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Gow-Mac 5102 Series Operating Manual

Continuous tc binary gas analyzer
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Operating Manual

5100 Series Continuous
TC Binary Gas Analyzer
READ INSTRUCTIONS
BEFORE OPERATING
277 Brodhead Road, Bethlehem, PA 18017- 8600 U.S.A. Tel: (610) 954-9000
5100 Series: 110 V, 60 Hz
5102 Series: 230 V, 50 Hz
March 2018
Rev. 6

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  • Page 1: Operating Manual

    Operating Manual 5100 Series Continuous TC Binary Gas Analyzer 5100 Series: 110 V, 60 Hz 5102 Series: 230 V, 50 Hz March 2018 Rev. 6 READ INSTRUCTIONS BEFORE OPERATING 277 Brodhead Road, Bethlehem, PA 18017- 8600 U.S.A. Tel: (610) 954-9000...
  • Page 2 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 3 Instrument Co. reserves the right to make improvements and/or changes to the product(s) and/or programs ® described in this manual at any time and without notice. All information referred to and/or included in this report is current as of the original issue date of this manual. GOW-MAC Instrument ®...
  • Page 4 Certain parts such as batteries, fuses, filaments, etc., are expendable in normal use, and their service life is unpredictable. Such items are not covered by this warranty. All requests for service or repair under this warranty must be received within the warranty period by GOW-MAC or its authorized ®...

  • Page 5: Important Information

    IMPORTANT INFORMATION These instructions are written for personnel operating the GOW-MAC 5100 Series Continuous TC Binary ® Gas Analyzer. Read and understand the safety precautions in this manual to become familiar with the safe practices for operating this equipment. Dangers, Warnings, Cautions, and Notes Dangers, Warnings, Cautions, and Notes appear throughout this manual.
  • Page 6 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 7: Table Of Contents

    Section 8 Maintenance & Service ..................59 Section 9 Troubleshooting ..................... 63 Section 10 Repair/Replacement Parts List ................65 Appendix A: 5100 Series Quick Start Reference Flow Chart ..........67 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 8 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 9 Operate the 5100 Series Continuous TC Gas Analyzer according to the operating procedures stated herein. Any questions concerning the safe and proper use of your instrument should be addressed to: Mail: GOW-MAC Instrument Co. 277 Brodhead Road Bethlehem, PA 18017 Tel:...
  • Page 10 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 11: Safety

    It is not intended to supersede, replicate, or replace any safety documentation or procedures NOTE provided from or established by official safety sources. Do NOT operate the GOW-MAC 5100 Series Continuous TC ® Binary Gas Analyzer until you read and understand the operating, maintenance, and safety instructions included in this manual.
  • Page 12 Labels attached in appropriate areas of the analyzer warn you of inherent hazards associated with the system. For personal safety, read the labels and perform directed precautions before handling the equipment. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 13 DANGER SECURED IN PLACE. TO GUARD AGAINST ELECTRICAL SHOCK AND POSSIBLE ELECTROCUTION, THE ANALYZER SHOULD BE SERVICED ONLY BY A GOW-MAC SERVICE TECHNICIAN. Adherence to the following guidelines helps guard against electrical shock: • For safety and proper performance, this analyzer must be connected to a properly grounded three-wire source of electrical power.
  • Page 14 Safe Repair Procedures Any repair work must be performed by a GOW-MAC service technician. Analyzer manifold purging must be performed by experienced personnel. Ventilate working area to prevent any leaking supply gas from accumulating.

  • Page 15: Principle Of Operation

    (Figure 2-1). GOW-MAC uses reference filaments in the “opposite” legs of the bridge in all its 5100 Series Gas Analyzers in order to provide better stability due to variations in temperature and barometric pressure.
  • Page 16 A solid state constant current power supply is used for increased stability. All detectors are enclosed in an insulated enclosure which is controlled at 100 °C by a proportional temperature controller, which is located on the front panel. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 17: Specifications

    Specifications Customer: Job #: Instrument Part Number: Instrument Serial Number: Power Requirements: 5100 Series: 600 W at 115 V, 60 Hz 5102 Series: 600 W at 230 V, 50 Hz Gas Connections: 1/8 inch compression Detector: Type: Filaments: Bridge Current:...
  • Page 18 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 19: Installation

    Notify the company of any discrepancies. The packing box should be retained for use should the instrument ever need to be returned to the factory for repair or modification. GOW-MAC does not supply field repair service. All repairs are made at Bethlehem, PA or by an authorized representative.
  • Page 20 NOTE line compatible with the fittings on the analyzer. Torque the unions as specified by the manufacturer. Go on to Step 5. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 21 After all connections have been made, it is IMPORTANT that they be tight and free from leaks. Leaks in the system will cause baseline drift, noise and may reduce sensitivity or damage the detector. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 22 The use of soap or other organic substances to check for leaks IS NOT RECOMMENDED. They may contaminate the system. The easiest way to locate leaks in the system is through the use of a GOW-MAC Gas Leak Detector (Model 21-070).
  • Page 23 METERING VALVE, CONTROL PURGE PRESSURE 2.37 PURGE GAS VENT, 1/8 NPTF PURGE GAS MUST BE VENTED TO A NON-HAZARDOUS AREA GOW-MAC PURGE PRESSURE, SET 0.1 TO 0.5 INCHES WATER INCHES OF WATER (4) 0.28 DIA. HOLES FOR VERTICAL MOUNT BREATHER VENT 3.56...
  • Page 24 The protected enclosure shall be constantly maintained at a positive pressure of at least 0.1 inches water above the surrounding atmosphere during operation of the protected equipment. The GOW-MAC 5100 Series enclosure requires a minimum supply pressure of less than 5 psig to maintain 0.1 inches water. The purge gas supply pressure should be controllable between 0 to 5 psig to maintain analyzer cabinet pressure in the range between 0 to 0.5 inches water.
  • Page 25 Ready Output Cable (if necessary)* • Remote Zero (if necessary)* • Remote Calibration (if necessary)* • Calibration Indication (if necessary)* *There should be no AC or unexpected signals on these lines. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 26 (2) knock out holes in the back of the case. Remove the five (5) screws on the back of the case. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 27 GAS ANALYZER ® SAMPLE INSTRUMENT CO. GOW-MAC INSTRUMENT CO., BETHLEHEM, PA, USA 50 SERIES Figure 4-4: Front panel (typical) Carefully slide the chassis out of the case. Locate the terminal strip at the back of the chassis (shown in schematic).
  • Page 28 The exhaust should not have a large negative pressure as this can pull sample through analyzer at an uncontrolled rate and affect the results. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 29: Operating Controls

    Sample rotameter: Displays the sample gas flow rate to the detector. REFERENCE REF. SHIFT POWER/ CIRCUIT BREAKER THERMAL CONDUCTIVITY GAS ANALYZER SAMPLE ® INSTRUMENT CO. GOW-MAC INSTRUMENT CO., BETHLEHEM, PA, USA 5100 SERIES Figure 5-1: Front Panel 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 30 (optional, part of purge option) Pressure Switch (optional, part of purge option) PURGE REF. PRESSURE REFERENCE PURGE OUT ELECTRICAL KNOCKOUT HOLES SAMPLE SAMPLE DWYER SPAN ZERO PURGE IN Figure 5-2: Back Panel GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 31 Bottom shown in Fig. 5-3 VENT DRAIN LOW PRESS. HIGH PRESS. FRONT Figure 5-3: Bottom of chassis Purge In (optional) [1/4-inch compression] Pressure Switch (optional, part of purge option) 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 32 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 33: Operation Of Manually Operated 5100 Series

    2. The detector will begin to heat up to 100 °C when the power is turned on. The controller is located inside the instrument and cannot be seen during normal operations. It is factory set and cannot be changed. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 34 NOTE required. For ppm level analysis, OVERNIGHT warm-up is recommended. Start-up screen reveals Firmware Revision Number (V-xxxxxx), and Model Number (GOW-MAC xxxxxxxx). Record these for future reference. Firmware Revision Number:_________________________________ GOW-MAC Model Number:_________________________________ Use F1 to F4 buttons below screen to enter calibration parameters as instructed in the following directions.
  • Page 35 At that point, you have the option to press the “SETUP” button (F1), and re-enter the SETUP procedure. ALL values MUST BE RE-ENTERED as they are not saved from previous SETUP. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 36 For example, entering 1000 (or 10:00) would create an interval of 7:59 minutes (10:00 minus 02:01 = 07:59) over which the SAMPLE Gas will flow and be analyzed. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 37 Set the EPC pressure for the Sample, Span, and Zero gases in format “XXX”. A pressure setting of 10 psi should produce a flow rate of roughly 100 mL/min (20 » 200 mL/min), as indicated on flow meter (lower meter) on front of instrument. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 38 Enter “1” to designate Alarm 1 as a HIGH ALARM, which will be activated if measured concentration value increases above alarm setting value. iii. Enter “2” to turn Alarm 1 OFF. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 39 With the cycle times programmed to “00:00” for the Zero and the Span cycle times, the instrument will operate in the Continuous Sample Mode. During the programming setup of the instrument, there is an option to activate the “Remote Zero” function. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 40 10 minutes. After the calibration sequence is complete, the selected run mode will start again. The remote calibration comes with an additional option called “Cal. Ind.” The “Cal. Ind.” is located inside the instrument terminal strip at terminals 33 & 34. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 41 9) At this point, you may re-enter the SET UP procedure if you wish to make any changes or corrections. If you choose to re-enter SET UP, go back to step 1 under initial Setup. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...

  • Page 42: Section C: Quick Start-Up

    BEFORE continuing to the next step. 1. Press “1” on the keypad to display the Main Menu 2. Press “5” for “Current On” to turn ON the TCD current. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 43 Gas. (i.e. a “positive” concentration reading is displayed on the screen in Calibration Mode). An example would be Helium impurity in Nitrogen base gas. Anytime “SHIFT” is pressed, the word “SHIFT” should appear on the screen. If it does not, press “SHIFT” again. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 44 - If CONTINUOUS SAMPLE mode was selected, “CONT” will appear at the bottom left of the screen. The sample will be continuously analyzed. Press “SHIFT”, then “9” to enter CAL mode to Calibrate. Be sure the screen displays : CALIBRATION MODE GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 45 SPAN SET VALUE to confirm reproducibility. Re-set SPAN if outside the precision required for your application, if so desired. (See 6 C.8). c) Repeat calibration procedure until readings replicate within desired tolerance without having to Re-ZERO or Re-SPAN instrument. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 46 “NOT READY” message will be displayed on the screen. The instrument will turn off zero gas and return to sample gas at the programmed time. The 4-20 mA output and alarms will be active. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 47 Press “1” again to close the menu and key the function you wish to execute. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 48 Press ESCAPE (ESC) at any time if you wish to exit CAPTURE Mode, change run parameters, or change settings. This step takes approximately 30 secs to finalize and shut down the cap- ture process. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 49: Section D: Detailed Start-Up

    “4” key CURRENT INC to increase the bridge current. If the CURRENT ON occurs after the initial bridge setting without a power down, the last entered bridge cur- rent will resume. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 50 TESTING WITH THE SETTING INDICATED ON THE QC RECORD SUPPLIED FOR YOUR APPLICATION. INCREMENTAL ADJUSTMENTS FROM THIS SETTING CAN BE MADE IF NECESSARY. FOR MORE INFORMATION, REFER TO THE ENCLOSED GENERAL SERVICE BULLETIN INCLUDED WITH THIS MANUAL. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 51 BUTTONS>>> SPAN (F3) F3 key pressed to accept Span Voltage “Z” or “S” Indicator of Zero or Span gas flowing ZERO (F4) F4 key pressed to accept Zero Voltage 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 52 If you are unable to achieve a ZERO (Z) value above 0.1V, with fluctuation of the “R” value, proceed to Section 9 - Troubleshooting. *NOTE: If this does not work call GOW-MAC. There is an internal adjustment needed. 6. Span Calibration Press “SHIFT”, then “3”...
  • Page 53 If an ALARM CONDITION is indicated on screen during CAPTURE: Press “1” to view MENU if you would like to see available options. Press “1” again to exit MENU. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 54 REMOTE CALIBRATION — Refer to Section 6, B, 12. Calibration Frequency Calibrate the 5100 Series Continuous Analyzer: After initial start-up After prolonged shutdown. Weekly or as experience and application requirements dictate. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 55 GAS BEFORE SHUTDOWN USING AN INERT GAS - INCLUDING THE SAMPLE INLET. THIS IS REQUIRED FOR SAMPLES WITH HIGH CONCENTRATIONS OF COMPOUNDS THAT FORM ACIDS (HF, HCL, HBR, ETC.) OR REACT VIOLENTLY AND/OR CORROSIVELY WITH ATMOSPHERIC ELEMENTS. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 56 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 57: Electrical Accessories

    RS232 OUT- Records continuously in CAPTURE Mode. Marks OVER-RANGE readings, DayCount*, Time, ZERO, SPAN and alarms on recorded concentration readings. Each field is separated by a comma, i.e., comma delimited. *not functional 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 58 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 59: Maintenance & Service

    GOW-MAC will clean, repair and re-filament your TCD to the specifications of a new detector if it is returned to the factory. (Note: Additional charges will be incurred if complete oven assemblies are returned to us.
  • Page 60 7/16-inch and 5/16-inch open end wrenches. Completely unscrew the four (4) screws located at the base of the detector block (Figure 8-1, Screws 1, 2, 3, & 4). GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 61 Unscrew insulation block from detector. To replace detector, go in reverse order of above steps. Leak check system. Maintenance Check zero. Check flow rates. Observe whether heater indicator is at set temperature. 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 62 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 63: Troubleshooting

    TCD housing hotter a. Sensor probe shorted Check for bare wires & tape than normal over; Replace probe b. Set point on pot. incorrectly set Call GOW-MAC Eng. c. Controller defective Replace controller Unable to Zero TCD a. Filaments oxidized Replace filaments Baseline unstable a.
  • Page 64 (See QC Record or General Service Bulletin) b. Leak in system Leak check all gas lines and fittings Phone GOW-MAC for technical support or service @ (610) 954-9000. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 65: Section 10 Repair/Replacement Parts List

    *180-889-1 ....Electronic Pressure Regulator, light gases (He & H only) *180-889-2 ....Electronic Pressure Regulator, heavy gases (all other gases) **180-250 ..... Neon rotameter, aluminum **180-338 ..... Air rotameter, aluminum **180-376 ..... Hydrogen rotameter, stainless steel 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 66 Electronic pressure regulator depends on the major component of the gas mixture of the specified analysis at time of ordering. **Note: Rotameter depends on zero gas of the specified analysis at time of ordering. GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

  • Page 67: Appendix A: 5100 Series Quick Start Reference Flow Chart

    (F4) (F4) Enter SAMPLE Enter SAMPLE SWITCH-OFF Time SWITCH-OFF Time (Enter 00:00) XX:XX Enter Standard Concentration Format XXX.XX Press ENTER (F4) PROCEED TO EPC Pressure and Alarms (page 2) 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 68 2 = Alarm 3 OFF Alarm 4 Type: 0 = Low Alarm INPUT: 1 = High Alarm 0 = Turn OFF 2 = Alarm 4 OFF 1 = Turn ON GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 69 ALARM 3 XXX.X Return to top of Page 1 to change SETUP Enter Setpoint for ALARM 4 XXX.X Is SETUP PROCEED TO COMPLETE CALIBRATE & ANALYZE (page 4) CORRECT? 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 70 (”S” will be on display) If concentration displays “000” or “OVERRANGE”, Were see Calibration Section of ZERO & SPAN operating manual. verified? Press Press “9” to “ESC” ANALYZE to exit SAMPLE GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 71 5100 Series Continuous Gas Analyzer GOW-MAC Instrument Co. 03/18, Rev. 6...
  • Page 72 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...
  • Page 73 Failed Safety Inspection. DO NOT proceed to Repair Dept. RMA No: __________________ ( ) On Back >>>> □ REP-005 Health-Safety Declaration Doc REV 6 (0212).docx Rev. 6 2/15/2012, gsj 277 Brodhead Road, Bethlehem, PA 18017 U.S.A. Tel: (610) 954-9000 Fax: (610) 954-0599 E-mail: sales@gow-mac.com URL: www.gow-mac.com...
  • Page 74 GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer 03/18, Rev. 6...

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