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Bacharach Neutronics 5124BE-N1-WO Installation Manual

Oxygen analyzer - percent range with remote sensor module
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High Purity Instruments
MODEL 5124BE-N1-WO
OXYGEN ANALYZER – PERCENT RANGE
WITH REMOTE SENSOR MODULE
INSTALLATION MANUAL
File Name: MN-A-0177
Manual Part Number: 5-06-4900-65-0
Revision Level: A Revision Date: 8/19/08
ECO: 8541
Phone: 610.524.8800 • Fax: 610.524.8807 • Email: info@neutronicsinc.com
Neutronics Inc.
456 Creamery Way, Exton, PA 19341
www.neutronicsinc.com

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Summary of Contents for Bacharach Neutronics 5124BE-N1-WO

  • Page 1 High Purity Instruments MODEL 5124BE-N1-WO OXYGEN ANALYZER – PERCENT RANGE WITH REMOTE SENSOR MODULE INSTALLATION MANUAL File Name: MN-A-0177 Manual Part Number: 5-06-4900-65-0 Revision Level: A Revision Date: 8/19/08 ECO: 8541 Neutronics Inc. 456 Creamery Way, Exton, PA 19341 Phone: 610.524.8800 • Fax: 610.524.8807 • Email: info@neutronicsinc.com www.neutronicsinc.com...

  • Page 3: Table Of Contents

    Table of Contents TABLE OF CONTENTS ............................ III FOR YOUR SAFETY: ............................IV THANK YOU FOR PURCHASING THE MODEL 5124BE-N1-WO ANALYZER FOR 0-25 % RANGE OXYGEN MEASUREMENT..............................V CHAPTER 1 – INTRODUCTION AND OVERVIEW ................... 1 CHAPTER 2 – SYSTEM INSTALLATION AND START-UP ..............3 1 –...

  • Page 4: For Your Safety

    For Your Safety: PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING INSTALLATION OR OPERATION! Attempting to operate the Model 5124BE-N1-WO without fully understanding its features and functions may result in unsafe conditions. • Always use protective eye wear and observe proper safety procedures when working with pressurized gases.

  • Page 5: Thank You For Purchasing The Model 5124Be-N1-Wo Analyzer For 0-25 % Range Oxygen Measurement

    Thank you for purchasing the Model 5124BE-N1-WO Analyzer for 0-25 % range Oxygen measurement. The Model 5124BE-N1-WO Compact Analyzer is a user friendly, microprocessor-controlled Oxygen measuring instrument. It has many features to offer the user, which will be described in this manual. We require that all personnel who use the instrument read this manual to become more familiar with its proper operation.

  • Page 7: Chapter 1 - Introduction And Overview

    Installation and Operations Manual 1 – I HAPTER NTRODUCTION AND VERVIEW The Model 5124BE-N1-WO analyzer is a microprocessor-based instrument for measuring percent level oxygen in an inert gas background. The analyzer is based on an amperometric zirconium oxide remote sensor. This sensor assures reliability and fast response for oxygen concentration measurements, in inert gas backgrounds, in the percent range.
  • Page 8 NEMA 4 PANEL MOUNTING STUDS MOUNTING GASKET ELECTRICAL CONNECTION PORT TO REMOTE EARTH GROUND REMOVABLE SENSOR TERMINAL TERMINAL BLOCKS Figure 1 – Model 5124BE-N1-WO Rear View Manual Part Number: Revision Level: A File Name: MN-A-0177 Page 2 5-06-4900-65-0 ECO 8541...

  • Page 9: Chapter 2 - System Installation And Start-Up

    Installation and Operations Manual 2 – S HAPTER YSTEM NSTALLATION TART STEP 1: ANALYZER INSTALLATION STEP 2: SENSOR INSTALLATION STEP 3: ELECTRICAL CONNECTIONS STEP 4: POWER UP STEP 5: AIR VERIFICATION/CALIBRATION Figure 2 – Power Up Sequence Manual Part Number: Revision Level: A File Name: MN-A-0177 Page 3...

  • Page 10: Step 1 - Analyzer Installation

    Step 1 – Analyzer Installation WARNING: The internal components of the Model 5124BE-N1-WO analyzer and the remote sensor are fragile. Do not drop the analyzer or the remote sensor during installation. Do not expose the unit to shock or vibration during installation. Failure to comply may damage the fragile components inside the analyzer and remote sensor may result in loss of warranty.

  • Page 11: Step 2 - Sensor Installation

    Step 2 – Sensor Installation All pneumatic connections are to be made to the Model 5124BE-N1-WO remote sensor. The remote sensor is designed to be screwed-on in-situ to the process vessel at which the oxygen concentration measurements are to be made. Drill the Sample Port.
  • Page 12 Figure 4 – Sensor mounting detail Manual Part Number: Revision Level: A File Name: MN-A-0177 Page 6 5-06-4900-65-0 ECO 8541...

  • Page 13: Step 3 - Electrical Installation

    Step 3 – Electrical Installation CAUTION: Be sure all mains power supply is off before attempting the electrical connections to the analyzer and remote sensor. DO NOT WORK WITH LIVE WIRES! Do not leave any exposed wire at the connectors or cables. Before applying power, ensure terminal blocks are fully inserted into the mating connector at the analyzer.
  • Page 14 CAUTION: In order to comply with CE EN61326-1:2006 standards, all electrical connections to the three terminal blocks on the back of the analyzer are to be made using shielded cable conductors. Each electrical connection to the terminal blocks must be looped through the ferrite clamp provided. If more than one shielded cable conductor is used, the individual wires from the different cables may share the same ferrite clamp.
  • Page 15 Figure 5 – Recommended electrical connection to the analyzer terminal blocks Manual Part Number: Revision Level: A File Name: MN-A-0177 Page 9 5-06-4900-65-0 ECO 8541...
  • Page 16 A label depicting the terminal block arrangement is affixed to the top of the chassis for easy reference during installation and maintenance. The terminal blocks feature screwed terminals. The terminal blocks are also removable for ease of wiring or removal of the analyzer module. Figure 6 –...
  • Page 17 VDC+ VDC POWER INPUT, 18-30 VDC Range FAILSAFE V-Out TEMP FAULT Alarm 2 Alarm 1 NC NO C NO NC NO Normally Open Normally Bat. Closed RS-232 C = Common RX RTN Service Port Figure 8 – Analyzer chassis electrical connections The following is a list of all possible electrical connections to the Model 5124BE-N1-WO analyzer: External Sensor Interface The Model 5124BE-N1-WO analyzer is electrically connected to the external sensor via the...
  • Page 18 Oxygen Alarm-1 Relay Output Use 18-22 AWG, shielded cable for the connections. The shielded cable must be grounded at both ends to comply with EN61326-1:2006 specifications. Loop individual connectors around the ferrite clamp provided. Relay Type: Form 1 C, SPDT, 5A @ 250 VAC, 5A @ 30VDC Connections: Common: Terminal Block TB2 Pin 8 Normally Closed Output: Terminal Block TB2 Pin 9...
  • Page 19 Analog Voltage Output The analog voltage output is factory pre-set to be either 0-1, 0-5, or 0-10 volts. Use 20-26 AWG, shielded cable for the connections. The shielded cable must be grounded at both ends to comply with EN61326-1:2006 specifications. Loop individual connectors around the ferrite clamp provided.
  • Page 20 Mains Power Use 18-22 AWG, shielded cable for the connections. The shielded cable must be grounded at both ends to comply with EN61326-1:2006 specifications. The ground shielding at the analyzer end is to be connected to terminal block TB1 pin 1. Loop individual connectors around the ferrite clamp provided.

  • Page 21: Chapter 3 - Operating Instruction

    Installation and Operations Manual 3 – O HAPTER PERATING NSTRUCTION A. First Time Power Up The Model 5124BE-N1-WO analyzer and its remote sensor are shipped ready to use, right from the carton. Its default configuration has been set to your application. Review the default configuration settings, as shown in the analyzer software setup log sheet, shipped with your Model 5124BE-N1-WO analyzer.
  • Page 22 First Time Power Up Instructions 1. Apply Ambient Air to the External Sensor Sample Port: Apply clean, dry oil-free ambient air to the process vessel. See the analyzer installation manual for more detail. Regulate the ambient air supply in your process vessel to match process conditions. Do not exceed 10 PSI.

  • Page 23: Normal Power Up And Power Down Instructions

    6. Verify Outputs: If the Model 5124BE-N1-WO analyzer indicates between 20.8% and 21.0% after warm-up, and all the first-time power-up verifications have been completed, Check the fault, temperature OK, and oxygen alarm relay contacts to ensure that they are wired properly and functioning normally.

  • Page 24: Features

    D. Features The Model 5124BE-N1-WO analyzer is intended to be used to measure oxygen concentrations in inert background. The analyzer comes equipped with several operational features. Each feature will be discussed in detail separately: • Four relay outputs: TEMPERATURE OK, FAULT, ALARM 1 and ALARM 2. •...

  • Page 25: Oxygen Alarm 1 & Alarm 2 Relays

    Troubleshooting Oxygen Alarm 1 & Alarm 2 Relays The Oxygen Alarm 1 and Alarm 2 relay activation depend on the following Model 5124BE- N1-WO Analyzer settings. Refer to the software setup log shipped with the analyzer to determine your actual settings. ...

  • Page 26: Analog Voltage & Analog Current Output

    Analog Voltage & Analog Current Output The analog voltage and analog current output produce either a voltage or a current output proportional to the measured oxygen concentration. For the analog voltage, the zero scale is always 0 volts. The full scale is programmed at the factory to be either 1, 5, or 10 volts. For the analog current output, the zero-scale output is 4 milliamperes and the full-scale output is 20 milliamperes.

  • Page 27: Chapter 4 - Maintenance And Troubleshooting

    Troubleshooting 4 – M HAPTER AINTENANCE AND ROUBLESHOOTING WARNING: The Model 5124BE-N1-WO analyzer has no field-serviceable parts, with the exception of the sensor and sensor cable. Do not attempt to repair the unit. All repairs are to be performed either at the factory or at any of the certified service centers.
  • Page 28 Troubleshooting (continued) Contaminated sensor: Avoid the use of silicone-based lubricants and sealants in the sample stream. Contamination should be monitored at commissioning, as detailed in the maintenance table in this section of the manual. Approved Service Centers for the Model 5124BE-N1-WO Analyzer Neutronics, Inc.

  • Page 29: Chapter 5 - Specifications

    Installation and Operations Manual 5 – S **** HAPTER PECIFICATIONS Revision A Release Date: August 2008 OXYGEN SENSOR External Miniature Zirconia Amperometric Sensor SIGNAL INTERFACE Serial Service Port: Bi-directional RS-232 Analog Voltage Output: 0–1, 0–5, or 0–10 VDC Non-isolated 4 – 20 mA, 12 VDC, negative Analog Current Output: ground, powered by analyzer, maximum electrical load 250 Ohms...
  • Page 30 Revision A Release Date: August 2008 RESPONSE TIME < 15 seconds 60 seconds for sensor warm up, WARM UP TIME 45 minutes for temperature equilibrium. HUMIDITY 0-95 % non-condensing OPERATING 32-113° F (0–45° C) TEMPERATURE STORAGE 23-149° F (-5–65° C) TEMPERATURE SAMPLE PRESSURE 1-10 PSIG...

  • Page 31: Warranty

    Installation and Operations Manual Warranty Neutronics warrants to the original purchaser, that the Model 5124BE-N1-WO oxygen analyzer and remote sensor are free from defects in material and workmanship for a period of one (1) year from the date of shipment from Neutronics or from one of Neutronics’ authorized dealers.

  • Page 32: Intended Use For The Model 5124Be-N1-Wo

    Intended Use for The Model 5124BE-N1-WO The Model 5124BE-N1-WO oxygen analyzer and remote sensor were designed to provide the trained operator with useful information relating to the concentration of oxygen. This information may be used in process control or to minimize possible hazardous conditions, which may be present in various processes.

  • Page 33: Appendix A: Ambient Air Calibration

    Appendix A: Ambient Air Calibration The Model 5124BE-N1-WO analyzer, along with its remote sensor is shipped from the factory fully calibrated for its operational measurement range. It may be necessary, however, to perform air calibration at commissioning to account for differences in atmospheric pressures at the installation site.
  • Page 34 RUN 20.9 % ALM1 ALM2 FLT 5,11 RUN 20.9 % ALM1 ALM2 FLT 5,11 *RUN 20.9 % ALM1 ALM2 FLT 5,11 RUN 20.9 % ALM1 ALM2 FLT 5,11 RUN 20.9 % ALM1 ALM2 FLT 5,11 • Pause RS-232 serial output stream: Carefully type the following command string: “sserfmt=0”...
  • Page 35 • Restart the RS-232 serial output stream: Type “sserfmt=1” to restart the RS-232 serial output stream. The analyzer will resume its timed serial output. See example below: *sserfmt=1 *RUN 20.9 % ALM1 ALM2 FLT 5,11 RUN 20.9 % ALM1 ALM2 FLT 5,11 RUN 20.9 % ALM1 ALM2 FLT 5,11 RUN 20.9 % ALM1 ALM2 FLT 5,11 RUN 20.9 % ALM1 ALM2 FLT 5,11...

  • Page 36: Appendix B: System Faults

    Appendix B: System Faults If the Model 5124BE-N1-WO Analyzer detects one or more system faults, it will display the fault code number on the RS-232. The analyzer will first indicate that there is at least one fault active by displaying the string “FLT”. It will then display all the active faults by displaying all the fault code numbers separated by commas.
  • Page 37 • “11” – Non-Native Display Range: The analyzer is measuring an oxygen concentration that is either higher or lower than the display range. For example, if the Display Range is set to 0-25% Fixed and the analyzer measures 30% oxygen, Fault 11 will activate.

  • Page 38: Appendix C: Oxygen Alarm Level Settings

    Appendix C: Oxygen Alarm Level Settings The Model 5124BE-N1-WO Analyzer is shipped from the factory with the oxygen alarm level set to your desired process. However, the oxygen alarm level settings may be changed using the procedures below. WARNING: Altering the Oxygen Alarm Level setting may affect the Model 5124BE-N1-WO analyzer’s performance in your process.

  • Page 39: Appendix D: Rs-232 Port

    • Pause RS-232 serial output stream: Carefully type the following command string: “sserfmt=0” and press “enter”. The serial output stream should stop. If the serial output stream does not stop, reset the serial input buffer again and retype the command string. Also note that the input characters will be mixed in with the output characters on the RS-232 terminal.
  • Page 40 The RS-232 port may be used to send data to a host computer. There are four available formats that the Model 5124BE-N1-WO may send data to the host computer. The speed of the data transmission can vary from 300BPS to 38.4KBPS. Unless otherwise specified, the following is the default transmission format: PROPERTIES MODEL 5124BE-N1-WO...
  • Page 41 Setting Up RS-232 Terminal Interfacing using Microsoft Windows 95 or later: • Open HyperTerminal. On your PC computer, open HyperTerminal: Navigate from the Windows desktop – Select Start → Programs → Accessories → Communications → HyperTerminal. • Configure HyperTerminal. In HyperTerminal, create and configure a new connection –...

  • Page 42: Appendix E: System Setup

    Appendix E: System Setup The Model 5124BE-N1-WO is shipped ready to install and operate. It has been factory configured to meet the requirements of your application. The user, however, may change the settings from the setup menu accessed RS-232 terminal. Altering the system setup settings will alter the performance of the WARNING: oxygen analyzer, and may affect its performance in your process.
  • Page 43 Accessing the System Setup Menu To access the Setup Menu, press “enter” to reset the RS-232 serial input buffer. Then, type “setup” and press “enter”. The following menu will appear on the RS-232 terminal: *****> SETUP MAIN MENU <***** (U00) Press To Change (F3-Exit Setup Mode Now) - - -------------------------------------------------------...

  • Page 44: Appendixf - Spare Parts List

    Appendix F – Spare Parts List PART NUMBER DESCRIPTION 5-06-4900-65-0 Operations Manual Replacement terminal block – TB1 C1-17-0052-00-0 Replacement terminal block – TB2 C1-17-0142-00-0 Replacement terminal block – TB3 C1-17-0112-00-0 C7-01-5124-03-0 Model 5124BE-N1-WO Oxygen Analyzer C6-01-1001-38-3 Sensor Interface Cable, 3 Meters C6-02-4000-00-1 External Oxygen Sensor Assembly 1-11-0000-14-0...

  • Page 45: Appendixg - Msds Material Safety Data Sheet

    Appendix G – MSDS Material Safety Data Sheet 1. Product Identification Model 5124BE-N1-WO Analyzer with External Sensor furnished by Neutronics Inc. • 456 Creamery Way • Exton, PA USA, 19341 • Telephone: 610-524-8800. 2. Hazardous Ingredients of Solution None. 3. Health Hazard None.

  • Page 46: Appendixh - Declaration Of Conformity

    Appendix H – Declaration of Conformity Manual Part Number: Revision Level: A File Name: MN-A-0177 Page 40 5-06-4900-65-0 ECO 8541...

  • Page 47: Appendixi - Decommissioning The Model 5124Be-N1-Wo Analyzer

    Appendix I – Decommissioning the Model 5124BE-N1-WO Analyzer Concerning Neutronics' environmental compliance, in regards to producing new electrical equipment, the RoHS directive, 2002/95/EC, a European directive, requires manufacturers of certain types of electrical equipment, not to use materials that contain restricted quantities of "lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls (PBB) or polybrominated diphenyl ethers (PBDE)".

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