Instruction Sheet
HAS1xE-IS-BKS
October 2004
www.EmersonProcess.com
Series 100 Gas Analyzers
BINOS
®
100, BINOS
®
100 M
BINOS
®
100 2M, BINOS
®
100 F
OXYNOS
®
100, HYDROS
®
100, CAT 100
Instruction Manual Addendum to Manual ETC00781
Regarding BKS 20 Hardware Upgrade
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
st
edition: 2004-10
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
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG I-1
The BINOS
®
100 series analyzers are subject
to a consistent improvement as well as all
EMERSON PROCESS MANAGEMENT
products. Within this improvement the main
board BKS 10 was replaced by the successor
BKS 20.
Due to the short term development of this new
printed circuit board the BINOS
®
100 analyzer
series instruction manual ETC00781 could not
be adapted in time. This means that all
illustrations and references within this manual
still refer to the old board.
While during operation this is not a
disadvantage, it may cause problems when
servicing and maintaining the analyzer.
For this reasons EMERSON PROCESS
MANAGEMENT has created this instruction
sheet.
INTRODUCTION
This Instruction sheet is
intended to be used in
conjunction with the
BINOS
®
100 analyzer series
instruction manual ETC00781
delivered together with the
analyzer.
It deals with service aspects and
replaces respectively
completes the corresponding
chapters of the original
instruction manual ETC00781.
We recommend to replace the
corresponding chapters inside the manual
by the chapters of this sheet. For this the
pages in this sheet are numbered
corresponding to the manual.
A new section is the attachment containing
block diagrams for the different analyzer
variations.
Contents
Chapter 16............... List of Failures.......................................................... Pages 16-1 to 16-8
Chapter 17............... Measuring Points ..................................................... Pages 17-1 to 17-6
Chapter 18............... Allocation of Connectors........................................... Pages 18-1 to 18-6
Chapter 19............... BKS Jumper Configuration....................................... Pages 19-1 to 19-2
Attachment............... Block Diagrams ........................................................... Pages A-1 to A-6
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHGI-2
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG 16-1
Error Code Possible Reasons Check / Correct
16. List of Failures
Some of the failures possibly coming up during
operation are reported on the displays by the
use of error codes.
In such a case the display's show the current
concentration value alternating with
(E = error, XX = code).
If there is an "error message", an optional
digital status signal "Failure" may be set
(see chapter 10.3)!
Be sure to observe the safety
measures while working at the
analyzer!
The following table lists all error codes, some
related reasons and measures to repair.
1. Press any key.
Check parameter dOFF
(see chapter 8.7).
2. Check connection mains to P/S
Check external power supply
Check electrical supply
(see Fig. 1-5 and 1-6, Item 3
Fig. 1-7 to 1-9, Item 10).
Check internal fuse on board BKS
(s. page 18-1)
Check internal fuses F1 and F2
3. Check connection
BKB to BKS (X1) (see chapter 18.1).
1. Displays are “switched OFF”
2. Voltage supply missing
BINOS
®
100 F
3. Connection front panel /BKS
interrupted
Display dark
Error Code Possible Reasons Check / Correct
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHG16-2
Error Code Possible Reasons Check / Correct
Battery buffer failure
The EPROM default
values have been loaded
If only one code is shown:
1. A/D converter of related
channel is not driven correctly
If both codes are shown:
2. Positive or negative
reference voltage missing
3. Light barrier signal missing
4. IR channel:
Chopper drive inoperative
5. Supply voltage
(internal 6 V DC) missing
1. Failed to start A/D-
conversion for temperature
channel
2. Supply voltage
(internal 6 V DC) absent.
Check, if Jumper J 7
is set (see chapter 19.).
Replace battery,
if battery voltage < 3,5 V
(BKS - Jumper J7 set).
The error code is cleared by pressing
any key or by serial interface
instruction $627.
1. Switch analyzer off and then on again.
2. Check reference voltage
(see chapter 17.1.2/17.1.3).
3. Check connection X9 / light barrier
(see chapter 18.)
Solder bridge LB 18 not configured
properly, check measuring point (17.1.5)
4. Check connection X2 / chopper drive
(see chapter 18)
Check measuring point (17.1.4)
5. Check measuring point (17.1.1)
1. Switch analyzer off and then on again.
2. Check measuring point 17.1.1
Flashing
Channel 1
Channel 2
A/D Conversion Interrupt
missing
Temperature compensation
incorrect
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG 16-3
Error Code Possible Reasons Check / Correct
1. Span gas in use exceeds
measuring range
1. Wrong zero gas in use.
2. IR channel:
Photometer section
contaminated.
3. Analyzer not calibrated.
1. Wrong nominal value.
2. Wrong span gas in use.
3. IR channel:
Photometer section
contaminated.
4. Analyzer not calibrated.
1. Concentration of sample gas
too high.
1. Check span gas in use and replace
by gas with correct nominal value
1. Check zero gas in use.
2. Check analysis cell and windows for
contamination.
Clean contaminated parts
(see chapter 24.3).
3. Switch off the tolerance check
before starting a calibration
(see chapter 8.6).
1. Enter the correct nominal value
(refer to span gas bottle certificate)
(see chapter 9.1.2).
2. Check span gas in use.
Use another or a new gas bottle.
Enter the correct nominal value
3. Check analysis cell and windows for
contamination.
Clean contaminated parts
(see chapter 24.3).
4. Switch off the tolerance check
before starting a calibration
(see chapter 8.6).
1. Check concentration of sample gas
2. Use an analyzer suitable for
the existing concentration range
Channel 1
Channel 2
Tolerance error
Channel 1
Channel 2
Tolerance error
Zero gas value differs from
zero more than 10% of
measuring range .
Channel 1
Channel 2
Tolerance error
Span gas value differs from
nominal value more than
10% .
Channel 1
Channel 2
Measuring value more than
10% over full scale range.
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHG16-4
Error Code Possible Reasons Check / Correct
Channel 1
Channel 2
Wrong nominal value entered
for span gas
1. Absorber in NVE:
lifetime cycle ended
2. Parameter “AbS.” not set to “0”
XON (serial interface)
timed out.
1. Replace absorber. Enter menu
“SYS.-PArA” and set parameter
“AbS” to “2” (new life time cycle)
2. Enter menu “SYS.-PArA” and set
parameter “AbS.” to “0”
XON - character is missing while
driving the serial interface
(time out > 60 s).
Channel 1
Channel 2
Failure while entering limits
wrong limit value entered due
to shift of decimal point
Correct limit value in line “LI.”
Wrong nominal value entered
due to shift of decimal point
1. Correct nominal value by performing
a span gas calibration
2. Correct nominal value via serial
interface by sending “$029”
Channel 1
Channel 2
Wrong offset value entered
Wrong offset value entered
due to shift of decimal point
1. Correct offset value “OFS.x”
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG 16-5
Error Code Possible Reasons Check / Correct
1. Measuring range failure.
2. Connection faulty.
3. Pressure sensor faulty.
1. EPROM faulty.
2. BKS faulty.
SRAM IC's / BKS
faulty.
BKS faulty.
1. Leakage in gas path
2. Ambient air contains gas
component to be measured
in a concentration influencing
measurement
1. Pressure not within the sensor
measuring range
2. Check connection P1 (at BAF 01) /
pressure sensor (see chapter 18.).
3. Replace pressure sensor.
1. Replace EPROM (see chapter 28.).
2. Replace BKS.
Replace BKS.
Replace BKS.
1. Perform a leakage test
(see chapter 22)
2. Replace absorber material for IR
sources and chopper housing
Use sealed photometer (Option)
Purge analyzer with inert gas
Pressure measurement
failure
EPROM checksum
failure
Test for SRAM - IC's
failed
Analog output signal
missing
Fluctuating or
erroneous display
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHG16-6
Error Code Possible Reasons Check / Correct
3. Gas pressure subject to
considerable variation
4. IR detector / Oxygen senor
not connected.
5. Electrochemical oxygen
sensor is weared
6. IR channel:
IR source not connected
or faulty.
7. Faulty analog
preamplifying
8. Contamination of the gas
paths.
3. Check the gas lines preceding and
beyond the sensor cell.
Eliminate any restrictions
beyond the gas outlet fitting.
Reduce pump rate or flow rate.
4. Check connections:
BKS X5 detector channel 1
(Oxygen sensor or IR detector)
BKS X6 detector channel 2
(IR detector)
(see 18.)
5. Replace sensor (see 25.)
6. Checkconnection:
BKS X3(1/2) - IR source channel 1
BKS X4(1/2) - IR source channel 2
(see 18.)
If IR source housing is cold:
For dual IR channel analyzer
interchange the two IR sources.
Replace the suspect IR source
(see 24.2).
7. Check measuring point 17.1.7 or
17.2.1 resp.
8. Check analysis cell and windows for
contamination.
Clean contaminated parts
(see 24.3).
Check gas paths for contamination.
Fluctuating or
erroneous display
(cont’d)
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG 16-7
Error Code Possible Reasons Check / Correct
9. Influence by barometric
pressure
10. Temperature in the gas
paths below dew point.
11. A/D converter failure
1. Incorrect response time
( t
90
time) settings.
2. Pump rate too low
3. Contamination of the gas
paths.
9. Enter the correct value for baro-
metric pressure (see chapter 8.1).
Pressure sensor failure (E.37).
10. Check the temperature of the gas
paths and remove any cold spots
Keep all temperatures at values at
least 10 °C above the dew point of
the gas.
11. Replace BKS.
1. Check the value for t
90
time
(see chapter 8.11).
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. Check gas paths and gas
conditioning for contamination.
Clean gas paths and replace the
filter elements.
Fluctuating or
erroneous display
(cont’d)
Response time too long
(t
90
time)
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHG16-8
Error Code Possible Reasons Check / Correct
1. Optional needle valve not
opened
2. Sample gas pump (Option)
is not switched on
3. Membrane of pump is
defective
4. Sample gas pump is
defective
5. Solenoid valves (Option)
defective
6. Contamination of gas paths
1. Open needle valve
(Option, see Fig. 1-2)
2. Press “PUMP” key
3. Replace membrane of the pump.
4. Replace sample gas pump
5. External valves:
Check connection between valves
and analyzer`s digital outputs
Valves controlled by optional serial
interface / digital inputs:
Any valve activated?
Check the valve seat of the solenoid
valves and replace if necessary.
Replace solenoid valves
6. Check gas paths including filters for
contamination.
Clean gas lines and replace
the filter elements.
No gas flow
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG
17-1
17. Measuring Points of BKS and OXS
17.1 Measuring points of BKS
(Connector’s pins 1 on the board are identified
by a mark or a square solder pad)
All measuring points are measured against
ground (X 11 or X 28) !
17.1.1 Supply Voltage +6 V
Measuring point: X14
Measuring device: DVM
Signal: + 6 V DC (+10 mV / -200 mV)
(adjust with potentiometer R90, if necessary)
Failure: No signal
Possible reasons: a) Supply voltage is missing
b) Supply voltage < 9 V
or of reverse polarity
c) BKS faulty (replace)
d) Fuse F2 opened
17.1.2 Positive Reference Voltage
Measuring point: X5, pin 6
Measuring device: DVM
Signal: + 5,535 V DC (± 60 mV)
Possible reasons: a) Supply voltage (+6V) is faulty
b) Reference voltage +3 V not
correct (measure at C179,
pin 1(left pin in fig. 17-1a))
Be sure to observe the safety measures !
Fig. 17-1a: PCB “BKS”, measuring points
Front panel side
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHG
17-2
17.1.3 Negative Reference Voltage
Measuring point: X5, pin 4
Measuring device: DVM
Signal: inverted positive
reference voltage
The difference between negative reference
voltage and positive reference voltage must not
be more than 10 mV (U
ref. pos.
+ U
ref. neg.
≤ ± 10 mV)
!
If the difference is higher, replace BKS.
17.1.4 Temperature Sensor
Measuring point: X8
Measuring device: DV M
Signal: approx. 0 ± 500 mV DC
(at ambient temperature)
Possible reasons
- IR measurement or paramagnetic oxygen
measurement
a) Temperature sensor not connected
(see chapter 18.1).
b) Temperature sensor faulty (replace sensor).
c) Broken temperature sensor cable
(replace sensor).
d) BKS faulty (replace BKS).
- Electrochemical oxygen measurement:
a) Temperature sensor not connected
(see chapter 18.2).
b) PCB OXS faulty (replace OXS).
c) PCB BKS faulty (replace BKS).
Fig. 17-1b: PCB “BKS”, measuring points
Front panel side
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG
17-3
17.1.5 Light Barrier Signal
Measuring point: X9, pin 2
Measuring device: Oscilloscope
Signal: square impulse, level see below
Frequency = 24 Hz (± 0,1 Hz)
Failure: No signal or incorrect measuring values
Possible reasons (IR measurement):
Expected signal level: U = 6 V
SS
(± 0,3 V)
a) Chopper not connected (see chapter 18.1).
b) Chopper inoperative (switch analyzer off and then on again).
c) Light barrier not connected (see chapter 18.1).
d) Light barrier defect (replace chopper)
e) Broken cable of light barrier or faulty light barrier (replace
chopper).
f) BKS faulty (replace BKS).
Possible reasons (oxygen measurement without IR channel):
Expected signal level: LOW < 0.45 V; HIGH > 2.4 V (TTL logic signal)
a) Solder bridge LB 18 not configured properly (pins 1-2 connected)
b) µP not operating (switch analyzer off and on)
c) BKS faulty (replace BKS).
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHG
17-4
17.1.6 Analog Preamplifiers
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. - % O
2
):
100 % O2 measuring cell: approx. 840 mV
25 % O2 measuring cell: approx. 3.36 V
(for identification of cell see nameplate label on cell)
Failure: No signal or incorrect measuring values.
Possible reasons: a) oxygen sensor not connected (see chapter 18.).
b) oxygen sensor faulty (replace sensor).
c) BKS faulty (replace BKS).
a) 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) Detector not connected (see chapter 18.).
b) Detector faulty (replace detector).
c) BKS faulty (replace BKS).
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG
17-5
Fig. 17-2: PCB “OXS”, assembled, horizontal projection
17.2 Measuring points of OXS (electrochemical oxygen measurement)
17.2.1 Sensor Signal
Measuring point: Tp 1 (Signal)
Tp 2 (
⊥⊥
⊥⊥
⊥)
Measuring device: DVM
Signal: At ambient air (approx. 21 Vol. - % O
2
): approx. 3.36 V (new cell)
Failure: No signal or faulty voltage
Possible reasons: a) Oxygen sensor not connected to PCB "OXS"
b) PCB “OXS” not connected / faulty
c) Oxygen sensor faulty or weared (replace)
d) BKS faulty (replace)
Note !
If the measured value is less than 2.8 V at gas flow with ambient air, the sensor is weared.
Replace the sensor.
Tp 1
Tp 2
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHG
17-6
Instruction Sheet
HAS1xE-IS-BKS
10/2004
BKS 20 Upgrade
EMERSON Process Management Manufacturing GmbH & Co. OHG 18-1
Front panel
18. Allocation of Connectors on Printed Circuit Boards
Be sure to observe the safety measures !
18.1 BKS
X19 (+)
X20 (GND) 24 V DC power supply input
F2 Fuse for 24 V DC input
type: Wickmann 372
rating: T 4 A / 250 V
P 1 or P2 24 V DC distribution for
optional internal load
(e.g. heater for paramagn. O
2
sensor)
X 1 Front panel BXF (P8)
X 16 Digital Outputs, parallel
X 18 Analog Outputs
J 9 Option BSI 10:
Status signals and
serial interface
Fig. 18-1: PCB “BKS”, location of connectors
BKS 20 Upgrade
Instruction Sheet
HAS1xE-IS-BKS
10/2004
EMERSON Process Management Manufacturing GmbH & Co. OHG18-2
18.1.1 IR measurement without Oxygen Channel
X 2 Chopper
X 3 (pins 1 & 2) IR source channel 1
X 4 (pins 1 & 2) IR source channel 2
X 5 IR detector (channel 1)
X 6 IR detector (channel 2)
X 7 Temperature sensor (chopper)
X 9 Light barrier (chopper)
18.1.2 Oxygen Measurement without IR channel
X 5 Oxygen sensor (channel 1)
[ electrochemical measurement:
PCB OXS (cable P1, 5 pin connector)]
X 6 Oxygen sensor (channel 2)
[electrochemical measurement:
PCB OXS (cable P1, 5 pin connector)]
X 7 Temperature sensor
[electrochemical measurement:
PCB OXS (cable P1, 2 pin connector)]
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