Emerson Process Management Series 100 Gas Analyzers Hydros Users Manual ETC00781 BINOS Instruction

BINOS 100 M BINOS 100 2M to the manual 01b01516-1d3f-4c75-a4ce-d3c3f81bb112

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Instruction Manual
ETC00781
February 2004

Series 100 Gas Analyzers
BINOS® 100, BINOS® 100 M
BINOS® 100 2M, BINOS® 100 F
OXYNOS® 100, HYDROS® 100

Software Version 5.1x

www.EmersonProcess.com

ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management (Rosemount Analytical) designs, manufactures and tests
its products to meet many national and international standards. Because these
instruments are sophisticated technical products, you MUST properly install, use, and
maintain them to ensure they continue to operate within their normal specifications. The
following instructions MUST be adhered to and integrated into your safety program when
installing, using and maintaining Emerson Process Management (Rosemount Analytical)
products. Failure to follow the proper instructions may cause any one of the following
situations to occur: Loss of life; personal injury; property damage; damage to this
instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson Process
Management (Rosemount Analytical) representative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the
product.
• Inform and educate your personnel in the proper installation, operation, and
maintenance of the product.
• Install your equipment as specified in the Installation Instructions of the
appropriate Instruction Manual and per applicable local and national codes.
Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update,
program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement
parts specified by Emerson Process Management (Rosemount Analytical).
Unauthorized parts and procedures can affect the product’s performance, place the
safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place,
except when maintenance is being performed by qualified persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice.
1. Edition: 10/2001
2. Edition: 11/2002
Emerson Process Management
Manufacturing GmbH & Co. OHG
Industriestrasse 1
D-63594 Hasselroth
Germany
T +49 (0) 6055 884-0
F +49 (0) 6055 884-209
Internet: www.EmersonProcess.com

3. Edition: 01/2003
4. Edition: 02/2004

SAFETY SUMMARY
GENERAL

Safety Summary
I.

Intended Use Statement

The series 100 instruments are intended for use an industrial measurement device only. It is not
intended for use in medical, diagnostic, or life support applications, and no independent agency
certifications or approvals are to be implied as covering such applications.

II.

Safety Symbols

Several symbols attached to the analyzer or printed in the instruction manual are used to point
out special sources of danger:

Source of danger !
See Operation Manual!

Electrostatic Discharge (ESD) !

Explosives !

Hot components !

Toxic !

Risk to health !

Analyzer specific notes for the user !

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

ETC00781(4) Series 100 e 02/2004

S-1

SAFETY SUMMARY
GENERAL

III.

General

X

To avoid explosion, loss of life, personal injury and damages to this equipment and other
property, all personnel authorized to install, operate and service this equipment should be
thoroughly familiar with and strictly follow the instructions in this manual !
Save these instructions !

X

If this equipment is used in a manner not specified in these instructions, protective features
may be impaired !

X

Correct and safe operation of analyzers calls for appropriate transportation and storage,
expert installation and commissioning as well as correct operation and meticulous
maintenance !

X

Emerson Process Management does not take responsibility (liability) for the customer´s
failure to comply with these requirements !

X

Do not attempt internal service or adjustment unless other person, capable of rendering first
aid and resuscitation, is present !

X

Because of the danger of introducing additional hazards, do not perform any unauthorized
modification to the instrument !
Return the instrument to a Emerson Process Management Sales and Service office for
service or repair to ensure that safety features are maintained !

X

Instruments which appear damaged or defective should be made inoperative and secured
against unintended operation until they can be repaired by qualified service personnel.

S-2

ETC00781(4) Series 100 e 02/2004

SAFETY SUMMARY
GENERAL / GASES AND GAS CONDITIONING (SAMPLE HANDLING)

Do not open instrument when energized !
Component replacement and internal adjustments requires servicing by
qualified personnel only !
Read this instruction manual before attempting to operate the instrument !
Be sure to observe the additional notes, safety precautions and warnings
given in the instruction manual !
Operate analyzer as table-top version or as rack-mountable version (built-in) only
(except of BINOS® 100 F: designed for wall mounting only) !
Do not operate the instrument in the presence of flammable gases or explosive
atmosphere without supplementary protective measures !
Hot components may exist at the photometer or in heated versions !

BINOS 100 F
The analyzer has a weight of approx. 30 - 35 kg.
Lift or carry this unit with at least 2 persons.
For easy transport use a suitable cart or comparable tools.
Verify that the cable fittings with installed cables are hermetic to be
in agreement with protection class IP 65 (according to DIN standard 40050).
The permissible outside diameters of the cables are 7 to 12 mm !
The analyzer is intended to be wall mounted. Use bolts which are
suitable for the weight of the unit and appropriate anchors.
Make sure the wall where the analyzer is intended to be mounted is solid to
hold the analyzer!

ETC00781(4) Series 100 e 02/2004

S-3

SAFETY SUMMARY
GASES AND GAS CONDITIONING (SAMPLE HANDLING) / SUPPLY VOLTAGE

IV. Gases and Gas Conditioning (Sample Handling)
Be sure to observe the safety regulations for the gases
(sample gas and test gases / span gases) and the gas bottles !
Inflammable or explosive gas mixtures must not be purged into the instrument
without supplementary protective measures !
To avoid risks for the operators by explosive, toxic or unhealthy gas
components, first purge the gas lines with ambient air or nitrogen (N2) before
cleaning or exchanging parts of the gas paths.

V.

Supply Voltage
The socket outlet shall be installed near the equipment and shall be easily
accessible to disconnect the device from the socket outlet.
Verify whether the line voltage stated on the instrument or power supply is in
accordance with that of your mains line!
Be sure to observe the safety precautions and warnings given by
manufacturer of power supply !

X

BINOS® 100(M), BINOS® 100 2M (external PS), HYDROS® 100 and OXYNOS® 100 are
Safety Class III instruments.
Verify correct polarity for 24 V DC operation !
Use only power supply VSE 2000, UPS 01 T, DP 157, SL5, SL10 (DP 157 and
SL for rack installation only) or equivalent power supplies to keep the
instrument safe.
If using equivalent power supplies they must have SELV output voltage !

S-4

ETC00781(4) Series 100 e 02/2004

SAFETY SUMMARY
SUPPLY VOLTAGE

X

BINOS® 100 2M (internal PS) and BINOS® 100 F are Safety Class 1 instruments
The analyzer is provided with a protective earth terminal.
To prevent shock hazard, the instrument chassis and cabinet must be connected
to an electrical ground. The instrument must be connected to the AC power
supply mains through a three-conductor power cable, with the third wire firmly
connected to an electrical ground (safety ground) at the power outlet.
If the instrument is to be energized via an external power supply, that goes for the
power supply too.
Any interruption of the protective (grounding) conductor or disconnection of the
protective earth terminal will cause a potential shock hazard that could result in
personal injury. Deliberate disconnection is inadmissible / prohibited !

The analyzer BINOS® 100 F (field housing) has no switch with disconnect
function. The customer has to provide a switch or circuit breaker into his
installation. This switch has to be installed near by analyzer, must be easily
attainable for operator and has to be characterized as disconnector for analyzer.
Cables to external data processing have to be double-insulated against mains
voltage for analyzer BINOS® 100 F !
Use cables suitable for intrinsic safe applications only ! Install internal data lines
that they have a distance to mains voltage lines of at least 5 mm.
This distance has to be valid permanently (e.g. via cable holder) !

24 VDC supply to external components/analyzers with the internal power
supply of BINOS® 100 2M requires a fuse to be connected in series to the
consumer which limits the current consumption to max. 2 A !
Verify correct polarity for 24 V DC supply of external components !

ETC00781(4) Series 100 e 02/2004

S-5

SAFETY SUMMARY
ANALYZER SPECIFIC NOTES FOR USER

VI.

Analyzer specific notes for the user
The installation site for the instrument has to be dry and remain above
freezing point at all times.
The instrument must be exposed neither to direct sunlight nor to strong
sources of heat. Be sure to observe the permissible ambient temperature !
For outdoor sites, we recommend to install the instrument in a protective
cabinet. At least the instrument has to be protected against rain (e.g., shelter).
Do not interchange gas inlets and gas outlets !
All gases have to be supplied to the analyzer as conditionned gases !
If corrosive gases are inserted into the instrument, it has is to be verified that there
are no gas components which may damage the gas path components.
Ensure that all gas connections are made as labeled and are leak free !
Improper gas connections could result in explosion and death !
The unit´s exhaust may contain hydrocarbons and other toxic gases such as
carbon monoxide ! Carbon monoxide is highly toxic !
Permissible gas pressure of sample gas / test gases max. 1,500 hPa !
The exhaust gas lines have to be mounted in a declining, descending,
pressureless and frost-free and according to the valid emission legislation !
In case it is necessary to open the gas paths, close the analyzers
gas connections with PVC caps immediatly to avoid pollution of gas paths !
BINOS® 100 F lift points are labeled ! Labels showing down side for transport !
Do not use electronics of the optional pressurization system as handle !
Use only optional delivered cables from our factory or equivalent shielded cables
to be in agreement with the CE conformity.
The customer has to prove that the shield is connected correctly (chapter 29.10).
Shield and connectors housing have to be connected conductive.
Sub. min. D plugs/sockets have to be screwed to the analyzer.
The analyzer (excepting BINOS® 100 F) is not in agreement with the CE
conformity if optional terminal strip adapters are used In this case CE
conformity must be declared by customer as “manufacturer of system”.

S-6

ETC00781(4) Series 100 e 02/2004

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

VII.

BINOS® 100 F specific notes for use in hazardous areas (EX Zones)
Be sure to observe the additional notes, safety precautions and warnings
given in the supplemental manual for analyzers intended to be used in
hazardous areas.
If you do not have the additional manual available, please contact your
Emerson Process Management Sales Office!

VII.a

Z purge for CSA-C/US Ex Zone 2 Non-Flammable Atmospheres
This enclosure shall not be opened unless the area is known to be free of
flammable materials or unless all devices within have been de-energized !
Upon start-up or after loss of continuous dilution requiring switching off the
electrical supply, purge for 11 minutes with flow rate approx. 55 scfh (26 l/min.,
see chapter 5.3.3) unless the internal atmosphere is known to be well below
the lower explosive limit (LEL) !
This analyzer is not designed for analysis of flammable sample !
Introduction of flammable samples into this equipment could result in explosion,
causing severe personal injury, death or property damage !
Consult factory if flammable samples are to be measured !
Do not open while energized unless it is known that no explosive atmosphere is
present !

ETC00781(4) Series 100 e 02/2004

S-7

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

VIII.

Additional notes for service / maintenance
Do not open instrument when energized !
Component replacement and internal adjustments requires servicing by
qualified personnel only !
Always disconnect power, discharge circuits and remove external voltage
sources before troubleshooting, repair or replacement of component !
Any work inside the instrument without switching off the power must be
performed by a specialist who is familiar with the related danger, only !
To avoid a danger to the operators by explosive, toxic or unhealthy gas
components, first purge the gas lines with ambient air or nitrogen (N2) before
the gas paths are cleaned or parts are replaced.

Hot components may exist at the photometer or in heated versions !
In case of replacing fuses the customer has to be certain that fuses of specified
type and rated current are used. It is prohibited to use repaired fuses or defective
fuse holders or to short-circuit fuse carriers (fire hazard).
Do not open BINOS® 100 F for use in hazardous areas (EX Zones) while
energized unless it is known that no explosive atmosphere is present !
Cleaning of BINOS® 100 F front panel for EX Zone 1:
Danger of electrostatic discharge !
Use damp cloth only for cleaning front panel !

S-8

ETC00781(4) Series 100 e 02/2004

SAFETY SUMMARY
ADDITIONAL NOTES FOR SERVICE / MAINTENANCE

VIII.a

Electrostatic Discharge

The electronic parts of the analyzer can be irreparably damaged if exposed to electrostatic
discharge (ESD).
The instrument is ESD protected when the covers have been secured and safety precautions
observed. When the housing is open, the internal components are not ESD protected anymore.

Although the electronic parts are reasonable safe to handle, you should be aware of the following
considerations:
Best ESD example is when you walked across a carpet and then touched an electrical grounded
metal doorknob. The tiny spark which has jumped is the result of electrostatic discharge (ESD).

You prevent ESD by doing the following:
Remove the charge from your body before opening the housing and maintain during work with
opened housing, that no electrostatic charge can be built up.
Ideally you are opening the housing and working at an ESD protecting workstation.
Here you can wear a wrist trap.

However, if you do not have such a workstation, be sure to do the following procedure exactly:
Discharge the electric charge from your body. Do this by touching a device that is grounded
electrically (any device that has a three - prong plug is grounded electrically when it is plugged
into a power receptacle).
This should be done several times during the operation with opened housing (especially after
leaving the service site because the movement on a low conducting floors or in the air might
cause additional ESDs).

ETC00781(4) Series 100 e 02/2004

S-9

SAFETY SUMMARY
ELECTROSTATIC DISCHARGE

IX.

Operating Conditions according to DMT Approval
(The following is a reprint of chapter 6 of the supplement I to the DMT reports
“IBS/PFG-No. 41300392 NIII” and “IBS/PFG-No. 41300292 NIII” about the performance
test of the stationary gas analyzers BINOS® 100 (M/2M) and OXYNOS® 100).

According to the system version and measuring results included in this report, the stationary
gas analyzers BINOS® 100 (M/2M) from Fisher-Rosemount GmbH & Co. [now: Emerson
Process Management; the editor] are suitable for measuring the concentrations of methane
between 0 and 80 % CH4, of carbon dioxide between 0 and 80 % CO2, of carbon monoxid
between 0 - 200 ppm CO and 0 - 10 Vol.% CO and the stationary gas analyzers BINOS® 100
(M/2M) and OXYNOS® 100 are suitable for measuring of oxygen between 0 - 10 Vol.-%, if the
features and system version go conform with the details contained in the enclosed documents
as stated in this report, if the analysis system is operated accordingly and if the following
requirements are met:

X

When using the gas warning system, it must be ensured that the permissible variations
will not be exceeded, taking into account the systematic failures of the measuring signals
(as indicated in this report) and the local operating conditions. Consider the Code of
Pratice No. T032 of the Labor Association of the Chemical Industry "Usage of stationary
gas warning systems for explosion protection".

X

Verify that the explosion protection requirements are met when using the gas warning
system.

X

Depending on the situation, it must be verified that the preset values are low enough to
allow the system to activate the necessary protection and emergency measures and,
thus, to prevent any critical situations in a minimum period of time.

X

When at system installation, a release of one or both measuring components in the
ambient air might occur, its influence on the measuring result should be proved. A sealed
cell or an external housing purging with sample-free air of measuring gases can be used,
if required.

X

The operability of the alarms and the displays of each system should be tested with clean
air and test gas after the initial operation, after each long-time interruption, and
periodically. The tightness of gas pathes should also be tested. The tests must be
documented by keeping accounts.

S - 10

ETC00781(4) Series 100 e 02/2004

SAFETY SUMMARY
OPERATING CONDITIONS ACCORDING TO DMT APPROVAL

X

The intervals for the periodical tests must be settled by the person being responsible for
the system´s security and in accordance with the Code of Pratice No. T023 of the Labor
Association of the Chemical Industry "Maintenance of stationary gas warning systems for
explosion protection".

X

Consider the superproportional dependency of the barometric pressure on the
measured value for CO2.

X

The system control with serial interfaces described in this operation manual have not
been subject to this investigation.

X

Sample gas condensation in analyzer (components) must be prevented by taking the
necessary steps.

X

When the system is used with aggressive gases, it is to be verified that there are no gas
components which might damage the gas path components.

X

Appropriate dust filters must precede the used systems.

X

The pressure and flow values recommended by the manufacturer should be observed.
An external monitoring of the sample gas flow through the analyzer should be provided.

X

The results of this investigation are based on the systems using software versions “3.03”,
“4.00”, “4.01” and “4.11”. A change of the software version used must be certified by the
Testing Association.

X

It should be ensured that the system parameters for the analog output have been correctly
adjusted. End of range of low concentration should not be identical or lower than the begin
of range. Disregarding these versions, the measurement range should be adjusted
between 0 to 80 % CH4, 0 to 80 % CO2, 0 to 10 % CO or 0 to 10 % O2 resp. when the systems
are used for explosion protection.

X

Read and follow the operation and maintenance manual supplied to and certified by PFG.
It is important that the temperature is kept between 5 and 45 °C.

ETC00781(4) Series 100 e 02/2004

S - 11

SAFETY SUMMARY
OPERATING CONDITIONS ACCORDING TO DMT APPROVAL

X

The analyzer housings must be provided with a permanent type plate indicating the name
of the manufacturer, model number, serial number, and the following reference and date
of testing:
"IBS/PFG-Nr. 41300392" (for CH4, CO2 or CO)
"IBS/PFG-Nr. 41300292" (for O2)
Other designation requirements, such as these according to ElexV, are still valid. With
this type plate, the manufacturer conformes that the features and technical data of the
delivered system are identical with those described in this report. Any system which is not
provided with such a type plate does not go conform with this report.

X

The chapter 6 of this report must be included in the operation and maintenance manual.

X

The manufacturer has to supply the customer with a copy of this report, if required.

X

A print of the report in an abridged version requires the agreement of PFG.

X

The results included in this report may not be altered in publications produced by the
manufacturer.

S - 12

ETC00781(4) Series 100 e 02/2004

SAFETY SUMMARY
OPERATING CONDITIONS ACCORDING TO DMT APPROVAL

ETC00781(4) Series 100 e 02/2004

S - 13

SAFETY SUMMARY

S - 14

ETC00781(4) Series 100 e 02/2004

PREFACE

PREFACE
General Overview
The series 100 of analyzers offers multi-component, multi-method analysis. Different measurement methods can be combined in one analyzer. The following measuring methods of the
individual measuring channels are possible:
IR =
non-dispersive infrared measurement
PO2 =
paramagnetic oxygen measurement
EO2 =
electrochemical oxygen measurement
TC =
thermal conductivity measurement
All analyzers are designed to measure 1 or 2 gas components except of HYDROS® 100 and
OXYNOS® 100 in case of PO2 measurement (both 1 channel only).

a)

Software Versions

Different software versions and analyzer options are available:
BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 (1/4 19" housing, external power supply):
Version 4.11 with optional RS 232/485 Interface (according to DMT Approval)
Version 5.10 with optional RS 232/485 Interface
BINOS® 100 2M (1/2 19" housing, internal power supply):
Version 4.11 with optional RS 232/485 Interface (according to DMT Approval)
Version 5.10 with optional RS 232/485 Interface*)
BINOS® 100 2M (1/2 19" housing, external power supply):
Version 4.11 with optional RS 232/485 Interface (according to DMT Approval)
Version 5.10 with optional RS 232/485 Interface*) and/or with optional 7 digital inputs
Version 5.11 with optional 7 digital inputs and FOUNDATION™ Fieldbus**)
BINOS® 100 F (field housing, internal power supply):
Version 4.11 with optional RS 232/485 Interface (according to DMT Approval)
Version 5.10 with optional RS 232/485 Interface*) and/or with optional 7 digital inputs
Version 5.11 with optional 7 digital inputs and optional FOUNDATION™ Fieldbus**)
*)

not in combination with FOUNDATION™ Fieldbus

**)

not in combination with RS 232/485 interface

ETC00781(4) Series 100 e 02/2004

P-1

PREFACE

b)

Housing Versions

Different housing versions are delivered (for detailed informations see price list):
BINOS® 100
BINOS® 100 M
BINOS® 100 2M

BINOS® 100 F
HYDROS® 100
OXYNOS® 100

P-2

= 1/4 19" housing, ext. PS
= 1/4 19" housing, ext. PS,
= 1/2 19" housing,
internal or external PS,

one or two IR channel
one IR channel and one EO2 channel
one or two IR channel(s) or
one IR channel and one EO2 channel or
one IR channel and one PO2 channel or
one IR channel and one TC channel or
one PO2 channel and one TC channel or
one EO2 channel and one TC channel or
one ot two PO2 channels
one ot two EO2 channels
one or two TC channels
with standard options: one internal sample gas pump
one internal solenoid valve block
one integrated fine dust filter
one integrated flow indicator
= field housing, int. PS,
measuring channels see BINOS® 100 2M
with standard options: see BINOS® 100 2M (dust filter for GP only)
= 1/4 19" housing, ext. PS, one TC channel
= 1/4 19" housing, ext. PS, one or two EO2 channel or
one PO2 channel

ETC00781(4) Series 100 e 02/2004

PREFACE

Area Classification
a)

General Purpose

All analyzer components are installed into a 1/4 19" housing (BINOS® 100 (M), OXYNOS® 100,
HYDROS® 100) or a 1/2 19" enclosure (BINOS® 100 2M), 3 height units. These housings are go
conform to DIN-standard protection class IP 20. The housings are available as rack-mountable
or as table-top versions. The table-top housings are fitted with an additional carrying handle and
additional rubber feets.
Additionally we can deliver a field housing version (BINOS® 100 F). All componets are installed
into a protection housing conforming to DIN-standard protection class IP 65 (approx. NEMA 4/4X).
This enclosure is designed for wall mounting.

b)

Hazardous Areas

For installation in hazardous areas special versions of BINOS® 100 F are avaliable with
adapted options and specifications. These versions are not subject of this manual (except the
variation with Z-purge). For all other analyzer versions intended to be used in hazardous areas
pls. refer to the separate manuals.

Ex Zone 2
The BINOS® 100 F is equipped with
- Pressurization system for ATEX EX Zone 2 Applications
- Z purge for CSA-C/US EX Zone 2 Non-Flammable Atmospheres

Ex Zone 1
The BINOS® 100 F is equipped with
- Pressurization system for ATEX EX Zone 1 Applications

ETC00781(4) Series 100 e 02/2004

P-3

PREFACE

P-4

ETC00781(4) Series 100 e 02/2004

CONTENTS

Table of Contents
SAFETY SUMMARY
I.
II.
III.
V.
VI.
VII.
VII.a
VIII.
VIIIa
IX.

S- 1

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

PREFACE

P- 1

General Overview
a)
Software Versions
b)
Housing Versions

P- 1
P- 1
P- 2

Area Classification
a)
General Purpose
b)
Hazardous Areas
Ex Zone 2
Ex Zone 1

PPPPP-

1.

TECHNICAL DESCRIPTION

1.1
1.2
1.3
1.3.1
a)
b)

Front Panel
Rear Panel
Internal Construction
Internal Gas Paths
Gas Path Material
Gas Path Layout (internal tubing)

ETC00781(4) Series 100 e 02/2004

3
3
3
3
3

1- 1
1- 1
1- 5
1 - 11
1 - 25
1 - 25
1 - 26

I

CONTENTS

2.
2.1
2.1.1
2.1.2
2.1.3
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.2
2.3.3

3.
3.1
3.2

5.
5.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.3
5.3.1
5.3.2
5.3.3
5.4
5.4.1
5.4.2

II

MEASURING PRINCIPLE
IR Measurement
Interference Filter Correlation (IFC Principle)
Opto-Pneumatic Measuring Principle
Technique
Oxygen Measurement
Paramagnetic Measurement
Electrochemical Measurement
Thermal Conductivity Measurement
Sensor Design
Analysis Cell
Measurement Method

PHOTOMETER ASSEMBLY
Photometer with Pyroelectrical Detector (Solid-state detector)
Photometer with Gas Detector

PREPARATION OF START-UP
Installation Site
Gas Conditioning (Sample Handling)
Fine Dust Filter (Option BINOS® 100 2M/F)
Gas Sampling Pump (Option BINOS® 100 2M/F)
Pressure Sensor (Option)
Gas Flow
Gas Connections
Standard
Internal Solenoid Valves (Option BINOS® 100 2M/F)
Purge gas connection of BINOS® 100 F for Ex zones
Additional Hints to BINOS® 100 F (Field Housing)
Wall Mounting
Electrical Connections

2- 1
2- 1
2- 1
2- 3
2- 5
2- 6
2- 6
2- 8
2 - 10
2 - 10
2 - 10
2 - 11

3- 1
3- 1
3- 4

5- 1
5- 2
5- 3
5- 4
5- 4
5- 4
5- 4
5- 5
5- 5
5- 8
5 - 10
5 - 11
5 - 12
5 - 13

ETC00781(4) Series 100 e 02/2004

CONTENTS

6.
6.1
6.2
6.3
6.3.1
6.3.2

7.
7.1
7.2
7.3
7.4

8.
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17
8.18

SWITCHING ON
General
24 V DC Supply
230/120 V AC Supply
BINOS® 100 2M
BINOS® 100 F

KEY FUNCTIONS
FUNCTION
ENTER
INPUT - CONTROL
PUMP (BINOS® 100 2M/F only)

SETTING SYSTEM PARAMETERS
Pressure Correction
Cross Compensation (internal)
Cross Compensation Calibration (internal)
Hold
Automatic Calibration
Tolerance Check
Display Off
Analog Signal Outputs
Flushing Period
User Code
Response Time (t90)
Offset (Begin of range)
End of Range Value
Reset
Program Version
Serial - No.
Pump *)
Pump Control *)

ETC00781(4) Series 100 e 02/2004

6- 1
66666-

1
2
2
4
5

7- 1
7777-

2
4
6
7

8- 1
8- 2
8- 2
8- 3
8- 4
8- 4
8- 5
8- 6
8- 7
8- 8
8- 8
8- 9
8 - 10
8 - 11
8 - 12
8 - 13
8 - 13
8 - 14
8 - 14

III

CONTENTS

9.

CALIBRATION

9.1
9.1.1
9.1.2
9.2
9.2.1
9.2.2
9.3

Manual Calibration
Zeroing
Spanning
Time-Controlled Calibration Mode (Option)
Zeroing
Combined Zeroing and Spanning
Remote-Controlled Calibration Mode (Option)

10. MEASUREMENT / SWITCHING OFF
10.1
10.2

Measurement
Switching Off

11. DIGITAL OUTPUTS
11.1
11.2
11.3

Concentration Limits
Valve Control
Status Signals (Option non-voltage-carrying relay contacts)

12. SERIAL INTERFACE (OPTION)
12.1
12.2
12.3
12.3.1
12.3.2
12.3.3
12.3.4
12.4
12.4.1
12.4.2
12.4.3
12.4.4
12.4.5
12.4.6
12.4.7
12.5
12.5.1
12.5.2

IV

Upgrading Serial Interface / Status Signals
General
Start Up
RS 232 C
RS 485
Switching ON/OFF Interface Operation
Setting Interface Parameters
Telegram Syntax
Start Character ( “$” = Hex 24)
Terminate Character ( “CR” = Hex OD)
Instruction Code
Hyphen Character ( “;” = Hex 3B)
Status Telegram
Numerical Representations
Block Parity Check
Instruction Syntax
Instruction Listing
Response Telegrams

9- 1
9- 2
9- 2
9- 4
9- 7
9- 7
9- 9
9 - 10

10 - 1
10 - 1
10 - 1

11 - 1
11 - 2
11 - 4
11 - 4

12 - 1
12 - 1
12 - 2
12 - 4
12 - 4
12 - 5
12 - 6
12 - 6
12 - 8
12 - 8
12 - 8
12 - 8
12 - 8
12 - 9
12 - 10
12 - 10
12 - 11
12 - 12
12 - 13

ETC00781(4) Series 100 e 02/2004

CONTENTS

13. DIGITAL INPUTS / FOUNDATION™ FIELDBUS
(BINOS® 100 2M/F OPTION ONLY)
13.1
13.1.1
13.1.2
13.1.3
13.1.4
13.2

Digital Inputs
General
Start of Calibration
Valve Control
Pump Control
Foundation™ Fieldbus *)

13 - 1
13 13 13 13 13 13 -

1
1
1
2
2
2

14. CROSS COMPENSATION / SETTING OF RESPSONSE TIME
(TC OPTION ONLY)
14 - 1
14.1
14.1.1
14.1.2

Cross Compensation
Preparing Actions
Adjustment Procedure

14 - 1
14 - 2
14 - 3

16. LIST OF FAILURES

16 - 1

17. MEASURING POINTS OF BKS AND OXS

17 - 1

17.1
17.1.1
17.1.2
17.1.4
17.1.5
17.1.6
17.1.7
17.2
17.2.1

Measuring points of BKS
Supply Voltage + 6 V
Reference Voltage positive
Motor Drive (for IR channel only)
Temperature Sensor
Light Barrier Signal
Analog Preamplifiering
Measuring points of OXS (EO2 measurement)
Sensor Signal

ETC00781(4) Series 100 e 02/2004

17 17 17 17 17 17 17 17 17 -

1
1
1
2
3
4
5
6
6

V

CONTENTS

18. PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS
18.1
18.1.1
18.1.2
18.1.3
18.1.4
18.1.5
18.1.6
18.2
18.3

Plug Pin Allocation of BKS
IR measurement without oxygen channel
Oxygen Measurement without IR channel
IR / Oxygen Measurement combined
TC Measurement without IR channel
IR / TC Measurement combined
Oxygen / TC Measurement combined
Plug Pin Allocation OXS (EO2 measurement only)
Plug Pin Allocation WAP 100 (TC measurement only)

18 - 1
18 18 18 18 18 18 18 18 18 -

1
2
2
3
3
4
4
5
6

19. JUMPER ALLOCATION OF BKS

19 - 1

21. FINE DUST FILTER (OPTION)

21 - 1

22. LEAK TESTING

22 - 1

23. HOUSING

23 - 1

23.1
23.2
23.2.1
23.2.2
a)
b)
23.2.3

Cleaning of Housing Surface
Opening the Housing
1/4 19" Housing
BINOS® 100 2M
Housing Cover
Front Panel
BINOS® 100 F (Field Housing)

23 23 23 23 23 23 23 -

1
2
2
3
3
4
5

24. REPLACEMENT AND CLEANING OF PHOTOMETRIC
COMPONENTS
24.1
24.2
24.3
24.3.1
24.3.2
24.3.3
24.4
24.5
24.6
24.6.1
VI

Taking out the Photometer Assembly
Light Source Replacement
Cleaning of Analysis Cells and Windows
Removal of Analysis Cells
Cleaning
Reinstalling the Analysis Cells
Chopper Replacement
Reinstalling of the Photometer Assembly
Physical Zeroing
Standard Photometer (not sealed version)

24 - 1
24 24 24 24 24 24 24 24 24 24 -

1
2
3
3
4
5
6
6
7
7

ETC00781(4) Series 100 e 02/2004

CONTENTS

24.6.2

Sealed Photometer (Option)

25. CHECKING / REPLACING AN ELECTROCHEMICAL
OXYGEN SENSOR
25.1
25.2
25.2.1
a)
b)
25.2.2
25.2.3
a)
b)
25.2.4

Checking the Sensor
Replacing the Sensor
Remove the old Sensor
Oxygen Measurement without IR - channel
IR / Oxygen Measurement combined
Removing the Sensor
Reinstalling the Sensor
Oxygen Measurement without IR - channel
Combined IR / Oxygen Measurement
Basic settings for the Oxygen Sensor

27. TECHNICAL DATA
27.1
27.2
27.3
27.4
27.5
27.5.1
27.5.2

Options
Housing
Signal Inputs / Outputs, Interfaces
General Specifications
Voltage Supply
Electrical Safety
Power Supplies [UPS 01 T / SL10 / SL5]

24 - 8

25 - 1
25 25 25 25 25 25 25 25 25 25 -

2
3
3
3
5
6
6
6
6
7

27 - 1
27 27 27 27 27 27 27 -

1
1
2
3
9
9
9

28. REPLACING THE EPROM

28 - 1

30. CABLES AND CORDS

30 - 1

30.1
30.2
30.3
30.3
30.3.1
30.3.2

24 V DC Supply Cable
230/120 V AC Input (BINOS® 100 2M, UPS power supply)
Power Supply for Wall Mounted Analyzers (BINOS® 100 F)
Data / Signal Lines
Sub D Sockets, 9 pin
Sub D Plugs, 9 pin

32. FAILURE CHECK LIST
a)
b)

Customer Service
Training

ETC00781(4) Series 100 e 02/2004

30 30 30 30 30 30 -

1
2
2
3
3
3

32 - 1
32 - 4
32 - 4

VII

CONTENTS

VIII

ETC00781(4) Series 100 e 02/2004

CONTENTS

ETC00781(4) Series 100 e 02/2004

IX

CONTENTS

X

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
FRONT VIEW

1.

Technical Description

The different analyzers are based on the same internal main components and differ only by
available options and enclosures.
BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 (1/4 19" enclosures)
BINOS® 100 2M (1/2 19" enclosure )
All analyzer components are installed into enclosure, 3 height units tall. These housings are
classified protection class IP 20. The housings are available as rack-mountable or as table-top
versions. The table-top housings are fitted with an additional carrying handle and additional
rubber feets.
BINOS® 100 F (field housing, wall mountable)
Additional we can deliver a field housing version . All components are installed into a protective
enclosure, classified IP 65 acc. IEC 60529 (approx. NEMA 4/4X). This enclosure is designed
for wall mounting. An magnetically operated impact tested front panel is available as an option.
Special versions are available for installation in hazardous areas, which meet the
requirements of either ATEX (Europe), CENELEC (outside Europe) or North America
(CSA-C/US; Z-purge).
The special conditions for operating ATEX analyzers are described in a supplemental manual.

1.1

Front Panel

The front panel includes the LED displays for both analysis channels and all of the analyzer
operating controls.
The BINOS® 100 2M and BINOS® 100 F front panels show status LEDs for the options
“Solenoid Valves” and “Gas Sampling Pump” and include a key “PUMP” *) to switch on and off
the gas sampling pump.
The front panels of BINOS® 100 2M and BINOS® 100 F may be equipped with an optional fine
dust filter with integrated needle valve or/and a flow meter (for general purpose applications
only).
These options are not available if BINOS® 100 F is intended to be used in hazardous areas (EX
Zones) or if IP 65 is required.

ETC00781(4) Series 100 e 02/2004

1-1

TECHNICAL DESCRIPTION
FRONT VIEW

11

12

250 ppm
CO

1

% O2
para.

paramagnetic
oxygen sensor

% O2
chem.

electrochemical
oxygen sensor

% O2
chem.

2

FUNCTION

ENTER

INPUT - CONTROL

7

4

6

5

Fig. 1-1: BINOS® 100 (M), OXYNOS® 100, HYDROS® 100 Front view
1
2
4
5
6
7
11
12

1-2

LED display (channel 1)
LED display (channel 2)
Input setting control key DOWN
Input setting control key UP
Key ENTER
Key FUNCTION
Fastening screws for the carrying-strap bracket
or rack-mounting purposes
Housing cover fastening screw

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
FRONT VIEW

Needle valve (option)

1

2

³
% O2

1000
ppm

11

10

9

3

8

7

6

5

4

Fig. 1-2: BINOS® 100 2M (standard version), front view
1
2
3
4
5
6
7
8
9
10
11

ETC00781(4) Series 100 e 02/2004

LED display (channel 1)
LED display (channel 2)
Function LED for options "Solenoid Valves / Gas Sampling Pump"
Input setting control key DOWN
Input setting control key UP
ENTER key
FUNCTION key
Key for option “Gas Sampling Pump”
Flow indicator (option)
Fine dust view filter with needle valve (option)
Fastening screws for the carrying strap bracket
or rack-mounting purposes
1-3

TECHNICAL DESCRIPTION
FRONT VIEW

Wall mounting
holder

Fig. 1-2 for
General Purpose
Fastener
front panel

Operation front panel

Fig. 1-4 for
hazardous areas
(ex zones)

Front panel

Fig. 1-3: BINOS® 100 F, front view

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

1-4

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
REAR PANEL

1.2

Rear Panel

The rear panels include
R

the gas line fittings

R

the plug for the electrical supply input

R

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

R

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

R

optionally the subminiature “D” mating plug for analog signal inputs
(interference cross compensation, TC only)

R

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

R

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

For BINOS® 100 2M/F only:
R

optionally the solenoid valve block

R

optionally the terminal strips for the 7 digital inputs

R

optionally the terminal strips for the FOUNDATION™ Fieldbus **) ***)

**)

*)

not in combination with FOUNDATION™ Fieldbus
**)
BINOS® 100 2M with external power supply only
***)
not in combination with RS 232/485 interface

ETC00781(4) Series 100 e 02/2004

1-5

TECHNICAL DESCRIPTION
REAR PANEL

K1

K2

K1

K2

6

5

1

IN

OUT
CROSS COMP.

8
X1 OUTPUT

3

INTERFACE

7

24 V
max.

W

2+

9
1

X3 OUTPUT

X2 OUTPUT

4

2

MADE IN GERMANY

3

Fig. 1-5: BINOS® 100 (M), OXYNOS® 100 (EO2), HYDROS® 100, Rear view
1
2
3
4
5
6
7
8
9

1-6

Gas inlet line fittings
Analog signal output mating socket
24 VDC supply input terminal
Plug for Digital signal output
Gas outlet line fittings
Housing cover fastening screws
mating socket Serial Interface [RS 232 C / 485] (Option)
Plug for Output Relays (Option)
Plug for analog signal inputs
(interference cross compensation, HYDROS® 100 only)

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
REAR PANEL

X2 OUTPUT

INTERFACE

X1 OUTPUT

7

6
IN

1
2

8

3
OUT

24 V
max. 40 W

5

2+
3
1

4
X3 OUTPUT

MADE IN GERMANY

Fig. 1-6: OXYNOS® 100 (PO2), Rear view
1
2
3
4
5
6
7
8

ETC00781(4) Series 100 e 02/2004

Gas inlet line fittings
Analog signal output mating socket
24 VDC supply input terminal
Plug for Digital signal output
Gas outlet line fittings
Housing cover fastening screws
mating socket Serial Interface [RS 232 C / 485] (Option)
Plug for Output Relays (Option)

1-7

TECHNICAL DESCRIPTION
REAR PANEL

1

2

3

4

6

5

7

8

9

17
10

FLOW

11

16

15

14

13

12

Fig. 1-7: BINOS® 100 2M, version A (shown with internal power supply), Rear view with all options
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

1-8

Gas inlet line fitting
2nd gas inlet line fitting (option)
Gas outlet line fitting
2nd gas outlet line fitting (option)
Plug for analog signal inputs
(interference cross compensation, TC only)
“Solenoid valves”: common gas outlet line fitting
“Solenoid valves”: Test gas inlet 1
“Solenoid valves”: Test gas inlet 2
24 VDC output (max. 2 A, see technical data)
Power supply [UPS 01 T (Universal Power Supply)]
Plug Power Supply (Mains line)
“Solenoid valves”: Zero gas inlet
“Solenoid valves”: Sample gas inlet
Plug Digital Outputs (threshold contacts)
Mating socket Serial Interface [RS 232 C / 485] (option)
Mating socket Analog Signal Outputs
Plug Output Relays (status signal option)

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
REAR PANEL

1

2

K1

K2

3

4

K1

8

5

7

9

K2

DIGITAL IN
ANALOG IN
IN

V+
V-

OUT

E1
E2

SPAN 1

E3
E4
E5

X1 OUTPUT

SPAN 2
FLOW
DURCHFLUSS

IN/OUT

MAX.1L/MIN

X2 OUTPUT

E6
E7

OUT
24V
max.120W

X3 OUTPUT

SAMPLE

FB+
FBFB+
FB-

ZERO
1

2
3

16

15 17

14

6

13

12

11

10

Fig. 1-8: BINOS® 100 2M, version B (with external power supply), Rear view with all options
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Gas inlet line fitting
2nd gas inlet line fitting (option)
Gas outlet line fitting
2nd gas outlet line fitting (option)
Plug for analog signal inputs
(interference cross compensation, TC only)
“Solenoid valves”: common gas outlet line fitting
“Solenoid valves”: Test gas inlet 1
“Solenoid valves”: Test gas inlet 2
Terminal strips for the 7 Digital Inputs (option)
Terminal strips for FOUNDATION™ Fieldbus (option)*)
24 V DC supply input terminal
“Solenoid valves”: Zero gas inlet
“Solenoid valves”: Sample gas inlet
Plug Digital Outputs (threshold contacts)
Mating socket Serial Interface **) [RS 232 C / 485] (option)
Mating socket Analog Signal Outputs
Plug Output Relays (status signal option)
*)
**)

ETC00781(4) Series 100 e 02/2004

only possible if serial interface RS 232/485 is not request !
only possible if FOUNDATION™ Fieldbus is not request !

1-9

TECHNICAL DESCRIPTION
REAR PANEL

1

2

K1

K2

3

4

K1

8

5

7 8

7

K2

!
ANALOG IN
IN

OUT

SPAN 1
X1 OUTPUT

SPAN 1

!
SPAN 2
FLOW
DURCHFLUSS

X4 IN/OUT

24V
120W
OUT
OUT

MAX.1L/MIN

X2 OUTPUT

SPAN 2

1

X3 OUTPUT

SAMPLE

2
3

SAMPLE

ZERO

ZERO

15 17

16

14

6

13

12

11

12

13

Fig. 1-9: BINOS® 100 2M (special version), Rear view with all options
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

1 - 10

Gas inlet line fitting channel 1
Gas inlet line fitting channel 2
Gas outlet line fitting channel 1
Gas outlet line fitting channel 2
Plug for analog signal inputs
(interference cross compensation, TC only)
“Solenoid valves”: common gas outlet line fitting
“Solenoid valves”: Test gas inlet 1
“Solenoid valves”: Test gas inlet 2
(open)
(open)
24 V DC supply input terminal
“Solenoid valves”: Zero gas inlet
“Solenoid valves”: Sample gas inlet
Plug Digital Outputs (threshold contacts)
Mating socket Serial Interface [RS 232 C / 485] (option)
Mating socket Analog Signal Outputs
Plug Output Relays (status signal option)

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

1.3

Internal Construction

The analyzers includes the following components:
R

Depending on analyzer configuration
- one or two IR photometer benches
- one IR photometer and one EO2 sensor
- one IR photometer and one PO2 sensor
- one IR photometer and one TC sensor
- one PO2 sensor and one TC sensor
- one EO2 sensor and one TC sensor
- one or two PO2 sensors
- one ot two EO2 sensors
- one or two TC sensors

R

Optionally one pressure sensor (range of 800 to 1,100 hPa).
The concentration values computed by the analyzer will then be corrected to reflect the
barometric pressure to eliminate faulty measurements due to changes in barometric
pressure (see technical data).

R

Optionally one gas sampling pump (BINOS® 100 2M/F only, see chapter 7.4 and 8.17).
[pumping rate maxi. 2,5 l/min. (special solution with 2 pumps with parallel gas paths)].

R

BINOS® 100 2M (standard version) / BINOS® 100 F:
Integrated power supply (230/120 V AC).

R

Optionally solenoid valve unit
(BINOS® 100 2M/F only, special solution with 2 valve blocks with parallel gas paths).
For this case there are built-in 4 (8) solenoid valves (Sample Gas - Zero Gas Span Gas 1- Span Gas 2) at the analyzer.
For manual or automatical adjustment the zero gas and the span gases will be fed to
the solenoid valves controlled by the analyzer.
If a solenoid valve is open there is illuminated a green LED (Fig. 1-2, Item 3) at the front
panel.

ETC00781(4) Series 100 e 02/2004

1 - 11

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Cover metal plate

IR photometer bench
(depending on analyzer
configuration)

PCB BKS

(channel 2)

(channel 1)

Pressure sensor
(option)

Front panel
Fig. 1-10: Inside View BINOS® 100
(1 IR channel analyzer, high measuring range with gas detector)
1 - 12

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Cover metal plate

PCB BKS

IR photometer bench
(depending on analyzer
configuration)

electrochemical
oxygen sensor
with PCB “OXS”

(channel 2)

(channel 1)

Pressure sensor
(option)

Front panel
Fig. 1-11: Inside View BINOS® 100 M
(IR channel / electrochemical oxygen measurement)
ETC00781(4) Series 100 e 02/2004

1 - 13

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

to Sensor
from Sensor

Inlet
Outlet

Security dust filter

Heat exchanger view "X" (180° rotate)

Gas line fittings

Heat exchanger

PCB BKS

O2 sensor

Front panel
Fig. 1-12: OXYNOS® 100, Inside View with paramagnetic sensor
1 - 14

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Security dust filter

channel 2

channel 1

Pressure sensor
(Option)

Front panel
Fig. 1-13: OXYNOS® 100, Inside view with electrochemical sensor
ETC00781(4) Series 100 e 02/2004

1 - 15

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

PCB WAP 100

PCB BKS
Out

Thermal conductivity sensor

In

Front panel
Fig. 1-14: HYDROS® 100, Inside view
1 - 16

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Solenoid valves
(Option)

Circuit board BKS
(below physical bench)

Power supply option
(UPS 01)

IR photometer bench
(depending on analyzer
configuration)

Electrochemical
oxygen sensor
with circuit board “OXS”
(depending on analyzer
configuration)
(Channel 2)

(Channel 1)

(Channel 1)

Pressure sensor
(option)

Paramagnetic
oxygen sensor
(depending on analyzer
configuration)

Gas sampling pump
(option)

Fine dust filter
with integrated
needle valve for
regulation of gas
flow rate (option)

Flow indicator
(option)

Fig. 1-15: Inside View dual-channel BINOS® 100 2M (version A)
(IR channel / oxygen measurement, combined)
ETC00781(4) Series 100 e 02/2004

1 - 17

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Solenoid valves
(Option)

Circuit board BKS
Power supply option
(UPS 01)

(Channel 1)

Electrochemical
oxygen sensor
with circuit board “OXS”

Pressure sensor
(option)

Gas sampling pump
(option)

Fine dust filter
with integrated
needle valve for
regulation of gas
flow rate (option)

Flow indicator
(option)

Fig. 1-16: Inside View BINOS® 100 2M (version A)
(1 channel oxygen measurement, electrochemical)
1 - 18

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Solenoid valves
(Option)

Circuit board BKS
(below physical bench)

Power supply option
(UPS 01)

IR photometer bench
(depending on analyzer
configuration)

PCB WAP 100

Electrochemical
oxygen sensor
with circuit board “OXS”
(depending on analyzer
configuration)

Thermal conductivity
sensor
(depending on analyzer
configuration)
Gas sampling pump
(option)

Fine dust filter
with integrated
needle valve for
regulation of gas
flow rate (option)

Flow indicator
(option)

Fig. 1-17: Inside View dual-channel BINOS® 100 2M (version A)
(IR / EO2 , TC / EO2 or IR / TC measurement, combined)
ETC00781(4) Series 100 e 02/2004

1 - 19

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Solenoid valves
(Option)

Circuit board BKS
Power supply option
(UPS 01)

PCB WAP 100

Thermal conductivity
sensor
Paramagnetic
oxygens sensor

Gas sampling pump
(option)

Fine dust filter
with integrated
needle valve for
regulation of gas
flow rate (option)

Flow indicator
(option)

Fig. 1-18: Inside View dual-channel BINOS® 100 2M (version A)
(oxygen measurement (paramagnetic) / thermal conductivity measurement, combined)
1 - 20

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Solenoid valves
(Option)

Circuit board BKS
(below physical bench)

Digital inputs and
FOUNDATION™
Fieldbus
(options)

IR photometer bench
(depending on analyzer
configuration)

Electrochemical
oxygen sensor
with circuit board “OXS”
(depending on analyzer
configuration)

PCB`s WAP 100 and
HEX 01
(intrinsically safe TC
measurement for
potentially explosive
atmosphere,
consult factory)

(Channel 2)

(Channel 1)

(Channel 1)

Thermal conductivity
sensor
(depending on analyzer
configuration)

Gas sampling pump
(option)

Fig. 1-19: Inside View dual-channel BINOS® 100 2M (version B)
(IR channel / oxygen measurement, combined)
ETC00781(4) Series 100 e 02/2004

1 - 21

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

Solenoid valves
(Option)

Circuit board BKS
Digital inputs and
FOUNDATION™
Fieldbus
(options)

PCB`s WAP 100 and
HEX 01
(intrinsically safe
measurement for
potentially explosive
atmosphere,
consult factory)
Thermal conductivity
sensor

Paramagnetic
oxygen sensor

Gas sampling pump
(option)

Fig. 1-20: Inside view dual-channel BINOS® 100 2M w. external P/S (here: version for CAT)
(parmagnetic oxygen measurement & thermal conductivity measurement)
1 - 22

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Gas line fittings

*

Solenoid valves
channel 2
(option)

*

*

*

Solenoid valves
channel 1
(option)

Gas sampling pump
channel 2 (option)

IR photometer benches
(depending on analyzer
configuration)

Gas sampling pump
channel 1
(option)

Fig. 1-21: Inside View dual-channel BINOS® 100 2M (special version)
(two gas sampling pumps and two solenoid valve blocks)
ETC00781(4) Series 100 e 02/2004

1 - 23

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

Terminal strips
for output / input signals

Power Input Fuses

DC 24 V distribution

Photometer / sensor assembly
is dependening on
analyzer configuration

Power supply

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

1 - 24

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

1.3.1

Internal Gas Paths

The materials used for the gas paths are selected according to the application. In marking such
selection the diffusion rates of the individual gas components, their corrosivity, and the temperature and pressure of the sampled gas must be taken into account.

a)

Gas Path Material

The physical and chemical properties of the sampled gas and the operating conditions
(temperature and pressure) of the analyzer determine the materials which are used for gas paths
and gas fittings.

Safety Dust Filter
All analyzers are equipped with a PTFE safety dust filter.This filter is no substitute for the necessary
dust filter to be provided with sample handling systems (described in chapter 5.2).

Fittings
As standard the analyzers are provided with PVDF fittings, 6/4 mm.The analyzers can be delivered
with swagelok® fittings, stainless steel, 6/4 mm or 1/4" as option.
Additional fittings are delivered as special options.

Tubing
As standard the analyzers are provided with Viton tubings or PTFE tubings (6/4 mm).
Additional tubings (e.g. stainless steel) are delivered as special options.

ETC00781(4) Series 100 e 02/2004

1 - 25

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

b)

Gas Path Layout (internal tubing)

The principle various possible layouts of the internal gas lines are summarized in the following
figures.

Analyzer

Gas outlet
(OUT K1)

Gas inlet
(IN K1)

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

Analyzer

Gas outlet
(OUT K1)

Gas outlet
(OUT K2)
Gas inlet
(IN K1)
Gas inlet
(IN K2)

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

1 - 26

ETC00781(4) Series 100 e 02/2004

TECHNICAL DESCRIPTION
INTERNAL CONSTRUCTION

span gas 1
(SPAN 1 / V1)

Analyzer

solenoid valves
(Option)

span gas 2
(SPAN 2 / V2)

sample gas
(SAMPLE / V3)

Gas outlet
(OUT K1)

sample gas pump
(Option)
Flow indicator,
Filter and throttle*)
(Options)

zero gas
(ZERO / V4)

Gas inlet
(IN K1)

Gas outlet
(OUT)

*)

not for BINOS® 100 F in hazardous areas

Gas inlet
(IN K1)

Gas outlet
(OUT)

zero gas
(ZERO / V4)

sample gas
(SAMPLE / V3)

not used

span gas 1
(SPAN 1 / V1)

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

Gas outlet
(OUT K1)

Flow indicator

Gas outlet
(OUT K2)

Gas inlet
(IN K2)

Gas outlet
(OUT)

zero gas
(ZERO / V4)

sample gas
(SAMPLE / V3)

span gas 2
(SPAN 2 / V2)

not used

sample gas pump
(Option)

Fig. 1-26: Tubing in parallel (special version of BINOS® 100 2M analyzer)
(equipped with all options)
ETC00781(4) Series 100 e 02/2004

1 - 27

TECHNICAL DESCRIPTION

1 - 28

ETC00781(4) Series 100 e 02/2004

MEASURING PRINCIPLE
IR MEASUREMENT

2.

Measuring Principle

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

2.1

IR Measurement

The analyzers are non-dispersive infrared photometers (NDIR) using measurement of selective
absorption in a column of gas.
The measuring effect derived from absorption of infrared radiation is due to the gas being
measured. The gas specific wavelengths of the absorption bands characterize the type of gas
while the strength of the absorption gives a measure of the concentration of the component
measured. Due to a rotation chopper wheel, the radiation intensities coming from measuring and
reference side of the analysis cell produce periodically changing signals within the detector.
The detector signal amplitude thus alternates between concentration dependent and concentration independent values.The difference between the two is a reliable measure of the concentration
of the absorbing gas component.
Dependent on measuring component and measuring concentration, two different measuring
methods will be used.

2.1.1

Interference Filter Correlation (IFC Principle)

The undivided analysis cell is alternately illuminated with filtered light concentrated in one of two
spectral separated wave length ranges. One of these two spectrally separated wave length bands
is chosen to coincide with an absorption band of the sample gas, and the other is chosen such
that none of the gas constituents expected to be encountered in practice absorbs anywhere within
the band.
The spectral transmittance curves of the interference filters used in the 100 series analyzer and
the spectral absorption of the gases CO and CO2 are shown in Fig. 2-1. It can be seen that the
absorption bands of these gases each coincide with the passbands of one of the interference
filters. The fourth interference filter, used for generating a reference signal, has its passband in a
spectral region where none of these gases absorb. Most of the other gases of interest also do not
absorb within the passband of this reference filter.
ETC00781(1) Series 100 e 10/2001

2-1

MEASURING PRINCIPLE
IR MEASUREMENT

CO2

45

60

75

Absorption Band

54

Interference Filter

36

CO

CO2

0

HC

18

Reference

Transmittance [%]

72

90

0

15

30

Transmittance [%]

90

CO

3000

3200

3400

3600

3800

4000

4200

4400

4600

4800

5000

5200

5400

5600

5800

6000

Wave Length [nm]

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

The signal generation happens by a pyroelectrical (solid-state) detector.
The detector records the incoming IR radiation. This radiation intensity is reduced by the
absorption of the gas at the corresponding wave lengths. By comparing the intensity at measuring
and reference wave length an alternating voltage signal is developed. This signal results from
cooling and heating of the pyroelectrical material of the detector.

2-2

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE
IR MEASUREMENT

2.1.2

Opto-Pneumatic Measuring Principle

A thermal radiator generates the infrared radiation passing through a chopper wheel. This
radiation alternately passes through a filter cell and reaches the measuring and reference side of
the analysis cell with equal intensity.
After passing another filter cell the radiation reaches the pneumatic detector.
The pneumatic detector compares and evaluates the radiation from the measuring and reference
sides and converts them into voltage signals proportional to their intensity via a preamplifier.
The detector consists of a gas-filled absorption and a compensation chamber which are
interconnected via a flow channel.

Absorption chamber

CaF2 Window

Gas intake connection

Flow channel with
Microflow sensor

Compensation chamber

Fig. 2-2: Principle Design of Gas Detector

ETC00781(1) Series 100 e 10/2001

2-3

MEASURING PRINCIPLE
IR MEASUREMENT

In principle the detector is filled with the infrared active gas to be measured and is only sensitive
to this distinct gas with its characteristic absorption spectrum.The absorption chamber is sealed
with a window which are transparent for infrared radiation [usually CaF2 (Calcium fluoride)].
When the IR radiation passes through the reference side of the analysis cell into the detector, no
preabsorption occurs.Thus the gas inside the absorption chamber is heated, expands and some
of it passes through the flow channel into the compensation chamber.
When the IR radiation passes through the open measurement side of the analysis cell into the
detector, a part of it is absorbed depending on sample gas concentration.The gas in the absorption
chamber then is heated less than in the case of radiation coming from reference side. Absorption
chamber gas become colder, gas pressure in the absorption chamber is reduced and some gas
of compensation chamber passes through the flow channel into the absorption chamber.

The flow channel geometry is designed in such a way that it hardly impedes the gas flow by
restriction. Due to the radiation of chopper wheel, the different radiation intensities lead to
periodically repeated flow pulses within the detector.
The microflow sensor evaluates this flow and converts it into electrical voltages.
The electronics, which follow, evaluate the signals and convert them into the corresponding display
format.

2-4

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE
IR MEASUREMENT

2.1.3

Technique

The broadband emission from two IR sources (in the case of dual channel analyzers) passes
through the chopper blade, then, if IFC, through combinations of interference filters, if
optopneumatic principle depending on application through an optical filter (reduction of influences) and enters the analysis cells. The light transmitted through these cells is focused by filter
cells onto the according detector.The preamplified detector output signal is sent to microprocessor
circuitry, which converts the analytical signals to results expressed directly in physical concentration units (Vol.-%, ppm, mg/Nm3 etc.).

MOTOR

Light source
123
123

123456789012345678
12345678901234567890123456
123456789012345678
12345678901234567890123456

Duplex filter disc
Adapter cell
(high measuring range)

Analysis cell measuring side

Analysis cell
(undivided)

Analysis cell reference side

Filter cell

Preamplifier
Filter cell

Pyroelectrical detector
(solid-state detector)

Gas detector

Preamplifier

Chopper blade

Fig. 2-3: Principle Representation
ETC00781(1) Series 100 e 10/2001

2-5

MEASURING PRINCIPLE
OXYGEN MEASUREMENT (PO2 PARAMAGNETIC PRINCIPLE)

2.2

Oxygen Measurement

Depending on analyzer model different measuring methods will be used.
The installed type of oxygen sensor is to identify at the channel code (see Fig. 1-1).
% O2 para. = paramagnetic Sensor
% O2 chem. = electrochemical Sensor

2.2.1

Paramagnetic Measurement

The determination of O2 concentration is based on the paramagnetic principle (magnetomechanic principle).
Two nitrogen filled (N2 is diamagnetic) quartz spheres are arranged in a "dumbbell" configuration
and suspended free to rotate on a thin platinum ribbon in a cell.
A small mirror that reflects a light beam coming from a light source to a photodetector, is mounted
on this ribbon. A strong permanent magnet especially shaped to produce a strong highly inhomogeneous magnetic field inside the analysis cell, is mounted outside the wall.
When oxygen molecules enter the cell, their paramagnetism will cause them to be drawn towards
the region of greatest magnetic field strength.The O2 molecules thus exert different forces which
produce a torque acting on the sphere arrangement, and the suspended “dumbbell”, along with
the mirror mounted on its suspension ribbon, will be angulary rotated away from the equilibrium
position.
The mirror then will deflect an incident light beam onto the photodetector which itself produces an
electric voltage. The electric signal is amplified and fed back to a conducting coil at the “dumbbell”,
forcing the suspended spheres back to the equilibrium position.
The current required to generate the restoring torque to return the “dumbbell” to its equilibrium
position is a direct measure of the O2 concentration in the gas mixture.
The complete analysis cell consists of analysis chamber, permanent magnet, processing
electronics, and a temperature sensor. The sensor itself is thermostat controlled up to approx. 55
°C. For warming up the measuring gas is conducted via a heat-exchanger.
Optionally we have built-in a solvent resistant cell or an intrinsic safe cell for potentially explosive
atmosphere.
2-6

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE
OXYGEN MEASUREMENT (PO2 PARAMAGNETIC PRINCIPLE)

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

ETC00781(1) Series 100 e 10/2001

1
2
3

Permanent magnet
Platinum wire
Mirror

4
5
6
7
8
9

Quartz spheres
Wire loop
Photodetector
Light source
Amplifier
Display

2-7

MEASURING PRINCIPLE
OXYGEN MEASUREMENT (EO2 ELECTROCHEMICAL PRINCIPLE)

2.2.2

Electrochemical Measurement

The determination of O2 concentrations is based on the principle of a galvanic cell.
The principle structure of the oxygen sensor is shown in Fig. 2-5.

(Black)
Lead wire (Anode)
Lead wire (Cathode)

(Red)

Anode (1) (Lead)
O - ring (8)
Plastic disc (9)
Plastic top (10)

Resistor (6)
Thermistor (5)
Acid electrolyte (3)
Sponge disc (7)
Cathode (2) (Gold film)
Teflon membrane (4)

Fig. 2-5: Structure of electrochemical Oxygen Sensor

The oxygen senor incorporate a lead/gold oxygen cell with a lead anode (1) and a gold cathode
(2), using a specific acid electrolyte.To avoide moisture losses at the gold electrode a sponge sheet
is inserted on the purged side.
Oxygen molecules diffuse through a non-porous Teflon membrane (4) into the electrochemical cell
and are reduced at the gold-cathode. Water results from this reaction.
On the anode lead oxide is formed which is transferred into the electrolyte. The lead anode is
regenerated continuously and the electrode potential therefore remains unchanged for a long
time.
The rate of diffusion and so the response time (t90) of the sensor is dependent on the thickness
of the Teflon membrane.

2-8

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE
OXYGEN MEASUREMENT (EO2 ELECTROCHEMICAL PRINCIPLE)

(Red)

(Black)
(11)

Thermistor (5)

Resistor (6)

(-)

(+)

GoldCathode (2)

LeadAnode (1)

O2 + 4 H + + 4 e - ¤ 2 H 2 O

2 Pb + 2 H2O ¤ 2 PbO + 4 H+ + 4 e-

Electrolyte (3)
(ph 6)
Summary reaktion O2 + 2 Pb ¤ 2 PbO

Fig. 2-6: Reaction of galvanic cell

The electric current between the electrodes is proportional to the O2 concentration in the gas
mixture to be measured.The signals are measured as terminal voltages of the resistor (6) and the
thermistor (5) for temperature compensation.
The change in output voltages (mV) of the senor (11) represents the oxygen concentration.

Note !
Depending on measuring principle the electrochemical O2 cell needs a minimum internal consumption
of oxygen (residual humidity avoids drying of the cell). Supply cells continuously with dry sample gas
of low grade oxygen concentration or with oxygen-free sample gas could result a reversible detuning
of O2 sensitivity. The output signal will become instabil.
For correct measurement the cells have to be supplied with O2 concentrations of at least 0.1 Vol.-%.
We recommend to use the cells in intervall measurement (purge cells with conditioned (dust removal
but no drying) ambient air during measurement breaks).
If it is necessary to interrupt oxygen supply for several hours or days, the cell has to regenerate (supply
cell for about one day with ambient air). Temporary flushing with nitrogen (N2) for less than 1 h (e.g.
analyzer zeroing) will have no influence to measuring value.
ETC00781(1) Series 100 e 10/2001

2-9

MEASURING PRINCIPLE
THERMAL CONDUCTIVITY (TC) MEASUREMENT

2.3

Thermal Conductivity Measurement

To measure gases like Hydrogen (H2), Argon (Ar) or Helium (He), the measurement method of
thermal conductivity (TC) will be used.
2.3.1

Sensor Design

The sensor consists of four small PT 100 resistors arranged in a Wheatstone Bridge which is
mounted into a block made of either aluminum, stainless steel or hastelloy, depending on the
application (e.g. stainless steel / hastelloy for corrosive gases). The block is thermostatted to
supress influence of external temperature change.

Fig. 2-7: Thermal conductivity sensor

2.3.2

Analysis Cell

Both the volume of the block and the mass of the resistors have been minimized on order
to obtain short response time.
The block contains two gas paths for sample and reference gas, whereat the reference gas
path is closed for standard applications. Always two sensors are located in the sample and
the reference gas path. The resistors are full glass packaged to withstand agressive gases.
The material in contact with the gases are glass, Gold, Aluminum, stainless steel and
Hastelloy, so a high resistance against corrosion by agressive gases is provided by this
cell.

2 - 10

ETC00781(1) Series 100 e 10/2001

MEASURING PRINCIPLE
THERMAL CONDUCTIVITY (TC) MEASUREMENT

2.3.3

Measurement Method

The entire measurement cell is thermostatted to a temperature of up to 75 °C. The four sensors
are electrically heated to a higher temperature and the signal of the Wheatstone Bridge is
monitored. Depending on the thermal conductivity of the gases that pass the cell, the
temperature of the sensors in contact with the gas changes and thus their electrical resistance.
This changes the output signal of the Wheatstone Bridge and electronic circuitry processes this
signal to obtain standardized signal amplitudes, and transmits these to both an indicator
instrument and to the signal output connector.

ETC00781(1) Series 100 e 10/2001

2 - 11

MEASURING PRINCIPLE
THERMAL CONDUCTIVITY (TC) MEASUREMENT

2 - 12

ETC00781(1) Series 100 e 10/2001

PHOTOMETER ASSEMBLY
PYROELECTRICAL DETECTOR

3.

Photometer Assembly

Depending on gas component and measuring range, different photometer assemblies will be
realized in 100 series.
Optional the photometer can be sealed to ambient air. In this case all parts are sealed with O- rings.
The entire photometer assembly is mounted as a unit on the main circuit board (BKS) by means
of a bracket. The main circuit board is inserted into guide rails in the analyzer housing, to which
the front panel (membrane keypad) and the rear panel are assembled.

3.1

Photometer with Pyroelectrical Detector (Solid-state detector)

Fig. 3-1 shows the schematical photometer assembly for dual channel operation.
The base element for the photometer assembly is the chopper housing (03), upon which the light
source (thermal radiator, 07), the analysis cell (cuvette, 09), and the signal detection unit [filter cell
(14/15), pyroelectrical (solid-state) detector with integrated preamplifier (16)] are all mounted.
The chopper housing also incorporates the duplex filters (04/05) for the selection of spectral bandpass ranges from the broadband emission of the light sources.
Between the two halves of the chopper housing (03), which are sealed together with an O-ring,
is the chopper blade, driven by a stepping motor. Both the chopper housing and the motor
encapsulation are hermetically sealed with respect to the ambient in order to prevent entry of
gases, such as atmospheric CO2, which could produce background absorptivity (preabsorption)
leading to drift effects. An absorber material provides for constant removal of any traces of CO2
which may enter the interior of the chopper housing via diffusion.
The chopper housing additionally incorporates a photoelectric gate for providing a reference
signal for the phase angle of the chopper blade, plus a temperature sensor (28) for monitoring
continuously the photometer assembly temperature.This temperature information is used by the
signal processing electronics for the compensation of thermal effects.

The analysis cells are merely aluminum tubes equipped with sample gas inlet and outlet fittings.
ETC00781(4) Series 100 e 02/2004

3-1

PHOTOMETER ASSEMBLY
PYROELECTRICAL DETECTOR

This extremely simple and windowless design enables easy cleaning of the cells in the event of
contamination.
The only optical surfaces which also might become contaminated are the chopper windows and
the windows of the filter cells; these are accessible upon removal of the cell body.
The filter cell (14/15) has a necked conical shape for optimal adaptation of the analysis cell beam
cross - sectional profile to the active area of the detectors.
For high measurement ranges (up to 100 %), an adapter cell (10) is required.
The use of a spacer ring (08) creates an analysis cell in the space between the exit window of the
adapter cell and the entrance window of the filter cell.

3-2

ETC00781(4) Series 100 e 02/2004

ETC00781(4) Series 100 e 02/2004

3-3

03
04 / 05
06
07
08
09
10
14/15
16
17
18-21
22
23 (24)
25
26
27
28

Chopper Housing
Duplex Filter Disc
Zero - Adjustment Baffle (not for sealed photometer)
Light Source (thermal radiator)
Analysis Cell 1 - 7 mm (spacer ring)
Analysis Cell 50 - 200 mm
Adapter Cell
Filter Cell
Detector
Flange (light source)
O - Rings
Clamp (analysis cells 1-7 mm)
Clamping Collar (analysis cells 1-7 mm)
Clamp (analysis cells 10-200 mm)
Light Source Mounting Screws
Mounting Screws for Analysis Cells/Adapter Cells
Temperature Sensor

PHOTOMETER ASSEMBLY
PYROELECTRICAL DETECTOR

Fig. 3-1: Photometer Assembly with Pyroelectrical Detector

Legends:

PHOTOMETER ASSEMBLY
GAS DETECTOR

3.2

Photometer with Gas Detector

Fig. 3-2 shows schematically the photometer assembly.
This assembly is similar to the assembly with pyroelectrical detector.
The analysis cells are separated into two halves by means of an internal wall along its axis and
both ends are sealed with windows.This divided the analysis cell in measuring side and reference
side.
Sample gas is flowing through measuring side while the closed reference side contains inert gas
(N2).
To prevent measuring errors by preabsorption, two absorber, fitted to the gas connections of the
reference side, absorb CO2 parts.
The filter cell has a single stage conical shape.
The gas detector is connected by a shielded cable to the separate preamplifier.
For small measuring ranges the preamplifier is mounted at the analysis cell.
For high measuring ranges the preamplifier is mounted at two holding clamps.

3-4

ETC00781(4) Series 100 e 02/2004

PHOTOMETER ASSEMBLY
GAS DETECTOR

1

1

2

4

3

6

5

4

5

4

6

2 3

Fig. 3-2: Photometer Assembly 100 Series with Gas Detector
[example above and middle: high measuring ranges,
example below: small measuring ranges.
1
2
3
4
5
6
ETC00781(4) Series 100 e 02/2004

Analysis Cell
Filter Cell
Gas Detector
Holding Device
Preamplifier
Absorber
3-5

PHOTOMETER ASSEMBLY

3-6

ETC00781(4) Series 100 e 02/2004

PREPARATION

5.

Preparation of Start-up

Please check the package and its contents immediately upon receipt.
If any item is damaged or lost you are requested to notify the contractor to undertake a damage
survey and report the loss or damage to us immediately.

BINOS® 100 F:
Unscrew transfer safety lock of photometer sliding carriage (Fig. 5-1) !
Lock the system during transport !

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

ETC00781(4) Series 100 e 02/2004

5-1

PREPARATION
INSTALLATION SITE

5.1

Installation Site

The analyzers must not operate in explosive atmosphere without supplementary
protective measures !
Free flow of air into and out of the analyzers (ventilation slits) must not be
hindered by nearby objects or walls !
Operate analyzer as table-top version or as rack-mountable version (built-in) only
(except of BINOS® 100 F: designed for wall mounting only) !
The installation site for the analyzers has to be dry and remain above freezing
point at all times. The analyzers must be exposed neither to direct sunlight nor
to strong sources of heat.
Be sure to observe the permissible ambient temperatures (c.f. chapter 27:
Technical Data). For outdoor installation, we recommend to install the analyzers
in a protective cabinet. At least, the analyzers has to be protected against rain
(e.g., shelter).

The BINOS 100 series analyzer has to be installed as near as possible to the sample point,
in order to avoid low response time caused by long sample gas lines.
In order to decrease the response time, a sample gas pump with a matching high pumping rate
may be used, while the analyzers has to be operated in the bypass mode or by an overflow
valve to prevent too high flow and too high pressure (Fig. 5-2).

Exhaust

analyzer

Exhaust

Overpressure valve
Filter

Flow meter

Gas sampling pump
Fig. 5-2: 100 series, Bypass installation

5-2

ETC00781(4) Series 100 e 02/2004

PREPARATION
GAS CONDITIONING (SAMPLE HANDLING)

5.2

Gas Conditioning (Sample Handling)

The conditioning of the sample gas is of greatest importance for the successful operation of any
analyzer according to extractive method.
All gases have to be supplied to the analyzers as conditionned gases !
If corrosive gases are inserted into the instrument, it has is to be verified that there
are no gas components which may damage the gas path components.

The gas has to fullfil the following conditions:
It must
R
R
R
R

be free of condensable constituents
be free of dust
be free of aggressive constituents which are not compatible with the material of the gas
paths.
have temperatures and pressures which are within the specifications stated in “Technical
Data” of this manual.

Inflammable or explosive gas mixtures may not be introduced into the analyzers
without supplementary protective measures !

When analysing vapours, the dewpoint of the sample gas has to be at least 10 °C below the
ambient temperature in order to avoid the precipitation of condensate in the gas paths.
Suitable gas conditionning hardware may be supplied or recommended for specific analytical
problems and operating conditions.

ETC00781(4) Series 100 e 02/2004

5-3

PREPARATION
GAS CONDITIONING (SAMPLE HANDLING)

5.2.1

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

A fine dust filter with a pore size of 2 µm may optionally be integrated into the
BINOS® 100 2M/F front panel (Fig. 1-2, Item 10, not for 2 channel analyzers with parallel gas
paths and for BINOS® 100 F analyzers used in hazardous area (Ex zones)).

5.2.2

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

Optional BINOS® 100 2M/F can be equipped with a gas sampling pump (pumping rate max. 2.5
l/min., see chapter 7.4). For special solutions with 2 parallel measuring channels and 2 gas
sampling pumps consult factory.
Lifetime max. 5,000 hours of operation !

5.2.3

Pressure Sensor (Option)

It is possible to integrate a pressure sensor with a range of 800 - 1,100 hPa.
The concentration values computed by the analyzer will then be corrected to reflect the barometric
pressure to eliminate faulty measurements due to changes in barometric pressure (see technical
data, chapter 27.).

5.2.4

Gas Flow

The gas flow rate should be within the range 0.2 l/min to max. 1.5 l/min !
A constant flow rate of about 1 l/min is recommended.
The allowed gas flow rate for analyzers with paramagnetic oxygen sensor and
for BINOS® 100 F analyzers used in hazardous area (Ex zones) is max. 1.0 l/min!
BINOS® 100 2M/F with an optional fine dust filter (see chapter 5.2.1) allow to adjust the flow
with a screw driver via an optional integrated throttle.
It is possible to integrate up to two flow indicators into the BINOS® 100 2M/F front panel
(Fig. 1-2 to 1-4).
5-4

ETC00781(4) Series 100 e 02/2004

PREPARATION
GAS CONNECTIONS

5.3

Gas Connections

The installed gas connections are depending on gas analyzer specification and model. All
fittings are clearly marked.
The fittings are located on the rear panel of the instrument or on the left bottom side.
The exhaust gas lines have to be mounted in a declining, pressureless
and frost-free way and according to the valid emission legislation !
Do not interchange gas inlets and gas outlets !
Ensure that all gas connections are made as labeled and are leak free !
Improper gas connections could result in explosion and death !
The unit´s exhaust may contain hydrocarbons and other toxic gases such as
carbon monoxide ! Carbon monoxide is highly toxic !
Permissible gas pressure max. 1,500 hPa !

5.3.1

Standard Configuration

Depending on analyzer version the following gas connections are installed:
in = Gas inlet
K 1 = measuring channel 1

out = Gas outlet
K 2 = measuring channel 2 *)

Zero gas and span gas are introduced directly via the sample gas inlet. The test gas containers
have to be set up according to the current legislation.
Be sure to observe the safety regulations for the respective gases
(sample gas and test gases / span gases) and the gas bottles !

*)

for HYDROS® 100 with open reference side of sensor the gas fittings of channel 2 are used to
connect the reference gas.

ETC00781(4) Series 100 e 02/2004

5-5

PREPARATION
GAS CONNECTIONS

K1

Gas inlet
fittings

K2

K1

K2

Gas outlet
fittings

OUT

IN

CROSS COMP.

X1 OUTPUT

INTERFACE

3
24 V
max.

W

2+

1

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

X2 OUTPUT

INTERFACE

X1 OUTPUT

IN

Gas inlet
fittings

OUT

24 V
max. 40 W

Gas outlet
fittings

2+
3
1

X3 OUTPUT

MADE IN GERMANY

Fig. 5-3b: OXYNOS® 100 (PO2), gas connections
5-6

ETC00781(4) Series 100 e 02/2004

PREPARATION
GAS CONNECTIONS

Gas inlet
fittings

Gas outlet
fittings

Wall mounting holder

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

Gas connections
Fig. 5-3d: BINOS® 100 F, standard gas connections
ETC00781(4) Series 100 e 02/2004

5-7

PREPARATION
GAS CONNECTIONS

5.3.2

Internal Solenoid Valves (BINOS® 100 2M/F Option)

For operation with optional internal solenoid valves, the following indications have to be
considered:
All necessary gases have to be connected at the corresponding solenoid valve at an overpressure
of 50 - max. 500 hPa.
For 2 channel analyzer with parallel gas paths we can deliver a special solution with 2 valve blocks.
Be sure to observe the safety regulations for the respective gases
(sample gas and test gases / span gases) and the gas bottles !
The test gas containers have to be set up according to the valid regulations.
If a solenoid valve is open there is illuminated a green LED (Fig. 1-2, Item 3) at the front panel.

Solenoid valve:
common gas outlet
(to standard gas inlet K1)

Solenoid valve:
span gas 1

Solenoid valve:
span gas 2

Solenoid valve:
sample gas

Solenoid valve:
zero gas

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

5-8

ETC00781(4) Series 100 e 02/2004

PREPARATION
GAS CONNECTIONS

Solenoid valve:
span gas 1
K1

K2

K1

K2

ANALOG IN
IN

OUT

Solenoid valve:
span gas 2

SPAN 1
X1 OUTPUT

SPAN 2
DURCHFLUSS

IN/OUT

MAX.1L/MIN

X2 OUTPUT

OUT
24V
max.120

X3 OUTPUT

Solenoid valve:
common gas outlet
(to standard gas inlet K1)

SAMPLE

Solenoid valve:
sample gas

ZERO
1

2
3

Solenoid valve:
zero gas

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

Solenoid valve:
not used

Solenoid valve:
Span gas 1
channel 1

!
ANALOG IN

Solenoid valve:
not used

SPAN 1

SPAN 1

SPAN 2

Solenoid valve:
common gas outlet
channel 1
(to standard gas inlet K1)

1

SAMPLE

Solenoid valve:
sample gas
channel 1
Solenoid valve:
zero gas
channel 1

SPAN 2

Solenoid valve:
Common gas outlet
channel 2
(to standard gas inlet K2)

24V
120W
OUT
OUT
T

ZERO

Solenoid valve:
Span gas 2
channel 2

2
3

SAMPLE

ZERO

Solenoid valve:
sample gas
channel 2
Solenoid valve:
zero gas
channel 2

Fig. 5-4c: BINOS® 100 2M (special version), gas connections with 2 solenoid valve blocks

ETC00781(4) Series 100 e 02/2004

5-9

PREPARATION
PURGE GAS CONNECTIONS OF BINOS® 100 F / CONTINUOUS PURGE

5.3.3
a)

Purge gas connection of BINOS® 100 F for Ex zones
ATEX Applications
Refer to the supplemental manual for installing analyzers in hazardous
areas where ATEX is applicable.

b)

Z purge for CSA-C/US Ex Zone 2 Non-Flammable Atmospheres
This analyzer is not designed for analysis of flammable sample !
Introduction of flammable samples into this equipment could result in explosion,
causing severe personal injury, death or property damage !
Consult factory if flammable samples are to be measured !

Z Purge kit is designed for protection against the invasion of flammable gases into enclosure from
outside atmosphere only. It does not provide protection against the release of inflammable gases
contained in the sample gas via internal leakages.
P

Connect purge gas (air or N2) to the BINOS® 100 F inlet via 1/4" O.D. tube connection
(see Fig. 27-4) !
Outlet is done via 3/8" O.D. fitting with analyzer specific insert throttle.

P
.

Use purge gas supply under pressure of 58 psig (4 bar; 5,000 hPa abs.).
This will provide a flow rate approx. 55 scfh (26 l/min.). At this flow rate, five case volumes
of purge gas will pass through the instrument in 11 minutes.
After 11 minutes, reduce the pressure to 5.1 psig (350 mbar; 1,350 hPa abs.), resulting in
a flow rate of approx. 18 scfh (8.5 l/min.). This will provide an enclosure over-pressure of
approx. 0.24 inch H2O (0.6 hPa) for continuous purge.
Pressure inside the housing must not exceed 5 hPa at normal operation or
10 hPa for a short time of less than 1/2 hour resp. !

5 - 10

ETC00781(4) Series 100 e 02/2004

PREPARATION
PURGE GAS CONNECTIONS OF BINOS 100 F / Z PURGE
®

5.4

Additional Hints to BINOS® 100 F (Field Housing)

In the field housing version BINOS® 100 F all componets are incorporated into a protection
housing going conform to DIN-standard protection class IP 65 (approx. NEMA 4/4X). This
housing is designed for wall mounting.
For installation in hazardous areas the BINOS® 100 F is equipped with an impact tested front
panel (according to CENELEC, EN 50014) with touch screen keypad. Optionally we can
provide additional intrinsically safe I/O's and/or ex interface relays (couplers). For European ex
zone 2 a simplified pressurization is installed and individual approval is provided. An EExp
approved “purge system” for European ex zone 1 (both according to CENELEC, EN 50016) or
with Z Purge for measurement of non-flammable gases in hazardous areas (according to CSAC/US for North American Ex zone 2) is another option.

Be sure to observe the additional notes, safety precautions and warnings given
in the individual manuals (simplified pressurization for ex zone 2 /
EExp approved “purge system” for ex zone 1) and in section “Safety Summary,
subsection VII.!

ETC00781(4) Series 100 e 02/2004

5 - 11

PREPARATION
ADDITIONAL HINTS ON BINOS® 100 F (FIELD HOUSING)

5.4.1

Wall Mounting

This housing is designed for wall mounting.
Location of fixing points: see Fig. 5-5.
Lift or carry housing with at least 2 persons because of the high weight of field
housing BINOS® 100 F (approx. 30 - 35 kg for standard housing).
For easy transport use a suitable cart.
Lift points are labeled ! Labels showing down side for transport !
Do not use electronics of optional “purge system” as handle !
Take care to use anchors and bolts specified to be used for the weight
of the units!
Take care the wall the unit is intended to be installed at is solid and
stable to hold the units!

550
492

300

332

approx. 355

10

18

18

Glands
(connection cables)

Fig. 5-5: Dimensional sketch / Drill drawing BINOS® 100 F Standard version
[all dimensions in mm]

5 - 12

ETC00781(4) Series 100 e 02/2004

PREPARATION
®

ADDITIONAL HINTS ON BINOS 100 F (FIELD HOUSING)

5.4.2

Electrical Connections
Be sure to observe the safety precautions and warnings !
Verify, that the cable glands together with installed cables are hermetic
to ensure protection class IP 65 (according to IEC 60529).
The permissible outside diameters of the cables are 7 to 12 mm !

a)

Mains Supply

The analyzer is rated for an operating voltage of 230 V AC or 120 V AC, 47-63 Hz.
The built-in power supply is either of type SL5 or of type SL10 and provides a switch to
manually select the nominal voltage.
P

Open the analyzers front door.

P

Insert the mains line through the cable glands (Fig. 5-6 or 5-5) into the housing.
Connect L , N and PE to the terminals located nearby the powerline filter (Fig. 5-8).
Verify that the line voltage given on the identification plate
(front door inside) complies with that of your power supply line !
Verify that the position of the power supply's voltage selector switch complies
with the voltage of your power supply line (Fig. 27-7, 27-8 and 5-8) !
The BINOS® 100 F (field housing) has no switch with disconnect function.
The customer has to provide a switch or circuit breaker into his installation. This
switch has to be installed near by analyzer, must be easily attainable for operator
and has to be charaterized as disconnector for analyzer.

Front door

cable glands
for data lines
cable gland
for mains line
Wall mounting
holder

Gas connections

Fig. 5-6: BINOS® 100 F, cable glands for lines (side view from left)
ETC00781(4) Series 100 e 02/2004

5 - 13

PREPARATION
ADDITIONAL HINTS ON BINOS® 100 F (FIELD HOUSING)

b)

Optional Signal Lines

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

Open the analyzer's front door.

P

Insert the cable through the cable glands (Fig. 5-6 and 5-5) into the housing.
Connection is to be done to the respective terminal strips (Fig. 5-7 and 5-8).
Assignment see chapter 2.
Cables to external dataprocessing have to be double-insulated against mains
voltage for analyzer BINOS® 100 F !
Use only shielded cables for signal lines! To ensure proper electromagnetic
compatibility (EMC) it is recommended to follow the installation steps given
below.
All unused cable glands need to be sealed using a sealing plug
(part no. ETC00791 or similiar)
Unused cable gland openings in the enclosure need to be covered using a
special screw (part no. ETC 000790 or similiar).

Cable Gland Assembly Instruction
for Shielded Cables
1. Strip the
insulation
2. Uncover
shielding

cable
the

3. Feed cable through
gland nut and into
fixing element
4. Put the shielding
net over the element
the way that it
covers the o-ring 2
mm.
5. Stick the fixing
element into the
neck and fix the
gland.
5 - 14

ETC00791
Cable gland sealing plug

ETC00790
Cable gland allen
screw sealing plug
ETC00781(4) Series 100 e 02/2004

PREPARATION

Terminal strips for
data lines

X11

X9

Terminal strip Interface:
serial interface option

X10
Interface
Serial out

12

1234

F100.1
F100.2

11

Power supply

Fig. 5-7: BINOS® 100 F, Data line connections
Inside view from front (detail, without front door)

ETC00781(4) Series 100 e 02/2004

5 - 15

PREPARATION
ADDITIONAL HINTS TO BINOS® 100 F (FIELD HOUSING)

Terminal strip X3:

analog outputs

digital outputs

Tterminal strips
for mains cord

Powerline filter
(connection of L and N of mains line)

PE
N

X3 Digital out

X2 Analog out

Terminal strip X2:

X1 Status

L

N L PE

Terminal strip X1:
output (status) relays option

Ground conductor pin
(PE mains line)

Fig. 5-8: BINOS® 100 F, Connection data lines / mains line
(inside view, left side panel)

5 - 16

ETC00781(4) Series 100 e 02/2004

SWITCHING ON
GENERAL

6.

Switching On

6.1

General
Be sure to observe the safety precautions and warnings !

Once the instrument has been correctly assembled and installed in accordance with the general
instructions given in section 5., the equipment is ready for operation.
The equipment is switched on by providing the required voltage.
The presence of the supply voltage will be indicated by the illumination of the LED displays.
Upon connection of the supply voltage, the analyzer will perform a self diagnostic test routine.
First the actual program version will be shown.

(analyzers without fieldbus)

or

(analyzers with fieldbus)

Finally either concentration values or error messages will be displayed
If as a result of a battery fault the default values were charged, this will be shown by a flushing “batt.”
This message will disappear after depressing any key.
Analyzer warming-up takes about 15 to 50 minutes, depending on the
installed detectors !

Before starting an analysis, however, the following should be performed:
R entry of the desired system parameters,
R calibration of the analyzer.

Note:
The "X’s" shown in the display indicate a number or combinations of numbers.

ETC00781(4) Series 100 e 02/2004

6-1

SWITCHING ON
24 V DC SUPPLY

6.2

24 V DC Supply

The analyzers of series 100 (with except of BINOS® 100 F and BINOS® 100 2M with internal power
supply) are specified for an operating voltage of 24 V DC. This voltage has to be provided via
a 3-pole XLR flange (male).
The DC supply voltage has to be provided by one of the optional power supplies VSE 2000,
UPS 01 T, DP 157, SL5, SL10 or an equivalent power supply.

P

Connect power supply and analyzer (Fig. 6-1, Plug 24 V DC).
Verify correct polarity before operation (Fig. 29-1) !

P

Connect mains line and power supply.
Be sure to observe the safety precautions and warnings given by
manufacturer of power supply !

6.3

230/120 V AC Supply
X1 OUTPUT

INTERFACE

X2 OUTPUT

Plug 24 V DC
Input

3
24 V
max.

W

2+

1

X3 OUTPUT

MADE IN GERMANY

Fig. 6-1a: BINOS® 100 (M), OXYNOS® 100 (EO2), HYDROS® 100, Voltage supply
6-2

ETC00781(4) Series 100 e 02/2004

SWITCHING ON
24 V DC SUPPLY

INTERFACE

X2 OUTPUT

X1 OUTPUT

IN

Plug 24 V DC
Input

OUT

24 V
max. 40 W
2+
3

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

K1

K2

K1

K2

DIGITAL IN
ANALOG IN
IN

V+
V-

OUT

E1
E2

SPAN 1

E3
E4
E5

X1 OUTPUT

SPAN 2
IN/OUT

X2 OUTPUT

DURCHFLUSS
MAX.1L/MIN

OUT

X3 OUTPUT

24V
max.120W
SAMPLE

E6
E7
FB+
FBFB+
FB-

ZERO
1

2
3

Plug 24 V DC
Input
Fig. 6-1c: BINOS® 100 2M (version B) with external power supply, Voltage supply

ETC00781(4) Series 100 e 02/2004

6-3

SWITCHING ON
230/120 V AC SUPPLY

6.3.1

BINOS® 100 2M

The analyzer BINOS® 100 2M is optional lly equipped with an internal “autoranging” power
supply and is specified for an operating voltage of 230 V AC or 120 V AC resp., 47-63 Hz.
For supply of external components / analyzers there is built in a 24 VDC outlet (a 3-pole XLR flange,
female, max. 2 A).
P

Connect internal power supply and external components (Fig. 6-2, 24 V DC out).
24 VDC supply to external components/analyzers with the internal power
supply of BINOS® 100 2M requires a fuse to be connected in series to the
consumer which limits the current consumption to max. 2 A !
Verify correct polarity for 24 V DC supply to external components before
operation (Section 29.) !

P

Connect mains line and internal power supply (Fig. 6-2, V AC in).
Verify beforehand that the line voltage stated on the power supply meets that
of your power supply line !
The socket outlet shall be installed near the equipment.

6-4

ETC00781(4) Series 100 e 02/2004

SWITCHING ON
230/120 V AC SUPPLY

Socket 24 V DC out

Input
230/120 V AC
POWER
Fig. 6-2: BINOS® 100 2M (version A) shown with internal power supply, Voltage supply

6.3.2

BINOS® 100 F

The analyzer is specified for an operating voltage of 230 V AC or 120 V AC resp., 47-63 Hz..
Built-in power supply (manual switch between 230/120 VAC) is either power supply of type SL5
or of type SL10.

Once the instrument has been correctly assembled and installed in accordance with the general
instructions given in section 5., 5.3.3 and 5.4, the equipment is ready for operation.
The analyzer is switched on by providing the required voltage.

ETC00781(4) Series 100 e 02/2004

6-5

SWITCHING ON

6-6

ETC00781(4) Series 100 e 02/2004

KEY FUNCTIONS

7.

Key Functions

By default the analyzer is operated and programmed by using the membrane keypad with its
four keys (see Fig. 1-1 and 1-2, Item 4 to 7).
If either the BINOS100® 2M or BINOS 100 F analyzer is equipped with an internal pump, the
fifth key “PUMP” is activated by software. (see Fig. 1-2. Item 8 and chapter 7.4).
BINOS® 100 F for use in rough surroundings may optionally be equipped with a touch screen
keypad without fifth key for gas sampling pump. In this case the pump is controlled via software
menu.
Operator guidance prompts will appear on the 4 digit LED displays.
Battery buffering of the stored parameters prevents their loss in the absense of voltage supply.

ETC00781(4) Series 100 e 02/2004

7-1

KEY FUNCTIONS
FUNCTION

7.1

FUNCTION

Pressing this key (Fig. 1-1 and 1-2, Item 3) addresses the individual analyzer functions in
sequence. Merely addressing an analyzer function will not initiate an analyzer action or operation.
The analyzer will stay in measurement mode until the ENTER key is pressed.

Remark concerning the optional touch screen keypad:
To avoid unintended keypad activation all the keys are secured by an additional
user code. This code has to be entered each time before leaving the
measurement display:
After pressing the FUNCTION key the text "Code" appears in the upper display and
the following keys have to be pressed within a time period of 20 seconds: DOWN,
UP, ENTER, FUNCTION. Pressing the correct sequence shows the text "Code" in
the lower display too and menu scrolling is enabled.
If the correct code is not entered within the time period of 20 seconds menu scrolling
will still be locked and the measurement display is shown again.

7-2

ETC00781(4) Series 100 e 02/2004

KEY FUNCTIONS

The following analyzer functions and their sequences (see also Fig. 7-1) are shown:

Zeroing channel 1

Zeroing channel 2

Spanning channel 1

Spanning channel 2

Interval Time for automatic Zeroing

Only in combination of internal
solenoid valves or digital outputs
and external solenoid valves , and

Interval Time for automatic Spanning

if Auto = 1

Entry of concentration limits

Entry of system parameters.

Entry of serial interface parameters

ETC00781(4) Series 100 e 02/2004

Only with Option RS 232 C/485 Serial
Interface

7-3

KEY FUNCTIONS
ENTER

7.2

ENTER

The ENTER - key (Fig. 1-1 and 1-2, Item 4) is used for the transfer of (keyed-in) numerical data
to the corresponding operating parameters and for the initiation of certain operations, such as
zeroing and spanning.

First time the ENTER key is pressed within the function sequences (following the sequences
from "Zeroing (0 - 1)" to the "interface - parameter (SIP.)") the display will show the message

This indicates that - for safety reasons - a password (user code, “CODE”) must be entered in
order to enable access to the specific level.
If a wrong password is entered, the “CODE” display will remain and the display will be reset
to the value “0”.
When the correct password has been entered access to the specific level is permitted.

This password (“CODE”) has a factory
setting value “1” !

7-4

ETC00781(4) Series 100 e 02/2004

ETC00781(4) Series 100 e 02/2004

9

8

7

6

5

4

3

2

1

FUNCTION

0

SIP.

PArA

SYS.-

1

CodE

CodE

CodE

CodE

t-AS

LI.

CodE

CodE

CodE

CodE

CodE

t-A0

S -2

S -1

0 -2

0 -1

----

----

ENTER

0.-1

0..-1

2

On Line

Calibrate

0..-.2

Calibrate

0..-.1

Calibrate

Ch 2

3

RS485-

4

RS232/

232C

5
6

Baudrate

bAUd

Hold

Ch 2

L.-2H

Echo

7

Echo

Auto

8

LPb.

tol.
L-0

9

10

bAUd
0 = 4800
1 = 2400
2 = 1200
3=
600

d.OFF

Low = lower threshold
High = upper threshold

11

4 = 9600
5 = 19200
6 = 38400

tPur

Threshold of Limit-Outputs

Interval-Time (hrs.); 0 = off

Automatic Zero-Level/Span Adjustment

Interval-Time (hrs.); 0 = off

C . - O n C.CAL

Ch 1

Span Adjustment Channel 2

Span Adjustment Channel 1

Zero-Level Adjustment Channel 2

Zero-Level Adjustment Channel 1

Automatic Zero-Level Adjustment

Calibrate

L.-1H L . - 2 L

only with
Auto = 1

Nominal

S..-2 S..-.2

Nominal

S..-1 S..-.1

Nominal

0..-2

Nominal

On.-L Id.No

PrES

Ch 1

L.-1L

t-AS.

t-A0.

Actual

S.-2

Actual

S.-1

Actual

0.-2

Actual

t90.1

t90.2

12

13

14

LPb.
longitudinal-parity-byte-check
on/off
only with Option
"Serial Interface"

CodE

CODE: factory setting “1”
Touch screen release:
DOWN, UP, ENTER, FUNCTION

End1

End2

rES.

15

16

17

18

19

20

Serial-Interface-Parameters

OFS.1 OFS.2

21

22

P.-N.o S.-N.o

S.N.o.

PUMP

P.Ctl

Status
input
on/off
on/off
on/off
on/off
on/off
on/off
on/off
input
input
input
input
input
input
input
input
input
display
display
display
on/off/dis.
input

Meaning
actual air-pressure (hPa)
correction of cross-sensitivity
calibrate cross-correction by span calibration
hold measure- and limit-outputs during a calibration
automatice calibration with a installed valve unit
tolerance check of calibration gases
display off, if no key pressed
"Live-Zero" for analoge measure outputs
purge-delay of gas supply (sec.)
user-code
t90-time channel 1
t90-time channel 2
concentration for 0(0,2) V resp. 0(4) mA at analog-output ch.1
concentration for 0(0,2) V resp. 0(4) mA at analog-output ch.2
concentration for 1 V resp. 20 mA at analog-output channel 1
concentration for 1 V resp. 20 mA at analog-output channel 2
reset of device; adjustment of fabrication-data
program version
serial number of device part 1
serial number of device part 2
pump status
pump control y number

Name
PrES
C.-On
C.CAL
Hold
Auto
tol.
d.OFF
L-0
tPur
CodE
t90.1
t90.2
OFS.1
OFS.2
End1
End2
rES.
P.-No
S.-N.o
S.-N.o.
PUMP
P.Ctl

SYS.-PArA: System Parameters

Programm - Version 5.1x

BINOS 100
BINOS 100 F
BINOS 100 M
BINOS 100 2M
HYDROS 100
OXYNOS 100

KEY FUNCTIONS
KEY FUNCTION OVERVIEW

Fig. 7-1: 100 Series Operating Function Matrix

7-5

KEY FUNCTIONS
INPUT - CONTROL

7.3

INPUT - CONTROL

This keys (Fig. 1-1 and 1-2, Item 5 and 6) are used for the adjustment of the individual input
parameter values. A single press on either key will change the current value by +/- 1.

UP

increase current value by 1

DOWN

decrease current value by 1

If either of these keys is held pressed, the value will be altered continuously. Altering rate starts
with the slower rate and shifts automatically to the faster rate. When the minimum value is
reached, the analyzer will automatically revert to the slower rate in order to facilitate entering
the minimum value .
For any parameter a tolerance range is defined which has to be considered when entering
parameter values. In addition, all values are plausibility checked as added protection against
operator errors.

If within about 60 - 120 seconds no further keys have been pressed,
the analyzer will automatically revert to the “analysis display”.

7-6

ETC00781(4) Series 100 e 02/2004

KEY FUNCTIONS
PUMP (BINOS 100 2M/F ONLY)
®

PUMP

7.4

PUMP (BINOS® 100 2M/F only)

Optionally there is built-in a gas sampling pump (pumping rate max. 2,5 l/min.) into analyzers
of type BINOS® 100 2M/F.
The pump can be switched on and switched off by either
• the key “PUMP” at the front panel [Fig. 1-2, Item 8, (standard BINOS® 100 2M/F only)],
• the keypad [System Parameter “PUMP” *) (chapter 8.17)],
• via optional RS 232/485 instructions*) **) (chapter 12.5),
• via optional FOUNDATION™ Fieldbus instructions*) **) (chapter 13.2) or
• via optional digital inputs *) **) (chapter 13.1).
Optional the status of gas sampling pump is output via a digital status signal "Pump"(see Item
11.3)!
If the pump is turned on a green LED (PUMP, Fig. 1-2, Item 3) will light up at the front panel.

*)
**)

BINOS® 100 2M from program version 5.0 is required
not in combination with FOUNDATION™ Fieldbus

***)

not in combination with RS 232/485 interface

ETC00781(4) Series 100 e 02/2004

7-7

KEY FUNCTIONS

7-8

ETC00781(4) Series 100 e 02/2004

SETTING SYSTEM PARAMETERS

8.

Setting System Parameters

Push the key

until the text

appears.

Press the key
If the Code had not already been entered, there
will appear

Use the keys

to select the Code

and then using

The display will now show:

ETC00781(4) Series 100 e 02/2004

8-1

SETTING SYSTEM PARAMETERS
PRESSURE CORRECTION / CROSS COMPENSATION (INTERNAL)

8.1

Pressure Correction

To eliminate faulty measurements due to changes in barometric pressure or sample gas
pressure, the operator is offered the opportunity to enter the current pressure expressed in hPa
(mbar) in a range of 800 to 1,300 hPa. The concentration values computed by the analyzer will
then be corrected to reflect the barometric pressure or sample gas pressure resp. entry.
Input values using

and

It is possible to integrate a pressure sensor with a range of 800 - 1,100 hPa.
The concentration values computed by the analyzer will then be corrected to reflect the
barometric pressure to eliminate faulty measurements due to changes in barometric
pressure (see technical data). .
In this case it is not possible to enter pressure value manually. In attempting to enter
pressure value manually, the analyzer will automatically revert to the display of measured
pressure value.

8.2

Cross Compensation (internal)

This control permits switching the electronic cross compensation feature on and off.
The cross compensation feature is designed minimize mutual interferences between the two
gases (e. g., CO2 and CO) measured by the analyzer.
Input value 0: cross - compensation is disabled
Input value 1: cross - compensation is enabled

Change values using

and
8-2

ETC00781(4) Series 100 e 02/2004

SETTING SYSTEM PARAMETERS
CROSS COMPENSATION CALIBRATION (INTERNAL)

8.3

Cross Compensation Calibration (internal)

Determination of cross compensation correction factors is performed during the span adjustment.
Pure test gases are required for this operation. Once cross compensation corrections have been
determined, span adjustments may be performed using test gas mixtures.

Input value 0:
Input value 1:

spanning without cross compensation correction (test gas mixtures)
spanning with cross compensation correction (pure test gases)

Change values using

and

To perform a calibration with cross compensation correction, proceed as follows:
First perform a zeroing for both analysis channels (see chapter 9.1.1).
Then perform a spanning for both analysis channels as described in chapter 9.1.2.
Repeat spanning for the analysis channel that has been spanned first.

The values entered as described in chapters 8.2 and 8.3 must be “1” for
performing a calibration with cross compensation correction !
Use pure test gases only!
When using test gas mixtures, “C.Cal” must be set to “0” !

ETC00781(4) Series 100 e 02/2004

8-3

SETTING SYSTEM PARAMETERS
HOLD / AUTOMATIC CALIBRATION

8.4

Hold

The analyzer function HOLD is used to lock the analog signal outputs and the concentration
limits during a calibration procedure to hold the last measured values.
Input value 0: The outputs remain unlocked.
Input value 1: The outputs will be locked.

Change values using

and

8.5

Automatic Calibration

For operation with optional, internal or external solenoid valves it can be selected, if there a timecontrolled (automatic) resp. a remote-controlled calibration is possible or not (in combination with
solenoid valves controlled via digital outputs).
Input value 0: Time-controlled / remote-controlled calibration is not possible
Input value 1: Time-controlled / remote-controlled calibration is possible

Change values using

and

8-4

ETC00781(4) Series 100 e 02/2004

SETTING SYSTEM PARAMETERS
TOLERANCE CHECK

8.6

Tolerance Check

The tolerance function is for the activation and deactivation of the tolerance check procedure for
various calibration gases.
If the tolerance check procedure has been activated, the microprocessor will verify during
calibration procedures whether the used calibration gas shows a deviation of more than 10 %
from measuring range of zero (zero - level) or more than 10 % of the nominal concentration value
entered resp. (span).
If this tolerance is exceeded, no calibration will be performed, and an error message will
appear (see chapter 16). By default the error message will be erased after 2 - 3 minutes. Setting
the tolerance check parameter to "2" will hold the error message till either a correct calibration
has been performed or the analyzer has been resetted.
Input value 0: Tolerance check is deactivated.
Input value 1: Tolerance check is activated,
error message will be erased after 2 - 3 minutes.
Input value 2: Tolerance check is enabled, error message is held

Change values using

and

ETC00781(4) Series 100 e 02/2004

8-5

SETTING SYSTEM PARAMETERS
DISPLAY OFF

8.7

Display Off

Entering "1" will turn the DISPLAY off about 1 to 2 minutes after the last key was pressed.
Pressing any key will turn the display on again.

Input value 0:
Input value 1:

Display is always turned on
Display is will be automatically turned of

Change values using

and

8-6

ETC00781(4) Series 100 e 02/2004

SETTING SYSTEM PARAMETERS
ANALOG SIGNAL OUTPUTS

8.8

Analog Signal Outputs

The analog signal outputs (optically isolated) are brought out to a 9 pin sub miniature D
connector X2 on the analyzer rear panel. Refer to the wiring hints in chapter 29.10 !
Input value 0: Output signal is 0 - 10 Vdc (Option: 0 - 1 Vdc) / 0 - 20 mA.
Input value 1: Output signal is 2 - 10 Vdc (Option: 0.2 - 1 Vdc) / 4 - 20 mA (life zero mode)

Change values using

and

Note:
The begin of range concentration (OFS.) and the end of range concentration (END) are freely
programmable (see chapter 8.12 and 8.13).
For type of voltage output (standard or option)please refer to order confirmation or identification
label.

5
1

5

1

6

9

9

6

1
2
3
4
5
6
7
8
9

⊥ (V DC)
0 (2) - 10 V DC [Option: 0 (0,2) - 1 V DC], channel 1
0 (4) - 20 mA, channel 1 (RB ≤ 500 Ω)
0 (2) - 10 V DC [Option: 0 (0,2) - 1 V DC], channel 2
0 (4) - 20 mA, channel 2 (RB ≤ 500 Ω)
⊥ (mA)

Fig. 8-1: Pin assignments mating socket X 2 (analog signal outputs)

ETC00781(4) Series 100 e 02/2004

8-7

SETTING SYSTEM PARAMETERS
FLUSHING PERIOD / USER CODE

8.9

Flushing Period

For calibration, the gas paths must be supplied with sufficient calibration gas.The flushing period
has to be fixed adequate; perform calibration only after a suitable flushing period (the calibration
gas flow should be identical with sample gas flow).
This period may be set within the range 0 - 99 sec. depending on calibration conditions.

Change values using

and

8.10

User Code

Factory default setting is "1".
To prevent parameter alterations by unauthorized persons, the operator may specify another
password (user code).
Set the code using

and

Please take care for filing the user code.

8-8

ETC00781(4) Series 100 e 02/2004

SETTING SYSTEM PARAMETERS
RESPONSE TIME (T90)

8.11

Response Time (t90)

For some types of analysis an alteration of the analyzer damping factor, i.e. its electrical response
time, t90, may be required. The operator is offered the option of selecting an optimal response
time for each application.
The range of accepted values is 2 - 60 sec.

Change values using

and

Input indicator for channel 2

Change values using

and

ETC00781(4) Series 100 e 02/2004

8-9

ENTRY OF SYSTEM PARAMETERS
OFFSET (BEGIN OF RANGE)

8.12

Offset (Begin of range)

The operator is here offered the opportunity to introduce a scale offset for the analog signal output
(begin of range).

Example:
For an analyzer concentration range of 0 - 25 % it is desired to measure only concentrations in
the range 10 - 25 %. If the operator enters here the value 10 %, the analog signal outputs of
0 V / 0 mA or 2 (0.2) V / 4 mA will then correspond to a gas concentration of 10 %.
The displayed values are not affected.

Effect the entry using

and

Entry possibility for channel 2

Use the keys

and

for the entry.

Note:
The specifications of the analyzer written in the data sheet are only for OFS. = 0 and
END = full - scale range set in our factory !
It is part of customer to enter logical values for OFS. and END !

8 - 10

ETC00265(4) Series 100 e 02/2004

ENTRY OF SYSTEM PARAMETERS
END OF RANGE VALUE

8.13

End of Range Value

The operator is here offered the opportunity to introduce a full scale range for the analog signal
output.

Example:
For an analyzer concentration range of 0 - 25 % it is desired to measure only concentrations in
the range 0 - 15 %. If the operator enters here the value 15 %, the analog signal outputs of
10 (1) V / 20 mA will then correspond to a gas concentration of 15 %.
The displayed values are not affected.

Use the keys

and

for the entry.

Entry possibility for channel 2

Use the keys

and

for the entry.

Note:
The specifications of the analyzer written in the data sheet are only for OFS. = 0 and
END = full - scale range set in our factory !
It is part of customer to enter logical values for OFS. and END !

ETC00265(4) Series 100 e 02/2004

8 - 11

ENTRY OF SYSTEM PARAMETERS
RESET

8.14

Reset

The reset operation restores the settings of the analyzer to the parameters and calibration factors
set in our factory at the time of its manufacture.
This is equivalent to switching off the electrical supply line and switching off the battery buffering
of the RAM’s by removing the battery jumper, J7.
All parameters and calibration factors entered by the user will be lost whenever a reset
operation is performed.
The currently valid user identification code must be entered before a reset will be executed; this
will prevent inadvertent resets.

Entry is performed using

followed by

Whenever a reset operation is initiated, the analyzer operating program will be restarted, just as
it is when the instrument is first switched on (see chapter 6).

Jumper J6, which activates the watchdog circuitry must be inserted if the
reset operation is to be correctly executed.

8 - 12

ETC00265(4) Series 100 e 02/2004

ENTRY OF SYSTEM PARAMETERS
PROGRAM VERSION / SERIAL NUMBER

8.15

Program Version

The Program Version (No. of the installed software - version) will be displayed.

Press the key

8.16

Serial - No.

The Serial - No. will be displayed. (Please note this number for further contact with our factorymaintenace, service, etc.)

Push the key

Continuation of Serial - No.

Press the key

ETC00265(4) Series 100 e 02/2004

8 - 13

ENTRY OF SYSTEM PARAMETERS
GAS SAMPLING PUMP

8.17

Pump *)

This display shows the status of gas sampling pump.
If the function is enabled in “Pump Control” (“P.Ctl.”, see chapter 8.18), the pump can be switching
On or Off via this input.
Display / Entry of 0: gas sampling pump is Off
Display / Entry of 1: gas sampling pump is On

Entry is performed using

followed by

8.18

Pump Control *)

In this item you can determine the input for pump control.
Entry of 0:
Entry of 1:
Entry of 2:

pump control via front panel key
pump control via system parameter “PUMP” (chapter 8.17)
pump control via optional digital input (Item 13.1)

Entry is performed using

followed by

Push the key

until

the displays show
The analyzer now is back in the analysis mode.
*)

BINOS® 100 2M/F with software version 5.0 or higher only

8 - 14

ETC00265(4) Series 100 e 02/2004

CALIBRATION

9.

Calibration

To insure correct measurement results, zeroing and spanning should be carried out once a week.
Spanning can be performed only after zeroing before.
For the calibration procedure the analyzer has to be supplied with unpressurized test gases
through the respective gas inlets (cf. chapter 5.3) at a gas flow rate of about 1 l/min (the same
as with sample gas) !
After switching on the analyzer, wait at least approx. 15 to 50 minutes
(depending on installed detectors) before admit gas to the analyzer !

Note !
For operation with optional, internal or external solenoid valves the solenoid valves are activated
automatically by the respective function (via digital outputs). If the analyzer is in “calibration mode”,
a digital status signal “calibration” may be set (see chapter 11.3).

Zeroing
For zeroing, the analyzer has to be flushed with nitrogen (N2) or adequate zerogas
(e. g. synth. air or conditionned air).
Spanning
The span gas concentration should be in a range of 80 % - 110 % of full - scale range !
For lower span gas concentrations the measuring accuracy could be decreased for
sample gas concentrations which are above the span gas concentration !
Spanning for oxygen measurement can be done using ambient air as span gas, if the
oxygen concentration is known and constant.

When using span gas mixtures the entry for “C.Cal” must be set to “0” (see chapter 8.3)!
If there is no built-in pressure sensor, the correct pressure must be entered before
performing the calibration, if you want to have the possibility of pressure correction
(see chapter 8.1) !

ETC00781(4) Series 100 e 02/2004

9-1

CALIBRATION
MANUAL ZEROING

9.1

Manual Calibration

9.1.1

Zeroing

Zeroing will set the actually measured gas concentration to “zero”.

Push the key

until the display shows

(Zeroing channel 1) or

(Zeroing channel 2) resp.

Press the key

There will appear

to select the correct user - code

Use the keys

and enter using.

The displays will now show

resp.

The actual zero - level will be displayed.
Wait at least the entered flushing period and t90 time to go by.

9-2

ETC00781(4) Series 100 e 02/2004

CALIBRATION
MANUAL ZEROING

Push the key

The nominal value

or

will be displayed.

If the actual and nominal zero levels match, the next function can be selected using the
FUNCTION key (without zeroing).
If the two values dismatch,
press the key

The actual measuring value

or

To start zeroing press

will be displayed

again.

As soon as zeroing has finished, the display indicates

the actual measuring value

resp.

will be displayed.

The keyboard will only be released after another flushing period and t90 time.
If Hold = 1, the analog signal outputs and the concentration limits are released, too.

To leave “calibration mode” press

ETC00781(4) Series 100 e 02/2004

9-3

CALIBRATION
MANUAL SPANNING

9.1.2

Spanning

Verification of the span calibration is essential for accurate concentration measurement.
Spanning can be performed only after zeroing has been done.
Spanning will set the actually measured gas concentration to the entered “span gas setpoint”.

Note:

The span gas concentration should be in a range of 80 % - 110 % of full - scale range !
For lower span gas concentrations the measuring accuracy could be decreased for
sample gas concentrations, which are above the span gas concentration !
Spanning for oxygen measurement can be done using ambient air as span gas, if the
oxygen concentration is known and constant.

When using span gas mixtures the entry for “C.Cal” must be set to “0” (see chapter 8.3)!
If there is no built-in pressure sensor, the correct pressure must be entered before
performing the calibration, if you want to make use of pressure correction
(see chapter 8.1) !

9-4

ETC00781(4) Series 100 e 02/2004

CALIBRATION
MANUAL SPANNING

Push the key

until the display shows

(Spanning channel 1) or

(Spanning channel 2) resp.

Press the key

Enter the correct user code, if not already entered

The displays will now show

resp.

The actual concentration - level will be displayed.
Wait at least the entered flushing period and t90 time to go by.

Push the key

The test gas setpoint

resp.

will be displayed.

If necessary, enter the test gas setpoint value, taken from the manufacturer’s certificate on the
gas bottle
using the keys

and
ETC00781(4) Series 100 e 02/2004

9-5

CALIBRATION
MANUAL SPANNING

The actual measuring value

resp.

will be displayed

Quit the calibration mode by pressing the FUNCTION - key (nominal value is entered without
span calibration)

or push

again to start spanning .

As soon as spanning has finished, the display indicates

the actual measuring value

resp.

will be displayed.

The keyboard will only be released after another flushing period and t90 time.
If Hold = 1, the analog signal outputs and the concentration limits are released, too.

To leave calibration mode press

When using span gas mixtures the entry for “C.Cal” must be set to “0” (see chapter 8.3)!
If there is no built-in pressure sensor, the correct pressure must be entered before
performing the calibration, if you want to make use of pressure correction
(see chapter 8.1) !

9-6

ETC00781(4) Series 100 e 02/2004

CALIBRATION
AUTOMATIC ZEROING (OPTION)

9.2

Time-Controlled Calibration Mode (Option)

A time-controlled calibration only can be done with internal or separate external solenoid valves
via digital outputs. The automatic function of the analyzer must also be activated correctly (cf.
chapter 8.5).

With this function, the analyzer can perform an automatic calibration at preset time intervals.
The displays of the analyzer shows additional the functions t - AO and t - AS using the
FUNCTION - key.

Note !
For a time-controlled calibration procedure, the test gases must be supplied through “solenoid
valves” controlled by the analyzer in order to ensure the supply of test gases in correct
sequence.
If the test gas concentration has changed, the correct setpoint is to enter first (see chapter 9.1.2).

9.2.1

Zeroing

Push the key

until the displays show

Press the key

ETC00781(4) Series 100 e 02/2004

9-7

CALIBRATION
AUTOMATIC ZEROING (OPTION)

If the correct user code has not yet been entered,

the displays show

to select the correct user - code

Use the keys

and enter using

It appears

You can enter a time interval (hours), when an automatic zeroing has to be performed.
Point of reference is the current time.
Range of accepted entries: 0 - 999 (hours)

Note !
If the entry is “0” (zero), the time - controlled calibration is deactivated.

Entry is performed using

followed by

After entry of interval, zeroing will be done automatically at the end of the entered time interval.

9-8

ETC00781(4) Series 100 e 02/2004

CALIBRATION
AUTOMATIC ZEROING AND SPANNING (OPTION)

9.2.2

Combined Zeroing and Spanning

With this function a span calibration will be performed after completion of zeroing.
Press the key

until the message

appears

Press the key

Enter the correct user code, if not already entered

The displays will now show
You can enter a time interval (hours), when a automatic zeroing and after that a spanning has to
be performed.
Point of reference is the current time.
Range of accepted entries: 0 - 999 (hours)
Note !
If the entry is “0” (zero), the time - controlled calibration is switched off.

Entry is performed using

followed by

After entry of interval, calibration will be done automatically at the end of the entered time interval.

ETC00781(4) Series 100 e 02/2004

9-9

CALIBRATION

9.3

Remote-Controlled Calibration Mode (Option)

A remote-controlled calibration requires internal solenoid valves or external solenoid valves
controled via digital outputs. Additional the correct test gas setpoint has to be set first (manually:
chapter 9.1.2 / serial interface option chapter 12.5). The automatic function of the analyzer must
also be activated correctly (cf. chapter 8.5).

A calibration can be started via
P

serial interface option (chapter 12.5)

P

digital inputs option (chapter 13.1)

P

FOUNDATION™ Fieldbus (chapter 13.2)

A calibration will be performed as described in either chapter 9.1 (single channel zeroing or
spanning) or in chapter 9.2.2 (combined zeroing and spanning), depending on start command.

9 - 10

ETC00781(4) Series 100 e 02/2004

MEASUREMENT/SWITCHING OFF
MEASUREMENT

10.

Measurement / Switching Off

10.1

Measurement

Analyzer warming-up after switching on takes about 15 to 50 minutes,
depending on the installed detectors !
P

Supply sample gas to the gas inlet fitting (chapter 5.3).

P

Switching on optional sample gas pump (c.f. chapter 7.4).

P

Adjust the gas flow rate (with optional needle valve) within the specified rate.

The analyzer must be in the “analysis mode”, i. e. the displays must show

Note !
If another mode has been selected, the analyzer will automatically return to the analysis display when a
period of 60 - 120 seconds has elapsed after the last key actuation or after the last completion of an
operation !
The analyzer will remain at analysis display until another mode is selected.
Note for analyzers with electrochemical O2 cell!
On account of the measuring principle the electrochemical O2 cell needs a minimum internal
consumption of oxygen (residual humidity avoids the cell running dry). Continuously supplying cells
with dry sample gas of low grade oxygen concentration or with oxygen-free sample gas could result
a reversible change of O2 sensitivity. The output signal will become unstable.
For correct measurement the cells have to be supplied with O2 concentrations of at least 0.1 Vol.-%.
We recommend to use the cells in intervall measurement (purge cells with conditioned (removal of dust
but no drying) ambient air during measurement breaks).
If it is necessary to interrupt oxygen supply for several hours or days, the cell has to regenerate (supply
cell for about one day with ambient air). Temporary flushing with nitrogen (N2) for less than 1 h (e.g.
analyzer zeroing) does not influence the measuring quality.

ETC00781(1) Series 100 e 10/2001

10.2

Switching Off

10 - 1

MEASUREMENT/SWITCHING OFF
SWITCHING OFF

Before switching off the analyzer purge all the gas lines for about 5 minutes with zero gas (N2)
or adequate conditioned air. The full procedure for shutting down is as follows:
For analyzers with electrochemical O2 cell purge all gas lines with
conditioned ambient air before closing the gas line fittings for transport or
depositing the analyzer.

P

Supply zero gas to the gas inlet fitting.

P

Switch on the optional sample gas pump (see chapter 7.4).

P

Adjust the gas flow rate (with optional needle valve) within the specified rate.

P

Wait 5 minutes

P

Switch Off by disconnecting the voltage supply.

P

Shut Off the gas supply.

P

Close all gas line fittings immediately.

10 - 2

ETC00781(1) Series 100 e 10/2001

DIGITAL OUTPUTS

11.

Digital Outputs

All standard digital outputs are available on plug X 3 at the rear panel.
The maximum output load is 30 V DC / 30 mA (“Open Collector”).
Observe the wiring hints in chapter 29.10 !

5

1

5

1

9
6

6

9

1
2
3
4
5
6
7
8
9

Limits channel 2 max.
Limits channel 2 min.
Limits channel 1 max.
Limits channel 1 min.
⊥
Valve control span gas 2
Valve control span gas 1
Valve control zero gas
Valve control sample gas

Fig. 11-1: Pin Assignments X 3 (Digital Outputs)

ETC00781(4) Series 100 e 02/2004

11 - 1

DIGITAL OUTPUTS
CONCENTRATION LIMITS

11.1

Concentration Limits

One upper and one lower concentration limit can be assigned for each channel, freely
selectable by the operator within the available concentration range.
The last right decimal point of the related display will start to flash whenever a concentration
limit value is reached.
Additional digital signal outputs for the concentration limits are available at plug X 3 on the rear
panel (“Open Collector”, max. 30 V DC / 30 mA).

Press the key

until the text

appears.

Press the key
If the correct user code has not yet been entered,
the message

appears.

Press the keys

to select the correct user code,

enter with the

key.

The displays show

lower limit channel 1

Use the keys

to set the limit value.

Push the key

to enter the value.

11 - 2

ETC00781(4) Series 100 e 02/2004

DIGITAL OUTPUTS
LIMIT VALUES

The displays show

upper limit channel 1

Use the keys

to set the limit value.

Press the key

to enter the value.

Now the displays show

lower limit channel 2

Use the keys

to set the limit value.

Press the key

to enter the value.

The displays show

upper limit channel 2

Use the keys

to set the limit value.

Press the key

to enter the value.

Press

until

the displays show

The analyzer is now back in the analysis display.

ETC00781(4) Series 100 e 02/2004

11 - 3

DIGITAL OUTPUTS
VALVE CONTROL / STATUS SIGNALS (OPTION)

11.2

Valve Control

Optional external solenoid valves have to be connected to plug X 3 on the rear panel to be
controlled by the analyzer. Observe the wiring hints in chapter 29.10 !

11.3

Status Signals (Option non-voltage-carrying relay contacts)

Three optional status signals are available on the 9 pin subminiature D plug X 1 on the rear
panel of the analyzer (see chapter 7.4, 9. and 13., too).
These signals are floating contacts with a maximum load of 30 V / 1 A / 30 W !
Observe the wiring hints in chapter 29.10 !

5

1

5

1

9
6

6

9

1
2
3
4
5
6
7
8
9

OK (open) / Failure (closed)
OK (closed) / Failure (open)
Measure (open) / Calibration (closed)
Measure (closed) / Calibration (open)
Pump OFF (open) / Pump ON (closed) *)
OK / Failure (Common)
Measure / Calibration (Common)
Gas sampling pump (Common) *)
Pump OFF (closed) / Pump ON (open) *)

Fig. 11-2: Pin Assignments X 1 (Status Signals)

*)

11 - 4

BINOS® 100 2M/F with software revision 5.0 or higher only

ETC00781(4) Series 100 e 02/2004

SERIAL INTERFACE (OPTION)
RETROFITTING

Rosemount Analytical

12.

Serial Interface (Option)

12.1

Upgrading Serial Interface / Status Signals
(status signals only:
PCB BSI 10, Catalog - No.: 43 001 590,
RS 232 - Interface:
PCB BSI 10 with PCB SIF 232, Catalog - No.: CH 000 069
RS 485 - Interface:
PCB BSI 10 with PCB SIF 485, Catalog - No.: CH 000 070,
see chapter 12.3.2, too)
Be sure to observe the safety measures !

P

Switch off the analyzer and open the housing (see 23.)

P

Mount the circuit board to the threated bolts at the rear panel and fix it using the
washers and the screws.

P

Connect the signal cable to connector J9 on BKS paying attention to the coding pin.

Rear panel
Threated bolt
Rear panel
1/2 19"
analyzers

PCB BSI 10
123456
123456
123456
123456

J9

Code pin

1/4 19"
analyzers

12
12
12
12
12
12

J9

1

Fig. 12-1: Installation of PCB BSI 10

P

For upgrading a serial interface insert the EPROM delivered together with the board
(see chapter 28.).

ETC00781(1) Series 100 e 10/2001

12 - 1

SERIAL INTERFACE (OPTION)
GENERAL

12.2

Rosemount Analytical

General

The analyzer is equipped with a serial interface enabling communication with a host computer.
The host computer can call up, prescribe, or alter parameters as well as initiate analyzer
operations, using standardized protocols.The optional BSI 10 plug in circuit board constitutes the
hardware interface. This may be configured as RS 232 C or RS 485 interface. The RS 485
interface permits networking several analyzers. Each analyzer may then be addressed using
an assignment numerical ID -code.
Communication is always initiated by the host computer; i.e., analyzer behave passively until
the host computer requests information from them or demands commencement of an action.
Communications use so - called “telegrams” being exchanged between the host computer and
the analyzer(s). Syntax for these telegrams is established in protocols.
Telegrams always commence with the "$" start character, immediately followed by a three - digit
instruction code.
Subsequent elements of telegrams are segregated by the ";" hyphen character.
The final element of all telegrams transmitted must be the “CR” termination character.
Upon receipt of the terminate character, the analyzer attempts to evaluate the current contents
of its input buffer as a valid telegram. If the syntax of the transmitted telegram is correct, the
analyzer will transmit a response telegram to the host computer. This consists of the start
character, an instruction code, requested data, a block - parity byte, and the termination character.

If the syntax of the transmitted telegram was not correct, the analyzer will transmit a status telegram
containing an error message to the host computer. Each terminate character reception thus
initiates an analyzer response.

12 - 2

ETC00781(1) Series 100 e 10/2001

Rosemount Analytical

SERIAL INTERFACE (OPTION)
GENERAL

To avoid detecting transmission errors, the host computer can insert a message -length parity
byte immediately preceding the terminate character for verification by the analyzer.
The analyzer invariably transmits message length parity bytes immediately preceding termination
characters.
The elapsed time between the reception of start characters and termination characters is not
limited by the analyzer; i.e., there are no “time out” periods.
If the host computer transmits any new characters before the analyzer has responded to the
preceding telegram, the analyzer’s input buffer will reject them; i.e., these characters will be
ignored by the analyzer.
The transmission rate may be set between 600 and 38,400 baud.
An echo mode may also be activated.
The analyzer software is configured such as that telegrams may be sent to the host computer at
time intervals of 150 ms and greater.

ETC00781(1) Series 100 e 10/2001

12 - 3

SERIAL INTERFACE (OPTION)
START UP

12.3

Rosemount Analytical

Start Up

The analyzer has been set in our factory to RS 232 C or RS 485 interface via the plugged PCB
SIF 232 or SIF 485 on the PCB BSI 10.
The parameter 232c has also been set to 0 = NO or 1 =YES in the SIP (Serial Interface Parameters)
line.
Interconnection to the interface is via the 9 pin socket „Interface“ or “X4 Output” on the analyzer
rear panel. Observe the wiring hints in chapter 29.10 !

12.3.1 RS 232 C
This interface requires a shielded cable having at least three internal conductors.

5
1

5

1

6

9

9

6

1
2
3
4
5
6
7
8
9

GND
RxD
TxD
not used
GND
not used
not used
not used
not used

Fig. 12-2: Pin Assignments “RS 232 Interface”

12 - 4

ETC00781(1) Series 100 e 10/2001

SERIAL INTERFACE (OPTION)
START UP

Rosemount Analytical

12.3.2 RS 485
Configure 2- or 4-wire operation via solder bridge LB 1 of PCB SIF 485 before mounting the PCB.
Connecting of [1 - 2] 2-wire-operation is selected. Connecting of [2 - 3] 4-wire-operation is active.
Switch on network termination via soldering bridges at both ends of interface connection. For
network operation with several analyzers via RS485 interface, termination has to be done at both
ends of network connection only. For the other analyzers the soldering bridges have to be open.
Close soldering bridge LB2 for 2-wire-operation. For 4-wire-operation close LB2 and LB3.

5
1

5

1

6

9

9

6

1
2
3
4
5
6
7
8
9

GND
RxDRxD+
TxD+
TxDnot used
not used
not used
not used

Fig. 12-3: Pin Assignments “RS 485 Interface”

In contrast to RS 232 C operation, simultaneous transmission and reception is not implemented
in this standard. This would not result in damage to the electronics, but could lead to destroy of
data.The analyzer behaves passively in this mode of operation; i.e., it keeps its transceiver set for
reception whenever it is not transmitting. Since the time periods for transmission and reception are
controlled by protocols, “data collisions” are excluded.

ETC00781(1) Series 100 e 10/2001

12 - 5

SERIAL INTERFACE (OPTION)
START UP (INTERFACE - PARAMETER)

Rosemount Analytical

12.3.3 Switching ON/OFF Interface Operation
The analyzer may be set to either “online” or “offline” status.This setting may be performed either
from the keypad or via telegram input.
Keyboard setting:
SIP parameter On.-L. = 1
SIP parameter On.-L. = 0

for online status
for offline status

Telegram setting:
Instruction code 6:
Instruction code 7:

sets analyzer online status
sets analyzer offline status

If the analyzer is set to offline status, it will accept only instruction code 6. All other instructions
will be ignored and result in transmission of appropriate status telegrams.

12.3.4 Setting Interface Parameters
Agreement of interface parameters between analyzer and host computer is a fundamental
requirement for communication without errors.
The following analyzer parameters are concerned:
R
R
R
R
R
R
R

12 - 6

baud rate:
data bits:
stop bits:
parity bit:
echo mode:
LPB-test:
ID-no.:

600 / 1,200 / 2,400 / 4,800 / 9,600 / 19,200 / 38,400 bits/s
8
2
none
on / off (received characters will be retransmitted immediately)
on / off (message - length parity check)
0 to 99 (device ID - no. in RS 485 mode)

ETC00781(1) Series 100 e 10/2001

SERIAL INTERFACE (OPTION)
START UP (INTERFACE - PARAMETER)

Rosemount Analytical

All entries are made using the keys

and

Press the key

until

appears,

then push the key

The unit is now ready for code entry, if such has not already been performed.

0 = off - line status
1 = on - line status
Each device is assigned a device number for operation
through the RS 485 interface (0 - 99).
Select interface type:
0 = RS 485
1 = RS 232 C
Set baud rate:
0 = 4,800
1 = 2,400
4 = 9,600
5 = 19,200

2 = 1,200
6 = 38,400

3=

600

Echo-mode operation:
0 = OFF 1 = ON
Message - block parity check
0 = OFF 1 = ON
ETC00781(1) Series 100 e 10/2001

12 - 7

SERIAL INTERFACE (OPTION)
TELEGRAM SYNTAX

12.4

Rosemount Analytical

Telegram Syntax

Telegrams are assembled as follows:

12.4.1 Start Character ( “$” = Hex 24)
If the start character is missing, this will result in transmission of an appropriate status telegram
by the analyzer.

12.4.2 Terminate Character ( “CR” = Hex OD)
If the terminate character is missing, no decoding of the transmitted information will be performed,
and the analyzer will not respond. No response message will be transmitted.

12.4.3 Instruction Code
Each instruction is assigned a unique three digit numerical instruction code. If a received
instruction code should be other than three digits in length or contain non-numerical ASCIIcharacters, the analyzer will transmit an appropriate status telegram. Reception of unassigned
instruction codes will also result in the transmittal of a status telegram.
In the RS 232 C mode of operation, the instruction code immediately follows the start character;
in the RS 485 mode of operation, the start character is followed by a two digit device identification
code, the separator character “;”, and a three digit instruction code, in this order.

12.4.4 Hyphen Character ( “;” = Hex 3B)
Individual elements of a telegram line are separated by this hyphen character. Missing hyphen
characters can lead to misinterpretations of telegrams, and will result in transmission of an
appropriate status telegram.

12 - 8

ETC00781(1) Series 100 e 10/2001

SERIAL INTERFACE (OPTION)
STATUS TELEGRAM

Rosemount Analytical

12.4.5 Status Telegram
If telegram syntax is faulty, or analyzer is unable to act upon an instruction received, then the
analyzer will transmit a status telegram to the host computer.
These status telegrams are listed here for reference:
$ID;000;S100;LPB

unrecognized instruction code

$ID;000;S101;LPB

LP byte in error

$ID;000;S102;LPB

start character missing

$ID;000;S103;LPB

input buffer overflow

$ID;xxx;S104;LPB

analyzer offline status

$ID;xxx;S105;LPB

text line too long

$ID;xxx;S106;LPB

undefined instruction

$ID;xxx;S107;LPB

invalid integer value

$ID;xxx;S108;LPB

numerical value outside defined range

$ID;xxx;S109;LPB

invalid failure/status code

$ID;xxx;S110;LPB

instruction can not be done here

$ID;xxx;S111;LPB

failure in transmitted character

$ID;xxx;S112;LPB

zeroing running

$ID;xxx;S113;LPB

spanning running

$ID;xxx;S114;LPB

invalid real number

$ID;xxx;S115;LPB

automatic calibration mode off

$ID;xxx;S116;LPB

parameter outside defined range

$ID;xxx;S117;LPB

preflushing period is running

xxx:
ID:
LPB:
:

instruction code
device ID no. in RS 485 mode
message length parity byte
terminate character

ETC00781(1) Series 100 e 10/2001

12 - 9

SERIAL INTERFACE (OPTION)
NUMERICAL REPRESENTATION / BLOCK PARITY CHECK

12.4.6 Numerical Representations
Telegrams may contain integers or real numbers. The formats for these numbers are subject to
the following restrictions.
Integers:

- maximum value = 216 - 1
- positive numbers only accepted
- no decimal points allowed

Real:

- maximum of 6 digits accepted
- no alphabetic characters (e.g. 2.2E-6) allowed
- analyzer output is 6 - digit real numbers

12.4.7 Block Parity Check
The master control computer may insert a message length parity byte into telegrams. These
invariably consist of two characters.
The message - length parity byte is the cumulatively EXCLUSIVE - OR correlation of all previously
transmitted characters of the telegram line. Representation is in hexadecimal format. For example,
if the decimal value should be decimal 13, this will be represented by the two characters “OD”, i.e.,
030H and 044H.
The verification procedure may be enabled or disabled at the analyzer (see chapter 12.3.4).

12 - 10

ETC00781(4) Series 100 e 02/2004

SERIAL INTERFACE (OPTION)
INSTRUCTION SYNTAX

12.5

Instruction Syntax

Code definitions:
RP:
SP:
RI:
k:
m:
w:
:
LPB:
:

receive parameters
analyzer is accepting values
send parameters
analyzer is sending values
receive instructions
channel numbers 0 to 2
range number
value
analyzer ID - no. for RS 485 mode of operation; follows start character
message - length parity byte
terminate character

Receipt of any instruction codes not listed in the following section will be acknowledged by
transmittal of status code 106. Future expansions will make use of code numbers not currently in
use.

ETC00781(4) Series 100 e 02/2004

12 - 11

SERIAL INTERFACE (OPTION)
INSTRUCTION LIST

12.5.1 Instruction Listing
Instruction syntax:

Instruction description:

$ID;001;k;LPB

RI stand-by status (all valves closed)

$ID;002;k;LPB

RI sample gas valve open

$ID;003;k;LPB

RI zero gas valve open

$ID;005;m;k;LPB

RI span gas valve open

$ID;006;LPB

RI on - line status

$ID;007;LPB

RI off - line status

$ID;008;LPB *)

SP pump status *)

$ID;009;w;LPB *)

RI pump status *) w=0: pump Off, w=1: pump On

$ID;011;m;k;LPB

SP at full scale range

$ID;013;k;LPB

SP t90 (response time)

$ID;014;w;k;LPB

RP t90 (response time)

$ID;017;k;LPB

SP preflushing period (zero gas)

$ID;018;w;k;LPB

RP preflushing period (zero gas)

$ID;019;k;LPB

SP preflushing period (span gas)

$ID;020;w;k;LPB

RP preflushing period (span gas)

$ID;023;k;LPB

SP concentration

$ID;028;m;k;LPB

SP span gas concentration

$ID;029;m;w;k;LPB

RP span gas concentration

$ID;030;LPB

SP status messages

$ID;031;t;LPB

SP serial number (t=0, max. 10 characters)
channel identification (t=1: ch.1, t=2: ch. 2)

$ID;603;k;LPB

SP gas component

$ID;604;k;LPB

RI automatic zeroing

$ID;605;k;LPB

RI automatic spanning

$ID;606;0;LPB

RI automatic zeroing & spanning

$ID;626;LPB

SP E-Prom / Software version

$ID;627;LPB

SP failure message (possible error batt. is
clearing by read out)

$ID;645;0;LPB

SP pressure value

$ID;646;w;LPB

SP solenoid valve status (w=1: samplegas valve,
w=2: zerogas valve, w=4: spangas 1, w=8: spangas 2)

*)

BINOS® 100 2M/F from program version 5.0 is required

12 - 12

ETC00781(4) Series 100 e 02/2004

SERIAL INTERFACE (OPTION)
RESPONSE TELEGRAMS

12.5.2 Response Telegrams
Response telegrams follow with the same syntax as the appropiate (SP-) commands (see 12.5).

12.5.2.1Status Messages (Instruction 030)
The response telegram for instruction
“$ID;030;LPB SP Status messages”
shows as follows:
$ID;030;a;b;c;LPB
This means:
a: OK-Status

0 = Relay without power

b: Value of variable “calibration”

0 = Relay without power >0 = Relay active

c: Gas sampling pump *)
*)

1 = Relay active

b

Meaning

0
1
2
3
4
5
6
7
8
9
10

No Calibration
Zeroing channel 1
Zeroing channel 2
Zeroing channel 1 + 2
Spanning channel 1
Spanning channel 2
Spanning channel 1 + 2
Spanning channel 1 first, then channel 2
reserved
reserved
Waiting for flushing time and t90 response time

0 = Relay without power
(pump OFF)

1 = Relay active
(pump ON)

BINOS® 100 2M/F from program version 5.0 is required

ETC00781(4) Series 100 e 02/2004

12 - 13

SERIAL INTERFACE (OPTION)
RESPONSE TELEGRAMS

12.5.2.2

Pump Status (Instruction 008)

*)

The response telegram for instruction
“$ID;008;LPB SP Pump status”
shows as follows:
$ID;008;w;LPB
with w = pump status

0: Pump Off

1: Pump On

*)

12 - 14

BINOS® 100 2M/F from program version 5.0 is required
ETC00781(4) Series 100 e 02/2004

DIGITAL INPUTS / FOUNDATION™ FIELDBUS (OPTIONS)
DIGITAL INPUTS

13.

Digital Inputs / Foundation™ Fieldbus (BINOS® 100 2M/F option only)
Be sure to observe the safety measures for all workings at the analyzer!

13.1

Digital Inputs

13.1.1 General
To remotely control different conditions of analyzer BINOS® 100 2M/F, the analyzer can
optionally be equipped with 7 digital inputs . They are available at terminals on the rear side
of the analyzer (Fig. 1-8, Item 9). The inputs are active only if the analyzer is equipped with builtin solenoid valve block or if the solenoid valves are connected to the digital outputs (see
chapter 29.5.1). Observe the wiring hints in chapter 29.10 !
V+

+ 5 V DC

V-

⊥

E1
E2

start zero calibration channel 1 & 2

E3

start span calibration channel 2

E4

open zero gas valve

E5
E6

open span gas valve 1

E7

close sample gas valve / sample gas pump off

start span calibration channel 1

open span gas valve 2

Fig. 13-1: Terminal assignments “Digital Inputs”

The analyzer may be controlled by either control voltages or floating contacts.
A “low signal” has to be < 1.4 V dc, a“high signal” has to be > 3.5 V dc (max. 30 V dc). Reference
⊥).
point is terminal “V-” (⊥
To work with floating contacts, customer can use the intrinsic-safe output voltage of “+ 5 V DC”
at terminal “V+”.

13.1.2 Start of Calibration
Inputs “E1 to E3”: The analyzer will start a calibration procedure if control signal changes from
“low-level” to “high-level”. These inputs have a higher priority than inputs “E4 to E7”

ETC00781(4) Series 100 e 02/2004

13 - 1

DIGITAL INPUTS / FOUNDATION™ FIELDBUS (OPTIONS)

13.1.3 Valve Control
The inputs “E4 to E7” are level sensitive with descending priority. That means “E4” has highest
priority and “E7” has lowest priority.
At input “E4” (open zero gas valve) a “high-signal” opens the zero gas valve and closes all the
other valves, no matter of the signal levels at “E5 to E7”.
A “high-signal” at “E5” opens the span gas valve 1and closes all the other valves if “E4” has
“low-level”, no matter of the signal levels at “E6 and E7”.
Input “E7” has a special logic: A “low-level” opens and a “high-level” closes the sample gas
valve, whereat the inputs “E4 to E6” have to be at “low-level”.

13.1.4 Pump Control
For the case, that the optional gas sampling pump is controlled via digital input (see chapter
8.18) this is done using input “E7”, too. A “low-level” on “E7” switches on and a “high-signal”
switches off the gas sampling pump, irrespective of the signals at “E1 to E6”.

13.2

FOUNDATION™ Fieldbus *)

For communication via FOUNDATION™ Fieldbus terminals are available at the analyzer's rear
side(Fig. 1-8, Item 9).
For exact description see separate FOUNDATION™ Fieldbus specific manual!
Observe the wiring hints in chapter 29.10 !

FB +

Fieldbus +

FB -

Fieldbus -

FB +

Fieldbus +

FB -

Fieldbus -

Fig. 13-2: Terminal strip assignments “Fieldbus connection”

*)

only possible if serial interface RS 232/485 is not request !

13 - 2

ETC00781(4) Series 100 e 02/2004

CROSS COMPENSATION / SETTING OF RESPSONSE TIME (TC ONLY)
CROSS COMPENSATION

14.

Cross Compensation / Setting of Respsonse time (TC Option only)

14.1

Cross Compensation

For gas mixtures of two gas components (binary gas mixtures) with different thermal
conductivities the analyzer may be calibrated to directly show the concentration of one of the
gas component. The same is applicable for “quasi-binary” gas mixtures of more than two
components with only a single component (the component to be measured) of varying
concentration. The compostition of the remainder of the gas mixture remains constant in time.
For the more common case that more than one component of a sample gas mixture has varying
concentrations the result of this measuring principle is non-selective; i.e., it will not be
unambiguously related to the true concentration of the gas component of interest.
If the concentrations of interfering gas components are detected by using other gas analyzers
and the analytical signals thus obtained are supplied to the analyzer via rear panel plug
“CROSS COMP.” (Item 9 of Fig. 1-5) or “Analog In” (Item 5 of Fig. 1-7 and 1-8), then the disturbing
effects of any interfering gas component may be electronically compensated .
The analyzer is designed for compensating up to 3 interfering gas components.
Possible signal inputs are 0 (0.2)- 1 V, 0 (2)- 10 V or 0 (4) - 20 mA.
Observe the wiring hints in chapter 29.10 !

1
5

1

5

9
6

6

9

1
2
3
4
5
6
7
8
9

interfering gas 1
⊥ (GND) interfering gas 1
interfering gas 2
⊥ (GND) interfering gas 2
not used
interfering gas 3
⊥ (GND) interfering gas 3
not used
not used

Fig. 14-1: Pin assignments “Cross. Comp:” / “Analog In”
(TC-Option analog signal inputs for interference compensation)

ETC00781(4) Series 100 e 02/2004

14 - 1

CROSS COMPENSATION / SETTING OF RESPSONSE TIME (TC ONLY)
CROSS COMPENSATION

14.1.1 Preparing Actions
The adjustment procedure for alteration the factory settings of cross compensation is as
follows:
The number of interfering gases and the type of analog input signal is selected by configuring
solder bridges on the printed circuit boards “WAP 100” (TC signal processing) and “BSE 01”
(analog input signals).
P

Open the analyzer housing (cf. Section 23).

P

Remove the PCB´s and check and / or alter the solder bridges (cf. table 14-1).
PCB WAP 100

PCB BSE 01

1

LB 9

LB 8

LB 1

LB 9

2

LB 6

LB 7

LB 2

LB 6

3

LB 13

LB 12

LB 3

LB 12

0 - 1 V DC

1-2

open

open

closed

0 - 10 V DC

1-2

open

open

open

0 - 20 mA

1-2

open

closed

closed

0.2 - 1 V DC

2-3

closed

open

closed

2 - 10 V DC

2-3

closed

open

open

4 - 20 mA

2-3

closed

closed

closed

not used

open

open

open

open

Number

Analog Input

Signal

Table 14-1: Solder bridges
(TC option analog signal inputs for cross compensation)

P

14 - 2

Reinstall the PCB´s and correctly replace any connector.

ETC00781(4) Series 100 e 02/2004

CROSS COMPENSATION / SETTING OF RESPSONSE TIME (TC ONLY)
CROSS COMPENSATION

14.1.2 Adjustment Procedure
P

Switch on the TC analyzer (chapter 6.) and all analyzers used for measuring interfering
gas components.

P

Perform zeroing and spanning of all relevant measuring channels.

P

Connect the gas paths of all analyzers in series and purge with zero gas (N2, nitrogen).

P

Connect the analog signals of the analyzers used for measureing interfering gas
components to the respective analog input (Fig. 14-1) of the TC analyzer.

The following steps have to be executed for each interfering gas seperately.
P

Supply the maximum concentration of the respective interfering gas (maximum
concentration should be full-scale of the analyzer measuring the interfering gas).
For external analyzers with different measuring ranges be sure that the analog signal
connected to the TC analyzer is related to the highest measuring range and that
this measuring range does not change while adjusting the cross compensation.

P

Adjust the correlated potentiometers of the PCB “WAP 100” to set the analog signal output
of TC measurement to “Zero”.
The potentiometer assignments is as follows:
Interfering gas / analog input 1:
Interfering gas / analog input 2:
Interfering gas / analog input 3:

P

Q 1 (R 71)
Q 2 (R 84)
Q 3 (R 118)

Purge with zero gas (N2, nitrogen), check the zero point and start a zero calibration via
keypad again if necessary.
Supply the maximum concentration of the respective interfering gas again and perform
a fine setting of zero-point using the corrrelated potentiometers of PCB “WAP 100”.

When the adjustment has been finished
P

Close the analyzer housing (cf. Section 23).

ETC00781(4) Series 100 e 02/2004

14 - 3

CROSS COMPENSATION / SETTING OF RESPSONSE TIME (TC ONLY)

14 - 4

ETC00781(4) Series 100 e 02/2004

LIST OF FAILURES

Error Code

16.

Possible Reasons

Check / Correct

List of Failures

Some of the failures which may arise during measurement will be reported on the displays in forms
of error codes.
When such a failure arises, the display's will show the concentration value
alternating with

(E = ERROR).

Note !
If there is an "error message", a digital status signal "Failure" can be given optional (see Item 10.3)!

Be sure to observe the safety measures for all workings at the analyzer!

Error Code

Possible Reasons

1. Displays are “switched OFF”

Check / Correct

1. Press any key.
Check parameter dOFF
(see chapter 8.7).

No Display
2. Voltage supply absent.

2. Check connection mains line/PS
Check external power supply
Check electrical supply
(see Fig. 1-5 and 1-6, Item 3
Fig. 1-7 to 1-9, Item 10).

BINOS® 100 F
3. Connection front panel /BKS
absent.
ETC00781(4) Series 100 e 02/2004

Check internal fuses F1 and F2
3. Check connection
BKB - BKS (X1) (see chapter 18.1).
16 - 1

LIST OF FAILURES

Error Code

Possible Reasons

Check / Correct

Flashing
Battery buffer faulty.

Check, if Jumper J 7
is plugged (see chapter 19.).

The EPROM default
values were charged.

Exchange battery,
if battery voltage < 3,5 V
(BKS - Jumper J7 plugged).
The error is clearing after depressing
any key or with serial interface
instruction $627.

1. Jumper not or incorrect
plugged.

1. Channel 1: Check Jumper J1
Channel 2: Check Jumper J2
(see chapter 18.)

Channel 1
Switch analyzer off and then on again.

Channel 2

2. Positive or negative
reference voltage absent.

2. Check reference voltage
(see chapter 17.1.2/17.1.3).

3. Light barrier signal absent.

3. Check connection X9 / light barrier
(see chapter 18.)

A/D-Conversion-End-Signal
absent

Check measuring point 17.1.6

4. IR channel:
Chopper drive inoperative

4. Check connection X2 / chopper drive
(see chapter 18.)
Check measuring point 17.1.4

Temperature compensation
interferred

16 - 2

4. Supply voltage
(internal 6 V DC) absent.

4. Check measuring point 17.1.1

1. Start-up of A/D-conversion
in temperature channel
absent.

1. Switch analyzer off and then on again.

2. Supply voltage
(internal 6 V DC) absent.

2. Check measuring point 17.1.1

ETC00781(4) Series 100 e 02/2004

LIST OF FAILURES

Error Code

Possible Reasons

Check / Correct

1. Incorrect zero gas in use.

1. Check zero gas in use.

2. IR channel:
Photometer section
contaminated.

2. Check analysis cell and windows for
contamination.

Channel 1

Channel 2

Cleaning of contaminated parts
(see chapter 24.3).

Tolerance error
Zero-gas value differs more
than 10% of measuring
range from zero.

3. Analyzer not calibrated.

3. Switch off the tolerance check
before starting an adjustment
(see chapter 8.6).

1. Incorrect nominal value.

1. Enter the correct nominal value
(certification of span gas bottle)
(see chapter 9.1.2).

2. Incorrect span gas in use.

2. Check span gas in use.

Channel 1

Use another or a new gas bottle.

Channel 2

Enter the correct nominal value

Tolerance error
Span-gas value differs more
than 10% from nominal
value.

3. IR channel:
Photometer section
contaminated.

3. Check analysis cell and windows for
contamination.
Cleaning of contaminated parts
(see chapter 24.3).

4. Analyzer not calibrated.

4. Switch off the tolerance check
before starting an adjustment
(see chapter 8.6).

1. Concentration of measuring
gas too high.

1. Check concentration of measuring
gas.

Channel 1
Use another analyzer suitable for
the concentration-range involved.
Channel 2
Measuring value more than
10% over full-scale range.

ETC00781(4) Series 100 e 02/2004

16 - 3

LIST OF FAILURES

Error Code

Possible Reasons
Parameter ABS. does not
set to “0”.

Set parameter ABS. to “0”
(see chapter 8.16).

Time out for XON of
serial interface.

At drive of serial interface
XON - character is absent
(Time - out > 60 s).

1. Measuring range failure.

1. pressure not into the sensor
measuring range
(800 - 1,100 hPa).

2. Connection faulty.

2. Check connection P1 (at BAF 01) /
pressure sensor (see chapter 18.).

3. Pressure sensor faulty.

3. Exchange pressure sensor.

1. EPROM faulty.

1. Exchange EPROM (see chapter 28.).

2. BKS faulty.

2. Exchange BKS.

Pressure sensor defective

EPROM Checksummary
defective

Test for RAM - IC's
defective

Check / Correct

RAM IC's / BKS
faulty.

Exchange BKS.

BKS faulty.

Exchange BKS.

Analog output absent

Fluctuating or
erroneous display

1. Leakage into gas circuit.

1. Perform a leakage check.
(see chapter 22.).

2. Ambient air contains gas
constituent to be measured
in excessive concentration.

2. Replace absorber material for the light
sources and chopper housing.
Use sealed photometer (Option).
Flush out the analyzer.

16 - 4

ETC00781(4) Series 100 e 02/2004

LIST OF FAILURES

Error Code

Possible Reasons
3. Gas pressure subject to
excessive fluctuations.

Check / Correct
3. Check the gas lines preceding and
following the sensor cell.
Eliminate any restrictions found
beyond the gas outlet fitting.
Reduce pumping rate or flow rate.

Fluctuating or
erroneous display

4. Oxygen senor / detector
not connected.

4. Check connections:
BKS X5 / Oxygen sensor (detector
channel 1)
BKS X6 / detector channel 1 (channel 2)
(see 18.).

5. Electrochemical oxygen
sensor is already consumed.

5. Exchange sensor (see 25.)

6. IR channel:
Light source not connected
or faulty.

6. Checkconnection:
BKS X3(1/2) / light source channel 1
BKS X3(4/5) / light source channel 2
(see 18.)
Light source is cold:
For dual IR channel analyzer
interchange the two light-sources.
Replace the suspect light source
(see 24.2).

7. Faulty analog
preamplifiering.

7. Check measuring point 17.1.7 or
17.2.1 resp.

8. Contamination of the gas
paths.

8. Check analysis cell and windows for
contamination.
Cleaning of contaminated parts
(see 24.3).
Check gas paths and gas
conditionning to contamination.

ETC00781(4) Series 100 e 02/2004

16 - 5

LIST OF FAILURES

Error Code

Possible Reasons
9. Barometric pressure
effects.

Fluctuating or
erroneous display

10. Temperature below the
dew point in the gas paths.

Check / Correct
9. Enter the correct value for
barometric pressure (see chapter 8.1).
Pressure sensor faulty (E.37).

10. Check the temperature of the gas
paths and eliminate any reason of
condensation,
Maintain all temperatures at values
at least 10 °C above the dew point of
sample gas.

11. Faulty A/D converter.

11. Exchange BKS.

1. Incorrect response time
( t90 time) settings.

1. Check the value for t90 time
(see chapter 8.11).

2. Pumping rate inadequate.

2. The feeder line between the
sampling point and the analyzer is
too long.
Use a larger, external pump;
consider adding a bypass line to the
process stream for sampling
purposes (see chapter 5.1).

3. Contamination of the gas
paths.

3. Check gas paths and gas
conditionning to contamination.

Response - time too long
(t90 - time)

Clean gas paths and exchange the
filter elements.

16 - 6

ETC00781(4) Series 100 e 02/2004

LIST OF FAILURES

Error Code

No gas flow

Possible Reasons

Check / Correct

1. Needle valve is not opened
(Option)

1. Open needle valve
(Option, see Fig. 1-2)

2. Sample gas pump (Option)
is not switched on

2. Press key PUMP

3. Membrane of pump is
defective

3. Exchange membrane of the pump.

4. Sample gas pump is
defective

4. Exchange sample gas pump

5. Solenoid valves defective
(Option)

5. Check the valve face of the solenoid
valves and exchange if necessary.
Exchange solenoid valves

6. Contamination of the
gas lines

6. Check gas lines including filters to
contamination.
Clean the gas lines and exchange
the filter elements.

ETC00781(4) Series 100 e 02/2004

16 - 7

LIST OF FAILURES

Error Code

16 - 8

Possible Reasons

Check / Correct

ETC00781(4) Series 100 e 02/2004

MEASURING POINTS OF BKS AND OXS
MEASURING POINTS OF BKS

Rosemount Analytical

17.

Measuring Points of BKS and OXS
Be sure to observe the safety measures !

X 18

X 16

17.1

Measuring points of BKS
X 14

All measuring points are measured against
ground (X 11 / X 28 or X 29) !

17.1.1 Supply Voltage + 6 V

X 28
1

X9

Measuring point: X 14
Measuring device: DVM
Signal:
+ 6 V DC (+10 / -200 mV)

X 29
X 10

X 12
X 11

(adjust with Potentiometer R 90, if necessary)

Failure:

X8

No signal

Possible reasons: a)

b)

c)

Voltage supply
is absent.

X 27

Voltage supply < 9 V
or polarity reversal

X 25

BKS faulty.
LB 1

U2
1

17.1.2 Reference Voltage positive
Measuring point: X 10
Measuring device: DVM
Signal:
+ 5,535 V DC (± 60 mV)

U3

U1
1

1

Front panel
Fig. 17-1: PCB “BKS”, measuring points
(principle drawing)

ETC00781(1) Series 100 e 10/2001

17 - 1

MEASURING POINTS OF BKS AND OXS
MEASURING POINTS OF BKS

Rosemount Analytical

17.1.3 Reference Voltage negative
Measuring point: X 12
Measuring device: DVM
Signal:
inverse [reference voltage positive]
The difference between negative reference voltage and positive reference voltage must
be no more than 10 mV (Uref. pos. + Uref. neg. ≤ ± 10 mV) !
If the difference is bigger, exchange BKS.

17.1.4 Motor Drive (for IR channel only)
Measuring point: LB 1
Measuring device: Oscilloscope
Signal:
square impuls U = 6 VSS (± 0,3 V)
frequency = 1152 Hz (± 20 Hz)
Failure:

No signal or incorrect frequency

Possible reasons: a) internal 6 V DC absent (see chapter 17.1.1)
b) µP do not work:
1.
Is the EPROM insert correctly ? (see chapter 28)
2.
Perform a RESET (see chapter 8.14).
3.
BKS faulty (exchange BKS).

17 - 2

ETC00781(1) Series 100 e 10/2001

MEASURING POINTS OF BKS AND OXS
MEASURING POINTS OF BKS

Rosemount Analytical

17.1.5 Temperature Sensor
Measuring point: X 8
Measuring device: DVM
Signal:
approx. 0 ± 500 mV DC (at ambient temperature)
Failure.

Signal > + 3,5 V DC

Possible reasons (IR measurement or paramagnetic oxygen measurement):
a)
b)
c)
d)

Temperature sensor not connected (see chapter 18.1).
Temperature sensor faulty (exchange sensor).
Broken cable of temperature sensor (exchange sensor).
BKS faulty (exchange BKS).

Possible reasons (electrochemical oxygen measurement):
a)
b)
d)

ETC00781(1) Series 100 e 10/2001

Temperature sensor not connected (see chapter 18.2).
PCB OXS faulty (exchange OXS).
PCB BKS faulty (exchange BKS).

17 - 3

MEASURING POINTS OF BKS AND OXS
MEASURING POINTS OF BKS

Rosemount Analytical

17.1.6 Light Barrier Signal
Measuring point: Plug 9, pin 2
Measuring device: Oscilloscope
Signal:
square impulse U = 6 VSS (± 0,3 V)
Frequency = 24 Hz (± 0,1 Hz)
Failure:

No signal

Possible reasons (IR measurement):
a)
b)
c)
d)
e)

Chopper not connected (see chapter 18.1).
Chopper inoperative (switch analyzer off and then on again).
Light barrier not connected (see chapter 18.1).
Broken cable of light barrier or faulty light barrier (exchange
chopper).
BKS faulty (exchange BKS).

Possible reasons (oxygen measurement without IR channel):
a) Solder bridge LB 18 not closed.
b) BKS faulty (exchange BKS).

17 - 4

ETC00781(1) Series 100 e 10/2001

MEASURING POINTS OF BKS AND OXS
MEASURING POINTS OF OXS

Rosemount Analytical

17.1.7 Analog Preamplifiering
a)

paramagnetic oxygen measurement
Measuring point:

X 25 channel 1

Measuring device: DVM
Signal:

At zero gas purge: 0 V dc (± 50 mV)
At ambient air (approx. 21 Vol. - % O2): 500 mV dc (± 50 mV)

Failure:

No signal or incorrect measuring values.

Possible reasons: a)
b)
c)

a)

oxygen sensor not connected (see chapter 18.).
oxygen sensor faulty (exchange sensor).
BKS faulty (exchange BKS).

IR measurement
Measuring point:

X 25 channel 1 (not for analyzer with oxygen measurement)
X 27 channel 2

Measuring device: DVM
Signal:

At zero gas purge: 0 V dc (± 100 mV)
There should be a minimum difference of 600 mV
(measuring ranges < 1000 ppm difference 500 mV) between
zeropoint voltage and sensitivity voltage.

Failure:

No signal or incorrect measuring values.

Possible reasons: a)
b)
c)

ETC00781(1) Series 100 e 10/2001

Detector not connected (see chapter 18.).
Detector faulty (exchange detector).
BKS faulty (exchange BKS).

17 - 5

MEASURING POINTS OF BKS AND OXS

17.2

Rosemount Analytical

Measuring points of OXS (electrochemical oxygen measurement)

17.2.1 Sensor Signal
Measuring device: DVM
Measuring point:

Tp 1 (Signal)
⊥)
Tp 2 (⊥

Signal:

At ambient air (approx. 21 Vol. - % O2): 700 mV to 1000 mV

Failure:

No signal or faulty voltage

Possible reasons:

a)
b)
c)
d)

Oxygen sensor not connected to PCB "OXS"
PCB “OXS” not connected / faulty
Oxygen sensor faulty or consumed
BKS faulty

Note !
If the measuring value is lower than < 700 mV at gas flow with ambient air, the sensor is consumed.
Exchange the sensor.

Tp 2

Tp 1

Fig. 17-2: PCB “OXS”, assembled, horizontal projection

17 - 6

ETC00781(1) Series 100 e 10/2001

PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS
PLUG PIN ALLOCATION OF BKS

Rosemount Analytical

18.

Plug Pin Allocation of Printed Circuit Boards
Be sure to observe the safety measures !

18.1

P 1 or P2

X1

X 18

X 16

Plug Pin Allocation of BKS

24 V DC supply to
optional internal consumer
(heater of paramagn. O2 sensor e.g.)

P1
P2

Front panel BXF (P8)
1

J9

Digital Outputs, parallel
1

X 36/
D 30

Option BAF 01:
Pressure sensor PCB

Marked

X7

1

P1
EPROM

Option BSI 10:
Status signals and
serial interface resp.

Option
BAF 01

1

(D 30 at BKS)

J9

X 36

Analog Outputs

EPROM

X 18

(at BAF 01)

X 16

X9

X6

Marked

1

X5

P1

at Option BAF 01:
Connector for pressure sensor
X2
1

X1

8

X3
1

7

1

4

Front panel
Fig. 18-1: PCB “BKS”, Plug Pin Allocation
(principle drawing)
ETC00781(1) Series 100 e 10/2001

18 - 1

PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS
PLUG PIN ALLOCATION OF BKS

Rosemount Analytical

18.1.1 IR measurement without oxygen channel
X2

Chopper

X3

(4/5)

Light source channel 1

X3

(1/2)

Light source channel 2

X5

IR detector (channel 1)

X6

IR detector (channel 2)

X7

Temperature sensor (chopper)

X9

Light barrier (chopper)

18.1.2 Oxygen Measurement without IR channel
X5

Oxygen sensor (channel 1)
[at electrochemical measurement:
PCB OXS (cable P1, 5 pin connector)]

X7

Oxygen sensor (channel 2)
[at electrochemical measurement:
PCB OXS (cable P1, 5 pin connector)]

X7

Temperature sensor
[at electrochemical measurement:
PCB OXS (cable P1, 2 pin connector)]

18 - 2

ETC00781(1) Series 100 e 10/2001

PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS
PLUG PIN ALLOCATION OF BKS

Rosemount Analytical

18.1.3 IR / Oxygen Measurement combined
X2
X3

Chopper
(4/5)

Light source channel 2

X5

Oxygen sensor

X6

IR detector (channel 2)

X7

Temperature sensor (chopper)

X9

Light barrier (chopper)

18.1.4 TC Measurement without IR channel
In preparation !

ETC00781(1) Series 100 e 10/2001

18 - 3

PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS
PLUG PIN ALLOCATION OF BKS

Rosemount Analytical

18.1.5 IR / TC Measurement combined
X2
X3

Chopper
(4/5)

Light source channel 2

X5

TC sensor (from PCB WAP 100, cable P15, 5 pin connector))

X6

IR detector (channel 2)

X7

Temperature sensor (chopper)

X9

Light barrier (chopper)

18.1.6 Oxygen / TC Measurement combined
In preparation !

18 - 4

ETC00781(1) Series 100 e 10/2001

Rosemount Analytical

18.2

PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS
PLUG PIN ALLOCATION OF OXS (ELECTROCHEMICAL O2 MEASURMENT)

Plug Pin Allocation OXS (electrochemical oxygen measurement only)

Pin base P2

Oxygen sensor

Cable P1, 5 pin connector

PCB BKS, X 5 (sensor signal)

Cable P1, - pin connector

PCB BKS, X 7 (temperature sensor)
(not used for combination with IR measurement)

View A: PCB OXS assembled, horizontal projection

Connection
Oxygen sensor

PCB
“OXS”

View A
↓

(Pin-base“P 2”)

Cable
“P 1”

Fig. 18-2: PCB “OXS”

ETC00781(1) Series 100 e 10/2001

18 - 5

PLUG PIN ALLOCATION OF PRINTED CIRCUIT BOARDS
PLUG PIN ALLOCATION OF WAP 100 (TC MEASURMENT)

18.3

Rosemount Analytical

Plug Pin Allocation WAP 100 (TC measurement only)

Terminals P 18

to sensor

Cable P15, 5 - pin connector

PCB BKS, X 5 (sensor signal)

P 16

heater of sensor

P 10

PCB BSE 01 (analog input for cross compensation)

blue
green
yellow

24 V DC supply from PCB BKS (P1 or P2)

orange

P2

P 18

1

1

P 10
P 16

P 15
1

P2

Fig. 18-3: PCB “WAP 100”, Plug Pin Allocation
(principle drawing)

18 - 6

ETC00781(1) Series 100 e 10/2001

JUMPER ALLOCATION OF BKS

Rosemount Analytical

19.

Jumper Allocation of BKS

J1

A/D conversion start channel 1

J2

A/D conversion start channel 2

X 18

X 16

(open for 1 channel analyzer)

J6

J6

Watchdog signal

J7

Buffer Battery

J7

J2
1

J1
1

Front panel
Fig. 19-1: PCB “BKS”, Jumper Allocation
(principle drawing)
ETC00781(1) Series 100 e 10/2001

19 - 1

JUMPER ALLOCATION OF BKS

19 - 2

Rosemount Analytical

ETC00781(1) Series 100 e 10/2001

FINE DUST FILTER (OPTION)

21.

Fine Dust Filter (Option)

The optional fine dust filter (see Fig. 1-2) should be checked in intervals appropriate to the type
of process and application. If the filter element shows contamination, the element should be
replaced immediately with a new unit.
To avoid risks by explosive, toxic or unhealthy gas components purge the gas
lines with ambient air or nitrogen (N2) before cleaning or replacing parts
of the gas paths.

P

Remove the glass filter cover and unscrew the mounting bracket
(switch off optional gas sampling pump before).

P

Replace contaminated filter element, using only new units (Order - No.: 42 707 676).
Dispose contaminated filter elements in accordance with applicable regulations.
Filter elements are single-use disposable items !
Do not clean and replace used filter elements; use new replacements only !

P

Reinstall mounting bracket and close filter with the glass cover (see Fig. 21-1).

P

Perform a leak testing (see Item 22.)

Filter element
Glass cover
Mounting bracket

12345678901234
12345678901234
12345678901234

Fig. 21-1: Fine Dust Filter
ETC00781(4) Series 100 e 02/2004

21 - 1

FINE DUST FILTER (OPTION)

21 - 2

ETC00781(4) Series 100 e 02/2004

LEAK TESTING

22.

Leak Testing

Testing for gas leakage should be performed at bimonthly intervals and always immediately after
any repair or replacement of gasline components is performed.The test procedure is as follows:

Analyzer

Overpressure
approx. 50 hPa

Valve

Water

Fig. 22-1: Leak Testing with an U - Tube - Manometer

P

Install a waterfilled U - tube manometer at the sample gas outlet;

P

Install a shut-off valve at the sample gas inlet.
Admit air into the instrument at the shut-off valve until the entire analyzer is subjected
to an overpressure of 50 hPa (approximately 500 mm water column; see Fig. 22-1).

Close the shut-off valve and verify that following a brief period required for pressure equilibrium,
that the height of the water column does not drop over a period of about 5 minutes.
Any external devices, such as sample gas cooling hardware, dust filters etc., should be checked
in the course of leak testing.
Overpressure max. 500 hPa !
For analyzers with parallel gas paths leak testing must be performed for
each gas path separately !

ETC00781(4) Series 100 e 02/2004

22 - 1

LEAK TESTING

22 - 2

ETC00781(4) Series 100 e 02/2004

HOUSING
CLEANING OF HOUSING SURFACE

23.

Housing

23.1

Cleaning of Housing Surface

For cleaning the analyzer housing surface use a soft, fluff free cloth and all purpose detergent.

P

Disconnect all voltage supplies.
To avoid risks by explosive, toxic or unhealthy gas components,
first purge the gas lines with ambient air or nitrogen (N2) before
cleaning or replacing parts of the gas paths.
If it is necessary to disconnect the gas connections, the gas line fittings of the
analyzer have to be closed with PVC-caps before cleaning to avoid pollution!

P

Moisten the soft, fluff free cloth with the cleaning solution
(mixture of 3 parts water, 1 part all purpose detergent max.).
Be sure to use a moisted, but not wet cloth only !
Be sure, that no liquid can drop into the housing inside !

P

Clean the analyzer housing surface with the damped cloth.

P

If required, rub off the housing, but not the front panel, with a dry cloth afterwards.

ETC00781(4) Series 100 e 02/2004

23 - 1

HOUSING
OPENING THE HOUSING (1/4 19" HOUSING)

23.2

Opening the Housing

The housing must be opened for checking the electrical connections and for replacement or
cleaning of any of theinternal components of the analyzer.
Be sure to observe chapter VIII. of the safety measures !

23.2.1 1/4 19" Housing
P

Disconnect all voltage supplies.

P

Table-top analyzers only
* Remove the rubber feet.
* Unscrew the screws shown in Fig. 1-1, Item 8.
* Remove the front mounting frame and carrying strap to rear.

P

Unscrew the screws shown in Fig. 1-1, Item 7 and Figs. 1-5 and 1-6, Item 6.

P

Remove the analyzer housing top cover panel.

Closing the housing is performed in reverse order.

23 - 2

ETC00781(4) Series 100 e 02/2004

HOUSING
OPENING THE HOUSING (BINOS® 100 2M)

23.2.2 BINOS® 100 2M
a)

Housing Cover

P

Disconnect all voltage supplies.

P

Unscrew fastening screws for rack mounting / front frame if necessary (Fig. 1-2, Item 11).
Remove analyzer out of rack or remove the front mounting frame and carrying strap to rear.

P

Unscrew the respective fastening screws at both housing sides (Fig. 23-1)

P

Remove the respective housing top cover panel.

Closing the housing is performed in reverse order.

fastening screws housing cover

Fig. 23-1: BINOS® 100 2M
(Fastening screws housing cover)

ETC00781(4) Series 100 e 02/2004

23 - 3

HOUSING
OPENING THE HOUSING (BINOS® 100 2M)

b)

Front Panel

P

Opening housing cover (Item 23.2.2 a).

P

Unscrew the 6 fastening screws at both housing sides (Fig. 23-2)

P

Remove front panel to the front carefully.
If the optional components fine dust filter and flow meter are mounted at front
panel - take care of gas lines (see Fig. 1-2) !

Closing the housing is performed in reverse order..
Do not squeeze gas lines !

Fastening screws,
front panel

Fig. 23-2: BINOS® 100 2M
(Fastening screws front panel, viewed without options filter and flow sensor)

23 - 4

ETC00781(4) Series 100 e 02/2004

HOUSING
OPENING THE HOUSING (BINOS® 100 F)

23.2.3 BINOS® 100 F (Field Housing)

P

Open all 4 fasteners with a square key (Fig. 23-3)

P

Carefully swing out the front panel to the right side.

P

Pull out the phometer slide-in cart to the front carefully.

Photometer components may be hot!

Closing the housing is performed in reverse order.

Fastener for front panel

Fastener for front panel
Fig. 23-3: BINOS® 100 F (Field housing) (fastener for front panel)

ETC00781(4) Series 100 e 02/2004

23 - 5

HOUSING

23 - 6

ETC00781(4) Series 100 e 02/2004

REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS
REMOVAL OF THE PHOTOMETER ASSEMBLY

24.

Replacement and Cleaning of Photometric Components

24.1

Taking out the Photometer Assembly

P

Open the analyzer housing (cf. chapter 23).

P

Disconnect all electrical connections between photometer assembly and electronic unit
and disconnect all gas lines from the photometer assembly.
P

Only analyzers with gas detector:
Remove preamplifier (Fig. 3-2, Item 5) from holding device (Fig. 3-2, Item 4).

P

Remove the two screws shown in Fig. 24-1 as Item 1.

P

Take the photometer assembly out of the analyzer housing.

2

3

4
5
5
1

1

Fig. 24-1: Analyzer Photometer Assembly
(2 channel IR analyzer, viewed from the front panel side)

1
2
3
4
5
ETC00781(4) Series 100 e 02/2004

Fastening screw, photometer assembly mounting bracket
Light source with mounting flange
Temperature sensor
Zero level adjustment baffle (not for sealed version)
Light source mounting screw
24 - 1

REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS
LIGHT SOURCE REPLACEMENT

24.2

Light Source Replacement

P

Open the analyzer housing (cf. chapter 23).

P

TTake the photometer assembly out of the analyzer housing (see chapter 24.1).

P

Remove the two light source mounting screws (shown in Fig. 24-1 as Item 5) or the
temperature sensor (shown in Fig. 24-1 as Item 3) resp.

P

Remove the light source together with its mounting flange.

P

Remove the mounting flange from the light source and position it on the new light source.

P

For sealed version with pyroelectrical detector only:
Remove the tight baffle (zero level adjustment baffle) from the light source and
position it in the new light source.

P

For sealed version only:
Place the O-rings on the adapter cell and filter cell.

P

Insert the new light source and flange in the same position as the old one.

P

Insert and tighten the two light source mounting screws (shown in Fig. 24-1 as Item 5)
or the temperature sensor (shown in Fig. 24-1 as Item 3) resp.

P

Reinstall the photometer assembly (see chapter 24.5).

P

Perform the physical zeroing procedure (see chapter 24.6).

24 - 2

ETC00781(4) Series 100 e 02/2004

REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS
REMOVAL OF ANALYSIS CELLS

24.3

Cleaning of Analysis Cells and Windows

24.3.1 Removal of Analysis Cells
P
P

Open the analyzer housing (cf. chapter 23).
Take the photometer assembly out of the analyzer housing (see chapter 24-1).

a)

For analysis cells of lengths 1 mm and 7 mm
P
P

b)

Remove the clamp (Fig. 24-2, Item 2).
Remove the clamping collar and the filter cell with signal detector assembly.

For analysis cells of lengths 50 mm - 200 mm:
P
P
P
P

Remove the clamp (Fig. 24-2, Item 3).
Remove the filter cell with signal detector assembly.
Remove the mounting screws shown in Fig. 24-2, Item 4.
Remove the analysis cell body from the chopper housing.

Only analyzers with gas detector:
P Remove preamplifier from analysis cell
1

4

4

2

3

Fig. 24-2: Photometer Assembly (2 channel photometer, side view)

1
2
3
4
ETC00781(4) Series 100 e 02/2004

Filter cell with signal detector assembly
Clamp with clamping collar
Clamp
Mounting screws for analysis cells of lengths 50 - 200 mm
24 - 3

REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS
CLEANING

24.3.2 Cleaning
a)

Windows

The windows on the filter cell, chopper housing, the adapter cell resp. analysis cell may be
cleaned with a soft, lint-free cloth.
Use a highly volatile alcohol for the cleaning procedure.
To remove any remaining lint and dust particles, blow off the cleaned components with nitrogen
(N2).

b)

non-divided analysis cells

The analysis cell may be cleaned with a soft, lint free cloth.
Use a highly volatile alcohol for the cleaning procedure.
To remove any remaining lint and dust particles, blow off analysis cell with nitrogen (N2).

c)

divided analysis cells

If pollution is visible in the analysis cell, it can be removed with suitable solvents e. g. acetone
or spirit. Afterwards the analysis cell has to be flushed with an alcohol which evaporates easily
and dried by blowing nitrogen (N2).

Max. pressure in analysis cell 1,500 hPa !

24 - 4

ETC00781(4) Series 100 e 02/2004

REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS
REINSTALLING OF ANALYSIS CELLS

24.3.3 Reinstalling the Analysis Cells
a)

b)

For analysis cells of lengths 1 mm and 7 mm
P

Place the O-rings on the adapter cell and filter cell.

P

Fit the components together.

P

Install the clamping collars with the clamp and tighten it.

Analysis cells of lengths 50 mm - 200 mm:
P

Place the O-ring on the chopper housing side of the cell body.

P

Position the cell body in place and fasten it using the two mounting screws
(Fig. 24-2, Item 4).

P

Place the O-ring on the filter cell.

P

Fit the filter cell on the cell body.

P

Install the clamp and tighten.

Only analyzer with gas detector:
P

Assembly preamplifier to analysis cell

Then:
P

Reinstall the photometer assembly (see chapter 24.5).

ETC00781(4) Series 100 e 02/2004

24 - 5

REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS
CHOPPER REPLACEMENT / REINSTALLING OF THE PHOTOMETER ASSEMBLY

24.4

Chopper Replacement

P

Open the analyzer housing (cf. chapter 23).

P

Take the photometer assembly out of the analyzer housing (see chapter 24.1).

P

Remove the light source(s) from chopper housing (see chapter 24.2).

P

Remove the analysis cell(s) from chopper housing (see chapter 24.3.1).

P

Remove the analysis cell(s) from chopper housing (see chapter 24.3.1).

P

Reinstall the analysis cell(s) to new chopper housing (see chapter 24.3.3).

P

Insert the light source(s) to new chopper housing (see chapter 24.2).

P

Reinstall the photometer assembly (see chapter 24.5).

24.5

P

Reinstalling of the Photometer Assembly

Insert the photometer assembly into the analyzer housing and fasten in position using
the mounting bracket screws (Fig. 24-1, Item 1).
P

Only analyzers with gas detector:
Insert preamplifier (Fig. 3-2, Item 5) to holding device (Fig. 3-2, Item 4).

P

Reconnect all gas lines to the assembly.

P

Reconnect all electrical connections between the photometer assembly and the electronic
unit (see chapter 18.).

P

Perform a leakage test (see chapter 22).

P

Perform the physical zeroing procedure (see chapter 24.6).

24 - 6

ETC00781(4) Series 100 e 02/2004

REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS
PHYSICAL ZEROING

24.6

Physical Zeroing

Adjustment of the physical zero - level will only be required if a light source, a filter cell, or an analysis
cell have been replaced or repositionned.
Be sure to observe the safety measures !
Take care of the photometer temperature: Photometers heat up when powered!

Needed for the adjustment are a digital voltmeter (DVM) with a range of 2 VDC and a 3 mm
hexagon wrench SW 3.
P

Switch on the analyzer (cf. chapter 6).

P

Admit zero gas to the analyzer.

P

Connect the DVM to the measuring points:
X 25 and X 28 ( ⊥ ) for

channel 1 (IR measurement only).

X 27 and X 28 ( ⊥ ) for

channel 1 (Combined Oxygen / IR measurement).
channel 2 (IR measurement only).
Depending on the installed photometer model continue with step 24.6.1 or 24.6.2
24.6.1 Standard Photometer (not sealed version)
P

Slightly loosen the light source mounting screws (shown in Fig. 24-1 as Item 5) or the
temperature sensor (shown in Fig. 24-1 as Item 3) resp. for channel 1 or channel 2.

P

Set the zero level precisely to 0 V (± 100 mV) by turning the corresponding light source.
If the turning of the light source is not sufficient, the zero point can be adjusted by sliding
the zero level adjustment baffle (Fig. 24-1, item 4).

P

Tighten the light source mounting screws (shown in Fig. 24-1 as Item 5) or the
temperature sensor (shown in Fig. 24-1 as Item 3) resp. for channel 1 or channel 2.

When the physical zeroing has been correctly set, perform an electrical zeroing (see chapter 9.).
ETC00781(4) Series 100 e 02/2004

24 - 7

REPLACEMENT AND CLEANING OF PHOTOMETRIC COMPONENTS
PHYSICAL ZEROING

24.6.2 Sealed Photometer (Option)
P

Slightly loosen the light source mounting screws (shown in Fig. 24-1 as Item 5) or the
temperature sensor (shown in Fig. 24-1 as Item 3) resp. for channel 1 or channel 2.

P

Set the zero level precisely to 0 V (± 100 mV) by turning the corresponding light source.

P

P

For photometer with pyroelectrical detector only:
To enable physical zero level adjustment, one out of three different fix apertures
(zero level adjustment aperture) are installed inside the light source.
For simple replacement the aperture is fixed inside the source with a magnet.
If turning the light source is not sufficient, use another fix aperture (zero level
adjustment aperture; see item 24-2) and again turn the light source.

Tighten the light source mounting screws (shown in Fig. 24-1 as Item 5) or the
temperature sensor (shown in Fig. 24-1 as Item 3) resp. for channel 1 or channel 2.

When the physical zeroing has been set correctly, perform an electrical zeroing (see chapter
9.).

24 - 8

ETC00781(4) Series 100 e 02/2004

CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR

25.

Checking / Replacing an Electrochemical Oxygen Sensor

On account of the measuring principle the oxygen sensor has a limited life time.
The life time of the oxygen sensor depends on the sensor itself and on the measured oxygen
concentration and is calculated as follows:
life time =

sensor time (hours)
O2 - concentration (%)

The so-called “sensor time” (operation without oxygen at 20 °C ) is
approx. 900.000 hours for sensors with a response time of about 12 s
approx. 450.000 hours for sensors with a response time of about 6 s

The sensors have the following life time at approx. 21 % Oxygen and 20 °C :
approx. 42.857 hours (approx. 5 years) for sensors with a response time of about 12 s
approx. 21.428 hours (approx. 2.5 years) for sensors with a response time of about 6 s

Note !
The values given above are presented as guidelines only. The actual values are depending on
operation temperatures (the result of higher temperatures, for example 40 °C, could be the half
life time) and measured concentrations.
Note !
On account of the measuring principle the electrochemical O2 cell needs a minimum internal
consumption of oxygen (residual humidity avoids the cell running dry). Continuously supplying cells
with dry sample gas of low grade oxygen concentration or with oxygen-free sample gas could result
a reversible change of O2 sensitivity. The output signal will become unstable.
For correct measurement the cells have to be supplied with O2 concentrations of at least 0.1 Vol.-%.
We recommend to use the cells in intervall measurement (purge cells with conditioned (removal of dust
but no drying) ambient air during measurement breaks).
If it is necessary to interrupt oxygen supply for several hours or days, the cell has to regenerate (supply
cell for about one day with ambient air). Temporary flushing with nitrogen (N2) for less than 1 h (e.g.
analyzer zeroing) does not influence the measuring quality.
For analyzers with electrochemical O2 cell purge all analyzer gas lines with conditioned ambient air
before closing the gas line fittings for transport or depositing the analyzer.
ETC00781(4) Series 100 e 02/2004

25 - 1

CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR
CHECKING THE SENSOR

25.1

Checking the Sensor

Replace the sensor, if the voltage is less than 70 % of the initial output voltage.

The check requires a digital voltmeter (DVM) with a range of 5 V DC.
P

Open the housing (see chapter 23.).

P

Switch On the analyzer (see chapter 6.).

P

Supply ambient air to the analyzer (approx. 21 Vol. - O2).

P

Connect the DVM to the measuring points
Tp 1 (Signal) and Tp 2 ( ⊥ ) of the PCB OXS, mounted directly at the connection block
(Fig. 25-1, see also Fig. 25-2, 1-11, 1-13, 1-15 to 1-17 and 1-19).

The measuring signal should be in a range of 2,4V DC to 3,36 V DC.

Note !
If the measuring value is lower than 2,4V at gas flow with ambient air, the sensor is consumed.
Replace the sensor.

Tp 1

Tp 2

Fig. 25-1: PCB “OXS”, assembled, horizontal projection

25 - 2

ETC00781(4) Series 100 e 02/2004

CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR
REPLACING THE SENSOR

25.2

Replacing the Sensor
Be sure to observe the safety measures !

25.2.1 Remove the old Sensor
a)

Oxygen Measurement without IR - channel

P

Open the analyzer housing (see chapter 23.).

P

Disconnect all electrical connections between the PCBs OXS and BKS (X5, X6 and X7,
see chapter 18.).

P

Remove all gas lines from the sensors.

P

Unscrew both allen screws (fastening screws, see Fig. 25-2).
Gas connections

Fastening srew
Fastening srew

Front panel

Fig. 25-2: Inside View BINOS® 100 2M
(Oxygen Measurement without IR channel, assembly similar in OXYNOS® 100 EO2)
ETC00781(4) Series 100 e 02/2004

25 - 3

CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR
REPLACING THE SENSOR

P

Take out the complete support (see Fig. 25-1) to the top of the analyzer.

P

Disconnect the connector for the sensor from “P2” of circuit board “OXS” (see Fig. 25-5).

P

Cut through the cable tie (see Fig. 25-3).

P

Unscrew both fastening screws for the fitting (phillips screws, see Fig. 25-3).

P

Remove the fitting including the sensor (see Fig. 25-3).

Connector for
Sensor
Potentiometer (R4)
PCB OXS
gas outlet

Front panel

Gas connections

gas inlet

Sensor
Cable tie
Sensor name plate

Fitting
Fastening screw
fitting
(phillips screw)

Fig. 25-3: Sensor support BINOS® 100 2M
(Oxygen Measurement without IR channel)

25 - 4

ETC00781(4) Series 100 e 02/2004

CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR
REPLACING THE SENSOR

b)

IR / Oxygen Measurement combined

P

Open the analyzer housing (see chapter 23.).

P

Disconnect the connector for the sensor from “P2” of circuit board “OXS” (see Fig. 25-5).

P

Unscrew both fastening screws for the fitting (see Fig. 25-4) and remove the fitting
completely with the sensor.

Gas connections
Fastening
screws
Fitting

Front panel

Fig. 25-4: Inside View BINOS® 100 2M
(combined IR / Oxygen Measurement, assembly similar in BINOS® 100 M)
ETC00781(4) Series 100 e 02/2004

25 - 5

CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR
REPLACE / REINSTALL THE SENSOR

25.2.2 Removing the Sensor
P

Take the consumed sensor out of the fitting.

P

Take off the stopper from new sensor and place the new sensor into the fitting, so
that the name plate is at the top of the sensor.

P

Close the consumed sensor with the stopper and send it back to our factory.

25.2.3 Reinstalling the Sensor
a)

Oxygen Measurement without IR - channel

P

Put the fitting with the (new) sensor onto the support, move to the stop and screw with
the two fastening screws (phillips screws, see Fig. 25-3)

P

Fix the sensor with a cable tie to the support (see Fig. 25-3).

P

Connect the connector for the sensor to “P2” of circuit board “OXS” (see Fig. 25-5 / chapter 18.).

P

Insert the complete support (see Fig. 25-3) into the analyzer and fix it with the two
allen screws (fastening screws, see Fig. 25-2).

P

Reconnect all gas lines to the fittings (see Fig. 25-2 and Fig. 25-3).
Do not interchange gas inlets and gas outlets.

P

Reconnect all electrical connections between OXS and BKS (X5 and X7, see chapter 18.).

P

Perform a leakage test (see chapter 22.) and set the sensor (see chapter 25.2.4).

b)

Combined IR / Oxygen Measurement

P

Put the fitting with the (new) sensor onto the support, move to the stop and fix it with
the two fastening screws (see Fig. 25-4)

P

Connect the connector for the sensor to “P2” of circuit board “OXS” (see Fig. 25-5 / chapter 18.).

P

Perform a leakage test (see chapter 22.) and set the sensor (see chapter 25.2.4).

25 - 6

ETC00781(4) Series 100 e 02/2004

CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR
BASIC SETTINGS

25.2.4 Basic settings for the Oxygen Sensor

P

Supply ambient air to the analyzer (approx. 21 Vol. - O2) and switch on (see chapter 6.).

P

Connect the DVM to the measuring points
Tp 1 (Signal) and Tp 2 ( ⊥ ) of the PCB OXS, mounted directly at the connection block
(Fig. 25-1, see also Fig. 25-2, 1-11, 1-13, 1-15 to 1-17 and 1-19).

P

Set the signal to 3,36 V DC (± 5 mV) with potentiometer R4 (Fig. 25-5) of the
corresponding circuit board “OXS”.
Note !
Do not change this setting for this sensor again !

P

Switch off the analyzer and close the analyzer housing (see chapter 23.).
Slide the module into platform if necessary.

P

A complete recalibration of the instrument must be performed after a sensor replacement.

Potentiometer “R4”

Tp 1

Tp 2

Connection
oxygen sensor
(“P2”)

Fig. 25-5: PCB “OXS”, assembled, view at component side

ETC00781(4) Series 100 e 02/2004

25 - 7

CHECKING AND REPLACING AN ELECTROCHEMICAL OXYGEN SENSOR

25 - 8

ETC00781(4) Series 100 e 02/2004

TECHNICAL DATA

27.

Technical Data

Certifications

EN 61326, EN 61010-1

(for measurment of non flammable gases or non
explosive gases resp. (< 50 % LEL).
Higher concentrations require supplementary

NAMUR, CSA-C/US,
C-Tick, PAC, GOSSTANDART

protective measures !)

Suitability tests TÜV Nord mbH, report no.: 95CU054/B,
TÜV Bavaria, report no.: 1563793,
Carbon monoxide (CO): TI Air, 13th BImSchV
Oxygen (O2):
TI Air, 13th BImSchV, 17th BImSchV
DMT:
CO2 / CH4 :
CO
:
O2
:

IBS/PFG-No. 41300392NIII/41300292NIII
0-80 Vol.-%
0-200 ppm / 0-10 Vol.-%
0-10 Vol.-%

For information about the configuration, measuring components and ranges of the actual
analyzer refer to the nameplate label, which is located on the left or right side of the analyzer
cover (all table top and rack mount versions) or inside the front door (BINOS 100 F).
How to read a name plate label:
Analyzer type and
measuring prinziples

Serial number
Channel 1:
Component and
full scale range

Analog output
settings

27.1
Options
Pressure sensor
Fine dust filter (BINOS® 100 2M/F)
Sample gas pump (BINOS® 100 2M/F)

ETC00781(4) Series 100 e 02/2004

Channel 2:
Component and
full scale range

DMT approval number
(if applicable)

Measuring range 800 - 1,100 hPa
Filter material PTFE, Pore size approx. 2 mm
Pumping rate max. 2.5 l/min.
Suction pressure min. 900 hPa
Lifetime max. 5,000 hours
27 - 1

TECHNICAL DATA
HOUSING / OPTIONS

27.2

Housing

Gas connections

BINOS® (M)/ OXYNOS® / HYDROS® 100
BINOS® 100 2M
BINOS® 100 F (standard version)

Standard 6/4 mm PVDF
Option:
6/4 mm or 1/4", ss
additional fittings on request
max. 4 fittings
max. 9 fittings
max. 6 fittings

Dimensions

see dimensional sketches (Fig. 27-1)

Weight (depending on analyzer configuration)
BINOS® (M)/ OXYNOS® / HYDROS® 100
BINOS® 100 2M
BINOS® 100 F (standard version)

approx. 4 - 7 kg
approx. 10 - 12 kg
approx. 30 - 35 kg

Protection class
BINOS® (M/2M)/ OXYNOS® / HYDROS®
BINOS® 100 F (standard version)

(according to DIN standard 40050)
IP 20
IP 65 (NEMA4/4X)

Permissible ambient temperature

+ 5 °C to + 40 °C
(higher ambient temperatures (45 °C) on request)

Humidity (non condensing)

< 90 % rel. humidity at + 20 °C
< 70 % rel. humidity at + 40 °C

Rain, drop / splash water

The analyzer must not be exposed to rain or
drop/splash water

Explosive atmosphere

The analyzer must not be operated in
explosive atmosphere without
supplementary protective measures

Altitude

0-2000 m (above sea level)

27 - 2

ETC00781(4) Series 100 e 02/2004

TECHNICAL DATA
SIGNAL OUTPUTS, INTERFACES

27.3

Signal Inputs / Outputs, Interfaces

2 analog outputs per channel
0 - 10 V and 0 - 20 mA (RB < 500 W)
[(optically isolated: 2 channels, common ground),
or
offset (begin of range)and end of range
2 - 10 Vand 4 - 20 mA (RB < 500 W),
are free programmable]
adjustable via keyboard
Option:
0 (0.2) - 1 V and 0 (4) - 20 mA (RB < 500 W)
3 analog inputs (Option for TC),
for electronic cross compensation
of up to 3 interfering components
(external signals)

0 - 10 V, 0 - 20 mA,
2 - 10 V, 4 - 20 mA,
0 - 1 V or 0.2 - 1 V

8 digital outputs, parallel (optically isolated)

2 threshold contacts per channel,
Sample gas valve,
Zero gas valve,
Span gas valve 1,
Span gas valve 2 (dual channel only)
“Open Collector”, max. 30 V DC / 30 mA

7 digital inputs, parallel
(Option)

Zero gas calibration ch.1 & ch.2,
Span gas calibration ch.1,
Span gas calibration ch.2,
open Zero gas valve,
open Span gas valve 1,
open Span gas valve 2 (dual channel only)
close Sample gas valve/
sample gas pump Off
Description: see chapter 13 and 29.8!

serial interface (Option, optically isolated)
(not in combination with field bus)

RS 232 C or RS 485 (2 or 4 wire support)

FOUNDATION™ fieldbus (Option)

(not in combination with serial interface)

3 output relays (Option status signals)

“Measure/Calibration” / “Failure Analyzer” /
“Sample Gas Pump On/Off”
“non-voltage carrying contacts”
max. 30 V / 1 A / 30 W

ETC00781(4) Series 100 e 02/2004

27 - 3

TECHNICAL DATA

Diagram/dimensions without 24 VDC elbow socket (+ approx. 30 mm)
402

105

129,0

19

3

3
377

20

106,3

14

400
417

1 2 8 .4

Fig. 27-1: Dimensional sketch BINOS® 100 (M) / OXYNOS® 100 / HYDROS® 100 (dimensions in [mm])

1 1 2

2 1 3

19

4 6 2 .6

5 2 .5

Fig. 27-2: Dimensional sketch BINOS® 100 2M (dimensions in [mm])
27 - 4

ETC00781(4) Series 100 e 02/2004

TECHNICAL DATA

550
492

300

332

approx. 355

10

18

18

Glands
(connection cables)

Fig. 27-3: Dimensional sketch/ Drill drawing BINOS® 100 F Single Section Housing
for General Purpose Applications (dimensions in mm)

40

30

PURGE IN

38

SAMPLE IN

SAMPLE OUT

PURGE OUT

[all dimensions in mm]

25

75
105
135

Fig. 27-4: Dimensional sketch BINOS® 100 F
with Continuous Purge for CENELEC Ex Zone 1 Applications or
with Z purge for CSA-C/US Ex Zone 2 Non-Flammable Atmospheres

ETC00781(4) Series 100 e 02/2004

27 - 5

TECHNICAL DATA

27.4

Gas Related Specifications

For information about measuring components and ranges of the actual analyzer refer to the
nameplate label, which is located on the left or right side of the analyzer cover (all table top
and rack mount versions) or inside the front door (BINOS 100 F).
See chapter 27 for information about how to read a name plate label.

Available Measuring Components and Ranges
(some components / ranges may not be available with all analyzer versions)
Gas Component
Argon

Ar

0-

50

%

0-

100

%

CO2

0-

100

ppm

0-

100

%

Carbon monoxide

CO

0-

200

ppm

0-

100

%

C 2H 4

0-

400

ppm

0-

100

%

Helium

He

0-

10

%

0-

100 %

Hexane

C 6H14

0-

500

ppm

0 - 9,000 ppm
0-

100

%

0-

100

%

ppm

0-

100

%

%

0-

100

%

4,000 ppm

0-

100 %

0-

1,000 ppm

0-

100 %

0-

5,000 ppm

0-

1,2 %

H2

Methane

CH 4

0-

2

C 4H10

0-

800

O2

0-

1

Propylene

C 3H 6

0-

Propane

C 3H 8

Toluene

C 7H 8

Oxygen

***)

0- 5%(2 %

Hydrogen
n - Butane

**)

Maximum Ranges

Carbon dioxide
Ethylene

*)

Minimum Ranges

***)

)

%
***)

****)

Other components and configurations on request
Dew point must not exceed ambient temperature
Non-standard specifications

27 - 6

ETC00781(4) Series 100 e 02/2004

TECHNICAL DATA

Measuring System Specifications
(Values refer to the lowest ranges. Standard ranges with better specs.)
NDIR

Oxygen Sensor (PO2 and EO2)

Thermal Conductivity

Detection limit
Linearity
Zero-point drift
Span (sensitivity) drift
Repeatability
Total response time (t90)

<1%
< 1 % 1) 4)
< 2 % per week 1) 4)
< 1 % per week 1) 4)
< 1 % 1) 4)
< 5 s 3) 5)

<1%
< 1 % 1) 4)
< 2 % per week 1) 4)
< 1 % per week 1) 4)
< 1 % 1) 4)
< 5 s 3) 6) / Approx. 12 s 3) 9)

< 2 % 1) 4)
< 1 % 1) 4)
< 2 % per week 1) 4)
< 1 % per week 1) 4)
< 1 % 1) 4)
3 s < t90 < 20 s 3) 7)

Permissible gas flow
Influence of gas flow

0.2 - 1.5 l/min
-

0.2 - 1.0 l/min6) / 0.2 - 1.5 l/min9)
< 1 % 1) 4)

0.2 - 1.0 l/min (± 0.1 l/min)
< 1 % 1) 4) 13)

Max. pressure
Influence of pressure
(At constant temperature)

< 1,500 hPa abs.

Atm. pres. 6) / < 1,500 hPa abs. 9)

< 1,500 hPa abs.

< 0.10 % per hPa 2)
(< 0.15 % / hPa at CO2) 2)
< 0.01 % per hPa 2)
(< 0.015 % / hPa at CO2) 2)

< 0.10 % per hPa 2)

< 0.10 % per hPa 2)

< 0.01 % per hPa 2)

< 0.01 % per hPa 2)

+ 5 °C to + 40 °C 10)

+ 5 °C to + 40 °C 10)

+ 5 °C to + 40 °C 10)

< 1 % per 10 K 1)
< 5 % (+ 5 to + 40 °C) 1) 11)
Approx. 15 to 50 minutes 5)

< 1 % per 10 K 1)
< 1 % per 10 K 1)
Approx. 55 °C 6) 12) / None 9)
Approx. 50 minutes 6)

< 1 % per 10 K in 1 h 1)
< 2 % per 10 K in 1 h 1)
Approx. 75 °C 12)
Approx. 15 minutes

- With pressure compensation 8)
Permissible ambient temperature
Influence of temperature
(at constant pressure)
- On zero point
- On span (sensitivity)
Thermostat control
Heating-up time
1)
2)
3)

Related to full scale at system parameter
END = final value set in our factory and OFS = 0
Related to measuring value
From gas analyzer inlet at 1.0 l/min gas flow
(electr. = 2 s)

1) 4)

4)
5)
6)
7)

Constant pressure and temperature
Dependent on integrated photometer bench
Paramagnetic oxygen measurement (PO2)
dependent on measurement range

Cross sensitivities
electrochemical oxygen measurement:

Not for use with sample gases containing
FCH´s, inorganic gases with chlorines
and fluorines !
Not for Ozone, H2S (> 100 ppm), NH3 (> 20 ppm)

ETC00781(4) Series 100 e 02/2004

1) 4)

8) Pressure sensor required
9) Electrochemical oxygen measurement (EO2),
not for use with sample gas containing FCHC´s
10) Higher ambient temperatures (45 °C) on request
11) Starting from 20 °C (to + 5 °C or to + 40 °C)
12) Sensor / cell only

paramagnetic oxygen measurement:

100 % Gas
N2
CO2
H2
Ar
Ne
He
CO
CH4
C2 H6
C2 H4
C3 H8
C3 H6
NO
NO2
N2O

zerolevel effect % O2
0,00
- 0,27
+ 0,24
- 0,22
+ 0,13
+ 0,30
+ 0,01
- 0,20
- 0,46
- 0,26
- 0,86
- 0,55
+ 43,0
+ 28,0
- 0,20
27 - 7

TECHNICAL DATA
GENERAL SPECIFICATIONS

27.5

Voltage Supply

BINOS® 100 (M) / OXYNOS® 100 / HYDROS® 100 / BINOS® 100 2M (external power supply)
Input
3-pole XLR- Flange (male), lockable
Voltage Supply
24 V DC (+/- 5 %)
[DC voltage supplied by optional power supplies SL5, SL10 (both for rack mounting only) or UPS 01 T
or equivalent power supply]

Power Consumption (analyzer itself)

BINOS® 100 (M)
OXYNOS® 100
HYDROS® 100
BINOS® 100 2M

<
<
<
<

20 W
40 W
35 W
120 W

BINOS® 100 2M (internal power supply)
Input
integrated power supply

plug
UPS (input voltage see chapter 27.5.2)

Power Consumption

max. 240 VA

Output to external consumers
Available power supply to
external consumers

3-poliger XLR- Flange (female)
max. 2.0 A (depends on internal configuration)

BINOS® 100 F
Input
Internal power supply
Power consumption
Fuses (internal)

27.5.1 Electrical Safety
Over-voltage category
Pollution degree
Safety Class

all I/O´s

27 - 8

terminal strips
SL5 (input voltage see chapter 27.5.2)
max. 350 VA
T 3.15 A / 250 V (2 pieces)

I
2
2 for BINOS® 100 (M)/ OXYNOS® 100 /
HYDROS® 100/BINOS® 100 2M (ext. PS)
instruments.
1 for BINOS® 100 2M (int. PS)/ BINOS® 100 F
instruments
SELV voltage
optically isolated to electrical supply

ETC00781(4) Series 100 e 02/2004

TECHNICAL DATA
VOLTAGE SUPPLY

27.5.2 Power Supplies [UPS 01 T (Universal Power Supply) / SL5 / SL10]
Input (UPS/SL5/SL10)
Nominal voltage
Input voltage
UPS / SL5 or SL10
Input power
UPS or SL5 / SL10
Fuses UPS (internal)

plug / terminal s / terminal s
230 / 120 V AC, 50 / 60 Hz
196–264 V AC and 93–132 V AC, 47-63 Hz
with autoranging / manual switch

Output

3-pole XLR- Flange (female) (UPS) /
terminals (SL10 / SL5)
24 V DC
max. 5.0 A / max. 5.0 A / max. 10.0 A

Output voltage
UPS / SL5 / SL10
Output power
UPS / SL5 / SL10
Dimensions
UPS Rack module
Installation depth (with plug / cable)
UPS table-top module
SL5 (mountable on DIN supporting rails TS35)
SL10 (mountable on DIN supporting rails TS35)

ETC00781(4) Series 100 e 02/2004

max. 350 VA / max. 700 VA
T 3.15A/250V (2 pcs.)

max. 120 W / max. 120 W / max. 240 W

19" 3 HU, 21 DU
min. 400 mm
see Fig. 27-10
125 x 65 x 103 mm (HxWxD),
see Fig. 27-8 and 27-9
125 x 122 x 103 mm (HxWxD),
see Fig. 27-7 and 27-9

27 - 9

TECHNICAL DATA

Fig. 27-9:
Side view SL10/SL5

275.3

57.7

Fig. 27-8:
Front view SL 5

54.2

Fig. 27-7:
Dimensional sketch SL10 (Front view) [mm]

105.9

Fig. 27-10: Dimensional sketch UPS 01 T (Universal Power Supply), table-top version
rack module turn around 90° [all dimensions in mm, without cable and plugs]

27 - 10

ETC00781(4) Series 100 e 02/2004

REPLACING THE EPROM

28.

Replacing the EPROM

The EPROM may be easily replaced by a new unit when faulty or update the software.
The EPROM - replacement procedure is as follows:
P Disconnect the analyzer from the source of electric power.
P
Open the housing (see chapter 23.).
P
Remove jumper J7 (for the battery buffering; see the chapter 19.).
P
Pull out the EPROM (chapter 18.).

○ ○ ○ ○ ○

EPROM

○ ○ ○ ○ ○

Align the EPROM with respect to the socket before re-insertion.

mark

The EPROM is aligned correctly if the mark points to the front panel.
P Insert the EPROM.
P
Reconnect jumper J7 (see the chapter 19.).
P
Reconnect the instrument to the source of electric power and switch it on
[see chapter 6. (the displays must show a flashing "batt.")].
All stored data have now been replaced by default values.
All user and application data, such as system parameters, threshold values etc., must be
re-entered.

A complete re-calibration of the instrument (see chapter 9.) must be
performed after an EPROM replacement.

ETC00781(4) Series 100 e 02/2004

28 - 1

REPLACING THE EPROM

28 - 2

ETC00781(4) Series 100 e 02/2004

CABLES AND CORDS
24 V DC INPUT / OUTPUT

30.

Cables and Cords
To stay in conformance with EMC requirements use our shielded data cables
(optionally available) or equivalent data cables only!
The operator has to ensure that the cable shield is connected in correct manner
(chapter 29.10):
Shield and connector's housing have to be electrically linked and the housing
screwed to the analyzer.
Analyzers with external terminal adaptors (option) do not meet the EMC
requirements if the adaptors are not installed in a shielding enclosure.
In this case the customer acts like a "manufacturer of system" and has
to confirm conformance.
The standard terminal adaptors inside BINOS® 100 F and optional terminal
adaptors for other BINOS 100 series analyzers connect the submin D connector
pins to terminals of the same denominator (submin D pin 1 is connected to
terminal 1, pin 2 to terminal 2, ...), so pin assignments given in this manual do not
change when using adaptors.

30.1

24 V DC Supply Cable

NGA-ACC-PS5

Power supply cable for connection of 100 series with UPS/BINOS® 100 2M,
1 m, one elbow socket/ one straight plug

NGA-ACC-PS6

Power supply cable for connection of 100 series with UPS/BINOS® 100 2M,
2 m, one elbow socket/ one straight plug

NGA-ACC-PS7

Power supply cable for connection of 100 series with 5 A / 10 A power
supply, 2 m, one side elbow socket, other side 3 single conductors

ETC00781(4) Series 100 e 02/2004

30 - 1

CABLES AND CORDS
230/120 V AC INPUT / ANALOG SIGNAL OUTPUT

30.2

230/120 V AC Input (BINOS® 100 2M, UPS power supply)

03 861 008

30.3

Supply voltage cord to connect a BINOS® 100 2M with mains, 1 m
(for Germany only [Schuko plug])
Other locations:
Use cords with an IEC60320 female at one end and an appropriate
plug at the other end to meet your local requirements!
Power cords must have a separate grounding conductor!
In case of doubt contact your local Emerson Process Management sales
office to order an appropriate cord!

Power Supply for Wall Mounted Analyzers (BINOS® 100 F)
Power cords must have a separate grounding conductor!
Variation 1
Use cords with an appropriate plug at the one end to meet your local
requirements and single conductors at the other end, to be connected to
the terminals inside the analyzer.
In case of doubt contact your local Emerson Process Management sales
office to order an appropriate cord!
Variation 2
For permanently connected equipment use cords rated to meet your local
requirements and single conductors at the other end, to be connected to
the terminals inside the analyzer.
In case of doubt contact your local Emerson Process Management sales
office to order an appropriate cord!

*)

30 - 2

BINOS® 100 2M/F from program version 5.0 or hoigher only
ETC00781(4) Series 100 e 02/2004

CABLES AND CORDS

30.3

Data / Signal Lines

30.3.1 Sub D Sockets, 9 pin
The following cables are availble for analog signal outputs (X2 Output) and RS 232/485 serial
interface option (Interface or X4 Output):
ETC-ACC-101

shielded cable, 2 m, both ends sub D plug and one terminal adaptor

ETC-ACC-102

shielded cable, 2 m, both ends sub D plug

ETC-ACC-103

terminal adaptor with sub D socket, 9 pin and screw terminals

30.3.2 Sub D Plugs, 9 pin
The following cables are availble for digital signal outputs (“X3 Output”), status signal option
(relay outputs, “X1 Output”) and analog signal input option (TCD, “Cross Comp.” or “Analog In”):
ETC-ACC-104

shielded cable, 2 m, both ends sub D socket and one terminal adaptor

ETC-ACC-105

shielded cable, 2 m, both ends sub D socket

ETC-ACC-106

terminal adaptor with sub D plug, 9 pin and screw terminals

ETC00781(4) Series 100 e 02/2004

30 - 3

CABLES AND CORDS

30 - 4

ETC00781(4) Series 100 e 02/2004

FAILURE CHECK LIST

32.

Failure Check List

If you experience failures with your analyzer pls. take this checklist to mark the failure(s) before contacting our
service department or sending back the unit (together with a copy of this list). The enclosed information may speed
up trouble shooting and result in cost reduction.
Some failures may need to mark more than one of the following items!
Serial. - No. (to be found on the name plate label):
Measuring range / gas channel 1:
Software - Version - No.:

channel 2:

Ch1 CH2

1.

No Display (defective)

R

17.

R R

Analog Output absent

CH1 CH2

2.

BATT. is flushing

R

18.

Fluctuating display without error

3.

E 11 is flushing

R

19.

Response time to long

4.

E 12 is flushing

R

20.

Chopper has loud noise

5.

E 14 is flushing

R

21.

Measuring values to high

R R
CH1 CH2

R R
R
CH1 CH2

R R
CH1 CH2

6.

E 16 is flushing

R

22.

Measuring values to low

7.

E 17 is flushing

R

23.

Misalignment Display/Analog output

8.

E 18 is flushing

R

24.

Limiting values function incorrect

9.

E 19 is flushing

R

25.

Adjustment not possible

10.

E 20 is flushing

R

26.

Analyzer drift

11.

E 21 is flushing

R

27.

Transverse sensitivity to high

12.

E 22 is flushing

R

28.

Contamination of analyzer

R R
CH1 CH2

R R
CH1 CH2

R R

CH1 CH2

R R
CH1 CH2

R R
CH1 CH2

R R

CH1 CH2

R R
CH1 CH2

13.

E 27 is flushing

R

29.

Condensation

14.

E 37 is flushing

R

30.

Overhaul complete analyzer with
cost estimate

R

15.

E 38 is flushing

R

31.

Removal of failures with cost estimate

R

16.

E 39 is flushing

R

32.

Removal of failures without cost estimate

R

ETC00781(4) Series 100 e 02/2004

R R

32 - 1

FAILURE CHECK LIST

Additional tests of electronics (see chapter 17):

33.

Supply voltage + 6 V incorrect

R

34

Reference voltage positive incorrect

R

35

Reference voltage negative incorrect

R

36.

Motor drive incorrect

R

37.

Light barrier signal incorrect

R

38.

Temperature sensor incorrect

R

39.

Supply voltage + 18 V incorrect

R

40.

Analog preamplifiering incorrect

R

41.

Are you satisfied with the services offered by
Emerson Process Management?
(If no, give us a short comment please)

Yes

o

No

o

Comment or additional failure description:

32 - 2

ETC00781(4) Series 100 e 02/2004

FACTORY REPAIRFAILURE
CHECK LIST

If factory repair of defective equipment is required, proceed as follows:
1.

Secure a return authorization from a Emerson Process Management Sales Office or
Representative before returning the equipment. Equipment must be returned with complete
identification in accordance with Rosemount instructions or it will not be accepted.

2.

In no event will Rosemount be responsible for equipment without proper authorization
and identification.

3.

Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to
ensure no additional damage will occur during shipping.

4.

In a cover letter, describe completely:
a. The symptoms that determined the equipment is faulty.
b. The environment in which the equipment was operating (housing, weather, vibration,
dust, etc.).
c. Site from which equipment was removed.
d. Whether warranty service or nonwarranty service is requested.
e. Complete shipping instructions for the return of the equipment.
f. Enclose the completed check list

5.

Enclose a cover letter and purchase order and ship the defective equipment according to
instructions provided in a Rosemount Return Authorization, prepaid, to:

In Europe:
Emerson Process Management Manufacturing GmbH & Co. OHG
Service Department
Germany
+49 6055 884-470/-472
In US:
Rosemount Analytical Inc.
Process Analytic Division
Customer Service Center
1-800-433-6076
In Asia Pacific:
Emerson Process Management
Asia Pacific Pte Limited
1 Pandan Crescent
Singapore 128461
+65-6-777-8211
If warranty service is expected, the defective unit will be carefully inspected and tested at the
factory. If failure was due to conditions listed in the standard Rosemount warranty, the defective
unit will be repaired or replaced at Rosemount’s option, and an operating unit will be returned
to the customer in accordance with shipping instructions furnished in the cover letter.
For equipment no longer under warranty, the equipment will be repaired at the factory and
returned as directed by the purchase order and shipping instructions.
ETC00781(4) Series 100 e 02/2004

32 - 3

SERVICES

Customer Service
For order administration, replacement parts, applicaton assistance, on-site or factory repair,
service or maintenance contract information, contact:
In Europe:
Emerson Process Management Manufacturing GmbH & Co. OHG
Service Department
Germany
+49 6055 884-470/-472
In US:
Rosemount Analytical Inc.
Process Analytic Division
Customer Service Center
1-800-433-6076
In Asia Pacific:
Emerson Process Management
Asia Pacific Pte Limited
1 Pandan Crescent
Singapore 128461
+65-6-777-8211

Training
A comprehensive Factory Training Program of operator and service classes is available.
For a copy of the training schedule contact:
In Europe:
Emerson Process Management Manufacturing GmbH & Co. OHG
Service Department
Germany
+49 6055 884-470/-472
In US:
Rosemount Analytical Inc.
Process Analytic Division
Customer Service Center
1-800-433-6076
In Asia Pacific:
Emerson Process Management
Asia Pacific Pte Limited
1 Pandan Crescent
Singapore 128461
+65-6-777-8211
32 - 4

ETC00781(4) Series 100 e 02/2004

Instruction Manual

Series 100 Gas Analyzers

EUROPE
Emerson Process Management MFG GmbH & Co. OHG
Industriestrasse 1
63594 Hasselroth
Germany
T +49 (6055) 884-0
F +49 (6055) 884-209
Internet: www.emersonprocess.de

EUROPE, MIDDLE EAST, AFRICA
Emerson Process Management Shared Services Limited
Heath Place
Bognor Regis
West Sussex PO22 9SH
England
T +44-1243-863121
F +44-1243-845354
Internet: www.emersonprocess.co.uk

NORTH AMERICA
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T +1 (330) 682-9010
F +1 (330) 684-4434
Internet: www.emersonprocess.com

LATIN AMERICA
Emerson Process Management Ltda
Avenida Hollingsworth, 325
Iporanga-SorocabeSP 18087-000
Brazil
T:+55 (152) 38-3788
F:+55 (152) 38-3300
Internet: www.emersonprocess.com.br

ASIA - PACIFIC
Emerson Process Management Asia Pacific Pte Ltd
1 Pandan Crescent
Singapore 128461
Tel +65 6777 8211
Fax +65 6777 0947
Internet: www.ap.emersonprocess.com

© Emerson Process Management Manufacturing GmbH & Co. OHG 2004

ETC00781
02/2004



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