Series 100 Gas Analyzers

Instruction Sheet HAS1xE-IS-BKS October 2004 Series 100 Gas Analyzers BINOS® 100, BINOS® 100 M BINOS® 100 2M, BINOS® 100 F OXYNOS® 100, HYDROS® 100, ...
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Instruction Sheet HAS1xE-IS-BKS October 2004

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

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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. 1st edition: 2004-10

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade INTRODUCTION

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.

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

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade

Error Code

16.

Possible Reasons

Check / Correct

List of Failures

Some of the failures possibly coming up during operation are reported on the displays by the use of error codes.

If there is an "error message", an optional digital status signal "Failure" may be set (see chapter 10.3)!

In such a case the display's show the current concentration value alternating with (E = error, XX = code).

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.

Error Code

Possible Reasons 1. Displays are “switched OFF”

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

2. Voltage supply missing Display dark

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)

BINOS® 100 F 3. Connection front panel /BKS interrupted

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

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade Error Code

Flashing

Possible Reasons

Check / Correct

Battery buffer failure

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

The EPROM default values have been loaded

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.

If only one code is shown:

Channel 1

1. A/D converter of related channel is not driven correctly

1. Switch analyzer off and then on again.

If both codes are shown: Channel 2

A/D Conversion Interrupt missing

2. Positive or negative reference voltage missing

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

3. Light barrier signal missing

3. Check connection X9 / light barrier (see chapter 18.) Solder bridge LB 18 not configured properly, check measuring point (17.1.5)

4. IR channel: Chopper drive inoperative

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

Temperature compensation incorrect

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5. Supply voltage (internal 6 V DC) missing

5. Check measuring point (17.1.1)

1. Failed to start A/Dconversion for temperature channel

1. Switch analyzer off and then on again.

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

2. Check measuring point 17.1.1

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Instruction Sheet HAS1xE-IS-BKS 10/2004

Error Code

Channel 1

BKS 20 Upgrade Possible Reasons

Check / Correct

1. Span gas in use exceeds measuring range

1. Check span gas in use and replace by gas with correct nominal value

1. Wrong 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 2 Tolerance error

Channel 1

Channel 2

Clean contaminated parts (see chapter 24.3).

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

3. Analyzer not calibrated.

3. Switch off the tolerance check before starting a calibration (see chapter 8.6).

1. Wrong nominal value.

1. Enter the correct nominal value (refer to span gas bottle certificate) (see chapter 9.1.2).

2. Wrong span gas in use.

2. Check span gas in use.

Channel 1

Use another or a new gas bottle. Channel 2 Tolerance error

Enter the correct nominal value 3. IR channel: Photometer section contaminated.

Span gas value differs from nominal value more than 10% .

Channel 1

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

4. Analyzer not calibrated.

4. Switch off the tolerance check before starting a calibration (see chapter 8.6).

1. Concentration of sample gas too high.

1. Check concentration of sample gas 2. Use an analyzer suitable for the existing concentration range

Channel 2 Measuring value more than 10% over full scale range.

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade Error Code

Possible Reasons

Check / Correct

1. Absorber in NVE: lifetime cycle ended

1. Replace absorber. Enter menu “SYS.-PArA” and set parameter “AbS” to “2” (new life time cycle)

2. Parameter “AbS.” not set to “0”

2. Enter menu “SYS.-PArA” and set parameter “AbS.” to “0” XON - character is missing while driving the serial interface (time out > 60 s).

XON (serial interface) timed out.

wrong limit value entered due to shift of decimal point

Correct limit value in line “LI.”

Channel 1

Channel 2 Failure while entering limits

Wrong nominal value entered due to shift of decimal point

1. Correct nominal value by performing a span gas calibration

Channel 1 2. Correct nominal value via serial interface by sending “$029” Channel 2 Wrong nominal value entered for span gas Wrong offset value entered due to shift of decimal point

1. Correct offset value “OFS.x”

Channel 1

Channel 2 Wrong offset value entered

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Instruction Sheet HAS1xE-IS-BKS 10/2004

Error Code

Pressure measurement failure

BKS 20 Upgrade Possible Reasons

Check / Correct

1. Measuring range failure.

1. Pressure not within the sensor measuring range

2. Connection faulty.

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

3. Pressure sensor faulty.

3. Replace pressure sensor.

1. EPROM faulty.

1. Replace EPROM (see chapter 28.).

2. BKS faulty.

2. Replace BKS.

EPROM checksum failure SRAM IC's / BKS faulty.

Replace BKS.

BKS faulty.

Replace BKS.

Test for SRAM - IC's failed

Analog output signal missing

Fluctuating or erroneous display

1. Leakage in gas path

1. Perform a leakage test (see chapter 22)

2. Ambient air contains gas component to be measured in a concentration influencing measurement

2. Replace absorber material for IR sources and chopper housing Use sealed photometer (Option) Purge analyzer with inert gas

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BKS 20 Upgrade Error Code

Possible Reasons

Check / Correct

3. Check the gas lines preceding and beyond the sensor cell.

3. Gas pressure subject to considerable variation

Eliminate any restrictions beyond the gas outlet fitting. Reduce pump rate or flow rate.

Fluctuating or erroneous display (cont’d)

4. IR detector / Oxygen senor not connected.

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

5. Electrochemical oxygen sensor is weared

5. Replace sensor (see 25.)

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

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. Faulty analog preamplifying

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. Clean contaminated parts (see 24.3). Check gas paths for contamination.

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Instruction Sheet HAS1xE-IS-BKS 10/2004

Error Code

BKS 20 Upgrade Possible Reasons

9. Influence by barometric pressure

Fluctuating or erroneous display (cont’d)

10. Temperature in the gas paths below dew point.

Check / Correct

9. Enter the correct value for barometric 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. A/D converter failure

11. Replace BKS.

1. Incorrect response time ( t90 time) settings.

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

2. Pump rate too low

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 conditioning for contamination.

Response time too long (t90 time)

Clean gas paths and replace the filter elements.

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BKS 20 Upgrade Error Code

No gas flow

Possible Reasons

Check / Correct

1. Optional needle valve not opened

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

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

2. Press “PUMP” key

3. Membrane of pump is defective

3. Replace membrane of the pump.

4. Sample gas pump is defective

4. Replace sample gas pump

5. Solenoid valves (Option) defective

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. Contamination of gas paths

6. Check gas paths including filters for contamination. Clean gas lines and replace the filter elements.

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Instruction Sheet HAS1xE-IS-BKS 10/2004

17.

BKS 20 Upgrade

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

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))

Front panel side Fig. 17-1a: PCB “BKS”, measuring points

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade 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 (Uref. pos. + Uref. neg. ≤ ± 10 mV) ! If the difference is higher, replace BKS.

17.1.4 Temperature Sensor Measuring point: X8 Measuring device: DVM 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). Front panel side

- Electrochemical oxygen measurement: a) Temperature sensor not connected (see chapter 18.2). b) PCB OXS faulty (replace OXS). c) PCB BKS faulty (replace BKS).

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Fig. 17-1b: PCB “BKS”, measuring points

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade

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 VSS (± 0,3 V) a) b) c) d) e) f)

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

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BKS 20 Upgrade

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. - % O2): 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) b) c) a)

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

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

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Instruction Sheet HAS1xE-IS-BKS 10/2004

17.2

BKS 20 Upgrade

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. - % O2): approx. 3.36 V (new cell)

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 weared (replace) 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 2

Tp 1

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

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18.

BKS 20 Upgrade

Allocation of Connectors on Printed Circuit Boards Be sure to observe the safety measures !

18.1

BKS

X19 (+) X20 (GND) F2

P 1 or P2

24 V DC power supply input Fuse for 24 V DC input type: Wickmann 372 rating: T 4 A / 250 V 24 V DC distribution for optional internal load (e.g. heater for paramagn. O2 sensor)

X1

Front panel BXF (P8)

X 16

Digital Outputs, parallel

X 18

Analog Outputs

J9

Option BSI 10: Status signals and serial interface

Front panel Fig. 18-1: PCB “BKS”, location of connectors

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade

18.1.1 IR measurement without Oxygen Channel X2

Chopper

X 3 (pins 1 & 2)

IR source channel 1

X 4 (pins 1 & 2)

IR 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) [ electrochemical measurement: PCB OXS (cable P1, 5 pin connector)]

X6

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

X7

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

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade

18.1.3 IR / Oxygen Measurement Combination X2

Chopper

X 4 (pins 1 & 2)

IR 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 !

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BKS 20 Upgrade

18.1.5 IR / TC Measurement combined X2

Chopper

X 4 (pins 1 & 2)

IR 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 !

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Instruction Sheet HAS1xE-IS-BKS 10/2004

18.2

BKS 20 Upgrade

OXS (electrochemical oxygen measurement)

Strip P2

Oxygen sensor

Cable P1, 5 pin connector

PCB BKS, X 5 (sensor signal)

Cable P1, 2 pin connector

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

View A: PCB OXS assembled, horizontal projection

PCB “OXS”

View A ↓

Connection Cable Oxygen sensor “P 1” (Pin-base“P 2”)

Sensor cell

Fig. 18-2: PCB “OXS”

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BKS 20 Upgrade

18.3

WAP 100 (TC measurement)

Terminals P 18

to sensor

Cable P15, 5 - pin connector

PCB BKS, X 5 (sensor signal)

P 10

PCB BSE 01 (analog input for cross compensation)

P 16

sensor heater

orange

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

blue green yellow

P2

P 18

1

1

P 10 P 16

P 15 1

P2 Fig. 18-3: PCB “WAP 100”, (principle drawing)

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Instruction Sheet HAS1xE-IS-BKS 10/2004

19.

BKS 20 Upgrade

BKS Jumper Configuration

There is only one jumper on board BKS 20: J7, which activates battery buffering for the SRAM data. Opening J7 deletes all data changed by the operator when power supply is disconnected. The analyzer configuration in this case is reset to default values (stored into EPROM at factory startup).

J7

Buffer Battery (normally closed)

Front panel Fig. 19-1: PCB “BKS”

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BKS 20 Upgrade

ATTACHMENT

A.1

BINOS® 100 (M) / HYDROS® 100 / OXYNOS® 100 Block Diagram

X19 (+) X20 (GND)

A.

EMERSON Process Management Manufacturing GmbH & Co. OHG

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade BINOS® 100 2M Block Diagram

X19 (+) X20 (GND)

A.2

A-2

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Instruction Sheet HAS1xE-IS-BKS 10/2004

X19 (+) X20 (GND)

BKS 20 Upgrade

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Instruction Sheet HAS1xE-IS-BKS 10/2004

BKS 20 Upgrade BINOS® 100 2M for CAT Block Diagram

X19 (+) X20 (GND)

A.3

A-4

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Instruction Sheet HAS1xE-IS-BKS 10/2004

A.4

BKS 20 Upgrade

CAT 100 Block Diagram

EMERSON Process Management Manufacturing GmbH & Co. OHG

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BKS 20 Upgrade BINOS® 100 F Block Diagram

X19 (+) X20 (GND)

A.5

A-6

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Instruction Sheet

BKS 20 Upgrade

EUROPE Emerson Process Management Manufacturing 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

HAS1xE-IS-BKS 10/2004