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Bacharach Neutronics 5100E Operation Manual

Oxygen analyzer / controller
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High Purity Instruments
MODEL 5100E
OXYGEN ANALYZER / CONTROLLER – PERCENT RANGE
OPERATIONS MANUAL
N
TRON
R
EMOTE
S
ENSOR
File Name: MN-A-0008
Manual Part Number: C5-06-4900-08-0
Revision Level: C Revision Date: 11/27/06
ECO: 8029
Phone: 610.524.8800 • Fax: 610.524.8807 • Email: info@neutronicsinc.com
MODEL 5100 O
P
ERCENT
20.9
RUN
FAULT
Neutronics Inc.
456 Creamery Way, Exton, PA 19341
www.neutronicsinc.com
Analyzer
2
O
XYGEN
ALM 1
ALM 2
MODE

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Summary of Contents for Bacharach Neutronics 5100E

  • Page 1 High Purity Instruments MODEL 5100E OXYGEN ANALYZER / CONTROLLER – PERCENT RANGE OPERATIONS MANUAL MODEL 5100 O Analyzer TRON ERCENT XYGEN 20.9 EMOTE ENSOR FAULT ALM 1 ALM 2 MODE File Name: MN-A-0008 Manual Part Number: C5-06-4900-08-0 Revision Level: C Revision Date: 11/27/06 ECO: 8029 Neutronics Inc.

  • Page 3: Table Of Contents

    Table of Contents TABLE OF CONTENTS ..............................III FOR YOUR SAFETY: ..............................V WELCOME ................................. VI CHAPTER 1 – INTRODUCTION AND OVERVIEW ......................1-1 ................................1-1 ENERAL ................................1-1 EATURES ..........................1-3 YSTEM ARDWARE VERVIEW 1.3.1 Main Board .............................. 1-3 1.3.2 Relay Board ..............................
  • Page 4 ............................3-1 YSTEM RGANIZATION USER M ..............................3-1 ODES 3.2.1 CALIBRATE Mode & Calibration Procedure ....................3-1 3.2.2 SET/VIEW ALARM-1 Mode ........................3-3 3.2.3 SET/VIEW ALARM-2 Mode ........................3-4 3.2.4 VIEW ACTIVE FAULTS Mode ........................3-4 3.2.5 Return to RUN Mode ..........................3-4 ..............................

  • Page 5: For Your Safety

    For Your Safety: PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING INSTALLATION OR OPERATION! Attempting to operate the Model 5100E 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 6: Welcome

    WELCOME Thank you for purchasing the Model 5100E Analyzer for zero to 100 % range Oxygen measurement. The Model 5100E 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

    1 – I HAPTER NTRODUCTION AND VERVIEW General The Model 5100E Compact Series analyzer by Neutronics offers an efficient solution in a small package for oxygen measurement and control applications. The Model 5100E is a microprocessor-based instrument for measuring zero to 100 % oxygen. At the heart of the analyzer is the Model ZR-500E rapid-response Zirconium Oxide oxygen sensor.
  • Page 8 Model 5100E – Introduction and Overview RISK OF ELEC TRIC AL SHO C K. SERVIC E B Y AUTHO RIZED TEC HN IC IAN O N LY. Rear view Front view Figure 1 – Model 5100E oxygen analyzer front and rear view Control Panel Power Supply Board...

  • Page 9: System Hardware Overview

    System Hardware Overview System Hardware Overview 1.3.1 Main Board The main board houses the microprocessor, and supporting electronics for controlling the operation of the Model 5100E Analyzer. The main board receives the sensor input, and provides the control and display functions of the analyzer.

  • Page 10: Sensor

    Model 5100E – Introduction and Overview 1.3.6 Sensor The Neutronics Inc ZR-500E mini Zirconia sensor for measuring percent range oxygen is a cost effective solution for many applications. It is a solid-state device based on a Zirconia solid electrolyte sensor with a low power, on-board heater, and two electrodes.

  • Page 11: Chassis

    System Hardware Overview Figure 4 – Sensor flow-through head 1.3.8 Chassis The chassis is manufactured from stainless steel. It is designed to provide a general level of protection against mechanical damage from the local environment. It is also an important component of the electrostatic discharge (ESD) shielding design.
  • Page 12 Model 5100E – Introduction and Overview 4-20 mA Output RS-232 COM Line Analog Voltage Output Range ID Output Fault Relay Outputs Alarm 1 & 2 Relay Outputs Relay Board Remote Power Mains Power Main Board Sensor Input Supply Display Board Control Panel Figure 6 –...

  • Page 13: Analyzer Inputs And Outputs

    Analyzer Inputs and Outputs Analyzer Inputs and Outputs 1.4.1 The Oxygen Sensor Input The oxygen sensor electrical input to the Model 5100E is used to indicate the oxygen concentration measured by the Model ZR-500E oxygen sensor. It is proportional to the oxygen present in the measured gas at the sensor membrane.
  • Page 14 Model 5100E – Introduction and Overview The user can set the Analog voltage scale (section 4.1 – system setup). Available settings are 0-1VDC, 0- 5VDC, or 0-10VDC. The factory default setting is 0-1 VDC. The Analog voltage output is scaled according to the analyzer’s selected range, and must be used in conjunction with the Range ID voltage when the Analyzer is configured for auto-ranging (section 1.4.9).

  • Page 15: Analog Current Output

    Analyzer Inputs and Outputs 1.4.7 Analog Current Output The Analog Current output is a dynamic current flow used to indicate to a remote device the displayed oxygen concentration during normal analyzer operation and system maintenance. The Analog Current output follows the oxygen readout displayed on the 7-segment LED display during all system and user modes except for user setup.

  • Page 16: 7-Segment Alphanumeric Display

    Model 5100E – Introduction and Overview 1.5.4 7-Segment Alphanumeric Display The 7-Segment alphanumeric display feeds back information from the Model 5100E to the user via the control panel. The primary purpose of the 7-Segment display is to show the oxygen concentration readout. It is also used for feedback of operational status, fault codes, and other information necessary to perform system setup and maintenance.

  • Page 17: Chapter 2 - System Installation And Start-Up

    2 – S HAPTER YSTEM NSTALLATION TART Installing the Analyzer PANEL CUTOUT Figure 7 – Installation outline Manual Part Number: Revision Level: C File Name: MN-A-0008 Page 2-1 C5-06-4900-08-0 ECO 8029...

  • Page 18: Step 1 - Locate And Mount The Analyzer Unit

    System Installation and Startup 2.1.1 Step 1 – Locate and Mount the Analyzer Unit The Model 5100E is designed to be mounted flush to the surface of an equipment control panel. Select a suitable location for the analyzer unit where the digital display and status LED’s will be easy to read, and the interface buttons on the display panel will be easy to access.

  • Page 19: Step 2 -Install The Remote Sensor

    Installing the Analyzer 2.1.2 Step 2 –Install the Remote Sensor The Model 5100E is supplied with a Model ZR-500E oxygen sensor, and sensor flow-through head for connection to a sampled process gas stream, and a sensor interface cable. The Model 5100E can also be supplied with a Neutronics Inc.
  • Page 20 System Installation and Startup SAMPLING POSITION Sample Flow Sample Gas Remote Sensor 1-10 PSIG@1 LPM Module Calibration Gas CALIBRATE POSITION Remote Sensor Sample Gas Module 1-10 PSIG@1 LPM Sample Flow Calibration Gas Figure 10 – Calibration gas fixture configuration (typical) – see calibration section (3.2.1) for calibration procedure details.
  • Page 21 Installing the Analyzer Connect the sensor to the flow-through head. Verify the supplied o-ring is in place at the base of the sensor, over the 3/4-16 threaded connector. Do not lubricate the o-ring. Verify the supplied gasket is seated in the bottom of the flow-through head sensor receptacle. Screw the sensor into the flow-through head sensor receptacle, and hand-tighten.

  • Page 22: Step 3 -Electrical Installation

    System Installation and Startup 2.1.3 Step 3 –Electrical Installation DANGER: Electrical connections on the rear of the Model 5100E Oxygen analyzer may have hazardous voltages present once power has been applied to the unit. High voltages may remain present for a short time even after power has been disconnected from the analyzer. Take care in observing standard electrical practices when making electrical connections to the Model 5100E Oxygen analyzer.
  • Page 23 Installing the Analyzer A label depicting the terminal block arrangement is affixed to the top of the chassis for easy reference during installation and maintenance (VAC configuration shown below). The terminal blocks feature screwed terminals. The terminal blocks are also removable for ease of wiring or removal of the analyzer module. AC Unit Label DC Unit Label Figure 10 –...
  • Page 24 System Installation and Startup VDC POWER INPUT, VDC+ 18-30 VDC - or - VAC POWER INPUT, AC-L AC-N 90-264 VAC, 47-63 Hz +/- 10% Regulation Range Failsafe V-Out Fault Alarm 2 Temp Alarm 1 NC NO C NO NC NO NO = Normally Open NC = Normally Closed Bat.
  • Page 25 Installing the Analyzer 2.1.3.1 Alarm-1 Relay Output Connections from the Alarm-1 relay contacts to the user’s process control equipment are made at terminal block TB2 on the rear of the analyzer chassis. The Oxygen Alarm relay contacts are voltage-free Form 1 C relay contacts, SPDT, 5A @ 250 VAC, 5A @ 30 VDC.
  • Page 26 System Installation and Startup 2.1.3.5 Analog Voltage Output Connections from the Analog Voltage output to the user’s auxiliary equipment are made at terminal block TB3 on the rear of the analyzer chassis. Be certain to match the terminal pins against the terminal ID label on the top of the analyzer chassis.
  • Page 27 Installing the Analyzer 2.1.3.8 RS-232 Service Port Connections from the Range ID output to the user’s auxiliary equipment are made at terminal block TB3 on the rear of the analyzer chassis. Be certain to match the terminal pins against the terminal ID label on the top of the analyzer chassis.

  • Page 28: Starting Up And Commissioning The System

    System Installation and Startup Starting up and Commissioning the System STEP 1: POWER UP STEP 2: INITIAL CALIBRATION STEP 3: SET ALARM 1 & 2 Figure 13 – Start-up outline The Model 5100E is shipped ready to use, right from the carton. Factory default configuration settings are listed in Appendix C for your information.
  • Page 29 Starting up and Commissioning the System When the warm-up period is complete, the Model 5100E will check the sensor signal, update the display and status LED’s, and enter into the appropriate system mode according to programmed parameters (refer to the Software Setup Log that is supplied by the factory, for the configuration details of your Model 5100E).

  • Page 30: Step 2 - Calibrate The Unit

    System Installation and Startup 2.2.2 STEP 2 – Calibrate the Unit All units are calibrated at the Neutronics factory before shipping. However, it is recommended that the Model 5100E be calibrated at commissioning, under ambient and process conditions similar to those encountered while in-service.

  • Page 31: Chapter 3 - Analyzer Operation

    3 – A HAPTER NALYZER PERATION System Organization The Model 5100E has two types of operational modes – User-type, and Operating-type. User modes are initiated and controlled by the user, and are used to setup and maintain the analyzer. The User modes are: Calibration, Set/View Alarm-1, Set/View Alarm-2, View Active Faults, and Setup.
  • Page 32 Analyzer Operation Disconnect the measured process from the sensor by completely removing the installed 1/8” MNPT fittings from the sensor flow-through head sample inlet port (this step is not necessary if using a fixed gas manifold – section 2.3.1). If it is necessary to exhaust to an alternate path during calibration, completely remove the installed 1/8”...

  • Page 33: Set/View Alarm-1 Mode

    SYSTEM Modes Warning: Do not use a span calibration gas concentration below 1% or above 95%. Failure to comply will significantly compromise the accuracy of the analyzer. Warning: All span calibration gases, except for compressed air, must be certified test gases. Failure to comply will significantly compromise the accuracy of the analyzer.

  • Page 34: Set/View Alarm-2 Mode

    Analyzer Operation 3.2.3 SET/VIEW ALARM-2 Mode To enter Set Alarm-2 mode from run mode using the keypad; scroll through the user mode menu by pressing momentarily the “MODE” key three (3) times, until the 7-segment alphanumeric display reads “AL2” (set alarm-2 level) and the “RUN” and “ALM2” indicator LED’s flash. The display will show momentarily “AL2”...

  • Page 35: Alarm-1 Active Mode

    SYSTEM Modes When the measured process oxygen concentration falls outside of programmed alarm parameters, and/or the system experiences a fault condition, the Model 5100E analyzer enters into Alarm-1 Active, Alarm-2 Active, and/or Fault Active mode accordingly. The system does not abort Run mode, and the “RUN” indicator LED stays lit.
  • Page 37 4 – M HAPTER AINTENANCE AND ROUBLESHOOTING System Setup The Model 5100E is shipped ready to install and operate with complete factory configuration already programmed and tested. The user may however wish to change the system configuration to suit the application of the analyzer.

  • Page 38: Chapter 4 - Maintenance And Troubleshooting

    Maintenance and Troubleshooting Valid Settings: 1 (fixed range 0-1 %) • 2 (fixed range 0-10 %) • 3 (fixed range 0-25 %) • 4 (fixed range 0-50 %) • 5 (fixed range 0-100 %) • 8 (low auto-range 0-25%) • 9 (high auto-range 10-100%) • 10 (full auto-range) 4.1.1.2 User Setup 1: Alarm-1 Relays Ascending/Descending Action This parameter allows the user to set the Alarm-1 relay action to ascending (the relay is set to its active...

  • Page 39: System Setup

    System Setup 4.1.1.9 User Setup B: RS-232 Baud Rate This parameter allows the user to set the RS-232 communications baud rate. Valid Settings: 1 (300BPS) • 2 (1200BPS) • 3 (2400BPS) • 4(4800BPS) • 5 (9600BPS) 6 (19200BPS) • 7 (38400BPS) 4.1.1.10 User Setup 8: Factory Setup Restore.
  • Page 40 Maintenance and Troubleshooting Select “Apply” and “OK” as prompted. The Hyper Terminal program will immediately begin communicating with the Model 5100E, and the Model 5100E will commence sending data via ASCII code dump to the PC. The information from the analyzer will be sent in ASCII strings, at 1-second intervals. Data will be sent in the factory default “Human Readable”...
  • Page 41 System Setup The STANDARD ACCESS level commands TYPED COMMAND DESCRIPTION OF QUERIED FUNCTION Short software version Analyzer Model number Sensor output in Percent Oxygen Sensor output in Volts Active Fault codes (32 bit codes in hex) Active Fault code descriptions Long software version Unit Serial Number There are several data formats of the ASCII data dump available.
  • Page 42 Maintenance and Troubleshooting 4.1.2.4.4 Machine Code Format WITH Checksum Machine code with checksum can be selected via the analyzer control panel, or through the RS-232 interface in Standard Access level. Machine format with checksum data is streamed in packets defined by start/stop transmit bits.
  • Page 43 System Setup 4.1.2.7 (U00) SETTING UP THE MODEL 5100E – The RS-232 User Setup Menu The RS-232 User Setup menu U00 (see Figure 14) is the “Home” screen in Advanced Level-1 access (section 4.1.2.5), and provides access to all the parameters that may need to be adjusted by the user. The interactive menu is initiated by typing “setup”...
  • Page 44 Maintenance and Troubleshooting 4.1.2.8 Return all Settings to Factory Delivered Settings In case of severe corruption of calibration and setting information, this setting will allow the user to restore the Model 5100E analyzer to its “out-of-box” setting. The user may type “Y” at the prompt to initiate a restore, or “N”...
  • Page 45 System Setup 4.1.2.10 (U20) Alarm Relay Setup Menu The RS-232 Alarm/Relay Setup menu U20 (see Figure 16) provides access to all of the settings related to the Alarms, controls, and relays on the Model 5100E analyzer. It is accessed from the Setup Main Menu by typing “2”...
  • Page 46 Maintenance and Troubleshooting 4.1.2.10.3 Alarm-1 Descending This setting configures Alarm-1 to either ascending or descending action. Ascending is defined as Alarm-1 active when the oxygen concentration is above the Alarm-1 setpoint level. Descending is defined as; Alarm- 1 active when the oxygen concentration is below the alarm-1 setpoint level. The descending setting may be set to “YES”...
  • Page 47 System Setup 4.1.2.11 (U30) Analog Output Setup Menu The RS-232 Analog Output Setup menu U30 (see Figure 17) provides access to all of the settings related to the Analog Voltage Output (TB3-Pin 5, TB3-Pin 6) and Analog Current Output (TB3-Pin 7, TB3-Pin 8). It is accessed from the Setup Main Menu by typing “3”...
  • Page 48 Maintenance and Troubleshooting 4.1.2.11.4 Force minimum Voltage Output to O Concentration This menu sets the Oxygen concentration at which the Analog Voltage output is at zero. This setting is entered in percent oxygen increments, and can be anywhere from 0.0 % to 100.0 %. This menu is accessed from the Analog Output Setup menu by typing “4”...
  • Page 49 System Setup 4.1.2.11.6 Force minimum Current Output to O Concentration This menu sets the Oxygen concentration at which the Analog Current output is at minimum range (section 4.1.2.11.2). This setting is entered in percent oxygen increments and can be anywhere from 0.0 % to 100.0 %.
  • Page 50 Maintenance and Troubleshooting 4.1.2.13 (U50) RS-232 Serial Setup Menu This menu (see Figure 19) provides access to set the RS-232 serial communications options. It is accessed from the Setup Main Menu by typing “5” or “S” on the RS-232 terminal. To navigate backwards, use the <Esc>...
  • Page 51 System Setup 4.1.2.13.2 Automatic Serial Output Format This menu sets the format of the automatic timed RS-232 serial output (section 4.1.2.4). The timed serial output format may be set to 0 (Output on Request), 1 (Human Readable), 2 (Machine Code), 3 (Machine Code with Checksum), 4 (Tab delimited) 5 (OA1 style;...

  • Page 52: Change Factory Settings Via Hardware Jumpers

    Maintenance and Troubleshooting 4.1.2.17 220 Volt Line Voltage – NOT USED, DO NOT CHANGE 4.1.3 Change factory settings via Hardware Jumpers 4.1.3.1 Analog Voltage Output The Analog voltage output must be configured using the hardware settings (see Figure 19). In addition, the software settings must match the jumper settings.
  • Page 53 System Setup 4.1.3.1.1 Remove the unit from service Make certain that all interfacing to the Model 5100E is disabled at the user device. Make sure that interrupting outputs, from the unit will not interfere with normal process monitoring or control. Disconnect power from the Model 5100E unit.

  • Page 54: Routine Periodic Maintenance

    Maintenance and Troubleshooting Routine Periodic Maintenance Maintenance for the Model 5100E Oxygen analyzer is very simple. Apart from the normal maintenance for any instrument, such as cleaning the chassis, wiping the display, and replacing the sensor, the Model 5100E does not require any major periodic servicing. Calibration of the sensor on a known gas source should be performed during the customer’s regular maintenance schedule.

  • Page 55: Troubleshooting

    Troubleshooting Troubleshooting 4.3.1 Fault Codes When trouble occurs during normal operation of the Model 5100E, the user has several tools available to aid in isolating the cause(s) of given symptoms. As a starting point, the user may use the control panel to enter into “View Active Faults”...
  • Page 56 Maintenance and Troubleshooting 4.3.1.5 Fault Code 6 – Analog Output range underflow Fault 6 is activated when the analog outputs (4-20mA and 0-1/0-5/0-10VDC) cannot represent the measured analyzer reading because the oxygen concentration is lower than the set display range (section 4.1.2.11.1).

  • Page 57: Chapter 5 - Appendices

    5 – A HAPTER PPENDICES Appendix A – Spare Parts List PART NUMBER DESCRIPTION 5-06-4900-08-0 Operations Manual C1-11-1220-03-0 VAC Fuses for Power Supply Board (for Vac units only). – 1A, 250 VAC, Slo-Blo C1-17-0052-00-0 Replacement terminal block – TB1 C1-17-0142-00-0 Replacement terminal block –...

  • Page 58: Appendixb - Specifications

    Appendices Appendix B - Specifications OXYGEN SENSOR External Compact Zirconium Oxide DISPLAY 0.75” 7-segment LED digital display, 4 characters Displays oxygen from 0 to 100 percent. Resolution: 0.00–0.99 % X.XX 1.00–9.99 % X.XX 10.0–99.9 % XX.X 100.0 % XXX.X Color -Coded LED’s for system status: RUN: Green FAULT:...
  • Page 59 Appendix B - Specifications 0–1 % • 0–10 %• 0–25 % • 0–50 % • 0–100 % • Low Auto (0–25 %) RANGE • High Auto (10–100 %) • Full Auto (0–100 %) MEASUREMENT 0-25%, 0-100%** RANGE ACCURACY OF + .5% of measurement range MEASUREMENT RANGE .05% @ 0-25% measurement range, .1% @ 0-100% measurement range...

  • Page 60: Appendix C - Analyzer Factory Configuration Settings

    Appendices APPENDIX C – ANALYZER FACTORY CONFIGURATION SETTINGS Alarm and Relay Setup Information NON-FAILSAFE Alarm-1/Alarm-2 Relays Failsafe/Non-Failsafe ASCENDING Alarm-1/Alarm-2 Relay Ascending/Descending Alarm-1 Trigger Level 10 % Alarm-2 Trigger Level Display Range Analog Voltage Output 0–1 % Fixed 0–1 VDC 0–5 VDC 0–10 % Fixed 0–10DC 0–25 % Fixed...

  • Page 61: Appendix D - Control Panel Hot-Key Functions

    Appendix D – Control Panel Hot-Key Functions APPENDIX D – Control Panel Hot-Key Functions For convenience in operating and troubleshooting, the Model 5100E has four Control panel Hot-Key functions that can be performed quickly via the control panel without entering the normal Control panel, or Service Port user menus.

  • Page 62: Appendix E - Range / Output Chart

    Appendices APPENDIX E – Range / Output Chart DISPLAY MEASURED RANGE DISPLAY ANALOG RANGE RANGE ID RANGE NAME VOLTAGE OUTPUT FULL AUTO 0.00 % – .99 % X.XX 0–1 % 5.63 VDC RANGE 1.00 % – 9.99 % X.XX 0–10 % 6.25 VDC 10.0 % –...

  • Page 63: Appendix F - Msds Material Safety Data Sheet

    Appendix G – MSDS Material Safety Data Sheet APPENDIX F – MSDS Material Safety Data Sheet Product Identification Oxygen sensor solid state type, Model ZR-500E, furnished by Neutronics Inc. • 456 Creamery Way • Exton, PA USA, 19341 • Telephone: 610-524-8800. Hazardous Ingredients of Solution None Health Hazard...

  • Page 64: Appendix G - Warranty

    Appendices APPENDIX G – Warranty Neutronics warrants to the original purchaser, that the Model 5100E Oxygen analyzer is 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’...

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