Bacharach Neutronics Mini-ICS Operation Manual Download

Page: 1 / 66

456 Creamery Way, Exton, PA 19341

Phone: 610.524.8800 • Fax: 610.524.8807 • Email: [email protected]

www.neutronicsinc.com

MODEL Mini-ICS

OXYGEN ANALYZER / CONTROLLER

– PERCENT

RANGE

OPERATIONS MANUAL

Manual Part Number: 5-06-4900-53-0
Document Control Number: MN-A-0031

Revision Level: C

– ECO 044952

Revision Date:

May 08, 2018

MODE

NORMAL

FAULT

LOW FLOW

ALARM

20.9

ERCENT

XYGEN

MODEL Mini-ICS O

Controller

Neutronics

Reference Manual for

Installation and

Operation Instructions

Summary of Contents for Neutronics Mini-ICS

Page 1: ...YGEN ANALYZER CONTROLLER PERCENT RANGE OPERATIONS MANUAL Manual Part Number 5 06 4900 53 0 Document Control Number MN A 0031 Revision Level C ECO 044952 Revision Date May 08 2018 MODE NORMAL FAULT LOW...

Page 2: ......

Page 3: ...1 6 1 4 4 Inert Gas Control Relay Output 1 6 1 4 5 Fault Relay Output 1 6 1 4 6 Remote Calibration Relay Output 1 7 1 4 7 Analog Voltage Output 1 7 1 4 8 Analog Current Output 1 7 1 4 9 Range ID Outp...

Page 4: ...nert Gas Control limit 2 12 2 2 3 3 Set Low Inert Gas Control limit 2 12 3 CHAPTER 3 ANALYZER OPERATION 3 1 3 1 SYSTEM ORGANIZATION 3 1 3 2 USER MODES 3 1 3 2 1 CALIBRATE Mode 3 1 3 2 1 1 When to cali...

Page 5: ...20 Alarm and Relay Setup Menu 4 9 4 1 2 10 U30 Analog Output Setup Menu 4 11 4 1 2 11 U04 Display Analog Output Range 4 13 4 1 2 12 U50 RS 232 Serial Setup Menu 4 13 4 1 2 13 U60 Front Panel Locks Men...

Page 6: ...1 APPENDIX A SPARE PARTS LIST 5 1 5 2 APPENDIX B SPECIFICATIONS 5 2 5 3 APPENDIX C ANALYZER FACTORY CONFIGURATION SETTINGS5 4 5 4 APPENDIX D FRONT PANEL HOT KEY FUNCTIONS 5 6 5 5 APPENDIX E WARRANTY...

Page 7: ...to the MSDS and local policies when it has expired Ensure the MODEL Mini ICS has been properly calibrated before use Never expose the analyzer chassis or sensor to water high humidity or moisture The...

Page 8: ...Mini ICS analyzer please contact the Neutronics Inc Application Engineering Department If you have questions or comments we would like to hear from you Neutronics Inc 456 Creamery Way Exton PA 19341...

Page 9: ...eart of the analyzer is a remote mounted Neutronics zero maintenance disposable galvanic Oxygen sensor Remote mounting allows the sensor to be installed close to a process sampling point for the faste...

Page 10: ...de Select Button for easy scrolling through menu options Large LED Digital Display Reference Manual for Installation and Operation Instructions Other Features Include User adjustable Oxygen Alarm with...

Page 11: ...he Mini ICS The relays are mapped discretely to each alarm or control function to provide electrical outputs for reporting and process control use 1 3 3 Power Supply The power supply board is designed...

Page 12: ...r equipment panel The gasketed panel is suitable for NEMA type 4 IP20 environments when properly installed 1 3 6 Chassis The chassis is manufactured of specially coated steel It is designed to provide...

Page 13: ...Page 1 5 Relay Board RS 232 COM Line Mains Power Input Power Supply Main Board Display Board Control Panel Line Filter Fault and Remote Calibration Relay Outputs O2 Alarm Inert Gas Control Relay Outpu...

Page 14: ...n level allowable activation The relay output may be configured for fail safe relay coil de energized in alarm state or non fail safe relay coil energized in alarm state activation Factory default set...

Page 15: ...splayed Oxygen concentration in dynamic electrical current flow The minimum scale deflection may be set to either 0 mA or 4 mA Full scale is fixed at 20 mA The Analog current output is scaled accordin...

Page 16: ......

Page 17: ...mation during modes of operation Fault codes and operational mode indications such as setup and calibration 1 5 5 Normal Indicator LED The purpose of the NORMAL Indicator LED is to inform the user via...

Page 18: ...Level C ECO 044952 Revision Date May 08 2018 Page 2 2 2 CHAPTER 2 SYSTEM INSTALLATION AND START UP 2 1 Installing the Analyzer STEP 1 LOCATE THE ANALYZER PANEL CUTOUT STEP 2 INSTALL THE SENSOR Samplin...

Page 19: ...ntilation louver on the analyzer chassis To maintain a watertight seal on the control panel ensure that all burrs and deformities at the cutout and mounting holes are removed before insertion of the a...

Page 20: ...ICS analyzer is not rated intrinsically safe or explosion proof Be certain that no flammable gases are present in the area where the Model Mini ICS analyzer will be installed CAUTION The model Mini IC...

Page 21: ...ange V Out 1 2 3 TB3 4 5 6 7 8 9 10 11 Bat BU V Out mA Out RS 232 TX RX RTN 12 VDC no connection 5 VDC 2 4 no connection Service Port Sensor Flow Switch In TB4 Power In TB1 TB2 Alarms Range ID Out TB3...

Page 22: ...uit are made at terminal block TB4 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 Refer to Appendix F refere...

Page 23: ...3 5 Fault Relay Outputs Connections from the Fault relay contacts to the user s process control equipment are made at terminal block TB2 on the rear of the analyzer chassis The Fault relay contacts a...

Page 24: ...s supplied by the Model Mini ICS analyzer Be certain to match the terminal pins against the terminal ID label on the top of the analyzer chassis Use 20 AWG 2 conductor stranded wire twisted pairs for...

Page 25: ...mputer SIGNAL DESIGNATION AT ANALYZER ANALYZER TB2 CONNECTION SIGNAL DESIGNATION AT COMPUTER COMPUTER DB9 SERIAL PORT CONNECTION RX Pin 9 TX Pin 2 TX Pin 10 RX Pin 3 RTN Pin 11 RTN Pin 5 2 1 3 11 Batt...

Page 26: ...tain to match the terminal pins against the terminal ID label on the top of the analyzer chassis For VAC versions use minimum16 AWG 3 conductor stranded wire for the connections Supply single phase 11...

Page 27: ...way from exposure to rain dripping water or hose down Correctly installed the sensor sampling system Correctly installed all of the analyzer wiring Including barrier interfaces where required Read thi...

Page 28: ...Level For most Inert Gas Control applications this should be set to the highest level of Oxygen allowable in your process Refer to section 3 2 2 for information about setting the Oxygen Alarm level 2...

Page 29: ...View Active Faults modes will be covered in this chapter System Configuration modes will be covered in section 4 1 3 2 1 CALIBRATE Mode Calibration mode allows the Oxygen Sensor to be tuned to a gas...

Page 30: ...y CAL then an Oxygen concentration value Adjust the displayed Oxygen concentration value to read the applied calibration gas Oxygen concentration or if you are using compressed or ambient air 20 9 Oxy...

Page 31: ...t without saving press and release the MODE key 3 2 4 SET LOW INERT GAS CONTROL LIMIT Mode To enter Set Low Inert Gas Control Limit mode from any Run mode using the keypad scroll through the User Mode...

Page 32: ...USER modes accordingly Gas Calibration Set O2 Alarm Set High ICS Limit Set Low ICS Limit View Active Faults and User Setup section 4 1 The analyzer does not abort Normal mode when user input is detec...

Page 33: ...ing Control Limit The Inerting Control relays will return to their non active state according to their configuration 3 3 4 FAULT ACTIVE Mode The Model Mini ICS initiates Fault Active mode when it has...

Page 34: ......

Page 35: ...access adjustable parameters sequentially by continuing to press and release the MODE key to scroll through the Setup menu When you reach the mode that you wish to change use the UP and DOWN key to ad...

Page 36: ...ncentration Valid Settings 0 0 1 1 0 10 2 0 25 3 0 50 4 Auto range 5 Manual Range 4 1 1 6 User Setup 6 RS 232 Baud Rate This parameter allows the user to set the RS 232 communications baud rate Valid...

Page 37: ...6 Set Current Hour NOT ACTIVE FOR THIS RELEASE 4 1 1 17 User Setup 17 Set Current Minute NOT ACTIVE FOR THIS RELEASE 4 1 1 18 User Setup 18 Factory Setup Restore This parameter allows the user to retu...

Page 38: ...g Your HyperTerminal Interface If serial communications with the Model Mini ICS fails isolate the problem by performing the following tests Disconnect the RS 232 cable from the Model Mini ICS by remov...

Page 39: ...ult human readable format section 4 1 2 4 2 There are no commands necessary to begin viewing information transmitted by the Model Mini ICS in Standard Level access To request and view specific informa...

Page 40: ...libration solenoid valve is sticking that valve may be cycled manually by pressing 3 on the PC keyboard and then pressing it again There are several data formats of the ASCII data dump available They...

Page 41: ...checksum data is streamed in packets defined by start stop transmit bits The order of data in each packet is as follows Start Transmit O2 Concentration Display 1 Display 2 Fault codes active Fault Co...

Page 42: ...ccess to Advanced Level 1 can be accomplished on a PC by typing setup when viewing the Human Readable ASCII output The User Setup menu will be displayed on the PC screen allowing access for changing t...

Page 43: ...d to the Alarms controls and relays on the Model Mini ICS analyzer It is accessed from the Setup Main Menu by typing 2 on the RS 232 Terminal To navigate backwards use the Esc or Q key on the RS 232 t...

Page 44: ...ault 10 low sensor output This fault is used to determine that the gas sensor may be disabled The Low Sensor Fault level may be set anywhere from 0 0 to 100 0 This setting is accessed from the Alarm a...

Page 45: ...analog current output to either 0 0 20mA or 1 4 20mA 4 1 2 10 3 Analog Output Calibration and Range Control This menu is used to test and calibrate the Analog Voltage Output and Analog Current Output...

Page 46: ...ay Range Full Scale menu 4 1 2 10 10 Oxygen Concentration at Current Manual Zero This menu sets the oxygen concentration at which the analog current output is at minimum scale This option may be set a...

Page 47: ...values which are between 0 to 25 Entering Y at the prompt resets the Analog current zero and full scale Entering N at prompt retains the current setting This menu is accessed from the Analog Output Se...

Page 48: ...r may not execute Gas Auto calibration or the Front Panel User Setup menu The Master Lockout setting is accessed from the Front Panel Locks menu by typing 1 on the RS 232 terminal 4 1 2 13 2 Gas Calib...

Page 49: ...is number from the front panel to initiate the Front Panel User Setup mode A setting of 0 disables the password feature The User Setup Password setting is accessed from the Front Panel Locks menu by t...

Page 50: ...ed to determine the thresholds for fault code 7 Sensor Calibration Signal High section 4 2 1 7 and fault code 8 Sensor Calibration Signal Low section 4 2 1 8 This percentage error may be set anywhere...

Page 51: ...2 terminal 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 In addition the software settings m...

Page 52: ...r Division Division of Neutronics Inc 456 Creamery Way Exton PA 19341 RA JP4 JP5 Jumper access port in analyzer Case Model Mini ICS Bottom View JP4 JP5 JUMPERS 1 SHORTED 0 OPEN SELECT VOLTAGE OUTPUT R...

Page 53: ...re any major servicing Periodic calibration of the sensor on known gas should be performed on a regular basis see section 4 2 The chart below should serve as a general guide for maintenance personnel...

Page 54: ...has dropped below the mechanical set point of the Flow Switch in you Neutronics Inc Process Sampling system or Sample Conditioning Package In this flow condition the Oxygen reading may not be represen...

Page 55: ...ured process not isolated from sensor during calibration calibration gas not applied incorrect calibration gas sensor nearing the end of its useful service period Helpful Hint Fault Code 8 is an accur...

Page 56: ...1 and is not monitoring the process 4 3 1 15 Fault Code 28 Calibration Mode active The Calibration Mode active fault indicates that the system is in a maintenance mode Calibration mode is part of the...

Page 57: ...Sensor Model CAG 250N 0 100 5 06 4900 53 0 Operations Manual C6 01 1000 02 0 Vac Power supply for Vac units only 6 01 1000 17 0 12 24 Vdc Power Supply for Vdc units only C6 01 1000 13 0 Relay Board C6...

Page 58: ...ge Output 0 1 0 5 0 10V Analog Current Output 0 20mA 4 20 mA Range ID Voltage 0 1 O2 5 63 V 0 10 O2 6 25 V 0 25 O2 6 88 V 0 50 O2 7 50 V RELAY OUTPUTS O2 Alarm Field Adjustable Form C DPDT Voltage fre...

Page 59: ...ilization POWER AC Unit 90 264 VAC 47 63 Hz Single Phase 2 5 Watts VDC Unit 10 30VDC 2 5 Watts WARRANTY Analyzer 12 months from date of shipment Sensor Model GP 6 months from date of shipment Model CA...

Page 60: ...m and Relay Setup Information ICS And O2 Alarm Relays Failsafe Non Failsafe FAIL SAFE O2 Alarm Relay Ascending Descending ASCENDING O2 Alarm Trigger Level In 8 High ICS Start Inert Level In 7 Low ICS...

Page 61: ...dable Format X Machine Code Machine Code With Checksum Tab Delimited Spreadsheet Rs 232 Delay Time Between Output 1 second X Auto Calibration Information Delay Between Calibration Relay On To Start Of...

Page 62: ...N mode press simultaneously and release the keys indicated in figure 14 To return to normal operation press and release the same keys again To access the remaining available functions described in fig...

Page 63: ...repair or service of the products and to modify the design as deemed suitable in so far as these materials or modifications maintain the stated warranty It is the sole responsibility of the buyer use...

Page 64: ...t for the Model Mini ICS will be determined by the area classification in which it will be installed The enclosure type will also affect the user interface with the front panel The following figures w...

Page 65: ...Date May 08 2018 Page 5 9 5 7 2 Rack Mount Enclosure Users will activate the three push buttons mounted on the enclosure door to interface with the module Each button corresponds to one button on the...

Page 66: ...s to interface with the unit The left side has a three position spring return to center from left or right switch Turning the switch counter clockwise and releasing corresponds to incremental up UP an...

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