... 5-27

CHAPTER 6 DESCRIPTION OF OPTIONS

Fig. 6-1: Relay status Signals, schematic .......................................................................................... 6-2

Fig. 6-2: Pin assignment X1 (relay status signals)............................................................................ 6-2

Fig. 6-3: Socket X4 - Pin Assignment (Serial interface)..................................................................... 6-4

Fig. 6-4: Digital Inputs, Pin assignments for BINOS® 100 2M .......................................................... 6-14

Fig. 6-5: Foundation™ Fieldbus, terminal assignment BINOS® 100 2M .......................................... 6-16

Fig. 6-6: Plug "Analog In", pin assignment (cross compensation) .................................................. 6-17

Fig. 6-7: Fine Dust Filter with Needle V alve at BINOS® 100 2M Front Panel.................................... 6-18

Fig. 6-8: Filter carrier with needle valve, view at screw for flow adjustment screw ........................ 6-18

Fig. 6-9: Flowmeters installed behind magnetically operated front panel.........................................6-19

CHAPTER 8 TROUBLESHOOTING ON ELECTRONICS

Fig. 8-1: 1/4 19" Housing..................................................................................................................... 8-2

Fig. 8-2: BINOS® 100, interior view (1 IR channel configuration)...................................................... 8-3

Fig. 8-3: BINOS® 100 M, interior view (IR channel & electrochemical Oxygen sensor)................... 8-4

Fig. 8-4: OXYNOS® 100, interior view (w/ paramagnetic Oxygen sensor)........................................ 8-5

Fig. 8-5: OXYNOS® 100, interior view, (dual channel w/ electrochemical Oxygen sensors)............. 8-6

Fig. 8-6: HYDROS® 100, interior view................................................................................................. 8-6

Fig. 8-7: BINOS® 100 2M..................................................................................................................... 8-8

Fig. 8-8: BINOS® 100 2M..................................................................................................................... 8-8

Fig. 8-9: BINOS® 100 2M (variation A), dual channel,interior view...................................................... 8-9

Fig. 8-10: BINOS® 100 2M (variation A), dual channel,interior view.................................................... 8-10

Fig. 8-1 1: BINOS® 100 2M (variation B), dual channel,interior view ................................................... 8-10

Fig. 8-13: BINOS® 100 2M (special version),dual channel, interior view ............................................ 8-12

Fig. 8-12: BINOS® 100 2M (variation B), dual channel, interior view .................................................. 8-13

Fig. 8-14: BINOS® 100 F, front side view ............................................................................................ 8-15

Fig. 8-15: BINOS® 100 F, photometer carriage slide .......................................................................... 8-15

Fig. 8-16: Junction box ........................................................................................................................ 8-17

Fig. 8-17: Dome, fixing screws ........................................................................................................... 8-17

Fig. 8-18: View at analyzer module..................................................................................................... 8-18

Fig. 8-19: Plate with detents................................................................................................................ 8-19

Fig. 8-20: CAT 100,Junction Box, Interior V iew................................................................................... 8-21

Fig. 8-21: CAT 100, Cast Iron housing, Interior V iew.......................................................................... 8-21

Fig. 8-22: CAT 100, internal analyzer module (BINOS® 100 2M) exemplary...................................... 8-23

Fig. 8-23: Pcb. "BKS" (section), measuring points ............................................................................. 8-22

Fig. 8-24: Light barrier signal............................................................................................................... 8-25

Fig. 8-25: Pcb OXS, assembled, top view.......................................................................................... 8-27

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Instruction Manual

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T able of Illustrations

Fig. 8-26: "BKS", Position of Connectors ........................................................................................... 8-28

Fig. 8-27: Pcb "OXS" ( Electrochemical Oxygen Measurement) ...................................................... 8-31

Fig. 8-28: Pcb "WAP 100"................................................................................................................... 8-32

Fig. 8-29: "BKS" (section) ................................................................................................................... 8-33

CHAPTER 9 MAINTENANCE

Fig. 9-1: Fine Dust Filter ...................................................................................................................... 9-2

Fig. 9-2: Leak Testing with u-turn manometer .................................................................................... 9-3

Fig. 9-3: Internal configuration, dual channel electrochemical Oxygen measurement .................... 9-6

Fig. 9-4: Sensor holder with pcb, gas fittings and sensor .................................................................. 9-6

Fig. 9-5: Internal configuration of a dual channel instrument with IR and electrochemical channel...9-7

Fig. 9-6: Pcb OXS, top view................................................................................................................ 9-8

Fig. 9-7: Distance between glass and key pad bar ............................................................................. 9-9

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Instruction Manual

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1-1 General Description

BINOS® 100 Series

Chapter 1

Technical Description

BINOS® 100 series analyzers are characterized by

• compact design

• highly integrated main board, containing all necessary basic functions and interfaces

• microprocessor based user interface

• multi-component and multi-method analysis with the opportunity to combine several methods in one single analyzer.

BINOS® 100 series analyzers are designed to measure 1 or 2 gas components, except OXYNOS® 100 for Oxygen measurement with paramagnetic cell and HYDROS® 100 (Thermal conductivity measurement): These two analyzers are single channel units.

The following methods are available: I R = non-dispersive infrared measurement PO2= paramagnetic Oxygen measurement EO2= electrochemical Oxygen measurement TC = thermal conductivity measurement

An IP 65 protected field housing (BINOS® 100 F) for outdoor installation is available, too.This enclosure is intended to be wall mounted.

Installation in Hazardous Areas Note!

This manual does not deal with special conditions for analyzers in hazardous areas, related to installation, operation, maintenance etc. For such applications refer to the se-

parate instruction manuals, delivered together with the analyzers.

For installation in hazardous areas the BINOS® 100 F analyzer is provided with an adapted pressurization system (ATEX type approved for Zone 1 resp. Zone 2 in Europe) and an impact tested magnetically operated front panel. Optionally intrinsically safe signal couplers are available, too. A simplified z-purge system permits installation in North America Zone 2 environments.

For applications with solvent and/or corrosive components in the gas stream special resistant measuring cells are available. For measuring flammable gases special solutions are available too (e.g. intrinsically safe cells).

Standard General Purpose Applications

Several enclosure variations are available: Tabletop and rack mount versions of 1/4 19“ size (BINOS® 100 (M), OXYNOS® 100, HYDROS® 100) and 1/2 19" size (BINOS® 100 2M) are available. They are IP 20 protected (acc. to EN 60529), tabletop versions are equipped with a handle and rubber feet.

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The CA T 100 analyzer, designed to be inst alled in hazardous areas, too, comprised of a BINOS® 100 2M analyzer installed into a flameproof enclosure. This model is CSA-C/US and ATEX approved for installation in NorthAmerican and European hazardous areas.

BINOS® 100 Series

Overview

The BINOS® 100 series analyzers offer a wide range of available configurations and options, to be combined according to the selected model:

 Measuring principles All offered principles may be combined, depending on analyzer model and other options:

Instruction Manual

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03/2005

Table 1-1: BINOS® 100 Series

Combinations of Measuring Principles

 Options Depending on which model is selected, one or more of the following options are available:

• Soleniod valve block (BINOS® 100 2M / BINOS® 100 F / CA T 100 only; (special solution with 2 valve blocks and parallel gas paths available) This option uses 4 (8) internal solenoid valves to control sample, zero, span gas 1 and span gas 2. These gases are fed to the analyzers to provide manual or controlled automatic calibration (initialized by keypad, digital inputs, RS 232/485 or FOUNDATION™ Fieldbus commands). If any valve is open this is indicated by a green LED on the analyzer‘s front panel.

• Barometric Pressure sensor (Measuring range 800 to 1,100 hPa) Used to compensate atmosperic pressure variations to improve precision of results (see measurement specification, pg. 2-6). Special sensors for e.g. corrosive gas on request.

• Sample pump (BINOS® 100 2M / BINOS® 100 F / CA T 100 only) Maximum flow rate 2.5 l/min (special solution with 2 pumps and parallel gas paths available)

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BINOS® 100 Series

Overview

All models may be configured to use several interfaces (in part optional), depending on model and other configuration:

• analog outputs (standard)

• digital outputs (standard; threshold contacts / valve control)

Analyzers use several software revisions, depending on selected options (actual installed revision is shown during analyzer boot sequence in lower 7 segment display on the front panel)

BINOS® 100 (M), OXYNOS® 100, HYDROS® 100:

V ersion 5.x0 with optional RS 232/485 interface

BINOS

100 2M (V ariation with internal power supply):

V ersion 5.x0 with optional RS 232/485 interface

Options:

• analog signal inputs (external cross compensation, for TC cell only!)

• serial interface RS 232 / RS 485 *)

• status signals (relay outputs)

• 7 digital inputs **)

• Foundation™ Fieldbus **) ***)

BINOS® 100 2M (V ariation with external power supply):

V ersion 5.x0 with optional RS 232/485 interface*) and/or 7 digital inputs V ersion 5.x1 with optional 7 digital inputs and FOUNDA TION

™

Fieldbus

**)

BINOS® 100 F:

V ersion 5.x0 with optional RS 232/485 interface V ersion 5.x1 with optional 7 digital inputs and FOUNDA TION™ Fieldbus

and/or 7 digital inputs

**)

CAT 100:

V ersion 5.x0 with optional RS 232/485 interface*) and/or 7 digital inputs V ersion 5.x1 with optional 7 digital inputs and FOUNDA TION

not in combination with FOUNDATION™ Fieldbus

**)

BINOS® 100 2M with external power supply resp. BINOS® 100 F / CAT 100 only

***)

not in combination with RS 232/485 interface

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™

Fieldbus

**)

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

Overview

The different BINOS® 100 series models and their appearance.

BINOS® 100 (M), OXYNOS® 100, HYDROS® 100

(see section 1-2, page 1-5)

The following sections 1-2 to 1-5 give detailed descriptions for all available configurations.

BINOS® 100 2M

(see section 1-3, page 1-9)

BINOS® 100 F

(see section 1-4, page 1-15)

CAT 100

(see section 1-5, page 1-22)

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1-2 BINOS® 100,

BINOS® 100 M, OXYNOS® 100, HYDROS® 100

BINOS® 100 Series

1-2 BINOS® 100 (M), OXYNOS® 100, HYDROS® 100

These analyzers are the most compact variations within the BINOS® 100 series: 1/4 19“ enclosure, external power supply unit.

Table 1-2: BINOS® 100 (M), OXYNOS® 100, HYDROS® 100,

Combinations of measurement principles

All variations with 2 measuring channels allow serial tubing (1 gas inlet) as well as parallel tubing (separate gas inlet for each channel).

The front panel shows 7 segment displays for both channels and pushbuttons for operating the analyzer (see fig. 1-1).

Up to 4 gas connections, DC 24 V power input and submin-d connectors for interfaces (some of

The various designators are based on the measuring principles used with the analyzer: BINOS® 100: IR measurement only BINOS® 100 M: IR measurement combined

with Oxygen measurement OXYNOS® 100: Oxygen measurement only HYDROS® 100: Thermal conducitvity mea-

surement

them optional) are located at the rear panel (see fig. 1-2).

Compared to the other analyzer versions the rear panel of OXYNOS

100 with paramagnetic

measuring cell is rotated by 90° (see fig. 1-3). Chapter 8 shows several internal variations of

components as a result of combinations given by table 1-2.

Note!

The analyzers may optionally provide a gas fitting for purging the enclosure (e.g. with nitrogen) when measuring

• aggressive components: purging with air

gives additional safety in the event of leakage inside the instrument.

• low CO2 concentrations: N2 minimizes interference by ambient air

• flammable gases: N2 gives additional safety in the event of leakage inside the

Purge medium must be dry, clean and free of corrosive and solvent components!

instrument

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BINOS® 100 Series

1-2 BINOS® 100 (M), OXYNOS® 100, HYDROS® 100

Instruction Manual

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03/2005

% O2paramagnetic para. Oxygen sensor

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

1 7 segment display (channel 1) 6 Pushbutton ENTER 2 7 segment display (channel 2) 7 Pushbutton FUNCTION 4 Pushbutton DOWN 1 1 Screw for fixing handle/plug-in module 5 Pushbutton UP 12 Screw for fixing enclosure cover

% O2elektrochemical chem. Oxygen sensor

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BINOS® 100 Series

1-2 BINOS® 100 (M), OXYNOS® 100, HYDROS® 100

X4 IN / OUT

1 A max

Fig. 1-2: BINOS® 100 (M), OXYNOS® 100 (EO2), HYDROS® 100, rear side view

1 Gas inlet fittings 6 Screw for fixing enclosure cover 2 Socket "analog signal output“ 7 Socket "serial interface“ [RS 232 / 485] (option) 3 24 V DC power connection 8 Plug "status messages“ (relay outputs, option) 4 Plug "digital outputs“ 9 Plug "analog signal inputs“ 5 Gas outlet fittings (external cross compensation, HYDROS® 100 only)

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BINOS® 100 Series

1-2 BINOS® 100 (M), OXYNOS® 100, HYDROS® 100

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Fig. 1-3: OXYNOS® 100 (PO2), rear side view

1 Gas inlet fitting 2 Socket "analog signal output“ 3 24 V DC power connection 4 Plug "digital outputs“

5 Gas outlet fittings 6 Screw for fixing enclosure cover 7 Socket "serial interface“ [RS 232 / 485] (option) 8 Plug "status messages“ (relay outputs, option)

Continue with section 1-6 "Internal gas paths“ , page 1-30

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1-3 BINOS® 100 2M

BINOS® 100 Series

1-3 BINOS® 100 2M

The BINOS® 100 2M model represents the variation that may be upgraded from a tabletop/ rack mountable analyzer to an analyzer system by integrating optional sample handling components (sample pump, valve blocks, flowmeters and fine dust filter). The integrated power supply unit allows to use the BINOS® 100 2M analyzer for stationary as well as for mobile applications. In addition the internal power supply unit provides a DC output to supply external components with 24 V / 2 A max.

The 1/2 19“ enclosure provides twice the volume compared to a standard BINOS® 100 enclosure to include e.g. 2 thermalcoductivity cells. The option of alternatively using an external power supply unit allocates even more internal volume, which may be used to integrate 2 paramagnetic and/or up to 2 software controlled solenoid valve blocks. An optional "FOUNDA TION™ Fieldbus“ interface enables integration into process control systems. Nevertheless not all imaginable combinations of measuring principles, measuring ranges and options are available - refer to the pricebook for restrictions!

Table 1-3: BINOS® 100 2M

Combinations of Measuring Principles

All variations with 2 measuring channels allow serial tubing as well as parallel tubing, also in combination with up to 2 solenoid valve blocks.

In addition the BINOS® 100 2M front panel shows status LEDs for solenoid valves and sample pump (options) and a pushbutton to

switch the pump. The front panel shows 7 segment displays for both channels and pushbuttons for operating the analyzer (see fig. 1-4).

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BINOS® 100 Series

1-3 BINOS® 100 2M

Interfaces are accessible at the analyzer‘s rear panel via submin-d connectors (male / female), except FOUNDA TION™ Fieldbus and 7 digital inputs, which are available on screw terminals.

The multitude of internal configurations (see table 1-3) result in various rear panel designs, shown on page 1-12 et. sqq., while some representative configurations of the internal configurations are given in chapter 8.

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Note!

The analyzers may optionally provide a gas fitting for purging the enclosure (e.g. with nitrogen) when measuring

• low CO2 concentrations: N2 minimizes interference by ambient air

• flammable gases: N2 gives additional safety in the event of leakage inside the instrument

• aggressive components: purging with air gives additional safety in the event of leakage inside the instrument.

Purge medium must be dry, clean and free of corrosive and solvent components!

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Nadelventil (Option)



1-3 BINOS® 100 2M

BINOS® 100 Series

% O

80 %

45678391011

Fig. 1-4: BINOS® 100 2M (standard version)

front side view

1 7 segment display (channel 1) 7 Pushbutton FUNCTION 2 7 segment display (channel 2) 8 Pushbutton for optional sample pump 3 LEDs "valves / sample pump" 9 Flowmeter (option) 4 Pushbutton DOWN 10 Fine dust filter with needle valve (option) 5 Pushbutton UP 1 1 Screw for fixing handle/plug-in module 6 Pushbutton ENTER

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BINOS® 100 Series

12 34 56789

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1-3 BINOS® 100 2M

FLOW

Fig. 1-5: BINOS

1 Gas inlet fitting channel 1 2 Gas inlet fitting channel 2 (option) 3 Gas outlet fitting channel 1 4 Gas outlet fitting channel 2 (option) 5 Plug "analog signal inputs“

(external cross compensation, TC only) 6 "Solenoid valve block“: span gas 1 in 7 "Solenoid valve block“: span gas 2 in 8 "Solenoid valve block“: shared gas out 9 24 V DC output (2 A max., see techn. data)

1416 15

100 2M, variation A (internal power supply)

Rear side view with all options

10 Power supply [UPS 01 (Universal Power Supply)] 1 1 Mains connector 12 "Solenoid valve block“: zero gas in 13 "Solenoid valve block“: sample gas in 14 Plug "digital outputs“ 15 Socket "serial interface“ [RS 232 / 485] (option) 16 Socket "analog signal output“ 17 Plug "status messages“ (relay outputs, option)

Emerson Process Management Manufacturing GmbH & Co. OHG1-12

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-3 BINOS® 100 2M

1234 5

16 15 14

Fig. 1-6: BINOS

100 2M, variation B (external power supply),

Rear side view with all options

1 Gas inlet fitting channel 1 2 Gas inlet fitting channel 2 (option) 3 Gas outlet fitting channel 1 4 Gas outlet fitting channel 2 (option) 5 Plug "analog signal inputs“

(external cross compensation, TC only) 6 "Solenoid valve block“: shared gas out 7 "Solenoid valve block“: span gas 1 in

10 T erminal block for FOUNDATION™ Fieldbus (option) 11 24 V DC supply 12 "Solenoid valve block“: zero gas in 13 "Solenoid valve block“: sample gas in 14 Plug "digital outputs“ 15 Socket "serial interface“ [RS 232 / 485] (option) 16 Socket "analog signal output“ 17 Plug "status messages“ (relay outputs, option)

**)

8 "Solenoid valve block“: span gas 2 in 9 T erminal block for 7 digital input s (option)

Emerson Process Management Manufacturing GmbH & Co. OHG 1-13

not in combination with serial interface RS 232/485

**)

not in combination with FOUNDATION™ Fieldbus

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-3 BINOS® 100 2M

1234 5

16 15 1714

1 Gas inlet fitting channel 1 2 Gas inlet fitting channel 2 (option) 3 Gas outlet fitting channel 1 4 Gas outlet fitting channel 2 (option) 5 Plug "analog signal inputs“

(external cross compensation, TC only)

6 "Solenoid valve block“: shared gas out 7 "Solenoid valve block“: span gas 1 in 8 "Solenoid valve block“: span gas 2 in

Fig. 1-7: BINOS

100 2M (special variation),

Rear side view with all options

11 24 V DC supply 12 "Solenoid valve block“: zero gas in 13 "Solenoid valve block“: sample gas in 14 Plug "digital outputs“ 15 Socket "serial interface“ [RS 232 / 485] (option) 16 Socket "analog signal output“ 17 Plug "status messages“ (relay outputs, option)

Emerson Process Management Manufacturing GmbH & Co. OHG1-14

12 13

Continue with section 1-6 "Internal gas paths“ , page 1-30

Instruction Manual

HAS1xE-IM-HS 03/2005

1-4 BINOS® 100 F

BINOS® 100 Series

1-4 BINOS® 100 F

With BINOS® 100 F Emerson Process Management offers a gas analyzer designed for wall mounting and outdoor installation due to it‘s stainless steel enclosure. Without the optional fine dust filter the analyzer is IP 65 protected against dust and water .

The BINOS® 100 F offers similiar potentials as the BINOS® 100 2M, that is it can be upgraded to an analyzer system by integrating sample handling options like sample pump, solenoid valve blocks, flowmeters and fine dust filter.

The enclosure has enough volume to integrate 2 paramagnetic or thermal conductvity cells (see table 1-4), if required as well in combination with up to 2 software controlled solenoid valve blocks. Variations with 2 measuring channels allow serial or parallel tubing, again also in combination with up to 2 valve blocks, if required by application. For examples of internal configurations see chapter 8.

Table 1-4: BINOS® 100 F

Combinations of measuring principles

An optional "FOUNDATION™ Fieldbus“ interface enables integration into process control systems.

In addition the BINOS® 100 F front panel shows status LEDs for solenoid valves and sample pump (options) and a pushbutton to switch the pump (pushbutton "Pump“ not in combination

The front panel shows 7 segment displays for

with optional impact tested front panel). both channels and pushbuttons for operating the analyzer (see fig. 1-9).

Emerson Process Management Manufacturing GmbH & Co. OHG 1-15

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-4 BINOS® 100 F

The optional impact protected front panel enables installation at harsh locations (or even in hazardous area when combined with a pressurization system for the enclosure). Such analyzers are contactless operated using a special magnetic tool. The pump (option) is controlled by a software menu entry , the front panel pushbutton is omitted. All interface signals (partial options) are accessible on internal screw terminal blocks. That applies to mains power supply, too.

Take care of the special installation instructions in chapter 3 "Installation“!

Provided with an appropriate pressurization system the BINOS® 100 F is suitable for installation in hazardous areas. Installation, startup and maintenance are described in detail in a separate instruction manual, shipped together with each such analyzer, and are not subject of this current instruction manual!

Connection of mains and interface signals are to be established via internal screw terminal blocks. This requires working inside an opened analyzer, near by potentially live components!

Installation of this analyzer is allowed by qualified personnel only, familiar with the potential risks of working near live components!

The model BINOS

100 F (field housing) does not provide a mains switch. A mains switch or circuit breaker must be provided in the building installation. This switch has to be installed near by the analyzer , must be easily operator accessible and has to be designated as disconnector for the analyzer.

Cables for external data processing must be double insulated for mains voltage. If not available, signal cables inside the analyzer must be installed with a distance of at least 5 mm to mains cables. Distance has to be ensured permanently , e.g. by using cable ties!

Emerson Process Management Manufacturing GmbH & Co. OHG1-16

Instruction Manual

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BINOS risk of electric shock the enclosure must be connected to earth! Therefore connecting the analyzer is allowed only by using a 3 pole mains cable providing a separate earthing conductor.

Any interruption of the earthing conductor inside or outside the analyzer as well as loosening the earthing connection may cause serious injury! Intended interruption of earthing connections is not permissible!

BINOS® 100 Series

1-4 BINOS® 100 F

Risk of electric shock!

100 F analyzers provide earth connection terminals. To minimize

Heavy instrument!

BINOS

100 F analyzers ,designed for wall mounting and/or outdoor

installation may weigh up to 30 kg, depending on installed options! Use two persons or a suitable lifting device to move or carry the instrument!

Note!

The analyzers may optionally provide a gas fitting for purging the enclosure (e.g. with nitrogen) when measuring

• low CO2 concentrations: N2 minimizes interference by ambient air

• flammable gases: N2 gives additional safety in the event of leakage inside the instrument

• aggressive components: purging with air gives additional safety in the event of leakage inside the instrument.

Purge medium must be dry, clean and free of corrosive and solvent components!

Emerson Process Management Manufacturing GmbH & Co. OHG 1-17

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-4 BINOS® 100 F

Fig. 1-8: BINOS® 100 F

Standard version, front side view

1 Front panel (without options; for details see fig. 1-9) 2 Sash fasteners (4 pcs) 3 Wall mount bracket (4 pcs) 4 Gas fittings 5 Cable glands for signals and mains

Emerson Process Management Manufacturing GmbH & Co. OHG1-18

34521

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-4 BINOS® 100 F

Needle valve (option)



% O

80 %

1211

3910 8

Fig. 1-9: BINOS® 100 F

Standard front panel incl. sample handling options

1 7 segment display (channel 1) 7 Pushbutton FUNCTION 2 7 segment display (channel 2) 8 Pushbutton for optional sample pump 3 LEDs "valves / sample pump" 9 Flowmeter (option) 4 Pushbutton DOWN 10 Fine dust filter with needle valve (option) 5 Pushbutton UP 1 1 Sample gas designator (channel 1) 6 Pushbutton ENTER 12 Sample gas designator (channel 2)

Emerson Process Management Manufacturing GmbH & Co. OHG 1-19

456

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-4 BINOS® 100 F

% O

80 %

Magnetically operated front panel (option)

1 7 segment display (channel 1) 2 7 segment display (channel 2) 3 LEDs "valves / sample pump" 4 Sensor field DOWN 5 Sensor field UP

Fig. 1-10: BINOS® 100 F

6 Sensor field ENTER 7 Sensor field FUNCTION 8 Sample gas designator (channel 1) 9 Sample gas designator (channel 2) 10 Flowmeter (option)

Emerson Process Management Manufacturing GmbH & Co. OHG1-20

456

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-4 BINOS® 100 F

421 3 67 8 59

Fig. 1-11: BINOS® 100 F

Interior view (without components)

1 Mains EMC filter 5 T erminals for DC 24 V 2 Mains terminals 6 Carriage slide for components 3 Mains fuses 7 Cable glands 4 Power supply (behind barrier) 8 Mains voltage selector switch

9 Gas fittings

Continue with section 1-6 "Internal gas paths“ , page 1-30

Emerson Process Management Manufacturing GmbH & Co. OHG 1-21

BINOS® 100 Series

1-5 CAT 100

Instruction Manual

HAS1xE-IM-HS

03/2005

1-5 CAT 100

The CAT 100 is an analyzer with flameproof enclosure, designed especially for operation in hazardous areas. It is approved to meet the requirements of the European Directive for equipment intended to be used in hazardous areas (commonly know as "A TEX 95“) and of the North American S tandards (certified by the Canadian Standards Association, CSA International). The enclosure meets IP 65 (optional: IP 66, tropicalisation), has robust design and is prepared for wall mounting. Therefore the analyzer may be used for general purpose applications requiring outdoor installation, too.

This current instruction manual covers using the CAT 100 analyzer for general purpose applications only!

Installation, startup and maintenance for operation in hazardous areas are described in detail in a separate instruction manual, shipped together with each such analyzer and are not subject of the current instruction manual!

Installed inside the flameproof enclosure an analyzer module holds all measuring components. As the module corresponds to a BINOS® 100 2M with external power supply unit, a CAT 100 analyzer offers almost the same options, e.g. integration of sample pump, solenoid valve blocks and flowmeter. The analyzer module is big enough to include (depending on application) 2 paramagnetic or thermal conductivity cells (see table 1-5), if required in combination with a software controlled solenoid valve block.

Dual channel variations allow serial and parallel tubing, again in combination with solenoid valve block, if required. The front panel shows 7 segment displays for both channels and status LEDs for solenoid valves and sample pump (options). Because of the intention to used in hazardous areas the front panel is located behind a safety glas window. The analyzer is touchless operated by using a magnetically tool, whereat the standard pushbuttons are replaced by sensor fields (see fig. 1-14). The optional sample pump is controlled by a software menu entry . An optional "FOUNDA TION™ Fieldbus“ interface enables integration into process control systems.

All interface signals (partial options) are accessible on screw terminal blocks, located in a separate junction box. That applies to mains power supply , too.

Take care of the special installation instructions in chapter 3 "Installation“!

Located below the junction box is a second volume consisting of dome housing, extender housing and base, containing analyzer module, power supply unit, fuses and gas pipes (see fig. 1-12). All three p arts of the enclosure are threated together. Unthreading the parts gives access to the internal components.

For detailled interior views see chapter 8.

Emerson Process Management Manufacturing GmbH & Co. OHG1-22

Instruction Manual

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BINOS® 100 Series

1-5 CAT 100

Table 1-5: CAT 100

Combinations of measuring principles

Heavy instrument!

CAT 100 analyzers, designed for wall mounting and/or outdoor installation may weigh up to 70 kg, depending on installed options!

Use two persons or a suitable lifting device to move or carry the instrument!

Note!

The analyzers may optionally provide a gas fitting for purging the enclosure (e.g. with nitrogen) when measuring

• low CO2 concentrations: N2 minimizes interference by ambient air

• flammable gases: N2 gives additional safety in the event of leakage inside the instrument

• aggressive components: purging with air gives additional safety in the event of leakage inside the instrument.

Purge medium must be dry, clean and free of corrosive and solvent components!

Emerson Process Management Manufacturing GmbH & Co. OHG 1-23

BINOS® 100 Series

Connection of mains and interface signals are to be established via internal screw terminal blocks. This requires working inside an opened analyzer, near by potentially live components!

Installation of this analyzer is allowed by qualified personnel only, familiar with the potential risks of working near live components!

The model CAT 100 does not provide a mains switch. A mains switch or circuit breaker must be provided in the building installation. This switch has to be installed near by the analyzer , must be easily operator accessible and has to be designated as disconnector for the analyzer.

Instruction Manual

HAS1xE-IM-HS

03/2005

1-5 CAT 100

The Junction Box must be protected by fuse supply which has a breaking capacity adjusted to the short circuit of the equipment. The 10 A fuse has to be installed in the building installation.

Risk of electric shock!

100F analyzers provide earth connection terminals. T o minimize risk of

CA T electric shock the enclosure must be connected to earth! Therefore connecting the analyzer is allowed only by using a 3 pole mains cable providing a separate earthing conductor.

Emerson Process Management Manufacturing GmbH & Co. OHG1-24

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-5 CAT 100

567

Fig. 1-12: CAT 100

Exterior view

1 Eye bolts (2 pcs) 2 Cable glands for signal cables (3 pcs max) 3 Eye bolts (2 pcs) 4 Mounting holes (4 pcs.) 5 Base 6 Extender housing

Emerson Process Management Manufacturing GmbH & Co. OHG 1-25

7 Dome housing 8 Front panel behind safety glass 9 Interlock screw 10 Interlock screw 1 1 Junction box

BINOS® 100 Series

6 5

Instruction Manual

HAS1xE-IM-HS

03/2005

1-5 CAT 100

4 3

Fig. 1-13: CAT 100

(Dome and extender housing removed)

1 Analyzer module 2 Gas fittings with internal flame arrestors 3 Bracket for analyzer module 4 Nameplate label

5 Cable gland for mains cable 6 External earth connector

Emerson Process Management Manufacturing GmbH & Co. OHG1-26

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-5 CAT 100

4 3 2 1

Fig. 1-14: CAT 100

Front panel

1 Sensor field DOWN 2 Sensor field UP 3 Sensor field ENTER 4 Sensor field FUNCTION 5 7 segment display (channel 2)

Emerson Process Management Manufacturing GmbH & Co. OHG 1-27

6 7 segment display (channel 1) 7 Sample gas designator (channel 1) 8 Sample gas designator (channel 2) 9 Flowmeter (option) 10 LEDs "valves / sample pump"

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-5 CAT 100

124

241

1 234 5 678

Fig. 1-15: CAT 100

Junction box, interior view

1 Cable gland for mains cable 2 Mains terminals 3 Mains EMC filter 4 Feed thru for mains

5 Feed thru for mains (3) 6 Upper signal terminals (24) 7 Lower signal terminals (24) 8 Cable gland for signal cables (3)

Emerson Process Management Manufacturing GmbH & Co. OHG1-28

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-5 CAT 100

12 34

567

8 9 10 11

* St andard: Output = gas out, valve block out is internally connected to analyzer module gas inlet. Option: valve block output available for external sample handling system (special configuration)

Fig. 1-16: CAT 100

Gas fittings and assignment

Emerson Process Management Manufacturing GmbH & Co. OHG 1-29

BINOS® 100 Series

1-6 Internal Gas Paths

Various materials are available to provide a best possible analyzer adaption to the application. Materials are selected taking into account e.g. diffusion rate, corrosiveness, temperature and pressure of the applied gas.

1-6-1 Gas Paths Materials

Physical and chemical characteristics of applied gases and working conditions (temperature and pressure) affect the available materials.

Instruction Manual

HAS1xE-IM-HS

03/2005

1-6-2 Safety Filter

All analyzers provide an internal PTFE safety filter. This filter(s) is (are) not a substitute for a dust filter to be installed in the sample handling system!

1-6-3 Fittings

By default all analyzers are equipped with PVDF fittings (ø 6/4 mm), except CAT 100: Swagelok® 1/4“ with integrated flame arrestors). Swagelok® or stainless steel fittings(ø 6/4 mm or 1/4") are available alternatively . Other fittings are available on request.

1-6-4 Piping

Analyzers are piped with Viton oder PTFE (ø 6/4 mm). Other materials (e.g. stainless steel) are used optionally , depending on application.

Emerson Process Management Manufacturing GmbH & Co. OHG1-30

Instruction Manual

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1-6-5 Gas Path Variations

BINOS® 100 Series

1-6-5 Gas Path Variations

Depending on the application and the selected options several gas paths configurations are

Analyzer

Gas inlet

(IN K1)

Fig. 1-17: Single channel or serial tubing

available, as shown in the following figures:

Gas outlet

(OUT K1)

Gas outlet

Analyzer

Gas inlet

(IN K1)

Gas inlet

(IN K2)

(OUT K1)

Gas outlet

(OUT K2)

Fig. 1-18: Dual channel parallel tubing

Emerson Process Management Manufacturing GmbH & Co. OHG 1-31

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-6-5 Gas Path Variations

Span gas 1

(SPAN 1 / V1)

Span gas 2

(SPAN 2 / V2)

Sample gas

(SAMPLE / V3)

Zero gas

(ZERO / V4)

Gas outlet

(OUT)

Solenoid valves

(option)

Sample pump

(option)

Gas inlet

(IN K1)

Analyzer

Flowmeter,

fine dust filter with throttle

(options)

not for CAT 100 resp.

BINOS® 100 F with magn. front panel

Gas outlet

(OUT K1)

Fig. 1-19: Single channel resp. serial tubing, with options

(not BINOS® 100 (M), OXYNOS® 100, HYDROS® 100)

Emerson Process Management Manufacturing GmbH & Co. OHG1-32

Instruction Manual

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BINOS® 100 Series

1-6-5 Gas Path Variations

Span gas 1

(SPAN 1 / V1)

frei

Sample gas 1

(SAMPLE / V3)

Zero gas 1

Sample gas pump

(option)

(ZERO / V4)

(OUT)

Gas outlet

(IN K1)

Gas inlet

Gas outlet

(OUT K1)

Flowmeter

(option)

Gas outlet

(OUT K2)

frei

(OUT)

Span gas 2

(SPAN 2 / V2)

Sample gas 2

(SAMPLE / V3)

Zero gas 2

Gas outlet

(ZERO / V4)

(IN K12

Gas itput

Fig. 1-20: Parallel tubing, with options

(not BINOS® 100 (M), OXYNOS® 100, HYDROS® 100)

Emerson Process Management Manufacturing GmbH & Co. OHG 1-33

BINOS® 100 Series

1-7 Technical Data

Instruction Manual

HAS1xE-IM-HS

01/2007

1-7 Technical Data

This section lists all the analyzers technical data, separated into common and model

the appropriate section depending on his analyzer.

specific data, therefore the user has to select

1-7-1 Common Technical Data

Site of installation

Permissible ambient temperature (operation):

- OXYNOS/HYDROS 100, BINOS 100 (M/2M/F) +5 °C to +40 °C (+45 °C on request)

- CA T 100 0 to +50 °C; -30 °C (GP/ CSA-C/US only)

Permissible storage temperature -20 to +70 °C Humidity (non condensing) < 90 % r. h. at + 20 °C

< 70 % r . h. at + 40 °C

Pollution degree 2 Installation category I I

Altitude 0 - 2000 m above NN Sourrounding atmosphere Analyzers must not be operated in hazar-

(Analyzers must not be operated in dous or flammable atmoshere without corrosive atmoshere) additional safety measures.

Compliances

Electrical safety Europe CE, based on EN 61010-1

CAN / USA CAN/CSA-C22.2 No. 1010.1-92

UL 61010A-1 IEC IEC 61010-1 China PAC

Electromagnetic compatibility

Europe CE, based on EN 61326 Australia C-Tick other NAMUR

Purge Option

Purge medium (e.g. for minimizing CO2 inter- ference, safety in events of internal leakage of flammable or/and aggressive gas etc.) must

For pressure and flow specification consult factory or your local EMERSON Process Management sales office!

be dry , clean and free of corrosive and solvent components and on ambient temperature (at least 20 ... 35 °C) !

Emerson Process Management Manufacturing GmbH & Co. OHG1-34

Instruction Manual

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BINOS® 100 Series

1-7-1 Common Technical Data

Interfaces, signal inputs / outputs

2 analog outputs per channel

0 - 10 V and 0 - 20 mA (RB < 500 Ω) [(galv . separated:, common ground), or start and end concentration user configurable] 2 - 10 V and 4 - 20 mA (RB < 500 Ω)

Not for CAT 100 (see section 1-7-2-4) ! configurable by keypad

Option:0 (0.2) - 1 and 0 (4) - 20 mA (RB < 500 Ω)

3 analog inputs (option for TC), 0 - 10 V, 0 - 20 mA, for cross compensation of up to 3 interfering 2 - 10 V, 4 - 20 mA, components (via external signals) 0 - 1 V or 0.2 - 1 V

8 digital outputs, parallel (galv . separated) 2 thresholds per channel,

sample gas valve,

zero gas valve,

span gas valve 1,

span gas valve 2 (2 channel analyzer only)

“Open Collector”, max. 30 V / 30 mA 7 digital inputs, parallel zero calibration ch1 & ch2,

(option) span calibration ch1,

span calibration ch2,

open zero gas valve,

open span gas 1 valve,

open span gas 2 valve

(2 channel analyzer only)

open sample gas valve /

switch off sample pump

Serial interface (option, galv . separated) RS 232 or (not in combination with FOUNDA TION™ Fieldbus) RS 485 (2- or 4-wire)

FOUNDATION™ Fieldbus (option) ( not in combination with serial interface) 3 relay outputs (option "status signals“) “Measuring / calibration”

“Analyzer failure”

“Sample gas pump on / off”

floating contacts, max. 30 V; 1 A; 30 W

Emerson Process Management Manufacturing GmbH & Co. OHG 1-35

BINOS® 100 Series

1-7-2 Model Specific Data 1-7-2-1 BINOS® 100,

BINOS® 100 M, OXYNOS® 100, HYDROS® 100

(0.75)

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2 Model Specific Specification

(15.9)

(4.13)

(0.1)

(14.8)

(0.1)

(15.7)

(16.4)

Fig. 1-21: BINOS® 100 (M) / OXYNOS® 100 / HYDROS® 100

Dimensions [approx.; mm (inch) ]

(0.55)

(5.1)

(4.3)

Housing

Weight: approx. 4 - 7 kg (depending on analyzer configuration)

Protection class to EN 60529: IP 20 for indoor installation

Analyzer must not be supposed to dripping or sprayed water.

Gas fittings: quantity: max. 4

specification: 6/4 mm PVDF optional 6/4 mm or 1/4", stainless

steel, other on request

Power Supply

Rated input voltage 24 V (+- 5 %) Rated input power BINOS® 100 (M) max. 20 W

OXYNOS® 100 max. 40 W

HYDROS® 100 max. 35 W Input 3-pole XLR plug (Fig. 1-22) Fuse (inside analyzer , s. section 8-3, pg. 8-27) T 4 A / 250 V External power supply unit s. power supply options, pg. 1-60

Emerson Process Management Manufacturing GmbH & Co. OHG1-36

Instruction Manual

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BINOS® 100 Series

1-7-2-1 BINOS® 100, BINOS® 100 M, OXYNOS® 100, HYDROS® 100 Specification

Pin 1: ME

(Shield)

Pin 2: + 24 V Pin 3: 0 V (

⊥⊥

⊥)

⊥⊥

1 3

(Shield)

Shield: housing

Fig. 1-22: Pin assignment 24 V DC input plug

Signal inputs / outputs

All signal lines need to be connected to 9 pole submin-Dplugs and sockets located at the analyzer‘s rear panel.

Available signals: standard: Analog signal outputs

Digital signal outputs

optional: Analog inputs (TC; cross compensation)

Serial interface (RS232; RS 485) Relay status signals

Analog signal outputs

Fig.1-23: Socket X2 pin assignment (analog signal outputs; standard)

Note!

Take care of the special installation instructions in section 3-5!

1 2 0 (2) - 10 V DC [option: 0 (0.2) - 1 V DC], channel 1 3 0 (4) - 20 mA, channel 1 (R 4 0 (2) - 10 V DC [Option: 0 (0.2) - 1 V DC], channel 2 5 0 (4) - 20 mA, channel 2 (R 6 7 8 9

The current configuration of voltage output (standard:10 V DC or optional: 1 V DC) is given on order acknowledgement and on

⊥⊥

⊥ (V DC)

⊥⊥

⊥ (mA)

⊥⊥

≤ 500 Ω)

nameplte label. Further configurations: see section 5-4-1

Emerson Process Management Manufacturing GmbH & Co. OHG 1-37

Instruction Manual

BINOS® 100 Series

1-7-2-1 BINOS® 100, BINOS® 100 M, OXYNOS® 100, HYDROS® 100 Specification

HAS1xE-IM-HS

03/2005

Digital Outputs

Electrical specification: max. 30 V , 30 mA Configuring outputs: s. section 5-4-2

Note!

Take care of the special installation instructions in section 3-5!

(external power supply)

load

(external power supply)

Fig.1-24: Connecting digital outputs

1 Threshold channel 2 max. 2 Threshold channel 2 min. 3 Threshold channel 1 max. 4 Threshold channel 1 min. 5 6 Solenoid valve span gas 2 7 Solenoid valve span gas 1 8 Solenoid valve zero gas 9 Solenoid valve sample gas

⊥⊥

⊥

⊥⊥

Fig.1-25: Plug X3 pin assignment (digital outputs; standard)

Analog inputs (TC; cross compensation)

Permissible signal ranges: 0 (0.2)- 1 V, 0 (2)- 10 V or 0 (4) - 20 mA, depending on configuration

Functional description: s. section 6-4

Fig.1-26: Plug Analog IN pin assignment (cross compensation; option)

Note!

Take care of the special installation instructions in section 3-5!

Emerson Process Management Manufacturing GmbH & Co. OHG1-38

1 Interfering gas 1 2 3 Interfering gas 2 4 5 not used 6 Interfering gas 3 7 8 not used 9 not used

⊥⊥

⊥ (GND) Interfering gas 1

⊥⊥

⊥ (GND) Interfering gas 2

⊥⊥

⊥ (GND) Interfering gas 3

⊥⊥

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-1 BINOS® 100, BINOS® 100 M, OXYNOS® 100, HYDROS® 100 Specification

Serial Interface

Specification and driving the interface: see section 6-2

Note!

Take care of the special installation instructions in section 3-5!

RS 232 configuration

RS 485 configuration

1 GND 2 RxD 3 TxD 4 not used 5 GND 6 7 8 9

1 GND 2 RxD3 RxD+ 4 TxD+ 5 TxD6 7 8 9

not used

Fig.1-27: Socket X4 pin assignment (serial interface; option)

Emerson Process Management Manufacturing GmbH & Co. OHG 1-39

Instruction Manual

BINOS® 100 Series

1-7-2-1 BINOS® 100, BINOS® 100 M, OXYNOS® 100, HYDROS® 100 Specification

Relay status Signals

HAS1xE-IM-HS

03/2005

Design: floating relay contacts Electrical specification: max. 30 V , 1 A, 30 W

Signal configuration: see section 6-1

Note!

T ake care of the special installation instructions in section 3-5!

Signal output (opener)

Signal output (closer)

Fig.1-28: Relay status signals, block diagram

1 2 3 4 5 6 7 8 9

OK / failure

Measuring / Calibration Pump off / on

OK / failure COM Measuring / Calibration COM Pump off / on COM

Pump off / on

*) BINOS® 100 2M / BINOS® 100 F / CAT 100 only

Fig.1-29: Plug X1 pin assignment (relay status signals; option)

Continue with section 1-7-2-5 "Power Supply“ on page 1-60

Emerson Process Management Manufacturing GmbH & Co. OHG1-40

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-2 BINOS® 100 2M Specification

1-7-2-2 BINOS

(4.4)

(0.75)

100 2M

(18.2)

Fig. 1-30: BINOS® 100 2M

Dimensions [approx.; mm (inch) ]

(5.1)

(2.1)

Housing

Weight: approx. 10 - 12 kg (depending on analyzer configuration)

Protection class to EN 60529: IP 20 for indoor installation

Analyzer must not be supposed to dripping or sprayed water.

Gas fittings: quantity: max. 9

specification: 6/4 mm PVDF optional 6/4 mm or 1/4", stainless

steel; other on request

Power Supply

(8.4)

a) with external power supply unit

Rated input voltage 24 V

(+- 5 %) Rated input power max. 100 W Input 3-pole XLR plug (fig. 1-31a) Fuse (inside analyzer, s. section 8-3, pg. 8-27) T 4 A / 250 V External power supply unit s. power supply options, section 1-7-2-5

b) with internal power supply unit

Rated input voltage 120 / 230 V

50/60 Hz Input voltage range 99 - 138 / 187-264 V Rated input power max. 240 VA Input IEC plug (fig. 1-31c) Fuse (inside analyzer, s. section 8-3, pg. 8-27) T 4 A / 250 V

Emerson Process Management Manufacturing GmbH & Co. OHG 1-41

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-2 BINOS® 100 2M Specification

Pin 1: ME

(Schirm)

Pin 2: + 24 V Pin 3: 0 V (

⊥⊥

⊥)

⊥⊥

(Schirm)

Shield: housing

Fig. 1-31a: Pin assignment 24 V DC input plug Fig. 1-31b:Pin assignment 24 V DC output socket

Fig. 1-31c: IEC mains input plug

c) Separate power output for supplying external components

The internal power supply unit provides an additional DC power output enabling the BINOS® 100 2M analyzer to supply external components, e.g. solenoid valves, pump, etc.

Output 3-pole XLR socket (fig. 1-31b) Rated output voltage 24 V

(+- 5 %)

Output current max. 2 A

The DC power output is not fuse protected against overload or short circuit! In case of overload or failure internal circuitry reduces the output voltage to

protect the power supply unit, but this reduces the internal voltage for the analyzer, too, and therefore operation is not longer assured.

We recommend to protect external components by installing an adequate fuse to assure analyzer operation even in case of failure or overload at these components!

Emerson Process Management Manufacturing GmbH & Co. OHG1-42

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-2 BINOS® 100 2M Specification

Signal inputs / outputs

Signals accessible at 9-pole submin-d plugs and sockets located at the analyzer‘s rear panel:

standard: Analog signal outputs

Digital signal outputs

optional: Analog inputs (TC; cross compensation)

Serial interface (RS232; RS 485) Relay status signals

Signals accessible at screw terminal blocks located at the analyzer‘s rear panel (options): Digital outputs

FOUNDATION

™

Fieldbus

Signal inputs / outputs

Fig.1-32: Socket X2 pin assignment (analog signal outputs; standard)

Note!

Take care of the special installation instructions in section 3-5!

1 2 0 (2) - 10 V DC [option: 0 (0.2) - 1 V DC], channel 1 3 0 (4) - 20 mA, channel 1 (R 4 0 (2) - 10 V DC [Option: 0 (0.2) - 1 V DC], channel 2 5 0 (4) - 20 mA, channel 2 (R 6 7 8 9

⊥⊥

⊥ (V DC)

⊥⊥

⊥ (mA)

⊥⊥

≤ 500 Ω)

The current configuration of voltage output (standard:10 V DC or optional: 1 V DC) is given on order acknowledgement and on nameplte label. Further configurations: see section 5-4-1

Emerson Process Management Manufacturing GmbH & Co. OHG 1-43

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-2 BINOS® 100 2M Specification

Digital Outputs

Electrical specification: max. 30 V , 30 mA Configuring outputs: s. section 5-4-2

Note!

Take care of the special installation instructions in section 3-5!

(external power supply)

load

(external power supply)

Fig.1-33: Connecting digital outputs

⊥⊥

⊥

⊥⊥

Fig.1-34: Plug X3 pin assignment (digital outputs; standard)

Analog inputs (TC; cross compensation)

Permissible signal ranges: 0 (0.2)- 1 V, 0 (2)- 10 V or 0 (4) - 20 mA.

Functional description: s. Abschn. 6-4

Fig.1-34: Plug Analog IN pin assignment (cross compensation; option)

Note!

Take care of the special installation instructions in section 3-5!

Emerson Process Management Manufacturing GmbH & Co. OHG1-44

1 Interfering gas 1 2 3 Interfering gas 2 4 5 not used 6 Interfering gas 3 7 8 not used 9 not used

⊥⊥

⊥ (GND) Interfering gas 1

⊥⊥

⊥ (GND) Interfering gas 2

⊥⊥

⊥ (GND) Interfering gas 3

⊥⊥

Instruction Manual

HAS1xE-IM-HS 03/2005

1-7-2-2 BINOS® 100 2M Specification

Serial Interface

Specification and driving the interface: see section 6-2

Note!

Take care of the special installation instructions in section 3-5!

BINOS® 100 Series

RS 232 configuration

RS 485 configuration

1 GND 2 RxD 3 TxD 4 not used 5 GND 6 7 8 9

1 GND 2 RxD3 RxD+ 4 TxD+ 5 TxD6 7 8 9

not used

Fig.1-36: Socket X4 pin assignment (serial interface; option)

Emerson Process Management Manufacturing GmbH & Co. OHG 1-45

BINOS® 100 Series

Relay status Signals

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-2 BINOS® 100 2M Specification

Design: floating relay contacts Electrical specification: max. 30 V , 1 A, 30 W

Signal configuration: see section 6-1

Note!

T ake care of the special installation instructions in section 3-5!

Signal output (opener)

Signal output (closer)

Fig.1-37: Relay status signals, block diagram

1 2 3 4 5 6 7 8 9

OK / failure

Measuring / Calibration Pump off / on

OK / failure COM Measuring / Calibration COM Pump off / on COM

Pump off / on

*) BINOS® 100 2M / BINOS® 100 F / CAT 100 only

Fig.1-38: Plug X1 pin assignment (relay status signals; option)

Emerson Process Management Manufacturing GmbH & Co. OHG1-46

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-2 BINOS® 100 2M Specification

Digital Inputs

Functional description, configuration and electrical specification: see section 6-3

Note!

T ake care of the special installation instructions in section 3-5!

FOUNDA TION™ Fieldbus

Functional description, configuration and electrical specification: see section 6-3

+ 5 V DC

⊥⊥

⊥

⊥⊥

Start zero calibration channel 1 & 2 Start span calibration channel 1 Start span calibration channel 2 Open zero gas valve Open span gas 1 valve Open span gas 2 valve Close sample gas valve / switch sample pump off

Fig.1-39: Digital inputs (option),

terminal assignment

Fieldbus + Fieldbus Fieldbus + Fieldbus -

Note!

T ake care of the special installation instructions in section 3-5!

Fig.1-40: FOUNDATION™ Fieldbus (option),

terminal assignment

Continue with section 1-7-2-5 "Power Supply“ on page 1-60

Emerson Process Management Manufacturing GmbH & Co. OHG 1-47

BINOS® 100 Series

1-7-2-3 BINOS® 100 F

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-3 BINOS® 100 F Specification

(21.7)

(19.4)

(14)

(13.1)

(11.8)

Fig. 1-41: BINOS® 100 F

Dimensions [approx.; mm (inch) ]

Housing

Weight: approx. 30 - 35 kg (depending on analyzer configuration)

Protection class to EN 60529: IP 65 Gas fittings: quantitiy: max. 8

specification: 6/4 mm PVDF optional 6/4 mm or 1/4", stainless

steel; other on request

(0.7)

(0.4)

(0.7)

Emerson Process Management Manufacturing GmbH & Co. OHG1-48

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-3 BINOS® 100 F Specification

Power supply

Rated input voltage 120 / 230 V 50/60 Hz

manual selector switch at powersupply unit

Input voltage range 85 - 132 V / 176 - 264 V

, 47 - 63 Hz Rated input power max. 350 V A Connection via internal screw terminal near

cable glands, in front of EMC filter (fig. 1-42), cross section: max. 4 mm2, using conductor sleeves is

not required Cable entry via 1 cable gland, classified IP 68 Permissible outer cable diameter for mains cable: 7 - 12 mm.

L N PE

Fig. 1-42:Screw terminals for mains

Emerson Process Management Manufacturing GmbH & Co. OHG 1-49

Instruction Manual

HAS1xE-IM-HS

BINOS® 100 Series

1-7-2-3 BINOS® 100 F Specification

Signal inputs / outputs

Connection via internal screw terminal, located on adaptor elements (fig. 1-43) inside analyzer

Cable entry via up to 3 ca ble g lands, classified IP 68 Permissible outer cable diameter for signal cables: 7 - 12 mm.

internal wiring

03/2005

Fig. 1-43: 9-pole adaptor element for signal cables;

submin-d to screw terminals

Each adaptor is at one side connected to one BINOS® 100 electronic signal output connector and marked accordingly (e.g. signal connector "X1“ --> adaptor element "X1“).

terminals for external wiring

Refer to the schematics later in this manual for correlations between signals and adaptors.

Emerson Process Management Manufacturing GmbH & Co. OHG1-50

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-3 BINOS® 100 F Specification

Available signals standard: Analog signal outputs

Digital signal outputs

optional: Analog inputs (TC; cross compensation)

Serial interface (RS 232; RS 485) Relay status signals Digital outputs FOUNDATION™ Fieldbus

Analog signal outputs

1 2 0 (2) - 10 V DC [option: 0 (0.2) - 1 V DC], channel 1 3 0 (4) - 20 mA, channel 1 (R 4 0 (2) - 10 V DC [Option: 0 (0.2) - 1 V DC], channel 2 5 0 (4) - 20 mA, channel 2 (R 6 7 8 9

Fig.1-44: Pin assignment adaptor element X 2 (analog signal outputs; standard)

Note!

Take care of the special installation instructions in section 3-5!

⊥⊥

⊥ (V DC)

⊥⊥

⊥ (mA)

⊥⊥

≤ 500 Ω)

The current configuration of voltage output (standard:10 V DC or optional: 1 V DC) is given on order acknowledgement and on nameplte label. Further configurations: see section 5-4-1

Emerson Process Management Manufacturing GmbH & Co. OHG 1-51

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-3 BINOS® 100 F Specification

Digital Outputs

Electrical specification: max. 30 V , 30 mA, "open collector“

Configuring outputs: s. section 5-4-2

Fig.1-45:Pin assignment adaptor element X3

(digital outputs; standard)

⊥⊥

⊥

⊥⊥

Note!

Take care of the special installation instructions in section 3-5!

(external power supply)

load

(external power supply)

Fig.1-46: Connecting digital outputs

Analog inputs (TC; cross compensation)

Permissible signal ranges: 0 (0.2)- 1 V, 0 (2)- 10 V or 0 (4) - 20 mA, depending on configuration

Functional description: s. section 6-4

1 Interfering gas 1 2 3 Interfering gas 2 4 5 not used 6 Interfering gas 3 7 8 not used 9 not used

Fig.1-47: Pin assignment adaptor element Analog IN (cross compensation; option)

Note!

Take care of the special installation instructions in section 3-5!

⊥⊥

⊥ (GND) Interfering gas 1

⊥⊥

⊥ (GND) Interfering gas 2

⊥⊥

⊥ (GND) Interfering gas 3

⊥⊥

Emerson Process Management Manufacturing GmbH & Co. OHG1-52

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-3 BINOS® 100 F Specification

Serial Interface

Specification and driving the interface: see section 6-2

1 GND 2 RxD 3 TxD 4 not used 5 GND 6 7 8 9

not used

RS 232 configuration

Fig.1-48: Pin assignment adaptor element X4 (serial interface; option)

Relay status Signals

Design: floating relay contacts Electrical specification: max. 30 V , 1 A, 30 W

Signal configuration: see section 6-1

Note!

Take care of the special installation instructions in section 3-5!

1 GND 2 RxD3 RxD+ 4 TxD+ 5 TxD6 7 8 9

not used

RS 485 configuration

Note!

Take care of the special installation instructions in section 3-5!

Signal output (opener)

Signal output (closer)

1 2 3 4 5 6 7 8 9

*) BINOS® 100 2M / BINOS® 100 F / CAT 100 only

OK / failure

Measuring / Calibration Pump off / on

OK / failure COM Measuring / Calibration COM Pump off / on COM

Pump off / on

Fig.1-50: Pin assignment adaptor X1

(relay status signals; option)Fig.1-49: Relay status signals, block diagram

Emerson Process Management Manufacturing GmbH & Co. OHG 1-53

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-3 BINOS® 100 F Specification

Digital Inputs

Functional description, configuration and electrical specification: see section 6-3

Note!

T ake care of the special installation instructions in section 3-5!

FOUNDA TION™ Fieldbus

Functional description, configuration and electrical specification: see section 6-3

+ 5 V DC

⊥⊥

⊥

⊥⊥

Fig.1-51: Digital inputs (option),

terminal assignment

Fieldbus + Fieldbus Fieldbus + Fieldbus -

Note!

T ake care of the special installation instructions in section 3-5!

Fig.1-52: FOUNDATION™ Fieldbus (option),

terminal assignment

Continue with chapter 2 "Measuring principles“, page 2-1

Emerson Process Management Manufacturing GmbH & Co. OHG1-54

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-4 CAT 100 Specification

1-7-2-4 CAT 100

(14.3)

(0.63)

(25.4)

Fig. 1-53: CAT 100

Dimensions [approx.; mm (inch) ]

(0.85)

(13)

Housing

Weight: approx. 70 kg

(depending on analyzer configuration)

(27)

Protection class to EN 60529: IP 65 (IP 66 w/o breather), optional with

internal tropicalization

Gas fittings: quantity: max. 1

specification: 1/4“ stainless steel

Power Supply

Rated input voltage 1 15-230 V 50/60 Hz Input voltage range 85 - 264 V , 47 - 63 Hz Rated input power max. 240 W Connection via screw terminal blocks in

junction box (fig. 1-54), cross section: 4 mm

max. Cable entry: 1 cable gland, to be provided by customer Cable gland specification: Threat M20 x 1.5 metric, minimum protection

class to meet housing protection class as given on name plate label (IP 65 or IP 66 or better)

Emerson Process Management Manufacturing GmbH & Co. OHG 1-55

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-4 CAT 100 Specification

124

241

1 2345

Fig. 1-54: CAT 100

junction box, interior view

1 Cable gland mains 2 Mains terminals 3 Upper signal terminals (24)

4 Lower signal terminals (24). 5 Signal cable glands (max. 3)

Emerson Process Management Manufacturing GmbH & Co. OHG1-56

Instruction Manual

HAS1xE-IM-HS 03/2005

Signal inputs / outputs

BINOS® 100 Series

1-7-2-4 CAT 100 Specification

Connection via screw terminal blocks in junction box (fig. 1-54), cross section: 0.2 - 4 mm

Cable entry: max. 3 cable glands, to be provided by

customer

Cable gland specification: Threat M16 x 1.5 metric, minimum protection

class to meet housing protection class as given on name plate label (IP 65 or IP 66 or better)

Available signals standard: 2 analog signal outputs

8 digital signal outputs

optional: 3 analog inputs (TC; cross compensation)

3 relay status signals 7 digital inputs FOUNDA TION

™

Fieldbus

Serial interface (RS 232; RS 485)

FOUNDA TION™ Fieldbus not in

*) **)

combination with serial interface!

Note!

**)

Either RS 232 or RS 485

Assignment of signals to signal terminals inside junction box varies depending on selected analyzer options. For assignments of your specific analyzer refer to the label on the inner side of the junction box cover.

General terminal assignments (examples) for the different kinds of available signals are given on the following pages.

Emerson Process Management Manufacturing GmbH & Co. OHG 1-57

BINOS® 100 Series

Analog Signal Outputs

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-4 CAT 100 Specification

By default two analog outputs are configured to provide 0(4) to 20 mA signals (one for each channel). V oltage outputs (standard:10 V DC or optional: 1 V DC) may be ordered optionally .

Terminal No. Upper Lower

1 Channel 1 signal GND 2 Channel 2 signal GND

Table 1-6: Terminal assignments analog outputs

The current analog output configuration for a specific instrument is given on order acknowledgement and on the nameplate label of the analyzer module. Further configurations: see section 5-4-1.

Note!

Take care of the special installation instructions in section 3-5!

Emerson Process Management Manufacturing GmbH & Co. OHG1-58

Instruction Manual

HAS1xE-IM-HS 03/2005

Digital Outputs

BINOS® 100 Series

1-7-2-4 CAT 100 Specification

Electrical specification: max. 30 V , 30 mA, "open collector“

Configuring outputs: s. section 5-4-2

Note!

Take care of the special installation instructions in section 3-5!

T erminal No. Upper Lower

5 GND

Thresholds 6 Ch1: upper threshold Ch1: lower threshold

7 Ch2: upper threshold Ch2: lower threshold

Valve controls 8 Ch1: span gas Ch2: span gas

9 Zero gas Sample gas

Table 1-7: Terminal assignments digital outputs

(external power supply)

load

(external power supply)

Fig. 1-55: Connecting digital outputs

Emerson Process Management Manufacturing GmbH & Co. OHG 1-59

BINOS® 100 Series

1-7-2-4 CAT 100 Specification

Analog inputs (TC; cross compensation)

Permissible signal ranges: 0 (0.2)- 1 V, 0 (2)- 10 V or 0 (4) - 20 mA, depending on configuration

Functional description: s. section 6-4

Terminal No. Upper Lower

13 Interfering Gas 1 GND 1 14 Interfering Gas 2 GND 2 15 Interfering Gas 3 GND 3

Instruction Manual

HAS1xE-IM-HS

03/2005

Note!

Take care of the special installation instructions in section 3-5!

Table 1-8: Terminal assignments analog inputs

Serial Interface

Specification and driving the interface: see section 6-2

Terminal No. Upper Lower

RS 232 3 RxD GND

4 TxD GND

Terminal No. Upper Lower

RS 485 3 RxD + GND

4 TxD + TxD 5 RxD -

Note!

Take care of the special installation instructions in section 3-5!

Table 1-9: Terminal assignments serial interface

Emerson Process Management Manufacturing GmbH & Co. OHG1-60

Instruction Manual

HAS1xE-IM-HS 03/2005

Relay status Signals

BINOS® 100 Series

1-7-2-4 CAT 100 Specification

Design: floating relay contacts Electrical specification: max. 30 V , 1 A, 30 W

Signal configuration: see section 6-1

Terminal No. Upper Lower

10 OK / Failure OK / Failure 11 Meas / Calib Meas / Calib 12 Pump Pump

Table 1-10:Terminal assignment relay status signals

Note!

Take care of the special installation instructions in section 3-5!

Signal "input"

Fig.1-56: Relay status signals, block diagram

Emerson Process Management Manufacturing GmbH & Co. OHG 1-61

Signal "output" (opener)

Signal "output" (closer)

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

1-7-2-4 CAT 100 Specification

Digital Inputs

Functional description, configuration and electrical specification: see section 6-3

Terminal No. Upper Lower

16 +V5 GND 17 zero cal I&II span I 18 span II zero valve 19 span valve I span valve II 20 sample valve

Table 1-11: Terminal assignment digital inputs

FOUNDATION™ Fieldbus

Functional description, configuration and electrical specification: see section 6-3

Note!

Take care of the special installation instructions in section 3-5!

Note!

Take care of the special installation instructions in section 3-5!

Terminal No. Upper Lower

3 FB + FB - 4 FB + FB -

Table 1-12: Terminal assignment FOUNDATION™ Fieldbus

Emerson Process Management Manufacturing GmbH & Co. OHG1-62

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

1-7-2-5 UPS 01 Power Supply Specification

1-7-2-5 External Power Supply Unit for

Tabletop and Rack Mount Analyzers

This power supply unit may be ordered for supplying tabletop analyzers and rack mount analyzers not requiring a rail mounted power supply .

Model designation UPS 01 T

Input

Rated input voltage 120 / 230 V 50/60 Hz Input voltage range 99 - 138 / 187-264 V Rated input power max. 240 VA Input connector IEC plug (fig. 1-58a)

Output

Rated output voltage 24 V

(+- 5 %) Rated output current max. 5 A Output connector 3 pole XLR socket (fig. 1-58b)

Protection measures

Overload protection Current limitation, typ. 1 10% I

rated

, straight characteristic, output permanent short-circuit proof

Overtemperature protection Reduction of output voltage until unit

switches off. Return to normal operation after cooling down.

Emerson Process Management Manufacturing GmbH & Co. OHG 1-63

BINOS® 100 Series

1-7-2-5 UPS 01 Power Supply Specification

54,2

Instruction Manual

HAS1xE-IM-HS

03/2005

57,7

105,9

Fig. 1-58a: IEC mains input plug

275,3

Pin 1: ME Pin 2: + 24 V Pin 3: 0 V ( Shield: Housing

Fig. 1-57: Power supply UPS 01 / 01 T

Dimensions (approx. [mm])

Fig. 1-58b: 24 V DC output socket

Weight approx. 2.5 kg

(shield)

⊥⊥

⊥)

⊥⊥

Pin assignment

Compliances

Electrical safety EN 60950, UL1950, CSA22.2 NO 950-95 Electromagnetic compatibility EN 50081-1 (emmision)

EN 50082-2 (immunity) and others

Emerson Process Management Manufacturing GmbH & Co. OHG1-64

Instruction Manual

HAS1xE-IM-HS 03/2005

1-7-2-6 5 A Rail Mount Power Supply Specification

1-7-2-6 5 A Power Supply Unit for DIN Rail

Installation

This power supply unit may be ordered for supplying analyzers installed in a rack, where mounting the power supply on a DIN rail is required.

Model designation SL5

Input

BINOS® 100 Series

Rated input voltage (manual switch) 100-120 / 220-240 V

Input voltage range 85 - 132 / 176 - 264 V

50/60 Hz

, 47 - 63 Hz

Rated input current < 2.6 A (switch at 115 V position)

< 1.4 A (switch at 230 V position)

Input Screw terminals at front (bottom)

Output

Rated voltage 24 V

(+ 5 %, -1 %) Output current max. 5 A Output Screw terminals at front (top)

Efficiency

Efficiency typ. 90 % (230 VAC, 24 V / 5 A) Losses typ. 13.3 W (230 VAC, 24 V / 5 A)

Protection Measures

Overload protection against short circuit, overload and

open circuit

Overtemperature protection Derating > 60° C

Emerson Process Management Manufacturing GmbH & Co. OHG 1-65

BINOS® 100 Series

1-7-2-6 5 A Rail Mount Power Supply Specification

Instruction Manual

HAS1xE-IM-HS

03/2005

Right side Front side Bottom side

Fig. 1-59: Power Supply SL05

Dimensions (approx. [mm])

Design and Installation

Weight ca. 0.62 kg Dimensions (w x h x d) 65 mm x 125 mm x 103 mm Sp acing for cooling above / below 25 mm each

left / right sides 15 mm each

Compliances

Electrical safety EN 60950, EN 50178, UL1950,

CSA22.2 Nr. 234-M90

Electromagnetic compatibility EN 50081-1, class B (emission)

EN 50082-2, class A (immunity) and others

Emerson Process Management Manufacturing GmbH & Co. OHG1-66

Instruction Manual

HAS1xE-IM-HS 03/2005

1-7-2-7 10 A Rail Mount Power Supply Specification

1-7-2-7 External 10A Power Supply Unit

for DIN Rail Installation

This power supply unit may be ordered for supplying analyzers installed in a rack, where mounting the power supply on a DIN rail is required.

Model designation SL10

Input

BINOS® 100 Series

Rated input voltage (manual switch) 100-120 / 220-240 V

Input voltage range 85 - 132 / 176 - 264 V

50/60 Hz

, 47 - 63 Hz

Rated input current < 6 A (switch at 1 15 V position)

< 2.8 A (switch at 230V position)

Input Screw terminals at front (left side)

Output

Rated voltage 24 V

(+ 5 %, -1 %) Output current max. 10 A Output Screw terminals at front (right side)

Efficiency

Efficiency typ. 89 % (230 VAC, 24 V / 10 A) Losses typ. 29 W (230 VAC, 24 V / 10 A)

Protection Measures

Overload protection against short circuit, overload and

open circuit

Overtemperature protection Derating > 60° C

Emerson Process Management Manufacturing GmbH & Co. OHG 1-67

BINOS® 100 Series

1-7-2-7 10 A Rail Mount Power Supply Specification

Instruction Manual

HAS1xE-IM-HS

03/2005

Right side Front side Bottom side

Fig. 1-60:Power Supply SL 10

Dimensions (approx. [mm])

Design and Installation

Weight approx. 1.2 kg Dimensions (w x h x d) 120 mm x 124 mm x 102 mm Sp acing for cooling above / below 25 mm each

left / right sides 15 mm each

Compliances

Electrical safety EN 60950, EN 50178, UL1950,

CSA22.2 Nr. 234-M90

Electromagnetic compatibility EN 50081-1, class B (emission)

EN 50082-2, class A (immunity) and others

Emerson Process Management Manufacturing GmbH & Co. OHG1-68

Instruction Manual

HAS1xE-IM-HS 03/2005

1-7-2-8 10 A Tabletop Power Supply Unit

1-7-2-8 10 A T abletop Power Supply Unit

BINOS® 100 Series

This power supply unit may be ordered for supplying two tabletop analyzers by one shared power supply unit.

A variation for installation in a module rack is available, too, with output currents of 10 A or 5 A

Model designations 10 A tabletop power supply unit

10 A rack module power supply unit 5 A rack module power supply unit

For electrical input and output data, efficiency , protection measures and compliances (internal power supply unit only) see

section 1-7-2-7 for 10 A versions section 1-7-2-6 for 5 A version.

Rear side

Front side

Interior view (cover removed)

Fig. 1-61: 10 A Tabletop Power Supply

Dimensions (approx. [mm])

Design and Installation

Dimensions, approx. (w x h x d) 142 mm x 260 mm x 128 mm Sp acing for cooling front / rear side 15 mm each

Emerson Process Management Manufacturing GmbH & Co. OHG 1-69

BINOS® 100 Series

1-7-3 Specifications at the Nameplate Label

Instruction Manual

HAS1xE-IM-HS

03/2005

The analyzer nameplate label gives important information about the instrument‘s configuration, installed measuring principle(s), sample gas(es), measuring range(s), power supply and analog output configuration. In case an instrument is built according a suitability approval the related certificate number is given, too.

Model and installed measuring principles (here: 2 x IR)

Channel 1: Gas and measuring range (here: CO, 1000 ppm)

Analog output configuration

Certificate no. of suitability test (if applic.)

The nameplate label is located either on the instruments left or right housing side or at the inner side of the front door (BINOS

100 F). The CAT nameplate label is located at the housings left side whereat the label as it is shown below is affixed to the inner analyzer module.

Serial number

Channel 2: Gas and measuring range (here: CO2, 100 ppm)

Power supply rating

International approval marks

Fig. 1-62: Analyzer Nameplate Label (example)

Emerson Process Management Manufacturing GmbH & Co. OHG1-70

Instruction Manual

HAS1xE-IM-HS 01/2007

BINOS® 100 Series

1-8 Suitability Approvals

Instrument Components & Ranges Approvals & Report No.

BImSchV

BINOS 100 M

BINOS 100 2M BINOS 100 F CAT 100

OXYNOS 100

CO: 0 - 250 ppm (0 - 250 mg/Nm³)

: 0 - 25 % (electrochemical)

CO: 0 - 250 ppm (0 - 250 mg/Nm³) O2: 0 - 25 % (electrochemical)

: 0 - 25 % (paramagnetic) TUEV Bavaria report no. 156 3793

O2: 0 - 25 % (electrochemical) O

: 0 - 25 % (paramagnetic) TUEV Bavaria report no. 156 3793

TI Air, 13 EN ISO 14956, EN 14181 (QAL 1)

TUEV Nord report no. 95 CU 054/B

TI Air, 13

TUEV Nord report no. 95 CU 054/B

TI Air, 13

TUEV Nord report no. 95 CU 054/B

Emerson Process Management Manufacturing GmbH & Co. OHG 1-71

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

01/2007

Emerson Process Management Manufacturing GmbH & Co. OHG 1-72

Instruction Manual

HAS1xE-IM-HS 03/2005

BINOS® 100 Series

Chapter 2

Measuring Principles

BINOS® 100 series analyzers utilize several measuring principles or combinations of principles, depending on measured gas components. This provides best possible results as the principle always is adjusted to meet the specific characteristics of the particular gas. The following sections introduce the available measuring principles and show their specific characteristics.

2-1 Infrared Measurement (IR)

This principles makes use of infrared light absorbed by the sample gas. The wave length of the absorbed portion of IR light characterizes the gas component whereas the intensity of absorption is a measure of concentration.

Two different IR measuring principles are available, both comparing concentration depend and concentration independ signals. The difference of these two signals results in a measure of concentration.

2-1-1 Interference Filter Correlation (IFC)

An undivided analysis cell is alternately passed by light of two different wave lengths, filtered by interference filter out of the spectrum of an IR source: One wavelength covers the absorption band of the measured gas component, the other is selected to cover a region where no absorption occures.

Fig. 2-1 shows an example of interference filter transmissions and absorption bands of the gas components CO can CO2. It‘s easy to see that the interference filters‘ transmissible spectral bands overlap the absorption bands of the gases, whereas within the bandwidth of the reference filter no absorptin takes place. Other gases (CH4) and HC do not affect the measuring result because they do not absorb IR light of these wavelengths.

The gas component to be measured and the concentration defines which principle is used in a certain application:

Emerson Process Management Manufacturing GmbH & Co. OHG 2- 1

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

2-1 Infrared Measurement (IR)

9075604530150

Transmisson [%]

Reference

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

Wavelength [nm]

Absorption bands

Interference

filters

Fig. 2-1: Absorption bands of measured gases and

transmission of interference filters

Transmission [%]

18 36 54 72 900

A pyroelectrical detector generates a signal using the effect of charge flow caused by heat flow within a piezo crystal: The IR radiation passing measuring cell and filters results in a change of temperature when arriving at the detector. The IR absorption is different for measuring wavelength and reference wavelength so the crystal is alternately more or less heated. As result the detector gives an alternating voltage signal which is passed to electronics for further processing.

Emerson Process Management Manufacturing GmbH & Co. OHG2-2

Instruction Manual

HAS1xE-IM-HS 03/2005

2-1 Infrared Measurement (IR)

2-1-2 Opto Pneumatic Measuring Principle

BINOS® 100 Series

This principle utilizes a separated analysis cell whose one side is passed by the sample gas. The other side (reference side) is either filled with an inert gas (e.g. nitrogen) or passed by a reference gas stream, depending on application. Both sides of the cell are alternately irradiated with IR light of same intensity , which afterwards passes a filtering cell before it arrives at the detector. The opto pneumatical detector, which is used instead of the pyroelectrical detector with the

absorption chamber

flow channel

with

micro flow detector

IFC principle, converts the radiation from sample side and reference side into a voltage signal proportional to the radiation intensity . The pneumatical detector consists of a gas filled absorption chamber and a compensation chamber, both connected by a flow channel. A micro flow detector is placed within this channel to measure least flows.

CaF2 window

gas filler

compensation chamber

Fig. 2-2: Gas Detector Design Principle

Emerson Process Management Manufacturing GmbH & Co. OHG 2- 3

BINOS® 100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

2-1 Infrared Measurement (IR)

The detector is filled with the gas to be measured and therefore sensitive to the related characteristic wavelength band only .

The absorption chamber is sealed with a window transparent for IR radiation [CaF (Calziumfluorid)] .

There is no absorption when the IR radiation passes the reference side of the analysis cell , so the intensityis at a maximum when it arrives at the detector. The gas within the detector is heated, therefore expands and flows from absorption chamber through flow channel to the compensation chamber. This flow generates a voltage signal.

When the IR radiation passes the sample side of the analysis cell, part of it is absorbed by the sample gas decreasing the radiation intensity . As an effect the gas within the detector cools down and flows from the compensatoin chamber back into the absorption chamber. This flow again causes a voltage signal by the micor flow detector which is now reverse to the previous signal.

So the micro flow detector generates alternating signals. The flow channel is designed to not influence the gas flow and therefore the change in signal is proportional to the change in radiation intensity which is proportional to the concentration of gas to be measured.

2-1-3 Technical Implementation

The broadband IR radiation emitted by a special source passes a chopper wheel (fig. 2-3 showing a dual channel analyzer). In case

of IFC principle it passes additional optical filters, before entering the analysis cell. The radiation leaving the cell is focused to the detector by means of a filter cell. The detector output signal is passed to micro processor controlled electronics conditioning and converting it to reasonable units (V ol-%, ppm, mg/m³, etc.) shown on the 7 segment display .

Depending on gas component and measuring range several photometer designs are used with BINOS® 100 series analyzers, differing in analysis cell length, kind of detector and used filters. Optionally the assemby may be sealed against ambience: O-rings between the components prevent ambient air to come in the optical path and interfere the measurement.

The photometer assembly is mounted on the BKS main board, which itself is placed in housings rail.

The flow detector signal is passed to electronics conditioning the signal and converting it into a usefull format.

Emerson Process Management Manufacturing GmbH & Co. OHG2-4

Rosemount BINOS 100 Series Analyzers including OXYNOS 100, HYDROS 100 and CAT 100-5th Ed. Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

PREAMBLE

DEFINITIONS

SAFETY INSTRUCTIONS

1-1 General Description

1-3 BINOS® 100 2M

1-4 BINOS® 100 F

1-5 CAT 100

1-6 Internal Gas Paths

1-6-1 Gas Paths Materials

1-6-2 Safety Filter

1-6-3 Fittings

1-6-4 Piping

1-6-5 Gas Path Variations

1-7 Technical Data

1-7-1 Common Technical Data

1-7-2 Model Specific Data 1-7-2-1 BINOS® 100,

1-7-2-4 CAT 100

1-7-2-8 10 A Tabletop Power Supply Unit

1-7-3 Specifications at the Nameplate Label

1-8 Suitability Approvals

2-1 Infrared Measurement (IR)

2-1-1 Interference Filter Correlation (IFC)

2-1-2 Opto Pneumatic Measuring Principle

2-1-3 Technical Implementation